DCF 180-250 Forklift Maintenance Manual

Forklift Trucks 18-25 tonnes
Publ. no UDCF06.01GB
Maintenance Manual in original
MAINTENANCE MANUAL
DCF 180–250
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Maintenance Manual
2 Transmission
DCF 180–250
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:1
A Foreword
Contents A Foreword
Foreword ............................................................................................................ A:3
About the maintenance manual ...................................................................... A:3
General ...................................................................................................... A:3
Conditions .................................................................................................. A:3
Storage....................................................................................................... A:3
About the machine version......................................................................... A:3
Copyright .................................................................................................... A:3
Reading instructions ....................................................................................... A:4
Warning information ................................................................................... A:4
Important information ................................................................................. A:4
Read operator's manual ............................................................................. A:4
Read maintenance manual ........................................................................ A:4
Maintenance manual's content................................................................... A:5
Function group structure ............................................................................ A:6
Product alternatives and optional equipment ............................................. A:6
Machine card.............................................................................................. A:7
Function descriptions ................................................................................. A:7
About the documentation .............................................................................. A:10
The documentation's parts ....................................................................... A:10
Ordering of documentation....................................................................... A:10
Feedback .......................................................................................................A:11
Form for copying .......................................................................................A:11
Maintenance Manual DCF 180–250
UDCF06.01GB
A:2
UDCF06.01GB
Maintenance Manual DCF 180–250
A Foreword – Foreword
A:3
A Foreword
About the maintenance manual
General
Thank you for selecting Cargotec as your machine supplier. We hope
that we will meet your expectations.
The maintenance manual contains information about how the machine
should be maintained for maximal operating reliability and service
life as well as troubleshooting information for fast correction of any
malfunctions.
Conditions
The instructions are based on use of general tools available in stores.
All lifting devices, e.g., straps, slings, ratchet blocks, etc., must meet
governing national regulations for lifting devices.
Cargotec will not accept any responsibility for modifications performed
without permission from Cargotec or in the event of the use of lifting
devices, tools or work methods other than those described in this
manual.
Storage
NOTE
The maintenance manual shall be accessible to service personnel.
About the machine version
The information in this publication corresponds to the machine's
design and appearance when delivered from Cargotec. There may be
differences due to customisation of the machine.
Cargotec reserves the right to change specifications and equipment
without prior notification. The information in the manual is valid at the
time of publication.
DANGER
External equipment may only be used if it is approved
by Cargotec.
Risk of fatal accidents and property damage!
Only used equipment approved by Cargotec.
Copyright
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.
Duplication by any means such as copying, printing, etc., is prohibited.
Maintenance Manual DCF 180–250
UDCF06.01GB
A:4
A Foreword – Reading instructions
Reading instructions
Warning information
Warnings inform of potential hazards that, if warnings are not heeded,
may result in personal injury or product damage.
DANGER
Situation that may lead to severe personal injury or
fatality if the rule is not followed.
WARNING
Situation that may lead to personal injury if the rule is
not followed.
CAUTION
Situation that may lead to product damage if the rule
is not followed.
Important information
Important information is indicated by NOTE, and is provided to
facilitate the work process, handling or increase understanding of the
information.
NOTE
Information that is important without being related to safety.
Read operator's manual
000262
The symbol to the left is used in certain cases on the machine and
refers to important information in the operator's manual.
Read the operator's manual
001128
Read maintenance manual
The symbol to the left is used in certain cases on the machine and
refers to important information in the maintenance manual.
Read the maintenance manual
UDCF06.01GB
Maintenance Manual DCF 180–250
A Foreword – Reading instructions
A:5
Maintenance manual's content
The information in the maintenance manual is divided into function
groups (0-12) to facilitate searching for information. The manual is
divided in 20 sections A-C, 0-12, D-G. The sections with letters contain
specific 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 about function groups, see Function group
structure, page A:6.
A
Foreword
General information about the maintenance manual's purpose, content and
reading 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
5
Steering
Technical description, description of the machine's functions with schematic
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
accessories
10
Common hydraulics
11
Common electrics
12
Common pneumatics
D
Error codes
Error code information is found in the Workshop manual and Operator's manual.
E
Diagrams
Wiring diagrams and hydraulic diagrams are found in the 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.
Maintenance Manual DCF 180–250
UDCF06.01GB
A:6
A Foreword – Reading instructions
Function group structure
The information in the manual is divided in a structure of functions
at different levels, based on the machine's design and use, called
function groups.
The upper level (called main group) determines group, e.g., group 7
Load handling. The second level (called two-digit) determines function,
e.g., 7.2 Lifting/lowering. The third and fourth levels are used to break
down functions into smaller parts (components).
The function groups' structure for main group and two-digit group level
are common for all machines from Cargotec, e.g., 4.3 Power-assisted
brake system. Machine-unique adaptations of function groups 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 some function groups (headings)
will be left out of the documentation for certain machines since the
machine does not have that particular function or component. In turn,
this means that the function groups' numbering may 'skip', e.g., the
three-digit heading level 4.8.7 Oil cooler may be included for some
machines but not for others.
The idea is that the function groups are intended to work as a search
term to find different types of information between different sections and
manuals. The information under a function group is divided into smaller
sections according to the type of content, e.g., description or change.
The maintenance manual and workshop manual contain different
information. The maintenance manual only includes information
needed for preventive maintenance as well as simpler troubleshooting.
The workshop manual includes more in-depth information and repair
instructions.
References between sections in the same manual are indicated with
section and group number, e.g., "see section 4 Brakes, group 4.3.9
Wheel brake". References within a section are indicated with a page
number, e.g., "see Sensor fuel level, description page 24".
References are not given between Maintenance manual and Workshop
manual. If more information is desired for a function group, the primary
recommendation is to search under the same function group in the
other manual.
Product alternatives and optional equipment
The information in the manual is divided in modules. For product
alternatives and optional equipment, handling of the modules differs
depending on if it is the one or the other that is described, see below.
Special equipment is not described in the manual. If you're uncertain
about what equipment the machine should have, use the machine card
to decide which information applies, see Machine card, page A:7.
Product alternatives
000264
Product alternatives
Symbol indicating optional equipment
Product alternatives are such options that exclude certain standard
equipment (e.g., engine alternative).
Equivalent information for different product alternatives is described
in separate sections following each other under the same function
group. To indicate that there are different alternatives, the supplement
"Product alternative" is used in the heading together with a simple
description of which alternative is described, e.g., "(Product alternative
Climate control unit ECC)". In addition, alternatives that are optional
are marked with the symbol for optional equipment.
UDCF06.01GB
Maintenance Manual DCF 180–250
A Foreword – Reading instructions
A:7
Optional equipment
Optional equipment are options that can be added to the standard
equipment to obtain additional or improved functions.
Information for optional equipment is described in separate sections
with the standard equipment as starting point. Description of the
optional equipment describes how the standard function is affected by
the option as well as which additional components are added.
Machine card
NOTE
If the machine has been modified after delivery the information on
the machine card may be lacking or incorrect.
IMPORTANT
Changes done on the machine shall be reported to
Cargotec so that the machine card can be updated. A
new updated machine card is sent on the request of
the customer.
The machine card indicates of which drawings the machine consists,
in many cases these can be associated to options and product
alternatives. For more information on handling product alternatives and
optional equipment, see Product alternatives and optional equipment,
page A:6. The machine card is supplied with the spare parts catalogue
and should be in the cab.
The machine card is divided in the same function groups as the spare
parts catalogue, maintenance manual, and workshop manual. For
practical reasons, the machine card only uses the first and second
level of the function group index. The function groups are written in
groups of four characters, e.g., group 0107 corresponds to group 1.7
Cooling system in the manual.
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 Cargotec.
NOTE
All documents that accompany the machine are non-registered
documents and there will be no notification of changes.
Function descriptions
Function descriptions are schematic overviews that describe how a
function works as well as which components and signals work together.
The function descriptions describe the function in a logical flow from
input signal to desired output signal. Most functions require that
pre-determined conditions are fulfilled for that function to be activated.
In these cases the conditions are listed above the figure.
Function descriptions use symbols to illustrate components such as
valves, sensors, etc.
Maintenance Manual DCF 180–250
UDCF06.01GB
A:8
A Foreword – Reading instructions
1
8
7
2
6
5
3
014779
4
Example of function description
1.
Hydraulic force (solid double line)
6.
2.
Flag diagnostic test, indicates that the signal can be
checked with diagnostic test, see section 8 Control
system, group 8.4 Diagnostics
Flag pressure check connection (Check point),
indicates that there is a measuring outlet for checking
the pressure signal
7.
Electric power (solid single line)
3.
Illustration of function, (lifting/lowering)
8.
Electric signal (dashed single line)
4.
Component list
5.
Position number in illustration, reference to
component list
UDCF06.01GB
Maintenance Manual DCF 180–250
A Foreword – Reading instructions
Symbol explanation function descriptions
1
2
3
4
5
Symbol explanation function descriptions
The following symbols are used in function descriptions, the symbols
are based on standard symbols used in wiring and hydraulic diagrams.
6
7
8
9
A:9
M
10
1.
Electric control signal
2.
Electric force
3.
Hydraulic control signal
4.
Hydraulic force
5.
Hydraulic motor
6.
Hydraulic oil pump with variable displacement
7.
Hydraulic oil pump with fixed displacement
8.
Electric motor
9.
Accumulator
10. Disc brake
11. Filter
11
12. Radiator
12
13. Bulb
14. Control system, two control units with CAN-bus
D790-1
13
15. Restriction
14
16. Adjustable restriction
D797-F
17. Inductive position sensor
15
16
17
18
18. Electrically controlled servo valve
19. Thermal bypass valve
19
°C
21
°C
23 Pa
20. Temperature-controlled switch
21. Temperature sensor
20 °C
22
22. Pressure sensor
23. Pressure-controlled switch
Pa
24. Hydraulic cylinder
25. Double-acting hydraulic cylinder
24
26. Spring brake cylinder
27. Valve block
25
28. Shuttle valve
26
27
28
29
014726
29. Non-return valve
Maintenance Manual DCF 180–250
UDCF06.01GB
A:10
A Foreword – About the documentation
About the documentation
The documentation's parts
The documentation for the machine consists of the following parts:
Operator's manual
The operator's manual is delivered with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
delivered to the machine as a separate documentation kit.
Supplementary documentation
Supplementary documentation can be ordered for the machine.
•
Workshop manual
•
Supplier documentation for engine, transmission and drive axle.
Ordering of documentation
The documentation is ordered from the dealer for Cargotec.
Always specify publication number when ordering.
For publication number, see the machine card.
UDCF06.01GB
Maintenance Manual DCF 180–250
A Foreword – Feedback
A:11
Feedback
Form for copying
Cargotec's ambition is that you who work with maintenance of Kalmar
machines shall have access to correct information.
Your feedback is important to be able to improve the information.
Copy this form, write down your views and send it to us. Thanks for
your help!
To:
Cargotec Sweden AB
Technical Documentation
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: +46 372 263 93
From:
Company / Sender: ..........................................................................................................................................
Telephone: ..........................................................................................................................................................
E-mail: .................................................................................................................................................................
Date: .................................... - .................. - ..................
Manual information
Name / Publication number: .............................................................................................................................
Section / page number: ......................................................................................................................................
Suggestions,
views, remarks,
etc.
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
Maintenance Manual DCF 180–250
UDCF06.01GB
A:12
UDCF06.01GB
Maintenance Manual DCF 180–250
B:1
B Safety
Contents B Safety
Safety.................................................................................................................. B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:4
Hydraulic system, depressurising............................................................... B:5
Oils ............................................................................................................. B:5
Fuel system ................................................................................................ B:6
AdBlue........................................................................................................ B:7
Clothing, etc. .............................................................................................. B:8
Several mechanics on the same machine.................................................. B:8
Working under machine ............................................................................. B:8
Lifting heavy components .......................................................................... B:9
Vibrations ................................................................................................... B:9
Noise ........................................................................................................ B:10
Solvents ................................................................................................... B:10
Fire and explosion risks.............................................................................B:11
Fluid or gas under pressure ..................................................................... B:13
Coolant ..................................................................................................... B:13
Refrigerant ............................................................................................... B:14
Air pollution .............................................................................................. B:14
Tensioned springs .................................................................................... B:15
Electric motors ......................................................................................... B:15
Rotating components and tools................................................................ B:15
Tyres and rims.......................................................................................... B:16
Lifting equipment ...................................................................................... B:16
Spare parts............................................................................................... B:18
Non-ionised radiation ............................................................................... B:19
Environment.................................................................................................. B:20
General .................................................................................................... B:20
Maintenance Manual DCF 180–250
UDCF06.01GB
B:2
UDCF06.01GB
Maintenance Manual DCF 180–250
B Safety – Safety
B:3
B Safety
General safety information
Safety concerns everyone!
The safety information concerns everyone who works with the machine!
Persons who do not follow the safety instructions in this manual must
make absolutely sure that the work is performed without risks of
personal injury, without risks of machine damage, or property damage!
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 be careful. Do not take any risks!
Cargotec has in this publication documented and warned for situations
and risks that may occur in connection with using as well as service or
repairs of the machine during normal circumstances.
Therefore, it is very important that all who work with the machine, or
carry out repairs or service work, acquaint themselves with and act
according to the information in the Maintenance Manual and Operator's
Manual.
A near accident is a warning!
An incident is an unforeseen event where neither a person, the
machine, nor property is damaged. However, incidents indicate that
there is a risk of injury and actions must be taken to avoid injury risks.
Maintenance Manual DCF 180–250
UDCF06.01GB
B:4
B Safety – Safety instructions
Safety instructions
General
Read, consider and follow the safety instructions below before starting
to work in the machine:
•
Service position, page B:4
•
Hydraulic system, depressurising, page B:5
•
Oils, page B:5
•
Fuel system, page B:6
•
AdBlue, page B:7
•
Clothing, etc., page B:8
•
Several mechanics on the same machine, page B:8
•
Working under machine, page B:8
•
Lifting heavy components, page B:9
•
Vibrations, page B:9
•
Noise, page B:10
•
Solvents, page B:10
•
Fire and explosion risks, page B:11
•
Fluid or gas under pressure, page B:13
•
Coolant, page B:13
•
Refrigerant, page B:14
•
Air pollution, page B:14
•
Tensioned springs, page B:15
•
Electric motors, page B:15
•
Rotating components and tools, page B:15
•
Tyres and rims, page B:16
•
Lifting equipment, page B:16
•
Spare parts, page B:18
•
Non-ionised radiation, page B:19
Service position
General
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
014404
Service position means:
Machine with forks and trolley in completely lowered
position
UDCF06.01GB
•
Machine parked, that is, applied parking brake.
•
Forks and trolley in completely lowered position.
•
Engine off.
•
System voltage off (with battery disconnector).
Maintenance Manual DCF 180–250
B Safety – Safety instructions
B:5
Hydraulic system, depressurising
1
Machine in service position, see Service position, page B:4.
2
Depressurise the hydraulic system by opening the drain valve on
the accumulator charging valve.
NOTE
Keep the accumulator drain valve open as long as work is in
progress.
NOTE
After the work has been finished, close the drain valve and
tighten the lock ring.
Oils
The following safety instructions shall be followed for work when
handling oils.
WARNING
Warm and pressurised oil.
Always depressurise the hydraulic system before
starting work in the system. The hydraulic system is
pressurised and its oil can cause personal injury.
Avoid skin contact with the oil, use protective gloves.
Hot oil may cause burns, rashes and irritation! Oil may
also be corrosive to mucous membranes in, e.g., eyes,
skin, and throat.
IMPORTANT
Always clean the area around components and
connections before loosening them. Dirt in oil systems
causes increased wear, which results in material
damage.
Always take actions to avoid spills. Where a container
cannot be used for draining, 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 start fires. Waste oils/fluids shall always
be handled and taken care of by companies that are
authorised for this work.
Maintenance Manual DCF 180–250
UDCF06.01GB
B:6
B Safety – Safety instructions
Fuel system
The following safety instructions shall be followed for work when
handling 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.
Ensure that naked flames, sparks or red-hot/glowing
objects have been extinguished before starting work
on or in the vicinity of the fuel system.
Do not smoke in the vicinity of the machine when work
on the fuel system is in progress.
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel may be corrosive to mucous
membranes in, e.g., eyes, skin, and throat.
CAUTION
Always clean the area around components and
connections before loosening them. Dirt in the fuel
system can cause malfunctions and engine stops in
unwanted situations, as well as increased wear and
material damages.
UDCF06.01GB
Maintenance Manual DCF 180–250
B Safety – Safety instructions
B:7
IMPORTANT
Always take actions to avoid spills. Where a container
cannot be used for draining, 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 environment
and may also start fires. Fuel shall always be handled
and taken care of by companies that are authorised for
this work.
AdBlue
The following safety instructions shall be followed for work when
handling AdBlue.
CAUTION
AdBlue can irritate the skin and eyes and when inhaled.
Health hazard!
Handle with care and avoid contact with skin, use
gloves. In the event of contact with skin and spillages
on clothing, rinse the skin with large amounts of water
and replace contaminated clothing and gloves. In
the event of contact with eyes, rinse thoroughly with
water for several minutes and seek medical advice if
necessary. In the event of inhalation, breath fresh air
and seek medical advice if necessary.
CAUTION
AdBlue spilled onto hot components evaporates
quickly.
Irritation of eyes and respiratory system.
Turn your face away. Evaporated AdBlue can harm
mucus membranes in, for example, the eyes and throat.
In the event of contact with eyes, rinse thoroughly with
water for several minutes and seek medical advice if
necessary. In the event of inhalation, breath fresh air
and seek medical advice if necessary.
IMPORTANT
Avoid spilling AdBlue on the ground and in
watercourses.
Spillages on the ground must be absorbed with sand or
other absorbent, non-combustible material.
Maintenance Manual DCF 180–250
UDCF06.01GB
B:8
B Safety – Safety instructions
Clothing, etc.
Clothes should be in good repair. Remove loose, hanging items (e.g.,
tie, scarf). Do not wear clothes with wide sleeves, pant legs, etc.
Remove jewellery as it may conduct electricity and get caught in
moving parts.
Long hair should be put up securely since it may otherwise get caught
in moving parts. Be careful when working with a welder or open flame
since hair is flammable.
Several mechanics on the same machine
WARNING
If several mechanics are working on the same vehicle,
be extra careful so that accidental movements do not
injure another person. Communicate so that everyone
knows where everyone is 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 or injury.
Movements performed from the operator's station, e.g., all movement
of lifting equipment, may cause severe personal injuries.
Safety actions
•
Make sure that the machine's lifting equipment is completely
lowered or secured in another way.
•
Move the battery disconnector to position zero and remove the key.
•
Be aware of the risks when several persons work around the
vehicle.
•
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
Working under the cab
Loose objects must not be present in cabs that are to be tilted.
The cab must always be tipped to its end position and secured with
the stop device.
When the work does not allow the cab to be tilted to its end position, or
for work with cab suspension, the cab must always be secured with
the stop device.
On machines with vertically adjustable cab the cab must be secured
in the raised position with the intended lock.
UDCF06.01GB
Maintenance Manual DCF 180–250
B Safety – Safety instructions
B:9
Working under frame
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 wheel axle.
Risks
Mechanical or hydraulic tools and lifting devices can fall over or
accidentally be lowered due to malfunctions or incorrect use.
Safety actions
•
Use axle stands and supports that stand securely.
•
Lifting tools should be inspected and type approved for use.
Lifting heavy components
WARNING
Careless handling of heavy components may 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 sturdy and intact.
Risks
Unsuitable lift slings, straps, etc. may break or slide.
The centre of gravity of the component can change during the course of
the work, and the component may then make unexpected movements
which may cause severe personal injuries and material damage.
A component lifted with lifting equipment can start to turn if the centre
of gravity changes.
A component lifted using an overhead crane may start to swing
back and forth, which can cause severe crushing injuries or material
damage.
Safety actions
Lift with lifting device. Use lifting tools or other devices, especially
when such items are available for certain jobs. 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 your legs and arms,
do not bend your back. Do not twist your body while lifting. Ask for
assistance - before lifting.
•
Wear gloves. They're often good protection to reduce crushing
and cutting injuries to fingers.
•
Always use protective shoes.
Vibrations
Use of vibrating tools, e.g. impact nut runner or grinder, for an extended
period of time may cause injuries as vibration is transmitted from tool
to hands. Most of all when fingers are cold.
Maintenance Manual DCF 180–250
UDCF06.01GB
B:10
B Safety – Safety instructions
Safety actions
•
Use heavy gloves to protect against the cold and transfer of
vibrations.
•
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
Noise louder than 85 dB (A) lasting for longer than 8 hours is deemed to
damage hearing. (Limit values may differ between different countries.)
High tones (high frequency) is more damaging than low tones at the
same sound level. Noise in the form of impulse sounds may also be
damaging, e.g., hammer blows.
Risks
Hearing damage may occur at noise levels higher than the limit value.
In severe cases, damage may be permanent.
Safety actions
•
Use hearing protection. Make sure that it's tested and protects
against the right noise level.
•
Limit noise with noise-absorbing dividers, for example,
noise-absorbing materials in roof and on walls.
Solvents
Fluids that (unlike water) dissolve grease, paint, lacquer, wax, oil,
glue, rubber, etc., are called organic solvents. Examples: Naphtha,
gasoline, thinner, alcohols, diesel, xylene, trichloroethylene, toluene.
Many solvents are flammable.
Risks
Products with solvents give off vapours that may cause dizziness,
headache, and nausea. They may also cause irritation of mucous
membranes in the throat and respiratory tracts.
If dissolvent comes into direct contact with the skin it can dry and crack.
Higher risk of skin allergies. Solvents may also cause injuries if they
penetrate the skin and are absorbed by the blood.
If the body is continuously exposed to solvents, the central nervous
system may be injured. This manifests itself as trouble sleeping,
depressions, nervousness, poor memory, and general tiredness.
Continuous inhalation of gasoline and diesel vapours is suspected
of causing cancer.
Safety actions
UDCF06.01GB
•
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 a low content of aromatic compounds. This
reduces the risk of injuries.
•
Avoid skin contact.
•
Use protective gloves.
•
Make sure that work clothes are solvent-resistant.
Maintenance Manual DCF 180–250
B Safety – Safety instructions
B:11
Fire and explosion risks
DANGER
The operator's safety may not be jeopardised in case
of fire.
If possible, take the following actions at the slightest
sign of fire:
1. Stop the machine and turn the start key to stop
position.
2. Leave the cab.
3. Turn off the system voltage with the battery
disconnector.
4. Call the fire department.
5. Try to put out the fire.
If this is not possible, leave the machine and the
danger area.
DANGER
Smoke from a fire may be very toxic.
Smoke anaesthetises, suffocates, and kills! Smoke
from fires, even small amounts, can damage lungs and
respiratory organs.
Avoid inhaling smoke gases, do not stand in the
smoke. Use breathing protection when putting out a
fire and working with burnt materials.
Examples of flammable and explosive substances are oils, gasoline,
diesel fuel oil, organic solvents (lacquer, plastics, cleaning agents),
rustproofing agents, welding gas, gas for heating (acetylene), high
concentration of dust particles consisting of combustible materials.
Rubber tyres are flammable and cause explosive fires.
Risks
Examples of causes of ignition are welding, cutting with a welding
torch, smoking, sparks from grinding machines, contact between
hot machine parts and flammable materials, heat generation in rag
drenched with oil or paint (linseed oil), and oxygen. Oxygen cylinders,
lines, and valves shall be kept free from oil and grease.
Fumes from, e.g., fuel are heavier than air and may "run" down into a
sloping plane, or down in a grease pit, where welding flames, grinding
sparks or cigarette glow may cause an explosion. Evaporated gasoline
explodes very forcefully.
Maintenance Manual DCF 180–250
UDCF06.01GB
B:12
B Safety – Safety instructions
Special cases
Gas oil with added gasoline has a reduced flash point. Risk of
explosion already at room temperature. Explosion risk for heated gas
oil is higher 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 machine. If diesel and or other oils have leaked out
and been absorbed by rags, absorbent agents, paper or other porous
material, glowing welding sparks can cause ignition and explosive fires.
When a battery is being charged, the battery electrolyte's water is
divided 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 device is used since this increases the risk of sparks.
In today's machines there are a lot of electronics. When welding,
all control units must be unplugged and the electric power must be
turned off with the battery disconnector. Powerful welding currents may
otherwise short-circuit the electronics, destroy expensive equipment,
and may cause an explosion or fire.
Never weld on painted surfaces (remove paint, preferably by blasting at
least 10 cm around the welding or cutting point). Use gloves, breathing
protection, and protective safety glasses. Also, never weld near plastic
or rubber materials without first protecting them from the heat. Paint,
plastic, and rubber generate many substances when heated, and these
may be hazardous to health. Be careful with machines that have been
exposed to intense heat or fire.
Safety actions
DANGER
Remains of fuel, oils, grease, and other flammable
materials on the engine or in the engine compartment
are fire hazards.
Risk of fire!
Remove remains of flammable materials from the
engine compartment as soon as they are discovered,
be extra thorough with hot surfaces such as the
exhaust system, manifold, or turbo. If leaks of oil, fuel,
or coolant are detected, find the cause and solve the
problem before starting the engine.
UDCF06.01GB
•
Make a habit of performing a visual check of the engine and engine
compartment before starting the engine and after operation, when
the engine has been stopped. This ensures fast detection if
anything abnormal has happened or is about to occur. Pay special
attention to oil, fuel, or coolant leaks, loose bolts, worn or poorly
tensioned drive belts, loose connections, damaged hoses, and
electrical cables. The inspection only takes a few minutes and may
prevent serious problems and expensive repairs.
•
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.
Maintenance Manual DCF 180–250
B Safety – Safety instructions
B:13
Fluid or gas under pressure
Lines with high pressure may be damaged during work and fluid or
gas may jet out.
There may be high pressure in a line even if the pump has stopped,
therefore gas or fluid may leak out when the connection for the hose
is loosened.
A gas cylinder exposed to outside forces may explode, e.g., if it falls on
a hard surface. Gas may flow out from damaged valves.
Risks
Risk of damage/injuries in connection with work on:
•
Hydraulic systems (e.g., working hydraulics and brake system).
•
Fuel system.
•
Changing tyres.
•
Climate control unit (air conditioning).
Safety actions
•
Use protective goggles and protective gloves.
•
Never work in a pressurised system.
•
Never adjust a pressure limiting valve to a higher pressure than
the manufacturer's recommendations.
•
A hydraulic hose that swells, e.g., at a connection, shows that it
is about to rupture. Replace it as soon as possible! Check the
connections thoroughly.
•
Use fluid when checking for leaks.
•
Never blow clothes clean with compressed air.
•
Failed pressure accumulators shall first be drained of pressure
and then punctured before being discarded (to avoid risk of
explosion). Carefully drill a hole with 3 mm diameter after draining
the pressure.
•
Never feel with your hands to check for any leaks. A fine jet from
a hydraulic hose may have such high pressure that it easily cuts
through, e.g., a hand, causing very severe injuries.
Coolant
The coolant in the machine’s cooling system consists of water,
anti-corrosion compound and 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 is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in case of leaks or when the
cap on the expansion tank (filling point) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety actions
•
Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
•
First open the cap for the filling point, to release the high pressure.
Be careful. Hot steam and coolant may jet out.
•
If possible, avoid working on the cooling system when the coolant
is hot.
Maintenance Manual DCF 180–250
UDCF06.01GB
B:14
B Safety – Safety instructions
Refrigerant
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 injuries.
Refrigerant that is heated (e.g., when repairing leaking climate/AC
system), generates gases that are very dangerous to inhale.
Safety actions
•
Follow special instructions and equipment for refrigerant according
to the manual when working on the air conditioning unit. Any
person doing the work must have special accreditation. (Note
national legislation and local 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
Air pollution is the pollution in the air around us and that are regarded
as hazardous to health. Certain pollutants are more prevalent in some
environments.
The following health-hazardous air pollution is especially prominent in
workshops:
•
Carbon monoxide (fumes) is found in exhaust gases. Odourless
and therefore extremely dangerous.
•
Nitrogen oxides (nitrous gases) are present in exhaust fumes.
•
Welding smoke especially hazardous to health when welding on
oily surfaces, galvanised 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
Sulphuric acid mist is corrosive and injures the respiratory tracts.
(Generated when heating certain plastics and paints.)
Isocyanates may be released in the form of vapour, dust (or may
be found in aerosol) when cutting, grinding, or welding. May cause
mucous membrane irritation with asthma-like symptoms and impaired
lung function. Even brief exposures to high concentrations may cause
problems with persistent hypersensitivity.
UDCF06.01GB
Maintenance Manual DCF 180–250
B Safety – Safety instructions
B:15
Safety actions
•
Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
generated.
•
Use suitable protective gloves and breathing protection when there
is risk of oil mist. Make sure that the protection is oil-resistant.
•
Apply oil-resistant protective lotion to unprotected skin.
•
Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
•
Avoid unnecessary operation of the machine inside the workshop.
Connect air extraction to the exhaust pipe so that exhausts are led
out from the workshop.
Tensioned springs
Examples of tensioned springs:
1.
Torque springs in, e.g., pedals.
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 uncontrolled
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 actions
•
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
Safety actions
Always turn off the battery disconnector when working on electric
motors.
Always block the machine’s wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before
starting any work on the machine.
Rotating components and tools
Examples of rotating components and tools:
•
Cooling fan
•
Drive belts
•
Propeller shafts
•
Drills
•
Grinding machines
Maintenance Manual DCF 180–250
UDCF06.01GB
B:16
B Safety – Safety instructions
Risks
Rotating components, e.g., 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 actions
•
Do not use gloves when working with a drill.
•
Remove loose, hanging clothing, scarf or tie.
•
Never use clothing with wide sleeves or pant 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 jewellery from hands, arms and
neck.
Tyres and rims
DANGER
Tyres are to be considered as pressurised containers.
Handling incorrectly, they are a fatal hazard.
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, and lock rings may be ejected.
Inflating tyres: Tyres, rims, or lock rings may be ejected.
Safety actions
•
Always deflate the tyre before starting to work on the wheel.
•
Check that tyres, rims, and lock rings are free from damage. Never
repair damaged rims or lock rings.
•
Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
•
Use protective screen and safety glasses.
Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest care must be taken with regard to
securing the mast and carriage.
Get into the habit of always keeping the carriage lowered to the lowest
position when working on the machine.
UDCF06.01GB
Maintenance Manual DCF 180–250
B Safety – Safety instructions
B:17
Risks
If the machine's lifting equipment is not lowered or secured, there is a
risk of crushing.
Risk of crushing is extra high when depressurising the hydraulic
system, see Hydraulic system, depressurising, page B:5.
Safety actions
Do not start work until the carriage is fully lowered. If the nature of the
work requires the carriage to be raised, it must be secured in some way.
Maintenance Manual DCF 180–250
UDCF06.01GB
B:18
B Safety – Safety instructions
Spare parts
WARNING
For safety reasons, the following spare parts may only
be replaced by genuine spare parts:
UDCF06.01GB
•
Brake valve
•
Drive axle
•
Valve for mini-wheel/joystick control
•
Steering valve (Orbitrol)
•
Steering valve incl. priority valve
•
Steering axle
•
Steering cylinder
•
Rim
•
Solid wheels
•
Control valve, hydraulic servo
•
Mast, carriage
•
Lift cylinder incl. load control valve
•
Separate load control valve
•
Lifting chains
•
Chain tightener and shaft
•
Forks, fork carrier
•
Lift cylinder
•
Tilt cylinder
•
Twistlock
•
Control breaker (for hydraulic function)
•
Emergency switch
•
Hydraulic cylinder, cab tilt
•
Accumulator
•
Tilt valve
•
Main valve load handling
•
Accumulator charging valve
•
All control units
Maintenance Manual DCF 180–250
B Safety – Safety instructions
B:19
Non-ionised radiation
WARNING
Extra equipment such as two-way radio, RMI, telephone,
etc. may emit non-ionised radiation.
Risk of interference with active or non-active medical
products.
Use a two-way radio, RMI, telephone, etc., when no
persons with active or non-active medical products
are nearby.
NOTE
When persons with active or non-active medical products are not
nearby, then telephone and two-way radio may be used in the cab.
Equipment should not be used when operating or load handling
since this reduces your concentration as operator.
Cargotec does not assume any responsibility for extra equipment
not installed by Cargotec or according to installation instructions
approved by Cargotec.
Maintenance Manual DCF 180–250
UDCF06.01GB
B:20
B Safety – Environment
Environment
General
Our global environment is significantly affected by the world's
ever-increasing industrialisation. Nature, animals, and humans are
exposed daily to great risks in connection with handling of chemicals in
various forms.
Still there are no environmentally safe chemicals, e.g., oils and
coolants, on the market. Therefore, all who handle, perform service, or
repair machines must use the tools and methods that are necessary to
protect the environment in an environmentally correct way.
By following the simple rules below, you will contribute to protecting
our environment.
Recycling
Well-planned recycling of the machine is the starting point for finishing
the life cycle and making use of materials for re-use in new products.
According to calculations by Cargotec, the machine can be recycled to
more than 90% by weight.
Environmentally hazardous waste
Components such as batteries, oils and other chemicals, and other
materials that may constitute environmentally 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 environmentally
safe manner and according to national regulations.
Oils and fluids
Oils freely released cause damage to the environment and may also
start fires. When emptying and draining oils or fuel, take actions 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 any leaks.
Air conditioning system
The refrigerant in the air conditioning unit for the cab contributes to
the greenhouse effect if it escapes into the open air. Special training
is required for all service work on the air conditioning unit. Many
countries also require certification by an authority for such work. When
scrapping an air conditioning unit, the refrigerant shall be taken care
of by a certified company.
Working in a contaminated area
The machine shall be equipped for work within a contaminated area
(polluted environment or health-hazardous area) before starting the
work. Also, special local instructions apply for handling and service
work on such a machine.
UDCF06.01GB
Maintenance Manual DCF 180–250
B Safety – Environment
B:21
Declarations
The machine does not contain asbestos.
The machine contains lead in batteries and electrical wiring. Some
models have cast lead counterweights.
If the machine is equipped with air conditioning, refrigerant of the type
R134a and an amount between 1-3 kg is used.
Maintenance Manual DCF 180–250
UDCF06.01GB
B:22
UDCF06.01GB
Maintenance Manual DCF 180–250
C:1
C Preventive maintenance
Contents C Preventive maintenance
Preventive maintenance ................................................................................... C:3
Preventive maintenance, general ................................................................... C:3
Preventive maintenance, work instructions..................................................... C:3
Check and service log..................................................................................... C:4
50h-check ....................................................................................................... C:5
Service schedule............................................................................................. C:7
Washing ........................................................................................................ C:14
Lubricating 500h ........................................................................................... C:15
Lubricating 1000h ......................................................................................... C:20
Checking for cracks ...................................................................................... C:24
Maintenance Manual DCF 180–250
UDCF06.01GB
C:2
UDCF06.01GB
Maintenance Manual DCF 180–250
C Preventive maintenance – Preventive maintenance
C:3
C Preventive maintenance
Preventive maintenance, general
It’s very important that preventive maintenance is performed according
to recommended intervals.
