HEAVY EQUIPMENT TECHNICIAN (H.E.

T)
SPECIALIST IN CATERPILLAR – DIAGNOSTICS AND REPAIRS GENERATORS (Cat & Perkins)
WHEEL LOADERS , DOZERS, EXCAVATORS, CRADERS
CAT – JCB – SANY – HITACHI – KOMATSU – VOLVO – PERKINS – CUMMINSS- KOBELCO

Douala, le 17
1 Janvier 2024

KALMAR FORKLIFT DCE160

DCE160-12
S/N :A40200438
REPAIR PROCEDURES

INITIAL OBSERVATION
1. Hard starting
2. Revolution per minute
minute(RPM) reduces after successive acceleration,
maximum attained on throttle ((2010 RPM),, minimum attained on
maximum throttle (1100RPM)
YOUR ENGINE VOLVO CUMINES QSB 6.7
This engine achieves or exceeds rated RPM at fullll throttle under any
steady operating condition when accelerating from idle to throttle (800RPM
(
to 3075RPM).
From my interpretations of the diagnosis yesterday, with all the codes
and troubleshooting it can be concluded that the low RPM is either:
- Fuel delivery issue to the engine
- Internal fuel leakage
- Or an issue with the pump.
There is a series of steps that are needed in order to isolate this to see if
it has a pump failure, injector over return issue, or inlet restriction
problem. I will list them below.
 Troubleshoot
roubleshoot all fault codes listed above (on
on the diagnostic sheet)
sheet
 Check the fuel supply ((check
check for adequate fuel supply)
sup
 Inspect the fuel g gage in the fuel tank
 Check for debris in fuel tank, filters, sensors, rails……..
rails
 Checkk for fuel inlet restriction above specification
 Check for air in fuel
 Check for fuel drain line restriction above specification
 Check for gear pump out put pressure below specification
 Check for fuel filter restriction above specification

CONTACT (+237) 653676928

653676928cont.
cont. P068815215523M
  Check for fuel leakage from iinjectors
njectors and high pressure
connectors
 Check if injector return flow meets specification
A cause of this problem could be the machine is operating on fuels lighter
than specified. Fuels with low viscosity result in high leakage and greater
drain flow rate.
 Inspect injector sealings, washers, and O-rings
rings for damage
 Check the high pressure fuel rail return flow ((check for leakage
too)
 Check fuel pump actuator
 Verify if electric supplies to injectors and sensors meets
specifications
 Clean all sensors, valves and rails related to the fuel system
 System testt
 Clear fault codes

Your machine will take us four to five working days to completion starting
Friday.

Cost of maintenance 200.000 FRS (two

two hundred thousand francs)
francs
An advance of 100.000 FRS (one hundred thousand
nd francs)
francs paid upfront

Le responsable technique

CONTACT (+237) 653676928

653676928cont.
cont. P068815215523M