HƯỚNG DẪN VẬN HÀNH DCE70 90e

/* Publ No 920935-0341 01-10 Instruction Manual DCE70-90E Contents Safety regulations Introduction Signs Operation Instrument and controls Heating and air conditioning system 16 Operator’s seat, adjustments 18 Engine heater 19 Running in 19 Starting the engine 19 Warming up of engine 19 Functional checks 20 Stopping of engine, parking 20 Power steering 20 Lifting technique 22 Empty container side-lift 21 Special procedures 23 Supervision 24 Daily supervision 24 Tyres 25 Fuel system 26 Cooling system 26 Engine oil 27 Air cleaner 27 Checking the accumulators 27 Hydraulic system 28 Gearbox oil 28 Windscreen washer 28 Electrical system 29 Lubrication chart 31 Technical data 35 Oil and lubricant recommendations 36 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 DCE70-90E Safety regulations It is important that you read the instruction manual Incorrect handling can lead to personal injury or damage to products and/or property Therefore, read the instruction 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 useful information that will make operations easier for you in your daily work The instruction manual must always be kept in the machine 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 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 contained in the instruction manual Make sure that warning 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, possible 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 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 function 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 so z Laws and other regulations relating to driving licence, operator ID, log book, etc., must be followed 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 ensure 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 (optional), 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 without the approval of the work supervisor z If the truck is fitted with tyres not approved by Kalmar Continued on next page 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 DCE70-90E Safety regulations Continued from previous page Operating regulations z Before starting, always check to ensure that nobody is in the way of the truck or its equipment z Make sure that nobody walks or stands underneath raised forks or other equipment, whether they are loaded or not z The operator must always face the direction of operation 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 operator 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 condition 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 position 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 operator shall always moderate the speed of the truck when turning so as to avoid the risk of lateral skidding or tipping z The operator shall take particular care when operating in the vicinity of electrical power lines, viaducts, 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 EMERGENCY 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 pressure hydraulic accumulators Always be extremely careful when working with the hydraulic system and avoid being unnecessarily close to the hydraulic equipment, lines and hoses Before working 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 functions 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 gasses 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 system, 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 seriously 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 thoroughly 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 Kalmar are CE marked, which indicates that they comply with the requirements of the EU Machine Safety Directive In addition, each truck has a so called, “EU Declaration of Conformity” which is the legal proof that the truck complies with the “health and safety” requirements 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 vibration standard PREN 13059 Introduction Kalmar empty container handlers DCE70-90E with lifting capacities of 7-9 tonnes are part of the Kalmar range, which includes forklift trucks rated between 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 Standard cab position Generation 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 DCE70-90E Introduction Mast, free-visibility mast, with two lifting cylinders Operator’s cab, rubber suspended Engine, six-cylinder diesel engine with turbocompressor Steering axle, with pendulum suspension and double-acting steering cylinder DCE70-90E Gearbox, combined with torque converter Drive axle, with hub gearing and wet disc brake system Carriage, with hydraulically controlled side-lift Signs The information plates on the machine are shown below The operator 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 numbers are stated on respective plates They can also be found in the