Preventive maintenance should be performed by Cargotec, or by a
service organisation authorised by Cargotec.
CAUTION
Service intervals shall be followed.
This is to maintain the machine's safety and to fulfil
warranty and service agreements!
Use spare parts and fluids approved by Cargotec to
fulfil the warranty.
Preventive maintenance, work instructions
1
For a new machine it is very important to check-tighten the wheel
nuts during the first work week until they are seated properly. This
should be done at an interval of 4–5h (up to approx. 40–50h).
2
For a new machine, perform the checking action after 50 hours of
operating time, see 50h-check, page C:5.
Note completed 50h-check in the service log, see Check and
service log, page C:4.
3
Regular service shall be performed according to service schedule,
see Service schedule, page C:7. The service schedule shall be
followed to ensure high machine reliability and safety.
Note completed service in the service log, see Check and service
log, page C:4.
Maintenance Manual DCF 180–250
UDCF06.01GB
C:4
C Preventive maintenance – Preventive maintenance
Check and service log
Model:
Serial number:
Completed maintenance
Operating
hours
Actions
50h
50h-check
500h
500h service
1000h
1000 service
1500h
500h service
2000h
2000h service
2500h
500h service
3000h
1000 service
3500h
500h service
4000h
2000h service
4500h
500h service
5000h
1000 service
5500h
500h service
6000h
2000h service
6500h
500h service
7000h
1000 service
7500h
500h service
8000h
2000h service
8500h
500h service
9000h
1000 service
9500h
500h service
10000h
2000h service
UDCF06.01GB
Operating
hours
Date
Maintenance Manual DCF 180–250
Signature
C Preventive maintenance – Preventive maintenance
C:5
50h-check
On a new machine, the following checks shall be performed after 50
operating hours. The checks are performed to increase reliability and
safety.
In addition to the following checks, lubrication should also take place in
accordance with the 500h-service, see Lubricating 500h, page C:15.
1 Engine
Reference
Bolted joints, attachments, mountings, hose clamps, wear and chafing
of hoses, cable harnesses, etc.
Sealing check oil, coolant, exhaust system
Fuel prefilter, water draining
Section 1 Engine, group 1.2.3 Fuel prefilter
Air filter indicator, check
Operator's manual
Air filter main cartridge, inspection
Air filter safety cartridge, inspection
Drive belt tension, check
Section 1 Engine, group 1.7.5 Cooling fan
Coolant level, check
Operator's manual
Oil and oil filter, change
Section 1 Engine, group 1.8 Lubrication system
Oil pressure
2 Transmission
Leakage check
Oil and oil filter, change
Section 2 Transmission, group 2.6 Transmission
oil, changing.
3 Driveline/Axle
Mounting propeller shaft, check-tightening
Section 3 Driveline/Axle, group 3.2 Propeller shaft
Mounting drive axle, inspection
Section 3 Driveline/Axle, group 3.3 Drive axle
4 Brake system
Leakage check
Power-assisted brake, function check
Parking brake, function check
Operator's manual
Section 10 Common hydraulics Group 10.3.2
Accumulator
5 Steering
Sensor steering wheel reading mini-wheel/joystick control, function
check
Section 5 Steering, group 5.2.11 Sensor steering
wheel reading
6 Suspension
Steering axle suspension, checking
Section 6 Suspension, group 6.2.1 Steering axle
cradle
Tyres and rims, check
Section 6 Suspension, Group 6.3.1 Tyres
Wheel nuts, check-tightening
7 Load handling
Hose connections, checking the O-ring seal. Check-tightening in the
event of leaks.
For additional attachments, see the manufacturer's instructions.
8 Control system
Check that there are no active error codes
Section 8 Control system, group 8.3 Error codes
Maintenance Manual DCF 180–250
UDCF06.01GB
C:6
C Preventive maintenance – Preventive maintenance
9 Frame, body, cab and accessories
Hose fittings, air conditioning (ECC Electric Climate Control),
check-tightening
Air conditioning system, performance tests
Section 9 Frame, body, cab, and accessories,
group 9.4 Air conditioning.
Counterweights, checking
Section 9 Frame, body, cab and accessories,
group 9.13.4 Counterweights
10 Common hydraulics
Hose connections, check-tightening in the event of leakage
Leakage check
Section 10 Common hydraulics, group 10.5.2
Main valve
Hydraulic oil filter, changing
Section 10 Common hydraulics, group 10.6.8
Hydraulic oil filter
Oil level, check
Section 10 Common hydraulics, group 10.6.9
Hydraulic oil
11 Common electrics
Batteries, check
UDCF06.01GB
Section 11 Common electrics, group 11.3.1 Start
battery
Maintenance Manual DCF 180–250
C Preventive maintenance – Preventive maintenance
C:7
Service schedule
Service shall be performed every 500h. Actions are divided 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 operating
hours: 1000h, 3000h, 5000h, etc.
Actions for 2000h service are performed at even thousands of
operating hours: 2000h, 4000h, 6000h, etc.
After service is performed, make a note in the check and service log,
see Check and service log, page C:4.
In the column for service below, the following abbreviations are used:
R = replace
C = check or inspection
L = lubrication
h= operating hour
CAUTION
Lubrication intervals are based on normal handling
and environment and are subject to the use of the
recommended grades and quantities.
In other conditions, e.g. cold, hot, dusty, we recommend
halving the intervals.
The lubrication interval must never exceed 12 months.
Service
Object, action
500h,
1500h,
2500h,
etc.
1000h,
3000h,
5000h
etc.
2000h,
4000h,
6000h
etc.
C
C
Comment
Reference
C
Check and remove remains
of flammable materials in
the engine compartment,
pay extra attention to hot
surfaces such as exhaust
system, manifold, or turbo.
If leaks of oil, fuel, or
coolant are detected, find
the cause and solve the
problem.
Section B Safety
C
C
Visual check in connection
with greasing.
L
L
Lubricating 500h, page
C:15
L
L
Lubricating 1000h, page
C:20
0 complete machine
Checking cleanliness and
leakage
Attachments (stub axles)
Lubricating 500h
Lubricating 1000h
Checking for cracks
L
C*
* Check every 4000h or
every year.
Checking for cracks, page
C:24
1 Engine
Maintenance Manual DCF 180–250
UDCF06.01GB
C:8
C Preventive maintenance – Preventive maintenance
Service
Object, action
Bolted joints, attachments,
mountings, etc.
500h,
1500h,
2500h,
etc.
1000h,
3000h,
5000h
etc.
2000h,
4000h,
6000h
etc.
C
C
C
Fuel tank
Fuel prefilter
C
R
Comment
Reference
C
Clean if necessary.
Section 1 Engine, group
1.2.1 Fuel tank
R
Drain water/impurities.
Section 1 Engine, group
1.2.3 Fuel prefilter
Change filter earlier if error
code is displayed.
R
R
Change filter earlier if error
code is displayed.
Section 1 Engine, group
1.2.4 Fuel filter
AdBlue tank
C
Cleaning
Section 1 Engine, group
1.2.12 AdBlue tank
AdBlue filter
R
Fuel filter
Valve clearance
C
Section 1 Engine, group
1.2.13 AdBlue filter
First check after 500 h,
then every 1500 h.
NOTE
After engine replacement
or engine overhaul
check/adjust after 250
h.
Performed by service
shop authorised by Volvo
Penta.
Section 1 Engine, group
1.6.1 Air cleaning system
Air filter main cartridge
C/R
C/R
C/R
Checking indicators,
change when indicated.
Air filter safety cartridge
C
C/R
C/R
Changed every other time
main cartridge is changed.
Air filter, hood
C
R
R
Washed every 500
operating hours. Filter
change every 1000
operating hours.
Section 1 Engine, group
1.6.1 Air cleaning system
Exhaust system
C
C
C
Sealing check
Section 1 Engine, group
1.6.3 Exhaust system
C
C
Sealing check
Section 1 Engine, group
1.6.4 Intercooler
C
C
External check and
cleaning.
Section 1 Engine, group
1.7.4 Radiator and
expansion tank
Charge-air hoses
Radiator
C
NOTE
Do not use high pressure
wash.
Drive belts
C/R
C/R
Belt tensioner
Coolant
R
Section 1 Engine, group
1.7.5 Cooling fan
C
C
C
C / R*
Level check.
* Change after 5000 h or
once every two years.
For volume and quality, see
section F F Technical data.
Coolant, freezing point
UDCF06.01GB
C
C
C
For volume and quality, see
section F F Technical data.
Maintenance Manual DCF 180–250
Section 1 Engine, group
1.7.7 Coolant
C Preventive maintenance – Preventive maintenance
C:9
Service
Object, action
500h,
1500h,
2500h,
etc.
1000h,
3000h,
5000h
etc.
2000h,
4000h,
6000h
etc.
Turbo
C
Injectors
C*
Comment
* Every 3000 h.
Reference
NOTE
Performed by service
shop authorised by Volvo
Penta.
Engine oil
R
R
R
Engine oil filter
R
R
R
R
R
For volume and quality, see
section F F Technical data.
Section 1 Engine, group
1.8 Lubrication system
R
At each transmission oil
change.
Section 2 Transmission,
group 2.6.4 Oil filter
R
Change transmission oil
every 1000h or every year.
Section 2 Transmission,
group 2.6 Lubrication
system
2 Transmission
Transmission oil filter
Transmission oil
C
Also change on indication
from the filter monitor.
Transmission, calibration
C
C
Calibration of transmission
is recommended every
1,000 operating hours.
Section 2 Transmission,
group 2.8 Control system
C
C
Section 3 Driveline/Axle,
group 3.2 Propeller shaft
C
C
Section 3 Driveline/Axle,
group 3.3 Drive axle
C
R
R
Section 3 Driveline/Axle,
group 3.3 Drive axle
Power-assisted brake
C
C
C
Brake pedal and pedal
assembly
C
C
C
Section 4 Brakes, group
4.1.1 Brake pedal
Brake pressure, checking
C
C
C
Section 4 Brakes, group
4.3.6 Distribution block
C/R
C/R
C/R
Link arms
C
C
C
Sensor steering wheel
reading mini-wheel/joystick
C
C
C
Steering axle suspension
C
C
Suspension in the frame.
Section 6 Suspension,
group 6.2.1 Steering axle
cradle
Wheel spindle, check
C
C
Clearance in wheel
suspension shall be
checked. Max. 0.25
mm.
Section 6 Suspension,
group 6.2.2 Wheel spindle
3 Driveline/Axle
Propeller shaft
C
Drive axle
Drive axle oil
4 Brake system
Parking brake
Function check.
Check pad thickness,
change when needed.
Section 4 Brakes, group
4.5.4.2 Parking brake pads
Checking the bearings and
lock screws for the shafts.
Section 5 Steering, group
5.2.6 Link arm
5 Steering
Section 5 Steering, group
5.2.11 Sensor steering
wheel reading
control
6 Suspension
Maintenance Manual DCF 180–250
UDCF06.01GB
C:10
C Preventive maintenance – Preventive maintenance
Service
Object, action
500h,
1500h,
2500h,
etc.
Wheel hub, checking
1000h,
3000h,
5000h
etc.
2000h,
4000h,
6000h
etc.
*)
C
Comment
Reference
Check bearing pre-load.
Section 6 Suspension,
group 6.2.3 Wheel hub
*) Check the first time after
1000 h, then every 2000 h.
Tyres and rims
C
C
C
Damage, wear and
pressure, change as
needed.
Section 6 Suspension,
group 6.3 Tyres and rims
Wheel nuts
C
C
C
Check-tighten.
Section 6 Suspension,
group 6.3 Tyres and rims
C*
* Checking for cracks,
every 2,000 hours and
in connection with tyre
changes.
Section 6 Suspension,
group 6.3.2 Rim
C
C
Check that the welds
are intact and check the
bearings.
Section 7 Load handling,
group 7.2.6 Mast
C
C
Check for damage.
Section 7 Load handling,
group 7.2.8 Chains
Rim
7 Load handling
Mast suspension
Lifting chains
C
Tension chain when
needed.
Support roller
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
cylinder
Tilt cylinder
C
C
C
Lifting forks
C
C
C
C
C
Calibrating the scales
Section 7 Load handling,
Group 7.10.1 Electric
scales
Attachment
C
C
Damage
Section 7 Load handling,
group 7.10.5 Side lift
attachment
Twistlocks
C
C/R
Check for cracks every
other year or every 4000
operating hours.
Section 7 Load handling,
group 7.10.5 Side lift
attachment
Scales
Check that the welds
are intact and check the
bearings.
Section 7 Load handling,
group 7.7.5 Tilt cylinder
Section 7 Load handling,
group7.9.1 Lifting forks
Replace every 10,000
operating hours. Reset
time counter for twistlocks
after replacement.
Sensors
C
C
C
C
C
C
Section 7 Load handling,
group 7.10.5 Side lift
attachment
8 Control system
Service indicator, reset
UDCF06.01GB
A special code is required
in addition to the service
code.
Maintenance Manual DCF 180–250
Section 8 Control system,
group 8.2.4 Service
indicator
C Preventive maintenance – Preventive maintenance
C:11
Service
Object, action
500h,
1500h,
2500h,
etc.
1000h,
3000h,
5000h
etc.
2000h,
4000h,
6000h
etc.
C
C
C
Function check
C
C
C
Checking function.
Comment
Reference
9 Frame, body, cab and accessories
Instruments and controls
Air conditioning unit
Function check of drive belt
Section 9 Frame, body,
cab, and accessories,
group 9.4 Air conditioning.
Section 1 Engine, group
1.7.5 Cooling fan
Fresh air filter
C/R
R
R
Depending on the external
environment.
Certain models have
washable prefilters. Fine
filters are changed when
necessary.
Condenser
C
C
C
Clean when needed.
NOTE! Not high-pressure
washer.
Section 9 Frame, body,
cab, and accessories,
group 9.4.4 Fresh air filter
Section 9 Frame, body, cab
and accessories, Group
9.4.9 Condenser unit
C/R
C/R
C/R
Windshield wipers
C
C
C
Lighting and audible signals
C
C
C
Communication equipment
C
C
C
Roof window
C
C
Check damage, change
when needed.
Section 9 Frame, body, cab
and accessories, Group 9.9
Glass/windows/mirrors
Cab frame
C
C
Check rust damage,
deformation or cracks.
Section 9 Frame, body, cab
and accessories, group
9.10 Cab frame
C
C
Check doors' mounting
points.
Section 9 Frame, body, cab
and accessories, Group
9.10.2 Doors
C
C
Check mountings, isolators
and bolted joints.
Section 9 Frame, body, cab
and accessories, group
9.10.3 Cab undercarriage
C
C
Check the pin for the
cab and the lift cylinder's
mounting.
Section 9 Frame, body, cab
and accessories, group
9.10.3 Cab undercarriage
Moisture filter
Hinges for doors and cover
lids
C
Cab undercarriage
Hydraulic tilting of the cab
C
Checking, change if
indication is grey.
Section 9 Frame, body, cab
and accessories, group
9.4.21 Moisture filter
Incl. flushing.
Section 9 Frame, body, cab
and accessories, Group
9.5 Wiping and cleaning of
windows
See separate subcontractor
information
Section 9 Frame, body, cab
and accessories, Group
9.10.4 Cab tilting
Frame
C
C
Check for any deformation
and rust damage as well as
cracks in welded joints.
Non-slip plate for cab steps
and on cab floor
C
C
Check and replace non-slip
plate in poor condition.
Maintenance Manual DCF 180–250
UDCF06.01GB
C:12
C Preventive maintenance – Preventive maintenance
Service
Object, action
500h,
1500h,
2500h,
etc.
Counterweight mounting/box
Central lubrication
C
1000h,
3000h,
5000h
etc.
2000h,
4000h,
6000h
etc.
C
C
Section 9 Frame, body, cab
and accessories, Group
9.13.4 Counterweights
C
C
Section 9 Frame, body, cab
and accessories, group
9.14 Central lubrication
Paint/coatings
C
Comment
Check the machine's
painted surfaces for stone
chips and scratches
Reference
Section 9 Frame, body, cab
and accessories, group
9.15 Paint/coatings
Repair damage
immediately to avoid
corrosion.
Safety decals
C
C
C
Check that safety decals
are legible, securely
fastened, and not
damaged. Clean dirty
decals and replace decals
as needed.
See Operator's manual,
section 3 Overview, group
3.2 Signs
Hydraulic pressure, checking
C
C
C
Accumulator
C
C
C
Check the precharge
pressure.
Section 10 Common
hydraulics Group 10.3.2
Accumulator
C
C
External check and
cleaning.
Section 10 Common
hydraulics, group 10.6.2
Hydraulic oil cooler
10 Common hydraulics
Cooler for hydraulic oil
Section 10 Common
hydraulics
NOTE
Do not use high pressure
wash.
Breather filter hydraulic oil
tank
Hydraulic oil filter
UDCF06.01GB
C/R
R
R
R
R
Change at indication.
Maintenance Manual DCF 180–250
Section 10 Common
hydraulics, group 10.6.7
Breather filter hydraulic oil
tank
Section 10 Common
hydraulics, group 10.6.8
Hydraulic oil filter
C Preventive maintenance – Preventive maintenance
C:13
Service
Object, action
500h,
1500h,
2500h,
etc.
1000h,
3000h,
5000h
etc.
Hydraulic oil
2000h,
4000h,
6000h
etc.
C/R
Comment
Reference
Checked with oil sample.
Section 10 Common
hydraulics, group 10.6.9
Hydraulic oil
•
If oil sample OK after
2000h, operate for a
further 1000h and take
new oil sample.
•
If oil sample OK after
3000h, operate for
a further 1000h and
change oil.
Note! Max. 4000h change
interval.
Additive: Lubrizol should
be added when changing
hydraulic oil. Concentration
3%.
For volume, see section F
Technical data.
11 Common electrics
Position sensors
C
C
C
Should be free from grease
and dirt, clean as needed.
Fuses
C
C
C
Check that fuses are intact,
change if needed.
Section 11 Common
electrics, group 11.2.2
Fuses
Batteries
C
C
C
Clean when needed.
Section 11 Common
electrics, group 11.3.1 Start
battery
Check the electrolyte level.
Battery cable
C
C
C
Test-run
C
C
C
After test-run
C
C
C
Section 11 Common
electrics, group 11.3.1 Start
battery
Test-run the machine and
check the following:
•
Instruments
•
Brakes
•
Gearshifting
•
All load handling
functions
•
Communication
equipment
•
Steering
•
Any noise
Check the following after
test-run:
•
Sealing (no leakage)
•
Fluid levels
Maintenance Manual DCF 180–250
UDCF06.01GB
C:14
C Preventive maintenance – Preventive maintenance
Washing
CAUTION
High-pressure washing of sensitive components can
lead to short-circuiting and may cause malfunctions.
Product damage!
Do not use high-pressure washing on cab, radiator,
battery compartment, electric components, control
units, connectors, cable splices, cylinder seals, stub
axles, axle/shaft seals, and chains.
UDCF06.01GB
Maintenance Manual DCF 180–250
C Preventive maintenance – Preventive maintenance
C:15
Lubricating 500h
1
Turn off the engine and turn off the system voltage.
2
Clean the area around each grease cup before greasing.
3
Lubricate the machine's lubrication points with lubricant in
accordance with the recommendation, see section F Technical
data. Also do a visual check of all lubricated mounts.
IMPORTANT
On machines with central lubrication, check that the
central lubrication's lubrication points are lubricated,
see section 9 Frame, body, cab and accessories, group
9.14 Central lubrication.
Maintenance Manual DCF 180–250
UDCF06.01GB
C:16
C Preventive maintenance – Preventive maintenance
6
5
14
14
2
2
15
15
7
3
4
8
2
3
9
10
1
13
12 11
Lubrication points, lubricating grease
Pos.
Lubrication points
Reference
1
Cab lock
Cab lock, page C:17
2
Hinges doors
Hinges doors, page C:17
3
Key lock door/engine cover
Key lock door/engine cover, page C:17
4
Pedal assembly, brake pedal
Brake pedal, page C:17
5
Slide plates.
Mast, page C:19
6
Mast top support rollers, if applicable.
7
Chain wheel
8
Lifting chains
9
Support rollers and fork wheels, forks
Support rollers, forks, page C:18
10
Side shift cylinder
Side shift cylinder, page C:17
11
Support rollers
Mast, page C:19
12
Mast wheel
13
Mast mount
14
Link arm
Link arm, page C:18
15
Tilt cylinder
Tilt cylinders, page C:18
16
Side lift attachment
UDCF06.01GB
(not positioned in the figure)
Side lift attachment, page C:20
Maintenance Manual DCF 180–250
014458
9
C Preventive maintenance – Preventive maintenance
C:17
Cab lock
1
Tilt the cab.
2
Lubricate the cab locks with lubricating grease.
Hinges doors
3
Lubricate the door's hinges with lubricating grease. If necessary,
lift the door to facilitate lubrication.
Lubricate the mechanism in the hood.
Key lock door/engine cover
Lubricate the key locks on doors and hood with lock oil.
007874
4
Brake pedal
5
Lubricate the brake pedal's hinge with grease.
6
Wipe off excess grease.
Lubrication points brake pedal
Side shift cylinder
7
Lubricate the side shift cylinder with lubricating grease.
Maintenance Manual DCF 180–250
UDCF06.01GB
C:18
C Preventive maintenance – Preventive maintenance
Support rollers, forks
8
Lubricate the support rollers and fork wheels with lubricating
grease.
Link arm
1
9
Lubricate the link arms' bearings with lubricating grease.
3
007869
2
4
1.
Lubrication point, upper king pin bearing.
2.
Lubrication point, inner link arm bearing
3.
Lubrication point, outer link arm bearing
4.
Lubrication point, lower king pin bearing.
Tilt cylinders
007871
10 Grease the tilt cylinder axles with lubricating grease. There is one
lubrication point on each end of the tilt cylinder.
UDCF06.01GB
Maintenance Manual DCF 180–250
C Preventive maintenance – Preventive maintenance
C:19
Mast
4
11 Start the machine and raise the mast to facilitate access to
lubrication points.
3
12 Turn off the engine.
4
13 Secure the mast in a way that ensures safety.
14 Lubricate slide plate (position 1), support rollers (position 2), chain
wheel (position 4) and mast wheel (position 5), as well as top
support rollers (position 3) if applicable, with lubricating grease,
see section F Technical data.
15 Brush or spray the chains with chain oil. Make sure that the chains
are well lubricated.
1
2
5
5
007275
2
Lubrication points for mast.
Mast mount
16 Remove the load from the mast mountings in an appropriate
manner. Unload using one of the following methods:
–
Fit a jack under the mast and lift so that the mast does not
hang on the mast mounting.
–
Tilt the mast backwards, fit something under the mast that
withstands the load and then tilt forwards.
007868
17 Lubricate the mast mounting with lubricating grease.
Lubrication point, mast mounting.
Maintenance Manual DCF 180–250
UDCF06.01GB
C:20
C Preventive maintenance – Preventive maintenance
Side lift attachment
18 Lubricate all slide surfaces with slide grease (pos. 1) with
attachment in max. extended position.
2
2
2
1
1
2
3
5
4
014772
5
19 Lubricate the hydraulic cylinders' shafts with lubricating grease
(pos. 2).
20 Lubricate the twistlock cylinder's shaft with lubricating grease
(pos. 3).
21 Lubricate the twistlocks with lubricating grease (pos. 4).
22 Lubricate the contact pins with lubricating grease (pos. 5).
Lubricating 1000h
UDCF06.01GB
1
Turn off the engine and turn off the system voltage.
2
Clean the area around each grease cup before greasing.
3
Lubricate the machine's lubrication points with lubricant in
accordance with the recommendation, see section F Technical
data. Also do a visual check of all lubricated mounts.
Maintenance Manual DCF 180–250
C Preventive maintenance – Preventive maintenance
C:21
3
3
2
2
1
014459
4
3
Lubrication points, lubricating grease
Lubrication points
Reference
Lubricating 500h
Lubricating 500h, page C:15
1
Hose wheels
Hose wheels, page C:21
2
King pin bearing
King pin bearing, page C:22
3
Wheel bearings, steering axle
Wheel bearings, steering axle, page C:22
Turnable operator's station
Turnable operator's station, gears and chain
Electric connectors (not shown on diagram)
Electric connectors, page C:23
4
5
6
Side lift attachment
(not positioned in the figure)
, page C:22
Side lift attachment, page C:23
Hose wheels
1
Remove the lock plate to release the hose wheel.
2
Remove the hose wheels.
3
Apply slide grease to the shaft.
4
Fit the hose wheels.
5
Fit the lock plate.
007876
Pos.
Maintenance Manual DCF 180–250
UDCF06.01GB
C:22
C Preventive maintenance – Preventive maintenance
King pin bearing
1
6
3
Lubricate the wheel spindle's bearings (upper and lower) with
lubricating grease on both sides.
If necessary, turn the wheels for better access.
4
007869
2
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
007862
Be careful so that the seal is not damaged.
Turnable operator's station, gears and chain
8
UDCF06.01GB
Remove the cover plate and clean and lubricate the gears with
universal grease.
Maintenance Manual DCF 180–250
C Preventive maintenance – Preventive maintenance
9
C:23
Remove the cover plate and clean and lubricate the chain with
universal grease.
Electric connectors
006645
10 Grease electric connectors with electric connector grease.
Electric connector, example
Side lift attachment
11 Machine in service position, see section B Safety.
014771
1
12 Lubricate the rotary coupling (pos. 1) with lubricating grease.
13 Clean and lubricate the twistlocks with lubricating grease.
Maintenance Manual DCF 180–250
UDCF06.01GB
C:24
C Preventive maintenance – Preventive maintenance
Checking for cracks
DANGER
Welds in areas of high stress concentration must be
checked in accordance with recommended intervals.
The interval is calculated according to the machine
being used for normal handling and on a level, smooth
ground surface. For other handling or, e. g., rough
surface, the interval should be shortened.
If the welds show signs of cracking, take the machine
out of operation immediately and contact Cargotec
Support.
1
Turn off the engine and turn off the system voltage.
2
Clean every weld carefully before inspection.
3
Visually inspect for damage and cracks in the areas with high
stress concentration, see Checkpoints, page C:26. Check the
whole length of every weld.
Welds where cracks are suspected following visual inspection are
tested with magnetic particle inspection and liquid penetrant if
appropriate in accordance with the following:
a.
The magnetic particle method is used to determine if there's a
crack or not, and where it is. See Magnetic particle method,
page C:24.
b.
Confirmed cracks are investigated further with penetrating
fluid. See Checking cracks with penetrating fluid, page C:25.
001703
Magnetic particle method
Rim
1
Blast the applicable area clean so that it is completely free of
paint residue.
2
Test using magnetic particle inspection and the following
equipment:
•
•
•
Equipment: Yoke Tiede
Method:
a
Alternating current AC
b
Contrast colour
Checking medium:
a
Wet
b
Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic particle method,
checking is finished and the applicable area is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.
UDCF06.01GB
Maintenance Manual DCF 180–250
C Preventive maintenance – Preventive maintenance
C:25
001704
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.
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.
Rim
1
2
4
Spray detection fluid part no. 923626.0670 on the area.
5
Let the sprayed area dry 1-2 hours.
6
Visually inspect the area.
If the tested area does not show signs of linear or point-shaped
cracks, it is approved.
001705
If the crack check indicates linear or point-shaped cracks, contact
Cargotec Support.
Examples of cracks
1.
Linear crack
2.
Pointed crack
Maintenance Manual DCF 180–250
UDCF06.01GB
C:26
C Preventive maintenance – Preventive maintenance
Checkpoints
Check the following welds carefully:
6
5
8
3
5
1
4
4
7
2
Checking for cracks
Pos.
Checkpoint
Reference
1
Mast mount
Mast mount, page C:26
2
Tilt mount
Tilt mount, page C:28
3
Drive axle mount
Drive axle mount, page C:28
4
Lifting forks
Lifting forks, page C:29
5
Lifting equipment
Lifting equipment, page C:29
6
Counterweight box
Counterweight box mounting against the frame, page C:31
7
Steering axle mounts
Steering axle mounts, page C:31
8
Mounting of frame beam to back piece
Mounting of frame beam to back piece, page C:32
Mast mount
1
Mast mount in frame
009485
a)
UDCF06.01GB
Maintenance Manual DCF 180–250
014460
5
C Preventive maintenance – Preventive maintenance
C:27
Welds between mast beam and mount tab.
c)
Mast mount in frame, bottom view
d)
Weld between mast beam and mount tab, bottom view.
009524
009523
009487
b)
Maintenance Manual DCF 180–250
UDCF06.01GB
C:28
C Preventive maintenance – Preventive maintenance
Tilt mount
2
Tilt mount in mast.
b)
Tilt mount in frame.
009482
009481
a)
Drive axle mount
3
Drive axle mount in frame
009483
a)
UDCF06.01GB
Maintenance Manual DCF 180–250
C Preventive maintenance – Preventive maintenance
C:29
Lifting forks
4
NOTE
009480
There may be other variants of forks than those shown here.
a)
The fork's suspension bracket against the carriage beams.
Mounting of support rollers.
When checking fork material, see section 7 Load handling, group
7.9.1 Lifting forks.
Fork upper mounting bracket, bottom view.
009529
b)
Lifting equipment
5
NOTE
There may be other variants of trolleys than those shown here.
Trolley side's welds against the trolley beams.
009536
a)
Maintenance Manual DCF 180–250
UDCF06.01GB
C Preventive maintenance – Preventive maintenance
b)
Outer struts' welds against the trolley beams.
c)
Chain mounting in the trolley.
009535
C:30
009479
Also check the mounting pin to the chain and its split pin.
d)
Chain mounting in the mast.
009478
Also check the chain tightener, mounting pin to the chain and its
split pin.
e)
The wheel pin welds in the trolley.
009530
Check the inner mast wheel pins as well.
UDCF06.01GB
Maintenance Manual DCF 180–250
C Preventive maintenance – Preventive maintenance
C:31
Counterweight box mounting against the frame
6
a)
Counterweight box mounting against the frame, under rear
mudguard.
009533
Angle the steering wheels on the ground for easier access.
Steering axle mounts
7
a)
Steering axle mounts in the frame.
b)
Steering axle mounts in the steering axle cradle.
a
009525
b
Maintenance Manual DCF 180–250
UDCF06.01GB
C:32
C Preventive maintenance – Preventive maintenance
Mounting of frame beam to back piece
8
Mounting of frame beam to back piece.
b)
Mounting of frame beam to back piece, bottom view.
009531
014766
a)
UDCF06.01GB
Maintenance Manual DCF 180–250
0:1
0 Complete machine
Contents 0 Complete machine
Complete machine..............................................................................................0:3
Maintenance Manual DCF 180–250
UDCF06.01GB
0:2
UDCF06.01GB
Maintenance Manual DCF 180–250
0 Complete machine – Complete machine
0:3
0 Complete machine
Complete machine, description
The Kalmar DCF 180-250 is a forklift truck. The machine has a lifting
capacity of 18-25 tonnes depending on version.
The engine is a six-cylinder, four-stroke diesel engine with direct
injection.
The transmission is hydro-mechanical with gears in constant mesh. It
has three forward gears and three reverse gears. The engine's power
is transmitted using a torque converter.
The power transmission consists of propeller shaft and a rigid drive
axle with hub reduction. The machine has front-wheel drive.
The service brake is of the type disc brake in oil, which is integrated
with the driving wheels' wheel hubs. The parking brake is of the disc
brake type and acts on the drive axle's input shaft.
The machine is steered with the rear wheels using a double-acting
hydraulic cylinder. The steering axle is oscillation-mounted in the frame.
The wheels are mounted on the hubs with nuts and washers. The
drive axle has twin wheels, the steering axle has single wheels. The
wheel rims are detachable.
Load handling consists of components and functions for handling
loads. Loads are lifted with forks secured to a carriage that is fitted on
a mast. Load handling is divided into the functions lifting/lowering, tilt,
side shift, spreading, levelling and load carrier.
•
Lifting/lowering is the function that lifts and lowers the fork carriage.
•
Side shift is for repositioning the forks in parallel at the same
distance from each other laterally along the carriage.
•
Spreading is for adjusting the width between the forks on the
carriage.
•
Tilt is for angling the load in the longitudinal direction of the
machine by means of the mast.
•
Levelling is for angling the load in the lateral direction of the
machine.
•
The load carrier is for holding or gripping the load.
The control system includes functions to warn the operator of
dangerous situations and faults. The control system has diagnostic
options that facilitate troubleshooting.
The frame supports the machine. Fitted on the frame are the engine,
transmission, drive axle and steering axle, etc. On the sides of the
frame are tanks for fuel, AdBlue and hydraulic oil. The cab has a
central location and can be tilted laterally.
Maintenance Manual DCF 180–250
UDCF06.01GB
0:4
UDCF06.01GB
Maintenance Manual DCF 180–250
1:1
1 Engine
Contents 1 Engine
1
Engine..................................................................................................................1:3
1.2
Fuel system......................................................................................................1:8
1.2.1
Fuel tank .....................................................................................................1:9
1.2.3
Fuel prefilter ................................................................................................1:9
1.2.4
Fuel filter ...................................................................................................1:12
1.2.12
AdBlue tank ...............................................................................................1:13
1.2.13
AdBlue filter ...............................................................................................1:15
1.6
Air intake and exhaust outlet..........................................................................1:18
1.6.1
Air cleaning system ...................................................................................1:19
1.6.3
Exhaust system .........................................................................................1:22
1.6.4
Intercooler .................................................................................................1:22
1.7
Cooling system ..............................................................................................1:24
1.7.4
Radiator and expansion tank ....................................................................1:24
1.7.5
Cooling fan ................................................................................................1:24
1.7.7
Coolant ......................................................................................................1:25
1.8
Lubrication system .........................................................................................1:30
1.9
Control system engine ...................................................................................1:33
1.10
Ignition/heating...............................................................................................1:34
1.11
Start/stop........................................................................................................1:35
Maintenance Manual DCF 180–250
UDCF06.01GB
1:2
UDCF06.01GB
Maintenance Manual DCF 180–250
1 Engine – Engine
1:3
1 Engine
Engine, description
The engine provides power for propulsion and the working hydraulics.
The engines are low emission engines and meet emission regulations
from the USA (California) and Europe. The new engines provide
considerable improvement, not only for exhaust emissions but also
for the power and torque curve.
The machine is equipped with Volvo TAD761VE.
Maintenance Manual DCF 180–250
UDCF06.01GB
1:4
1 Engine – Engine
Engine alternative Volvo TAD761VE,
function description
Volvo TAD761VE is a straight 6-cylinder, 4-stroke turbocharged
low-emission diesel engine with unit injectors and air-to-air intercooler.
0
I
P
II
°C
III
1
7 <°
10
.
rpm
kph
<°
4
bar
ECU790
EDU795
F
9
N
R
R
1
11
4
5
M
3
ECU794
UDS
SENSORS
8 H2O
2
6
12
M
13
15
16
14
1.
Ignition key lock (S144)
9.
2.
