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20 Electrical system
Technical
Handbook 30 Engine
DCE80-100E
40 Transmission,
This Handbook deals with the design
drive axle, brakes
and maintenance of Kalmar empty
container trucks, type DCE.
70 Hydraulic system
We reserve the right to modify
our design and material speci-
fications without prior notice.
TDCE01.04GB
90 Periodic supervision
DCE80-100E TDCE01
04GB
Technical Handbook Contents Group 00 P. 1
Group 00
Contents
Safety regulations ..................................................................... 2
General ..................................................................................... 5
Applications ......................................................................... 5
Design ................................................................................. 6
Component units ................................................................. 6
Main components ................................................................ 8
Supplementary books .......................................................... 9
Replacement system – Spare parts .................................... 9
Tools .................................................................................... 9
Tightening torques ............................................................. 10
System of units .................................................................. 12
DCE80-100E Safety regulations TDCE01
04GB
Technical Handbook Group 00 P. 2
It is important that you read the instruction Safety regulations aimed at reducing the
manual. risk of personal injury and damage to
Incorrect handling can lead to personal injury or dam- loads or other property.
age to products and/or property. Therefore, read the in-
struction book very carefully before operating the truck. Intended of use
The instruction manual contains important information z The truck may only be used for the purpose for
about your Kalmar truck, about the operation of the which it was intended, namely, to lift and transport
truck, about safety during operation and about the goods, the weight of which does not exceed the
truck's daily maintenance. In addition, you will find use- maximum permitted load capacity of the truck.
ful information that will make operations easier for you z The truck may not, without specific permission
in your daily work. from Kalmar, be modified or re-built so that its func-
The instruction manual must always be kept in the ma- tion or performance is altered.
chine. If the manual should be lost, a replacement must z The truck may not be driven on public highways if
be immediately obtained. Never use a machine with a it has not been adapted to comply with national
missing instruction manual. road safety regulations.
Ask your foreman/group leader if there is anything in Operator requirements
the manual that you do not understand or if you feel that z The truck may only be driven by operators who
information is missing in any area. have been specially trained and who have the
company's authority to do so.
The symbol is used on our products in certain z Laws and other regulations relating to driving li-
cases and then refers to important information con- cence, operator ID, log book, etc., must be fol-
tained in the instruction manual. Make sure that warn- lowed at all times.
ing and information symbols are always clearly visible z The operator must be aware of and follow all local
and legible. Replace symbols that have been damaged safety regulations.
or painted over.
z It is always the responsibility of the operator to en-
In this instruction manual warnings are inserted that ap- sure that the truck has approved fire extinguishing
ply to your own safety. Warnings point out the risk of ac- equipment in accordance with currently applicable
cident that can cause personal injury. regulations.
Operation of the truck is prohibited:
z If any of the fitted safety equipment, such as rear
WARNING! view mirrors, headlights, reversing alarm (option-
al), does not function correctly.
Warns of the risk of serious personal injury, pos- z If there is a fault with the brakes, steering or lift
sible death and/or serious damage to product or equipment.
property if the regulations are not followed.
z If it has been repaired, modified or adjusted with-
out the approval of the work supervisor.
For technical warnings, that point out the risk of break z If the truck is fitted with tyres not approved by
down, the word IMPORTANT is used: Kalmar.
Continued from previous page z Handle batteries and junction boxes with great
care. The batteries must always be protected over
Operating regulations
the poles and connections.
z Before starting, always check to ensure that no-
z Always rectify any damage or wear and tear that
body is in the way of the truck or its equipment.
can risk personal safety or that can affect the
z The operator must always face the direction of op- functions of the truck or its service life.
eration and take particular care in areas where
z Avoid touching oils and greases. Avoid inhaling
persons or other vehicles are likely to appear in
the vicinity. If visibility is limited by the load, the op- exhaust and oil fumes.
erator should operate the truck in reverse. z Always use steps and handrails when entering or
z It is prohibited to walk or stand underneath raised leaving the machine - Never jump!
forks or other equipment, whether they are loaded To avoid the risk of slipping, tread only on anti-slip
or not. surfaces. If the anti-slip protection has become
worn, loose or in any way less effective, it should
z It is prohibited to transport passengers on the be replaced.
truck outside the cab or on the load. Passengers
may be transported inside the cab only on condi- z Welding painted steel produces poisonous gas-
tion that it is equipped with a fixed passenger ses. Paint should therefore be stripped before
seat. welding, good ventilation ensured and/or face
mask with filter used.
z It is prohibited to lift people if the truck is not
z Mobile phones used in the cab must always have
equipped with an approved lift cage.
fixed connections to the machine’s electrical sys-
z It is prohibited to exceed the load capacity of the tem, with a fixed antenna outside the machine,
truck. See capacity plate and loading diagram. mounted in accordance with the manufacturer’s
z It is prohibited to transport loads in the raised po- instructions. This will avoid interference with the
sition as this entails a risk of the truck tipping. All machine’s important electronic functions.
transportation shall take place with the load in the z The tensile strength of the top pane can be seri-
transport position. ously weakened by exposure to elements that
z The operator must adapt the speed of the truck to contain: Aromatic hydrocarbon, ketone, esters or
the character of the load, conditions of visibility, chlorinated hydrocarbon.
the character of the roadway/surface, etc. Regularly check the surface condition of the top
z The operator shall avoid powerful acceleration pane and clean only with screen wash or other
and braking when turning. In addition, the opera- mild cleaning fluid. After cleaning, rinse thorough-
tor shall always moderate the speed of the truck ly with warm water. It is prohibited to modify or in
when turning so as to avoid the risk of lateral skid- any other way make alterations to the top pane.
ding or tipping. Immediately replace damaged top panes that
show signs of cracking or scratching.
z The operator shall take particular care when oper-
ating in the vicinity of electrical power lines, via- Operating with attachments
ducts, quay-sides, ramps, gates/doors etc. z The operator must always take the effect of the
z Safety belts must always be worn, if fitted. In the wind into account when handling containers.
event of the truck tipping, always remain in the Avoid lifting with a wind strength in excess of 12
cab and grip the steering wheel securely. Never m/s (27 mph/40 feet per second).
try to jump out of the cab. z Always drive carefully so as to avoid attachments
z The parking brake can also be used as an EMER- colliding with pillars, cables, etc.
GENCY BRAKE. However, having been used for z Carefully study the "Lift methods" section of the
emergency braking, the brake linings must be instruction manual.
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 CE marking
z Always check that the gear lever is in the neutral All trucks and equipment (though not thoses fitted on
position before turning the ignition key to restart or the truck or intended as spare parts) supplied from Ka-
to reset an emergency stop. lmar are CE marked, which indicates that they comply
z Never leave the operator's cab without applying with the requirements of the EU Machine Safety Direc-
the parking brake (ON position). tive. In addition, each truck has a so called, “EU Dec-
z Always remove the ignition key if the truck is to be laration of Conformity” which is the legal proof that the
left unattended. truck complies with the “health and safety” require-
Other important points to remember ments laid down in the Machine Safety Directive, the
z The truck's hydraulic system includes high pres- EMC directive (electro-magnetic compatibility) and the
sure hydraulic accumulators. Always be extreme- LVD directive (electrical equipment).
ly careful when working with the hydraulic system
and avoid being unnecessarily close to the hy-
draulic equipment, lines and hoses. Before work- Vibration standard
ing on the hydraulic system, the accumulators The truck is tested according to test method described
must be emptied into the tank, with the help of the in EN 13059, see Technical data.
special accumulator evacuation valve.
DCE80-100E Safety regulations TDCE01
04GB
Technical Handbook Group 00 P. 4
Safety regulations
z Tyre changing can be dangerous and should only – Do not use over-size tyres, too large for the
be carried out by specially trained personnel using rims, e.g. 14.5 inch tyres with 14 inch rims or
proper tools and procedures. 16.5 inch tyres with 16 inch rims.
Failure to comply with these procedures may re- – Never use damaged, worn or corroded rims/
sult in faulty positioning of the tyre and/or rim and wheels or fitting hardware. Always verify that the
cause the assembly to burst with explosive force rim is in a serviceable conditioning.
sufficient to cause physical injury or death. Never – Always clean and repaint lightly rusted rims.
fit or use damaged tyres or rims. – Never use a rim/wheel component that can not
z Never attempt to weld on an inflated tyre/rim be identified. Check rim parts against multi-
assembly. piece rim/wheel matching charts.
z Assembly and inflation
z Never let anyone assemble or disassemble tyres
without proper training. – It is important that the inflation equipment is
equipped with a water separator to remove
z Never run the truck on one tyre of a dual assembly. moist-ure from the air line in order to prevent co-
The load capacuty of a single tyre is then danger-
orosion. Check the separator periodically to en-
ous-ly exceeded and operation in this manner may sure that it is working properly.
damage the rim. – Make sure that the lockring is in its right position.
z Deflation and dismantling – Never mix different manufacurer’s parts since
– Always block the tyre and wheel on the opposite this is potentially dangerous. Always check
side of the vehicle before you place the jack in manu-
position. Always crib up the blocks to prevent facturer for approval.
the jack from slipping. – Never seat rings with hammering while the tyre
– Always check the tyre/rim assembly for proper is inflated. Do not hammer on an inflated or par-
component seating prior to removal from the tially inflated tyre/rim assembly.
truck. – Always double check to ensure that the rim as-
– Always deflate the tyre by removing the valve semblies have been correctly assembled and
core prior to removing the complete assembly that securing studs and nuts are tightened to the
from the truck or dismantling any of the compo- correct torque setting.
nent. Before loosening mounting bolts, run a – Never inflate tyres before all side and lockrings
wire through the valve stem to ensure that it is are in place. Check components for proper
not blocked. Ice or dirt can prevent all the air assembly after pumping to approximately 5 psi
from escaping. Deflate and remove valve cores (=34 kPa, =0.34 bar)
from both tyres of a dual assembly. – When adding air to a tyre on an industrial truck,
– Never position body in front of the rim during de- use a clip-on chuck and stay out of the danger
flation. area. If the tyres has been run flat then the rim
– Always follow assembly and dismantling proce- must be dismantled and all parts inspected for
dures outlined in the manufacturer’s instruction damage.
manual, or other reconized industry instruction – Under-inflated tyres have a serious effect on the
manuals. Use proper rubber lubricant. stability of the truck and reduces the safe load
– Never use a steel hammer to assembling or dis- handling capacity. Always maintain tyres at the
mantling rim components – use a lead, brass or correct inflation pressures. Check inflation
plastic type mallets. The correct tools are avail- pressure daily. Do not over-inflate.
able through rim/wheel distributors. – Inspect tyres regulary – every day if possible.
– remove bead seat band slowly to prevent acci- Look for and remove broken glass, torn pieces
dents. support the band with your thigh and roll of tread, embedded metal chips etc. Inspect for
it slowly to the ground in order to protect back uneven or rapid tread wear, usually caused by
and toes. mechanical irregularities, such as brakes out of
– Disassembly tools apply pressure to rim flanges adjustment or excessive toe-in and toe-out. If
to unseat tyre beads. Keep your fingers clear. discovered, correct the irregularity immediately.
Slant disassembly tool about 10 degrees to z When installing and tightening trail wheel bolts, ob-
keep it firmly in place. Always stand to one side serve the following:
when applyin g hydraulic pressure. Should the – Ensure that trail wheel or hub mounting surfac-
tool slip off, it may cause fatal injury . es and trail wheel fastener mounting surfaces
z Rim inspection are clean and free from paint and grease.
– Check rim components periodically for fatigue – Tighten bolts to specified torque settings. use
cracks. Replace all cracked, badly worn, staggered sequence; i.e. top bolt, bottom bolt
damaged and severely rusted components. etc.
– Always select the correct tyre size and construc-
tion matching the manufacturer’s rim or wheel
rating and size.
DCE80-100E General TDCE01
04GB
Technical Handbook Group 00 P. 6
Applications
The Kalmar DCE80-100E is a range of trucks is based on an en-
tirely new approach to the design and production of heavy diesel-
powered trucks. The trucks are durable and safe and their acces-
sibility for service and maintenance is unexcelled.
The trucks are intended for handling of empty containers in har-
bours and container terminals with stacking up to 8 containers
high
Design – general survey
Kalmar DCE80-100E diesel trucks are of sturdy design for heavy
duty. They are built around a chassis which has high strength and
torsional stiffness and an extremely low centre of gravity.
The operator’s cab is provided with vibration isolation and sound
insulation and offers excellent all-round visibility.
The operator is provided with many facilities for adjusting his
seating attitude. The seat, backrest and springing of the opera-
tor’s seat can be adjusted in a wide variety of ways.
The engine is easily accessible through a casing.
The six-cylinder turbocharged engine combined with a three-
speed gearbox with torque converter, provides smooth power
whenever needed.
The drive axle with hub reductions, the oil-cooled hydraulic brake
system and the pendulum-mounted steered axle with double-act-
ing steering cylinder satisfy very strict demands on strength and
mobility when travelling on irregular surfaces.
The hydraulic system is reliable and has high performance
charged by two, three or four hydraulic pumps.
For further details, see group 70.
DCE80-100E General TDCE01
04GB
Technical Handbook Group 00 P. 7
1
2
4 3 5 6 7
1. Lifting mast, free lift mast with double cylinders 5. Gearbox, combined with torque converter
2. Operator’s cab, rubber suspended 6. Drive axle, with hub reduction and oil sooled, hydraulic
3. Engine, six cylinder diesel with turbocompressor brake system
4. Steering axle with pendular suspension and 7. Carriage with side lift attachment
double-acting steering cylinder Hydraulically controlled length adjustment and side-shift
DCE80-100E General TDCE01
04GB
Technical Handbook Group 00 P. 8
Component units
z Sound-insulated operator’s cab with excellent all-round visi-
bility. The non-slip, substantial steps provide convenient ac-
cess to the cab.
z Centrally positioned steering column.
z Clearly arranged instrument panel.
z Engine – Volvo TAD720VE (standard) six-cylinder, four-
stroke, turbocharged diesel engine with direct injection and
thermostatically controlled water cooling.
z Gearbox with torque converter
– Constant-mesh gearbox in which hydraulically actuated
clutches for the different gears. The clutches are electri-
cally operated.
– Torque converter, which is a hydraulic coupling that ampli-
fies the output torque on an increase in load. Torque con-
version takes place smoothly and steplessly throughout
the engine speed range.
– Oil cooler connected to the engine cooling system for
cooling the oil in the gearbox and torque converter.
– Oil pump which supplies oil under pressure to the gearbox
and torque converter.
– Full-flow oil filter for effective cleaning of the gearbox oil.
z Drive axle with two-stage reduction - in the differential and
the hub reductions.
– Oil cooled hydraulic brakes for the foot brake, e.g. Wet
disc brakes.
– Disc type parking brake applied by a sturdy spring and
released by hydraulic oil pressure. Tha parking is electri-
cally activated by a switch in the operator’s cab.
z Hydraulic system with
– Hydraulic pumps connected to take-offs on the torque
converter. In the standard version, the system has one
pump for lift and one pump for other working hydraulics.
Some machines have a separate system for side-lift which
is then fed by a separate pump.
The optional cab tilt is also fed by a separate pump.
– Main valve for controlling the main hydraulics. The valve
is controlled hydraulically from the cab.
– A high pressure filter after each pump for effective clean-
ing of the hydraulic fluid before it is fed to the system.
– Steering valve (Orbitrol) - flow-control valve which sup-
plies hydraulic fluid to the steering cylinder.
– Oil cooler with electrically powered fan.
z Steered axle with pendulum mounting and double-acting
steering cylinder.
z Sturdy clear-vision mast.
– Outer mast with hydraulically controlled forward and back-
ward tilting.
– Tilting cylinders with back-pressure valves to prevent the
load from tilting the mast forward.
– Inner mast with support wheels that carry the axial forces
on the mast. Sliding plastic plates to carry sideforces.
Yoke with guide rollers for the hydraulic hoses and guide
sprockets for the lifting chains.
– Lifting cylinders - two cylinders mounted on the outer
mast.
z Carriage with:
– Support wheels to carry axial forces
– .Sliding plastic plates to carry side forces
DCE80-100E General TDCE01
04GB
Technical Handbook Group 00 P. 9
Supplementary books
Tools
Kalmar offers a wide range of tools for truck maintenance work.
For further information, please contact Kalmar's service depart-
ment.
DCE80-100E General TDCE01
04GB
Technical Handbook Group 00 P. 10
Tightening torques
The tightening torques are applicable to steel bolts and nuts tight-
ened with a torque wrench under the following conditions:
Surface treatment
Condition Lubriation
Bolt Nut
1 untreated untreated oiled
bright galvanised untreated
2 bright galvanised bright galvanised dry or oiled
bright galvanised bright galvanised
3 hot-dip galvanised bright galvanised dry or oiled
System of units
The SI system of units is employed in this handbook:
The conversion factors are as follows:
Pressure
megapascal bar Kilogram-force per Pound-force
square centimetre, per square
kpf/cm² inch,
Atmosphere, at psi
1 10 10,2 145
0,1 1 1,02 14.5
0,098 0,98 1 14.2
Torque
Newton- Kilogram force-metre Pound-force foot
meter kgf m lbf ft
Nm
1 0,102 0.74
9,81 1 7.23
Power
1 1,36 1.34
0,735 1 0.986
DCE80-100E TDCE01
04GB
Technical Handbook Contents Group 10 P. 1
Group 10
Chassis and cab
Specifications ........................................................................... 2
Chassis...................................................................................... 3
Description ........................................................................... 3
Operator’s cab ........................................................................... 4
Description ........................................................................... 4
Steering column .............................................................. 7
Service ................................................................................. 8
Changing the fresh air filter ............................................. 8
Check and lubrication of brake pedal .............................. 8
Windscreen wipers .......................................................... 9
Air conditioning unit ................................................................. 10
Description ......................................................................... 10
Service ............................................................................... 13
Checking the air conditioning unit ................................. 13
DCE80-100E Specifications TDCE01
04GB
Technical Handbook Group 10 P. 2
Air conditioner
z Cab unit
Circulated air flow 500-600 m3/h
Electric power consumption approx 350 W
z Compressor
Max. speed 4000 r/min
Refrigerant R134a *)
Electric power consumption approx 50 W
Oil capacity Zexel PAG SP-20 1.5 dl
z Condenser
Electric power consumption 250 W
Chassis
The chassis consists of:
z A unit construction frame built up around two beams with a
minimum of welds for best possible strength.
z Mountings for the drive axle, steered axle, mast, lifting cylin-
ders and transmission.
z The necessary counterweights to provide a very low centre
of gravity. Moreover, the steered axle is designed to serve as
an additional counterweight.
z The hydraulic oil tank and the fuel tank are produced as sep-
arate units and are bolted to the side of the chassis. The
tanks have a low profile, which contributes to the good visi-
bility.
z Separate mounting for cab, attached with screws to the
chassis. Two different heights are available. Steps and plat-
form on the left hand side, optional also right hand side.
3 2 1
7 Chassis
DCE80-100E Operator’s cab TDCE01
04GB
Technical Handbook Description Group 10 P. 4
Operator’s cab
The operator’s cab is a separate structure and rests on the chas-
sis on rubber dampers. The operator’s seat, steering wheel and
hydraulic control levers can be adjusted for best possible opera-
tor comfort. Effective insulation minimises the vibrations and
sound level in the cab.
The standard heating system consists of a fan and heater for
heating the air in the cab by recirculation. Fresh air is drawn in
through a ventilation air filter. Full air conditioning, with cooling,
heating and dehumidification, is available to special order.
3 1 4 5 2 6
4 3 2 1
N
L 0
R
R
1 4 5
2 3
a b c d e
KL1733
7 8 9 10 11 12 13 14 15
KL743
6
1. Gear lever
FORWARD/NEUTRAL/REVERSE 1/2/3
2. Lever DIRECTION INDICATORS/HORN
FRONT WINDSCREEN WASHER/ 13
FRONT WIPERS/MAIN BEAM
3. Instrument panel 14
4. Steering wheel panel
5. Starting switch 15
KL1734
6. Control lever, hydraulic functions,
See Instruction Manual Option: Joy-stick
a. Lift
b. Tilt
c. Sideshift
d. Length adjustment 20’-40’ a b c d
e. Locking/Unlocking twist-locks 6
7. Electrical central unit with fuses and relays
8. Brake pedals, normal driving brake
9. Release clutch 13
10. Accelerator pedal
11. Steering wheel adjustment
12. Operator’s seat 14
13. Parking brake
14. Emergency switch for all hydraulic functions 15 KL1735
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. Switch with lamp DIAGNOSIS (QSB5.9)
22. Fuel gauge 41. a. Warning lamp STOP ENGINE (QSB5.9)
23. Temperature gauge, engine coolant temperature b. Indicating lamp CHECK ENGINE (QSB5.9)
24. Switch, working lights 42. Warning lamp, battery charging
25. Switch, working lights 43. Warning lamp, low engine oil pressure
26. Switch, working lights 44. Warning lamp, low gearbox oil pressure
27. Switch, flashing beacon 45. Warning lamp, low brake pressure
28. Switch, hazard warning lights (accumulator pressure)
29. Switch, driving lights 46. Warning lamp, low engine coolant level
30. Spare 47. Indicating lamp, preheating
31. Spare 48. Warning lamp, high engine coolant temperature
32. Switch with lamp ENGINE MAINTENANCE 49. Warning lamp, high gearbox oil temperature
(QSB5.9) 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 55. Orange lamp ALIGNMENT
38. Control, heat 56. Red lamp TWIST-LOCKS UNLOCKED
39. Control, cold 1) 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
DCE80-100E Operator’s cab TDCE01
04GB
Technical Handbook Description Group 10 P. 7
Steering column
Surrounding the steering column are multi-function levers for
gear changing, indicators, windshield wipers, etc., as well as the
instrument panel with the ECS terminal. At the very foot of the
steering column is the steering valve (Orbitrol), activated by the
steering wheel via an angled gear. The steering column is
equipped with an adjustment handles for the alteration of steering
wheel height and rake.
