Kalmar DCE80-100E Release Note

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

DCE80-100E
Technical Handbook Contents 1
P.Group 00
TDCE01
04GB
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
Technical Handbook Safety regulations
2
P.Group 00
TDCE01
04GB
It is important that you read the instruction
manual.
Incorrect handling can lead to personal injury or dam-
age to products and/or property. Therefore, read the in-
structionbookverycarefullybeforeoperating the truck.
The instruction manual contains important information
about your Kalmar truck, about the operation of the
truck, about safety during operation and about the
truck's daily maintenance. In addition, you will find use-
ful information that will make operations easier for you
in your daily work.
The instruction manual must always be kept in the ma-
chine.If the manual shouldbelost,a replacement must
be immediately obtained. Never use a machine with a
missing instruction manual.
Ask your foreman/group leader if there is anything in
themanualthatyoudonotunderstandor ifyoufeelthat
information is missing in any area.
The symbol is used on our products in certain
cases and then refers to important information con-
tained in the instruction manual. Make sure that warn-
ing and information symbols are always clearly visible
andlegible. Replace symbols thathavebeen damaged
or painted over.
In this instruction manual warnings are inserted that ap-
ply to your own safety. Warnings point out the risk of ac-
cident that can cause personal injury.
For technical warnings, that point out the risk of break
down, the word IMPORTANT is used:
For information that facilitates the working process or
handling, N.B. is used:
N.B. Draws attention to useful information that
helps the working process.
Safety regulations aimed at reducing the
risk of personal injury and damage to
loads or other property.
Intended of use
zThe truck may only be used for the purpose for
which it was intended, namely, to lift and transport
goods, the weight of which does not exceed the
maximum permitted load capacity of the truck.
zThe truck may not, without specific permission
from Kalmar, be modified or re-built so that its func-
tion or performance is altered.
zThe truck may not be driven on public highways if
it has not been adapted to comply with national
road safety regulations.
Operator requirements
zThe truck may only be driven by operators who
have been specially trained and who have the
company's authority to do so.
zLaws and other regulations relating to driving li-
cence, operator ID, log book, etc., must be fol-
lowed at all times.
zThe operator must be aware of and follow all local
safety regulations.
zIt is always the responsibility of the operator to en-
sure that the truck has approved fire extinguishing
equipment in accordance with currently applicable
regulations.
Operation of the truck is prohibited:
zIf any of the fitted safety equipment, such as rear
view mirrors, headlights, reversing alarm (option-
al), does not function correctly.
zIf there is a fault with the brakes, steering or lift
equipment.
zIf it has been repaired, modified or adjusted with-
out the approval of the work supervisor.
zIf the truck is fitted with tyres not approved by
Kalmar.
Continued on next page
WARNING!
Warns of the risk of serious personal injury, pos-
sible death and/or serious damage to product or
property if the regulations are not followed.
IMPORTANT!
Is used to draw attention to such occurrences
that can cause damage to the product or
property.

