Kalmar DCD90, DCD180 Service Manual

4.5 (26)

Technical

Handbook

DCD90-180

DCD70-32E3 - 70-40E5

This Handbook deals with the design and maintenance of Kalmar forklift trucks, type DCD.

In addition, it gives details of troubleshooting and the most common corrective maintenance.

Operation and other matters that are primarily of interest to the operator are included in the Instruction Manual.

Kalmar Industries AB

We reserve the right to modify our design and material specifications without prior notice.

Publ. No. 920 937 – 9350 02-08

AdEra Dokument AB, Växjö 2002

00

General

 

 

10

Chassis and cab

 

 

20

Electrical system

 

 

30

Engine

 

 

40

Transmission,

 

drive axle, brakes

 

 

50

 

 

 

60

Steered axle

 

 

70

Hydraulic system

 

 

80

Lifting mast and

 

fork carriage

 

 

90

Periodic supervision

 

 

DCD90-180

Technical Handbook Contents

9350

00-11

Group 00 P. 1

Group 00

 

Contents

 

Safety regulations .....................................................................

2

General .....................................................................................

5

Applications .........................................................................

5

Design .................................................................................

6

Component units .................................................................

6

Main components ................................................................

8

Supplementary books ..........................................................

9

Replacement system – Spare parts ....................................

9

Tools ....................................................................................

9

Tightening torques .............................................................

10

System of units ..................................................................

12

DCD90-180

Safety regulations

Technical Handbook

9350

00-11

Group 00 P. 2

It is important that you read the instruction manual

Incorrect handling can lead to personal injury or damage to products and/or property. Therefore, read the instruction book very carefully before operating the truck. The instruction manual contains important information about your Kalmar truck, about the operation of the truck, about safety during operation and about the truck’s daily maintenance. In addition, you will find useful information that will make operations easier for you in your daily work.

Ask your foreman/group leader if there is anything in the manual that you do not understand or if you feel that information is missing in any area.

The symbol is used on our products in certain cases and then refers to important information contained in the instruction manual. Make sure that warning and information symbols are always clearly visible and legible. Replace symbols that have been damaged or painted over.

Safety regulations

In this handbook warnings are inserted that apply to your own safety. Warnings point out the risk of accident that can cause personal injury.

WARNING!

Warns of the risk of serious personal injury, possible death and/or serious damage to product or property if the regulations are not followed.

For technical warnings, that point out the risk of break down, the word IMPORTANT is used:

IMPORTANT!

Is used to draw attention to such occurrences that can cause damage to the product or property.

For information that facilitates the working process or handling, N.B. is used:

N.B. Draws attention to useful information that helps the working process.

DCD90-180

Safety regulations

Technical Handbook

9350

00-11

Group 00 P. 3

Safety regulations aimed at reducing the risk of personal injury and damage to loads or other property.

Intended of use

ζThe truck may only be used for the purpose for which it was intended, namely, to lift and transport goods, the weight of which does not exceed the maximum permitted load capacity of the truck.

ζThe truck may not, without specific permission from Kalmar, be modified or re-built so that its function or performance is altered.

ζThe truck may not be driven on public highways if it has not been adapted to comply with national

road safety regulations.

Operator requirements

ζThe truck may only be driven by operators who have been specially trained and who have the company’s authority to do so.

ζLaws and other regulations relating to driving licence, operator ID, log book, etc., must be followed at all times.

ζThe operator must be aware of and follow all local

safety regulations.

Operation of the truck is prohibited:

ζIf any of the fitted safety equipment, such as rear view mirrors, headlights, reversing alarm (optional) does not function correctly.

ζIf there is a fault with the brakes, steering or lift equipment.

ζIf the truck is fitted with tyres not approved by

Kalmar.

Operating regulations

ζBefore starting, always check to ensure that nobody is in the way of the truck or its equipment.

ζMake sure that nobody walks or stands underneath raised forks or other equipment, whether they are loaded or not.

ζThe operator must always face the direction of operation and take particular care in areas where persons or other vehicles are likely to appear in the vicinity. If visibility is limited by the load, the operator should operate the truck in reverse.

ζIt is prohibited to transport passengers on the truck outside the cab or on the load. Passengers may be transported inside the cab only on condition that it is equipped with a fixed passenger seat.

ζIt is prohibited to lift people if the truck is not equipped with an approved lift cage.

ζIt is prohibited to exceed the load capacity of the truck. See capacity plate and loading diagram.

ζIt is prohibited to transport loads in the raised position as this entails a risk of the truck tipping. All transportation shall take place with the load in the lowered position and with the mast tilted backwards to the maximum.

ζThe operator must adapt the speed of the truck to the character of the load, conditions of visibility, the character of the roadway/surface, etc.

ζThe operator shall avoid powerful acceleration and braking when turning. In addition, the operator shall always moderate the speed of the truck when turning so as to avoid the risk of lateral skidding or tipping.

ζThe operator shall take particular care when operating in the vicinity of electrical power lines, viaducts, quay-sides, ramps, gates/doors etc.