F
4 3 2 1
L 0
R
R
1 1 2 3
2
4 5
3
KL580A
KL1752
1. Gear lever
2. Multi-function lever
3. ECS terminal
4. Steering wheel adjustment
handles
5. Orbitrol steering valve
5
KL1751
Steering column
DCE80-100E Operator’s cab TDCE01
04GB
Technical Handbook Service Group 10 P. 8
KL1839
DCE80-100E Operator’s cab TDCE01
04GB
Technical Handbook Service Group 10 P. 9
3
4
1. Brake pedal
2. Lubricating nipple
3. Locking screw
4. Shaft
DCE80-100E Operator’s cab TDCE01
04GB
Technical Handbook Service Group 10 P. 10
Windscreen wipers
The wiper arms are fixed to the wiper motor shafts via conical
splines. The shafts are manufactured of hardened steel and the
wiper arm mounting of soft, pressed metal. When fitting, the nuts
must be tightened so hard that the splines are pressed well into
the mounting and function as a carrier.
Removal
1. Remove the wiper arms by loosening the nuts and thereafter
tapping and carefully rocking the arms to and fro.
Fitting
1. Check to ensure that the splines on the motor shaft are free
from the softer material from the wiper arm mounting.
1 If this is not the case, clean the splines so that they can
pressed fully into the wiper arm mounting.
2. Fit the wiper arms onto the motor shafts and tighten the nuts
to a torque of 16-20 Nm.
Hold the wiper arm to take up the torque pressure so that it
is not transferred to the motor, which could result in damage
.
IMPORTANT!
The nuts must be tightened sufficiently hard, otherwise
2 the shafts may start to slip inside the wiper arm mounting,
resulting in damage.
3
4
3
8
9
7
2
15 16
12 14
10
1. Heating control
2. Heat exchanger
3. Vapourizer
4. Expansion valve
5. To condenser
6. To compressor 11
7. Heating valve
8. From engine 13
9. To engine
10. Fan
11. Fan
12. Fan control
13. Fresh air filter
14. Air disperser
15. Control defrost/cab
16. Defroster outlet
2
4
D C
E E
7 A B
6 1
G
Compressor
The air conditioning system is driven by the compressor. This
performs as a pump, drawing cold, low-pressure gas from the
evaporator, compressing it and thereby raising its temperature,
and discharging it at high pressure to the condenser.
The compressor is driven by V-belts directly from the diesel en-
gine. Switching between operation and idling is controlled by an
electro-magnetic clutch which, in turn, is controlled by a thermo-
stat whose sensor is located between the fins of the evaporator
coil. The thermostat switches off the compressor at low tempera-
tures, to prevent icing of the evaporator.
Condenser
The function of the condenser is to convert the hot high-pressure
gas from the compressor into liquid form. The tubes and fins of
the condenser coil absorb heat, which is then removed by the air
delivered by the fan.
The temperature of the refrigerant in the condenser varies from
about +50°C to +70°C. The pressure varies between 12 and 20
bar, depending on the ambient temperature and the flow of air
through the condenser. When the refrigerant is condensed into
liquid form, it is transferred under pressure to the liquid receiver/
filter dryer.
Expansion valve
The expansion valve throttles the flow and passes an optimised
quantity of refrigerant that the evaporator is capable of evaporat-
ing.
The expansion valve is also the part of the circuit which separates
the high- pressure side from the low-pressure side. The refriger-
ant flows to the expansion valve under high pressure and leaves
it under low pressure.
The amount of refrigerant which passes the evaporator varies,
depending on the thermal load. The valve operates from ’fully
open’ to ’fully closed’ and in-between searches for a point to give
optimum evaporation.
Evaporator
The heat necessary for evaporating the refrigerant is extracted
from the cab air which is circulated by a fan through the evapora-
tor coil. The cab air is thus cooled, and is distributed and returned
to the cab.
In the evaporator, the refrigerant reverts to the gaseous state and
returns to the compressor suction, thereby completing the cycle.
DCE80-100E Air conditioning unit TDCE01
04GB
Technical Handbook Service Group 10 P. 14
RD 1,5
RD 1,5
A
L GL 1,5
M SV 1,5
H RD 1,5
1 4 4
C
R R 5 8
BR 1,5
M
30 87 9
2 GL 1,5 85 86 BR 1,5
M M
BR 1,5
6
3
VT 1,5
HIGH
LOW
10
1. Fan switch
2. Cooler on/off
3. Anti-freeze thermostat
4. Resistor
5. Fan motor
6. Indicator lamp – cold (in push button)
7. High-/low-pressure monitor
8. Relay
9. Condenser fan
10. Compressor
Group 20
Electrical system
Specifications .............................................................................2
Electrical system ........................................................................3
Description ............................................................................3
Service ..................................................................................5
Checking the electrolyte level of the batteries..................5
Fuses ...............................................................................5
Bulbs ................................................................................5
Relays ..............................................................................6
Sockets in electrical central..............................................7
Electrical diagram explanations .......................................8
List of circuit diagrams...........................................................9
Component list
DCE80-100E Specifications TDCE01
04GB
Technical Handbook Group 20 P. 2
The system voltage is 24V and the supply is taken from two 12V
batteries connected in series and charged by an alternator
IMPORTANT! across electronic rectifying and voltage stabilisation circuits. .
Always open the main switch when- The positive pole is connected across a main switch. The nega-
ever work is to be carried out on the tive pole is connected to the chassis.
electrical system, if the truck is to Warning lamps and instruments are clearly arranged on the in-
remain idle for some time and when-
ever welding work is to be carried out strument panel. The central electrical unit with fuses and relays
on the truck. is located on the lower section of the cab’s rear wall.
2 3
5 5
1 5
4
1. Driving lights 6
2. Washer fluid container
3. Electrical central
4. Rear lights 7
5. Position lights
6. Main switch
7. Battery
DCE80-100E Electrical system TDCE01
04GB
Technical Handbook Description Group 20 P. 4
1 2 3 4 5 6
8 7
9 10
1. Sensor, warning lamp low oil pressure and gearbox oil pressure gauge
2. Sensor, warning lamp high oil temperatur and gearbox oil temperature gauge
3. Fuse
4. Relay preheater element
5. Sensor, coolant temp gauge
6. Sensor, high coolant temp warning lamp
7. Sensor, engine oil pressure instrument
8. Starter motor
9. Sensor, low coolant level warning lamp
10. Engine wiring
1 2 3 4 5
9 8 7 6
10
1. Sensor, warning lamp low oil pressure and gearbox oil pressure gauge
2. Sensor, warning lamp high oil temperatur and gearbox oil temperature gauge
3. Sensor, coolant temp gauge
4. Solenoid, fuel shut off valve
5. Alternator
6. Sensor, engine oilpressure
7. Relay, preheater element
8. Main fuse
9. Sensor, outgoing engine speed
10. Starter motor
1 2 3 4 5 6 7 8
9
10 11 12
Electrical system
The electrical system operates at 24 V. The source of power sup-
ply are two 12 V batteries which are charged by an alternator. The
N.B. negative pole is connected to the chassis.
The starting batteries accompanying The positive pole is connected to a main switch A.
the truck are of the maintenance-free
type, which implies that it should not IMPORTANT!
be necessary to top-up with electro- When working with the electrical system, when carrying
lyte during the life of the batteries. out welding on the truck or at long time parking, always
isolate 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.
A Main switch
DCE80-100E Electrical system TDCE01
04GB
Technical Handbook Electrical system Group 20 P. 8
Relays
305 Reversing light
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
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
A
1)
Optional equipment
Main fuse
for electrical
system
Fitted on the engine
2 x 50 A
A
DCE80-100E SUPERVISION TDCE01
04GB
Technical Handbook Diagram explanations Group 20 P. 11
A B E C F G D
KL1083
KL1081
KL1082
DCE80-100E SUPERVISION TDCE01
04GB
Technical Handbook Diagram explanations Group 20 P. 12
Diagram Circuit
A35082.0200 Current, Volvo 730/731 VE
A35083.0100 Gearchanging
A35083.0300 ECS 01, aut gearchanging 1)
A35084.0300 Sensors, instruments
A35084.0200 ECS 07, monitoring 1)
A35085.0300 Accelerator 1-Ped. ECS 01/ECS 07 1)
A35086.0100 ECU 1 1)
A35087.0100 Lever/Mini steering ECS 04/06 1)
A35088.0100 Wipers
A35089.0100 AC
A35089.0200 Termostatically controlled AC 1)
A35090.0100 Driving lights
A35091.0100 Working lights
A35092.1100 Cabin
A35093.0200 Central lubrication, hydraulic fluid cooler 1)
A35093.0300 Blinking brakelights when reversing 1)
A35093.0400 Autom. engine stop, alarm function (valve)
All faults after the same set time 1)
A35093-0900 Autom. engine stop, low oil pressure after 6 sec.
other faults after 25 sec.
A35094.0100 Side lift attachment -Truck (Twistlocks)
A35094.0200, Side lift attachment-Truck (Hooks)
A35094.1200
A35094.0400, Side lift attachment-Truck (ECS 08)
A35094.1400
A35094.0500- Side lift attachment-Truck (option)
A35094.0700
A35095.0200 ECU 4 at ECS 08 1)
A35096.0200 ECS 08, linear levers 1)
A35097.0100 Side lift attachment (Twistlocks)
A35097.0200 Side lift attachment (Hooks)
A35098.0100 CAN-Bus (Trucks with more than one ECU) 1)
A42796.0100 Hydraulic oil cooler
1) Optional equipment
A35093.0200 04
Komponentförteckning / List of Components
NUMBER CATEG SVENSKA ENGLISH
30 G Batteri Battery
32 A Kretskort elcentral Printed circuit board, Junction box
37 X Terminal stomanslutning Earthing terminal on chassis
39 X Terminal minusanslutning Terminal, negative terminal
51 F Säkringshållare 1-polig Fuse holder, 1-pole
52 F Säkringshållare 2-polig Fuse holder, 2-pole
56 F Säkringshållare 6-polig Fuse holder, 6-pole
58 F Säkringshållare 8-polig Fuse holder, 8-pole
59 F Säkringshållare 12-polig Fuse holder, 12-pole
62 F Batterihandske 2-polig Battery connector, 2-pole
64 F Batterihandske 4-polig Battery connector, 4-pole
72 X Stickuttag 2-polig Outlet, 2-pole
77 X Stickuttag 7-polig Outlet, 7-pole
78 X Stickuttag extra 7-polig Outlet, extra, 7-pole
100 S Strömställare ljus Switch, light
101 S Strömställare omk hel/halvljus Switch, main/dipped beam
102 S Strömställare dimljus Switch, fog light
103 S Strömställare fjärrljus Switch, distance light
104 S Strömställare lastljus Switch, mast lights
105 S Strömställare arbetsljus Switch, working lights
106 S Strömställare containerljus Switch, container light
107 S Strömställare park broms Switch, parking brake
108 S Strömställare centr smörjning Switch, central lubricator
109 S Strömställare varningsljus Switch, hazard lights
110 S Strömställare rot varningsljus Switch, rotating hazard beacon
111 S Strömställare fönsterhiss Switch, window regulator
112 S Strömställare kylanläggning (AC) Switch, air conditioner (AC)
113 S Strömställare styrning alt Switch, alternative steering
114 S Strömställare läsbelysning Switch, reading light
115 S Strömställare instr belysning Switch, instrument illumination
116 S Strömställare innerbelysning Switch, interior lighting
117 S Strömställare värme Switch, heating
118 S Strömställare fläktm värme Switch, heater fan
119 S Strömställare vindrutetorkare Switch, wiper
120 S Strömställare spolare Switch, washer
121 S Strömställare blackout Switch, blackout
122 S Strömställare nöd hydraulpump Switch, emergency hydraulic pump
123 S Strömställare backspegel Switch, observation mirror
124 S Strömställare kallstart Switch, cold start
125 S Strömställare avgasbroms Switch, exhaust brake
126 S Strömställare diff spärr/broms Switch, diff. Block
127 S Strömställare värmesystem diesel Switch, heating system diesel
128 S Strömställare kraftuttag sida Switch, power take off side
129 S Strömställare kraftuttag bak Switch, power take off rear
130 S Strömställare hög/lågväxel Switch, high/low gear
131 S Strömställare färdväljare fram Switch, gear selector forward
132 S Strömställare färdväljare bak Switch, gear selector rear
135 S Strömställare växelväljare Switch, gear shift
136 S Strömställare framhjuls styrning Switch, forward wheel steering
137 S Strömställare 4-hjuls styrning Switch, 4-wheel steering
138 S Strömställare crab styrning Switch, crab steering
139 S Strömställare defroster Switch, defroster
2006-05-11 Page 1 of 18
NUMBER CATEG SVENSKA ENGLISH
141 S Strömställare Stegbelysning Switch, Steplight
142 S Strömställare fot Switch, foot
143 S Strömställare sitsvärme Switch, seat heater
144 Q Batterifrånskiljare Battery disconnecting switch
145 S Strömställare AT-regulator Switch, AT-regulator
147 S Strömställare körvisare Switch, direction indicators
149 S Strömställare signalhorn Switch, horn
150 S Strömställare startlås/ellas Switch, main key switch
152 S Strömställare intervalltorkare Switch, intermittent wiper
156 S Strömställare kupevärmare Switch, cab heating
157 S Strömställare stoltilt Switch, seat tilt
158 S Strömställare dimbakljus Switch, rear fog light
159 S Strömställare extra fram/back väljare Switch, extra direction selector
160 S Strömställare komb fram/back Switch, combi-forward/reverse
161 S Strömställare komb signal, ljus hel/halv Switch, combi-horn, light main/dipped
spol,torkare m intervall körvisare beam, washer, wiper (intermittent),
direction indicator
162 S Strömställare komb signal ljus hel/halv, Switch, combi horn, light main/dipped
spol, torkare m 2 int, fram/bacK beam, washer, wiper w 2int.,
forward/revers
163 S Strömställare start på 2-an Switch, start 2nd gear
165 S Strömställare stolvärme Switch, seat heater
166 S Strömställare låsning vändskiva Switch, interlocking of turntable
167 S Strömställare luftfjädring Switch, pneumatic springing
168 S Strömställare låsn stol Switch, interlocking of seat
169 S Strömställare stolsvändning Switch, reversible seat
170 S Strömställare förångare (LPG) Switch, evaporator (LPG)
171 S Strömställare v-skiva upp/ner Switch, fifth wheel up/down
172 S Strömställare v-skiva fr/back Switch, fifth wheel forward/reverse
173 S Strömställare v-skiva skevning Switch, fifth wheel, levelling
174 S Strömställare,utskjut Switch, projecting
175 S Strömställare hyttlyft upp Switch, cab hoist up
176 S Strömställare hyttlyft ner Switch, cab hoist down
177 S Strömställare hyttskjutning Switch, cab movement
178 S Strömställare nollställning Switch, reset
179 S Strömställare Aut/man växling Switch Aut/man gearshifting
180 S Strömställare fyrhjulsdrift Switch, 4-WD
190 S Strömställare klimatanläggning Switch, air conditioner
191 S Strömställare recirkulation Switch, re-circulation
192 S Strömställare vattenavskiljare
195 S Strömställare joy-stick X Switch, joy-stick X
196 S Strömställare joy-stick X+Y Switch, joy-stick X+Y
197 S Strömställare längs/tvärskörning Switch, length/sideways driwing
198 S Strömställare flytläge skevning Switch, equalizing fifth wheel
199 S Strömställare option Switch, option
200 S Brytkontakt lampa park broms Contact, breaking,warning lamp,parking
brake
201 S Brytkontakt lampa färdbroms Contact, breaking, warning lamp, brake
202 S Brytkontakt lampa oljetryck motor Contact, breaking, warning lamp, oil
pressure engine
204 S Brytkontakt tryck ackumulator Contact, breaking, pressure
accumulatortank
205 S Brytkontakt innerbelysning Contact, breaking, interior lighting
2006-05-11 Page 2 of 18
NUMBER CATEG SVENSKA ENGLISH
206 S Brytkontakt handskfack belysning Contact, breaking, glove
207 S Slutkontakt diff spärr Contact, making, diff. interlock
208 S Slutkontakt lampa temperatur spolkrets Contact, making, warning lamp
bromsar temperature brake
214 S Slutkontakt överväxel Contact, making, over drive
215 S Slutkontakt temp motor Contact, making, temperature engine
216 S Slutkontakt bromsljus Contact, making, brake lights
217 S Slutkontakt backljus Contact, making, reversing light
218 S Slutkontakt AT-regulator Contact, making, AT-control
219 S Slutkontakt lampa luftfilter Contact, making, indicating light air filter
2006-05-11 Page 3 of 18
NUMBER CATEG SVENSKA ENGLISH
270 S Slutkontakt överlastskydd Contact, making, overload protection
299 S Slut/brytkontakt option Contact, making/braking option
300 K Relä hel/halvljus Relay, main/dipped beam
301 K Relä dimljus Relay, fog light
302 K Relä fjärrljus Relay, distance light
303 K Relä lastljus Relay, mast light
304 K Relä arbetsljus Relay, working light
305 K Relä backljus Relay, reversing light
306 K Relä helljus Relay, main beam
307 K Relä halvljus Relay, dipped beam
308 K Relä bromsljus Relay, brake light
309 K Relä parkeringsbroms Relay, parking light
310 K Relä körvisare vä Relay, direction indicator left
311 K Relä körvisare hö Relay, direction indicator right
312 K Relä startelement Relay,element preheater
313 K Relä vändbar förarstol Relay, rotating driver´s seat (VBFS)
314 K Relä parkeringsbroms Relay, parking brake
315 K Relä tändningslås Relay, ignition key
316 K Relä torkare Relay, wiper
317 K Relä strålkastartorkare Relay, roading lights wiper
318 K Relä AT-regulator Relay, AT-regulator
319 K Relä varningsblinkers Relay, hazard blinkers
320 K Relä elektrisk stopp Relay, electical stop
321 K Relä intervalltorkare Relay, intermittent wiper
322 K Relä kylvätskenivå Relay, coolant level
323 K Relä blinkers Relay, blinkers
324 K Relä rangespärr Relay, range interlock
325 K Relä blinkande bromsljus (back) Relay, flashing brake lights (reversing)
326 K Relä blinkande bromsljus (runt) Relay, flashing hazard brake lights
327 K Relä växel neutral Relay, gear neutral
328 K Relä växelskifte Relay, gear shift
329 K Relä växel hög/låg Relay, high/low gear
330 K Relä startspärr Relay, start interlock
331 K Relä drivning fram Relay, forward driving
332 K Relä drivning bak Relay, reversing driving
333 K Tidrelä förvärmning Time relay, automatically preheating
334 K Relä frikoppling/drivbrytning Relay, free wheel/drive disconnection
335 K Relä växelventil 1:a (diesel, gas) Relay, gear change valve 1-gear
(diesel,LPG)
336 K Relä växelventil 2:a (diesel, gas) Relay, gear change valve 2-gear
(diesel,LPG)
337 K Relä drivriktning motor Relay, motor drive direction
338 K Relä kylfläkt drivmotor Relay, cooling fan drive motor
339 K Relä kylfläkt elskåp Relay, cooling fan electrical box
340 K Tidrelä fördröjt tillslag Time relay, start delay
341 K Tidrelä fördröjt frånslag Time relay, stop delay
342 K Relä drivning 2/4 hjul Relay, switching 2/4 WD
343 K Relä dimbakljus Relay, fog light rear
344 K Relä momentförstärkare Relay, torque amplifier
345 K Relä låsning vändskiva Relay, interlocking of turntable
346 K Relä frikoppling stollåsning Relay, releasing of seat interlocking
347 K Relä stolvändning/ljussignal Relay, multifunction, seat rotation/light
signal
2006-05-11 Page 4 of 18
NUMBER CATEG SVENSKA ENGLISH
348 K Relä fläktmotor värmare Relay, fan heating
349 K Relä fartreglage Relay, speed control
350 K Relä pumpkontaktor/pumpkontroll Relay, pump contactor/pump control
351 K Relä hyttlyft upp Relay, cab hoist up
352 K Relä hyttlyft ner Relay, cab hoist down
353 K Relä säkerhetsslinga Relay, safety loop
354 K Relä styrsystem Relay, signal control system
355 K Relä sensorstyrning Relay, sensor control
356 K Skiftrelä längskörning/tvärskörning Shift relay, length/sideways driving
357 K Relä roterande varningsljus Relay, hazard beacon
358 K Relä komressor luft Relay, compressor air
359 K Relä Hydrauloljekylare Relay hydraulic oil cooler
360 K Relä startsolenoid Relay, starting solenoid
361 K Relä kompressor AC Relay, compressor air conditione
362 K Relä vattenventil AC Relay, water valve air conditioner
363 K Relä kondensor AC Relay, condenser air conditione
364 K Relä stolsbrytare Relay seat switch
365 K Relä fönsterhiss upp Relay, electrical screen elevator up
366 K Relä fönsterhiss ner Relay, electrical screen elevator down
401 E G-lampa vä bak Light bulb, roading light left hand front
401 E G-lampa hö bak Light bulb, roading light right hand rear
2006-05-11 Page 5 of 18
NUMBER CATEG SVENSKA ENGLISH
404 E G-lampa arbetsljus Light bulb, working light
405 E G-lampa backljus Light bulb, rear light
406 E G-lampa cont belysning vänster Container light left-hand
406 E G-lampa cont belysning höger Container light right-hand
408 E G-lampa park ljus vä fram Light bulb, parking light, left-hand
forward
408 E G-lampa park ljus hö fram Light bulb, parking light, right-hand
forward
410 H G-lampa broms ljus vä fram Light bulb, brake light, left-hand forward
410 H G-lampa broms ljus hö fram Light bulb, brake light, right-hand
forward
411 H G-lampa broms ljus vä bak Light bulb, brake light, left-hand rear
411 H G-lampa broms ljus hö bak Light bulb, brake light, right-hand rear
412 H G-lampa bak ljus vä bak Light bulb, rear light, left-hand rear
412 H G-lampa bak ljus hö bak Light bulb, rear light right-hand rear
413 H G-lampa bak ljus vä fram (VBFS) Light bulb, rear light, left-hand forward
(VBFS)
413 H G-lampa bak ljus hö fram (VBFS) Light bulb, rear light,right-hand forward
(VBFS)
416 H G-lampa sidomarkering vä fram Light bulb, side position light, left-hand
forward
416 H G-lampa sidomarkering vä bak Light bulb, side position light, left-hand
rear
417 H G-lampa sidomarkering hö fram Light bulb, side position light, right -hand
forward
417 H G-lampa sidomarkering hö bak Light bulb, side position light, right-hand
rear
420 H G-lampa positionsljus vänster Light bulb, position light, left-hand
421 H G-lampa positionsljus höger Light bulb, position light, right-hand
422 H G-lampa körvisare vä fram Light bulb, direction indicator left-hand
forward
