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Kalmar DCE80-100E Technical Handbook

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Technical
Handbook
DCE80-100E
This Handbook deals with the design
and maintenance of Kalmar empty
container trucks, type DCE.
In addition, it gives details of
troubleshooting and the most common
corrective maintenance.
Operation and other matters that are
primarily of interest to the operator are
included in the Instruction Manual.
Kalmar Industries AB
We reserve the right to modify
our design and material speci-
fications without prior notice.
TDCE01.04GB
00
General
10
Chassis and cab
20
Electrical system
30
Engine
40
Transmission,
drive axle, brakes
50
60
Steered axle
70
Hydraulic system
80
Lifting mast, carriage
and side lift attachment
Periodic supervision
90

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Summary of Contents for Kalmar DCE80-100E

  • Page 1 Engine DCE80-100E Transmission, drive axle, brakes This Handbook deals with the design and maintenance of Kalmar empty container trucks, type DCE. In addition, it gives details of troubleshooting and the most common corrective maintenance. Operation and other matters that are...

  • Page 3: Table Of Contents

    DCE80-100E TDCE01 04GB Contents Technical Handbook Group 00 Group 00 Contents Safety regulations ..............2 General ..................5 Applications ................. 5 Design ................. 6 Component units ..............6 Main components ..............8 Supplementary books ............9 Replacement system – Spare parts ........9 Tools ..................

  • Page 4: Group 00

    The truck may not, without specific permission in your daily work. from Kalmar, be modified or re-built so that its func- tion or performance is altered. The instruction manual must always be kept in the ma- chine.
  • Page 5 Safety regulations DCE80-100E TDCE01 04GB Technical Handbook Group 00 Continued from previous page Handle batteries and junction boxes with great care. The batteries must always be protected over Operating regulations the poles and connections. Before starting, always check to ensure that no- Always rectify any damage or wear and tear that body is in the way of the truck or its equipment.
  • Page 6 Safety regulations DCE80-100E TDCE01 04GB Technical Handbook Group 00 Safety regulations Never run hands or fingers along any tubes, pipes or hoses whilst investigating for possible leaks as some of these lines (diesel fuel, hy- draulic, steering, etc.) operate at extremely...
  • Page 7 Safety regulations DCE80-100E TDCE01 04GB Technical Handbook Group 00 Safety instructions for working with tyres Tyre changing can be dangerous and should only – Do not use over-size tyres, too large for the be carried out by specially trained personnel using rims, e.g.

  • Page 8: General

    Technical Handbook Group 00 Applications The Kalmar DCE80-100E is a range of trucks is based on an en- tirely new approach to the design and production of heavy diesel- powered trucks. The trucks are durable and safe and their acces- sibility for service and maintenance is unexcelled.
  • Page 9 General DCE80-100E TDCE01 04GB Technical Handbook Group 00 1. Lifting mast, free lift mast with double cylinders 5. Gearbox, combined with torque converter 2. Operator’s cab, rubber suspended 6. Drive axle, with hub reduction and oil sooled, hydraulic brake system 3.

  • Page 10: Component Units

    General DCE80-100E TDCE01 04GB Technical Handbook Group 00 Component units Sound-insulated operator’s cab with excellent all-round visi- bility. The non-slip, substantial steps provide convenient ac- cess to the cab. Centrally positioned steering column. Clearly arranged instrument panel. Engine – Volvo TAD720VE (standard) six-cylinder, four- stroke, turbocharged diesel engine with direct injection and thermostatically controlled water cooling.

  • Page 11: Supplementary Books

    For the contents of these kits, see the Spare parts catalogue. Tools Kalmar offers a wide range of tools for truck maintenance work. For further information, please contact Kalmar's service depart- ment.

  • Page 12: Tightening Torques

    General DCE80-100E TDCE01 04GB Technical Handbook Group 00 Tightening torques The tightening torques are applicable to steel bolts and nuts tight- ened with a torque wrench under the following conditions: Surface treatment Condition Lubriation Bolt untreated untreated oiled bright galvanised...
  • Page 13 General DCE80-100E TDCE01 04GB Technical Handbook Group 00 To reduce the risk of settlement of the material and the associated reduction in the preloading force if the hardness of the surface supporting the bolt head or nut is lower than 200 HB, a washer should be fitted under the bolt head and nut.

  • Page 14: System Of Units

    General DCE80-100E TDCE01 04GB Technical Handbook Group 00 Quality 10,9 12,9 Tightening torque, Nm Condition Thread 5/16 7/16 9/16 1050 1058 1320 1560 1 1/8 1350 1200 1525 1900 2250 1 1/4 1860 1655 2100 2630 3110 1 3/8 2500...
  • Page 15 DCE80-100E TDCE01 04GB Contents Technical Handbook Group 10 Group 10 Chassis and cab Specifications ................2 Chassis..................3 Description ................3 Operator’s cab ................4 Description ................4 Steering column .............. 7 Service ................. 8 Changing the fresh air filter ..........8 Check and lubrication of brake pedal ......
  • Page 16 DCE80-100E Specifications TDCE01 04GB Technical Handbook Group 10 Air conditioner Cab unit Circulated air flow 500-600 m Electric power consumption approx 350 W Compressor Max. speed 4000 r/min Refrigerant R134a *) Electric power consumption approx 50 W Oil capacity Zexel PAG SP-20 1.5 dl...

  • Page 17: Chassis

    DCE80-100E Chassis TDCE01 04GB Description Technical Handbook Group 10 Chassis The chassis consists of: A unit construction frame built up around two beams with a minimum of welds for best possible strength. Mountings for the drive axle, steered axle, mast, lifting cylin- ders and transmission.

  • Page 18: Description

    DCE80-100E Operator’s cab TDCE01 04GB Description Technical Handbook Group 10 Operator’s cab The operator’s cab is a separate structure and rests on the chas- sis on rubber dampers. The operator’s seat, steering wheel and hydraulic control levers can be adjusted for best possible opera- tor comfort.

  • Page 19: Description

    DCE80-100E Operator’s cab TDCE01 04GB Description Technical Handbook Group 10 KL1733 KL743 1. Gear lever FORWARD/NEUTRAL/REVERSE 1/2/3 2. Lever DIRECTION INDICATORS/HORN FRONT WINDSCREEN WASHER/ FRONT WIPERS/MAIN BEAM 3. Instrument panel 4. Steering wheel panel 5. Starting switch KL1734 6. Control lever, hydraulic functions,...
  • Page 20 DCE80-100E Operator’s cab TDCE01 04GB Description Technical Handbook Group 10 KL581 37 38 39 35 36 40 41 42 43 44 45 47 48 49 50 51 54 55 56 60 59 KL582 KL1307 KL580 57 58 64 62 63 21.

  • Page 21: Steering Column

    DCE80-100E Operator’s cab TDCE01 04GB Description Technical Handbook Group 10 Steering column Surrounding the steering column are multi-function levers for gear changing, indicators, windshield wipers, etc., as well as the instrument panel with the ECS terminal. At the very foot of the steering column is the steering valve (Orbitrol), activated by the steering wheel via an angled gear.

  • Page 22: Service

    DCE80-100E Operator’s cab TDCE01 04GB Service Technical Handbook Group 10 Changing the fresh air filter (every 200 hours or when needed) 1. Remove the filter casing retaining bolts and remove the filter element. 2. Wash the filter insert with water and detergent or by using a high pressure washer.

  • Page 23: Check And Lubrication Of Brake Pedal

    DCE80-100E Operator’s cab TDCE01 04GB Service Technical Handbook Group 10 Check and lubrication of brake pedal (every 1000 hours) Check and tighten the locking screws 3, so that the brake pedal is securely fitted in the console. Lubricate the brake pedal shaft through the nipples 2.

  • Page 24: Windscreen Wipers

    DCE80-100E Operator’s cab TDCE01 04GB Service Technical Handbook Group 10 Windscreen wipers The wiper arms are fixed to the wiper motor shafts via conical splines. The shafts are manufactured of hardened steel and the wiper arm mounting of soft, pressed metal. When fitting, the nuts must be tightened so hard that the splines are pressed well into the mounting and function as a carrier.

  • Page 25: Air Conditioning Unit

    DCE80-100E Air conditioning unit TDCE01 04GB Description Technical Handbook Group 10 Air conditioning unit The air conditioning unit consists of the parts shown in the illu- stration and its function is to maintain the climate in the ope-ra- tor’s cab as comfortable as possible. The air conditioning unit:...
  • Page 26 DCE80-100E Air conditioning unit TDCE01 04GB Description Technical Handbook Group 10 1. Liquid receiver/filter dryer A High-pressure gas 2. Evaporator B High-pressure liquid 3. Fan C Low-pressure liquid 4. Expansion valve D Low-pressure gas 6. Condenser E Warm air in cab 7.
  • Page 27 DCE80-100E Air conditioning unit TDCE01 04GB Description Technical Handbook Group 10 Compressor The air conditioning system is driven by the compressor. This performs as a pump, drawing cold, low-pressure gas from the evaporator, compressing it and thereby raising its temperature, and discharging it at high pressure to the condenser.

  • Page 28: Service

    DCE80-100E Air conditioning unit TDCE01 04GB Service Technical Handbook Group 10 The liquid refrigerant should be completely evaporated before it is allowed to flow from the evaporator. The refrigerant is still cold WARNING! even when it has completely evaporated. The cold vapour which flows through what remains of the evaporator continues to absorb heat, and then becomes overheated.
  • Page 29 DCE80-100E Air conditioning unit TDCE01 04GB Service Technical Handbook Group 10 IN CAB CLIMATE UNIT CONDENSER UNIT GL 1,5 SV 1,5 RD 1,5 BR 1,5 BR 1,5 GL 1,5 VT 1,5 HIGH 1. Fan switch 2. Cooler on/off 3. Anti-freeze thermostat 4.
  • Page 30 DCE80-100E Empty page TDCE01 04GB Technical Handbook Group 10...
  • Page 31 DCE80-100E TDCE01 04GB Contents Technical Handbook Group 20 Group 20 Electrical system Specifications ................2 Electrical system ................3 Description ................3 Service ..................5 Checking the electrolyte level of the batteries....5 Fuses ................5 Bulbs ................5 Relays ................6 Sockets in electrical central..........7 Electrical diagram explanations ........8 List of circuit diagrams............9...

