DCD200-3000,2006 Maintenance Manual

A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Maintenance
manual 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 Terminology and index

A Foreword 1
A Foreword
Table of Contents A Foreword

mm mm mm mm mm mm
Foreword......................................................................................................... 3
About the Maintenance 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
Maintenance manual's content .......................................................................... 5
Function group structure ................................................................................... 6
Product alternatives and optional equipment .................................................... 7
Machine card ..................................................................................................... 8
Function descriptions ........................................................................................ 9
About the documentation ......................................................................... 12
Documentation sections .................................................................................. 12
Ordering of documentation .............................................................................. 12
Feedback .................................................................................................. 13
Forms for copying ............................................................................................ 13
Maintenance manual DCD 200–300, 2006 - UDCD01.02GB

2 A Foreword
UDCD01.02GB Maintenance manual DCD 200–300, 2006 -

A Foreword – Foreword 3
Foreword
mm mm mm mm mm mm
About the Maintenance Manual

General
page
–
Thank you for choosing Kalmar Industries as your machine supplier.

We hope that we'll meet your expectations.
This maintenance manual contains information about how the ma-
chine should be maintained for maximal operating reliability and serv-
ice life as well as troubleshooting information for fast correction of any
malfunctions.
Conditions
page
–
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.
Kalmar Industries will not accept any responsibility for modifications
performed without permission from Kalmar Industries or if other lifting
devices, tools or work methods are used other than those described in
this manual.
Storage
page
–
NOTE
The maintenance manual shall be accessible to service person-
nel.
About the machine version

page
–
The information in this publication corresponds to the machine's de-

sign and appearance at the time of delivery from Kalmar Industries.
Due to customizations, there may be variations and/or deviations.
Kalmar Industries 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.
Copyright
page
–
Kalmar Industries AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Kalmar Industries AB.
Duplication by any means such as copying, printing, etc., is prohibited.

4 A Foreword – Reading instructions
Reading instructions
Warning information
page
–
Warnings inform on potential dangers which can, if the warnings are

not heeded, result in personal injury or product damage.
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.
Important information
page
–
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.
Read operator's manual

page
–
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the operator’s manual.
000262
Read the operator's manual
Read maintenance manual

page
–
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the maintenance manual.
001128
Read the maintenance manual

A Foreword – Reading instructions 5
Maintenance manual's content

page
–
The information in the maintenance manual is divided in function

groups (0-12) to facilitate information searches. The manual is divided
in 20 sections A-C, 0-12, D-G. The sections with letters contain specif-
ic information that applies to several function groups and is not bound
to a function, e.g., section "F Technical data". This is described in
greater detail in the table below.
For more information on function groups, see Function group structure
page 6.
A Foreword General information about the maintenance manual's purpose, content and read-
ing instructions as well as survey for feedback of views and eventual inaccuracies.
B Safety Keep in mind for your safety.
C Preventive maintenance General information about preventive maintenance of the machine.
0 Complete machine
1 Engine
2 Transmission
3 Driveline/axle
4 Brakes
Technical description, description of the machine's functions with schematic
5 Steering
drawings and explanatory texts for the included components.
6 Suspension Overviews with the components' position on the machine.
7 Load handling Work instructions for preventive maintenance.
8 Control system Work instructions for checking and adjusting.
9 Frame, body, cab and accesso-

ries
11 Common electrics
12 Common pneumatics
D Error codes Error code information please refer to Operator’s manual and
Workshop manual
E Schematics Wiring and hydraulic diagrams please refer to Workshop manual
F Technical data Technical data, conversion tables, information for conversion of units.
G Terminology and index General terminology and abbreviations, explanations of terms and abbreviations
that may appear in the manual, index for headings in the manual.

Function group structure

page
–
The information in the manual is divided in a structure of functions at

different levels, based on the machine's design and use, called func-
tion groups.
The upper level (called main group) determines area, e.g., group 7
Load handling. The second level (called two-digit) determines func-
tion, e.g., 7.2 Lift and lower. The third and fourth levels are used to
break down functions in smaller parts (components).
The function groups' structure for main group and two-digit group level
are common for all machines from Kalmar Industries, e.g., 4.3 Servo
brake system. Machine-unique adaptations of functions are done at
the third and fourth group level, e.g., 4.3.9 Wheel brake and 4.3.9.1
Disc pack. This means that certain function groups (headings) will be
left out in the documentation for certain machines since the machine
is missing that specific function or component. In turn, this means that
there may be skips in the function groups' numbering (e.g., the three-
digit heading level 4.8.7 Oil cooler may be included for some ma-
chines, but is missing 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 ac-
cording to the type of content, e.g., description or change.
The maintenance manual and Workshop manual contain different in-
formation. The maintenance manual contains only the information
needed for preventive maintenance and simpler troubleshooting. The
Workshop manual contains more in-depth information and repair in-
structions.
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 page
number, e.g., "see Sensor fuel level, description page 24".
References between Maintenance manual and Workshop manual are
not given. If more information is desired for a function group, the pri-
mary recommendation is to search in the same function group in the
other manual.

Product alternatives and optional equipment

page
–
The information in the manual is divided in modules. For product alter-

natives 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. When uncertain
about the equipment with which the machine is provided, use the ma-
chine card to decide which information applies, see Machine card
page 8.
Product alternatives
Product alternatives are such options that exclude certain standard
equipment (e.g., engine alternative).
Similar information for different product alternatives are described in
separate sections following each other in the same function group. To
show that there are different alternatives, the added text "Product al-
ternative" is used in the heading, together with a simple description of
which alternative is described, e.g., "(Product alternative Air condition-
ing ECC)".
Optional equipment
000264
Optional equipment are options that can be added to the standard

equipment to obtain additional or improved functions.
Symbol indicating optional equipment
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.

Machine card
page
–
NOTE
If the machine has been modified after delivery the information on
the machine card may be lacking or incorrect.
The machine card indicates of which drawings the machine consists,
in many cases these can be connected to options and product alterna-
tives. For more information about handling of product alternatives and
optional equipment, see Product alternatives and optional equipment
page 7. The machine card is delivered with the parts catalogue and
shall be kept in the cab.
The machine card is divided in the same functions groups as the parts
catalogue, maintenance and Workshop manual. For practical reasons,
the machine card uses only the first and second level in the function
group register. The function groups are written in groups of four char-
acters, e.g. group 0107 matches group 1.7 Cooling system in the man-
ual.
For more information about how the machine card is used for ordering
spare parts, see the parts catalogue's foreword.
If the information on the machine card does not help, contact Kalmar
Industries AB.
NOTE
All documents that accompany the machine are non-registered
documents and there will be no notification of changes.

Function descriptions
page
–
Function descriptions are schematic overviews that describe how a

function works as well as which components and signals work togeth-
er.
Function descriptions describe the function in a logical flow from input
signal to desired output signal. Most functions require that preset con-
ditions are fulfilled for the function to be activated. In these cases, the
conditions are listed above the illustration.
Function descriptions use symbols to illustrate components such as
valves, sensors, etc.
6
13
5
1
3
2
008070
Example of function description

1. Elektric force (solid single line)

2. Illustration of function, (lift and lower)
3. Component list
4. Position number in illustration, reference to component list
5. Flag pressure check connection (Check point), indicates that
there is pressure check connection for checking pressure signal
6. Hydraulic force (solid double line)
7. Flag diagnostic test, indicates that signal can be checked with di-
agnostic test, see section 8 Control system, group 8.4 Diagnostics
8. Elektric control signal (dashed single line)

Symbol explanation function descriptions

The following symbols are used in function descriptions, the symbols
1 2 are based on standard symbols used in wiring and hydraulic diagrams.
3 4 1. Electric control signal
2. Electric force
3. Hydraulic control signal
5 6
4. Hydraulic force
5. Hydraulic motor
6. Hydraulic oil pump with variable displacement
7 8 M 7. Hydraulic oil pump with fixed displacement
8. Electric motor
9 10 9. Accumulator
10. Disc brake
11. Filter
11 12
12. Radiator
D790-1 13. Bulb
13 14 14. Control and monitoring system, two control units with CAN-bus
D797-F 15. Restriction
16. Adjustable restriction
15 16
17. Inductive position sensor
17 18 18. Electrically controlled servo valve
19. Thermal by-pass valve
19 ˚C 20 ˚C
20. Temperature-controlled switch
˚C Pa 21. Temperature sensor
21 22
22. Pressure sensor
23 Pa 24 23. Pressure-controlled switch
24. Hydraulic cylinder
25 25. Double-acting hydraulic cylinder
26. Spring brake cylinder
27. Valve block
26 27
28. Shuttle valve
29. Non-return valve
28 29
007991
000523

12 A Foreword – About the documentation
About the documentation

Documentation sections
page
–
The documentation to the machine comprises the following sections:
Operator's manual
The Operator's manual is supplied with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
supplied with the machine as a separate documentation kit.
Supplementary documentation
There are Supplementary documentation that can be ordered for the
machine.
• Workshop manual.
• Supplier’s documentation for e.g. engine, transmission and drive
axle etc.
Ordering of documentation
page
–
Documentation is ordered from the dealer.

Always indicate publication number when ordering.

A Foreword – Feedback 13
Feedback
Forms for copying
page
–
Kalmar Industries’ ambition is that as someone who works with main-

tenance of Kalmar machines, you shall have access to correct infor-
mation.
Your views are important for facilitating the improvement of the infor-
mation.
Copy this form, write down your views and send it to us. Thank you for
your co-operation!
To: Kalmar Industries AB

SE-341 81 Ljungby
SWEDEN
Fax: +46 372 263 90
From:
Company / Sender: ..........................................................................................................................................
Telephone: ...........................................................................................................................................................
E-mail: .................................................................................................................................................................
Date: .................................... - .................. - ..................
Manual
informa- Name / Publication number: .............................................................................................................................
tion
Section / page number:.........................................................................................................................................
Sugges-
tions, .............................................................................................................................................................................
views,
notes etc.
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................

14 A Foreword – Feedback

B Safety 1
B Safety
Table of Contents B Safety

mm mm mm mm mm mm
Safety .............................................................................................................. 3
General safety information ......................................................................... 3
Safety concerns everyone! ................................................................................ 3
A near-accident is a warning signal! .................................................................. 3
Safety instructions ...................................................................................... 4
General ............................................................................................................. 4
Service position ................................................................................................. 4
Hydraulic system, depressurizing ...................................................................... 5
Oils .................................................................................................................... 5
Fuel system ....................................................................................................... 6
Clothing etc. ...................................................................................................... 7
Several mechanics on the same machine ......................................................... 8
Working under machine .................................................................................... 8
Lifting heavy components ................................................................................. 9
Vibrations ........................................................................................................ 10
Noise ............................................................................................................... 10
Solvents .......................................................................................................... 10
Fire and explosion risks ................................................................................... 11
Fluid or gas under pressure ............................................................................ 12
Coolant ............................................................................................................ 13
Refrigerant ...................................................................................................... 14
Air pollution ..................................................................................................... 14
Tensioned springs ........................................................................................... 15
Electric motors ................................................................................................. 15
Rotating components and tools ....................................................................... 16
Tyre system ..................................................................................................... 17
Lifting equipment ............................................................................................. 17
Environment ............................................................................................. 18
General ........................................................................................................... 18

2 B Safety

B Safety – Safety 3
Safety
mm mm mm mm mm mm
General safety information

Safety concerns everyone!
page
–
The safety information concerns everyone who works with the ma-
chine! Persons who do not follow the safety instructions given in this
manual must make absolutely sure that the work is performed without
risks of personal injury and without risk of damage to machine or ma-
chine property!
Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools for the job
• wear the correct clothes
• use common sense and work carefully. Do not take any risks!
Kalmar Industries has in this publication documented and warned for
situations and risks that may occur in connection with using as well as
service/repairs of the machine during normal circumstances.
That' s why it's important that all who work with the machine, or repair/
service the machine read and follow the information in the Mainte-
nance manual and Operator's manual.
A near-accident is a warning signal!

page
–
A near-accident is an unexpected event where neither persons, ma-

chine or property are injured or damaged. However, a near-accident
indicates that there is an injury risk and actions must be taken to avoid
the risk of injuries.

4 B Safety – Safety instructions
Safety instructions
General
page
–
Read, consider and follow the safety instructions below before starting
to work in the machine:
• Service position page 4
• Hydraulic system, depressurizing page 5
• Oils page 5
• Fuel system page 6
• Clothing etc. page 7
• Several mechanics on the same machine page 8
• Working under machine page 8
• Lifting heavy components page 9
• Vibrations page 10
• Noise page 10
• Solvents page 10
• Fire and explosion risks page 11
• Fluid or gas under pressure page 12
• Coolant page 13
• Refrigerant page 14
• Air pollution page 14
• Tensioned springs page 15
• Electric motors page 15
• Rotating components and tools page 16
• Tyre system page 17
• Lifting equipment page 17
Service position
page
–
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position entails:
• The machine is parked, i.e. parking brake applied.
• Forks and lifting carriage in totally lowered position.
• The engine is switched off.
• The main circuit is disconnected (using the battery disconnect
switch).
007945
Machine with forks and lifting carriage in totally low-

ered position

B Safety – Safety instructions 5
Hydraulic system, depressurizing

page
–
1 Machine in service position.

2 Depressurize the hydraulic system by opening the accumulator
drain valve (position A).
DANGER
Fatal danger!
Fatally dangerous to work with the hydraulics when

the hydraulic system is pressurized.
Depressurize the hydraulic system. Open the accu-

mulator drain valve.
3 Verify that the accumulator pressure has been released, meas-

ure with a pressure gauge on the pressure check connection by
007894
A the accumulator charging valve (see section 10 Common hydrau-

A. Accumulator drain valve's control lics, group 10.5.2 Main valve).
NOTE
Keep the drain valve open as long as work is in progress.
Oils
page
–
The following safety instructions shall be followed for work when han-
dling oils.
WARNING
Warm and pressurised oil.
Always depressurise the hydraulic system complete-

ly before starting to work in the system. The hydraulic
system is pressurised and the oil may cause personal
injuries.
Avoid skin contact with the oil, use protective gloves.

Warm oil can cause burn injuries, rashes and irrita-
tion! The oil may also be corrosive to mucous mem-
branes in, e.g., the eyes, skin and throat.

IMPORTANT
Always clean the area around components and con-
nections before they are loosened. Dirt in oil systems
causes increased wear, resulting in subsequent ma-
terial damages.
Always take action to avoid spills. In places where

drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs seal tight before collection

containers are moved.
Handle all oil as environmentally hazardous waste.

Oils freely released cause damage to the environment
and may also cause fires. Waste oils/fluids shall al-
ways be handled by an authorised company.
Fuel system
page
–
The following safety instructions shall be followed for work when han-
dling fuel.
DANGER
Pay attention to the risk of fire when working on the
fuel system.
Work on the fuel system shall be avoided when the

engine is warm since fuel can spill on hot surfaces
and may ignite.
WARNING
Use protective gloves and protective goggles. If a
component is to be disconnected, hold a rag over the
connection as protection and to collect fuel. The en-
gine's fuel system operates at very high pressure.
The pressure is so high that the jet can injure the skin,
resulting in severe injuries. Risk of personal injuries.
Avoid skin contact with fuel, use protective gloves.

Fuel is corrosive to mucous membranes in, e.g., eyes,
skin and throat.

CAUTION
Always clean the area around components and con-
nections before they are loosened. Dirt in the fuel may
cause malfunctions and engine stop in undesirable
situations as well as increase wear, resulting in sub-
sequent material damages.
IMPORTANT
Always take action to avoid spills. In places where
drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs and connections seal tight

before moving collection containers.
Handle the fuel as environmentally hazardous waste.

Fuel freely released causes damage to the environ-
ment and may also cause fires. Fuel shall always be
handled by an authorised company.
Clothing etc.
page
–
Clothes should be in good condition. Remove loosely hanging clothing

(tie, scarf, etc.). Do not wear clothes with wide sleeves, wide trouser
legs, etc.
Remove jewelry as it may conduct electricity and get caught in moving
parts.
Long hair must be tied up securely, otherwise it may easily get caught
in moving parts. Be careful when performing welding work or work re-
quiring open flames since hair catches fire easily.

Several mechanics on the same machine

page
–
WARNING
Be extra careful if several mechanics work on the
same vehicle, so that unintentional movements do
not injury another person. Communicate so that eve-
ryone knows where all are and what they are doing.
Risks
Work with wheels or axle suspension, mountings, etc. may result in
components on the other side moving and causing damage/injury.
Movements performed from the operator's station, e.g., movement of
lifting equipment, may cause severe personal injuries.
Safety actions
• Make sure that the machine's lifting equipment is completely low-
ered or secured in another way.
• Move battery disconnector to position zero, remove the key.
• Be aware of the risks when several persons work around the ve-
hicle.
• Make your co-workers aware of what you’re working with.
• Do not work with drive wheels on the machine's both sides at the
same time.
Working under machine

page
–
Working under cab

No loose objects are allowed in a cab that is to be tipped.
The cab must always be tipped fully. Always secure the cab with a stop
device.
In cases where the work requires that the cab is not tipped to the end
position, or when working with the cab mounting, always secure the
cab with a stop device.
On machines with a cab that can be lifted, the cab shall be secured in
lifted position with appropriate lock device.
Work under chassis

A raised vehicle may not, for any reason, be supported or lifted in parts
that belong to the wheel suspension or steering. Always support under
the frame or drive axle.

Risks
Mechanical or hydraulic tools and lifting devices can fall over or acci-
dentally be lowered due to malfunctions or incorrect use.
Safety actions
Use axle stands and supports that stands steadily.
Lifting tools should be inspected and type approved for use.
Lifting heavy components

page
–
WARNING
Careless handling of heavy components can lead to
serious personal injury and material damage.
Use type approved lifting tools or other devices to

move heavy components. Make sure that the device is
stable and intact.
Risks
Unsuitable lift slings, straps, etc. may break or slip.
The centre of gravity (balance point) of the component can change
during the course of the work, and the component may then make un-
expected movements which may cause severe personal injuries and
material damage.
A component lifted with lifting equipment can start to turn if the equilib-
rium is upset.
A component lifted using an overhead crane may start to swing back
and forth, which can cause severe crushing injuries or material dam-
age.
Safety precautions
Lift using a lifting device. Use lifting tools or equipment, especially
when such equipment is available for specific work operations. See
the workshop manual for methods.
If lifting must be performed without lifting device:
• Lift near the body.
• Keep your back vertical. Raise and lower with legs and arms, do
not bend your back. Do not rotate your body while lifting. Ask for
assistance in advance.
• Wear gloves. They're good protection against minor crushing in-
juries and cuts to fingers.
• Always use protective shoes.

Vibrations
page
–
In case of long-term use of vibrating tools, for example, impact nut run-
ners or grinders, injuries may be sustained as vibrations can be trans-
mitted from tools to hands. Especially when fingers are cold.
Safety actions
Use heavy gloves to protect against cold and somewhat against vibra-
tions.
Switch between work duties to give the body time to rest.
Vary work position and grip so that the body is not stressed in only one
position by the vibrations.
Noise
page
–
Noise louder than 85 dB (A) that lasts for longer than 8 hours is con-
sidered harmful to hearing. (Limit values may vary between different
countries.) High tones (high frequencies) are more damaging than low
tones at the same sound level. Impact noise can also be hazardous,
e.g. hammer blows.
Risks
At noise levels higher than the limits hearing damage can occur. In
more severe cases, hearing damage can become permanent.
Safety precautions
Use hearing protection. Make sure that it is tested and protects against
the noise level in question.
Limit noise with noise-absorbing dividers, for example, noise-absorb-
ing materials in roof and on walls.
Solvents
page
–
Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax,
oil, adhesive, rubber, etc. are called organic solvents. Examples:
White (petroleum) spirits, gasoline, thinner, alcohols, diesel, xylene,
trichloroethylene, toluene. Many solvents are flammable and consti-
tute a fire hazard.
Risks
Products containing solvents produce vapors that can cause dizzi-
ness, headaches and nausea.They may also irritate mucous mem-
branes in the throat and respiratory tracts.
If the solvent comes into direct contact with the skin, this may cause
drying and cracking.Risk for skin allergies increases. Solvents may
also cause injury if they penetrate through the skin and are absorbed
by the blood.
If the body is continuously exposed to solvents, the nervous system
may be damaged. Symptoms include sleep disorders, depressions,
nervousness, poor memory or general tiredness and fatigue. Continu-
ous inhalation of gasoline and diesel fumes is suspected to cause can-
cer.

Safety precautions
Avoid inhaling solvent fumes by providing good ventilation, or wearing
a fresh-air mask or respiratory device with a suitable filter for the toxic
gases.
Never leave a solvent container without tight-sealing lid.
Use solvents with low content of aromatic substances. This reduces
the risk of injuries.
Avoid skin contact.
Use protective gloves.
Make sure that work clothes are solvent-resistant.
Fire and explosion risks

page
–
Examples of explosion-prone substances are oils, petrol, diesel fuel,

organic solvents (lacquer, plastic, cleaning agents), rustproofing
agents, welding gas, gas for heating (acetylene), high concentration of
dust particles of combustible materials. Rubber tyres are highly flam-
mable and cause fires that spread explosively.
Risks
Examples of causes of ignition include welding, cutting, smoking,
sparks produced by grinding, inflammable materials coming into con-
tact with hot machine parts, the generation of heat in rags saturated
with oil or paint (linseed oil) and oxygen.Oxygen cylinders, lines and
valves must be kept free from oil and grease.
Fumes from gasoline, for example, are heavier than air and can thus
“run down” a sloping grade, or down into a grease pit, where welding
flames, grinding sparks or a burning cigarette can cause an explosion.
Evaporated gasoline has a very powerful explosive force.

Special cases
Diesel fuel oil with an additive of petrol has a reduced flash point. Ex-
plosion risk even at room temperature. The explosion risk due to
warmed diesel fuel oil is greater than for gasoline.
When changing oil in the engine, hydraulic system and transmission,
keep in mind that the oil may be hot and can cause burn injuries.
Welding on or near the machine. If diesel or other oils have leaked out
and have been absorbed by rags, absorbing agent, paper or other po-
rous material, glowing welding sparks can cause ignition and an explo-
sive spread of fire.
When a battery is being charged, the battery electrolyte water is divid-
ed into oxygen and hydrogen gas. This mixture is very explosive. The
risk of explosion is especially high when a booster battery or a rapid-
charge unit is used, as these increase the risk of sparks.
The machines nowadays contain a lot of electronic equipment. During
welding work, the control units must be disconnected and current
turned off using the battery disconnect switch. Otherwise, strong weld-
ing currents can short-circuit the electronics, destroy expensive equip-
ment, and may also cause an explosion or fire.
Welding work must never be carried out on painted surfaces (remove
paint by blasting at least 10 cm around the welding or cutting point.)
Use gloves, breathing protection and protective safety glasses. Also,
welding work must never take place near plastic or rubber materials
without first protecting them from the heat. Paints, plastics and rubber
generate various substances when heated that may be hazardous to
health. Be careful with machines that have been exposed to intense
heat or a fire.
Safety precautions
Store hazardous substance in approved and sealed container.
Make sure that there is no ignition source near flammable or explosive
substances.
Make sure that ventilation is adequate or there is an air extraction unit
when handling flammable substances.
Fluid or gas under pressure

page
–
High-pressure lines can be damaged during work, and fluid or gas can
stream out.
There may be high pressure in a line even if the pump has stopped.
Therefore, gas or fluid can leak out when the connection to the hose
is loosened.
A gas cylinder subjected to careless handling can explode, for exam-
ple, if it falls onto a hard surface. Gas can stream out through dam-
aged valves.

Risks
There are injury risks in connection with work on:
• Hydraulic system (for example, working hydraulics and brake sys-
tem).
• Fuel system.
• Tyre replacement.
• Air conditioning.
Safety precautions
• Use safety glasses and protective gloves.
• Never work in on a pressurized system.
• Never adjust a pressure limiting valve to a higher pressure than
recommended by the manufacturer.
• A hydraulic hose that swells, for example, at a connection, is
about to rupture. Replace it as soon as possible! Check connec-
tions thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Discarded pressure accumulators must first be punctured before
they are deposited as waste (to avoid risk of explosion). Carefully
drill a hole with 3 mm diameter after depressurizing.
• Never use your hands directly to detect a leak.A fine high-pres-
sure stream from a hydraulic hose can easily penetrate a hand
and causes very severe injuries.
Coolant
page
–
The coolant in the machine’s cooling system consists of water, anti-

corrosion compound and (when needed) anti-freeze fluid, for example,
ethylene glycol.
Coolant must not be drained into the sewer system or directly onto the
ground.
Risks
The cooling system operates at high pressure when the engine is
warm. Hot coolant can jet out and cause scalding in case of a leak or
when the expansion tank cap (filler cap) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety precautions
• Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
• Open the filler cap first, to release the excess pressure. Open
carefully.Hot steam and coolant can stream out.
• If possible, avoid working on the cooling system when the coolant
is hot.

Refrigerant
page
–
Refrigerant is used in the machine’s air conditioning system.

Work on the air conditioning system must be performed by accredited/
authorised and trained personnel according to national legislation and
local regulations.
Risks
The air conditioning operates at high pressure. Escaping refrigerant
can cause frostbite.
Refrigerant that is heated (e.g., when repairing leaking climate/AC
system), generates gases that are very dangerous to inhale.
Contact the importer for further information.
Safety actions
• Use special instructions and equipment for refrigerant according
to the Workshop manual when working on the air conditioning
system. Special certification and authorization is often required of
the person who may do the work. (Note national legislation and lo-
cal regulations!)
• Use protective gloves and safety glasses if there’s a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).
Air pollution
page
–
Air pollution is the impurities in the air around us and which are regard-
ed as hazardous to health. Certain pollution is more prominent in cer-
tain environments.
The following health-hazardous air pollution is especially prominent in
workshops:
• Carbon monoxide (fumes) is present in exhaust fumes. Odor-
less and therefore especially dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke especially hazardous to health when welding on
oily surfaces, galvanized or lacquered materials.
• Oil mist for example, when applying anti-corrosion agent.
• Grinding dust and gases generated when grinding and heating
plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.
• Isocyanates are present in certain paints, fillers, adhesives and
foam plastics used on machines.
Risks
Sulfuric acid mist is corrosive and injures the respiratory tracts. (Gen-
erated when heating certain plastics and paints.)
Isocyanates can be released in the form of steam, dust (or may be
present in aerosols) when cutting, grinding or welding. Can irritate mu-
cous membranes producing symptoms similar to asthma and impair-
ing lung function. Even brief exposure to high concentrations can give
problems with persistent high sensitivity.

Safety precautions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are gen-
erated.
• Use suitable gloves and breathing protection when there’s a risk
of oil mist. Make sure that protective gear is oil-resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eye-wash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the workshop.
Connect an air extractor to the exhaust pipe so that the exhaust
fumes are removed from the workshop.
Tensioned springs
page
–
Examples of tensioned springs:

1. Torque springs in pedals for example.
2. Return spring (cup springs) in parking brake cylinder.
3. Lock rings
4. Gas springs
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries.
Parking brake springs are tensioned with high force and can cause
very severe accidents if they are accidentally released in an uncon-
trolled manner.
Gas springs and gas-charged shock absorbers are tensioned with
high force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety precautions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.
Electric motors
page
–
Safety actions
Always turn off the battery disconnector when working on electric mo-
tors.
Always block the machine’s wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before start-
ing any work on the machine.

Rotating components and tools

page
–
Examples of rotating components and tools:

• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinders
Risks
Rotating components, for example, fans or shafts, can cause severe
injuries if touched.
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothes or hair get caught and are wound up in the
machine.
Safety precautions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or trouser legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair-net or similar.
• Remove large or loose hanging jewelry from hands, arms and
neck.

Tyre system
page
–
DANGER
Tyres should be regarded as pressurized containers.
They constitute fatal danger if handled incorrectly.
Parts can be thrown with explosive force and may

cause severe injuries.
Never repair damaged tyres, rims or lock rings. Tyre

changes shall be performed by authorised personnel.
Risks
Dismantling wheels: Tyres, rims or lock rings can be thrown.
Inflating wheels: Tyres, rims and lock rings can be thrown.
Safety actions
• Deflate the tyres before starting to work on the wheel.
• Check that wheels, rims and lock rings aren’t damaged. Never re-
pair damaged rims or lock rings.
• Wheels must be inflated on the machine or in a protective device
which is designed and dimensioned to withstand or divert a pres-
sure wave from an exploding tyre, and to catch the pieces which
are thrown out.
• Use protective screen and safety glasses.
Lifting equipment
page
–
When working on the machine in general, and with the lifting equip-
ment in particular, the greatest caution must be exercised with respect
to securing the mast and carriage.
Always make a habit of lowering the carriage to its lowest position be-
fore working on the machine.
Risks
If the lifting equipment on the machine is not lowered or secured, there
is a pinch risk.
The pinch risk is much greater when the pressure in the hydraulic sys-
tem is being released, see Hydraulic system, depressurizing page 5.
Safety actions
Do not start work before the carriage has been completely lowered. If
the nature of the work requires the carriage to be raised then this must
be secured in some way.

18 B Safety – Environment
Environment
General
page
–
Ever-increasing industrialisation of our world is having a significant im-

pact on our global environment. Nature, animals and man are subject-
ed daily to risks in connection with various forms of chemical handling.
There are still no environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices
and methods necessary to protect the environment in an environmen-
tally sound manner.
By following the simple rules below, you will contribute to protecting
our environment.
Recycling
Carefully considered recycling of the machine is the basis for ending
the life cycle and being able to utilise the material for re-use in new
products. Our estimates show that more than 90% of the weight of the
machine can be re-used
Environmentally hazardous waste

Components such as batteries and other items that may constitute en-
vironmentally hazardous waste must be handled and taken care of in
an environmentally safe and sound manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an environmental-
ly safe manner and according to national regulations.
Oils and fluids

Oils freely discharged cause environmental damage and can also be
a fire hazard. Therefore, when emptying and draining oils or fuel, take
appropriate action to prevent unnecessary spills.
Waste oils and fluids must always be taken care of by an authorised
disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal the leaks.
Air conditioning system

The refrigerant in the air conditioning system for the cab adds to the
greenhouse effect and must not be deliberately released to the atmos-
phere. Special training is required for all service work on the air condi-
tioning system. Many countries require special certification by an
authority for such work.
Working in a contaminated area

The machine must be equipped for work in a contaminated area (en-
vironmentally contaminated or hazardous to personal health) before
work is started. In addition, special local regulations apply when han-
dling and servicing such a machine.

C Preventive maintenance 1
C Preventive maintenance
Table of Contents C Preventive maintenance

mm mm mm mm mm mm
Preventive maintenance ................................................................................ 3

Preventive maintenance, general ........................................................................... 3
Preventive maintenance, work instructions ............................................................ 3
Check and service log ............................................................................................ 4
50h-check ............................................................................................................... 5
Service schedule .................................................................................................... 7
Washing ............................................................................................................... 16
Lubrication 500 hours ........................................................................................... 17
Lubrication 1000 hours ......................................................................................... 24
Crack checking ..................................................................................................... 29

2 C Preventive maintenance

C Preventive maintenance – Preventive maintenance 3
Preventive maintenance
mm mm mm mm mm mm
Preventive maintenance, general

page
–
It’s very important that preventive maintenance is performed accord-

ing to recommended intervals.
Preventive maintenance should be performed by Kalmar Industries, or
by a service organization authorized by Kalmar Industries.
CAUTION
The warranty is not valid if service intervals are not
followed.
Preventive maintenance shall be performed accord-

ing to the prescribed intervals and extent.
Use spare parts, oils and fluids approved by Kalmar

Industries.
Preventive maintenance, work

page
–
instructions
1 For new machine it is very important to check-tighten the wheel
nuts during the first work week, until they are securely tightened.
This shall be performed at an interval of 4–5 operating hours (up
to approx. 40–50 operating hours).
2 For new machine, checking actions shall be performed after 50
hours of operation, see 50h-check page 5.
Note completed 50h check in the service log, see Check and
service log page 4.
3 Service at regular intervals shall be performed according to serv-
ice schedule, see Service schedule page 7. The service schedule
shall be followed to ensure the machine’s high operating reliabil-
ity.
Note completed service in the service log, see Check and service
log page 4.