Spare Parts catalogue 401 307 A 403 713 709 701 403 802 811 B 711 122 815 301 203 305 303 402 104 107 102 101 C 112 102 DCE70-90E Signs 10 Chassis, Cab 101 423049.0100 Lift point Fixing point for lift equipment when lifting the truck 102 A26939.0100 Warning! Read the Instruction Manual 305 A30532.0200 Warning! Hot surface 307 A32439.0300 Engine oil (TWD731VE: The plate is located on the filler cap on the engine) 40 Transmission, tyres 401 455949.0100 Transmission oil 811 A33852.0100 Type, attachment S/N = Serial number 815 A33808.0800 Type, sidelift 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 accordance 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 the battery’s plus pole is isolated 30 Engine 301 450202.0100 Fuel 402 A30533.0200 Warning! Rotating parts 403 A32049.0100 Tyre pressure, 1,0 MPa S/N = A= H= D= Q= C= Serial number Model, attachment Lifting height Tyngdpunktsavstånd Lift capacity Load centre height Vertical distance from the container connecting point to load centre 70 Hydraulic system 701 450203.0100 Hydraulic fluid 709 A30168.0300 Hydraulic pressure See Technical Handbook 711 A36163.0100 Warning! High pressure! Always release pressure from the accumulator before working on the hydraulic system 713 A37823.0100 No Lubrizol 80 Mast, attachments 802 A30771.0100 Warning! Do not walk under the load D 450202.0100 303 A30530.0200 Warning! Rotating fan DCE70-90E Signs Instruments and controls F L N R R a b c d e KL1306 10 11 14 12 13 KL743 Gear lever 12 FORWARD/NEUTRAL/REVERSE 1/2/3 Lever DIRECTION INDICATORS/HORN 12 FRONT WINDSCREEN WASHER/ FRONT WIPERS/MAIN BEAM Instrument panel Steering wheel panel Starting switch 11 Control lever, hydraulic functions 13 a Lift b Tilt c Sideshift d Length adjustment 20’-40’ e Locking/Unlocking twist-locks Electrical central unit with fuses and relays 29 Brake pedals, normal driving brake 15 Release clutch 15 10 Accelerator pedal 15 11 Steering wheel adjustment 15 12 Key switch for by-passing safety system 15 13 Parking brake 15 14 Operator’s seat 18 DCE70-90E OPERATION Instruments and controls 21 23 22 KL581 29 25 26 27 30 31 32 33 34 37 38 39 35 36 40 41 42 43 44 45 46 52 53 28 24 47 48 49 50 51 54 55 56 60 59 KL582 F N L KL1307 R KL580 R 66 57 58 64 21 Pressure gauge, gearbox oil pressure 22 Fuel gauge 23 Temperature gauge, engine coolant temperature 24 Switch, working lights 25 Switch, working lights 26 Switch, working lights 27 Switch, flashing beacon 28 Switch, hazard warning lights 29 Switch, driving lights 30 Spare 31 Spare 32 Spare 33 Spare 34 Switch, compressor air conditioning 1) 35 Control, recirculation/fresh air 36 Control, defrost/cab 37 Switch, fan 38 Control, heat 39 Control, cold 1) KL675 61 62 63 40 Spare 41 Spare 42 Warning lamp, battery charging 43 Warning lamp, low engine oil pressure 44 Warning lamp, low gearbox oil pressure 45 Warning lamp, low brake pressure (accumulator pressure) 46 Warning lamp, low engine coolant level 47 Indicating lamp, preheating 48 Warning lamp, high engine coolant temperature 49 Warning lamp, high gearbox oil temperature 50 Spare 51 Warning lamp, parking brake ON 52 Spare 53 Spare 54 Green lamp TWIST-LOCKS LOCKED LOCKING PLATES LOCKED 55 Orange lamp ALIGNMENT 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) 62 Switch, windscreen wiper, rear 63 Switch, windscreen wiper, roof 64 Spare 65 Fuses 66 Hour meter 1) 65 DCE70-90E Optional SPECIAL PROCEDURES Towing 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 machine 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 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 accumulator, 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 counterweight 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 A3638501L WARNING! Follow existing safety rules If the machine is equipped with fire extinguishers these should be of the ABE type, in accordance with EN parts 1, 2, and 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 environments, e.g., in explosive environments, it is a strict requirement 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 Note the position of the adjusting screw A Release the brake by loosening the locknut at A, and then screw out the adjusting screw anti-clockwise Once the fault has been rectified, reset the parking brake function by returning the screw (A) to the same position as in point WARNING! Block the wheels before releasing the parking brake DCE70-90E WARNING! If the parking brake has been mechanically released it must always be reset in order to restore the parking brake function 23 SUPERVISION Daily supervision Supervision IMPORTANT! The following must be carried out in addition to daily and periodic supervision: Service during the running-in period z Tighten the wheel and prop shaft nuts after 8, 16 and 24 hours of operation Tightening torque