GB

Publ. No. 920935-0341 01-10

Instruction Manual
Safety regulations
It is important that you read the instruction
manual.
Incorrect handling can lead to personal injury or dam-
age to products and/or property. Therefore, read the in-
struction book very carefully before operating the truck.
The instruction manual contains important information
about your Kalmar truck, about the operation of the
truck, about safety during operation and about the
truck's daily maintenance. In addition, you will find use-
ful information that will make operations easier for you
in your daily work.
The instruction manual must always be kept in the ma-
chine. If the manual should be lost, a replacement must
be immediately obtained. Never use a machine with a
missing instruction manual.
Ask your foreman/group leader if there is anything in
the manual that you do not understand or if you feel that
information is missing in any area.
The symbol is used on our products in certain
cases and then refers to important information con-
tained in the instruction manual. Make sure that warn-
ing and information symbols are always clearly visible
and legible. Replace symbols that have been damaged
or painted over.
In this instruction manual warnings are inserted that
apply to your own safety. Warnings point out the risk of
accident that can cause personal injury.
WARNING!
Warns of the risk of serious personal injury, pos-
sible death and/or serious damage to product or
property if the regulations are not followed.
For technical warnings, that point out the risk of break
down, the word IMPORTANT is used:
IMPORTANT!
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 DCE70-90E
Safety regulations aimed at reducing the
risk of personal injury and damage to
loads or other property.
Intended of use
z The truck may only be used for the purpose for
which it was intended, namely, to lift and transport
goods, the weight of which does not exceed the
maximum permitted load capacity of the truck.
z The truck may not, without specific permission
from Kalmar, be modified or re-built so that its func-
tion or performance is altered.
z The truck may not be driven on public highways if
it has not been adapted to comply with national
road safety regulations.
Operator requirements
z The truck may only be driven by operators who
have been specially trained and who have the
company's authority to do so.
z Laws and other regulations relating to driving li-
cence, operator ID, log book, etc., must be fol-
lowed at all times.
z The operator must be aware of and follow all local
safety regulations.
z It is always the responsibility of the operator to en-
sure that the truck has approved fire extinguishing
equipment in accordance with currently applicable
regulations.
Operation of the truck is prohibited:
z If any of the fitted safety equipment, such as rear
view mirrors, headlights, reversing alarm (option-
al), does not function correctly.
z If there is a fault with the brakes, steering or lift
equipment.
z If it has been repaired, modified or adjusted with-
out the approval of the work supervisor.
z If the truck is fitted with tyres not approved by
Kalmar.
Continued on next page
Safety regulations
Continued from previous page
Operating regulations
z Before starting, always check to ensure that no-
body is in the way of the truck or its equipment.
z Make sure that nobody walks or stands under-
neath raised forks or other equipment, whether
they are loaded or not.
z The operator must always face the direction of op-
eration and take particular care in areas where
persons or other vehicles are likely to appear in
the vicinity. If visibility is limited by the load, the op-
erator should operate the truck in reverse.
z It is prohibited to transport passengers on the
truck outside the cab or on the load. Passengers
may be transported inside the cab only on condi-
tion that it is equipped with a fixed passenger
seat.
z It is prohibited to lift people if the truck is not
equipped with an approved lift cage.
z It is prohibited to exceed the load capacity of the
truck. See capacity plate and loading diagram.
z It is prohibited to transport loads in the raised po-
sition as this entails a risk of the truck tipping. All
transportation shall take place with the load in the
transport position.
z The operator must adapt the speed of the truck to
the character of the load, conditions of visibility,
the character of the roadway/surface, etc.
z The operator shall avoid powerful acceleration
and braking when turning. In addition, the opera-
tor shall always moderate the speed of the truck
when turning so as to avoid the risk of lateral skid-
ding or tipping.
z The operator shall take particular care when oper-
ating in the vicinity of electrical power lines, via-
ducts, quay-sides, ramps, gates/doors etc.
z Safety belts must always be worn, if fitted. In the
event of the truck tipping, always remain in the cab
and grip the steering wheel securely. Never try to
jump out of the cab.
z The parking brake can also be used as an EMER-
GENCY BRAKE. However, having been used for
emergency braking, the brake linings must be
checked and replaced if necessary. If the parking
brake has been mechanically released, it must
always be reset in order for the truck to regain the
parking brake function.
Interrupted operation, parking
z Always check that the gear lever is in the neutral
position before turning the ignition key to restart or
to reset an emergency stop.
z Never leave the operator's cab without applying
the parking brake (ON position).
z Always remove the ignition key if the truck is to be
left unattended.
Other important points to remember
z The truck's hydraulic system includes high pres-
sure hydraulic accumulators. Always be extremely
careful when working with the hydraulic system
and avoid being unnecessarily close to the hy-
draulic equipment, lines and hoses. Before work-
ing on the hydraulic system, the accumulators
must be emptied into the tank, with the help of the
special accumulator evacuation valve.
DCE70-90E
z Handle batteries and junction boxes with great
care. The batteries must always be protected over
the poles and connections.
z Always rectify any damage or wear and tear that
can risk personal safety or that can affect the func-
tions of the truck or its service life.
z Avoid touching oils and greases. Avoid inhaling
exhaust and oil fumes.
z Always use steps and handrails when entering or
leaving the machine - Never jump!
To avoid the risk of slipping, tread only on anti-slip
surfaces. If the anti-slip protection has become
worn, loose or in any way less effective, it should
be replaced.
z Welding painted steel produces poisonous gas-
ses. Paint should therefore be stripped before
welding, good ventilation ensured and/or face
mask with filter used.
z Mobile phones used in the cab must always have
fixed connections to the machine’s electrical sys-
tem, with a fixed antenna outside the machine,
mounted in accordance with the manufacturer’s
instructions. This will avoid interference with the
machine’s important electronic functions.
z The tensile strength of the top pane can be seri-
ously weakened by exposure to elements that
contain: Aromatic hydrocarbon, ketone, esters or
chlorinated hydrocarbon.
Regularly check the surface condition of the top
pane and clean only with screen wash or other
mild cleaning fluid. After cleaning, rinse thorough-
ly with warm water. It is prohibited to modify or in
any other way make alterations to the top pane.
Immediately replace damaged top panes that
show signs of cracking or scratching.
Operating with attachments
z The operator must always take the effect of the
wind into account when handling containers.
Avoid lifting with a wind strength in excess of 12
m/s (27 mph/40 feet per second).
z Always drive carefully so as to avoid attachments
colliding with pillars, cables, etc.
z Carefully study the "Lift methods" section of the
instruction manual.
CE marking
All trucks and equipment (though not thoses fitted on
the truck or intended as spare parts) supplied from Ka-
lmar are CE marked, which indicates that they comply
with the requirements of the EU Machine Safety Direc-
tive. In addition, each truck has a so called, “EU Dec-
laration of Conformity” which is the legal proof that the
truck complies with the “health and safety” require-
ments laid down in the Machine Safety Directive, the
EMC directive (electro-magnetic compatibility) and the
LVD directive (electrical equipment).
Vibration standard
The truck complies with and is below the limits for vi-
bration standard PREN 13059.
3
Introduction
Kalmar empty container handlers DCE70-90E with lifting capaci-
ties of 7-9 tonnes are part of the Kalmar range, which includes
forklift trucks rated between 2 and 90 tonnes. This series of trucks
is based on a system of 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. All trucks in the
series have a high built cab.
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