DCE80-100E
Technical Handbook Safety regulations
3
P.Group 00
TDCE01
04GB
Continued from previous page
Operating regulations
zBefore starting, always check to ensure that no-
body is in the way of the truck or its equipment.
zThe operator must always face the direction of op-
eration and take particular care in areas where
persons or other vehicles are likely to appear in
thevicinity. Ifvisibility is limited bythe load, the op-
erator should operate the truck in reverse.
zIt is prohibited to walk or stand underneath raised
forksorotherequipment, whethertheyareloaded
or not.
zIt is prohibited to transport passengers on the
truck outside the cab or on the load. Passengers
may be transported inside the cab only on condi-
tion that it is equipped with a fixed passenger
seat.
zIt is prohibited to lift people if the truck is not
equipped with an approved lift cage.
zIt is prohibited to exceed the load capacity of the
truck. See capacity plate and loading diagram.
zIt is prohibited to transport loads in the raised po-
sition as this entails a risk of the truck tipping. All
transportation shall take place with the load in the
transport position.
zThe operator must adapt the speed of the truck to
the character of the load, conditions of visibility,
the character of the roadway/surface, etc.
zThe operator shall avoid powerful acceleration
and braking when turning. In addition, the opera-
tor shall always moderate the speed of the truck
when turning so as to avoid the risk of lateral skid-
ding or tipping.
zThe operator shall take particular care when oper-
ating in the vicinity of electrical power lines, via-
ducts, quay-sides, ramps, gates/doors etc.
zSafety belts must always be worn, if fitted. In the
event of the truck tipping, always remain in the
cab and grip the steering wheel securely. Never
try to jump out of the cab.
zThe parking brake can also be used as an EMER-
GENCY BRAKE. However, having been used for
emergency braking, the brake linings must be
checked and replaced if necessary. If the parking
brake has been mechanically released, it must
always be reset in order for the truck to regain
the parking brake function.
Interrupted operation, parking
zAlways check that the gear lever is in the neutral
positionbeforeturningtheignitionkeytorestartor
to reset an emergency stop.
zNever leave the operator's cab without applying
the parking brake (ON position).
zAlways remove the ignition key if the truck is to be
left unattended.
Other important points to remember
zThe truck's hydraulic system includes high pres-
sure hydraulic accumulators. Always be extreme-
ly careful when working with the hydraulic system
and avoid being unnecessarily close to the hy-
draulic equipment, lines and hoses. Before work-
ing on the hydraulic system, the accumulators
must be emptied into the tank, with the help of the
special accumulator evacuation valve.
zHandle batteries and junction boxes with great
care.Thebatteriesmustalwaysbeprotectedover
the poles and connections.
zAlways rectify any damage or wear and tear that
can risk personal safety or that can affect the
functions of the truck or its service life.
zAvoid touching oils and greases. Avoid inhaling
exhaust and oil fumes.
zAlways use steps and handrails when entering or
leaving the machine - Never jump!
To avoid the risk of slipping, tread only on anti-slip
surfaces. If the anti-slip protection has become
worn, loose or in any way less effective, it should
be replaced.
zWelding painted steel produces poisonous gas-
ses. Paint should therefore be stripped before
welding, good ventilation ensured and/or face
mask with filter used.
zMobile phones used in the cab must always have
fixed connections to the machine’s electrical sys-
tem, with a fixed antenna outside the machine,
mounted in accordance with the manufacturer’s
instructions. This will avoid interference with the
machine’s important electronic functions.
zThe tensile strength of the top pane can be seri-
ously weakened by exposure to elements that
contain: Aromatic hydrocarbon, ketone, esters or
chlorinated hydrocarbon.
Regularly check the surface condition of the top
pane and clean only with screen wash or other
mild cleaning fluid. After cleaning, rinse thorough-
ly with warm water. It is prohibited to modify or in
any other way make alterations to the top pane.
Immediately replace damaged top panes that
show signs of cracking or scratching.
Operating with attachments
zThe operator must always take the effect of the
wind into account when handling containers.
Avoid lifting with a wind strength in excess of 12
m/s (27 mph/40 feet per second).
zAlways drive carefully so as to avoid attachments
colliding with pillars, cables, etc.
zCarefully study the "Lift methods" section of the
instruction manual.
CE marking
All trucks and equipment (though not thoses fitted on
the truck or intended as spare parts) supplied from Ka-
lmar are CE marked, which indicates that they comply
with the requirements of the EU Machine Safety Direc-
tive. In addition, each truck has a so called, “EU Dec-
laration of Conformity”which is the legal proof that the
truck complies with the “health and safety” require-
ments laid down in the Machine Safety Directive, the
EMCdirective (electro-magnetic compatibility)andthe
LVD directive (electrical equipment).
Vibration standard
The truck is tested according to test method described
in EN 13059, see Technical data.