ζSafety belts must always be worn, if fitted. In the event of the truck tipping, always remain in the cab and grip the steering wheel securely. Never try to jump out of the cab.

ζThe parking brake can also be used as an EMERGENCY BRAKE. However, having been used for emergency braking, the brake linings must be inspected and replaced if needed. If the parking brake has been mechanically released, it must always be reset in order for the truck to regain

the parking brake function.

Interrupted operation, parking

ζAlways check that the gear lever is in the neutral position before turning the ignition key to restart or to reset an emergency stop.

ζNever leave the operator’s cab without applying the parking brake (ON position).

ζAlways remove the ignition key if the truck is to be

left unattended.

Other important points to remember

ζThe truck’s hydraulic system includes high pressure hydraulic accumulators. Always be extremely careful when working with the hydraulic system and avoid being unnecessarily close to the hydraulic equipment, lines and hoses. Before working on the hydraulic system, the accumulators must be emptied into the tank, with the help of the special accumulator evacuation valve.

ζHandle batteries and junction boxes with great care. The batteries must always be protected over the poles and connections.

ζAlways rectify any damage or wear and tear that can risk personal safety or that can affect the functions of the truck or its service life.

ζTrucks with tippable cabs: The cab must always be tipped over the point of balance. If there is insufficient lateral space the cab must always be secured against accidental lowering with a brace or similar.

ζAvoid touching oils and greases. Avoid inhaling exhaust and oil fumes.

ζWelding painted steel produces poisonous gasses. Paint should therefore be stripped before welding, good ventilation ensured and/or face

mask with filter used.

Operating with attachments

ζ The operator must always take the effect of the wind into account when handling containers. Avoid lifting with a wind strength in excess of 12 m/s (27 mph/40 feet per second).

ζ Always drive carefully so as to avoid attachments colliding with pillars, cables, etc.

ζ Carefully study the "Lift methods" section of the instruction manual.

DCD90-180

Safety regulations

Technical Handbook

9350

00-11

Group 00 P. 4

Safety instructions for working with tyres

ζTyre changing can be dangerous and should only be carried out by specially trained personnel using proper tools and procedures.

Failure to comply with these procedures may result in faulty positioning of the tyre and/or rim and cause the assembly to burst with explosive force sufficient to cause physical injury or death. Never fit or use damaged tyres or rims.

ζNever attempt to weld on an inflated tyre/rim assembly.

ζNever let anyone assemble or disassemble tyres without proper training.

ζNever run the truck on one tyre of a dual assembly. The load capacuty of a single tyre is then danger- ous-ly exceeded and operation in this manner may damage the rim.

ζDeflation and dismantling

Always block the tyre and wheel on the opposite side of the vehicle before you place the jack in position. Always crib up the blocks to prevent the jack from slipping.

Always check the tyre/rim assembly for proper component seating prior to removal from the truck.

Always deflate the tyre by removing the valve core prior to removing the complete assembly from the truck or dismantling any of the component. Before loosening mounting bolts, run a wire through the valve stem to ensure that it is not blocked. Ice or dirt can prevent all the air from escaping. Deflate and remove valve cores from both tyres of a dual assembly.

Never position body in front of the rim during deflation.

Always follow assembly and dismantling procedures outlined in the manufacturer’s instruction manual, or other reconized industry instruction manuals. Use proper rubber lubricant.

Never use a steel hammer to assembling or dismantling rim components – use a lead, brass or plastic type mallets. The correct tools are available through rim/wheel distributors.

remove bead seat band slowly to prevent accidents. support the band with your thigh and roll it slowly to the ground in order to protect back and toes.

Disassembly tools apply pressure to rim flanges to unseat tyre beads. Keep your fingers clear. Slant disassembly tool about 10 degrees to keep it firmly in place. Always stand to one side when applyin g hydraulic pressure. Should the tool slip off, it may cause fatal injury .

ζRim inspection

Check rim components periodically for fatigue cracks. Replace all cracked, badly worn, damaged and severely rusted components.

Always select the correct tyre size and construction matching the manufacturer’s rim or wheel rating and size.

Do not use over-size tyres, too large for the rims, e.g. 14.5 inch tyres with 14 inch rims or 16.5 inch tyres with 16 inch rims.

Never use damaged, worn or corroded rims/ wheels or fitting hardware. Always verify that the rim is in a serviceable conditioning.

Always clean and repaint lightly rusted rims.

Never use a rim/wheel component that can not be identified. Check rim parts against multipiece rim/wheel matching charts.

ζAssembly and inflation

It is important that the inflation equipment is equipped with a water separator to remove moist-ure from the air line in order to prevent coorosion. Check the separator periodically to ensure that it is working properly.

Make sure that the lockring is in its right position.

Never mix different manufacurer’s parts since this is potentially dangerous. Always check manu-

facturer for approval.

Never seat rings with hammering while the tyre is inflated. Do not hammer on an inflated or partially inflated tyre/rim assembly.

Always double check to ensure that the rim assemblies have been correctly assembled and that securing studs and nuts are tightened to the correct torque setting.

