Dce 80-1 0 0 e

DCE 80-100E
Publ. no IDCE01.03GB
IDCE01.03

Contents
Safety regulat
Safety regulations...........
ions..................
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..... 2
Introduction.......
Introduction.............
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...... 4
Signs..........................................................................................
Signs................................................................................. ......... 6
Operation................
Operation.......... .............
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...... 8
Instrument
Instrume nt and controls.......
controls..............
..............
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......... 8
Heating
Heatin g and air condition
conditioning ing system .............
...................
.............
.............
........
.. 18
Operator’s seat, adjustments..............................................
adjustments................ .............................. 20
Engine heater ..................................................................... 21
Running
Runnin g in ......
.............
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... 21
Starting the engine .............
....................
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.. 21
Warming
Warmi ng up of engine ....... ..............
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.............
.............
.............
..............
.............
.........
... 21
Functional checks.................
checks...............................................................
.............................................. 24
Stopping of engine, parking................................................
parking.. .............................................. 24
Power
Pow er steering....................................................................
steering .................................................................... 24
Lifting
Lifting techniq
technique ue .......
.............
.............
.............
............
............
.............
..............
..............
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...... 27
Empty container side-lift ..................................................... 25
Special procedures
procedures..................................................................
.................................................................. 28
Supervision..............................................................................
Supervision... ........................................................................... 30
Daily supervision ................................................................ 30
Tyres ................................................................................... 31
Fuel system ........................................................................ 32
Cooling system ................................................................... 34
Engine oil..............................
oil............................................................................
.............................................. 35
Air cleaner .......................................................................... 36
Checking
Check ing the accumulator
accumulators s .............
...................
.............
.............
.............
..............
.........
.. 36
Hydraulic system ................................................................ 37
Gearbox oil ......................................................................... 37
Windscreen washer ............................................................ 37
Electrical
Elect rical system .............
...................
.............
.............
.............
..............
.............
.............
............
..... 38
Technical data..........................................................................
data......................................... ................................. 41
Lubrication chart ...................................................................... 42
Oil and lubricant recommendations ......................................... 46
Detailed technical descriptions with circuit diagrams, periodic

supervision, trouble shooting and repairs are dealt with in the
Technical Handbook
We reserve the right to alter design and material without
notice.
DCE80-90E 1

Safety regulations
It is important that you read the instruction Safety regulations aimed at reducing the
manual. risk of personal injury and damage to
Incorrect handling can lead to personal injury or dam- loads or other property.
age to products and/or property. Therefore, read the in-
struction book very carefully before operating the truck. Intended of use
The instruction manual contains important information  The truck may only be used for the purpose for
about your Kalmar truck, about the operation of the which it was intended, namely, to lift and transport
truck, about safety during operation and about the goods, the weight of which does not exceed the
truck's daily maintenance. In addition, you will find use- maximum permitted load capacity of the truck.
ful information that will make operations easier for you  The truck may not, without specific permission
in your daily work. from Kalmar, be modified or re-built so that its func-
The instruction manual must always be kept in the ma- tion or performance is altered.
chine. If the manual should be lost, a replacement
r eplacement must  The truck may not be driven on public highways
hig hways if
be immediately obtained. Never use a machine with a it has not been adapted to comply with national
missing instruction manual. road safety regulations.
Ask your foreman/group leader if there is anything in Operator requirements
the manual that you do not understand or if you feel that  The truck may only be driven by operators who
information is missing in any area. have been specially trained and who have the
company's authority to do so.
The symbol is used on our products in certain  Laws and other regulations relating to driving li-
cases and then refers to important information con- cence, operator ID, log book, etc., must be fol-
tained in the instruction manual. Make sure that warn- lowed at all times.
ing and information symbols are always clearly visible 
and legible. Replace symbols that have been damaged
damage d The
safetyoperator must be aware of and follow all local
regulations.
or painted over.
over.
 It is always the responsibility of the operator to en-
In this instruction manual warnings are inserted that sure that the truck has approved fire extinguishing
apply to your own safety.
safety. Warnings point out the risk of equipment in accordance with currently applicable
accident that can cause personal
perso nal injury. regulations.
Operation of the truck is prohibited:
 If any of the fitted safety equipment, such as rear
WARNING! view mirrors, headlights, reversing alarm (option-
al), does not function correctly.
Warns of the risk of serious personal injury, pos-  If there is a fault with the brakes, steering or lift
sible death and/or serious damage to product or equipment.
property if the regulations are not followed.
 If it has been repaired, modified or adjusted with-
out the approval of the work super visor.
For technical warnings, that point out the risk of break  If the truck is fitted with tyres not approved by
Kalmar.
down, the word IMPORTANT is used:
IMPORTANT! Continued on next page
Is used to draw attention to such occurrences
that can cause damage to the product or
property.
For information that facilitates the working process or

handling, N.B. is used:
N.B. Draws attention to useful information that

helps the working process.
2 DCE80-90E

Safety regulations
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-
body is in the way of the truck tr uck or its equipment.  Always rectify any damage or wear and tear that
can risk personal safety or that can affect the func-
 The operator must always face the direction of o f options of the truck or its service life.
eration and take particular care in areas where
persons or other vehicles are likely to appear in  Avoid
Avoid touching oils and greases. Avoid inhaling
the vicinity.
vicinity. If visibility is limited by the load, the op- exhaust and oil fumes.
erator should operate the truck tr uck in reverse.  Always use steps and handrails when entering or
 It is prohibited to walk or stand underneath raised leaving the machine - Never jump!
forks or other equipment, whether they are loaded To avoid the
surfaces. riskanti-slip
If the of slipping, tread only
protection hason anti-slip
become
or not.
worn, loose or in any way less effective, it should
 It is prohibited to transport passengers on the be replaced.
truck outside the cab or on the load. Passengers
may be transported inside the cab only on condi-  Welding painted steel produces poisonous gas-
tion that it is equipped with a fixed passenger ses. Paint should therefore be stripped before
seat. welding, good ventilation ensured and/or face
mask with filter used.
 It is prohibited to lift people if the truck is not
equipped with an approved lift cage.  Mobile phones used in the cab must always have
fixed connections to the machine’s electrical sys-
 It is prohibited to exceed the load capacity of the tem, with a fixed antenna outside the machine,
truck. See capacity plate and loading diagram. mounted in accordance with the manufacturer’s
 It is prohibited to transport loads in the raised po- instructions. This will avoid interference with the
sition as this entails a risk of the truck tipping. All machine’s important electronic functions.
transportation shall take place with the load in the th e  The tensile strength of the top pane can be seri-
transport position. ously weakened by exposure to elements that
 The operator must adapt the speed of o f the truck to contain: Aromatic hydrocarbon, ketone, esters or
the character of the load, conditions of visibility, visibility, chlorinated hydrocarbon.
the character of the roadway/surf
ro adway/surface,
ace, etc. Regularly check the surface condition of the top
 The operator shall avoid powerful acceleration pane and clean only with screen wash or other
and braking when turning. In addition, the opera- mild cleaning fluid. After cleaning, rinse thorough-
tor shall always moderate the speed of the truck ly with warm water. It is prohibited to modify or in
when turning so as to avoid the risk of lateral skid- any other way make alterations to the top pane.
ding or tipping. Immediately replace damaged top panes that
show signs of cracking or scratching.
 The operator shall take particular care when oper-
ating in the vicinity of electrical
electr ical power lines, via- Operating with attachments
ducts, quay-sides, ramps, gates/doors etc.  The operator must always take the effect of the
 Safety belts must always be worn, if fitted. In the wind into account when handling containers.
event of the truck tipping, always remain in the cab Avoid lifting with a wind strength in excess of 12
and grip the steering wheel securely
securely.. Never try to m/s (27 mph/40 feet per second).
jump out of the cab.  Always drive carefully so as to avoid attachments
 The parking brake can also be used as an EMER- colliding with pillars, cables, etc.
GENCY BRAKE. HoweverHowever,, having been used for  Carefully study the "Lift methods" section of the
emergency braking, the brake linings must be instruction manual.
checked and replaced if necessary
necessar y. If the par
parking
king
brake
always has
be been
resetmechanically
in order for thereleased,
reset in it must
truck to regain the
parking brake function.
Interrupted operation, parking CE marking
 Always check that the gear lever is in the neutral All trucks and equipment (though not thoses fitted on
position before turning the ignition key to restart or the truck or intended as spare parts)
par ts) supplied from Ka-
to reset an emergency stop. lmar are CE marked, which indicates that they comply
 Never leave the operator's cab without applying with the requirements of the EU Machine Safety Direc-
the parking brake (ON position). tive. In addition, each truck has a so called, “EU Dec-
 Always remove
remove the ignition key if the truck is to be laration of Conformity” which is the legal proof that the
left unattended. truck complies with the “health and safety” require-
Other important points to remember ments laid down in the Machine Safety Directive, the
 The truck's hydraulic system includes high pres- EMC directive (electro-magnetic compatibility) and the
sure hydraulic accumulators. Always be extremely LVD directive (electrical equipment).
careful when working with the hydraulic system
and avoid being unnecessarily close to the hy-
draulic equipment, lines and hoses. Before work- Vibration standard
ing
mustonbe
the hydraulic
emptied intosystem, the
the tank, accumulators
with the help of the The truck
bration complies
standard ENwith and is below the limits for vi-
13059.
special accumulator evacuation valve.
valve.
DCE80-90E 3

Introduction
Kalmar empty container handlers DCE80-90E with lifting capaci-
ties of 8-9 tonnes are part of the Kalmar range, which includes
forklift trucks rated between 5 and 90 tonnes. This series
ser ies of trucks
is based on a system of o f modules, and provides flexibility in the
selection of engine and gearbox.
The visibility is very good, due to the large windows and the clear
field of vision through the mast and the carriage.
The Instruction Manual applies to all models unless otherwise
stated.
Since the trucks are delivered with different equipment, minor
deviations from the Instruction Manual may occur.
Kalmar
Type designation
DCE70-45E8
DCD80-45E8
Diesel engine
Counterweighted truck

Generation
Lift capacity, decitonnes
Standard cab position
Wheel base, decimetres
Empty container handling

Max number of containers at stacking
IMPORTANT!
BEFORE USING THE TRUCK CHECK:
– engine oil
– fuel level
– coolant level
– tyre pressure
For further information, see the section entitled

SUPERVISION.
DCE70-45E8

Option: Raised cab
4 DCE80-90E

Introduction
4 3 5 6 7
1. Mast, ffree-v
ree-visibili
isibility
ty mast
mast,, with tw
two
o liftin
lifting
g cylind
cylinders
ers 5. Gearb
Gearbox,
ox, combin
combined ed wi
with
th to
torque
rque conv
converter
erter
2. Opera
Operator’
tor’ss ca
cab,
b, rubber suspended
suspended 6. Driv
Drive
e axle
axle,, wit
with
h hub gearing and w wet
et dis
discc
3. Engin
Engine,
e, six-cylin
six-cylinder
der diesel
diesel engine
engine wwith
ith turbo-
turbo- brake system
compressor 7. Carri
Carriage,
age, with
with hhydrau
ydraulicall
lically
y contr
controlled
olled si
side-lif
de-liftt
4. Steer
Steering
ing axle,
axle, with pendulu
pendulumm suspensio
suspension n and
double-acting steering cylinder
DCE80-90E 5

Signs
The information plates on the machine are shown
sh own below
below.. The op-
erator shall be aware of and follow the warnings and instructions
instru ctions
given on them. Plates that have disappeared, been damaged or
become illegible shall be immediately replaced. Spare parts num-
bers are stated on respective plates. They can also be found in
the Spare Parts catalogue.
401 307

403 713 709 701 403
802
811
812
711 122 123 203

815 301
305 303
402
104
107
102
101 
112 102
6 DCE80-90E

Signs
10 Chassis, Cab 30 Engine 80 Mast, attachments

101 423049.0100 Lift point. 301 450202.0100 Fuel. 802 A30771.0100 Warning!
Fixing point for lift Do not walk under
equipment when lift-  the load.

ing the truck.