DCD70-45E8
DCE70-45E8

Diesel engine
Counterweighted truck
KL1476
Generation
Standard cab position Lift capacity, decitonnes
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

KL1477

Option: Raised cab

4 DCE70-90E
Introduction

1
2

4 3 5 6 7

1. Mast, free-visibility mast, with two lifting cylinders
2. Operator’s cab, rubber suspended
3. Engine, six-cylinder diesel engine with turbo-
compressor
4. Steering axle, with pendulum suspension and
double-acting steering cylinder
5. Gearbox, combined with torque converter
6. Drive axle, with hub gearing and wet disc
brake system
7. Carriage, with hydraulically controlled side-lift

DCE70-90E 5
Signs
The information plates on the machine are shown below. The op-
erator shall be aware of and follow the warnings and instructions
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

B
711 122 203
815 301
305 303
402
104

107

102
C
101

112 102

6 DCE70-90E
Signs

10 Chassis, Cab
101 423049.0100 Lift point.
Fixing point for lift
equipment when lift-
ing the truck.
102 A26939.0100 Warning!
Read the Instruction
Manual.

104 A26940.0100 Parking brake

ON-OFF.

107 A30536.0300 Warning!

No Riders!
Passengers may be
carried in the cab
only if it is equipped
with a fixed
passenger seat.
112 A32442.0100 Warning!
Do not jump!
Always remain in the
truck and firmly grip
the steering wheel
when there is a risk
of tipping.
122 A33806.0400 Type, machine

M = Model
S/N = Serial number
Q = Classified lift capacity of the
truck at lift height in accord-
ance with EN1551, EN1459
standards
D = Load Centre - horizontal
H = Classified lift height
W = Unloaded weight of machine
C = Load centre height
Vertical distance from the
container connecting point
down to load centre
20 Electrical system
203 A30537.0100 Main switch.
In position 0 the
battery’s plus pole is
isolated.
30 Engine
301 450202.0100 Fuel.

303 A30530.0200 Warning!

Rotating fan.

DCE70-90E 7
Signs Instruments and controls

3 1 4 5 2 6

4 3 2 1
N

L 0
R

R
1

2
4

3
5
a b c d e

KL1306

8 9 10 11 14 12 13

KL743

1. Gear lever ............................................................... 12 7. Electrical central unit with fuses and relays ............ 29
FORWARD/NEUTRAL/REVERSE 1/2/3 8. Brake pedals, normal driving brake......................... 15
2. Lever DIRECTION INDICATORS/HORN ................ 12 9. Release clutch ........................................................ 15
FRONT WINDSCREEN WASHER/ 10. Accelerator pedal .................................................... 15
FRONT WIPERS/MAIN BEAM 11. Steering wheel adjustment...................................... 15
3. Instrument panel ....................................................... 9 12. Key switch for by-passing safety system ................. 15
4. Steering wheel panel ................................................ 9 13. Parking brake .......................................................... 15
5. Starting switch......................................................... 11 14. Operator’s seat........................................................ 18
6. Control lever, hydraulic functions ............................ 13
a. Lift
b. Tilt
c. Sideshift
d. Length adjustment 20’-40’
e. Locking/Unlocking twist-locks

8 DCE70-90E
OPERATION Instruments and controls

21 22 23

KL581

37 38 39
35 36
34
33 40 41 42 43 44 45 46 52 53
32
31
30
29
28
27
26
25
24 47 48 49 50 51
54 55 56 60 59
KL582

KL1307
F
4 3 2 1

L 0
R

KL580
R
66 1 2 3

4 5

57 58 64 61 62 63

21. Pressure gauge, gearbox oil pressure 40. Spare

22. Fuel gauge 41. Spare
23. Temperature gauge, engine coolant temperature 42. Warning lamp, battery charging
24. Switch, working lights 43. Warning lamp, low engine oil pressure
25. Switch, working lights 44. Warning lamp, low gearbox oil pressure
26. Switch, working lights 45. Warning lamp, low brake pressure
27. Switch, flashing beacon (accumulator pressure)
28. Switch, hazard warning lights 46. Warning lamp, low engine coolant level
29. Switch, driving lights 47. Indicating lamp, preheating
30. Spare 48. Warning lamp, high engine coolant temperature
31. Spare 49. Warning lamp, high gearbox oil temperature
32. Spare 50. Spare
33. Spare 51. Warning lamp, parking brake ON
34. Switch, compressor air conditioning 1) 52. Spare
35. Control, recirculation/fresh air 53. Spare
36. Control, defrost/cab 54. Green lamp TWIST-LOCKS LOCKED
37. Switch, fan LOCKING PLATES LOCKED
38. Control, heat 55. Orange lamp ALIGNMENT
39. Control, cold 1) 56. Red lamp TWIST-LOCKS UNLOCKED
LOCKING PLATES RELEASED
57. Spare
58. Spare
59. Indicating lamp, headlights
60. Indicating lamp, direction indicators
61. ECS terminal 1)
KL675
62. Switch, windscreen wiper, rear
63. Switch, windscreen wiper, roof
64. Spare
65. Fuses
66. Hour meter
1) Optional
65

