Kalmar Forklift Truck DCF180-250 Workshop Manual VDCF06.01GB

[Hyundai]

Download this document, you need 2725 Gallons

Kalmar Forklift Truck DCF180-250 Workshop Manual VDCF06.01GB
Size: 52.80 MB
Format: PDF
Language: English
Brand: Kalmar
Type of Machine: Forklift Truck
Type of Manual: Workshop Manual, Electric and Hydraulic Diagrams
Model: Kalmar DCF180-250 Forklift Truck
Part Number: VDCF06.01GB
Number of Pages: 718 Pages

Contents:
Workshop Manua lDCF180-250
A Foreword

About the Workshop Manual​

Reading instructions​

About the documentation​

Feedback​

B Safety

General safety information​

Safety instructions​

Environment​

C Preventive maintenance
0 Complete machine
1 Engine

1.1 Controls and instruments​

1.1.1 Ignition​

1.1.2 Accelerator​

1.2 Fuel system​

1.2.1 Fuel tank​

1.2.2 Sensor fuel level​

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 SCR system​

1.6.9 Pipes and hoses​

1.7 Cooling system​

1.7.4 Radiator and expansion tank​

1.7.5 Cooling fan​

1.7.7 Coolant​

1.7.8 Coolant level sensor​

1.7.10 Engine heater​

1.9 Control system, engine​

1.9.1 Engine control unit​

1.11 Start/stop​

1.11.1 Starter motor​

1.11.2 Stopping device​

1.11.3 Automatic engine stop 5 minutes after driver's seat is em​

1.11.5 Warning and engine power limitation​

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 Break contact (opening switch) declutch​