303 A30530.0200 Warning!
102 A26939.0100 Warning! Rotating fan.
Read the Instruction
Manual.
305 A30532.0200 Warning! 811 A33852.0100 Type, attachment
Hot surface.
104 A26940.0100 Parking brake
ON-OFF.
307 A32439.0300 Engine oil
(TWD731VE: The
plate is located on
107 A30536.0300 Warning! S/N = Serial numbe
numberr
the filler cap on the
No Riders! 812 A33853.0100 Type, sidelift
engine)
Passengers may be
carried in the cab 40 Transmission, tyres
only if it is equipped 401 455949.0100 Transmission oil
with a fixed
passenger seat.
112 A32442.0100 Warning!
Do not jump! 402 A30533.0200 Warning!
Always remain in the Rotating parts. A= Mo
Mode
del,
l, atta
attach
chme
mentnt
truck and firmly grip S/N = Serial numbe
numberr
the steering wheel H= Max
Max pre
pressssur
ure
e att
attac
achm
hmenentt
when there is a risk 403 A3204
A32049.0100
9.0100 Tyre press
pressure,
ure, W= Atta
Attach
chme
mentnt wei
weigh
ght,
t, n
no
o lo
load
ad
of tipping.
122 A33806.0400 Type, machine 1,
1,0
0 MPa
MPa Q=
D = LLo
iftacdace
cpeanctity
itre
y
815 A33808.0800 Type, sidelift
70 Hydraulic system
701 450203.0100 Hydraulic fluid.
709 A3016
A30168.0300
8.0300 Hydr
Hydraulic
aulic pressure
pressure.. S/N = Serial numbe
numberr
See Technical A= Model, attachment
M = Model Handbook. H= Lifting hei
height
S/N = Serial number
number D= Load cecentre
Q = ClClas
assif
sifie
ied
d li
lift
ft c
cap
apac
acit
ity
y of ththe
e Q= Lift capacity
ity
truck at lift height in accord- C= Load
Load cecen
ntre
tre hhe
eigh
ight
ance with EN1551, EN1459 Vertical distance from the
standards container connecting point to
D = LoLoad
ad Ce
Centntre
re - hor
horiz
izon
ontatall load centre
H= Cl
Clas
assi
sifi
fied
ed lift
lift he
heig
ight
ht
W= Un
Unlo
load
adeded wei
weighghtt of mach
machin
ine
e
C= Load
Load ce
centntre
re heieigh
ghtt
Vertical distance from the
container connecting point
down to load centre 711 A36163.0100 Warning!
123 A42483.0100 Sound power level High pressure!
-1300 104 -116 dB. Always release
Selected for actual pressure from the
machine accumulator before
working on the
hydraulic system.
20 Electrical system 713 A3782
A37823.010
3.0100
0 No Lu
Lubrizol
brizol
203 A30537.0100 Main switch.
In position 0 the
battery’s plus pole is
isolated.
DCE80-90E 7

Operation Instruments and controls
3 1 4 5 2 6



 





  
 
a b c d e

7 8 9 10 11 12 13 14 15
KL743
Se sid
6
1. Gear leve
leverr .....
...........
...........
...........
...........
...........
............
...........
...........
...........
...........
........
.. 12
FORWARD/NEUTRAL/REVERSE 1/2/3
2. Lev
Lever
er DIRECTI
DIRECTION ON IND INDICAICATOR
TORS/HORS/HORN N ......
...........
..........
..... 12 13
FRONT WINDSCREEN WASHER/ See page
FRONT WIPERS/MAIN BEAM 14
3. Instrum
Instrumentent panel..........
panel................
............
............
...........
...........
............
............
..........
.... 9
4. Steeri
Steeringng w wheel
heel panel...............
panel.....................
...........
...........
............
...........
..........
..... 9 15
5. Starting swi switch
tch ......
...........
...........
............
...........
...........
...........
...........
...........
...........
...... 11 
6. Contr
Control ol le
lever
ver,, hyd
hydrauli
raulic c functions
functions ......
...........
...........
...........
...........
...... 13 Option: Joy-stick, page 15
a. Lift
b. Tilt
c. Sideshift
d. Length adjustment 20’-40’
   
e. Locking/Unlocking twist-locks
7. Elect
Electrical
rical centr
central
al unit
unit with
with ffuses
uses a and
nd rrelay
elays s ......
............
...... 39
6
8. Brak
Brakee pedals,
pedals, normal driving brak brake e ...........
.................
...........
.......
.. 17
9. Releas
Release e clu
clutch
tch .....
...........
...........
...........
............
............
............
...........
...........
...........
..... 17
10. Accelerator pedal.................................................... 17
13
11. Steeri
Steeringng wheel adjust
adjustment
ment ......
............
...........
...........
............
...........
........
... 17
12. Operator’s seat ..................................
......................................................
.................... 20
13. Parking brake ......................................................... 17 14
14. Emerg
Emergencyency cut-ou
cut-outt for all hydraulic
hydraulic functi
functions ons .....
.........
.... 13 15 
15. Saf
Safety
ety syst
system
em by-pas
by-pass s switch.......
switch..............
.............
.............
.............
..........
.... 15
Option: Electric servo, page 16
8 DCE80-90E

OPERATION Instruments and controls
21 22 23
KL581
37 38 39
35 36
34
33 40 41 42
4 2 43 44 45
4 5 46 52 53
32
30 31
29
28
27
26
25
24 47 48 49 50 51
54 55
54 55 56 60 59
KL582
F
KL1307
1
2
N L
3
0
4
R
KL580
R
1 2 3
66 4 5
57 58 64 61 62 63
21. Pressure gauge, gearbox oil pressure 40. Switch with lamp DIAGNOSIS (QSB5.9)
22. Fuel gauge 41. a. Warning lamp STOP ENGINE (QSB5.9)
23. Temperature
Temperature gauge, engine coolant temperature b. Indicating lamp CHECK ENGINE
24. Switch, working lights (QSB5.9)
25. Switch, working lights 42. Warning lamp,
lamp, battery charging
26. Switch, working lights 43. Warning lamp, low
low engine oil pressure
27. Switch, flashing beacon 44. Warning lamp, low
low gearbox oil pressure
28. Switch, hazard warning lights 45. Warning lamp, low
low brake pressure
29. Switch,
Switch, driving lights (accumulator pressure)
30. Spare
Spare 46. Warning lamp, low engine coolant level
level
31. Spare
Spare 47. Indicating lamp,
lamp, preheating
32. Switch with lamp ENGINE MAINTENANC
MAINTENANCE E 48. Warning lamp, high engine
engine coolant temperature
33. (QSB5.9)
Spare
Spare 49.
50. Warning
Spare lamp, high
Spare high gearbox oil temperature
34. Switch, compressor air conditioning 1) 51. Warning lamp,
lamp, parking brake ON
35. Control, recirculation/fresh air 52. Spare
Spare
36. Control,
Control, defros
defrost/cab
t/cab 53. Spare
Spare
37. Switch,
Switch, fan 54. Green lamp TWIST
TWIST-LOCKS
-LOCKS LOCKED
38. Control,
Control, heat LOCKING PLATES LOCKED
Control, cold 1)
39. Control, 55. Orange lamp ALIGNMENT
56. Red lamp TWIST
TWIST-LOCKS
-LOCKS UNLOCKED
LOCKING PLATES RELEASED
57. Spare
Spare
58. Spare
Spare
59. Indicating lamp,
lamp, headlights
KL675
60. Indicating lamp, direction indicators
terminal 1)
61. ECS terminal
62. Switch, windscreen wiper,
wiper, rear
63. Switch, windscreen wiper,
wiper, roof
64. Spare
Spare
65. Fuses
Fuses
66. Hour meter
meter
65
DCE80-90E 9

OPERATION Instrument and controls

Warning lamps
(Trucks
(Trucks equipped with ECS System, module 07, have no
warning lamps 43, 44, 45, 46, 48, 49)
42 All of these lamps should be extinguished when the truck is in op-

eration. A steady light and a buzzer indicate failure.
Battery charging lamp (42)

If the lamp should light up this indicates that the alternator is not
43 charging. If this should happen, identify the cause and
a nd remedy it.
Never use the truck when the charging lamp lights.
Lubricating oil pressure, engine (43)

The lamp will light briefly on starting, and somewhat longer in
44 wintertime when the oil is cold and viscous.
If the lamp lights up when the truck is travelling, stop immediately
and make sure that the cause is identified and remedied.
Oil level? See Supervision.
45 Oil pressure, gearbox (44)

The lamp should go out immediately after the engine has started.
Pressure is too low if the lamp lights up while the truck is in op-
eration. If this happens, stop immediately and make sure that the
cause is identified and remedied.
46
Low brake pressure (45)
The lamp will light up if the hydraulic pressure in the accumulator,
i.e. the brake system pressure, should drop below 100 bar. After
the lamp has lit, sufficient capacity
cap acity is still available for applying
the brakes a number of times.
If the pressure is not built up and maintained, check the accumu-
47 KL598
lators for leakage in accordance with the section entitled Super-
vision.
48 Engine coolant level (46)

The lamp will light momentarily on starting. If the lamp lights up
when the truck is travelling, the coolant level is too low. Check the
level and top up as necessary.
49
Engine preheating (47)
The lamp will lights during the preheating period.
Engine coolant temperature (48)

The lamp will light up if the coolant temperature becomes too
high. Make sure that the cause is identified and remedied.
50
Oil temperature, gearbox (49)
51 The lamp will light up if the temperature of the gearbox oil ex-
ceeds 120°C.
120°C. Stop the tru
truck
ck and make sure that the cause is
identified and remedied.
Spare (50)
Parking brake lamp (51)

The lamp will lights while the parking brake is applied.
10 DCE80-90E


Trucks equipped with ECS System, module 07, have no
instruments 21, 22 and 23.
Pressure gauge, gearbox oil pressure (21)

21 The gauge shows the clutch pressure which should be
16.9–19.3 bar.
Activated parking brake. Idle speed 400–600 r/min. Working tem-
perature
peratu re 8
82–93°
2–93°C.
C.
22 Fuel gauge (22)

The tank is full when the gauge reading is 4/4. The tank is half-
full when the pointer is vertical.
Always refuel before the gauge reading has dropped to 0.
Air may otherwise be drawn into the fuel system, which will then
have to be bled.
23
Temperature gauge (23)
The temperature gauge shows the engine coolant temperature,
which should normally
nor mally be approx
appr ox 80°C. This temperature will be
KL581 reached after the engine has run for about 5 minutes. The tem-
perature
peratu re may vary b
between
etween 75 anda nd 97°C.
97°C.
A higher temperature may be an indication that coolant level is
low.. Check and top up as re
low required,
quired, see under Supervision.
Super vision.
If the temperature is still too high, the cause must be identified
and remedied.
Don’t run the engine if the coolant temperature is too high.
Operating hour meter (66)

The operating hour meter records the number of engine operat-
66
ing hours. Use the meter to determine when the truck is due for
periodic service – all service is based on the operating hours of
the truck.
KL1307
Starting switch (5)