4 C Preventive maintenance – Preventive maintenance
Check and service log

page
–
Model:
Serial number:
Completed maintenance
Operating Action Operating Date Signature

time time
50h 50h control
500h 500h service
1000h 1000h service
1500h 500h service
2000h 2000h service
2500h 500h service
3000h 1000h service
3500h 500h service
4000h 2000h service
4500h 500h service
5000h 1000h service
5500h 500h service
6000h 2000h service
6500h 500h service
7000h 1000h service
7500h 500h service
8000h 2000h service
8500h 500h service
9000h 1000h service
9500h 500h service
10000h 2000h service

50h-check
page
–
For new machine, checks shall be performed after 50h operating time.
Checks are performed to increase the machine’s reliability.
In addition to the following checks, lubrication should also be per-
formed according to 500h service, see Lubrication 500 hours page 17.
1 Engine Reference
Bolted joints, attachments, mountings, hose clamps, wear and chafing
of hoses, cable harnesses, etc.
Leakage check, oil, coolant, exhaust system
Fuel pre-filter, water draining Section 1 Engine, group 1.2.3 Fuel pre-filter
Air filter indicator, check Operator's manual DCD 200-300
Air filter main cartridge, inspection
Air filter safety cartridge, inspection
Fan belt tension, check Section 1 Engine, group 1.7.5 Cooling fan
Coolant level, check Operator's manual DCD 200-300
Engine oil, changing Section 1 Engine, group 1.8 Lubrication
Oil filter, changing Section 1 Engine, group 1.8.4 Oil filter
2 Transmission
Leakage check
Oil level, check Operator's manual DCD 200-300
Oil filter, changing Section 2 Transmission, group 2.6.4 Oil filter
3 Driveline/axle
Mounting propeller shaft, check-tightening Section 3 Driveline/axle, group 3.2 Propeller shaftl
Mounting drive axle, inspection Section 3 Driveline/axle, group 3.3 Drive axle
Drive axle oil, changing
4 Brakes
Leakage check
Servo brake, function check
Parking brake, function check Operator's manual DCD 200-300

Section 10 Common hydraulics, group 10.3.2 Ac-
cumulator
5 Steering
Sensor, steering wheel angle, mini-wheel/lever steering, function Section 5 Steering, group 5.2.11 Sensor steering
check wheel angle

6 Suspension
Steering axle suspension, check Section 6 Suspension, group 6.2.1 Steering axle
cradle
Tyre system, check Section 6 Suspension, group 6.3.1 Tyres
Wheel nuts, check-tightening
7 Load handling
Hose connections, check-tightening in case of leaks
When external attachment, see producers instructions.
8 Control system
Check that there are no active error codes Section 8 Control system, group 8.3 Error codes

Hose couplings air conditioning system (ECC Electric Climate Control),
check-tightening
Climate control system, performance test Section 9 Frame, body, cab and accessories,
group 9.4 Air conditioning
Counterweights, check Section 9 Frame, body, cab and accessories,

group 9.13.4 Counterweights
Hose connections, check-tightening
Leakage check Section 10 Common hydraulics, group 10.5.2

Main valve
High pressure filter, replacement Section 10 Common hydraulics, group 10.6.8

High-pressure filter
Oil level, check Section 10 Common hydraulics, group 10.6.9 Hy-

draulic oil
11 Common electrics
Batteries, check Section 11 Common electrics, group 11.3.1 Start
battery

Service schedule
page
–
Service shall be performed every 500 operating hours. Actions are di-
vided into 500h, 1000h and 2000h service.
Actions for 500h service are performed between 1000h and 2000h
service, which means at 500h, 1500h, 2500h, etc.
Actions for 1000h service are performed at odd thousands of operat-
ing hours: 1000h, 3000h, 5000h, etc.
Actions for 2000h service are performed at even thousands of oper-
ating hours: 2000h, 4000h, 6000h, etc.
After completed service a note shall be made in the Check and service
log, see Check and service log page 4.
In the column for service below, the following abbreviations are used:
R = replace
C = check or inspection
L = lubrication
h = operating hour
CAUTION
The lubrication interval is based on normal handling
and environment and requires use of the recommend-
ed grades and quantities.
For other conditions, e.g., cold, hot, dusty, we recom-

mend halving the interval.
The lubrication interval must never exceed 12

months.
Object, action Service Comment Reference
500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h 5000h 6000h
etc. etc. etc.
General
Leakage check C C C
Attachments (axle pins) C C Visual check in connection

with lubrication.
Lubrication 500h L L L Lubrication 500 hours page

17
Lubrication 1000h L L Lubrication 1000 hours

page 24

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h 5000h 6000h
etc. etc. etc.
Crack checking C* * Check every 4,000 h or Crack checking page 29
every year.
1 Engine (engine alternative Volvo)

Bolted joints, attachments, C C C
mountings, etc.
Fuel tank C C Clean if necessary. Section 1 Engine, group

1.2.1 Fuel tank
Fuel filter R R Section 1 Engine, group

1.2.2 Fuel filter
Fuel pre-filter C C/R C/R Drain water/ impurities. Section 1 Engine, group
1.2.3 Fuel pre-filter
Valve clearance C Check/adjust NOTE

On newly renovated en- Must be done by an
gine adjust valve clearance authorized Volvo Pen-
after 250h. ta workshop.
Injector C
Turbo C
Air filter main cartridge C/R C/R C/R Check indicator, change fil- Section 1 Engine, group
ter at indication. 1.6.1 Air cleaning system
Air filter safety cartridge C C/R C/R Change every second time
the main insert is changed.
Exhaust system C C C Leakage check. Section 1 Engine, group

1.6.3 Exhaust system
Charge air hoses C C C Leakage check. Section 1 Engine, group

1.6.4 Intercooler
Radiator C C C External check and clean- Section 1 Engine, group

ing 1.7.4 Radiator and expan-
sion tank
NOTE
Do not use a high-
pressure washer.
Drive belts C C/R C/R Change when needed. Section 1 Engine, group
1.7.5 Cooling fan

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h 5000h 6000h
etc. etc. etc.
Coolant C C/R C Level check. Section 1 Engine, group
Coolant change after 1.7.7 Coolant
5000h, when changing
also check/ clean cooling
system.
For volume, see section F
Technical data
Coolant freezing point C C C
Engine oil R R R For volume and quality, Section 1 Engine, group

see section F Technical 1.8 Lubrication
data
Engine oil filter R R R Change the filters during Section 1 Engine, group
each oil change. 1.8.4 Oil filter
Lubrication and cooling sys- C C C Leakage check.

tem
1 Engine (engine alternative Cummins)

Bolted joints, attachments, C C C
mountings, etc.
Fuel tank C C Clean if necessary. Section 1 Engine, group

1.2.1 Fuel tank
Fuel filter R R Section 1 Engine, group

1.2.2 Fuel filter
Fuel pre-filter C C/R C/R Drain water/ impurities. Section 1 Engine, group
Valve clearance C Check/adjust after 5000h / Section 1 Engine, group

every four years. 1.5.4 Valve mechanism
Air filter main cartridge C/R C/R C/R Check indicator, change fil- Section 1 Engine, group
ter at indication. 1.6.1 Air cleaning system
Air filter safety cartridge R C/R C/R Change every second time
the main insert is changed.
Exhaust system C C C Leakage check. Section 1 Engine, group

Charge air hoses C C C Leakage check. Section 1 Engine, group

1.6.4 Intercooler

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h 5000h 6000h
etc. etc. etc.
Radiator C C C External check and clean- Section 1 Engine, group
ing 1.7.4 Radiator and expan-
sion tank
NOTE
Do not use a high-
pressure washer.
Drive belts C/R C/R C/R Change when needed. Section 1 Engine, group
1.7.5 Cooling fan
Drive belt tensioner C/R C/R Check after 1000h / every
year. Change when need-
ed.
Fan hub C C Check after 1000h / every

year.
Vibration damper, viscous C Check after 2000h / every

two years.
Coolant C C C Level check. Section 1 Engine, group

Coolant change after 1.7.7 Coolant
2000h, when changing
also check/ clean cooling
system.
For volume, see section F
Technical data
Coolant freezing point C C C
Engine oil R R R For volume and quality, Section 1 Engine, group

see section F Technical 1.8 Lubrication
data
Engine oil filter R R R Change the filters during Section 1 Engine, group
each oil change. 1.8.4 Oil filter
2 Transmission
Transmission oil C R R Section 2 Transmission,
group 2.6 Lubrication
Transmission oil filter R R Section 2 Transmission,

group 2.6.4 Oil filter
Transmission, calibration C C Calibration of the transmis- Section 2 Transmission,

sion is recommended group 2.8 Control system
every 1000h.

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h 5000h 6000h
etc. etc. etc.
3 Driveline/axle
Propeller shaft C C C Section 3 Driveline/axle,
group 3.2 Propeller shaft
Drive axle C C Section 3 Driveline/axle,

group 3.3 Drive axle
Drive axle oil C R R First oil change at the 50h-
check, see 50h-check
page 5.
4 Brakes
Servo brake C C C Function check.
Brake pedal and pedal rack C C C Section 4 Controls and in-

struments, group 4.1.1
Brake pedal.
Brake pressure, checking C C C Section 4 Brakes, group

4.3.6 Distribution block
Parking brake C/R C/R C/R Check pad thickness, Section 4 Brakes, group
change when needed. 4.5.4.2 Parking brake pads
5 Steering
Link arms C C C Check bearings and the Section 5 Steering, group
shafts lock plate. 5.2.6 Link arms
Sensor, steering wheel an- C C C Section 5 Steering, group

gle, steering wheel/lever 5.2.11 Sensor steering
wheel angle
steering
6 Suspension
Steering axle mounting C C Mounting in frame. Section 6 Suspension,
group 6.2.1 Steering axle
cradle
Wheel spindle, check C C Clearance in wheel sus- Section 6 Suspension,

pension shall be checked. group 6.2.2 Wheel spindle
Max 0,25 mm clearance for
DCD 200-250.
No clearance for DCD 280-
300.
Wheel hub, check *) C Check bearing pre-load. Section 6 Suspension,

*) Check first time after group 6.2.3 Wheel hub
1,000 h, then every 2,000
h.

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h 5000h 6000h
etc. etc. etc.
Tyres and rims C C C Damage, wear and pres- Section 6 Suspension,
sure, change as needed. group 6.3 Tyre and rim sys-
tem
Wheel nuts C C C Check-tighten.
Rim C* C* * When changing tyres or Section 6 Suspension,

every 12 months. group 6.3.2 Rims
7 Load handling
Mast mounting C C Check that the welding is Section 7 Load handling,
intact and check the bear- group 7.2.6 Mast
ings.
Lifting chains C C C Check for damages. Section 7 Load handling,

Tension chain as neces- group 7.2.8 Chains
sary.
Support rollers mast C C C Section 7 Load handling,

group 7.2.14 Support roller
and 7.2.15 Top support
roller
Side shift cylinder C C C Section 7 Load handling,

group 7.4.4 Side shift cylin-
der
Tilt cylinder C C C Check that the welding is Section 7 Load handling,

intact and check the bear- group 7.7.5 Tilt cylinder
ings.
Lifting forks C C C Section 7 Load handling,

group 7.9.1 Lift forks
C C Calibration of scales Section 7 Load handling,

Scales
group 7.10.1 Electric
scales
C C Damages Section 7 Load handling,

Attachment
group 7.10.5 Side lift at-
C C/R Check for cracks every tachment
Twistlocks
other year or every 5000h.
Change every 10 000h.
C C C
Sensor

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h 5000h 6000h
etc. etc. etc.
8 Control system
Service indicator, reset C C C Special code in addition to Section 8 Control system,
service code required. group 8.2.4 Service indica-
tor.

Instrumens and controls C Functions check
C C C Function check. Section 9 Frame, body,

Air conditioning system
cab and accessories,
group 9.4 Air conditioning.
Fresh air filter C/R R R Dependent on external en- Section 9 Frame, body,
vironment. cab and accessories,
Some models have washa- group 9.4.4 Fresh air filter
ble pre-filters. Fine filter re-
placed as needed.
C C C Clean when needed. Section 9 Frame, body,

Condenser
NOTE! Do not use a power cab and accessories,
washer. group 9.4.9 Condenser unit
Windshield wipers C C C Incl. washing. Section 9 Frame, body,

group 9.5 Wiper/washer
system
Lighting and audible warn- C C C

ings
Communication equipment C C C See separate supplier doc-

umentation
Roof window C C Check for damages, Section 9 Frame, body,

change when needed. cab and accessories,
group 9.9 Glass/windows/
mirrors
Cab body C C Check for corrosion, defor- Section 9 Frame, body,

mation or cracks. cab and accessories,
group 9.10 Cab body
Hinges for doors and panels C C C Section 9 Frame, body,

group 9.10.2 Doors, check.

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h 5000h 6000h
etc. etc. etc.
Cab substructure C C Check bolted joints, attach- Section 9 Frame, body,
ments and mountings. cab and accessories,
group 9.10.3 Cab substruc-
ture
Hydraulic tipping of cab C C C Check pin for cab and lift Section 9 Frame, body,
cylinder mounting. cab and accessories,
group 9.10.3 Cab mounting
Section 9 Frame, body,
group 9.10.4 Cab tilt
Frame C C Check for corrosion, defor-

mation or cracks in welds.
Slip protection on steps and C C Check and replace defec-

cab floor tive slip protection.
Counterweight mounting/box C C Section 9 Frame, body,

group 9.13.4 Counter-
weights
Central lubrication C C C Section 9 Frame, body,

group 9.14 Central lubrica-
tion
Paint/coatings C Check paint/coatings for Section 9 Frame, body,

damages. cab and accessories,
Touch-up damages to group 9.15 Paint/coatings
avoid corrosion.
Painting and protection C C Touch up.

markings
Accumulator C C C Check precharge pres- Section 10 Common hy-
sure. draulics, group 10.3.2 Ac-
cumulator
Hydraulic pressure, check C C C Section 10 Common hy-

draulics, group 10.5.2 Main
valve
C C Section 10 Common hy-

Hydraulic oil cooler
draulics, group 10.6.2 Hy-
draulic oil coolerr

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h 5000h 6000h
etc. etc. etc.
Breather filter C/R R R Section 10 Common hy-
draulics, group 10.6.7
Breather filter hydraulic oil
tank
Hydraulic oil filter R R Section 10 Common hy-

draulics, group 10.6.8
High-pressure filter
Hydraulic oil C/R Check with oil sample. Section 10 Common hy-
• If oil sample OK after draulics, group 10.6.9 Hy-
2000h, run another draulic oil, check.
1000h and take new
oil sample.
• If oil sample OK after
3000h, run another
1000h and change oil.
Note: Max. 4000h change
interval.
Additive: Lubrizol should
be added when changing
hydraulic oil. Concentra-
tion 3%.
For volume and quality,
see section F Technical
data
11 Common electrics
Position sensor C C C Must be free from grease
and dirt, clean as neces-
sary
Fuses C C C Check that fuses are intact, Section 11 Common

change if needed. electrics, group 11.2.2 Fus-
es
Batteries C C C Clean if necessary. Section 11 Common

Check electrolyte level. electrics, group 11.3.1
Start battery, check.

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h 5000h 6000h
etc. etc. etc.
Test-run C C C Test-run the machine and

check the following:
• Instruments
• Brakes
• Gearshifting
• All load handling func-
tions
• Communication equip-
ment
• Steering
• Any noise
After test-run C C C Check the following after

test-run:
• Sealing (no leakage)
• Fluid levels
Washing
page
–
CAUTION
When using a high-pressure washer to clean the ma-
chine, do not aim the water jet directly at the radiator,
linkages, bearings or electrical components, for ex-
ample, control units, connectors and sensors.

Lubrication 500 hours

page
–
1 Turn off the engine and the main electric power.

2 Clean the area around each grease nipple before greasing.
3 Grease all grease points on the machine with lubricants as rec-
ommended, see section F Technical data. Also perform a visual
check of all attachments that are greased.
IMPORTANT
On machines with central lubrication, check that the
central lubrication's grease points are lubricated, see
section 9 Frame, body, cab and accessories, group
9.14 Central lubrication.
6
5
7 15 15
3 4
2 8
2 2
3
16 16
9,11
10
9
12
1 14 13 007872
Lubrication points, grease
Pos Lubrication point Reference

.
1 Cab lock Cab locks page 18
2 Hinge doors Hinges, doors page 18
3 Key lock, door/engine cover Key lock, door/engine cover page 18
4 Pedal rack, brake pedal Brake pedal page 19

5 Mast, slide plates Mast page 21
6 Mast, top support rollers, when fitted.
7 Chain wheel
8 Lifting chains
9 Support rollers and fork wheels, forks Support rollers, forks page 20
10 Side shift cylinder Side shift cylinder page 19
11 Side movement frame Side shift frame page 19
12 Support rollers Mast page 21
13 Mast wheels
14 Mast anchorage
15 Link arm Link arms page 20
16 Tilt cylinders Tilt cylinders page 21
17 Side lift attachment Side lift attachment page 23
Cab locks
1 Tip the cab.
2 Lubricate the cab locks with grease.
007874
Hinges, doors
3 Lubricate the door hinges with grease. Lift the door to facilitate
greasing.
Lubricate the mechanism in the engine hood.
Key lock, door/engine cover

4 Lubricate the key lock on doors and engine coves using lock oil

Brake pedal
5 Lubricate the brake pedal hinge using grease.
6 Wipe off surplus grease.
Lubrication point brakepedal

Side shift cylinder
7 Lubricate the side shift cylinder with grease.
Side shift frame

8 Lubricate the side shift frame slide grease.
009587

Support rollers, forks

9 Lubricate the mast wheel and the support rollers with grease.
Link arms
10 Lubricate the link arm bearings with grease.
1 1
3 3
2 2
007869
4
007870
4
DCD 200-250 DCD 280-300
1. Lubrication point, upper king pin bearing 3. Lubrication point, outer link bearing
2. Lubrication point, inner link bearing 4. Lubrication point, lower king pin bearing

Tilt cylinders
11 Lubricate the tilt cylinder axles with grease. There is a lubrication
point at each end of the tilt cylinder.
007871
Mast
12 Start the machine and lift the mast, for better access to the lubri-
4 3 cation points.
13 Stop the engine.
4
14 Support the mast securely.
15 Lubricate slide plates (position 1), support rollers (position 2),
chain wheels (position 4) and mast wheels (position 5), and also
top support rollers (position 3) when fitted, with grease, please re-
fer to insert F Technical data.
1 If there are lowered grease points, the top support rollers and
wheels can be greased down on the mast .
2 16 Brush or spray the chains with chain oil. Make sure that the
chains are well lubricated.
5
007275
Lubrication points for mast.

Mast anchorage
17 Unload the mast anchorage in a suitable manner. Unload it by do-
ing one of the following:
– Put a jack under the stand and lift, so that the stand does not
hang from the stand anchorage.
– Tilt the stand back, put something under the stand that can
support the load, then tilt forwards again.
18 Lubricate the mast anchorage with grease.
007868
Lubrication point for mast anchorage.

2 2
1
1
3
4
6
007925
Side lift attachment
19 Grease all slide surfaces using slide grease (pos. 1) with the at-
tachment in max. extended position.
20 Grease the hydraulic cylinders using universal grease (pos. 2).
21 Grease the twistlock cylinders using universal grease (pos. 3).
22 Grease the twistlocks using universal grease (pos. 5).
23 Grease the contact pins using universal grease (pos. 6).

Lubrication 1000 hours

page
–
1 Turn off the engine and the main electric power.

2 Clean the area around each grease nipple before greasing.
3 Lubricate all grease points on the machine with lubricants as
recommended, see section F Technical data. Also perform a vis-
ual check of all attachments that are greased
4 1 3 3
2 2
007873
3
Lubrication points, grease
Pos. Lubrication points Reference

Lubrication 500 hours Lubrication 500 hours page 17
1 Hose wheels See Hose wheels page 25
2 King pin bearing See King pin bearings page 25
3 Wheel bearings, steering axle See Wheel bearings, steering axle page 26
4 See Reversible operator’s seat, sprocket and chain page

Reversible operator’s seat
26
5 Connectors (not positioned in figure) See Connectors page 27
6
Side lift attafchment (not positioned in figure) See Side lift attachment page 28

Hose wheels
1 Remove the securing plate to release the hose wheel.
2 Remove the hose wheels.
3 Smear the axle with slide grease.
4 Fit the hose wheels.
5 Fit the securing plate.
007876
King pin bearings
6 Lubricate the steering spindle bearing assemblies (upper and
lower) on both sides using grease.
If needed, turn the steering wheels for better acces.
1 1
3 3
2
2
007869
4
007870
4
DCD 200-250 DCD 280-300
1. Lubrication point, upper king pin bearing 3. Lubrication point, outer link bearing
2. Lubrication point, inner link bearing 4. Lubrication point, lower king pin bearing

Wheel bearings, steering axle

7 Grease the wheel hub until grease comes out at the seal on the
hub's inside.
Lift the seal ring's lip with a small screwdriver to facilitate pressing
out of air. Grease until grease comes out by the seal.
NOTE
Work carefully so that the seal is not damaged.
Lubrication point wheel hub 280-300

007862
Lubrication point wheel hub DCD 200-250

Reversible operator’s seat, sprocket and chain
8 Remove the cover plate, clean and grease the sprocket.

9 Remove the cover plate, clean and grease the chain.
Connectors
10 Grease the connectors with contact grease
006645
Connector, example

2 2
1
1
3
4
6
007925
Side lift attachment

11 Machine in service position, see section B Safety.
12 Grease the connection (pos. 4) using universal grease.
13 Clean and grease twistlocks with universal grease.

Crack checking
page
–
DANGER
All welds on the machine must be checked at the rec-
ommended intervals. The interval is based on the as-
sumption that the machine is used in normal material
handling on a flat floor. In other operation, such as
when on rough ground, the interval should be short-
ened.
If any cracks are found in any weld, the machine must

immediately be taken out of service and Kalmar Serv-
ice must be contacted.
1 Stop the engine and turn the main switch off.

2 Clean every weld carefully before checking it.
3 Check for damage and cracks in areas with high stress concen-
trations. Please refer to Check points page 31. Check the full
length of every weld.
Doubtful welds should be checked with magnetic powder and
possibly with penetrating fluid, as follows:
a. The magnetic powder method is used to determine whether
there are any cracks, and where they are. Please refer to
Magnetic powder method page 29.
b. Any cracks found must be investigated more closely with
penetrating fluid. Please refer to Crack checking with pene-
trating fluid page 30.
Magnetic powder method

1 Grit blast the area in question, to make it completely free from
paint residue.
2 Use the following equipment for magnetic testing:
• Equipment: Tiede Yoke
• Technology:
a. Alternating Current AC
b. Contrast dye
• Test medium:
a. Wet
b. Dye (e.g. Tiede Ferrolux)
If no cracks are discovered with magnetic powder, the check is
completed and the area in question is approved.
If cracking is indicated, the crack must be investigated with pen-
etrating fluid.

Crack checking with penetrating fluid

1 Clean the area with cleaning fluid, part no. 923626.0668.
2 Spray penetrating fluid, part no. 923626.0669 on the cleaned sur-
face and allow to dry for 10 min.
3 Wash the penetrating fluid off with cleaning fluid, part no.
923626.0668.
Wipe the cleaning fluid off carefully with a cleaning rag and pos-
sibly allow the remaining cleaning fluid to evaporate away.
4 Spray developing fluid, part no. 923626.0670 on the area.
5 Leave the sprayed area to dry for 1-2 hours.
6 Inspect the area visually.
1 2
If no linear or point cracks are found in the tested area, it is ap-
proved.
If linear or point cracks are found in the crack test, contact Kalmar
Service.
001705
Examples of cracks
1. Linear crack
2. Point crack

Check points
Check the following welds extra carefully:
5
6
5
3
5
1
4
7 2
009467
Crack checking
Pos. Lubrication points Reference

1 Mast anchorage Mast anchorage page 32
2 Tilt anchorage Tilt anchorage page 34
3 Drive axle anchorage Driving axle anchorage page 35
4 Lifting forks Lifting forks page 35
5 Lifting equipment Lifting equipment page 36
6 Counterweight box Counterweight anchorage to frame. page 38
7 Steering axle anchorage Steering axle anchorage page 38
8 Anchorage between frame member and rear section Anchorage between frame sides and rear section page 39

Mast anchorage
1
009485
DCD 200-250
a) Mast anchorage in chassis.
009486
DCD 280-300
b) Weld between mast member and attachment lug.
009487

c) Mast anchorage in chassis, seen from underneath
009523
d) Weld between mast member and attachment lug, seen from

underneath.
009524

Tilt anchorage
2
a) Tilt anchorage on the mast
009481
Machine without tilt arch

009526
Machine with tilt arch

b) Tilt anchorage on the chassis.
009482
Machine without tilt arch

c) Tilt anchorage on the tilt arch.
009527

d) Tilt arch anchorage on the chassis.
009528
Driving axle anchorage
3
009483
DCD 200-250
a) Driving axle anchorage on chassis
009484
DCD 280-300
Lifting forks
4
NOTE
Other fork variants may be found, apart from the ones
shown here.
a) Fork mounting on vehicle members.
Support roller anchorages.
To check the material in the forks, please refer to section7
Load handling, group 7.9.1 Lifting forks.
009480

b) Fork upper hanging bracket, seen from underneath.
009529
Lifting equipment
5
NOTE
Other lifting equipment variants may be found, apart from
the ones shown here.
a) Weld between vehicle side and vehicle members.
009536
b) Weld between outer stay and vehicle members.

009535

c) Chain anchorage to lifting carriage.

Also check the fixing pin for the chain and its split pin.
009479
d) Chain anchorage to the mast
Also check the chain tensioner, the fixing pin for the chain and
its split pin.
009478
e) Weld between wheel stub axle and lifting carriage.

Also check the wheel stub axles on the inner mast.
009530

Counterweight anchorage to frame.

6
a) Counterweight anchorage to frame under rear mudguard
(fender).
Turn the steering wheels to one side, for better access.
009533
DCD 200-250
009534
DCD 280-300
Steering axle anchorage
7
a) Steering axle anchorage in chassis.
a
b) Steering axle anchorage on steering axle subframe.
b
009525

Anchorage between frame sides and rear section

8
a) Anchorage between frame sides and rear section.
009532
b) Anchorage between frame sides and rear section, seen from
009531
underneath.


0 Complete machine 1
0 Complete machine
Table of Contents 0 Complete machine

mm mm mm mm mm mm
Complete machine ......................................................................................... 3

Complete machine, description ............................................................................. 3

2 0 Complete machine

0 Complete machine – Complete machine 3
Complete machine
mm mm mm mm mm mm
Complete machine, description

page
–
The Kalmar DCD 200-300 is a forklift truck. The machine has a lifting
capacity of 20–30 tons depending on design.
The engine is a six cylinder four-stroke direct-injected diesel engine.
The transmission is hydromechanical with gear wheels constantly
meshed. It has three forward gears and three reverse gears. The pow-
er is transferred using a torque converter.
The driveline/axle consists of a propeller shaft and a rigid drive axle
with hub reduction. Drive takes place on the front wheels.
The service brake is of the type disc brake in oil which is built together
with the driving wheel's wheel hub. The parking brake is of the type
disc brake and acts on the drive axle's input shaft.
Steering takes place on the rear wheels with a double-acting hydraulic
cylinder. The steering axle is oscillation-mounted in the frame.
The wheels are secured to the hubs with nuts and washers. There are
double wheels on the drive axle, and single on the steering axle. The
wheels have split rims.
Load handling comprises components and functions for managing
loads. Loads are lifted with forks, secured to the carriage attached to
a mast. The load handling is divided into functions lift and lower, tilt,
sideshift, spreading, levelling and carrying loads. Lift and lower is the
function to raise and lower the fork carriage. Side shift is to move the
forks parallel at the same distance with each other laterally along the
carriage. Spreading is to adjust the width between the forks on the car-
riage. Tilt is to angle the load in the machine's longitudinal direction us-
ing the mast. Levelling is to angle the load laterally to the machine.
Load carrying is to grasp the load.
The control systems are functions for warning the operator of danger-
ous situations and faults. The control system has diagnostic resources
that simplify troubleshooting.
The frame carries the machine. Within the frame the engine, transmis-
sion, drive axle, steering axle etc. are secured. On the side of the
frame are tanks for fuel and hydraulic oil. The cab is located centrally
and can be tipped laterally.

4 0 Complete machine – Complete machine

1 Engine 1
1 Engine
Table of Contents 1 Engine

mm mm mm mm mm mm
1 Engine ............................................................................................................. 3
1.2 Fuel system .............................................................................................. 11
1.2.1 Fuel tank .............................................................................................. 13
1.2.2 Fuel filter .............................................................................................. 14
1.2.3 Fuel pre-filter ........................................................................................ 16
1.3 Device for extra exhaust emission control ................................................ 18
1.3.1 Particle filter ......................................................................................... 18
1.5 Mechanical parts ...................................................................................... 19
1.5.4 Valve mechanism ................................................................................ 19
1.5.6 Crank mechanism ................................................................................ 23
1.6 Air intake and exhaust outlet .................................................................... 24
1.6.1 Air cleaning system .............................................................................. 24
1.6.3 Exhaust system ................................................................................... 26
1.6.4 Intercooler ............................................................................................ 27
1.7 Cooling system ......................................................................................... 29
1.7.4 Radiator and expansion tank ............................................................... 29
1.7.5 Cooling fan ........................................................................................... 30
1.7.7 Coolant ................................................................................................ 34
1.7.9 Sensor coolant temperature ................................................................ 40
1.8 Lubrication ................................................................................................ 41
1.8.3 Sensor oil pressure .............................................................................. 41
1.8.4 Oil filter ................................................................................................. 42
1.9 Control system engine .............................................................................. 44
1.10 Ignition/heating ......................................................................................... 45
1.11 Start/stopp ................................................................................................ 46

2 1 Engine

1 Engine – 1 Engine 3
1 Engine
mm mm mm mm mm mm
Engine, general
page
–
The engine provides power for propulsion and working hydraulics. The
following engine alternatives are available:
• Volvo TAD750VE (182 kW).
• Cummins QSB6.7 (194 kW).
Emission requirements
The low emission engines have a new design of combustion bowl, in-
jection equipment and charge air cooler that mean that they meet
emission requirements from USA (California) and Europe. With the
new engines a significant improvement is achieved, not just with ex-
haust emissions, but also with the output curve and the torque curve.
Noise requirements
The engines fulfil the noise and vibration requirements in force
(EN13059).

4 1 Engine – 1 Engine
Engine, function descritption

page
–
(engine alternative Volvo)
0
P I
II
III ˚C
. bar
7 <˚ 1
rpm
<˚
10 kph
ECU790
4
9 F
EDU795 R
R
1 2 3
4 5
ECU793
11
ECU794
2
007970
5 M 3 6 SENSORS 8 H2O
1. Ignition 7. Throttle pedal

2. Control unit engine (ECU794) 8. Switch normally closed (NC) coolant level
3. Preheating coil 9. Control unit terminal (EDU795)
4. Control unit general (ECU790) 10. Sensor fuel level (B757)
5. Starter 11. Control unit transmission (ECU793)
6. Engine sensors

Engine, function descritption

page
–
(engine alternative Cummins)
0
P I
II
III ˚C
H2O
11 . bar
<˚ 1
8 rpm
<˚
10 kph
ECU790
5
9 F
EDU795 R
R
1 2 3
4 5
ECU793
4
ECU794
2
6 M SENSORS
008000
3 7
1. Ignition 7. Engine sensors

2. Control unit engine (ECU794) 8. Throttle pedal
3. Preheating coil 9. Control unit terminal (EDU795)
4. Control unit transmission (ECU793) 10. Sensor fuel level (B757)
5. Control unit general (ECU790) 11. Switch normally closed (NC) coolant level
6. Starter

Electric components machine,

page
–
position
1 2 3 6
4
10b
9
0
P I
8 II 7
10a III
009569
Electric components machine
1. Control unit steering (ECU792) 7. Ignition

2. Control unit hydraulics (ECU796) 8. Throttle pedal
3. Control unit general (ECU790) 9. Control unit transmission (ECU793)
4. Fuel tank 10a. Control unit engine Volvo (ECU794)
5. Sensor fuel level (B757) 10b. Control unit engine Cummins (ECU794)
6. Control unit terminal (EDU795)

Engine, component position (engine

page
–
alternative Volvo TAD750VE)

The engine TAD750VE (182 kW) is a straight 6-cylinder, 4-stroke tur-
bocharged low-emission diesel engine with unit injectors, air-to-air in-
tercooler and electronically controlled fuel injection.
13
12
11
10
9
4 14
15
16
3 17
18
19
20
2 21
22
23
24
007975
1 25
Volvo TAD750VE, left side (in machine's travel direction)
1 Speed sensor, camshaft 14 Alternator

2 Flywheel housing 15 Fuel pump
3 Electrical connection for control unit engine (D794) 16 Coolant pump
4 Coolant temperature sensor 17 Sensor oil pressure
5 High pressure pumps 18 Oil filter
6 Crankcase ventilation 19 Engine mounting
7 Distribution manifold with pressurereduction valve 20 Sensor fuel pressure
8 Injector (6 pc.) 21 Fuel filter
9 Preheating (heater plug) 22 Oil sump
10 Inlet after intercooler 23 Oil dip stick
11 Filling point engine oil 24 Oil drain plug
12 Venting 25 Return oil from separator
13 Fuel pressure in common rail

10
9
8
7
6
5
4
007976
Volvo TAD750VE, right side (in machine's travel direction)
1 Coolant from engine to radiator, after thermostat 6 Turbo

2 Charge air pressure and temperature sensor 7 Speed sensor, flywheel
3 Exhaust manifold 8 Drive belt
4 Starter 9 Coolant inlet
5 Lubricating oil pipe to turbo 10 Fan

Engine, component position (engine

page
–
alternative Cummins QSB6.7)

The engine QSB6.7 (194 kW) is a straight 6-cylinder, 4-stroke turbo-
charged low-emission diesel engine with unit injectors, air-to-air inter-
cooler and electronically controlled fuel injection.
6 7
8
9
10
11
12
3 13
14
2
15
007397
1 16
Cummins QSB 6.7, left side (in machine's travel direction)
1 Clutch mounting holes 9 Coolant inlet

2 Flywheel/flexplate 10 Lubricating oil cooler
3 Crankcase breather tube 11 Oil filter
4 Injector drain line 12 Turbocharger wastegate
5 Lifting bracket 13 Turbocharger compressor inlet
6 Oil fill cap 14 Exhaust manifold
7 Coolant outlet 15 Starter
8 Alternator 16 Flywheel housing

7
6
8
10
5
11
4
12
13
14
15
007396
16
Cummins QSB 6.7, right side (in machine's travel direction)
1 Belt tensioner 9 Intake pressure sensor

2 Water pump 10 Fuel rail
3 Fan drive 11 Rail pressure relief valve
4 Air inlet 12 Fuel filter
5 Coolant temperature sensor 13 Dipstick
6 Turbocharger compressor inlet 14 Electronic control module
7 Turbocharger air outlet 15 Engine speed sensor (crankshaft)
8 High-pressure fuel lines 16 Vibration damper

1 Engine – 1.2 Fuel system 11
1.2 Fuel system

Fuel system, description
page
–
For position of components, see Engine, component position (engine

alternative Volvo TAD750VE) page 7 or Engine, component position
(engine alternative Cummins QSB6.7) page 9.
NOTE
Read the safety instructions for fuel system before working, see
section B Safety.
A
001537
A. Filling point, fuel

Sensor
A. Sensor fuel level
The sensor can be replaced and is installed in the cover on the fuel
tank's top side. See also illustration in section Fuel tank, cleaning page
A 13.
008075

12 1 Engine – 1.2 Fuel system
Fuel system, bleeding (engine alternative Volvo)

page
–
The fuel system must be bled, e.g., after fuel filter replacement, if the
fuel tank has been run dry or after long periods of operation.
NOTE
section B Safety.

2 Open the breather screw (position 1).
1
3 Turn the hand pump anti-clockwise to open the pump.
4 Pump until the flowing fuel is free of air.
5 Tighten the venting screw (position 1) and close the hand fuel
2 pump.
6 Start the engine and check carefully that no leakage occurs.
008065
Volvo TAD750VE

1 Engine – 1.2.1 Fuel tank 13
Fuel system, bleeding (engine alternative

page
–
Cummins)
The fuel system must be bled, e.g., after fuel filter replacement, if the
fuel tank has been run dry or after long periods of operation.
NOTE
section B Safety.

2 Open the breather screw.
3 Turn the hand pump anti-clockwise to open the pump.
4 Pump until the flowing fuel is free of air.
5 Tighten the venting screw and close the hand fuel pump.
008002
Cummins QSB6.7
1.2.1 Fuel tank

Fuel tank, cleaning
page
–
NOTE
section B Safety.
On the top side of the tank is a manhole cover to allow the tank to be
cleaned.
1. Machine in service position, see section B Safety.
2. Empty the fuel out of the tank. Use a pump.
3. Remove the drain plugs under the fuel tank.
4. Flush the fuel tank clean through the fuel filler hole.
5. Put the drain plugs back.

14 1 Engine – 1.2.2 Fuel filter
1.2.2 Fuel filter

Fuel filter, changing (engine alternative Volvo)
page
–
NOTE
section B Safety.

2 Remove the filter.
3 Clean the filter mating surface on the filterbracket
4 Moisten the O-ring on the new filter with fuel.
NOTE
Do not fill the new fuel filter with fuel before installing. There
is a risk that impurities may enter the fuel system, resulting
in malfunctions or damage.
5 Fit the new filter to the engine.
Tighten the fuel filter in accordancewith the instructions on the
fuel filter
6 Bleed the fuel system if necessary, see Fuel system, bleeding
(engine alternative Volvo) page 12.
006434
Volvo TAD750VE
Fuel filter

1 Engine – 1.2.2 Fuel filter 15
Fuel filter, changing (engine alternative Cummins)

page
–
NOTE
section B Safety.

2 Remove the filter.
3 Clean the filter mating surface on the filterbracket
4 Moisten the O-ring on the new filter with fuel.
NOTE
Do not fill the new fuel filter with fuel before installing. There
is a risk that impurities may enter the fuel system, resulting
in malfunctions or damage.
5 Fit the new filter to the engine.
Tighten the fuel filter on by hand until the rubber seal just touches
008003
the mating surface on the filter bracket.