423 H G-lampa körvisare hö fram Light bulb, direction indicator right-hand
forwrd
426 H G-lampa körvisare vä bak Light bulb, direction indicator left-hand
rear
427 H G-lampa körvisare hö bak Light bulb, direction indicator right-hand
rear
428 H G-lampa roterande varningsljus Light bulb, flashing beacon lamp
429 E G-lampa cigarettändare belysning Light bulb, cigarett lighter illumination
431 E G-lampa instrument belysning Light bulb, instrument illumination
432 E G-lampa handsfack belysning Light bulb, glove pocket light
433 E G-lampa instegs belysning Light bulb, step-in lighting
434 E G-lampa innerbelysning Light bulb, interior lighting
435 E G-lampa låsbelysning Light bulb, reading lighting
436 E G-lampa identifikationsljus Light bulb, identification light
437 E G-lampa identifikationsljus/takskylt Light bulb, identification light/roof sign
438 E G-lampa motorrumsbelysning Light bulb, engine compartment light
439 E Nummerskyltsbelysning Light license plate
440 E G-lampa värmereglage belysning Light bulb, heating control light
445 H G-lampa körvisare vä (extra) Light bulb, extra direction indicator left
446 H G-lampa körvisare hö (extra) Light bulb, extra direction indicator right
2006-05-11 Page 6 of 18
NUMBER CATEG SVENSKA ENGLISH
451 H G-lampa dimbakljus vänster Light bulb, fog light rear left
452 H G-lampa dimbakljus höger Light bulb, fog light rear right
453 H G-lampa bromsljus/körvisare vänster Light bulb, brake light/dir. indicator left-
hand
453 H G-lampa bromsljus/körvisare höger Light bulb, brake light/dir. indicator right-
hand
454 H G-lampa bromsljus blackout vänster Light bulb, brake light blackout left-hand
454 H G-lampa bromsljus blackout höger Light bulb, brake light blackout right-
hand
456 E G-lampa backljus blackout IR vänster Light bulb, rear light blackout IR left-
hand
456 E G-lampa backljus blackout IR höger Light bulb, rear light blackout IR right-
hand
457 H G-lampa positionsljus blackout vänster Light bulb, position light blackout left-
hand
457 H G-lampa positionsljus blackout höger Light bulb, position light blackout right-
hand
458 E G-lampa fram blackout vänster Light bulb, roading light blackout left-
hand
458 E G-lampa fram blackout höger Light bulb, roading light blackout right-
hand
459 E G-lampa fram blackout IR vänster Light bulb, roading light blackout IR left-
hand
459 E G-lampa fram blackout IR höger Light bulb, roading light blackout IR right-
hand
460 E G-lampa arb.belysning hytt blackout IR Light bulb, working light cab blackout IR
vä left
460 E G-lampa arb.belysning hytt blackout IR Light bulb, working light cab blackout IR
hö right
461 E G-lampa arb.bel. bom 20' blackout IR Light bulb, working light boom20' b.out
vä IR left
461 E G-lampa arb.bel. bom 20' blackout IR Light bulb, working light boom20' b.out
hö IR right
462 E G-lampa arb.bel. bom 40' blackout IR Light bulb, working light boom40' b.out
vä IR left
462 E G-lampa arb.bel. bom 40' blackout IR Light bulb, working light boom40' b.out
hö IR right
463 H G-lampa bak ljus vänster bak, blackout Light bulb, rear light left-hand rear,
blackout
463 H G-lampa bak ljus höger bak, blackout Light bulb, rear light right-hand rear,
blackout
464 E G-lampa cont belysning IR vänster Light bulb,Container light IR left-hand
464 E G-lampa cont belysning IR höger Light bulb,Container light IR right-hand
503 H Varn lampa oljetryck motor Warning lamp, oil pressure engine
504 H Kont lampa helljus Indicating lamp, main beam
2006-05-11 Page 7 of 18
NUMBER CATEG SVENSKA ENGLISH
505 H Varn lampa laddning Warning lamp, loading
506 H Varn lampa laddning (extra) Warning lamp, loading extra
507 H Varn lampa färdbroms Warning lamp, brake
508 H Varn lampa parkerings broms Warning lamp, parking brake
509 H Varn lampa nivå kylvatten Warning lamp, coolant level
510 H Kont lampa diff spärr Indicating lamp, diff. interlock
512 H Varn lampa temp momentförst Warning lamp, temperature converter
514 H Kont lampa överväxel Indicating lamp, overdrive clutch
519 H Kont lampa halvljus Indicating lamp, dipped lights
524 H Kont lampa luftfilter Indicating lamp, air filter
525 H Kont lampa UNIKAT Indicating lamp, UNIKAT
528 H Kont lampa förvärmning Indicating lamp, preheating
530 H Kont lampa framhjuls styrning Indicating lamp, forward wheel steering
560 H Varn lampa temp drivmotor el Warning lamp, temperature, drive motor
579 H Kontroll lampa klämläge bakre ben Indicator lamp, clamp position rear legs
2006-05-11 Page 8 of 18
NUMBER CATEG SVENSKA ENGLISH
580 H Kontroll lampa främre ben uppe Indicator lamp, front legs upper position
581 H Kontroll lampa främre ben nere Indicator lamp, front legs lower position
2006-05-11 Page 9 of 18
NUMBER CATEG SVENSKA ENGLISH
647 Y M-ventil stolstilt Solenoid valve, seat tilt
648 Y M-ventil luftfjädring Solenoid valve, pneumatic springing
649 B Termostat klimatannläggning Thermostat, air condition
650 M Torkarmotor fram
650 M Torkarmotor fram
650 M Torkarmotor fram
650 M Torkarmotor fram
651 M Vindrutespolarmotor Washer motor
652 M Strålkastarmotor Light motor
653 M Strålkastarspolarmotor Light washer motor
654 M Startmotor Starter motor
655 M Kylfläkt drivmotor (EC) Cooling fan, main motor (EC)
656 M Kylfläkt elskåp (EC) Cooling fan, electrical box (EC)
657 M Fläktmotor värme Heating fan
658 G Generator (extra) Alternator extra
659 G Generator utan laddregulator Alternator without loading regulator
660 G Generator med laddregulator Alternator with loading regulator
661 M Fönsterhissmotor Screenelevator motor
662 G Laddregulator Loading regulator
663 M Doseringspump klimatanläggning Dosage pump, air condition
664 M Cirk pump klimatanläggning Circulating pump, air condition
665 V Diod Diode
666 M Fläktmotor cirkulation Circulation fan
667 M Cirkulationspump värmesystem Circulation pump heating system
668 M Kylfläkt hydraulolja Cooling fan, hydraulic oil
669 E Värmare kupe/ motor diesel Heater compartment/engine diesel
670 M Kompressor Compressor
671 M Doseringspump diesel Dosage pump diesel
672 M Spjäll motor, ECC Draught valve motor, ECC
673 Y Vatten ventil motor, ECC Water valve motor, ECC
674 M Kylfläkt bromsolja Cooling fan, brake fluid
675 M Motor, Stolsvändning Motor, Seat rotation
676 Y Solenoid Broms stolsvändning Solenoid brake , seat rotation
685 A Reglerenhet termostat AC Control unit, termostat AC
690 B Fartreglage (EC) Speed control (EC)
693 M Pump centralsmörjning Pump, central lubrication
694 M Styrmotor Steering motor
695 M Drivmotor (EC) Drive motor (EC)
696 M Pumpaggregate nödstyrning Pump, emergency steering
697 B Elbroms Electric brake
698 M Pumpmotor (EC) Pump motor (EC)
699 Y M-ventil option Solenoid valve, option
700 P Hastighetsmätare Speedometer
701 P Mätare oljetemp v-låda Gear box oil temperature gauge
702 P Klocka Clock
703 P Varvtalsmätare Engine rev meter
704 P Tryckluftsmätare Air pressure gauge
705 P Mätare oljetryck v-låda Gear box oil pressure gauge
706 P Termometer temp kylvätska motor Temperature gauge, engine coolant
707 P Bränslemätare Fuel gauge
708 P Timräknare Hour meter
709 P Kapacitetsmätare batteri Capacity gauge, battery
710 P Tidur motor/kupevärmare Timer, engine- and cab heater
711 P Räknare, impuls Counter, impulse
2006-05-11 Page 10 of 18
NUMBER CATEG SVENSKA ENGLISH
712 P Mätare oljetryck motor Motor oil pressure gauge
714 P Mätare, temp. Hydraulolja Hydraulic fluidtemperature, guage
715 P Extra instrument allm Extra instrument, general
720 S Givare vändbar förarstol Transmitter, revolving driver´s seat
(VBFS)
740 D FleetManager kontrollenhet FleetManager control unit
741 U FleetManager batterifilter FleetManager battery filter
742 D FleetManager kortläsare FleetManager card device
743 D FleetManager accelerations givare FleetManager acceleration sensor
751 B Givare varvtal turbin Transmitter, speed turbin
752 B Givare varvtal inre växellåda Transmitter, speed internal gear chain
2006-05-11 Page 11 of 18
NUMBER CATEG SVENSKA ENGLISH
790 D Elektronisk kontrollenhet ECU, hytt Electronic Control Unit ECU, cab
791 D Elektronisk kontrollenhet aggregat Electronic Control Unit, attachment
792 D Elektronisk kontrollenhet styrning Electronic Control Unit, steering system
2006-05-11 Page 12 of 18
NUMBER CATEG SVENSKA ENGLISH
960 A Logik rev-spärr/aut-vxl Logic unit, reversing interlock/automatic
gear changing
961 A Motor/kupevärmare Engine- and cab heater
962 E Logik slitageind kol elmotor Logic indication of wear, brush electrical
motor
965 H Backvarnare Reversing alarm
1001 S Strömställare, TW Switch, TW
1002 S Strömställare, lossa TW Switch, unlocking of TW
1003 S Strömställare, låsa TW Switch, locking of TW
1004 S Strömställare, stopp vid 30'-35' Switch, stop at 30 -35¿
1005 S Strömställare, förbikoppling av Switch, overriding of the safety system
säkerhetssystem
1006 S Strömställare, fällning främre ben Switch, front legs down
1007 S Strömställare, fällning bakre ben Switch, rear legs down
1008 S Strömställare, klämma/lossa ben Switch, clamping/-releasing legs
1009 S Strömställare, Motor information Switch, Engine information
1010 S Srömställare, tilt av hytt Switch, tilt of cab
1011 S Strömställare IR ljus Switch IR light
1012 S Strömställare utskjut 20¿-40¿ Switch, Extension 20¿-40¿
1013 S Strömställare stödben Switch, Support jacks
1014 S Strömställare förbikoppling Switch, over ride rotation stop
rotationstopp
1015 S Strömställare förbikoppling höjdbeg/tp- Switch, over ride height limit/tp-limit
beg
1016
1017 S Strömställare diagnostik öka/minska Switch, diagnostics increase/decrease
2006-05-11 Page 13 of 18
NUMBER CATEG SVENSKA ENGLISH
1042 S Strömställare höjdjustering stol Switch, Seat height level
1043 S Strömställare längdjustering stol Switch, Seat for/aft adjustment
1044 S Strömställare Tankväljare Switch, Tankselector
1045 S Strömställare Avstängning backalarm Switch, Rev. Alarm on/off
2000 D Elektronisk kontrollenhet, Electronic control unit, propotional valve
proportionalventil
3001 K Relä rotation Relay, rotation
3002 K Relä tilt Relay, tilt
3003 K Relä sidoföring Relay, side shifting
3004 K Relä längdinställning Relay, length adjustment
3005 K Relä twist lock Relay, twist lock
3006 K Relä spridning Relay, spreading
3007 K Relä lyft/sänk Relay, lifting/lowering
3008 K Relä hydraulfunktion extra Relay, extra hydraulic function
3009 K Relä manöverbrytare hydr Relay, operating switch
3010 K Relä bromsljus vxl std/blackout Relay, brake light shift std/blackout
3011 K Relä backljus vxl std/blackout Relay, reversing light shift std/blackout
3012 K Relä arb.bel hytt vxl std/blackout Relay, working light cab, shift
std/blackout
3013 K Relä arb.bel. bom 20' vxl std/blackout Relay,working light boom20' shift
std/b.out
3014 K Relä arb.bel. bom 40' vxl std/blackout Relay,working light boom40' shift
std/b.out
3015 K Relä vxl bromsljus/blinkers vä Relay, shift brake light/direction
indicator left
3015 K Relä vxl bromsljus/blinkers hö Relay, shift brake light/direction
indicator right
3016 K Relä signalhorn relay, horn
3017 K Relä containerbelysning Relay, Container light
3018 K Relä containerbelysning IR Relay, Container light IR
3305 K Relä VBFS, backljus Relay, rotating driver´s seat, reversing
light
3306 K Relä VBFS, helljus Relay, rotating driver´s seat, main beam
3412 K Relä bak ljus Relay, rotating driver´s seat, rear light
3768 K Relä oljetryck hydraulik Relay, hydraulic pressure
2006-05-11 Page 14 of 18
NUMBER CATEG SVENSKA ENGLISH
3769 K Relä, blockering av hyttilt Relay, blocking of cab tilt
3770 K Relä anliggning Relay, alignment
3771 K Relä Krok Relay, Hook
3772 K Relä laddsignal (D+) Relay, charge signal (D+)
3773 K Relä 12V för minne radio Relay 12V for radio memory
3774 Relä kylfläkt olja Relay, cooling fan oil
3775
5000 H Kont lampa tryck lyfttång Indicating lamp, pressure lift tong
5001 H Varn lampa, Over Height ben uppe Warn. Lamp, Over Height leg upper pos
2006-05-11 Page 15 of 18
NUMBER CATEG SVENSKA ENGLISH
6032 Y M-ventil vänster bakhjul styrning vänster Solenoid valve, left rear wheel, steering
left
6033 Y M-ventil vänster bakhjul styrning höger Solenoid valve, left rear wheel, steering
right
6034 Y M-ventil skevning Solenoid valve, levelling
6035 Y M-ventil skevning höger Solenoid valve, levelling right
6036 Y M-ventil skevning vänster Solenoid valve, levelling left
6037 Y M-ventil kylfläkt Solenoid valve, Cooling fan
6038 Y M-ventil frikoppling koppling Solenoid valve, lockup clutch
6039 Y M-ventil öppna twistlock Solenoid valve, unlocked twist lock
6040 Y M-ventil låsa twistlock Solenoid valve, locked twist lock
6041 Y M-ventil nöd, twistlock Solenoid valve, emergency, twistlock
6042 Y M-ventil mellan bom Solenoid valve, middle boom
6043 Y Magnetventil, fällning torn (RTCH) Solenoid valve, boom lowering (RTCH)
2006-05-11 Page 16 of 18
NUMBER CATEG SVENSKA ENGLISH
6078 Y M-ventil,Avstängning Övre klämarm Solenoid valve, upper arm off
6079 Y M-Ventil, Sidoföring/Övre armar Solenoid valve, Sideshift/Upper arms
6080 Y M-ventil, aktivering hyttkörning Solenoid valve, activate sliding cab
7200 S Givare, axeltryck höger Sensor, axle pressure right
7201 S Givare, axeltryck vänster Sensor, axle pressure left
7202 S Givare, anliggning vänster fram Sensor, alignment left front
7202 S Givare, anliggning höger fram Sensor, alignment right front
7203 S Givare, anliggning vänster bak Sensor, alignment left rear
7203 S Givare, anliggning höger bak Sensor, alignment right rear
7204 S Givare, öppen vänster twistlock Sensor, unlocked twistlock left
7204 S Givare, öppen höger twistlock Sensor, unlocked twistlock right
7205 S Givare, låst vänster twistlock Sensor, locked twistlock left
7205 S Givare, låst höger twistlock Sensor, locked twistlock right
7206 S Givare, gaffel aggregat Sensor, fork attachment
7207 S Givare, 2WD/4WD Sensor, 2WD/4WD
7208 S Givare, hytt i körläge Sensor, Cab in drive position
7209 S Givare, oljefilter indikering Sensor, Oil filter indication
7210 S Givare, hytt i transportläge Sensor, Cab in transportation position
2006-05-11 Page 17 of 18
NUMBER CATEG SVENSKA ENGLISH
8081 R Potentiometer tiltvinkel Potentiometer tilt angle
8082 R Potentiometer fläkthastighet, ECC Potentiometer fan speed, ECC
8083 R Potentiometer temperatur, ECC Potentiometer temperature, ECC
8084 R Potentiometer spjäll, ECC Potentiometer draught valve, ECC
8085 R Potentiometer rotation Potentiometer rotation
8086 R Potentiometer sax Potentiometer extender
8087 R Potentiometer klämma Potentiometer clamp
8088 R Potentiometer skevning Potentiometer levelling
8089 R Potentiometer kroklåsning Potentiometer flaps
8090 V Laser, pappersaggretgat Lase, Pulp an Paper
8091
9000 M Motor höj/sänkbar stolspelare Motor rise/lower seat column
9001 D Åkerströms fjärrkontroll Åkerströms Remote Control
9002
9003 H Varningssignal aut. rörelse Warning alarm aut. movement
9888 A test
93774 K Relä hållkrets Relay, Holdcircuit
2006-05-11 Page 18 of 18
DCE80-100 TDCE01
04GB
Technical Handbook Contents Group 30 P. 1
Group 30
Volvo TWD731VE Cummins QSB5.9
See also Cummins Operation and Maintenance Manual
Specifications ..............................................................2 Specifications ........................................................... 36
Engine TWD731VE .....................................................3 Engine QSB 5.9 ....................................................... 37
Description .............................................................3 Description .......................................................... 37
Overview ...........................................................3 Overview........................................................ 37
Cooling system .................................................5 Cooling system .............................................. 39
Fuel system.......................................................7 Fuel system ................................................... 40
Lubrication system ..........................................10 Lubrication system......................................... 41
Combustion air system ...................................12 Combustion air system .................................. 42
Service .................................................................14 Service ................................................................ 44
Coolant quality ................................................14 Coolant quality............................................... 44
Lubrication oil quality ......................................14 Lubrication oil quality ..................................... 44
Draining the water from the fuel tank ..............14 Draining the water from the fuel tank............. 44
Inspection of air cleaner and changing insert .14 Inspection of air cleaner and changing insert 44
Changing the oil and oil filter ..........................15 Changing the oil and oil filter ........................ 45
Checking V-belt tension ..................................15 Checking V-belt tension................................. 45
Checking and adjusting the valve clearances.16 Checking and adjusting the valve clearances 46
Changing the fuel filter ....................................16 Changing the fuel filter................................... 47
Preventive maintenance on turbo-charger......17 Preventive maintenance on turbo-charger .... 48
Volvo TAD720VE
Specifications ............................................................19
Engine TWD1031VE/TWD1231VE ...........................20
Description ...........................................................20
Overview .........................................................20
Cooling system ...............................................22
Fuel system.....................................................24
Lubrication system ..........................................26
Combustion air system ...................................28
Service .................................................................30
Coolant quality ................................................30
Lubrication oil quality ......................................30
Draining the water from the fuel tank ..............30
Inspection of air cleaner and changing insert .30
Changing the oil and oil filter ..........................31
Checking V-belt tension ..................................31
Checking and adjusting the valve clearances.32
Changing the fuel filter ....................................33
Preventive maintenance on turbo-charger......34
DCE80-100 TDCE01
04GB
Technical Handbook Contents Group 30 P. 2
DCE80-100E Specifications TDCE01
04GB
Technical Handbook Group 30 P. 2
Coolant volume, l 41
Number of cylinders 6
Thermostat,
starts to open at °C 75
fully open at °C 88
Volume, l 19
DCE80-100E Engine TWD731VE TDCE01
04GB
Technical Handbook Description Group 30 P. 3
Overview
The TWD731VE engine is a 6-cylinder, inline, 4-stroke, low emis-
sion diesel engine with overhead valves. The engine is turbo-
charged, i.e. combustion air is supplied under pressure. As a
result, the quantity of fuel injected can be increased, which in-
creases the engine output. The turbocharger is driven by the ex-
haust gases and uses energy that would otherwise be lost.
In order to further increase the engine efficiency, the engine is
equipped with a water to air intercooler.
The engine is pressure-lubricated by an oil pump which delivers
oil to all lubrication points. A full-flow oil filter effectively cleans the
lubricating oil. The fuel system is protected against impurities by
replaceable filters. The engine has replaceable wet cylinder lin-
ers and two cylinder heads, each covering three cylinders.
The low emission engine has a new design of combustion cham-
ber, injection equipment and charge air cooler (intercooler) which
satisfy future emission requirements from both the USA (Califor-
nia) and Europe. The new engines represent a considerable im-
provement, not only in terms of exhaust gas emissions, but also
in terms of power and torque curves.
In addition, all Volvo engines comply with the R24 exhaust smoke
requirements.
DCE80-100E Engine TWD731VE TDCE01
04GB
Technical Handbook Description Group 30 P. 4
TWD731VE
1. Fan hub 1 2 3 4 25 5 6 7
2. Gear driven coolant pump
3. Lift eyelet
4. Twin fuel filters of throw-away type
5. Turbo-charger
6. Air cooled exhaust manifold
7. Lift eyelet
8. Coolant pipe, inlet
9. Pump coupling guard
10. Smoke limiter
11. Oil cooler
12. Fuel shut-off valve
13. Injection pump
14. Relay for inlet manifold heater
15. Cable iron
16. -
17. Coolant pipe, outlet
18. Flywheel housing SAE 2
(Adaptor for SAE3)
19. Starter motor
20. Crankcase ventilation
21. Full-flow filter of spin-on type
22. By-pass filter of spin-on type
23. Vibration damper
24. Automatic belt tensioner
25. Intercooler
8 9 10 11 12 13
18 14 15 17
KL 1645
19 20 21 22 23 24
Cooling system
The engine is liquid-cooled and equipped with a closed cooling
system consisting of the following main components:
z Coolant pump
z Radiator
z Expansion tank
z Thermostat
z Radiator fan
z Coolant passages
z Engine oil cooler
z Gearbox oil cooler
The coolant flows through a longitudinal passage into the engine
block. The opening into the cooling jacket of each cylinder is in-
dividually sized to ensure that each cylinder will be supplied with
the same rate of coolant flow.
The coolant flows in the separate return lines converge into a
common pipe in the thermostat housing. The coolant then flows
to the coolant pump and then into the engine and to the oil cooler.
When the engine has reached its normal operating temperature,
the thermostat will open the circuit to the radiator.
The piston-type thermostat is capable of passing a high coolant
flow rate at a minimum of pressure drop, thus contributing to fa-
vourable coolant circulation in the engine.