P -
0 All functi
functions
ons swswitc
itched
hed off
off,, the
the key
key can be rremo
emoveved
d
I Operat
Operating
ing positi
position.
on. All electri
electrical
cal functi
functions
ons are ene
energi
rgized
zed..
The key may be set to this position to swith on the lighting,
for instance, when the engine is not running.
II Glow
Glow posit
position
ion.. In tthis
his positi
positionon th
the
e glow-
glow-plu
plug
g is energiz
energized.
ed.
The glow mode is indicated by lamp 47. Turn directly to
position III if the engine is warm.
III
III Start
Starter
er m
mot
otor
or ene
energ
rgiz
ized
ed..
The truck has an electrical restart guard protecting the starter

motor from meshing while the engine is rotating.
WARNING!
Risk of explosion.
Never use start spray to assist in starting.
DCE80-90E 11


Gearr lev
Gea lever
er – For
Forwar
ward/N
d/Neut
eutral
ral/Re
/Rever
verse
se (1)
– 1/2/3
The gear-changing mechanism is electrical, and the gearbox is
operated via solenoid valves.
F – FORWARD
2 3 N – NEUTRAL
1 4 F
R – REVERSE
TURN, lever 1, 2, 3
1
2 The engine cannot be started unless the gear lever is in neutral.
3
4 The truck is fitted with a reversing block that prevents gear chang-
ing between forward and reverse gears if the speed is in excess
of 3 km/h. The truck should, however, be stopped completely be-
KL676
fore changing between forward and reverse,
r everse, in order to prevent
R overloading the gearbox and power transmission.
 Run the engine at idle speed, select the direction of travel

with the gear lever and engage first gear, using the rotary
control. Never pull away in a higher gear, since this may lead
to unnecessary overheating.
 Release the parking
par king brake, and accelerate carefully.
 To change up, turn the gear selector handle to second gear,
release the accelerator pedal and the second gear will be en-
IMPORTANT! gaged, accelerate, and so on.
The truck must be stopped com-
 Reverse the procedure when changing down. Remember to
pletely before changing between for-
ward and reverse, in order to prevent increase
the truck engine speed before
will otherwise engaging
brake heavily. a lower gear, since
heavily.
overloading the power transmission.
Trucks with ECS, automatic gear

ge ar changing
The points at which the gearbox changes gear are optimized to
the truck's transmission system. The operator can limit gear
changing by twisting the gear selector from 3rd to 2nd or 1st
gears. If for example, 2nd gear is selected, the system auto-
matically changes gear between 1st and 2nd gears.
The ECS system

 prevents the gears being engaged if engine revolutions ex-
ceed 1100 r.p
r.p.m.
.m.
 prevents changing between forward and reverse gears if the
truck speed is in excess of 3 k.p.h. (reversing preventor).

locks the shaft
propeller gearbox in the
sensor is current gear
excessive or ifif the
the signal
signal from the
ceases.
 reduces engine revolutions when changing to a higher gear
to ensure smothest possible gear changing.
 disengages the gearbox if the operator applies the brakes (at
simulatenous activation of the clutch) and the speed is less
than 3 k.p.h. (Not QSB 5.9)


 provides the required engine revolutions based on the posi-
tion of the accelerator pedal.
 continually shows the gear engaged on the ECS terminal
 display.
Direction indicators/Dip switch/Horn (2)

FOR
FORWARD/
ARD/BA
BACK
CKW WARDS
ARDS – Direc
Directi
tion
on indi
indica
cato
tors
rs
UPWARDS – Headlamp flashing
DOWNWARDS – Full beam
INWARDS, button – Hor n
INWARDS, lever – Screen wash
TURN – Screen wiper, front
0 = Off/J = Intermittent/
I = Continuous wiping/II = –
12 DCE80-90E


Control levers (6)
The control levers are hydraulically connected to the main valve.
Electric servo control is available as optional equipment.
The speed of the various hydraulic functions, such as lifting, tilt-
ing,etc, will vary depending on the displacement of the corre-
 sponding control lever. The speeds of the hydraulic functions can
also be varied by varying the engine speed.
a. Lift Lower
LIFT – pull the lever back

LOWER – push the lever forward
The lowering speed can only be varied by the amount of dis-

placement of the control lever, ie, engine speed does not affect
the lowering rate.
b. Tilt
BACKWARDS – pull the lever back
     FORWARD
FORW ARD – push
pu sh the lever forward
c. Sideshift
RIGHT – pull the lever back
LEFT – push the lever forward
c+button. Levelling
 CLOCKWISE - pull the lever back
COUNTER-CLOCKWISE - push the lever forward
d. Length adjustment 20-40’

20-40’ – pulll the lever back
40-20’ – push the lever forward
e. Twist-locks
 Alternative for hook coupling, locking plates
LOCKING – pull the lever back
UNLOCKING – push the lever forward
13.Parking brake
14 Emergency
Emergency cut-out servo circuits
Cuts off all hydraulic functions
15.Safety system by-pass switch
(Only in emergency situations)
13 WARNING!
14 By-passing of the safety system involves a risk of drop-
 ping a container.

By-passing is at one's own risk.
15
It is prohibited to lift or transport load when the safety
system is by-passed.
DCE80-90E 13


Joystick,
Joystick, Side lift with twist-locks
1 2 3
1.SIDE
IDESHSHIFIFTT
2.LENGTH
LENGTH A ADJU
DJUSTM
STMENT
ENT 2
20-4
0-40’
0’
3.LOWER
4.TILT
TILT FOR
FORW WARD
ARDS S
5.Twis
wist-l
t-loc
ocksks RE
RELEA
LEASE
SE
B 6.TILT
TILT BBAC
ACKWKWARD
ARDS S
4 7.LIFT
A.Green lampa
lampaTWIST
TWIST-LOCK
-LOCKSS
A C LOCKED
B Or
Oran
angege lam
lamp p ALI
ALIGN
GNMEMENT
NT
C Red lamp
lamp TW
TWIST
IST-LO
-LOCK
CKS
S
RELEASED
5 6 7
Joystick,
Joystick, sidelift with hook attachment
1. LEV
LEVELLI
ELLINGNG
2. SIDES
IDESHIHIFT
FT
1 2 3a 4 3A.Locking plates LOCKING
3b 3b. Locking plates UNLOCKING
4. LOWER
5. TIL
TILT FOR
FORW WAR
ARDS
DS
6. LEN
LENGTH
GTH A ADJU
DJUSTM
STMENT
ENT 20-
20-40’
40’
7. TIL
TILT
T BA
BACKW
CKWAR
ARDS
DS
5 B 8. LIFT
A. Gree
Greenn lam
lampa
pa LOCK
LOCKIN
ING
G PLATES
TES
LOCKED
A C B OrOran
ange
ge lamp
lamp AL
ALIG
IGNM
NMEN
ENTT,
C Red lamp LOCKING PLATES
UNLOCKED
6 7 8
14 DCE80-90E


Switch functions,
functions, mach
machines
ines with “joystick”
13
13.. Parkin
arkingg brak
brake e
14 Emergenc
Emergency y cut-
cut-out
out serv
servoo circu
circuits
its
13 14 15 15. Safety
Safety system
system by-pa
by-pass
ss switch
switch
(Only in emergency situations)
The safety system
the hydraulic by-pass
console and mayswitch
onlyisbelocated
used inon the side ofsi-
emergency
tuations. With this switch the LOCK, RELEASE, ALIGNME-
NT and LIFT functions can be by-passed.
1. If the si
side-
de-lif
liftt fas
fasten
tens
s in a positio
position
n where
where the twist
twist-lo
-lock
cks
s are
neither locked nor released, or if the locking plates are
neither locked or released, this switch must be used to by-
pass the safety system. Lamp 50 lights to indicate the by-
50 lights
passing of the safety system.
The switch is spring-loaded and must therefore be continual-
ly pressed down the whole time the safety system is being
by-passed.
2. Ther
Thereaf
eafter
ter,, run the LOCK/
LOCK/RERELEA
LEASESE functi
function
on until
until the twis
twist-
t-
locks or the locking plates are released (red lamp lights).
3. Rel
Releas
ease
e the s swit
witch
ch back
back to
to the operati
operatingng posit
position
ion..
4.
WARNING!

By-passing of the safety system involves a risk of drop-
ping a container.

g i system is by-passed.
Posi
ositio
ion
n 1 Position 0 Positio
tion 2 g. Automa
Automatictic/Man
/Manual
ual loc
locking
king of twi
twist-l
st-lock
ockss
Position 1: Automatic locking at alignment
Position 0: Locking of twist-locks not activated
ac tivated
Position 2: Spring loaded, manual locking of twist-locks.
When locking twist-locks automatically
- Parking brake OFF
- alignment activated or safety system by-passed.
 twist-locks, see lever functions on previous
Unlocking of twist-locks,
page.
i. Stop at 30’ (Extra)
Position 1: Normal length setting 20’-40’ and 40’-20’
Position 2: Spring loaded, provides crawler speed the whole
time during extension and retraction. At 30’ the movement
stops automatically
automatically..
 
50 50.Warning lamp, safety system by-passed

DCE80 90E 15

Control levers, electric servo (6)
The control levers are connected to the main valve by means of
an electric servo.
The speed of the various hydraulic functions, such as lifting, tilt-
ing,etc, will vary depending on the displacement of the corre-
sponding control lever. The speeds of the hydraulic functions can
also be varied by varying the engine speed.
a. Lift Lower
LIFT – pull the lever back
 
 
 LOWER – push the lever forward

The lowering speed can only be varied by the amount of dis-
placement of the control lever, ie, engine speed does not affect
the lowering rate.
b. Tilt
BACKWARDS – pull the lever back
FORWARD
FORW ARD – push
pu sh the lever forward
c. Sideshift
RIGHT – pull the lever back
LEFT – push the lever forward
d. Length adjustment 20-40’
20-40’ – pulll the lever back
40-20’ – push the lever forward
Switch functions, machines with electric servo

f. Re
Relelea
ase of twtwis
ist-
t-lo
loc
cks
The switch is spring loaded. Move the switch to the right r ight or
to the left to release the twist-locks, lift at the same time. Re-
lease the switch and the system returns to locking as per g.
g. Automa
Automatic tic/Man
/Manual
ual loc
locking
king of twi
twistl-
stl-ock
ocks s

Position 1: Automatic locking at alignment
Position 0: Locking of twist-locks not activated
ac tivated
Position 2: Spring loaded, manual locking of twist-locks.
When locking twist-locks automatically
- Parking brake OFF
- alignment activated or safety system by-passed.
h. Extra
i. Stop at 30’ (Extra)
Position 1: Normal length setting 20’-40’ and 40’-20’
Position 2: Spring loaded, provides crawler speed the whole
time during extension and retraction. At 30’ the movement
stops automatically
automatically..
j. Extra
k. Extra

13
13.. Parkin
arking
g brak
brake e
14 Emergenc
Emergency y cut-
cut-out
out serv
servoo circu
circuits
its
f g h i j k 13 14 15 15. Safety
Safety system
system by-pa
by-pass
ss switch
switch
(Only in emergency situations) see page 15.
WARNING!
Läge 1 Läge 0 Läge 2
ping a container.