  • Page 32: Group 20

    DCE80-100E Specifications TDCE01 04GB Technical Handbook Group 20 Alternator rating 2240 W Starting battery, voltage 2 x 12 V capacity 140 Ah earthing negative...

  • Page 33: Electrical System

    DCE80-100E Electrical system TDCE01 04GB Description Technical Handbook Group 20 The system voltage is 24V and the supply is taken from two 12V batteries connected in series and charged by an alternator across electronic rectifying and voltage stabilisation circuits. IMPORTANT! The positive pole is connected across a main switch.
  • Page 34 DCE80-100E Electrical system TDCE01 04GB Description Technical Handbook Group 20 1. Sensor, warning lamp low oil pressure and gearbox oil pressure gauge 2. Sensor, warning lamp high oil temperatur and gearbox oil temperature gauge 3. Fuse 4. Relay preheater element 5.
  • Page 35 DCE80-100E Electrical system TDCE01 04GB Description Technical Handbook Group 20 1. Sensor, warning lamp low oil pressure and gearbox oil pressure gauge 2. Sensor, warning lamp high oil temperatur and gearbox oil temperature gauge 3. Sensor, coolant temp gauge 4. Solenoid, fuel shut off valve 5.
  • Page 36 DCE80-100E Electrical system TDCE01 04GB Description Technical Handbook Group 20 11 12 1. Sensor, outgoing speed gearbox. 2. sensor, warning lamp low oil pressure and gearbox oil pressure gauge 3. Starter motor relay 4. Main fuse 5. Starter motor 6. Sensor, coolant temperature gauge 7.

  • Page 37: Checking The Electrolyte Level Of The Batteries

    DCE80-100E Electrical system TDCE01 04GB Electrical system Technical Handbook Group 20 Electrical system The electrical system operates at 24 V. The source of power sup- ply are two 12 V batteries which are charged by an alternator. The N.B. negative pole is connected to the chassis.
  • Page 38 DCE80-100E Electrical system TDCE01 04GB Electrical system Technical Handbook Group 20 Relay box in cab – fuses Fuse Rating, A Circuit protected TWD TAD QSB 731 720 5.9 Hazard lights, ignitions key, preheater relay, start relay Cab lighting, seat buzzer, parking brake sen-...

  • Page 39: Relays

    DCE80-100E SUPERVISION TDCE01 04GB Electrical system Technical Handbook Group 20 Relays Reversing light Parking brake, disengagement High power (Starting switch) Wiper motor, front Electric stop (ECS 07) 322-1 Coolant level 322-2 Coolant level (ECS 07) Pulse relay, direction indicators Lever steering (ECS 04)

  • Page 40: Sockets In Electrical Central

    DCE80-100E SUPERVISION TDCE01 04GB Electrical system Technical Handbook Group 20 Sockets in electrical central Socket Destination pins XK1-XK5 Internally electrical central X6-X7 Right instrument panel, indicating lamps Instruments X9-X10 Left instrument panel, switches for driving and working lights X11-X12 Left instrument panel, other switches...

  • Page 41: Electrical Diagram Explanations

    DCE80-100E SUPERVISION TDCE01 04GB Diagram explanations Technical Handbook Group 20 Electrical diagram explanations H C L A. Connector, located outside the central electrical unit circuit board. X = Connector 33 = Pin number /4 = Pin number 4 in connector number 33 B.

  • Page 42: List Of Circuit Diagrams

    DCE80-100E SUPERVISION TDCE01 04GB Diagram explanations Technical Handbook Group 20 List of circuit diagrams Every truck is electrically described by a selection of circuit diagrams from the following list Diagram Circuit A35082.0200 Current, Volvo 730/731 VE A35083.0100 Gearchanging A35083.0300 ECS 01, aut gearchanging A35084.0300...
  • Page 93 Komponentförteckning / List of Components NUMBER CATEG SVENSKA ENGLISH Batteri Battery Kretskort elcentral Printed circuit board, Junction box Terminal stomanslutning Earthing terminal on chassis Terminal minusanslutning Terminal, negative terminal Säkringshållare 1-polig Fuse holder, 1-pole Säkringshållare 2-polig Fuse holder, 2-pole Säkringshållare 6-polig Fuse holder, 6-pole Säkringshållare 8-polig Fuse holder, 8-pole...
  • Page 94 NUMBER CATEG SVENSKA ENGLISH Strömställare Stegbelysning Switch, Steplight Strömställare fot Switch, foot Strömställare sitsvärme Switch, seat heater Batterifrånskiljare Battery disconnecting switch Strömställare AT-regulator Switch, AT-regulator Strömställare körvisare Switch, direction indicators Strömställare signalhorn Switch, horn Strömställare startlås/ellas Switch, main key switch Strömställare intervalltorkare Switch, intermittent wiper Strömställare kupevärmare...
  • Page 95 NUMBER CATEG SVENSKA ENGLISH Brytkontakt handskfack belysning Contact, breaking, glove Slutkontakt diff spärr Contact, making, diff. interlock Slutkontakt lampa temperatur spolkrets Contact, making, warning lamp bromsar temperature brake Slutkontakt överväxel Contact, making, over drive Slutkontakt temp motor Contact, making, temperature engine Slutkontakt bromsljus Contact, making, brake lights Slutkontakt backljus...
  • Page 96 NUMBER CATEG SVENSKA ENGLISH Slutkontakt överlastskydd Contact, making, overload protection Slut/brytkontakt option Contact, making/braking option Relä hel/halvljus Relay, main/dipped beam Relä dimljus Relay, fog light Relä fjärrljus Relay, distance light Relä lastljus Relay, mast light Relä arbetsljus Relay, working light Relä...
  • Page 97 NUMBER CATEG SVENSKA ENGLISH Relä fläktmotor värmare Relay, fan heating Relä fartreglage Relay, speed control Relä pumpkontaktor/pumpkontroll Relay, pump contactor/pump control Relä hyttlyft upp Relay, cab hoist up Relä hyttlyft ner Relay, cab hoist down Relä säkerhetsslinga Relay, safety loop Relä...
  • Page 98 NUMBER CATEG SVENSKA ENGLISH G-lampa arbetsljus Light bulb, working light G-lampa backljus Light bulb, rear light G-lampa cont belysning vänster Container light left-hand G-lampa cont belysning höger Container light right-hand G-lampa park ljus vä fram Light bulb, parking light, left-hand forward G-lampa park ljus hö...
  • Page 99 NUMBER CATEG SVENSKA ENGLISH G-lampa dimbakljus vänster Light bulb, fog light rear left G-lampa dimbakljus höger Light bulb, fog light rear right G-lampa bromsljus/körvisare vänster Light bulb, brake light/dir. indicator left- hand G-lampa bromsljus/körvisare höger Light bulb, brake light/dir. indicator right- hand G-lampa bromsljus blackout vänster Light bulb, brake light blackout left-hand...
  • Page 100 NUMBER CATEG SVENSKA ENGLISH Varn lampa laddning Warning lamp, loading Varn lampa laddning (extra) Warning lamp, loading extra Varn lampa färdbroms Warning lamp, brake Varn lampa parkerings broms Warning lamp, parking brake Varn lampa nivå kylvatten Warning lamp, coolant level Kont lampa diff spärr Indicating lamp, diff.
  • Page 101 NUMBER CATEG SVENSKA ENGLISH Kontroll lampa främre ben uppe Indicator lamp, front legs upper position Kontroll lampa främre ben nere Indicator lamp, front legs lower position Varningslampa överlast Warning lamp overload Kontroll lampa anliggning ett ben Indicator lamp, alignment one leg Kontroll lampa anliggning alla ben Indicator lamp, alignment all legs Kont lampa option...
  • Page 102 NUMBER CATEG SVENSKA ENGLISH M-ventil stolstilt Solenoid valve, seat tilt M-ventil luftfjädring Solenoid valve, pneumatic springing Termostat klimatannläggning Thermostat, air condition Torkarmotor fram Torkarmotor fram Torkarmotor fram Torkarmotor fram Vindrutespolarmotor Washer motor Strålkastarmotor Light motor Strålkastarspolarmotor Light washer motor Startmotor Starter motor Kylfläkt drivmotor (EC) Cooling fan, main motor (EC)
  • Page 103 NUMBER CATEG SVENSKA ENGLISH Mätare oljetryck motor Motor oil pressure gauge Mätare, temp. Hydraulolja Hydraulic fluidtemperature, guage Extra instrument allm Extra instrument, general Givare vändbar förarstol Transmitter, revolving driver´s seat (VBFS) FleetManager kontrollenhet FleetManager control unit FleetManager batterifilter FleetManager battery filter FleetManager kortläsare FleetManager card device FleetManager accelerations givare...
  • Page 104 NUMBER CATEG SVENSKA ENGLISH Elektronisk kontrollenhet ECU, hytt Electronic Control Unit ECU, cab Elektronisk kontrollenhet aggregat Electronic Control Unit, attachment Elektronisk kontrollenhet styrning Electronic Control Unit, steering system Elektronisk kontrollenhet växellåda Electronic Control Unit, gearbox Elektronisk kontrollenhet motor Electronic Control Unit, engine Display Display Elektronisk kontrollenhet, lasthantering Electronic Control Unit, Loadhandling...
  • Page 105 NUMBER CATEG SVENSKA ENGLISH Logik rev-spärr/aut-vxl Logic unit, reversing interlock/automatic gear changing Motor/kupevärmare Engine- and cab heater Logik slitageind kol elmotor Logic indication of wear, brush electrical motor Backvarnare Reversing alarm 1001 Strömställare, TW Switch, TW 1002 Strömställare, lossa TW Switch, unlocking of TW 1003 Strömställare, låsa TW...
  • Page 106 NUMBER CATEG SVENSKA ENGLISH 1042 Strömställare höjdjustering stol Switch, Seat height level 1043 Strömställare längdjustering stol Switch, Seat for/aft adjustment 1044 Strömställare Tankväljare Switch, Tankselector 1045 Strömställare Avstängning backalarm Switch, Rev. Alarm on/off 2000 Elektronisk kontrollenhet, Electronic control unit, propotional valve proportionalventil 3001 Relä...
  • Page 107 NUMBER CATEG SVENSKA ENGLISH 3769 Relä, blockering av hyttilt Relay, blocking of cab tilt 3770 Relä anliggning Relay, alignment 3771 Relä Krok Relay, Hook 3772 Relä laddsignal (D+) Relay, charge signal (D+) 3773 Relä 12V för minne radio Relay 12V for radio memory 3774 Relä...
  • Page 108 NUMBER CATEG SVENSKA ENGLISH 6032 M-ventil vänster bakhjul styrning vänster Solenoid valve, left rear wheel, steering left 6033 M-ventil vänster bakhjul styrning höger Solenoid valve, left rear wheel, steering right 6034 M-ventil skevning Solenoid valve, levelling 6035 M-ventil skevning höger Solenoid valve, levelling right 6036 M-ventil skevning vänster...
  • Page 109 NUMBER CATEG SVENSKA ENGLISH 6078 M-ventil,Avstängning Övre klämarm Solenoid valve, upper arm off 6079 M-Ventil, Sidoföring/Övre armar Solenoid valve, Sideshift/Upper arms 6080 M-ventil, aktivering hyttkörning Solenoid valve, activate sliding cab 7200 Givare, axeltryck höger Sensor, axle pressure right 7201 Givare, axeltryck vänster Sensor, axle pressure left 7202 Givare, anliggning vänster fram...
  • Page 110 NUMBER CATEG SVENSKA ENGLISH 8081 Potentiometer tiltvinkel Potentiometer tilt angle 8082 Potentiometer fläkthastighet, ECC Potentiometer fan speed, ECC 8083 Potentiometer temperatur, ECC Potentiometer temperature, ECC 8084 Potentiometer spjäll, ECC Potentiometer draught valve, ECC 8085 Potentiometer rotation Potentiometer rotation 8086 Potentiometer sax Potentiometer extender 8087 Potentiometer klämma...
  • Page 113 DCE80-100 TDCE01 04GB Contents Technical Handbook Group 30 Group 30 Volvo TWD731VE Cummins QSB5.9 See also Cummins Operation and Maintenance Manual Specifications ..............2 Specifications ............36 Engine TWD731VE .............3 Engine QSB 5.9 ............37 Description .............3 Description ............37 Overview ............3 Overview............
  • Page 114 DCE80-100 TDCE01 04GB Contents Technical Handbook Group 30...