Control unit engine (ECU794)
10. Sensor fuel level (B757)
3.
Preheating coil (E800)
11. Control unit, transmission (D793)
4.
Control unit general (ECU790)
12. Control unit SCR (UDS)
5.
Starter motor (M654)
13. AdBlue pump
6.
Electric components engine
14. Water valve
7.
Accelerator pedal (B690)
15. Sensor exhaust temperature
8.
Make-contact (closing switch) coolant level (B759)
16. Level and temperature sensor AdBlue
UDCF06.01GB
Control unit terminal (EDU795)
Maintenance Manual DCF 180–250
014282
ECU793
5
1 Engine – Engine
1:5
Engine, component location
5
4
6
3
7
2
8
9
1
20
18
16
14
12
10
014761
21
19
17
15
13
11
Volvo TAD761VE left-hand side (in the machine's direction of travel)
1.
Sensor flywheel speed
12. Fuel filter
2.
Crankcase ventilation
13. Sensor fuel pressure
3.
Filling point engine oil
14. Control unit engine (D794)
4.
Injector and preheating (6 pcs.)
15. Sensor oil pressure
5.
Sensor coolant level (B757)
16. Oil plug
6.
Sensor coolant temperature
17. Dipstick
7.
Thermostat housing
18. Fuel prefilter
8.
Alternator
19. Sensor water-in-fuel
9.
Water pump
20. Water trap
10. Fuel pump
21. Sensor camshaft speed
11. Oil filter
Maintenance Manual DCF 180–250
UDCF06.01GB
1:6
1 Engine – Engine
4
3
2
5
1
6
7
11
014762
10
9
8
Volvo TAD761VE, right side (in the machine's direction of travel)
1.
Expansion tank
7.
Starter motor
2.
Filling point coolant
8.
Intercooler
3.
Preheating of air after intercooler
9.
Condenser
4.
Sensor boost pressure and temperature
10. Transmission oil cooler
5.
Sensor fuel pressure (fuel distribution pipe)
11. Radiator engine
6.
Turbo
UDCF06.01GB
Maintenance Manual DCF 180–250
1 Engine – Engine
1
2
1:7
4
3
6
5
10
9
0
P
I
8
II
7
014408
III
Electric components machine
1.
Control unit, steering (ECU792)
6.
Control unit terminal (EDU795)
2.
Control unit, hydraulics (ECU796)
7.
Ignition key lock
3.
Control unit general (ECU790)
8.
Accelerator pedal
4.
Fuel tank
9.
Control unit, transmission (ECU793)
5.
Sensor fuel level (B757)
10. Control unit engine (ECU794)
Maintenance Manual DCF 180–250
UDCF06.01GB
1:8
1 Engine – Fuel system
1.2 Fuel system
Fuel system, description
The fuel tank is located on the left-hand side of the machine and is
equipped with a sensor for the fuel level. The amount of fuel in the
tank is shown on an operating menu on the display in the cab. Fuel
prefilter with water trap and fuel filter are on the engine. The water trap
is equipped with electrical indication, an event menu appears on the
display when the water trap must be emptied of water.
For component locations see, see Engine, component location, page
1:5.
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel may be corrosive to mucous
membranes in, e.g., eyes, skin, and throat.
Fuel system, bleeding
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
The fuel system must be bled after fuel filter replacement, if the fuel
tank has been run dry or after long periods of operation for example.
1 Machine in service position, see section B Safety.
1
2
Open the hand pump (position 1) by pressing it in and turning
anticlockwise.
3
Bleed the fuel system by pumping the hand pump at least 250
times.
Pump quickly to maintain the pressure in the pump.
NOTE
Bleeding is not complete until there is no resistance in the pump.
Close the hand pump by pressing in and turning clockwise.
5
Start the engine and allow it to idle for about five minutes before
increasing speed.
014767
4
1.
Hand pump
UDCF06.01GB
Maintenance Manual DCF 180–250
1 Engine – Fuel tank
1:9
1.2.1 Fuel tank
Fuel tank, cleaning
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
1
Machine in service position, see section B Safety.
2
Empty the fuel tank of fuel. Use a pumping device.
3
Remove the drain plug from the fuel tank.
4
Rinse the fuel tank clean through the fuel filler hole.
5
Reinstall the drain plug.
2
1
014210
3
1.
Fuel filler
2.
Drain plug, under tank
3.
Fuel tank
1.2.3 Fuel prefilter
Fuel prefilter, draining condensation
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
NOTE
Water traps must be emptied of water as necessary or at least every
50 operating hours.
1
Machine in service position, see section B Safety.
2
Close the fuel cock.
3
Place a container under the fuel prefilter.
Maintenance Manual DCF 180–250
UDCF06.01GB
1:10
1 Engine – Fuel prefilter
4
Open the drain cock (position 1) on the underneath and allow the
condensation water to run out. Close the cock when clean fuel
without water runs out.
5
Remove the water trap (position 2) from the fuel filter by turning it
clockwise.
6
Clean the water trap and refit it on the filter cartridge.
7
Close the drain cock and open the fuel cock.
8
Bleed the fuel system, see Fuel system, bleeding, page 1:8.
9
Turn on the system voltage and start the engine. Check that the
filter seals tight.
2
014216
1
1.
Drain cock
2.
Water trap
Fuel prefilter, replacement
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
UDCF06.01GB
1
Machine in service position, see section B Safety.
2
Clean the fuel prefilter and water trap.
Maintenance Manual DCF 180–250
1 Engine – Fuel prefilter
3
1:11
Drain the fuel prefilter of fuel and water.
See Fuel prefilter, draining condensation, page 1:9.
4
Remove the water trap (position 3) from the old filter.
5
Remove the fuel filter (position 2) from the filter holder, use a filter
tool. Collect any fuel in a container.
6
Lubricate the gasket on the new fuel filter.
7
Install the new fuel prefilter on the filter holder.
2
1
014214
3
1.
Wiring
2.
Fuel prefilter
3.
Water trap
Tighten in accordance with the instructions on the filter.
8
Install a new O-ring on the water trap and lubricate with diesel oil.
Install the water trap on the new fuel prefilter.
9
Bleed the fuel system, see Fuel system, bleeding, page 1:8.
10 Turn on the system voltage and start the engine. Check that the
filter seals tight.
2
1
014215
3
1.
Wiring
2.
Fuel prefilter
3.
Water trap
Maintenance Manual DCF 180–250
UDCF06.01GB
1:12
1 Engine – Fuel filter
1.2.4 Fuel filter
Fuel filter, replacement
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
NOTE
Do not fill the fuel filter with fuel prior to installation. There is a risk
of contaminants entering the fuel system and causing malfunctions
or damage.
1
Machine in service position, see section B Safety.
NOTE
The fuel filter is self-draining. Wait a few seconds after the engine
has been switched off before removing the filter cover and filter
insert.
1
2
2
Clean around the filter.
3
Remove the filter cover (position 1).
4
Remove the O-ring (position 2) and filter insert (position 3).
5
Fit a new filter insert and new O-ring.
6
Fit the filter cover, tighten to a torque of 25 Nm
7
Bleed the fuel system, see Fuel system, bleeding, page 1:8.
8
Start the engine and check sealing.
014217
3
UDCF06.01GB
Maintenance Manual DCF 180–250
1 Engine – AdBlue tank
1:13
1.2.12 AdBlue tank
AdBlue tank, cleaning
NOTE
Read safety recommendations for AdBlue before starting work, see
section B Safety.
1
Machine in service position, see section B Safety.
2
Remove the drain plug (position 1) on the underside of the AdBlue
tank. Drain any remaining AdBlue into a container.
3
Replace the drain plug gasket and reinstall the plug, tighten to
a tightening torque of 30 Nm.
NOTE
Remove the filler cap and filler pipe.
5
Lower the filler cap and filler pipe in a water bath. Let them remain
for at least two minutes.
014225
4
014226
1
014224
Only use gaskets that can withstand AdBlue.
Maintenance Manual DCF 180–250
UDCF06.01GB
1 Engine – AdBlue tank
6
Detach and remove the tank connections.
7
Check the strainer on the connections. Clean when needed.
014227
1:14
NOTE
014228
Always replace a damaged strainer.
8
Flush the tank with hot water for at least ten minutes.
014229
Then check that the tank is completely drained of water.
UDCF06.01GB
Maintenance Manual DCF 180–250
1 Engine – AdBlue filter
Reinstall the tank connections.
014230
9
1:15
10 Reinstall the filler pipe.
014231
11 Fill the tank with AdBlue. Refit the filler cap.
1.2.13 AdBlue filter
AdBlue filter, replacement
NOTE
Read safety recommendations for AdBlue before starting work, see
section B Safety.
CAUTION
Wait at least two minutes after switching the engine off
before removing the hoses for AdBlue so that the SCR
system has time to drain and depressurise.
1
Machine in service position, see section B Safety.
2
Remove the plate covering the pump unit from below. The plate is
placed under the battery compartment on the machine's left-hand
side.
Maintenance Manual DCF 180–250
UDCF06.01GB
1:16
1 Engine – AdBlue filter
3
Remove the connection for the heating element.
NOTE
014232
Pull the connection straight out.
4
Drain any remaining AdBlue into a container.
014233
Place a container under the pump unit. Connect a plastic tube to
the drain screw located on the filter holder. Open the screw and
allow the remaining AdBlue solution to run down into the container.
Remove the hose from the filter holder by pressing in the catches.
014234
5
UDCF06.01GB
Maintenance Manual DCF 180–250
1 Engine – AdBlue filter
6
1:17
Remove the filter holder (position 1) from the pump unit. Remove
the filter insert (position 3).
NOTE
If the filter has been detached, it must be removed completely
before being reinstalled, even if it is to be reused.
7
Install a new O-ring (position 2) in the new filter holder.
Install a new filter insert in the filter holder.
Install the filter insert and filter holder as one unit in the pump.
Tighten the filter holder using a toque wrench.
3
NOTE
Check that the drain valve is closed.
8
Install the hose to the filter holder. Check that the locks lock
securely.
9
Reconnect the connection to the heating element. Check that
the connection locks securely.
NOTE
Ensure that the connection is connected straight.
10 Start the engine and check sealing.
014236
1
014235
2
Maintenance Manual DCF 180–250
UDCF06.01GB
1:18
1 Engine – Air intake and exhaust outlet
1.6 Air intake and exhaust outlet
Air intake and exhaust outlet, description
There is an air cleaner on the machine. The air cleaner is equipped
with an indicator that indicates when the air filter needs replacing. The
air cleaner has two filter inserts, one main insert and a safety insert.
The air cleaner is connected to the engine by the turbocharger.
Volvo Stage 3B engines are equipped with SCR technology to reduce
nitrogen oxides (NOx) in exhaust gases. SCR technology means that
AdBlue is injected into the exhaust gases before it reaches the SCR
catalyst. A sensor measures the exhaust gases' NOx levels. The SCR
is located on the left-hand side of the machine.
AdBlue contains deionised water mixed with 32.5% urea. The urea is
broken down into ammonia, which reacts with NOx to create harmless
nitrogen and water vapour.
The exhaust system consists of pipe and silencer.
UDCF06.01GB
Maintenance Manual DCF 180–250
1 Engine – Air cleaning system
1:19
Exhaust outlet, component location
4
5
3
2
1
7
6
11
8
9
014288
10
1.
Control unit SCR (UDS)
7.
Level and temperature sensor AdBlue
2.
Silencer with integrated SCR catalyst
8.
Exhaust pipe
3.
Catalyst
9.
AdBlue tank
4.
End-pipe
10. Pump unit
5.
Heat shield
11. Heating valve
6.
Injector unit
1.6.1 Air cleaning system
Air filter, hood, changing
1
Machine in service position, see section B Safety.
Maintenance Manual DCF 180–250
UDCF06.01GB
1:20
1 Engine – Air cleaning system
2
Detach and remove the air filter holder.
3
Change the filter in the filter holder and refit the filter holder.
Air filter, changing
1
Machine in service position, see section B Safety.
2
Fold up the hood.
3
Clean the outside of the air filter housing.
C
B
A
Position for air filter holder
B
Replacement indicator
C
Dust reservoir
UDCF06.01GB
014077
A
Maintenance Manual DCF 180–250
1 Engine – Air cleaning system
4
Remove the cap from the air filter housing.
5
Remove the filter insert.
6
Clean the dust reservoir.
Maintenance Manual DCF 180–250
1:21
UDCF06.01GB
1:22
1 Engine – Exhaust system
7
Check the safety insert, change as needed. (The safety insert
should be changed every other time the filter insert is changed).
8
Fit a new filter insert.
NOTE
The filter insert should be changed, not cleaned.
9
Fit the cover to the air cleaner casing.
10 Check that the hoses from the air filter housing (and other parts)
are intact and sealed.
11 Reset the indicator.
1.6.3 Exhaust system
Exhaust system, checking
WARNING
Hot exhaust system!
Risk of burn injuries.
Never touch the turbo, exhaust pipe, or muffler when the
machine is in operation or has recently been turned off!
1
Machine in service position, see section B Safety.
2
Check the exhaust system's sealing and other wear.
3
Check that the exhaust system suspension is intact.
1.6.4 Intercooler
Intercooler, checking
1
UDCF06.01GB
Machine in service position, see section B Safety.
Maintenance Manual DCF 180–250
1 Engine – Intercooler
2
1:23
Clean the intercooler with compressed air.
NOTE
Do not use high pressure wash.
1
Intercooler
Charge-air pipe, checking
1
Machine in service position, see section B Safety.
2
Check the charge air pipes for visible cracks and other external
damage. If the pipes are damaged or if connections leak, the
boost pressure will be too low and engine power is reduced.
014249
1.
Check the sealing and check that the intercooler's hoses and
clamps are in good condition.
014471
3
Maintenance Manual DCF 180–250
UDCF06.01GB
1:24
1 Engine – Cooling system
1.7 Cooling system
Cooling system, description
The engine radiator is located together with the intercooler and the
transmission oil cooler in one unit, a cooling unit.
For component locations see, see Engine, component location, page
1:5.
1.7.4 Radiator and expansion tank
Radiator, cleaning
1
Machine in service position, see section B Safety.
2
Clean the radiator with compressed air.
NOTE
Do not use high pressure wash.
3
Check that the cooling flanges are whole.
1.7.5 Cooling fan
Drive belt, inspection
Check after operating when the belts are warm.
It should be possible to press down the drive belt approx. 3-4 cm
between the belt pulleys.
The drive belt has an automatic belt tensioner and does not need to be
adjusted. Check the condition of the belts, replace if necessary, see
Drive belt, replacement, page 1:24.
IMPORTANT
Always change a drive belt that looks to be worn or
has cracks.
Drive belt, replacement
1
UDCF06.01GB
Machine in service position, see section B Safety.
Maintenance Manual DCF 180–250
1 Engine – Coolant
1:25
2
Loosen the belt tensioner and lock it with a drift (position 1).
3
Remove the belt from the coolant pump (position 2) first.
4
Install the new belt.
Let back the belt tensioner and check that the belt is positioned
correctly in the grooves and is tensioned correctly.
2
014242
1
1.7.7 Coolant
Coolant level, check
WARNING
The cooling system is pressurised. Steam or hot fluid
may jet out.
Risk of scalding and burn injuries!
C
B
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before topping
up.
A
Coolant should be filled in the system's expansion tank (position A).
The coolant should be visible in the sight glass (position C) on the
expansion tank.
NOTE
014063
Open very carefully as hot coolant may jet up.
A
Position for coolant reservoir (expansion tank)
B
Filling point
C
Sight glass
If the coolant level should become too low then an error code is
shown in the control system's display (position 41).
NOTE
A low coolant level may cause engine damage or may cause the
engine to stop.
1
Machine in service position, see section B Safety.
Maintenance Manual DCF 180–250
UDCF06.01GB
1:26
1 Engine – Coolant
2
If needed, top up with ready-mixed recommended coolant. For
volume and quality, see section F F Technical data.
CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.
IMPORTANT
On machines with ECC or AC, it is of the utmost
importance that the engine's cooling system be refilled
with coolant that contains the correct mixture of
anti-freeze fluid; otherwise there is a risk that the air
conditioning will freeze up and fail during use.
Coolant, changing
Radiator performance is reduced due to deposits in the radiator and
radiator ducts. Clean the system in conjunction with changing the
coolant.
WARNING
The cooling system is pressurised. Steam or hot fluid
may jet out.
Risk of scalding and burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before topping
up.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid contact with skin, use
protective goggles and protective gloves. In the event
of contact with skin, wash the skin.
UDCF06.01GB
Maintenance Manual DCF 180–250
1 Engine – Coolant
1:27
IMPORTANT
Cleaning may not be performed if there can be a risk
of freezing in the cooling system since the cleaning
solution does not have anti-freeze properties.
NOTE
Read safety instructions for coolant before starting work, see section
B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.
Draining
1
B
A
014063
C
Remove the filler cap from the cooling system's expansion tank.
A
Position for coolant reservoir (expansion tank)
B
Filling point
C
Sight glass
Maintenance Manual DCF 180–250
UDCF06.01GB
1:28
1 Engine – Coolant
2
Open all drain points. Drain the coolant from the radiator and
engine block with drain hose. The drain nipples are under the
radiator and on the right-hand side of the engine block.
3
Check that all coolant drains.
NOTE
There may be deposits inside the cock or the plug that must
be cleaned; otherwise there is a risk that coolant may remain
and cause freezing damage.
007394
Check whether the installation has additional cocks or plugs on
the coolant line's lowest points. Allow the drain cocks or plugs to
remain open and ensure that the heating knob is set to full heat
during cleaning.
Drain point engine.
4
Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
5
If there still are impurities after flushing for some time, cleaning
with coolant can be performed. Otherwise continue with Cleaning
with coolant, page 1:28.
Cleaning with coolant
1
Fill the cooling system with 15-20 % concentrated coolant mixture.
Only use recommended concentrated coolant mixed with clean
water.
2
Drain the cooling system after 1-2 days of operation.
NOTE
In order to avoid dissolved materials getting into the cooling
system, drain quickly, within 10 minutes, without the engine
having been stationary for a long time.
Remove the filler cap from the expansion tank and any lower
radiator hose to increase the drain speed.
3
Immediately flush the system thoroughly with clean hot water to
prevent dirt getting on the internal surfaces. Flush until clean water
runs out. Make sure the heat control is at full heat during cleaning.
4
If impurities should remain after a long time of flushing, cleaning
can be performed with radiator cleaning agent and after-treatment
with neutraliser.
NOTE
Use only cleaning agent approved by the engine manufacturer.
Carefully follow the instructions on the packaging.
UDCF06.01GB
Maintenance Manual DCF 180–250
1 Engine – Coolant
1:29
Filling point
1
When the cooling system is completely free from impurities, close
the drain cocks.
CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.
NOTE
Only use recommended coolant.
2
Add coolant so that the level lies between the MIN and MAX
markings. The engine must not be started until the system
has been bled and filled fully.
3
Start the engine when the system is bled and completely filled.
Open any bleeder valves some time after start, so that the trapped
air can escape.
Open all heat controls on the heater unit so that it is bled.
4
Stop the engine after about one hour and check the coolant level,
top up if needed.
Maintenance Manual DCF 180–250
UDCF06.01GB
1:30
1 Engine – Lubrication system
1.8 Lubrication system
Lubrication system, description
The engine's lubrication system is completely closed and has no
connections to the machine.
For component locations see, see Engine, component location, page
1:5.
Oil and oil filter, change
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
Run the engine until warm.
2
Machine in service position, see section B Safety.
3
Remove the drain plug from the engine and drain the engine of oil.
4
Place a container under the oil filter.
5
Clean around the oil filter.
014238
1
UDCF06.01GB
Maintenance Manual DCF 180–250
1 Engine – Lubrication system
1
1:31
6
Carefully remove the filter cover (position 1).
7
Remove the O-ring (position 2) and filter insert (position 3).
Allow the oil to drain from the filter into the container.
2
3
8
Fit the new filter insert and a new O-ring.
9
Fit the filter cover and tighten to a torque of 40+10 Nm.
10 When the oil has run out fit the oil plug with a new gasket. Tighten
to a maximum torque of 55±10 Nm.
NOTE
Do not tighten the oil plug with higher tightening torque, the
threads will be damaged.
11 Fill with engine oil to the correct level. Do not fill over MAX-level.
For volume and quality, see section F Technical data.
12 Start the engine, let it idle. Check that the oil pressure is normal.
014237
13 Turn off the engine and check the oil level, see Oil level, check,
page 1:32. Top up as needed.
Maintenance Manual DCF 180–250
UDCF06.01GB
1:32
1 Engine – Lubrication system
Oil level, check
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
The engine's filler pipe (position B) and dipstick (position C) are under
the engine hood.
1 Machine in service position, see section B Safety.
2
Check the oil level when the engine has been warmed up. Wipe
off the dipstick before checking.
The dipstick has two markings, MAX and MIN, and the oil level
should be between them.
NOTE
On certain machines the oil dipstick is long. Wear gloves.
A
3
Top up with new engine oil if necessary (position B). For volume
and quality, see section F Technical data).
4
Fill - wait awhile - check on the dipstick.
C
B
NOTE
014768
Work carefully when filling to prevent other fluids or particles
from contaminating the oil, which means risk of engine damage.
B
A
Location for filling and dipstick for engine oil
B
Filling point
C
Dipstick
UDCF06.01GB
Maintenance Manual DCF 180–250
1 Engine – Control system engine
1:33
1.9 Control system engine
Control system engine, description
The engine is controlled by a control system, for which the central
unit is a control unit.
Amongst other things the system consists of sensors, control unit and
electric injectors. The sensors emit input signals to the control unit,
which in turn controls the injectors.
The control unit receives input signals on the engine's operating
condition from the following components:
•
sensor camshaft speed
•
sensor flywheel speed
•
sensor coolant temperature
•
sensor boost pressure and temperature
•
sensor oil pressure
•
sensor water-in-fuel
•
sensor fuel pressure
•
sensor coolant level (B757)
•
accelerator pedal (B690)
•
control unit SCR (UDS)
•
control breaker
•
level and temperature sensor AdBlue
•
sensor exhaust temperature
Based on the input signals the control unit controls:
•
main relay
•
preheating relay
•
starter motor (M654)
•
injector diesel
•
injector AdBlue
•
accelerator pedal actuator
•
fuel pump (MPROP)
•
control unit SCR (UDS)
If serious malfunctions are detected by the control and monitoring
system on the engine, then engine power is limited to protect the
engine from further damage.
The information from the sensors accurately advises the current
operating conditions and allows the processor in the control unit to
calculate the correct fuel quantity and check the engine condition.
For more information about control unit engine, see section 11 Common
electrics, group 11.5.3 Control units and supplier documentation
engine.
Maintenance Manual DCF 180–250
UDCF06.01GB
1:34
1 Engine – Ignition/heating
1.10 Ignition/heating
Ignition/heating, description
The engine features preheating of the induction air, for faster start
at low temperatures. Preheating is activated when the ignition key
is in position I. When preheating is activated the preheating symbol
illuminates in the display. The ignition key lock sends signals to Control
unit General (ECU790) which sends messages via CAN-bus drivetrain
to Control unit engine (ECU794).
For component locations see, see Engine, component location, page
1:5.
UDCF06.01GB
Maintenance Manual DCF 180–250
1 Engine – Start/stop
1:35
1.11 Start/stop
Start/stop, general
The electrical system operates at 24 volts.
The positive terminal is connected to a battery disconnector (A).
A-D
A
D
1.
When starting the gear selector must be in neutral position.
2.
Turn the ignition key lock to position 1, the preheating is activated
if the engine senses that it is required. The display shows the
preheating symbol down at the left-hand edge.
3.
Turn the ignition key lock to position 3, ECU790 sends a signal
to the engine via the CAN bus.
4.
The engine is stopped by the ignition key lock being turned to
position 0.
NOTE
The battery disconnector must not be used as an emergency
switch!
C
014409
B
A
Battery disconnector
B
Knob for opening the battery cover
C
Position for main current on
D
Position for main current off
There is a stop button on the engine that can be used to stop the engine
in an emergency, e.g. if the engine cannot be stopped by other means.
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1:36
UDCF06.01GB
Maintenance Manual DCF 180–250
2:1
2 Transmission
Contents 2 Transmission
2
2.3
2.6
2.7
2.8
Transmission ......................................................................................................2:3
Mechanical transmission..................................................................................2:6
Lubrication system ...........................................................................................2:7
Cooling system ..............................................................................................2:10
Control system transmission.......................................................................... 2:11
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2:2
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Maintenance Manual DCF 180–250
2 Transmission – Transmission
2:3
2 Transmission
Transmission, function description
The transmission transfers the engine power to the drive wheels (drive
axle) via the drive shaft and also power to drive the hydraulic oil pumps
for the hydraulic system.
The machine is equipped with ZF 3WG171.
The transmission is manual with torque converter. The transmission
has three gears in each direction.
The torque converter and transmission work together via a common
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 and the oil pump for control and lubrication
of the transmission are fitted on the torque converter but directly
connected to the torque converter input shaft, i.e. they are directly
driven by the engine and are not affected by the torque converter.
The gear position is selected by modulating pressure via electrical
valves that are controlled by the transmission control unit (ECU793).
The control unit uses sensors for pressure, temperature, and rpm to
decide which gear position should be activated as well as solenoid
valves to activate the gear.
Maintenance Manual DCF 180–250
UDCF06.01GB
2:4
2 Transmission – Transmission
Transmission, function description
3
F
R
1
F
N
°<
20
R
<°
R
6
1
4
5
19
2
18 Pa
ECU790
EDU795
16
17
UDS
ECU794
8
14
ECU793
7
9, 10, 11, 12, 13
SENSORS
5
15
014410
4
1.
Gear selector (S160)
11. Sensor output shaft speed (B758)
2.
Control unit general (ECU790))
12. Sensor temperature converter (B766)
3.
Switch parking brake (S107)
13. Sensor engine speed (B753)
4.
Oil pump transmission
14. Filter monitor
5.
Oil filter transmission
15. Transmission oil cooler
6.
Accelerator pedal (R690-1)
16. Control unit terminal (EDU795)
7.
Control unit, transmission (D793)
8.
Solenoid valves for travel direction and gear position
in valve block transmission control (KV, KR, K1-K3)
18. Break contact (opening switch) declutch (S1039)
9.
Sensor turbine speed (B751)
19. Switch for inching (S220-1)
17. Control unit engine (ECU794)
10. Sensor inner transfer shaft speed (B752)
UDCF06.01GB
20. Brake pedal potentiometer (R690-2)
Maintenance Manual DCF 180–250
2 Transmission – Transmission
2:5
Transmission, component location
1
2
3
4
5
12
6
11
7
8
014461
10
9
1.
Filter monitor
7.
Sensor inner transfer shaft speed (B752)
2.
Sensor engine speed (B753)
8.
Oil drain plug
3.
Output to oil cooler
9.
Sensor output shaft speed (B758)
4.
Sensor temperature converter (B766)
10. Oil filter transmission
5.
Input from oil cooler
11. Oil filling
6.
Sensor turbine speed (B751)
12. Transmission oil cooler
Maintenance Manual DCF 180–250
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2:6
2 Transmission – Mechanical transmission
2.3 Mechanical transmission
Mechanical transmission, description
The transmission is built with all gears in constant mesh. It is shifted
by hydraulic pressurising of clutch discs for each of the gears. The
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 FORWARD and REVERSE clutches are electro-hydraulically
modulated, which means that the clutch pressure is built up gradually.
This allows for switching between FORWARD and REVERSE and
vice versa whilst travelling at a speed that is lower than the set limit.
Modulation also allows for smooth shifts between FORWARD and
REVERSE.
High modulation (i.e. smooth driving/intensive slippage between gears)
gives high wear on the transmission and high oil temperature. Sensor
for oil temperature gives a warning when the oil is hotter than 120 °C.
If the oil temperature sensor indicates 125 °C the transmission stops
working.
There are three gears in each direction for the transmission.
Disengaging the drive normally takes place at a certain brake pressure.
The electronic gearshifting system is either manual or automatic. Using
inching
avoids the transmission being fully disengaged.
For component locations see Transmission, component location, page
2:5.
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Maintenance Manual DCF 180–250
2 Transmission – Lubrication system
2:7
2.6 Lubrication system
Lubrication system, description
The transmission has its own lubrication system that is used for
lubrication, control, and cooling of the transmission. The transmission
oil cooler is located at the bottom in the cooling unit behind the
engine, a thermostat in the cooler enables the oil to reach operating
temperature faster.
For component locations see Transmission, component location, page
2:5.
Oil and oil filter, change
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
NOTE
Do not over-fill the transmission!
NOTE
It is recommended that the transmission is calibrated after changing
the oil.
1
Operate and warm up the transmission oil.
2
Machine in service position, see section B Safety.
3
Place a container under the transmission.
4
Remove the drain plug for transmission oil and let the oil drain
into the receptacle.
NOTE
014746
Make sure that the drain plug's washer seal is also removed.
Drain plug transmission oil
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2:8
2 Transmission – Lubrication system
5
Clean the area around the oil filter.
6
Change oil filter.
Lubricate the O-ring on the new oil filter with transmission oil.
Tighten to contact and then another one-third to one-half turn.
7
When the transmission oil has drained, fit the drain plug.
NOTE
009416
Make sure that the washer for the oil plug is included.
Oil filter transmission
8
Remove the oil dipstick for transmission oil and fill new
transmission oil through the oil dipstick's filler pipe until the oil level
is at the bottom marking on the oil dipstick marked "COLD".
The oil dipstick has three marks. The lowermost, marked "COLD",
is a rough estimate for cold transmission. The two uppermost are
marked "HOT" and are marks for maximum, MAX, and minimum,
MIN, oil level at operating temperature. The oil level must be
between MIN and MAX.
For volume and quality, see section F F Technical data.
9
Start the engine and let it idle.
10 Check that the drain plug for transmission oil seals tightly.
11 Check the transmission oil level with the engine running at idle and
top up to the marking for "COLD".
12 Run the transmission to operating temperature by driving the
machine in all gears so that the transmission oil temperature is
80-90°C on the display.
a
Operating menu oil temperature
a
Transmission oil temperature
b
Battery voltage
UDCF06.01GB
b
006995
- +
Use operating menu to check the transmission oil temperature
(position a, upper horizontal row in display).
13 Check the transmission oil level and top up to the marking for
maximum level, MAX.
14 Calibrate the transmission, see Transmission, calibration, page
2:12.
Maintenance Manual DCF 180–250
2 Transmission – Lubrication system
2:9
Oil level, check
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
The transmission oil filling pipe and dipstick are under the hood on
the left-hand side of the machine.
1 Check the oil level with the engine idling, the transmission in
neutral, and at operating temperature (approx. 80-90°C on the
display).
The dipstick has three marks. The lowermost, marked "COLD", is
a rough estimate for cold transmission. The two uppermost are
marked "HOT" and are marks for maximum, MAX, and minimum,
MIN, oil level at operating temperature. The oil level must lie
between MIN and MAX when the transmission is hot at idle in
neutral.
Wipe off the dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
Transmission oil dipstick and filling
2
Fill the transmission oil through the filler pipe, if necessary. For
volume and quality, see section F F Technical data.
3
Fill - wait awhile - check the level marks on the oil dipstick.
NOTE
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil, which means risk
of transmission damage.
Maintenance Manual DCF 180–250
UDCF06.01GB
2:10
2 Transmission – Cooling system
2.7 Cooling system
Cooling system, description
The transmission is cooled by the lubrication system see Lubrication
system, description, page 2:7.
For component locations see Transmission, component location, page
2:5.
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Maintenance Manual DCF 180–250
2 Transmission – Control system transmission
2:11
2.8 Control system transmission
Control system transmission, description
Control unit transmission controls shifting based on signals from
pressure, temperature, and speed (rpm) sensors. Gear selection takes
place by activation of solenoid valves that distribute control pressure in
the transmission, so that the selected gear gives the right speed.
For component locations see section 11 Common electrics, group
11.5.3 Control units.
In the event of a fault in the transmission, use the control unit's four
different modes with reduced functionality in order to protect the
transmission: Substitute clutch control, Limp-home and Transmission
shutdown and ECU793 shutdown.
SUBSTITUTE CLUTCH CONTROL mode
Shown as an alarm in the KCS display if a fault arises.
In this mode, the operator can use the machine as usual. On the
other hand, shifting and changing direction are not under the control
of normal modulating. The control unit uses the standard values for
modulating the clutches.
LIMP-HOME mode
Shown as an alarm in the KCS display if a fault arises.
In this mode, the operator can use one of the transmission gears in
each direction, and in some cases only in one direction of travel. In
order to continue driving in the event of a fault with the “Limp home”
limitation the machine must be brought to a standstill, the gear selector
moved to neutral before the gear can be selected again.
TRANSMISSION-SHUTDOWN mode
Shown as an alarm in the KCS display if a fault arises.
In this mode, the transmission is permanently in the neutral position
when the solenoid valves for the clutches and elements of power to
the transmission are switched off. Park the machine and switch off
the engine.
ECU793-SHUTDOWN mode
Shown as an alarm in the KCS display if a fault arises.
In this mode, the transmission is permanently in the neutral position
when all solenoid valves and all power to the transmission are switched
off. Park the machine and switch off the engine.
Maintenance Manual DCF 180–250
UDCF06.01GB
2:12
2 Transmission – Control system transmission
Transmission, calibration
DANGER
Do not leave the machine during calibration. The
machine may start to move.
Stop the machine on level ground, select neutral, apply the parking
brake. Run the engine at idle and check the oil level and that the
transmission oil temperature is between 70-90 ºC.
2
To select the function to calibrate, first navigate to the service
menu. Then press Enter.
3
Enter the code for calibration.
000056
1
The code is obtained from Cargotec Support.
1 23
4 5
000060
NOTE
AUTOMATIC
2(2)
GEAR SHIFT ECU793
CALIBRATION
5
Select CALIBRATION by scrolling with the arrow keys (1 and 2)
and confirm with Enter.
6
Only shown when the engine is running.
007741
Select AUTOMATIC GEAR SHIFT ECU 793 by scrolling with the
arrow keys (1 and 2) and confirm with Enter.
1(2)
The signals for parking and declutch have been temporarily
disconnected to make it possible to run “Heat mode”, the highest
gear possible is always selected.
009098
CALIBRATION
4
007742
AUTOMATIC GEAR SHIFT
ECU793
The code determines which service menu shall be activated
(Service, Diagnostics, Initiation or Calibration).
GEARBOX HEAT MODE
ACTIVATE P-BRAKE!
7
CALIBRATION
Increase the oil temperature in the transmission as follows:
009541
FWD<->NTRL 15S CYCLE!
SELECTED GEAR F3
TEMPERATURE
70”C
“Heat Mode” is a function for heating the transmission when the
machine is stationary by using the parking brake to slow the
machine and allowing the converter to heat the gearbox oil.
A. Apply the parking brake so that the machine is stationary.
B. Select direction of travel forward or backward and apply half
to full throttle for 30 seconds.
C. Engage neutral position and apply half throttle for 15 seconds,
run the engine at idle.