Then tighten further 3/4 of a turn, no more.
Cummins QSB6.7 6 Bleed the fuel system if necessary, see Fuel system, bleeding
Fuel filter (engine alternative Cummins) page 13.
ell

16 1 Engine – 1.2.3 Fuel pre-filter

Fuel pre-filter, changing (engine alternative Volvo)
page
–
NOTE
section B Safety.
2 Unscrew the water reservoir, empty any water and clean the res-
ervoir.
3 Unscrew the filter cartridge.
4 Check that the new filter cartridge is absolutely clean and that the
seal is undamaged. Wipe a film of oil on the gasket.
5 Screw the filter cartridge together with the water reservoir and in-
stall them on the filter bracket.
6 Bleed the fuel system, see Fuel system, bleeding (engine alter-
native Volvo) page 12.
1 7 Start the engine and check carefully that no leakage occurs.
008066
Volvo TAD750VE
1. Fuel pre-filter.
Fuel pre-filter, water draining, (engine alternative

page
–
Volvo)
NOTE
section B Safety.
NOTE
The fuel pre-filter should be drained of water daily.

2 Open the drain valve (position 1) and drain off fuel/water.
3 Close the drain valve and bleed the system, see Fuel system,
bleeding (engine alternative Volvo) page 12.
2
1
008067
Volvo TAD750VE

1 Engine – 1.2.3 Fuel pre-filter 17
Fuel pre-filter, changing, (engine alternative

page
–
Cummins)
NOTE
section B Safety.

2 Open the drain valve and drain off fuel/water.
3 Unscrew the filter cartridge.
4 Check that the new filter cartridge is absolutely clean and that the
seal is undamaged. Wipe a film of oil on the gasket.
5 Screw the filter cartridge together with the water reservoir and in-
stall them on the filter bracket.
6 Bleed the fuel system, see Fuel system, bleeding (engine alter-
1 native Cummins) page 13.
008023
Cummins QSB6.7
1. Fuel pre-filter.
Fuel pre-filter, water draining, (engine alternative

page
–
Cummins)
NOTE
section B Safety.
NOTE
The fuel pre-filter should be drained of water daily.

2 Open the drain valve (position 1) and drain off fuel/water.
NOTE
When closing the drain valve, do not overtighten the valve.
Overtightening can damage the threads.
008004
1
3 Close the drain valve by lifting the valve and turn clockwise until
it is hand-tight, bleed the system, see Fuel system, bleeding (en-
Cummins QSB6.7 gine alternative Cummins) page 13.

18 1 Engine – 1.3 Device for extra exhaust emission control
1.3 Device for extra exhaust

emission control
1.3.1 Particle filter
Particle filter, maintenance
page
–
Every year or every 1500nd hour the particle filter should be cleaned
of fuel and lubricant residue in accordance with the following:
1 Clean burn the filter as normal, see Operator’s manual DCD 200–
300.
2 Allow the filter to cool for 3–4 hours.
3 Detach the clamps and remove the filter section (centre section).
4 Set the filter section vertically and flush with water (not high-pres-
sure) from the outlet side. Flush thoroughly until the water is
clean.
5 Allow the water to run off thoroughly.
6 Refit the filter with new gaskets.

1 Engine – 1.5 Mechanical parts 19
1.5 Mechanical parts

1.5.4 Valve mechanism
Valves, check/adjusting (engine alternative
page
–
Cummins)
2 Preperatory steps:
Disconnect the batteries.
3 Prior to removing any components, clean around the mounting
fasteners and sealing joints with compressed air to remove any
loose debris.
4 Remove:
Disconnect the breather tube connection at the back of the rocker
lever cover, Remove the capscrews to disconnect the breather
tube connection from the rocker lever cover.
008025
NOTE
Do not remove the rocker lever gasket on engines in which
the rocker lever cover gasket is fit into a groove at the base
of the rocker lever cover. The gasket is reusable. Once the
the gasket is removed from the rocker lever cover it must be
replaced.
Remove the mounting nuts and isolators from the rocker lever
cover.
008026
NOTE
If equipped, it may be necessary to gently pry the breather
tube connection from the back of the rocker lever cover
while removing.
Remove the rocker lever cover.

20 1 Engine – 1.5.4 Valve mechanism
NOTE
Check the gasket while it is installed in the valve cover.
Once the gasket is removed from the cover it must be re-
placed.
Check the gasket for cracks on the sealing surface. Replace the
gasket if damage is present or it has been removed from the
groove in the rocker lever cover.
008027
7 If replacing the rocker lever gasket, the following installation pro-
cedure must be used when installing the press-in gasket:
1. Press the molded gasket into the corners of the rocker lever
cover.
2. Press the remaining gasket into the rocker lever cover.
008029
8 Inspect the rubber isolators for cracks, replace if cracked or bro-

ken.
008028
9 Adjust
NOTE
Engine coolant temperature must be less than 60°C.
Using the barring tool, Part Number 3824591, rotate the crank-
shaft until the Number 1 cylinder is at TDC.
TDC can be determined by the following method:
008030

1 Engine – 1.5.4 Valve mechanism 21
NOTE
The TDC indicator is on the vibration damper/crankshaft
speed indicator ring.
Align the vibration damper/crankshaft speed indicator ring so that
the TDC indicator is at the 12 o´clock position. If both number 1
cylinder rocker levers are loose, move to the following steps. If
both number 1 cylinder rocker levers are not loose, rotate the
crankshaft 360 degrees.
NOTE
008031
Cylinder 1 is the cylinder closest to the fan.
10 With the engine in this position, lash can be checked on the fol-
lowing rocker arms:
(E = exhausts, I = intake)
Cylinder 1I, 1E, 2I, 3E, 4I and 5E.
008032
11
Lash Check Limits

mm
Intake 0.152 MIN
0.381 MAX
Exhaust 0.381 MIN
0.762 MAX
NOTE
008033
Checking the overhead setting is usually performed as part

of a troublshooting procedure, and resetting is not required
during checks as long as the lash measurements are within
the above ranges.
NOTE
The clearance is correct when some resistance is “felt”
when the feeler gauge is slipped between the crosshead
and the rocker lever socket.

22 1 Engine – 1.5.4 Valve mechanism
12 Measure lash by inserting a feeler gauge between the crosshead

and the rocker lever socket. If the lash measurement is out of
specification, loosen the locknut, and adjust the lash to nominal
specifications.
Lash specifications
mm
Intake 0.254
Exhaust 0.508
Tighten the locknut and remeasure, torque to 24 Nm.
008034 13 Using barrel tool, Part Number 3824591, rotate the crankshaft
360 degrees.
Following the same steps and specifications as previously stated,
measure lash for the following rockers:
(E = exhausts, I = intake)
Cylinder 2E, 3I, 4E, 5I, 6I and 6E.
008030
14 Install:
Install the rocker lever cover over the mounting capscrews.
Install the isolators and mounting nuts.
Tighten the mounting nuts and torque to 24 Nm.
008026
15 Prior to connecting the breather connection tube to the rocker le-

ver cover, apply clean engine oil to the o-ring located on the
breather tube connection.
16 Connect the breather tube connection to the rocker lever cover.
Tighten the capscrews and torque to 10 Nm.
17 Finishing steps:
Connect the batteries.
18 Operate the engine and check for leaks.
008035

1 Engine – 1.5.6 Crank mechanism 23
1.5.6 Crank mechanism

Vibration damper, viscous, inspect (engine
page
–
alternative Cummins)
CAUTION
The silicone fluid in the vibration damper will become
solid after extended service and will make the damper
inoperative. An inoperative vibration damper can
cause major engine or drivetrain failures.
Check the vibration damper for evidence of fluid loss, dents, and wob-
ble. Inspect the vibration damper thickness for any deformation or rais-
ing of the damper cover plate.
If any of these conditions are identified, contact your local Cummins
Authorized Repair Location to replace the vibration damper.
For vibration damper location, see Engine, component position (en-
gine alternative Cummins QSB6.7) page 9.
008038

24 1 Engine – 1.6 Air intake and exhaust outlet
1.6 Air intake and exhaust outlet

1.6.1 Air cleaning system
Air filter, changing
page
–

2 Raise the engine hood.
A
A
C C
001539
B
A. Position for air filter housing
B. Change indicator
009555
C. Soot outlet
A. Position for air filter housing

B. Change indicator
C. Soot outlet

1 Engine – 1.6.1 Air cleaning system 25
3 Check that the dust ejector has emptied itself. Otherwise, empty
the ejector.
4 Clean the outside of the air filter housing
5 Remove the cap from the air filter housing.
6 Remove the primary filter.
7 When needed, change the safety insert. The safety insert is

changed every other time.
8 Fit the new primary filter.
NOTE
Filter must be changed, not cleaned.
9 Fit the cover to the air cleaner casing.
10 Check that the hoses from the cleaner casing are sealed.

26 1 Engine – 1.6.3 Exhaust system
11 Reset the air filter indicator, press the button on the top side.

Exhaust system, check
page
–
WARNING
Hot exhaust system! When the machine is operated
the exhaust system, and mainly the turbo and silenc-
er, become scorching hot.
Risk of burn injuries!
Never touch turbo and silencer when the machine is

running or immediately after it has been switched off!

2. Check the exhaust system for leakage and other wear.
3. Check that the exhaust system mountings are intact.

1 Engine – 1.6.4 Intercooler 27
1.6.4 Intercooler
Intercooler, check
page
–
CAUTION
Avoid the intercooler when using a power washer.

2 Remove the protective grille.
3 Clean the intercooler with compressed air.
NOTE
Do not use a high-pressure washer.
4 Check that the intercooler mounting is intact.
5 Check that hoses and clamps for the intercooler are in good con-
dition and that no leakage exists.

28 1 Engine – 1.6.4 Intercooler
Charge air hose, check

–

2. Check the charge air hoses, hose connections and clamps for vis-
ible cracks and external damage. If there is leakage in the system
the charge pressure will be too low and engine power will be re-
duced.
3. Check that there is no oil in the charge air hoses. I If the hoses
have internal oil contamination, this indicates oil leakage from the
turbocharger spindle seal. In this case, the turbo charger must be
changed as a unit.
NOTE
If there is oil in the charge air hoses, the intercooler and all
pipes and hoses in the charge air system must be cleaned
very carefully before the engine is started.

1 Engine – 1.7 Cooling system 29
1.7 Cooling system

1.7.4 Radiator and expansion tank
Radiator, cleaning
page
–

2 Remove the protective grille.
3 Clean the radiator with compressed air.
NOTE
Do not use a high-pressure washer.
NOTE
Avoid the fuel cooler.
4 Check that the cooling flanges are intact.

30 1 Engine – 1.7.5 Cooling fan
1.7.5 Cooling fan

Drive belt/Alternator belt, check
page
–
Inspection should be done after operation, when the belts are hot.
Check the belts for intersecting cracks. Tranverse (across the belt
width) cracks are acceptable, Longitudinal (direction of the belt length)
cracks that intersect with transverse cracks are not acceptable. Re-
place the belt if it is frayed or has pieces of material missing. See Drive
belt changing (engine alternative Volvo) page 30 or Drive belt chang-
ing (engine alternative Cummins) page 31 for belt adjustment and re-
placement.
Belt damage can be caused by:
008011 • Incorrect tension
• Incorrect size or length
• Pulley misalignment
• Incorrect installation
• Severe operating enviroment
• Oil or grease on the side of the belts
It should be possible to press the alternator belts and drive belts down
about 3-4 mm (0.12-0.16") betweenthe pulleys.
The alternator belts and drive belts have automatic belt tensioners and
do not need to be adjusted.
IMPORTANT
Always change a drive belt which appears worn or
cracked
008012
Drive belt changing (engine alternative Volvo)

page
–

2. Undo the belt tensioner and fix it with a mandrel (position 1).
008064
Volvo TAD750VE

1 Engine – 1.7.5 Cooling fan 31
3. First remove the belts from the coolant pump.

4. Install the new belts.
Undo the belt tensioner. Check that the belts are correctly aligned
in their grooves and are correctly tensioned.
007969
Volvo TAD750VE
Drive belt changing (engine alternative Cummins)

page
–

2. Lift the tensioner to remove the drive belt.
NOTE
The belt tensioner winds in the direction that the spring tang
is bent over the tensioner body. To loosen the tension on the
belt, rotate the tensioner to wind the spring tighter.
CAUTION
008013
Applying excessive force in the opposite direction of

windup or after the tensioner has been wound up to
the positive stop can cause the tensioner arm to
break.
3. Lift the tensioner and install the drive belt. If difficulty is experi-
enced installing the drive belt (the belt seems to short), position
the belt over the grooved pulley first; then, while holding the ten-
sioner up, slide the belt over the water pump pulley.
Undo the belt tensioner. Check that the belts are correctly aligned
in their grooves and are correctly tensioned.

32 1 Engine – 1.7.5 Cooling fan
Cooling fan belt tensioner, check (engine alternative

page
–
Cummins)
With the engine turned off, check that neither the top nor the bottom
tensioner arm stop is touching the cast boss on the tensioner body. If
either of the stops is touching a boss, the alternator belt must be re-
placed. Check to make certain the correct belt part number exists.
008014
Check the tensioner pulley and body for cracks. If any cracks are no-
ticed, the tensioner must be replaced. See Supplier documentation
engine.
Check the tensioner for dirt buildup. If this condition exists, the tension-
er must be removed and steam cleaned.
008015
With the cooling fan belt removed, check that the bottom tensioner arm
stop is in contact with the bottom tensioner arm stop boss on the ten-
sioner body. If these two are not touching, the tensioner must be re-
placed.
008016
Inspect the tensioner for evidence of the pivoting tensioner arm con-
tacting the stationary circular base. If there is evidence of these two ar-
eas touching, the pivot tube bushing has failed and the tensioner must
be replaced.
008017

1 Engine – 1.7.5 Cooling fan 33
The worn tensioner that has play in it or a belt that “walks” of its pulley
possibly indicates pulley misalignment.
NOTE
Maximum pulley misalignment is 3 degrees
This measurement can be taken with a straight edge and an inclinom-
eter.
Install the belt.
008018
Fan hub, check (engine alternative Cummins)
page
–

2. Remove the drive belt, see Drive belt changing (engine alternative
Cummins) page 31.
NOTE
The fan hub must rotate without any wobble or excessive
end play.
Fan Hub End Play

mm
0,15 MAX
008019

34 1 Engine – 1.7.7 Coolant
1.7.7 Coolant
Coolant, check
page
–
NOTE
Read the safety instructions for cooling system before working,
see section B Safety.

2 Open the pressure cap on the expansions tank.
3 Measure the content of glycol antifreeze with the coolant tester.
NOTE
The coolant must comprise water and at least 40 percent
volume glycol antifreeze in those countries where the tem-
perature can fall below 0 °C. The glycol antifreeze content
must not exceed 60 percent volume in mixed coolant.
If only glycol antifreeze and water have been used as cool-
ant then the value must exceed -15 °C or 30 percent volume
C A B
for the corrosion protection to be adequate.
4 Check the coolant level, the level must be between MAX and
MIN.
MAX
NOTE
The coolant level must be checked on a engine cold.
MIN
001540
A. Position of coolant reservoir (expansion tank)

B. Pressure cap for filling
C. Level marking, MIN and MAX

1 Engine – 1.7.7 Coolant 35
Coolant system, changing and cleaning (engine

page
–
alternative Volvo)
Cooling performance is reduced by deposits in the radiator and cool-
ing galleries. The cooling system should be cleaned out when the cool-
ant is changed.
IMPORTANT
Cleaning must not be done if there is any risk of the
cooling system freezing, since the cleaning solution
does not have any frost prevention ability.
NOTE
NOTE
The engine must be stopped before draining, and the filler cap
unscrewed.
1 Remove the filler cap from cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block, using the drain hose.The drain nipples are situated
under the radiator on the right side of the engine block.
3 Check that all coolant drains out.
NOTE
Deposits may be found inside the drain plug/tap, and need
to be cleared away. There is otherwise a risk that cool-ant
could remain and cause frost damage.
Check whether the installation has any further taps or plugs at the
007394
lowest points of the cooling water pipes. Leave the drain taps /
plugs open and make sure that the heater is set to full heating
Volvo TAD750VE while it is being cleaned.
4 Put a hose into the filling hole in the expansion tank and flush with
pure water, until the water which runs out is completely clear.
5 If there should still be some contamination left after flushing for a
long time, cleaning can be done with coolant. Otherwise, contin-
ue as in item 10 below.
6 Cleaning with coolant:
Fill the cooling system with 15-20% mixture of concentrated cool-
ant. Only use the recommended concentrated coolant, mixed
with pure water.

7 Drain the coolant after 1-2 days of operation
NOTE
To prevent suspended material from settling back in the system,
emptying should be done rapidly, within the space of 10 minutes,
when the engine has not been standing still for a long time. Re-
move the filler cap from the expansion tank and possibly the low-
er radiator hose to increase the speed of emptying.
8 Flush the system at once, very carefully, with pure hot water to
stop dirt from settling on the inner surfaces again. Flush until the
water that runs out is completely clean. Make sure that any heat-
er controls are set to full heating during emptying.
9 If contamination should still be left after a long period of flushing,
you can do a clean-out with radiator cleaner, followed by finish-
ing-off with neutraliser.
NOTE
Only use cleaning material approved by the engine manu-
facturer. Follow the instructions on the package carefully.
10 When the cooling system is completely free from contamination,
close the drain taps and plugs.
NOTE
Only use recommended coolant.
IMPORTANT
It is extremely important that the correct concentra-
tion and volume of coolant is put in the system. Mix in
a separate clean vessel before filling the cooling sys-
tem. Make sure that the liquids mix.
11 Fill up with coolant, so that the level ends up between the MIN
and MAX markings. Do not start the engine until the system is
vented and completely filled.
12 Start the engine when the cooling system has been completely
filled and bled.
Open all heater controls on the heater unit, to ensure that it is
vented.
13 Stop the engine after about an hour and check the coolant level.
Top up as necessary.

Coolant system, changing and cleaning (engine

page
–
alternative Cummins)
Cooling performance is reduced by deposits in the radiator and cool-
ing galleries. The cooling system should be cleaned out when the cool-
ant is changed.
IMPORTANT
Cleaning must not be done if there is any risk of the
cooling system freezing, since the cleaning solution
does not have any frost prevention ability.
NOTE
NOTE
The engine must be stopped before draining, and the filler cap
unscrewed.
1 Remove the filler cap from cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block. One drain nipple is situated under the radiator and an-
other one on the underside of the coolant inlet on the engine
block.
3 Check that all coolant drains out.
NOTE
Deposits may be found inside the drain plug/tap, and need
to be cleared away. There is otherwise a risk that cool-ant
could remain and cause frost damage.
008020
Check whether the installation has any further taps or plugs at the
lowest points of the cooling water pipes. Leave the drain taps /
plugs open and make sure that the heater is set to full heating
while it is being cleaned.
CAUTION
The system must be filled properly to prevent air
locks. During filling, air must be vented from the en-
gine coolant passages. Wait for 2 to 3 minutes to al-
low the air to be vented; then add mixture to bring the
level to the top.

5 Cleaning:
NOTE
Do not install the radiator cap. The engine is to be operated
without the cap for this process.
Fill the system with a mixture of sodium carbonate and water (or
a commercially available equivalent).
NOTE
008021
Use 0.5 kg of sodium carbonate for every 23 liters of water.
6 Operate the engine for 5 minutes with the coolant temperature

above 80°C.
Shut the engine off, and drain the cooling system.
7 Fill the system with good-quality water.
NOTE
Be sure to vent the engine for complete filling.
NOTE
Do not install the radiator cap.
008022
8 Operate the engine for 5 minutes with the coolant temperature

above 80°C.
Shut the engine off, and drain the cooling system.
NOTE
If the water being drained is still dirty, the system must be
flushed again until the water is clean.
9 When the cooling system is completely free from contamination,
close the drain taps and plugs.
NOTE
Only use recommended coolant.
NOTE
Never use water alone for coolant. Damage from corrosion can
be the result of using water alone for coolant.
IMPORTANT

10 Fill:
Fill up with coolant, so that the level ends up between the MIN
and MAX markings. Do not start the engine until the system is
vented and completely filled.
11 Start the engine when the cooling system has been completely
filled and bled.
Open all heater controls on the heater unit, to ensure that it is
vented.
Coolant, mixing
page
–
NOTE
IMPORTANT
Ethylene glycol must not be mixed with other types of
glycol.
Use glycol which applies to ASTM4985 (GM6038M)
Mix:
50% glycol.
50% water.
This mixture prevents against internal corrosion, cavitation and frost
bursting down to about -36°C and a boiling point up to 108°C. (At 60%
glycol concentration, the freezing point is lowered to -54°C. Never mix
more than 60% concentrate in the coolant. This will give reduced frost
protection and poorer cooling effect, with a consequent risk of over-
heating.
IMPORTANT
The coolant must be mixed with pure water.
007395
IMPORTANT

40 1 Engine – 1.7.9 Sensor coolant temperature
NOTE
It is important that the coolant is correctly mixed, all year round,
to ensure full protection against corrosion. The corrosion protec-
tion properties fall as time passes, so the coolant must be
changed at the specified intervals.
1.7.9 Sensor coolant temperature

Sensor coolant temperature, component position
page
–
For an overview with the locations of engine sensors, see Engine,

component position (engine alternative Volvo TAD750VE) page 7 or
Engine, component position (engine alternative Cummins QSB6.7)
page 9.

1 Engine – 1.8 Lubrication 41
1.8 Lubrication
Lubrication, description
page
–
The engine's lubrication system is a completely closed system and

has no connections to the machine.
page 9.
Engine oil, change

page
–
NOTE
Read the safety instructions for oil before working, see section B
Safety.
Always follow the recommended oil change interval and always
change the oil filter during oil changes.
1 Run the engine until warm.
3 Remove the drain plug on the engine and drain the engine of oil.
4 When the engine oil has drained, install the oil plug with new gas-
ket. Torque with max. 79 Nm for engine alternative Volvo and
with 80 Nm for engine alternative Cummins.
NOTE
Do not tighten the oil plug with higher tightening torque, the
threads will be damaged.
5 Change oil filter, se Oil filter, changing page 42.
6 Fill up with oil to the correct level. For volume and grade, see sec-
tion F Technical data.
007317
NOTE
Do not fill over the MAX level.
7 Start the engine and let it idle. Check that the oil pressure is nor-
mal.
8 Stop the engine, check the oil level, see Oil level, checking page
43 and that no oil leakage occurs around the filters. Top up with
oil as necessary.
1.8.3 Sensor oil pressure

Sensor oil pressure, component position
page
–

page 9.

42 1 Engine – 1.8.4 Oil filter
1.8.4 Oil filter

Oil filter, changing
page
–
NOTE
Safety.
NOTE
Oil filters must be changed at every oil change
1. Drain the oil, see Engine oil, change page 41.
007360
Engine alternative Volvo

2. Remove the oil filter.
3. Check that the mating surfaces on the filter bracket are clean and
that no gasket residue from the old filter has been left behind.
Put a thin layer of oil on the seal ring of the new oil filter and mating
surface on the filter bracket, fill up the new oil filter with clean oil.
For volume and grade, see section F Technical data.
4. Screw the filter on by hand until the rubber seal just touches the
mating surface on the filter bracket.
Engine alternative Volvo: Then tighten a further turn, no more.
Engine alternative Cummins: Then tighten further 3/4 of a turn,
008006
no more.
Engine alternative Cummins 5. Top up with oil, see Engine oil, change page 41
6. Start the engine and check that no oil leakage occours.

1 Engine – 1.8.4 Oil filter 43
Oil level, checking

page
–
NOTE
Safety.
The engine's fill poin (position B) and oil dipstick (position A) are lo-
cated under the engine hood, for engine alternative Volvo on the left-
hand side and for engine alternative Cummins on the right-hand side.
009554
Volvo TAD750VE
A. Oil dipstick
B. Fill point engine oil
2 Check the oil level when the engine is warm. The oil dipstick has
two markings, MAX. and MIN., the oil level should be between
these markings.
Wipe off the oil dipstick before checking.
3 Fill engine oil (position B) as needed (for volume and oil quality,
see section F Technical data).
4 The recommendation is that engine oil is filled when the engine
and oil are at operating temperature. Fill – wait awhile – check on
the oil dipstick.
NOTE
Work carefully when filling to prevent other fluids or particles
from contaminating the engine oil, which means risk of en-
B
gine damage.
007390
Cummins QSB6.7
A. Oil dipstick
B. Fill point engine oil

44 1 Engine – 1.9 Control system engine
1.9 Control system engine

Control system engine, description
page
–
The engine is controlled by a control system, for which the central unit
is a control unit.
The system is among other things sensors, control unit and elektrical
injectors. Sensors sends information to the control unit which controlls
the fuel injectors.
Control unit receives information about the engines condition from the
following components:
• Camshaft position sensor
• Flywheel position and speed sensor
• Sensor coolant temperature
• Sensor charge pressure and temperature
• Sensor oil pressure
• Sensor water-in-fuel
• Sensor fuel pressure
• Sensor low fuel pressure (only applies to engine alternative Volvo)
• Sensor coolant level (only applies to engine alternative Volvo)
• Sensor ambient air temperature (only applies to engine alternative
Volvo)
• Sensor barometric pressure (only applies to engine alternative
Cummins)
Based on this information control unit controls:
• injection time
• electronic pre-heating (heater plug)
If a serious problem is detected by the control system for the engine,
engine power is reduced to protect the engine from further damage.
Signals from the sensors gives exact information about the engines
present condition and makes it possible for the processor in the control
unit, to among other things calculate the correct amount of fuel needed
and control the engine status.
For further information about control unit engine, see section 11 Com-
mon electrics, group 11.5.3 Control units and supplier documentation
engine.

1 Engine – 1.10 Ignition/heating 45
1.10 Ignition/heating
Ignition/heating, description
page
–
The engine is equipped with preheating of the inlet air, for faster start
at low temperatures. Preheating is activated when the starter key is in
position I. When preheating is activated, the preheating symbol is lit in
the display. The ignition sends signals to Control unit General
(ECU790) which sends messages via the CAN-bus link to the engine
control unit (ECU794).
page 9.

46 1 Engine – 1.11 Start/stopp
1.11 Start/stopp
Start/stop, general
page
–
The electrical system works with 24 volts voltage.

The plus terminal is connected to a battery disconnect switch (A).
1. When starting, gear lever must be in neutral.
2. Turn the ignition to position 1, pre-heating is activated if needed
and a pre-heating symbol is lit in the display.
3. Turn the ignition to position 3, ECU790 sends signal to the engine
on CAN-bus for engine alternative Volvo or pulls the starter direct
on the digital outlet for engine alternative Cummins until engine
A-C starts.
4. Engine is stopped by turning the ignition to position 0.
NOTE
The battery disconnect switch cannot be used as emergency
stop!
A. Battery disconnect switch
B. Sign to depict battery disconnect switch in ON position, i.e. main
electric power connected, and battery disconnect switch in OFF posi-
tion, i.e. main electric power disconnected
C. Handle to open/close cover
001549
A B C

2 Transmission 1
2 Transmission
Table of Contents 2 Transmission

mm mm mm mm mm mm
2 Transmission.................................................................................................. 3
2.3 Mechanical transmission ............................................................................ 6
2.6 Lubrication system ..................................................................................... 7
2.6.4 Oil filter ................................................................................................... 9
2.7 Cooling system ......................................................................................... 10
2.8 Transmission control system .................................................................... 11

2 2 Transmission

2 Transmission – 2 Transmission 3
2 Transmission
mm mm mm mm mm mm
Transmission, function description

page
–
The transmission converts the engine power to the drive wheels (drive
axle) via the propeller shaft and also power to drive the hydraulic oil
pumps for the hydraulic system.
The transmission is manual with torque converter. The transmission
has three speeds in each direction.
The torque converter and the transmission work together via a com-
mon hydraulic system. The torque converter is a hydraulic clutch
placed between the engine's output shaft and the transmission's input
shaft. The hydraulic oil pumps as well as the oil pump for the transmis-
sion's control and lubrication are mounted on the torque converter, but
are directly connected to the input shaft of the torque converter, i.e.
they are directly driven by the engine and are not affected by the
torque converter.
Gear positions are selected by pressure modulation with electrical
valves that are controlled by Control unit transmission (ECU793). The
control unit uses sensors for pressure, temperature and speeds to de-
termine which gear position shall be activated as well as solenoid
valves to activate the gear.

4 2 Transmission – 2 Transmission
F
R
1 F
3 D2 N
18 R
D3 <˚ D1 R
6 1
4
2
5
3
D5 20
D4 ECU790
19 Pa
2 16
EDU795
9 17
ECU793 ECU794
7, 8, 10, 11, 12, 13, 14 SENSORS
5
15
009542
1. Gear selector (S160) 11. Sensor turbine speed (B751)
2. Control unit general (ECU790) 12. Sensor drum speed (B752)
3. Switch parking brake (S107) 13. Sensor output shaft speed (B758)
4. Oil pump transmission 14. Temperature monitor torque converter (S221)
5. Oil filter transmission 15. Oil cooler
6. Accelerator pedal (R690-1) 16. Control unit terminal (EDU795)
7. Sensor oil pressure 17. Control unit engine (ECU794)
8. Sensor engine speed and oil temperature (B753) 18. Inching pedal
9. Control unit transmission (D793) 19.

Switch (NO) declutch
10. Solenoid valves for travel direction and gear position 20.
Switch for inching (S220-1)
in valve block transmission control

2 Transmission – 2 Transmission 5
Transmission, component position

–
1 2 3 4 5 6
5
9
10
11
8
15 12
14
007771
13
1. Control unit transmission (ECU 793) 9. Hoses cooling

2. Gear box 10. Thermal by-pass valve
3. Sensor temperature outgoing, for oil cooler 11. Sensor turbine speed (B752)
4. Torque converter 12. Sensor output shaft speed (B758)
5 Sensor engine speed (input shaft) temperature in the 13. Transmission oil cooler
sump
6. Sensor oil pressure 14. Oil filler
7. Sensor, coupling drum speed 15. Cross toothed flange (for connection to propeller shaft)
8. Oil filter transmission

6 2 Transmission – 2.3 Mechanical transmission
2.3 Mechanical transmission

Mechanical transmission, description
page
–
The transmission is built with all gears in constant mesh. It is shifted

through hydraulic pressurising of clutch discs for each one of the
gears. The clutch discs connect the input shaft with the main shaft or
tubular shaft, depending on which gear has been selected. Shifting
takes place without disengaging the transmission from the engine.
The clutches for FORWARD and REVERSE are modulated electro-
hydraulically, which means that the clutch pressure builds up gradual-
ly. This allows shifting between FORWARD and REVERSE, and vice
versa, while operating at a speed lower than set limit value. Modulation
also gives smooth shifting between FORWARD and REVERSE.
High modulation (that is, soft operation/intensive slipping between
gear positions) results in high transmission wear and high oil temper-
ature. The sensor for oil temperature generates a warning when the oil
gets warmer than 100 °C. If the oil temperature sensor indicates
125 °C, the transmission’s function ceases.
There are three gears in each direction for the transmission. Discon-
nection of drive occurs naturally at a certain brake pressure.
The electronic gear change system is either manual or automatic. A
clutch (disengagement) function is operated with a separate clutch
pedal that starts to function at a certain brake pressure.
For position of components see Transmission, component position
page 5.

2 Transmission – 2.6 Lubrication system 7
2.6 Lubrication system

Lubrication system, description
page
–
The transmission has its own lubrication system that is used for lubri-
cation, control and cooling of the transmission. The transmission oil
cooler is located at the bottom in the cooler unit behind the engine, a
thermostat in the cooler enables the oil to reach operating temperature
faster.
At high oil temperature (100 °C) a warning is activated in Control unit
terminal (ECU795) and performance is reduced, if the oil temperature
goes above 125 °C the transmission is disengaged.
For component positions, please refer to Transmission, component
position page 5.
Transmission oil, changing

page
–
NOTE
Safety.
NOTE
The transmission must not be overfilled!
Equipment: collection vessel for transmission oil (30 l)
NOTE
The oil filter must be changed at the same time as an oil change
is done.
1 Operate and warm up the transmission oil.
3 Stop the engine and turn the main switch off.
4 Place a receptacle under the transmission and let the oil drain
into the receptacle.
5 Remove the drain plug from the transmission.
6 Clean the drain plug and sealing surface on the transmission.
7 When the transmission oil has drained, fit the drain plug.
NOTE
Make sure that the washer for the oil plug is included.

8 2 Transmission – 2.6 Lubrication system
8 Remove the transmission oil dipstick and fill new transmission oil
through the oil dipstick's hole to the marking for low level on the
dipstick.
For volume and quality, see section F Technical data.
9 Start the engine and let it idle for at least two minutes.
10 Check that the drain plug for transmission oil seals tight.
11 Check the transmission oil level with the engine running at idle
(600 rpm) and the transmission in neutral position. Top up to the
marking for low level.
Oil dipstick and filling point transmission oil

12 Warm up the transmission so that the oil temperature is 60-70 °C.
Use the operating menu to check the transmission oil tempera-
60 ˚C a
ture.
13 Check the oil level and top up to the MAX marking for oil level.
- +
28.7 V b
006995
NOTE
After an oil change, we recommend that the transmission should
Operation menu oil temperature be calibrated, please refer fo Transmission, calibration page 12.
a. Transmission oil temperature
b. Battery voltage

2 Transmission – 2.6.4 Oil filter 9
2.6.4 Oil filter

Transmission oil filter, changing
page
–
NOTE
Safety.
NOTE
The transmission must not be overfilled!
Special tools: filter tool
Equipment: collection vessel (5 l)
2 Place a collection vessel underneath the transmission oil filter.
3 Remove the transmission oil filter, pour out the oil in the collection
vessel.
4 Moisten the O-ring on the new filter with clean transmission oil.
5 Fit the new transmission oil filter.
Tighten to contact and then a further two-thirds revolution.
6 Switch on the main circuit and start the engine.
7 Check that no leakage occurs.
8 Check the oil level, see Transmission oil, changing page 7

10 2 Transmission – 2.7 Cooling system
2.7 Cooling system

Cooling system, description
page
–
The transmission is cooled by the lubrication system see Lubrication

system, description page 7.
page 5.

2 Transmission – 2.8 Transmission control system 11
2.8 Transmission control system

Transmission control system, description
page
–
The transmission control unit controls shifting based on pressure sen-

sors, temperature sensors and speed sensors. Gear selection takes
place by activating solenoid valves that distribute control pressure in
the transmission, so that selected gear gives the correct speed.
page 5 and section 11 Common electrics, group 11.5.3 Control units.
In case of serious transmission problems, the control unit uses two
modes with reduced functionality to protect the transmission, Shut-
down and Limp-home.
Mode Limp-Home
Display on Control unit transmission shows LH.
In case of:
• a malfunction of a control output from the transmission is detect-
ed.
• a malfunction connected to a sensor for “engine speed” is detect-
ed.
• two of three “vehicle speed” sensors are defective.
In case any of the above points occur, the transmission will be placed
in neutral position. To enable continued operation, gears have to be
selected using the gear selector.
In this mode the operator can use the transmission's two first gears in
both directions. If the malfunction occurs at a higher gear, the operator
has to downshift manually to first or second gear to continue.
The control unit uses standard values for modulation.
Mode Shut-Down
Display on Control unit transmission shows “Sd”.
The transmission has a built-in secondary solenoid and pressure sen-
sor that monitor the transmission's internal oil pressure. The second-
ary solenoid is handled by the control unit.
When the control unit gives a control signal for “Shut-Down“, the oil
pressure releases for all pressure modulators. This happens in case
of a serious malfunction.
In this mode the transmission is in permanent neutral position as there
is no oil pressure to enable selection of a gear.