Never inflate tyres before all side and lockrings are in place. Check components for proper assembly after pumping to approximately 5 psi (=34 kPa, =0.34 bar)

When adding air to a tyre on an industrial truck, use a clip-on chuck and stay out of the danger area. If the tyres has been run flat then the rim must be dismantled and all parts inspected for damage.

Under-inflated tyres have a serious effect on the stability of the truck and reduces the safe load handling capacity. Always maintain tyres at the correct inflation pressures. Check inflation pressure daily. Do not over-inflate.

Inspect tyres regulary – every day if possible. Look for and remove broken glass, torn pieces of tread, embedded metal chips etc. Inspect for uneven or rapid tread wear, usually caused by mechanical irregularities, such as brakes out of adjustment or excessive toe-in and toe-out. If discovered, correct the irregularity immediately.

ζWhen installing and tightening trail wheel bolts, observe the following:

Ensure that trail wheel or hub mounting surfaces and trail wheel fastener mounting surfaces are clean and free from paint and grease.

Tighten bolts to specified torque settings. use staggered sequence; i.e. top bolt, bottom bolt etc.

DCD90-180

General

Technical Handbook

9350

00-11

Group 00 P. 5

Applications

The Kalmar DCD90-180 range of trucks is based on an entirely new approach to the design and production of medium-heavy, diesel-powered forklift trucks. The trucks are durable and safe and their accessibility for service and maintenance is unexcelled.

Due the their versatility, the trucks can be used in a number of applications, such as:

ζSteelworks and heavy engineering industry, where the trucks handle individual tasks in the handling of mediumheavy goods.

ζThe forest industry for handling logs by means of a log grapple attachment, sorting of logs at sawmills and handling of sawn timber in units loads.

ζPorts and container terminals for handling medium-heavy goods and handling empty containers.

ζFactories producing houses – lifting of house sections.

KL734

DCD90-180

DCD90-180

General

Technical Handbook

9350

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Group 00 P. 6

Design – general survey

Kalmar DCD90-180 diesel trucks are of sturdy design for heavy duty. They are built around a chassis which has high strength and torsional stiffness and an extremely low centre of gravity.

The operator’s cab is provided with vibration isolation and sound insulation and offers excellent all-round visibility.

The operator is provided with many facilities for adjusting his seating attitude. The seat, backrest and springing of the operator’s seat can be adjusted in a wide variety of ways.

The cab is tiltable and offers excellent accessibility to the transmission and pumps. The engine is easily accessible through a casing, divided in two halves.

The Volvo or Perkins six-cylinder turbocharged engine TD640VE or TD730VE/TWD731VE, combined with a three-speed gearbox with torque converter, provides smooth power whenever needed.

The drive axle with hub reductions, the oil-cooled hydraulic brake system and the pendulum-mounted steered axle with double-act- ing steering cylinder satisfy very strict demands on strength and mobility when travelling on irregular surfaces.

The hydraulic system is reliable and has high performance charged by two or three hydraulic pumps.

For further details, see group 70.

Component units

ζSound-insulated and safety-tested operator’s cab with excellent all-round visibility. The non-slip, substantial steps provide convenient access to the cab. All models in the series can be equipped with a rotatable operator’s seat.

ζClearly arranged instrument panel.

ζEngine – Volvo TD640VE or TD730VE/TWD731VE six-cyl- inder, four-stroke, turbocharged diesel engine with direct injection and thermostatically controlled water cooling.

The engine is equipped with:

Injection pump with centrifugal governor that compensate for load variations.

Alternator.

For alternatives, see separate table.

DCD90-180

General

Technical Handbook

9350

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Group 00 P. 7

ζGearbox with torque converter

Constant-mesh gearbox in which hydraulically actuated clutches for the different gears. The clutches are electrically operated.

Torque converter, which is a hydraulic coupling that amplifies the output torque on an increase in load. Torque conversion takes place smoothly and steplessly throughout the engine speed range.

Oil cooler connected to the engine cooling system for cooling the oil in the gearbox and torque converter.

Oil pump which supplies oil under pressure to the gearbox and torque converter.

Full-flow oil filter for effective cleaning of the gearbox oil.

ζDrive axle with two-stage reduction - in the differential and the hub reductions.

Oil cooled hydraulic brakes for the foot brake, e.g. Wet disc brakes.

Disc type parking brake applied by a sturdy spring and released by hydraulic oil pressure.

ζHydraulic system with

Gear type hydraulic pumps connected to take-offs on the torque converter. One pump for working hydraulics and one for steering and accumulator charging, which in turn serves the brake circuits.

Main valve for controlling the main hydraulics. The valve is controlled hydraulically from the cab. An electro-hy- draulic servo system is available as an option.

A high pressure filter after each pump for effective cleaning of the hydraulic fluid before it is fed to the system.

Steering valve (Orbitrol) - flow-control valve which supplies hydraulic fluid to the steering cylinder.

ζSteered axle with pendulum mounting and double-acting steering cylinder.

ζSturdy clear-vision mast. Of duplex or triplex design, with or without free lift.