D. Repeat steps B and C until the oil is above 70 °C or maximum
90 °C. The temperature display starts to flash when calibration
of the clutches can be started.
UDCF06.01GB
Maintenance Manual DCF 180–250
2 Transmission – Control system transmission
009101
CALIBRATION
>SELECT NEUTRAL
>P-BRAKE ACTIVE
>TEMP >70grC
8
Only shown when the engine is running. Press “Enter” to access
the next menu.
9
The following requirements must be fulfilled in order to start
calibration: Transmission in neutral position and parking brake
activated. Check that all requirements are fulfilled and that the
oil temperature is 70 ºC before proceeding to the next menu by
pressing Enter.
009100
CALIBRATION
2(2)
AUTOMATIC CLUTCH
FILLING PARAMETER
ADJUSTMENTS (AEB)
2:13
10 When the TCU has started the calibration the display shows
information about the calibration process in clear text. Any error
messages are also shown here.
009103
CALIBRATION
STATUS
K1 ADJUST!
11 During the calibration process engine speed is governed
automatically to a preset value that is adapted to each respective
transmission.
After completion of calibration the following text is shown in the
display: "ADJUSTMENT FINISHED SWITCH OFF IGNITION
FOR 5 SECONDS!"
12 Only shown when the engine is switched off and inching is
installed, this is an option.
2(2)
INCH PEDAL
009104
CALIBRATION
To able to see "CALIBRATION INCH PEDAL" requires that the
engine is already switched off, otherwise this is not shown at all.
--> Engine switched off = INCH PEDAL CALIBRATION Engine
running = AEB CLUTCH CALIBRATION
13 When the TCU has started the calibration the display shows
information about the calibration process in clear text. Any error
messages are also shown here.
PRESS PEDAL SLOW!
009105
CALIBRATION
STATUS
14 Depress the pedal slowly and hold until the information in the
display changes to "Release pedal slow!". Release the pedal
slowly.
If everything has worked the following is shown: ADJUSTMENT
FINISHED SWITCH OFF IGNITION FOR 5 SECONDS!"
Maintenance Manual DCF 180–250
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2:14
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Maintenance Manual DCF 180–250
3:1
3 Driveline/Axle
Contents 3 Driveline/Axle
3
3.2
3.3
Driveline/Axle......................................................................................................3:3
Propeller shaft..................................................................................................3:3
Drive axle .........................................................................................................3:4
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3:2
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Maintenance Manual DCF 180–250
3 Driveline/Axle – Driveline/Axle
3:3
3 Driveline/Axle
Driveline/Axle, description
The machine's power transmission consists of propeller shaft and drive
axle with differential and hub reduction.
3.2 Propeller shaft
Propeller shaft, description
The propeller shaft transmits the engine power from the transmission
to the drive axle.
Propeller shaft, checking
1.
Clean.
•
Check-tighten the retaining bolts at the mountings for the drive
axle and transmission to 98 Nm (oil).
•
Check clearance in universal joints.
014778
1
•
Propeller shaft
Maintenance Manual DCF 180–250
UDCF06.01GB
3:4
3 Driveline/Axle – Drive axle
3.3 Drive axle
Drive axle, description
The drive axle transmits the engine power to the wheels. After the
drive axle's input shaft there is a differential that changes the gear ratio,
distributes the power between the right and left drive wheel, and makes
it possible for the drive wheels to have different speeds when cornering.
The half shaft transmits the power from the differential to the wheel
hubs. At the wheel hubs there are hub reductions that change the gear
ratio between wheels and engine to reduce the stress on the half shaft.
1
2
3
014412
4
1.
Hub reduction
2.
Insert shaft
3.
Differential
4.
Drive axle housing
Drive axle, checking
UDCF06.01GB
1
Machine in service position, see section B Safety.
2
Check the drive axle's attachment to the frame so that there is no
corrosion on structural elements (e.g., attaching bolts).
Maintenance Manual DCF 180–250
3 Driveline/Axle – Drive axle
3
Check-tighten the drive axle's attaching bolts (position A) to
1350 Nm.
4
Visually inspect the drive axle's welding seams (position A) at the
mountings.
5
Check that the drive axles and hub reductions are sealed. Listen
for noise.
6
Check the bolted joint to the parking brake caliper's attaching plate
and brake disc.
7
Check whether the drive axles' wheel bearings have play by
means of the following:
A
014770
007804
A
3:5
–
Lift the machine under the mast beam. Support under the
drive axle in a secure way.
–
Check whether the drive axle's wheel bearings have play.
Loose bearings should be adjusted, see the Workshop
Manual.
Maintenance Manual DCF 180–250
UDCF06.01GB
3:6
3 Driveline/Axle – Drive axle
Drive axle oil, level check
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
Equipment: Receptacle (30 l).
1 Position the machine so that the drain plug on one of the hub
reductions is in the lowest position.
2
Turn off the engine and apply the parking brake.
3
Position a receptacle by the hub. Position a piece of sheet metal
or similar in the wheel rim to lead any oil to the receptacle.
4
Remove the level plug.
5
Check that the oil level is at the lower edge of the filler hole. Top
up as needed.
6
Fit the hub reduction's filler plug.
NOTE
Make sure that the sealing washer is fitted in place.
Repeat steps 1 and 6 on the other hub.
007845
7
Drive axle oil, changing
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
Equipment: Receptacle (30 l).
1 Position the machine so that the hub reductions' drain plugs at the
wheels are in the lowest position.
Wheel 1: move forwards or backwards to obtain the correct
position.
Wheel 2: lift the wheel from the ground (raise the machine under
the drive axle) and rotate the wheel into the correct position.
Lower the wheel.
2
Turn off the engine and apply the parking brake.
3
Place a receptacle under the differential carrier's drain plug.
NOTE
The drive axle has a capacity of approx. 44 l oil.
UDCF06.01GB
Maintenance Manual DCF 180–250
3 Driveline/Axle – Drive axle
3:7
4
Remove the differential carrier's drain plug.
5
Position a receptacle by each hub. Position a piece of sheet metal
or similar in the wheel rim to lead oil into the receptacle.
6
Remove the drain plug and the level plug.
7
Repeat steps 5 and 6 on the other hub.
8
When the oil has drained, fit the drain plugs.
NOTE
Make sure that the sealing washers are fitted in place.
007844
9
Fill one hub with oil until the oil level is at the lower edge of the
filler hole.
NOTE
The oil is very viscous, fill the oil slowly. Check the level in
stages so that the oil has time to settle.
10 Fit the hub reduction's filler plug.
NOTE
Make sure that the sealing washer is fitted in place.
007845
11 Repeat steps 9 and 10 on the other hub.
Maintenance Manual DCF 180–250
UDCF06.01GB
3:8
3 Driveline/Axle – Drive axle
12 Remove the filler plug for the differential carrier.
13 Fill the differential with new oil until the oil is level with the filler hole.
14 Fit the differential carrier's filler plug.
NOTE
Make sure that the sealing washer is fitted in place.
15 Remove and clean the drive axle's ventilation.
007846
16 Clean the axle from oil spillage.
17 Remove the receptacles and pieces of sheet metal. Handle the oil
as environmentally hazardous waste.
18 Test drive the machine for a short distance without load.
19 Check the oil level in hubs and differential carrier assembly.
UDCF06.01GB
Maintenance Manual DCF 180–250
4:1
4 Brakes
Contents 4 Brakes
4
Brakes..................................................................................................................4:3
4.1
Controls and instruments .................................................................................4:4
4.1.1
Brake pedal .................................................................................................4:4
4.3
Power-assisted brake system ..........................................................................4:5
4.3.6
Distribution block .........................................................................................4:8
4.5
Parking brake system ......................................................................................4:9
4.5.4
Parking brake unit ..................................................................................... 4:11
4.8
Temperature control, cleaning and hydraulic oil.............................................4:13
Maintenance Manual DCF 180–250
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4:2
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Maintenance Manual DCF 180–250
4 Brakes – Brakes
4:3
4 Brakes
Brakes, general
There are brakes to stop the machine. The brakes act on the drive axle
(steering axle does not have brakes).
The brake system is divided into three functions:
•
Power-assisted brake system, function description, page 4:5
•
Parking brake system, function description, page 4:9
•
Temperature control, cleaning and hydraulic oil, function
description, page 4:13
Maintenance Manual DCF 180–250
UDCF06.01GB
4:4
4 Brakes – Controls and instruments
4.1 Controls and instruments
4.1.1 Brake pedal
Brake pedal, checking and adjusting
1
Clean the floor around the brake pedal and check that nothing
blocks movement of the brake pedal.
2
Check that the brake pedal returns all the way and that the
clearance between the brake pedal and brake valve is 1–1.5 mm.
If needed, adjust the brake pedal's stop bolt so that the clearance
becomes correct.
3
Check that the pedal's travel is smooth.
4
Grease the pedal hinges with EP2 universal grease.
5
Check that the rubber on the pedal is intact and that the tread
pattern isn't worn out. Change when needed.
Stop bolt screw for adjusting clearance between brake
pedal and brake valve. (Illustration shows loose brake
pedal.)
Brake pedal lubrication points. (Figure shows
unattached brake pedal)
UDCF06.01GB
Maintenance Manual DCF 180–250
4 Brakes – Power-assisted brake system
4:5
4.3 Power-assisted brake system
Power-assisted brake system, function
description
The power assisted brake system consists of a hydraulic oil tank,
hydraulic oil pump, hydraulic oil filter, accumulator charging valve,
accumulator, brake valve, pressure sensors, brake cylinder and wheel
brake units.
The hydraulic oil pump pumps oil (from the tank) which is cleaned
in the oil filter. The accumulator charging valve directs pressure to
the accumulator that stores the pressure or directs the oil through the
wheel brake for cooling of the brake discs. The brake valve directs
pressure from the accumulator to the brake cylinder. The brake cylinder
compresses the discs in the brake units that brake the machine.
Make-contact (closing switch) brake pressure emits a signal so that the
brake light is switched on when the brake cylinder is pressurised.
When the accumulator is charged, the accumulator charging valve
directs oil through the drive axle's brake units; it cools the brakes and
then directs the oil back to the tank.
On machines with turnable operator's station there is an extra brake
pedal for driving backwards. This brake pedal is connected in parallel
with the brake pedal for driving forwards. A shuttle valve selects the
strongest pressure signal and forwards it to the wheel brakes.
Maintenance Manual DCF 180–250
UDCF06.01GB
4:6
4 Brakes – Power-assisted brake system
ECU790
12,14
D
<°
5
D
13b
B
Pa
10
P
T
D
16
13a Pa
11
4
Pa
9
C
C
6
B
15
3
P
8
X
ACC
7
T
P
B
C
2
B
1.
Hydraulic oil pump
10. Relay, brake light (K308-1)
2.
Hydraulic oil filter
3.
Accumulator charging valve
11. Break contact (opening switch), low accumulator
pressure
4.
Accumulator
12. Control unit general (ECU 790)
5.
Brake valve
13. a. Break contact (opening switch), declutch (S220)
6.
Distribution block
b. Inching potentiometer
7.
Brake cylinder
14. Control unit general (ECU 790)
8.
Wheel brake
15. Brake valve
9.
Make-contact brake lights (S216)
16. Shuttle valve
UDCF06.01GB
Maintenance Manual DCF 180–250
014413
1
4 Brakes – Power-assisted brake system
4:7
Power-assisted brake system, component
location
1
2
6
3
4
7
5
8
11
10
9
014415
12
1.
Hydraulic oil pump
7.
Shuttle valve
2.
Brake valve
8.
Distribution block
3.
Break contact (opening switch), low accumulator
pressure
9.
Wheel brake
4.
Make-contact brake lights (S216)
5.
Break contact (opening switch), declutch (S220)
6.
Accumulator charging valve
10. Hydraulic oil filter
11. Hydraulic oil tank
12. Accumulator
Maintenance Manual DCF 180–250
UDCF06.01GB
4:8
4 Brakes – Distribution block
4.3.6 Distribution block
Brake pressure, checking
1
Operate and warm up the machine so that the oil in the hydraulic
system reaches operating temperature, at least 50 ºC.
2
Machine in service position, see section B Safety.
3
Connect the pressure gauge to the measuring outlet on the
distribution block, see also Power-assisted brake system,
component location, page 4:7.
4
Start the engine and let it idle.
5
Depress the brake pedal and read the pressure. Compare with
the permissible pressure on the pressure plate (located next to the
cab tilting device for the machine).
6
Remove the pressure gauge and fit the protective cap on the
measuring outlet.
Measuring nipple, brake pressure on the distribution
block
UDCF06.01GB
Maintenance Manual DCF 180–250
4 Brakes – Parking brake system
4:9
4.5 Parking brake system
Parking brake system, function description
The parking brake consists of a hydraulic oil tank, hydraulic oil pump,
hydraulic oil filter, accumulator charging valve, accumulator, pressure
sensors, parking brake valve and parking brake unit.
The hydraulic oil pump pumps oil (from the tank) which is cleaned
in the oil filter. The accumulator charging valve directs pressure to
the accumulator that stores the pressure. The parking brake unit is
released with pressure from the accumulator by means of the parking
brake valve pressurising the parking brake caliper. Make-contact
(closing switch) parking brake emits a signal so that the symbol for
activated parking brake is shown when the parking brake is applied.
rpm
km/h
800
0
N
10
U
13
EDU795
F
N
R
R
1
4
ECU790
5
D
4
10,12
D
5,11
9
C
8 Pa
6
ACC
C
3
7
H
P
2
T
1
014414
B
1.
Hydraulic oil pump
8.
Break-contact parking brake (S200)
2.
Hydraulic oil filter
9.
Relay parking brake (K314)
3.
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 (Y642)
13. Control unit terminal (EDU 795)
7.
Parking brake unit
Maintenance Manual DCF 180–250
UDCF06.01GB
4:10
4 Brakes – Parking brake system
Parking brake system, component location
2
1
3
4
7
6
5
014416
8
1.
Hydraulic oil pump
5.
Parking brake unit
2.
Accumulator charging valve
6.
Hydraulic oil filter
3.
Make-contact (closing switch) parking brake (S200)
7.
Hydraulic oil tank
4.
Solenoid valve, parking brake (Y642)
8.
Accumulator
UDCF06.01GB
Maintenance Manual DCF 180–250
4 Brakes – Parking brake unit
4:11
4.5.4 Parking brake unit
Brake shoe lining, changing
1
Machine in service position and blocked wheels.
2
Remove the cover from the brake caliper. Check that there is no
oil inside the cover.
3
Loosen the lock nut.
4
Loosen the adjusting screw so that the brake pads become loose.
5
Remove the split pin and loosen the nut on the attaching bolt
holding the parking brake caliper.
6
Pull out the attaching bolt so that the brake pads can be twisted
out and removed.
NOTE
The bolt does not have to be removed.
7
Remove the parking brake pads.
8
Clean the brake disc with methylated spirit.
9
Fit the new parking brake pads.
10 Press back the attaching bolt.
11 Fit the nut and fit a new split pin.
12 Start the engine and let it idle.
13 Release the parking brake.
Maintenance Manual DCF 180–250
UDCF06.01GB
4:12
4 Brakes – Parking brake unit
14 Adjust the adjustment screw so that the brakes are applied.
15 Turn back the adjusting screw so that the clearance between pad
and disc becomes 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 on the caliper.
18 Check the function of the parking brake.
UDCF06.01GB
Maintenance Manual DCF 180–250
4 Brakes – Temperature control, cleaning and hydraulic oil
4:13
4.8 Temperature control, cleaning
and hydraulic oil
Temperature control, cleaning and hydraulic oil,
function description
The wheel brakes are cooled when the hydraulic oil is pumped through
the brake unit.
The temperature control system consists of hydraulic oil tank, hydraulic
oil pump, hydraulic oil filter, accumulator charging valve and wheel
brake units.
The hydraulic oil pump pumps oil (from the tank) which is cleaned
in the oil filter. When the accumulator is charged, the accumulator
charging valve directs oil through the drive axle's brake units; it cools
the brakes and then directs the oil back to the tank.
C
C
4
P
2
T
5
3
002611
1
1.
Hydraulic oil pump
4.
Wheel brake
2.
Hydraulic oil filter
5.
Bypass valve in distribution block
3.
Accumulator charging valve
Maintenance Manual DCF 180–250
UDCF06.01GB
4:14
4 Brakes – Temperature control, cleaning and hydraulic oil
Temperature control, cleaning and hydraulic oil,
component location
2
1
3
5
4
014417
6
1.
Hydraulic oil pump
4.
Wheel brake
2.
Accumulator charging valve
5.
Hydraulic oil filter
3.
Bypass valve in distribution block
6.
Hydraulic oil tank
UDCF06.01GB
Maintenance Manual DCF 180–250
5:1
5 Steering
Contents 5 Steering
5
Steering ...............................................................................................................5:3
5.2
Power assisted system ....................................................................................5:4
5.2.6
Link arm ......................................................................................................5:9
5.2.11
Sensor steering wheel reading....................................................................5:9
Maintenance Manual DCF 180–250
UDCF06.01GB
5:2
UDCF06.01GB
Maintenance Manual DCF 180–250
5 Steering – Steering
5:3
5 Steering
Steering, general
The function steering means to steer the machine while operating. The
machine is steered with the rear wheels by a power-assisted steering
system.
Joystick or mini-wheel steering is available as an option and means
that the machine is steered electronically by a control in the driver
seat armrest.
On machines with turnable operator's stations, the steering reading is
alternated with the directional control valve for the turnable operator's
station when driving with the operator's station turned backward so that
the steering wheel actuation and steering deflection are in agreement.
Maintenance Manual DCF 180–250
UDCF06.01GB
5:4
5 Steering – Power assisted system
5.2 Power assisted system
Power assisted system, function description
The function power assisted system refers to steering the machine.
The machine's steering is power-assisted with pressure from the
hydraulic oil pump for steering and load handling.
Steering consists of steering wheel, steering wheel shaft, steering
valve, hydraulic oil pump, priority valve, steering cylinder, link arms
and wheel spindles.
The steering wheel (via the steering shaft) acts on the steering valve
which in turn directs oil pressure from the hydraulic oil pump to the
steering cylinder. The priority valve, located between the hydraulic oil
pump and the steering valve, gives priority to oil supply for the steering
valve ahead of load handling. The steering cylinder acts on the wheel
spindles. The link arms are located between the steering cylinder and
wheel spindles.
5
2
PP
C
P
LS
CF
6
T
P
LS
L
T
R
3
4
7
014418
1
1.
Hydraulic oil pump
5.
Steering wheel
2.
Priority valve
6.
Steering valve
3.
Shuttle valve
7.
Steering cylinder
4.
Shuttle valve
UDCF06.01GB
Maintenance Manual DCF 180–250
5 Steering – Power assisted system
5:5
Power-assisted system, turnable operator's
station, function description
On machines with turnable operator's stations, the steering reading is
alternated with the directional control valve for the turnable operator's
station when driving with the operator's station turned backward so that
the steering wheel actuation and steering deflection are in agreement.
10
10
5
R
D
2
PP
C
ECU790
6
P
CF
11
P
LS
LS
T
3
T
4
L
R
8
1
7
7
D
014419
9
1.
Hydraulic oil pump
8.
Directional control valve
2.
Priority valve
9.
Steering cylinder
3.
Shuttle valve
4.
Shuttle valve
10. End position switch, seat forward (S720-1) and seat
backward (S720-2)
5.
Steering wheel
6.
Steering valve
7.
Solenoid valve steering forward (Y636-1) and
steering backward (Y636-2)
11. Control unit (ECU 790)
Maintenance Manual DCF 180–250
UDCF06.01GB
5:6
5 Steering – Power assisted system
Power-assisted system, mini-wheel/joystick
control, function description
Joystick control or mini-wheel steering means that the machine is
controlled by an electrical control in the left armrest of the operator's
seat. The electrical control sends signals to the control system. The
steering cylinder is pressurised by a control valve that is also controlled
by the control system.
Joystick control 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 control
or mini-wheel steering. Joystick control or mini-wheel steering are
disabled as soon as a steering wheel movement is made.
UDCF06.01GB
Maintenance Manual DCF 180–250
5 Steering – Power assisted system
5:7
Condition
Reference value
Joystick control
activated
Voltage signal from switch mini-wheel/joystick steering.
Steering wheel
stationary
No signal from sensor steering wheel reading.
Speed
Under 2 km/h (when activated)
Control breaker
Not activated
6
7
ECU790
8
9
ECU792
EDU795
5
D8
D4
10
4
C1
D7
D10
14
P
3
13
12
EF
LS
2
11
Ps
P
Ts
T
T
CL
CR
L
R
014840
1
15
1.
Hydraulic oil pump
9.
2.
Shuttle valve
10. Sensor steering column (B770)
Steering wheel
3.
Shuttle valve
11. Steering valve
4.
Feedback joystick control: Sensor, wheel angle
(R807)
12. Steering control valve
5.
Control unit terminal (EDU 795)
6.
Control unit general (ECU 790)
7.
Control unit, steering (ECU 792)
8.
Potentiometer, joystick control (R825) mini-wheel
(R825)
13. Solenoid valve, steering (Y615)
14. Priority valve
15. Steering cylinder
Maintenance Manual DCF 180–250
UDCF06.01GB
5:8
5 Steering – Power assisted system
Power assisted system, component location
2
3
6
4
7
1
5
8
15
9
14
13
11
10
014421
12
12
1.
Steering cylinder
8.
Steering valve
2.
Hydraulic oil pump
9.
Steering valve (for joystick control/mini-wheel)
3.
Steering control valve
10. Sensor steering wheel reading (B770)
4.
Solenoid valve, steering (Y615)
11. Directional control valve
5.
Priority valve (for joystick control/mini-wheel)
12. Solenoid valve (Y636-1 and Y636-2)
6.
Priority valve
13. Hydraulic oil tank
7.
Potentiometer, joystick control (R825) mini-wheel
(B825)
14. Sensor (S720-1 and S720-2)
UDCF06.01GB
15. Shuttle valve
Maintenance Manual DCF 180–250
5 Steering – Link arm
5:9
5.2.6 Link arm
Link arm, checking
007918
Check the link arms' guide bearings, axles and the bolts that lock
the link arms' axles.
5.2.11 Sensor steering wheel reading
Sensor steering wheel reading, checking
1
(product option mini-wheel or joystick steering)
Check that the joystick control and mini-wheel disconnect when the
steering wheel is turned.
Also check that the sensor for the steering wheel reading is secure in
its bracket and that the multi-function levers are secure by unfastening
the bottom of the steering wheel panel.
014420
2
1.
Metal plate (with four gears)
2.
Sensor steering wheel reading
Maintenance Manual DCF 180–250
UDCF06.01GB
5:10
UDCF06.01GB
Maintenance Manual DCF 180–250
6:1
6 Suspension
Contents 6 Suspension
6
Suspension .........................................................................................................6:3
6.2
Suspension ......................................................................................................6:4
6.2.1
Steering axle cradle ....................................................................................6:4
6.2.2
Wheel spindle..............................................................................................6:5
6.2.3
Wheel hub ...................................................................................................6:5
6.3
Tyres and rims .................................................................................................6:7
6.3.1
Tyres .........................................................................................................6:19
6.3.2
Rim ............................................................................................................6:20
Maintenance Manual DCF 180–250
UDCF06.01GB
6:2
UDCF06.01GB
Maintenance Manual DCF 180–250
6 Suspension – Suspension
6:3
6 Suspension
Suspension, description
The machine's wheel suspension is made up of its tyres (with
associated rims and bolts), steering axle with hubs, wheel spindles,
and the steering axle's suspension in the frame. The drive axle belongs
to the power transmission, see section 3 Power transmission, group
3.3 Drive axle.
Maintenance Manual DCF 180–250
UDCF06.01GB
6:4
6 Suspension – Suspension
6.2 Suspension
Suspension, description
The steering axle cradle is mounted 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 journalled shafts. The wheel spindle is flexible to enable
steering. On the wheel spindles there are journalled wheel hubs where
the wheels are mounted.
Suspension, component location
Suspension refers to:
4
2
5
1
•
Steering axle cradle
•
Steering spindle
•
Wheel hub
11
10
9
8
7
1.
Steering axle cradle
2.
Attaching lug
3.
Rubber damper
4.
Tyres
5.
Rim
6.
Steering cylinder
7.
Piston rod
8.
Link arm
9.
Wheel spindle
6
007811
3
10. Hub
11. Bolts
6.2.1 Steering axle cradle
Steering axle cradle, checking
UDCF06.01GB
1
Machine in service position, see section B Safety, with transverse
wheels.
2
Check that the bushings in the suspension are intact.
Maintenance Manual DCF 180–250
6 Suspension – Wheel spindle
6:5
3
Measure the distance between the frame and the steering axle
cradle. Note the measurement.
4
Lift the machine under the rear counterweight.
NOTE
Do not lift under the steering axle.
5
Again, measure the distance between the frame and the steering
axle cradle. Note the measurement.
6
Calculate the difference between the two measurements. The
difference may be max. 3 mm. If the difference is greater, the
bushing must be replaced.
6.2.2 Wheel spindle
Wheel spindle bearing, checking
1
Machine in service position, see section B Safety, with transverse
wheels.
2
Measure dimension A with a feeler gauge. Note the measurement.
3
Lift the machine under the rear counterweight.
4
Re-measure measurement A.
5
Calculate the difference between the two measurements. The
difference must be max. 0.25 mm.
If the difference is greater, shimming must be repeated, see
Workshop manual.
007812
A
6.2.3 Wheel hub
Wheel hub, checking
Clean the hub covers on the control wheels.
2
Remove the hub cover.
3
Wipe off grease from hub cap and hub nut. Handle it as
environmentally hazardous waste.
007859
1
Maintenance Manual DCF 180–250
UDCF06.01GB
6:6
6 Suspension – Wheel hub
4
Bend up the lock washer's tabs, remove the lock nut and the
locking washer.
5
Torque the bearing nut as follows.
A. Lube the thread on the spindle and the side of the nut that
faces the bearing with oil SAE 80W/140 or equivalent.
B. Tighten the nut while the wheel hub is being rotated.
C. Rotate the wheel hub at least ten turns.
D. Retighten the nut while the wheel hub is being rotated.
009177
E. Repeat points B-D until the nut cannot be tightened any
further.
F.
Check the friction resistance in accordance with the following:
The lower limit for zero play is obtained when the bearing is
tensioned until no play is felt when the wheel is tilted.
The upper limit can be checked with a spring balance, which
gives maximum friction torque. The friction torque should be
about 19 Nm.
510 mm
009580
Max 8 kg
Wind a wire rope a few turns around the wheel bolts before the
wheel is fitted and suspend with a spring balance. Read from the
spring balance when the hub rotates.
6
Fit the lock washer and outer lock nut.
7
Tighten to at least 250 Nm or as tight as required to fold the
locking washer into the closest groove.
8
Fill the bearing cap 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 pressing
out of air. Grease until grease comes out by the seal.
NOTE
Be careful so that the seal is not damaged.
UDCF06.01GB
Maintenance Manual DCF 180–250
6 Suspension – Tyres and rims
6:7
6.3 Tyres and rims
Tyres and rims, safety
DANGER
Always block wheels on the side of the axle that is
not going to be worked on before placing the jack.
Always secure the jack to prevent it from slipping out
of position.
Deflate the tyres before removing. Otherwise the lock
ring and lock lugs can release and shoot off when the
pressure changes. For twin tyres, both tyres must be
deflated!
The air should always be released through the valve. If
this is not possible - drill holes in the tread to release
the air. Damaged tyres may explode.
Never stand in front of the tyre when deflating or
inflating. Lock ring and lock lugs may release and
shoot off when the pressure changes.
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, tyres, and rims are dimensioned and selected
for each machine type so that max. wheel loads
and operating speeds are not exceeded. Therefore,
changing of tyre dimension, tyre brand, tyre type, rim
type, or rim brand is not permitted without approval
from Cargotec.
Maintenance Manual DCF 180–250
UDCF06.01GB
6:8
6 Suspension – Tyres and rims
CAUTION
When removing wheels, leave the wheel nuts in place
after they have been loosened. If the wheel nuts are
removed immediately the wheel may release from the
hub.
When removing drive wheels, make sure that the
wheels are secured when removing the spacer rings.
If the wheels move they may move the spacer rings,
which may result in crushing injuries.
When installing drive wheels, ensure that the clamps
clamp straight on the spacer ring.
Wheel nuts should be check-tightened after 4-5
operating hours.
Always follow the tyre manufacturer's or other approved
instructions when changing tyres.
Never use a steel hammer to install or remove rim
components. Instead, use a lead, brass, or plastic
mallet.
Keep tyre pressures at the prescribed level. Loosely
inflated tyres impair stability and reduce the machine's
capacity.
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 points of contact between the machine and the
ground, and the tyres absorb unevennesses and provide suspension.
The drive axle is exposed to high forces during operation, if the drive
wheels' rolling circumference is different the stresses increase on
the drive axle. It is important that the tyres on the drive axle are the
same model, type and make, and have equal wear and proper inflation
pressure.
Tyres and rims, check
Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:7.
UDCF06.01GB
Maintenance Manual DCF 180–250
6 Suspension – Tyres and rims
6:9
DANGER
Never stand in front of the tyre when deflating or
inflating! Lock ring and lock lugs may release and
shoot off when the pressure changes.
The air should always be released through the valve. If
this is not possible - drill holes in the tread to release
the air. Damaged tyres may explode.
Do not exceed prescribed air pressure! When changing
tyre or rim version, another air pressure may apply,
contact Cargotec.
1
1
2
3
4
Check the rims.
•
Check that the spacer rings and clamps are installed correctly.
•
Check that there are no cracks in the rims' parts.
In case of damage, the tyre and rim must be removed and
checked.
007892
6
5
1. Inner rim
2. Outer rim
3. Inner spacer ring
4. Outer spacer ring
5. Clamp
6. Nut
Maintenance Manual DCF 180–250
UDCF06.01GB
6:10
6 Suspension – Tyres and rims
2
Check the air pressure in the tyres, see section Tyres, inflating,
page 6:19.
The pressure must be 1.0 MPa, inflate if necessary.
3
Check the tyres.
•
Check for uneven and fast wear, this is caused by mechanical
defects such as, e.g., uneven brake action. Make sure that
such defects are repaired immediately.
•
Remove penetrating objects such as crushed glass, pieces of
wood, metal filings, etc.
If the tyre is damaged, the wheel shall be dismantled and the tyre
shall be changed, see Tyre, change, page 6:20.
4
If the tyres and rims have no defects, check-tighten the wheel nuts.
Tighten crosswise to a torque of:
350 Nm.
013940
•
Examples: The figure shows inflation of drive wheel.
UDCF06.01GB
Maintenance Manual DCF 180–250
6 Suspension – Tyres and rims
6:11
Tyre and rim system, removing and fitting (drive
axle)
Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:7.
Removing
1
Machine in service position, see section B Safety.
2
Lift the machine under the mast or under the drive axle with a
jack at the wheel in question. Support under the drive axle in
a secure way.
DANGER
With double wheel fitting both tyres must be deflated
otherwise the inner may explode when the outer is
removed.
Risk of tyre explosion! Fatal danger!
Empty both tyres of air.
Maintenance Manual DCF 180–250
UDCF06.01GB
6:12
6 Suspension – Tyres and rims
3
Release the air from the tyres by:
Unscrewing the valve and releasing the air.
b)
If this does not work, undo the valve in the rim and release the air.
c)
If this does not work, break off, cut or saw off the valve pipe.
d)
If it is not possible to release the air via the valve connection, the
tyre must be emptied by drilling a hole in the tyre's tread. Use a
drill bit of a max. Ø 5 mm.
005123
014572
014573
014571
a)
Loosen the inner drive wheel's valve from the bracket.
007881
4
UDCF06.01GB
Maintenance Manual DCF 180–250
6 Suspension – Tyres and rims
6:13
Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
6
Remove all wheel nuts and clamps.
7
Remove the spacer ring.
007878
005124
5
Pull the wheel out a bit so that the spacer ring comes loose.
NOTE
The spacer ring weighs approx. 20 kg.
Lift the outer wheel away and position it safely so that it does not
fall or move.
9
Secure the inner drive wheel with lifting equipment.
007879
8
Maintenance Manual DCF 180–250
UDCF06.01GB
6:14
6 Suspension – Tyres and rims
10 Remove the spacer ring between the outer and inner drive wheel.
NOTE
The spacer ring weighs approx. 20 kg.
007880
11 Remove the inner drive wheel and position it safely so that it does
not fall or move.
Installing
Make sure the mounting surfaces (location A) on the hub and
wheel are clean and free from paint and grease.
2
Lift the inner wheel into place with lifting equipment. Turn the
wheel so that the guide lug runs into the groove on the hub. This
work is facilitated if the hub's groove is aligned towards the top
and bottom.
3
Fit the inner spacer ring.
007882
1
NOTE
007880
The inner ring is not split.
UDCF06.01GB
Maintenance Manual DCF 180–250
6 Suspension – Tyres and rims
6:15
Lift the outer wheel into place with lifting equipment. Turn the
wheel so that the guide lug enters the groove on the hub.
5
Fit the outer spacer ring.
007883
4
NOTE
007884
The outer spacer ring is spit. Turn the ring so that the opening
ends up directly opposite the groove on the hub.
6
Fit clamps and nuts on the wheel studs. Fit washers as well where
applicable.
NOTE
Don not forget the bracket for the inner tyre's valve extender.
Remove the lifting equipment.
8
Tighten the wheel nuts crosswise, start at the guide lugs and move
outwards to prevent the spacer rings from aligning incorrectly.
9
Tighten the wheel nuts crosswise in turn with increasing torque
to 350 Nm.
007878
7
10 Fill wheel with air, see Tyres, inflating, page 6:19.
11 Lower the axle and remove the jack.
12 Test-drive the machine and check that the wheels are secure.
007885
13 Check-tighten the wheel nuts crosswise to a torque of 350 Nm.
Maintenance Manual DCF 180–250
UDCF06.01GB
6:16
6 Suspension – Tyres and rims
Tyre and rim system, removing and fitting
(steering axle)
Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:7.
Removing
1
Machine in service position, see section B Safety.
2
Lift the machine under the steering axle at the wheel in question
with a jack. Support under the steering axle in a secure way.
3
Release the air from the tyres by:
Unscrewing the valve and releasing the air.
b)
If this does not work, undo the valve in the rim and release the air.
014573
014571
a)
UDCF06.01GB
Maintenance Manual DCF 180–250
6 Suspension – Tyres and rims
6:17
If this does not work, break off, cut or saw off the valve pipe.
d)
If it is not possible to release the air via the valve connection, the
tyre must be emptied by drilling a hole in the tyre's tread. Use a
drill bit of a max. Ø 5 mm.
005123
014572
c)
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
Make sure the mounting surfaces on the hub and wheel are clean
and free from paint and grease.
8
Lift the wheel into place with lifting equipment.
005124
7
Adjust the position of the wheel so that the steering pin passes
over the notch in the hub and so that the wheel is lying against
the hub.
Maintenance Manual DCF 180–250
UDCF06.01GB
6:18
6 Suspension – Tyres and rims
9
Fit clamps and nuts on the wheel studs. Fit washers as well where
applicable.