DCE70-90E 9
OPERATION Instrument and controls
Warning lamps
(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 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 the truck immediately and report to
the service personnel.
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 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. Stop the truck 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 DCE70-90E
OPERATION Instrument and controls
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 82–93°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 be approx 80°C. This temperature will be
KL581 reached after the engine has run for about 5 minutes. The tem-
perature may vary between 75 and 97°C.
A higher temperature may be an indication that coolant level is
low. Check and top up as required, see under Supervision.
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 functions switched off, the key can be removed
I Operating position. All electrical functions are energized.
The key may be set to this position to swith on the lighting,
for instance, when the engine is not running.
II Glow position. In this position the glow-plug is energized.
The glow mode is indicated by lamp 47. Turn directly to
position III if the engine is warm.
III Starter motor energized.

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.

DCE70-90E 11
OPERATION Instrument and controls
Gear lever – Forward/Neutral/Reverse (1)
– 1/2/3
The gear-changing mechanism is electrical, and the gearbox is
operated via solenoid valves.

2 3 F F – FORWARD
1 4
N – NEUTRAL
R – REVERSE
21

TURN, lever 1, 2, 3
4 3

The engine cannot be started unless the gear lever is in neutral.

KL676 The truck must be stopped completely before changing between
forward and reverse, in order to prevent overloading the gearbox
R and power transmission.

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

IMPORTANT!
The truck must be stopped com-
pletely before changing between for-
ward and reverse, in order to prevent
overloading the power transmission.
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.
z Release the parking brake, and accelerate carefully.
z To change up, turn the gear selector handle to second gear,
release the accelerator pedal and the second gear will be en-
gaged, accelerate, and so on.
z Reverse the procedure when changing down. Remember to
increase engine speed before engaging a lower gear, since
the truck will otherwise brake heavily.

Trucks with ECS, automatic gear 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

z prevents the gears being engaged if engine revolutions ex-
ceed 1100 r.p.m.
z prevents changing between forward and reverse gears if the
truck speed is in excess of 3 k.p.h. (reversing preventor).
z locks the gearbox in the current gear if the signal from the
propeller shaft sensor is excessive or if the signal ceases.
z reduces engine revolutions with a change to a higher gear to
ensure that the truck maintains an unchanged speed.
z disengages the gearbox if the operator applies the brakes
and the speed is less than 3 k.p.h.
z provides the required engine revolutions based on the posi-
0 J

tion of the accelerator pedal.

z continually shows the gear engaged on the ECS terminal
KL677
display.

Direction indicators/Dip switch/Horn (2)

FORWARD/BACKWARDS – Direction indicators
UPWARDS – Headlamp flashing
DOWNWARDS – Full beam
INWARDS, button – Horn
INWARDS, lever – Screen wash
TURN – Screen wiper, front
0 = Off/J = Intermittent/
I = Continuous wiping/II = –

12 DCE70-90E
OPERATION Instrument and controls
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.

Lift Lower (a)

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.

Tilt (b)
BACKWARDS – pull the lever back
FORWARD – push the lever forward

Sideshift (c)
RIGHT – pull the lever back
a b c d e LEFT – push the lever forward

Levelling (c + button)
CLOCKWISE - pull the lever back
COUNTER-CLOCKWISE - push the lever forward

Length adjustment 20-40’(d)

KL1319a
20-40’ – pulll the lever back
40-20’ – push the lever forward

Twist-locks (e)
Alternative for hook coupling, locking plates
LOCKING – pull the lever back
UNLOCKING – push the lever forward

DCE70-90E 13
OPERATION Instrument and controls
Joystick, Side lift with twist-locks

1 2 3
1.SIDESHIFT
2.LENGTH ADJUSTMENT 20-40’
3.LOWER
4.TILT FORWARDS
5.Twist-locks RELEASE
B 6.TILT BACKWARDS
4 7.LIFT
A.Green lampaTWIST-LOCKS
A C LOCKED
B Orange lamp ALIGNMENT
C Red lamp TWIST-LOCKS
RELEASED
5 6 7

Joystick, sidelift with hook attachment

1. LEVELLING
2. SIDESHIFT
1 2 3a 4 3A.Locking plates LOCKING
3b 3b. Locking plates UNLOCKING
4. LOWER
5. TILT FORWARDS
6. LENGTH ADJUSTMENT 20-40’
7. TILT BACKWARDS
5 B 8. LIFT
A. Green lampa LOCKING PLATES
LOCKED
A C B Orange lamp ALIGNMENT,
C Red lamp LOCKING PLATES
UNLOCKED

6 7 8

14 DCE70-90E
OPERATION Instrument and controls
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
F
come on.
4 3 2 1

L 0
R
The brake pedal (8) is used as the ordinary foot brake.
R
4 3
The brake pedal is combined with a separate release clutch acti-
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 and instrument panel
can be adjusted to the desired driving position.
Upper handle upwards: Steering wheel height position
Upper handle downwards: Steering wheel angle
Lower handle: Steering column angle
11 Loosen the handle clockwise and
adjust as required.
Tighten the knob firmly after
adjustment

KL588

Parking brake (13)

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 actuated hydraulically
by means of lever 13.
A warning buzzer will be sound if the operator inadvertently
leaves his seat before applying the parking brake.
Warning lamp 51 will show a steady light when the parking brake
is applied.
If the accumulator pressure should drop below a certain level,
KL1308
warning lamp 45 will light up. But sufficient capacity will still be
available for releasing the parking 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! 23.
The parking brake may also be used as emergency brake. If the
Never leave the operator’s seat with- parking brake has been used for emergency braking, the brake
out applying the parking brake pads should be inspected and replaced if needed.