16 DCE80-90E

Brake pedals and release clutch activator (8 and 9)
The brake pedals are hydraulically-actuated and connected to
the hydraulic system of the truck via accumulators which ensure
that there will always be sufficient pressure for braking, even in
the event of the engine stopping for a brief period. If the accumu-
lator pressure falls below a certain level, lamp 45 on the panel will
1
2
F
N L
come on.
3
0
The brake pedal (8) is used as the ordinar

ordinaryy foot brake.
4
R
The brake pedal is combined with a separate release clutch acti-

R
4 3
vator (9). When this pedal is pressed at the same as the brake
pedal, the clutch is activated (gearbox disengaged) at a certain
brake pressure. The clutch feature is used if hydraulic functions
are required while a gear is engaged.
KL597
Accelerator (10)
8 9 10 The accelerator pedal is mechanical and actuates the fuel injec-
tion pump by means of a wire.
Options: Some trucks are equipped with hydraulic or electrical
accelerator.
Adjusting the steering wheel (11)

The slope and height of the steering wheel
whee l and instrument panel
can be adjusted to the desired driving position.
Uppe
Upperr han
handl
dle
euupw
pwar
ards
ds:: St
Stee
eeri
ring
ng whee
wheell h
hei
eigh
ghtt pos
posit
itio
ion
n
Upper
Upp er han
handle
dle dow
downwa
nwards
rds:: Steerin
Steeringg whee
wheell a
angl
ngle
e
Lower handle: Steering column angle
11 Loosen the handle clockwise and
adjust as required.
Tighten the knob firmly after
adjustment
KL588
Parking brake (13)

The parking brake consists of a disc brake on the input shaft of
the drive axle and is applied by a powerful spring in the hydraulic
cylinder of the parking brake. The brake is released by means of
hydraulic pressure.
The brake is controlled electrically
electrically,, by means of switch 13.
In turn, this switch activates a solenoid valve that directs the
hydraulic pressure to and from the brake cylinder.
A warning buzzer will be sound if the operator inadvertently
leaves his seat before applying the parking brake.
13 Warning lamp 51 will show a steady light when the parking
par king brake
is applied.
 If the accumulator pressure should drop below a certain level,
warning lamp 45 will light up. But sufficient capacity will still be
available for
for releasing the par
parking
king brake. After that, the parking
brake is applied automatically by a heavy spring in the brake cyl-
inder. If the wheels then need to be rotated – deactivate the
brake, see section Mechanical release of the parking brake, page
WARNING!
28.
Never leave the operator’s seat with-
out applying the parking brake
DCE80-90E 17
OPERATION Heating and air conditioning system

Heating and air conditioning system
The standard version of the truck is equipped with heater and de-
froster only.
The heating system is connected to the engine coolant system
and starts delivering heat after the engine has warmed up.
34 The fan is controlled by control 37. The air conditioning system
can be switched on and off by means of o f switch 34.
35
NOTE. The air conditioner is optional equipment.
34. Switch,
Switch, compressor
compressor air conditioner
conditioner
35. RECIRCULA
RECIRCULATION TION switch
switch
Closed – 100% air from outside of cab
Open – 20% air from outside of cab
36 39 36. Contro
Controll DEFRO
DEFROSTESTER/C
R/CAB
AB
KL599 37 37
37.. Fan con
contrtrol
ol
38.
38. HE
HEAAT contro
controll
38 39. COOLIN
COOLING G control
control (Option
(Optional)
al)
Setting the heating mode

 Close the recirculation control 35. Open if the weather is very
cold.
 Switch off the air conditioner, switch 34.
 Set the heater control 38 and the fan 37 as required.
During the autumn and early winter when high air humidity
causes misting of the windows
 Switch on the air conditioner, switch 34.
 Open the recirculation control 35.
 Set the COOLING control 39 to MAX.
KL733
 Increase the temperature as required with 38.
 Set the fan to maximum speed with 37.
 When the windows have been demisted, set the cooling con-
A A trol 39 so that the cooling thermostat will trip at regular inter-
vals for defrosting the cooling element.
 Close recirculation with 35.
Note that the cooling is used
u sed for dehumidifing the air in the cab.
Setting the cooling mode

 Close the recirculation control with 35. Open during hot
weather and high humidity.
 Set the heater control 38 to COOL.
 Switch on the air conditioner, switch 34.
 Adjust the cooling control 39 as required.
 Open and direct the panel
p anel nozzles A towards the roof.
18 DCE80-90E
OPERATION Heating and air conditioning system

Thermostatically controlled Air Conditioning unit
As an optional extra, a thermostatically controlled system for air
conditioning, cooling, demisting/dehumidifying and heating, is
available.
The system is equipped with a sensor that senses both inner and
outer temperatures and automatically regulates the temperature
to the pre-set level, either by heating or by cooling.
33. Switch
Switch DEMIST/DE
DEMIST/DEHUMID HUMIDIFYING
IFYING FUNCTION.
FUNCTION.
33
34. Switch
Switch COOLING
COOLING FU FUNCTION
NCTION OFF.
OFF.
34 35. Switch
Switc
Switchh forwards
RE-CI
RE-CIRCULA
RCULATION.
- air TION.
from outside.
35 Switch backwards - air from inside.
36. Contro
Controll DEMI
DEMIST/
ST/CAB
CAB..
37. Control
Control FAN.
FAN. Infinitely
Infinitely variable
variable setting
setting of fan
fan speed.
38. Control
Control TEMPERATURE.
TEMPERATURE. Infinitely
Infinitely variable
variable setting
setting of cab
temperature from 16-26°C.
36 39 Control fully clockwise: Full heating effect = heating valve
KL599A
continuously open.
37 Control fully anti-clockwise: Full cooling effect = cooling func-
tion running continuously.
continuously.
38 N.B. When the controls are in respective
re spective full positions, pre-
cise temperature regulation cannot be achieved.
39. Cover
Cover.. The climate equipment’
equipment’s s demist thermostat
thermostat is located
located
under this cover. The thermostat must always be set in the
max. clockwise position.
Normal operation
N.B. Run the compressor from time 1. Set control
controls
s 37 FAN and
and 38 TEMPERA
TEMPERATURE TURE to the the required
required
to time, even during the winter, in fan speed and temperature.
order to lubricate and ensure The fan must be running for cooling to function. (If the fan is
correct function. switched off, the compressor and condenser stop.)
2. The sy syste
stem
m then opera
operates
tes au
autom
tomati
atical
cally
ly,, as fo
follo
llows:
ws:
N.B. The cooling is not operative at – When heat is required:
tempe ratures
temperatur es below 0 °C.
°C. The system operates in 10 second cycles. The water valve
opens for heating at intervals
inter vals from 0 seconds, extending
to 4 seconds
seconds.. Thereafte
Thereafter,
r, the valve
valve is open for continual
continual
heating.
– When cooling is required:
The system operates in 2 minute cycles. The compressor
operates at intervals from 30 seconds, extending to con-
tinual operation. The condenser operates continuously as
long as cooling is required.
Demisting/Dehumidifying the air in the cab
1. Thi
Thiss functio
function
n is used
used when the the windsc
windscree
reen/w
n/wind
indows
ows mmist
ist up.
up.
2. Sta
Start
rt demis
demistin
ting
gb byy press
pressing
ing switc
switch
h3 33.
3.
The fan then runs at full speed
spee d for 3 minutes, the compressor
and condenser run r un continuously. The switch lamp lights.
N.B. The cooling system is used for dehumidifying air.
3. Aft
After
er 3 mi
min.
n. the fan
fan speed
speed returns
returns autom
automati
aticall
cally
y to the pre
previ-
vi-
ously set level. Control 37 can be used to select a lower fan
speed at any time.
4. Pre
Press
ss swit
switch
ch 33 again
again to s
swit
witch
ch off the
the demisti
demisting
ng functi
function.
on.
The switch lamp extinguishes.
Operating without automatic cooling
1. Pres
Presss swi
switc
tch
h 34 tto
o the
the OFF
OFF posi
positi
tion.
on.
The compressor and condenser then stop. The switch lamp
lights. the cooling function is thereby de-selected in all posi-
tions
TUREand does
is set not MIN.
to the start even when control 38 TEMPERA-
position.
2. Set control
control 38 to the require
required
d ttempe
emperat
rature
ure..
DCE80-90E 19
OPERATION Operator’s seat

Operator’s seat adjustments
The operator’s seat is provided with the following adjustment
facilities:
A Di
Dist
stan
ance
ce fr
from
om th
the
e ped
pedal
als
s.
G Release the seat by means of the lever and move it forward
or towards the rear.
B Heig
Heightht of th
the
e se
seat
at cush
cushio
ion.
n.
Turn the knob until the desired height is achieved. The
springing
weight. will automatically correspond to the operator’s
C Backrest rraake
Turn the knob.
D Armrest slope
E Tilt – si
simul
multane
taneous
ous slo
slopin
pinggooff s
seat
eat and backre
backrest.
st.
F Adju
Adjuststme
ment
nt of
of cush
cushio
ionin
ning
g in th
thre
ree
e steps
steps..
1. Normal position – lever pulled out. Used in normal opera-
tion.
2. Restricted – lever pushed in to the intermediate position.
Used in operation on rough surfaces and restricts the spring
travel to 25 mm.
3. Locked position – lever pushed in fully. Used when spring-
ing is not required.
G Back suppor t
Stepless adjustment
20 DCE80-90E
OPERATION Engine heater, running-in, start, warming-up

Engine heater
The truck can be equipped with an engine heater to facilitate
starting at temperatures below 0°C.
The engine heater consists of a heater cartridge fitted into the en-
gine block and is designed to heat the engine coolant.
The engine heater must be connected to a 220 V a.c. earthed
outlet.
Running-in
A new engine should always be treated with care during a certain
running-in period. During this period, the surfaces of the bores,
gears and bearings will become hard and polished, and this will
ensure a long useful life of the engine.
Avoid
Avoid running the engine at full load during
du ring the first 50 hours. The
load can then be gradually increased.
Try to extend the running-in
r unning-in period to 200
20 0 hours. This will pay in
the long run – the stoppages and breakdowns will be fewer.
Start
WARNING!
IMPORTANT!
IF THE ENGINE DOES NOT START Never use a starting spray to facilitate starting, since
this may cause an explosion.
Make a new attempt after 15 to 20
seconds.
Do not run the starter motor for more
than 10 seconds at each  Set the gear lever to NEUTRAL.
attempt.  Turn the starter key directly to position II. Then:
If the engine still refuses to start, the Below +5°C
cause should be determined and Hold the key in position II, the pre-heater position, for approx-
remedied. imately 50 seconds.
Turn the key further to position III – the star ting position – and
Air in the fuel system? – see page 32. release it as soon as the engine has fired.
Above +5°C
Turn the key directly to position III – the star
starting
ting position –
and release it as soon as the engine has fired.
Warming-up
Never race a cold engine. Run the engine at 1400–1500 r/min un-
til it starts to warm up. It is essential that the engine oil be warm
and that it is circulating correctly before the turbocharger starts
running at high speeds. Nor should the engine be run at critically
cr itically
low speeds. Start using the truck only when the engine has
reached normal working temperature, i.e. when the temperature
gauge on the instrument panel reads about 80°C. 80°C.
DCE80-90E 21
OPERATION Cummins QSB