  • Page 115: Volvo Twd731Ve

    DCE80-100E Specifications TDCE01 04GB Technical Handbook Group 30 Manufacturer, type Volvo TWD731VE Coolant volume, l Rating ISO 3046 kW (Hk) 167 (227) at r/min 2200 Torque ISO 3046, Nm at r/minl 1300-1450 Number of cylinders Swept volume, l 6.73 Valve clearance, engine cold inlet, mm 0.40...
  • Page 116 DCE80-100E Engine TWD731VE TDCE01 04GB Description Technical Handbook Group 30 Overview The TWD731VE engine is a 6-cylinder, inline, 4-stroke, low emis- sion diesel engine with overhead valves. The engine is turbo- charged, i.e. combustion air is supplied under pressure. As a result, the quantity of fuel injected can be increased, which in- creases the engine output.

  • Page 117: Engine Twd731Ve

    DCE80-100E Engine TWD731VE TDCE01 04GB Description Technical Handbook Group 30 TWD731VE 1. Fan hub 2. Gear driven coolant pump 3. Lift eyelet 4. Twin fuel filters of throw-away type 5. Turbo-charger 6. Air cooled exhaust manifold 7. Lift eyelet 8. Coolant pipe, inlet 9.

  • Page 118: Cooling System

    DCE80-100E Engine TWD731VE TDCE01 04GB Description Technical Handbook Group 30 Cooling system The engine is liquid-cooled and equipped with a closed cooling system consisting of the following main components: Coolant pump Radiator Expansion tank Thermostat Radiator fan Coolant passages Engine oil cooler...
  • Page 119 DCE80-100E Engine TWD731VE TDCE01 04GB Description Technical Handbook Group 30 The cooling system is equipped with a sensor which activates the ”Low coolant level” warning lamp on the instrument panel. The engine lubricating oil is cooled efficiently and reliably in a plate oil cooler that requires no external pipes on the engine.

  • Page 120: Fuel System

    DCE80-100E Engine TWD731VE TDCE01 04GB Description Technical Handbook Group 30 Fuel system The fuel circulates in two circuits - the high-pressure circuit and the low-pressure circuit. When the engine is started, the feed pump draws fuel from the tank and delivers it at relatively low pressure through fine filters up to the injection pump.
  • Page 121 DCE80-100E Engine TWD731VE TDCE01 04GB Description Technical Handbook Group 30 Fuel shut off valve At normal operation, the solenoid in the shut off valve is activated and fuel is fed to the injection pump. When the starting key is turned to 0, the solenoid valve is deacti- vated and the flow is reversed.
  • Page 122 DCE80-100E Engine TWD731VE TDCE01 04GB Description Technical Handbook Group 30 Fuel filters - two filters connected in parallel and with a common cover. The filters are of disposable type, with the filter elements made of spirally wound paper. Fuel filter Injectors - each with a nozzle holder and a nozzle.
  • Page 123 DCE80-100E Engine TWD731VE TDCE01 04GB Description Technical Handbook Group 30 Lubricating system The engine is pressure-lubricated, and the oil is supplied by a pump in the oil sump. All lubricating oil flows through a full-flow filter. One part of the oil flows through a by-pass filter for separa- tion of extremely small particles.

  • Page 124: Lubrication System

    DCE80-100E Engine TWD731VE TDCE01 04GB Description Technical Handbook Group 30 Reducing valve – located just before the filter. The valve will open if the lubricating oil pressure is too high and will return excess oil back to the sump. Oil filter – of full-flow type, with a filter element of pleated filter paper.

  • Page 125: Combustion Air System

    DCE80-100E Engine TWD731VE TDCE01 04GB Description Technical Handbook Group 30 Combustion system Large quantities of air are necessary for burning the fuel supplied to the engine. Free, unrestricted flow of fresh air and exhaust gases is therefore essential to allow the engine to run efficiently.
  • Page 126 DCE80-100E Engine TWD731VE TDCE01 04GB Description Technical Handbook Group 30 Turbocharger The turbocharger supplies more air to the combustion chambers than the engine would be capable of drawing naturally. This ena- bles the engine to burn more fuel which, in turn, increases the en- gine output.

  • Page 127: Service

    60% of water and 40% of ethylene glycol. The coolant should be changed and the cooling system should be flushed once a year. Always add a corrosion inhibitor (Kalmar part No. 923.110.0003) to the coolant, if the above mixture is not used in the cooling sys- tem.

  • Page 128: Changing The Oil And Oil Filter

    Stop the engine and check the oil level after a few minutes. Top up as necessary to the MAX level on the dipstick. N.B. To avoid serious damage to the engine, use only genu- ine Kalmar filters. Checking the V-belt tension Check at regular intervals that the V-belts are correctly ten- sioned.

  • Page 129: Changing The Fuel Filter

    DCE80-100E Engine TWD731VE TDCE01 04GB Service Technical Handbook Group 30 Checking and adjusting the valve clearances N.B. Never attempt to check the valve clearances when the engine is running. The engine must be stationary but may be cold or hot.

  • Page 130: Preventive Maintenance On Turbo-Charger

    DCE80-100E Engine TWD731VE TDCE01 04GB Service Technical Handbook Group 30 Preventive maintenance on the turbocharger The turbocharger may be damaged and, in the worst case, may break down if the engine is not properly serviced. Check that the engine air inlet system is in good condition, i.e.

  • Page 131: Volvo Tad720Ve

    DCE80-100E TDCE01 04GB Technical Handbook Group 30 Volvo TAD720VE...
  • Page 132 DCE80-100E Specifications TDCE01 04GB Technical Handbook Group 30 Manufacturer, type Volvo TAD720VE Coolant volume, l Rating ISO 3046 kW (Hk) 174 (237) at r/min 2300 Torque ISO 3046, Nm at r/minl 1400 Number of cylinders Swept volume, l 7,15 Valve clearance, engine cold...

  • Page 133: Description

    DCE80-100E Engine TAD720VE TDCE01 04GB Description Technical Handbook Group 30 Overview The TAD720VE engine is a 6-cylinder, inline, 4-stroke, low emis- sion diesel engine with overhead valves. The engine is turbo- charged, i.e. combustion air is supplied under pressure. As a result, the quantity of fuel injected can be increased, which in- creases the engine output.
  • Page 134 DCE80-100E Engine TAD720VE TDCE01 04GB Description Technical Handbook Group 30 1. Coolant connection, outlet 2. Turbo-compressor 3. Manifold 4. Lifting eylet 5. Crankcase ventilation 6. Starter motor 7. Injection pump 8. Oil cooler 9. Generator 10. Oil dip stick 11. Full flow filter, of “spin-on” typ 12.

  • Page 135: Cooling System

    DCE80-100E Engine TAD720VE TDCE01 04GB Description Technical Handbook Group 30 Cooling system The engine is liquid-cooled and equipped with a closed cooling system consisting of the following main components: 1. Charge air cooler Coolant pump air-to-air 2. Radiator, Radiator with integrated intercooler and gearbox oil cooler...
  • Page 136 DCE80-100E Engine TAD720VE TDCE01 04GB Description Technical Handbook Group 30 The cooling system is equipped with a sensor which activates the ”Low coolant level” warning lamp on the instrument panel. The engine lubricating oil is cooled efficiently and reliably in a plate oil cooler.