Outer mast with hydraulically controlled 5° forward and 10° backward tilting.

Tilting cylinders with back-pressure valves to prevent the load from tilting the mast forward.

Inner mast with support rollers that carry the forces on the mast. Yoke with guide rollers for the hydraulic hoses and guide sprockets for the lifting chains.

Lifting cylinders - two cylinders mounted on the outer mast.

ζFork carriage designed for optimum visibility and equipped hydraulic with fork positioning and sideshifting (optional).

Kalmar DCD90, DCD180 Service Manual

DCD90-180

General

Technical Handbook

9350

00-11

Group 00 P. 8

1

2

3

 

7

KL734

1.Free -visibility mast, with two lifting cylinders

2.Operator’s cab, rubber suspended cab

3.Engine, six-cylinder diesel engine with turbo-compressor

4.Steering axle, with pendulum suspension and double acting steering cylinder

6

5

4

5.Gearbox, combined with torque converter

6.Drive axle, with hub gearing and oil-cooled hydraulic brake

7.Fork carriage, hydraulically controlled fork positioning and sideshift

Main component units

DCD90-180

General

Technical Handbook

9350

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Group 00 P. 9

Main components

Alternative drive lines

 

6-90

6-100

12-100

6-120

6-136

12-120

12-150

6-160

9-160

12-160

6-180

 

 

 

 

 

 

 

 

 

 

 

 

= Standard = Optional

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine

*Turbo **Turbo, intercooler

 

 

 

 

 

 

 

 

 

 

 

Volvo TD640VE*

 

129 kW/690 Nm

 

 

 

 

 

 

 

 

 

 

 

Perkins 1006-60T1*

 

85 kW/465 Nm

 

 

 

 

 

 

 

 

 

 

 

Volvo TD730VE*

 

150 kW/800 Nm

 

 

 

 

 

 

 

 

 

 

 

Volvo TWD731VE**

 

167 kW/893 Nm

 

 

 

 

 

 

 

 

 

 

 

Perkins 1006-60T2*

 

114 kW/620 Nm

 

 

 

 

 

 

 

 

 

 

 

Scania DI9**

 

167 kW/930 Nm

 

 

 

 

 

 

 

 

 

 

 

Cummins 6BTA5.9-C200**

162 kW/814 Nm

 

 

 

 

 

 

 

 

 

 

 

Gearbox with powershift, 3+3 gears

 

 

 

 

 

 

 

 

 

 

 

Clark 13.7HR 28000

 

 

 

 

 

 

 

 

 

 

 

 

(Volvo TD640VE, TD730VE,

 

 

 

 

 

 

 

 

 

 

 

 

Perkins 1006-60T2, Cummins 6BTA)

 

 

 

 

 

 

 

 

 

 

 

Clark 1207 FT 20302

 

 

 

 

 

 

 

 

 

 

 

 

(Perkins 1006-60T1)

 

 

 

 

 

 

 

 

 

 

 

 

 

Clark 13.7HR 32000

 

 

 

 

 

 

 

 

 

 

 

 

(Volvo TD640VE, TD730VE, Volvo TWD731VE,

 

 

 

 

 

 

 

 

 

 

 

Scania DI9, Cummins 6BTA)

 

 

 

 

 

 

 

 

 

 

 

 

Drive axle with Wet Disc Brakes

 

 

 

 

 

 

 

 

 

 

 

Pneumatic tyres

10.00x20ÆÆ/16PR

 

 

 

 

 

 

 

 

 

 

 

 

11.00x20ÆÆ/16PR

 

 

 

 

 

 

 

 

 

 

 

 

12.00x20ÆÆ/20PR

 

 

 

 

 

 

 

 

 

 

 

Optional: Semi-solid tyres (Super-Elastic)

 

 

 

 

 

 

 

 

 

 

 

Supplementary books

In addition to the Instruction Manual and the Technical Handbook, the following books are delivered with every truck.

Spare parts catalogue

Instruction Manual for Volvo Industrial engines

Workshop Manual for Industrial engines

Workshop Manual for the Perkins engine

Replacement system - Spare parts

Kalmar operates a system of replacement parts, repair kits and gasket sets covering most of the vital components of the truck.

For the contents of these kits, see the Spare parts catalogue.

Tools

Kalmar offers a wide range of tools for truck maintenance work.

For further information, please contact Kalmar’s service department.

DCD90-180

General

Technical Handbook

9350

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Group 00 P. 10

Tightening torques

The tightening torques are applicable to steel bolts and nuts tightened with a torque wrench under the following conditions:

 

Surface treatment

 

Condition

 

 

Lubriation

 

 

 

 

 

Bolt

Nut

 

 

 

 

 

1

untreated

untreated

oiled

 

 

 

 

 

bright galvanised

untreated

 

2

bright galvanised

bright galvanised

dry or oiled

 

bright galvanised

bright galvanised

 

 

 

 

 

3

hot-dip galvanised

bright galvanised

dry or oiled

 

 

 

 

The values specified in Table 1 are applicable to nut-and-bolt joints, but can also be used for bolts fitted into tapped holes. However, in the latter case, the preloading force will be somewhat lower, depending on its depth of engagement.

