DCD 90-180

DCD 70-32E3 - 70-40E5

Publ. no 920935.0272 0208

 Contents
Safety regulations ...................................................................... 2
Introduction................................................................................ 4
Signs.......................................................................................... 6
Operation................................................................................... 8
Instrument and controls........................................................ 8
Heating and air conditioning system .................................. 16
Operator’s seat, adjustments.............................................. 18
Tilting the cab ..................................................................... 19
Engine heater ..................................................................... 20
Running-in .......................................................................... 20
Starting the engine ............................................................. 20
Warming up of engine ........................................................ 20
Functional checks............................................................... 21
Stopping of engine, parking................................................ 21
Power steering.................................................................... 21
Lifting technique ................................................................. 22
Side-lift ............................................................................... 23
Special procedures.................................................................. 27
Supervision.............................................................................. 28
Daily supervision ................................................................ 28
Tyres ................................................................................... 29
Fuel system ........................................................................ 30
Engine oil............................................................................ 31
Air cleaner .......................................................................... 32
Cooling system ................................................................... 32
Checking the accumulators ................................................ 33
Hydraulic system ................................................................ 34
Gearbox oil ......................................................................... 34
Windscreen washer ............................................................ 34
Electrical system ................................................................ 35
Technical data.......................................................................... 37
Lubrication chart...................................................................... 38
Oil and lubricant recommendations ......................................... 42