  • Page 137: Fuel System

    DCE80-100E Engine TAD720VE TDCE01 04GB Description Technical Handbook Group 30 Fuel system The fuel circulates in two circuits - the high-pressure circuit and the low-pressure circuit. When the engine is started, the feed pump draws fuel from the tank and delivers it at relatively low pressure through fine filters up to the injection pumps.
  • Page 138 DCE80-100E Engine TAD720VE TDCE01 04GB Description Technical Handbook Group 30 Fuel pre filter - with washable filter insert and draining valve for condensate . 1. Filter holder 2. Sealing between fil- ter holder and filter insert 3. Filter insert, washa- 4.

  • Page 139: Lubrication System

    DCE80-100E Engine TAD720VE TDCE01 04GB Description Technical Handbook Group 30 Lubricating system The engine is pressure-lubricated, and the oil is supplied by a pump in the oil sump. All lubricating oil flows through a full-flow filter. One part of the oil flows through a by-pass filter for separa- tion of extremely small particles.
  • Page 140 DCE80-100E Engine TAD720VE TDCE01 04GB Description Technical Handbook Group 30 Reducing valve – located just before the filter. The valve will open if the lubricating oil pressure is too high and will return excess oil back to the sump. Oil filter – of full-flow type, with a filter element of pleated filter paper.
  • Page 141 DCE80-100E Engine TAD720VE TDCE01 04GB Description Technical Handbook Group 30 Air system Large quantities of air are necessary for burning the fuel supplied to the engine. Free, unrestricted flow of fresh air and exhaust gases is therefore essential to allow the engine to run efficiently.
  • Page 142 DCE80-100E Engine TAD720VE TDCE01 04GB Description Technical Handbook Group 30 Turbocharger The turbocharger supplies more air to the combustion chambers than the engine would be capable of drawing naturally. This ena- bles the engine to burn more fuel which, in turn, increases the en- gine output.

  • Page 143: Service

    60% of water and 40% of ethylene glycol. The coolant should be changed and the cooling system should be flushed once a year. Always add a corrosion inhibitor (Kalmar part No. 923.110.0003) to the coolant, if the above mixture is not used in the cooling sys- tem.

  • Page 144: Changing The Oil And Oil Filter

    Stop the engine and check the oil level after a few minutes. Top up as necessary to the MAX level on the dipstick. N.B. To avoid serious damage to the engine, use only genu- ine Kalmar filters. Checking the V-belt tension Check at regular intervals that the V-belts are correctly ten- sioned.

  • Page 145: Checking And Adjusting The Valve Clearances.32

    DCE80-100E Engine TAD720VE TDCE01 04GB Service Technical Handbook Group 30 Checking and adjusting the valve clearances N.B. Never attempt to check the valve clearances when the engine is running. The engine must be stationary and cold. 1. Remove valve cover and crankcase ventilation Crankshaft position 1 2.

  • Page 146: Changing The Fuel Filter

    DCE80-100E Engine TAD720VE TDCE01 04GB Service Technical Handbook Group 30 Changing the fuel filter Clean the outsides of the filter. Remove the filter and discard it. Clean the filter head. Check that the new filter is perfectly clean and that the seal is in good condition.

  • Page 147: Preventive Maintenance On Turbo-Charger

    DCE80-100E Engine TAD720VE TDCE01 04GB Service Technical Handbook Group 30 Preventive maintenance on the turbocharger The turbocharger may be damaged and, in the worst case, may break down if the engine is not properly serviced. Check that the engine air inlet system is in good condition, i.e.

  • Page 148: Engine Qsb 5.9

    Engine Cummins QSB 5.9 TDCE01 04GB Description Technical Handbook Group 30 Cummins QSB 5.9 The following information concerns mainly the specific Kalmar in- stallation. For general engine information such as system de- scriptions, diagnosis and error codes, refer to the separate Cummins documents.
  • Page 149 DCE80-100E Specifications TDCE01 04GB Technical Handbook Group 30 Manufacturer, type Cummins QSB 5.9 Coolant volume, l Rating ISO 3046 kW (Hk) 160 (215) at r/min 2200 Torque ISO 3046, Nm at r/minl 1300-1500 Number of cylinders Swept volume, l Valve clearance, engine cold...

  • Page 150: Overview

    DCE80-100E Engine Cummins QSB 5.9 TDCE01 04GB Description Technical Handbook Group 30 Overview The Cummins QSB 5.9 engine is a 6-cylinder, inline, 4-stroke, low emission diesel engine with overhead valves. It has an Elec- tronic Controlled Fuel system. The engine is turbocharged, i.e. combustion air is supplied under pressure.
  • Page 151 DCE80-100E Engine Cummins QSB 5.9 TDCE01 04GB Description Technical Handbook Group 30 KL1699 1. Coolant outlet to charge air cooler 10. Oil dip stick 11. Full flow filter, of “spin-on” typ 2. Turbo-compressor 12. Fuel pre-filter with condensate separator 3. Air cooled manifold 13.

  • Page 152: Cooling System

    DCE80-100E Engine Cummins QSB 5.9 TDCE01 04GB Description Technical Handbook Group 30 Cooling system The engine is liquid-cooled and equipped with a closed cooling system consisting of the following main components: Coolant pump Radiator with integrated intercooler and gearbox oil cooler...

  • Page 153: Fuel System

    DCE80-100E Engine Cummins QSB 5.9 TDCE01 04GB Description Technical Handbook Group 30 Fuel system The fuel circulates in two circuits - the high-pressure circuit and the low-pressure circuit. When the engine is started, the feed pump draws fuel from the tank and delivers it at relatively low pressure through fine filters up to the injection pump.

  • Page 154: Lubrication System

    DCE80-100E Engine Cummins QSB 5.9 TDCE01 04GB Description Technical Handbook Group 30 Lubricating system The engine is pressure-lubricated, and the oil is supplied by a gear pump. All lubricating oil flows through a full-flow filter. The lubricating oil is cooled in a plate oil cooler by the engine coolant.
  • Page 155 DCE80-100E Engine Cummins QSB 5.9 TDCE01 04GB Description Technical Handbook Group 30 Air system Large quantities of air are necessary for burning the fuel supplied to the engine. Free, unrestricted flow of fresh air and exhaust gases is therefore essential to allow the engine to run efficiently.
  • Page 156 DCE80-100E Engine Cummins QSB 5.9 TDCE01 04GB Description Technical Handbook Group 30 Turbocharger The turbocharger supplies more air to the combustion chambers than the engine would be capable of drawing naturally. This ena- bles the engine to burn more fuel which, in turn, increases the en- gine output.

  • Page 157: Service

    60% of water and 40% of ethylene glycol. The coolant should be changed and the cooling system should be flushed once a year. Always add a corrosion inhibitor (Kalmar part No. 923.110.0003) to the coolant, if the above mixture is not used in the cooling sys- tem.

  • Page 158: Changing The Oil And Oil Filter

    Top up as necessary to the MAX level on the dipstick. N.B. To avoid serious damage to the engine, use only genu- ine Kalmar filter. Checking the drive belt tension Check at regular intervals that the V-belts are correctly ten- sioned.
  • Page 159 DCE80-100E Engine Cummins QSB 5.9 TDCE01 04GB Service Technical Handbook Group 30 Checking and adjusting the valve clearances N.B. Never attempt to check the valve clearances when the engine is running. The engine must be stationary and the temperature below 60°C.

  • Page 160: Changing The Fuel Filter

    DCE80-100E Engine Cummins QSB 5.9 TDCE01 04GB Service Technical Handbook Group 30 Changing the fuel filter Clean the outsides of the filter. Place a container underneath the filter. Drain any water and fuel from the filter container. Push drain- ing valve upwards, see picture.

  • Page 161: Preventive Maintenance On Turbo-Charger

    DCE80-100E Engine Cummins QSB 5.9 TDCE01 04GB Service Technical Handbook Group 30 Preventive maintenance on the turbocharger The turbocharger may be damaged and, in the worst case, may break down if the engine is not properly serviced. Check that the engine air inlet system is in good condition, i.e.
  • Page 163 DCE80-100E TDCE01 04GB Contents Technical Handbook Group 40 Group 40 Transmission, drive axle, brakes Specification ................2 Transmission ................3 Description ................3 Torque converter ............. 3 Gearbox................4 Oil circuit................5 Service ................. 6 Oil level check ..............6 Changing gearbox oil and filter........
  • Page 164 DCE80-100E Specifications TDCE01 04GB Technical Handbook Group 40 Torque converter and gearbox Model Clark - 13.7 HR 32000 Number of gears 3F – 3R Oil capacity, total system, l Oil grade See group 90 Oil operating temperature, °C 82–93 Max. permissible temperature, °C Clutch pressure, bar 17–20...

  • Page 165: Transmission

    DCE80-100E Transmission TDCE01 04GB Description Technical Handbook Group 40 The transmission consists of a torque converter integrated with the gearbox, and a propeller shaft, driven axle with differential, hub reductions and brakes. The torque converter and gearbox run together, using a common hydraulic system.
  • Page 166 DCE80-100E Transmission TDCE01 04GB Description Technical Handbook Group 40 1. Turbine wheel 2. Pump impeller 3. Stator 4. Torque converter 5. Oil filter 6. Oil pump 7. Clutch disc Gearbox Clark 28000/32000...
  • Page 167 DCE80-100E Transmission TDCE01 04GB Description Technical Handbook Group 40 The valve body mounted on the side of the gearbox includes spool valves which guide the oil flow to the various clutches. The spools, in turn, are electrically activated from the selector lever in the cab.

