Kalmar DCE90 180 Forklift Trucks Service & Repair Workshop

A Foreword B Safety C Preventive maintenance 0 Complete machine 1 Engine 2 Transmission 3 Driveline/axle 4 Brakes 5 Steering 6 Suspension 7 Load handling 8 Control system 9 Frame, body, cab and accessories 10 Common hydraulics 11 Common electrics 12 Common pneumatics D Error codes E Schematics F Technical data G Terminologi och Index Workshop manual

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006 - A Foreword 1 A Foreword mm mm mm mm mm mm Table of Contents A Foreword A Foreword ..................................................................................................... 3 About the Workshop Manual ...................................................................... 3 General ............................................................................................................. 3 Conditions ......................................................................................................... 3 Storage .............................................................................................................. 3 About the machine version ................................................................................ 3 Copyright ........................................................................................................... 3 Reading instructions ................................................................................... 4 Warning information .......................................................................................... 4 Important information ........................................................................................ 4 Read operator’s manual .................................................................................... 4 Read maintenance manual ............................................................................... 4 Workshop manual contents ............................................................................... 5 Function group structure ................................................................................... 6 References between different information types ............................................... 7 Product alternatives and optional equipment .................................................... 8 Machine card ..................................................................................................... 9 Function descriptions ...................................................................................... 10 About the documentation ......................................................................... 13 Documentation sections .................................................................................. 13 Ordering of documentation .............................................................................. 13 Feedback .................................................................................................. 14 Form for copying ............................................................................................. 14

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006 - 2 A Foreword

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006 - A Foreword – A Foreword 3 mm mm mm mm mm mm A Foreword About the Workshop Manual page – General Thank you for choosing Cargotec as your machine supplier. We hope that we'll meet your expectations. page – Conditions The instructions are based on the use of generally available standard tools. All lifting devices, for example, slings, straps, ratchet blocks, etc., must meet governing national standards and regulations for lifting devices. Cargotec will not accept any responsibility for modifications performed without permission from Cargotec or if other lifting devices, tools or work methods are used other than those described in this manual. page – Storage NOTE The Workshop Manual should be accessible to the service per- sonnel. page – About the machine version The information in this publication corresponds to the machine's design and appearance at the time of delivery from Cargotec. Due to cus- tomizations, there may be variations and/or deviations. Cargotec reserves the right to modify specifications and equipment without prior notice. All information and data in this manual are valid at the time of publication. page – Copyright Cargotec Sweden AB Duplication of the content in this manual, in whole or in part, is strictly prohibited without written permission from Cargotec Sweden AB. Duplication by any means such as copying, printing, etc., is prohibited. DANGER External equipment may only be used if it is approved by Cargotec. Risk of fatal accidents and property damage! Only used equipment approved by Cargotec.

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006 - 4 A Foreword – Reading instructions Reading instructions page – Warning information Warnings inform on potential dangers which can, if the warnings are not heeded, result in personal injury or product damage. page – Important information Important information marked with NOTE facilitates the work process, operation/handling or increases understanding of the information. NOTE Information that is important without being safety related. page – Read operator’s manual Read the operator’s manual The symbol to the left is used in certain cases on the machine and re- fers to important information in the operator’s manual. page – Read maintenance manual Read the maintenance manual The symbol to the left is used in certain cases on the machine and re- fers to important information in the maintenance manual. DANGER Situation that may result in serious personal injury, possible death, if the instruction is not followed. WARNING Situation that may result in serious personal injury if the instruction is not followed. CAUTION Situation that may result in damage to the product if the instruction is not followed. 000262 001128

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006 - A Foreword – Reading instructions 5 page – Workshop manual contents The Workshop Manual contains information to facilitate maintenance (part replacement) and is a supplement to the Maintenance Manual. The supplier documentation for engine, transmission and drive axle also supplements the Workshop Manual. If possible, the Workshop Manual provides reference to supplier documentation instead of printing the same information twice. Methods for preventive maintenance and certain checks are found in the Maintenance Manual; no references are given. Use the function groups to locate the information in the Maintenance Manual. The Workshop Manual is divided into the following sections: A Foreword General information about the workshop manual's purpose, contents and reading instructions as well as survey for feedback of views and any inaccuracies. B Safety Keep in mind for your safety. C Preventive maintenance Reference to maintenance manual: Preventive maintenance. 0 Complete machine Technical description, comprehensive function descriptions and a description of the function of components included in the machine, divided into function groups. The components used for each function are described under each subfunction. Consequently, common components are described in several places, but in general under the first function to use the component. Together with the general description is a detailed description of what is unique about the specific subfunction. The next subfunction to use the same component only has a description what is unique for the new function. Work instructions for corrective maintenance (replacement of components). 1 Engine 2 Transmission 3 Driveline/axle 4 Brakes 5 Steering 6 Suspension 7 Load handling 8 Control system 9 Frame, body, cab and accessories 10 Common hydraulics 11 Common electrics 12 Common pneumatics D Error codes Error code information and instructions for reading error code information. E Schematics Wiring and hydraulic diagrams F Technical data Technical data, conversion tables, information for conversion of units. G Terminology and index General terminology and abbreviations, explanation of terms and abbreviations that can appear in the sections, index for headings in the sections.