in accordance 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 Or when refuelling 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 Check Refill as required More details on page Brakes Operation Steering Operation All instruments: Direction indicators, horn, brake lights, headlights Operation All hydraulic functions, e.g.: Lift, tilt, sideshift, length adjustment, twist locks Operation Run every function to its end position in order to lubricate the cylinders and prevent corrosion Engine, gearbox, drive axle, hydraulic hoses Noises? Oil leakage? Fuel Amount The gauge reading should never drop to • 26 Level • 27 Engine oil Air cleaner • Indicator Coolant • Level • 26 Hydraulic oil • Level • 28 Gearbox oil • Level Windscreen washer • Fluid level Wheels • Tyre pressure Sidelift attachment • Check that all sensors are free from grease and that the sensor faces are undamaged 24 27 28 • 28 35 DCE70-90E SUPERVISION Tyres Tyres WARNING! Spare and replacement tyres shall be of a make approved by Kalmar Checks Check the tyres regularly, if possible, daily Remove objects that could penetrate the tyres, such as broken glass, pieces of wood, metal shavings, etc Check for uneven and rapid wear This is caused by mechanical faults such as unevenly acting brakes Make sure that such faults are immediately rectified Compressor for tyre inflation 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 Drain the water separator regularly KL1469 Locking ring Tyre inflation 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 Connect the compressor hose, with a grip-nozzle to the nipple on the tyre Move away to the side and remain there throughout the entire inflation process 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 condensing 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 z z z z A B Back off the bleed screw A on the fuel filter half a turn Release the pump handle B by turning it anti-clockwise 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 Tighten the pump handle 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 Bleed screw 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 therefore 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 before 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 B Change filter! The dust container is emptied automatically The filter element in the air cleaner is replaced by the service personnel as a routine measure If the truck is used under dusty conditions, 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 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 Start the engine and let it run until the accumulators are charged Stop the engine and then turn the starting key to position I Depress the brake pedal repeatedly with long strokes, holding it down in the depressed position for a brief while on every occation It should be possible to apply the brakes at least six times before lamp 45 lights up Start the engine, allow the accumulators to be charged and repeat the test a couple of times 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 accumulators are charged with nitrogen L1314 KL1314 WARNING! Charging of accumulators should be made only by authorized service personnel using approved equipment A A Quick evacuation valve, accumulators WARNING! KL1315 DCE70-90E The brake pressure acculumators have an internal pressure of up to 210 bar Take great care therefore when working on the system and always release pressure from the accumulators before removing any component from the system Discharge the pressure by opening the quickevacuation valve A 27 SUPERVISION Hydraulic system, gearbox oil, windscreen washer Hydraulic system The hydraulic tank is on the right-hand side of the truck A Refill B Sight glass AA 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 A KL1312 The oil filler cap and dipstick for the gearbox oil are beneath the left-hand engine cover A Filler pipe B Dipstick Check the level with the engine idling B Windscreen washer The windscreen washer container is beneath the left-hand engine cover Check that there is sufficient washer fluid in the bottle Refill if necessary Use anti-freeze fluid during the winter, e.g methylated spirits or special washer fluid KL1313 28 DCE70-90E SUPERVISION Electrical system 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 electrolyte 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 adding de-ionized water WARNING! The battery electrolyte contains corrosive 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 Electrical system The electrical system operates at 24 V The source of power supply 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 environment Discarded batteries must therefore be dealt with in accordance with current local/national regulations Relay box in cab – fuses Fuse No Circuit protected