When tightening by machine, the torque specified in Table 1 should be reduced by approx. 5%, due to the increased scatter and to prevent the bolt from being tightened beyond its yield point.

Quality

 

8,8

 

10,9

12,9

 

 

 

 

 

 

 

Tightening torque, Nm

 

 

 

 

Condition

 

 

 

 

 

 

 

 

Thread

 

 

 

 

 

M fin

1

2

3

1

1

 

 

 

 

 

 

M8×1

27

24

30

39

46

M10×1,25

54

48

61

76

91

M12×1,25

96

85

108

135

162

M16×1,5

230

205

260

323

388

M18×1,5

330

294

373

466

559

M20×1,5

460

409

520

647

777

M24×2

786

700

888

1100

1330

M30×2

2660

1388

1763

2200

2640

M36×3

1560

2367

3005

3730

4480

 

 

 

 

 

 

DCD90-180

General

Technical Handbook

9350

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Group 00 P. 11

To reduce the risk of settlement of the material and the associated reduction in the preloading force if the hardness of the surface supporting the bolt head or nut is lower than 200 HB, a washer should be fitted under the bolt head and nut. This is not applicable if flanged bolts or flanged nuts are used.

When tightening is carried out, the specified torque should be applied without pause, to ensure that the torque wrench will not be tripped by the static friction before the joint has been tightened to the specified torque.

Quality

 

8,8

 

10,9

12,9

 

 

 

 

 

 

 

Tightening torque, Nm

 

 

 

 

Condition

 

 

 

 

 

 

 

 

Thread

 

 

 

 

 

M

1

2

3

1

1

 

 

 

 

 

 

4

3,2

2,9

3,6

4,6

5,5

5

6,4

5,7

7,2

9,1

11

6

11

9,8

12,5

16

19

8

26

24

30

38

45

10

52

47

59

74

89

12

91

81

103

128

154

16

220

198

250

313

375

20

430

386

49

620

732

24

750

668

848

1050

1270

30

1480

1317

1672

2080

2500

 

 

 

 

 

 

 

 

 

 

 

 

Quality

 

8,8

 

10,9

12,9

 

 

 

 

 

 

 

Tightening torque, Nm

 

 

 

 

Condition

 

 

 

 

 

 

 

 

Thread

 

 

 

 

 

UNC

1

2

3

1

1

 

 

 

 

 

 

1/4

12,5

11,1

14,1

17,6

20

5/16

25

22,3

28,3

35

42

3/8

44

39

50

62

73

7/16

70

62

79

100

118

1/2

107

95

121

151

178

9/16

153

136

173

216

255

5/8

210

187

237

298

353

3/4

370

390

418

524

619

7/8

594

528

671

839

990

1

889

791

1005

1260

1480

1 1/8

1260

1120

1424

1780

2100

1 1/4

1760

1565

1990

2490

2940

1 3/8

2320

2065

2620

3280

3870

1 1/2

3060

2720

3455

4320

5100

 

 

 

 

 

 

DCD90-180

General

Technical Handbook

9350

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Group 00 P. 12

Quality

 

8,8

 

10,9

12,9

 

 

 

 

 

 

 

Tightening torque, Nm

 

 

 

 

Condition

 

 

 

 

 

 

 

 

Thread

 

 

 

 

 

UNF

1

2

3

1

1

 

 

 

 

 

 

1/4

13

11

14

19

22

5/16

26

23

29

37

44

3/8

47

42

53

67

79

7/16

75

66

85

107

126

1/2

114

101

128

162

191

9/16

164

145

185

231

273

5/8

227

202

256

321

379

3/4

396

352

447

559

661

7/8

629

560

710

889

1050

1

937

834

1058

1320

1560

1 1/8

1350

1200

1525

1900

2250

1 1/4

1860

1655

2100

2630

3110

1 3/8

2500

2225

2825

3530

4170

1 1/2

3260

2900

3680

4610

5450

 

 

 

 

 

 

System of units

The SI system of units is employed in this handbook: The conversion factors are as follows:

Pressure

megapascal

bar

Kilogram-force per

Pound-force

 

 

 

square centimetre,

per square

 

 

 

kpf/cm²

inch,

 

 

 

Atmosphere, at

psi

 

 

 

 

 

 

1

10

10,2

145

 

0,1

1

1,02

14.5

 

0,098

0,98

1

14.2

 

 

 

 

 

 

Torque

 

 

 

 

Newton-

Kilogram force-metre

Pound-force foot

 

meter

kgf m

lbf ft

 

Nm

 

 

 

 

 

 

 

 

1

0,102

0.74

 

9,81

1

 

7.23

 

 

 

 

 

 

Power

 

 

 

 

 

 

 

 

Kilowatt

Horsepower (metric)

Horsepower

 

kW

hp

 

hp

 

 

 

 

 

 

1

1,36

 

1.34

 

0,735

1

 

0.986

 

 

 

 

 

 

DCD90-180

Technical Handbook Contents

9350

00-11

Group 10 P. 1

Group 10

Chassis and cab

Specifications ...........................................................................