DCE70-90E 15
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 switch 37. The air conditioning system
can be switched on and off by means of switch 34.
35
NOTE. The air conditioner is optional equipment.
34. Switch, compressor air conditioner
35. RECIRCULATION switch
Closed – 100% air from outside of cab
Open – 20% air from outside of cab
36 39 36. Control DEFROSTER/CAB
KL599 37 37. Fan control
38. HEAT control
38 39. COOLING control (Optional)

Setting the heating mode

z Close the recirculation control 35. Open if the weather is very
cold.
z Switch off the air conditioner, switch 34.
z 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
z Switch on the air conditioner, switch 34.
z Open the recirculation control 35.
z Set the COOLING control 39 to MAX.
KL733
z Increase the temperature as required with 38.
z Set the fan to maximum speed with 37.
z 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.
z Close recirculation with 35.
Note that the cooling is used for dehumidifing the air in the cab.

Setting the cooling mode

z Close the recirculation control with 35. Open during hot
weather and high humidity.
z Set the heater control 38 to COOL.
z Switch on the air conditioner, switch 34.
z Adjust the cooling control 39 as required.
z Open and direct the panel nozzles A towards the roof.

16 DCE70-90E
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 33. Switch DEMIST/DEHUMIDIFYING FUNCTION.
34. Switch COOLING FUNCTION OFF.
34 35. Switch RE-CIRCULATION.
Switch forwards - air from outside.
35 Switch backwards - air from inside.
36. Control DEMIST/CAB.
37. Control FAN. Infinitely variable setting of fan speed.
38. Control TEMPERATURE. Infinitely variable 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.
38 N.B. When the controls are in respective full positions, pre-
cise temperature regulation cannot be achieved.
39. Cover. The climate equipment’s demist thermostat is 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 controls 37 FAN and 38 TEMPERATURE to the 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 system then operates automatically, as follows:
N.B. The cooling is not operative at – When heat is required:
temperatures below 0 °C. The system operates in 10 second cycles. The water valve
opens for heating at intervals from 0 seconds, extending
to 4 seconds. Thereafter, the valve is open for 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. This function is used when the windscreen/windows mist up.
2. Start demisting by pressing switch 33.
The fan then runs at full speed for 3 minutes, the compressor
and condenser run continuously. The switch lamp lights.
N.B. The cooling system is used for dehumidifying air.
3. After 3 min. the fan speed returns automatically to the previ-
ously set level. Control 37 can be used to select a lower fan
speed at any time.
4. Press switch 33 again to switch off the demisting function.
The switch lamp extinguishes.
Operating without automatic cooling
1. Press switch 34 to the OFF position.
The compressor and condenser then stop. The switch lamp
lights. the cooling function is thereby de-selected in all posi-
tions and does not start even when control 38 TEMPERA-
TURE is set to the MIN. position.
2. Set control 38 to the required temperature.

DCE70-90E 17
OPERATION Operator’s seat
Operator’s seat adjustments
The operator’s seat is provided with the following adjustment
facilities:

A Distance from the pedals.

G Release the seat by means of the lever and move it forward
or towards the rear.
B Height of the seat cushion.
Turn the knob until the desired height is achieved. The
springing will automatically correspond to the operator’s
weight.
C Backrest rake
Turn the knob.
D Armrest slope
E Tilt – simultaneous sloping of seat and backrest.
F Adjustment of cushioning in three 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 support
Stepless adjustment

18 DCE70-90E
OPERATION Engine heater, running-in, start, warming-up
IMPORTANT!
IF THE ENGINE DOES NOT START
Make a new attempt after 15 to 20
seconds.
Do not run the starter motor for more
than 10 seconds at each
attempt.
If the engine still refuses to start, the
cause should be determined and
remedied.
Air in the fuel system? – see page 26.
DCE70-90E
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 running the engine at full load during the first 50 hours. The
load can then be gradually increased.
Try to extend the running-in period to 200 hours. This will pay in
the long run – the stoppages and breakdowns will be fewer.
Start
WARNING!
Never use a starting spray to facilitate starting, since
this may cause an explosion.
z Set the gear lever to NEUTRAL.
z Turn the starter key directly to position II. Then:
Below +5°C
Hold the key in position II, the pre-heater position, for approx-
imately 50 seconds.
Turn the key further to position III – the starting position – and
release it as soon as the engine has fired.
Above +5°C
Turn the key directly to position III – the starting 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
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.
19
OPERATION Functional checks, stopping of engine, steering
Functional checks
When starting the truck and from time to time when using it, make
a habit of checking:
WARNING! z that the engine temperature gauge reading is about 80°C.
z 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. z that all warning lamps are extinguished.
z that the horn, lighting, brake lights and direction indicators
operate correctly.
z that all hydraulic functions operate correctly.
z that the saftey system for container coupling and all indicat-
ing lamps for container handling operate correctly.
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

z Apply the parking brake.
z Tilt the mast slightly forward on lower the forks onto the
ground.
z Set the gear lever in NEUTRAL.
z 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.
z Stop the engine by turning the ignition key to position 0.
z If the truck will not be used for a longer period, turn 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, 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 24. since no hydraulic pressure will then be available and the
steering of the truck will be very restricted.

20 DCE70-90E
OPERATION Empty container side-lift
Safety regulations
See also standard ISO 3691.
WARNING!

Exercise special care when operating th WARNING!

side-lift.
Always check to make sure that no
person is in the way for the truck or
side-lift.
Remember that the side-lift is wide and
ensure that it does not collide with
posts, overhead lines, etc
Risk for tipping!
It is prohibited to move the truck with the lifting attach-
ment raised higher than tranposrt position except when
stacking. The lifting attachment, with or without load,
may be lifted only when stacking.

WARNING!

The following applies!