10 Remove the lifting equipment.
11 Fit the wheel. Tighten the wheel nuts crosswise in turn with
increasing torque to 350 Nm.
12 Fill wheel with air, see Tyres, inflating, page 6:19.
13 Lower the axle and remove the jack.
14 Test-drive the machine and check that the wheels are secure.
000383
15 Check-tighten the wheel nuts crosswise to a torque of 350 Nm.
UDCF06.01GB
Maintenance Manual DCF 180–250
6 Suspension – Tyres
6:19
6.3.1 Tyres
Tyres, inflating
Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:7.
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 install rim components by striking with a
hammer while inflating. Never strike fully or partly
inflated tyres or rim sets.
Never inflate tyres before all parts are in place.
Wheels shall be inflated on the machine or in a
protective device, designed and dimensioned so that
it can handle or dissipate a shock wave from a tyre
explosion as well as catch the ejected parts.
013940
Do not exceed the prescribed tyre pressures which
must be checked at ambient temperature. When
changing tyre or rim version, another air pressure
may apply, contact Cargotec. Plate for air pressure
in tyres must be replaced with a plate that shows
applicable pressure.
Examples: The figure shows inflation of drive wheel.
Never stand in front of the tyre when deflating or
inflating. Lock ring and lock lugs may release and
shoot off when the pressure changes.
Check that all parts are in place when the tyre
pressure 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
position before inflating.
2
Connect the compressor with a locking air-chuck to the nipple
on the tyre.
3
Stand at an angle behind the tyre and remain there until inflating
has been completed in order to prevent being hit by rim parts in
the event of an explosion.
4
Inflate the tyre to prescribed pressure, see specifications.
When changing tyre or rim version, another air pressure may
apply, contact Cargotec.
Maintenance Manual DCF 180–250
UDCF06.01GB
6:20
6 Suspension – Rim
Tyre, change
DANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
Leave tyre work to authorised personnel/tyre company.
Check the rim in connection with tyre change, see Rim, check, page
6:20.
6.3.2 Rim
Rim, check
DANGER
Perform the following checks to minimise risks of
accidents for all split rims.
Always use the right tyre size and a design
corresponding to the manufacturer's rim type and size.
Over-dimensioned tyres may not be used.
Replace all damaged, worn or corroded rims or
mounting parts.
Dismantle the rim, see Tyre, change, page 6:20.
2
Carefully clean the outside of the rim edge with a steel brush.
3
Measure wear after the lock ring.
001703
1
The lock ring's wear on the tyre bead often gives a mark, A in the
figure. The mark occurs between the lock ring's ends.
Measure wear depth at point A using a steel ruler and sliding
gauge. If wear exceeds 0.5 mm then the wheel rim, lock ring and
the tapered rim must be discarded and replaced with new parts.
A
001715
Max 0,5 mm
UDCF06.01GB
Maintenance Manual DCF 180–250
6 Suspension – Rim
4
6:21
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 specified min.
measurement. If diameter is smaller, then the wheel rim, lock
ring, and the tapered rim must be discarded and replaced with
new parts.
Information about min. diameter can be obtained from Cargotec.
O
001701
D
O. Circumference
D. Diameter
5
Check for damage in the areas with high stress concentration.
Checking is done in two steps:
1.
The magnetic particle 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.
001702
Typical rim damages are circumference cracks, corrosive damage,
rust, warping and wear.
001703
Magnetic particle method
Rim
1
Blast the applicable area clean so that it is completely free of
paint residue.
2
Test using magnetic particle inspection and the following
equipment:
•
Equipment: Yoke Tiede
•
Method:
•
a
Alternating current AC
b
Contrast colour
Checking medium:
a
Wet
b
Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic particle method,
checking is finished and the applicable area is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.
Maintenance Manual DCF 180–250
UDCF06.01GB
6:22
6 Suspension – Rim
001704
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.
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.
Rim
1
2
4
Spray detection fluid part no. 923626.0670 on the area.
5
Let the sprayed area dry 1-2 hours.
6
Visually inspect the area.
If the tested area does not show signs of linear or point-shaped
cracks, it is approved.
001705
If the crack check indicates linear or point-shaped cracks, contact
Cargotec Support.
Examples of cracks
1.
Linear crack
2.
Pointed crack
UDCF06.01GB
Maintenance Manual DCF 180–250
7:1
7 Load handling
Contents 7 Load handling
7
Load handling .....................................................................................................7:3
7.2
Lifting/lowering .................................................................................................7:4
7.2.6
Mast ............................................................................................................7:7
7.2.8
Chains .........................................................................................................7:8
7.2.14
Support roller...............................................................................................7:9
7.2.15
Top support roller ......................................................................................7:10
7.4
Side shift ........................................................................................................ 7:11
7.4.4
Side shift cylinder ......................................................................................7:13
7.5
Spreading.......................................................................................................7:14
7.7
Tilt ..................................................................................................................7:18
7.7.5
Tilt cylinder ................................................................................................7:22
7.8
Levelling.........................................................................................................7:23
7.9
Load carrier....................................................................................................7:27
7.9.1
Lifting forks ................................................................................................7:27
7.9.2
Coil ram .....................................................................................................7:29
7.10
Other functions...............................................................................................7:30
7.10.1
Scales .......................................................................................................7:30
7.10.5
Side lift attachment....................................................................................7:31
Maintenance Manual DCF 180–250
UDCF06.01GB
7:2
UDCF06.01GB
Maintenance Manual DCF 180–250
7 Load handling – Load handling
7:3
7 Load handling
Load handling, general
The load handling function refers to lifting, lowering, side shifting and
tilting the load for example.
013929
Load handling has been divided into the following subfunctions:
Lifting/lowering
•
Tilt
•
Side shift
•
Spreading
•
Levelling
•
Load carrier
•
Side lift attachment
013930
Lifting/lowering
•
007916
Tilt
007910
Side shift
007917
Spreading
Levelling
Maintenance Manual DCF 180–250
UDCF06.01GB
7:4
7 Load handling – Lifting/lowering
7.2 Lifting/lowering
Lifting/lowering, description
Lifting/lowering means that the mast's components are raised and
lowered so that the fork carriage is raised and lowered. During lifting,
the inner mast is raised with the lift cylinders. The chain that is secured
in the carriage (and in the outer mast) runs over the chain wheel at
the top of the mast. By these means the carriage is also lifted at the
same time as the inner mast.
. The
The machine can be equipped with a special free-lift mast
fork carriage is raised in two stages, first the free-lift stage and then the
lifting stage. In the free-lift stage the fork carriage is raised to the top of
the inner mast (machine transport height is not affected) In the lifting
stage the inner mast is lifted to its max. position (machine transport
height is affected).
The free-lift cylinder and the lift cylinders are pressurised by the control
valve for load handling.
There are two versions of the lifting/lowering function, depending on
how the function is controlled:
•
Hydraulic servo means that the control levers are supplied with
hydraulic pressure, which controls the lifting/lowering function.
•
Electric servo means that the control levers are electrical and send
voltage signals to the control system to control the lifting/lowering
function.
In order to absorb and dampen the pressure surges that arise when
running on an uneven surface a piston accumulator is connected via a
male stud branch tee between the control valve and the lift cylinders.
The accumulator absorbs the pressure surges that arise when running
on an uneven surface and in the event of a sudden stop of the lowering
movement. This way the harmful impact on the hydraulic system and
mechanical parts is reduced, while operator comfort is improved.
UDCF06.01GB
Maintenance Manual DCF 180–250
7 Load handling – Lifting/lowering
7:5
Lifting/lowering, function description (hydraulic
servo)
9
7
8
5
11
10
C
4
T
C
6
PS
B2
11
P
EF
P
10
P
LS
T
A2
9
7
3
C
C
2
12
014428
1
8
1.
Hydraulic oil pump
7.
Load control valve
2.
Hydraulic oil pump
8.
Load control valve
3.
Shuttle valve
9.
Lift cylinder
4.
Priority valve
10. Load control valve
5.
Control lever, lifting/lowering
11. Free-lift cylinder
6.
Control valve load handling
12. Hydraulic oil filter
Maintenance Manual DCF 180–250
UDCF06.01GB
7:6
7 Load handling – Lifting/lowering
Lifting/lowering, function description (electric
servo)
Condition
Reference value
Control breaker
Not activated
11
9
6 ECU796
10
5
D
D
13
12
7
T
8
B2
C
4
13
P
EF
12
P
LS
T
A2
P
11
9
3
C
C
2
14
014427
1
10
1.
Hydraulic oil pump
8.
Control valve load handling
2.
Hydraulic oil pump
9.
Load control valve
3.
Shuttle valve
10. Load control valve
4.
Priority valve
11. Lift cylinder
5.
Control lever lifting/lowering (R8071)
12. Load control valve
6.
Control unit, hydraulics (ECU 796)
13. Free-lift cylinder
7.
Solenoid valve, lift mast (Y6005) lower mast (Y6004)
14. Hydraulic oil filter
UDCF06.01GB
Maintenance Manual DCF 180–250
7 Load handling – Mast
7:7
Lifting/lowering, component location
3
4
5
2
1
6
8
7
9
14
10
11
13
1.
Hydraulic oil pump for steering and load handling
8.
Lifting mast
2.
Hydraulic oil pump for lifting/lowering and tilt
9.
Lift cylinder
3.
Priority valve
10. Load control valve
4.
Control valve load handling, hydraulic servo
11. Load control valve
5.
Control valve load handling, electric servo
12. Free-lift cylinder
6.
Solenoid valve, lift mast (Y6005) (electric servo)
13. Shuttle valve
7.
Solenoid valve, lower mast (Y6004) (electric servo)
14. Hydraulic oil tank
014422
12
7.2.6 Mast
Mast suspension, checking bearings
1
Raise and secure the trolley
WARNING
Never work under a trolley that is not secured.
Risk of crushing!
Secure the trolley properly before beginning work.
2
Machine in service position, see section B Safety.
Maintenance Manual DCF 180–250
UDCF06.01GB
7 Load handling – Chains
3
Make a marking on the mast.
4
Remove the load from the mast mountings in an appropriate
manner.
5
Make a new marking on the mast. Measure the distance between
the markings. The measurement should be max. 2 mm.
6
If the difference is greater, the bearings in the mast mountings
must be replaced, see Workshop manual.
009520
7:8
7.2.8 Chains
Lifting chains, checking and adjusting
With the aim of increasing safety, the lifting chains should be checked
regularly according to the following:
The chains must be thoroughly cleaned over their entire length. The
check is performed without a load on the forks.
Wear checking
The chain must not have extended more than 3%. Measure the
length of the 25 links that first (and most often) travel over the
chain wheel during lifting. This is where the extension is greatest.
Compare with the value in the table. If the 3% limit is exceeded,
the chains must be replaced.
2
P-measurement = the distance between 2 pins
005670
1
P-measurement
[in]
P-measurement
[mm]
3/4
Measurement over 25 links
[mm]
New chain
Max.
measurement
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 pitch, it is possible to use a special
measuring tape intended to measure the wear.
The measuring tape is marked with:
•
Zulässige Verlängerung = permitted lengthening.
•
Kette austauschen = chain must be replaced.
The measuring tape can be ordered from Cargotec.
Adjusting
UDCF06.01GB
3
Check that the pins for the outer washers are securely fastened.
4
Check that the washers are free of visible cracks.
5
Check that the chain is free from mechanical damage.
6
Check that the chain is free of rust.
Maintenance Manual DCF 180–250
7 Load handling – Support roller
7:9
7
Check that the chain bends easily over the pulley (does not jam
when bending).
8
Place the machine on level surface with the mast vertical (0° tilt).
9
Lower the carriage to the bottom position.
10 Check that there is 10-20 mm of clearance between the underside
of the forks and the ground. Adjust the position by tensioning or
loosening the chains equally on the adjustment nut in the carriage.
NOTE
If the chain is slack when the carriage is in its lowest position,
the chain must be tightened.
11 Adjust the chains so that the carriage is lifted evenly in the mast.
•
Loosen the locking washers (position 1) and remove the lower
nut (position 2).
•
Lift the chain tightener (position 4) out of the carriage and
remove the old locking washer.
•
Reinstall with new locking washer, chain tightener, locking
washer and lower nut. Repeat on the other side.
3
NOTE
1
4
007850
2
Reinstall only new locking washers.
•
Adjust the nuts on each side to balance the carriage so that
the distance between the carriage and mast is 10-20 mm.
•
Tighten the nuts with 2000 Nm and lock them with locking
washers.
•
1.
Locking washer
2.
Lower nut
Test lift and check that the lifting chain stretches equally on
each side so that the carriage is balanced.
3.
Upper nut
Repeat adjustments as needed.
4.
Chain tightener
12 Lubricate the chains after completed inspection.
7.2.14 Support roller
Support roller, checking
Machine in service position.
2
Check that the support rollers run correctly and that all surfaces
of the support rollers and contact faces against the mast have a
normal appearance.
007851
1
Example of support roller
Maintenance Manual DCF 180–250
UDCF06.01GB
7:10
7 Load handling – Top support roller
7.2.15 Top support roller
Support roller, checking
See Support roller, checking, page 7:9.
UDCF06.01GB
Maintenance Manual DCF 180–250
7 Load handling – Side shift
7:11
7.4 Side shift
Side shift, description
Side shift means moving the lifting forks sideways. Control valve, load
handling, pressurises the side shift and spreading cylinders which
extend the fork brackets on the fork carriage in relation to the mast.
During side shift the rod side of one of the side shift and spreading
cylinders is pressurised. The pressure from the piston side on the
first cylinder is directed to the piston side of the second cylinder and
compresses the second cylinder.
With the spreading and side shift carriage the same hydraulic cylinders
are used for side shift as for fork spreading. (If there is no spreading
function then the cylinders are just for side shift, on the side shift
carriage.)
There are two versions of side shift, depending on how the function is
controlled.
•
Hydraulic servo means that the control levers are supplied with
hydraulic pressure, which controls the side shift.
•
Electric servo means that the control levers are electrical and send
a voltage signal to the control system to control the side shift.
Side shift, function description (hydraulic servo)
5
7
C
4
T
C
6
PS
B
P
EF
P
LS
T
A
8
3
C
2
9
014429
1
1.
Hydraulic oil pump
6.
Control valve load handling
2.
Shuttle valve
7.
Side shift cylinder
3.
Shuttle valve
8.
Side shift cylinder
4.
Priority valve
9.
Hydraulic oil filter
5.
Control lever side shift
Maintenance Manual DCF 180–250
UDCF06.01GB
7:12
7 Load handling – Side shift
Side shift, function description (electric servo)
Condition
Reference value
Control breaker
Not activated
6 ECU796
D
5
D
9
7
T
B
C
4
8
P
EF
P
LS
T
A
3
10
2
C
11
014430
1
1.
Hydraulic oil pump
2.
Shuttle valve
7.
Solenoid valve, side shift left (Y6020), side shift right
(Y6021)
3.
Shuttle valve
8.
Control valve load handling
4.
Priority valve
9.
Side shift cylinder
5.
Control lever side shift (R8073)
10. Side shift cylinder
6.
Control unit, hydraulics (ECU 796)
11. Hydraulic oil filter
UDCF06.01GB
Maintenance Manual DCF 180–250
7 Load handling – Side shift cylinder
7:13
Side shift, component location
2
3
4
5
1
6
7
9
014423
8
1.
Hydraulic oil pump for steering and load handling
2.
Priority valve
3.
Control valve load handling, hydraulic servo
4.
Control valve load handling, electric servo
5.
Solenoid valve, side shift left (Y6020) (electric servo)
6.
Solenoid valve, side shift right (Y6021) (electric
servo)
7.
Side shift cylinder
8.
Shuttle valve
9.
Hydraulic oil tank
7.4.4 Side shift cylinder
Side shift cylinder, checking
007849
Visually check that the cylinders are straight and that the mounting
points and welding seams are intact.
Maintenance Manual DCF 180–250
UDCF06.01GB
7:14
7 Load handling – Spreading
7.5 Spreading
Spreading, description
Spreading involves changing the relative distance between the lifting
forks. Control valve side shift, spreading and levelling, pressurises the
spreading cylinders which in turn move the forks.
There is a flow distributor between the valve and the cylinders that
ensures that the forks move uniformly even if the resistance on the
forks should be different.
With the spreading and side shift carriage the same hydraulic cylinders
are used for side shift as for fork spreading.
There are two versions of spreading, depending on how the function is
controlled.
•
Hydraulic servo means that the control levers are supplied with
hydraulic pressure, which controls the spreading.
•
Electric servo means that the control levers are electrical and send
a voltage signal to the control system to control the spreading.
UDCF06.01GB
Maintenance Manual DCF 180–250
7 Load handling – Spreading
7:15
Spreading, function description (hydraulic servo)
8
7
5
8
C
4
T
6
PS
B
P
EF
P
LS
T
A
3
C
2
9
014431
1
1.
Hydraulic oil pump
6.
Control valve load handling
2.
Shuttle valve
7.
Flow distributor
3.
Shuttle valve
8.
Spreading cylinder
4.
Priority valve
9.
Hydraulic oil filter
5.
Control lever, spreading
Maintenance Manual DCF 180–250
UDCF06.01GB
7:16
7 Load handling – Spreading
Spreading, function description (electric servo)
Condition
Reference value
Control breaker
Not activated
10
6 ECU796
9
D
5
D
10
7
T
8
B
C
4
P
EF
P
T
A
LS
3
C
2
11
014432
1
1.
Hydraulic oil pump
7.
Solenoid valve, spreading inwards (Y6019) outwards
(Y6018)
2.
Shuttle valve
3.
Shuttle valve
8.
Control valve load handling
4.
Priority valve
9.
Flow distributor
5.
Control lever, spreading (R8074)
10. Spreading cylinder
6.
Control unit, hydraulics (ECU 796)
11. Hydraulic oil filter
UDCF06.01GB
Maintenance Manual DCF 180–250
7 Load handling – Spreading
7:17
Spreading, component location
2
3
4
5
1
6
7
8
10
014424
9
1.
Hydraulic oil pump for steering and load handling
6.
Solenoid valve, spreading outwards (Y6018) (electric
servo)
2.
Priority valve
3.
Control valve load handling, hydraulic servo
7.
Spreading cylinder
4.
Control valve load handling, electric servo
8.
Flow distributor
5.
Solenoid valve, spreading inwards (Y6019) (electric
servo)
9.
Shuttle valve
10. Hydraulic oil tank
Maintenance Manual DCF 180–250
UDCF06.01GB
7:18
7 Load handling – Tilt
7.7 Tilt
Tilt, description
Tilt means the angling of the mast in relation to the machine. Control
valve lifting/lowering and tilt pressurises the tilt cylinders which angle
the mast in relation to the machine. Tilt is controlled with control lever,
tilt.
There are two versions of tilt, depending on how the function is
controlled.
•
Hydraulic servo means that the control levers are supplied with
hydraulic pressure, which controls the tilting.
•
Electric servo means that the control levers are electrical and send
a voltage signal to the control system to control the tilting.
UDCF06.01GB
Maintenance Manual DCF 180–250
7 Load handling – Tilt
7:19
Tilt, function description (hydraulic servo)
5
7
4
T
C
8
6
B1
C
PS
7
P
EF
P
P
8
A1
LS
T
3
C
2
9
014433
1
C
1.
Hydraulic oil pump
6.
Control valve load handling
2.
Hydraulic oil pump
7.
Load holding valve
3.
Shuttle valve
8.
Tilt cylinder
4.
Priority valve
9.
Hydraulic oil filter
5.
Control lever, tilt
Maintenance Manual DCF 180–250
UDCF06.01GB
7:20
7 Load handling – Tilt
Tilt, function description (electric servo)
Condition
Reference value
Control breaker
Not activated
6 ECU796
5
D
D
9
7
4
T
10
B1
C
8
9
P
EF
P
P
T
10
A1
LS
3
C
2
11
014434
1
C
1.
Hydraulic oil pump
7.
Solenoid valve, tilt in (Y6011), tilt out (Y6010)
2.
Hydraulic oil pump
8.
Control valve load handling
3.
Shuttle valve
9.
Load holding valve
4.
Priority valve
10. Tilt cylinder
5.
Control lever tilt (R8072)
11. Hydraulic oil filter
6.
Control unit, hydraulics (ECU 796)
UDCF06.01GB
Maintenance Manual DCF 180–250
7 Load handling – Tilt
7:21
Tilt, component location
3
4
5
2
1
6
7
11
8
014425
10
9
1.
Hydraulic oil pump for steering and load handling
7.
Solenoid valve, tilt in (Y6011) (electric servo)
2.
Hydraulic oil pump for lifting/lowering and tilt
8.
Tilt cylinder
3.
Priority valve
9.
Load holding valve
4.
Control valve load handling, hydraulic servo
10. Shuttle valve
5.
Control valve load handling, electric servo
11. Hydraulic oil tank
6.
Solenoid valve, tilt out (Y6010) (electric servo)
Maintenance Manual DCF 180–250
UDCF06.01GB
7:22
7 Load handling – Tilt cylinder
7.7.5 Tilt cylinder
Tilt cylinder, checking
Visually check that the mounting points and welding seams are intact.
Tilt mount, checking bearings
NOTE
There may be other variants of tilt cylinder mountings than those
shown here.
Machine in service position, see section B Safety.
2
Make marks on the mast and frame when the mast is vertical.
3
Add blocks under the outer mast in order to unload the tilt
mountings and tilt out to the maximum. Measure the distance to
the marking. The measurement should be max. 2 mm.
4
If the difference is greater, the bearings in the tilt mounting must
be replaced, see Workshop manual.
009521
009522
1
UDCF06.01GB
Maintenance Manual DCF 180–250
7 Load handling – Levelling
7:23
7.8 Levelling
Levelling, description
Levelling means that the load is angled in the horizontal direction. This
enables the machine to handle loads on uneven ground surfaces.
There are two different types of levelling, fork levelling and central
levelling (with the central levelling carriage specified).
For machines with fork levelling, one of the forks (right or left) is
suspended via a hydraulic cylinder that moves the fork vertically
through a sleeve secured to the carriage.
With central levelling the front section of the fork carriage is levelled
(turned) around the centre line of the carriage, four degrees up or down.
There are two versions of levelling, depending on how the function is
controlled.
•
Hydraulic servo means that the control levers are supplied with
hydraulic pressure, which controls the levelling.
•
Electric servo means that the control levers are electrical and send
a voltage signal to the control system to control the levelling.
Maintenance Manual DCF 180–250
UDCF06.01GB
7:24
7 Load handling – Levelling
Levelling, function description (hydraulic servo)
5
T
6
PS
B
C
4
P
EF
7
P
T
A
LS
3
C
2
8
014435
1
1.
Hydraulic oil pump
5.
Control lever, levelling
2.
Shuttle valve
6.
Control valve load handling
3.
Shuttle valve
7.
Load holding valve
4.
Priority valve
8.
Hydraulic oil filter
UDCF06.01GB
Maintenance Manual DCF 180–250
7 Load handling – Levelling
7:25
Levelling, function description (electric servo)
Condition
Reference value
Control breaker
Not activated
6 ECU796
D
5
D
7
T
B
C
4
8
P
EF
9
P
T
A
LS
3
C
2
10
014436
1
1.
Hydraulic oil pump
6.
Control unit, hydraulics (ECU 796)
2.
Shuttle valve
7.
Solenoid valve, levelling down (Y6022) up (Y6023)
3.
Shuttle valve
8.
Control valve load handling
4.
Priority valve
9.
Levelling cylinder
5.
Control lever, levelling (R8075)
10. Hydraulic oil filter
Maintenance Manual DCF 180–250
UDCF06.01GB
7:26
7 Load handling – Levelling
Levelling, component location
2
3
4
6
5
1
7
9
014426
8
1.
Hydraulic oil pump for steering and load handling
2.
Priority valve
3.
Control valve load handling, hydraulic servo
4.
Control valve load handling, electric servo
5.
Solenoid valve, levelling down (Y6022) (electric
servo)
UDCF06.01GB
6.
Solenoid valve, levelling up (Y6023) (electric servo)
7.
Levelling cylinder
8.
Shuttle valve
9.
Hydraulic oil tank
Maintenance Manual DCF 180–250
7 Load handling – Load carrier
7:27
7.9 Load carrier
Load carrier, general
The load carrier is designed to lift a load when required. There are
several ways to lift the load, such as:
•
Lifting forks, normal and inverted.
•
Coil ram
•
Side lift attachment
7.9.1 Lifting forks
Lifting forks, component location
1
2
3
4
5
014438
6
7
1.
Lifting fork
5.
Lock pin
2.
Support roller
6.
Mobile lock hook
3.
Inverted lifting forks
7.
Lower mounting hook
4.
Upper mounting hook
Maintenance Manual DCF 180–250
UDCF06.01GB
7:28
7 Load handling – Lifting forks
Lifting forks, checking
DANGER
Damaged lifting forks must be changed.
Repairs to lifting forks change their strength, which
may lead to dropped loads and fatalities.
1
Machine in service position, see section B Safety.
2
Check the fork arms with regard to blade thickness, cracks and
deformation.
•
Blade wear (at position a) must not exceed 10% (calculated
from initial dimensions and measured 150 mm from the heel
of the fork).
•
Visible cracks may not be present.
Pay special attention to the fork heel. Surface cracks are
generally no longer than 5 mm.
If surface cracks are discovered, grind down approx. 0.5 mm
and test with magnetic particle inspection to see if the crack
is still visible. Testing must be performed by an approved
company.
a
Check the forks' suspension mountings, e.g. clearance.
4
If the forks need repair - contact Cargotec or one of Cargotec's
approved service personnel, who will determine whether the forks
can be repaired.
007781
150 mm
3
NOTE
Surface cracks and wear must not be dealt with using welding.
5
UDCF06.01GB
Forks which have been hot-straightened must be heat treated
again (carried out by an approved firm).
Maintenance Manual DCF 180–250
7 Load handling – Coil ram
7:29
7.9.2 Coil ram
Coil ram, component location
2
1
014437
4
3
5
1.
Coil ram
2.
Upper mounting hook
3.
Lock pin
4.
Mobile lock hook
5.
Lower mounting hook
Maintenance Manual DCF 180–250
UDCF06.01GB
7:30
7 Load handling – Other functions
7.10 Other functions
7.10.1 Scales
Scales, description
The scales function is available in two configurations.
1.
Electric-hydraulic scales without indication in the display.
2.
Electric-hydraulic scales with indication in the display and functions
for taring and summation of the load. A pressure sensor in the lift
cylinder measures the pressure and so estimates the weight of the
load. The scales function can be used by other functions in the
machine independently of the indication in the display.
The accuracy depends on mast movement before measuring. The
scales are very sensitive and are affected by several factors such as
friction in the mast and fork carriage, oil temperature and bearings. The
mast must be in a vertical position and the fork carriage centred. The
fork carriage must be raised and then lowered to about 1 metre above
the ground before calibration and weighing. If the system is calibrated
after gentle lowering, and weighing is performed in the same way, then
an accuracy of about 5% of the maximum load capacity is achieved.
The weight is presented continuously on the display, in tonnes to one
decimal place (e.g. 5.2 tonnes).
Scales, calibration
The scales on a machine equipped with complete scales are always
adjusted and calibrated from the factory. For correct use of the scales
they must be calibrated regularly against a known test weight.
NOTE
The mast should be in a vertical position and the fork carriage should
be centred for weighing, calibration and taring.
Operate the trolley up and down a few times to remove any
mechanical tension.
2
Operate the machine for a few minutes before zero adjustment
and weight calibration take place.
3
To select the function to calibrate, first navigate to the service
menu. Then press Enter.
000056
1
4
Enter the code for calibration.
The code is obtained from Cargotec Support.
1 23
4 5
000060
NOTE
The code determines which service menu shall be activated
(Service, Diagnostics, Initiation or Calibration).
5
Select SCALE by scrolling with the arrow keys (1 and 2) and
confirm with Enter.
000803
SCALE
UDCF06.01GB
Maintenance Manual DCF 180–250
7 Load handling – Side lift attachment
6
SCALE
WITHOUT LOAD
1(2)
600
600
(mV)
above the ground. Reset to zero by pressing
7
in the menu 1 (2).
Load with a known weight (preferably a frequently used loading
weight or close to the machine's maximum load), adjust with 4
CALIBR
and 5
000805
2(2)
4000 8000 KG
4000 8000 KG
SCALE WITH LOAD
Unload, operate the trolley up and lower it slowly to about 1 metre
000804
CALIBR
7:31
to the correct weight and lower the trolley slightly. Confirm
the weight by pressing
in the menu 2 (2). For the weight to
be adjustable there must be a value in setup for maximum lifting
capacity.
7.10.5 Side lift attachment
Side lift attachment, description
Side lift attachments are designed on the basis of simple, safe and fast
handling, low weight and easy maintenance.
Both corner boxes of the side lift attachment are telescopic and
spring-mounted to the main beam, which allows levelling of 195 mm on
each side for coupling tilting containers. A hydraulic cylinder between
the attachment and carriage enables side shift.
A hydraulic system ensures that the container is locked via twistlocks
to the attachment before lifting.
An electric safety system blocks locking and release of twistlocks
unless the attachment is aligned properly in contact with the container.
The system also prevents lifting unless twistlocks are either fully locked
or released.
A lamp panel shows contact, locked container or released container.
Maintenance Manual DCF 180–250
UDCF06.01GB
7:32
7 Load handling – Side lift attachment
Twistlocks, checking
WARNING
Dropped load.
Fatal danger!
Twistlocks hold the load during load handling and
therefore it is crucial that twistlocks are checked
according to instructions and replaced at the slightest
sign of damage or wear.
WARNING
Make sure that the engine is off when working on the
twistlocks.
Twistlocks can be locked automatically if all sensors for
contact are activated manually.
1
2
1
3
Check that the twistlocks function correctly.
Lock and open the twistlocks, check that the indicator lights work,
both in cab and on attachment.
2
Clean the twistlocks from any dirt.
3
Under the rubber cover for twistlocks: check pin, link arm and
lock nut.
4
Clean the area around sensor contact.
5
Press in the contact pin so that the head is flush with the spreader
beam's underside. Check the distance to sensor contact, the
distance should be 5±1 mm. Adjust when needed
NOTE
4
1.
Sensor unlocked twistlock
2.
Sensor contact
3.
Sensor locked twistlock
4.
Lock guide
5.
Lift pin
6.
Contact pin
UDCF06.01GB
5
007922
6
The contact pin should move easily and spring back completely.
6
Check that the lock guide and lift pin can move freely.
7
Fit a pry bar between the lift pin (position 5) and the lock guide
(position 4) and check the clearance, max. clearance: 1-1.5 mm.
Maintenance Manual DCF 180–250
7:33
8
Turn twistlocks to locked position and check wear of the lift pin.
Replace the lift pin as required.
9
Repeat steps 1–8 on the other side.
Max. 4 mm
002311
M
in
.
70
m
m
7 Load handling – Side lift attachment
Wear limits lift pin.
Twistlocks, checking for cracks
DANGER
Material fatigue, reduced strength.
Fatal danger!
Change twistlocks that shows signs of cracks or
other external damage, or twistlocks with more than
10 000 operating hours.
1
Remove the lift pins from the attachment.
NOTE
002313
Twistlocks are heavy, be careful when removing.
Area for checking for cracks on lift pin.
2
Check for cracks within the marked area on the lift pins without
causing damage.
3
If the lift pins show signs of cracking, they must be replaced with
new ones.
4
Install approved twistlocks.
NOTE
Use the new attaching nut and spherical bearing.
Maintenance Manual DCF 180–250
UDCF06.01GB
7:34
7 Load handling – Side lift attachment
1
2
007782
Sensor contact, checking and adjusting
1
Check that the contact pins in the corner boxes can move freely up
and down. The contact pins shall spring down when not loaded.
2
Check that the sensor is free of damage and dirt.
3
Turn the start key to position I and check that the light indicators
on the sensor are turned off.
4
Lower the attachment onto a container and check that Indicator
light contact is lit.
5
Lift the container a little bit so that the Indicator light contact is
switched off.
6
With the container raised, check how much movement on the
contact pins is needed to detect contact (light indicator on the
sensor is lit). The movement should be 3–4 mm.
7
If necessary, loosen the lock nut and screw in/out the sensor until
the distance between the sensor and the contact pin is 5±1 mm.
Right side
1.
Sensor contact
2.
Contact pin
2
007919
1
Left side
1.
Sensor contact
2.
Contact pin
UDCF06.01GB
Maintenance Manual DCF 180–250
7 Load handling – Side lift attachment
7:35
Sensor twistlocks, checking and adjusting
1
Check that the sensors are free of damage and dirt.
2
Turn the start key to position I and check that the light indicator
on the sensor for unlocked twistlock is lit.
If necessary, loosen the lock nut and screw in/out the sensor until
the distance between the sensor and the indicator plate is 5±1 mm.
3
Check that indicator light twistlocks open is lit.
4
Lower the attachment over a container and lock twistlocks.
5
Check that the light indicator on the sensor for locked twistlock
is lit.
1
2
007783
If necessary, loosen the lock nut and screw in/out the sensor until
the distance between the sensor and the indicator plate is 5±1 mm.
6
Check that indicator light twistlocks locked is lit.
Right side
1.
Sensor unlocked twistlock
2.
Sensor locked twistlock
2
007920
1
Left side
1.
Sensor unlocked twistlock
2.
Sensor locked twistlock
Maintenance Manual DCF 180–250
UDCF06.01GB
7:36
UDCF06.01GB
Maintenance Manual DCF 180–250
8:1
8 Control system
Contents 8 Control system
8
Control system ...................................................................................................8:3
8.2
Monitoring functions.........................................................................................8:6
8.2.3
Speed limitation...........................................................................................8:6
8.2.4
Service indicator..........................................................................................8:7
8.3
Error codes ......................................................................................................8:8
8.4
Diagnostics ......................................................................................................8:9
8.4.1
ECU 790....................................................................................................8:10
8.4.2
ECU 792.................................................................................................... 8:11
8.4.4
ECU 796.................................................................................................... 8:11
8.4.5
Last alarms (latest alarm).......................................................................... 8:11
Maintenance Manual DCF 180–250
UDCF06.01GB
8:2
UDCF06.01GB
Maintenance Manual DCF 180–250
8 Control system – Control system
8:3
8 Control system
Control system, general
In many cases the machine's functions are controlled electrically. The
signals that control the machine are monitored to warn the operator or
limit the machine's functions in case of certain dangerous situations or
if there are malfunctions in the machine.
The function control system is divided into the following functions:
•
Monitoring functions
•
Error codes
•
Diagnostics
•
Settings
•
Software
Monitoring functions describe the machine’s monitoring functions that
warn the operator or limit the machine’s functions in the event of a
dangerous situation.
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.
Maintenance Manual DCF 180–250
UDCF06.01GB
8:4
8 Control system – Control system
Control system, description
B
The machine is equipped with an electronic system used for
controlling and monitoring certain of the machine's different functions.
C
The system provides information to the operator in the form of alarm
information and operating information. The information is presented
on the steering wheel panel's display (position B).