Detailed technical descriptions with circuit diagrams, periodic

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

DCD90-180 1
Safety regulations
It is important that you read the instruction
manual.
Incorrect handling can lead to personal injury or dam-
age to products and/or property. Therefore, read the in-
struction book very carefully before operating the truck.
The instruction manual contains important information
about your Kalmar truck, about the operation of the
truck, about safety during operation and about the
truck's daily maintenance. In addition, you will find use-
ful information that will make operations easier for you
in your daily work.
The instruction manual must always be kept in the ma-
chine. If the manual should be lost, a replacement must
be immediately obtained. Never use a machine with a
missing instruction manual.
Ask your foreman/group leader if there is anything in
the manual that you do not understand or if you feel that
information is missing in any area.
The symbol is used on our products in certain
cases and then refers to important information con-
tained in the instruction manual. Make sure that warn-
ing and information symbols are always clearly visible
and legible. Replace symbols that have been damaged
or painted over.
In this instruction manual warnings are inserted that
apply to your own safety. Warnings point out the risk of
accident that can cause personal injury.
WARNING!
Warns of the risk of serious personal injury, pos-
sible death and/or serious damage to product or
property if the regulations are not followed.
For technical warnings, that point out the risk of break
down, the word IMPORTANT is used:
IMPORTANT!
Is used to draw attention to such occurrences
that can cause damage to the product or
property.
For information that facilitates the working process or
handling, N.B. is used:
N.B. Draws attention to useful information that
helps the working process.
2 DCD90-180
Safety regulations aimed at reducing the
risk of personal injury and damage to
loads or other property.
Intended of use
z The truck may only be used for the purpose for
which it was intended, namely, to lift and transport
goods, the weight of which does not exceed the
maximum permitted load capacity of the truck.
z The truck may not, without specific permission
from Kalmar, be modified or re-built so that its func-
tion or performance is altered.
z The truck may not be driven on public highways if
it has not been adapted to comply with national
road safety regulations.
Operator requirements
z The truck may only be driven by operators who
have been specially trained and who have the
company's authority to do so.
z Laws and other regulations relating to driving li-
cence, operator ID, log book, etc., must be fol-
lowed at all times.
z The operator must be aware of and follow all local
safety regulations.
z It is always the responsibility of the operator to en-
sure that the truck has approved fire extinguishing
equipment in accordance with currently applicable
regulations.
Operation of the truck is prohibited:
z If any of the fitted safety equipment, such as rear
view mirrors, headlights, reversing alarm (option-
al), does not function correctly.
z If there is a fault with the brakes, steering or lift
equipment.
z If it has been repaired, modified or adjusted with-
out the approval of the work supervisor.
z If the truck is fitted with tyres not approved by
Kalmar.
Continued on next page
Safety regulations
Continued from previous page
Operating regulations
z Before starting, always check to ensure that no-
body is in the way of the truck or its equipment.
z The operator must always face the direction of op-
eration and take particular care in areas where
persons or other vehicles are likely to appear in the
vicinity. If visibility is limited by the load, the opera-
tor should operate the truck in reverse.
z It is prohibited to walk or stand underneath raised
forks or other equipment, whether they are loaded
or not.
z It is prohibited to transport passengers on the truck
outside the cab or on the load. Passengers may be
transported inside the cab only on condition that it
is equipped with a fixed passenger seat.
z It is prohibited to lift people if the truck is not
equipped with an approved lift cage.
z It is prohibited to exceed the load capacity of the
truck. See capacity plate and loading diagram.
z It is prohibited to transport loads in the raised posi-
tion as this entails a risk of the truck tipping. All
transportation shall take place with the load in the
lowered position and with the mast tilted back-
wards to the maximum.
z The operator must adapt the speed of the truck to
the character of the load, conditions of visibility, the
character of the roadway/surface, etc.
z The operator shall avoid powerful acceleration and
braking when turning. In addition, the operator
shall always moderate the speed of the truck when
turning so as to avoid the risk of lateral skidding or
tipping.
z The operator shall take particular care when oper-
ating in the vicinity of electrical power lines, via-
ducts, quay-sides, ramps, gates/doors etc.
z Safety belts must always be worn, if fitted. In the
event of the truck tipping, always remain in the cab
and grip the steering wheel securely. Never try to
jump out of the cab.
z The parking brake can also be used as an EMER-
GENCY BRAKE. However, having been used for
emergency braking, the brake linings must be in-
spected and replaced if needed. If the parking
brake has been mechanically released, it must al-
ways be reset in order for the truck to regain the
parking brake function.
Interrupted operation, parking
z Always check that the gear lever is in the neutral
position before turning the ignition key to restart or
to reset an emergency stop.
z Never leave the operator's cab without applying the
parking brake (ON position).
z Always remove the ignition key if the truck is to be
left unattended.
Other important points to remember
z The truck's hydraulic system includes high pres-
sure hydraulic accumulators. Always be extremely
careful when working with the hydraulic system
and avoid being unnecessarily close to the hydrau-
lic equipment, lines and hoses. Before working on
the hydraulic system, the accumulators must be
emptied into the tank, with the help of the special
accumulator evacuation valve.
DCD90-180
z Handle batteries and junction boxes with great
care. The batteries must always be protected over
the poles and connections.
z Always rectify any damage or wear and tear that
can risk personal safety or that can affect the func-
tions of the truck or its service life.
z Trucks with tippable cabs: The cab must always be
tipped over the point of balance. If there is insuffi-
cient lateral space the cab must always be secured
against accidental lowering with a brace or similar.
z Avoid touching oils and greases. Avoid inhaling ex-
haust and oil fumes.
z Always use steps and handrails when entering or
leaving the machine - Never jump!
To avoid the risk of slipping, tread only on anti-slip
surfaces. If the anti-slip protection has become
worn, loose or in any way less effective, it should
be replaced.
z Welding painted steel produces poisonous gas-
ses. Paint should therefore be stripped before
welding, good ventilation ensured and/or face
mask with filter used.
z Mobile phones used in the cab must always have
fixed connections to the machine’s electrical sys-
tem, with a fixed antenna outside the machine,
mounted in accordance with the manufacturer’s in-
structions. This will avoid interference with the ma-
chine’s important electronic functions.
z The tensile strength of the top pane can be seri-
ously weakened by exposure to elements that con-
tain: Aromatic hydrocarbon, ketone, esters or
chlorinated hydrocarbon.
Regularly check the surface condition of the top
pane and clean only with screen wash or other mild
cleaning fluid. After cleaning, rinse thoroughly with
warm water. It is prohibited to modify or in any oth-
er way make alterations to the top pane. Immedi-
ately replace damaged top panes that show signs
of cracking or scratching.
Operating with attachments
z The operator must always take the effect of the
wind into account when handling containers. Avoid
lifting with a wind strength in excess of 12 m/s
(27 mph/40 feet per second)
z Always drive carefully so as to avoid attachments
colliding with pillars, cables, etc.
z Carefully study the “Lift methods” section of the
instruction manual
CE marking
All trucks and equipment (though not thoses fitted on
the truck or intended as spare parts) supplied from Ka-
lmar are CE marked, which indicates that they comply
with the requirements of the EU Machine Safety Direc-
tive. In addition, each truck has a so called, “EU Decla-
ration of Conformity” which is the legal proof that the
truck complies with the “health and safety” require-
ments laid down in the Machine Safety Directive, the
EMC directive (electro-magnetic compatibility) and the
LVD directive (electrical equipment).
Vibration standard
The truck complies with and is below the limits for vibra-
tion standard EN 13059.
3
Introduction
Kalmar forklift trucks 90-180 with lifting capacities of 9 to 18
tonnes and empty container trucks 70 with lifting capacity of 7
tonnes comprise the medium-heavy standard series in the
Kalmar range, which includes forklift trucks rated between 2 and
90 tonnes. This series of trucks is based on a system of modules
and provides great flexibility in the selection of engine and
gearbox.
The visibility is very good, due to the large windows and the clear
field of vision through the mast and the fork carriage.
All trucks in the series are equipped with a tiltable cab.
The picture on the next page shows the most important units of
the truck.
The Instruction Manual applies to all models unless otherwise
stated.
Since the trucks are delivered with different equipment, minor
deviations from the Instruction Manual may occur.