The coolant pump is fitted on the transmission cover and is driven
by a gear wheel from the transmission wheel.
The intercooler is connected to the cooling system by a pipe from
the coolant pump. The outlet from the intercooler is connected to
the oil cooler.
Fuel system
The fuel circulates in two circuits - the high-pressure circuit and
the low-pressure circuit. When the engine is started, the feed
pump draws fuel from the tank and delivers it at relatively low
pressure through fine filters up to the injection pump. This then
delivers fuel at high pressure to the injectors which supply the fuel
in atomised form to the engine combustion chambers.
Excess fuel which is circulated in the low-pressure system is also
cleaned in the fine filters and is returned through a spill valve
back to the tank.
The fuel system includes the following components:
Spill valve - which restricts the fuel feed pressure and provides
continuous venting of the fuel system. Excess fuel flows through
the injection pump before returning to the tank, thus cooling the
fuel in the fuel chamber of the pump, which contributes to more
uniform distribution of the fuel to the various cylinders.
.
See diagram below
Normal operation
1. Coarse filter
2. Fuel shut off valve
8 3. Feeder pump
4. Fine filter
5. Fuel tank
6. Check valve
7. IInjection pump
8. Overflow valve
Shut down
8
Fuel system, schematic
DCE80-100E Engine TWD731VE TDCE01
04GB
Technical Handbook Description Group 30 P. 8
Fuel filter
Injectors - each with a nozzle holder and a nozzle. When the fuel
pressure has risen to the preset value, the needle will lift and at-
omised fuel will be injected into the combustion chamber through
accurately calibrated holes in the nozzle sleeve.
Injector
DCE80-100E Engine TWD731VE TDCE01
04GB
Technical Handbook Description Group 30 P. 10
Lubricating system
The engine is pressure-lubricated, and the oil is supplied by a
pump in the oil sump. All lubricating oil flows through a full-flow
filter. One part of the oil flows through a by-pass filter for separa-
tion of extremely small particles.
The lubricating oil is cooled in a plate oil cooler by the engine
coolant.
The lubricating system includes the following main components:
Oil pump - of gear type, which draws oil through a coarse strain-
er that arrests larger particles. The pump delivers oil through the
lubricating oil filters to the various passages of the lubricating sys-
tem.
1. Oil pump
2. Reducing valve
3. By-pass valve
4. Oil under pressure to
the lubrication system
5. Piston cooling valve
6. Oil under pressure for
piston cooling
7. Oil cooler
8. By-pass filter
9. Oil filter
Lubricating system
DCE80-100E Engine TWD731VE TDCE01
04GB
Technical Handbook Description Group 30 P. 11
Reducing valve – located just before the filter. The valve will
open if the lubricating oil pressure is too high and will return
excess oil back to the sump.
Oil filter – of full-flow type, with a filter element of pleated filter
paper. To protect the engine against insufficient lubricating oil, a
by-pass valve is fitted in the oil filter bracket. The valve will open
if the lubricating oil pressure should rise above a certain pressure
due to clogging of the filter. When the valve is open, unfiltered oil
will flow to the engine. The filter is of disposable type and should
be scrapped after use.
By-pass filter – approx. 5% of the oil passes through the by-pass
filter with very low speed. The low speed allows very small parti-
cles to be separated. The filter insert is of the disposable type.
Crankcase ventilation – prevents pressurising of the crank-
case and collects fuel vapour, steam and other gaseous products
of combustion. Crankcase ventilation is provided by a pipe con-
nected to the crankcase inspection cover on the right-hand side
of the engine, between the starter motor and the oil filter.
Lubrication system
DCE80-100E Engine TWD731VE TDCE01
04GB
Technical Handbook Description Group 30 P. 12
Combustion system
Large quantities of air are necessary for burning the fuel supplied
to the engine. Free, unrestricted flow of fresh air and exhaust
gases is therefore essential to allow the engine to run efficiently.
Air cleaner
The intake air is cleaned in a two-stage air cleaner, the first stage
of which collects coarse particles by cyclone action, and the par-
ticles are then collected in a dust receiver. The second stage con-
sists of a filter element - the main filter element. A safety filter
element is located on the inside of the main element. The safety
element prevents the ingress of impurities into the engine while
the main element is being changed and if the main element
should sustain damage while the engine is running, e.g. due to
incorrect installation.
1. To engine
2. Air restriction indicator
3. Dust exit
Air cleaner
DCE80-100E Engine TWD731VE TDCE01
04GB
Technical Handbook Description Group 30 P. 13
Turbocharger
The turbocharger supplies more air to the combustion chambers
than the engine would be capable of drawing naturally. This ena-
bles the engine to burn more fuel which, in turn, increases the en-
gine output.
The turbocharger consists of a turbine wheel and a centrifugal
compressor impeller, each with a separate casing but mounted
on a common shaft.
The exhaust gases provide the energy necessary for driving the
turbine wheel which, in turn, drives the compressor.
The turbocharger is lubricated and cooled by the lubricating oil
from the engine.
Intercooler
In intercooling, the air that has been compressed and heated by
the turbo is cooled in an intercooler.
The intercooler increases the oxygen supply for combustion so
allowing the injected fuel to be burnt more effectively whilst re-
1. Exhaust gases to silencer
2. Air to the engine intercooler ducing guel consumption as well as the level of exhaust emis-
3. Exhaust gases from the engine sion.
4. Intake air Intercooling also reduces the thermal stressed on the engine, in-
creasing durability and reducing oil consumption
Turbo charger
Coolant quality
Throughout the year, the coolant should consist of a mixture of
60% of water and 40% of ethylene glycol. The coolant should be
changed and the cooling system should be flushed once a year.
Always add a corrosion inhibitor (Kalmar part No. 923.110.0003)
to the coolant, if the above mixture is not used in the cooling sys-
tem.
Valve clearance
Engine TD730VE/TWD731VE
Inlet 0.40 mm
Exhaust 0.55 mm
Volvo TAD720VE
DCE80-100E Specifications TDCE01
04GB
Technical Handbook Group 30 P. 19
Coolant volume, l 40
Number of cylinders 6
Thermostat,
starts to open at °C 87
fully open at °C 102
Volume, l 20
DCE80-100E Engine TAD720VE TDCE01
04GB
Technical Handbook Description Group 30 P. 20
Overview
The TAD720VE engine is a 6-cylinder, inline, 4-stroke, low emis-
sion diesel engine with overhead valves. The engine is turbo-
charged, i.e. combustion air is supplied under pressure. As a
result, the quantity of fuel injected can be increased, which in-
creases the engine output. The turbocharger is driven by the ex-
haust gases and uses energy that would otherwise be lost.
In order to further increase the engine efficiency, the engine is
equipped with a air-to air intercooler.
The engine is pressure-lubricated by an oil pump which delivers
oil to all lubrication points. A full-flow oil filter effectively cleans the
lubricating oil. An integrated, side mounted oil cooler is cooling
the entire oil flow.
The fuel system is protected against impurities by replaceable fil-
ters.
To maintain a controlled working temperature in cylinders and
combustion chambers, the engine is provided with piston cooling.
The low emission engine has a new design of combustion cham-
ber, injection equipment and charge air cooler (intercooler) which
satisfy future emission requirements from both the USA (Califor-
nia) and Europe. The new engines represent a considerable im-
provement, not only in terms of exhaust gas emissions, but also
in terms of power and torque curves.
In addition, all Volvo engines comply with the R24 exhaust smoke
requirements.
DCE80-100E Engine TAD720VE TDCE01
04GB
Technical Handbook Description Group 30 P. 21
1 2 3 4 5
28516 10 11 12 13
Cooling system
The engine is liquid-cooled and equipped with a closed cooling
1. Charge air cooler system consisting of the following main components:
air-to-air z Coolant pump
2. Radiator, z Radiator with integrated intercooler and gearbox oil cooler
air-coolant
3. Oil cooler gearbox, z Expansion tank
air-oil z Thermostat
z Radiator fan
z Coolant passages
z Engine oil cooler
Fuel system
The fuel circulates in two circuits - the high-pressure circuit and
the low-pressure circuit. When the engine is started, the feed
pump draws fuel from the tank and delivers it at relatively low
pressure through fine filters up to the injection pumps. These then
deliver fuel at high pressure to the injectors which supply the fuel
in atomised form to the engine combustion chambers.
Excess fuel which is circulated in the low-pressure system is also
cleaned in the fine filters and is returned through a spill valve
back to the tank.
The fuel system includes the following components:
Fuel tank - a separate unit located on the left-hand side of the
truck. The fuel volume in the tank can be read on a gauge on the
instrument panel.
Feed pump - of piston type, supplies fuel at a certain pressure
and flow rate to the injection pumps.
Spill valve - which restricts the fuel feed pressure and provides
continuous venting of the fuel system. The excessive fuel is flow-
ing through the injection pumps before it is fed through the return
line to the fuel cooler and thereafter to the fuel tank.
Fuel cooler
The fuel cooler is positioned on top of the charge air cooler. Its
purpose is to lower the return fuel temperature and thereby also
the temperature in the fuel tank. A lower fuel temperature gives
higher combustion efficiency.
1. Fuel tank
2. Fuel hose to fuel pump
3. Feed pump
4. Fuel hose to fuel filter
5. Fuel filter
6. Fuel hose to fuel channel
7. Injection pumps, 6 pcs
8. Fuel line to injectors
9. Injector
10. Leak oil line
11. Over flow valve, return fuel
12. Return to fuel tank
13. Fuel line
14. Pre filter with water separator
15. Manual feed pump
16. Fuel cooler, air/fuel
Bränslesystem, principschema
DCE80-100E Engine TAD720VE TDCE01
04GB
Technical Handbook Description Group 30 P. 25
Fuel pre filter - with washable filter insert and draining valve for
condensate .
1. Filter holder
6 2. Sealing between fil-
ter holder and filter
insert
3
3. Filter insert, washa-
ble
4. Draining valve for
codensate
5. Filter container
5 6. Sealing ring
4
Bränsleförfilter
1. Injection pump
2. Injector
Lubricating system
The engine is pressure-lubricated, and the oil is supplied by a
pump in the oil sump. All lubricating oil flows through a full-flow
filter. One part of the oil flows through a by-pass filter for separa-
tion of extremely small particles.
The lubricating oil is cooled in a plate oil cooler by the engine
coolant.
The lubricating system includes the following main components:
Oil pump - of rotor type, draws oil through a strainer which sep-
arates coarse particles. The oil is fed from the pressure side of
the pump through the oil filter and is then distributed to the differ-
ent ducts of the lubricating system
Lubricating system
DCE80-100E Engine TAD720VE TDCE01
04GB
Technical Handbook Description Group 30 P. 27
Reducing valve – located just before the filter. The valve will
open if the lubricating oil pressure is too high and will return
excess oil back to the sump.
Oil filter – of full-flow type, with a filter element of pleated filter
paper. To protect the engine against insufficient lubricating oil, a
by-pass valve is fitted in the oil filter bracket. The valve will open
if the lubricating oil pressure should rise above a certain pressure
due to clogging of the filter. When the valve is open, unfiltered oil
will flow to the engine. The filter is of disposable type and should
be scrapped after use.
By-pass filter – approx. 5% of the oil passes through the by-pass
filter with very low speed. The low speed allows very small parti-
cles to be separated. The filter insert is of the disposable type.
Crankcase ventilation - prevents over-pressure in the crank-
case and separates fuel mist, water mist and other gaseous com-
bustion products. The crankcase ventilation is controlled by a
pressure regulator which discharges excessive pressure from the
crankcase through a pipe connceted to the turbo-compressor
suction line. .
4
1
5
2 3
7 1. Adapter
8 2. Fuel filter
3. Oil pump
4. Suction line
5. Suction strainer
6. Oil sump
7. Pressure regulator, crank-
case vantilation
8. Connecting pipe
Lubricating system
DCE80-100E Engine TAD720VE TDCE01
04GB
Technical Handbook Description Group 30 P. 28
Air system
Large quantities of air are necessary for burning the fuel supplied
to the engine. Free, unrestricted flow of fresh air and exhaust
gases is therefore essential to allow the engine to run efficiently.
Air cleaner
The intake air is cleaned in a two-stage air cleaner, the first stage
of which collects coarse particles by cyclone action, and the par-
ticles are then collected in a dust receiver. The second stage con-
sists of a filter element - the main filter element. A safety filter
element is located on the inside of the main element. The safety
element prevents the ingress of impurities into the engine while
the main element is being changed and if the main element
should sustain damage while the engine is running, e.g. due to
incorrect installation.
1
6 5 4
2
3 7 8
1. Air filter
2. Filter indikator
3. To engine
4. Dust exit
5. Prefilter (optional)
6. Charge air cooler
7. To turbo compressor
8. To charge air cooler
Air system
DCE80-100E Engine TAD720VE TDCE01
04GB
Technical Handbook Description Group 30 P. 29
Turbocharger
The turbocharger supplies more air to the combustion chambers
than the engine would be capable of drawing naturally. This ena-
bles the engine to burn more fuel which, in turn, increases the en-
gine output.
The turbocharger consists of a turbine wheel and a centrifugal
compressor impeller, each with a separate casing but mounted
on a common shaft.
The exhaust gases provide the energy necessary for driving the
3 turbine wheel which, in turn, drives the compressor.
The turbocharger is lubricated and cooled by the lubricating oil
1 from the engine.
Intercooler
4 In intercooling, the air that has been compressed and heated by
the turbo is cooled in an intercooler.
The intercooler increases the oxygen supply for combustion so
allowing the injected fuel to be burnt more effectively whilst re-
2 ducing guel consumption as well as the level of exhaust emis-
sion.
Intercooling also reduces the thermal stressed on the engine, in-
1. Exhaust gases to silencer creasing durability and reducing oil consumption
2. Air to the engine intercooler
The intercooler is of the air-to-air type and integrated with the ra-
3. Exhaust gases from the engine
4. Intake air diator and the gearbox oil cooler.
Inlet manifold heater
Before the air is admitted into the combustion chamber, it flows across
an electrically heated starting element. This has a high rating of 3 kW
Turbocharger and heats the intake air sufficiently for the engine to start at low ambi-
ent temperatures. The starter heater is automatically controlled
through separate electronic circuits.
1. Intercooler air-to-air
2. Radiator, air-coolant
3. Oil cooler gearbox, air-oil
4. Inlet manifold heater
KL1633
3
Radiator
DCE80-100E Engine TAD720VE TDCE01
04GB
Technical Handbook Service Group 30 P. 30
Coolant quality
Throughout the year, the coolant should consist of a mixture of
60% of water and 40% of ethylene glycol. The coolant should be
changed and the cooling system should be flushed once a year.
Always add a corrosion inhibitor (Kalmar part No. 923.110.0003)
to the coolant, if the above mixture is not used in the cooling sys-
tem.
KL1637
Change the filter element as follows:
1. The engine must not be running.
2. Clean the outside of the air cleaner.
3. Remove the cover.
4. Release and carefully remove the main filter element. Do not
1. Main filter element remove the safety filter element. Fit a new main filter ele-
2. Safety filter element ment. Carefully check that it is not damaged. Note on the
safety filter element when the main element was replaced.
5. Reset the filter indicator.
6. Change the safety filter element:
– after the main filter element has been changed five times
– at least every other year
– if the indicator shows red after the main element has been
changed
– if the engine has been run with the main element dam-
aged
The safety filter element must not be cleaned and reused. The
engine must not be run without the main filter element. If the main
element must be cleaned and refitted in emergency cases, don’t
use compressed air to clean it, since the filter element may be
damaged. Before refitting it, carefully check that the main filter el-
ement is undamaged.
DCE80-100E Engine TAD720VE TDCE01
04GB
Technical Handbook Service Group 30 P. 31
1. Remove the drain plug from the underside of the sump and
drain the oil. Fit the plug with a new gasket.
2. Clean the area round the filters and place a tray under the
filters to collect any spillage.
3. Remove and discard the filter canisters, which are of dispos-
able type.
4. Pour clean oil into the centre of the new filters, wait until the
oil has seeped through the filter paper and top up until the fil-
ters are full.
5. Lubricate the canister seals with oil.
6. Fit the new filters and tighten them - by hand only.
7. Fill the engine with oil (see Group 90, Lubrication chart).
8. Run the engine and check that no oil leaks at thefilters.
9. Stop the engine and check the oil level after a few minutes.
Top up as necessary to the MAX level on the dipstick.
N.B. To avoid serious damage to the engine, use only genu-
ine Kalmar filters.
Coolant-fuel pump
1. Loosen the screws 1 and 2
2. Push the fuel pump in the direction of the arrow 3 (A or B) until
the correct belt tension is achieved.
3. Tighten the screws 1 and 2
Alternator
1. Loosen the screws 1 and 2.
2. Move the alternator until the right belt tension is achieved.
3. Tighten the screws 1 and 2
Crankshaft position 1
2. Rotate the crankshaft until the valves of cylinder 1 overlap.
See picture for valve adjustment
N.B. Overlaping of valves means
The exhaust valve is just closing and the inlet valve is just open-
Crank- ing. Neither of the push-rods can be turned around in this posi-
shaft tion. Cylinder 1 is closest to the flywheel.
position 3. Adjust the valve clearances according to the black markings
1 in the adjoining picture.
Inlet valve: 0,30 mm
Exhaust valve: 0,50 mm
4. Tighten the lock nut with 20±2 Nm. Re-check the clearance
Crank- with a feeler guge.
shaft 5. Make a chalk mark on every adjusted valve.
position Crankshaft position 2
2 6. Rotate the crank shaft another turn (360°)
7. Adjust the valve clearances according to the black markings
in the adjoining picture.
9. Fit the valve cover and tighten the cover screws with 9+/-1
Nm.
DCE80-100E Engine TAD720VE TDCE01
04GB
Technical Handbook Service Group 30 P. 33
28516-1
1. Filter head
2. Sealing between filter head and filter
container
3. Filter insert, washable
4. Draining valve for condensate
5. Filter container
DCE80-100E Engine TAD720VE TDCE01
04GB
Technical Handbook Service Group 30 P. 34
Coolant volume, l 33
Number of cylinders 6
Thermostat,
starts to open at °C 84
fully open at °C 91
Volume, l 16
DCE80-100E Engine Cummins QSB 5.9 TDCE01
04GB
Technical Handbook Description Group 30 P. 37
Overview
The Cummins QSB 5.9 engine is a 6-cylinder, inline, 4-stroke,
low emission diesel engine with overhead valves. It has an Elec-
tronic Controlled Fuel system.
The engine is turbocharged, i.e. combustion air is supplied under
pressure. As a result, the quantity of fuel injected can be in-
creased, which increases the engine output. The turbocharger is
driven by the exhaust gases and uses energy that would other-
wise be lost.
In order to further increase the engine efficiency, the engine is
equipped with a water-to air intercooler.
The engine is pressure-lubricated by an oil pump which delivers
oil to all lubrication points. A full-flow oil filter effectively cleans the
lubricating oil. An integrated, oil cooler is cooling the entire oil
flow.
The fuel system is protected against impurities by replaceable fil-
ters.
To maintain a controlled working temperature in cylinders and
combustion chambers, the engine is provided with piston cooling.
The low emission engine satisfies future emission requirements
from both the USA (California) and Europe. The new engines
represent a considerable improvement, not only in terms of ex-
haust gas emissions, but also in terms of power and torque
curves.
In addition, all engines comply with the R24 exhaust smoke re-
quirements.
15 12 13
7 14 10 5
6 3 2 11 4 9 1 16
KL1699
Cooling system
The engine is liquid-cooled and equipped with a closed cooling
system consisting of the following main components:
z Coolant pump
z Radiator with integrated intercooler and gearbox oil cooler
z Expansion tank
z Thermostat
z Radiator fan
z Coolant passages
z Engine oil cooler
A. To engine
B. To engine
C. To radiator
KL1701
DCE80-100E Engine Cummins QSB 5.9 TDCE01
04GB
Technical Handbook Description Group 30 P. 40
Fuel system
The fuel circulates in two circuits - the high-pressure circuit and
the low-pressure circuit. When the engine is started, the feed
pump draws fuel from the tank and delivers it at relatively low
pressure through fine filters up to the injection pump. This then
delivers fuel at high pressure to the injection pump which sup-
plies the fuel in atomised form to the engine combustion cham-
bers.
Excess fuel which is circulated in the low-pressure system is also
cleaned in the fine filters and is returned through a spill valve
back to the tank.
The fuel system includes the following components:
Fuel tank - a separate unit located on the left-hand side of the
forklift. The fuel volume in the tank can be read on a gauge on the
instrument panel.
Feed pump - supplies fuel at a certain pressure and flow rate to
the injection pumps.
Spill valve - which restricts the fuel feed pressure and provides
continuous venting of the fuel system. The excessive fuel is flow-
ing through the injection pump before it is fed through the return
line to the fuel tank.
Fuel pre-filter - with drain valve for condensate
Injection pump and injectors
DCE80-100E Engine Cummins QSB 5.9 TDCE01
04GB
Technical Handbook Description Group 30 P. 41
Lubricating system
The engine is pressure-lubricated, and the oil is supplied by a
gear pump. All lubricating oil flows through a full-flow filter.
The lubricating oil is cooled in a plate oil cooler by the engine
coolant.
The lubricating system includes the following main components:
Oil pump - of rotor type, draws oil from the sump. The oil is fed
from the pressure side of the pump through the oil filter and is
then distributed to the different ducts of the lubricating system
Reducing valve – located just before the filter. The valve will
open if the lubricating oil pressure is too high and will return ex-
cess oil back to the sump.
Air system
Large quantities of air are necessary for burning the fuel supplied
to the engine. Free, unrestricted flow of fresh air and exhaust
gases is therefore essential to allow the engine to run efficiently.
Air cleaner
The intake air is cleaned in a two-stage air cleaner, the first stage
of which collects coarse particles by cyclone action, and the par-
ticles are then collected in a dust receiver. The second stage con-
sists of a filter element - the main filter element. A safety filter
element is located on the inside of the main element. The safety
element prevents the ingress of impurities into the engine while
the main element is being changed and if the main element
should sustain damage while the engine is running, e.g. due to
incorrect installation.
6 5 1 2 3 4 7 8
KL1698
1. Air filter
2. Air restriction indicator
3. To engine
4. Dust exit
5. Prefilter (optional)
6. Charge air coooler
7. To turbo-compressor
8. To Charge air coooler
Air system
DCE80-100E Engine Cummins QSB 5.9 TDCE01
04GB
Technical Handbook Description Group 30 P. 43
Turbocharger
The turbocharger supplies more air to the combustion chambers
2 than the engine would be capable of drawing naturally. This ena-
5 bles the engine to burn more fuel which, in turn, increases the en-
gine output.