The function keys are used to navigate in the display menus for
service and troubleshooting, for example.
F
N
R
R
2
4
5
3
007801
1
A
A
Function keys
B
Display
C
Alarm indicator
Function keys
Function keys
R
4
UDCF06.01GB
2
5
The function keys (position A) are used to navigate in the menu
system for information, setting and diagnostic menus.
3
000693
1
They are also used to enter values into the system and to confirm
error codes.
•
Function key 1 : Scroll anticlockwise in menu system as well
as enter value 1.
•
Function key 2
enter value 2.
•
Function key 3 R : cancel selection of menu or procedure in
progress and confirm the error codes displayed. Also acts as a
shortcut to the operating menus if held depressed for a short time.
•
Function key 4 : enter value 4, for gradual settings adjustment
and gradual decrease of values in menus (counts down when the
function key is held down, counts faster if held down longer).
•
Function key 5 : enter value 5, for gradual settings adjustment
and gradual increase of values in menus (counts up when the
function key is held depressed, counts faster if held down longer).
•
Function key 6 : confirms selection of menu and confirms value
entered (stored in memory).
1
2
: Scroll clockwise in menu system as well as
3
4
5
Maintenance Manual DCF 180–250
8 Control system – Control system
Operating menus
8:5
Operating menus
50
When the machine is started the operating menu is shown with
engine speed, speed, clock, current gear (gear positions 1-3 are not
shown with inching or declutch), as well as fuel level. This menu is
shown until another menu is selected or an event-controlled menu is
shown(e.g., in case of error code type "WARNING" and "STOP").
Menus are selected using the function keys for arrow right and arrow
left. Each press of the key changes the display to the next menu. To
quickly return to the original display hold the function key for Reset
(R) depressed.
U
This section describes the information that can be obtained from the
different operating menus. The figures show example data.
-/+
- +
NOTE
The availability of the menus is dependent on the machine's
equipment.
+
014087
The following operating menus are available to aid the operator:
Examples of available operating menus
Service menu
•
Operating menu
•
Operating menu engine
•
Operating menu transmission and electrical system
•
Operating menu service interval
•
Operating menu scale
•
Operating menu joystick control/mini-wheel
•
Operating menu trip computer
•
Operating menu statistics
•
Operating menu service
000056
Service menu
The service menu is the gateway to the machine's diagnostic
system. Different parts of the Service menus are made available by
pressing "Enter" and entering different codes. The code to access
the diagnosis menus is 11111, while the code to access the settings
menus requires special authority (contact Cargotec in the event of
any questions).
The different service menus are:
•
Error codes, description, page 8:8.
•
Diagnostics, general, page 8:9.
Maintenance Manual DCF 180–250
UDCF06.01GB
8:6
8 Control system – Monitoring functions
8.2 Monitoring functions
Monitoring functions, general
The machine is equipped with a number of control functions to increase
safety during load handling:
•
Speed limitation
•
Service indicator
8.2.3 Speed limitation
Speed limitation, description
Speed limitation prevents the machine's speed from exceeding a
preset value by controlling the engine speed.
UDCF06.01GB
Maintenance Manual DCF 180–250
8 Control system – Service indicator
8:7
8.2.4 Service indicator
Service indicator, resetting
Machine in service position, see section B Safety.
2
Navigate first to the service menu and press Enter.
3
Enter code for resetting service indicator.
000056
1
The code is obtained from Cargotec Support.
1 23
4 5
000060
NOTE
The code determines which service menu shall be activated
(Service, Diagnostics, Initiation or Calibration).
500h TO NEXT SERVICE
PRESS ENTER TO
CONFIRM!
Reset the service indication by pressing Enter.
000808
4
Maintenance Manual DCF 180–250
UDCF06.01GB
8:8
8 Control system – Error codes
8.3 Error codes
Error codes, description
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
error codes on the display and stores the error codes.
Explanation of error codes is found in Operator's manual and Workshop
manual.
Error code indication
41
Error code indication
42
Error code is indicated with illuminated indicator for active error codes
(position 42). Error codes are divided into three error code levels,
depending on how serious they are.
The error code levels are indicated as follows:
•
B
STOP is indicated with a STOP sign in the display together with a
fixed red light from the indicator for the control system (position
42).
Error code with level STOP is shown automatically in the display.
•
WARNING is indicated with a warning triangle in the display,
together with a fixed red light from the indicator for the control
system (position 42).
Error code with level WARNING is shown automatically in the
display.
•
INFORMATION is indicated with an adjustable wrench in the
display together with fixed red light from the indicator for the
control system (position 42).
007192
Error code with level INFORMATION is shown automatically on
display.
B. Symbol error code level
41. Display for control system (KCS)
42. Indicator for control system (KCS)
Error code display
Error code display
307
004257
Error code information is displayed with display images and symbols
that give an indication about the nature of the error arising.
Example of automatic display figure
The error code and figure can be removed temporarily with the Reset
(R) function key and then they disappear from the display. If the
error code is active then the indication returns in the display within
1-3 minutes.
If the error code is the information type and is removed with Reset (R)
then it is not displayed again until the system is restarted.
UDCF06.01GB
Maintenance Manual DCF 180–250
8 Control system – Diagnostics
8:9
8.4 Diagnostics
Diagnostics, general
The machine has built-in functions for troubleshooting called
diagnostic test. The diagnostic test consists of several menus that are
shown in the display. The menus are grouped according to control
unit for faster access.
000916
DIAGNOSTICS
The following pages show compilations of the diagnostic menus. The
workshop manual has a more detailed description of each diagnostic
menu.
The diagnostic test is divided into the following groups:
•
Control unit ECU 790, ECU 790, menu overview, page 8:10.
•
Control unit ECU 792, ECU 792, menu overview, page 8:11.
•
Control unit ECU 796, ECU 796, menu overview, page 8:11.
•
Error code history, Last alarms, description, page 8:11.
The diagnostic test varies between the different control units as to what
type of diagnostics can be carried out, but the following alternatives
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).
Diagnostics, operating instructions
To choose diagnostics, do the following:
1 Navigate to the service menu.
2
Press
3
Enter the code for diagnostics (11111).
000056
.
000060
1 23
4 5
4
Select Diagnostics by pressing
.
000916
DIAGNOSTICS
Maintenance Manual DCF 180–250
UDCF06.01GB
8:10
8 Control system – ECU 790
5
Main option for diagnostic test is now shown on the display.
Choose which control unit shall be investigated using the function
keys 1
DIAGNOSTICS ECU790
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 the selected
diagnosis group appears in the display. Select the next diagnosis
menu using 1
DIAGNOSTICS ECU792
and 2 .
DIAGNOSTICS ECU793
DIAGNOSTICS ECU796
007891
LAST ALARMS
8.4.1 ECU 790
ECU 790, menu overview
DIAGNOSTICS ECU 790
DIAG ECU 790
DIAG ECU 790
2(3)
VIEW OUTPUTS
DIAG ECU 790
3(3)
CONTROL OUTPUTS
007886
VIEW INPUTS
1(3)
UDCF06.01GB
Maintenance Manual DCF 180–250
8 Control system – ECU 792
8:11
8.4.2 ECU 792
ECU 792, menu overview
DIAGNOSTICS ECU 792
DIAG ECU 792
DIAG ECU 792
1(3)
2(3)
VIEW OUTPUTS
3(3)
CONTROL OUTPUTS
007887
VIEW INPUTS
DIAG ECU 792
8.4.4 ECU 796
ECU 796, menu overview
DIAGNOSTICS ECU 796
DIAG ECU 796
DIAG ECU 796
1(3)
2(3)
VIEW OUTPUTS
3(3)
CONTROL OUTPUTS
007890
VIEW INPUTS
DIAG ECU 796
8.4.5 Last alarms (latest alarm)
Last alarms, description
A history of the latest error codes generated can be viewed under
this menu. If the same error code is generated several times then
this is counted with a counter and the number of faults is shown
in the display. The date and time for when the error code was last
generated is also displayed.
000995
LAST ALARMS
Select diagnostics and Last alarms in accordance with Diagnostics,
operating instructions, page 8:9. This display indicates if Last alarms
is selected. Press function key
to proceed.
The 10 latest error codes are displayed in chronological order (with
error code number, number of error codes and the date and time for
the last error code of this type received).
LAST ALARMS
1(13)
ALARM NUMBER
354
COUNTER
11
16.01.2007 10:58
009350
If only one error code is saved then there is only the menu for that fault
and the last menu “Clear all alarms”. Accordingly, 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.
Maintenance Manual DCF 180–250
UDCF06.01GB
8 Control system – Last alarms (latest alarm)
LAST ALARMS
6(13)
ALARM NUMBER
384
COUNTER
1
16.01.2007 10:58
LAST ALARMS
7(13)
ALARM NUMBER
601
COUNTER
3
16.01.2007 10:58
LAST ALARMS
8(13)
ALARM NUMBER
610
COUNTER
1
16.01.2007 10:58
LAST ALARMS
9(13)
ALARM NUMBER
900
COUNTER
1
16.01.2007 10:58
UDCF06.01GB
4
Latest active error codes (4) in chronological order.
5
Latest active error codes (5) in chronological order.
6
Latest active error codes (6) in chronological order.
7
Latest active error codes (7) in chronological order.
8
Latest active error codes (8) in chronological order.
9
Latest active error codes (9) in chronological order.
009353
009352
009351
Latest active error codes (3) in chronological order.
009354
LAST ALARMS
5(13)
ALARM NUMBER
380
COUNTER
6
16.01.2007 10:58
3
009355
LAST ALARMS
4(13)
ALARM NUMBER
364
COUNTER
2
16.01.2007 10:58
Latest active error codes (2) in chronological order.
009356
LAST ALARMS
3(13)
ALARM NUMBER
361
COUNTER
3
16.01.2007 10:58
2
009357
LAST ALARMS
2(13)
ALARM NUMBER
358
COUNTER
8
16.01.2007 10:58
009358
8:12
Maintenance Manual DCF 180–250
8 Control system – Last alarms (latest alarm)
8:13
LAST ALARMS
12(13)
GEARBOX ALARM 1(X)
SPN:
5490
FMI:
11
PRESS (+) FOR NEXT
11 Latest active error codes (11) for the engine. In the event of more
than one error code, scroll through the codes by pressing function
009360
key 5 .
12 Latest active error codes (12) for the transmission. In the event of
more than one error code, scroll through the codes by pressing
function key 5 .
009361
LAST ALARMS
11(13)
ENGINE ALARM 1(X)
SPN:
110
FMI:
10
PRESS (+) FOR NEXT
009359
10 Latest active error codes (10) in chronological order.
LAST ALARMS
10(13)
ALARM NUMBER
1200
COUNTER
2
16.01.2007 10:58
13 Clear all error codes (only possible with service code). This menu
is shown if there is one or more error codes. Clear all error codes
by pressing on the function key
(Yes =
).
009362
13(13)
CLEAR ALL ALARMS?
YES = ENTER
This menu and function deletes the last active error codes under
"Last Alarms" and also the engine and transmission alternatives
and their control units that support the deletion of inactive error
codes, so-called DM3 in the J1939 CAN standard.
14 Shown if there are no error codes, and after reset. If there are no
error codes from the KCS system, only menus 11-13 are shown.
13(13)
009364
NO ALARMS
Maintenance Manual DCF 180–250
UDCF06.01GB
8:14
UDCF06.01GB
Maintenance Manual DCF 180–250
9:1
9 Frame, body, cab and accessories
Contents 9 Frame, body, cab and accessories
9
Frame, body, cab and accessories ...................................................................9:3
9.1
Controls and instruments .................................................................................9:5
9.2
Safety and emergency equipment .................................................................9:10
9.3
Seats.............................................................................................................. 9:11
9.4
Heating, ventilation and air conditioning ........................................................9:12
9.4.4
Fresh air filter ............................................................................................9:19
9.4.9
Condenser unit ..........................................................................................9:20
9.4.21
Moisture filter.............................................................................................9:20
9.5
Wiping and cleaning of windows....................................................................9:22
9.6
Lighting system ..............................................................................................9:23
9.7
Signalling system ...........................................................................................9:24
9.8
Entertainment and communication ................................................................9:25
9.9
Glass/windows/mirrors...................................................................................9:26
9.10
Construction and suspension of cab..............................................................9:27
9.10.1
Cab frame .................................................................................................9:27
9.10.2
Doors.........................................................................................................9:28
9.10.3
Cab undercarriage ....................................................................................9:28
9.10.4
Cab tilting ..................................................................................................9:29
9.11
Cab interior ....................................................................................................9:31
9.12
Frame.............................................................................................................9:32
9.13
Body structure................................................................................................9:33
9.13.4
Counterweights .........................................................................................9:33
9.14
Central lubrication ..........................................................................................9:35
9.15
Paint/coatings ................................................................................................9:37
Maintenance Manual DCF 180–250
UDCF06.01GB
9:2
UDCF06.01GB
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Frame, body, cab and accessories
9:3
9 Frame, body, cab and
accessories
Frame, body, cab and accessories,
description
The machine consists of frame, body and cab.
The frame (chassis) is the machine's structural part and is made of
high-strength steel.
The body consists of fenders, hood and other parts mounted on the
frame.
The cab is built separately and isolated from the frame using
heavy-duty rubber dampers. Operator's seat, steering wheel and
controls for hydraulics can be adjusted for optimal individual operating
position. Effective insulation gives a minimum of vibrations and a low
sound level. The machine is equipped with heating and ventilation, air
condition is available as an option.
WARNING
Each case of mechanical damage to the cab can involve
risks as the strength is changed. Consequently, making
holes in load bearing parts is forbidden.
Risk of personal injury.
Contact Cargotec for recommendations.
WARNING
Never work underneath a cab that is not tilted over its
balance point or secured in another way.
Risk of crushing injury.
Always tilt the cab as much as possible. At maximum
tilting angle (on a horizontal surface) align the cab's
centre of gravity so that it does not risk tilting back.
WARNING
The hood may be slippery.
Danger of slipping.
It is forbidden to walk on the hood when it has no
anti-slip protection or is not level.
Maintenance Manual DCF 180–250
UDCF06.01GB
9:4
9 Frame, body, cab and accessories – Frame, body, cab and accessories
WARNING
The strength of the roof window can be substantially
reduced by exposure to substances that contain
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at regular
intervals. Clean only with windscreen washer fluid or
a mild cleaning agent. Rinse thoroughly with plenty
of lukewarm water. Replace a damaged roof window
immediately if it is cracked or scratched!
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 indicate that the strength of the roof window is
affected and it must be replaced immediately.
UDCF06.01GB
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Controls and instruments
9:5
9.1 Controls and instruments
Cab overview Spirit Delta
1
2
3
4A
5
F
N
R
R
14
1
4
2
3
5
7A
6
13
12
11
10
9
8
1
Left-hand dashboard panel
2
Gear and travel direction 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
11
Brake pedal
12
Brake pedal
13
Electronic box with fuses and relays
14
Hour meter
Maintenance Manual DCF 180–250
014486
7B
4B
UDCF06.01GB
9:6
9 Frame, body, cab and accessories – Controls and instruments
Left-hand dashboard panel
31
30
32
Left-hand dashboard panel
33
19 .. 26
27 28 29
15
Control for heating
16
Control for fan
17
Control for defroster/cabin
18
Control for cooling AC
19
Switch for recirculation/fresh air
(Only for heater unit with cooling AC)
18
20
17
16
Switch for extra work lights
15
32
33
19 .. 26
AU
TO
M
O D
E
34
21
Switch for work lights on mast
22
Switch for extra work lights
23
Switch for extra work lights
24
Switch for revolving beacon
25
Switch for warning beacon
26
Switch for headlights
27
Switch for seat heating
27 28 29
(The switch may be on the driver's seat.)
006908
31
30
Switch for cooling AC
28
Left-hand dashboard panel, upper with heater and lower
with air conditioning
29
Switch for central lubrication
Switch for short-stop heater
30
Spare
31
Spare
32
Spare
33
Socket for 12/24V
34
Air conditioning ECC
See section Air conditioning ECC.
UDCF06.01GB
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Controls and instruments
Steering wheel panel
35 36 37 38 39 40
41
42
43
9:7
Steering wheel panel
There is a buzzer integrated below the steering wheel panel (not
visible). It is activated if:
•
starting attempts are made with a gear engaged and parking
brake not activated
•
the parking brake is not activated when the operator leaves the
driver's seat
•
the machine has low coolant level, low brake pressure or a
parking brake fault
•
an error code is generated, at which point a short sound signal
is emitted
F
N
R
R
45
Steering wheel panel
2
4
5
46
3
47
48
49
006903
44
1
35
Spare
36
Warning lamp, replace air filter
37
Indicator light for tilt control
38
Warning lamp for low battery charge
39
Indicator light for high beam
40
Indicator light for direction indicators
41
Display for control system, KCS
42
Alarm indicator for control system, KCS
43
Ignition key lock
44
Switch for turnable driver's seat
45
Switch for engagement and disengagement of alternative
direction of travel selector
46
Switch for inching
47
Function keys for control system, KCS
48
Switch for windscreen wiper, rear
49
Switch for windscreen wiper, roof
Maintenance Manual DCF 180–250
UDCF06.01GB
9:8
9 Frame, body, cab and accessories – Controls and instruments
Right-hand dashboard panel
Right-hand dashboard panel
007728
51 52 53 54 55 56 57 58 59
Right-hand dashboard panel
51
Switch for disengaging reverse alarm
52
Switch for raising/lowering the driver's seat
53
Switch for extra work lights
54
Switch for electrically heated rear view mirrors
55
Spare
56
Spare
57
Spare
58
Spare
59
Spare
Control for load handling
For more controls for load handling and associated functions, see
section Load handling.
UDCF06.01GB
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Controls and instruments
9:9
Operating menus, overview
50
U
1.
Operating menu
2.
Operating menu engine
3.
Operating menu transmission and electrical system
4.
Operating menu service interval
5.
Operating menu scale
6.
Operating menu fuel consumption
7.
Operating menu joystick control/mini-wheel
8.
Operating menu service
-/+
- +
014087
+
Examples of available operating menus
Maintenance Manual DCF 180–250
UDCF06.01GB
9:10
9 Frame, body, cab and accessories – Safety and emergency equipment
9.2 Safety and emergency equipment
General
A good working environment has safety and emergency equipment to
make the operator's work safe.
The machine may be equipped with the following:
8
2
11 9
8 7
1.
Reverse alarm
2.
Revolving beacon/flashing beacon
The revolving beacon is also vertically adjustable.
3.
Horn
4.
Electrically powered loud horn
5.
Fire extinguisher
A fire extinguisher is normally located on the left front fender, but
may also be located on the right front fender or inside the cab.
014439
If the machine is supplied with a fire extinguisher, it should be of
the type ABE in accordance with EN 3 part 1, 2, 4 and 5. With
such a fire extinguisher, it is possible to extinguish fires in both
solid organic materials and fluids. Adapted fire extinguishing
equipment can be ordered from Cargotec.
1, 8
6
10
3
5 4
9
8 6. Seat belt
7.
Buzzer in cab to indicate alarm or forgotten action, e.g. if the
operator leaves the driver's seat without first applying the parking
brake.
8.
Camera with monitor
Used to provide improved rearward vision when manoeuvring
and/or load handling with the machine. The monitor is usually
located inside the cab by the front right-hand door pillar.
9c
9.
9a
External rear view mirrors
:
Used to provide increased visibility for operating and load
handling.
9a shows a glimpse of the area in front of the machine
9b shows blocked area at the side/behind the machine
9c shows a glimpse of the area behind the machine
10. Control breaker for load handling
(servo circuits, only at electric servo controls for load handling).
9b
UDCF06.01GB
014440
11. Grating for roof window
Maintenance Manual DCF 180–250
.
9 Frame, body, cab and accessories – Seats
9:11
9.3 Seats
Seats, general
The function of the seat is to give the operator a good sitting position
and contribute to a good working environment. The cab's seat has
several adjustment features and meets high comfort requirements.
The machine can be equipped with turnable or reversible driver's seat
.
NOTE
Other alternative driver's seats may be installed.
Seats, description (product alternative Bege)
The seat has the following equipment:
1
2
3
4
5
8
mechanical adjustment
•
armrest right
•
seat belt, 2-point
•
seat belt, 3-point
•
armrest left
•
seat heating
•
head restraint
•
air suspension
•
integrated horizontal suspension (disengageable)
•
ventilated seat and backrest cushion (air-vent). The seat requires
compressed air. The option includes an externally mounted
compressor on the underside of the cab
.
006825
6
•
7
Controls Bege
1.
Adjustable lower back (lumbar) support
2.
Adjustable arm rest, right
3.
Adjustable arm rest, left
4.
Adjustable tilt, backrest
5.
Adjustable suspension position
6.
Adjustable seat angle
7.
Adjustable seat height
8.
Longitudinal adjustment
Maintenance Manual DCF 180–250
UDCF06.01GB
9:12
9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
9.4 Heating, ventilation and air
conditioning
Heating, ventilation and air conditioning, function
description
A standard equipped truck has a heater unit (cabin/defroster) that is
connected to the engine's cooling system and which provides heat
when the engine is warm. The heater unit consists of a fan and heater
elements for heating the air. The air is distributed through integrated
ducts in the cab's interior equipment and can be directed towards e.g.
defroster or floor.
Air conditioning, ECC (Electronic Climate Control, electronic control of
cooling, dehumidifying and heating) is available as an option
Air conditioning includes the parts presented in the illustration and
ensures that the operator's cab climate is as comfortable as possible.
Air conditioning function is to:
F
2
4
D
C
E
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
UDCF06.01GB
•
dehumidify the air when it is humid
•
clean the air from impurities
•
cool the air when it is warm
•
defrost (defroster function)
B
1
000762
G
warm the air when it is cold
The unit's fan is controlled in steps 0-I-II-III (with the fan control). For
air conditioning ECC the fan is steplessly variable 0-100 %.
A
5
•
The unit is controlled with switches and controls on the dashboard
panel.
E
3
6
.
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
9:13
Heating, ventilation and air conditioning,
component location
3
4
5
6
7
2
AU
TO
MO
DE
8
10
9
11
1
12
13
21
20
19
17
16
15
14
014446
18
1.
Condenser
12. Heat exchanger, heating
2.
Moisture filter
13. Engine, recirculation
3.
Sight glass
14. Expansion valve
4.
Pressure switch
15. Sensor, deicing ECC
5.
Sensor, outside temperature ECC
16. Heat exchanger, cooling
6.
Sensor, temperature air conditioning ECC
17. Fresh air filter
7.
Control for heater unit
18. Fan
8.
Air conditioning ECC
19. Water valve, standard heating
9.
Fine filter
20. Water valve ECC
10. Engine, air distribution
21. Compressor
11. Sensor, after heat exchanger ECC
Maintenance Manual DCF 180–250
UDCF06.01GB
9:14
9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
Air conditioning unit
General recommendations for work on the air conditioning
unit
CAUTION
Authorisation is required to perform repairs on the
climate control unit.
Check/performance test of air conditioning unit
NOTE
The air conditioning does not work at temperatures below approx.
0 ºC since the pressure in the refrigerant circuit is too low. If the
pressure in the refrigerant circuit becomes too low the low pressure
switch cuts off power supply to the compressor's magnet clutch,
which means that the air conditioning stops working.
Should be performed during continuous operation every week from
early spring to late autumn as well as in winter during long periods
of high humidity.
In winter, during cold and dry periods of low operation, the compressor
should be run for a few minutes every week so that the rubber hoses,
couplings, gaskets and axle seals are lubricated.
1.
Check that the condenser is not clogged – clean condenser fins
with compressed air as needed.
2.
Check that the compressor turns on and off without error.
3.
Check that the drain for the cooling element's condensation water
is not clogged.
4.
Check that there is no refrigerant leakage. In case of leakage, oil
and gas often form a dusty, dirty spot.
5.
Start the engine and engage the cooling function with setting on
maximum cooling. With ECC: Select Cool Mode and temperature
at min.
Let the engine run at min. 1,500 rpm. (At temperatures below
approx. 0 ºC, the cooling function will not start due to low pressure
in the system.)
6.
With AC: Set fan control to position I or II.
With ECC: Set fan to medium speed.
UDCF06.01GB
7.
After running for 10 minutes, check that there are no bubbles
visible in the moisture filter's sight glass. (Bubbles should occur
only when the compressor starts and stops).
8.
Place a thermometer by the air vent closest to the evaporator. After
5-10 minutes, the temperature should be under 10 ºC. (Deviations
in the measurement result can occur if the performance test is
conducted when the ambient temperature is below approx. 18 ºC).
If bubbles occur, subsequent filling should be done by an expert.
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
9:15
Check the temperatures on the hoses and similar items
as follows:
1.
Check that the hoses and components on the pressure side keep
a roughly even temperature by feeling them with your hand.
NOTE
In the event of a stop in one of cooling circuit's components, and
during long-term operation, certain parts (possibly hoses before
the condenser) can be very hot. Risk of burn injuries.
2.
All hoses and components on the pressure side (from the
compressor to the expansion valve) should be warm.
3.
All hoses and components on the suction side (from the evaporator
to the compressor) should be cold.
4.
Check the expansion valve. Frost or cold temperatures on
the intake side indicate that it is defective or clogged and that
circulation is limited or stopped on the pressure side.
5.
Check that the compressor engages and disengages normally.
Run the cab fan at low speed and let the compressor work at high
rpm. When the temperature in the air vents nozzles is close to 0
ºC, the compressor cuts out via the thermostat or ECC and cuts in
again when the temperature has increased approx. 3-7 ºC. (If the
compressor does not cut out, there is a risk of the evaporator icing
up and cooling performance decreasing.)
WARNING
If there is a rupture of a cooling hose or leakage on the
plant – turn off the unit immediately.
It is dangerous to allow refrigerants to come in contact
with skin or eyes.
Never release refrigerant in a closed rum; the gas can
cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air conditioning.
Work may only be performed on the refrigerant circuit
by an accredited company.
Maintenance Manual DCF 180–250
UDCF06.01GB
9:16
9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
Checking refrigerant quantity
WARNING
Electric fans can injure hands.
Risk of personal injury.
Avoid placing hands near the cooling fans when the
engine is running.
An estimation of the correct amount of refrigerant can be checked
using the sight glass. Normally it should not be possible to see bubbles
when the air conditioning system is operating. Bubbles may appear
if the system contains the wrong amount of refrigerant, in connection
with the compressor stopping and starting, and 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 starts. Then bubbles are usually seen
from a few seconds after the compressor has started, until the system
starts to work normally.
NOTE
Reliable checking of refrigerant quantity through the sight glass can
only be performed when the ambient temperature is above approx.
15 ºC.
On the left-hand side of the condenser is a sight glass on the line to
the evaporator. In the centre of sight glass is a coloured point for
moisture indication. Normally the indication is GREEN. If the indication
shows YELLOW then there may be moisture in the system (may occur
if the system is not properly evacuated before filling refrigerant or
if refrigerant has leaked).
Sight glass inspection
1
Machine in service position, see section B Safety.
2
Start the engine and let it idle.
3
Switch on the air conditioning with max. cooling and fan.
4
Check that no bubbles are visible in the sight glass on the particle
and moisture filter.
013669
Bubbles in the glass means that the quantity of refrigerant is
incorrect or that the condenser is defective, clogged by, e.g., dust,
or that the ambient temperature is very high.
UDCF06.01GB
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
9:17
Action in the event of leakage in the system
1
Turn off the air conditioning.
2
Check the cooling plant and pinpoint leaks. For this purpose, use
special leak detection equipment. If there still is refrigerant left,
the remaining refrigerant amount shall be evacuated and then
measured.
3
Rectify faults, seal leaks by replacing gaskets, hoses, etc.
4
Fill with the correct quantity of R-134a refrigerant in accordance
with the following points when all faults have been rectified.
5
The following work requires special filling equipment.
6
Connect the suction pressure gauge's blue hose to the service
valve on the compressor's suction side marked with S, SUC or
SUCTION.
7
Connect the pressure gauge's red hose to the service valve on the
compressor's pressure side marked with D, DIS or DISCHARGE.
8
Connect the hoses to the fluid reservoir.
9
Connect the yellow filler and vacuum hose to the nitrogen tube.
Open the cock on the tube and then the cock on the pressure
side. Open the valve on the cylinder and then the valve on the
pressure side. Now the gas flows through the system and back
to the suction side of the compressor, which can be seen on the
blue pressure gauge which slowly indicates a pressure equivalent
to the pressure in the cylinder (see red pressure gauge). (If the
blue pressure gauge does not move then there is a stop in the
system.) Turn off the valve on the pressure side and then the
cock on the tube.
10 Now the system contains a mix of nitrogen gas and air. This gas
amount is enough to indicate a leak.
11 Conduct leakage detection of all hose nipples and other
connections by applying leakage indicator around all sealing
surfaces and check whether gas bubbles arise.
12 Loosen the yellow hose from the nitrogen tube and connect it to
the vacuum pump.
13 Start the vacuum pump and open the cock on the suction side
very carefully, otherwise the oil is blown out of the vacuum pump.
Then, open the cock on the pressure side, use vacuum suction
for at least 30 minutes. Preferably longer.
14 First close both cocks on the pressure gauge set. Then turn off
the vacuum pump. Work in this order, otherwise the air will rush
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 cock
on the tube.
16 Bleed the yellow hose by unloading the service connection at the
manometer set until pure gas flows out.
17 Open the cock on the suction side and allow the gas to flow
around until the pressure gauges indicate the same pressure as
in the tube.
18 Start the compressor and set the cooling thermostat and fan to
max.
Maintenance Manual DCF 180–250
UDCF06.01GB
9:18
9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
19 Open the cock on the pressure side and let the compressor suck
from the tube. Observe the sight glass. At the beginning the fluid
is mixed with a lot of bubbles. The longer the compressor is
allowed to run in intake mode, the less bubbles there will be, and
the clearer the fluid will be. If the bubbles suddenly disappear the
cooling thermostat has probably cut out. Bypass the thermostat
using a cable directly from the connection 24 V or wait until the
thermostat cuts in again. Continue until the correct refrigerant
amount has been reached.
NOTE
Directly bypassing the compressor's coupling magnet can lead
to compressor damage caused by incorrect refrigerant quantity.
Close the cock on the suction side and then the cock on the tube.
Disconnect the service hoses from the compressor and install
the protective caps. Check for leaks according to step 11 or with
a special leak detector.
20 In case of overfilling, the pressure and temperature increase
slowly until the high-pressure monitor cuts off the current to the
compressor's electromagnet. This is due to the refrigerant rushing
around in the system without being evaporated or condensed in
the condenser. The result is that the cold in the cooling coil is lost
and high heat is generated in the condenser. In addition, a steady
stream of bubbles can be seen in the sight glass. Return to point 2.
21 In the event of underfilling or a lack of refrigerant, bubbles appear
in the sight glass - return to step 2.
Compressor cooling oil
1
At delivery, the compressor is filled with cooling oil. Under normal
conditions the oil should not be changed or refilled. In the event
of suspected incorrect oil quantity, see the instruction: "When
replacing the compressor."
2
In the event of refrigerant loss there may also be oil loss, because
about 25% of the oil volume is taken up by the refrigerant.
Recommended oil types that may be used are shown in the
section F Technical data.
When replacing the compressor
The compressor is filled with cooling oil when delivered. When
changing cooling compressor, change the oil as follows:
UDCF06.01GB
•
Drain the defective compressor of oil and measure the quantity.
•
Then drain the new compressor of oil and refill with the same
amount that was drained from the defective compressor. For oil
volume in the system, see section F Technical data.
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Fresh air filter
9:19
9.4.4 Fresh air filter
Fresh air filter, cleaning and replacement
The fresh air filter is also available as an option for the Spirit Delta
cab with AC or ECC
.
1 Machine in service position, see section B Safety.
2
Remove the filter insert.
3
Wash the filter insert with hot water and dishwashing detergent or
replace the filter when necessary.
4
Fit the filter.
Fine filter, air conditioning unit, replacement.
Fine filter is always available in combination with AC or ECC.
1
Machine in service position, see section B Safety.
2
Loosen the bolts and remove the air conditioning unit's front cover
(under the wiper motor).
3
Remove the filter insert.
4
Replace the filter when necessary.
5
Fit the filter insert.
NOTE
Make sure that the filter insert is fitted in accordance with the
arrow marking.
6
Fit the front cover.
Maintenance Manual DCF 180–250
UDCF06.01GB
9:20
9 Frame, body, cab and accessories – Condenser unit
9.4.9 Condenser unit
Condenser unit, checking
1.
Machine in service position, see section B Safety.
2
Check that the condenser's fins are not clogged with dust that
prevents air flow.
3
Clean the fins with compressed air.
014466
1
1
Condenser
9.4.21 Moisture filter
Moisture filter, checking
1
Machine in service position, see section B Safety.
2
Start the engine and let it idle.
3
Check the colour of the indicator on the moisture filter.
Blue indication = moisture filter ok.
009183
Grey or pink indication = change moisture filter (see Moisture filter,
changing, page 9:21).
Indicator moisture filter
UDCF06.01GB
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Moisture filter
9:21
Moisture filter, changing
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
1
Machine in service position, see section B Safety.
2
Drain the air conditioning of refrigerant R134a, with the intended
draining equipment.
IMPORTANT
009183
Working on the air conditioning requires special
authorisation.
3
Disconnect hoses and cabling from the moisture filter.
4
Disconnect the moisture filter pressure switch from the moisture
filter.
5
Change the moisture filter.
6
Fit the pressure switch and connect the hoses to the moisture filter.
7
Leak test and refill the machine with refrigerant R134a, using the
intended equipment.
For volume, see section F Technical data.
Maintenance Manual DCF 180–250
UDCF06.01GB
9:22
9 Frame, body, cab and accessories – Wiping and cleaning of windows
9.5 Wiping and cleaning of windows
Wiping and cleaning of windows, description
On the cab there are wipers for the front windshield, rear window,
and roof window. The function is to clean the windows and maintain
good visibility from the cab.
3
The wiper arm is attached to the wiper motor's shaft over a splined
taper. The shaft is made of hardened steel and the wiper arm's
bracket is made of a mild die cast material.
When installing it is important to make sure that the splines are free
from metal burrs or similar. Also, the nuts shall be tightened so tight
that the splines are pressed into the bracket and work like drive
flanges. Hold the wiper arm firmly when installing so that the torque
is not transmitted to the motor as it may be damaged (16–20 Nm
tightening torque).
2
001878
1
1.
Wiper, front
2.
Wiper, roof
3.
Wiper, rear
Wipers, checking
Check that:
UDCF06.01GB
1.
the motors are operating normally and without noise.
2.
the wiper arms are pressing the wiper blades against the windows.
Replace them if they show signs of damage or significant wear.
3.
the wiper blades are intact. Replace them if they are damaged
or worn.
4.
the washer function distributes washer fluid over the windows
satisfactorily. If necessary, fill the washer fluid and adjust the
washer nozzles.
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Lighting system
9:23
9.6 Lighting system
Lighting system, component location
The function of the lighting is to increase safety during operation and
load handling.
NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.
The following lighting is available:
6,10,12,14,15
8
7
9
13
11,12
1,2,3,4
16
014447
3,4,5
1.
Rear light, red
10. Extra work lights, cab roof, rear edge, 2 lamps
2.
Brake lights
11. Mast work lights, 2 lamps
3.
Direction indicators
12. Extra work lights, cab roof, rear edge, 2, 4 or 6 lamps
4.
Running lights
5.
Headlights
13. Extra work lights, cab roof, front edge, 2 lamps
6.
Back-up light, white
14. Extra work lights for container handling, 4 lamps
7.
Adjustable searchlight
15. Extra work lights for container handling, cab roof,
rear edge, 4 lamps
8.
Revolving beacon
9.
Interior lighting
16. Extra work light between the tilt cylinders, 1 lamp
Maintenance Manual DCF 180–250
UDCF06.01GB
9:24
9 Frame, body, cab and accessories – Signalling system
9.7 Signalling system
Signalling system, component location
The function of the signals is to increase safety during operation and
load handling. This can take place with light and sound. The machine
has the following signal systems:
NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.
7
4
8
5, 6
3, 5
014448
2
1
1.
Horn
5.
Direction indicators
2.
Electrically powered loud horn
6.
Reverse alarm
3.
Flashing hazard lights
7.
Back-up lights
4.
Revolving beacon
8.
Buzzer in cab
UDCF06.01GB
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Entertainment and communication
9:25
9.8 Entertainment and
communication
Entertainment and communication, description
For information and description of equipment, see supplier's
documentation for each product.
Maintenance Manual DCF 180–250
UDCF06.01GB
9:26
9 Frame, body, cab and accessories – Glass/windows/mirrors
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
Tempered safety glass is standard on all trucks. Tinted windows and
laminated glass are available as an option. Roof windows are a safety
feature and are therefore always made of polycarbonate plastic.
C
E
The mirrors are all the convex type. The inner rear view mirror is fitted
in all machines. Outer rear view mirrors are available as an option,
both with and without electrical heating.
A
As an option the machine can be equipped with a back-up
(reversing) camera and a screen in the cab to improve visibility.
007792
B
D
Overview, glass windows.
A
Side windows
B
Windscreen (front window)
C
Roof window
D
Rear window
E
Side windows, front
Roof window, checking
Check that the roof window is not damaged or cracked. If the roof
window is defective, change it immediately.
WARNING
The strength of the roof window can be substantially
reduced by exposure to substances that contain
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at regular
intervals. Clean only with windscreen washer fluid or
a mild cleaning agent. Rinse thoroughly with plenty
of lukewarm water. Replace a damaged roof window
immediately if it is cracked or scratched!
UDCF06.01GB
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Construction and suspension of cab
9:27
9.10 Construction and suspension of
cab
Design and suspension, description
The cab has a flat floor with a bracket for the operator's seat. It is
suspended in the cab undercarriage via heavy-duty rubber dampers
located on the cab's underside. This is to minimise vibrations from the
frame to the cab. Each damper has a rubber bushing and a bolt.
1
3
4
1.
Cab frame
2.
Door
3.
Cab suspension
4.
Cab undercarriage
003206
2
9.10.1 Cab frame
Cab frame, checking
1
Machine in service position, see section B Safety.
2
Check the cab frame with regard to rust damage, deformation
or cracks. Rectify if necessary.
Maintenance Manual DCF 180–250
UDCF06.01GB
9:28
9 Frame, body, cab and accessories – Doors
9.10.2 Doors
Doors, checking
Machine in service position, see section B Safety.
2
Visually inspect the door's mounting points.
3
Check the door's locking mechanism with regard to function and
wear.
4
Lubricate the door hinges if necessary.
006914
1
9.10.3 Cab undercarriage
Cab undercarriage, checking
Machine in service position, see section B Safety.
2
Check that the welding seams at the cab's mounting points are
intact and free of visible cracks.
3
Check that the dampers are intact. Replace damaged dampers.
4
Check that the bolted joints are tightened, that the locking devices
function (are not damaged) and that the brackets are undamaged.
Take appropriate action if necessary.
006913
1
UDCF06.01GB
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Cab tilting
9:29
9.10.4 Cab tilting
Cab tilting, description
The cab can be tilted up to a certain inclination, above its equilibrium
position, articulated around the suspension on the left-hand side, by
means of a hydraulic cylinder. The hydraulic oil pressure is generated
by a hand-operated pump with an integrated switch valve for up or
down tilting.
There are locking devices on the mounting on the right-hand side
which secure the cab to the frame and they can be easily released for
tilting the cab.
Electric tilting of the cab is available as an option.
Maintenance Manual DCF 180–250
UDCF06.01GB
9:30
9 Frame, body, cab and accessories – Cab tilting
Tilting the cab
WARNING
Never work underneath a cab that is not tilted over its
balance point or secured in another way.
Risk of crushing injury.
Always tilt the cab as much as possible. At maximum
tilting angle (on a horizontal surface) align the cab's
centre of gravity so that it does not risk tilting back.
A, B, D
C
The cab must always be tilted over the equilibrium position. If the
space is insufficient laterally then the cab must always be secured
against accidental lowering by means of a brace.
C
Preparation:
A
•
Set the gear and travel direction selector in neutral.
•
Tilt the mast forward and lower the forks.
•
Apply the parking brake.
•
Check that there is nothing loose in the cab.
•
Close the doors.
Tilting
B
1.
Turn both lock handles (position C) so that they reach their outer
position to loosen the cab from the frame.
2.
Set the pump valve (position B) in the right-hand position.
3.
Fit the pump rod in its bracket (position A).
4.
Pump until the cab has reached the end-position.
Lowering
D
1.
Set the pump valve (position B) in the 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.
4.
Turn both lock handles (position C) so that they reach their inner
position to lock the cab to the frame.
013939
Electric tilting
A. Pump rod bracket
B. Pump valve
C. Lock handle (figure shows open position)
1.
Turn both lock handles (position C) so that they reach their outer
position to loosen the cab from the frame.
2.
Set the pump valve (position B) in the right-hand position.
3.
Use the control buttons (position D) to raise the cab to the end
position. Press both buttons simultaneously.
Electric lowering
D. Control buttons
UDCF06.01GB
1.
Set the pump valve (position B) in the left-hand position.
2.
Use the control buttons (position D) to lower the cab until it makes
contact with the frame. Press both buttons simultaneously.
3.
Turn both lock handles (position C) so that they reach their inner
position to lock the cab to the frame.
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Cab interior
9:31
9.11 Cab interior
Cab interior, description
The cab is designed for best operator comfort. On the dashboard
panels there are grouped switches, controls, warning and indicator
lights to give the operator a good working environment.
Recyclable material is used for all parts.
•
Dashboard panels
•
Interior plastic parts
•
Interior textile/fabric parts
•
Insulation
Maintenance Manual DCF 180–250
UDCF06.01GB
9:32
9 Frame, body, cab and accessories – Frame
9.12 Frame
Frame, description
The frame consists of two longitudinal frame sides cut from steel plate.
Fenders, footsteps, tanks and counterweights are bolted to the frame.
The frame contains mounting points for the steering axle and cab.
Bolted to the frame are brackets for engine, transmission, drive axle
and the fuel and hydraulic tanks, see under each respective function.
The fenders are bolted or welded to the frame, depending on machine
model.
The space in the frame's rear part is used for counterweights, the
number and size of which are adapted to the machine in question.
5
3
6
2
4
1
014449
7
1.
Frame front section
5.
Drive axle mount
2.
Frame rear section
6.
Steering axle mounts
3.
Beam pair
7.
Mast mount
4.
Mounting, rear fenders
Frame, checking
UDCF06.01GB
1
Machine in service position, see section B Safety.
2
Inspect for deformation and rust damage, as well as cracks in the
welded joints. Rectify as necessary. See section C Preventive
maintenance.
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Body structure
9:33
9.13 Body structure
Body, safety
WARNING
The hood may be slippery.
Danger of slipping.
It is forbidden to walk on the hood when it has no
anti-slip protection or is not level.
Body, description
The body's function is a part of the frame. There are fenders to deflect
dirt, footsteps and handrail to facilitate access on the frame, engine
hood to deflect dirt and objects from the engine compartment and a
counterweight to balance the machine's lifting capacity.
1
2
4
014450
3
5
1.
Fenders, front
2.
Fenders, rear
3.
Hood
4.
Counterweight
5.
Battery compartment
9.13.4 Counterweights
Counterweights, checking
DANGER
The counterweights are factory fitted and are adapted
according to the machine's characteristics.
The machine's operating characteristics are changed!
Never change the number of counterweights.
Maintenance Manual DCF 180–250
UDCF06.01GB
9 Frame, body, cab and accessories – Counterweights
1
Machine in service position, see section B Safety, with transverse
wheels.
2
Visually inspect that the counterweights are positioned properly
and that the mounts and welding seams are intact and free of
visible cracks.
3
Check the bolted joints.
014451
9:34
UDCF06.01GB
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Central lubrication
9:35
9.14 Central lubrication
Central lubrication, description
Central lubrication (replaces manual lubrication) is available in different
variants. The alternatives are:
•
Manual central lubrication, hand pumping lubricant at a lubrication
point which is then spread to all selected lubrication points.
•
Automatic central lubrication lubricates selected lubrication points
automatically during operation at pre-programmed time intervals.
It is also possible to select the number of lubrication points as follows:
•
Total 14 lubrication points: 8 on the steering and 6 on the mast (the
only alternative with manual central lubrication).
•
Total 18 lubrication points: 8 on the steering and 6 on the mast and
4 on the carriage.
•
Total 23 lubrication points: 8 on the steering and 6 on the mast and
9 on the carriage (with central levelling carriage).
Automatic central lubrication is built up of the following components:
1
•
Pump unit, with lubricant reservoir.
•
Distribution block, that distributes and portions the grease
between the different lubrication points.
The distribution block lubricates one point at a time. If a point
cannot be lubricated properly, e.g. in the event of a line blockage,
the following points will not be lubricated. The grease is forced
out through the safety valve on the pump unit.
2
3
•
Lines, between main unit and distribution block as well as
distribution block and grease nipples.
•
Grease nipples, at lubrication points.
On the pump unit it is possible to adjust the lubrication interval's
frequency and duration.
007935
The central lubrication is supplied with voltage when the parking
brake is released.
1.
Pump unit
2.
Safety valve
3.
Distribution block
NOTE
Central lubrication does not lubricate all lubrication points, some
still need to be lubricated during preventive maintenance.
Maintenance Manual DCF 180–250
UDCF06.01GB
9:36
9 Frame, body, cab and accessories – Central lubrication
Central lubrication, checking
1
1
Check that no grease has been forced out through the safety
valve (position 2).
If grease is pushed out through the safety valve, this means that
there is a system blockage. Locate the blocked line by feeling the
connections at the distribution block. A blocked hose remains
pressurised and the connection becomes firm.
2
3
NOTE
4
If several distribution blocks are connected in series, a clogged
line will be pressurised all the way to the first distribution block.
2
Turn the start key to position I.
3
Operate the pump manually and check that the indicator pin
(position 3) moves in and out on the distribution blocks.
To operate the pump, loosen the cover and press in switch manual
operation (position 5).
If the indicator pins do not move even when the pump is running,
troubleshoot the pump unit.
NOTE
5
007941
The system can be lubricated manually through the grease
nipple on the distribution block.
Overview of central lubrication. Example figure.
1.
Lubricant nipple, filling point, lubricating grease
2.
Safety valve
3.
Indicator pin
4.
Lubricant nipple, manual lubrication of the
system
5.
Switch, manual operation
UDCF06.01GB
4
Fill grease in the pump unit through the filler nipple (position 1),
see section F Technical data.
Maintenance Manual DCF 180–250
9 Frame, body, cab and accessories – Paint/coatings
9:37
9.15 Paint/coatings
Paint/surface finish, description
The machine is finished with a paint that is applied by brush or spray.
For colour code (RAL), see machine card.
Check the machine often for stone chips, impact damage, and
scratches to the paintwork, repair these immediately to avoid corrosion
on the underlying metal. Only use touch-up paint for minor stone chip
damage and scratches, major damage to paintwork should be repaired
by a paint shop.
NOTE
Before performing touch-ups, the surface area must be carefully
cleaned.
For information on other surface and material colours, contact
Cargotec.
Maintenance Manual DCF 180–250
UDCF06.01GB
9:38
UDCF06.01GB
Maintenance Manual DCF 180–250
10:1
10 Common hydraulics
Contents 10 Common hydraulics
10 Common hydraulics .........................................................................................10:3
10.2
Safety valves..................................................................................................10:9
10.3
Tanks and accumulators ..............................................................................10:10
10.3.2
Accumulator ............................................................................................ 10:11
10.4
Pumps..........................................................................................................10:12
10.5
Hoses, pipes and valves ..............................................................................10:13
10.6
Temperature control, cleaning and hydraulic oil...........................................10:14
10.6.2
Hydraulic oil cooler ..................................................................................10:15
10.6.7
Breather filter hydraulic oil tank ...............................................................10:16
10.6.8
Hydraulic oil filter .....................................................................................10:16
10.6.9
Hydraulic oil.............................................................................................10:20
Maintenance Manual DCF 180–250
UDCF06.01GB
10:2
UDCF06.01GB
Maintenance Manual DCF 180–250
10 Common hydraulics – Common hydraulics
10:3
10 Common hydraulics
Common hydraulics, description
Hydraulic functions that are common to several of the machine's
main functions are found under the function common hydraulics. For
example, the hydraulic oil pumps that supply load handling, steering,
the brake system and certain cab functions with hydraulic pressure.
Maintenance Manual DCF 180–250
UDCF06.01GB
10:4
10 Common hydraulics – Common hydraulics
Pressure plate
On the machine there is a pressure plate with the most important
pressure information (stamped in). The pressure plate is located on
the right-hand side of the frame in front of the cab steps.
Pressure levels vary with the equipment and therefore they are unique
to each machine. When checking pressure the pressures must
correspond with the pressure plate.
2
3
4
1
5
6
014760
7
1.
Precharge pressure, accumulators
5.
Servo pressure, load handling functions
2.
Steering pressure
6.
Pressure for lifting/lowering and tilt
3.
Hydraulic pressure, accumulators
7.
Pressure for steering and load handling
4.
Max. brake pressure
UDCF06.01GB
Maintenance Manual DCF 180–250
10 Common hydraulics – Common hydraulics
10:5
Hydraulic pressure, checking
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
Servo pressure for control levers (PS)
Operate and warm up the machine so that the hydraulic oil
reaches operating temperature, approx. 50 ºC.
2
Turn off the engine.
3
Connect a pressure gauge (0–25 MPa) to the measuring outlet PS
on control valve, load handling.
4
Start the engine and check the servo pressure. Compare to the
pressure plate.
5
Switch off the engine and remove the pressure gauge and fit the
protective cap on the measuring outlet.
6
To adjust the hydraulic pressure, see Workshop Manual DCF
180–250.
014473
1
Pump pressure for steering and load handling
1
Operate and warm up the machine so that the hydraulic oil
reaches operating temperature, approx. 50 ºC.
2
Turn off the engine.
Maintenance Manual DCF 180–250
UDCF06.01GB
10:6
10 Common hydraulics – Common hydraulics
3
Connect a pressure gauge (0–25 MPa) to the measuring outlet on
the priority valve.
4
Start the engine and let it idle.
5
Check the standby pressure for one pump at a time as follows:
Hydraulic oil pump for steering and load handling: 3.0 MPa
Hydraulic oil pump for lifting/lowering and tilt: 2.8 MPa
Settings apply to standard machine, certain machines may have
higher standby pressure. For correct standby pressure, see
pressure plate. However, the difference in pressure between the
different pumps must always be maintained.
014473
6
Increase engine speed to approx. 1800 rpm and move the tilt
function to relief (overflow).
Tilt in the mast to the max. position and continue requesting max.
tilt in with the control lever. This will move the tilt function to relief
(overflow).
Check the max. pressure on the hydraulic oil pump for
lifting/lowering and tilt. The pressure should match the value on
the pressure plate.
7
Increase engine speed to approx. 1800 rpm and turn to max.
steering right or left and continue to activate the function.
Check the max. pressure on the hydraulic oil pump for steering
and load handling. The pressure should match the value on the
pressure plate.
8
Switch off the engine and remove the pressure gauge and fit the
protective cap on the measuring outlet.
9
To adjust the hydraulic pressure, see Workshop Manual DCF
180–250.
Steering pressure
Operate and warm up the machine so that the hydraulic oil
reaches operating temperature, approx. 50 ºC.
2
Turn off the engine.
3
Connect a pressure gauge (0–25 MPa) to the measuring outlet at
the priority valve.
4
Start the engine and increase engine speed to approx. 1200 rpm.
5
Turn the steering wheel to full deflection and read the pump
pressure during steering wheel movement. Compare this to the
control pressure on the hydraulics plate.
6
Switch off the engine and remove the pressure gauge and fit the
protective cap on the measuring outlet.
7
To adjust the hydraulic pressure, see Workshop Manual DCF
180–250.
014475
1
UDCF06.01GB
Maintenance Manual DCF 180–250
10 Common hydraulics – Common hydraulics
10:7
Pump pressure, brake system
Operate and warm up the machine so that the oil in the brake
system reaches operating temperature, at least 50 ºC.
2
Machine in service position, see section B Safety.
3
Depressurise the hydraulic system, see section B Safety.
4
Connect a pressure gauge (0–25 MPa) to the measuring outlet for
pump pressure on the accumulator charging valve.
5
Start the engine and let it idle.
6
Close the drain valve on the accumulator charging valve and
check the pump pressure during charging.
014477
1
Measuring outlet pump pressure
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
During charging the pressure should increase to 20.5±1.0 MPa
before the accumulator charging valve switches to cooling. The
pressure drops when the accumulator charging valve switches
to cooling.
014476
7
Close the accumulator charging valve
Check the pressure during cooling.
During cooling the pressure should be max. 0.10–0.15 MPa at
max. engine speed.
8
Turn off the engine.
9
Depressurise the hydraulic system, see section B Safety.
10 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
11 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
Maintenance Manual DCF 180–250
UDCF06.01GB
10:8
10 Common hydraulics – Common hydraulics
Checking accumulator charging
Depressurise the hydraulic system, see section B Safety.
2
Connect a pressure gauge (0–25 MPa) to the measuring outlet for
accumulator pressure on the accumulator charging valve.
3
Start the engine and let it idle.
4
Close the drain valve on the accumulator charging valve.
014478
1
Measuring outlet accumulator pressure
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
5
Check that the pressure rises slowly to 20.5±1.0 MPa.
6
Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
014476
The valve shall switch to cooling at 15.5±0.5 MPa.
Close the accumulator charging valve
7
Depressurise the hydraulic system, see section B Safety.
8
Remove the pressure gauge and fit the protective cap on the
measuring outlet.
9
Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
UDCF06.01GB
Maintenance Manual DCF 180–250
10 Common hydraulics – Safety valves
10:9
10.2 Safety valves
Safety valves, component location
NOTE
The valve shall be closed during operation and is opened to
depressurise the machine.
1.
Accumulator drain valve with opening knob and lock ring.
014452
1
Maintenance Manual DCF 180–250
UDCF06.01GB
10:10
10 Common hydraulics – Tanks and accumulators
10.3 Tanks and accumulators
Tanks and accumulators, component location
A. Sight glass
B. Breather filter
C. Filling point
B
C
A
UDCF06.01GB
Maintenance Manual DCF 180–250
10 Common hydraulics – Accumulator
10:11
10.3.2 Accumulator
Accumulator, checking
1
Start the machine and allow it to idle (until the accumulator
charging valve switches to cooling).
2
Switch off the engine and turn the start key to position l.
3
Apply and release the brake several times, and count the number
of times that the brake can be applied before the error code for
low brake pressure is shown in the display.
It should be possible to apply the brake at least 8 times before the
error code for low brake pressure is shown.
If the error code for low brake pressure is shown earlier then the
accumulator is probably faulty and should be investigated further.
Maintenance Manual DCF 180–250
UDCF06.01GB
10:12
10 Common hydraulics – Pumps
10.4 Pumps
Pumps, general
The machine's hydraulics are supplied from three pumps. Two of
them for load handling/steering, and one for the brake system.
1
2
3
1.
Pump 1 supplies steering and control valve load handling. The
priority valve ensures that there is always pressure for steering,
the residual flow goes to control valve load handling.
2.
Pump 2 supplies lifting/lowering and tilt via control valve load
handling.
3.
The fixed brake oil pump supplies the brake system's brake and
cooling circuit over an accumulator charging valve, see section
4 Brakes.
014442
The pumps are assembled into a pump bank which is mounted to
the transmission's power take-off.
Hydraulic oil pumps in standard version.
1.
Hydraulic oil pump for steering and load handling
2.
Hydraulic oil pump for lifting/lowering and tilt
3.
Hydraulic oil pump for brake system
UDCF06.01GB
Maintenance Manual DCF 180–250
10 Common hydraulics – Hoses, pipes and valves
10:13
10.5 Hoses, pipes and valves
Hoses, pipes and valves, component location
1
2
014453
3
1.
Priority valve
2.
Accumulator charging valve
3.
Shuttle valve
Maintenance Manual DCF 180–250
UDCF06.01GB
10:14
10 Common hydraulics – Temperature control, cleaning and hydraulic oil
10.6 Temperature control, cleaning
and hydraulic oil
Temperature control, cleaning and hydraulic oil,
function description
The return oil from control valve load handling is filtered through the
hydraulic oil filter in the hydraulic oil tank. A high pressure filter fitted
after the brake system's hydraulic oil pump also cleans the oil.
The cooling system lowers the temperature of the machine's hydraulic
oil. The cooling system consists of a hydraulic oil cooler with separate
temperature-controlled electric fan fitted in the wheel brakes' cooling
circuit. Return oil from the accumulator charging valve is led via the
wheel brakes and is cooled in the hydraulic oil cooler. An electric
cooling fan increases the air flow through the cooler when the
temperature needs to be reduced. A thermal bypass valve leads the
hydraulic oil past the cooler directly to the tank if the temperature is
below 55 °C. When the oil temperature above 65 °C all the oil is led
through the cooler.
The temperature sensor starts the electric fan if the oil temperature is
above than 60 °C and switches off the fan when it is below 50 °C.
C
C
4
P
T
5
3
°C 7
2
10
6
9
M
8
014454
1
1.
Hydraulic oil pump
2.
High-pressure filter
3.
Accumulator charging valve
4.
Wheel brake
5.
Distribution block
6.
Thermal bypass valve
UDCF06.01GB
7.
Make-contact (closing switch) hydraulic oil
temperature (S240-1)
8.
Relay (K359)
9.
Cooling fan (M668)
10. Radiator
Maintenance Manual DCF 180–250
10 Common hydraulics – Hydraulic oil cooler
10:15
Temperature control, cleaning and hydraulic oil,
component location
2
1
3
10
5
11
6
4
8
014455
7
9
1.
Hydraulic oil pump, brake system
7.
Tank heater
2.
High-pressure filter
8.
Thermal bypass valve
3.
Accumulator charging valve
9.
Make-contact (closing switch) cooling fan
4.
Hydraulic oil filter
10. Hydraulic oil cooler
5.
Breather filter hydraulic oil tank
11. Cooling fan
6.
Hydraulic oil tank
10.6.2 Hydraulic oil cooler
Hydraulic oil cooler, cleaning
1
Machine in service position, see section B Safety.
2
Clean the hydraulic oil cooler (position A) using compressed air.
Blow away dust and other loose dirt.
014456
A
Maintenance Manual DCF 180–250
UDCF06.01GB
10:16
10 Common hydraulics – Breather filter hydraulic oil tank
10.6.7 Breather filter hydraulic oil tank
Breather filter hydraulic oil tank, changing
2
4
1
Turn off the engine and turn off the main electric power.
2
Clean the area around the filter housing.
3
Remove the filter housing.
Press down and turn approx. 1/8 turn clockwise.
2
1
4
Replace the filter insert.
Handle the filter insert as environmentally hazardous waste.
5
Fit the filter housing.
Press down and turn approx. 1/8 turn anticlockwise.
6
Reset the filter indicator by pressing down the button in the middle
on the glass centred on the filter insert.
014457
3
1.
Cover plate for oil filter
2.
Filling point hydraulic oil
3.
Sight glass hydraulic oil
4.
Breather filter hydraulic oil tank
10.6.8 Hydraulic oil filter
High-pressure filter, changing
A high-pressure filter is fitted in the engine compartment.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
Receptacle for hydraulic oil (5 l).
1 Machine in service position, see section B Safety.
2
UDCF06.01GB
Tilt the cab.
Maintenance Manual DCF 180–250
10 Common hydraulics – Hydraulic oil filter
10:17
3
Clean the filter cover externally.
4
Place a receptacle under the hydraulic oil filter.
5
Drain the oil in the filter by loosening the drain plug on the
underside of the filter.
6
Remove the top of the filter cover.
7
Remove the filter insert. Handle the filter insert as environmentally
hazardous waste.
8
Fit the small O-ring, which is located in the packaging, onto the
new filter.
In case of doubt, compare with the old filter insert.
9
Fit the new filter insert in the filter holder.
NOTE
Use only original filters.
Maintenance Manual DCF 180–250
UDCF06.01GB
10:18
10 Common hydraulics – Hydraulic oil filter
10 Fit a new support ring (white) and O-ring (black), which are located
in the packaging with the new filter, in the groove on the filter cover.
011772
NOTE
It is important to fit the support ring under the O-ring as
illustrated.
11 Lubricate the filter cover (on the side) with universal grease EP2.
12 Fit the top of the filter cover.
13 Start the engine and check that there are no leaks.
14 Turn off the engine.
15 Remove the receptacle. Handle the oil as environmentally
hazardous waste.
16 Check the hydraulic oil level, see Hydraulic oil, level check, page
10:20.
UDCF06.01GB
Maintenance Manual DCF 180–250
10 Common hydraulics – Hydraulic oil filter
10:19
Hydraulic oil filter, changing
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
2
4
1
Turn off the engine and turn off the main electric power.
2
Remove the cover plates (position 1) over the hydraulic oil filters.
3
Lift up the filter unit and place it in the receptacle. Let the hydraulic
oil drain.
4
Part the filter unit and remove the filter insert. Handle the filter
insert as environmentally hazardous waste. Note position of the
parts.
5
Clean the filter holder's parts. Be especially thorough with the
magnetic rod.
6
Fit the new filters and assemble the filter units.
7
Install the filter units and cover plates. Tighten the bolts crosswise.
8
Check the oil level, see Hydraulic oil, level check, page 10:20.
2
1
014457
3
1.
Cover plate for oil filter
2.
Filling point hydraulic oil
3.
Sight glass hydraulic oil
4.
Breather filter hydraulic oil tank
Magnetic rod
Maintenance Manual DCF 180–250
UDCF06.01GB
10:20
10 Common hydraulics – Hydraulic oil
10.6.9 Hydraulic oil
Hydraulic oil, level check
NOTE
Check the hydraulic oil level with the trolley completely lowered and
the mast tilted completely inward.
1
Machine in service position, section B Safety.
2
Check the oil level in the hydraulic tank. The oil level should be
visible in the sight glass. Fill oil as required. For oil grade, see
section F Technical data.
Hydraulic oil, checking
The condition of the hydraulic oil must be checked by means of oil
samples aimed at avoiding unnecessary wear and unnecessary oil
changes. The intervals for oil samples are presented in the service
schedule. Oil samples are taken in accordance with the instructions
from the relevant institution or oil supplier.
Threshold value for efficient oil is 18/14 in accordance with SS-ISO
4406 “Hydraulic fluid power - Fluids - Method for coding the level of
contamination by solid particles”.
Hydraulic oil, changing
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1
UDCF06.01GB
Machine in service position, see section B Safety.
Maintenance Manual DCF 180–250
10 Common hydraulics – Hydraulic oil
2
2
Remove the filler cap and pump out the hydraulic oil in a collection
container.
3
When most possible oil has been pumped out. Place a container
under the hydraulic oil tank's drain plug and drain the last hydraulic
oil.
4
Fit the drain plug when the oil has drained.
4
2
10:21
1
NOTE
Make sure that the drain plug's washer seal is also removed.
5
If the hydraulic oil filters are to be changed, change them before
filling the tank with oil, see Hydraulic oil filter, changing, page
10:19.
6
Fill new hydraulic oil in the filler holes on the filter's cover
plates. This filters the oil and protects the hydraulic system from
contamination.
014457
3
1.
Cover plate for oil filter
2.
Filling point hydraulic oil
3.
Sight glass hydraulic oil
4.
Breather filter hydraulic oil tank
Fill oil until the oil level is in the middle of the sight glass. For
volume and quality, see section F F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked when all hydraulic
cylinders are in the retracted position.
Maintenance Manual DCF 180–250
UDCF06.01GB
10:22
UDCF06.01GB
Maintenance Manual DCF 180–250
11:1
11 Common electrics
Contents 11 Common electrics
11
Common electrics ............................................................................................11:3
11.2
Electrical protection........................................................................................ 11:4
11.2.2
Fuses ........................................................................................................ 11:5
11.3
Batteries......................................................................................................... 11:8
11.3.1
Start battery............................................................................................... 11:8
11.4
Alternator ..................................................................................................... 11:10
11.5
Distribution of electricity ............................................................................... 11:11
11.5.1
Voltage feed ............................................................................................ 11:11
11.5.2
Electronic box.......................................................................................... 11:12
11.5.3
Control units ............................................................................................ 11:14
11.6
Communication ............................................................................................ 11:16
11.6.1
CAN bus .................................................................................................. 11:16
11.6.2
Redundant CAN-bus ............................................................................... 11:16
11.6.3
CAN-bus drivetrain .................................................................................. 11:16
Maintenance Manual DCF 180–250
UDCF06.01GB
11:2
UDCF06.01GB
Maintenance Manual DCF 180–250
11 Common electrics – Common electrics
11:3
11 Common electrics
Common electrics, general
Electrical functions that are common to several of the machine's main
functions are found under the function common electrics. For example,
voltage feed and CAN-bus.
Maintenance Manual DCF 180–250
UDCF06.01GB
11:4
11 Common electrics – Electrical protection
11.2 Electrical protection
Electrical protection, component location
1
1.
Circuit fuses, electronic box cab
2.
Main fuses
3.
Battery disconnector
4.
Control breaker
4
2
014462
3
UDCF06.01GB
Maintenance Manual DCF 180–250
11 Common electrics – Fuses
11:5
11.2.2 Fuses
Fuses, checking
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-voltage), see
Distribution of electricity, general, page 11:11. The main circuits are
fused several times with main fuses and circuit fuses.
Main fuses
Main fuses
The main fuses divide the machine's voltage feed into smaller parts
to maintain as many functions as possible in case of damage to
cables harnesses.
The machine's electrical system has main fuses in the battery
compartment on the frame, 4 x 25 A.
Disconnects all electrical power.
When checking and replacing the main fuse:
1
Disconnect the system voltage with the battery disconnector
(position 2).
2.
Remove the plastic cover.
3.
Check and replace fuses if necessary. The fuses are 25 A.
4.
Reconnect the system voltage.
014463
2
1.
1.
Main fuses (25 A)
2.
Battery disconnector
Maintenance Manual DCF 180–250
UDCF06.01GB
11:6
Circuit fuses
11 Common electrics – Fuses
Circuit fuses
The circuit fuses are grouped in fuse holders that are located in the
electronic box in the cab. The electronic box is located behind the
driver's seat in the cab.
Adjacent to the electronic box is a fuse plate describing the various
fuses.
B
C
D
007482
A
Fuses
A. Fuse holder F58-1
B. Fuse holder F58-2
C. Fuse holder F58-3
D. Fuse holder F58-4
When checking and replacing fuses:
1.
Disconnect the system voltage with the battery disconnector.
2.
Remove the cover of the electronic box.
3.
Remove the cover from the fuse holder.
4.
Check that the fuses are intact. Change when needed.
Measure and check if necessary.
The fuse plate provides information on each fuse.
UDCF06.01GB
Maintenance Manual DCF 180–250
11 Common electrics – Fuses
Fuses, power supply engine
11:7
Fuses, power supply engine
When checking and replacing fuses:
1.
Power supply engine.
2.
Power supply
2
Disconnect the system voltage with the battery disconnector.
2.
Remove the cover from the fuse.
3.
Check and replace the fuse if necessary.
014274
1
1.
after-treatment system.
Maintenance Manual DCF 180–250
UDCF06.01GB
11:8
11 Common electrics – Batteries
11.3 Batteries
11.3.1 Start battery
Battery, component location
The batteries, two connected in series, are located behind a cover lid
on the machine's rear left-hand side (by the fuel tank).
014464
The battery's negative terminal is connected to the frame and the
positive terminal is connected to the battery disconnector.
Start battery, checking
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Hazardous to health!
Use protective safety goggles and protective work
gloves when working with batteries. Remove
immediately any electrolyte on the skin. Wash with
soap and plenty of water. If electrolyte has splashed in
the eyes, rinse immediately with plenty of water and
contact a doctor immediately.
UDCF06.01GB
Maintenance Manual DCF 180–250
11 Common electrics – Start battery
1
11:9
Check the battery's acid gravity with a hydrometer. In a fully
charged battery the acid gravity should be 1.28 g/cm3.
If the acid gravity is lower than 1.24 at +20 °C then the battery
must be charged.
NOTE
A discharged battery freezes at -5 °C.
NOTE
If the acid gravity differs between the batteries they must be
charged separately.
2
The fluid level should be level with the top of the round white
plastic ring that is visible down in the battery when the cover is
unscrewed.
NOTE
Use only distilled water if topping up is necessary.
3
Check that the batteries are clean on the top to prevent leakage
currents between cells, which can cause reduced battery capacity.
014464
Wipe clean with a cloth and clean warm water without detergent.
4
Check that the battery's terminals are free from dirt. If needed,
lube the battery terminals with terminal grease.
Battery cables, checking
DANGER
Check that the battery cables are correctly clamped
and free from damage.
Fire hazard! Risk of personal injury!
Repair or replace damaged clamps and check that no
machine parts wear or chafe against the battery cables.
Change damaged battery cables.
The following battery cables should be checked for clamping, risk of
rubbing and damage to the battery cables. Rectify incorrect clamping
and risks of rubbing. Change battery cables that show signs of damage.
Diesel-powered machines
•
Plus-cable between battery and battery disconnector.
•
Plus-cable between battery disconnector and starter motor.
•
Plus-cable between starter motor and alternator.
•
Plus-cable between battery disconnector and main fuses.
•
Plus-cable between starter motor and preheating relay.
•
Plus-cable between preheating relay and preheating coil.
•
Ground cable between battery and frame.
•
Ground cable between engine and frame.
Maintenance Manual DCF 180–250
UDCF06.01GB
11:10
11 Common electrics – Alternator
11.4 Alternator
Alternator, component location
014036
The alternator is fitted on the engine. Location is dependent on
engine alternative.