At any transport, the lifting attachment, with or without
load, must be in the transport position or lower.
The mast should be tilted to its max. backwards position.
If the load blocks the line of vision, the truck should be
driven in reverse.
While stacking, when the truck is moved with the lifting
attachment raised, the brakes should be applied gently
and carefully.

Transport position
Indicating lamps on side-lift
Sidelift with Sidelift with
twist-locks hook coupling
Lamp A (Green): Twist-locks Locking plates
locked locked
A B1 C Lamp B1 (orange): Alignment, Alignment, container,
extinguished when extinguished when
the container the container
B2 is lifted is lifted
Lamp B2 (orange): Alignment, hooks,
Only hook attachment the light is on after lift
Indicating lamps on sidelift Lamp C (Red): Twist-locks Locking plates
unlocked unlocked
Both B1 and B2 must
be lit before the
locking plates can be
unlocked.
D Indicating lamps in cab
A BC Lamp B (orange): Alignment, extinguished after lift.
Both B1 and B2 must be lit for B in
the cab to light up.
Lamp D (red): Lights up when the safety system is by-
F passed with the key switch.
4 3 2 1

N
L 0

R
1 4 5
N.B. B1 and B2 indicate two different alignment signals from
the sidelift. This is to facilitate fault tracing if lamp B in the
2 3
KL1097A

cab should not light up when coupling a container.

Indicating lamps in cab

DCE70-90E 21
OPERATION Empty container side-lift
Lifting technique
1. Set the length adjustment to the appropriate container
WARNING! length.
2. Drive slowly forwards towards the container, sideshift if
it is prohibited to use the side-lift if necessary.
the indicating lamps are faulty.
3. Lower the side-lift to the container.
The use of a side-lift with faulty 4. Container coupling:
indicating lamps involves a great Twist-locks:Tilt the mast slightly forwards, about 2°.
safety risk. Lower the side-lift to the container and fit the two twist-locks
into the container lock holes so that both ends of the side-lift
are resting on the container. Check that lamps B + B1 light
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
A B1 C on both hooks. Check that lamps B + B1 + B2 light up.
Lock the locking plates.
B2 5. Check that lamp A lights up, the container is now locked to
the sidelift.
6. Tilt the mast backwards and lift. Check that lamp B + B1 are
extinguished on lifting.
Indicating lamps on side-lift Hook coupling: Lamp B2 is lit even after lift.
7. Adjust lifting height to transport position or lower before
driving. See picture Transport position on page 21.

Operations close to high tension power lines

D Extreme care must be taken when working in close proximity to
A BC overhead, high tension power lines, particularly in respect of the
reach of the boom and attachment.

F WARNING!
4 3 2 1

N
L 0

1 4
R
5
If the machine comes into contact with overhead high
2 3
KL1097A tension power lines - remain seated in the cab and call for
help!
It is extremely dangerous to leave the cab as you will be
Indicating lamps in cab earthed when you come into contact with the ground.

Key switch for by-passing the safety system

The by-pass key is fitted adjacent to the parking brake and should
be used only in emergency situations.
The switch is used for by-passing LOCKING, UNLOCKING,
ALIGNMENT, LIFT.
1. If the sidelift gets stuck in a position where twist-locks are
neither locked nor unlocked alternately the locking plates
neither locked nor unlocked the safety system must be by-
passed by means of the key switch.
2. There after, operate the functions LOCKING and UNLOCK-
ING until the container is either locked or unlocked.
3. Reset the key switch to operational position and lift.

KL1478
WARNING!

It is prohibited to lift or transport load when the safety

Key switch for by-passing system is by-passed.
the safety system

22 DCE70-90E
SPECIAL PROCEDURES
WARNING!
If it is not possible to run the engine
running during towing, a tow bar must
be used.
Before preparations for towing begin
and after towing has been completed,
the parking brake must be applied and
the wheels chocked to prevent the ma-
chine rolling. The greatest possible
care must be exercised during towing
operations to prevent personal injury.
IMPORTANT!
The truck cannot be started by
being towed.
Any attempt to start the engine by
towing, will inevitably cause
damage to the tranmission.
A3638501L
WARNING!
Follow existing safety rules
WARNING!
Block the wheels before releasing the
parking brake.
DCE70-90E
Towing
If possible, the engine should be running during towing in order
to retain braking and steering functions. When the engine is not
running, there is no hydraulic pressure for the steering of the
truck which is then extremely limited. Furthermore, the gearbox
will be insufficiently lubricated.
z Towing may only take place over very short distances.
z If a tow bar is used, it shall be connected to the connection/
towing hitch at the rear of the machine.
z The brakes function as long as there is pressure in the accu-
mulator, thereafter the operating brakes cease to function
and the parking brake is automatically applied. If, thereafter,
it is necessary to move or tow the truck, the parking brake
must be released mechanically (see instructions below).
z The vehicle or machine use to for towing must be at least as
heavy as the machine to be towed and have sufficient engine
and brake capacity.
z For towing over longer distances or at speeds higher than 10
km/h, the propeller shaft must be disconnected.
Lifting the truck
The truck should be lifted according to the following:
z Dismantle the mast
z Place a lifting sling around the chassis, between the counter-
weight and the steered axle, se picture.
z Attach two lifting slings in the mast suspension ear-lugs, one
on each side.
The lifting device must be fitted in such a way that the lifting point
coincides with the centre of gravity of the truck.
Fire protection
If the machine is equipped with fire extinguishers these should be
of the ABE type, in accordance with EN 3 parts 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-
ments, e.g., in explosive environments, it is a strict re-
quirement that the machine be designed, constructed
and equipped in accordance with EN 1755.
Mechanical release of 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 level.
If the truck must be moved
1. Note the position of the adjusting screw A.
2. Release the brake by loosening the locknut at A, and then
screw out the adjusting screw anti-clockwise.
3. Once the fault has been rectified, reset the parking brake
function by returning the screw (A) to the same position as in
point 1.
WARNING!
If the parking brake has been mechanically released
it must always be reset in order to restore the parking
brake function.
23
SUPERVISION
IMPORTANT!
The following must be carried out in
addition to daily and periodic supervi-
sion:
Service during the running-in period
z Tighten the wheel and prop shaft
nuts after 8, 16 and 24 hours of oper-
ation. Tightening torque in accord-
ance with the Technical Handbook.
Tighten the wheel nuts in a zig-zag
sequence. Tighten the nuts in the
same way every time after changing
a wheel.
Guarantee service after 50 hours.
The guarantee service is performed by
Kalmar, or by personnel authorized by
Kalmar, and is part of the Kalmar delivery
commitments.
The guarantee service is also a condition
for continued validity of the guarantee.
Daily supervision
Supervision
Supervision is differentiated as follows:
z DAILY SUPERVISION – carried out by the operator
z PERIODIC SUPERVISION – carried out by specially trained
service personnel.
Proper supervision contributes to making the truck safe to work
with.
Periodic supervision is described in the Technical Handbook. The
operator must make sure that the truck is available for service
every 500 hours of operation.
N.B. Service at 200 and 400 hours for engine
All times refer to the hours of operation, ie, the time recorded by
the hour meter on the panel.
WARNING!
Only genuine Kalmar spare parts may be used. Spare
tyres and replacement tyres must be of a make approved
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
The gauge reading • 26
should never drop to
Engine oil Level • 27
Air cleaner • Indicator 27
Coolant • Level • 26
Hydraulic oil • Level • 28
Gearbox oil • Level 28
Windscreen washer • Fluid level • 28
Wheels • Tyre pressure 35
Sidelift attachment • Check that all sensors are free from grease and
that the sensor faces are undamaged.