Kalmar Industries AB

Type designation
Forklift trucks

DCD120-12
Diesel engine
Counterweighted truck
Generation
Lift capacity, decitonnes
Load centre distance, decimetres

Empty container trucks

DCD70-32E3
Diesel engine
Counterweighted truck
Generation
Lift capacity, decitonnes
Wheel base, decimetres
Empty container handling
Max number of containers at stacking

IMPORTANT!
BEFORE USING THE TRUCK CHECK:
– engine oil
– fuel level
– coolant level
– tyre pressure
For further information, see the section entitled
SUPERVISION.

4 DCD90-180
Introduction

1
2 3

KL734

6 5 4

1. Mast, free-visibility, with two lifting cylinders
2. Operator’s cab, rubber suspended tiltable cab
3. Engine, six-cylinder diesel engine with turbo-
compressor
4. Steering axle, with pendulum suspension and
double-acting steering cylinder
5. Gearbox, combined with torque converter, 3 gears in
each direction
6. Drive axle, with hub gearing and oil-cooled
hydraulic brake system
7. Fork carriage, with manually moveable forks or
hydraulically controlled fork positioning and
sideshift

DCD90-180 5
Signs
The information plates on the machine are shown below. The op-
erator shall be aware of and follow the warnings and instructions
given on them. Plates that have disappeared, been damaged or
become illegible shall be immediately replaced. Spare parts num-
bers are stated on respective plates. They can also be found in
the Spare Parts catalogue.

101

802

101 811,812

A34724.0100A

405 102 706 701 405

119

302

A34724.0100B

804 301 203 307

123 114 110 401 809 807 104

305 402

A34724.0100C

305 402 711

118 102

6 DCD90-180
Signs

10 Chassis, Cab
101 423049.0100 Lift point.
Fixing point for lift
equipment when lift-
ing the truck.
102 A26939.0100 Warning!
Read the instruction
Manual.
104 A26940.0100 Parking brake
ON-OFF.
123 A42483.0100 Sound power level 711 A36163.0100 Warning!
-1300 104 -116 dB. High pressure!
Selected for actual Always release
machine pressure from the
accumulator before
working on the
20 Electrical system hydraulic system.
Read the Instruction
203 A30537.0100 Main switch.
Manual
In position 0 the
battery’s plus pole is 80 Mast, attachments
isolated. 802 A30771.0100 Warning!
Do not walk under
30 Motor the load.
301 450202.0100 Fuel.

D
110 A30770.0300 Warning! 450202.0100

Air conditioning equipment,

read the Technical Handbook. 302 A30530.0100 Warning! 804 A33807.0200 Type, attachment
Coolant may be topped up only by Rotating fan.
authorized specialist Fitted on radiator

305 A30532.0200 Warning!

Hot surface.
S/N =Serial number
1
2
A= Model name, attachment
3
307 A32439.0300 Engine oil H= Lift height
1 = Refrigerant, type D= Load Centre - horizontal
2 = Amount, kg (TWD731VE: The
plate is located on Q= Lift capacity
3 = Pressure, bar C= Load Centre - vertical
114 A33806.0200 Type, machine the filler cap on the
engine) Distance from forks up to the
centre of gravity of the load
40 Transmission, tyres
807 A33808.0200 Type, forks
401 455949.0100 Transmission oil

