Kalmar DCE
KALMAR DCE 90–180, DCE 70-32E3–70-35E4-35e4 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS
KALMAR DCE 90–180, DCE 70-32E3–70-35E4-35e4 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - English Workshop Manual / Repair Manual and Wiring Diagrams, for forklift truck Kalmar DCE 90–180, DCE 70-32E3–70-35E4-35e4. CONTENTS: A Foreword - About the Workshop Manual - General - Conditions - Storage - About the machine version - Copyright - Reading instructions - Warning information - Important information - Read operator’s manual - Read maintenance manual - Workshop manual contents - Function group structure - References between different information types - Product alternatives and optional equipment - Machine card - Function descriptions - About the documentation - Documentation sections - Ordering of documentation - Feedback - Form for copying Safety - General safety information - Safety concerns everyone! - A near accident is a warning! - Safety instructions - General - Service position - Hydraulic system, depressurizing - Oils - Fuel system - Clothing, etc. - Several mechanics on the same machine - Working under machine - Lifting heavy components - Vibrations - Noise - Solvents - Fire and explosion risks - Fluid or gas under pressure - Coolant - Refrigerant - Air pollution - Tensioned springs - Electric motors - Rotating components and tools - Tyre and rim system - Lifting equipment - Spare parts - Non-ionised radiation - Environment - General C Preventive maintenance - Preventive maintenance Complete machine - Complete machine, description - Troubleshooting, general work instructions - Troubleshooting without an error code, example - Troubleshooting with error code, example - Troubleshooting cable harness - Troubleshooting hydraulic hoses 1 Engine - 1.1 Controls and instruments - 1.1.1 Ignition switch - 1.1.2 Accelerator pedal - 1.2 Fuel system - 1.2.1 Fuel tank - 1.2.2 Sensor, fuel level - 1.3 Additional exhaust cleaning system - 1.3.1 Combifilter - 1.3.2 Catalyst - 1.6 Air intake and exhaust outlet - 1.6.1 Air cleaning system - 1.6.3 Exhaust system - 1.6.4 Intercooler - 1.6.8 Pipes and hoses - 1.7 Cooling system - 1.7.4 Radiator and expansion tank - 1.7.7 Coolant - 1.7.8 Switch normally open (NO), coolant level - 1.7.10 Engine heater - 1.9 Engine control system - 1.9.1 Control unit engine (ECU 794) - 1.9.3 Cables engine - 1.11 Start/stop - 1.11.2 Stopping device - 1.11.3 Automatic engine stop 5 minutes after driver’s seat is empty - 1.11.5 Automatic engine power derate 2 Transmission - 2.1 Controls and instruments - 2.1.6 Gear and direction of travel selector - 2.1.7 Inching - 2.2 Torque converter/Clutch system - 2.2.1 Flex plates - 2.2.6 Switch normally closed (NC), disengagement - 2.6 Lubrication system - 2.7 Cooling system - 2.7.3 Oil cooler - 2.8 Transmission control system - 2.8.1 Transmission control unit (ECU 793) - 2.8.2 Cable harness transmission - 2.8.3 Display and menus - 2.8.4 Reversing lock - 2.8.5 Manual shifting - 2.8.6 Automatic transmission - 2.8.7 Inching - 2.8.8 OptimumDrive - 2.8.9 Diagnostics - 2.8.10 Calibration - 2.8.11 Service menus 3 Driveline/axle - 3.2 Propeller shaft - 3.3 Drive axle 4 Brakes - 4.1 Controls and instruments - 4.1.1 Brake pedal - 4.3 Power-assisted brake system - 4.3.1 Pump 3 - accumulator charging, flushing/cooling system, brake and servo pressure control levers - 4.3.2 High-pressure filter - 4.3.3 Main valve - 4.3.4 Accumulator - 4.3.5 Brake valve - 4.3.6 Distribution