4 The turbocharger consists of a turbine wheel and a centrifugal
compressor impeller, each with a separate casing but mounted
on a common shaft.
The exhaust gases provide the energy necessary for driving the
turbine wheel which, in turn, drives the compressor.
The turbocharger is lubricated and cooled by the lubricating oil
1 3 from the engine.
Intercooler
In intercooling, the air that has been compressed and heated by
the turbo is cooled in an intercooler.
3 The intercooler increases the oxygen supply for combustion so
allowing the injected fuel to be burnt more effectively whilst re-
1. Exhaust gases to the silencer ducing fuel consumption as well as the level of exhaust emission.
2. Compressed air to the intercooler Intercooling also reduces the thermal stressed on the engine, in-
3. Exhaust gases from the engine creasing durability and reducing oil consumption
4. Air from the filter
5. Intake air from the intercooler The intercooler is of the water-to-air type and integrated with the
radiator and the gearbox oil cooler.
Inlet manifold heater
Before the air is admitted into the combustion chamber, it flows across
an electrically heated starting element. This heats the intake air suffi-
Turbocharger ciently for the engine to start at low ambient temperatures. The starter
heater is automatically controlled through an electronic control
module.
DCE80-100E Engine Cummins QSB 5.9 TDCE01
04GB
Technical Handbook Service Group 30 P. 44
Coolant quality
Throughout the year, the coolant should consist of a mixture of
60% of water and 40% of ethylene glycol. The coolant should be
changed and the cooling system should be flushed once a year.
Always add a corrosion inhibitor (Kalmar part No. 923.110.0003)
to the coolant, if the above mixture is not used in the cooling sys-
tem.
KL1637
Change the filter element as follows:
1. The engine must not be running.
2. Clean the outside of the air cleaner.
3. Remove the cover.
4. Release and carefully remove the main filter element. Do not
1. Main filter element remove the safety filter element. Fit a new main filter ele-
2. Safety filter element ment. Carefully check that it is not damaged. Note on the
safety filter element when the main element was replaced.
5. Reset the filter indicator.
6. Change the safety filter element:
– after the main filter element has been changed five times
– at least every other year
– if the indicator shows red after the main element has been
changed
– if the engine has been run with the main element dam-
aged
The safety filter element must not be cleaned and reused. The
engine must not be run without the main filter element. If the main
element must be cleaned and refitted in emergency cases, don’t
use compressed air to clean it, since the filter element may be
damaged. Before refitting it, carefully check that the main filter el-
ement is undamaged.
DCE80-100E Engine Cummins QSB 5.9 TDCE01
04GB
Technical Handbook Service Group 30 P. 45
1. Remove the drain plug from the underside of the sump and
drain the oil. Fit the plug with a new gasket.
2. Clean the area round the filter and place a tray under the fil-
ters to collect any spillage.
3. Remove and discard the filter canister, which are of dispos-
able type.
4. Pour clean oil into the centre of the new filter, wait until the
oil has seeped through the filter paper and top up until the fil-
ter are full.
5. Lubricate the canister seal with oil.
6. Fit the new filter and tighten it - by hand only.
7. Fill the engine with oil (see Group 90, Lubrication chart).
8. Run the engine and check that no oil leaks at the filter.
9. Stop the engine and check the oil level after a few minutes.
Top up as necessary to the MAX level on the dipstick.
N.B. To avoid serious damage to the engine, use only genu-
ine Kalmar filter.
Crankshaft position 1
2. Using the barring tool, rotate the crankshaft to algin the top
dead center marks on the gear cover and fuel pump gear
With the engine in this position, valve clearanc can be
checked on following valves: 1I, 1E, 2I, 3E, 4I and 5E.
3. Adjust the valve clearances according to the nominal specifi-
cations.
Inlet valve: 0,25 mm
Exhaust valve: 0,50 mm
4. Tighten the lock nut with 24 Nm. Re-check the clearance with
a feeler guge.
5. Make a chalk mark on every adjusted valve.
Crankshaft position 2
6. Rotate the crank shaft another turn (360°)
7. Adjust the valve clearances according for valves 2E, 3I, 4E,
5I, 6I and 6E.
8. Inspect the valve cover gasket for cracks or other damage. Fit
the gasket, replace with a new gasket if needed..
9. Fit the valve cover and tighten the cover screws with 12 Nm.
DCE80-100E Engine Cummins QSB 5.9 TDCE01
04GB
Technical Handbook Service Group 30 P. 47
Group 40
Transmission, drive axle,
brakes
Specification .............................................................................. 2
Transmission ............................................................................. 3
Description ........................................................................... 3
Torque converter ............................................................. 3
Gearbox........................................................................... 4
Oil circuit.......................................................................... 5
Service ................................................................................. 6
Oil level check ................................................................. 6
Changing gearbox oil and filter........................................ 6
Checking pressures in the Clark gearbox ....................... 7
Drive axle................................................................................... 7
Description ........................................................................... 7
The differential................................................................. 7
Hub reduction .................................................................. 9
Service brake .................................................................. 9
Parking brake system.................................................... 10
Releasing the parking brake by mechanical means...... 10
Service ............................................................................... 11
Changing the drive-axle oil............................................ 11
Installation of disc brake................................................ 12
Installing the brake on the axle...................................... 14
Installing of hub reduction ............................................. 16
Dismantling the planet gear........................................... 18
Inspection of dismountable rims .................. see group 60
Safety test when changes tyres ................... see group 60
DCE80-100E Specifications TDCE01
04GB
Technical Handbook Group 40 P. 2
Number of gears 3F – 3R
Drive axle
Tightening torque
Torque converter
The most important components of the torque converter are the
pump impeller, turbine wheel and stator. Engine power is trans-
IMPORTANT! mitted mechanically to the pump impeller. The impeller starts an
The machine must not be run at stall oil flow in the torque converter, and is comparable to a centrifugal
speed longer than 30 seconds at a time. pump which draws oil into the centre and discharges it at the pe-
The torque converter will otherwise riphery.
overheat, causing damage to the seals The turbin wheel is located opposite the pump impeller and is
and thus necessitating expensive over-
haul. connected to the torque converter output shaft. The oil enters the
turbine wheel at the periphery and is discharged at the centre.
The stator is located between the pump impeller and the turbine
wheel, at their inside diameter. The function of the stator is to
guide the flow of oil from the inside diameter of the turbine wheel
back to the inside diameter of the pump impeller in the best pos-
sible way.
Torque conversion takes place in the oil circuit of the torque con-
verter. When the load on the truck increases, i.e. when the torque
required increases, the turbine wheel slows down in relation to
the pump impeller, and the oil flowing through the stator then in-
creases the torque.
The output torque gradually increases as the speed of the output
shaft decreases and is a maximum when the output shaft and
thus also the turbine wheel are stationary, i.e. are stalled, see
Technical data.
Gearbox
The gearbox is of constant-mesh type. Gear-changing is carried
out by clutch plates for the various gears being hydraulically ac-
tuated.
The valve body mounted on the side of the gearbox includes
spool valves which guide the oil flow to the various clutches. The
spools are activated in turn by solenoid valves. These are activat-
ed electrically by the gear selector in the cab. As an optional extra
an automatic gear changing system is available. See Group 20.
The gearbox has three ratios in each direction and is also provid-
ed with disengagement, which is actuated by the brake pedal and
comes into operation at a certain brake pressure.
DCE80-100E Transmission TDCE01
04GB
Technical Handbook Description Group 40 P. 4
1
5
2
3 6
KEY
1ST
2ND
3RD
1. Turbine wheel
2. Pump impeller
3. Stator
4. Torque converter
5. Oil filter
6. Oil pump
7. Clutch disc
Clark 32000
Gear Activated
solenoids
F3 F
F2 F, 2
F1 F, 1, 2
N3 -
N2 2
N1 1, 2
R3 R
3 R2 R, 2
2 R1 R, 1, 2
R
The gearbox valve housing,
Clark 32000
DCE80-100E Transmission TDCE01
04GB
Technical Handbook Description Group 40 P. 6
Oil circuit
The function of the oil is:
– to transmit the engine output to the gearbox. The torque
converter can multiply the engine torque by up to three
times, but at the expense of the speed rotation.
– to apply the clutches in the gearbox.
– to dissipate the heat from the torque converter.
– to lubricate the gearbox and the torque converter.
– to transport any solid particles to the filter.
When the engine is running, the oil pump draws oil through a suc-
tion strainer from the gearbox sump and then delivers it through
a fine filter to a pressure regulating valve.
The regulating valve delivers oil at the right pressure to the gear-
box valve body, which actuates the clutch plates for Forward/Re-
verse and 1st/2nd/3rd/4th. The clutches use only a small
proportion of oil delivered by the pump. The remainder is fed
through the torque converter circuit to the oil cooler, and returns
to the gearbox for lubrication.
1. Converter
2. Oil cooler
3. Converter safety valve
4. Lube manifold
5. -
6. Suction from transmission sump
7. Filter
8. Clutch pressure regulating valve
9. Solenoid valve, Forw
10. Solenoid valve, Rev
11. Clutches
12. -
13. Pump
Oil circuit
DCE80-100E Transmission TDCE01
04GB
Technical Handbook Service Group 40 P. 7
Clark 32000
Clark 32000
IMPORTANT!
In the event of gearbox damage, always replace the oil
cooler – the damage may have been caused by the oil
cooler being faulty.
1
1. Suction strainer
2. Drain plug
Checking pressures
Converter outlet pressure: (”Converter out”)
1. The pressure should always be checked when the oil is at
the normal working temperature of 80–95°C, the gearbox is
IMPORTANT! in neutral and the engine is running at 2000 r/min.
When the check is carried out under
identical conditions, the pressure 2. The pressure should be above 1.7 bar, although the pres-
must not vary by more than 0.4 bar sure must not exceed 4.9 bar when the engine is running at
between the various clutches. top speed.
N.B.
In case of incorrect clutch pressure, first check the gearbox
pressure sensor, see picture.
If more details concerning individual test outlets are re-
quired, contact KALMAR INDUSTRIES SERVICE
Clark 32000
1 2
1. Oil cooler
2. Clutch pressure sensor
3. Measurement point “converter outlet”
DCE80-100E Drive axle Kessler TDCE01
04GB
Technical Handbook Description Group 40 P. 9
The differential
The differential is a simple, hypoid type of taper gear drive, which
means that the centre line of the pinion is offset in relation to the
centre line of the crown wheel. The pinion is firmly journalled in
two robust bearings.
1. Parking brake
2. Hub reduction
3. Wet disc brakes
4. Differential
5. Differential gear
6. Crown wheel
7. Differential spider
8. Pinion
9. Bearing
DCE80-100E Drive axle Kessler TDCE01
04GB
Technical Handbook Description Group 40 P. 10
Hub reduction
The hub reduction consists of a cylindrical planetary gear in each
hub. The planetray gear comprises a sun gear, 4 planet gears,
and a ring gear that surrounds the planet gears. When the drive
axle, and thereby the sun gear, rotates, the rotational movement
is transmitted to the planet gears. Because the ring gear is fixed
firmly in the planetary gear carrier/hub, the planet gears move to-
wards the ring gear. The hub follows this movement and the ro-
tation is transmitted to the wheels. The gear ratio is determined
by the number of teeth in the various gears.
1. Planet gear
2. Ring gear carrier
3. Ring gear
4. Sun gear
5. Wheel hub/Planetary gear carrier
DCE80-100E Drive axle Kessler TDCE01
04GB
Technical Handbook Description Group 40 P. 11
Service brake
The service brake consists of oil-cooled discs that are alternately
fixed to and rotating with the hub. Hydrualic pressure is applied
to activate a piston in each hub, the discs are then pressed to-
gether, and the wheels are braked. The resulting heat caused by
friction is led away by the cooling oil circulating in the system. Oil
from the truck’s hydraulic system is used as cooling oil, and this
gives a high cooling capacity.
1. Brake piston
2. Brake discs
DCE80-100E Drive axle Kessler TDCE01
04GB
Technical Handbook Description Group 40 P. 12
Parking brake
The parking brake is a disc brake that acts on the drive axle’s in-
5 13 11 7 put shaft and is applied by means of a powerful spring in a spring
brake cylinder. The brake is released by a hydraulic pressure of
at least 10 MPA from the parking brake valve in the driver’s cab.
When the hydraulic pressure is too low, the parking brake is ap-
plied automatically. To be able to move the truck in that situation,
the parking brake must be released by mechanical means, see
below.
When the parking brake is applied, the parking brake valve evac-
uates hydraulic pressure from the brake cylinder. The cup spring
then expands and its force is transmitted through the piston (6) to
the adjusting screw (7) and then on to the thrust shaft (8), which
in turn transmits the braking force to the brake linings. The posi-
tion of the adjusting screw (7) determines the location of the
spring’s working range in relation to the brake linings.
Adjustment
1 4 3 8 10 6 9 12 1. Apply a pressure to the brake cylinder by putting the parking
brake valve in the ‘OFF’ position.
2 2. Unscrew the lid 12.
3. Loosen the lock nut 11 and screw in the adjusting screw 7
clockwise until the brake pads are close up to the brake disc.
4. Unscrew the adjusting screw 7 counter-clockwise until the
space between the pads and the disc is approx. 1 mm. Note
that the spring in the brake cylinder has a very small working
space.
5. Fix the adusting screw with a hexagonal socket head wrench
and lock the lock-nut 11.
6. Fasten the lid 12 by hand.
Releasing the parking brake by mechanical means
If the acumulator pressure drops below a certain level, the park-
ing brake is applied automatically.
WARNING!
1. Housing
2. Bolt If the truck needs to be moved:
3. Brake lining 1. Unscrew the lid 12.
4. Brake lining 2. Loosen the lock-nut 11 and unscrew the adjusting screw 7
5. Plate spring package counter-clockwise until the brake pads have loosened from
6. Piston the brake disc.
7. Adjusting screw
3. Fasten the lid 12 by hand.
8. Thrust shaft
9. Ring
10. Space for hydraulic oil on relea-
sing the parking brake
11. Lock-nut WARNING!
12. Lid
13. Lock ring If the parking brake has been mechanically disengaged it
must always be reset in order to restore the
parking brake function.
WARNING!
The parking brake contains a powerful, Dismantling of the parking brake cylinder
plate spring package under heavy tension. Normally, there is no need of dismantling the parking brake cylin-
If the cylinder is dismantled in an unproper der. However, if for some reason it needs dismantling, follow the
way, parts may become loose and fly out instructions below:
thus causing serious damage. 1. Unscrew the lid 12.
DANGER TO LIFE!
Always check that the spring package 2. Loosen the lock-nut 11 and unscrew the adjusting screw 7
tension is released before dismantling the counter-clockwise until the brake pads have loosened from
brake cylinder, see Dismantling of the the brake disc.
brake cylinder. 3. Remove the lock ring 13, thereafter the integral parts can be
removed.
DCE80-100E Drive axle Kessler TDCE01
04GB
Technical Handbook Service Group 40 P. 13
1 IMPORTANT!
To assure that the wheel ends of planetary axles with a
common wheel end/housing bowl oil level are initially
lubricated, fill each wheel end directly with oil before ve-
hicle is put back into operation. DO NOT FILL THE AXLE
THROUGH THE DRIVE UNIT OR DIFFERENTIAL HOUS-
ING ONLY.
1. Drive the truck forward until the oil drain plug on one of the
wheel hub reductions is at its lowest point of travel.
2. Remove the oil plug and drain the oil and refit the plug.
3. Repeat the procedure on the other wheel.
4. Remove the drain plug from the underside of the differential
and drain the oil. Refit and tighten the drain plug.
3 5. Drive the truck forward so that the mark at the filling hole hub
2 is horisontal.
6. Fill the hub reduction with oil and refit the plug.
4 Volume: See specifications.
7. Repeat for next wheel.
8. Remove the level plug from the differential and fill the differ-
ential with oil. Refit an tighten the leel plug.
Volume: See specifications.
9. Check oil level an refill as necessary.
3
2
1. Differential
2. Drain
3. Fill up/level
4. Hub
5. Fit the piston (3) so that the part with the largest diameter is
facing downwards. Then place the seals in the groove using
special installation tapers, one large and one small, free from
any scratches, and not lubricated.
Slide ring 6. Fit the O-ring in the lower groove using an installation taper,
and push it over the large slide ring with the thinner edge fac-
ing upwards.
7. Fit the O-ring in the upper groove using the other installation
taper, and push it over the small slide ring with the thinner
edge facing downwards.
Installation taper
1. Brake
2. Brake housing
3. Piston
4. Inner disc
5. Outer disc
6. O-ring
7. Screw
8. Plug
9. Seal
10. Seal
11. Connection piece
12. Breather
13. Sealing ring
14. Sealing ring
15. Spring
16. Screw
17. Seal
18. Plug
19. O-ring
20. Face seal
21. Washer
23. Screw
25. Tube
DCE80-100E Drive axle Kessler TDCE01
04GB
Technical Handbook Service Group 40 P. 16
8. Align and centre the discs (4) using the tool. Apply pressure
to the discs with the help of the brake’s hydraulic system.
9. Fit the wheel hub onto the axle’s splines. Release the brake
pressure.
10. Insert the taper roller bearing (8) against the stop in the ring
gear carrier (7). Fit the ring gear (6) onto the ring gear carrier
and secure with screws.
11. Fit the ring gear carrier and ring gear onto the axle’s splines.
Turn the ring gear carrier so that the oil flow hole faces down-
wards. Then push the carrier and ring gear into the hub.
12. Screw the bearing nuts on and tighten them so that the hub
can be turned by hand only with some difficulty. Then un-
screw the bearing nut 1/8 of a turn and secure the nut. Check
the resistance to roll – in the case of new bearings it should
be about 11–17 Nm.
DCE80-100E Drive axle Kessler TDCE01
04GB
Technical Handbook Service Group 40 P. 18
2. Push the sun gear (2) onto the spindle and secure with the
lock ring (3). Push the input shaft into the hub so that the
spacer washer, sun gear, and lock ring are closely flush with
each other.
DCE80-100E Drive axle Kessler TDCE01
04GB
Technical Handbook Service Group 40 P. 19
3. Push the needle bearing into the planet gear (4). The outer
cardboard sleeve in which the bearings are packed will then
Outer cardboard Inner slide off.
sleeve cardboard
sleeve
4. Fit the planet gears (4) onto the planetary gear carrier (5)
– with needle bearing, inner cardboard sleeve, and spacer
washer – as follows:
– Apply a sealant to the hole in the planetary gear carrier for
the planet gear shafts (6). (Fit an O-ring where applica-
ble).
– Press the planet gear shaft (6) in from the inside, and
make sure the security holes in the shaft and planetary
gear carrier are opposite each other. When the planet
gear shafts are pressed in, the inner cardboard sleeves in
the bearings will be pressed outwards.
Sealant 5. Secure the planet gears with the safety pin (7).
Cardboard sleeve
6. Install the planetary gear carrier onto the hub.
7. Screw the adjusting screw (8) in against the stop on the in-
sert shaft and then unscrew the adjusting screw 45–90°.
This corresponds to an axial clearance of between 0.2 and
0.4 mm for the insert shaft.
8. Secure the adjusting screw with the lock nut. Hold the adjust-
ing screw firmly to prevent it from turning with the lock nut.
DCE80-100E Drive axle Kessler TDCE01
04GB
Technical Handbook Service Group 40 P. 20
Group 60
Steering axle
Specifications ............................................................................ 2
Steering axle.............................................................................. 3
Description ........................................................................... 3
Service ................................................................................. 4
Replacement of steering cylinder .................................... 4
Replacement of steered wheel bearings ......................... 4
Replacement of knuckle pin bearings ............................. 6
Inspection of dismountable rims...................................... 8
Safety test when changing tyres ................................... 10
DCE80-100E Specifications TDCE01
04GB
Technical Handbook Group 60 P. 2
1)
Steered wheel bearings should be tightened during simulta-
neous rotation of the wheels. This makes the bearing rollers
set correctly.
Note that a jacked-up wheel gives a certain resistance when
rotated.
After tightening of steered wheel bearings, the truck should
be run for some 100 meters. After that the bearing nut should
be tightened again to 500 Nm. Then the bearing nut must not
be loosened.
DCE80-100E Steering axle TDCE01
04GB
Technical Handbook Description Group 60 P. 3
1 2
3
4
7
5
6
1. Rubber element
2. Steering cylinder
3. Upper bearing
4. Link lever
5. Lower bearing
6. Knuckle pin
7. Steering cradle
Steered axle
DCE80-100E Steering axle TDCE01
04GB
Technical Handbook Service Group 60 P. 4
Assembly
1. Pack the outer races of the bearings with grease and press
them into the hub.
Note that these are taper bearings. Fit the inner races so that
the larger inside diameter faces outwards.
A round plate should be made for each bearing size for
pressing in the races. A heavy hammer can then be used to
hammer the plate for driving in the race. Don’t hammer the
bearings directly since they may not enter straight and may
become jammed in the housing.
2. Press a new seal into the hub. Use a suitable round plate for
this purpose. Tapping the seal itself with a hammer will dam-
age it.
3. Clean the spacer and pack it with grease.
DCE80-100E Steering axle TDCE01
04GB
Technical Handbook Service Group 60 P. 5
1. Rubber element
2. Steering cylinder
3. Spindle
4. Locking screw
5. Lubricating nipple
6. Upper bearing
7. Wiper
8. Knuckle pin
9. Protective ring
10. Sealing ring
11. Lower bearing
12. Locking ring
13. Shims
14. Bearing holder
15. Steering cradle
16. Lubricating nipple
17. Spindle
18. Link lever
19. Sealing ring
20. Inner bearing
21. Wheel screw
22. Hub
23. Outer bearing
24. Washer
25. Bearing nut
26. Locking washer
27. Locknut
28. Protective cover
29. Wheel nut
4. Tap the inner race of the inner bearing onto the wheel axle,
using a suitable tube. Pack the inner race with grease.
5. Lift the hub onto the axle, fit the inner race of the outer bear-
ing position and pack it with grease.
6. Fit the plain washer and bearing nut with the flat surface fac-
ing inwards. Tighten the bearing to 500 Nm during simulta-
neous rotation of the wheel to make the bearing rollers set
correctly.
After tightening of the steered wheel bearings, the truck
should be run for some 100 meters. After that the bearing
nuts should be retightened to 500 Nm. Thereafter, the bear-
ing nut must not be loosened.