  • Page 168: Oil Circuit

    DCE80-100E Transmission TDCE01 04GB Description Technical Handbook Group 40 Oil circuit The function of the oil is: – to transmit the engine output to the gearbox. The torque converter can multiply the engine torque by up to three times, but at the expense of the speed rotation.

  • Page 169: Service

    DCE80-100E Transmission TDCE01 04GB Service Technical Handbook Group 40 Oil level check (transmission, incl. converter) Check the oil level daily with the engine at idling speed and the oil temperature between 82 and 93°C. Maintain the oil level at the FULL mark.
  • Page 170 N.B. In case of incorrect clutch pressure, first check the gearbox pressure sensor, see picture. If more details concerning individual test outlets are re- quired, contact KALMAR INDUSTRIES SERVICE Clark 32000 1. Oil cooler 2. Clutch pressure sensor 3. Measurement point “converter outlet”...

  • Page 171: Drive Axle

    DCE80-100E Drive axle Kessler TDCE01 04GB Description Technical Handbook Group 40 Downshifting in the drive axle is in two stages: in the differential, and in the hub reduction. This gives a minimum of stresses in the power transmission system since the final torque is achieved first at the driven wheels..

  • Page 172: Hub Reduction

    DCE80-100E Drive axle Kessler TDCE01 04GB Description Technical Handbook Group 40 Hub reduction The hub reduction consists of a cylindrical planetary gear in each hub. The planetray gear comprises a sun gear, 4 planet gears, and a ring gear that surrounds the planet gears. When the drive axle, and thereby the sun gear, rotates, the rotational movement is transmitted to the planet gears.

  • Page 173: Service Brake

    DCE80-100E Drive axle Kessler TDCE01 04GB Description Technical Handbook Group 40 Service brake The service brake consists of oil-cooled discs that are alternately fixed to and rotating with the hub. Hydrualic pressure is applied to activate a piston in each hub, the discs are then pressed to- gether, and the wheels are braked.

  • Page 174: Parking Brake System

    DCE80-100E Drive axle Kessler TDCE01 04GB Description Technical Handbook Group 40 Parking brake The parking brake is a disc brake that acts on the drive axle’s in- put shaft and is applied by means of a powerful spring in a spring brake cylinder.

  • Page 175: Service

    DCE80-100E Drive axle Kessler TDCE01 04GB Service Technical Handbook Group 40 Changing the drive axle oil IMPORTANT! To assure that the wheel ends of planetary axles with a common wheel end/housing bowl oil level are initially lubricated, fill each wheel end directly with oil before ve- hicle is put back into operation.

  • Page 176: Installation Of Disc Brake

    DCE80-100E Drive axle Kessler TDCE01 04GB Service Technical Handbook Group 40 Installation of disc brake Insert the brake discs (4) and (5) alternately in the brake housing (2). Measure the clearance A. Fit the piston (3) in the brake spider (1).
  • Page 177 DCE80-100E Drive axle Kessler TDCE01 04GB Service Technical Handbook Group 40 Check to marke sure the brake carrier (1) is free from scratches. Lubricate all internal surfaces, fit the brake piston (3), and align it to the tapped holes. Insert the springs (15) an washers (21) in the piston. Screw the piston firmly into the brake carrier (1) using the screws (16) coated and sealed with LOCTITE 262.

  • Page 178: Installing The Brake On The Axle

    DCE80-100E Drive axle Kessler TDCE01 04GB Service Technical Handbook Group 40 Installing the brake on the axle Check the sealing surfaces for the O-ring and apply a coat of LOCTITE 270 to the contact surfaces on the b rake spider.
  • Page 179 DCE80-100E Drive axle Kessler TDCE01 04GB Service Technical Handbook Group 40 Align and centre the discs (4) using the tool. Apply pressure to the discs with the help of the brake’s hydraulic system. Fit the wheel hub onto the axle’s splines. Release the brake pressure.
  • Page 180 DCE80-100E Drive axle Kessler TDCE01 04GB Service Technical Handbook Group 40 Installation of hub reduction Press the spacer wahser (1) onto the spindle and seal with LOCTITE 270. Push the sun gear (2) onto the spindle and secure with the lock ring (3).
  • Page 181 DCE80-100E Drive axle Kessler TDCE01 04GB Service Technical Handbook Group 40 Push the needle bearing into the planet gear (4). The outer cardboard sleeve in which the bearings are packed will then Outer cardboard Inner slide off. sleeve cardboard sleeve Fit the planet gears (4) onto the planetary gear carrier (5) –...

  • Page 182: Dismantling The Planet Gear

    DCE80-100E Drive axle Kessler TDCE01 04GB Service Technical Handbook Group 40 Dismantling the planet gear Tap the safety pin out from the inside. Press the planet gear shafts out from the outside and in- wards in the planetary gear carrier.
  • Page 183 DCE80-100E TDCE01 04GB Contents Technical Handbook Group 60 Group 60 Steering axle Specifications ................2 Steering axle................3 Description ................3 Service ................. 4 Replacement of steering cylinder ........4 Replacement of steered wheel bearings ......4 Replacement of knuckle pin bearings ......6 Inspection of dismountable rims........

  • Page 184: Group 60

    Specifications DCE80-100E TDCE01 04GB Technical Handbook Group 60 Tightening torques Nm (kpm) Wheel nuts 650 (66) Steered wheel bearing nuts 500 (51) Nuts for upper knuckle-pin 500 (51) bearings Nuts for lower knuckle-pin 500 (51) bearings Steering cylinder, 385 (39), oiled screw...

  • Page 185: Steering Axle

    Steering axle DCE80-100E TDCE01 04GB Description Technical Handbook Group 60 The steered axle is supported by a pendulum suspension and is operated by a double-acting steering cylinder. The mechanism includes the smallest possible number of moving parts to minimise the number of service points and to simplify maintenance.

  • Page 186: Service

    Steering axle DCE80-100E TDCE01 04GB Service Technical Handbook Group 60 Replacement of steering cylinder Disconnect the hydraulic connections from the steering cyl- inder, and protect the open ends of the cylinder and hoses by means of caps or plugs. Release and remove the piston rod pivot spindles.
  • Page 187 Steering axle DCE80-100E TDCE01 04GB Service Technical Handbook Group 60 1. Rubber element 2. Steering cylinder 3. Spindle 4. Locking screw 5. Lubricating nipple 6. Upper bearing 7. Wiper 8. Knuckle pin 9. Protective ring 10. Sealing ring 11. Lower bearing 12.

  • Page 188: Replacement Of Knuckle Pin Bearings

    Steering axle DCE80-100E TDCE01 04GB Service Technical Handbook Group 60 Tap the inner race of the inner bearing onto the wheel axle, using a suitable tube. Pack the inner race with grease. Lift the hub onto the axle, fit the inner race of the outer bear- ing position and pack it with grease.
  • Page 189 Steering axle DCE80-100E TDCE01 04GB Service Technical Handbook Group 60 Assembly Tap the outer race of the upper bearing into the steering cra- dle from below, using a piece of tube. Fit the screw back into the drift holes. Seal with sealing com- pound.

  • Page 190: Inspection Of Dismountable Rims

    Steering axle DCE80-100E TDCE01 04GB Service Technical Handbook Group 60 Inspection of dismountable rims Due to special operating conditions for dismountable rims, theres is a risk of excessive wear of the lock ring groove in the rim bead, the lock ring itself and the 45° face on the beadseat or loose flange.
  • Page 191 Information on the minimum diameter of your rim bead can be recieved from Kalmar LMV. High stress areas, how to identify rim damage High stress areas are marked with B on the illustration Typical faults are: circumferential cracks, fretting, corrosion pitting, distortion, wear.

  • Page 192: Safety Test When Changing Tyres

    Steering axle DCE80-100E TDCE01 04GB Service Technical Handbook Group 60 Safety test when changing tyres The test is intended for detecting cracks in wheels. Cracks can lead to safety risks if they are not detected and remedied. Potential cracks that cause air leakage are not detected in the test described here.
  • Page 193 DCE80-100E TDCE01 04GB Contents Technical Handbook Group 70 Group 70 Hydraulic system Specifications ................2 Main hydraulics................3 Description ................3 General survey ............... 3 Standad hydraulic system ..........3 Supply ................ 4 Hydraulic servo ............5 Electric servo ............. 6 Hydraulic system with separate side-lift hydraulics ..

  • Page 194: Group 70

    DCE80-100E TDCE01 04GB Technical Handbook Group 70 For different pressure settings, see the hydraulic plate on each truck 1. Test outlet and pressure setting separate lift section (14 and 12 on hydraulic diagram) 2. Test outlet and pressure setting working hydraulics (9 and 13 on hydraulic diagram) 3.

  • Page 195: Hydraulic System

    Main hydraulics DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 General survey There are two different hydraulic systems Standard with hydraulic servo Diagram A06195.0600 or with el-servo Hydraulic diagram A06195.0500 System with separate side-lift hydraulics Diagram 44866.0100 Standard hydraulic system, Diagram A06195.0600...
  • Page 196 Main hydraulics DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 The other hydraulic pump delivers fluid to the other functions of the main system and to the accumulator which in turn serves the parking brake, driving brake and servo system of the control levers (optional).
  • Page 197 Main hydraulics DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Standard hydralic system, hydraulic servo In its standard version, the hydraulic system is equipped with a hydraulic servo-operated main valve. A pressure reducing valve in the valve block delivers 35 bar servo pressure for the control- lever valves.
  • Page 198 Main hydraulics DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Standard hydraulic system, el-servo Standard hydraulic system can be equipped with a electronically servo-operated main valve. The ECS-system’s out-signals for the lever functions are fed to converters. The converters are electrically controlled pressure re- duction valves that convert the electrical signal to a proportional hydraulic pressure - servo pressure.