2.6 Lubrication system​

2.7 Cooling system​

2.7.3 Oil cooler​

2.8 Control system, transmission​

2.8.1 Transmission control unit (ECU 793)​

2.8.2 Transmission cable harness​

2.8.3 Display and menus​

2.8.4 Reversing lock​

2.8.5 Manual gear changing​

2.8.6 Automatic gearing​

2.8.7 Inching​

2.8.9 Diagnostics​

2.8.10 Calibration​

2.8.11 Service menus​

3 Power transmission

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 Hydraulic oil pump​

4.3.2 High-pressure filter​

4.3.4 Accumulator​

4.3.5 Brake valve​

4.3.6 Distribution block​

4.3.7 Break contact (opening switch) declutch​

4.3.8 Switch normally closed (NC), low brake pressure​

4.3.9 Make-contact (closing switch) brake lights​

4.3.10 Wheel brakes​

4.3.11 Pipes and hoses​

4.3.13 Accumulator charging valve​

4.3.14 Shuttle valve dual brake pedals​

4.5 Parking brake system​

4.5.1 Hydraulic oil pump​

4.5.2 High-pressure filter​

4.5.3 Solenoid valve parking brake​

4.5.4 Parking brake unit​

4.5.5 Normally closed (NC) switch, parking brake​

4.5.6 Pipes and hoses​

4.8 Temperature control, cleaning and oil brake system​

4.8.1 Hydraulic oil tank​

4.8.2 Tank heater​

4.8.3 Hydraulic oil pump​

4.8.4 Accumulator charging valve​

4.8.5 Distribution block​

4.8.6 Wheel brakes​

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 wheel shaft​

5.1.2 Mini-wheel​

5.1.3 Joystick control​

5.2 Power assisted system​

5.2.1 Hydraulic oil pump​

5.2.2 Priority valve​

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​

5.2.11 Sensor, steering wheel movement​

5.2.14 Control valve steering​

5.2.15 Directional control valve, turnable driver's seat​

5.2.16 Sensor turnable driver'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 Rim​

6.3.3 Nut, washer and clamp​

7 Load handling

7.1 Controls and instruments​

7.1.1 Control lever​

7.2 Lift and lower​

7.2.1 Hydraulic oil pump​

7.2.3 Control valve load handling​

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 Trolley​

7.2.11 Load control valve​

7.2.12 Pipes and hoses​

7.2.14 Support roller​

7.2.15 Top support roller​

7.4 Side shift​

7.4.1 Hydraulic oil pump​

7.4.3 Control valve load handling​

7.4.4 Side shift cylinder​

7.4.6 Trolley​

7.4.7 Pipes and hoses​

7.5 Spreading (positioning)​

7.5.1 Hydraulic oil pump​

7.5.3 Control valve load handling​

7.5.4 Flow divider​

7.5.5 Spreading cylinder​

7.5.6 Trolley​

7.5.7 Pipes and hoses​

7.7 Tilt​

7.7.1 Hydraulic oil pump​

7.7.3 Control valve load handling​

7.7.4 Load holding valve (over-centre valve)​

7.7.5 Tilt cylinder​

7.7.6 Mast​

7.7.7 Pipes and hoses​

7.9 Load carrier​

7.9.1 Lift forks​

7.10 Other functions​

7.10.1 Scale​

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​

8.4.4 ECU 796​

8.4.5 Last alarms​

8.5 Setup​

8.5.1 ETC-Electronic Throttle Control (electronic throttle)​

8.5.2 Automatic gearing​

8.5.4 Joystick control​

8.5.6 Mini-wheel​

8.5.7 Electro-hydraulic servo​

8.5.8 Scale​

8.5.9 Monitoring​

8.5.21 Turnable operator'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 breaker​

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 rest cushion​

9.3.3 Heating coil​

9.3.4 Bumper​

9.3.5 Air suspension​

9.3.6 Compressor air-suspension seat​

9.3.7 Mechanical seat adjustment​

9.3.8 Passenger seat​

9.3.9 Reversible operator\qs seat​

9.3.10 Rotating driver's seat​

9.3.11 Arm rest​

9.3.12 Directional control valve, turnable driver's seat​

9.3.13 Sensor turnable driver's seat​

9.3.17 Head rest​

9.4 Heating, ventilation and air conditioning​

9.4.1 Fresh air / recirculation valve​

9.4.2 Defroster nozzles​

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 Cab 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 Running lights​

9.6.3 Tail lights​

9.6.4 Brake lights​

9.6.5 Back-up lights​

9.6.6 Direction indicators​

9.6.7 Warning lamp, Hazard​

9.6.8 Revolving 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 Revolving beacon​

9.7.4 Warning parking brake​

9.7.5 Back-up 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 substructure​

9.10.4 Cab tilting​

9.10.5 Door stop​

9.10.6 Roof and door mouldings​

9.10.7 Cab tilting cylinder​

9.11 Cab interior​

9.11.1 Instrument and control panels​

9.11.2 Interior fittings, plastic​

9.11.3 Interior fittings, textile​

9.11.4 Floor covering​

9.11.5 Insulation​

9.11.6 Sun visors​

9.11.7 Terminal console​

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 structure​

9.13.1 Wings​

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​

10.4.2 Axial piston pump with variable displacement​

10.4.3 Pipes and hoses​

10.5 Hoses, pipes and valves​

10.5.1 Pipes and hoses​

10.5.3 Priority valve​

10.5.4 Shuttle 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 Make-contact (closing switch), cooling fan​

10.6.5 Cooling fan​

10.6.6 Thermal bypass valve​

10.6.7 Breather filter hydraulic oil tank​

10.6.8 High-pressure filter​

10.6.9 Hydraulic oil​

10.6.10 Hydraulic oil pump​

10.6.11 Pipes and hoses​

10.7 Other​

10.7.1 Hydraulic cylinders​

11 Common electrics

11.1 Controls and instruments​

11.1.1 Hour meter​

11.2 Electric protection​

11.2.1 Battery disconnector​

11.2.2 Fuses​

11.3 Batteries​

11.3.1 Start battery​

11.4 Alternator​

11.4.1 Alternator​

11.5 Distribution of electricity​

11.5.1 Voltage feed​

11.5.2 Electronic box​

11.5.3 Control units​

11.5.4 Operation, electrical system​

11.5.5 Cable harness​

11.6 Communication​

11.6.1 CAN bus​

11.6.2 Redundant CAN bus​

11.6.3 CAN bus, driveline/axle​

D Error codes
1 Engine
2 Transmission
8 Control system
9 Frame, body, cab and accessories

9.4 Heating, ventilation and air conditioning​

E Schematics
Common hydraulics
Common electrics

A49842.0100​

List of Components​

F Technical data
G Terminology and index

Terminology​

Index​