7. Fit the tab washer and locknut. Grease the tab washer to
prevent damage by the nut. Tighten the locknut and lock
both the bearing nut and the locknut with the tabs.
8. Pack the outer bearing with grease, pack the bearing cover
with grease and fit it into position. Top up with grease through
the grease nipple.
Replacement of knuckle pin bearings
Dismantling
To replace the knuckle pin bearings, the wheel bearings
must also be removed.
1. To replace the knuckle pin bearings, the wheel bearings
must also be removed.
2. Remove the wheel nuts from the steered wheel and remove
the wheel.
N.B. A trolley with a rest for holding the wheel securely will
be needed for handling purposes.
Assembly
1. Tap the outer race of the upper bearing into the steering cra-
dle from below, using a piece of tube.
2. Fit the screw back into the drift holes. Seal with sealing com-
pound.
3. Attach the following parts to the knuckle pin: upper bearing’s
inner race and sealing, lower bearings nut, tab washer, spac-
er and inner race.
4. Mount the knuckle pin.
5. Tap the outer race of the lower bearing into the steering cra-
dle.
6. Tighten the cover and sealing upon the lower bearing.
7. Check that the knuckle pin rotates smoothly with a maximum
play of 0.25 mm. if not, adjust with the bearing nut and lock
with the tab washer. Make sure that the sealing ring align
tightly.
8. Lubricate the bearings by means of the lubricators.
9. Mount the link lever.
10. Mount the steering wheel bearing. See Replacement of
steering wheel bearing, Assembly.
Miscellaneous
The steered wheel alignment is not adjustable. If the link levers
1 have been deformed so that the wheel alignment has been dis-
turbed, the link levers must be replaced.
NOTE. The orientation of the link levers must be correct, since
they will otherwise be damaged by the wheels when the steering
movements are large. The correct orientation of the levers is
shown in the figure.
1. Link lever
2. Knuckle pin
DCE80-100E Steering axle TDCE01
04GB
Technical Handbook Service Group 60 P. 8
7
2
3
5 4
1. Lock ring
2. Beadseat
3. 45° surface on the beadseat or loose flange
4. Lock ring groove
5. Rim bead
6. O-ring
7. Support ring
Inspection procedure
1. Dismantle the rim according to the standard procedures, see
also Safety instructions when working with tyres, group 00.
2. Carefully clean the outside of the rim beadrim bead by using
a wire brush.
3. The wear of the lock ring on the rim bead outside diameter
can produce a mark A. The mark is located between the
ends of the lock ring, see picture.
4. Measure the depth of the wear at this point using av straight
A edge and feeler gauge. If the wear exceeds 0,5 mm, the
wheel, the lock ring, and the beadseat or loose flange must
be discarded and replaced with new.
5. If a wear mark is not possible to find, measure the circumfer-
ence of the rim bead using a measuring tape.
6. Calculate the diameter D = Circumference/3.14
7. If the diameter is below the minimum specified, the wheel,
the lock ring and the beadseat or loose flange must be dis-
carded.
Information on the minimum diameter of your rim bead can
be recieved from Kalmar LMV.
D
D
B
B
B
DCE80-100E Steering axle TDCE01
04GB
Technical Handbook Service Group 60 P. 10
Magnetic examination
1. Dismantle the loose componentes of the wheel
A
2. Clean area A on the the wheel totally for paint residue by us-
ing shot blasting.
3. Carry out magnetic examination by using e.g.:
Equipment: Yoke Tiede
Technique: a. Electricity AC
b. Contrast paint
Test medium: a. Wet
b. colour (E-G- Tiede ferrolux)
4. If no cracks are indicated in the magnetic examination, the
test is completed and the wheel approved. In case cracks
are indicated, carry out the penetrance test.
Penetrance test
1. Clean area B with cleaning fluid, part.no. 923626.0668.
2. Spray penetrance on the cleaned area and let the sprayed
area dry for approximately 10 minutes
Penetrance: Part no. 923626.0669
3. Clean off the penetrance by using cleaning fluid (Part.no.
B 923626.0668). All excessive penetrance should be re-
moved.
4. Wipe off the cleaning fluid with a cloth, the remaining pene-
trance must evaporate.
5. Spray developer on the area B.
Developer: Part.no 923626.0670
6. Let the sprayed area dry for 1-2 hours.
7. Inspect the lock ring groove visually.
8. If the marked area B shows no linear or dot shaped cracks
the wheel is approved.
9. If the marked area B shows linear or dot shaped cracks, the
wheel must be rejected.
Group 70
Hydraulic system
Specifications ........................................................................... 2
Main hydraulics.......................................................................... 3
Description ........................................................................... 3
General survey ............................................................... 3
Standad hydraulic system ............................................... 3
Supply ........................................................................ 4
Hydraulic servo .......................................................... 5
Electric servo ............................................................. 6
Hydraulic system with separate side-lift hydraulics ......... 7
Supply ........................................................................ 9
Electric servo ........................................................... 10
Lifting ............................................................................ 11
Lowering brake valve .................................................... 12
Tilting............................................................................. 13
Attachment supply......................................................... 14
Service ............................................................................... 15
Checking the hydraulic hoses ...................................... 15
Breather filter................................................................. 15
Changing the hydraulic fluid .......................................... 10
Mounting of fittings on hydraulic hoses ........................ 15
Checking the pressures and settings, standard system 16
Checking of pressure and setting, system with
separate side-lift hydraulics........................................... 17
Steering system 19
Description ......................................................................... 19
Steering valve ............................................................... 20
Brake system........................................................................... 22
Description ......................................................................... 22
Brake system WDB-system........................................... 22
Oil cooler ....................................................................... 24
Service ............................................................................... 25
Checking the brake system ........................................... 25
Parking brake .......................................................................... 26
Description ......................................................................... 26
Hydraulic pumps...................................................................... 27
Description ......................................................................... 27
Service ............................................................................... 30
Accumulator............................................................................. 32
Description ......................................................................... 32
High pressure filter .................................................................. 33
Description, service ............................................................ 33
Main valve ............................................................................... 34
Description ......................................................................... 34
Service ............................................................................... 37
Hydraulic cylinders .................................................................. 38
Service ............................................................................... 38
5 6 7
General survey .
There are two different hydraulic systems
z Standard with hydraulic servo Diagram A06195.0600
or with el-servo Hydraulic diagram A06195.0500
z System with separate side-lift hydraulics Diagram 44866.0100
Standard hydraulic system, Diagram A06195.0600
The hydraulic system consists of the following sub-systems.
z Main hydraulics with the following functions:
– Lifting
– Tilting
– Sideshift
– Length adjustment
– Twist-locks
z Steering system
z Driving brake system for wet brakes with:
– Brake circuit
– Cooling circuit
z Parking brake system
The hydraulic system is configured around two single hydraulic
pumps which are driven by take-offs on the torque converter.
All of the essential valve functions are concentrated to a valve
block that is directly connected to the main valve.
One of the pumps powers the lifting function. Some of the return
fluid is by-passed to the cooling circuit of the driving brake system
to dissipate heat and is then lead to the reservoir.
20a
20b 23
50
23
31
43
16
45
46
44
5 6
1 2 3
51
5 4
z Steering system
32
33
12
13 14 25 25
21
33 a b c d
b h e
15 f
24 e g
a c
9 d
20
10
8
7
6 6 6 6
32
2 31
3 1 4 5
30 KL1830
20a 53
20b
23 12
13
18
19
16
23
18a 17
51
23
31
54
2
51
1
Lifting
The lifting cylinders are supplied from a separate section in the
main valve. The lifting speed is determined by the position of the
lift control lever. The flow of fluid from the hydraulic pumps can be
changed by altering the engine speed, which thus provides an
additional means of controlling the lifting speed.
During lowering, the fork carriage and the effect of the load force
the fluid from the lifting cylinders into the reservoir. A lowering
brake valve in the supply line to each lifting cylinder determines
the lowering speed and also limits the flow of fluid in the event of
hose failure. The lowering brake valves are of pressure-compen-
sated type and therefore permit only a certain predetermined
flow, thus ensuring a constant lowering speed, regardless of the
actual load.
Some of the return fluid is by-passed to the valve block and from
there to the cooling circuit of the driving brake.
The lifting cylinders are filled with fluid on the piston side to pre-
vent corrosion. This fluid is not pressurized and is fed back to the
reservoir in step with movement of the piston. Any leakage is also
drained to the reservoir through these lines.
A
16 12
KL1834
27
26
26
27
31
2 3
1. Control plunger
2. Throttling slot
3. Orifice plate in the throttling position
4. Orifice plate in the open position
Tilting
The two tilting cylinders enable the mast to be tilted 3° forward
and 3° to the rear. (Optional 2°/3° or 3°/6°)
In each of the return lines is a valve which provides counter-pres-
sure to avoid inadvertent forward tilt, which would otherwise oc-
cur in unrestricted flow in the forward tilt mode.
KL1834
29
28
17
28
Tilting function
DCE80-100E Main hydraulics TDCE01
04GB
Technical Handbook Description Group 70 P. 14
Attachment supply
One section in the main valve for each of the functions sideshift,
length adjustment 20’-40’ and twist-locks feeds the attachment
cylinders.
18
19
44
Attachment supply
DCE80-100E Main hydraulics TDCE01
04GB
Technical Handbook Service Group 70 P. 15
WARNING!
Take great care during all work on the hydraulic system. Avoid
being close to pressurized hydraulic components and hoses.
Observe strict cleanliness, since the presence of foreign matter
42 can easily result in a valve seizing or in other operational distur-
bances.
Breather filter
The hydraulic reservoir is fitted with a breather filter which pre-
vents airborne impurities from entering the reservoir. Change the
filter as specified in the lubrication chart. The filter is of the spin-
on type. To change the filter, remove the old filter element, dis-
card it and screw on a new element.
3
1. Hose IMPORTANT!
2. Sleeve The above procedure may be used only on 1" and smaller
3. Adapter diameter hoses. In addition, it may only be used on hoses
4. Measure the hose shown in the spare parts catalogue, with the sleeve and
length like this: adapter separated from the hose.
4 Hoses shown in the spare parts catalogue as complete
units with the end connections fitted must be ordered as
complete units in accordance with the catalogue.
DCE80-100E Main hydraulics TDCE01
04GB
Technical Handbook Service Group 70 P. 16
Pressure side-lift
17.Connect the manometer to test outlet B on the sid-lift sidlyf-
tens main valve.
F
E 21.Connect the manometer to test outlet E on the cab tilt control
valve.
22.Run the cab tilt to its end position and read the manometer.
The pressure should be 70±5 bar.
Adjust if necessary on adjusting screw F
The adjusting screw must be sealed after making any adjust-
ment.
DCE80-100E Steering system TDCE01
04GB
Technical Handbook Description Group 70 P. 19
Steering system
The steering system comprises the steering valve and the steer-
ing cylinder. The system is supplied with fluid from the valve block
adjoining the main valve. An adjustable pressure limiting valve
provides the control pressure.
An LS signal from the steering valve actuates the priority valve in
the valve block to always ensure sufficient supply to the steering
system.
KL1834
25
24
37
31
Steering system
DCE80-100E Steering system TDCE01
04GB
Technical Handbook Description Group 70 P. 20
1. Steering valve
2. Valve block
3. Double shock valve with suction valve
4. Check valve
Steering valve
DCE80-100E Brake system TDCE01
04GB
Technical Handbook Description Group 70 P. 22
Brakesystem – WDB-system
The foot brake system is known as the wet disc brake system, in
which each hub is equipped with a multiple-disc assembly.
The disc assembly comprises stationary discs arranged alter-
nately with a number of rotating discs. The disc assembly is com-
pressed by hydraulic pressure to provided effective braking
action. The assembly is submerged in a hydraulic fluid bath to
dissipate the heat generated by braking. A separate cooling cir-
cuit is provided to cool the hydraulic fluid.
The advantages of the wet disc brake system include the fact that
no adjustment is needed, and that no fading or wear occur. More-
over, the enclosed oil bath keeps the system completely free from
water and impurities.
The brake system comprises three separate hydraulic circuits,
i.e. the foot-brake circuit, the cooling circuit and the parking brake cir-
cuit.
All circuits are supplied with hydraulic fluid under pressure from
the same hydraulic pump. The brake circuits are supplied from
four hydraulic accumulators and the cooling circuit from the valve
block. Excess fluid from the main hydraulic system is passed on
to the cooling circuit.
32
40
39
38
21
34
52
41 22
42
35
31
49
33
36a 36b
31
31. Tank
33. Service brake cylinder
36a. Brake cooling curcuit supply
36b. Brake cooling curcuit, return
49. Oil cooler
Oil cooler
A cooler with electrically powered fan is used for evacuation of
heat which is generated in the hydraulic system, mainly when
braking frequently.
49
Parking brake
The parking brake consists of a disc brake with a brake cylinder
on the drive axle input shaft. The brake is applied by a heavy
spring in the brake cylinder.
The parking brake can also be used as an EMERGENCY
BRAKE. During emergency braking, the brake linings are sub-
jected to very heavy wear. The linings should therefore be
checked after any emergency braking operations and changed if
necessary.
1 The parking brake is released by hydraulic pressure being sup-
plied to the cylinder to counteract the spring force.
The brake is controlled electrically by means of a switch adjacent
to the hydraulic levers. The switch is connected to a solenoid
valve which controls the brake cylinder hydraulic supply and re-
KL1739 turn.
When the parking brake is applied, the flow of fluid to the brake
cylinder is interrupted and the fluid in the cylinder is discharged
to the tank. The brake is then applied by the spring in the cylinder.
KL1756
Parking brake
DCE80-100E Hydraulpumpar TDCE01
04GB
Technical Handbook Description Group 70 P. 27
Hydraulpumpar
Pump 18 +19 is a kombination pump where the inner section is a
variable piston pump 18 of constant pressure type and the outer
section is a fixed vane pump19.
Pump 20 a+b is a double fixed vane pump.
Variable axialkolvpump, see illustration next page
Pumps 18 that feeds the side-lift attachment is a variable axial
piston pump with five pistons placed in a cylinder rotor. The
stroke length of the pistons is determined by the position of an an-
gled pressure plate. The pistons are secured in slip-shoes that
rotate against the pressure plate. The stroke volume area and the
1. Replaceable cartridge assembly, includes cam area within the pistons are filled with hydraulic fluid during the
ring, rotor, vanes, pins and sideplates suction phase. During the pressure phase, the hydraulic fluid is
2. Front and rear sideplates fed into the pressure lines via a valve plate. A hole in the head of
3. Ball bearing each of the pistons allows hydraulic fluid to be forced out and
4. Front sideplate, is fixed axially by discharge gives a balanced counter pressure from the pressure plate as
pressure to reduce internal leakage well as a film of fluid that lubricates the surfaces and inhibits wear.
5. –
Fixed vanepump, see illustrations below and next page
6. –
7. Vane, is urged outward at suction ramp by pin These pumps consist of a pump casing and a pump unit, and are
force and centrifugal force of simple design. A rotor in the pump unit comprises a number of
8. Cam ring vanes fitted in radial slots. The rotor is driven by a shaft and ro-
9. Suction ramp where unloaded ramp moves out tates in a cam ring. The rotor vanes follow the profile of the cam
10. Pressure ramp with working vanes which press ring, and each vane performs two cycles – each comprising one
likquid towards the discharge port suction stroke and one delivery stroke – per revolution. The fluid
11. Working vane on inor arc seals discharge pres- flows radially through the pump unit.
sure from the suction port The vanes are forced outwards towards the cam ring by centrifu-
12. Discharge ramp where unloaded vane gal force and by thrust pins which are subjected to the same pres-
moves in sure as the pump delivery pressure. This ensures that the vanes
13. Pin cavity is at a steady pressure slightly higher will alwqys be in contact with the cam profile. An fluid film pre-
than at discharge port vents the vanes from coming into metallic contact with the cam
14. Lub side holes, lubricate the sideplate surfaces profile. In the same way, an fluid film prevents metallic contact
15. Pressure pins, force the vanes outward with the side plates.
16. Vanes Since the vanes, ports and pressures are balanced diametrically,
the net load on the rotor is a pure torque caused by the pumping
action. Sturdy shaft bearings carry the forces caused by the
pump drive.
16
8
7 10
15 9
13 14
14
12
11
Fast vingpump, dubbel
DCE80-100E Hydraulpumpar TDCE01
04GB
Technical Handbook Description Group 70 P. 28
22
23
21
20 19 18
17
15 16 2 8
7 10
13
9
14
14
12
11
4
1. Pump body
2. Outlet
3. Driving gear
4. Gap between teeth
5. Inlet
6. Driven gear
1. Splines
2. Driving gear
3. Pump body
4. Pressure plate
5. Driven gear
Hydraulic pump
DCE80-100E Hydraulpump TDCE01
04GB
Technical Handbook Service Group 70 P. 30
9. Pump body
The pump pressure presses the pump gears towards the walls of
the body on the low-pressure side, and since the shafts and bear-
ings wear, the pump gears will rub against the body.
If the pump body has worn more than 0.13 mm, it must be
changed. Check by placing a straight edge inside the pump body,
and use feeler gauges to measure the wear.
13. Dowels
If a dowel or its hole has been damaged, the dowel and possibly
the section containing the dowel must be changed.
If more than reasonable force is needed for pressing in a dowel,
this may be due to inadequately deburred or fouled parts, defor-
mation of the dowel or poor fit of the dowel hole.
15. Seals
Replace all rubber and plastic seals, including all O-rings, seals
at the pressure plates, shaft seals and gaskets.
DCE80-100E Accumulator TDCE01
04GB
Technical Handbook Description Group 70 P. 32
Accumulator
The hydraulic system is connected to membrane type accu-mu-
lators which are pre-charged with nitrogen at a pressure of 100
bar. The membrane is forced upward causing the pressure of the
nitrogen to increase as the accumulator becomes charged with
hydraulic fluid. When the hydraulic system requires power from
the accumulator, the membrane presses fluid back into the sys-
tem.
The accumulator is fitted at the top with a connection for testing
the pressure of the nitrogen, and for refilling nitrogen with the aid
of special filling equipment.
The pressurized fluid from the accumulator is utilized to power
the driving brake and parking brake systems, and to supply the
42 pressure reducing valve of the servo hydraulics.
An evacuating valve is fitted between the accumulator and reser-
voir. This valve shall be used to relieve the accumulator of pres-
sure before carrying out any work on the hydraulic system.
WARNING!
1. Connection
2. Seal
3. Membrane
4. Safety plate
5. Steel bottle
Accumulator
DCE80-100E High pressure filter TDCE01
04GB
Technical Handbook Description, service Group 70 P. 33
IMPORTANT!
The high pressure filter cartridge must always be changed
when a pump has been exchanged.
The filter must always be fitted with its top arrow pointing
in the flow direction.
DCE80-100E Main valve TDCE01
04GB
Technical Handbook Description Group 70 P. 34
Valve block
Several hydraulic functions are concentrated to a valve block
which is connected directly to the main valve. .
KL1834
1. Main valve
2. Valve block
DCE80-100E Main valve TDCE01
04GB
Technical Handbook Description Group 70 P. 35
Main valve
The main valve, in its standard version, is actuated via a hydraulic
servo.
The valve consists of the following main components:
z Inlet section
z Control sections, corresponding to the number of functions
ofthe truck
z Combined control and outlet section
The main valve has a separate inlet and outlet section, and also
a separate main pressure limiting valve for the lifting section. The
entire flow from one of the hydraulic pumps goes to this section.
If the lifting function is not actuated, the flow from this pump goes
instead to the cooling circuit of the driving brake or to the reser-
voir.
In addition, any flow from the other pump that is not utilized in the
remaining main hydraulic functions is also supplied. When the lift-
ing function is not actuated, the return flow from this pump goes
1. Inlet section with main pressure limiting to the cooling circuit of the driving brake.
valve
2. Control section
3. Control/outlet section
4. Inlet/control/outlet section, LIFT
5. Valve block
Main valve
1. Inlet section
1a. Main pressure limiting valve
2. Control section
2a. Control spool
3. Control/outlet section
Main valve
DCE80-100E Main valve TDCE01
04GB
Technical Handbook Description Group 70 P. 36
Control valve
2
3
Main valve
The main valve is precision made and must be treated with great
care so that its performance will not be impaired. The following
rules apply whenever service work is carried out.
1. Protect the valve against moisture and dirt. Take particular
care to avoid dirt entering the connection ports. Also protect
the ports from damage by scratching or bruising. Keep un-
connected ports plugged with plastic plugs or the like.
2. Protect the ends of the spools and covers against blows. The
valve spool may be bent if handled carelessly, and it will then
immediately jam on being used.
DCE80-100E Hydraulic cylinders TDCE01
04GB
Technical Handbook Service Group 70 P. 38
– All piston seals are of the same design and consist of five
components, i.e. a centre sealing ring, two backing rings
and two guide rings.
– Dismantle the piston seal and start by fitting the sealing
ring onto the piston, and then fit the backing rings and the
guide rings. All of this must be done by hand.
1. Sealing ring
2. Backing rings
3. Guide rings
4. Piston head
DCE80-100E Hydraulic cylinders TDCE01
04GB
Technical Handbook Service Group 70 P. 39
KL1006
Lifting cylinder
1. The cylinder head is fitted ito the cylinder tube with 12
screws and nuts
1. Pin
2. Lowering brake valve
3. Piston rod guide
4. Cylinder tube
5. Piston rod tube
6. Spacer
7. Nut
8. Washer
9. O-ring
10. Screw
11. Cylinder head
12. Piston rod guide
13. Seal
14. Wiper
15. Air venting valve
Lift cylinder
DCE80-100E Hydraulic cylinders TDCE01
04GB
Technical Handbook Service Group 70 P. 41
Steering cylinder
1. The steering cylinder has a double-acting piston, with the
piston seal in the centre.
2. ,On each side of the cylinder tube there is a cyllinder head
which is fixed to the cylinder tube by means of a locking ring.
At disassembly, the O-ring could be jammed in the locking
ring groove thus making it very difficult to pull the piston out
of the cylinder tube. For instructions on disassembly, see
Supplement Technical Handbook, Hydraulic cylinders, publ
No. 920937-9279.
Tilt cylinder
1. The tilt cylinder is fitted with a clevis mounts. The piston rod
clevis is threaded onto the piston rod and is secured by lock-
nuts and locking plate.
2. The cylinder head is threaded and attached to the cylinder
tube with flange screws.