  • Page 199: - Hydraulic-Servo

    Main hydraulics DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Hydraulic system with separate side-lift hydraulics Hydraulic diabram A44866.0100 The hydraulic system consists of the following sub-systems: Working hydraulics, machine, that include: Servo hydraulics that supply pressure to the electro-hydraulic servo system –...
  • Page 200 Main hydraulics DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 KL1830 1. Variable axial piston pump 12. Accumulator 2. Relief valve 13. Accumulator evatuating valve 3. Fixed ving pump 14. Safety valve, accumulator 4. Fixed ving pump 15. Service brake system 5.
  • Page 201 Main hydraulics DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Working hydraulics, supply The hydraulic system is supplied from four different pumps. Pump 18+19 is a double combination pump where one section is a variable axial piston pump and the other section is a fixed ving pump.
  • Page 202 Main hydraulics DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Hydraulic system with separate side-lift hydraulics, el-servo This hydraulic system is equipped with a electronically servo- operated main valve. The ECS-system’s out-signals for the lever functions are fed to converters. The converters are electrically controlled pressure re- duction valves that convert the electrical signal to a proportional hydraulic pressure - servo pressure.

  • Page 203: Lifting

    Main hydraulics DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Lifting The lifting cylinders are supplied from a separate section in the main valve. The lifting speed is determined by the position of the lift control lever. The flow of fluid from the hydraulic pumps can be changed by altering the engine speed, which thus provides an additional means of controlling the lifting speed.

  • Page 204: Lowering Brake Valve

    Main hydraulics DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Lowering brake valve The lowering brake valves are screwed into the connecting pipes at the bottom of the cylinders. They are preset and no adjustment facilities are provided. The valve contains a spring-loaded control plunger and a mova- ble orifice plate, both of which interact to provide a constant flow through the valve regardless of the prevailing load.

  • Page 205: Tilting

    Main hydraulics DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Tilting The two tilting cylinders enable the mast to be tilted 3° forward and 3° to the rear. (Optional 2°/3° or 3°/6°) In each of the return lines is a valve which provides counter-pres- sure to avoid inadvertent forward tilt, which would otherwise oc- cur in unrestricted flow in the forward tilt mode.

  • Page 206: Attachment Supply

    Main hydraulics DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Attachment supply One section in the main valve for each of the functions sideshift, length adjustment 20’-40’ and twist-locks feeds the attachment cylinders. Only Standard hydraulic system. See also Group 80 Side-lift attachment The numbers correspond to the hydraulic diagram 18.

  • Page 207: Service

    Main hydraulics DCE80-100E TDCE01 04GB Service Technical Handbook Group 70 WARNING! The hydraulic system includes a high-pressure accumu- lator. Open the accumulator evacuating valve 42to re- lease pressure before working on the hydraulic system. Take great care during all work on the hydraulic system. Avoid being close to pressurized hydraulic components and hoses.
  • Page 208 Main hydraulics DCE80-100E TDCE01 04GB Service Technical Handbook Group 70 Checking the pressures and settings Open the accumulator evacuating valve 42 and start the en- gine. Stop the engine to check that the stopping device is working. When making the following tests, use a manometer with a hose of suficcient length so as the reading can be made from inside the operator’s cab.
  • Page 209 Main hydraulics DCE80-100E TDCE01 04GB Service Technical Handbook Group 70 Checking of pressures and settings, system with separate side-lift hydraulics 1. When making the following tests, use a manometer with a hose of suficcient length so as the reading can be made from inside the operator’s cab.
  • Page 210 Main hydraulics DCE80-100E TDCE01 04GB Service Technical Handbook Group 70 Pressure side-lift 17.Connect the manometer to test outlet B on the sid-lift sidlyf- tens main valve. 18.Increase the pump pressure by adjusting screw C. At 210 bar the main pressure limiting valve should open and the pressure should not increase further.

  • Page 211: Steering System Description

    Steering system DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Steering system The steering system comprises the steering valve and the steer- ing cylinder. The system is supplied with fluid from the valve block adjoining the main valve. An adjustable pressure limiting valve provides the control pressure.

  • Page 212: Steering Valve

    Steering system DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Orbitrol steering valve The steering valve is of the closed centre, non-reaction type with load sensing signal connection to the valve block. The load signal gives load-dependent control of the fluid pressure from the valve block to the steering valve.
  • Page 213 Steering system DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Item 12 – assembly pattern Tightening torquet: 30±5 Nm 1. Dust cover 17. Gear set 2. Body – spool – sleeve 18. O-ring 3. Ball 19. End plate 4. Threaded bush 20.

  • Page 214: Brake System

    Brake system DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Brakesystem – WDB-system The foot brake system is known as the wet disc brake system, in which each hub is equipped with a multiple-disc assembly. The disc assembly comprises stationary discs arranged alter- nately with a number of rotating discs.
  • Page 215 Brake system DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 36a 36b 31. Tank 33. Service brake cylinder 36a. Brake cooling curcuit supply 36b. Brake cooling curcuit, return 49. Oil cooler A. From brake pedal Brake system, cooling circuit supply...

  • Page 216: Oil Cooler

    Brake system DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Oil cooler A cooler with electrically powered fan is used for evacuation of heat which is generated in the hydraulic system, mainly when braking frequently. The numbers correspond to the hydraulic diagram...

  • Page 217: Service

    Brake system DCE80-100E TDCE01 04GB Service Technical Handbook Group 70 Checking the brake system The figures in the following text refer to the Hydraulic circuit dia- gram. See also Checking the pressures and settings, group 70 page 10 The checks are to be made with the hydraulic system at the work- ing temperature.

  • Page 218: Parking Brake

    Parking brake system DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Parking brake The parking brake consists of a disc brake with a brake cylinder on the drive axle input shaft. The brake is applied by a heavy spring in the brake cylinder.
  • Page 219 Hydraulpumpar DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Hydraulpumpar Pump 18 +19 is a kombination pump where the inner section is a variable piston pump 18 of constant pressure type and the outer section is a fixed vane pump19.
  • Page 220 Hydraulpumpar DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Fixed vane pump 12. Discharge ramp where unloaded vane moves in 1. Replaceable cartridge assembly, includes cam ring, 13. Pin cavity is at a steady pressure slightly higher than rotor, vanes, pins and sideplates at discharge port 2.

  • Page 221: Hydraulic Pumps

    Hydraulic pumps DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Hydraulic pump of gear type Machines that are not equipped with cab tilt supplied with hydrau- lic pumps of the gear type. The hydraulic pump is directly driven by the engine via splines.
  • Page 222 Hydraulpump DCE80-100E TDCE01 04GB Service Technical Handbook Group 70 Hydraulic pumps of gear type General instructions are given below for service operations that should be carried out on the pumps and how much wear is ac- ceptable on the various components before a particular compo- nent must be replaced.
  • Page 223 Hydraulpump DCE80-100E TDCE01 04GB Service Technical Handbook Group 70 Permissible wear of the pump components Pump body The pump pressure presses the pump gears towards the walls of the body on the low-pressure side, and since the shafts and bear- ings wear, the pump gears will rub against the body.

  • Page 224: Accumulator

    Accumulator DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Accumulator The hydraulic system is connected to membrane type accu-mu- lators which are pre-charged with nitrogen at a pressure of 100 bar. The membrane is forced upward causing the pressure of the nitrogen to increase as the accumulator becomes charged with hydraulic fluid.

  • Page 225: High Pressure Filter

    High pressure filter DCE80-100E TDCE01 04GB Description, service Technical Handbook Group 70 High pressure filter Two high pressure filters located immediately after the pumps are used to clean the fluid. The filter head is equipped with a by-pass valve which opens at 5 bar. The opening area is initially small but gradually increases with the pressure drop across the filter, ie, as the amount of impurities trapped by the filter cartridge increases.

  • Page 226: Main Valve

    Main valve DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Valve block Several hydraulic functions are concentrated to a valve block which is connected directly to the main valve. . Valve block, main functions: (Numbering is the same as in the Hydraulic Circuit Diagrams)
  • Page 227 Main valve DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Main valve The main valve, in its standard version, is actuated via a hydraulic servo. The valve consists of the following main components: Inlet section Control sections, corresponding to the number of functions...
  • Page 228 Main valve DCE80-100E TDCE01 04GB Description Technical Handbook Group 70 Control valve for servo control of the main valve The control valves are integrated into a block, and the number of valves corresponds to the number of functions of the truck.
  • Page 229 Main valve DCE80-100E TDCE01 04GB Service Technical Handbook Group 70 Main valve The main valve is precision made and must be treated with great care so that its performance will not be impaired. The following rules apply whenever service work is carried out.