12 2 Transmission – 2.8 Transmission control system
Transmission, calibration
page
–
DANGER
Do not leave the machine during calibration. The ma-
chine may start to move.
1 Park the machine on level ground, engage neutral position and

apply the parking brake. Run the engine at idling speed.
2 To select the function to calibrate, first navigate to the service
menu. Then press Enter.
000056
3 Enter code for calibration.

The code is obtained via Kalmar Industries Support.
1 23
4 5 NOTE
000060
The code determines which service menu shall be activated

(Diagnostics, Initiation or Calibration).
4 Select AUTOMATIC GEAR SHIFT ECU 793 by scrolling with the
arrow keys (1 and 2) and confirm with Enter.
AUTOMATIC GEAR SHIFT
ECU793
007741
5 Select CALIBRATION by scrolling with the arrow keys (1 and 2)

AUTOMATIC 2(2) and confirm with Enter.
GEAR SHIFT ECU793
CALIBRATION
007742
6 Select “Heat” by scrolling with the arrow keys (1 and 2) and con-
ECU793 D M firm with Enter.
E
007745
F S
7 Raise the temperature in the transmission by:

ECU793 D M A. Apply the parking brake so that the machine is stationary.
E
B. Select travel direction forward or backward and apply half to
007744
F S
maximum acceleration for 20 seconds.
C. Engage neutral position and apply half throttle for 10 sec-
onds, run the engine at idling speed.
D. Repeat steps B and C until the oil temperature is over 60 °C
or max 90 °C. The temperature display starts to flash when
calibration of the clutches can start.
8 Check that the gear control is in neutral position.

2 Transmission – 2.8 Transmission control system 13
9 Select “trAn” by scrolling with the arrow keys (1 and 2) and con-
ECU793 D M firm with Enter.
E 10 Start calibration by selecting travel direction forward.
007745
F S
11 The current temperature is displayed if it is lower than 60°C. If

ECU793 D M not, “Go F” is displayed. If all conditions to start calibration are
E met, the calibration process starts.
007743
F S The transmission will activate different gears during calibration.
NOTE
If the machine starts to move during calibration then use the
foot brake to keep the machine stationary.
IMPORTANT
The transmission calibration process can be inter-
rupted at all times by moving the shift lever into the
reverse position.
12 Calibration starts (takes approx. 15 minutes).

ECU793 D M During calibration, “c1.n1”, “c1.n2”, “c2.n1”, “c2.n2” etc. are dis-
E played. This means clutch 1 and mode 1-2, clutch 2 and mode 1-
007747
F S 2 etc.
13 Depending on the actual calibrating mode, a different engine
speed may be required.
– Whenever the actual engine speed is too low following dis-
ECU793 D M play is shown:
E
007748
F S
– When the actual engine speed is too high, the display looks
ECU793 D M as follows:
E
007749
F S
14 Change the throttle pedal position until the display looks like left.
ECU793 D M After the engine has been within limits for about three seconds,
E the calibration process proceeds.
007750
F S
After successful completion of the calibration process, the
calibration results are memorised in Flash memory.

14 2 Transmission – 2.8 Transmission control system
15 After calibrating, donE is shown in the display.

ECU793 D M When one or more errors were encountered during calibration
E the display shows vertical lines to indicate the calibration result of
007751
F S each clutch (the first line corresponds to clutch1, the second line
to clutch2,…). A blinking line indicates the calibration of the cor-
responding clutch was no successful.
16 Turn off the ignition to store the values.

3 Driveline/axle 1
3 Driveline/axle
Table of Contents 3 Driveline/axle

mm mm mm mm mm mm
3 Driveline/axle .................................................................................................. 3
3.2 Propeller shaft ............................................................................................ 4
3.3 Drive axle ................................................................................................... 5

2 3 Driveline/axle

3 Driveline/axle – 3 Driveline/axle 3
3 Driveline/axle
mm mm mm mm mm mm
Driveline/axle, description
page
–
The machine's power transmission consists of propeller shaft and

drive axle with differential and hub reduction.

4 3 Driveline/axle – 3.2 Propeller shaft
3.2 Propeller shaft

Propeller shaft, description
page
–
The propeller shaft transmits the engine power from transmission to

the drive axle.
Propeller shaft, checking

page
–
• Clean.
• Check-tighten attaching bolts at mountings to:
– drive axle for DCD 200-250 with 98 Nm and DCD 280-300
with 133 Nm
– transmission with 98 Nm (oil)
• Check clearance in universal joints.
1
007803
1. Propeller shaft

3 Driveline/axle – 3.3 Drive axle 5
3.3 Drive axle

Drive axle, description
page
–
The drive axle transmits the engine power to the wheels. After the
drive axle's input shaft is a differential which changes the reduction ra-
tio, distributes the power between right and left drive wheels and also
makes it possible for the drive wheels to rotate at different speed when
cornering. The drive shaft transmits the power from the differential to
the wheel hubs. There are hub reductions at the wheel hubs that
change the reduction ratio between wheel and engine to reduce the
stress on the drive shaft.
2
3
007809
DCD 200-250
1. Hub reduction
2. Drive shaft
3. Differential
4. Drive axle housing

6 3 Driveline/axle – 3.3 Drive axle
2
3
007810
DCD 280-300
1. Hub reduction
2. Drive shaft
3. Differential
4. Drive axle housing

Drive axle, checking

page
–

2 Check the drive axle's attachment to the frame so that there is no
corrosion on structural elements (e.g., attaching bolts).
A
007804
DCD 200-250
3 Check-tighten the drive axle's attaching bolt (position A) with
1350 Nm.
007805
DCD 280-300

4 Make a visual check of the drive axle welding joints (position A)

at the mountings.
5 Check that drive axle and hub reductions seals tight. Listen for
unwanted noise.
6 Check the bolted joint to the parking brake calliper’s attaching
plate and brake disc.
007806
7 Check if the wheel bearings in the driving axle are slack by:
– Lift the machine under the mast member. Install secure sup-
ports under the driving axle.
– Check if the wheel bearings in the driving axle are slack. If
there is any slack in the wheel bearings, they must be adjust-
ed, please refer to Workshop manual DCE 200-300.

Drive axle oil, level check

page
–
NOTE
Read the safety instructions for oil before work, see section B
Safety.
Equipment: receptacle (30 l).

1 Position the machine so that the hub reduction drain plugs on the
wheels are at the bottom.
2 Switch off the engine and apply the parking brake.
3 Place a container at the hub. Lay a section of plate or similar on
the rim to guide the oil into the container.
4 Remove the level plug.
Fill one hub with oil until the oil level is on the lower edge of the filler
hole.
5 Check that the oil level is on the lower edge of the filler hole. Top
up if necessary.
6 Fit the hub reduction filler plug.
NOTE
Make sure that the seal is in place
7 Repeat steps 1 and 6 on the other hub.
007845
Drive axle oil, changing

page
–
NOTE
Safety
Equipment: receptacle (50 l)

1 Position the machine so that the hub reduction drain plugs on the
wheels are at the bottom.
Wheel 1: move forwards or backwards to obtain the correct posi-
tion.
Wheel 2: Lift the wheel from the ground (lift the machine under
the mast) and turn the wheel to the correct position. Lower the
machine. Lower the wheel.
2 Switch off the engine and apply the parking brake.
3 Place a receptacle underneath the differential carrier assembly
drain plug.
NOTE
The drive axle contains approx. 44 l of oil.

4 Remove the differential carrier assembly drain plug.

5 Place a container at each hub. Lay a section of plate or similar on
the rim to guide the oil into the container.
6 Remove the drain plug and the level plug.

8 When the oil has run out, refit the drain plugs.
NOTE
Make sure that the sealing washers are in place.
9 Fill one hub with oil until the oil level is on the lower edge of the
filler hole.
007844
NOTE
The oil is very viscous and filling should be slow and the lev-
el checked in stages so that the oil has time to disperse.
10 Fit the hub reduction filler plug.
NOTE
Make sure that the sealing washer is in place.
007845

12 Remove the filler plug from the differential carrier assembly.
007846
Applies to DCD 200-250
13 Fill the differential with new oil until the oil is level with the filler
hole.
14 Fit the differential carrier assembly filler plug.
NOTE
Make sure that the sealing washer is in place.
15 Remove and clean the drive axle bleed valve.
16 Clean the axle of spilled oil.
17 Remove the collection container and the sheet metal plates. Han-
007847
dle the oil as environmentally hazardous waste.

18 Test run the machine for a short distance without load.
Applies to DCD 280-300
19 Check the oil level in the hubs and differential carrier assembly.


4 Brakes 1
4 Brakes
Table of Contents 4 Brakes

mm mm mm mm mm mm
4 Brakes ............................................................................................................. 3
4.1 Controls and instrumentation ..................................................................... 4
4.1.1 Brake pedal ............................................................................................ 4
4.3 Servo brake system .................................................................................... 5
4.3.6 Distribution block ................................................................................... 8
4.5 Parking brake system ................................................................................. 9
4.5.4 Parking brake unit ................................................................................ 11
4.8 Temperature control, cleaning and hydraulic oil ....................................... 13

2 4 Brakes

4 Brakes – 4 Brakes 3
4 Brakes
mm mm mm mm mm mm
Brakes, general
page
–
There are brakes which are used to stop the machine. The brakes act
on the drive axle, (the steering axle has no brakes).
The brake system is divided into three functions:
• Power-assisted brake system, function description page 5
• Parking brake system, function description page 9
• Temperature control, cleaning and hydraulic oil, function descrip-
tion page 13

4 4 Brakes – 4.1 Controls and instrumentation
4.1 Controls and instrumentation

4.1.1 Brake pedal
Brake pedal, checking and adjusting
page
–
1 Clean the floor around the brake pedal and check that nothing
blocks movement of the brake pedal.
2 Check that the brake pedal springs back sufficiently and that the
clearance between brake pedal and brake valve is 1–1.5 mm. If
needed, adjust the brake pedal's set screw to obtain the correct
clearance.
3 Check that the pedal's travel is smooth.
4 Check that the rubber on the pedal is intact and that the tread pat-
tern isn't worn out. Change if necessary.
Set screw for adjusting clearance between brake ped-

al and brake valve. (Illustration shows loose brake
pedal.)

4 Brakes – 4.3 Servo brake system 5
4.3 Servo brake system

Power-assisted brake system, function
page
–
description
The power-assisted brake system consists of a hydraulic oil tank, hy-
draulic oil pump, hydraulic oil filter, accumulator charging valve, accu-
mulator, brake valve, pressure sensors, brake cylinder and service
brake units.
The hydraulic oil pump pumps oil (from tank) which is cleaned in the
oil filter. The accumulator charging valve directs pressure to the accu-
mulators that store pressure or direct the oil to the load handling func-
tions. The brake valve directs pressure from the accumulators to the
brake cylinder. The brake cylinder compresses the discs in the brake
units that brake the machine. Switch (NC) brake pressure gives a sig-
nal so that the brake lights are activated when the brake cylinder is
pressurised.
Part of the return flow from the valve block is directed through the drive
axle's brake units and cools the brakes, and back to the tank. Pressure
from the accumulators is also used for the load handling servo circuit.
On machines with reversible operator's seat there is an extra brake

pedal for driving backwards. The brake pedal is connected in parallel
with the brake pedal for driving forwards. A shuttle valve selects the
strongest pressure signal and conveys it to the wheel brakes.

6 4 Brakes – 4.3 Servo brake system
ECU790
12,14
D1
<˚ 13b D3
Pa
P
11 B 10
T 5
D2
16
Pa Pa
T 13a 9 8
B
7
P 6
15
X
C
4
C
2
3
D
P
ACK
007813
B
1. Hydraulic oil pump 10. Relay brake lights (K308-1)
2. Hydraulic oil filter 11. Switch normally open (NO), low accumulator pressure
3. Valve block, accumulator charging valve 12. Control unit general (ECU 790)
4. Brake valve 13a. Switch normally open (NO), declutch (S220)
5. Accumulator 13b. Inching potentiometer

6. Distribution block 14. Control unit general (ECU 790)
7. Brake cylinder 15. Brake valve
8. Wheel brake 16. Shuttle valve

9. Switch normally closed (NC) brake lights (S216)

4 Brakes – 4.3 Servo brake system 7
Power-assisted brake system, component

page
–
position
1 2 3 6 8
P2
DS
M
OL
SP
4
D
PP
PL M
D6 LS
OL
SP
D
O
O
LS
AC DS
K P2
PP
5
AC PP
KM
13 12 11 10
009616
1. Hydraulic oil pump 8. Shuttle valve
2. Brake valve 9. Distribution block
3. Switch normally open (NO), low accumulator pres- 10. Wheel brake
sure
4. Switch normally closed (NC) brake lights (S216) 11. Hydraulic oil filter
5. Switch normally open (NO), declutch (S220) 12. Hydraulic oil tank
6. Valve block 13. Accumulator
7. Accumulator charging valve

8 4 Brakes – 4.3.6 Distribution block
4.3.6 Distribution block

Brake pressure, checking
page
–
1 Warm the machine up so that the oil in the hydraulic system

reaches working temperature, at least 50 °C.
3 Connect the pressure gauge to the measuring connection on the
distribution block, see also Power-assisted brake system, com-
ponent position page 7.
4 Start the engine and let it idle.
Brake pressure measuring nipple on the distribution

block
5 Press the brake pedal and read off the pressure. Compare with
permitted pressure on the data plate (located beside the cab tip-
ping device for the machine).
6 Remove the pressure gauge and install the protective cover over
the measurement connection.
007911
Plate with pressure data

4 Brakes – 4.5 Parking brake system 9
4.5 Parking brake system

Parking brake system, function description
page
–
The parking brake consists of hydraulic oil tank, hydraulic oil pump, hy-
draulic oil filter, accumulator charging valve, accumulator, pressure
sensors, and parking brake valve parking brake unit.
The hydraulic oil pump pumps oil (from tank) which is cleaned in the
oil filter. The accumulator charging valve directs pressure to the accu-
mulators that store pressure. The parking brake unit is released with
pressure from the accumulator by the parking brake valve pressurising
the parking brake calliper. Switch (NC) parking brake gives a signal so
that the indicator light parking brake is activated when the parking
brake is applied.
800 rpm N
0 km/h
10
13
F
N
EDU795
R
1 2
R
3 8 Pa
4 5
6 ECU790
D1
10,12 D2 5,11
7 B A 9
C
C 4
2
3
D
P
PPD
ACK
P 009607
1. Hydraulic oil pump 8. Switch normally open (NO) parking brake (S200)
2. Hydraulic oil filter 9. Relay parking brake (K314)
3. Valve block, accumulator charging valve 10. Control unit general (ECU 790)
4. Accumulator 11. Indicator light in switch parking brake (S107)
5. Switch parking brake (S107) 12. Control unit general (ECU 790)
6. Solenoid valve parking brake valve (Y642) 13. Control unit terminal (EDU 795)
7. Parking brake unit

10 4 Brakes – 4.5 Parking brake system
Parking brake system, component positions

–
1 5
3
P2
DS
M
OL
SP
2
D
PP
PL M
D6 LS
OL
SP
D
O
4
O
LS
AC DS
K P2
PP
M
AC PP
KM
10 9 8 7
009617
1. Hydraulic oil pump 6. Accumulator charging valve
2. Parking brake valve 7. Parking brake unit
3. Switch normally closed (NC) parking brake (S200) 8. Hydraulic oil filter
4. Solenoid valve parking brake (Y642) 9. Hydraulic oil tank

4 Brakes – 4.5.4 Parking brake unit 11
4.5.4 Parking brake unit

Brake pads, changing
page
–
1 Machine in service position and chocks under the wheels, please

refer to insert B Safety.
2 Remove the cover over the brake calliper.
3 Undo the locknut.

4 Undo the adjustment screw to release the brake linings.
5 Remove the split pin and undo the nut on one of the fixing screws
that holds the parking brake yoke.
6 Pull the fixing screw out so that the brake pads can be angled out
and removed.
NOTE
The screw does not need to be removed.
7 Remove the parking brake pads.
8 Clean the brake disc with pure denatured alcohol.
9 Install new parking brake pads.
10 Press the fixing screw back.

12 4 Brakes – 4.5.4 Parking brake unit
11 Install the nut and a new split pin.

12 Start the engine and let it idle.
13 Release the parking brake.
14 Adjust the adjustment screw so that the brakes are applied.
15 Screw the adjustment screw back so that the clearance between
the pad and the disc is 0.5±0.1 mm.
16 Tighten the lock nut.
NOTE
To avoid turning the adjustment screw as well it must be
held still when tightening the lock nut.
17 Refit the cover to the calliper.
18 Test the operation of the parking brake.

4 Brakes – 4.8 Temperature control, cleaning and hydraulic oil 13
4.8 Temperature control,

cleaning and hydraulic oil
Temperature control, cleaning and hydraulic oil,
page
–
function description
The wheel brakes are cooled by means of hydraulic oil being pumped
through the brake unit.
Temperature control consists of a hydraulic oil tank, hydraulic oil
pump, hydraulic oil filter, valve block, and wheel brake units.
The hydraulic oil pump pumps oil (from the tank) which is cleaned in
the oil filter, to the hydraulic functions of the machine. Part of the return
oil from the valve block is directed through the drive axle brake units,
cooling the brakes, and back to the tank.
5
C
C
2 3, 4
D
P
SPOL
007819
1. Hydraulic oil pump 4. By-pass valve in valve block
2. Hydraulic oil filter 5. Wheel brake
3. Valve block

14 4 Brakes – 4.8 Temperature control, cleaning and hydraulic oil

page
–
component position
1 2
6 5 4
007817
1. Hydraulic oil pump 4. Wheel brake
2. Valve block 5. Hydraulic oil filter
3. Distribution block 6. Hydraulic oil tank

5 Steering 1
5 Steering
Table of Contents 5 Steering

mm mm mm mm mm mm
5 Steering........................................................................................................... 3
5.2 Power-assisted system .............................................................................. 4
5.2.6 Link arm ................................................................................................. 9
5.2.11 Sensor, steering wheel angle ................................................................ 9

2 5 Steering

5 Steering – 5 Steering 3
5 Steering
mm mm mm mm mm mm
Steering, general
page
–
The steering function involves steering the machine during operation.

The machine is steered by the rear wheels. The function includes con-
trols and instruments for steering and the power assisted steering sys-
tem function.
One machines with reversible operator's seat the steering angle with
directional control valve, reversible operator's seat, is changed when
operating with the operator's seat turned to the back so that the steer-
ing wheel angle and steering angle correspond.

4 5 Steering – 5.2 Power-assisted system
5.2 Power-assisted system

Power-assisted steering system, description
page
–
The function power-assisted steering system refers to steering the

machine. The machine's steering is power-assisted with pressure from
one of the hydraulic oil pumps.
Steering consists of steering wheel, steering wheel shaft, steering
valve, hydraulic oil pump, valve block, steering cylinder, link arms and
wheel spindles.
The steering wheel affects (via steering wheel shaft) the steering valve
which in turn directs oil pressure from the hydraulic oil pump to the
steering cylinder. Between the hydraulic oil pump and the steering
valve there's a valve block with a built-in priority valve which gives pri-
ority to supplying oil to the steering wheel before load handling. The
steering cylinder affects the wheel spindles. There are link arms be-
tween the steering cylinder and wheel spindles.
Power-assisted steering system, function

–
description
3
5
LSO
O
P T LS
4 C
2
L R
6
007820
1. Hydraulic oil pump 4. Steering valve

2. Hydraulic oil filter 5. Valve block
3. Steering wheel 6. Steering cylinder

5 Steering – 5.2 Power-assisted system 5
Power-assisted steering system, reversible

–
operator's station, function description
Applies to Spirit Delta cab.

One machines with reversible operator's position the steering angle
with directional control valve, reversible operator's position, is
changed when operating with the operator's position turned to the
back so that the steering wheel angle and steering angle correspond.
3
5
LSO
O
P
6 6
R
D6 P T LS
7 4
ECU790 C
L R
2
9
D7 8 8
1
10
009608
1. Hydraulic oil pump 6. Limit switch, seat forwards (S720-1) and seat back-
wards (S720-2)
2. Hydraulic oil filter 7. Control unit (ECU 790)
3. Steering wheel 8. Solenoid valve steering forward (Y636-1) and steering
back (Y636-2)
4. Steering valve 9. Directional control valve
5. Valve block 10. Steering cylinder

Power-assisted steering system, mini-wheel/

–
lever steering, function description
Lever steering or mini-wheel means that the machine is steered with

an electric control in the operator seat's left armrest. The electric con-
trol sends signals to the control and monitoring system. The steering
cylinder is pressurised by a control valve which also is controlled by
the control and monitoring system.
Lever steering and mini-wheel function in the same way, the difference
is in the design of the control.
NOTE
The standard steering wheel always has priority over joystick
steering or mini-wheel. As soon as a steering wheel movement is
made, then the joystick steering or mini-wheel is disengaged.
Requirements Nominal value

Lever steering activated Voltage signal from mini-wheel/lever steering switch
Steering wheel stationary No signal from steering lock sensor
Speed Below 2 km/h (on engagement)
Control switch Not activated

5 Steering – 5.2 Power-assisted system 7
9 D3 10
D1 D4
3 12
ECU792
5, 13
D2 6 D2
7
LSO
11
O
P
P1 P2 P
LS LSP LS
TP
2 C T
T1
A B L R
007822
1. Hydraulic oil pump 8. Steering cylinder
2. High pressure filter 9. Feedback lever steering: sensor, wheel angle (R807)
3. Valve block 10. Steering wheel
4. Potentiometer, lever steering (R825) mini-wheel 11. Steering valve
(R825)
5. Control unit (ECU 792) 12. Sensor steering wheel angle (B770)
6. Solenoid valve, steering right (Y615-1) Steering left 13. Control unit (ECU 792)
(Y615-2)
7. Control valve

Power-assisted steering system, component

–
position
2 4 7 8
P2
DS
M
OL
SP
1
D
PP
PL M
D6 LS
OL
SP
6 AC
K DS
LS
O
O
P2
5 M
PP
AC PP
KM
15
14 12 11 10
13
009618
13
1. Steering cylinder 9. Steering valve
2. Hydraulic oil pump 10. Sensor steering wheel angle (B770)
3. Hydraulic oil pump for mini-wheel/lever steering 11. Hydraulic oil filter
4. Control valve for mini-wheel/lever steering 12. Directional control valve
5. Solenoid valve, steering right (Y615-1) 13. Solenoid valve (Y636-1 and Y636-2)
6. Solenoid valve, steering left (Y615-2) 14. Hydraulic oil tank
7. Valve block 15. Sensor (S720-1 and S720-2)

8. Potentiometer, lever steering (R825) mini-wheel 16. Feedback lever steering: sensor, wheel angle (R807)
(R825)

5 Steering – 5.2.6 Link arm 9
5.2.6 Link arm

Link arm, checking
page
–
Check the control arm pivot joints, shafts and the screws which hold
the control arm shafts.
007918
5.2.11 Sensor, steering wheel angle

Sensor, steering wheel angle, checking
page
–
Check that lever steering and the mini-wheel are disconnected when
the steering wheel is turned.
Also check that the steering angle sensor is securely fixed to its brack-
et and that the multi-function levers are secured, by undoing the lower
part of the steering wheel panel.

10 5 Steering – 5.2.11 Sensor, steering wheel angle

6 Suspension 1
6 Suspension
Table of Contents 6 Suspension

mm mm mm mm mm mm
6 Suspension..................................................................................................... 3
6.2 Suspension ................................................................................................. 4
6.2.1 Steering axle cradle ............................................................................... 5
6.2.2 Wheel spindle ........................................................................................ 6
6.2.3 Wheel hub .............................................................................................. 7
6.3 Tyre and rim system ................................................................................. 10
6.3.1 Tyres .................................................................................................... 20
6.3.2 Rims ..................................................................................................... 21

2 6 Suspension

6 Suspension – 6 Suspension 3
6 Suspension
mm mm mm mm mm mm
Suspension, description
page
–
The machine’s suspension consists of its tyres (with associated rims

and bolts), steering axle with hub, wheel spindles and the steering ax-
le's suspension in the frame. The drive axle belongs to power trans-
mission, see section 3 Driveline/axle, group 3.3 Drive axle.

4 6 Suspension – 6.2 Suspension
6.2 Suspension
Suspension, description
page
–
The steering axle cradle is attached to the frame with two bushings,
one at the leading edge and one at the trailing edge of the steering
axle cradle. In the steering axle cradle there are two wheel spindles
mounted on swivelling king pins. The king pins can be turned to enable
steering. The wheel spindles support the bearings for the wheel hubs,
to which the wheels are fixed.
Suspension, position of the components

–
Suspension refers to:

• Steering axle cradle
• Wheel spindle
• Wheel hub
4
1 2 3 4 5
5
1
2
3
007811
11 10 9 8 7 6 11 10 9 8 7 6 007818
DCD 200-250
DCD 280-300
1. Steering axle cradle
2. Fixing lug 1. Steering axle cradle
3. Rubber damper 2. Fixing lug
4. Tyre 3. Rubber damper
5. Rim 4. Tyre
6. Steering cylinder 5. Rim
7. Piston rod 6. Steering cylinder
8. Link arm 7. Piston rod
9. Wheel spindle 8. Link arm
10. Hub 9. Wheel spindle
11. Bolts 10. Hub

11. Bolts

6 Suspension – 6.2.1 Steering axle cradle 5
6.2.1 Steering axle cradle

Steering axle cradle, checking
page
–
Steering axle cradle, checking

1 Machine in service position, see section B Safety with wheels set
crosswise.
The figure shows the DCD 200-250

2 Measure the distance between the frame and steering cradle.
Record the measurement.
3 Lift machine under counterweight.
NOTE
Do not lift under the steering axle.
4 Re-measure the distance between the frame and steering cradle.
Record the measurement.
5 Calculate the difference between the two measurements. The dif-
ference must be max. 3 mm.
007842
The figure shows the DCD 280-300

6 6 Suspension – 6.2.2 Wheel spindle
6.2.2 Wheel spindle

Wheel spindle bearing, checking
page
–
Wheel spindle bearing, DCD 200-250, checking

1 Machine in service position, see section B Safety with wheels set
crosswise.
2 Measure dimension A with a feeler gauge. Record the measure-
ment.
3 Lift the machine under the rear counterweight.
4 Re-measure dimension A.
5 Calculate the difference between the two dimension. The differ-
ence should not exceed 0.25 mm.
If the difference is greater, re-do the shimming. Please refer to
Workshop manual, DCD 200-300.
A
007812
Wheel spindle bearing, DCD 280-300, checking

2 Lift and lower the machine under the steering axle, using a jack
under one wheel at a time, and check that there is no slack in the
bearings.
If there is any slack, check the bearings, king pin and tightening
torque, please refer to Workshop manual, DCD 200-300.
07843

6 Suspension – 6.2.3 Wheel hub 7
6.2.3 Wheel hub

Wheel hub, checking
page
–
Wheel hub DCD200-250, checking

1 Clean the hub covers on the steering wheels.
2 Remove the hub cover.
3 Wipe grease off the hub cover and the hub nut. Handle as envi-
ronmentally hazardous waste.
007859
4 Bend up the lock washer's tabs, remove the lock nut and the lock
washer.
5 Torque the bearing nut as follows:

A. Lubricate the thread on the spindle and the side of the nut
facing the bearing with oil SAE 80W/140 or similar.
B. Tighten the nut during rotation of the hub.
C. Rotate the hub at least 10 revolutions.
D. Retighten the nut during rotation of the hub.
E. Repeate procedure B-D until the nut does not move when
009177
retightened.
F. Check friction torque as below:
The lower limit with no play will be reached when tightening
the bearing nut until no play could be felt when trying to wob-
ble the wheel.
The upper limit could be checked with a spring balance which
gives the maximum friction torque, the friction torque should
be approximately 19 Nm.

8 6 Suspension – 6.2.3 Wheel hub
Max 8 kg
510 mm
009580
Wind a cord a few times around the wheelbolts before the wheel is
mounted and pull with the spring balance. Read the scale when hub is
rotated.
6 Fit the lock washer and outer lock nut.
7 Tighten with at least 250 Nm or as hard as is needed to bend the
lock washer in the closest groove.
8 Fill the bearing casing with grease and fit it.
9 Grease the wheel bearing with grease through the grease nipple.
Lift the seal ring's lip with a small screwdriver to facilitate the air
to escape. Grease until grease comes out by the seal.
NOTE
Work carefully so as not to damage the seal.
Wheel hub DCD280-300, checking

1 Clean the hub covers on the steering wheels.
2 Remove the hub cover.
3 Wipe grease off the hub cover and the hub nut. Handle as envi-
ronmentally hazardous waste.
4 Bend up the lock washer's tabs, remove the lock nut and the lock
washer.

6 Suspension – 6.2.3 Wheel hub 9
5 Torque the bearing nut as follows:

A. Lubricate the thread on the spindle and the side of the nut
facing the bearing with oil SAE 80W/140 or similar.
B. Tighten the nut during rotation of the hub.
C. Rotate the hub at least 10 revolutions.
D. Retighten the nut during rotation of the hub.
E. Repeate procedure B-D until the nut does not move when
009177
retightened.
F. Check friction torque as below:
The lower limit with no play will be reached when tightening
the bearing nut until no play could be felt when trying to wob-
ble the wheel.
The upper limit could be checked with a spring balance which
gives the maximum friction torque, the friction torque should
be approximately 19 Nm.
Max 8 kg
510 mm
009580
Wind a cord a few times around the wheelbolts before the wheel is
mounted and pull with the spring balance. Read the scale when hub is
rotated.
6 Fit the lock washer and outer lock nut.
7 Tighten with at least 250 Nm or as hard as is needed to bend the
lock washer in the closest groove.
8 Fill the bearing casing with grease and fit it.
9 Grease the wheel bearing with grease through the grease nipple.
Lift the seal ring's lip with a small screwdriver to facilitate the air
to escape. Grease until grease comes out by the seal.
NOTE
Work carefully so as not to damage the seal.

10 6 Suspension – 6.3 Tyre and rim system
6.3 Tyre and rim system

Tyre and rim system, safety
page
–
DANGER
Always block the wheels on the side of the axle where
no work is to be done before positioning the jack. Al-
ways secure the jack to prevent it from sliding out of
position.
Deflate the tyre before removal. The components of

the rim could otherwise come loose and be thrown
out with great force when the pressure is changed.
With double wheel fitting both tyres must be deflated!
Do not release air through the valve if the tyre or rim

is damaged. Drill a hole in the tread to release the air.
Damaged tyres may explode.
Never stand directly opposite the tyre when deflating

or inflating. The components of the rim can come
loose and be thrown out with great force when the
pressure is changed.
Never install damaged tyres or rims.
It's prohibited to repair rims with welding.
It's prohibited to operate the machine if one of the

tyres is flat.
Wheels, tires and rims are dimensioned and selected

for each machine type so that maximal wheel loads
and travel speeds are not exceeded. That is why it is
forbidden to change tire dimension, tire brand, tire
type, rim type or rim brand without approval from Ka-
lmar Industries AB

6 Suspension – 6.3 Tyre and rim system 11
CAUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
Wheel nuts should be check-tightened after 4-5 oper-

ating hours.
Always follow the tyre manufacturer's or other ap-

proved instructions when changing tyres.
Never use a steel hammer to install or remove rim

components. Instead, use a lead, brass or plastic mal-
let.
Keep the tyre pressure at the prescribed level. Insuf-

ficient tyre pressure impairs stability and reduces the
machine's capacity. Low pressure also leads to in-
creased tyre and rim wear.
Remove penetrating objects such as crushed glass,

pieces of wood, metal filings, etc.
Check if tyre wear is abnormal, this could indicate a

mechanical fault. Rectify faults immediately and
change damaged tyres.
Tyre and rim system, description

–
The tyres are the machine's contact with the ground, the tyres absorb
rough surfaces and act as suspension.
The drive axle is exposed to great stresses during operation, and the
stresses increase if the drive wheels' rolling circumference differs. It is
important that the tyres on the drive axle are of the same model, type
and make, and have similar wear and the correct air pressure.

Tyre and rim system, check

page
–
Read the safety instructions before working with the tyre and rim, see
section Tyre and rim system, safety page 10.
DANGER
Never stand directly opposite the tyre when deflating
or inflating. Components from the rim may release
and shoot off when the pressure changes.
Do not release air through the valve if tyre or rim is

damaged. Drill holes in the tread to release the air. If
the tyre explodes, the force of the explosion moves in
the direction of the valve.
Do not exceed the prescribed air pressure. When

changing tyre or rim version, another air pressure
may apply. Contact Kalmar Industries.
1 Check the rims.

1 2
• Check that spacer rings and clamps are installed correctly.
3 4 • Check that there are no cracks in the rims' parts.
In case of damage, the tyre and rim shall be dismantled and
checked.
2 Check the air pressure in the tyres, see Tyres, inflating page 20.
6 The pressure must be 1.0 MPa, inflate if necessary.

5
3 Check the tyres.
007892
• Check for uneven and fast wear, this is caused by mechani-

1. Inner rim cal problems such as, e.g., uneven brake action. Make sure
2. Outer rim that such malfunctions are taken care of immediately.
3. Inner spacer ring • Remove penetrating objects such as crushed glass, pieces
4. Outer spacer ring of wood, metal filings, etc.
5. Clamp
If the tyre is damaged, the wheel shall be dismantled and the tyre
6. Nut
shall be changed, see Tyres, changing page 21.
4 If the tyres and rims have no defects, check-tighten the wheel
nuts.
Tighten alternately with torque, 350 Nm.

Tyre and rim system, removing and installing

page
–
(drive axle)
Tyre and rim system, safety page 10.
Removing
2 Lift the machine under the drive axle by the wheel in question.
Support under the drive axle in a safe and adequate manner.
3 Deflate both tyres on the side from which the tyre shall be re-
moved.
If the tyre is in good condition, release the air through the valve.
DANGER
In twin wheel installation, both tyres must be deflated,
or the inner tyre could explode when the outer one is
removed.
If the tyre or rim is damaged, deflate the tyre by drilling a hole in the
tread.
4 Loosen the wheel nuts.
005123

5 Undo the inner drive wheel valve from its anchorage.
007881
6 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting by the lifting equipment.
005124
7 Remove all wheel nuts and clamps.

