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DCF 90-100
Kalmar DCF 90-100 User Manual
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A
Foreword
B
Safety
C
Preventive maintenance
0
Complete machine
1
Engine
2
T
ransmi
ssion
3
Driveline/axle
4
B
r
akes
5
S
t
eering
6
Suspension
7
L
oad handling
8
Control system
9
Frame, body, cab and accessories
10
Common
hydrau
l
i
cs
11
Common electrics
12
Common
pneu
m
ati
cs
D
Error codes
E
Schematics
F
T
e
chnical data
G
T
erminolog
y
and
Index
Workshop
manual
2
Table of Contents
A Foreword
3
Table of Contents
3
MM MM MM MM MM MM
5
Foreword
5
About the Workshop Manual
5
General
5
Workshop Manual Contents
5
References between Different Information Types
6
Function Group Breakdown
7
Conditions
7
Storage
7
About the Machine Version
7
Copyright
7
Optional Equipment
8
Read the Operator's Manual/Maintenance Manual
8
Important Information
8
Warning Information
8
Reading Instructions
8
Function Descriptions
9
About the Documentation
12
Documentation Sections
12
Ordering of Documentation
12
Feedback
13
Form for Copying
13
B Safety
15
A Near Accident Is a Warning
17
General Safety Information
17
MM MM MM MM MM MM
17
Safety
17
Safety Concerns Everyone
17
General
18
Safety Instructions
18
Service Position
18
Hydraulic and Brake Systems, Depressurizing
19
Oils
20
Fuel System
21
Clothing, Etc
22
Several Mechanics on the same Machine
22
Lifting Heavy Components
23
Working under Machine
23
Noise
24
Vibrations
24
Fire and Explosion Risks
25
Solvents
25
Fluid or Gas under Pressure
26
Coolant
27
Air Pollution
28
Refrigerant
28
Electric Motors
29
Tensioned Springs
29
Rotating Components and Tools
30
Lifting Equipment
31
Tyre and Rim System
31
Environment
32
General
32
0 Complete Machine
37
Complete Machine
39
Complete Machine, Description
39
MM MM MM MM MM MM
39
Troubleshooting, General Work Instructions
40
Troubleshooting with Error Code, Example
41
Troubleshooting Without an Error Code, Example
41
Troubleshooting Cable Harness
43
Troubleshooting Hydraulic Hoses
44
1 Engine
45
Engine
47
MM MM MM MM MM MM
47
Controls and Instruments
67
Ignition Switch
67
Accelerator Pedal
68
Fuel System
69
Fuel Tank
69
Sensor, Fuel Level
69
Air Cleaning System
70
Air Intake and Exhaust Outlet
70
Exhaust System
70
Intercooler
71
Cooling System
72
Radiator and Expansion Tank
73
Cooling Fan
74
Coolant
75
Engine Heater
81
Normally Open) Switch, Coolant Level
81
Control System Engine
82
Control Unit, Engine
82
Start/Stop
83
Starter Motor
83
Stopping Device
83
2 Transmission
85
MM MM MM MM MM MM
87
Transmission
87
Controls and Instruments
102
Gear Selector and Multi-Function Lever
102
Flex Plates
103
Torque Converter/Clutch System
103
Lubrication System
105
Oil Cooler
108
Oil Filter
110
Cooling System
111
Oil Cooler
111
Control Unit Transmission
112
Normally Closed (NC) Switch, Disengagement
112
Transmission Control System
112
Transmission Cable Harness
113
4 Brakes
125
Brake Pedal
127
Brakes
127
Controls and Instruments
127
MM MM MM MM MM MM
127
Power-Assisted Brake System
130
Hydraulic Oil Pump
133
Oil Filter
135
Accumulator Charging Valve
136
Accumulator
139
Brake Valve
143
Drive Axle Block
147
Brake Pressure NC (Normally Closed) Switch
