Kalmar DCE 90–180, DCE 70-32E3–70-35E4-35e4 - Workshop Manual / Repair Manual - Wiring Schematics

KALMAR DCE 90–180, DCE 70-32E3–70-35E4-35e4 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING SCHEMATICS

- English Workshop Manual / Repair Manual and Wiring Schematics, for forklift truck Kalmar DCE 90–180, DCE 70-32E3–70-35E4-35e4.
 
INDEX:

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