See also group 80 for Control of tilt cylinders
Tilt cylinder
DCE80-100E Empty page TDCE01
04GB
Technical Handbook Group 70 P. 43
DCE80-100E Hydraulic diagram TDCE01
04GB
Technical Handbook Components Group 70 P. 44
Components A06195.0500/0600
1. Accumulator charging valve
2. Pressure limiting valve, steering system
3. Differential valve, gives max. 11 bar difference between
LS-signal of the steering valve and the pump pressure
4. Priority valve for steering circuit. Gives 11 bar basic pressure
in the main valve. Actuated by LS-signal of the steering valve
and ensures sufficient supply to the steering system.
5. Pressure reducing valve for servo to the control levers
6. Safety valve in cooling circuit, permits max. 1 bar, opens to
the reservoir in event of higher pressure in the cooling sys-
tem.
7. Test point, brake system cooling circuit, max. 1,5 bar
8. Test point, servo pressure, non-adjustable
9. Test point, main hydraulics
(Shall be same pressure as 14)
10. Test point, accumulator charging
11. Test point, steering system
12. Main pressure limiting valve
Set the same as 13
13. Main pressure limiting valve
Set the same as 12
14. Test point, separate lifting section
Shall be same pressure as 9
15. Test point, LS-signal from steering valve
16. Control valve, LIFT
17. Control valve, TILT
18. Control valve, SIDESHIFTING
19. Control valve, LENGTH ADJUSTMENT 20’-40’
20. Hydraulic pump
21. Hydraulic accumulator, pre-charging pressure
22. Pressure limiting valve
23. High pressure filter
24. Orbitrol steering valve
25. Steering cylinder
26. Lifting cylinder
27. Lowering brake valve
28. Tilting cylinders
29. Counter pressure valve
30. Sideshifting cylinder
31. Hydraulic reservoir
32. Foot brake valve
33. Brake cylinders, foot brake
34. Parking brake valve
35. Parking brake cylinder
36. Oil cooled brake discs
37. Throttle-check valve for tank return counter pressure
38. Pressure switch, inching
39. Pressure switch, brake lights
40. Pressure switch, low brake pressure
41. Pressure switch, indicating lamp parking brake and seal
buzzer
42. Accumulator evacuating valve
43. Control levers
44. Control valve TWIST-LOCKS
45. Solenoid valves, interlocking system TWIST-LOCKS
46. Solenoid valve, interlocking system LIFT
47. Hydraulic cylinder, LENGTH ADJUSTMENT 20’-40’
48. Hydraulic cylinder, TWIST-LOCKS
49. Hydraulicil cooler, brake system cooling circuit
50. Breather filter
51. Electro-hydraulic converters
52. Test point, brake pressure
DCE80-100E Hydraulic diagram TDCE01
04GB
Technical Handbook Components Group 70 P. 45
26
27
26
16
28
12
29
14
29
28
17
30
18
47
51
19
47
50
44
48
31
13
48
20a 20b
7
23
2
8
4
42
3
21
9
22
1
10
15
40
32
49
52
38
39
36
34
33
35
41
24
25
33
37
36
Components A06195.0500/0600
1. Accumulator charging valve
2. Pressure limiting valve, steering system
3. Differential valve, gives max. 11 bar difference between
LS-signal of the steering valve and the pump pressure
4. Priority valve for steering circuit. Gives 11 bar basic pressure
in the main valve. Actuated by LS-signal of the steering valve
and ensures sufficient supply to the steering system.
5. Pressure reducing valve for servo to the control levers
6. Safety valve in cooling circuit, permits max. 1 bar, opens to
the reservoir in event of higher pressure in the cooling sys-
tem.
7. Test point, brake system cooling circuit, max. 1,5 bar
8. Test point, servo pressure, non-adjustable
9. Test point, main hydraulics
(Shall be same pressure as 14)
10. Test point, accumulator charging
11. Test point, steering system
12. Main pressure limiting valve
Set the same as 13
13. Main pressure limiting valve
Set the same as 12
14. Test point, separate lifting section
Shall be same pressure as 9
15. Test point, LS-signal from steering valve
16. Control valve, LIFT
17. Control valve, TILT
18. Control valve, SIDESHIFTING
19. Control valve, LENGTH ADJUSTMENT 20’-40’
20. Hydraulic pump
21. Hydraulic accumulator, pre-charging pressure
22. Pressure limiting valve
23. High pressure filter
24. Orbitrol steering valve
25. Steering cylinder
26. Lifting cylinder
27. Lowering brake valve
28. Tilting cylinders
29. Counter pressure valve
30. Sideshifting cylinder
31. Hydraulic reservoir
32. Foot brake valve
33. Brake cylinders, foot brake
34. Parking brake valve
35. Parking brake cylinder
36. Oil cooled brake discs
37. Throttle-check valve for tank return counter pressure
38. Pressure switch, inching
39. Pressure switch, brake lights
40. Pressure switch, low brake pressure
41. Pressure switch, indicating lamp parking brake and seal
buzzer
42. Accumulator evacuating valve
43. Control levers
44. Control valve TWIST-LOCKS
45. Solenoid valves, interlocking system TWIST-LOCKS
46. Solenoid valve, interlocking system LIFT
47. Hydraulic cylinder, LENGTH ADJUSTMENT 20’-40’
48. Hydraulic cylinder, TWIST-LOCKS
49. Hydraulicil cooler, brake system cooling circuit
50. Breather filter
51. Electro-hydraulic converters
52. Test point, brake pressure
DCE80-100E Hydraulic diagram TDCE01
04GB
Technical Handbook Components Group 70 P. 47
26
27
46
26
16
28
12
29
14
29
28
17
30
18
47
19
47
50
44
48
31
45
13
43
48
20a 20b
7
23
2
8
4
42
3
21
9
22
1
10
15
40
32
39
38
49
36
34
33
35
41
24
25
33
37
36
26
27
16
26
28
12
29
14
29
28
17
51
20b
53
13
23 23
19 20a
7
6
2
8
23
18
4
18a
42
3
9
22
21
10
1
49
54
40
32
38
39
36
52
34
33
36
41
24
25
33
37
36
7YTTPIQIRX
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All trucks 9279 02-09 1
Technical Handbook Contents Publ. Gr. P.
Contents
Clean hydraulics ........................................................................ 3
Measures to prevent pollution of the hydraulic system.............. 4
Fault finding for leakage ............................................................ 6
The function and removal of seals............................................. 7
Piston rod seals .................................................................... 7
Support ring and O ring ........................................................ 9
Wiper .................................................................................. 10
Single action V type piston seals with support ring ............ 11
Double action piston seals ................................................. 12
Repairing the piston rod surface.............................................. 12
Lubrication ............................................................................... 13
Dismantling the steering cylinder............................................. 14
All trucks Hydraulic Cylinders
9279 02-09 70 3
Technical Handbook Service Publ. Gr. S.
Clean hydraulics
Hydraulic systems are extremely sensitive to impurities - a hy-
draulic system is just as sensitive as a diesel engine’s fuel sys-
tem, with its pumps, filters and lines.
It is therefore extremely important that hydraulic systems are kept
clean and free from impurities. A clean system means that there
are no impurities in the system, whether it be in the hydraulic flu-
id, component parts of the system or hydraulic lines and hoses.
By impurity, we refer to everything and anything that is not intend-
ed to be in the system:
z solid particles such as dust, grit, threads of cotton waste,
flakes of rubber from hoses or seals, etc.
z liquids
z gasses
Solid particles
It is possible to see a particle of 40 µ in size with the naked eye,
but not one of 10 µ. (1 µ = 1/1000 mm).
By comparison, a strand of human hair is approx.70µ thick. The
smallest particles are less than 25 µ in size and are not visible to
the naked eye. If the number of small particles is sufficiently large,
they merely discolour the hydraulic fluid - by which time there are
far too many impurities in the system.
It is not, therefore, possible to judge, with the naked eye, whether
or not hydraulic fluid is sufficiently clean! A particle count using
special machinery or magnification equipment must be made to
establish the degree of impurity.
Solid impurities in hydraulic systems cause many different types
of problem. Large quantities of impurity dramatically reduce the
operative lifespan of the system. Hydraulic components break
down as a result of internal wear. Particles cause directional and
servo valves to seize, which, in turn, leads to the burning out of
the magnetic spools.
All trucks Hydraulic Cylinders
9279 02-09 70 4
Technical Handbook Service Publ. Gr. S.
Gasses
The most common gas that occurs as an impurity in a hydraulic
system is air. Unlike fluids, gasses can be compressed. If air is
allowed to enter a hydraulic system, this compression will be ex-
perienced as a “sponginess” of operation, making hydraulic
movements difficult to control.
Air in the hydraulic fluid can also cause corrosion damage, par-
ticularly when localized, sudden reductions in pressure, known
as cavitation, occur.
Liquids
The most common liquid impurity that occurs in a hydraulic sys-
tem is water, for example, through condensation. This can cause
rust to form, resulting in flakes or particles of rust entering the
system. This most commonly occurs in the tank and those parts
that are above the level of the hydraulic fluid. Such parts can be
inside single action cylinders where the complete length of the
hydraulic piston stroke, is seldom or never used. One simple pre-
ventive measure for such parts is to regularly run all hydraulic
functions to their end positions so that the whole of the cylinders
are lubricated.
IMPORTANT!
If there is the slightest doubt about the purity of the hy-
draulic fluid - send a fluid sample to the manufacturer
of the fluid, or to Kalmar Service
All trucks Hydraulic Cylinders
9279 02-09 70 6
Technical Handbook Service Publ. Gr. S.
Check surfaces
1. Check the surfaces of seals. Always think about how the seals
function and the type of sealing surfaces that they have. See
the following descriptions:
– O ring grooves internal and external
– piston rod seals in the cylinder head
– sealing groove on the piston
– cylinder pipe surface
– piston rod surface. The piston rod has a chromium plated
surface of 20-50 µ in thickness. Very minor damage to this
11 7 11 8 9 10 plated surface will not necessarily directly result in leakage
– all sliding surfaces (dynamic surfaces). These are always
1. Piston rod the most difficult to ensure a tight seal, for example, cylinder
2. Wiper pipe and piston rod.
3. Cylinder head
4. Piston rod seal
5. O ring with support ring
6. Cylinder pipe
7. Sleeve connection IMPORTANT!
8. Welded cylinder end When fitting the cylinder head:
9. Piston Fit the head absolutely straight, preferably by hand. Do
10. Piston seal, not, under any circumstances, hit it with a mallet or ham-
double action mer. If the cylinder head is fitted askew the lip of the pis-
11. Example of a weld ton rod seal can be damaged and any sealing function will
be lost. This applies to all types of piston rod seals.
Lift cylinder
All trucks Hydraulic Cylinders
9279 02-09 70 7
Technical Handbook Service Publ. Gr. S.
2
1
KL1009 7 5
1. Hydraulic pressure
2. Sealing lip pressed out against piston rod
3. Sealing lip pressed in against cylinder head
4. Sealing surface, piston rod
5. Sealing surface, cylinder head
6. Screwdriver
7. O ring
All trucks Hydraulic Cylinders
9279 02-09 70 8
Technical Handbook Service Publ. Gr. S.
5
7
KL1631
1. Hydraulic pressure
2. Inner sealing lip, pressed against the piston
rod
3. Outer sealing lip, pressed against the cylin-
der head
4. Beam for axial fixation
5. Sealing surface, piston rod
6. Sealing surface, cylinder head
7. Support ring
8. Screwdriver
All trucks Hydraulic Cylinders
9279 02-09 70 9
Technical Handbook Service Publ. Gr. S.
4
6
KL1010 5
1. Hydraulic pressure
2. Sealing lip pressed out against piston rod
3. Sealing lip pressed in against cylinder head
4. Sealing surface, piston rod
5. Sealing surface, cylinder head
6. Screwdriver
3
2 4
KL1011
1
1. Hydraulic pressure
2. O ring
3. Support ring
4. Sealing area, cylinder head
All trucks Hydraulic Cylinders
9279 02-09 70 10
Technical Handbook Service Publ. Gr. S.
Wiper
øD+10 The task of the wiper is to scrape the piston rod clean and prevent
any impurities being drawn into the cylinder pipe.
The wiper must be fitted with a special tool. This tool must have
a greater outer diameter than the wiper, so that the pressure
against the wiper ceases just as the wiper is pressed into posi-
1 tion. If the wiper should be pressed further in, the metal cap will
be deformed (se lower illustration) which would thereby reducing
the efficiency of the wiper.
2 4 To prevent the wiper “bottoming” in its slot in the cylinder head,
the slot in the cylinder head is somewhat deeper than the width
3 of the wiper.
øD
KL1007
2
IMPORTANT!
No tools should be introduced from the inside. This can
score the cylinder pipe, which in turn, can damage the pis-
ton rod. Scoring can also damage the piston rod seals
when the piston is fitted.
3
KL1012
1. Screwdriver
2. Wiper
3. Cylinder head
All trucks Hydraulic Cylinders
9279 02-09 70 11
Technical Handbook Service Publ. Gr. S.
KL1013 5
1. Hydraulic pressure
2. Seal pressed outwards against cylinder pipe
3. Seal pressed inwards against piston
4. Sealing surface, cylinder pipe
5. Sealing surface, piston
6. Screwdriver
The seal must always be fitted coupled together with the support
ring.
Always fit by hand, no tools should be used as the surface of the
piston can be easily damaged.
To make fitting easier, the seal can be warmed in hot water to sof-
ten it.
Lubricate with hydraulic fluid.
KL1014
All trucks Hydraulic Cylinders
9279 02-09 70 12
Technical Handbook Service Publ. Gr. S.
Dismantling
1. Remove guide rings and support rings.
2
2. Move the sealing body over to one side of the sealing groove.
KL1015
3. Press up the materials so that there is a gap between the seal
and the piston.
4. Without damaging the surface of the piston, cut the seal off
with a knife.
5. Carefully check the seal to discover any damage that can
1. Moving sealing surface against cylinder have caused leakage. This can be achieved most easily by
pipe bending over the seal section by section and checking the
2. Static sealing surface against piston sealing surface with a finger nail.
3. Guide ring
4. Support ring
5. Head of piston Fitting
6. Cylinder pipe 1. All double action piston seals are constructed in the same
way, a middle sealing body, thereafter support rings and final-
ly, guide rings, see illustration.
2. First fit the sealing body, thereafter the support rings and final-
ly the guide rings - everything must be done by hand, without
the use of tools, in order to prevent damage.
1 2 3
Lubrication
1. Within the actual hydraulic system - never anything other than
the normal hydraulic fluid used in the hydraulic system.
2. On the cylinder head thread - use copper paste (e.g., Moly-
1 cote CU 7439). Make sure that the paste does not enter the
system.
3. In areas where there is a risk of condensation building up -
grease with a thin layer of copper paste in the sealing groove
of the cylinder head, in order to prevent condensation. Con-
2 densation causes rust formation that can corrode the sealing
groove and cause leakage.
3 Apply the copper paste with a finger.
4. If any copper paste comes outside the sealing groove - wipe
4 clean with lint free paper. Never use cotton waste
KL1017
1. Wiper
2. Areas at risk for condensation
3. Piston rod seal
4. Rust formation on sealing surfac-
es causes leakage
5. Cylinder head
4. Use a strong, bent steel wire to hook onto the O ring, illustra-
tion A.
B 5. Draw up the O ring a little and get a grip on the O ring with a
pair of thin nosed pliers, illustration B.
6. Continue and draw out the O ring through the hole.
7. Maintain a grip on the O ring and cut through it with a knife.
C
8. Rotate the piston rod and simultaneously draw out the O ring
through the hole, illustration C.
KL1018
[[[OEPQEVMRHGSQ
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DCE80-100E TDCE01
04GB
Technical Handbook Contents Group 80 P. 1
Group 80
Lifting mast carriage and
side lift attachment
Specifications ............................................................................ 2
Lift mast and carriage ................................................................ 3
Description ........................................................................... 3
Service ................................................................................. 7
Inspection of lifting chains ............................................... 7
Inspection of the lifting mast............................................ 7
Dismantling the carriage.................................................. 8
Dismantling the lift mast .................................................. 8
Adjusting the support wheels ......................................... 9
Replacing the support wheels ......................................... 9
Lubrication of sliding surfaces and plates ..................... 10
Checking sliding plates.................................................. 10
Inserting shims for sliding plates ................................... 11
Bleeding lift cylinders..................................................... 11
Stretching of hoses........................................................ 11
Tilt cylinder mounting .................................................... 11
Checking tilt cylinders.................................................... 11
Lifting chains
Max. permissible wear 3%
(see instructions)
WARNING!
Lift mast
The mast on a Kalmar truck is of very sturdy design. The number
of welds has been kept down to a minimum, to ensure the highest
possible strength. The stresses on the mast components are low.
The mast sections are made of high-strength steel and have
slender dimensions, to restrict the field of vision as little as possi-
ble.
All support wheels for longitudinal forces are fitted with high qua-
lity roller bearings. The traditional side support rollers are repla-
ced by plastic sliding plates, there are 4 plates between inner and
outer mast. Between carriage and inner mast there are 4 plates
and 8 plates between carriage and sidelift attachment.
KL1125a
DCE80-100E Mast and carriage TDCE01
04GB
Technical Handbook Description Group 80 P. 4
Carriage
Two different integrated carriages are available - a fixed carriage
for attachments with twist-locks and a carriage with hydraulic lev-
elling ±4° for attachments with hooks. Both carriages have sup-
port wheels to bear longitudinal stresses and sliding plates for
lateral stresses.
KL1400
Carriage with hydraulic levelling
KL1401
Carriage without levelling
DCE80-100E Mast and carriage TDCE01
04GB
Technical Handbook Description Group 80 P. 5
1
32
4
5
6
8
6
4
6 5
10
11 1
32
11
7
8 6
Lifting chains must not be joined or For inspection, the whole length of each chain should be thor-
re-riveted. oughly clean. Carry out the inspection without any load on the
forks.
WARNING!
2
6
5
1
3
4
KL1683
1. Circlip
2. Inner bearing
3. Tubular dowel
4. Clamping screw
5. Sealing washer
6. Outer bearing
7. Support wheel
8.
DCE80-100E Lifting mast and fork carriage TDCE01
04GB
Technical Handbook Service Group 80 P. 10
IMPORTANT!
The lubricant should be of a brand approved by Kalmar,
or another of the same specification. The use of any other
lubricant can lead to excessive wear and also invalidate
the Kalmar guarantee. Lubricants can be ordered from
Kalmar’s spare parts department.
See group 90.
2 3, 4, 7
2 Min 3 mm
3
4 1. Shim
2. Sliding plate holder (x 4)
5 3. Sliding plate, against inner mast (x4)
4. Sliding plate, top edge attachment (x4)
5. Shim with fixing slot
4 6. Counter hole for 4 and 5
7. Sliding plate, bottom edge attachment
6 (x 4)
8. Shim
9. Fixing block for attachment, tightening
torque for fixing bolts 649 Nm.
KL1126
7
8 9
Carriage sliding plates
DCE80-100E Lifting mast and fork carriage TDCE01
04GB
Technical Handbook Service Group 80 P. 11
WARNING!
1 2 3
Risk of crack formation
1. Thread exit
2. Weld
3. Weld
DCE80-100E Lifting mast and fork carriage TDCE01
04GB
Technical Handbook Service Group 80 P. 12
1 2 3 4
KL1125
High-Lift Mast
DCE80-100E Sidelift attachment TDCE01
04GB
Technical Handbook Description Group 80 P. 13
Sidelift attachment
The sidelift attachment has been designed for easy, safe and rap-
id handling, low weight and ease of maintenance. The attach-
ment is integrated with the carriage.
Two different models of the attachment are available; with twist-
A B1 C locks or with hooks for container connection. The hook connec-
tions are used, for example, for the simultaneous lifting of two
containers.
B2 Both of the attachments’ corner pieces are telescopic and sus-
pended from the main beam by means of springs, which enables
195 mm levelling to both sides for the connection to leaning con-
tainers. A hydraulic cylinder between the attachment and the car-
A. Twist-locks locked (green) riage allows ±600 mm side-shift.
B1.Alignment container (orange) A hydraulic/mechanical system ensures that the container are
B2.Alignment hooks (orange) locked onto the attachment prior to lifting. Hook attachments are
Only hook attachment
C. Twist-locks unlocked (red)
equipped with side locking plates which lock the container onto
the attachment prior to lifting.
An electrical safety system prevents the locking and release of
the twist-locks if the attachment is not correctly positioned
against the container. The system also prevents lifting if the twist-
locks are not either completely locked or released.
Lamp panel
A lamp panel displays alignment, locked and released container
respectively. See also Group 70, Hydraulic diagram
7
2
3
KL1684
8
4
9
10 5
11 6
KL1688
KL1687
7 8 2 11 1 3 9 10 4
5 6
WARNING!
Alignment control
A spring-loaded contact pin and an inductive sensor at each
twist-lock is used for alignment control. The attachment is fully
8 aligned onto the container when all pins have been depressed
9 and the distance between each pin and sensor have decreased
to 4–5 mm. Then the indicating lamp ALIGNMENT B lights up
3 and the twist-locks are ready for locking.
10
Safety interlocking system
11 After locking of the twist-locks the lifting starts. A built in play be-
tween twist-locks and container corner boxes allows the attach-
ment to be lifted enough for the inductive sensors to be
deactivated, i.e. the distance between sensor and contact pin in-
creases to more than 8 mm.
This will brake the minus feed to the twist-lock solenoid valve,
3. Contact pin, alignment thus making it impossible to operate the twist-locks when lifting.
8. Sensor, twist-lock unlocked This electrical interlocking can, in emergency situations, be
9. Activator bridged by an override switch in the operator’s cab. The override
10. Sensor alignment switch will feed “false” alignment minus signal to the twist-lock so-
11. Sensor, twist-locks locked lenoid valve thus making it possible to operate the twist-locks. A
red warning lamp lights up in the operator’s cab when the electri-
cal interlocking is bridged.
WARNING!
KL1687
Alignment control
A spring-loaded contact pin and an inductive sensor at each side
is used for alignment control against the container. The sidelift is
7 8 12 11 fully in contact with the container when both pins have been de-
pressed and the distance between each pin and sensor is less
that 8 mm. On the hook-coupling sidelift there is an additional
alignment lamp B1 and B2. B2 lights up when the hooks have
been pressed down enough for activation of sensor 8. When both
B1 and B2 light up the locking plates are ready for locking.
Inductive sensors
The inductive sensors control the various functions of the con-
tainer attachments.