UDCF06.01GB
Maintenance Manual DCF 180–250
11 Common electrics – Distribution of electricity
11:11
11.5 Distribution of electricity
Distribution of electricity, general
This section describes distribution of electric power and communication
between control units. Electric power distribution describes the
foundation of the electrical system and the network of control units
The system's communication has three main parts:
•
Voltage feed of control units
•
Redundant CAN bus communication (no control unit can drop out
without the system losing all function)
See CAN-bus, description, page 11:16.
•
CAN bus communication for drivetrain (the drivetrain has its own
communication system)
See CAN-bus drivetrain, description, page 11:16.
11.5.1 Voltage feed
11.5.1.1 Battery voltage, 30-voltage
Battery voltage, 30-voltage, description
The voltage before the ignition key lock is normally called 30-voltage.
This is always approx. 24 V, even if the ignition is switched off (ignition
key in position 0).
11.5.1.2 Ignition voltage, 15 volts
Ignition voltage, 15 volts, description
The voltage after the ignition key lock is normally called 15-voltage.
This is at 24 V, only if the ignition is switched on (ignition key in position
1). Otherwise this voltage is 0 V.
11.5.1.3 Frame connections
Frame connections, description
Power supply takes place with cable harnesses (cables) which are
routed across the machine.
Communication takes place via twinned pair signal cable (30 rpm).
Grounding points, description
A grounding point in the frame acts as main ground, including for the
starter motor. From there the ground is routed to a common point in the
electronic box to which all current consumers' grounds are connected.
Maintenance Manual DCF 180–250
UDCF06.01GB
11:12
11 Common electrics – Electronic box
11.5.2 Electronic box
Electronic box, component location
1
2
3
4
5
6
7
8
10
11 12 13
14
15
007759
9
16
Electronic box
1.
Relay, intermittent wipers
10. Bolts, holders and straps
2.
Relay, ignition
11. Socket, relay 5-pin
3.
Relays
12. Socket, relay 9-pin
4.
Fuse holder F58-2
13. Flasher unit, 200 W, 24 V
5.
Fuse holder F58-3
14. Mini relay
6.
Fuse holder F58-4
15. Fuse holder F58-1
7.
Fuse holder
16. Cable terminal, washer and screw
8.
Sleeve block with 9 pins
17. Fitting plate
9.
Circuit board with diodes
UDCF06.01GB
Maintenance Manual DCF 180–250
17
11 Common electrics – Electronic box
1
2
3
11:13
4
5
6
7
8
10
11 12 13
14
15
008571
9
16
17
Electronic box, machine with turnable driver's seat.
1.
Relay, intermittent wipers
10. Bolts, holders and straps
2.
Relay, ignition
11. Socket, relay 5-pin
3.
Relays
12. Socket, relay 9-pin
4.
Fuse holder F58-2
13. Flasher unit, 200 W, 24 V
5.
Fuse holder F58-3
14. Mini relay
6.
Fuse holder F58-4
15. Fuse holder F58-1
7.
Fuse holder
16. Cable terminal, washer and screw
8.
Sleeve block with 9 pins
17. Fitting plate
9.
Circuit board with diodes
Maintenance Manual DCF 180–250
UDCF06.01GB
11:14
11 Common electrics – Control units
11.5.3 Control units
Control units, general
A
B
C
D
Part of the machine's different functions is managed by the control
system KCS, see section 8 Control system, where each control unit is
allotted responsibility for a number of functions.
Control units ECU 790, ECU 792 and ECU 796 have indicator lamps
that can be used to check basic information on control unit status.
ECU 796
ECU 790
The indicator lamps have the following significations:
0007760
ECU 792
A
ECU 792
B
ECU 796
C
ECU 790
D
Electronic box
Table Indicator lamps ECU 790 and ECU 792
Green (Power)
Battery voltage OK.
Green
(System)
Internal 5 VDC OK
Yellow (Mode)
Software check, flashes 0.5Hz if the program is
OK, flashes 5 Hz if no program is loaded, fixed
light if in setup mode
Red (Status)
Illuminates if a fault arises.
Table Indicator lamps ECU 796
All LEDs illuminate with fixed light for 3 seconds when starting up.
UDCF06.01GB
Green
Power, fixed light at 22-28 VDC, flashing if
outside limits
Yellow
CAN bus communication and application OK
Red
Flashes if the supply voltage for the PWM card
is under 12 VDC.
Maintenance Manual DCF 180–250
11 Common electrics – Control units
11:15
Control units, position
1
2
4
3
6
014465
5
1.
Control unit, steering (ECU 792)
4.
Control unit terminal (EDU 795)
2.
Control unit, hydraulics (ECU 796)
5.
Control unit, transmission (ECU 793)
3.
Control unit general (ECU 790)
6.
Control unit engine (ECU 794)
Maintenance Manual DCF 180–250
UDCF06.01GB
11:16
11 Common electrics – Communication
11.6 Communication
Communication, general
The machine's communication is handled by a so-called CAN bus
system. The CAN bus system consists of control units connected
together to form a network.
ECU 792
1
ECU 790
EDU 795
The idea with the network is to share information. Signal values are
sent out by the control unit that, e.g., is connected to a sensor, other
control units can use the signal for their functions.
ECU 796
The network consists of control units and segments. Segment is the
CAN-bus between control units.
ECU 794
1.
Segment
2.
CAN-bus drivetrain
007764
2
ECU 793
11.6.1 CAN bus
CAN-bus, description
The CAN-bus consists of two twisted cables (twisted pair).
11.6.2 Redundant CAN-bus
Redundant CAN-bus, description
ECU 790
CAN R
CAN L
EDU 795
CAN R
CAN L
Redundant CAN-bus means that each control unit has two
connections for communication. The CAN-bus is connected in series
between the control units. This means that the CAN-bus can handle
loss of a segment. If several segments fail, then one or some control
units lose contact with the network and work independently, often with
limited capacity to perform their task.
ECU 796
CAN R
CAN L
007765
High+/Low-
ECU 792
Signals can be checked with diagnostic menu.
Principle illustration redundant CAN-bus
11.6.3 CAN-bus drivetrain
CAN-bus drivetrain, description
The communication with Control unit engine (ECU 794) and Control
unit transmission (ECU 793) is separated from the redundant
CAN-bus.
EDU 795
ECU 794
ECU 793
007766
Signals can be checked with diagnostic menu.
Principle illustration CAN-bus drivetrain
UDCF06.01GB
Maintenance Manual DCF 180–250
D:1
D Error codes
D Error codes
Error codes
See Workshop manual DCF 180-250, section D Error codes.
Maintenance Manual DCF 180–250
UDCF06.01GB
D:2
UDCF06.01GB
Maintenance Manual DCF 180–250
E:1
E Diagrams
E Diagrams
Diagrams
See Workshop manual DCF 180-250, section E Diagrams.
Maintenance Manual DCF 180–250
UDCF06.01GB
E:2
UDCF06.01GB
Maintenance Manual DCF 180–250
F:1
F Technical data
Contents F Technical data
Technical data.................................................................................................... F:3
Data .................................................................................................................F:3
Volumes ...........................................................................................................F:4
Specifications for lifting capacity and dimensions............................................F:6
Oils and lubricants, recommendation...............................................................F:8
Tightening torques, recommendations...........................................................F:10
Tightening torque, ORFS connections ...........................................................F:11
Tightening torque, connections for air conditioning unit.................................F:12
Unit explanations ...........................................................................................F:13
Conversion SI-units........................................................................................F:14
Conversion table, length ................................................................................F:15
Conversion table, area...................................................................................F:15
Conversion table, volume ..............................................................................F:15
Conversion table, weight................................................................................F:15
Conversion table, pressure ............................................................................F:16
Maintenance Manual DCF 180–250
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F:2
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Maintenance Manual DCF 180–250
F Technical data – Technical data
F:3
F Technical data
Data
Machine weights and dimensions vary with equipment installed on the
machine and are described in detail in the product specification and
spec. sheet for the relevant machine.
0 complete machine
Volvo TAD761VE
Guaranteed sound power level in
accordance with 2000/14/EC and
2005/88/EC including measurement
uncertainty 1.5 dB.
LWA 109 dB(A)
1 Engine
Volvo TAD761VE
Output in accordance with ISO 3046
(marked output)
Torque ISO 3046
160 kW between 1300-2200 rpm
1180 Nm at 1200 rpm
Max. rpm
1800 rpm
Number of cylinders
6 cylinders
Alternator, power
3360 W
System voltage, voltage capacity
2 Transmission
24 V (2x12 V / 145 Ah)
ZF 3WG171
No. of gears, forward - reverse
3 – 3
3.3 Driveline/Axle, drive axle
Kessler
Drive axle, type
D91
4 Brakes
Footbrake system - wheels affected
Wet Disc Brake - drive wheel
Parking brake system - wheels affected
Spring brake - drive wheel
5 Steering
Steering system
Hydraulic servo
6 Wheels
Dimension, front and rear
14.00x24
Tyre pressure, also see pressure plate
1.0 MPa
Tyre type, front and rear
Air filled. Spare and replacement tyres must be of a brand approved by Cargotec.
9 Cab
Equivalent sound pressure level
in cab according to EN12053
with measurement uncertainty σR
= 2.5 dB. Measuring value with
standard engine.
LpAz 72 dB(A)
Whole-body vibration in accordance
with EN13059 with measurement
uncertainty k = 0.3 x measured value.
0.4 - 0.7 m/s2
Maintenance Manual DCF 180–250
UDCF06.01GB
F:4
F Technical data – Technical data
9.6 Lighting system
Instruments
3
Ba7s
Indicator lamps
1.2
W2x4.6d
Interior lighting
10
S8.5
Rear lights
5
BA15s
Brake lights
21
BA15s
Direction indicators
21
BA15s
Rear lights, brake lights & direction indicators
-
Replace complete
5
SV8,5
-
Replace complete
Headlights (during high, low beam)
75/70
P43t-38 (H4)
Back-up lights
70
PK22s (H3)
Work light bulb
70
PK22s (H3)
35
D1S Xenon tube. Cartridge and
ballast are replaced complete.
-
Replace complete
70
PK22s (H1)
LED
Running lights
Running lights LED
Work light, Xenon
Work lighting LED
Revolving beacon
Volumes
Any deviation from this table must be supported with written approval
from Cargotec.
1.2 Engine, fuel
system
Fuel tank, volume
Fuel quality
280 l
Diesel according to:
EN590,
ASTM D 975 No 1–D,
ASTM D 975 No 2–D.
AdBlue tank, volume
Quality
15 l
AdBlue, according to ISO standard 22241.
1.7 Engine, cooling system
Coolant volume
35 l
Coolant filling
Volvo Penta Coolant VCS, ready-mixed
CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling system if
different types of coolant are mixed.
When changing and topping up coolant, only use coolant of
the same type that was used before.
UDCF06.01GB
Maintenance Manual DCF 180–250
F Technical data – Technical data
F:5
1.8 Engine, lubrication system
Oil type, quality
See Oils and lubricants, recommendation, page F:8.
27 l
Oil volume incl. filter
2.6 Transmission, lubrication
system
Oil type
See Oils and lubricants, recommendation, page F:8
Oil volume
28 l
3.3 Driveline/Axle, drive axle
Oil grade
See Oils and lubricants, recommendation, page F:8.
Oil volume, differential
30 l
Oil volume, hub reduction
2x4 l
9 Frame, body, cab and accessories
R134a
Refrigerant air conditioning
Volume refrigerant
2200 g (see sign for air conditioning)
Lubricant air conditioning
ZXL100PG
Volume, lubricant
0.32 l
Volume, washer fluid
2.5 l
10 Common hydraulics
Oil grade
See Oils and lubricants, recommendation, page F:8.
Oil additive
Lubrizol 3%
Volume hydraulic oil tank
270 l
Maintenance Manual DCF 180–250
UDCF06.01GB
F:6
F Technical data – Technical data
Specifications for lifting capacity and
dimensions
a
b
H5
A1
100
100
H4
H3
b
V1
V B
T1
H6
H2
H8
R1
R2
L3
L
L2
S
L4
T2
L1
DCF 180-12LB
DCF 200-12LB
DCF 220-12LB
DCF 250-12LB
18
20
22
25
Lifting capacity
Classification (kg
x 103)
1200
Centre of gravity
distance (L4 [mm])
Dimensions
Truck length
without forks (L
[mm])
6070
6320
Truck width (B
[mm])
3050
Height, basic
machine (H6
[mm])
3270
Seat height (H8
[mm])
2150
Axle distance (L3
[mm])
4000
4250
Distance drive axle
- fork front shank
surface (L2 [mm])
1070
Track (front - rear)
(T [mm])
2200 - 2140
Minimum turning
radius, outer (R1
[mm])
5500
Slewing radius,
inner (R2 [mm])
550
Ground clearance,
min [mm]
300
Height for cab
tilting, max. (T1
[mm])
3800
Width for cab
tilting, max. (T2
[mm])
3700
UDCF06.01GB
Maintenance Manual DCF 180–250
014780
a
F Technical data – Technical data
DCF 180-12LB
Minimum track
width for 90°
stacking with forks
(A1 [mm])
Kerb weight [kg x
10 3]
DCF 200-12LB
F:7
DCF 220-12LB
9170
28.5
Axle load pressure
front, (without
load) [kg]
29.8
DCF 250-12LB
9470
31.2
15000
32.9
15500
Axle load pressure
front, (with
classified load)
[kg]
43200
46300
49500
53800
Axle load pressure
rear, (without load)
[kg]
13500
14800
16200
17400
Axle load pressure
rear, (with
classified load)
[kg]
3300
3500
3700
4100
Maintenance Manual DCF 180–250
UDCF06.01GB
F:8
F Technical data – Technical data
Oils and lubricants, recommendation
Cargotec's stated service intervals in the maintenance manual are
conditional on oil selection according to the following table. The
table states recommended viscosity for different oil types and grades
depending on outdoor temperature.
Any deviation from this table must be approved in writing by Cargotec,
and may mean changed service intervals.
Oil type, quality
°C
-30
-20
-10
0
+10
+20
+30
+40
+50
°F
-22
-4
+14
+32
+50
+68
+86
+104
+122
1.8 Engine, lubrication system
SAE 15W/40
VDS-3
SAE 5W/30
2.6 Transmission, lubrication
system
API: CD/CE/CF-4/CF/CG-4/
CH-4/CI-4/SF/SG/SH/SJ/SL
SAE 10W, 10W/30, 10W/40
SAE 15W/30, 15W/40
SAE 20W/20, 20W/40
ACEA: Categories A, B, E
SAE 30
3.3 Driveline/Axle, drive axle
Hypoid oil, API GL-5 and
MIL-L-2105B
SAE 80W140
SAE 80W90
SAE 90
SAE 85W140
10 Common hydraulics
Hydraulic oil
AV 32
SS 155434
Hydraulic oil
AV 46
HVLP 46
DIN 51524
Hydraulic oil
HLP 68
ISO - LHV 46
ISO 6743/4
UDCF06.01GB
ISO - LHM 68
Maintenance Manual DCF 180–250
F Technical data – Technical data
F:9
NOTE
Oil filters shall always be changed in connection with oil change.
The change interval for engine oil is conditional on the sulphur
content in the fuel not exceeding 0.5%.
*) API CH-4 or CI-4 are approved for markets outside the EU/EES.
ACEA = Association des Constructeurs Européenne d'Automobiles
API = American Petroleum Institute
VDS = Volvo Drain Specification
Grease
Use a universal grease type EP according to NLGI Grade 2 (EP2) for
all lubrication points except for lifting equipment and slide plates.
For lifting equipment, use a universal grease type EP according to
NLGI Grade 2 (EP2) with 3-5% Molybdenum disulfide intermix.
For slide plates, use lubricants approved by Cargotec. Order from
Cargotec Parts department. 0.65 kg cartridge for grease gun, part no.
923110.0360, and 5 kg can, part no. 923595.0003.
NOTE
Select grease grade according to relevant climate.
Electrical connector grease
Use electrical contact grease part no. 923836.0552.
Sealant silicone
Use silicone part no. 923107.0308.
Silicone adhesive
Use silicone adhesive part no. 923854.0100.
Coolant
Only use ready-mixed recommended coolant. Select mixture of the
coolant that is adapted for correct temperature.
CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.
Maintenance Manual DCF 180–250
UDCF06.01GB
F:10
F Technical data – Technical data
Tightening torques, 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 tightening
torque should be reduced by approx. 5%.
For soft materials (lower hardness than 200 HB), use washer under
both bolt head and nut. As an alternative, use flange bolt or flange nut.
Tighten to the prescribed torque without stopping.
Recommended tightening torque varies depending on surface
treatment. Certain combinations of bolts and nuts require lubrication
according to the following table.
State
Nut
Screw
Lubrication
1
untreated
untreated
oil
2
bright galvanised
untreated or bright galvanised
dry or oil
3
hot-galvanised
untreated
dry or oil
8.8
Quality
10.9
12.9
1
2
3
1
1
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
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
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
State
Fine M-thread
M-thread
UNC-thread
UDCF06.01GB
Maintenance Manual DCF 180–250
F Technical data – Technical data
F:11
8.8
Quality
10.9
12.9
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 torque, ORFS connections
Pipe and hose coupling
Pipe diameter
Tightening torque
mm
Nm
inch
6
1/4
8
5/16
10
3/8
12
1/2
14
-
15
-
16
5/8
18
3/4
20
-
22
7/8
25
1"
28
-
30
-
32
1"1/4
35
-
38
1"1/2
23-25
33-38
51-57
80-90
120-130
150-170
180-200
200-240
Wrench size
Tightening torque
mm
Nm
inch
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
Maintenance Manual DCF 180–250
UDCF06.01GB
F:12
F Technical data – Technical data
Goods coupling
UNF-UN
Metric-ISO
BSSP
Thread (inch)
Tightening torque
(Nm)
Thread
(mm)
Tightening torque
(Nm)
Thread (inch)
Tightening torque (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
Tightening torque, connections for air
conditioning unit
O-ring coupling cooling coils
Hose diameter
Thread
Tightening torque
mm
inch
inch
Nm
6
1/4"
7/16"
7-13 Nm
10
3/8"
5/8"
14-20 Nm
10
3/8"
11/16"
14-20 Nm
12
1/2"
3/4"
14-26 Nm
16
5/8"
7/8"
27-41 Nm
19
3/4"
1 1/16"
34-46 Nm
3/8"
7-13 Nm
Pressure switch
7/16"
The above values should be considered guidelines and may vary
depending on installation.
UDCF06.01GB
Maintenance Manual DCF 180–250
F Technical data – Technical data
F:13
Unit explanations
Unit
Abbreviation
Newton metre
Nm
Kilopond metre
kpm
Kilopascal
kPa
Megapascal
MPa
Kilowatt
kW
Kilojoule
kJ
British thermal unit
Btu
Calorie
ca
Inch
in
Feet
ft
Yard
yd
Mile
mile
Centimetre
cm
Meter
m
Kilometre
km
Maintenance Manual DCF 180–250
UDCF06.01GB
F:14
F Technical data – Technical data
Conversion SI-units
SI-unit
Conversion factor
Non-SI
Conversion factor
SI
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
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/cm2
N/mm 2
x 145.04
= psi
x 0.069
= bar
MPa
x 145
= psi
x 0.00689
= MPa
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
kJ
x 0.948
= Btu
x 1.055
= kJ
J
x 0.239
= calorie
x 4.19
= J
m/s2
x 3.28
= ft/s2
x 0.305
= m/s2
m/s
x 3.28
= ft/s
x 0.305
= m/s
km/h
x 0.62
= mph
x 1.61
= km/h
Torque
Pressure (Pa = N/ m2)
Power (W = J/s)
Energy (J = Nm)
Speed and acceleration
Horsepower/torque
Bhp x 5252 rpm= TQ (lb ft)
TQ x rpm 5252 = bhp
Temperature
°C = (°F – 32)/1.8
°F = (°C x 1.8) + 32
Flow factor
l/min (dm3 /min)
UDCF06.01GB
x 0.264
= US gal/min x 3.785
Maintenance Manual DCF 180–250
= litre/min
F Technical data – Technical data
F:15
Conversion table, length
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
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
1 ha = 100 a – 1 mile2 = 259 ha = 2.59 km2
Conversion table, volume
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
1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)
Conversion table, weight
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
1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)
Maintenance Manual DCF 180–250
UDCF06.01GB
F:16
F Technical data – Technical data
Conversion table, pressure
Unit
kp/cm2
bar
Pa=N/m2
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 = 735,56 Dry (mmHg) = 0.96784 atm
UDCF06.01GB
Maintenance Manual DCF 180–250
G:1
G Terminology and index
Contents G Terminology and index
Terminology and index .....................................................................................G:3
Terminology..................................................................................................... G:3
Index ............................................................................................................... G:7
Maintenance Manual DCF 180–250
UDCF06.01GB
G:2
UDCF06.01GB
Maintenance Manual DCF 180–250
G Terminology and index – Terminology and index
G:3
G Terminology and index
Terminology
Explanations
Term
Description
AC
Air Conditioning Heater unit with manual control of heating, cooling, dehumidifying
and air flow.
Accumulator
Reservoir that stores (accumulates) pressure for i.e. hydraulic functions.
Attachment
Part of the machine that grabs the load when lifting.
Anti-corrosion agent
Prevents oxidation, in simple terms, rustproofing.
Working hydraulics
All load handling functions, e.g. lift and lower, tilt, side shift, spreader and levelling.
Axle distance
Distance between drive axle and steering axle.
Bar
Unit for measuring pressure.
Battery disconnector
Cuts off current from battery.
Central lubrication
An automatic system for the lubrication of a preset number of lubrication points.
Daily inspection
The actions that should be performed daily to ensure the machine’s functionality.
Decitonne
Tenth of a tonne, measure of the machine's lifting capacity.
Displacement
The oil volume that the pump can supply per pump revolution.
Display
"Window" showing digital information on steering wheel panel in cab.
Operating hours
Number of hours machine has been in operation, shown on hour meter in cab.
Drive axle
Driving axle that receives the torque from the drivetrain.
Drivetrain
Parts in machine involved in power transmission; engine, torque converter, transmission,
propeller shaft and drive axle with differential and hub reduction.
ECC
Electric Climate Control. Air conditioning with automatic control of heating, cooling,
dehumidifying and air flow.
ECU
Electronic Control Unit.
EDU
Electronic Display Unit.
Electrolyte level
Fluid level in battery cells.
Electric servo
Load handling hydraulic components receive control signals from electro-mechanical
controls.
Expansion tank
Tank for coolant.
Fixed displacement
Non-adjustable volume (capacity) of a pump.
FlexCab
Safety cage with a strong frame structure. Lined.
FlexGuard
Safety cage with a strong frame structure. Open.
FMI
Fault Message Identifier.
Forks
Lifting gear that lifts the load.
Fork bracket
Brackets for forks, mounted on the trolley.
Main fuse
Located by battery. Cuts the power to all systems in the whole machine.
Hydraulic oil
Oil for hydraulic system. See specifications in operator's manual.
Hydraulic oil pump
Pump in hydraulic system.
Hydraulic servo
Load handling hydraulic components receive control signals from mechanical controls.
Hydraulic system
System that uses oil pressure to transmit power to different functions.
Hanging load
Lifted load.
Maintenance Manual DCF 180–250
UDCF06.01GB
G:4
G Terminology and index – Terminology
Term
Description
Indicator
Manual "sensor", e.g., shows that a filter is clogged and needs to be replaced.
KCS
Kalmar Control System. An electronic control system that monitors and regulates
certain systems in the machine that require KCS, e.g. certain engine and transmission
alternatives.
Piston rod
Rod that is inserted into the piston's cylinder barrel and is acted on by hydraulic pressure.
Refrigerant
Fluid/gas in air conditioning. May only be handled by authorised trained person.
LC
Load centre.
Lifting capacity
Indicates machine's maximum lifting capacity.
Lifting point
Attaching point for lift device when lifting an object.
Trolley
Lifts the load, located on the mast.
Low-emission engine
Engine with low emissions of hazardous substances. Manufactured according to
regulations.
Solenoid valve
An electro-magnetically controlled valve. See also proportional valve.
Control valve
Valves that can be used to control something, e.g. release pressure and thus lower a
mast or a fork.
Machine model
Machine type. Indicated, for example: DCF 180-250. See also type designation.
Environmental waste
Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Torque converter
Hydraulic, variable clutch.
Counterweight
Weights adapted to the machine's lifting capacity to provide a balancing load during
lifting.
Hub reduction
Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drivetrain.
Pilot oil pressure
A low control pressure to, for example, a valve.
Planetary gear
Type of transmission with gears in constant mesh.
Product alternatives
One of several alternatives is selected for a machine, e. g., engine alternative.
Progressive steering
Rapid steering wheel movements give larger steering deflection.
Proportional valve
An electro-magnetically controlled valve. If a current is applied, the valve is activated
in proportion to the current's amplitude. In everyday language, a stepless valve, as
opposed to an Off/On valve. On, e. g., the transmission's valve housing.
Frame beam
Supporting beams in the frame.
Recirculation
Circulation in a closed system.
Serial number
Unique machine designation. Available on machine plate.
Service position
How machine should be safely positioned before service may be started.
Servo
A small user movement results in a big machine movement, e.g. power steering.
Servo pressure
A low control pressure to control a higher pressure, for example, to a valve.
Side shift
Forks moved sidewards in parallel.
Levelling
Forks tilted, e. g. if a load is standing on an uneven surface.
SmartLink
Software for operating the KCS (Kalmar Control System).
Spirit Delta
Enclosed type of cab.
SPN
Suspect Parameter Number.
Spreading
Spreading the forks, e.g. changing the relative distance between the forks.
Mast
Carrier of the attachment and the load.
Dust reservoir
The air filter collects the coarsest particles in a dust reservoir, emptied automatically
during operation.
UDCF06.01GB
Maintenance Manual DCF 180–250
G Terminology and index – Terminology
G:5
Term
Description
Steering axle
Wheel axle with steering.
Buzzer
Audible alarm to catch the operator’s attention.
Option
Optional equipment for machine.
Tilt
The mast is leaned forward or backward.
Top lift
Attachment. See attachment.
Transmission oil
Oil for transmission and torque converter. See specifications in operator's manual.
Securing machine for transport
Actions before transporting machine.
Twistlocks
Two or four lock pins, one in each corner of the attachment, pushed down into
corresponding holes in the container and twisted to lock the container when lifting.
Type designation
Indicates type of machine and capacity. See also machine model.
Maintenance
Periodic maintenance actions so that machine functions safely and for long life.
Variable pump
Pump with adjustable flow rate.
Variable displacement
Adjustable volume (capacity) of a pump.
Valve slide
Moving part in the valve. Decides the oil's path.
Wet brakes
Brake discs in oil-bath.
Maintenance Manual DCF 180–250
UDCF06.01GB
G:6
UDCF06.01GB
Maintenance Manual DCF 180–250
G Terminology and index – Index
Index
Error codes . . . . . . . . . . . . . . . . . . 8:8, D:1
Exhaust system . . . . . . . . . . . . . . . . . . 1:22
A
F
About the documentation . . .
About the maintenance manual .
Accumulator . . . . . . . . .
AdBlue filter . . . . . . . . .
AdBlue tank . . . . . . . . .
Air cleaning system . . . . . .
Air intake and exhaust outlet . .
Alternator . . . . . . . . . .
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A:10
. A:3
10:11
. 1:15
. 1:13
. 1:19
. 1:18
11:10
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. 11:8
11:11
. 9:33
. 4:4
. 4:3
10:16
B
Batteries. . . . . . . . . . .
Battery voltage, 30-voltage . . .
Body structure . . . . . . . .
Brake pedal . . . . . . . . .
Brakes . . . . . . . . . . .
Breather filter hydraulic oil tank .
Feedback . . . . . . . . . . .
Foreword . . . . . . . . . . .
Frame . . . . . . . . . . . . .
Frame connections . . . . . . .
Frame, body, cab and accessories
Fresh air filter . . . . . . . . .
Fuel filter . . . . . . . . . . .
Fuel prefilter . . . . . . . . . .
Fuel system . . . . . . . . . .
Fuel tank . . . . . . . . . . .
Fuses . . . . . . . . . . . . .
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. A:11
. A:3
. 9:32
11:11
. 9:3
. 9:19
. 1:12
. 1:9
. 1:8
. 1:9
. 11:5
G
General safety information . . . . . . . . . . . . . . B:3
Glass/windows/mirrors . . . . . . . . . . . . . . . 9:26
H
C
Cab frame . . . . . . . . . . . .
Cab interior . . . . . . . . . . .
Cab tilting . . . . . . . . . . . .
Cab undercarriage . . . . . . . .
CAN bus . . . . . . . . . . . .
CAN-bus drivetrain . . . . . . . .
Central lubrication . . . . . . . .
Chains . . . . . . . . . . . . .
Coil ram . . . . . . . . . . . . .
Common electrics . . . . . . . .
Common hydraulics . . . . . . . .
Communication. . . . . . . . . .
Complete machine . . . . . . . .
Condenser unit . . . . . . . . . .
Construction and suspension of cab .
Control system . . . . . . . . . .
Control system engine. . . . . . .
Control system transmission . . . .
Control units . . . . . . . . . . .
Controls and instruments . . . . .
Coolant . . . . . . . . . . . . .
Cooling fan . . . . . . . . . . .
Cooling system . . . . . . . . . .
Counterweights. . . . . . . . . .
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9:27
9:31
9:29
9:28
11:16
11:16
. 9:35
. 7:8
. 7:29
. 11:3
. 10:3
11:16
. 0:3
. 9:20
. 9:27
. 8:3
. 1:33
. 2:11
11:14
4:4, 9:5
. . 1:25
. . 1:24
1:24, 2:10
. . . 9:33
D
Diagnostics . . . . . .
Diagrams . . . . . . .
Distribution block . . . .
Distribution of electricity .
Doors . . . . . . . . .
Drive axle . . . . . . .
Driveline/Axle . . . . .
G:7
Heating, ventilation and air conditioning .
Hoses, pipes and valves . . . . . . . .
Hydraulic oil . . . . . . . . . . . . .
Hydraulic oil cooler . . . . . . . . . .
Hydraulic oil filter . . . . . . . . . . .
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. . 9:12
. 10:13
. 10:20
. 10:15
. 10:16
I
Ignition voltage, 15 volts . . . . . . . . . . . . . . 11:11
Ignition/heating . . . . . . . . . . . . . . . . . . . 1:34
Intercooler . . . . . . . . . . . . . . . . . . . . . 1:22
L
Last alarms (latest alarm)
Levelling. . . . . . . .
Lifting forks . . . . . .
Lifting/lowering . . . . .
Lighting system. . . . .
Link arm . . . . . . . .
Load carrier . . . . . .
Load handling . . . . .
Lubrication system . . .
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. . 8:11
. . 7:23
. . 7:27
. . 7:4
. . 9:23
. . 5:9
. . 7:27
. . 7:3
1:30, 2:7
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M
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8:9
E:1
4:8
11:11
. 9:28
. 3:4
. 3:3
Mast . . . . . . . . .
Mechanical transmission.
Moisture filter . . . . .
Monitoring functions. . .
. 7:7
. 2:6
. 9:20
. 8:6
O
Other functions . . . . . . . . . . . . . . . . . . . 7:30
E
ECU 790 . . . . . . . . . . .
ECU 792 . . . . . . . . . . .
ECU 796 . . . . . . . . . . .
Electrical protection . . . . . . .
Electronic box . . . . . . . . .
Engine . . . . . . . . . . . .
Entertainment and communication
Environment . . . . . . . . . .
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8:10
8:11
8:11
11:4
11:12
. 1:3
. 9:25
B:20
P
Paint/coatings . . . . . . .
Parking brake system . . . .
Parking brake unit . . . . .
Power assisted system . . .
Power-assisted brake system
Preventive maintenance . . .
Maintenance Manual DCF 180–250
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. 9:37
. 4:9
. 4:11
. 5:4
. 4:5
. C:3
UDCF06.01GB
G:8
G Terminology and index – Terminology
Propeller shaft . . . . . . . . . . . . . . . . . . . 3:3
Pumps . . . . . . . . . . . . . . . . . . . . . 10:12
R
Radiator and expansion tank .
Reading instructions . . . .
Redundant CAN-bus . . . .
Rim . . . . . . . . . . . .
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. . 1:24
. . A:4
. 11:16
. . 6:20
S
Safety . . . . . . . . . . . . .
Safety and emergency equipment.
Safety instructions . . . . . . .
Safety valves. . . . . . . . . .
Scales . . . . . . . . . . . .
Seats . . . . . . . . . . . . .
Sensor steering wheel reading . .
Service indicator . . . . . . . .
Side lift attachment . . . . . . .
Side shift . . . . . . . . . . .
Side shift cylinder . . . . . . . .
Signalling system . . . . . . . .
Speed limitation . . . . . . . .
Spreading . . . . . . . . . . .
Start battery . . . . . . . . . .
Start/stop . . . . . . . . . . .
Steering . . . . . . . . . . . .
UDCF06.01GB
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B:3
9:10
B:4
10:9
7:30
9:11
5:9
8:7
7:31
7:11
7:13
9:24
8:6
7:14
11:8
1:35
5:3
Steering axle cradle . . . . . . . . . . . . . . . . . 6:4
Support roller . . . . . . . . . . . . . . . . . . . 7:9
Suspension . . . . . . . . . . . . . . . . . . 6:3–6:4
T
Tanks and accumulators . . . . . . . . . .
Technical data . . . . . . . . . . . . . .
Temperature control, cleaning and hydraulic
oil . . . . . . . . . . . . . . . . . . .
Terminology . . . . . . . . . . . . . . .
Terminology and index . . . . . . . . . .
Tilt . . . . . . . . . . . . . . . . . . .
Tilt cylinder . . . . . . . . . . . . . . .
Top support roller . . . . . . . . . . . . .
Transmission. . . . . . . . . . . . . . .
Tyres . . . . . . . . . . . . . . . . . .
Tyres and rims . . . . . . . . . . . . . .
. . . . 10:10
. . . . . F:3
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4:13, 10:14
. . . G:3
. . . G:3
. . . 7:18
. . . 7:22
. . . 7:10
. . . 2:3
. . . 6:19
. . . 6:7
V
Voltage feed . . . . . . . . . . . . . . . . . . .
11:11
W
Wheel hub . . . . . . . . . . . . . . . . . . . . . 6:5
Wheel spindle . . . . . . . . . . . . . . . . . . . 6:5
Wiping and cleaning of windows . . . . . . . . . . . 9:22
Maintenance Manual DCF 180–250
G Terminology and index – Index
Maintenance Manual DCF 180–250
G:9
UDCF06.01GB
last page
Cargotec improves the efficiency of cargo flows by offering solutions for
the loading and unloading of goods on land and at sea – wherever cargo
is on the move. Cargotec’s main daughter brands for cargo handling
Hiab, Kalmar and MacGregor are global market leaders in their fields.
Cargotec’s global network offers extensive services that ensure the
continuous, reliable and sustainable performance of equipment.
Cargotec Sweden AB
Torggatan 3
SE-340 10, Lidhult, Sweden
tel. +46 372 260 00
fax +46 372 263 90
www.cargotec.com