Cummins QSB 5.9
Machines that are equipped with the Cummins QSB 5.9 have a
separate engine monitoring system. The engine is not affected by
the machine’s ECS. An error code, that in the ECS would reduce
engine revolutions, does not have this effect with the QSB 5.9.
However,
Howev er, the ECS does display current values of, engine oil pres-
sure, coolant temperature, etc.
The engine monitoring system is separately installed on the
instrument panel and includes:
3. ENG
ENGINE
INE MAIN
MAINTEN
TENANC
ANCE,E, spring-
spring-loa
loaded
ded sswit
witch
ch with
with ora
orange
nge
lamp.
– Lamp lights up when maintenance of the engine is re-
quired
– In the DIAGNOSIS position, the spring-loaded switch is
used to move between ERROR CODES.
4. DIA
DIAGNO
GNOSIS SIS,, spring-
spring-loa
loaded
ded s swit
witch
ch wi
with
th green
green lamp
lamp..
– Used to activate the engine error codes, in the DIAGNO-
SIS position, i.e., switch 2 depressed.
5. STOP
STOP ENGI
ENGINE NE,, rred
ed lamp
lamp..
– Lamp lights up when a serious engine fault occurs.
Stop the engine as soon as is possible, without risking
safety.. Otherwise, there is a risk of permanent
safety per manent damage to
the engine. The engine must not then be run before the
1 2 3 4 fault in question has been rectified.
– The red lamp also shows the actual error code by means
of a blink system, when in the DIAGNOSIS position, see
table.
6. CHEC
CHECK K ENGI
ENGINE NE,, oran
orange
ge lamp
lamp..
– Lamp lights up when a less serious engine fault occurs.
It is still possible to run the
th e engine, but the fault must be
rectified as soon as possible.
– In the DIAGNOSIS position the lamp starts to blink after
the red lamp has shown the actual error code.
Lamp functions
The table below shows the lamp functions and significance at
start-up and during operation.
Function Significance Lamps and their patterns

DIAGNOSIS CHECK ENGINE STOP ENGINE
(Green in switch 2) (Orange) (Red)

Lamp check at engine Check to ensure LIGHTS UP, LIGHTS UP, LIGHTS UP,
start-up lamps function GOES OUT after 2 s GOES OUT after 2 s GOES OUT after 2 s
Engine protection System problem, BLINKS slowly
contact service
Maintenance monitor Time for service LIGHTS UP
continuously
Current service inter- BLINKS rapidly 3x5
val exceeded. blinks
Contact service
DIAGNOSIS Less serious fault LIGHTS UP
DIAGNOSIS switch in Error code registered continuously
OFF position Serious fault with risk LIGHTS UP
of engine damage. continuously
Error code registered

ERROR CODES Blinking of error codes BLINKS once per BLINKS the number
DIAGNOSIS switch in error code for the current error
ON position code, see list of error
codes, page 23
22 DCE80-90E
OPERATION Cummins QSB

Error Codes
1. Stop engine.
2. Turn the ig
ignit
nition
ion key
key to the
the operat
operating
ing posit
position
ion so that
that all
all
lamps light up.
3. Pres
Press sddow
ownn DIA
DIAGN
GNOSOSISIS switc
witch.
h.
4. If th
there
ere are
are no error
error codes
codes to be sshow
hown,n, the
the red and
and orang
orange e
lamps will show a continuous light.
5. If the
there
re are e
error
rror code
codess to be shown
shown,, the orange
orange ligh
lightt bli
blinks
nks
once. Thereafter the red light blinks in a pattern with first the
first number,
number of thethen the
error second
code number and lastly the third
number.
Example: Error code 143
1 blink, pause
4 blinks, pause
3 blinks
The pattern is repeated until the fault is rectified
(in the DIAGNOSIS position.
6. To see the n nex
extt error
error code,
code, pres
press
s the spring
spring-loa
-loaded
ded swit
switch
ch
(1) once.
Note. The orange lamp blinks before each new error code. co de.
The table below shows a number of common error e rror codes that
operators themselves can rectify.
There are a large number of additional error codes. Rectify as per
points 3 or 4 on the previous page.
IMPORTANT! Always contact service if the error code is still

IMPORTANT!
displayed. It is forbidden to operate the machine until the
fault has been rectified and the error code is no longer
displayed.
Error Code Description Lamp

number
143 Low oil pressure, check engine oil Orange
level and top-up as required.
151 High co
coolant te
temperature, st
stop Red
engine as soon as possible. Check
coolant level and top-up as required.
214 High oi oil te
temperature, st
stop en
engine as
as Red
soon as possible. Check oil level or
coolant and top-up oil/coolant as
required. Contact service if error code
still displayed.
415 Very low oil pr
pressure, st
stop e
en
ngine as
as Red
soon as possible. Check oil level and
top-up as required. Contact service if
error code still displayed.
441 Low battery voltage, Orange
check the battery
battery..
597 Low battery voltage, Orange
check the battery
battery..
598 Very low battery voltage, stop the Red
engine as soon as possible and con-
tact service.
DCE80-90E 23
OPERATION Functional checks, st

stopping of
of en
engine, st
steering
Functional checks
When starting the truck
tr uck and from time to time when using it, make
a habit of checking:
WARNING!  that the engine temperature gauge reading
r eading is about 80°C.
 that the reading on the fuel gauge is sufficiently above 0.
If results of the functional checks are N.B. The reading should never be allowed to drop to 0.
in any way doubtful, report
immediately to the supervisor.  that all warning lamps are extinguished.
 that the horn, lighting, brake lights and direction indicators
operate correctly
correctly..
 that all hydraulic functions operate correctly.
 that the saftey system for container coupling and all indicat-
ing lamps for container handling operate correctly
correct ly..
WARNING!
If mirrors or CC TV cameras are used

to aid vision, the speed of the ma-
chine must be adapted to the limited
vision.
Stopping the engine, parking

 Apply the parking brake.
 Tilt the mast slightly forward on lower the side lift onto the
ground.
 Set the gear lever in NEUTRAL.
 Allow the engine to run for 1/2–1 minute while at idling speed
before stopping it, This will allow the engine to cool down and
the turbo bearings to be lubricated.
 Stop the engine by turning the ignition key to position 0.
 If the truck will not be used for a longer period, turn
tur n the main
switch to the OFF position.
IMPORTANT!
Never turn the main switch to OFF when the engine is
running – the voltage regulator may be damaged.
Power steering
The truck has pure power assisted steering,
steering , and there is thus no
mechanical connection between the steering column and the
steered wheels. Movements of the steering wheel is transmitted
IMPORTANT!
Remember to carry out the daily hydraulically to the steered wheels.
supervision. Never let the truck run downhill when the engine is not running,
See page 30. since no hydraulic pressure will then be available and the
steering of the truck will be very restricted.
24 DCE80-90E
OPERATION Empty container side-lift

Safety regulations
WARNING!
1. Exer
Exercise
cise spe
special
cial car
care
e whe
when
n ope
operati
rating
ng the
the side-li
side-lift.
ft.
2. Risk ffo
or ttiippi
pping!
It is prohibited to move the truck with the side-lift
raised except when stacking.
The side-lift, with or without load, may be lifted high-
er than transport position only when stacking.
3. Alwa
Always
ys chec
checkk to ma
make
ke sur
suree that
that n
no
o
person is in the way for the truck or side-lift.
4. Rem
Remembe
emberr tha
thatt the side-li
side-lift
ft is wide
wide and ensu
ensure
re th
that
at it
it
does not collide with posts, overhead lines, etc
5. Av
Avoid
oid powe
powerful
rful acce
acceler
lerati
ation
on and brak
braking
ing w
when
hen tturn-
urn-
ing. In addition, the operator shall always moderate
the speed of the truck when turning during forwards
or reverse driving so as to avoid the risk of lateral
skidding or tipping.
6. Th
The
e foll
follow
owin
ing
g ap
appl
plie
ies!
s!
At any transport, the side-lift, with or without load,

must be in the transport position or lower.
The mast should be tilted to its max. backwards po-

Transport position sition.
If the load blocks the line of vision, the truck should

be driven in reverse.
While stacking, when the truck is moved with the

side-lift raised, the brakes should be applied gently
and carefully.
carefully.
DCE80-90E 25

Sidelift with twist-locks
Indicating
Indicating lamps on side-lift
side-lift
A B C Lamp A (Gree
(Green):
n): Twist-locks
wist-l ocks locked
Lamp B (Orange): Alignment, extinguished when
the container is lifted
Lamp C (Red): Twist-locks
wist-l ocks unlocked
Indicating lamps on sidelift
Indicating lamps in cab

Lamp A (Gree
(Green):
n): Twist-locks
wist-l ocks locked
Lamp B (Or
(Orang
ange):
e): Alignm
Alignment,
ent, extin
extinguis
guished
hed aft
after
er lif
lift.
t.
D Lamp C (Red): Twist-locks
wist-l ocks unlocked
A BC
Lamp D (Red): Lights up when the safety system is
by-passed with the key switch.
F
1
2
3
N L
0
4
R
R
1 4 5
2 3
KL1097A
Sidelift with hook coupling

Indicating
Indicating lamps on side-lift
side-lift
A B1 C Lamp A (Green): Locking plates locked

Lamp B1 (Orange): Alignment against container,
extinguished when the container is lifted
B2
Lamp B2 (Orange
(Orange):
): Alignment on hooks,
the light is on after lift
Lamp C (Red): Locking plates unlocked
Indicating lamps on sidelift Both B1 and
B1 and B2 must
B2 must be lit before the
locking plates can be unlocked.

Lamp A (Green): Locking plates locked
D Lamp B (ora
(orang
nge)
e):: Alig
Alignm
nment
ent,, ext
extin
ingui
guish
shed
ed a
aft
fter
er lift
lift..
A BC Both B1 and
B1 and B2 must
B2 must be lit for B in
the cab to light up.
Lamp C (Red): Locking plates unlocked
Lamp D (red): Lights up when the safety system is by-
passed with the key switch.
F
1
2
N L
3
0
4
R
1
2
4
3
5
KL1097A
N.B. B1 and B2 indicate two different alignment signals from
the sidelift. This is to facilitate fault tracing if lamp B in the
cab should not light up when coupling a container.
26 DCE80-90E

Lifting technique
1. Set tthe
he le
lengt
ngth
h adjust
adjustment
ment to the
the appropr
appropriat
iate
e contai
container
ner
length.
WARNING! 2. Drive slowly
slowly fforwar
orwards ds ttowar
owards
ds the
the contain
container
er,, sid
sideshift
eshift if
necessary.
it is prohibited to use the side-lift if 3. Low
Lower
er the side-l
side-lift
ift to the contai
container
ner..
the indicating lamps are faulty. 4. Cont
Contaiaine
nerr co
coup
upliling
ng::
Twist-locks:Tilt
Twist-locks: Tilt the mast slightly forwards, about 2°.
The use of a side-lift with faulty Lower the side-lift to the container and fit the two twist-locks
indicating lamps involves a great
safety risk. into the container
are resting on the lock holes so
container. Checkthat both ends B
that lamp of lights
the side-lift
up.
Lock the twist-locks.
Hook coupling: Set the mast vertical.
Fit the two hooks into the container locking holes. Drive
forward against the container until the side-lift is resting
against the container. Lift slightly so that the container rests
on both hooks. Check that lamps B1lamps B1 + B2 light up.
Lock the locking plates.
5. Check
eck tthhat lamp A lights up, the container is now locked to
the sidelift.
6. Tilt
Tilt the m mast
ast b
back
ackwar
wardsds an
and
d lift.
lift. Check
Check that
that lamp
lamp B/B1 are
A B C extinguished on lifting.
Hook coupling: Lamp B2 is B2 is lit even after lift.
7. Adj
Adjust
ust llift
ifting
ing heigh
heightt to tra
transp
nsport
ort posi
positio
tion
n or lower
lower before
before
Twist-locks
driving. See picture Transport position on page 25.
8. Rele
Releas
asin
ing
g a :cont
Twist-locks:
Twist-locks contai
aine
Lowerner:
r: container on the load surface. Check
the
that lamp B lights up. Unlock the twist-locks.
coupling: Lower the container on the load surface.
Hook coupling: Lower
Check that the lamps B1 B1 + B2 light up. If not, adjust LIFT and
B2 light
A B1 C TILT
TILT until the lamps light up. Then unlock the locking plates.
Safety system by-pass switch, see page 15

B2 (Only in emergency situations) .
Hook coupling
WARNING!

Indicating lamps on side-lift ping a container.