DCE80-100E
Technical Handbook Safety regulations
4
P.Group 00
TDCE01
04GB
zNever run hands or fingers along any tubes,
pipes or hoses whilst investigating for possible
leaks as some of these lines (diesel fuel, hy-
draulic, steering, etc.) operate at extremely
high pressures and even the most minute of
leaks can cause oil or fluid to penetrate the
skin.
zUnder no circumstances may compressed air
be used to remove a hydraulic piston from its
cylinder.
zAlways attend to damage and wear that may
be of significance to the performance and use-
ful life of the truck or to the safety of the person-
nel.
zFollow the safety rules whenever carrying out
service work on the air conditioner. The re-
friger-ant is injurious to the skin and eyes. Only
authorized service personnel may repair the
system.
Safety regulations

DCE80-100E
Technical Handbook Safety regulations
5
P.Group 00
TDCE01
04GB
zTyre changing can be dangerous and should only
be carried out by specially trained personnel using
proper tools and procedures.
Failure to comply with these procedures may re-
sult in faulty positioning of the tyre and/or rim and
cause the assembly to burst with explosive force
sufficient to cause physical injury or death. Never
fit or use damaged tyres or rims.
zNever attempt to weld on an inflated tyre/rim
assembly.
zNever let anyone assemble or disassemble tyres
without proper training.
zNeverrun thetruckonone tyre of a dualassembly.
The load capacuty of a single tyre is then danger-
ous-lyexceededand operation inthismanner may
damage the rim.
zDeflation and dismantling
– Alwaysblock the tyreandwheel ontheopposite
side of the vehicle before you place the jack in
position. Always crib up the blocks to prevent
the jack from slipping.
– Always check the tyre/rim assembly for proper
component seating prior to removal from the
truck.
– Always deflate the tyre by removing the valve
core prior to removing the complete assembly
from the truck or dismantling any of the compo-
nent. Before loosening mounting bolts, run a
wire through the valve stem to ensure that it is
not blocked. Ice or dirt can prevent all the air
from escaping. Deflate and remove valve cores
from both tyres of a dual assembly.
– Never position body in front of the rim during de-
flation.
– Always follow assembly and dismantling proce-
dures outlined in the manufacturer’s instruction
manual, or other reconized industry instruction
manuals. Use proper rubber lubricant.
– Never use a steel hammer to assembling or dis-
mantling rim components – use a lead, brass or
plastic type mallets. The correct tools are avail-
able through rim/wheel distributors.
– remove bead seat band slowly to prevent acci-
dents. support the band with your thigh and roll
it slowly to the ground in order to protect back
and toes.
– Disassemblytools apply pressureto rim flanges
to unseat tyre beads. Keep your fingers clear.
Slant disassembly tool about 10 degrees to
keep it firmly in place. Always stand to one side
when applyin g hydraulic pressure. Should the
tool slip off, it may cause fatal injury .
zRim inspection
– Check rim components periodically for fatigue
cracks. Replace all cracked, badly worn,
damaged and severely rusted components.
– Always select the correct tyre size and construc-
tion matching the manufacturer’s rim or wheel
rating and size.
– Do not use over-size tyres, too large for the
rims, e.g. 14.5 inch tyres with 14 inch rims or
16.5 inch tyres with 16 inch rims.
– Never use damaged, worn or corroded rims/
wheelsorfittinghardware.Alwaysverifythatthe
rim is in a serviceable conditioning.
– Always clean and repaint lightly rusted rims.
– Never use a rim/wheel component that can not
be identified. Check rim parts against multi-
piece rim/wheel matching charts.
zAssembly and inflation
– It is important that the inflation equipment is
equipped with a water separator to remove
moist-ure from the air line in order to prevent co-
orosion. Check the separator periodically to en-
sure that it is working properly.
– Make sure that the lockring is in itsright position.
– Never mix different manufacurer’s parts since
this is potentially dangerous. Always check
manu-
facturer for approval.
– Never seat rings with hammering while the tyre
is inflated. Do not hammer on an inflated or par-
tially inflated tyre/rim assembly.
– Always double check to ensure that the rim as-
semblies have been correctly assembled and
thatsecuringstudsandnutsaretightened tothe
correct torque setting.
– Never inflate tyres before all side and lockrings
are in place. Check components for proper
assembly after pumping to approximately 5 psi
(=34 kPa, =0.34 bar)
– When adding air to a tyre on an industrial truck,
use a clip-on chuck and stay out of the danger
area. If the tyres has been run flat then the rim
must be dismantled and all parts inspected for
damage.
– Under-inflatedtyreshave a seriouseffectonthe
stability of the truck and reduces the safe load
handling capacity. Always maintain tyres at the
correct inflation pressures. Check inflation
pressure daily. Do not over-inflate.
– Inspect tyres regulary – every day if possible.
Look for and remove broken glass, torn pieces
of tread, embedded metal chips etc. Inspect for
uneven or rapid tread wear, usually caused by
mechanical irregularities, such as brakes out of
adjustment or excessive toe-in and toe-out. If
discovered, correct the irregularity immediately.
zWhen installing and tightening trail wheel bolts, ob-
serve the following:
– Ensure that trail wheel or hub mounting surfac-
es and trail wheel fastener mounting surfaces
are clean and free from paint and grease.
– Tighten bolts to specified torque settings. use
staggered sequence; i.e. top bolt, bottom bolt
etc.
Safety instructions for working with tyres