007878

8 Remove the spacer ring.

Pull out the wheel a bit so that the spacer ring comes loose.
NOTE
The spacer ring weighs approx. 20 kg.
9 Lift the outer wheel away and position it safely so that it does not
fall or move.
10 Secure the inner drive wheel with lifting equipment.
007879
11 Remove the spacer ring between the outer and inner drive wheel.
NOTE
The spacer ring weighs approx. 20 kg.
12 Remove the inner drive wheel and position it safely so that it does
not fall or move.
007880

Installing
1 Make sure that the installation surfaces (position A) on the hub
and wheel are clean and free from grease and paint.
2 Lift the inner wheel into place with lifting equipment. Rotate the
wheel so that the guide lug enters the groove on the hub, this
work will be easier if the hub grooves are aligned towards the top
and bottom.
3 Fit the inner spacer ring.
NOTE
The inner ring is not split.
007880
4 Lift the outer wheel into place with lifting equipment. Rotate the
wheel so that the guide lug enters the groove on the hub.
007883

5 Fit the outer spacer ring
NOTE
The outer ring is split. Rotate the ring so that the opening
ends up in front of the groove on the hub.
007884
6 Place clamps and nuts on the wheel bolts. Where applicable, also
washers.
NOTE
Do not forget the retainer for the inner tyre's valve extension.
7 Remove the lifting equipment.
007878
8 Tighten the wheel nuts alternately, start at the guide heels and
work outwards to prevent the spacer rings from becoming wrong-
ly aligned.
9 Tighten the wheel nuts alternately in turns with increasing torque
to 350 Nm.
10 Inflate the tyre with air, 1 MPa, see Tyres, inflating page 20.
11 Lower the axle and remove the jack.
12 Test-run the machine and check that the wheels are installed se-
curely.
13 Check-tighten the wheel nuts with torque 350 Nm.
007885

Tyre and rim system, removing (steering axle)

page
–
Removing
2 Lift the machine under the steering axle by the wheel in question
with a jack. Support under the steering axle in a safe and ade-
quate manner.
3 Deflate the tyre in question.

If the tyre is in good condition, release the air through the valve.
If the tyre or rim is damaged, deflate the tyre by drilling a hole in the
tread.
005123

4 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
5 Remove all wheel nuts and clamps.
6 Remove the wheel and position it safely so that it does not fall or
move.
Installing
7 Make sure that the installation surfaces on the hub and wheel are
clean and free from grease and paint.
005124
8 Lift the wheel into place with the lifting equipment.

Adjust the wheel's position so that the guide pin fits over the
groove in the hub and the rim rests up against the hub.
9 Place clamps and nuts on the wheel bolts. Where applicable, also
washers.
10 Remove the lifting equipment.
11 Fit the wheel. Tighten the wheel nuts alternately in turns with in-
creasing torque to 350 Nm.
12 Inflate the tyre with air, see Tyres, inflating page 20.
13 Lower the axle and remove the jack.
14 Test-run the machine and check that the wheels are installed se-
curely.
15 Check-tighten the wheel nuts with torque 350 Nm.
000383

20 6 Suspension – 6.3.1 Tyres
6.3.1 Tyres
Tyres, inflating
page
–
DANGER
Always follow the instructions for inflating tyres to
avoid risk of accidents.
Only use approved rim components.
If the tyre has been completely deflated, the tyre must

be dismantled and the rim checked for damage.
Never fit rim components by striking with a hammer

during inflation. Never strike fully or partly inflated
tyres or rim assemblies.
Never inflate tyres before all parts are in place.
Do not exceed the prescribed tyre pressure. Other in-

flation pressure may apply when changing tyre or rim
version, contact Kalmar Industries.
Never stand directly in front of the wheel when deflat-

ing or inflating. The conical ring and locking clips can
007778
loosen and shoot out when the pressure is changed.
Check that all parts are in place when the tyre pres-
sure is 30 kPa.
NOTE
An air filter and water trap should be installed on the line from the
compressor that is used to inflate tyres to avoid rim corrosion.
1 Make sure that the lock ring and lock lugs are in the correct posi-
tion before inflating.
2 Connect the compressor with a locking air-chuck to the nipple on
the tyre.
3 Stand obliquely behind the tyre and remain there during the entire
pumping procedure to avoid being hit by pieces of rim if there is
an explosion.
4 Inflate the tyre to the prescribed level, see specifications.
Other inflation pressure may apply when changing tyre or rim ver-
sion, contact Kalmar Industries.

6 Suspension – 6.3.2 Rims 21
Tyres, changing
page
–
DANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
Leave tyre work to authorised personnel/ tyre compa-

ny.
During tyre changes, the rims must be checked. Please refer to Rim,
check page 21.
6.3.2 Rims
Rim, check
page
–
DANGER
Perform the following checks to minimise risks of ac-
cidents for all rims that can be dismantled.
Always use the correct size of tyre and a design that

is compatible with the type and size of the rim. Over-
dimensioned tyres must not be used.
Replace all damaged, worn or corroded rims or

mounting parts.
1 Dismantle the rim, see Tyres, changing page 21.

2 Carefully clean the outside of the rim edge with a steel brush.
001703
3 Measure the wear caused by the lock ring.

The lock ring's wear on the rim edge often leaves a mark, A in the
figure. The mark shows up between the ends of the lock ring.
Measure depth of the wear at point A with a steel ruler and sliding
callipers. If wear exceeds 0.5 mm, the rim, lock ring and the rim
bead seat taper must be discarded and replaced with new parts.
A
Max 0,5 mm
001715

22 6 Suspension – 6.3.2 Rims
4 Check the rim's diameter.

Measure the rim edge's circumference (O) with a measuring tape
and calculate the diameter (D). [D = Circumference (O) / 3.14]
Compare the value of the diameter with the specified min. meas-
urement. If the diameter is smaller, the rim, lock ring and the rim
bead seat taper must be discarded and replaced with new parts.
D
O Information about min. diameter can be obtained from Kalmar In-
dustries.
001701
O. Circumference
D. Diameter
5 Check for damage in the areas with high stress concentration.
Checking is done in two steps:
1. The magnetic powder method is used to determine if there's
a crack or not, and where it is.
2. Confirmed cracks are investigated further with penetrating
fluid.
Typical rim damages are circumference cracks, corrosive dam-
age, rust, warping and wear.
001702
Magnetic powder method

1 Blast clean the marked area around the entire rim so that it is
completely clean from all paint.
2 Test using magnetic powder and the following equipment:
001703
• Equipment: Yoke Tiede

• Method:
a. AC current
b. Contrast fluid
• Checking medium:
a. Wet
b. Fluid (e.g. Tiede Ferrolux)
If no cracks are detected with the magnetic powder method,
checking is finished and the rim is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.

6 Suspension – 6.3.2 Rims 23
Checking cracks with penetrating fluid

1 Clean the area with cleaning fluid part no. 923626.0668.
2 Spray penetrating fluid part no. 923626.0669 on the cleaned area
and let dry 10 min.
001704
3 Wash off penetrating fluid with cleaning fluid part no.
923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
any remaining cleaning fluid evaporate.
4 Spray detection fluid part no. 923626.0670 on the area.
5 Let the sprayed area dry 1-2 hours.
6 Visually inspect the lock ring groove.
1 2
If the tested area does not indicate linear or point-shaped cracks
in the lock ring groove the rim is approved.
If the crack check indicates linear or point-shaped cracks the rim
should be discarded.
001705
Example of cracks
1. Linear crack
2. Pointed crack

24 6 Suspension – 6.3.2 Rims

7 Load handling 1
7 Load handling
Table of Contents 7 Load handling

mm mm mm mm mm mm
7 Load handling................................................................................................. 3
7.2 Lifting/lowering ........................................................................................... 4
7.2.6 Mast ....................................................................................................... 8
7.2.8 Chains .................................................................................................... 8
7.2.14 Support roller ....................................................................................... 10
7.2.15 Top support roller ................................................................................. 10
7.4 Side shift ................................................................................................... 11
7.4.4 Side shift cylinder ................................................................................. 14
7.5 Spreading ................................................................................................. 15
7.7 Tilt ............................................................................................................. 19
7.7.5 Tilt cylinder ........................................................................................... 22
7.7.6 Mast ..................................................................................................... 22
7.8 Levelling ................................................................................................... 23
7.9 Load carrier .............................................................................................. 27
7.9.1 Lifting forks .......................................................................................... 27
7.9.2 Coil ram ............................................................................................... 29
7.10 Additional functions .................................................................................. 30
7.10.1 Electric scales ...................................................................................... 30
7.10.5 Side lift attachment .............................................................................. 31

2 7 Load handling

7 Load handling – 7 Load handling 3
7 Load handling
mm mm mm mm mm mm
Load handling, general

page
–
The load handling function refers to lifting, lowering, side shifting and
tilting the load for example.
Load handling has been divided into the following sub-functions:
• Lift and lower
007363
• Tilt
007364
• Side shift
007916
• Spreading
007910
• Levelling
• Load carrier
• Side lift attachment

007917

4 7 Load handling – 7.2 Lifting/lowering
7.2 Lifting/lowering
Lift and lower, function description
page
–
Lift and lower means that the mast parts are extended up and down so
that the fork assembly and lifting forks are raised and lowered.
During a lift, the inner mast is lifted by the lifting cylinders. The lifting
chain which is fixed to the carriage (and the outer mast), runs over
sprockets at the top of the mast, this lifts the carriage at the same time
007363
as the inner mast.
The machine can be equipped with a special free lifting mast . The
fork carriage is raised in two stages relative to the inner mast, first with
the free lift cylinder and then with the first stage in the two lifting cylin-
ders. The inner mast is lifted with the second stage in the two lifting cyl-
inders.
The free lift cylinder and the lifting cylinders are pressurised by the
load handling control valve.
The lift and lower is available in two versions depending on how the
function is controlled.
• Hydraulic servo means that the control levers are supplied with
hydraulic pressure which controls the lift and lower function.
•
Electrical servo means that the control levers are electrical and
send voltage signals to the control system to control the lift and
lower function. (Electrical servo is included if the machine is
equipped with reversible operator's position.)
A pressure accumulator containing a piston is connected between the

control valve and one of the lifting cylinders, using a T-junction, to ab-
sorb and damp the pressure pulses which occur when the vehicle is
driven on uneven ground. The pressure accumulator absorbs the
pressure pulses which arise, and can thus reduce the wear and tear
on the machine’s hydraulic system and mechanical structures, and in-
crease driver comfort.

7 Load handling – 7.2 Lifting/lowering 5
Lift and lower, function description

page
–
(hydraulic servo)
11
6 10
C 4
9
8
B
7 3, 5
PPD
PP
ACK
b
9
8
P2
D
A
P
a
11
10
2 2 C
1 1
1. Hydraulic oil pump 7. Control valve lift 007824
2. High pressure filter 8. Lowering brake valve
3. Valve block, accumulator charging valve 9. Free lift cylinder

4. Accumulator 10. Lowering brake valve
5. Valve block, reduction valve 11. Lift cylinder
6. Control lever, lift and lower

6 7 Load handling – 7.2 Lifting/lowering
Lift and lower, function description (el. servo)

page
–
Condition Reference value

7 ECU796
D
14
6 13
9
D
8
4
12
11
B
10 3, 5
PPD
ACK
PP
b
12
11
P2
D
A
P
a
14
13
2 C 2 C
1 1
007825
1. Hydraulic oil pump 8. Solenoid valve, lift mast (Y6005) lower mast (Y6004)
2. High pressure filter 9. Servo valve
3. Valve block, accumulator charging valve 10. Control valve lift
4. Accumulator 11. Lowering brake valve
5. Valve block, reduction valve 12. Free lift cylinder

6. Control lever, lift and lower (R8071) 13. Lowering brake valve
7. Control unit hydraulics (ECU 796) 14. Lift cylinder

7 Load handling – 7.2 Lifting/lowering 7
Lift and lower, component position

page
–
2
1
3
5
4
P2
DS
M
OL
SP
6
D
PP
PLD M
LS
6
P
OL
SP
D
O
O
LS
AC DS
K P2
PP
M
AC PP
KM
7
8
13
12 9
10
11
009611
1. Hydraulic oil pump 8. Lowering brake valve
2. Servo valve (electric servo) 9. Free lift cylinder
3. Solenoid valve, lower mast (Y6004) (electric servo) 10. Lowering brake valve
4. Solenoid valve, lift mast (Y6005) (electric servo) 11. High pressure filter
5. Valve block 12. Hydraulic oil tank
6. Lifting mast 13. Accumulator
7. Lift cylinder

8 7 Load handling – 7.2.6 Mast
7.2.6 Mast
Mast anchorage, checking the bearings
page
–
1 Raise the mast carriage and secure it.
WARNING
Never work underneath a mast carriage that has not
been secured.
Risk of pinch injury!
Fix the mast carriage securely before work starts.

3 Make a mark on the mast mounting on the frame.
4 Use a jack to remove the load from the mast anchorage.
5 Make a new mark on the mast mounting on the frame. Measure
the distance between the marks. The dimension should not ex-
ceed 2 mm.
6 If the difference is greater, change the bearings in the mast
mounting. Please refer to Workshop manual, DCD 200-300.
009520
7.2.8 Chains
Chains, checking and adjustment
page
–
With the aim of increasing safety, the lifting chains should be regularly
checked as per the following points.
The entire length of the chains shall be thoroughly cleaned. The check
is performed without load on the forks.
1 The chain may not have increased in length by more than 3%.
Measure across the 25 links that first (and most often) roll across
the chain wheel when lifting. That is where extension is the great-
est. Compare to the value in the table. If the 3% limit is exceeded,
then the chains shall be replaced.

7 Load handling – 7.2.8 Chains 9
2 P-length = distance between 2 pins.
P-length P-length Length over 25 links [mm]
005670
[in] [mm]
New chain Max. length
3/4 19,05 476,25 490
1 25,4 635 654
1.1/4 31,75 793,75 817
1.1/2 38,1 952,5 981
2 50,8 1270 1308
On chains with up to 1 inch division, a measuring tape specially

designed to measure wear can be used.
The measuring tape is marked with:
• Zulässige Verlängerung = permissible extension.
• Kette austauschen = replace the chain.
The measuring tape can be ordered from Kalmar.
1 Check that the pins in the outer washers are secure.
2 Check that the washers have no visible cracks.
3 Check that there is no mechanical damage.
4 Check that the chain shows no signs of rust.
5 Check that the chain bends easily over the chain wheel (does not
bind when bending).
6 Park the machine on a level floor with the mast vertical (0° tilt).
7 Lower the carriage to the bottom position.
8 Check that there is 10–20 mm space between the underneath
side of the forks and the ground. Adjust the position by tightening
or loosening the chains equally, with the adjustment nuts in the
vehicle.
NOTE
If the chain is slack when the carriage is in its lowest position, the
chain must be tensioned.
007671

10 7 Load handling – 7.2.14 Support roller
9 Adjust the chains so that the carriage lifts evenly in the mast.
• Undo the lock washers (position 1) and remove the old nut
(position 2).
• Lift the chain tensioner (position 4) out of the carriage and re-
3
move the old lock washer.
• Re-install with a new lock washer, chain tensioner, lock
washer and lower nut. Repeat on the other side.
1
NOTE
Only use new lock washers for re-installing.
2 4 • Adjust the nuts on each side to balance the carriage, so that

007850 the distance between the vehicle and stand becomes 10-20
mm.
1. Lock washer • Torque the nuts to 2000 Nm and lock them with lock wash-
2. Lower nut ers.
3. Upper nut
• Do a test lift and check that the lifting chain is tensioned
4. Chain tensioner
equally on each side, and the keeps the carriage in balance.
Repeat the adjustment as necessary.
10 Grease the chains after checking is concluded.
7.2.14 Support roller

Support roller, checking
page
–
1 Machine in service position

2 Check that the support rollers run correctly and that all surfaces
on the support rollers and mating surfaces against the mast do
look normal.
007851
Example of support roller
7.2.15 Top support roller

Support roller, checking
page
–
See Support roller, checking page 10

7 Load handling – 7.4 Side shift 11
7.4 Side shift

Side shift, description
page
–
Side shift means that the lifting forks are moved sideways. The load
handling control valve pressurises the side shift cylinders, which slide
the forks on the fork trolley sideways, left or right, depending on which
way the control lever is moved.
Side shift is controlled and activated by the side shift control lever. Dur-
ing side shift, the piston side of one of the side shift / spread cylinders
007916
is pressurised. Pressure from the piston side of the first cylinder is
transferred to the rod side of the other cylinder and compresses the
other cylinder.
Side shift is available in two versions depending on how the function
is controlled.
• Hydraulic servo means that the control lever is supplied with hy-
draulic pressure which controls side shift.
•
send the voltage signal to the control system to control side shift.

12 7 Load handling – 7.4 Side shift
Side shift, function description

page
–
(hydraulic servo)
6
8
C 4
7 B
3, 5
PPD
PP
ACK
b
D
9
A
P
a
2 C
007826
1. Hydraulic oil pump 6. Control lever, side shift
2. High pressure filter 7. Control valve side shift
3. Valve block, accumulator charging valve 8. Side shift cylinder
4. Accumulator 9. Side shift cylinder
5. Valve block, reduction valve

7 Load handling – 7.4 Side shift 13
Side shift, function description (electric servo)

page
–

7 ECU796
D
6
9 11
D
8
4
10
B
3, 5
PPD
ACK
PP
b
D
A
P
a
12
2 C
007827
1. Hydraulic oil pump 7. Control unit hydraulics (ECU 796)
2. High pressure filter 8. Solenoid valve, side shift left (Y6020), side shift right (Y6021)
3. Valve block, accumulator charging valve 9. Servo valve
4. Accumulator 10. Control valve side shift, spreading and levelling
5. Valve block, reduction valve 11. Side shift cylinder
6. Control lever, side shift 12. Side shift cylinder

14 7 Load handling – 7.4.4 Side shift cylinder
Side shift, component position

page
–
2
1
3
5
4
P2
DS
M
OL
SP
D
PP
PLD M
LS
6
P
OL
SP
D
O
O
LS
AC DS
K P2
PP
M
AC PP
KM
9
8
009612
1. Hydraulic oil pump 6. Side shift cylinder
2. Servo valve (electric servo) 7. High pressure filter
3. Solenoid valve, side shift right (Y6021) 8. Hydraulic oil tank
4. Solenoid valve, side shift left (Y6020) (electrical servo) 9. Accumulator

5. Valve block
7.4.4 Side shift cylinder

Side shift cylinder, check
page
–
Check visually that the cylinders are straight and that the mounting
points and welding seams are intact.
007849

7 Load handling – 7.5 Spreading 15
7.5 Spreading
Spreading, description
page
–
Spreading means changing the relative distance of the lifting forks.

Control valve load handling pressurise the spreading cylinders who
move the forks in their turn.
There is a flow distributor between the valve and the cylinders that en-
sures the forks move uniformly even if the resistance on the forks
007910
should be different.
When both spreading and side shift are installed, the same hydraulic
cylinders are used for side shift as for fork spreading.
Spreading is available in two versions depending on how the function
is controlled
• Spreading with hydraulic servo means that the control levers are
supplied with hydraulic pressure which controls the fork spread-
ing.
•
Electric Servo means that the control levers are electric, and send
voltage signals to the control and monitoring system to control the
spread function.

16 7 Load handling – 7.5 Spreading
Spreading, function description

page
–
(hydraulic servo)
6 9
8
C 4
9
7
B
3, 5
PPD
PP
ACK
b
D
A
P
a
2 C
007828
1. Hydraulic oil pump 6. Control lever spreading
2. High pressure filter 7. Control valve spreading
3. Valve block, accumulator charging valve 8. Flow distributor
4. Accumulator 9. Spreading cylinder

7 Load handling – 7.5 Spreading 17
Spreading, function description (electric servo)

page
–

7 ECU796 12
D
11
6
9
D
8
12
4
10
B
PPD 3, 5
ACK
PP
b
D
A
P
a
2 C
007829
2. High pressure filter 8. Solenoid valve spreading in (Y6019) out (Y6018)
4. Accumulator 10. Control valve spreading
5. Valve block, reduction valve 11. Flow distributor
6. Control lever, spreading 12. Spreading cylinder

18 7 Load handling – 7.5 Spreading
Spreading, component position

page
–
2
1
3
5
4
P2
DS
M
OL
SP
D
PP
PLD M
LS
6
P
OL
SP
D
O
O
LS
AC DS
K P2
PP
M
AC PP
KM
7
10
9
009613
1. Hydraulic oil pump 6. Spreading cylinder
2. Servo valve (electrical servo) 7. Flow distributor
3. Solenoid valve spreading out (Y6018) (electrical servo) 8. High pressure filter
4. Solenoid valve spreading in (Y6019) (electrical servo) 9. Hydraulic oil tank


7 Load handling – 7.7 Tilt 19
7.7 Tilt
Tilt, description
page
–
Tilt means angling the mast in relation to the machine. Control valve,
load handling, pressurises the tilt cylinders which extend and angle the
mast in relation to the machine. Tilt is controlled with control lever, tilt.
Tilt is available in two versions depending on how the function is con-
trolled.
007364
• Hydraulic servo means that the control levers are supplied with
hydraulic pressure which controls the tilting.
•
the send a voltage signal to the control system to control the
tilting.
Tilt, function description (hydraulic servo)

page
–
C 4
8
7 9
B
3, 5
PPD
PP
ACK
b
9
D
A
P
a
2 C
1
009122
1. Hydraulic oil pump 6. Control lever, tilt

2. High pressure filter 7. Control valve tilt
3. Valve block, accumulator charging valve 8. Load holding valve
4. Accumulator 9. Tilt cylinder

20 7 Load handling – 7.7 Tilt
Tilt, function description (electrical servo)

page
–

7 ECU796
D
6
9
D
8
4
12
10
B
3, 5
PPD
ACK
PP
b
11 12
VB C1
D VA C2
A
P
a
2 C
007831
2. High pressure filter 8. Solenoid valve, tilt in (Y6011) tilt out (Y6010)
3. Valve block, accumulator charging valve 9. Servo valve tilt
4. Accumulator 10. Control valve tilt
5. Valve block, reduction valve 11. Load holding valve
6. Control lever tilt (R8072) 12. Tilt cylinder

7 Load handling – 7.7 Tilt 21
Tilt, component position

page
–
2
1
3
5
4
P2
DS
M
OL
SP
D
PP
PLD M
LS
6
P
OL
SP
D
O
O
LS
AC DS
K P2
PP
M
AC PP
KM
10 7
009614
1. Hydraulic oil pump 6. Tilt cylinder
2. Servo valve (electrical servo) 7. Load holding valve
3. Solenoid valve, tilt out (Y6010) (electrical servo) 8. High pressure filter
4. Solenoid valve, tilt in (Y6011) (electrical servo) 9. Hydraulic oil tank


22 7 Load handling – 7.7.5 Tilt cylinder
7.7.5 Tilt cylinder

Tilt anchorage, checking the bearings
page
–
NOTE
Other tilt cylinder anchorage variants may be found, apart from
the ones shown here.

2 Make markings on the mast and the frame when the mast is ver-
tical.
3 Put blocks underneath the outer mast to relieve the load on the
tilt anchorages, and tilt the mast as far as it goes. Measure the
distance to the marks. The dimension should not exceed 2 mm.
4 If the difference is greater, change the bearings in the tilt mount-
ing. Please refer to Workshop manual, DCD 200-300.
009522
009521
7.7.6 Mast
Mast anchorage, checking
page
–
See Mast anchorage, checking the bearings page 8.

7 Load handling – 7.8 Levelling 23
7.8 Levelling
Levelling, description
page
–
Mechanical levelling means that the load is angled in horizontal direc-

tion. This enables the machine to handle loads on uneven surfaces.
There are two different types of levelling, levelling fork and central lev-
elling (with central levelling assembly specified).
For machines with fork levelling, one of the forks (right or left) is sus-
007917
pended via a hydraulic cylinder that moves the fork vertically through
a sleeve secured to the assembly.
With central levelling the front section of the fork assembly is levelled
(turned) around the centre line of the assembly, four degrees up or
down.
• Hydraulic servo means that the control levers is supplied with hy-
draulic pressure which controls the levelling.
•
send a voltage signal to the control system to control the levelling.

24 7 Load handling – 7.8 Levelling
Levelling, function description (hydraulic servo)

–
C 4
B
3, 5
PPD
PP
ACK
b
8
D
A
P
a
2 C
007832
1. Hydraulic oil pump 5. Valve block, reduction valve
2. High pressure filter 6. Control lever, levelling
3. Valve block, accumulator charging valve 7. Control valve levelling
4. Accumulator 8. Levelling cylinder

7 Load handling – 7.8 Levelling 25
Levelling, function description (electrical servo)

–

7 ECU796
D
6
9
D
8
4
10
B
3, 5
PPD
ACK
PP
b
11
D
A
P
a
2 C
007833
2. High pressure filter 8. Solenoid valve levelling down (Y6022) up (Y6023)
4. Accumulator 10. Control valve levelling
5. Valve block, reduction valve 11. Levelling cylinder
6. Control lever, levelling

26 7 Load handling – 7.8 Levelling
Levelling, component position

–
2
1
3
5
4
P2
DS
M
OL
SP
D
PP
PLD M
LS
6
P
OL
SP
D
O
O
LS
AC DS
K P2
PP
M
AC PP
KM
8 7
009615
1. Hydraulic oil pump 6. Levelling cylinder
2. Servo valve (electrical servo) 7. High pressure filter
3. Solenoid valve levelling down (Y6022) 8. Hydraulic oil tank
4. Solenoid valve levelling up (Y6023) 9. Accumulator

5. Valve block

7 Load handling – 7.9 Load carrier 27
7.9 Load carrier

Load carrier, general
page
–
The load carrying lifts any load. There are several ways to lift a load,
e.g.:
• Lifting forks, normal and inverted
•
Coil ram.
•
Side lift attachment.
7.9.1 Lifting forks

Lifting forks, component position
page
–
5
6 007841
1. Lifting fork 5. Locking pin

2. Support roller 6. Moveable lock handle
3. Inverted lifting forks 7. Lower attaching handle

4. Upper attaching handle

28 7 Load handling – 7.9.1 Lifting forks
Lifting forks, check

page
–
DANGER
Damaged lifting forks must be replaced.
Repairing lifting forks changes the strength, which

can lead to a dropped load and fatality.
1 Machine in service position, please refer to insert B Safety.

2 Check the fork arms in terms of blade thickness, crack formation
and deformation.
• The wear of the blade must not exceed 10% (counted from
the original dimensions and measured 150 mm from the fork
heel).
• Visible cracks must not exist.
Pay particular attention to the fork heel. Surface cracks are
generally no longer than 5 mm.
If surface cracks are detected, grind down approx. 0.5 mm
and test with magnetic powder if the crack is still visible. Test-
ing must be carried out by an approved company.
a
3 Check the forks' suspension equipment, i.e. for play.
150 mm
4 If the forks need repair - contact Kalmar Industries AB or one of
007781
Kalmar’s approved service personnel, who will determine if the

forks can be repaired.
NOTE
Surface cracks and wear must not be dealt with using weld-
ing.
5 Forks which have been hot-straightened must be heat treated
again (carried out by an approved firm).

7 Load handling – 7.9.2 Coil ram 29
7.9.2 Coil ram

Coil ram, component position
page
–
mm
mm
gk
GOC
CLL
W
n e d e w S y b g n uj L 1 8 1 4 3 E S
B A seirts u d nI ra mla K
aP M
mm
gk
A
H
D
N/ S
Q
1
4
3
007840
5
1. Coil ram 4. Moveable lock handle

2. Upper attaching handle 5. Lower attaching handle
3. Locking pin

30 7 Load handling – 7.10 Additional functions
7.10 Additional functions

7.10.1 Electric scales
Elektrical scale, description
page
–
The scales function is available in two versions.

1. Hydraulic scale that does not show anything to the operator, but
that can be used by other functions in the machinet. A pressure
sensor in the lift cylinder measures the pressure and thus esti-
mates the load's weight.
2. Electric scale, which has a more direct interface with the operator.
For the electric scale there are two load cells in the chain tensioners
with built-in amplifiers that give the load's weight. Accuracy depends
on the mast movement before measuring. The scale and load sensors
are very sensitive and are affected by several factors such as friction
in the mast and fork carriage, oil temperature and bearings. The mast
shall be vertical and the fork carriage centred. Under these conditions
the load sensors in the chain tensioners function optimally. The fork
carriage shall be raised and then lowered to approx. 1 m above the
ground before calibration and weighing. If the system is calibrated af-
ter lowering carefully and weighing is performed in the same way, an
accuracy of approx. ±1% of maximal load capacity is obtained. The
weight is presented continuously on the display, in tons, to one deci-
mal (e.g., 5.2 tons).
Electric scales, calibrating

page
–
When complete scale equipment is delivered, the scale is always fac-

tory-adjusted and factory-calibrated. For proper use of the scale regu-
larly calibrations with a known test weight is needed.
NOTE
The mast should stand vertical and fork carriage centred against
the mast when weighing, calibrating and zero adjusting (reset to
zero).
1 Run the fork carriage up and down a few times to remove any
mechanical stresses.
2 The machine should be operated a few minutes before zero ad-
justing (reset) and weight calibration occurs.
3 To select function for calibration, first navigate to the service
menu. Then press Enter.
000056

7 Load handling – 7.10.5 Side lift attachment 31
4 State code for calibration.

The code can be obtained from Kalmar Industries Support.
1 23
4 5 NOTE
000060
The code determines the service menu that will be activated
(Diagnostic test, Initiation or Calibration).
5 Select SCALE by scrolling with the arrow keys (1 and 2) and con-
firm with Enter.
SCALE
000803
6 Unload and slightly lower the fork carriage slowly until approxi-
mately 1m above ground. Then, reset the scale to zero by press-
CALIBR 1(2)
600 ing function key in menu 1(2).
SCALE 600
WITHOUT LOAD (mV)
000804
7 Load up with a known weight (preferably often used loading

weight or close to the maximum load for the machine), adjust with
CALIBR 2(2)
4000 8000 KG function key 4 and 5 to this weight and slightly lower the fork
4000 8000 KG
SCALE WITH LOAD carriage slowly. Confirm the weight by pressing function key
000805
in menu 2(2). There must be a value in the set-up for maximum

lift capacity, to allow the weight to be changed.
7.10.5 Side lift attachment

Side light attachment, description
page
–
The side lift attachment has been designed for easy, safe and rapid
handling, low weight and ease of maintenance.
Both of the attachments’ corner pieces are telescopic and suspended
from the main beam by means of springs, which enables 195 mm lev-
elling to both sides for the connection to leaning containers. A hydrau-
lic cylinder between the attachment and the carriage allows ±600 mm
side-shift
A hydraulic/mechanical system ensures that the container are locked
via Twistlocks onto the attachment prior to lifting.
An electrical safety system prevents the locking and release of the
twist-locks if the attachment is not correctly positioned against the con-
tainer. The system also prevents lifting if the twist-locks are not either
completely locked or released.
A lamp panel displays alignment, locked and released container re-
spectively.

32 7 Load handling – 7.10.5 Side lift attachment
Twistlocks, checking
page
–
1 2 3
DANGER
Make sure that the engine is off when working on the
Twistlocks.
Twistlocks can be locked automatically if all sensors

for alignment are activated manually.
1 Check that the Twistlocks function correctly.

Lock and open the Twistlocks, check that the indicator lights
4 work, both in cab and on the attachment.
2 Clean the Twistlocks from any dirt.
3 Under the rubber cover for Twistlocks: check pin, link arm and
007922
6 5 lock nut.
4 Clean the area around the sensor for alignment.
1. Sensor unlocked Twistlock
2. Sensor contact 5 Press in the alignment pin so that the head is flush with the
3. Sensor locked Twistlock spreader beam's underside. Check the distance to sensor align-
4. Lock guide ment, distance should be 5±1 mm. Adjust as needed
5. Lift pin
6. Contact pin NOTE
The alignment pin should move easily and spring back com-
pletely.
6 Check that the lock guide and lift pin can move freely.
7 Fit a pry bar between the lift pin (pos. 5) and the lock guide (pos.
4) and check the clearance max. clearance: 1–1.5 mm.
8 Turn the Twistlocks to locked position and check lift pin wear.
Change the lift pin if needed.
9 Repeat steps 1–10 on all four Twistlocks.
m
Max. 4 mm
m
0
.7
in
M
002311
Wear limits, lift pin.

Twistlock, checking for cracks

page
–
DANGER
Material fatigue, reduced strength.
Fatal danger!
Change Twistlocks that shows signs of cracks or oth-

er external damage, or Twistlocks with more than
10 000 operating hours.
1 Remove the lift pins from the attachment.
NOTE
Twistlocks are heavy. Take care when removing.
2 Test for cracks within the marked area on the pins without re-
working or damaging the part.
3 If the lift pins show signs of cracking, they must be replaced with
new ones.
002313
4 Fit approved Twistlocks.

Area for checking for cracks on lift shoe.
NOTE
Use new attaching nut and washers.

Contact sensor, inspection and adjustment

page
–
1 Check that the contact pins in the corner boxes can move up and
down freely. The contact pins should spring down when they are
not loaded.
2 Check that the sensor is free from dirt and damage.
3 Turn the starter key to position I and check that the LED on the
sensor has gone out.
4 Lower the clamp onto a container and check that the contact in-
dication lamp lights up.
5 Lift the container up a bit so that the contact indication lamp goes
out.
007782 6 With the container lifted, check how much movement is needed
1 2 in the contact pins to detect contact (the LED on the sensor lights
up). The movement should be 3 – 4 mm.
Right-hand side
1. Sensor, contact 7 If necessary, undo the locknut and screw the sensor in/out until
2. Contact pin the distance between the sensor and contact pin is 5±1 mm.
1 2
007919
Left-hand side
1. Sensor, contact
2. Contact pin

Sensor Twistlocks, check and adjustment

page
–
1 Check that the sensors are free from dirt and damage.
2 Turn the starter key to position I and check that the LED on the
sensor for unlocked Twistlocks has gone out.
If necessary, undo the locknut and screw the sensor in/out until
the distance between the sensor and indicator plate is 5±1 mm.
3 Check that the Twistlock Open indication lamp is lit.
4 Lower the clamp over a container and lock the Twistlocks.
5 Check that the LED on the Locked Twistlock sensor is lit.
If necessary, undo the locknut and screw the sensor in/out until
the distance between the sensor and indicator plate is 5±1 mm.
007783
6 Check that the Twistlock Locked indication lamp is lit.
1 2
Right-hand side
2. Sensor locked Twistlock
1 2
007920
Left-hand side
2. Sensor locked Twistlock


8 Control system 1
8 Control system
Table of Contents 8 Control system

mm mm mm mm mm mm
8 Control system ............................................................................................... 3

8.2 Monitoring ................................................................................................... 6
8.2.3 Speed limitation ..................................................................................... 6
8.2.4 Service indicator .................................................................................... 7
8.3 Error codes ................................................................................................. 8
8.4 Diagnostics ................................................................................................. 9
8.4.1 ECU 790 .............................................................................................. 10
8.4.2 ECU 792 .............................................................................................. 11
8.4.3 ECU 793 .............................................................................................. 11
8.4.4 ECU 796 .............................................................................................. 11
8.4.5 Last alarms ......................................................................................... 12

2 8 Control system

8 Control system – 8 Control system 3
8 Control system
mm mm mm mm mm mm
Control system, general

page
–
Many of the machines functions are controlled electrically. The signals

that control the machine are monitored to warn the operator or limit the
machine's functions in certain dangerous situations or in case of ma-
chine malfunctions.
The function control system is divided into the following functions:
• Monitoring functions
• Error codes
• Diagnostic test
• Settings
• Software
Monitoring functions describe the machine’s monitoring functions that
warn the operator or limit the machine’s functions in case of eventual
dangerous situations.
Error codes notify operators and mechanics when malfunctions have
been detected.
Diagnostic test is tool for performing service and troubleshooting with
menus in the machine’s display.
Settings is the tool for setting and adapting the machine’s functions.
The software creates the functions in the control system.