402 A30533.0200 Warning!

Rotating parts.
See 804.
M = Model 405 Tyre pressure, 809 A33808.0700 Type, pike boom
S/N = Serial number A32049.0300 0,7 MPa
Q = Classified lift capacity of the A32049.0500 0,8 MPa
truck at lift height in accord- A32049.0700 0,9 MPa
ance with EN1551, EN1459
standards
D = Load Centre - horizontal
H = Classified lift height 70 Hydraulic system See 804.
W = Unloaded weight of machine 701 450203.0100 Hydraulic fluid. 811 A33852.0100 Type, attachment
C = Load Centre - vertical
distance from forks up to the
centre of gravity of the load
118 A36203.0100 Warning! 706 920643.0021 Hydraulic pressure.
– Read the See Technical
Instruction Manual. Handbook..
– No Riders! S/N = Serial number
Passengers may be 812 A33853.0100 Type, attachment
MPa MPa MPa MPa MPa
carried in the cab
only if it is equipped
with a fixed
passenger seat. – Do not jump!
Always remain in the truck and firm- MPa

ly grip the steering wheel when

there is a risk of tipping.
119 A36692.0100 Cab tilting
920643.0021
A= Model name
S/N = Serial number
1. Electrical H= Max hydraulic pressure
1 2 W= Unloaded weight of attachm
2. Manual
Q= Lift capacity
D= Load Centre - horizontal

DCD90-180 7
OPERATION Instruments and controls

3 1 4 5 2 6

F
4 3 2 1

L 0
R

a
1 4 5

2 3
b c d

KL735

7 8 9 10 11 12 13 14

KL743

Page
1. Gear selector .......................................................... 12
FORWARD/NEUTRAL/REVERSE 1/2/3
2. Lever DIRECTION INDICATORS/HORN ................ 12
FRONT WINDSCREEN WASHER/
FRONT WIPERS/MAIN BEAM
3. Instrument panel ....................................................... 9
4. Steering wheel panel ................................................ 9
5. Starting switch......................................................... 11
6. Control lever, hydraulic functions ............................ 13
a. Lift, b. Tilt, c. Sideshift, d. Fork positioning
Page
7. Electrical central unit .............................................. 35
with fuses and relays
8. Brake pedals, normal driving brake......................... 14
9. Release clutch ........................................................ 14
10. Accelerator pedal .................................................... 14
11. Steering wheel adjustment...................................... 15
12. Stop control............................................................. 15
13. Parking brake .......................................................... 15
14. Operator’s seat........................................................ 18

8 DCD90-180
OPERATION Instruments and controls

21 22 23

KL581

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

66

F
4 3 2 1

L 0
R

KL580
R
1 2 3

4 5

57 58 64 61 62 63
21. Pressure gauge, gearbox oil pressure 1) 40. Spare
22. Fuel gauge 41. Spare
23. Temperature gauge, engine coolant temperature 42. Warning lamp, battery charging
24. Switch, working lights 43. Warning lamp, low engine oil pressure
25. Switch, working lights 44. Warning lamp, low gearbox oil pressure
26. Switch, working lights 1) 45. Warning lamp, low brake pressure
27. Switch, flashing beacon 1) (accumulator pressure)
28. Switch, hazard warning lights 46. Warning lamp, low engine coolant level
29. Switch, driving lights 47. Indicating lamp, preheating
30. Spare 48. Warning lamp, high engine coolant temperature
31. Spare 49. Warning lamp, high gearbox oil temperature
32. Spare 50. Warning lamp, safety locking by-passed 1)
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 1)
37. Switch, fan 55. Orange lamp ALIGNMENT 1)
38. Control, heat 56. Red lamp TWIST-LOCKS UNLOCKED 1)
39. Control, cold 1) 57. LOCK/UNLOCK TWIST-LOCKS 1)
58. LENGTH ADJUSTMENT 20-40’ 1)
Alt: Seat rotation, rotatable operator seat 1)
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. Switch, electric parking brake 1)
65. Fuses
66. Hour meter
1) Optional
65

DCD90-180 9
OPERATION Instrument and controls
Warning lamps
(Trucks equipped with ECS, module 07, have no warning
lamps 43, 44, 46, 48, 49)
All of these lamps should be extinguished when the truck is in
42 operation. A steady light and a buzzer indicate failure.