block - 4.3.7 Switch normally closed (NC), disengagement - 4.3.8 Switch normally closed (NC), low brake pressure - 4.3.9 Switch normally open (NO), brake lights - 4.3.10 Wheel brake - 4.3.11 Pipes and hoses - 4.3.14 Shuttle valve dual brake pedals - 4.5 Parking brake system - 4.5.1 Pump 3 - accumulator charging, flushing/cooling system, brake and servo pressure control levers - 4.5.2 High pressure filter - 4.5.3 Parking brake valve - 4.5.4 Parking brake unit - 4.5.5 Switch normally open (NO), parking brake - 4.5.6 Pipes and hoses - 4.8 Temperature control, cleaning and brake oil - 4.8.1 Hydraulic oil tank - 4.8.2 Tank heater - 4.8.3 Pump 3 - accumulator charging, flushing-/ cooling system brake and servo pressure control levers - 4.8.4 Accumulator charging valve - 4.8.5 Distribution block - 4.8.6 Wheel brake - 4.8.7 Oil cooler - 4.8.12 High pressure filter - 4.8.13 Pipes and hoses - 4.8.14 Hydraulic oil 5 Steering - 5.1 Controls and instruments - 5.1.1 Steering wheel and steering column - 5.1.2 Mini-wheel - 5.1.3 Lever steering - 5.2 Power assisted system - 5.2.1 Hydraulic oil pump, steering - 5.2.2 Main valve (priority valve for steering) - 5.2.3 Steering valve - 5.2.4 Steering cylinder - 5.2.5 Steering axle cradle - 5.2.6 Link arm - 5.2.7 Wheel spindle - 5.2.8 Wheel hub - 5.2.9 Sensor, wheel angle - 5.2.10 Control valve mini-wheel/lever steering - 5.2.11 Sensor, steering wheel movement - 5.2.12 Filter mini-wheel/lever steering - 5.2.13 Pressure reducing valve - 5.2.15 Directional valve reversible operator’s seat - 5.2.16 Sensor reversible operator’s seat - 5.2.17 Pipes and hoses 6 Suspension - 6.2 Suspension - 6.2.1 Steering axle cradle - 6.2.2 Wheel spindle - 6.2.3 Wheel hub - 6.3 Tyres and rims - 6.3.1 Tyres - 6.3.2 Rims - 6.3.3 Nut, washer and clamp (wedge) 7 Load handling - 7.1 Controls and instruments - 7.1.1 Control lever - 7.2 Lifting/lowering - 7.2.1 Hydraulic oil pump - 7.2.2 Accumulator - 7.2.3 Main valve - 7.2.4 Lift cylinder - 7.2.5 Accumulator damping - 7.2.6 Mast - 7.2.7 Mast wheels - 7.2.8 Chains - 7.2.9 Chain wheels and hose wheels - 7.2.10 Fork carriage - 7.2.11 Load control valve - 7.2.12 Pipes and hoses - 7.4 Side shift - 7.4.1 Hydraulic oil pump - 7.4.2 Accumulator - 7.4.3 Main valve - 7.4.4 Side shift cylinder - 7.4.5 Side shift frame - 7.4.6 Fork carriage - 7.4.7 Pipes and hoses - 7.5 Spreading - 7.5.1 Hydraulic oil pump - 7.5.2 Accumulator - 7.5.3 Main valve - 7.5.4 Flow divider - 7.5.5 Spreading cylinder - 7.5.6 Fork carriage - 7.5.7 Pipes and hoses - 7.7 Tilt - 7.7.1 Hydraulic oil pump - 7.7.2 Accumulator - 7.7.3 Main valve - 7.7.4 Load holding valve (over-centre valve) - 7.7.5 Tilt cylinder - 7.7.6 Mast - 7.7.7 Pipes and hoses - 7.8 Levelling - 7.8.1 Hydraulic oil pump - 7.8.2 Accumulator - 7.8.3 Main valve - 7.8.4 Levelling cylinder - 7.8.5 Fork carriage - 7.8.6 Levelling fork - 7.8.7 Pipes and hoses - 7.9 Load carrier - 7.9.1 Lift forks - 7.10 Other functions - 7.10.1 Electric scales - 7.10.2 Pre-selected lift height - 7.10.3 Vertical alignment - 7.10.4 Optimum lift - 7.10.5 Side lift attachment 8 Control system - 8.2 Monitoring - 8.2.3 Speed limitation - 8.3 Error codes - 8.4 Diagnostics - 8.4.1 ECU 790 - 8.4.2 ECU 792 - 8.4.3 ECU 793 - 8.4.4 ECU 796 - 8.4.5 Last alarms - 8.5 Setup - 8.5.1 ETC-Electronic Throttle Control (electronic throttle) - 8.5.2 Automatic shifting - 8.5.4 Feedback lever steering - 8.5.5 NON feedback lever steering - 8.5.6 Mini-wheel - 8.5.7 Electro-hydraulic servo - 8.5.8 Scale - 8.5.9 