4 8 Control system – 8 Control system
Control system, description

page
–
The machine is equipped with an electronic system used for control-

B C ling and monitoring the machine’s different functions.
The system gives the operator information in the form of alarm infor-
mation and operating information. The information is presented on the
steering wheel panel’s display (B).
The function keys are used to navigate in the display menus for serv-
ice and troubleshooting, for example.
F
R
1 2 3
4 5
007801
A
A. Function keys
B. Display
C. Alarm indicator
Function keys
R The function keys (position A) are used to navigate inside the menu
1 2 3 system of the information, settings and diagnosis menus.
They are also used to enter values into the system and to confirm error
codes.
000693
4 5
• Function key 1 1 : scroll anti-clockwise in the menu system and
enter value 1.
• Function key 2 2 : scroll clockwise in the menu system and enter

value 2.
• Function key 3 R : interrupt selection of menu or procedure in

3
progress and confirm error codes displayed. Also works as a

short-cut to the operational menus if held down for a short time.
• Function key 4 4 : enter value 4, gradual settings adjustment

and gradual values decrease in menus (counts down when the
function key is held down, counts faster if held down longer).
• Function key 5 5 : enter value 5, gradual settings adjustment

and gradual values increase in menus (counts down when the
function key is held down, counts faster if held down longer).
• Function key 6 : confirms selection of menu and confirms val-

ue entered (stored in memory).

8 Control system – 8 Control system 5
Operating menus
50
When the machine is started, the operating menu containing engine
speed, ground speed, current gear (during inching, or when the clutch
is not engaged, gear positions 1-3 are not displayed), time and fuel
level is displayed. This menu is shown until another menu is selected
82 ˚C or an event-controlled menu is shown (e.g., in case of error code of
type “WARNING” and “STOP”). Menus are selected using the function
2.4 bar keys for arrow right and arrow left. For each press of the key the dis-
play changes to the next menu. The Reset (R) function key can be
held depressed to quickly return to the original display.
-/+
60 ˚C
This section describes the information that can be obtained from
- +
28.7 V each operating menu. The figures are shown with example data.
2 L/H
1430 km NOTE
+
300 h Menu availability depends on machinery configuration.
12 L/H
The following operational menus are accessible for assisting opera-
(+/-) 1.2 tors:
75 t • Operating menu
007359
158 t • Operating menu engine

Example of operating menus • Operating menu transmission and electrical system
• Operating menu service interval
• Operating menu scale
• Operating menu fuel consumption
• Operating menu lever steering/mini-wheel

• Operating menu service
Service menu
The service menu is the gateway to the machine's diagnostic system.
By pressing “Enter” and entering different codes, different parts of the
service menus are accessible. The code to access the diagnosis men-
us is 11111, while the code to access the settings menus requires spe-
cial authority (contact Kalmar Industries with any questions).
000056
The different service menus are:

• Error codes, description page 8.
• Diagnostic test, general page 9.

6 8 Control system – 8.2 Monitoring
8.2 Monitoring
Monitoring functions, general
page
–
The machine is equipped with a number of control functions to in-

crease safety during load handling:
• Speed limitation
• Service indicator
8.2.3 Speed limitation

Speed limitation, description
page
–
Speed limitation prevents the machine's speed from exceeding pre-set

value by limiting gear position and engine rpm.

8 Control system – 8.2.4 Service indicator 7
8.2.4 Service indicator

Service indicator, resetting
page
–

2 Navigate first to the service menu and press Enter.
000056
3 Enter code for resetting service indicator.
The code is obtained via Kalmar Industries Support.
1 23
4 5 NOTE
000060
The code determines which service menu shall be activated

(Service, Diagnostic test, Initiation or Calibration).
4 Reset the service indication by pressing Enter.
500h TO NEXT SERVICE

PRESS ENTER TO
CONFIRM!
000808

8 8 Control system – 8.3 Error codes
8.3 Error codes

Error codes, description
page
–
When a malfunction occurs in the machine error messages (error

codes) are generated by the control unit in question that is sending the
error code via the CAN-bus to Control unit EDU 795 that shows the er-
ror codes on the display and stores the error codes.
Explanation of error codes is available in the Operator's manual and
Workshop manual.
Error code indication

Error code is indicated with activated Indicator for active error codes
41 42 (position 42). The error codes are divided into three error code levels
depending on how serious they are.
Error code levels are indicated as follows:
• STOP is indicated with a STOP-sign on the display together with
a constant red light from indicator for control system (position 42).
B
Error code with level STOP shown automatically on display.
• WARNING is indicated by a warning triangle in the display togeth-
er with constant red display from the control and monitoring sys-
tem indicator (position 42).
Error code with level WARNING shown automatically on display.
• INFORMATION is indicated by a spanner in the display together
with constant red display from the control and monitoring system
indicator (position 42).
Error code with level INFORMATION is shown automatically in
display.
007192
B. Symbol error code level

41. Display for control system (KCS)
42. Indicator for control system (KCS)
Error code display

Error code information is shown with display figures and symbols
307 which provide a guide to the fault which has occurred.
The error code and image can be temporarily removed by the Reset
(R) function key, which then disappears from the display. If the error
code is active the display indication will return within 1-3 minutes.
004257
If an information error code is deleted with Reset (R), this is not dis-
Example of automatic display figure played again until the system is re-started.

8 Control system – 8.4 Diagnostics 9
8.4 Diagnostics
Diagnostic test, general
page
–
The machine has built-in functions for troubleshooting called diagnos-

tic test. The diagnostic test consists of several menus that are shown
DIAGNOSTICS on the display. The menus are grouped according to control unit for
faster access.
The following pages contain compilations of diagnostic menus. In the
000916
Workshop manual there are more detailed descriptions of each diag-
nostic menu.
The diagnostic test is divided into the following groups:
• Control unit ECU 790, ECU 790, menu overview page 10.
• History for error codes, Last alarms, description page 12.
The diagnostic test varies between the different control units as to
what type of diagnostics can be carried out, but the following alterna-
tives are possible:
• View inputs – means that the inputs can be checked (digital and
analogue).
• View outputs – means that the outputs can be checked (digital and
analogue).
• Control outputs – means that the outputs can be checked and
controlled (digital and analogue).
Diagnostic test, work instruction

page
–
To select diagnostic test, proceed as follows:

1 Navigate to the service menu.
2 Press .
000056
3 Enter code for diagnostic test (11111).
1 23
4 5
000060
4 Select diagnostics by pressing .
DIAGNOSTICS
000916

10 8 Control system – 8.4.1 ECU 790
5 Main selection for diagnostic test now shown on display.

Choose which control unit shall be investigated using the function
DIAGNOSTICS ECU790 keys 1 and 2 and confirm with .
Only accessible control units on the machine are displayed.
Each diagnostic function comprises a sequence of a number of
diagnosis menus. The first diagnosis menu for selected diagnos-
DIAGNOSTICS ECU792 tic group appears in the display. Choose the next diagnosis menu
using 1 and 2 .
DIAGNOSTICS ECU793
DIAGNOSTICS ECU796
LAST ALARMS
007891
8.4.1 ECU 790

ECU 790, menu overview
page
–
DIAGNOSTICS ECU 790
DIAG ECU 790 1(3) DIAG ECU 790 2(3) DIAG ECU 790 3(3)
VIEW INPUTS VIEW OUTPUTS CONTROL OUTPUTS

007886

8 Control system – 8.4.2 ECU 792 11
8.4.2 ECU 792

page
–
DIAGNOSTICS ECU 792
007887
8.4.3 ECU 793
page
–
DIAGNOSTICS ECU 793
ECU793 D M
E
F S
007888
8.4.4 ECU 796
page
–
DIAGNOSTICS ECU 796

007890

12 8 Control system – 8.4.5 Last alarms
8.4.5 Last alarms

Last alarms, description
page
–
A history of the latest error codes generated can be seen under this
menu. If the same error code is generated several times this is count-
ed and the number of faults is shown on the display. The time counter
time for when the error code was last generated is also displayed.
Select diagnostics and Last alarms as per Diagnostic test, work in-
struction page 9. This display indicates if Last alarms is selected.
LAST ALARMS Press function key to proceed.
000995 The 10 latest error codes are displayed in chronological order (with er-
ror code number), number of error codes and relevant operation time
for the last error code of this type received.
If only one error code is saved there is only the menu for that fault and
the last menu “Clear all alarms”. So the number of menus under Last
alarms is dynamic. Max. number of error codes saved is 10.
1 Latest active error codes (1, latest) in chronological order.
LAST ALARMS 1(13)
ALARM NUMBER 354
COUNTER 11
16.01.2007 10:58
009350

LAST ALARMS 2(13)
ALARM NUMBER 358
COUNTER 8
16.01.2007 10:58
009351

LAST ALARMS 3(13)
ALARM NUMBER 361
COUNTER 3
16.01.2007 10:58
009352

LAST ALARMS 4(13)
ALARM NUMBER 364
COUNTER 2
16.01.2007 10:58
009353

LAST ALARMS 5(13)
ALARM NUMBER 380
COUNTER 6
16.01.2007 10:58
009354

8 Control system – 8.4.5 Last alarms 13

LAST ALARMS 6(13)
ALARM NUMBER 384
COUNTER 1
16.01.2007 10:58
009355
LAST ALARMS 7(13)
ALARM NUMBER 601
COUNTER 3
16.01.2007 10:58
009356
LAST ALARMS 8(13)
ALARM NUMBER 610
COUNTER 1
16.01.2007 10:58
009357

LAST ALARMS 9(13)
ALARM NUMBER 900
COUNTER 1
16.01.2007 10:58
009358

LAST ALARMS 10(13)
ALARM NUMBER 1200
COUNTER 2
16.01.2007 10:58
009359
11 Latest active error codes (11) for engine. If more than one code,
LAST ALARMS 11(13) scroll the error codes by pressing the function key 5 .
ENGINE ALARM 1(X)
SPN: 110
FMI: 10
009360
PRESS (+) FOR NEXT

12 Latest active error codes (12) for transmission. If more than one
LAST ALARMS 12(13) code, scroll the error codes by pressing the function key 5 .
GEARBOX ALARM 1(X)
SPN: 5490 This menu does not work for Dana TE17000.
FMI: 11
009361
PRESS (+) FOR NEXT

13 Clear all error codes (possible only with service code). This meny
13(13) is shown if there is one or more error codes. To clear error codes,
CLEAR ALL ALARMS? press on function key (Yes = ).
YES = ENTER
This menu does not clear the error codes for Dana TE17000 or
009362
Volvo TAD750VE.

14 8 Control system – 8.4.5 Last alarms
Shown if no saved error codes exist and after reset. If there are no er-
13(13) ror codes from the KCS system, only menus 11-13 are displayed.
NO ALARMS
009364

9 Frame, body, cab and accessories 1
Table of Contents 9 Frame, body, cab and accessories

mm mm mm mm mm mm
9 Frame, body, cab and accessories............................................................... 3

9.1 Controls and instruments ........................................................................... 5
9.2 Safety and emergency equipment ............................................................ 10
9.3 Seats ........................................................................................................ 11
9.4 Heating, ventilation and air conditioning ................................................... 14
9.4.4 Fresh air filter ....................................................................................... 24
9.4.9 Condenser unit .................................................................................... 25
9.5 Wiper/washer system ............................................................................... 27
9.6 Lighting system ........................................................................................ 28
9.7 Communication system ............................................................................ 29
9.8 Entertainment and communication ........................................................... 30
9.9 Glass/windows/mirrors ............................................................................. 31
9.10 Cab structure and suspension .................................................................. 32
9.10.1 Cab framework .................................................................................... 32
9.10.2 Doors ................................................................................................... 32
9.10.3 Cab structure ....................................................................................... 33
9.10.4 Cab tipping ........................................................................................... 34
9.11 Cab interior equipment ............................................................................. 36
9.12 Frame ....................................................................................................... 37
9.13 Body ......................................................................................................... 38
9.13.4 Counterweights .................................................................................... 39
9.14 Central lubrication .................................................................................... 40
9.15 Paint/coatings ........................................................................................... 42

2 9 Frame, body, cab and accessories

9 Frame, body, cab and accessories – 9 Frame, body, cab and accessories 3
9 Frame, body, cab and

mm mm mm mm mm mm
accessories
Frame, body, cab and accessories,
page
–
description
The machine consists of frame, body and cab.
The frame (chassis) is the machine's structural part and is made of re-
sistant steel.
The body comprises wings, engine cover, tanks and other parts
mounted on the frame.
The cab is built separately and isolated from the frame using heavy-
duty rubber dampers. The operator's seat, steering wheel and control
for hydraulics can be adjusted for optimal individual operating position.
Effective insulation results in minimal vibrations and a low sound level.
The machine is equipped with a heating and ventilation system, and
can be equipped with an optional air conditioning system.
WARNING
Each case of mechanical damage to the cab can in-
volve risks as strength is changed.
Consequently, making holes in weight bearing parts

is forbidden.
Contact Kalmar Industries for recommendations.
WARNING
Never work underneath a cab that is not tipped over
its balance point or secured in another way.
Danger of crushing.
Always tip the cap as far as possible. At maximum tip-

ping angle (on horizontal surface) arrange the cab’s
centre of gravity so that it does not risk tipping back.

4 9 Frame, body, cab and accessories – 9 Frame, body, cab and accessories
WARNING
Avoid walking on the engine cover without anti-slip
protection.
Slipping danger.
WARNING
The strength of the roof window can be significantly
reduced with exposure to substances that contain:
• Aromatic hydrocarbons
• Ketones
• Esters
• Chlorinated hydrocarbons
A roof window exposed to substances with such con-

tent does not always display visible change.
CAUTION
All reworking of the roof window is forbidden (e.g.
making holes, cutting or widening existing holes).
Risk of material damage.
Small cracks in the material around screw holes for

example indicates that the strength of the roof win-
dow is affected and it must be replaced
immediately.

9 Frame, body, cab and accessories – 9.1 Controls and instruments 5
9.1 Controls and instruments

Cab overview Spirit Delta
page
–
1 2 3 4A 5
R
1 4 5
14 2 3
7A
4B 7B
006910
13 12 11 10 9 8
1 Left-hand instrument panel
2 Gear and direction of travel selector
3 Steering wheel panel
4A Steering wheel
4B Joystick or mini-wheel
5 Multi-function lever
6 Parking brake
7A Control for load handling
7B Alternative control for load handling
8 Arm rest
9 Driver’s seat
10 Accelerator pedal
Accelerator with function for selecting travel direction (forward/reverse)
11 Brake pedals
12 Clutch pedal
Inching pedal
13 Fuse box with fuses and relays
14 Operating time gauge

6 9 Frame, body, cab and accessories – 9.1 Controls and instruments
Left-hand instrument panel
30 31 32 33 15 Control for heating
16 Controls for fan
17 Controls for defroster/cab
18 Controls for cooling AC

27 28 29
19 .. 26
19 Switch for recirculation/fresh air
(Only for heater unit with cooling AC)
18
17 20 Switch for cooling AC
16
15 Switch for extra working lamps
21 Switch for working lamps on mast
30 31 32 33
24 Switch for rotating warning lamp
27 28 29 25 Switch for warning lamp

19 .. 26
26 Switch for headlamps
006908
TO DE
AU MO
34 27 Switch for seat heating

(May appear in driver’s seat)
Left-hand instrument panel, upper with heater unit and
lower with climate control system
28 Switch for central lubrication
29 Switch for pause heater
30 Spare
31 Spare
32 Spare
33 Socket for 12/24V
34 Climate control system ECC

Steering wheel panel

A buzzer (not visible) is integrated under the steering wheel panel. It
is activated if:
• a start attempt is made with a gear engaged and the parking brake
is not activated
• the parking brake is not activated when the operator leaves the
driver’s seat
• the machine has a low coolant level, low brake pressure or a fault
in the parking brake
• error codes occur, a short audible signal sounds
35 36 37 38 39 40 41 42 43
35 Warning lamp for exhaust cleaning (particle filter)
36 Warning lamp for air filter replacement
37 Indicator lamp for vertical hold
38 Warning lamp for low battery charging
F 39 Indicator lamp for main beam

N
R
40 Indicator lamp for direction indicators
1 2
R
3
41 Display for the control and monitoring system, KCS
4
42 Alarm indicator for control and monitoring system, KCS
5
43 Ignition switch
006903
44 45 46 47 48 49 44 Switch for reversible driver’s seat

Steering wheel panel
45 Switch for engagement and disengagement of alternative di-
rection of travel selector
Switch for engagement/disengagement of alternative gear

selector
46 Switch for inching pedal
47 Function keys for control and monitoring system, KCS
48 Switch for windscreen wiper, rear
49 Switch for windscreen wiper, roof

8 9 Frame, body, cab and accessories – 9.1 Controls and instruments
Right-hand instrument panel
51 52 53 54 55 56 57 58 59
51 Switch for reversing alarm cutout
52 Switch for raising/lowering the driver’s seat
54 Switch for electrically heated rear-view mirrors
007728
55 Spare
Right-hand instrument panel 56 Spare
57 Spare
58 Spare
59 Spare

Operational menus, introduction

–
1. Operational menu
1 50
2. Operational menu engine
3. Operational menu transmission and electrical system
4. Operational menu service interval
8 2
82 ˚C 5. Operational menu scale
2.4 bar 6. Operational menu fuel consumption
7 3 7. Operational menu joystick/mini-wheel

-/+
60 ˚C
8. Operational menu service
- +
28.7 V
6 4
2 L/H
1430 km
+
12 L/H 300 h
5
(+/-) 1.2
75 t
007899
158 t

10 9 Frame, body, cab and accessories – 9.2 Safety and emergency equipment
9.2 Safety and emergency

equipment
General
page
–
A good working environment has safety and emergency equipment to

make the operator’s work easier and safer.
The machine may be equipped with the following safety equipment:
8 2 11 9 8 7 1. Reversing alarm
2. Rotating warning lamp/flashing warning lamp

The rotating warning lamp may be vertically adjustable.
3. Horn
4. Electrically operated loud horn
5. Fire extinguisher
The fire extinguisher is normally located on the left front fender,
but can also be located on the right front fender or inside the cab.
If the machine is equipped with a fire extinguisher, it should be of
1, 8 6 10 3 5 4 9 8 type ABE according to EN 3 parts 1, 2, 4 and 5. This type of extin-
009491
guisher can put out fires in both solid organic materials and fluids.
Suitable fire extinguishing equipment can be ordered from Kalmar
Industries.
6. Seat belt
7. Buzzer in cab to indicate alarm or forgotten action, for example,
leaving driver’s seat without applying the parking brake.
8. TV camera with monitor

Is used for improving the rear view when manoeuvring and/or load
handling with the machine. The monitor is usually located inside
the cab at the right front door post.
9c 9a 9. External mirrors :
Used to give improved visibility when operating and load handling.
9a shows the concealed area in front of the machine
9b shows the concealed area beside/behind the machine
9c shows the concealed area behind the machine
10. Breaker switch for load handling

(servo circuits, only in case of controls electric servo for load han-
dling).
009465
9b 11. Protective grating for roof window .

9 Frame, body, cab and accessories – 9.3 Seats 11
9.3 Seats
Seats, general
page
–
The seat's function is to give the operator a good sitting position and
contribute to a good work environment. The cab's seat can be adjust-
ed in several ways, and meets high comfort standards.
Machines with cab alternative Spirit Delta can be equipped with
reversible or swivelling operator’s seat .
NOTE
Other types of driver’s seat may occur.
Seats, description (product alternative Bege)

page
–
The seat is equipped with:

• mechanical adjustment of height and suspension
1 2 • air suspension
• integrated horizontal suspension (can be switched off)

3
• can be rotated 40°
4 • electrically reversible 180°

• mechanically adjustable lower back (lumbar) support
• mechanically adjustable seat cushion angle
• seat belt, 2-points
5
• seat belt, 3-points
• head restraint
8 6
006825
7 • adjustable arm rest, right

Controls Bege
1. Adjustment, lumbar support • adjustable arm rest, left
2. Adjustment, armrest right
• seat heater
3. Adjustment, armrest left • ventilated seat and backrest cushions (air-vent). The seat re-
4. Adjustment, backrest angle quires compressed air. The selection contains an externally
5. Adjustment, spring position
6. Adjustment, seat angle mounted compressor on the underside of the cab floor.
7. Adjustment, seat height
8. Adjustment, length

12 9 Frame, body, cab and accessories – 9.3 Seats
Seats, description (product alternative

page
–
Isringhausen 6500)
• air suspension
• air adjustable lumbar support
• mechanically adjustable damping
• horizontal suspension (can be shut off)
• seat belt, 2-point
• seat belt, 3-point
8 • head restraint
• adjustable arm rest, right
• adjustable arm rest, left

• seat heater
• integrated compressor
003712
2 3 6 1 5 7 4 9
Controls Isringhausen 6500
3. Adjustment, seat angle
4. Adjustment, backrest angle
5. Adjustment, damping
6. Seat heater
7. Adjustment, lumbar support
8. Adjustment, armrest left

9 Frame, body, cab and accessories – 9.3 Seats 13
Seats, description (product alternative Grammer

page
–
Actimo XXL)
• air suspension (height)
• air adjustable lumbar support
8
• mechanically adjustable seat length
• mechanically adjustable damping
• integrated horizontal suspension
9 • seat belt, 2-point
• head restraint
• adjustable arm rest, right
10
• adjustable arm rest, left
2
5
4 • seat heater
6 • integrated compresso
003710
3 1 7
Controls Grammer Actimo XXL
2. Adjustment, seat cushion
4. Adjustment, seat angle
5. Adjustment, backrest angle
6. Adjustment, damping
7. Yard damping
8. Adjustment, lumbar support
10. Adjustment, armrest left

14 9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning
9.4 Heating, ventilation and air

conditioning
Heating, ventilation and air conditioning,
page
–
A truck with standard equipment has a heater unit (cabin/defroster)
connected to the engine cooling system and provides heat when the
engine is warm. The heating unit comprises fan and elements for
warming the air. The air is distributed through integrated ducts in the
cab’s interior equipment and can be guided to defroster or floor for ex-
ample. In FlexCab cab the air is distributed through three adjustable
air nozzles and can be guided to defroster or floor for example.
Climate control available in different types:
• Climate control, AC (manual control of cooling and heating)

• Climate control, ECC (Electronic Climate Control, electronic con-
trol of cooling, dehumidifying and heating).

9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning 15
Air conditioning includes the parts presented in the illustration and en-
sures the driver’s cab climate is as comfortable as possible. Air condi-
F
tioning function is to:
• heat the air when it is cold
2 • dehumidify the air when it is damp
4 • clean the air of impurities
D
C • cool the air when it is hot
• defrost (defroster function)
E E
The unit is controlled with switches and controls on the instrument
3 panel.
The unit’s fan is controlled in steps 0-I-II-III (with the fan control). With
climate control ECC the fan is variable 0–100%.
6 A B
5 1
G
000762
1. Fluid reservoir/receiver dryer

2. Evaporator
3. Fan
4. Expansion valve
5. Condenser
6. Compressor
A. High pressure gas
B. High pressure fluid
C. Low pressure fluid
D. Low pressure gas
E. Heat, cab air
F. Cooled air to cab
G. Outdoor air for removal of heat

Heating, ventilation and air conditioning,

–
component position
1 2 3 4 5 6
O E
7 8
AUT MOD
9 10
11
18
17 16
15 14 13 12
007900
1. Sensor outdoor temperature ECC 10. Sensor, after heat exchanger ECC
2. Condenser 11. Heat exchanger, heating
3. Pressure switch 12. Expansion valve
4. Particle and moisture filter 13. Sensor de-icing ECC
5. Sight glass 14. Heat exchanger, cooling
6. Sensor, temperature air conditioning ECC 15. Fan

7. Control for cooling AC with thermostat 16. Water valve standard heating and AC
8. Air conditioning ECC 17. Water valve ECC
9. Fresh air filter 18. Compressor

Climate control system ECC

page
–
General instructions for work on the climate control sys-

tem
CAUTION
Authorisation is required for repair of the climate con-
trol system.
Checking/performance test of climate control system
NOTE
The climate control system does not work at temperatures below
approx. 0 °C since the pressure in the refrigerant circuit is too low.
If the pressure in the refrigerant circuit becomes too low, the low
pressure monitor cuts off electric power supply to the compres-
sor's magnetic clutch, which means that the air conditioning stops
functioning.
Shall be performed during continuous use every week from early
spring to late fall as well as in winter, during longer periods with high
humidity.
In winter during cold and dry periods with low utilization, the compres-
sor shall operate a few minutes every week so that rubber hoses, cou-
plings, gaskets and axle seal are lubricated.
1. Check that the condenser is not clogged – if necessary clean the
condenser flanges with compressed air.
2. Check that the compressor cuts in and out without problems.
3. Check that the outlet for the cooling coil's condensation water is
not clogged.
4. Check that there is no refrigerant leakage. If there is a leak, oil and
gas often form a dirty, dusty patch.
5. Start the engine and activate the cooling function with setting
maximal cooling. With ECC: Select Cool mode and the tempera-
ture at min.
Let the engine run at minimum 1500 r/min. (At temperature below
approx. 0 °C the cooling function does not start due to low pres-
sure in the system.)
6. With AC: Set the fan control to position I or II.
With ECC: Set the fan to medium speed.
7. Check after 10 minutes operation that there are no bubbles in the
receiver dryer's sight glass. (Bubbles shall only appear when the
compressor starts and stops).

8. Place a thermometer at the exhaust vent closest to the evapora-

tor. The temperature shall be, after 5-10 minutes, below 10 °C.
(Deviating measuring results may occur if performance test is
done when the ambient temperature is below approx. 18 °C.) If
there are bubbles, topping up should be performed by a trained
professional.
Check temperatures of hoses and similar as follows:

1. Check that hoses and components on the pressure side keep a
fairly even temperature by feeling them with your hand.
NOTE
If there is a blockage in any of the cooling circuit compo-
nents, and during long-term operation, some components
can become very hot (mainly the hoses in front of the con-
denser). Burn danger!
2. All hoses and components on the pressure side (from the com-
pressor to the expansion valve) shall be warm.
3. All hoses and components on the suction side (from the evapora-
tor to the compressor) shall be cold.
4. Check the expansion valve. If it is frosty or cold on the inlet side it
means that it is defective or clogged, that circulation is restricted
or stopped on the pressure side.
5. Check that the compressor is engaged and disengaged normally.
Run the cabin fan at low speed and let the compressor run at high
speed. When the temperature in the outlet reaches 0°C, the com-
pressor is disengaged via the thermostat or ECC, and is re-con-
nected when the temperature has risen to about 3-7°C. (If the
compressor is not disengaged, there is a risk that the evaporator
could ice up and the cooling effect would be reduced.)
WARNING
In case of a rupture of a cooling hose or leakage of the
plant – turn off the unit immediately.
It is dangerous to get refrigerant on the skin or in the

eyes.
Never release refrigerant in a closed room, the gas

may cause asphyxiation, e.g., in installation pits.
Never weld on or near a closed cooling system.
Drain the refrigerant when repairing the climate con-

trol unit.
Work on the refrigerant circuit may only be performed

by an accredited company.

Checking amount of refrigerant
WARNING
The electric fans may injure the hands.
Risk of personal injury.
Avoid keeping hands close to the cooling fans when

the engine is running.
With the sight glass it is possible to check an estimate of the correct

amount of refrigerant. Visible bubbles shall normally not be observed
when the air conditioning is operating. Bubbles may appear if the unit
contains incorrect amount of refrigerant, in connection with the com-
pressor starting as well as if the condenser is defective or at very high
ambient temperature.
It is easiest to confirm bubbles if you observe the sight glass at the
same time as the compressor is started. Bubbles are usually seen
from a few seconds after compressor start, until the system has start-
ed to operate normally.
NOTE
Reliable checking of the amount of refrigerant using the sight
glass can only be done when the ambient temperature is above
approx. 15°C.
There is a sight glass on the left side of the condenser, on the pipe
leading to the condenser. In the centre of the sight glass, there is a col-
oured dot for moisture indication. The indication is normally GREEN.
If the indicator turns YELLOW, there can be moisture in the system
(this can occur if the system is not evacuated before the refrigerant is
added, or if refrigerant has leaked out).
Inspection of sight glass on rear-mounted condenser, the

condenser mounted behind the roof or in a rearward posi-
tion
2 Check that the amount of refrigerant is correct using the sight
glass.
3 The sight glass can be inspected from below.

Inspection of sight glass on roof-mounted condenser

1 Machine in service position, see section B Safety
glass.
NOTE
Reliable inspection of the sight glass is difficult without in-
spection mirror.
Inspection can also be performed by loosening the condenser's
outer protective casing, see step 3-5.
Inspection with inspection mirror.

3 Remove the attaching screws on the left side of the condenser's
outer protective casing.

4 Carefully lift the left side of the condenser's outer protective cas-
ing.

glass.

Actions in case of leakage in the system

1. Turn off the unit.
2. Check the unit and pinpoint the leaks. For this purpose, use spe-
cial leak detection equipment. If there is still refrigerant in the unit,
evacuate the remaining refrigerant and then measure it.
3. Take action to fix defects, seal leaks by changing gaskets, hoses,
etc.
4. Fill refrigerant R-134A according to following steps in the correct
amount when all defects have been repaired.
5. The work in the following requires special filling equipment.
6. Connect the suction pressure gauge's blue hose to the service
valve on the compressor's suction side marked S, SUC or SUC-
TION.
7. Connect the pressure gauge's red hose to the service valve on the
compressor's pressure side marked D, DIS, or DISCHARGE.
8. Connect the hoses to the fluid reservoir.
9. Connect the yellow filling and vacuum hose to the nitrogen gas
tube. Open the valve on the tube and then the valve on the pres-
sure side. Now the gas rushes through the system and back to the
suction side on the compressor, which can be seen on the blue
pressure gauge slowly indicating a pressure, corresponding to the
pressure in the tube (see red pressure gauge). (If the blue pres-
sure gauge does not move, there is a clog in the system.) Close
the valve on the pressure side and then the valve on the tube.
10. Now the system contains a mixture of nitrogen gas and air. This
gas volume is sufficient to indicate any leakage.
11. Check all hose nipples and other connections for leaks by apply-
ing leak indication around all sealing surfaces and check if any
gas bubbles appear.
12. Loosen the yellow hose from the nitrogen gas tube and connect it
to the vacuum pump.
13. Start the vacuum pump and open the valve on the suction side
very carefully, otherwise the oil is blown out of the vacuum pump.
Then open the valve on the pressure side, vacuum pump for at
least 30 minutes. Preferably longer.
14. First close both valves on the pressure gauge set. Then turn off
the vacuum pump. Work in this sequence, otherwise the air rush-
es back. Wait approx. 15 min and check on the pressure gauges
that the vacuum does not change.
15. Move the yellow hose to the refrigerant tube and open the valve
on the tube.
16. Vent the yellow hose by loosening the service connection by the
pressure gauge set until clean gas flows out.
17. Open the suction side's valve and let the gas flow until the pres-
sure gauges indicate the same pressure as in the tube.
18. Start the compressor and set the cooling thermostat and fan to
max.

19. Open the valve on the pressure side and let the compressor suck
from the tube. Watch the sight glass. At the beginning, the fluid is
heavily mixed with bubbles. The longer the compressor sucks,
less bubbles appear and the fluid becomes clearer. If the bubbles
suddenly disappear, the cooling thermostat has probably disen-
gaged. Bridge the thermostat using a cable directly from the con-
nection 24 V or wait until the thermostat engages again. Continue
to fill until correct refrigerant amount has been reached.
NOTE
By-passing directly on the compressor's connecting magnet
can lead to compressor damage, caused by incorrect refrig-
erant amount.
Close the valve on the suction side and then the valve on the tube.
Loosen the service hoses from the compressor and fit the protec-
tive caps. Check for leaks according to step 11 or with a special
leak detector.
20. In case of overfilling, the pressure and temperature slowly in-
crease until the high pressure monitor cuts off the current to the
compressor solenoid. This is due to the refrigerant rushing around
in the system without being evaporated or condensed in the con-
denser. The result is that the cold in the cooling coil is lost and
high heat is generated in the condenser. In addition, a heavy flow
of bubbles can be seen in the sight glass. Return to step 2.
21. In case of insufficient filling or lack of refrigerant, there are bubbles
in the sight glass - return to step 2.
Compressor's cooling oil

1. When delivered, the compressor is filled with cooling oil. Under
normal conditions the oil shall neither be changed nor topped up.
In case incorrect oil amount is suspected, see instruction: “When
replacing compressor.”
2. In case of refrigerant loss there may also be an oil loss, since ap-
prox. 25% of the oil volume is absorbed by the refrigerant.
Recommended oil types that may be used are found in section F Tech-
nical data.
When replacing compressor

When delivered, the compressor is filled with cooling oil. When replac-
ing compressor, oil shall be replaced as follows:
• Drain the defective compressor of oil and measure the amount.
• Then drain the new compressor of oil and refill it with the same
amount that was drained from the defective compressor. For oil
volume in the system, see section F Technical data.

24 9 Frame, body, cab and accessories – 9.4.4 Fresh air filter
9.4.4 Fresh air filter

Fresh air filter, cleaning and changing
page
–
A fresh air filter is also available as an option on the Spirit Delta cab
with AC or ECC .

2 Remove the filter insert.
3 Clean the filter insert with hot water and dishwashing detergent
or replace the filter if necessary.
4 Fit the filter.
Fresh air filter, air conditioning, changing

page
–
. A fine filter is always installed in combination with AC or ECC.

2 Loosen the screws and remove the air conditioning unit's front
casing (under wiper motor).
3 Remove the filter insert.

4 Change filter as needed.
5 Install the filter insert.
NOTE
Make sure that the filter insert is installed with the arrow marking
facing the correct way.
6 Install the front casing.

9 Frame, body, cab and accessories – 9.4.9 Condenser unit 25
9.4.9 Condenser unit

Condenser unit, checking
page
–

2 Check that the condenser battery's fins are not clogged by dust
that obstructs air flow. (A sign that the condenser needs cleaning
may be low or lost cooling performance in combination with the
condenser fans running continuously in the highest speed
range.) If the condenser fans stop (cycling from stationary to
maximum speed), the reason could be an open circuit in the built-
in resistor for the condenser unit fans.)
3 Clean roof-mounted condenser as follows (rear-mounted is ac-
cessible without dismantling)
4 Check that the fans rotate.
5 Remove the condenser's outer protective casing, 4 pcs. M6
screws.
6 Remove the M8 nuts for the condenser's two front rubber damp-
ers.

26 9 Frame, body, cab and accessories – 9.4.9 Condenser unit
7 Carefully lift up the condenser at the leading edge and support it

with a suitable support.
8 Clean the fins with compressed air

9 Frame, body, cab and accessories – 9.5 Wiper/washer system 27
9.5 Wiper/washer system

Wiping/cleaning of windows, description
page
–
On the cab, there are wipers for front and rear windscreens as well as
the roof windows. Its function is to clean the windows and to maintain
good visibility from the cab.
The wiper arm is attached to the wiper motor's shaft over a splined
3 cone. The shaft is made of hardened steel and the wiper arm’s attach-
ment is made of mild die cast material.
When installing, it is very important to make sure that the splines are
free from metal filings etc. Also, the nuts shall be tightened so hard that
the splines are pressed into the attachment and act as a flange. Hold
still the wiper arm when installing so that the torque isn’t transmitted to
the motor, which may be damaged (16–20 Nm tightening torque).
2
1
001878
1. Wiper front
2. Wiper roof
3. Wiper rear
Drier, check
–
Check that:
1. the motors operate correctly, with no unwanted noise.
2. the wiper arms press the wiper blades against the windows.
Change them if they have signs of damage or considerable wear.
3. the wiper blades are undamaged. Change them if they are dam-
aged or worn.
4. the screenwasher function spreads screenwasher fluid over the
windows in a satisfactory manner. If necessary, top up the screen-
washer fluid and adjust the washer nozzles.