S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S17 S18 S19 S20 S21 S22 S23 S24 S25 S26 S27 S28 S29 S30 Rating A Hazard lights, ignitions key, preheater relay, start relay 15 Cab lighting, seat buzzer, parking brake sensor, disengagement relay (ECS 01), hydr oil cooler supply15 Spare Electric gear-changing Warning lamps, instrument illumination, coolant level relay brake pressure relay Horn, screenwash motor, front wiper motor, intermittent relay front wiper 10 Wiper motors and intermittent relay rear and roof 10 Heating fan, AC compressor, seat heater, recirculation motor.25 AC condensor, manual hydraulic oil cooler 15 Main fuse, driving lights, rear lights, position lights, direction indicators 15 Brake lights, flashing beacon 10 Reversing lights, reversing alarm .15 Working lights on mast 15 Working lights on cabin roof 15 Container lights 15 24/12 V converter (radio, com radio) 15 Compressor for air suspended seat 15 El-operated parking brake ECU (Aut gearchanging, lever steering, monitoring) 15 ECU (El-servo system) 10 Container attachment, safety interlock 10 Central lubrication 15 Spare Spare Left hand main beam Right hand main beam .5 Left hand dipped beam Right hand dipped beam Left hand rear light, right hand position light Right hand rear light, left hand position light S1-6 S7-12 S13-18 S19-24 S25-30 Bulbs Description A3611101A WARNING! Never use fuses of a higher amperage than stated on the lid decal Risk of damage or fire DCE70-90E Instruments Indicating lamps Cab lighting Rear lights, red Brake lights Direction indicators Position lights Driving lights (full/dipped beam) Reversing lights, white Working lights Hazard beacon Rating Watts .Base BA7s 1,2 W2x4,6d 10 S8,5 BA15s 21 BA15s 21 BA15s SV8,5 75/70 P43t-38 70 PK22s 70 PK22s 70 PK22s 29 SUPERVISION Electrical system Relays A 305 313-1 313-3 313-4 313-5 313-6 313-7 313-8 313-9 313-10 314 315 316 320 322-1 322-2 323 328 330 331 332 334 368 399 Reversing light Brake light (rear-front) 2) Direction indicators (right-left) 2) Direction indicators (left-right) 2) Rear light (rear-front) 2) Dipped beam (front-rear) 2) Reversing light (rear-front) 2) Main beam (front-rear) 2) Shifting (Rev-forw) 2) Shifting (Forw-rev) 2) Parking brake, disengagement High power (Starting switch) Wiper motor, front Electric stop (ECS 07) 1) Coolant level Coolant level (ECS 07) 1) Pulse relay, direction indicators Lever steering (ECS 04) 1) Starting interlock Propulsion forward Propulsion reverse Release clutch at automatic gearbox (ECS 01) 1) Low brake pressure (ECS 07) 1) Spare Miscellaneous 321-1 321-2 960 Intermittent relay wiper front Intermittent relay wiper rear 1) Reversing interlock 1) Optional equipment 2) Rotatable operator’s seat Main fuse for electrical system Fitted on the engine x 50 A B Starting from another battery z Make sure the auxiliary batteries are connected in series, so z 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 z 30 that 24 V will be supplied Note: Do not disconnect the truck-battery cables Connect the jumper cables in the following order: Red cable (+) to auxiliary battery Red cable (+) to truck battery Black cable (–) to auxiliary battery Black cable (–) to a location some distance away from the truck battery, such as the negative cable connection on the chassis Start the engine Do not disturb the jumper cables while starting, as sparks may otherwise be caused Do not lean over either battery Disconnect the jumper cables in exactly the reverse order DCE70-90E LUBRICATION CHART 10 11 6, 12 13 KL1318 17 16 15 14 19 A3638501S IMPORTANT! If the truck stands unused outdoors, with the hydraulic piston rods exposed, all piston rods must be greased to prevent corrosion DCE70-90E After they have been washed with degreasing agent, all pistons should be moved backwards and forwards several times to obtain a new protective film of oil 31 LUBRICATION CHART Item No Description Interval operating hours 200/ 400 500 1000 No of Remarks lub points Cylinder bearing, tilt cylinders L Mast suspension L Cylinder bearing L 4 Support rollers, mast and carriage Sliding plates Engine oil x Oil filter, engine x 10 Gearbox oil 11 Gearbox, oil filter x 12 Drive axle C 13 Propeller shaft L 14 Hydraulic oil filter 15 Hydraulic oil 16 Breather filter, hydraulic reservoir 17 Linkage, steered axle 18 Hinges, doors and hatches 19 Brake pedals Relieve the mast of load when lubricating 18 outer - innermast inneremast - carriage carriage - sidelift L L L 4 Use skylift or similar Lubricate all sliding surfaces with lubricating agent Use a brush and distribute evenly Operate the mast to max lifting height Every 500 hours, check the wear of the sliding plates If the remaining thickness of any plate is less than mm it must be replaced, see Technical Handbook x) Oil change every 200 hours 1) x) Filter change every 400 