2

Chassis......................................................................................

3

Description ...........................................................................

3

Operator’s cab ...........................................................................

4

Description ...........................................................................

4

Steering column ..............................................................

7

Pump and cylinder for cab tilting .....................................

8

Accelerator pedal with change-over switches for

 

forward and reverse ........................................................

9

Gear selector type RMH................................................

10

Hydraulic weight indicator .............................................

11

Service ...............................................................................

12

Changing the fresh air filter ...........................................

12

Check and lubrication of brake pedal ............................

12

Windscreen wipers ........................................................

13

Air conditioning unit .................................................................

14

Description .........................................................................

14

Service ...............................................................................

17

Checking the air conditioning unit .................................

17

DCD90-180

Specifications

Technical Handbook

9350

00-11

Group 10 P. 2

Air conditioner

ζ

Cab unit

500-600 m3/h

 

Circulated air flow

 

Electric power consumption

approx 350 W

ζ

Compressor

 

 

Max. speed

4000 r/min

 

Refrigerant

R134a *)

 

Electric power consumption

approx 50 W

 

Oil capacity Zexel PAG SP-20

1.5 dl

ζCondenser

 

Electric power consumption

250 W

ζ

Cooling effect

6-8,5 kW

ζ

Heating effect

approx 11 kW

*) Refrigerant R12 is no longer in production due to legislation

DCD90-180

Chassis

Technical Handbook

Description

9350

00-11

Group 10 P. 3

Chassis

The chassis consists of:

ζA unit construction frame built up around two beams with a minimum of welds for best possible strength.

ζMountings for the drive axle, steered axle, mast, lifting cylinders and transmission.

ζThe necessary counterweights to provide a very low centre of gravity. Moreover, the steered axle is designed to serve as an additional counterweight.

ζThe hydraulic oil tank and the fuel tank are produced as separate units and are bolted to the side of the chassis. The tanks have a low profile, which contributes to the good visibility.

1

2

3

4

1.Hydraulic tank

2.Counterweights

3.Service hatch for the battery

4.Fuel tank

Chassis 90-180

DCD90-180

Operator’s cab

Technical Handbook

Description

9350

00-11

Group 10 P. 4

Operator’s cab

The operator’s cab is a separate structure and rests on the chassis on rubber dampers. The operator’s seat, steering wheel and hydraulic control levers can be adjusted for best possible operator comfort. Effective insulation minimises the vibrations and sound level in the cab.

The standard heating system consists of a fan and heater for heating the air in the cab by recirculation. Fresh air is drawn in through a ventilation air filter. Full air conditioning, with cooling, heating and dehumidification, is available to special order.

1

4

2

3

1.Steering column with instrument panel and switches, ECS-terminal (option)

2.Air filter

3.Heating system

4.Electrical central unit

DCD90-180

 

 

 

Operator’s cab

 

 

 

 

 

 

9350

 

 

 

 

 

 

 

 

 

00-11

Technical Handbook

 

 

 

Description

 

 

 

 

 

 

 

 

 

 

 

 

Group

10

P. 5

 

3

1

 

4

 

 

 

5

2

6

 

 

 

 

 

 

 

F

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

N

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

L

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

R

 

 

 

 

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R

 

a

b

c

 

 

 

 

 

 

 

 

1

4

5

 

d

 

 

 

 

 

 

 

2

3

 

 

 

 

 

KL735

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7

8

9

 

 

10

11

12

13

14

 

 

 

 

 

KL743

 

 

 

 

 

 

 

 

 

 

 

 

1.

Gear selector

 

 

 

 

 

7. Electrical central unit with fuses and relays

 

 

 

FORWARD/NEUTRAL/REVERSE 1/2/3

 

 

 

 

8. Brake pedals, normal driving brake

 

 

 

 

2.

Lever DIRECTION INDICATORS/HORN

 

 

 

 

9. Release clutch

 

 

 

 

 

 

 

FRONT WINDSCREEN WASHER/

 

 

 

 

10. Accelerator pedal

 

 

 

 

 

 

FRONT WIPERS/MAIN BEAM

 

 

 

 

11. Steering wheel adjustment

 

 

 

 

 

3.

Instrument panel

 

 

 

 

 

12. Stop control

 

 

 

 

 

 

4.

Steering wheel panel

 

 

 

 

 

13. Parking brake

 

 

 

 

 

 

5.

Starting switch

 

 

 

 

 

14. Operator’s seat

 

 

 

 

 

 

6.