28 9 Frame, body, cab and accessories – 9.6 Lighting system
9.6 Lighting system

Lighting system, component position
page
–
The function of the lighting is to increase safety during operation and

load handling.
NOTE
It is important that the right type of lamp is used for each area.
See section F Technical data.
The following lighting is fitted to the machine:
10, 12, 15 8 7 9 13
11, 14
1, 2, 3, 4, 6 16
3, 4, 5
007909
1. Rear lights, red 9. Interior lightning
2. Brake light 10. Working lamps, cab roof, rear edge, 2 lamps
3. Driving direction indicator 11. Working lamps, mast, 2 lamps
4. Position light 12. Extra working lamps cab roof rear edge, 2, 4 or 6 lamps
5. Headlight 13. Extra working lamps for cab roof front edge, 2 lamps
6. Reversing lamp, white 14. Extra working lamps, mast, 2 lamps

15. Extra working lamps for container handling cab roof reear edge,
7. Manoeuvrable spot lamp
4 lamps,
8. Rotating warning light 16. Extra working lamps between tilt cylinders, 1 lamp

9 Frame, body, cab and accessories – 9.7 Communication system 29
9.7 Communication system

Communication system, component position
page
–
The function of the signals is to increase safety during operation and

load handling. This can be via light and sound. The following signal
systems are fitted to the machine:
NOTE
It is important that the correct type of lamp is used for each area.
Please refer to insert F Technical data.
7 4
5, 6
3, 5
007902
1
1. Horn 5. Driving direction indicator
2. Loud horn 6. Reversing alarm

3. Warning light 7. Reversing light
4. Rotating warning light 8. Buzzer in cab

30 9 Frame, body, cab and accessories – 9.8 Entertainment and communication
9.8 Entertainment and

communication
Entertainment and communication, description
page
–
For information and description of equipment, see supplier's docu-

mentation for respective product.

9 Frame, body, cab and accessories – 9.9 Glass/windows/mirrors 31
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
page
–
Hardened glass is standard on all trucks. Tinted windows and laminat-

C ed glass are optional. Roof windows are a safety component and are
thus always made from polycarbonate.
The mirrors are all convex type. The inner rear-view mirror is fitted in
D
all trucks. External rear view mirrors are available as options, both with
and without electric heating.
B
A As an option, the machine can be equipped with a reversing cam-
era and a monitor in the cab, to improve sight backwards.
007792
E
Overview, cab windows
A. Side windows
B. Windscreen (front window)
C. Roof window
D. Rear window
E. Side windows front
Roof window, check
–
Check that the roof window is not damaged or cracked. Change a de-
fective roof window at once.
DANGER
The strength of the roof window may be significantly
reduced in case of exposure to substances contain-
ing: aromatic hydrocarbons, ketones, esters and
chlorinated hydrocarbons.
Low strength! Fatal danger!
Check the outside surface of the roof window at reg-

ular intervals. Replace the roof window immediately if
it’s cracked or scratched!

32 9 Frame, body, cab and accessories – 9.10 Cab structure and suspension
9.10 Cab structure and

suspension
Cab structure and suspension, description
page
–
The cab has a level floor with a bracket for the operator's seat. It is sus-
pended in a cab undercarriage via heavy-duty rubber pads located on
the bottom of the cab. This is to minimise vibration from the frame to
1 the cab. Each rubber pad mounting has a rubber bushing and a bolt.
3
003206
1. Cab frame
2. Door
3. Suspension of cab
4. Cab undercarriage
9.10.1 Cab framework

Cab framework, check
page
–

2. Check the cab framework for rust damage, deformation and
cracks. Repair as necessary.
9.10.2 Doors
Doors, check
page
–

2 Visually check the door mounting points.
3 Check the door lock mechanism for function and wear.
006914

9 Frame, body, cab and accessories – 9.10.3 Cab structure 33
9.10.3 Cab structure

Cab mounting, check
page
–

2. Check that the welding joints at the cab attachment points are in-
tact and free from visible cracks.
3. Check that the dampers are undamaged. Change damaged

dampers.
4. Check that all screws are tightened, that all catches function (not
damaged) and all anchorages are undamaged. Repair as neces-
sary.
006913

34 9 Frame, body, cab and accessories – 9.10.4 Cab tipping
9.10.4 Cab tipping

Cab tipping, description
page
–
The cab can be tipped to an angle, over its centre of gravity, pivoted
around the left-hand side suspension, assisted by a hydraulic cylinder.
The hydraulic oil pressure is generated by a hand-controlled pump
with an integrated reset valve for tipping up or down.
On the right-hand side mounting are locking devices which secure the
cab to the frame and can be easily released for tipping the cab.
Electric tipping of the cab is available as an option.

Cab tipping, operating instructions
A, B C
WARNING
C Never work underneath a cab that is not tipped over
its balance point or secured in another way.
Danger of crushing.
Always tip the cap as far as possible. At maximum tip-

ping angle (on horizontal surface) arrange the cab's
centre of gravity so that it does not risk tipping back.
Preparations:
• Set the gear and direction of travel selector in neutral position.
• Tilt the mast forward and lower the forks.
• Apply the parking brake.
• Check the cab for any loose items.
• Close the doors.
Tilting
1. Turn both lock handles (position C) so that they end up in their out-
er position to release the cab from the frame.
001536
2. Set the pump valve (position B) in right hand position.

A B
3. Fit the pump rod in its bracket (position A).
A. Pump rod bracket
4. Pump until the cab is in the end-position.
B. Pump valve
C. Locking knobs (illustration shows open position) Lowering
1. Set the pump valve (position B) in left-hand position.
2. Fit the pump rod in its bracket (position A).
3. Pump all the way until the cab rests on the frame.
er position to lock the cab to the frame.

9 Frame, body, cab and accessories – 9.10.4 Cab tipping 35
Electric tilting
er position to release the cab from the frame.
2. Set the pump valve (position B) in right hand position.
3. Use the control buttons to raise the cab to end-position. Press in
both buttons at the same time.
Electric lowering
1. Set the pump valve (position B) in left-hand position.

2. Use the control buttons to lower the cab until it rests on the frame.
Press in both buttons at the same time.
er position to lock the cab to the frame.

36 9 Frame, body, cab and accessories – 9.11 Cab interior equipment
9.11 Cab interior equipment

Cab interior equipment, description
page
–
The cab is designed for optimum driver comfort. Switches, controls,

warning and indicator lamps are grouped on the instrument panels to
provide the driver with a good driving environment.
Recyclable materials have been used for all parts.
• Instrument panels
• Interior parts, plastic
• Interior parts, textile
• Insulation

9 Frame, body, cab and accessories – 9.12 Frame 37
9.12 Frame
Chassis, component position
page
–
There are attachment points in the frame for engine, gearbox, drive ax-
le, steering axle, fuel and hydraulic tanks and cab, mast and body
parts.
5
3
1 7
007940
1. Frame front section
2. Frame rear section
3. Member pair
4. Mounting, rear wings
5. Drive axle mounting
6. Steering axle mounting
7. Mast mountin

38 9 Frame, body, cab and accessories – 9.13 Body
9.13 Body
Body, safety
page
–
WARNING
Avoid walking on the engine cover without anti-slip
protection.
Slipping danger.
Body, description
page
–
The function of the body is to be part of the chassis. There are wings
to deflect dirt, footsteps and hand rail to facilitate access to the chas-
sis, engine cover to deflect dirt and objects from the engine compart-
ment and a counterweight to balance the machine's lifting capacity.
3 2 4
1 5 007904
1. Fenders front
2. Fenders rear
3. Engine hood
4. Counterweight
5. Battery compartment

9 Frame, body, cab and accessories – 9.13.4 Counterweights 39
9.13.4 Counterweights
Counterweights, check
page
–
WARNING
Factory fitted counterweights adapted to truck char-
acteristics.
Total weight of counterweights must not be changed

when the truck's driving characteristics, capacity and
safety is changed.
1 Machine in service position, see section B Safety, with slanted

wheels.
2 Check visually that the counterweights are set correctly and that
mounting points and welding seams are intact and free of visible
cracks.
3 Check the bolt joints.

40 9 Frame, body, cab and accessories – 9.14 Central lubrication
9.14 Central lubrication

Central lubrication, description
page
–
Central lubrication (replaces manual lubrication) is available in differ-

ent variants. The alternatives are:
• Manual central lubrication, hand pumping lubricant at a lubrication
point which is then spreads to all selected lubrication points.
• Automatic central lubrication automatically greases selected
grease points during operation, according to a pre-programmed
interval.
It is also possible to select the number of lubrication points as follows:
• Total of 14 grease points; 8 in the steering and 6 on the mast (only
alternative for manual central lubrication).
• Total of 18 grease points; 8 in the steering, 6 on the mast and 4
on the vehicle.
• Total of 23 grease points; 8 in the steering, 6 on the mast and 9
on the vehicle (if the vehicle has a centre levelling carriage).
Automatic central lubrication comprises the following components:
1 • Pump unit, with lubricant reservoir.
• Distribution block, with restrictions that distribute and dose grease
between the different grease points.
2 The distribution block lubricates one point at a time. If one point

can not be lubricated properly, if a pipe is blocked for example, the
downstream points will not be lubricated. Grease will be forced out
through the safety valve on the pump unit.
3 • Pipes, between the main unit and the distribution block, and be-
tween the distribution block and the grease nipples.
• Grease nipples, by grease points
At the pump unit, it is possible to adjust the frequency and duration of
the lubrication intervals.
007935
The central lubrication unit is supplied with current when the parking
brake has been released.
1. Pump unit
2. Safety valve NOTE
3. Distribution block
Central lubrication does not lubricate the propeller shaft’s univer-
sal joint, the brake pedal, fork shanks, mast wheels and support
rollers. These must still be lubricated during preventive mainte-
nance.

9 Frame, body, cab and accessories – 9.14 Central lubrication 41
Central lubrication, check

page
–
1
2 1 Check that no grease has been forced out through the safety
valve (position 2).
3
If grease has been forced out through the safety valve, there is a
stop in the system. Localise the pipe which has become blocked
by feeling the unions at the distribution block. A blocked hose will
4
stay under pressure and the union will be stiff.
NOTE
If several distribution blocks are series connected, a blocked
pipe will remain under pressure all the way back to the dis-
tribution block.
2 Turn the ignition key to position I.
3 Turn the pump manually and check that the indication pin (posi-
tion 3) on the distribution block moves in and out.
To operate the pump, undo the cover and press the manual op-
5 eration switch (position 5).
If the indication pin does not move, although the pump runs, the
007941
pump unit must be fault traced.
Summary, central lubrication. Example illustration NOTE

1. Grease nipple, filling grease
The system can be lubricated manually through the grease
2. Safety valve
nipple on the distribution block (position 4).
3. Indication pin
4. Grease nipple, manual lubrication of the system 4 Fill the pump unit with grease through the filling nipple (position
5. Switch, manual operation 1), please refer to insert F Technical data.

42 9 Frame, body, cab and accessories – 9.15 Paint/coatings
9.15 Paint/coatings
Paint/coatings, description
page
–
The machine is painted with paint which is applied by brush or spray.

For colour code (RAL), see machine card.
Check the machine frequently for stone chips, dents and paint scratch-
es, repair them at once to prevent corrosion on the underlying metal.
Only use touch-up paint for small stone chips and scratches. More ex-
tensive paint damage should be repaired by a paint workshop.
NOTE
Touching up, the surfaces to be touched up must be carefully
cleaned.
Please contact Kalmar Industries for information about other surface
treatment and material colours.

9 Frame, body, cab and accessories – 9.15 Paint/coatings 43

44 9 Frame, body, cab and accessories – 9.15 Paint/coatings

10 Common hydraulics 1
Table of Contents 10 Common hydraulics

mm mm mm mm mm mm
10 Common hydraulics....................................................................................... 3
10.2 Security valves ........................................................................................... 5
10.3 Tanks and accumulators ............................................................................ 6
10.3.2 Accumulator ........................................................................................... 7
10.4 Pumps ........................................................................................................ 8
10.5 Hoses, pipes and valves ............................................................................ 9
10.5.2 Main valve ............................................................................................ 11
10.6 Temperature control, cleaning and hydraulic oil ....................................... 14
10.6.2 Hydraulic oil cooler .............................................................................. 15
10.6.7 Breather filter hydraulic oil tank ........................................................... 16
10.6.8 High-pressure filter .............................................................................. 17
10.6.9 Hydraulic oil ......................................................................................... 19

2 10 Common hydraulics

10 Common hydraulics – 10 Common hydraulics 3
mm mm mm mm mm mm
Common hydraulics, description

page
–
The function common hydraulics includes functions that are common

to several of the machine's main functions. For example, hydraulic oil
pumps that serve load handling, steering, the brake system and cer-
tain cab functions with hydraulic pressure.

4 10 Common hydraulics – 10 Common hydraulics
Pressure plate
There's a pressure plate on the machine, stamped with the most im-
portant pressures. The pressure plate is located on the right side of the
frame in front of the steps.
Pressure levels vary with the equipment and are therefore unique to
each machine. When checking pressure, the pressures should match
the pressure plate.
1 2 3
4
5 4
007889
1. Max. brake pressure 5. Steering pressure

2. Hydraulic pressure accumulators 6. Pressure to load handling (not lift)
3. Gas pressure accumulators 7. Pressure to lifting function
4. Servo pressure load handling functions

10 Common hydraulics – 10.2 Security valves 5
10.2 Security valves

Security valves, component position
page
–
An accumulator drain valve is installed in the return pipe from the ac-
cumulators. The accumulators shall be drained with these controls be-
fore working on the hydraulic system. For draining the hydraulic
system, see section B Safety.
To verify that the accumulator pressure has been released, measure
with a pressure gauge on the pressure check connection by the accu-
mulator charging valve (see Measuring nipples, component position
page 11).
007894
A
A. Accumulator drainage valve control

6 10 Common hydraulics – 10.3 Tanks and accumulators
10.3 Tanks and accumulators

Tanks and accumulators, component position
page
–
A. Filling
B. Level glass
C. Breather filter
B
009454

10 Common hydraulics – 10.3.2 Accumulator 7
10.3.2 Accumulator
Accumulator, check
page
–
1 Start the machine and let it run at idling speed (until the accumu-
lators are charged).
2 Switch off the engine and turn the ignition key to position l.
3 Apply and release the brake several times and count the number
of times the brake can be applied before error code for low brake
pressure is shown in display.
It must be possible to apply the brake 8 times before error code
for low brake pressure comes on.
If error code for low brake pressure comes on sooner then the ac-
cumulator is faulty and should be investigated further.

8 10 Common hydraulics – 10.4 Pumps
10.4 Pumps
Pumps (fixed displacement), general
page
–
The hydraulics in the machine are supplied as standard from two fixed-
1 displacement gear wheel pumps. These are driven by splined shafts
from the engine. The pump shafts are carried in plain bearings that are
lubricated by the flowing oil. The pumps have the following functions:
1. Pump 1 supplies the lift function.
2. Pump 2 supplies the steering, other function related to load hand-
ing and the hydraulic accumulators, which in their turn supply the
brake system and the load handling servo circuit.
The priority valve in the valve block ensures that there is always
pressure for steering. The remaining fluid flow is available for load
2
handing.
When the accumulators are fully charged and the lifting function
lifted to its end position, the capacity of both pumps is used for
007893
maximum power in the lifting function.
Hydraulic oil pumps, standard version. 3. Pump 2 supplies also lever steering/mini-wheel .
1. Hydraulic oil pump for lifting function
The pumps are assembled to the gearbox power take-off.
2. Hydraulic oil pump for steering, load handling,
brake system and servo circuit for load handling

10 Common hydraulics – 10.5 Hoses, pipes and valves 9
10.5 Hoses, pipes and valves

Hoses, pipes and valves (control valve),
page
–
component position
The control valve (comprising a valve block and a control section with
directional valves), in the standard version, is acted on above the hy-
draulic servo from the driver station.
Main valve controlled by a hydraulic servo

1. Ventilblock
2. Lift and lower section
3. Inlet section
4. Tilt section
5. Side shift section
6. Spreading section
7. Levelling section
1
P2
DS
M
OL
SP
D
PP
2 PL M
3 D6 LS
OL
SP
4 D
O
O
5 AC
LS
6 K DS
P2
PP
008990
7 PP
M
AC
KM

10 10 Common hydraulics – 10.5 Hoses, pipes and valves
Main valve controlled by an electric servo
1. Ventilblock
2. Lift and lower section
3. Inlet section
4. Tilt section
5. Side shift section
6. Spreading section
7. Levelling section
1 8. Servoventil
9. Solenoid valves
a. Solenoid valve, lower (Y6004)
P2
DS
M
OL
SP
b. Solenoid valve, side shift right (Y6021)

D
PP
2 PL M
3 D6 LS
SP
OL
c. Solenoid valve, spreading out (Y6018)
4 D
5 LS
O
O
d. Solenoid valve tilt out (Y6010)
AC
6 K DS
P2
PP
e. Solenoid valve, levelling down (Y6022)
7 PP
M
10. Solenoid valves

AC
KM
9 (a-e) a. Solenoid valve, lift (Y6005)

b. Solenoid valve, side shift left (Y6020)
8 c. Solenoid valve, spreading in (Y6019)

d. Solenoid valve tilt in (Y6011)
009019
10 (a-e) e. Solenoid valve, levelling up (Y6023)

10 Common hydraulics – 10.5.2 Main valve 11
10.5.2 Main valve

Measuring nipples, component position
page
–
Located on the main valve are a number of measuring nipples and ad-
justment options for certain functions. Most measuring nipples are lo-
cated on the valve block and an occasional one on the direction
valves.
For pressure values for the various measuring nipples, see the pres-
sure sign (located beside the cab tipping control for the machine).
P2
10
DS
M
OL
SP
D
PP
PL M
D6 LS
OL
SP
D
O
O
LS
9 AC
K DS
P2
PP 5
8 6
009610
M
AC PP
KM
1. Adjustment of pressure to lift

2. Adjustment of pressure to load handling
3. Measuring nipple, cooling circuit for brakes (SPOLM)
4. Measuring nipple, pressure to steering (LSM)
5. Measuring nipple, pressure to servo control levers (PPM)
6. Accumulator charge valve (adjustment of max. pressure to accu-
mulator)
7. Measuring nipple, pressure to accumulator (ACKM)
8. Measuring nipple, pressure to load handling (PM)
9. Pressure relief valve for steering
10. Measuring nipple, pressure to lift (P2)

12 10 Common hydraulics – 10.5.2 Main valve
Hydraulic pressure, checking

page
–
NOTE
Safety
1 Warm the machine up so that the hydraulic oil reaches working

temperature, about 50 °C.
2 Switch off the engine.
3 Connect a pressure gauge to the relevant measurement union on
the main valve, please refer to the figure under Measuring nip-
ples, component position page 11 for positioning the measure-
ment unions.
4 Start the engine. Check each function as below.
Accumulator charging (ACKM)
– Allow the accumulator to charge until charging switches over
to cooling the brakes. Read the pressure off and compare
with the permissible pressure on the pressure sign.
– Apply the brakes repeatedly and read off the pressure at
which the accumulator starts to be charged again. This
should be about 13.5 MPa.
Steering (LSM)
– Increase the engine speed to about 1100 rpm.
– Turn the steering to full lock right or left and continue to acti-
vate the function.
– Read the pressure off and compare with the permissible
007911
pressure on the pressure sign.
Pressure data sign – Increase the engine speed to about 1800 rpm. Read the
pressure again. The difference should not exceed ±1.0 MPa.
Lift (P2)
– Activate the lift to its end position and continue to activate the
function.
– Increase the engine speed to about 1800 rpm. Read the
pressure again. The difference should not exceed ±1.0 MPa.

10 Common hydraulics – 10.5.2 Main valve 13
Tilt, side shift and spreading (PM)

– Activate tilt in to its end position and continue to activate the
function.
– Read the pressure again, and compare with the permissible
pressure on the pressure sign. The difference should not ex-
ceed ±1.0 MPa
Servo pressure for control levers (PPM)
5 To adjust the hydraulic pressure, please refer to Workshop man-
ual DCD 200-300.

14 10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil
10.6 Temperature control,

cleaning and hydraulic oil
page
–
The hydraulic system oil is cleaned through a high pressure located af-
ter each hydraulic oil pump.
The cooling system lowers the temperature of the hydraulic oil in the
vehicle. The cooling system consists of a hydraulic oil cooler with sep-
arate temperature-controlled electric fan, located in the service brake
cooling circuit.
The hydraulic oil pump pumps the oil (from the tank) via the high pres-
sure filter and the valve block, which is then cooled in the hydraulic oil
cooler. An electric cooling fan increases the air flow through the cooler
when the temperature needs to be lowered. A thermal bypass valve
directs the hydraulic oil past the cooler and direct to the tank if the tem-
perature is below 55°C. When the oil temperature is above 65°C, all
oil is directed through the cooler.
The temperature sensor starts the electric fan if the oil temperature is
above 60°C and shuts the fan off if it is below 50°C.
˚C 5
C 7
3 4 8
M
D
6
P
SPOL
C
2
9
1
007912
1. Hydraulic oil pump 6. Relay (K359)

2. High pressure filter 7. Cooling fan (M668)
3. Valve block 8. Radiator
4. Thermal by-pass valve 9. Wheel brake
5. Switch normally closed (NC) hydraulic oil temperature (S240-1)

10 Common hydraulics – 10.6.2 Hydraulic oil cooler 15

page
–
component position
3
4
5
2 8 7 6
009609
1. Thermal by-pass valve 5. High pressure filter
2. Switch normally closed (NC) cooling fan 6. Tank heater

3. Hydraulic oil cooler 7. Hydraulic oil pump
4. Cooling fan 8. Breather filter hydraulic oil tank
10.6.2 Hydraulic oil cooler

Hydraulic oil cooler, cleaning
page
–

2 Clean the hydraulic oil cooler (position A) using compressed air.
A Blow away dust and other loose dirt.
007914

16 10 Common hydraulics – 10.6.7 Breather filter hydraulic oil tank
10.6.7 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, replacement
page
–

2 Clean the area around the breather filter.
3 Remove the breather filter.
4 Fit the new breather filter.
009570

10 Common hydraulics – 10.6.8 High-pressure filter 17
10.6.8 High-pressure filter

High-pressure filter, changing
page
–
There are three hydraulic oil filters in the engine compartment. Two
large and one smaller (one large filter is added for option mini-wheel/
joystick steering). The method describes changing a filter but applies
to all filters.
NOTE
Safety.
IMPORTANT
Ensure cleanliness around the filters.
Dirt particles may cause machine damage.
Equipment: Collection container for hydraulic oil (5 l)

Consumables: Universal grease EP2.
2 Depressurize the hydraulic system, see section B Safety.
3 Tip the cab.
4 Clean the filter cover externally.
5 Place a receptacle underneath the hydraulic oil filter.
6 Remove the drain plugs in the bottom of the filters.
Let the oil drain, wait awhile since the oil drains slowly.
7 Remove the filter bracket.
NOTE
The filter brackets are heavy, loosen them carefully.
8 Remove the filter inserts
9 Fit the small O-ring, which is in the packaging, onto the new filter.
If uncertain, compare to the old filter insert.

18 10 Common hydraulics – 10.6.8 High-pressure filter
10 Fit the new filter insert into the filter holder.
NOTE
Use only original filters.
11 Fit the support ring (white) and O-ring (black), which are in the
packaging with the new filter, into the groove in the top of the filter
cover.
NOTE
It is important to fit the support ring under the O-ring as illustrated.
12 Grease the top of the filter cover (on the side) with universal
grease EP2.
13 Fit the filter cover.
14 Start the engine and check that no leakage occurs.
15 Switch off the engine.
16 Check the hydraulic oil level, see Hydraulic oil, level check page
19.

10 Common hydraulics – 10.6.9 Hydraulic oil 19
10.6.9 Hydraulic oil

Hydraulic oil, level check
page
–
NOTE
The hydraulic oil level is checked with the lifting carriage fully low-
ered and the mast fully tilted inwards
1 Machine in service position, section B Safety.

2 Check the oil level in the hydraulic tank. The oil level must be vis-
ible in the level glass. Top up with oil as necessary. For oil
grades, please refer to insert F Technical data.
Hydraulic oil, check

page
–
The condition of the hydraulic oil must be checked with oil tests aimed
at avoiding unnecessary wear and unnecessary oil changes. The in-
tervals for oil tests are advised in the service schedule. Oil tests are
carried out as per instructions from the relevant institution or oil suppli-
er.
Threshold value for efficient oil is 18/14 according to SS-ISO 4406
“Hydraulic equipment - fluids - Method for classifying impurities
through fixed particles”.
Hydraulic oil, changing

page
–
NOTE
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1 Machine in service position, section B Safety.

2 Place a receptacle underneath the drain plug.
3 Remove the drain plug.
4 Allow the oil to run out into the container.
5 Fit the drain plug.
NOTE
Ensure that the sealing washer on the drain plug is also fit-
ted.

20 10 Common hydraulics – 10.6.9 Hydraulic oil
6 Clean the area around the filler cap.

7 Remove the filler cap.
8 If the hydraulic oil filters are to be changed, replace them before
the tank is filled with oil, see High-pressure filter, changing page
17.
9 Fill with new hydraulic oil until the level is in the centre of the level
glass.
10 Fit the filler cap.
NOTE
Ensure that the sealing washer on the drain plug is also fit-
ted.

11 Common electrics 1
11 Common electrics
Table of Contents 11 Common electrics

mm mm mm mm mm mm
11 Common electrics .......................................................................................... 3

11.2 Electric protection ....................................................................................... 4
11.2.2 Fuses ..................................................................................................... 5
11.3 Batteries ..................................................................................................... 7
11.3.1 Start battery ........................................................................................... 8
11.4 Alternator .................................................................................................... 9
11.5 Distribution of electricity ........................................................................... 10
11.5.1 Voltage feed ......................................................................................... 10
11.5.2 Electrical distribution box ..................................................................... 11
11.5.3 Control units ......................................................................................... 13
11.6 Communication ........................................................................................ 15
11.6.1 CAN bus .............................................................................................. 15
11.6.2 Redundant CAN bus ............................................................................ 15
11.6.3 CAN bus driveline ................................................................................ 15

2 11 Common electrics

11 Common electrics – 11 Common electrics 3
11 Common electrics
mm mm mm mm mm mm
Common electrics, general

page
–
Under the function common electrics one finds electrical functions that
are common to several of the machine's main functions. For example,
voltage feed and CAN-bus.

4 11 Common electrics – 11.2 Electric protection
11.2 Electric protection

Electric protection, component position
page
–
1. Circuit fuses, electrical distribution box cab

2. Circuit fuses, engine options Cummins
3. Battery disconnect switch
1 4. Main fuses
5. Control switch
5 2
4 3
007905

11 Common electrics – 11.2.2 Fuses 5
11.2.2 Fuses
Fuses, checking
page
–
IMPORTANT
Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.
The electrical system has two main circuits (30 and 15 supplies),
please refer to Electrical distribution, general page 10. The main cir-
cuits are protected several times over, with main fuses and circuit fus-
es.
Main fuses
The main fuses splits the machine's voltage feed in smaller parts to
maintain as many functions as possible in case of damage in the ca-
bling.
The machine's electrical system has main fuses in the battery com-
partment on the frame, 4 pcs. 25 A. They cut off all electric power, ex-
cept fuse 7 in fuse holder F58-3 and fuse number 8 in fuse holder F58-
4.
Checking and changing main fuses:
1. Turn off the main electric power with the battery isolator.
2. Remove the plastic cover.
3. Check and change fuses as needed. Fuses are rated at 25 A.
4. Turn on the electric power again.
1
007936
1. Main fuses (25 A)

6 11 Common electrics – 11.2.2 Fuses
Circuit fuses
Circuit fuses are grouped in fuse holders that are located in the elec-
trical distribution box in the cab. The electrical distribution box is locat-
ed behind the operator’s seat in the cab.
There is a fuse sign beside the distribution box which describes each
fuse.
A B C D
007482
Fuses
A. Fuse holder F58-1
E
B. Fuse holder F58-2
C. Fuse holder F58-3
D. Fuse holder F58-4
E. Fuse holder F56 (engine alternative Cummins)
Checking and changing fuses:
1. Turn off the main electric power with the battery isolator.
2. Remove the cover over the electronic box.
3. Remove the cover from the fuse holder.
4. Check that fuses are intact. Change when needed.
007937
Check if necessary.
The fuse chart provides information about each fuse.

11 Common electrics – 11.3 Batteries 7
11.3 Batteries
Start battery, component position
page
–
The two series-connected batteries are located behind a cover on the

machine's rear left side (by the fuel tank).
The battery's minus terminal is connected to the chassis and the plus
terminal is connected to the battery isolator.

8 11 Common electrics – 11.3.1 Start battery
11.3.1 Start battery

Start battery, checking
page
–
WARNING
Battery electrolyte contains corrosive sulphuric
acid.
Risk of corrosive injuries, health hazard!
Electrolyte on skin should be removed immediately.

Wash with soap and plenty of water. If electrolyte has
splashed into the eyes, rinse immediately with plenty
of water and seek immediate medical attention.
Check the battery acid with a hydrometer. In a fully charged battery it

should be:
1.28 at +20 °C
1.30 at 0 °C
1.31 at -20 °C
If the acid value is lower than 1.24 at +20 °C, the battery must be
charged.
NOTE
A discharged battery freezes at -5 °C.
NOTE
If the acid values are different between batteries they must be
charged separately.
The fluid level must be at the height of the upper section of the round
white plastic ring seen down in the battery when the cover is screwed
off.
NOTE
Only use distilled water for topping up.
Check that the battery terminals are clean and free from dirt. If needed,
grease the battery terminals with terminal grease.

11 Common electrics – 11.4 Alternator 9
11.4 Alternator
Alternator, component position
page
–
The alternator is located on the engine. Position depends on engine

alternative.
007767
Volvo TAD750VE
007767
Cummins QSB6.7

10 11 Common electrics – 11.5 Distribution of electricity
11.5 Distribution of electricity

Electrical distribution, general
page
–
This section describes the distribution of electric power and communi-

cation between the control units. The distribution of electric power de-
scribes the basics of the electrical system and the network of control
units.
System communication has three main sections:
• Power supply of control units
• Redundant CAN bus communication (a control unit can drop away
without the system losing all functionality)
See CAN bus, description page 15.
• CAN bus communication for drivetrain (the drivetrain has its own
communication system)
See CAN bus drivetrain, description page 15.
11.5.1 Voltage feed

11.5.1.1 Battery voltage, 30-voltage
Battery voltage, 30 volts, description
page
–
The voltage before the ignition switch is usually called 30 volts. It is al-
ways approx. 24V, even if the ignition is switched off (ignition key in
position 0).
11.5.1.2 Ignition voltage, 15-voltage

Ignition voltage, 15 volts, description
page
–
The voltage after the ignition switch is usually called 15 volts. This is
at 24V only if the ignition is switched on (ignition key in position 1). Oth-
erwise this voltage is 0V.
11.5.1.3 Frame ground connections

Frame connections, description
page
–
Power supply takes place with cable harnesses (cables) which are
drawn across the truck.
Communication takes place via twinned pair signal cable (30 rpm).
Grounding points, description

page
–
A grounding point in the chassis works as main ground, including the

starter motor, From there the ground is drawn to a common point in the
fuse box to which all power consumer grounds are connected.

11 Common electrics – 11.5.2 Electrical distribution box 11
11.5.2 Electrical distribution box

Electrical distribution box, component position
page
–
1 2 3 4 5 6 7
9 10 11 12 13 14 15
009109
16 17
Electrical distrivution box

12 11 Common electrics – 11.5.2 Electrical distribution box
1 2 3 4 5 6 7
9 10 11 12 13 14 15
008571
16 17
Electrical distribution box, machine with revisible operator’s seat
1. Relay, interval wiper 10. Screw, holder and strap
2. Relay, ignition 11. Socket, relay 5-pin
3. Relays 12. Socket, relay 9-pin
4. Fuse holder F58-2 13. Blink module, 200 W, 24V
5. Fuse holder F58-3 14. Mini relay
6. Fuse holder F58-4 15. Fuse holder F58-1
7. Fuse holder 16. Cable shoe, washer and screw
8. Sleeve block with 9 pins 17. Fitting plate
9. Circuit board with diodes

11 Common electrics – 11.5.3 Control units 13
11.5.3 Control units

Control units, general
page
–
Part of the machine’s different functions are managed by the control

system KCS, see section 8 Control system where each control unit is
allotted responsibility for a number of functions.
The ECU 790, ECU 792 and ECU 796 control units have indication
lamps which can be used to check basic information about the status
of each Control unit.
The indication lamps have the following meanings:
Table 1. Indication lamps ECU 790 and ECU 792
A B C D
Green Battery voltage OK
(Power)
Green Internal 5 VDC OK

ECU 792 ECU 796 ECU 790 (System)
Yellow (Mode) Software check, flashes 0.5 Hz if the program is

OK, flashes 5 Hz if no program is downloaded,
fixed light glow if set-up mode
0007760
Red (Status) Activated if error occurs.

A. ECU 792
B. ECU 796 Table 2. Indication lamps ECU 796
C. ECU 790
All LEDs give constant light for 3 seconds when started up.
D. Electrical distribution box
Green Power, constant light at 22-28 VDC, flashing out-
side these limits
Yellow CAN bus communication and application OK
Red Flashes if the supply voltage to the PWM board is

less than 12 VDC.

14 11 Common electrics – 11.5.3 Control units
Control units, position

page
–
1 2 3 4
7 6 5
007908
1. Control unit, steering (ECU 792) 5. Control unit transmission (ECU 793)
2. Control unit hydraulics (ECU 796) 6. Control unit Volvo engine (ECU 794)
3. Control unit general (ECU 790) 7. Control unit Cummins engine (ECU 794)
4. Control unit thermal (EDU 795)

11 Common electrics – 11.6 Communication 15
11.6 Communication
Communication, general
page
–
The machine’s communication is handled by a CAN bus system. The

ECU 792 CAN bus system consists of control units connected to form a network.
1 The idea with a network is to share information. Signal values are sent
out by the control unit that, e.g., is connected to a sensor, other con-
trols units can use the signal for their functions.
ECU 790 EDU 795 ECU 796 The network consists of control units and segments. Segment is the
CAN bus between the control units.
2
007764
ECU 794 ECU 793
1. Segments
2. CAN bus drivetrain
11.6.1 CAN bus

CAN bus, description
page
–
The CAN bus consists of two twisted paired leads (twisted pair).
11.6.2 Redundant CAN bus

Redundant CAN bus, description
page
–
Redundant CAN bus means that every control unit has two connec-
ECU 790 EDU 795 ECU 796 tions for communication. The CAN bus is connected in series between
CAN R CAN L CAN R CAN L CAN R CAN L
the control units. This means that the CAN bus can handle loss of a
segment. If several segments are lost, some control unit(s) lose con-
tact with the network and work independently, often with limited capac-
High+/Low- ity to perform its task.
007765
ECU 792
The signals can be checked with diagnostic menu.
Principle illustration redundant CAN bus
11.6.3 CAN bus driveline

CAN bus drivetrain, description
page
–
Communication with Control unit engine EDC (D794) and Control unit
EDU 795 transmission (ECU 793) is separated from the redundant CAN bus.
The signals can be checked with diagnostic menu.
007766
ECU 794 ECU 793
Principle illustration CAN bus drivetrain

16 11 Common electrics – 11.6.3 CAN bus driveline

D Error codes – Error codes 1
D Error codes
Error codes
mm mm mm mm mm mm
Information is found in the

page
–
Workshop manual
Information is found in the Workshop manual.
For information how to order Workshop manual, see section
A Foreword.