The sensors are of the type PNP – positive/negative/positive, the
last P indicating that the sensor produces a positive signal when
activated. The sensor is activated when a magnetic object gets
closer than approx 8 mm from the top of the sensor.
The sensor has a light diode which can be used for checking of
the sensor function.
Inductive sensor
DCE80-100E Sidelift attachment TDCE01
04GB
Technical Handbook Service Group 80 P. 18
Control of twist-locks
3 N.B. This control should be first carried out after 5000 hours
of service, or after 2 years - which ever occurs first.
Thereafter, the twist-locks should be checked every year.
IMPORTANT!
IMPORTANT!
2. Refit the lifting hook and fixing screw 2. Secure the fixing
screw with a new locknut.
DCE80-100E Sidelift attachment TDCE01
04GB
Technical Handbook Service Group 80 P. 19
KL1809
A B1 C
B2
DCE80-100E Sidelift attachment TDCE01
04GB
Technical Handbook Service Group 80 P. 20
1 WARNING!
1. Shims
2. Sliding plate
3. Tool for removing/fitting of
sliding plates
1
2
3
DCE80-100E Sidelift attachment TDCE01
04GB
Technical Handbook Service Group 80 P. 21
KL1682
X 10. Push the extension beam into the main beam and refit 1-2-
X + 5 mm 3-4.
DCE80-100E Sidelift attachment TDCE01
04GB
Technical Handbook Service Group 80 P. 22
KL1797
1000 mm
KL1798
3. Remove the sliding plates and shims from the main beam.
Lift the inner beam slightly to relieve the load from the sliding
plates.
Right side
KL1799
Left side
KL1800
DCE80-100E Sidelift attachment TDCE01
04GB
Technical Handbook Service Group 80 P. 23
KL1801
Höger sida
KL1802
Vänster sida
DCE80-100E Sidelift, hooks, type C TDCE01
04GB
Technical Handbook Description Group 80 P. 24
1 2 3 4
5 6
Carriage
The carriage is of either of two different designs, both allowing le-
velling for hooking up leaning containers.
In the standard design the sidelift main beam is moveable over
sliding plates in the carriage. A vertical play admits ±3° levelling.
The optional design has hydraulical levelling by means of one hy-
draulic cylinder on each side..
1 2
2 2 Carriage with
mechanical levelling
1. Carriage wheels
2. Sliding plates 2 3 2
3. Hydraulic cylinder,
levelling
4. Bolts,
tightening torque
370Nm (dry bolts)
2
1 2
Carriage with
hydraulic levelling
2 2
DCE80-100E Sidelift, hooks, type C TDCE01
04GB
Technical Handbook Service Group 80 P. 26
8
7 Indicating lamps
on the sidelift WARNING!
Alignment control
6 A spring-loaded contact pin and an inductive sensor at each
twist-lock is used for control of alignment against one or two con-
4 tainers . The sidelift is fully aligned onto the container when the
contact pins on both sides have been depressed and the distance
between each pin and sensor is less than to 8 mm.
KL1792 When lifting one container: When lamps 5 and 6 light up, the side
locking plates can be locked.
3 2 1 When lifting two containers: When lamps 3, 4, 5 and 6 light up,
the side locking plates can be locked.
3 7 2 8 N.B. It is possible to lock the side locking plates without in-
dication of alignment. Therefore, never lock before lamps 5
and 6 (one container) or 3, 4, 5 and 6 (two containers) light
up.
In the locked position for one or two containers, the red lamps 1
and 2 go out and at the same time the green lamps 6 and 7 light
up. During lift operation the lamps 3, 4, 7, 8 should always be
alight while 5 and 6 should be extinguished..
Inductive sensors
The inductive sensors control the various functions of the con-
tainer attachments.
The sensors are of the type PNP – positive/negative/positive, the
last P indicating that the sensor produces a positive signal when
activated. The sensor is activated when a magnetic object gets
closer than approx 8 mm from the top of the sensor.
The sensor has a yellow light diode, which can be used for check-
ing of the sensor function.
Inductive sensor
DCE80-100E Sidelift, hooks, type C TDCE01
04GB
Technical Handbook Service Group 80 P. 28
IMPORTANT!
1 2
If any split or fracture is discovered then the lifting hook
must be immediately replaced.
1. Fixing screw If the lifting hook has any other visible damage, then it
2. Lifting hook must be immediately replaced.
2. Refit the lifting hook and fixing screw 2. Secure the fixing
screw with a new locknut.
1000 mm KL1803
KL1804
DCE80-100E Sidelift, hooks, type C TDCE01
04GB
Technical Handbook Service Group 80 P. 30
KL1805
Höger sida
KL1806
Vänster sida
KL1807
DCE80-100E Sidelift, hooks, type C TDCE01
04GB
Technical Handbook Service Group 80 P. 31
1 2 3 6 7 8
1 2
3 D
4 D
5 6
4
7 C 8 C
5
9
Opt.
XB777
10
11
12
25x1,5mm²
Block diagram
17
16
19
18
DCE80-100E
Technical Handbook
8 8
B A B A 8 B A 8 B A PS
9 9 TPB
T1
10 10
P2B
Service
3 3 3 12
14 2 2 2 2
11
Sidelift, hooks, type C
4 5 6 7
15
13 T2B
1
T3B
P1 LSPB
A46141.0100
1. Direct controlled shock valve 8. Converter electric servo/hydraulic 12. Internal coarse filter for pilot circuit
2. Pressure compensator with inte- servo 13. Constant pressure pump
gral check valve 9. Combined shock- and anticavita- 14. Relief valve
3. Feed reducer tion valve 15. Filter
4. Control valve, sideshift 10. Anticaviation valve 16. Hydraulic cylinder, sideshift
Group 80
5. Control valve, twistlocks 11. Reducing valve with separate 17. Hydraulic cylinder, twistlocks
6. Control valve, length adjustment safety valve for internal pilot pres- 18. Hydraulic cylinder, length adjust-
7. Control valve, levelling sure suppy ment
P. 32
+24V +24V
/ 1 0 . E 3 / 1 0 . C 3
Chassis WH WH Chassis
A / 1 0 . D 3 / 1 0 . B 3 A
C XSP1 XSP2 C
2
2
XB72031Lm XB72031Lf XB72031Rf XB72031Rm
BN A A 1 1 A A BN
B72031L B72031R
BK C C 3 3 C C BK
B B WH WH B B
ALIGNMENT LEFT LOW ALIGNMENT RIGHT LOW
BU BU
D D
XB72032Lm XB72032Lf XB72032Rf XB72032Rm
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
BN A A 1 1 A A BN
B72032L B72032R
BK C C 6 6 C C BK
B B WH WH B B
ALIGNMENT LEFT UP ALIGNMENT RIGHT UP
BU BU
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
1 X410 & X411 T. 050276 CJS 050225 Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
6
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 050225 Klass/Class Circuit Hook Att. A45760.0100 06
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
H562L H562R
1 2 RD RD 2 1
FLAP LEFT UNLOCKED (red) FLAP RIGHT UNLOCKED(red)
H5641L H5641R
1 2 RD RD 2 1
ALIGNMENT LEFT UP (yellow) ALIGNMENT RIGHT UP (yellow)
B B
H5642L H5642R
1 2 RD RD 2 1
ALIGNMENT LEFT LOW (yellow) ALIGNMENT RIGHT LOW (yellow)
H563L H563R
1 2 RD RD 2 1
XSP6
C Alignment_L_Up BK 2 2 BK 2 2 BK C
/ 3 . F 1
+24V RD 3 3 RD 3 3 RD
/ 4 . A 8
X BU 4 4 BU 4 4 BU
/ 3 . F 1
Locked_R YE 5 5 YE 5 5 YE
/ 3 . E 1
Alignment_RLow GN 6 6 GN 6 6 GN
/ 3 . E 1
Alignment_R_Up BN 7 7 BN 7 7 BN
/ 3 . E 1
D Alignment_L_Low WH 8 8 WH 8 8 WH D
/ 3 . F 1
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
Unlocked_R VT 9 9 VT 9 9 VT
/ 3 . E 1
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
1 X410 & X411 T. 050276 CJS 050225 Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
6
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 050225 Klass/Class Circuit Hook Att. A45760.0100 06
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Chassis A2V
/ 4 . B 8
Chassis A2A
/ 4 . B 8
A A
A2U A2T A2S
86 86 85 85 86 86 85 85 86 86 85 85 86 86 85 85
30 30 87 87 30 30 87 87 30 30 87 87 30 30 87 87
87A 87A 87A 87A
86 86 85 85 86 86 85 85 86 86 85 85 86 86 85 85
30 30 87 87 30 30 87 87 30 30 87 87 30 30 87 87
87A 87A 87A 87A
1
FLAP RIGHT UNLOCKED FLAP RIGHT LOCKED ALIGNMENT RIGHT LOW ALIGNMENT RIGHT UP
C A2E A2F A2G A2H C
A8226B
K37711 K37712 K37701
A8225B 86 86 85 85 86 86 85 85 A8227B 86 86 85 85
30 30 87 87 30 30 87 87 30 30 87 87
87A 87A 87A
FLAPS LOCKED
1
D FLAPS UNLOCKED ALIGNMENT LOW D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
A8237B A8239B
A8238B
Open A8211
/ 4 . D 8
Locked A8212
/ 4 . D 8
Alignment_Low A8210
/ 4 . C 8
X82
A8225A 25 4 Unlocked_R
/ 1 . E 7
E X82 A8226A 26 5 Locked_R E
/ 1 . E 7
Unlocked_R VT 33 A8233 A8227A 27 3 Alignment_RLow
/ 2 . D 2 / 1 . E 7
Locked_R YE 34 A8234 A8228 28 6 Alignment_R_Up
/ 2 . D 2 / 1 . E 7
Alignment_RLow GN 35 A8235
/ 2 . D 2
Alignment_R_Up BN 36 A8236
/ 2 . D 2
X82
A8229 29 4 Unlocked_L
/ 1 . E 1
A8230 30 5 Locked_L
/ 1 . E 1
X82 A8231 31 3 Alignment_L_Low
/ 1 . E 1
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stöd av gällande lag.
Unlocked_L GY 37 A8237A A8232 32 6 Alignment_L_Up
/ 2 . C 2 / 1 . E 1
X BU 38 A8238A
F / 2 . C 2 F
Alignment_L_Low WH 39 A8239A
/ 2 . D 2
Alignment_L_Up BK 40 A8240
/ 2 . C 2
R
1 Kabel flyttad från 87a till 87. 050276 CJS 050225 Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
6
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 050225 Klass/Class Circuit Hook Att. A45760.0100 06
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A RD +24V A
/ 2 . C 2
11
Frame contact
El. box
attachment
+24V
/ 8 . B 2
X46m X81 X410f X410m X82 1 +24V
/ 1 . E 7
A35094.XXXX 4 464-1 1 GY 1 1 1 1 + 1 +24V
/ 1 . E 1
464-2 2 BK 2 2 2 2
12 Chassis
/ 8 . B 7
X49m X410f X410m 2 Chassis
/ 1 . E 1
Chassis 2 492-3 3 RD 3 3 3 3 2 Chassis
A 3 5 0 9 6 . 0 4 0 0 / 4 . E 7 / 1 . E 7
492-4 4 BU 4 4 4 4 9 Chassis
/ 5 . C 7
A2V Chassis
/ 3 . A 1
B A2A Chassis B
/ 3 . A 1
A3006-85A Chassis
/ 1 0 . B 2
A447
7 7 447-6 6 GN 6 6 6 6 Workinglight Left Carriage 7 Worklight_Right
/ 7 . B 2
448-7 7 BN 7 7 7 7
A448
X44f X44m
8 8 448-8 8 WH 8 8 8 8 Workinglight Right Carriage 7 Worklight_Right
/ 7 . C 2
C X44f X44m C
A449
9 9 449-9 9 VT 9 9 9 9
X46f X46m
30 stop knapp A188 8 8 468-10 10 OG 10 10 10 10 30 Stop A3006-30A 30 stop
/ 1 0 . A 2 / 1 0 . C 1
X46m
A35094.XXXX 5 465-11 11 WH/BK 11 11 11 11 Alignment A8210 Alignment_Low
/ 3 . E 1
X46m
A35094.XXXX 6 466-12 12 WH/RD 12 12 12 12 Unlocked A8211 Open
/ 3 . E 1
X46m X411m X411f
A35094.XXXX 7 467-13 13 WH/BU 1 1 1 13 Locked A8212 Locked
/ 3 . E 1
14 WH/YE 2 2 2 14 8 Chassis
/ 7 . B 2
D D
15 WH/GN 3 3 3 15 8 Chassis
/ 7 . C 2
8114
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
1
8115
Chassis
Chassis
X62m X411m X411f
LoweringBreak 3 622-16 16 WH/BN 4 4 4 16 Lowering Break 10 LoweringBreak
A 3 5 0 9 6 . 0 4 0 0 / 1 . F 7 / 8 . B 7
X49m
Spreading_Out 5 495-17 17 WH/VT 5 5 5 17 Spreading Out 1 Spreading_Out
A 3 5 0 9 6 . 0 4 0 0 / 1 . D 7 / 5 . A 2
X49m
E Spreading_In 7 497-18 18 WH/OG 6 6 6 18 Spreading In 2 Spreading_In E
A 3 5 0 9 6 . 0 4 0 0 / 1 . D 7 / 5 . B 2
X49m
Sideshift_Left 1 491-19 19 BK/GY 7 7 7 19 Side shift Left 3 Sideshift_Left
A 3 5 0 9 6 . 0 4 0 0 / 1 . C 7 / 5 . C 2
X49m
Sideshift_Right 3 493-20 20 BK/RD 8 8 8 20 Side shift Right 4 Sideshift_Right
A 3 5 0 9 6 . 0 4 0 0 / 1 . C 7 / 5 . C 2
X62m
Unlocked 2 621-21 21 BK/BU 9 9 9 21 TW / Flaps Unlocked 5 Unlocked
A 3 5 0 9 6 . 0 4 0 0 / 1 . E 7 / 5 . D 2
X50m
Locked 8 508-22 22 BK/YE 10 10 10 22 TW / Flaps Locked 6 Locked
A 3 5 0 9 6 . 0 4 0 0 / 1 . E 7 / 5 . D 2
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
X50m
Levelling_Left 1 501-23 23 BK/GN 11 11 11 23 OPT (Levelling Left) 7 Levelling_Left
F A 3 5 0 9 6 . 0 4 0 0 / 1 . D 7 / 6 . B 2 F
X50m
Levelling_Right 3 503-24 24 BK/BN 12 12 12 24 OPT (Levelling Right) 8 Levelling_Right
A 3 5 0 9 6 . 0 4 0 0 / 1 . E 7 / 6 . C 2
R
1 Cable 8114 T. 050276 CJS 050225 Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
6
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 050225 Klass/Class Circuit Hook Att. A45760.0100 06
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6018
X409f X409m
Spreading_Out 1 1 1 1 1 1 2 2 WH
/ 4 . E 8
SPREADING OUT
Y6019
X409f X409m
Spreading_In 2 2 2 2 1 1 2 2 WH
/ 4 . E 8
B B
SPREADING IN
Y6020
X409f X409m
Sideshift_Left 3 3 3 3 1 1 2 2 WH
/ 4 . E 8
X409m X409f
SIDESHIFT LEFT XSP4 9 9 9 9 Chassis
/ 4 . B 8
Y6021
C X409f X409m C
Sideshift_Right 4 4 4 4 1 1 2 2 WH
/ 4 . E 8
SIDESHIFT RIGHT
Y6039
X409f X409m
Unlocked 5 5 5 5 1 1 2 2 WH
/ 4 . F 8
FLAPS UNLOCKED
D D
Y6040
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
X409f X409m
Locked 6 6 6 6 1 1 2 2 WH
/ 4 . F 8
FLAPS LOCKED
E Chassis WH E
/ 6 . B 7
Chassis WH
/ 6 . C 7
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
1 X410 & X411 T. 050276 CJS 050225 Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
6
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 050225 Klass/Class Circuit Hook Att. A45760.0100 06
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
Y60341
X409f X409m
Levelling_Left 7 7 7 7 1 1 2 2 WH Chassis
/ 4 . F 8 / 5 . E 2
LEVELLING LEFT
C Y60342 C
X409f X409m
Levelling_Right 8 8 8 8 1 1 2 2 WH Chassis
/ 4 . F 8 / 5 . E 2
LEVELLING RIGHT
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
1 X410 & X411 T. 050276 CJS 050225 Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
6
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 050225 Klass/Class Circuit Hook Att. A45760.0100 06
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X406Lf X406Lm WH
Chassis 8 8 8 WH XSP9 WH
/ 4 . D 8
B B
X406Lf X406Lm E4041L
Worklight_Right 7 7 7 7 XSP7 7 2 1
/ 4 . C 8
7
WORKING LIGHT
LIFTING CARRIAGE, LEFT UP
E4042L
2 1
WORKING LIGHT
LIFTING CARRIAGE, LEFT LOW
C C
X406Rf X406Rm WH
Chassis 8 8 8 WH XSP10 WH
/ 4 . D 8
E4042R
D 7 2 1 D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
WORKING LIGHT
LIFTING CARRIAGE, RIGHT LOW
E E
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
1 X410 & X411 T. 050276 CJS 050225 Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
6
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 050225 Klass/Class Circuit Hook Att. A45760.0100 06
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
1 X410 & X411 T. 050276 CJS 050225 Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
6
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 050225 Klass/Class Circuit Hook Att. A45760.0100 06
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X45m X81Bf X81Bm XE4031f XE4031m E4031 XE4031m XE4031f X81Bm X81Bf
A102 1 451A XSP11 1 451B 1 1 811 1 1 1 2 2 2 813 3 3 813A
B A35091.XXXX B
WORK LIGHT MAST LEFT
D D
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written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
1 X410 & X411 T. 050276 CJS 050225 Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
6
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 050225 Klass/Class Circuit Hook Att. A45760.0100 06
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
+15
+15 S1004
A X18f X18m 1 A
30 stop knapp A188 8 8 188B 0
/ 4 . C 1 1 1 184C
5 5
X18m X18f
188C 10 10 9 9 183B 183A 3 3 A35094.XXXX
183C
30 STOP X372
Chassis A3006-85A
/ 4 . B 8
XB777Rf XB777Rm
A A 1 BN
B777L
Chassis WH B B BU 3 BK
B / 1 . A 7 B
X406Rf X406Rm 2
3035 STOP
A8241 X82 41 11 11 11 11 C C YE BU
X83R
K3006R2 GY 1
2
2
86 86 85 85 3
4
30 stop A3006-30A 30 30 87 5
/ 4 . C 8 X406Rf X406Rm XK3006Rm XK3006Rf
A8282 X82 10 10 BN 6
2
5
C 4 C
30 30 87
87A 87a
3035 STOP
A3006-30B
A3006-85B
Y6018R
1 1 1 2 2
K3006L2
3035 STOP
86 86 85 85
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
Chassis WH B B BU
INVERT SIGNAL 3035 STOP / 1 . A 1 2
X406Lf X406Lm 3035 STOP
BU
A8244 X82 44 10 10 10 10 C C YE
X83L
GY 1
2
2
3
4
5
X406Lf X406Lm XK3006Lm XK3006Lf
A8243 X82 11 11 BN 6
2
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stöd av gällande lag.
F 3035 STOP F
R
1 X410 & X411 T. 050276 CJS 050225 Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
6
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 050225 Klass/Class Circuit Hook Att. A45760.0100 06
1 2 3 4 5 6 7 8
DCE80-100E TDCE01
04GB
Technical Handbook Contents Group 90 P. 1
Group 90
Periodic supervision
General survey
To extend the service life of the truck and to prevent the risk of
faults causing injury to personnel or damage to equipment, the
truck must be subjected to regular periodic supervision.
If the truck is used under conditions in which road traffic regula-
tions are applicable, the special maintenance instructions issued
by the authorities must be followed.
The intervals at which service measures are carried out can be
determined on the basis of the operating hour meter readings.
When carrying out a 1000-hour service, it is advisable to work in
the following order:
Maintenance intervals,
hours
1000 z z
1500 z
2000 z z
...
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 After they have been washed with degreasing
hydraulic piston rods exposed, all piston rods agent, all pistons should be moved back-
must be greased to prevent corrosion. wards and forwards several times to obtain a
new protective film of oil.
DCE80-100E Periodic supervision TDCE01
04GB
Technical Handbook Lubrication Group 90 P. 5
4
4
1 1
3 3
KL1598
5 6
KL1599
Twist-locks
KL1601
KL1600
L = Lubricate
C = Check
DCE80-100E Periodic supervision TDCE01
04GB
Technical Handbook Lubrication, C-hook Side-lift Group 90 P. 8
3
2 4
1
4
KL1792
5 6
KL1814
KL1813
L=Lubricate
C=check
DCE80-100E Periodic supervision TDCE01
04GB
Technical Handbook Daily Group 90 P. 10
Brakes Operation
Steering Operation
All instruments: Operation
Direction indicators, horn,
brake lights, headlights
Lift mast: Damage?
Lifting chains
Links, suspension
All hydraulic functions, e.g.: Operation
Lift, tilt, sideshift, Run every function to its end position in
length adjustment order to lubricate the cylinders and pre-
vent corrosion
Engine, gearbox, drive axle, Noises?
hydraulic hoses Oil leakage?
Fuel Amount •
The gauge reading should never drop to
Drain condensate from the fuel prefilter
(if applicable)
Engine oil Level •
Air cleaner • Indicator
Coolant • Level •
Hydraulic oil • Level •
Gearbox oil • Level
Windscreen washer • Fluid level •
Wheels • Tyre pressure
Sidelift attachment • Check that all sensors are undamaged
and free from grease.
Check the function, see group 80.
DCE80-100E Periodic supervision TDCE01
04GB
Technical Handbook Group 90 P. 11
IMPORTANT!
Always attend to any damage, wear or faults that are im-
portant to the performance of the truck
and its service life or the safety of the personnel.
DCE80-100E Periodic supervision TDCE01
04GB
Technical Handbook Group 90 P. 13
7 Batteries Check
IMPORTANT!
Always attend to any damage, wear or faults that are im-
portant to the performance of the truck
and its service life or the safety of the personnel.
DCE80-100E Oil and lubricant recommendations TDCE01
04GB
Technical Handbook Group 90 P. 14
Grease
Use EP universal grease to NLGI Grade 2 with 3–5% molybde-
num disulphide additive for all lubrication points, including wheel
bearings.