Battery charging lamp (42)

If the lamp should light up this indicates that the alternator is not
charging. If this should happen, identify the cause and remedy it.
43 Never use the truck when the charging lamp lights.

Lubricating oil pressure, engine (43)

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

Oil pressure, gearbox (44)

45 The lamp should go out immediately after the engine has started.
Pressure is too low if the lamp lights up while the truck is in oper-
ation. If this happens, stop the truck immediately and report to the
service personnel.

46 Low brake pressure (45)

The lamp will light up if the hydraulic pressure in the accumulator,
i.e. the brake system pressure, should drop below 100 bar. After
the lamp has lit, sufficient capacity is still available for applying
the brakes a number of times.
If the pressure is not built up and maintained, check the accumu-
lators for leakage in accordance with the section entitled Super-
vision.
47 KL598

Engine coolant level (46)

48 The lamp will light momentarily on starting. If the lamp lights up
when the truck is travelling, the coolant level is too low. Check the
level and top up as necessary.

Engine preheating (47)

49
The lamp will lights during the preheating period.

Engine coolant temperature (48)

The lamp will light up if the coolant temperature becomes too
high. Make sure that the cause is identified and remedied.

50 Oil temperature, gearbox (49)

The lamp will light up if the temperature of the gearbox oil ex-
ceeds 120°C. Stop the truck and make sure that the cause is
51 identified and remedied.

Spare (50)

Parking brake lamp (51)

The lamp will lights while the parking brake is applied.

10 DCD90-180
OPERATION Instrument and controls
Trucks equipped with ECS, module 07, have no instruments
21, 22, and 23.

Pressure gauge, gearbox oil pressure (21)

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

Fuel gauge (22)

22 The tank is full when the gauge reading is 4/4. The tank is half-
full when the pointer is vertical.
Always refuel before the gauge reading has dropped to 0.
Air may otherwise be drawn into the fuel system, which will then
have to be bled.

23
Temperature gauge (23)
The temperature gauge shows the engine coolant temperature,
which should normally be approx 80°C. This temperature will be
reached after the engine has run for about 5 minutes. The tem-
KL581 perature may vary between 75 and 97°C.
A higher temperature may be an indication that coolant level is
low. Check and top up as required, see under Supervision.
If the temperature is still too high, the cause must be identified
and remedied.
Don’t run the engine if the coolant temperature is too high.

Operating hour meter (66)

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

KL1307

Starting switch (5)

P Option: Stop solenoid (activated in stop position)
0 All functions switched off, the key can be removed
I Operating position. All electrical functions are energized.
The key may be set to this position to switch on the lighting,
for instance, when the engine is not running.
II Glow position. In this position the glow-plug is energized.
The glow mode is indicated by lamp 47. Turn directly to
position III if the engine is warm.
III Starter motor energized.
The truck has an electrical restart guard protecting the starter
motor from meshing while the engine is rotating.

WARNING!

Risk of explosion.
Never use start spray to assist in starting.

DCD90-180 11
OPERATION Instrument and controls
Gear lever – Forward/Neutral/Reverse (1)
– 1/2/3
The gear-changing mechanism is electrical, and the gearbox is
operated via solenoid valves.

2 3 F F – FORWARD
1 4
N – NEUTRAL
R – REVERSE (Optional extra: Acoustic warning signal)
21