D. Warning lamp, safety system by-passed

D
A BC
Operations close to high tension power lines
Extreme care must be taken when working in close proximity to
overhead, high tension power lines, particularly in respect of the
1
2
3
F
N L
reach of the boom and attachment.
0
4
R
WARNING!
1 4 5
2 3
KL1097A
If the machine comes into contact with overhead high

tension power lines - remain seated in the cab and call for
help!
It is extremely dangerous to leave the cab as you will be
earthed when you come into contact with the ground.
DCE80-90E 27
SPECIAL PROCEDURES
Towing
If possible, the engine should be running during towing in order
WARNING!
to retain braking and steering functions. When the engine is not
running, there is no hydraulic pressure for the steering of the
If it is not possible to run the engine
truck which is then extremely limited. Furthermore, the gearbox
running during towing, a tow bar must
be used. will be insufficiently lubricated.
 Towing may only take place over very short distances.
distan ces.
Before preparations for towing begin  If a tow bar is used, it shall be connected to the connection/
and after towing has been completed, towing hitch at the rear of the machine.
the parking brake must be applied and  The brakes function as long as there is pressure in the accu-
the wheels
chine chocked
rolling. to prevent
The greatest the ma-
possible mulator, thereafter the operating brakes cease to function
and the parking brake is automatically applied. If, thereafter,
care must be exercised during towing it is necessary to move or tow the truck, the parking brake
operations to prevent personal injury. must be released mechanically (see instructions below).
 The vehicle or machine use to for towing must be at least as
heavy as the machine to be towed and have sufficient engine
IMPORTANT! and brake
b rake capacity.
The truck cannot be started by  For towing over longer distances or at speeds higher than 10
being towed. km/h, the propeller shaft must be disconnected.
Any attempt to start the engine by
towing, will inevitably cause Lifting the truck
damage to the tranmission. The truck should be lifted according to the following:
 Dismantle the mast
 Place a lifting sling around the chassis, between the counter-
weight and the steered axle, se picture.
 Attach two lifting slings in the mast suspension ear-lugs, one
on each side.
The lifting with
coincides device
themust be of
centre fitted in such
gravity a way
of the that the lifting point
truck.
Fire protection
If the machine is equipped with fire extinguishers these should be
of the ABE type, in accordance with EN 3 par ts 1, 2, 4 and 5. With
such a fire extinguisher it is possible to extinguish a fire in both
fixed organic materials and liquids. Furthermore, the medium
used to extinguish fire does not conduct electricity.
Suitable fire extinguishers can be ordered from Kalmar.

 WARNING!
If the machine is used in highly inflammable environ-

WARNING! ments, e.g., in explosive environments, it is a strict re-
quirement that the machine be designed, constructed
Follow existing safety rules and equipped in accordance with EN 1755.
Mechanical release of the parking brake
WARNING!
Block the wheels before releasing the parking brake

The parking brake is automatically applied by powerful springs in
the braking cylinders if the pressure of the hydraulic accumulator
drops below a certain
certa in level. If the truck must be moved:
1. Not
Note
e the
the posit
position
ion of tthe
he adju
adjusti
sting
ng scre
screw
w A.A.
2. Rel
Releas
ease e the br
brake
ake by
by looseni
loosening
ng th
thee locknu
locknutt at A, a
and
nd then
then
screw out the adjusting
ad justing screw anti-clockwise.
3. Onc
Oncee the fault
fault has
has been
been rectif
rectified
ied,, rese
resett the parki
parking
ng br
brak
akee
function by returning the screw (A) to the same position as in
point 1.
WARNING! WARNING!
Block the wheels before releasing the If the parking brake has been mechanically released it must
parking brake. always be reset in order to restore the parking brake function.
f unction.
28 DCE80-90E
SPECIAL PROCEDURES
Transport
When transporting the DEC80-90E the mast and side-lift must be
dismantled and transported
transpo rted separately
sepa rately. The truck tr uck should be
transported on a trailer sufficiently wide to be able to support the
inner wheels of the drive
dr ive axle.
1. ReReve
verse
rse the
the truc
truckk up onto
onto the
the tra
traililer
er..
2. If the drive
drive wheels
wheels g go
o outs
outside
ide the
the traile
trailerr then a an
n approv
approved
ed e
ex-
x-
tension of the trailer width must be used.
 3. Secure
Secure the
the fro
front
nt sectio
sectionn of the
the chassis
chassis using using chai
chains
ns eq
equipp
uipped
ed
Securing on the trailer withfront

the hooks of and tensioners.
the chassis andAttach
to the the front chains
designated securely to
attachment
points on the trailer.
4. Secure
Secure thethe rear
rear se
secti
ction
on of the
the chass
chassis is using
using chain
chainss equippe
equippedd
with hooks and tensioners. Attach the chains to the tow bar
and the designated attachment points of the trailer.
5. Use woode
wooden n cho
chocks
cks uunder
nder tthe
he tilt
tilt cylinde
cylindersrs to p
pre
reven
ventt dam
damage
age
to them.
6. When trantransporti
sportingng a truck
truck with
with high-le
high-leve vell cab,
cab, the cab
cab must
must be
lowered in order to achieve the correct transporttranspor t profile, see il-
lustration.
1
– Loosen the the steps from the cab platform.
platform.
– Remove
Remove the v vertical
ertical section
section of the the exhaust
exhaust pipe.
pipe.
– Loosen and removeremove the brabracing
cing plate from the cab support.
support.
– Attach lift-shac
lift-shackles
kles to the
the holes in the c corners
orners of the
the cab
platform.
– Attach the cab with lift straps
straps to a fork-lift
fork-lift truck or other lifting
device.
– Loosen the
the cab support
support from the sides of the frame. frame.
– Lower the cab
cab so that the cab
cab support
support goes down between
the tank and the frame.
 – Secure the cab support with three transport screws screws to each
2 3 side of the frame, see illustration.
1. Attac
Attachment
hment holes for lift shackles
shackles
2. Fix
Fixing
ing sc
scre
rews
ws for
for brac
bracing
ing plate
plate
3. Transpo
ransport
rt scre
screws
ws,, cab support
support WARNING!
Lowering of high-level cab Always follow applicable safety regulations
1. Protec
Protectio
tion
n und
under
er ti
tilt
lt cy
cylin
lin--
ders
2. Attach
Attachmen
mentt po
point
ints
s on ffron
rontt
edge of chassis
3. Tens
ension
ioner
er de
devic
vice
e

4. Attach
Attachmen
mentt poi
points
nts o
on
n tr
trail
ailer
er
Securing at the front of the trailer

DCE80-90E 29
SUPERVISION Daily supervision

Supervision
IMPORTANT! Supervision is differentiated as follows:
The following must be carried out in
addition to daily and periodic supervi-  DAILY SUPERVISION – carried out by the operator
sion:  PERIODIC SUPERVISION
SUPERVISION – carried out by specially trained
service personnel.
Service during the running-in period
 Tighten the wheel and prop shaft Proper supervision contributes to making the truck safe to work
nuts after 8, 16 and 24 hours of oper- with.
ation. Tightening torque in accord- Periodic supervision is described
descr ibed in the Technical Handbook. The
ance with the Technical
Technical Handbook. operator must make sure that the truck is available for service
Tighten the wheel nuts in a zig-zag every 500 hours of operation.
sequence. Tighten the nuts in the N.B. Service at 200 and 400 hours for engine
same way every
every time after changing
a wheel.
All times refer to the hours of operation, ie, the time recorded by
Guarantee service after 50 hours. the hour meter on the panel.
The guarantee service is performed by
Kalmar, or by personnel authorized by
Kalmar, and is part of the Kalmar delivery
commitments.
WARNING!
The guarantee service is also a condition
for continued validity of the guarantee.
Only genuine Kalmar spare parts may be used. Spare
tyres and replacement tyres must be of a make approved
app roved
by Kalmar.
DAILY SUPERVISION Or when Check Refill as re- More details

refuelling quired on page
Brakes Operation
Steering Operation
All instruments: Operation
Direction indicators, horn,
brake lights, headlights
All hydraulic functions, e.g.: Operation
Lift, tilt, sideshift, Run every function to its end position in order to lubricate the
length adjustment, twist locks cylinders and prevent corrosion
Engine, gearbox, drive axle, Noises?
hydraulic hoses Oil leakage?
Fuel Amount • 32
The gauge reading
should never drop to
Drain condensate from the fuel prefilter (if applicable)
Engine oil Level • 35
Air cleaner • Indicator 36
Coolant • Level • 34
Hydraulic oil • Level • 37
Gearbox oil • Level 37
Windscreen washer • Fluid level • 37
Wheels • Tyre pressure 41
Sidelift attachment • Check that all sensors are free from grease and
that the sensor faces are undamaged.
Check that all indicating lamps are operational
30 DCE80-90E
SUPERVISION Tyres
Tyres
Checks
WARNING! 1. Che
Checkck the
the tyre
tyres
s regularl
regularlyy, if pos
possib
siblele,, dail
daily
y.
2. Rem
Remov ove
e object
objectss that
that cou
could
ld pen
penetr
etrate
ate the
the tyres
tyres,, such
such as bro-
bro-
Spare and replacement tyres shall be ken glass, pieces of wood, metal shavings, etc.
of a make approved by Kalmar. 3. Che
Checkck for
for une
uneve
venn and rapid
rapid wear
wear.. This isis caused
caused by mecha
mechan-n-
ical faults such as unevenly acting brakes. Make sure that
such faults are immediately rectified.
Compressor for tyre inflation

1. An ai
airr filter
filter wi
with
th water
water separ
separato
atorr should
should be ffitt
itted
ed in the
the line
line
from the compressor that is used for tyre inflation.
The water separator minimises the risk of the rims rusting.
2. Dra
Drain
in the water
water sep
separa
arator
tor regular
regularlyly..
Tyre inflation
1. Bef
Before
ore infla
inflatin
ting,
g, make
make sure that
that the whee
wheell lockin
lockingg ring is iin
n
the correct position, see illustration.
N.B. If the tyre has been completely deflated, the wheel
must be dismantled and checked for damage.
2. Con
Connect
nect the cocompr
mpress
essor
or hose,
hose, with
with a ggrip-
rip-noz
nozzle
zle tto
o the nip-
nip-
ple on the tyre.
3. Mov
Move e away
away tto o the si
side
de and
and rema
remainin th
there
ere throu
throughou
ghoutt the en
en--
tire inflation process.
KL1592 4. Inflat
Inflatee the tyr
tyre
e to the rec
recomm
ommende
ended d pres
pressur
sure,e, see
see Tech
Technica
nicall
Data.
Locking ring With a change of tyres or rim type, another tyre pressure
may apply, contact KALMAR.
WARNING!
Never stand in front of a tyre being inflated.

Do not exceed the recommended tyre pressure, see
Technical Data.
With a change of tyres or rim type, another tyre
pressure may apply
app ly,, contact KALMAR.
Always follow the instructions for tyre inflation

inflati on to avoid
serious accidents.
When changing tyres, see “Safety instructions for work-
ing with tyres” in Technical Handbook.
470EC
Tyre inflation
DCE80-90E 31
SUPERVISION Fuel system

Fuel system
Always refuel with ordinary diesel oil.
Never use any additives for the diesel oil.
In the winter, it is advisable to refuel the truck
tr uck immediately after
the day’s work
work has been completed, ie, to avoid moisture con-
densing inside the fuel tank.
Never add water-absorbing agents, such as alcohol, to the fuel.
Tank capacity, see Technical Data.
The filling pipe is on the left-hand side of the truck.
Before refuelling, make sure that the area around
aro und the filler cap is
clean.