  • Page 230: Service

    Hydraulic cylinders DCE80-100E TDCE01 04GB Service Technical Handbook Group 70 Repairs to leaking hydraulic cylinders – replacing the seal IMPORTANT! Never use compressed air for re- moving the piston from the cylinder. Se also separate information You could sustain serious injuries.
  • Page 231 Hydraulic cylinders DCE80-100E TDCE01 04GB Service Technical Handbook Group 70 Lubrication of single acting cylinders This type of cylinders have no oil supply on the piston side. If the cylinders are operated in a limited stroke (1), there is a risk of corrosion damage to the upper part of the cylinder in- ner surface (4).
  • Page 232 Hydraulic cylinders DCE80-100E TDCE01 04GB Service Technical Handbook Group 70 Lifting cylinder The cylinder head is fitted ito the cylinder tube with 12 screws and nuts Note that the lowering brake valve is integrated in the cylin- der tube 1. Pin 2.
  • Page 233 Hydraulic cylinders DCE80-100E TDCE01 04GB Service Technical Handbook Group 70 Steering cylinder The steering cylinder has a double-acting piston, with the piston seal in the centre. ,On each side of the cylinder tube there is a cyllinder head which is fixed to the cylinder tube by means of a locking ring.
  • Page 234 Hydraulic cylinders DCE80-100E TDCE01 04GB Service Technical Handbook Group 70 Tilt cylinder The tilt cylinder is fitted with a clevis mounts. The piston rod clevis is threaded onto the piston rod and is secured by lock- nuts and locking plate.
  • Page 235 Empty page DCE80-100E TDCE01 04GB Technical Handbook Group 70...
  • Page 236 Hydraulic diagram DCE80-100E TDCE01 04GB Components Technical Handbook Group 70 Hydraulic circuit diagram Components A06195.0500/0600 Accumulator charging valve Pressure limiting valve, steering system Differential valve, gives max. 11 bar difference between LS-signal of the steering valve and the pump pressure Priority valve for steering circuit.
  • Page 237 Hydraulic diagram DCE80-100E TDCE01 04GB Components Technical Handbook Group 70 Hydraullic system, electric servo A06195.0500...
  • Page 238 Hydraulic diagram DCE80-100E TDCE01 04GB Components Technical Handbook Group 70 Hydraulic circuit diagram Components A06195.0500/0600 Accumulator charging valve Pressure limiting valve, steering system Differential valve, gives max. 11 bar difference between LS-signal of the steering valve and the pump pressure Priority valve for steering circuit.
  • Page 239 Hydraulic diagram DCE80-100E TDCE01 04GB Components Technical Handbook Group 70 Hydraulsystem, hydraulservo A06195.0600...
  • Page 240 Hydraulic diagram DCE80-100E TDCE01 04GB Components Technical Handbook Group 70 Hydraulic circuit diagram Components A44866.0100 Accumulator charging valve Pressure limiting valve, steering system Differential valve, gives max. 11 bar difference between LS-signal of the steering valve and the pump pressure Priority valve for steering circuit.
  • Page 241 Hydraulic diagram DCE80-100E TDCE01 04GB Components Technical Handbook Group 70 Hydraulic system, hydraulic servo A44866.0100...
  • Page 242 Empty page DCE80-100E TDCE01 04GB Technical Handbook Group 70...
  • Page 243 4YFPRS   +& 7YTTPIQIRX ,]HVEYPMG ']PMRHIVW 8IGLRMGEP ,ERHFSSO %PP 8VYGOW...
  • Page 245 All trucks 9279 02-09 Contents Technical Handbook Publ. Gr. P. Contents Clean hydraulics ................ 3 Measures to prevent pollution of the hydraulic system....4 Fault finding for leakage ............6 The function and removal of seals..........7 Piston rod seals ..............7 Support ring and O ring ............

  • Page 247: Hydraulic Cylinders

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Clean hydraulics Hydraulic systems are extremely sensitive to impurities - a hy- draulic system is just as sensitive as a diesel engine’s fuel sys- tem, with its pumps, filters and lines. It is therefore extremely important that hydraulic systems are kept clean and free from impurities.

  • Page 248: Measures To Prevent Pollution Of The Hydraulic System

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Gasses The most common gas that occurs as an impurity in a hydraulic system is air. Unlike fluids, gasses can be compressed. If air is allowed to enter a hydraulic system, this compression will be ex- perienced as a “sponginess”...
  • Page 249 Never fit components where the protective plugs have fallen out - impurities may have entered the system IMPORTANT! If there is the slightest doubt about the purity of the hy- draulic fluid - send a fluid sample to the manufacturer of the fluid, or to Kalmar Service...

  • Page 250: Fault Finding For Leakage

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Fault finding for leakage 1. All fault finding should take place with the minimum hydraulic pressure required to actually discover the leakage. High pres- sure will tighten all seals and make it more difficult to discover any leakage.

  • Page 251: The Function And Removal Of Seals

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. The function and removal of seals Piston rod seals The piston rod seal is the seal that sits in a groove in the hydraulic cylinder head forming a seal against the piston rod. This seal is very exposed as it performs both dynamic and static sealing func- tions, i.e., it is seals against the moving surface of the piston rod whilst the sealing surface against the cylinder head is static.
  • Page 252 Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Piston rod seal type TICLA is of compact design with integrated support ring. It has an inner sealing lip against the piston rod and an outer sealing lip which seals with press fit against the cylinder head.

  • Page 253: Support Ring And O Ring

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. The compressible piston rod seal consists of a solid rubber profile and gives a greater sealing area than V seals. Use a screwdriver to remove the seal, see illustration. Lever out and twist up the seal.

  • Page 254: Wiper

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Wiper The task of the wiper is to scrape the piston rod clean and prevent øD+10 any impurities being drawn into the cylinder pipe. The wiper must be fitted with a special tool. This tool must have a greater outer diameter than the wiper, so that the pressure against the wiper ceases just as the wiper is pressed into posi- tion.

  • Page 255: Single Action V Type Piston Seals With Support Ring

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Single action V type piston seals with support ring On single action V seals it is always the long side that seals against the static and the short side that seals against the moving surface.

  • Page 256: Double Action Piston Seals

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Double action piston seals Double action seals function with pressure from both directions, e.g., in a steering cylinder. The whole of the surface within the cylinder pipe is the sealing surface, it is therefore extremely important that this surface is not damaged in any way.

  • Page 257: Lubrication

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Lubrication 1. Within the actual hydraulic system - never anything other than the normal hydraulic fluid used in the hydraulic system. 2. On the cylinder head thread - use copper paste (e.g., Moly- cote CU 7439).

  • Page 258: Dismantling The Steering Cylinder

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Dismantling the steering cylinder On the steering cylinder, it can be very difficult to remove the pis- ton from the cylinder as the O ring in the cylinder head sticks in the locking ring groove of the cylinder pipe.
  • Page 260 [[[OEPQEVMRHGSQ % 4EVXIO 'SQTER] /EPQEV -RHYWXVMIW 7ZIVMKI %& 7)  0NYRKF] 7[IHIR XIP     JE\    ...
  • Page 261 DCE80-100E TDCE01 04GB Contents Technical Handbook Group 80 Group 80 Lifting mast carriage and side lift attachment Specifications ................2 Lift mast and carriage ..............3 Description ................3 Service ................. 7 Inspection of lifting chains ..........7 Inspection of the lifting mast..........7 Dismantling the carriage..........

  • Page 262: Specifications

    DCE80-100E Specifications TDCE01 04GB Technical Handbook Group 80 Lifting chains Max. permissible wear (see instructions) WARNING! Risk for injuries by squeezing! At any work with the mast or carriage, the carriage must be secured against unitentional lowering by means of...

  • Page 263: Description

    Group 80 Lift mast The mast on a Kalmar truck is of very sturdy design. The number of welds has been kept down to a minimum, to ensure the highest possible strength. The stresses on the mast components are low.
  • Page 264 DCE80-100E Mast and carriage TDCE01 04GB Description Technical Handbook Group 80 Carriage Two different integrated carriages are available - a fixed carriage for attachments with twist-locks and a carriage with hydraulic lev- elling ±4° for attachments with hooks. Both carriages have sup- port wheels to bear longitudinal stresses and sliding plates for lateral stresses.
  • Page 265 DCE80-100E Mast and carriage TDCE01 04GB Description Technical Handbook Group 80 1. Control valve, LENGTH ADJUSTMENT 2. Control valve, TWIST-LOCKS 3. Control valve, SIDESHIFT 4. RETURN from sidelift 5. FEED to sidelift 6. Hydraulic cylinder, TWIST-LOCKS/LOCKING PLATES 7. Hydraulic cylinder, SIDESHIFT 8.
  • Page 266 DCE80-100E Mast and carriage TDCE01 04GB Description Technical Handbook Group 80 1. Control valve, LENGTH ADJUSTMENT 2. Control valve, TWIST-LOCKS/LOCKING PLATES 3. Control valve, SIDESHIFT 4. RETURN from sidelift 5. FEED to sidelift 6. Hydraulic cylinder, TWIST-LOCKS/LOCKING PLATES 7. Hydraulic cylinder, SIDESHIFT 8.

  • Page 267: Service

    DCE80-100E Mast and carriage TDCE01 04GB Service Technical Handbook Group 80 Inspection of lifting chains To increase safety, the lifting chains should be inspected regularly in accordance with the points below. This should be carried out IMPORTANT! during each 1000 h service.

  • Page 268: Dismantling The Carriage

    DCE80-100E Mast and carriage TDCE01 04GB Service Technical Handbook Group 80 Dismantling the carriage Disconnect all the hoses that connect the cylinders on the carriage with the hydraulic system. Put immediately protecti- ve caps on all hoses and connectors. Raise the carriage a little.

  • Page 269: Adjusting The Support Wheels

    DCE80-100E Mast and carriage TDCE01 04GB Service Technical Handbook Group 80 Adjusting the support wheels in the carriage and inner mast Remove the carriage. Use a drift to tap out the tubular dowel from the inside. Screw in the clamping screw so that the wheel is firmly locked.

  • Page 270: Lubrication Of Sliding Surfaces And Plates

    8 plates between carriage and sidelift attachment. IMPORTANT! The lubricant should be of a brand approved by Kalmar, or another of the same specification. The use of any other lubricant can lead to excessive wear and also invalidate the Kalmar guarantee.

  • Page 271: Inserting Shims For Sliding Plates

    DCE80-100E Lifting mast and fork carriage TDCE01 04GB Service Technical Handbook Group 80 Inserting shims for sliding plates - general Check the play in the mast and between the carriage and the mast. When a noticeable gap occurs, equivalent to a play of at least 2 mm, reduce the play with shims.
  • Page 272 DCE80-100E Lifting mast and fork carriage TDCE01 04GB Service Technical Handbook Group 80 2 3 4 KL1125 1. Bleed nipples at the top of the lift cylinders 2. Shim 3. Sliding plate holder 4. Sliding plate (x 4) 5. Hose holder, mounted on carriage...

  • Page 273: Sidelift Attachment

    DCE80-100E Sidelift attachment TDCE01 04GB Description Technical Handbook Group 80 Sidelift attachment The sidelift attachment has been designed for easy, safe and rap- id handling, low weight and ease of maintenance. The attach- ment is integrated with the carriage. Two different models of the attachment are available; with twist- locks or with hooks for container connection.
  • Page 274 DCE80-100E Sidelift attachment TDCE01 04GB Description Technical Handbook Group 80 KL1688 KL1687 1. Hook for container coupling 2. Spring for mechanical levelling 3. Hydraulic cylinder, side locking plate 4. Side locking plate 5. Hydraulic cylinder, sideshift 6. Hydraulic cylinder, length adjustment 20'-40 7.