148
Normally Open) Switch, Brake Lights
149
Wheel Brake
151
Pipes and Hoses
153
Parking Brake System
154
Hydraulic Oil Pump
157
M-Valve Parking Brake
157
Oil Filter
157
Parking Brake Unit
158
Parking Brake NC Switch
161
Pipes and Hoses
161
Hydraulic Oil Tank
162
Temperature Control, Cleaning and Hydraulic Oil
162
Accumulator Charging Valve
163
Breather Filter Hydraulic Oil Tank
163
Cooling Fan
163
Drive Axle Block
163
Hydraulic Oil Pump
163
Oil Filter
163
Pipes and Hoses
163
Sensor Hydraulic Oil Temperature
163
Thermal Bypass Valve
163
Wheel Brake
163
Hydraulic Oil
164
5 Steering
165
MM MM MM MM MM MM
167
Power Assisted System
167
Steering
167
Hydraulic Oil Pump
169
Priority Valve
170
Steering Valve
172
Steering Cylinder
174
Link Arm
176
Steering Axle Cradle
176
Wheel Hub
176
Wheel Spindle
176
Pipes and Hoses
177
Shuttle Valve
177
6 Suspension
179
MM MM MM MM MM MM
181
Suspension
181
Steering Axle Cradle
182
Wheel Spindle
184
Wheel Hub
186
Tyre and Rim System
191
Tyres
193
Rims
194
Nut, Washer and Clamp
195
7 Load Handling
197
Load Handling
199
MM MM MM MM MM MM
199
Control Levers
201
Controls and Instruments
201
Switch, Lock Twistlock/Lock Tongue
203
Switch, Spreading 20'-40
203
Switch, Automatic Spreading
204
Switch, Stop at 30
204
Lifting/Lowering
205
Hydraulic Oil Pump
208
Servo Filter
208
Pressure Reducer
209
Accumulator Servo Circuit
210
Control Valve, Lift and Tilt
211
Lift Cylinder
213
Sensor Hydraulic Pressure Lift Cylinder
213
Shuttle Valve
213
Mast
215
Mast Position Sensor
224
Lifting Carriage
225
Pipes and Hoses
229
Valve Block Quick-Lift
229
Side Shift
230
Control Valve Attachment
232
Hydraulic Oil Pump
232
Shuttle Valve
236
Side Shift Cylinder
236
Lifting Carriage
237
Attachment Relief Valve
238
Pipes and Hoses
238
Valve Block, Main Pump Relief
238
Spreading
239
Control Valve Attachment
246
Hydraulic Oil Pump
246
Spreading Cylinder
247
Spreader Beam
248
Main Beam, Side Lifting Attachment
249
Buzzer, Automatic Spread 20'-40
254
Position Sensor Positioning
254
Pipes and Hoses
255
Tilt
256
Accumulator
258
Control Valve, Lift and Tilt
258
Hydraulic Oil Pump
258
Pressure Reducer
258
Servo Filter
258
Load Retention Valve
259
Tilt Cylinder
259
Mast
260
Pipes and Hoses
260
Levelling
261
Control Valve Attachment
263
Hydraulic Oil Pump
263
Levelling Cylinder
264
Lifting Carriage
264
Pipes and Hoses
264
Valve Block, Main Pump Relief
264
Load Carrier
265
Twistlocks
265
Lifting Hook
276
Container Counter
289
Other Functions
289
8 Control System
293
Control System
295
MM MM MM MM MM MM
295
Controls and Instruments
296
Error Code Menu
296
Bypass
299
Monitoring
299
Overload Protection
299
Speed Limitation
299
Service Indicator
300
Diagnostics
301
Can/Power
303
Lights
318
Cab
329
Climate
337
Hyd
343
Engine
350
Transm
357
Elserv
368
Attach, Dcf360-450Csg
382
ATTACH, DCF 90-100 with Lifting Hook Attachment
399
ATTACH, DCF 90-100 with Twistlock Attachment
415
Ols
429
Extra
431
Initiation
463
Settings
463
Calibration
500
5
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Kalmar DCF 90-100 Specifications
General
Brand
Kalmar
Model
DCF 90-100
Category
Industrial Equipment
Language
English
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