Bleeding the fuel system
Volvo engines
Air will be drawn into the fuel system if the truck is used when the
fuel tank is completely empty. It will then be necessary to bleed
the system after refuelling. This is carried out as follows:
 Back off the bleed screw A half a turn.

 Release the pump handle B by turning it anti-clockwise
(TWD).
 Pump by means of the hand pump B until the fuel flowing
past the bleed screw is completely free
fre e from air. Continue
pumping and tighten screw A.
 Tighten the pump handle (TWD).
 Run the starter motor in 20–30 second bursts, with a pause
of a couple of seconds between each run. The engine will
start after 2–3 minutes.
A Bleed screw
B Hand pump
Volvo TWD731VE
B
KL1596
Volvo TAD720VE
32 DCE80-90E
SUPERVISION Fuel system

Cummins QSB 5.9
1. Pla
Placece a con
contai
tainer
ner under
under the
the fuelfuel pre
pre filt
filter
er..
2. Loo
Loosensen the
the return
return banj
banjoo fit
fittin
ting g on the
the fuel
fuel lift
lift p
pump
ump....
3. Run tthehe fuel
fuel lift
lift pump
pump until
until aallll the
the air has beenbeen vent
vented.
ed.
To run the fuel
fu el pump for 25 seconds, crank the engine for a
split second, and leave the key in the ON-position.
4. Whe
When n bub
bubble
ble-fre
-freee air come
comes s out of tthehe fitti
fitting,
ng, retig
retighte
hten
n the
fitting.
A Vent screw
Draining of condensate
(Only certain engines)
Cummins QSB 5.9 (Draining required daily)
IMPORTANT! Wait draining until the engine has cooled
down
1. Pla
Placece a con
contai
tainer
ner under
under the
the fuel
fuel pre
pre filt
filter
er..
2. Ope
Open, n, by h
hand
and,, the drain
drain valv
valvee C in the bott
bottom
om of the
the fuel pre
pre
filter.
 QSB 5.9:5.9: Turn the valv
valvee appr
approx
ox 3.5
3.5 turn until
until the valv
drops down 1 inch and the draining starts.
valve
e
3. Pus
Push h the v
valv
alvee up and turn
turn it cloc
clockwi
kwise
se to cl close
ose the
the drain
drain vval-
al-
ve by hand when clear fuel is visible. )
C Drain valve, condensate
IMPORTANT! Tighten the valve only by hand, overtightening

can damage the threads. Dispose of the fuel in accordance
with environmental regulations.
DCE80-90E 33
SUPERVISION Cooling system

Cooling system
The coolant is topped up via the radiator filling cap accessible
through an aperture in the engine cover.
N.B. TAD and QSB engines have separate e expansion
xpansion tanks.
WARNING!
Do not open the cap when the engine is hot, since steam
or hot water may spray out.
Fill with water containing at least 40% glycol. If glycol is not used,
a corrosion inhibitor must always be added to the coolant.
co olant. But the
corrosion inhibitor is not an anti-freeze agent, and should there-
fore be used only if the ambient temperature is constantly above
KL1310 0°C.
If the coolant level should drop below the minimum level, warning
lamp 46 on the instrument panel will light up.
IMPORTANT!
Insufficient coolant may impair the coolant circulation
which may cause the coolant to boil and give rise to
engine damage.
Volvo TWD731VE
KL1593
Volvo TAD720VE
Cummins QSB5.9
34 DCE80-90E
SUPERVISION Engine oil

Eng
ngin
ine
e oil
The dipstick for the engine oil (B( B) is on the left-hand side of the
engine (Cummins QSB, right-hand side).
The dipstick has two markings, MIN and MAX, and the oil level
should be between these.
Clean the dipstick before checking the oil level.
It is advisable to top up with oil when the engine is warm and the
oil flows easily. Top
Top up – wait a while – check on the dipstick.
A
A Oil filler cap
B Oil dipstick
Volvo TWD731VE
T WD731VE
B KL1595
Volvo TAD720VE
A
B
KL1597
Cummins QSB5.9
DCE80-90E 35
SUPERVISION Air cleaner, accumulator

Air cleaner
The dust container is emptied automatically.
automatically.
The filter element in the air cleaner is replaced by the service per-
Change
sonnel as a routine measure. If the truck is used under dusty con-
filter! ditions, the filter may become clogged after a relatively short
period of time.
An indicator, which turns red when the filter has become clogged,
KL1314a is located in the air intake system between
be tween the air cleaner and the
engine.
Check the indicator regularly and get in touch with the service
personnel as soon as the indicator has turned red.
IMPORTANT!
Inadequately filtered intake air may quickly cause
serious damage to the engine.
L1314
KL1314
Checking the brake system accumulators

The accumulators are charged with nitrogen. If lamp 45 for low
brake pressure should light up, check for leakage as follows.
1. Sta
Start
rt the engi
engine
ne an
and d let iitt run until
until the accu
accumulmulato
ators
rs are
are
charged.
2. Sto
Stopp the engi
engine
ne an
andd the
thenn turn thethe startin
startingg key
key to posit
position
ion I.
I.
3. Dep
Depress
ress the
the brake
brake pe
pedal
dal repea
repeated
tedly
ly with
with long strok
strokes,
es, hold
hold--
ing it down in the depressed position for a brief brie f while on eve-
ry occation.
4. It sh
shoul
ouldd be pos
possib
sible
le to appl
apply y the bbrak
rakes
es at le
least
ast six
six times
times be
be--
fore lamp 45 lights up.
5. Sta
Start
rt the engin
engine,
e, al
allow
low tthe
he ac accum
cumulaulator
tors
s to be c charg
hargeded an
and
d
repeat the test a couple of times.
6. If th
the
e brake
brakess can
cannot
not be
be applie
applied d six times
times befo
beforere lamp
lamp 45
lightsrecieves
up, the accumulators are faulty.
faulty. If so, ensure
and thatthat
thethe
A fault attention as soon as possible
cumulators are charged with nitrogen.
ac-
WARNING!
KL1315
Charging of accumulators should be made only by au-
thorized service personnel using approved equipment.
A. Quick evacuation valve, accumulators.

A. Quick
WARNING!
The brake
sure of up pressure acculumators
to 210 bar. Take have
Take great care an internal
ttherefore
herefore whenpres-
working on the system and always release pressure
pressur e from
the accumulators before removing any component from
the system. Discharge the pressure by opening the quick-
evacuation valve A.
36 DCE80-90E
SUPERV
SUPERVISI
ISION
ON Hydrau
Hydraulic
lic syste
system,
m, gearbo
gearbox
x oil,
oil, win
windsc
dscree
reen
n was
washer
her
Hydr
Hydrau
auli
lic
cssys
yste
tem
m
The hydraulic tank is on the right-hand side of the truck.
A Refill
AA B Sight gl
glass
The fluid level should be in the middle of the sight glass when all
hydraulic cylinders are in bottom position.
Additive, see Oil and lubricant recommendations page 46.

B
B
KL1316
Gearbo
Gearbox
x oi
oill
The oil filler cap and dipstick for the gearbox oil are beneath the
left-hand engine cover
cover..
A A Filler pi
pipe
B Dipstick
Check the level with the engine idling.
KL1312
B
Windscreen washer
The windscreen washer container is beneath the left-hand en-
gine cover.
Check that there is sufficient washer fluid in the bottle. Refill if
necessary. Use anti-freeze fluid during the winter, e.g. methyl-
ated spirits or special washer fluid.
KL1313
DCE80-90E 37
SUPERVISION Electrical system

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
negative pole is connected to the chassis. The positive pole is
IMPORTANT! connected to a main switch A. When working with the electrical
The starting batteries accompanying
the truck are of the maintenance-free system, when carrying out welding on the truck or at long time
type, which implies that it should not parking, always isolate the batteries.
be necessary to top-up with electro-
lyte during the life of the batteries.
However, the level of the electrolyte
should preferably be checked once or IMPORTANT!
twice a year. Fill as required by add- When working with the electrical system, when carrying
ing de-ionized water. out welding on the truck or at long time parking, always
isolate the batteries.
Machines with ECS: Always disconnect the ECU when
welding.
Checking the electrolyte level of the batteries

WARNING!
The batteries are fitted behind a cover on the left-hand side of the
truck. The electrolyte level should be about 10 mm above the
The battery electrolyte contains corro- cells. Top
Top up with de-ionized water as necessar
necessary y.
sive sulphuric acid. Immediately remove
any electrolyte that comes into contact Batteries contain substances dangerous to health and the envi-
with the skin. Wash with soap and lots ronment. Discarded batteries must therefore be dealt with in ac-
of water. If electrolyte gets into the eyes, cordance with current local/national regulations.
immediately rinse with lots of water and
immediately contact a doctor.
Bulbs
Rating
Description Watts ...................................... B
Baase
Instruments 3 ............................................. BBAA7s
Indicating lamps 1,2.2..................................... W2x4,6d
Cab lighting 10 .............................................. S8
S8,5
Rear lights, red 5 ............................................. B
BA
A15s
Brake lights 21 ........................................... BA
BA15s
D
Poirec
irsecti
itition
oon indi
n lignd
htisca
cato
tors
rs 21...
21.
5 ..........
.....
.......
......
.....
......
.....
......
....
.......
......
.....
......
......
......
.......
......
.....
......
.....BA
....BA15
.SV15s
SV s
8,5
Driving lights 75/70 .................................... P P4 43t-38
(full/dipped beam)
Reve
Re versi
rsing
ng ligh
lightsts,, wh
whit
ite
e 70.....
70....... ....
....
....
....
.....
.....
....
....
....
....
.....
.....
....
....
....
....PK
..PK22s
22s
Working lights 70 ........................................... P
PK
K22s
Hazard b beeacon 70 ........................................... P
PK
K22s
A Main switch
38 DCE80-90E

Relay box in cab – fuses
Fuse Rating, A
No. Circuit protected TWD TTAAD QQSSB
731 720 5.9
S1 Haz
Hazard
ard lights
lights,, ign
igniti
itions
ons k
key
ey,, pre
prehea
heater
ter rrela
elay
y, 15 15 15
start relay
S2 buzzer,, parking brake sen- 15
Cab lighting, seat buzzer 15 15
sor, disengagement relay (ECS 01), hydr oil
cooler supply
S4
S3 Sp
E leacrteric gear-changing -5 -5 -5
S5 Warning lamps, instrument illumination, 5 5 5
coolant level relay brake pressure relay
S6 Horn
Horn,, s scre
creenw
enwash
ash motor
motor,, fron
frontt w
wipe
iperr moto
motorr, 10 10 10
S1-6 S7-12 S13-18 S19-24 S25-30 intermittent relay front wiper
S7 Wi
Wipeperr moto
motorsrs an
andd in
inte
termi
rmitttten
entt re
rela
lay
y re
rear
ar an
andd 10 10 10
roof
S8 Heating fan, AC compressor, seat heater, 25 25 25
recirculation motor
S9 AC condensor, manual hydraulic oil cooler 15 15 15
S10 Mai
Main n fus
fuse,
e, dr
drivin
iving
g lig
lights
hts,, rea
rearr lig
lights
hts,, pos
positi
ition
on 15 15 15
lights, direction indicators
S11 Brake lights, flashing beacon 10 10 10
S12 Reversing lights, reversing alarm 15 15 15
S13 Working lights on mast 15 15 15
S31-36
S14 Working lights on cabin roof 15 15 15
S15 Container lights 15 15 15
S16 24/12 V conver ter (radio, com radio) 15 15 15
S17 Compressor for air suspended seat 15
Spare - -
S18 El-operated parking brake 5 5 5
S19 EC
ECUU 1 ((Au
Autt ge
gearc
archan
hangin
ging,
g, lev
lever
er s
stee
teering
ring,, 15 15 15
monitoring
S20 ECU 4 (El-ser vo system) 15 15 15
S21 Container attachment, safety interlock 10 10 10
S22 Central lubrication 15
Spare -
Motor 10
S23 Working lights, chassis front 15 15 15
WARNING!
S24 Spare - - -
S25 Left hand main beam 5 5 5
Never use fuses of a higher amperage
than stated on the lid decal. S26 Right hand main beam 5 5 5
Risk of damage or fire. S27 Left hand dipped beam 5 5 5
S28 Right hand dipped beam 5 5 5
S29 Left hand rear light, right hand position light 5 5 5
S30 Right hand rear light, left hand position light 5 5 5
S31 Waterseparator 20 20
S32 Central lubrication 15 15
S33 Compressor for air suspended seat 15 15
S34 Compressed air hor n 15 15
S35 Spare - -
S36 Spare - -
NB. The table contains extra equipment
DCE80-90E 39