  • Page 275: Service

    DCE80-100E Sidelift attachment TDCE01 04GB Service Technical Handbook Group 80 Sidelift with twist-locks Indicating lamps on side-lift Lamp A (Green): Twist-locks locked Lamp B (orange): Alignment, extinguished when the container is lifted Lamp C (Red): Twist-locks unlocked Indicating lamps on sidelift...

  • Page 276: Sidelift With Hook-Coupling

    DCE80-100E Sidelift attachment TDCE01 04GB Service Technical Handbook Group 80 Sidelift with hook coupling Indicating lamps on sidelift Lamp A (Green): Locking plates locked Lamp B1 (orange): Alignment against container, extinguished when the container is lifted Lamp B2 (orange): Alignment on hooks,...

  • Page 277: Inductive Sensors

    DCE80-100E Sidelift attachment TDCE01 04GB Service Technical Handbook Group 80 Inductive sensors The inductive sensors control the various functions of the con- tainer attachments. The sensors are of the type PNP – positive/negative/positive, the last P indicating that the sensor produces a positive signal when activated.

  • Page 278: Control Of Twist-Locks

    DCE80-100E Sidelift attachment TDCE01 04GB Service Technical Handbook Group 80 Control of twist-locks N.B. This control should be first carried out after 5000 hours of service, or after 2 years - which ever occurs first. Thereafter, the twist-locks should be checked every year.
  • Page 279 DCE80-100E Sidelift attachment TDCE01 04GB Service Technical Handbook Group 80 Control and adjustment of alignment against container, hook attachment 1. Check the sensor for alignment and adjust if necessary. 2. The measure A over the contact pin in its outer position should be 35 mm.
  • Page 280 The tools, one for side plates and one for bottom and KL1681 top plates can be ordered from Kalmar Industries. 1. Shims 2. Sliding plate 3. Tool for removing/fitting of...
  • Page 281 DCE80-100E Sidelift attachment TDCE01 04GB Service Technical Handbook Group 80 Remove sliding plates and shims from the main beam. Measure the extension beam’s width X and height Y at the sliding plate positions, see picture, measuring position A and Refit the sliding plates and put a sufficient number of shims...
  • Page 282 DCE80-100E Sidelift attachment TDCE01 04GB Service Technical Handbook Group 80 Changing the main beam sliding plates New main beam design from 2005 1. Using the LENGTH ADJUSTMENT function, extend the inner beam approx 1000 mm. No cables or hoses have to be disconnected..
  • Page 283 DCE80-100E Sidelift attachment TDCE01 04GB Service Technical Handbook Group 80 4. Reinstall the sliding plates. Fit sufficient number of shims un- der the sliding plates to achieve 1-3 mm clearance between sliding plates and main beam both horisontally and vertically.
  • Page 284 DCE80-100E Sidelift, hooks, type C TDCE01 04GB Description Technical Handbook Group 80 Sidelift with hooks, type C The sidelift attachment has been designed for easy, safe and rap- id handling, good visibility, low weight and ease of maintenance. The attachment is integrated with the carriage.
  • Page 285 DCE80-100E Sidelift, hooks, type C TDCE01 04GB Description Technical Handbook Group 80 Carriage The carriage is of either of two different designs, both allowing le- velling for hooking up leaning containers. In the standard design the sidelift main beam is moveable over sliding plates in the carriage.

  • Page 286: Alignment Control

    DCE80-100E Sidelift, hooks, type C TDCE01 04GB Service Technical Handbook Group 80 Indicating lamps on side-lift 1. Red lamp Left locking plate released 2. Red lamp Right locking plate released 3. Orange lamp Alignment Left, upper container 4. Orange lamp Alignment Right, upper container 5.

  • Page 287: Sensor For Interrupting Of Lowering

    DCE80-100E Sidelift, hooks, type C TDCE01 04GB Service Technical Handbook Group 80 Sensor for interrupting of lowering Between the carriage and the flexibly suspended main beam is a sensor wich gives a signal when the sidelift has reached its bot- tom position.

  • Page 288: Control Of Lifting Hooks

    DCE80-100E Sidelift, hooks, type C TDCE01 04GB Service Technical Handbook Group 80 Control of lifting hooks N.B. This control should be first carried out after 5000 hours of service, or after 2 years - which ever occurs first. Thereafter, the hooks should be checked every year.
  • Page 289 DCE80-100E Sidelift, hooks, type C TDCE01 04GB Service Technical Handbook Group 80 Changing the main beam sliding plates 1. Using the LENGTH ADJUSTMENT function extend the inner beam 1000 mm. 1000 mm KL1803 2. Unscrew screws and nuts that hold the sliding plates.
  • Page 290 DCE80-100E Sidelift, hooks, type C TDCE01 04GB Service Technical Handbook Group 80 3. Remove sliding plates ans shims from the main beam.. Lift the inner beam slightly to relive the load from the sliding plates. KL1805 Höger sida KL1806 Vänster sida 4.

  • Page 291: Block Diagram

    DCE80-100E Sidelift, hooks, type C TDCE01 04GB Service Technical Handbook Group 80 Opt. XB777 25x1,5mm² 1. Sensor alignment, left side 2. Work light, left side 3. Work light right side 4. Sensor, stop at 30’ (optional) 5. Relys and valves, stop at 30’ (optional) 6.

  • Page 292: Hydraulic System A46141.0100

    DCE80-100E Sidelift, hooks, type C TDCE01 04GB Service Technical Handbook Group 80 Hydraulic system A46141.0100...
  • Page 303 DCE80-100E TDCE01 04GB Contents Technical Handbook Group 90 Group 90 Periodic supervision Periodic supervision ..............3 General survey ..............3 General survey chart ............3 Lubricating chart ..............4 Daily supervision ..............10 Every 500 hours ..............11 Every 1000 hours ............... 12...
  • Page 304 DCE80-100E Empty page TDCE01 04GB Technical Handbook Group 90...

  • Page 305: Periodic Supervision

    DCE80-100E Periodic supervision TDCE01 04GB Technical Handbook Group 90 General survey To extend the service life of the truck and to prevent the risk of faults causing injury to personnel or damage to equipment, the truck must be subjected to regular periodic supervision.
  • Page 306 DCE80-100E Periodic supervision TDCE01 04GB Lubrication Technical Handbook Group 90 6, 7 10 11 KL1318 A3638501S IMPORTANT! If the truck stands unused outdoors, with the After they have been washed with degreasing hydraulic piston rods exposed, all piston rods agent, all pistons should be moved back- must be greased to prevent corrosion.
  • Page 307 DCE80-100E Periodic supervision TDCE01 04GB Lubrication Technical Handbook Group 90 Item Description Interval No. of Remarks operating hours lub. points 200/ 1000 Cylinder bearing, tilt cylinders Mast suspension Relieve the mast of load when lubricating Cylinder bearing Support rollers, mast and carriage...
  • Page 308 DCE80-100E Periodic supervision TDCE01 04GB Lubrication, Standard side-lift Technical Handbook Group 90 KL1598 KL1599 Twist-locks KL1601 KL1600 Hook coupling Hook coupling, locking plate...
  • Page 309 DCE80-100E Periodic supervision TDCE01 04GB Lubrication, Standard side-lift Technical Handbook Group 90 Description Interval No. of Remark lub. points 1000 Sliding surfaces, length adjustment Brush onto all sliding surfaces with the attachment in the fully extended position Sliding surfaces, sideshift...
  • Page 310 DCE80-100E Periodic supervision TDCE01 04GB Lubrication, C-hook Side-lift Technical Handbook Group 90 KL1792 KL1814 Carriage with hydraulic levelling KL1813 Carriage without hydraulic levelling...
  • Page 311 DCE80-100E Periodic supervision TDCE01 04GB Lubrication, C-hook Side-lift Technical Handbook Group 90 Benämning Intervall Antal smörj- 1000 Cylinders, side locking plates Check that the sensors are free from grease and that the sensor faces are undamaged Check the function, see group 80...

  • Page 312: Daily Supervision

    DCE80-100E Periodic supervision TDCE01 04GB Daily Technical Handbook Group 90 DAILY SUPERVISION Or when Check Refill as required refuelling Brakes Operation Steering Operation All instruments: Operation Direction indicators, horn, brake lights, headlights Lift mast: Damage? Lifting chains Links, suspension All hydraulic functions, e.g.:...

  • Page 313: Every 500 Hours

    DCE80-100E Periodic supervision TDCE01 04GB Technical Handbook Group 90 Every 500 hours Item Unit Action Remarks Truck Wash Note! Do not use high-pressure on bearings or bearing housings Radiator Clean the fins of the radiator with Note! Do not use high-pressure.
  • Page 314 DCE80-100E Periodic supervision TDCE01 04GB Technical Handbook Group 90 IMPORTANT! Always attend to any damage, wear or faults that are im- portant to the performance of the truck and its service life or the safety of the personnel.

  • Page 315: Every 1000 Hours

    DCE80-100E Periodic supervision TDCE01 04GB Technical Handbook Group 90 Every 1000 hours Item Unit Action Remarks Cabin filter element Change filter element See Group 10 Engine Check valve clearances, cooling See engine maufacurer’s system, starter motor, alternator Workshop Manual and Group 30...

  • Page 316: Oil And Lubricant Recommendations

    Use EP universal grease to NLGI Grade 2 with 3–5% molybde- num disulphide additive for all lubrication points, including wheel bearings. Grease for Plastic plates Use grease recommended by Kalmar. Ordered from Kalmar’s Spares department. 0,65 kg cartridge for grease gun Art. no 923110.0360 5 kg can Art.
  • Page 317 DCE80-100E Empty page TDCE01 04GB Technical Handbook Group 90...

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