Control lever, hydraulic functions

 

 

 

 

 

 

 

 

 

 

 

 

 

a. Lift, b. Tilt, c. Sideshift, d. Fork positioning

 

 

 

 

 

 

 

 

 

 

 

DCD90-180

Operator’s cab

Technical Handbook

Description

9350

00-11

Group 10 P. 6

21

22

23

 

 

 

 

KL581

 

 

 

 

34

35

36 37 38 39

 

 

 

 

 

 

 

30 31 32

33

 

40 41 42 43 44 45 46

52

53

 

 

 

 

 

 

 

 

 

 

29

 

28

 

27

 

26

 

25

24

47 48 49 50 51

54 55 56 60 59

 

KL582

66

1 2

3 4

F

N

L

0

R

KL580

 

 

 

 

R

 

 

 

1

2

3

 

 

 

4

5

 

 

57

58

64

61

62

63

21.Pressure gauge, gearbox oil pressure

22.Fuel gauge

23.Temperature gauge, engine coolant temperature

24.Switch, working lights

25.Switch, working lights

26.Switch, working lights

27.Switch, flashing beacon

28.Switch, hazard warning lights

29.Switch, driving lights

30.Spare

31.Spare

32.Spare

33.Spare

34.Switch, compressor air conditioning 1)

35.Control, recirculation/fresh air

36.Control, defrost/cab

37.Switch, fan

38.Control, heat

39.Control, cold 1)

KL675

40.Spare

41.Spare

42.Warning lamp, battery charging

43.Warning lamp, low engine oil pressure

44.Warning lamp, low gearbox oil pressure

45.Warning lamp, low brake pressure (accumulator pressure)

46.Warning lamp, low engine coolant level

47.Indicating lamp, preheating

48.Warning lamp, high engine coolant temperature

49.Warning lamp, high gearbox oil temperature

50.Spare

51.Warning lamp, parking brake ON

52.Spare

53.Spare

54.Spare (Green lamp TWIST-LOCKS LOCKED) 1)

55.Spare (Orange lamp ALIGNMENT) 1)

56.Spare (Red lamp TWIST-LOCKS UNLOCKED) 1)

57.Spare (LOCK/UNLOCK TWIST-LOCKS) 1)

58.Spare (LENGT ADJUSTMENT 20-40’) 1)

59.Indicating lamp, headlights

60.Indicating lamp, direction indicators

61.ECS terminal 1)

62.Switch, windscreen wiper, rear

63.Switch, windscreen wiper, roof

64.Spare

65.Fuses

66.Hour meter

1) Optional

DCD90-180

Technical Handbook

1 2

3 4

1

1.Gear lever

2.Multi-function lever

3.ECS terminal

4.Steering wheel adjustment handles

5.Angled gear

6.Orbitrol steering valve

Operator’s cab

 

 

 

 

9350

 

 

 

 

 

 

 

00-11

Description

 

 

 

 

 

 

 

Group 10

P. 7

Steering column

Surrounding the steering column are multi-function levers for gear changing, indicators, windshield wipers, etc., as well as the instrument panel with the ECS terminal. At the very foot of the steering column is the steering valve (Orbitrol), activated by the steering wheel via an angled gear. The steering column is equipped with an adjustment handles for the alteration of steering wheel height and rake.

F

N

L

0

R

R

1 2 3

2

4 5

3

KL580A

4

KL588

6

5

Steering column

DCD90-180

Operator’s cab

Technical Handbook

Description

9350

00-11

Group 10 P. 8

Pump and cylinder for cab tilting

A hydraulic cylinder is provided for tilting the cab. The hydraulic fluid pressure for this purpose is generated by a manually operated pump. The pump is fitted with a reversing valve for upward or downward tilting.

1

2

3

2

4

1.Cab tilting cylinder

2.Manual pump

3.Vibration damper

4.Cab tilting cylinder

Pump and cylinder for cab tilting

DCD90-180

Operator’s cab

Technical Handbook

Description

9350

00-11

Group 10 P. 9

3

4

1

2

1.Push-button, reverse gear

2.Push-button, forward gear

3.Microswitch

4.Engagemant and disenagagement of the foot operated gear changing system

Accelerator pedal with change-over switches for forward and reverse

DCD90-180

Operator’s cab

 

9350

 

00-11

Technical Handbook

Description

 

Group 10

P. 10

 

 

Gear selector type RMH

DCD90-180

Operator’s cab

 

 

9350

 

 

00-11

Technical Handbook

Description

 

 

Group

10

P. 11

 

1

 

 

 

 

 

4

 

 

 

3

 

 

 

2

 

 

 

 

1.

Indicator scale in the cab

 

 

 

2.

Tank connection to the brake valve connecting block

 

 

 

3.

Foot switch for weighing

 

 

 

4.

Connection to the main valve LIFT section

 

 

 

 

 

Hydraulic weight indicator

DCD90-180

Operator’s cab

Technical Handbook

Service

9350

00-11

Group 10 P. 12

Changing the fresh air filter

(every 200 hours or when needed)

1.Remove the filter casing retaining bolts and remove the filter element.

2.Wash the filter insert with water and detergent or by using a high pressure washer. Replace the insert if necessary.

3.Reinstall the filter insert.

1

2

 

3

 

4

1.

Brake pedal

2.

Lubricating nipple

3.

Locking screw

4.

Shaft

Check and lubrication of brake pedal

(every 1000 hours)

1.Check and tighten the locking screws 3, so that the brake pedal is securely fitted in the console.

2.Lubricate the brake pedal shaft through the nipples 2.