DCE80-100E
Technical Handbook General
6
P.Group 00
TDCE01
04GB
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.Theyare built arounda chassis whichhas highstrengthand
torsional stiffness and an extremely low centre of gravity.
The operator’s cab is providedwith 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
Technical Handbook General
7
P.Group 00
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04GB
1
2
3 5
467
1. Lifting mast, free lift mast with double cylinders
2. Operator’s cab, rubber suspended
3. Engine, six cylinder diesel with turbocompressor
4. Steering axle with pendular suspension and
double-acting steering cylinder
5. Gearbox, combined with torque converter
6. Drive axle, with hub reduction and oil sooled, hydraulic
brake system
7. Carriage with side lift attachment
Hydraulically controlled length adjustment and side-shift

DCE80-100E
Technical Handbook General
8
P.Group 00
TDCE01
04GB
Component units
zSound-insulated operator’s cab with excellent all-round visi-
bility. The non-slip, substantial steps provide convenient ac-
cess to the cab.
zCentrally positioned steering column.
zClearly arranged instrument panel.
zEngine – Volvo TAD720VE (standard) six-cylinder, four-
stroke, turbocharged diesel engine with direct injection and
thermostatically controlled water cooling.
zGearbox 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.
– Oilpump whichsuppliesoil underpressuretothe gearbox
and torque converter.
– Full-flow oil filter for effective cleaning of the gearbox oil.
zDrive 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.
zHydraulic 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.
Somemachineshave aseparatesystemfor side-liftwhich
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.
zSteered axle with pendulum mounting and double-acting
steering cylinder.
zSturdy 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.
zCarriage with:
– Support wheels to carry axial forces
– .Sliding plastic plates to carry side forces

DCE80-100E
Technical Handbook General
9
P.Group 00
TDCE01
04GB
Supplementary books
In addition to the Instruction Manual and the Technical Hand-
book, the following books are delivered with every truck.
Spare parts catalogue
Instruction Manual for engine
Workshop Manual för Engine
Replacement system - Spare parts
Kalmar operates a system of replacement parts, repair kits and
gasket sets covering most of the vital components of the truck.
For the contents of these kits, see the Spare parts catalogue.
Tools
Kalmar offers a wide range of tools for truck maintenance work.
For further information, please contact Kalmar's service depart-
ment.

DCE80-100E
Technical Handbook General
10
P.Group 00
TDCE01
04GB
Tightening torques
The tightening torques are applicable to steel bolts and nuts tight-
ened with a torque wrench under the following conditions:
The values specified in Table 1 are applicable to nut-and-bolt
joints, butcan also be used for bolts fitted into tapped holes. How-
ever, in the latter case, the preloading force will be somewhat
lower, depending on its depth of engagement.
When tightening by machine, the torque specified in Table 1
should be reduced by approx. 5%, due to the increased scatter
and to prevent the bolt from being tightened beyond its yield
point.
Surface treatment
Condition Lubriation
Bolt Nut
1 untreated untreated oiled
2bright galvanised
bright galvanised
bright galvanised
untreated
bright galvanised
bright galvanised dry or oiled
3 hot-dip galvanised bright galvanised dry or oiled
Quality 8,8 10,9 12,9
Tightening torque, Nm
Condition
Thread
M fin 12311
M8×1
M10×1,25
M12×1,25
M16×1,5
M18×1,5
27
54
96
230
330
24
48
85
205
294
30
61
108
260
373
39
76
135
323
466
46
91
162
388
559
M20×1,5
M24×2
M30×2
M36×3
460
786
2660
1560
409
700
1388
2367
520
888
1763
3005
647
1100
2200
3730
777
1330
2640
4480