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006 - 6 A Foreword – Reading instructions page – Function group structure The information in the manual is divided in a structure of functions at different levels, based on the machine’s design and use, called function groups. The upper level (called main group) determines area, e.g., group 7 Load handling. The second level (called two-digit) determines function, e.g., 7.2 Lifting and lowering. The third and fourth levels are used to break down functions in smaller parts (components). The main group and two-position group level structure for the function groups is used for all Cargotec machines, e.g. 4.3 Power-assisted brake system. Machine-specific function group adaptations are done and the third and fourth group level, e.g. 4.3.9 Wheel brake and 4.3.9.1 Disc assembly. Function groups (headings) are only included in the documentation of a machine if the machine has that function or component. Thus, there may be gaps in function group numbering (e.g. the three-position heading level 4.8.7 Oil cooler is included for some machines but not for others). The function groups are intended to be used as search terms to find different types of information between different sections and manuals. The information in a function group is divided in smaller sections according to the type of content, e.g., description or change. The maintenance manual and Workshop manual contain different information. The maintenance manual contains only the information needed for preventive maintenance and simpler troubleshooting. The Workshop manual contains more in-depth information and repair instructions. References between sections in the same manual are indicated with section and group number, e.g., "see section 4 Brakes, group 4.3.9 Wheel brake ". References within a section are indicated with a page number, e.g., "see Sensor fuel level, description page 24 ". There are no references between the Maintenance Manual and Work- shop Manual. If more information on a function group is required, search under the same function group in the other manual. For more in-depth information on where different types of information are locat- ed and what references are made, see References between different information types page 7.

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006 - A Foreword – Reading instructions 7 page – References between different information types The maintenance manual and workshop manual are mainly divided into function groups, see Workshop manual contents page 5. Certain parts are broken out as separate parts to increase usability, e.g., "Technical data". The basic rule of searching for information is to use function groups to find different types of information regarding the function or component in question. As a complement to this, there are references according to the below. • From Function description to Component description, to enable fast finding of more information about the different components that create a function. • From Function description to Hydraulic diagram, to enable fast finding of the right hydraulic diagram for the function in question. • From Component description or Function description to Diagnos- tics, to enable fast finding of the right diagnostic menu that can be used to check the component (only applies to electrical components). • From Diagnostics to Schematics. to enable fast finding of the right circuit diagram for further troubleshooting. • From Diagnostics to Component description or Function description. To enable fast finding of more information about the component's appearance and position when troubleshooting. • From Error codes to Diagnostics, to enable fast finding of the right diagnostic menu to troubleshoot component or function in question. • From Error codes to Function description or Component description, to enable fast finding of more information about components or function. Function descriptions (Technical description) Hydraulic diagrams (Section E) Component descriptions (Technical description, usually in Workshop manual) Error codes (Section D) Diagnostics (Group 8.4) Schematics (Section E)

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006 - 8 A Foreword – Reading instructions page – Product alternatives and optional equipment The information in the manual is divided in modules. For product alternatives and optional equipment, handling of the modules differs de- pending on if it is the one or the other that is described, see below. Special equipment is not described in the manual. If you’re uncertain about what equipment the machine should have, use the machine card to decide which information applies, see Machine card page 9. Product alternative Product alternatives are such options that exclude certain standard equipment (e.g., engine alternative). Equivalent information for different product alternatives are described consecutively in separate segments within the same function group. To indicate that there are different alternatives, "Product alternative" is added to the heading together with a simple description of the alternative, e.g. "(Product alternative Climate control system ECC)". In addi- tion, the alternative that is an option is marked with the symbol for optional equipment. Symbol indicating optional equipment Optional equipment Optional equipment are options that can be added to the standard equipment to obtain additional or improved functions. Information for optional equipment is described in separate sections with standard equipment as the starting point. The description of the optional equipment describes how the standard function is affected by the option as well as which components are added. 000264

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Kalmar DCE90 180 Forklift Trucks Service & Repair Workshop

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