Monitoring - 8.5.10 Pre-selected lifting height - 8.5.11 Tilt control - 8.5.12 OptimumLift - 8.5.14 Clamp and lift function/lower and open function - 8.5.15 Automatic clamping function - 8.5.16 Protection against loose chain tension - 8.5.17 Protection against inadvertent opening of the clamp - 8.5.18 Automatic lowering stop - 8.5.19 Driving interlock - 8.5.20 Speed limitation related to lift height - 8.5.21 Reversible driver’s station - 8.6 Software - 8.6.1 Kalmar Smart Link 9 Frame, body, cab and accessories - 9.1 Controls and instruments - 9.1.1 Multi-function lever - 9.2 Safety and emergency equipment - 9.2.1 Control switch - 9.2.2 Seat belt - 9.2.3 Fire extinguisher - 9.2.4 Seat buzzer - 9.2.5 Roof grating - 9.3 Seat - 9.3.1 Seat cushion - 9.3.2 Back cushion - 9.3.3 Electric heater - 9.3.4 Shock absorbers - 9.3.5 Air suspension - 9.3.6 Compressed air-suspended seat - 9.3.7 Mechanical seat adjustment - 9.3.8 Passenger seat - 9.3.9 Reversible operator's seat - 9.3.10 Rotating operator's seat - 9.3.11 Armrest - 9.3.12 Direction valve, reversible driver’s seat - 9.3.13 Sensor, reversible driver’s seat - 9.3.14 Reversible driver’s station - 9.3.15 Directional valve, reversible driver’s station - 9.3.16 Potentiometer, reversible driver’s seat - 9.3.17 Head restraint - 9.4 Heating, ventilation and air conditioning - 9.4.1 Fresh air / recirculation valve - 9.4.2 Air vents - 9.4.3 Cab fan - 9.4.4 Fresh air filter - 9.4.5 Heat exchanger heat - 9.4.6 Water valve - 9.4.7 AC Compressor - 9.4.8 Thermostat - 9.4.9 Condenser unit - 9.4.10 Expansion valve - 9.4.11 Evaporator - 9.4.12 Sensor for ECC - 9.4.13 Control unit ECC - 9.4.14 Air distributor - 9.4.15 Fine filter - 9.4.16 Pause heater - 9.4.18 Cabin heater - 9.4.20 Cooling unit - 9.4.21 Particle and moisture filter - 9.4.22 Actuator motor - 9.5 Wiper/washer system - 9.5.1 Wiper front - 9.5.2 Wiper roof - 9.5.3 Wiper rear - 9.5.4 Washer motor and reservoir - 9.5.5 Wiper motor, front - 9.5.6 Wiper motor, roof - 9.5.7 Wiper motor, rear - 9.6 Lighting system - 9.6.1 Headlights - 9.6.2 Position light - 9.6.3 Tail light - 9.6.4 Brake light - 9.6.5 Reversing light - 9.6.6 Driving direction indicator - 9.6.7 Warning lamp, Hazard - 9.6.8 Rotating beacon - 9.6.9 Working lights, mast - 9.6.10 Working lights, cab - 9.6.11 Interior lighting - 9.6.12 Working lights, fenders - 9.6.13 Engine room lighting - 9.7 Signalling system - 9.7.1 Horn - 9.7.2 Warning lamp, Hazard - 9.7.3 Rotating beacon - 9.7.4 Warning parking brake - 9.7.5 Reversing alarm - 9.7.6 Flashing brake light for reversing - 9.8 Entertainment and communication - 9.8.1 Radio with CD - 9.8.2 Communication radio - 9.8.3 Telephone - 9.8.4 Terminal - 9.8.5 Screen - 9.8.6 Computer - 9.8.7 Voltage converter - 9.9 Glass/windows/mirrors - 9.9.1 Windscreen - 9.9.2 Side window - 9.9.3 Roof window - 9.9.4 Rear window - 9.9.5 Rear-view mirror - 9.9.6 Protective panel in front of windscreen - 9.9.8 Reversing camera - 9.9.9 Monitor, reversing camera - 9.10 Cab structure and suspension - 9.10.1 Cab frame - 9.10.2 Doors - 9.10.3 Cab mounting - 9.10.4 Cab tipping - 9.10.5 Door stop - 9.10.6 Roof and door mouldings - 9.10.7 Cab tipping cylinder - 9.11 Cab interior - 9.11.1 Instrument and control panels - 9.11.2 Interior plastic components - 9.11.3 Interior textile components - 9.11.4 Floor covering - 9.11.5 Insulation - 9.11.6 Sunshield curtains - 9.11.7 Terminal table - 9.11.8 Writing desk - 9.11.9 Compartment for A4 papers - 9.11.10 Holder for pump lever - 9.12 