DCE80-100E
Technical Handbook General
11
P.Group 00
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04GB
To reduce the risk of settlement of the material and the
associatedreductioninthe preloadingforceif thehardnessofthe
surface supporting the bolt head or nut is lower than 200 HB, a
washer should be fitted under the bolt head and nut. This is not
applicable if flanged bolts or flanged nuts are used.
When tightening is carriedout, the specified torque should be ap-
plied without pause, to ensure that the torque wrench will not be
tripped by the static friction before the joint has been tightened to
the specified torque.
Quality 8,8 10,9 12,9
Tightening torque, Nm
Condition
Thread
M12311
4
5
6
8
10
3,2
6,4
11
26
52
2,9
5,7
9,8
24
47
3,6
7,2
12,5
30
59
4,6
9,1
16
38
74
5,5
11
19
45
89
12
16
20
24
30
91
220
430
750
1480
81
198
386
668
1317
103
250
49
848
1672
128
313
620
1050
2080
154
375
732
1270
2500
Quality 8,8 10,9 12,9
Tightening torque, Nm
Condition
Thread
UNC 12311
1/4
5/16
3/8
7/16
1/2
12,5
25
44
70
107
11,1
22,3
39
62
95
14,1
28,3
50
79
121
17,6
35
62
100
151
20
42
73
118
178
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
153
210
370
594
889
1260
1760
2320
3060
136
187
390
528
791
1120
1565
2065
2720
173
237
418
671
1005
1424
1990
2620
3455
216
298
524
839
1260
1780
2490
3280
4320
255
353
619
990
1480
2100
2940
3870
5100

DCE80-100E
Technical Handbook General
12
P.Group 00
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04GB
System of units
The SI system of units is employed in this handbook:
The conversion factors are as follows:
Pressure
Torque
Quality 8,8 10,9 12,9
Tightening torque, Nm
Condition
Thread
UNF 12311
1/4
5/16
3/8
7/16
1/2
13
26
47
75
114
11
23
42
66
101
14
29
53
85
128
19
37
67
107
162
22
44
79
126
191
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
164
227
396
629
937
1350
1860
2500
3260
145
202
352
560
834
1200
1655
2225
2900
185
256
447
710
1058
1525
2100
2825
3680
231
321
559
889
1320
1900
2630
3530
4610
273
379
661
1050
1560
2250
3110
4170
5450
megapascal bar Kilogram-force per
square centimetre,
kpf/cm²
Atmosphere, at
Pound-force
per square
inch,
psi
1
0,1
0,098
10
1
0,98
10,2
1,02
1
145
14.5
14.2
Newton-
meter
Nm
Kilogram force-metre
kgf m Pound-force foot lbf ft
1
9,81 0,102 10.74 7.23
Power
Kilowatt
kW Horsepower (metric) hp Horsepower
hp
1
0,735 1,36 11.34
0.986

DCE80-100E
Technical Handbook Contents 1
P.Group 10
TDCE01
04GB
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
Technical Handbook Specifications 2
P.Group 10
TDCE01
04GB
Air conditioner
zCab unit
Circulated air flow 500-600 m3/h
Electric power consumption approx 350 W
zCompressor
Max. speed 4000 r/min
Refrigerant R134a *)
Electric power consumption approx 50 W
Oil capacity Zexel PAG SP-20 1.5 dl
zCondenser
Electric power consumption 250 W
zCooling effect 6-8,5 kW
zHeating effect approx 11 kW
*) Refrigerant R12 is no longer in production due to legislation