24 DCE70-90E
SUPERVISION Tyres
Tyres

WARNING!
Spare and replacement tyres shall be
of a make approved by Kalmar.
Checks
1. Check the tyres regularly, if possible, daily.
2. Remove objects that could penetrate the tyres, such as bro-
ken glass, pieces of wood, metal shavings, etc.
3. Check for uneven and rapid wear. This is caused by mechan-
ical faults such as unevenly acting brakes. Make sure that
such faults are immediately rectified.

Compressor for tyre inflation

1. An air filter with water separator should be fitted in the line
from the compressor that is used for tyre inflation.
The water separator minimises the risk of the rims rusting.
2. Drain the water separator regularly.

Tyre inflation
1. Before inflating, make sure that the wheel locking ring is in
the correct position, see illustration.
N.B. If the tyre has been completely deflated, the wheel
must be dismantled and checked for damage.
2. Connect the compressor hose, with a grip-nozzle to the nip-
KL1469
ple on the tyre.
3. Move away to the side and remain there throughout the en-
Locking ring tire inflation process.
4. Inflate the tyre to the recommended pressure, see Technical
Data.
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, contact KALMAR.

Always follow the instructions for tyre inflation to avoid

serious accidents.

470EC

Tyre inflation

DCE70-90E 25
SUPERVISION Fuel system, Cooling 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 immediately after
the day’s 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 the filler cap is
clean.
KL1309

Bleeding the fuel system

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:

z Back off the bleed screw A on the fuel filter half a turn.
z Release the pump handle B by turning it anti-clockwise.
z Pump by means of the hand pump B until the fuel flowing
past the bleed screw is completely free from air. Continue
pumping and tighten screw A.
z Tighten the pump handle.
z 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

Cooling system
The coolant is topped up via the radiator filling cap accessible
through an aperture in the engine cover.

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. But the
corrosion inhibitor is not an anti-freeze agent, and should there-
fore be used only if the ambient temperature is constantly above
0°C.
If the coolant level should drop below the minimum level, warning
lamp 46 on the instrument panel will light up.
KL1310

IMPORTANT!
Insufficient coolant may impair the coolant circulation
which may cause the coolant to boil and give rise to
engine damage.

26 DCE70-90E
SUPERVISION Engine oil, Air cleaner, Accumulators
Engine oil
The dipstick for the engine oil (B) is on the left-hand side beneath
the engine cover. The dipstick has two markings, MIN and MAX,
and the oil level should be between these. Clean the dipstick be-
fore checking the oil level.
It is advisable to top up with oil when the engine is warm and the
oil flows easily. Top up – wait a while – check on the dipstick.
A Oil filler cap
B Oil dipstick
A
Air cleaner
The dust container is emptied automatically.
B The filter element in the air cleaner is replaced by the service per-
sonnel as a routine measure. If the truck is used under dusty con-
ditions, the filter may become clogged after a relatively short
period of time.
An indicator, which turns red when the filter has become clogged,
is located in the air intake system between 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.
Change
filter! IMPORTANT!
Inadequately filtered intake air may quickly cause
serious damage to the engine.
KL1314a

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. Start the engine and let it run until the accumulators are
charged.
2. Stop the engine and then turn the starting key to position I.
3. Depress the brake pedal repeatedly with long strokes, hold-
ing it down in the depressed position for a brief while on eve-
ry occation.
4. It should be possible to apply the brakes at least six times be-
fore lamp 45 lights up.
5. Start the engine, allow the accumulators to be charged and
repeat the test a couple of times.
6. If the brakes cannot be applied six times before lamp 45
lights up, the accumulators are faulty. If so, ensure that the
fault recieves attention as soon as possible and that the ac-
L1314
KL1314 cumulators are charged with nitrogen.

WARNING!

Charging of accumulators should be made only by au-

thorized service personnel using approved equipment.

A A. Quick evacuation valve, accumulators.

WARNING!

The brake pressure acculumators have an internal pres-

sure of up to 210 bar. Take great care therefore when
KL1315 working on the system and always release pressure from
the accumulators before removing any component from
the system. Discharge the pressure by opening the quick-
evacuation valve A.

DCE70-90E 27
SUPERVISION Hydraulic system, gearbox oil, windscreen washer
Hydraulic system
The hydraulic tank is on the right-hand side of the truck.
A Refill

AA B Sight glass

The fluid level should be in the middle of the sight glass when all
hydraulic cylinders are in bottom position.
The fluid should not contain any additives.