Frame - 9.13 Body - 9.13.1 Fenders - 9.13.2 Hood engine compartment - 9.13.3 Footstep - 9.13.4 Counterweight - 9.13.5 Battery compartment - 9.13.7 Mud guards - 9.13.8 Tool kit - 9.13.9 Lifting lugs - 9.14 Central lubrication - 9.14.1 Pump unit - 9.14.2 Distribution block - 9.14.3 Lines - 9.14.4 Grease nipples - 9.15 Paint/coatings 10 Common hydraulics - 10.2 Safety valves - 10.2.1 Accumulator drain valve - 10.2.2 Pipes and hoses - 10.3 Tanks and accumulators - 10.3.1 Tank - 10.3.2 Accumulator - 10.3.3 Sensor, low brake pressure - 10.3.4 Pipes and hoses - 10.4 Pumps - 10.4.1 Gear pump with fixed displacement - 10.4.3 Pipes and hoses - 10.5 Hoses, pipes and valves - 10.5.1 Pipes and hoses - 10.5.2 Main valve - 10.5.3 Priority valve - 10.5.5 Proportional valve - 10.6 Temperature control, cleaning and hydraulic oil - 10.6.1 Tank heater - 10.6.2 Hydraulic oil cooler - 10.6.3 Sensor hydraulic oil temperature - 10.6.4 Switch (NC) cooling fan - 10.6.5 Cooling fan - 10.6.6 Thermal by-pass valve - 10.6.7 Breather filter hydraulic oil tank - 10.6.8 High-pressure filter - 10.6.9 Hydraulic oil - 10.6.10 Pump 3 - accumulator charging, flushing/cooling system and servo system control levers - 10.6.11 Pipes and hoses - 10.7 Auxiliaries - 10.7.1 Hydraulic cylinders 11 Common electrics - 11.1 Controls and instruments - 11.1.1 Operating time gauge - 11.2 Electric protection - 11.2.1 Battery disconnector - 11.2.2 Fuses - 11.3 Batteries - 11.3.1 Start battery - 11.3.3 Auxiliary start connector - 11.4 Alternator - 11.4.1 Alternator - 11.5 Distribution of electricity - 11.5.1 Power supply - 11.5.2 Electrical distribution box - 11.5.3 Control units - 11.5.4 Operation, electrical system - 11.5.5 Cables - 11.6 Communication - 11.6.1 CAN bus - 11.6.2 Redundant CAN bus - 11.6.3 CAN bus driveline Error codes - Error codes, explanation - Error code menu, description - Reading out error code 1 Engine - Error codes engine, general - Error codes engine alternative Volvo TAD650VE, TAD660VE, TAD750VE and TAD760VE - Error codes engine alternative Cummins QSB6.7 - Error codes engine alternative Caterpillar C6.6 2 Transmission - Error codes transmission alternative Dana TE13000 and TE17000 - Error codes transmission alternative ZF 3WG161 8 Control system - Error codes machine 9 Frame, body, cab and accessories - 9.4 Heating, ventilation and air conditioning - ECC: Reading out error code - ECC: Error code table 10 Common hydraulics - Hydraulic diagrams, compilation - Hydraulic diagram A40750.1800 - Hydraulic diagram A40750.1900 - Hydraulic diagram A40750.2000 - Hydraulic diagram A40750.2100 - Hydraulic diagram A40750.2200 - Hydraulic diagram A40750.3000 11 Common electrics - Circuit diagram, description - Component designations - Circuit diagrams, compilation - A49842.0100 - List of components Technical data - Specifications for data and volume - Specifications for lift capacity and dimensions - Recommended oils and lubricants - Tightening torques, recommendations - Tightening torques, ORFS- couplings - Tightening torque, climate control system connections - Unit explanations - Conversion table, SI-units - Conversion table, length - Conversion table, area - Conversion table, volume - Conversion table, weight - Conversion table, pressure Terminology and index - Explanation - Index
DCE 90–180, DCE 70-32E3–70-35E4-35e4- Repair, Workshop Manual and Electrical Wiring Diagrams
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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