DCD90-180

Operator’s cab

Technical Handbook

Service

9350

00-11

Group 10 P. 13

1

2

3 4

Windscreen wipers

The wiper arms are fixed to the wiper motor shafts via conical splines. The shafts are manufactured of hardened steel and the wiper arm mounting of soft, pressed metal. When fitting, the nuts must be tightened so hard that the splines are pressed well into the mounting and function as a carrier.

Removal

1.Remove the wiper arms by loosening the nuts and thereafter tapping and carefully rocking the arms to and fro.

Fitting

1.Check to ensure that the splines on the motor shaft are free from the softer material from the wiper arm mounting.

If this is not the case, clean the splines so that they can pressed fully into the wiper arm mounting.

2.Fit the wiper arms onto the motor shafts and tighten the nuts to a torque of 16-20 Nm.

Hold the wiper arm to take up the torque pressure so that it is not transferred to the motor, which could result in damage

.

IMPORTANT!

The nuts must be tightened sufficiently hard, otherwise the shafts may start to slip inside the wiper arm mounting, resulting in damage.

1.Wiper arm fitting

2.Securing nut, wiper arm

3.Grooved cone on motor shaft

4.Wiper motor

DCD90-180

Air conditioning unit

Technical Handbook

Description

9350

00-11

Group 10 P. 14

Air conditioning unit

The air conditioning unit consists of the parts shown in the illustration and its function is to maintain the climate in the ope-ra- tor’s cab as comfortable as possible. The air conditioning unit:

ζheats the air when it is cold

ζdehumidifies the air when it is humid

ζremoves impurities from the air

ζcools the air when it is warm

The equipment is steered by switches and controls on the instrument panel.

5

6

1

4

3

8

9

7

2

15 16

12

14

10

1.

Heating control

 

2.

Heat exchanger

 

3.

Vapourizer

 

4.

Expansion valve

 

5.

To condenser

11

6.

To compressor

 

7.

Heating valve

13

8.

From engine

9.To engine

10.Fan

11.Fan

12.Fan control

13.Fresh air filter

14.Air disperser

15.Control defrost/cab

16.Defroster outlet

The heating and ventilating system

DCD90-180

Air conditioning unit

Technical Handbook

Description

9350

00-11

Group 10 P. 15

F

2

4

D

 

C

 

 

 

E E

3

7

A

 

B

 

 

 

 

 

 

 

 

 

 

 

 

 

6

1

G

1.

Liquid receiver/filter dryer

A

High-pressure gas

2.

Evaporator

B

High-pressure liquid

3.

Fan

C

Low-pressure liquid

4.

Expansion valve

D

Low-pressure gas

6.

Condenser

E Warm air in cab

7.

Compressor

F

Cooled air to the cab

G Outside air for removing heat

DCD90-180

Air conditioning unit

Technical Handbook

Description

9350

00-11

Group 10 P. 16

Compressor

The air conditioning system is driven by the compressor. This performs as a pump, drawing cold, low-pressure gas from the evaporator, compressing it and thereby raising its temperature, and discharging it at high pressure to the condenser.

The compressor is driven by V-belts directly from the diesel engine. Switching between operation and idling is controlled by an electro-magnetic clutch which, in turn, is controlled by a thermostat whose sensor is located between the fins of the evaporator coil. The thermostat switches off the compressor at low temperatures, to prevent icing of the evaporator.

Condenser

The function of the condenser is to convert the hot high-pressure gas from the compressor into liquid form. The tubes and fins of the condenser coil absorb heat, which is then removed by the air delivered by the fan.

The temperature of the refrigerant in the condenser varies from about +50°C to +70°C. The pressure varies between 12 and 20 bar, depending on the ambient temperature and the flow of air through the condenser. When the refrigerant is condensed into liquid form, it is transferred under pressure to the liquid receiver/ filter dryer.

Liquid receiver with filter-dryer

The function of the liquid receiver with integrated filter dryer is to collect the liquid coolant, bind the moisture, and to filter and remove impurities. The receiver, which is located in the condenser housing, also serves as the expansion vessel in the refrigeration circuit.

After flowing through the dryer in the bottom of the liquid receiver, the refrigerant flows through a riser tube. A sight glass enables the operator to check that the liquid flows without the presence of any bubbles, and that the system is filled with a sufficient amount of refrigerant.

Expansion valve

The expansion valve throttles the flow and passes an optimised quantity of refrigerant that the evaporator is capable of evaporating.

The expansion valve is also the part of the circuit which separates the highpressure side from the low-pressure side. The refrigerant flows to the expansion valve under high pressure and leaves it under low pressure.

The amount of refrigerant which passes the evaporator varies, depending on the thermal load. The valve operates from ’fully open’ to ’fully closed’ and in-between searches for a point to give optimum evaporation.

Evaporator

The heat necessary for evaporating the refrigerant is extracted from the cab air which is circulated by a fan through the evaporator coil. The cab air is thus cooled, and is distributed and returned to the cab.

In the evaporator, the refrigerant reverts to the gaseous state and returns to the compressor suction, thereby completing the cycle.

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