Relays
305 Reversing light
314 Parking brbrake, ddiisengagement
315 High power (Start rtiing switch)
316 Wiper motor, front
320 Electric stop (ECS 07) 1)
322-1 Coolant lleevel
322-
322-2
2 Co
Cool
olan
antt lev
level (E
(ECS 07) 1)
CS 07)
323 Pulse rre
elay, d
diirec
rection in
indicat
ato
ors
1)
33
320
8 Letavretrinsgteinetreinrlgoc(E
S k CS 04)
331 Propulsion forward
332 Propulsion reverse
334
334 Rele
Releas ase ec clu
lutctch h at
at aut
autom
omat
atic
ic gear
gearbo
box
x (EC
(ECS 01) 1)
S 01)
368 Low brake pressure (ECS 07) 1)
399 Spare
Miscellaneous
32
321-
1-1
1 Inte
Interm
rmit
itte
tent
nt rela
relay
y wi
wipe
perr fr
fron
ontt
32
321-
1-2
2 Inte
Interm
rmit
itte
tent
nt rela
relay
y wi
wipe rear 1)
perr rear
960 Reversing interlock

1) Optional equipment
Main fuse
for electrical
system
Fitted on the engine
2 x 50 A
Starting from another battery

 Make sure the auxiliary batteries are connected in series, so
that 24 V will be supplied.
Note: Do not disconnect the truck-battery cables
 Connect the jumper cables in the following order:
1. Red cable (+) to auxiliary battery
2. Red cable (+) to truck battery
3. Black cable (–) to auxiliary battery
4. Black cable (–) to a location some distance away from
WARNING! the truck battery, such as the negative cable connection on
the chassis.
Batteries emit oxyhydrogen which  Start the engine
is an explosive gas. A spark, for Do not disturb the jumper cables while starting, as
example from incorrectly connected sparks may otherwise be caused. Do not lean over ei-
starting cables, could cause a battery ther battery.
to
andexplode and result in serious injury
damage.  Disconnect the jumper cables in exactly the reverse order.

40 DCE80-90E
TECHNICAL DATA
DCE80-45E8
DCE90-45E7
Engine
Make – type designation Volvo – TWD731VE Volvo – TAD720VE Cummins QSB5.9
Fuel – type of engine Diesel – 4-stroke Diesel – 4-stroke Diesel – 4-stroke
er ISO 3046 1) – at speed
Power
Pow kW -r/m 167 – 2200 174 – 2300 160 – 2200
Torque ISO 3046 – at speed Nm-r/m 893 – 1300-1450 854 – 1400 938 – 1400
No. of cylinders – compression ratio 6 – 17.7:1 6 – 18.4:1 6 – 16.3:1

Alternator, type – capacity AC – 2240 W AC – 2240 W AC – 1680 W
Starting
Sta rting batte
battery
ry,, voltage
voltage – capac
capacity
ity V-Ah 2x12 – 140 2x12 – 140 2x12 – 140
Transmission
Gearbox, make – type designation Clark – 13,7HR32000
Clutch, type Torque converter
Gearbox, principle Powershift
No. of gears, forward – reverse 3–3
Drive axle, make – type designation Dubbel reduction,
differential and hub reduktion
Wheels DCE80-45E8 DCE90-45E7

Wheels, front and rear 2) Pneumatic Pneumatic
Dimension, front - rear 12,00x24 - 14,00x24 -
Tyre pressure, front and rear MPa 12,00x24 14,00x24

1,0 1,0
Steering- and brake system

Steering system Hydraulic servo - Steering wheel
Driving brake system, type – wheels braked Wet disc brakes – drive wheels
Parking brake system, type – wheels braked Spring brake – drive wheels
Equivalent noise level in cab

In accordance with machine directive.
direct ive.
Limit 70 dB(A)
with standard engine dB(A) max 72 dB(A)
Volumes
Fuel L 380
Hydraulic oil L 320
Volvo – Volvo – Cummins

TWD731VE TAD720VE QSB5.9
Coolant L 40 28 33
Engine oil, incl filter L 28 20 16
Drive axle (incl hub reductions)B=4

reductions)B=4000
000 L 3.5 each hub, 51 differential
B=4500 L 2 each hub, 63 differential
Gearbox L 32
Truck weights and sizes vary depending on o n how the truck is

equipped and this is shown in detail by the product specification
and data sheets for the truck in question.
question . The combination of en-
gine–gearbox is also specified in the product specification.
1) ISO 3046 = Net power

2) Spare tyres and replacement tyres be of a make approved by
Kalmar.
DCE80-90E 41
LUBRICATION CHART

8 9 6, 7 10 11
12
13
KL1318
17 16 15 14
19 1
4
3
2

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. wards and forwards several times to obtain a
new protective film of oil.
42 DCE80-90E
LUBRICATION CHART
Item Description Interval No. of Remarks
No. operating hours lub.
points
200/ 500 1000
400
1 Cylinder bearing, tilt cylinders L 4
2 Mast suspension L 2 Relieve the mast of load when lubricating
3 Cylinder bearing L 4
4 Suppor t rollers, mast and carriage 18
5 Sliding plates outer - innermast L 4 Use skylift or similar.
inneremast - carriage L 4 Lubricate all sliding surfaces with
carriage - sidelift L 8 lubricating agent. Use a brush and
distribute evenly.
Operate the mast to max lifting height.
Every 500 hours, check the wear of the slid-
ing plates. If the remaining thickness of any
plate is less than 3 mm it must be replaced,
see Technical Handbook.
6 Engine oil x x) Oil change every 200 hours 1)
7 Oil filter, engine x 2 x) Filter change ever y 400 hours
8 Steered wheel bearings 2 Dismantle, clean, inspect and pack with
grease every 4000 hours
9 Knuckle pin bearing 4
10 Gearbox oil x 1 x) Oil change. Check level while idling
11 Gearbox, oil filter x 1 x) Filter change
12 Drive axle C x 3 x) Oil change, differential and hubs.
First oil change after 200 h, thereafter every
1000 h.
Drain the oil at working temperature
Check the levels after refill
13 Propeller shaft L 3
14 Hydraulic oil filter x 2 x) Filter change
15 Hydraulic oil 1 Oil change ever y 2000 hours
16 Breather filter, hydraulic reservoir x 1 x) Filter change
17 Linkage, steered axle L 4
18 Hinges, doors and hatches L Dismount doors and hatches
19 Brake pedals CL 2 Check and retighten the pedal axle locking
screws. Lubricate axle nipples
1) The interval is greatly dependent on the fuel and lubricant

quality as well as the operating conditions.
If intervals longer than 200 hours are desired, the condition
of the oil must be checked by the company making the oil, by
means of regular lubricant tests.
Quantities, see Technical Data.
L=Lubricate
C=Check
DCE80-90E 43
LUBRICATION CHART, SIDELIFT
4
4
1 1
3 3

5 6

Twist-locks
5 6


Hook coupling Hook coupling, locking plate
44 DCE80-90E
LUBRICATION CHART, SIDELIFT

Pos Description Interval No. of Remark
No. lub.
points
500 1000
1 Sliding surfaces, length adjustment L Brush onto all sliding surfaces with the
sidelift in the fully extended position
2 –
3 Cylinders, sideshift L 2
4 Cylinders, length adjustment L 4

5 Locking cylinders L 4 Check that the sensors are free from grease
and that the sensor faces are undamaged
6 Lifting pin twist connection L 4
7 Lifting pin L C 4 Disassemble the twist-locks and check the
lifting pins every 5000 h. See Technical
Handbook group 80.
Same procedure should be used at sus-
pected damage.
8 Contact pin L 4 Check that the sensors are free from grease
and that the sensor faces are undamaged
9 Axle, hook coupling L 2 Disassemble and check the hooks every
5000 h. See Technical Handbook group 80.
Same procedure should be used at sus-
pected damage.
L = Lubricate
C = Check
DCE80-90E 45
Oil and lubricant recommendations
       
  
  

   
   

 
   
    

 
 


        
     
       
Grease
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
0,65 kg cart
cartri
ridg
dge
e ffor
or gre
greas
ase
eggun
un Art.
Art. nno
o 923
92311
110.
0.03
0360
60
5 kg can Ar t. no 923595.0003
Coolant for air conditioning unit

IMPORTANT! ZXL100 Seltec PAG oil
Any deviations from the above table
must be supported by written approval
from Kalmar.
46 DCE80-90E

Dce 80-1 0 0 e

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Detailed technical descriptions with circuit diagrams, periodic

For information that facilitates the working process or

N.B. Draws attention to useful information that

Empty container handling

For further information, see the section entitled

Option: Raised cab

403 713 709 701 403

711 122 123 203

10 Chassis, Cab 30 Engine 80 Mast, attachments

ing the truck.

Operation Instruments and controls

OPERATION Instruments and controls

OPERATION Instrument and controls

42 All of these lamps should be extinguished when the truck is in op-

Battery charging lamp (42)

Lubricating oil pressure, engine (43)

45 Oil pressure, gearbox (44)

48 Engine coolant level (46)

Engine coolant temperature (48)

Parking brake lamp (51)

OPERATION Instrument and controls

Pressure gauge, gearbox oil pressure (21)

22 Fuel gauge (22)

Operating hour meter (66)

Starting switch (5)

The truck has an electrical restart guard protecting the starter

OPERATION Instrument and controls

 Run the engine at idle speed, select the direction of travel

Trucks with ECS, automatic gear

The ECS system

Direction indicators/Dip switch/Horn (2)

OPERATION Instrument and controls

LIFT – pull the lever back

The lowering speed can only be varied by the amount of dis-

d. Length adjustment 20-40’

14 By-passing of the safety system involves a risk of drop-

 ping a container.

OPERATION Instrument and controls

OPERATION Instrument and controls

It is prohibited to lift or transport load when the safety

50 50.Warning lamp, safety system by-passed

OPERATION Instrument and controls

Switch functions, machines with electric servo

OPERATION Instrument and controls

The brake pedal (8) is used as the ordinar

The brake pedal is combined with a separate release clutch acti-

Adjusting the steering wheel (11)

Parking brake (13)

OPERATION Heating and air conditioning system

Setting the heating mode

Setting the cooling mode

OPERATION Heating and air conditioning system

OPERATION Operator’s seat

OPERATION Engine heater, running-in, start, warming-up

OPERATION Cummins QSB

Function Significance Lamps and their patterns

(Green in switch 2) (Orange) (Red)

Error code registered

OPERATION Cummins QSB

IMPORTANT! Always contact service if the error code is still

Error Code Description Lamp

OPERATION Functional checks, st