DCE80-100E
Technical Handbook Chassis
Description 3
P.Group 10
TDCE01
04GB
Chassis
The chassis consists of:
zA unit construction frame built up around two beams with a
minimum of welds for best possible strength.
zMountings for the drive axle, steered axle, mast, lifting cylin-
ders and transmission.
zThe necessary counterweights to provide a very low centre
ofgravity. Moreover, thesteered axle is designedto serve as
an additional counterweight.
zThe 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.
zSeparate 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.
1. Mounting for mast
2. Mounting for tilt cylinder
3. Space for counter weights
4. Mounting for steering cylinder
5. Mounting for cab
6. Step with platform on the left
hand side of the cab, standard
7. Step with platform on the right
hand side of the cab, optional
1
2
5
4
3
6
7
Chassis

DCE80-100E
Technical Handbook Operator’s cab
Description 4
P.Group 10
TDCE01
04GB
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.
1. Steering column with instrument panel and switches, ECS-terminal (option)
2. Air filter
3. Heating system
4. Electrical central unit
1
2
3
4

DCE80-100E
Technical Handbook Operator’s cab
Description 5
P.Group 10
TDCE01
04GB
1. Gear lever
FORWARD/NEUTRAL/REVERSE 1/2/3
2. Lever DIRECTION INDICATORS/HORN
FRONT WINDSCREEN WASHER/
FRONT WIPERS/MAIN BEAM
3. Instrument panel
4. Steering wheel panel
5. Starting switch
6. Control lever, hydraulic functions,
See Instruction Manual
a. Lift
b. Tilt
c. Sideshift
d. Length adjustment 20’-40’
e. Locking/Unlocking twist-locks
7. Electrical central unit with fuses and relays
8. Brake pedals, normal driving brake
9. Release clutch
10.Accelerator pedal
11. Steering wheel adjustment
12.Operator’s seat
13.Parking brake
14.Emergency switch for all hydraulic functions
15.Key switch for by-passing safety system
KL743
7
1
23
4
N
R
F
145
23
R
0
L
KL1733
31 4 52 6
151413111098 12
abcde
KL1734
KL1735
abcd
Option: Elservo
Option: Joy-stick
6
6
13
15
14
13
14
15

DCE80-100E
Technical Handbook Operator’s cab
Description 6
P.Group 10
TDCE01
04GB
KL58
1
2
1
22 23
24 252627
37 38 39
31 32 33
282930
34 35 36
KL580
54 55 56 60 59
57 58 64 61 62 63
1
23
4
N
R
F
1
45
23
R
0
L
21. Pressure gauge, gearbox oil pressure
22. Fuel gauge
23. Temperature gauge, engine coolant temperature
24.Switch, working lights
25.Switch, working lights
26.Switch, working lights
27.Switch, flashing beacon
28.Switch, hazard warning lights
29.Switch, driving lights
30.Spare
31.Spare
32.Switch with lamp ENGINE MAINTENANCE
(QSB5.9)
33.Spare
34.Switch, compressor air conditioning 1)
35.Control, recirculation/fresh air
36.Control, defrost/cab
37.Switch, fan
38.Control, heat
39.Control, cold 1)
40. Switch with lamp DIAGNOSIS (QSB5.9)
41. a. Warning lamp STOP ENGINE (QSB5.9)
b. Indicating lamp CHECK ENGINE (QSB5.9)
42.Warning lamp, battery charging
43.Warning lamp, low engine oil pressure
44.Warning lamp, low gearbox oil pressure
45.Warning lamp, low brake pressure
(accumulator pressure)
46.Warning lamp, low engine coolant level
47.Indicating lamp, preheating
48.Warning lamp, high engine coolant temperature
49.Warning lamp, high gearbox oil temperature
50.Spare
51.Warning lamp, parking brake ON
52.Spare
53.Spare
54.Green lamp TWIST-LOCKS LOCKED
55.Orange lamp ALIGNMENT
56.Red lamp TWIST-LOCKS UNLOCKED
57.Spare
58.Spare
59.Indicating lamp, headlights
60.Indicating lamp, direction indicators
61.ECS terminal 1)
62.Switch, windscreen wiper, rear
63.Switch, windscreen wiper, roof
64.Spare
65.Fuses
66.Hour meter
1) Optional
KL582
40 41 42 43 44 45 52 53
47 48 49 50 51
46
KL1307
66
KL675
65