hours Steered wheel bearings Knuckle pin bearing Dismantle, clean, inspect and pack with grease every 4000 hours x x x) Oil change Check level while idling x) Filter change x) Oil change, differential and hubs Drain the oil at working temperature Check the levels after refill x x L x) Filter change Oil change every 2000 hours x) Filter change L CL 1) Dismount doors and hatches Check and retighten the pedal axle locking screws Lubricate axle nipples 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 DCE70-90E Hook coupling, locking plate 33 LUBRICATION CHART Pos No Description Sidelift Interval 500 1000 No of Remark lub points Sliding surfaces, length adjustment L Brush onto all sliding surfaces with the attachment in the fully extended position Sliding surfaces, sideshift L Brush onto all sliding surfaces with the sideshift to the limit in each direction Cylinders, sideshift L Cylinders, length adjustment L Locking cylinders L Lifting pinion twist connection L Lifting pinion L Contact pin Axle, hook coupling C Check that the sensors are free from grease and that the sensor faces are undamaged Disassemble the twist-locks every 2000 h Check for wear If needed, chenge components accordingly Clean and pack with grease Same procedure should be used at suspected damage to the twist-locks L Check that the sensors are free from grease and that the sensor faces are undamaged L L = Lubricate C = Check 34 DCE70-90E TECHNICAL DATA DCE70-45E8 DCE90-45E7 Volvo – TD730VE Diesel – 4-stroke 150 – 2400 800 – 1400-1500 - 17.7:1 AC – 2240 W 2x12 – 140 Volvo – TWD731VE Diesel – 4-stroke 167 – 2200 893 – 1300-1450 - 17.7:1 AC – 2240 W 2x12 – 140 Clark – 13,7HR28000 Torque converter Powershift 3–3 Dubbel reduction, differential and hub reduktion Clark – 13,7HR32000 Torque converter Powershift 3–3 Dubbel reduction, differential and hub reduktion Pneumatic 12,00x24 - 12,00x24 1,0 Pneumatic 14,00x24 - 14,00x24 1,0 Engine Make – type designation Fuel – type of engine Power ISO 3046 1) – at speed kW -r/m Torque ISO 3046 – at speed Nm-r/m No of cylinders – compression ratio Alternator, type – capacity Starting battery, voltage – capacity V-Ah Transmission Gearbox, make – type designation Clutch, type Gearbox, principle No of gears, forward – reverse Drive axle, make – type designation Wheels Wheels, front and rear 2) Dimension, front - rear Tyre pressure, front and rear MPa Steering- and brake system Steering system Driving brake system, type – wheels braked Parking brake system, type – wheels braked Hydraulic servo - Steering wheel Wet disc brakes – drive wheels 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 Hydraulic oil Coolant Engine oil, incl filter Drive axle (incl hub reductions) Gearbox 380 320 40 28 2×2.5 + 54 30 L L L L L L 380 320 41 28 2×2.5 + 54 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 engine–gearbox is also specified in the product specification 1) ISO 3046 = Net power Spare tyres and replacement tyres be of a make approved by Kalmar 2) DCE70-90E 35 Oil and lubricant recommendations 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 IMPORTANT! Any deviations from the above table must be supported by written approval from Kalmar Service 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 with 3–5% molybdenum 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 kg can 36 Art.no 923110.0360 Art.no 923595.0003 DCE70-90E Oil and lubricant recommendations Gearbox oil IMPORTANT! On delivery from Kalmar, the gearbox is filled with APICD 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 Relevant ambient temperatures Temperature range Recommended oil (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 (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 (a) *Dexron (b) *Dexron II D – See below! (a) MIL-L-46167 (b) MIL-L-46167 A (a) Conoco Polor Start DN-600 Fluid IMPORTANT! Recommended lubricants for Temperature ranges and may be used in lower ambient temperatures when the sump is pre-heated IMPORTANT! Any deviations from the above table must be supported by written approval from Kalmar Service DCE70-90E Lubricants for Temperature range 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 COMPLIES WITH THE APPROVED C-3 SPECIFICATION 37 ... tests Quantities, see Technical Data L=Lubricate C=Check 32 DCE70- 90E LUBRICATION CHART Sidelift Twist-locks KL1322 Hook coupling DCE70- 90E Hook coupling, locking plate 33 LUBRICATION CHART Pos... tyre pressure For further information, see the section entitled SUPERVISION DCE70- 45E8 KL1477 Option: Raised cab DCE70- 90E Introduction Mast, free-visibility mast, with two lifting cylinders Operator’s... free from grease and that the sensor faces are undamaged L L = Lubricate C = Check 34 DCE70- 90E TECHNICAL DATA DCE70- 45E8 DCE90-45E7 Volvo – TD730VE Diesel – 4-stroke 150 – 2400 800 – 1400-1500