B
B

KL1316

Gearbox oil
The oil filler cap and dipstick for the gearbox oil are beneath the
left-hand engine cover.
A Filler pipe
A 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

28 DCE70-90E
SUPERVISION
IMPORTANT!
The starting batteries accompanying
the truck are of the maintenance-free
type, which implies that it should not
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
twice a year. Fill as required by add-
ing de-ionized water.
WARNING!
The battery electrolyte contains corro-
sive sulphuric acid. Immediately remove
any electrolyte that comes into contact
with the skin. Wash with soap and lots
of water. If electrolyte gets into the eyes,
immediately rinse with lots of water and
immediately contact a doctor.
S1-6 S7-12 S13-18 S19-24 S25-30
A3611101A
WARNING!
Never use fuses of a higher
amperage than stated on the lid decal.
Risk of damage or fire.
DCE70-90E
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
connected to a main switch A. When working with the electrical
system, when carrying out welding on the truck or at long time
parking, always isolate the batteries.
Checking the electrolyte level of the batteries
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
cells. Top up with de-ionized water as necessary.
Batteries contain substances dangerous to health and the envi-
ronment. Discarded batteries must therefore be dealt with in ac-
cordance with current local/national regulations.
Relay box in cab – fuses
Fuse Rating
No. Circuit protected A
S1 Hazard lights, ignitions key, preheater relay, start relay ...........15
S2 Cab lighting, seat buzzer, parking brake sensor,
disengagement relay (ECS 01), hydr oil cooler supply15
S3 Spare ..........................................................................................-
S4 Electric gear-changing ............................................................ 5
S5 Warning lamps, instrument illumination, coolant level relay
brake pressure relay ..................................................................5
S6 Horn, screenwash motor, front wiper motor,
intermittent relay front wiper.....................................................10
S7 Wiper motors and intermittent relay rear and roof ...................10
S8 Heating fan, AC compressor, seat heater, recirculation motor.25
S9 AC condensor, manual hydraulic oil cooler ..............................15
S10 Main fuse, driving lights, rear lights, position lights,
direction indicators ...................................................................15
S11 Brake lights, flashing beacon ...................................................10
S12 Reversing lights, reversing alarm .............................................15
S13 Working lights on mast.............................................................15
S14 Working lights on cabin roof.....................................................15
S15 Container lights ........................................................................15
S16 24/12 V converter (radio, com radio)........................................15
S17 Compressor for air suspended seat .........................................15
S18 El-operated parking brake..........................................................5
S19 ECU 1 (Aut gearchanging, lever steering, monitoring).............15
S20 ECU 4 (El-servo system) .........................................................10
S21 Container attachment, safety interlock.....................................10
S22 Central lubrication ....................................................................15
S23 Spare ..........................................................................................-
S24 Spare ..........................................................................................-
S25 Left hand main beam .................................................................5
S26 Right hand main beam ...............................................................5
S27 Left hand dipped beam ..............................................................5
S28 Right hand dipped beam............................................................5
S29 Left hand rear light, right hand position light ..............................5
S30 Right hand rear light, left hand position light..............................5
Bulbs
Rating
Description Watts .............................................Base
Instruments 3 ................................................... BA7s
Indicating lamps 1,2 ...........................................W2x4,6d
Cab lighting 10 .................................................. S8,5
Rear lights, red 5 ................................................. BA15s
Brake lights 21 ............................................... BA15s
Direction indicators 21 ............................................... BA15s
Position lights 5 .................................................. SV8,5
Driving lights 75/70 ........................................ P43t-38
(full/dipped beam)
Reversing lights, white 70 ............................................... PK22s
Working lights 70 ............................................... PK22s
Hazard beacon 70 ............................................... PK22s
29
SUPERVISION Electrical system
Relays
305 Reversing light
313-1 Brake light (rear-front) 2)
313-3 Direction indicators (right-left) 2)
313-4 Direction indicators (left-right) 2)
313-5 Rear light (rear-front) 2)
313-6 Dipped beam (front-rear) 2)
313-7 Reversing light (rear-front) 2)
313-8 Main beam (front-rear) 2)
313-9 Shifting (Rev-forw) 2)
313-10 Shifting (Forw-rev) 2)
314 Parking brake, disengagement
315 High power (Starting switch)
316 Wiper motor, front
320 Electric stop (ECS 07) 1)
322-1 Coolant level
322-2 Coolant level (ECS 07) 1)
323 Pulse relay, direction indicators
328 Lever steering (ECS 04) 1)
330 Starting interlock
331 Propulsion forward
A 332 Propulsion reverse
334 Release clutch at automatic gearbox (ECS 01) 1)
368 Low brake pressure (ECS 07) 1)
399 Spare

Miscellaneous
321-1 Intermittent relay wiper front
321-2 Intermittent relay wiper rear 1)
960 Reversing interlock
1) Optional equipment
2) Rotatable operator’s seat

Main fuse
for electrical
system
Fitted on the engine
2 x 50 A

Starting from another battery

WARNING!
Batteries emit oxyhydrogen which
is an explosive gas. A spark, for
example from incorrectly connected
starting cables, could cause a battery
to explode and result in serious injury
and damage.
z Make sure the auxiliary batteries are connected in series, so
that 24 V will be supplied.
Note: Do not disconnect the truck-battery cables
z 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
the truck battery, such as the negative cable connection on
the chassis.
z Start the engine
Do not disturb the jumper cables while starting, as
sparks may otherwise be caused. Do not lean over ei-
ther battery.
z Disconnect the jumper cables in exactly the reverse order.

30 DCE70-90E
LUBRICATION CHART

8 9 6, 7 10 11

12

13

KL1318

17 16 15 14

19 1

4
3
2

A3638501S

IMPORTANT!
If the truck stands unused outdoors, with the
hydraulic piston rods exposed, all piston rods
must be greased to prevent corrosion.
After they have been washed with degreasing
agent, all pistons should be moved back-
wards and forwards several times to obtain a
new protective film of oil.