2 D Error codes – Error codes

E Schematics – Schematics 1
E Schematics
Schematics
mm mm mm mm mm mm
Information is found in the

page
–
Workshop manual
Information is found in the Workshop manual.
For information how to order Workshop manual, see section
A Foreword.

2 E Schematics – Schematics

F Technical data 1
F Technical data
Table of Contents F Technical data

mm mm mm mm mm mm
Technical data ................................................................................................ 3

Specifications for data and volume ........................................................................ 3
Specifications for lift capacity and dimensions ....................................................... 7
Recommended oils and lubricants ......................................................................... 9
Tightening torques, recommendations ................................................................. 11
Tightening torques, ORFS-couplings ................................................................... 12
Unit explanations .................................................................................................. 14
Conversion table, SI-units .................................................................................... 15
Conversion table, length ....................................................................................... 16
Conversion table, area ......................................................................................... 16
Conversion table, volume ..................................................................................... 16
Conversion table, weight ...................................................................................... 17
Conversion table, pressure .................................................................................. 17

2 F Technical data

F Technical data – Technical data 3
Technical data
mm mm mm mm mm mm
Specifications for data and volume

page
–
Data
1 Engine Volvo TAD750VE Cummins QSB6.7
Power acc. to ISO 3046 (net 181 kW at 2300 rpm 194 kW at 2200 rpm
power) 182 kW at 2200 rpm
Torque ISO 3046 1050 Nm at 1500 rpm 949 Nm at 1500 rpm
Alternator 2240 W 1960 W
Battery 2x12V - 140 Ah 2x12V - 140 Ah
1.3 Engine, device for extra

exhaust cleaning
Particle filter
Voltage 400 V
Output 13.5 kW
2 Transmission Dana-Spicer Off Highway
TE17000
Number of gears, forward - re- 3-3

verse
Stall speed 1914 rpm (engine: TAD750VE)
1879 rpm (engine: QSB6.7)
3.3 Driveline/axle, drive DCD 200-250 DCD 280-300

axle
Drive axle, type Kessler D91 Kessler D91
Drive axle, mounting Tightening torque 1350 Nm
Propeller shaft, mounting Tightening torque towards Tightening torque towards

gearbox 98 Nm gearbox 98 Nm
Tightening torque towards Tightening torque towards
drive axle 98 Nm drive axle 133 Nm
4 Brakes
Service brake system - affected Wet Disc Brake - Drive wheels
wheels

4 F Technical data – Technical data
Parking brake system - affected Spring brake - Drive wheels

wheels
Brake pedal – pedal pressure 27 bar (with half depressed pedal)

100 bar (with fully depressed pedal)
4.3 Servo brake system, DCD 200-250 DCD 280-300

Accumulator
Precharge pressure nitrogen gas 70 bar 100 bar
Max. accumulator pressure 165 bar
5 Steering
Steering system Hydraulic servo
Mini-wheel 2-channel potentiometer
Joystick – Resistance 5 kOhm
6 Suspension DCD 200-250 DCD 280-300
Dimension, front and rear 14.00x24 16.00x25
Ring pressure, see also pressure 1.0 MPa

plate
Tyre type, front and rear Air inflated. Spare and replacement tyres shall be from a manufacturer approved by
Kalmar Industries.
Wheel nuts, tightening torque 350 Nm
9 Frame, body, cab and ac-

cessories
Equivalent sound pressure level max 73 dB(A)
in cab according to EN12053.
LpAz (Internal).
9.4 Frame, body, cab and ac-

cessories, heating, ventilation
and air conditioning
Stated heat output 10 kW at -10 °C
9.6 Frame, body, cab and accessories, lighting system
Bulb Output (W) Socket
Bulb 3 Ba72
Instruments 1,2 W2x4,6d

9.6 Frame, body, cab and accessories, lighting system
Bulb Output (W) Socket

Control lights 10 S8,5
Interior lighting 5 BA15s
Rear light, red 21 BA15s
Brake lights 21 BA15s
Indicator light for direction indicators 5 W2,1x9,5d
Running lights 75/70 P43t-38
Headlights (with high and low beam) 70 PK22s
Working light 70 PK22s
35 D1S Xenon tubes. The insert and bal-

Working light Xenon last must be changed as a unit.
Rotating beacon 70 PK22s
Volumes
For oil types see Recommended oils and lubricants page 9.
1.2 Engine, fuel system DCD 200-220 DCD 240 DCD 250-300
Fuel tank, capacity 300 l 230 l 350 l
Fuel quality Diesel, according to EN590
1.7 Engine, cooling system Volvo TAD750VE Cummins QSB6.7
Coolant volume 40 l 40 l
1.8 Engine, lubrication sys- Volvo TAD750VE Cummins QSB6.7

tem
Oil type, quality See Recommended oils and lubricants page 9.
Oil volume 23 l at first filling 20 l

21.5 l at replacement including filter
2.6 Transmission, lubrica- Dana TE17000

tion system
Oil type, quality See Recommended oils and lubricants page 9
Oil volume 35 l
3.3 Driveline/axle, drive DCD 200-250 DCD 280-300

axle
Oil quality See Recommended oils and lubricants page 9.

Oil volume, differential 30 l 38 l
Oil volume, hub reduction 2x4 l 2x3,5 l
9 Frame, body, cab and ac- Condenser with two fans Condenser with four fans
cessories
Refrigerant air conditioning R134a
Volume refrigerant 1700 g (see plate for air conditioning) 2200 g (see plate for air conditioning)
Lubricant in air conditioning ZXL100PG
Volume lubricant 0,27 l 0,32 l
Volume washer fluid 2,0 l
10 Common hydraulics DCD 200-220 DCD 240 DCD 250-300
Oil quality See Recommended oils and lubricants page 9.
Oil additive Lubrizol 3%
Hydraulic system volume 270 l 260 l 320 l

Specifications for lift capacity and

page
–
dimensions
008073
DCD DCD DCD DCD DCD DCD DCD DCD DCD DCD DCD DCD
200- 200- 220- 220- 240- 240- 250- 250- 280- 280- 300- 300-
12 12LB 12 12LB 6LB 9LB 12 12LB 12 12LB 12 12LB
Lifting capacity
Classed (kg x 103) 20 20 22 22 24 24 25 25 28 28 30 30
Centre of gravity dis- 1200 600 900 1200

tance (L4 [mm])
Dimensions
Truck length without 6060 6070 5710 6320 6675
forks (L [mm])
Truck width (B [mm]) 3050 3410
Height, basic machine 3450 3270 3450 3270 3270 3270 3450 3270 3650 3415 3650 3415
(H6 [mm])
Seat height (H8 [mm]) 2150 2300
Wheelbase (L3 [mm]) 4000 3650 4250 4500
Distance drive axle - 1060 1070 1060 1070 1125

fork front shank sur-
face (L2 [mm])
Track width (front - 2200 - 2140 2440 - 2540

rear) (S [mm])
Turning radius, outer 5500 5100 5800 6350

(R1 [mm])

DCD DCD DCD DCD DCD DCD DCD DCD DCD DCD DCD DCD
200- 200- 220- 220- 240- 240- 250- 250- 280- 280- 300- 300-
12 12LB 12 12LB 6LB 9LB 12 12LB 12 12LB 12 12LB
Turning radius, inner 550 250 450 750

(R2 [mm])
Ground clearance, 300

min. [mm]
Height at cab tilt, max. - 3800 - 3800 3800 3800 - 3800 - 3800 - 3800
(OHG) (T1 [mm])
Width at cab tilt, max. - 3700 - 3700 - 3700 - 3850 - 3850

(OHG) (T2 [mm])
Minimum track width 9160 9170 8760 9470 10075

for 90° stacking with
forks (A1 [mm])
Operating weight [kg x 29,8 29,8 31,2 31,2 29,4 31,9 32,9 32,9 37,7 37,7 39,0 39,0
10 3]
Axle pressure front, 15000 1550 19000

(without load) [kg] 0
Axle pressure front, 46300 49500 4990 5190 53800 61500 64500
(with classed load) [kg] 0 0
Axle pressure rear, 14800 16200 1440 1690 17400 18700 20000
(without load) [kg] 0 0
Axle pressure rear, 3500 3700 3500 4000 4100 4200 4500
(with classed load) [kg]

Recommended oils and lubricants

page
–
The service intervals indicated by Kalmar Industries in the mainte-

nance manual only apply if oils are selected according to the table be-
low. The table indicates recommended viscosity for different oil types
and grades depending on the ambient temperature.
Any deviation from this table must be approved in writing by Kalmar
Industries, and may mean changed service intervals.
°C -30 -20 -10 0 +10 +20 +30 +40 +50

Oil type, quality °F -22 -4 +14 +32 +50 +68 +86 +104 +122
1.8 Engine, lubrication system
*) -15°C SAE 15W/40
Volvo: VDS-2, VDS-3
-25°C SAE 10W/30
API: CH-4, CI-4
SAE 5W/30
ACEA: E4-99, E4-99 (Synthetic),
E5, E7
Cummins: CES-20071, CES-
20072, CES-20076, CES-20077,
CES-20078
API: CH-4/SJ, CI-4/SK
ACEA: E5, E7
2.6 Transmission, lubrication
system
Transmission oil ATF DEXRON III (trademark)
3.3 Power transmission, drive

shaft
Hypoid oil, API GL-5 and MIL-L- SAE 80W140
2105B SAE 80W90
SAE 90
SAE 85W140
Hydraulic oil AV 32
SS 155434 AV 46
Hydraulic oil HVLP 46

DIN 51524 HLP 68
Hydraulic oil ISO - LHV 46

ISO 6743/4 ISO - LHM 68

NOTE
Oil filters must always be replaced in conjunction with oil chang-
es.
The interval for engine oil changes assumes that the sulphur con-
tent in the fuel does not exceed 0.5%.
*) API CH-4 or CI-4 is approved for markets outside the EU/EEA.
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
VDS = Volvo Drain Specification
CES = Cummins Engine Standard
Other matters
Grease Use a universal grease of the type EP acc. to NLGI Grade 2 (EP2) with 3-5% molybde-
num sulphide content for all lubrication sites except glide plates.
Slide grease Use a Kalmar approved lubricant for glide plates. Ordered from Kalmar spare parts de-
partment.
0.65 kg cartridge for grease gun, part no. 923110.0360, and 5 kg can, part no.
923595.0003.
Electrical connection grease Electrical connection grease 923836.0552.

Tightening torques,
page
–
recommendations
The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torquing using a machine, for example, bolt runner, the tighten-
ing torque should be reduced by approx. 5%.
For mild surfaces (hardness below 200 HB), washer shall be used un-
der both bolt head and nut. Alternatively, use flange bolt or flange nut.
Tighten to the prescribed torque without stopping.
Recommended tightening torque may vary depending on surface
treatment. Certain combinations of nut and bolt require lubrication ac-
cording to the table below.
State Bolt Nut Lubrication
1 untreated untreated oil
2 bright-galvanized untreated or bright-galvanized dry or oil
3 hot-galvanized untreated dry or oil
Quality 8.8 10.9 12.9
State 1 2 3 1 1
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101,25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M121,25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm
M161.5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm
M181.5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm
M-thread
M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm
M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm
M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm
M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm
M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm
M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm
UNC-thread

Quality 8.8 10.9 12.9
1/4 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm
5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
7/16 70 Nm 62 Nm 79 Nm 100 Nm 118 Nm
1/2 107 Nm 95 Nm 121 Nm 151 Nm 178 Nm
9/16 153 Nm 136 Nm 173 Nm 216 Nm 255 Nm
5/8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm
3/4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm
7/8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm
1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm
1 1/8 1260 Nm 1120 Nm 1424 Nm 1780 Nm 2100 Nm
1 1/4 1760 Nm 1565 Nm 1990 Nm 2490 Nm 2940 Nm
1 3/8 2320 Nm 2065 Nm 2620 Nm 3280 Nm 3870 Nm
1 1/2 3060 Nm 2720 Nm 3455 Nm 4320 Nm 5100 Nm
Tightening torques, ORFS-

page
–
couplings
Pipe and hose coupling
Pipe diameter Tightening torques
mm inch Nm
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"

Pipe diameter Tightening torques
mm inch Nm
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
Socket width Tightening torques
mm inch Nm
17 11/16 23-25
22 13/16 33-38
24 15/16 51-57
36 1 3/8 120-130
41 1 5/8 150-170
Flange coupling
UNF-UN Metric-ISO BSSP

Thread (inch) Tightening torques Thread Tightening torques Thread (inch) Tightening torques
(Nm) (mm) (Nm) (Nm)
7/16-20 21 10x1 20 1/8-28 20
1/2-20 27 12x1,5 35 1/4-19 35
9/16-18 40 14x1,5 45 3/8-19 70
3/4-16 78 16x1.5 55 1/2-14 100
7/8-14 110 18x1.5 68 3/4-14 190
1"1/16-12 180 20x1.5 80 1"-11 300
1"3/16-12 230 22x1.5 98 1"1/4-11 330
1"5/16-12 285 26x1.5 170 1"1/2-11 400
1"5/8-12 320 27x2 180
1"7/8-12 400 33x2 310
42x2 330
48x2 400

Unit explanations
page
–
Unit Abbreviation
Newton metre Nm
Kilo pound metre kpm
Kilo Pascal kPa
Mega Pascal MPa
Kilowatt kW
kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km

Conversion table, SI-units

page
–
SI-unit Recalculation fac- Non-SI Recalculation fac- SI

tor tor
Torque
Nm x 10,2 = kg·cm x 0,8664 = lb·in
Nm x 0,74 = lbf·ft x 1,36 = Nm
Nm x 0,102 = kg·m x 7,22 = lb·ft
Pressure (Pa = N/m 2)
kPa x 4,0 = in.H2O x 0,249 = kPa
kPa x 0,30 = in.Hg x 3,38 = kPa
kPa x 0,145 = psi x 6,89 = kPa
bar x 14,5 = psi x 0,069 = bar
kp/cm 2 x 14,22 = psi x 0,070 = kp/cm 2
N/mm 2 x 145,04 = psi x 0,069 = bar
MPa x 145 = psi x 0,00689 = MPa
Power (W = J/s)
kW x 1,36 = hp (cv) x 0,736 = kW
kW x 1,34 = bhp x 0,746 = kW
kW x 0,948 = Btu/s x 1,055 = kW
W x 0,74 = ft·lb/s x 1,36 =W
Energy (J = Nm)
kJ x 0,948 = Btu x 1,055 = kJ
J x 0,239 = calorie x 4,19 =J
Speed and acceleration
m/s2 x 3,28 = ft/s 2 x 0,305 = m/s 2
m/s x 3,28 = ft/s x 0,305 = m/s
km/h x 0,62 = mph x 1,61 = km/h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
ºC = (ºF – 32)/1,8 ºF = (ºC x 1,8) + 32
Flow factor
l/min (dm 3 /min) x 0,264 = US gal/min x 3,785 = litre/min

Conversion table, length

page
–
Unit cm m km in ft yd mile
cm 1 0,01 0,00001 0,3937 0,03281 0,01094 0,000006
m 100 1 0,001 39,37 3,2808 1,0936 0,00062
km 100000 1000 1 39370,7 3280,8 1093,6 0,62137
in 2,54 0,0254 0,000025 1 0,08333 0,02777 0,000015
ft 30,48 0,3048 0,000304 12 1 0,3333 0,000189
yd 91,44 0,9144 0,000914 36 3 1 0,000568
mile 160930 1609,3 1,6093 63360 5280 1760 1
1 mm = 0,1 cm - 1 mm = 0,001 m
Conversion table, area

page
–
Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0,0001 - 0,000001 0,001076 0,000012 0,155000
m2 10000 1 0,000001 0,01 10,764 1,1958 1550,000
km2 - 1000000 1 10000 1076400 1195800 -
a 0,01 100 0,0001 1 1076,4 119,58 -
ft2 - 0,092903 - 0,000929 1 0,1111 144,000
yd2 - 0,83613 - 0,008361 9 1 1296,00
in2 6,4516 0,000645 - - 0,006943 0,000771 1
1ha = 100a - 1mile2 = 259ha = 2,59km 2
Conversion table, volume

page
–
Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0,000001 0,001 0,061024 0,000035 0,000001
m3 1000000 1 1000 61024 35,315 1,30796
dm3 (l) 1000 0,001 1 61,024 0,035315 0,001308
in3 16,387 0,000016 0,01638 1 0,000578 0,000021
ft3 28316,8 0,028317 28,317 1728 1 0,03704
yd3 764529,8 0,76453 764,53 46656 27 1
1gal (US) = 3785,41cm 3 = 231in3 = 0,83267gal (UK)

Conversion table, weight

page
–
Unit g kg t oz lb
g 1 0,001 0,000001 0,03527 0,0022
kg 1000 1 0,001 35,273 2,20459
t 1000000 1000 1 35273 2204,59
oz 28,3495 0,02835 0,000028 1 0,0625
lb 453,592 0,45359 0,000454 16 1
1ton (metric) = 1,1023 ton (US) = 0,9842 ton (UK)
Conversion table, pressure

page
–
Unit kp/cm2 bar Pa = N/m 2 kPa lbf/in2 lbf/ft2
kp/cm2 1 0,98067 98066,5 98,0665 14,2233 2048,16
bar 1,01972 1 100000 100 14,5037 2088,6
Pa = N/m2 0,00001 0,001 1 0,001 0,00015 0,02086
kPa 0,01020 0,01 1000 1 0,14504 20,886
lbf/in2 0,07032 0,0689 6894,76 6,89476 1 144
lbf/ft2 0,00047 0,00047 47,88028 0,04788 0,00694 1
kg/cm2 = 735,56Dry (mmHg) = 0,96784atm


G Terminology and index 1
G Terminology and index
Table of Contents G Terminology and index

mm mm mm mm mm mm
Terminology and index.................................................................................. 3

Explanation ............................................................................................................. 3
Index ....................................................................................................................... 6

2 G Terminology and index

G Terminology and index – Terminology and index 3
Terminology and index

mm mm mm mm mm mm
Explanation
page
–
Term Description
AC Air Conditioning. Heating unit with manual control of heating, cooling, dehumidification
and air flow.
Accumulator Reservoir that stores (accumulates) pressure for hydraulic functions for example.
Attachment The part of the machine that grips the load when lifting.
Anti-corrosion agent Prevents oxidising, in daily use rust inhibitor.
Operating hydraulics All load handling functions, i.e. lift and lower, tilt, side shift, spreading and levelling.
Wheelbase Distance between the drive and steering axles.
Bar Unit for measuring pressure.
Battery disconnect switch Interrupts the current from the battery.
Central lubrication An automatic system for lubricating a preselected number of lubrication points.
Daily inspection Those actions that must be carried out every day to ensure the functionality of the ma-
chine.
Decitonne A tenth of a tonne, unit of measurement of the machine’s lifting capacity.
Displacement The oil volume that the pump can supply per pump revolution.
Display “Window” that shows digital information on the steering wheel panel in the cab (with
KCS).
Operating time Number of hours that the machine has been operating, shown on the operating time
gauge in the cab.
Drive axle Driving axle which receives torque from the drive line.
Drive line Parts of the machine that contribute to the power transmission; engine, torque converter,
gearbox, propeller shaft and driving axle with differential and hub reduction.
ECC Electronic Climate Control. Climate control system with automatic control of heating, cool-
ing, dehumidification and air flow.
ECU Electronic Control Unit
EDU Electronic Display Unit
Electrolyte level Fluid level in the battery cells.
Electric servo Load handling hydraulic components receive control signals from electro mechanical
controls.
Expansion tank Reservoir for coolant.
Fixed displacement Pump with fixed pump volume.
FMI Fault Message Identifier.
Forks Lifting device that lifts the loads.
Fork mountings Mountings for forks, mounted on the lift assembly.
Main fuse Located beside the battery. Interrupts the current to every system in the machine.
Hydraulic oil Oil for hydraulic system. See specifications in the Operator’s manual.
Hydraulic oil pump Pump in the hydraulic system.

4 G Terminology and index – Terminology and index
Term Description
Hydraulic system System that uses oil pressure to transfer power to different functions.
Hydraulic servo Load handling hydraulic components receive control signals from mechanical controls.
Hanging load Raised load.
Indicator Manual “sensor”, indicates, for example, if a filter is blocked and needs replacing.
KCS Kalmar Control System. An electronic control and monitoring system that monitors and
handles certain systems in the machine which require KCS, e.g., certain engine and
transmission alternatives.
Piston The bar that slides into the piston cylinder and is affected by hydraulic pressure.
Refrigerant Liquid/gas in the Air conditioning. May only be handled by authorised trained personnel.
Lifting capacity Indicates how great a load the machine can lift.
Lifting point Attachment point for lifting device when lifting objects.
Lift assembly Lifts the load, located on the mast.
Low emission engine Engine with low emissions of dangerous substances. Manufactured according to regula-
tions.
Solenoid An electro magnetically controlled valve. See also proportional valve.
Control valve Valves that can be used for controlling items, for example, releasing pressure and thereby
lowering a mast or a fork. See also control valve.
Machine model Machine type. Given as, for example: DCD 200-300. See also type designation.
Environmental waste Used oil filters etc. must be handled according to applicable national laws and regula-
tions.
Torque converter Hydraulic, stepless clutch.
Counterweight Weights adapted to the machines lifting capacity to provide counter weight when lifting.
Hub reduction Type of final drive (often with drive wheels) that reduces the speed and increases the
torque from the driveline.
Pilot oil pressure A low control pressure, for example, to a valve.
Planetary gear Type of gearbox with the gears in constant mesh.
Product alternative One of several alternatives selected for the machine, i.e. engine alternative.
Progressive steering Faster steering wheel movements give greater steering response.
Proportional valve An electro magnetically controlled valve. If a current is applied, the valve is activated pro-
portionally to the size of the current. In everyday speech, a stepless valve, as opposed to
an on/off valve. On the gearbox valve housing for example.
Frame members Bearing members of the frame.
Recirculation Circulation in a closed system.
Serial number Unique machine designation. On the machine plate.
Service position How the machine must stand securely before service is started.
Servo A small movement by the user gives a greater effect, i.e. power steering.
Servo pressure A low control pressure to control a higher pressure, for example to a valve.
Side shift The forks are moved parallel sideways.
Levelling The forks are inclined if the load is on an uneven surface.
SmartLink Software for handling KCS (Kalmar Control System).

Term Description
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading Spreading of forks, that is, changing the internal distance between the forks.
Mast Carriers of unit and load.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which empties automatical-
ly while driving.
Steering axle Wheel axle with steering.
Buzzer Audible alarm for gaining the driver’s attention.
Option Optional equipment for the machine.
Tilt The mast is tilted forwards or backwards.
Top-lift Attachment. See attachment.
Transmission oil Oil for the gearbox and torque converter. See specifications.
Transport safety for the vehicle Precautions before machine transport.
Twistlocks Two detent bolts, one in each corner of the unit, which slide into corresponding holes in
the container and are twisted to lock the container into position when lifting.
Type designation Indicates type of machine and capacity. See also machine model.
Maintenance Periodic maintenance operations so that the machine functions safely and lasts well.
Variable pump Pump with adjustable flow speed
Variable displacement Controllable volume (capacity) in a pump.
Valve slide Moveable section of the valve. Determines the path of the oil.
Wet brakes Brake friction plates in an oil bath.

Index
page
–
Title Tab Functiongroup

50h-check C Preventive maintenance -
A near-accident is a warning signal! B Safety -
About the documentation A Foreword -
About the machine version A Foreword -
About the Maintenance Manual A Foreword -
Accumulator 10 Common hydraulics 10.3.2
Additional functions 7Load handling 7.10
Air cleaning system 1 Engine 1.6.1
Air intake and exhaust outlet 1 Engine 1.6
Air pollution B Safety -
Alternator 11 Common electrics 11.4
Batteries 11 Common electrics 11.3
Body 9 Frame, body, cab and accessories 9.13
Brake pedal 4 Brakes 4.1.1
Brakes 4 Brakes 4
Breather filter hydraulic oil tank 10 Common hydraulics 10.6.7
Cab framework 9 Frame, body, cab and accessories 9.10.1
Cab interior equipment 9 Frame, body, cab and accessories 9.11
Cab structure 9 Frame, body, cab and accessories 9.10.3
Cab structure and suspension 9 Frame, body, cab and accessories 9.10
Cab tipping 9 Frame, body, cab and accessories 9.10.4
CAN bus 11 Common electrics 11.6.1
CAN bus driveline 11 Common electrics 11.6.3
Central lubrication 9 Frame, body, cab and accessories 9.14
Chains 7Load handling 7.2.8
Check and service log C Preventive maintenance -
Clothing etc. B Safety -
Coil ram 7Load handling 7.9.2
Common electrics 11 Common electrics 11
Common hydraulics 10 Common hydraulics 10
Communication 11 Common electrics 11.6
Communication system 9 Frame, body, cab and accessories 9.7


Complete machine, description 0 Complete machine -
Condenser unit 9 Frame, body, cab and accessories 9.4.9
Conditions A Foreword -
Control system 8 Control system 8
Control system engine 1 Engine 1.9
Control units 11 Common electrics 11.5.3
Controls and instrumentation 4 Brakes 4.1
Controls and instruments 9 Frame, body, cab and accessories 9.1
Conversion table, area F Technical data -
Conversion table, length F Technical data -
Conversion table, pressure F Technical data -
Conversion table, SI-units F Technical data -
Conversion table, weight F Technical data -
Conversion table, volume F Technical data -
Coolant 1 Engine 1.7.7
Coolant B Safety -
Cooling fan 1 Engine 1.7.5
Cooling system 1 Engine 1.7
Cooling system 2 Transmission 2.7
Copyright A Foreword -
Counterweights 9 Frame, body, cab and accessories 9.13.4
Crack checking C Preventive maintenance -
crank mechanism 1 Engine 1.5.6
Device for extra exhaust emission control 1 Engine 1.3
Diagnostics 8 Control system 8.4
Distribution block 4 Brakes 4.3.6
Distribution of electricity 11 Common electrics 11.5
Documentation sections A Foreword -
Doors 9 Frame, body, cab and accessories 9.10.2
Drive axle 3 Driveline/axle 3.3
Driveline/axle 3 Driveline/axle 3
ECU 790 8 Control system 8.4.1


Electric motors B Safety -
Electric protection 11 Common electrics 11.2
Electric scales 7Load handling 7.10.1
Electrical distribution box 11 Common electrics 11.5.2
Engine 1 Engine 1
Entertainment and communication 9 Frame, body, cab and accessories 9.8
Environment B Safety -
Error codes 8 Control system 8.3
Exhaust system 1 Engine 1.6.3
Feedback A Foreword -
Fire and explosion risks B Safety -
Fluid or gas under pressure B Safety -
Forms for copying A Foreword -
Frame 9 Frame, body, cab and accessories 9.12
Frame, body, cab and accessories 9 Frame, body, cab and accessories 9
Fresh air filter 9 Frame, body, cab and accessories 9.4.4
Fuel filter 1 Engine 1.2.2
Fuel pre-filter 1 Engine 1.2.3
Fuel system 1 Engine 1.2
Fuel system B Safety -
Fuel tank 1 Engine 1.2.1
Function descriptions A Foreword -
Function group structure A Foreword -
Fuses 11 Common electrics 11.2.2
General A Foreword -
General B Safety -
General B Safety -
General safety information B Safety -
Glass/windows/mirrors 9 Frame, body, cab and accessories 9.9
Heating, ventilation and air conditioning 9 Frame, body, cab and accessories 9.4
High-pressure filter 10 Common hydraulics 10.6.8
Hoses, pipes and valves 10 Common hydraulics 10.5
Hydraulic oil 10 Common hydraulics 10.6.9


Hydraulic oil cooler 10 Common hydraulics 10.6.2
Hydraulic system, depressurizing B Safety -
Ignition/heating 1 Engine 1.10
Important information A Foreword -
Intercooler 1 Engine 1.6.4
Last alarms 8 Control system 8.4.5
Levelling 7Load handling 7.8
Lifting equipment B Safety -
Lifting forks 7Load handling 7.9.1
Lifting heavy components B Safety -
Lifting/lowering 7Load handling 7.2
Lighting system 9 Frame, body, cab and accessories 9.6
Link arm 5 Steering 5.2.6
Load carrier 7Load handling 7.9
Load handling 7Load handling 7
Lubrication 1 Engine 1.8
Lubrication 1000 hours C Preventive maintenance -
Lubrication 500 hours C Preventive maintenance -
Lubrication system 2 Transmission 2.6
Machine card A Foreword -
Main valve 10 Common hydraulics 10.5.2
Maintenance manual's content A Foreword -
Mast 7Load handling 7.2.6
Mast 7Load handling 7.7.6
Mechanical parts 1 Engine 1.5
Mechanical transmission 2 Transmission 2.3
Monitoring 8 Control system 8.2
Noise B Safety -
Oil filter 1 Engine 1.8.4
Oil filter 2 Transmission 2.6.4
Oils B Safety -
Ordering of documentation A Foreword -
Paint/coatings 9 Frame, body, cab and accessories 9.15
Parking brake system 4 Brakes 4.5


Parking brake unit 4 Brakes 4.5.4
Particle filter 1 Engine 1.3.1
Power-assisted system 5 Steering 5.2
Preventive maintenance, general C Preventive maintenance -
Preventive maintenance, work instructions C Preventive maintenance -
Product alternatives and optional equipment A Foreword -
Propeller shaft 3 Driveline/axle 3.2
Pumps 10 Common hydraulics 10.4
Radiator and expansion tank 1 Engine 1.7.4
Read maintenance manual A Foreword -
Read operator's manual A Foreword -
Reading instructions A Foreword -
Recommended oils and lubricants F Technical data -
Redundant CAN bus 11 Common electrics 11.6.2
Refrigerant B Safety -
Rims 6 Suspension 6.3.2
Rotating components and tools B Safety -
Safety and emergency equipment 9 Frame, body, cab and accessories 9.2
Safety concerns everyone! B Safety -
Safety instructions B Safety -
Seats 9 Frame, body, cab and accessories 9.3
Security valves 10 Common hydraulics 10.2
Sensor coolant temperature 1 Engine 1.7.9
Sensor oil pressure 1 Engine 1.8.3
Sensor, steering wheel angle 5 Steering 5.2.11
Service indicator 8 Control system 8.2.4
Service position B Safety -
Service schedule C Preventive maintenance -
Servo brake system 4 Brakes 4.3
Several mechanics on the same machine B Safety -
Side lift attachment 7Load handling 7.10.5
Side shift 7Load handling 7.4
Side shift cylinder 7Load handling 7.4.4
Solvents B Safety -


Specifications for data and volume F Technical data -
Specifications for lift capacity and dimensions F Technical data -
Speed limitation 8 Control system 8.2.3
Spreading 7Load handling 7.5
Start battery 11 Common electrics 11.3.1
Start/stopp 1 Engine 1.11
Steering 5 Steering 5
Steering axle cradle 6 Suspension 6.2.1
Storage A Foreword -
Support roller 7Load handling 7.2.14
Suspension 6 Suspension 6
Suspension 6 Suspension 6.2
Tanks and accumulators 10 Common hydraulics 10.3
Temperature control, cleaning and hydraulic oil 10 Common hydraulics 10.6
Temperature control, cleaning and hydraulic oil 4 Brakes 4.8
Tensioned springs B Safety -
Tightening torques, ORFS-couplings F Technical data -
Tightening torques, recommendations F Technical data -
Tilt 7Load handling 7.7
Tilt cylinder 7Load handling 7.7.5
Top support roller 7Load handling 7.2.15
Transmission 2 Transmission 2
Transmission control system 2 Transmission 2.8
Tyre and rim system 6 Suspension 6.3
Tyre system B Safety -
Tyres 6 Suspension 6.3.1
Unit explanations F Technical data -
Valve mechanism 1 Engine 1.5.4
Warning information A Foreword -
Washing C Preventive maintenance -
Wheel hub 6 Suspension 6.2.3
Wheel spindle 6 Suspension 6.2.2
Vibrations B Safety -
Wiper/washer system 9 Frame, body, cab and accessories 9.5


Voltage feed 11 Common electrics 11.5.1
Working under machine B Safety -

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A Foreword

9 Frame, body, cab and accessories

G Terminology and index

Table of Contents A Foreword

Maintenance manual DCD 200–300, 2006 - UDCD01.02GB

UDCD01.02GB Maintenance manual DCD 200–300, 2006 -

About the Maintenance Manual

Thank you for choosing Kalmar Industries as your machine supplier.

The instructions are based on the use of generally available standard

About the machine version

The information in this publication corresponds to the machine's de-

Maintenance manual DCD 200–300, 2006 - UDCD01.02GB

Warnings inform on potential dangers which can, if the warnings are

Important information marked with NOTE facilitates the work process,

Read operator's manual

Read the operator's manual

Read maintenance manual

Read the maintenance manual

UDCD01.02GB Maintenance manual DCD 200–300, 2006 -

Maintenance manual's content

The information in the maintenance manual is divided in function

B Safety Keep in mind for your safety.

C Preventive maintenance General information about preventive maintenance of the machine.

9 Frame, body, cab and accesso-

E Schematics Wiring and hydraulic diagrams please refer to Workshop manual

Maintenance manual DCD 200–300, 2006 - UDCD01.02GB

Function group structure

The information in the manual is divided in a structure of functions at

UDCD01.02GB Maintenance manual DCD 200–300, 2006 -

Product alternatives and optional equipment

The information in the manual is divided in modules. For product alter-

Optional equipment are options that can be added to the standard

Maintenance manual DCD 200–300, 2006 - UDCD01.02GB

UDCD01.02GB Maintenance manual DCD 200–300, 2006 -

Function descriptions are schematic overviews that describe how a

Example of function description

Maintenance manual DCD 200–300, 2006 - UDCD01.02GB

1. Elektric force (solid single line)

UDCD01.02GB Maintenance manual DCD 200–300, 2006 -

Symbol explanation function descriptions

D790-1 13. Bulb

Maintenance manual DCD 200–300, 2006 - UDCD01.02GB

About the documentation

The documentation to the machine comprises the following sections:

Documentation is ordered from the dealer.

UDCD01.02GB Maintenance manual DCD 200–300, 2006 -

Kalmar Industries’ ambition is that as someone who works with main-

To: Kalmar Industries AB

Date: .................................... - .................. - ..................

Section / page number:.........................................................................................................................................

Maintenance manual DCD 200–300, 2006 - UDCD01.02GB

UDCD01.02GB Maintenance manual DCD 200–300, 2006 -

Table of Contents B Safety

Maintenance manual DCD 200–300, 2006 - UDCD01.02GB

UDCD01.02GB Maintenance manual DCD 200–300, 2006 -

General safety information

A near-accident is a warning signal!

A near-accident is an unexpected event where neither persons, ma-

Maintenance manual DCD 200–300, 2006 - UDCD01.02GB

Machine with forks and lifting carriage in totally low-

UDCD01.02GB Maintenance manual DCD 200–300, 2006 -

Hydraulic system, depressurizing

1 Machine in service position.