DCE70-90E 31
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 Support 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 every 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.
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 every 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

32 DCE70-90E
LUBRICATION CHART Sidelift

Twist-locks

KL1322
Hook coupling Hook coupling, locking plate

DCE70-90E 33
LUBRICATION CHART Sidelift

Pos Description Interval No. of Remark

No.
1 Sliding surfaces, length adjustment
2 Sliding surfaces, sideshift
3 Cylinders, sideshift
4 Cylinders, length adjustment
5 Locking cylinders
6 Lifting pinion twist connection
7 Lifting pinion
8 Contact pin
9 Axle, hook coupling
lub.
points
500 1000
L Brush onto all sliding surfaces with the at-
tachment in the fully extended position
L Brush onto all sliding surfaces with the side-
shift to the limit in each direction
L 2
L 4
L 4 Check that the sensors are free from grease
and that the sensor faces are undamaged
L 4
L C 4 Disassemble the twist-locks every 2000 h.
Check for wear. If needed, chenge compo-
nents accordingly. Clean and pack with
grease. Same procedure should be used at
suspected damage to the twist-locks.
L 4 Check that the sensors are free from grease
and that the sensor faces are undamaged
L 2

L = Lubricate
C = Check

34 DCE70-90E
TECHNICAL DATA
DCE70-45E8 DCE90-45E7

Engine
Make – type designation Volvo – TD730VE Volvo – TWD731VE
Fuel – type of engine Diesel – 4-stroke Diesel – 4-stroke
Power ISO 3046 1) – at speed kW -r/m 150 – 2400 167 – 2200
Torque ISO 3046 – at speed Nm-r/m 800 – 1400-1500 893 – 1300-1450
No. of cylinders – compression ratio 6 - 17.7:1 6 - 17.7:1
Alternator, type – capacity AC – 2240 W AC – 2240 W
Starting battery, voltage – capacity V-Ah 2x12 – 140 2x12 – 140
Transmission
Gearbox, make – type designation Clark – 13,7HR28000 Clark – 13,7HR32000
Clutch, type Torque converter Torque converter
Gearbox, principle Powershift Powershift
No. of gears, forward – reverse 3–3 3–3
Drive axle, make – type designation Dubbel reduction, Dubbel reduction,
differential and hub reduktion differential and hub reduktion
Wheels
Wheels, front and rear 2) Pneumatic Pneumatic
Dimension, front - rear 12,00x24 - 12,00x24 14,00x24 - 14,00x24
Tyre pressure, front and rear MPa 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.
Limit 70 dB(A)
with standard engine dB(A) max 72 dB(A)
Volumes
Fuel L 380 380
Hydraulic oil L 320 320
Coolant L 40 41
Engine oil, incl filter L 28 28
Drive axle (incl hub reductions) L 2×2.5 + 54 2×2.5 + 54
Gearbox L 30 32

Truck weights and sizes vary depending on how the truck is

equipped and this is shown in detail by the product specification
and data sheets for the truck in 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.

DCE70-90E 35
Oil and lubricant recommendations
IMPORTANT!
Any deviations from the above table
must be supported by written approval
from Kalmar Service.
36
Engine oil
Grade:API – CD oil for turbocharged engines,
from a reputable oil company.
Viscosity: See the chart below
*) If these oils are used at temperatures above +15°C or +30°C,
engine wear may increase.
**) Synthetic or semi-synthetic oil.N.B. Only SAE 5W/30 may be
used.
Drive axle oil
Grade: API GL-5
Viscosity: SAE 80W-140
Hydraulic fluid
Grade: Hydraulic fluid for mobile applications
from a reputable oil company.
Viscosity: Class HV, ISO VG46 at normal working temperatures.
Class HM, ISO VG 68 at tropical conditions
Class HV, ISO VG 32 at extremely cold conditions
Grease .
Use EP universal grease to NLGI Grade 2 with 3–5% molybde-
num disulphide additive for all lubrication points, including wheel
bearings
Lubricant for sliding plates
Use lubricant improved by Kalmar. Order from Kalmar Spare
Parts Department
0,65 kg cartridge for greasegun Art.no. 923110.0360
5 kg can Art.no. 923595.0003
DCE70-90E
Oil and lubricant recommendations
Gearbox oil
Relevant ambient temperatures
Temperature range
IMPORTANT!
Any deviations from the above table
must be supported by written approval
from Kalmar Service.
DCE70-90E
IMPORTANT!
On delivery from Kalmar, the gearbox is filled with API-
CD SAE 10W/30 motor oil.
The gearbox must not be re-filled with ATF oil.
If another recommended oil is chosen, ensure that the
gearbox is completely drained of old oil before re-filling
with the new oil.
Recommended oil
1 (a) C-2 SAE Grade 30
(b) C-3 SAE Grade 30
(c) Motor oil, SAE Grade 30 API-CD/SE
or CD/SF
(d) MIL-L-2104C-SAE Grade 30
(e) MIL-L-2104D-SAE Grade 30
2 (a) MIL-L-2104C-SAE Grade 10
(b) MIL-L-2104D-SAE Grade 10
(c) C-2 SAE Grade 10
(d) C-3 SAE Grade 10
(e) Motor oil, SAE Grade 10 API-CD/SE
or CD/SF
(f) Quintolubric 822-220 (Quintolubric
822-220 (Phosphate-free ester
fire-resistant liquid fluid
3 (a) *Dexron
(b) *Dexron II D – See below!
4 (a) MIL-L-46167
(b) MIL-L-46167 A
5 (a) Conoco Polor Start DN-600 Fluid
IMPORTANT!
Recommended lubricants for Temperature ranges 2 and
3 may be used in lower ambient temperatures when the
sump is pre-heated.
Lubricants for Temperature range 4 should only be used
in the stated temperature range.
IMPORTANT!
Dexron II D is not compatible with the graphite friction
materials used in the clutch plates UNLESS IT COM-
PLIES WITH THE APPROVED C-3 SPECIFICATION.
37