TURN, lever 1, 2, 3
4 3

RMH control (Optional extra): Lever inwards/outwards for 1, 2,

KL676
R
Option: RMH
IMPORTANT!
Stop the truck before changing from
forward to reverse gears and vice ver-
sa. Otherwise, the transmission can
be damaged.
For the Clark 20000 gearbox, that is
equipped with a modulator, changes
from forward to reverse gears can
take place at a speed of up to 6 km/
hour.
3. Lift lever to engage 1st gear
The engine cannot be started unless the gear lever is in neutral.
The truck must be stopped completely before changing between
forward and reverse, in order to prevent overloading the gearbox
and power transmission.
z Run the engine at idle speed, select the direction of travel
with the gear lever and engage first gear, using the rotary
control. Never pull away in a higher gear, since this may lead
to unnecessary overheating.
z Release the parking brake, and accelerate carefully.
z To change up, turn the gear selector handle to second gear,
release the accelerator pedal and the second gear will be en-
gaged, accelerate, and so on.
z Reverse the procedure when changing down. Remember to
increase engine speed before engaging a lower gear, since
the truck will otherwise brake heavily.
Trucks with ECS, automatic gear changing (Optional)
The points at which the gearbox changes gear are optimized to
the truck's transmission system. The operator can limit gear
changing by twisting the gear selector from 3rd to 2nd or 1st
gears. If for example, 2nd gear is selected, the system automati-
cally changes gear between 1st and 2nd gears.
The ECS system
z prevents the gears being engaged if engine revolutions ex-
ceed 1100 r.p.m.
z prevents changing between forward and reverse gears if the
truck speed is in excess of 3 k.p.h. (reversing preventor).
z locks the gearbox in the current gear if the signal from the
propeller shaft sensor is excessive or if the signal ceases.
z reduces engine revolutions with a change to a higher gear to
ensure that the truck maintains an unchanged speed.
z disengages the gearbox if the operator applies the brakes
and the speed is less than 3 k.p.h.
z provides the required engine revolutions based on the posi-
tion of the accelerator pedal.
z continually shows the gear engaged on the ECS terminal
display.

Direction indicators/Dip switch/Horn (2)

0 J

FORWARD/BACKWARDS – Direction indicators

UPWARDS – Headlamp flashing
DOWNWARDS – Full beam
KL677
INWARDS, button – Horn
INWARDS, lever – Screen wash
TURN – Screen wiper, front
0 = Off/J = Intermittent/
I = Continuous wiping/II = –

12 DCD90-180
OPERATION Instrument and controls
Control levers (6)
The control levers are hydraulically connected to the main valve.
Electric servo control is available as optional equipment.
The speed of the various hydraulic functions, such as lifting,
tilting, etc, will vary depending on the displacement of the corre-
sponding control lever. The speeds of the hydraulic functions can
also be varied by varying the engine speed.
The control levers 6 a-d shown in the illustration are the ones nor-
mally fitted. Lever e is only fitted as optional equipment.

Lift Lower (a)

LIFT – pull the lever back
LOWER – push the lever forward

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

ment of the control lever, i.e., engine speed does not affect the
lowering rate.

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

Sideshift (c)
LEFT – push the lever forward
RIGHT – pull the lever back

The forks cannot be sideshifted if fork positioning is set at its

outer position.

Fork positioning (d)

OUTWARDS – push the lever forward
INWARDS – pull the lever back

Note that further positioning is blocked when one of the forks

reaches its outermost position. Sideshift to the centre and posi-
tion again.

Fork levelling (Optional equipment) (e)

Fork levelling acts on the right-hand or the left-hand fork.
FORK UPWARDS – pull the lever back
FORK DOWNWARDS – push the lever forward
f
Press-button controlled hydraulic function
(Extra) (f)
As an optional extra, certain trucks can be equipped with an extra
hydraulic function, electrically controlled by means of a press
button on lever d.
Press the button down and at the same time move the lever FOR-
WARDS/BACKWARDS to control the extra hydraulic function.

DCD90-180 13
OPERATION Instrument and controls
Hydraulic weight indicator
A A: Indicator
B: Twist control for zero-setting
C: Foot switch for weighing
B
1. Before weighing and with the truck unloaded, set the indica-
tor to zero, by twisting the twist control B.
2. To weigh a load, press foot switch C down.

KL1445

Brake pedals and release clutch activator (8 and 9)

The brake pedals are hydraulically-actuated and connected to
the hydraulic system of the truck via accumulators which ensure
that there will always be sufficient pressure for braking, even in
the event of the engine stopping for a brief period. If the accumu-
lator pressure falls below a certain level, lamp 45 on the panel will
come on.
The brake pedal (8) is used as the ordinary foot brake.
The brake pedal is combined with a separate release clutch acti-
vator (9). When this pedal is pressed at the same as the brake
F
pedal, the clutch is activated (gearbox disengaged) at a certain
4 3 2 1

N
brake pressure. The clutch feature is used if hydraulic functions
L 0

are required while a gear is engaged.

R
4 3

Accelerator (10)
The accelerator pedal is mechanical and actuates the fuel injec-
tion pump by means of a wire.
Options: Some trucks are equipped with hydraulic or electrical
KL597 accelerator.

57 8 9 10 Optional Extra: Accelerator pedal with change-over

switches for forward and reverse
Connect and disconnect the system with switch 57, see illustra-
tion.
F Disconnected system: Normal gear changing with gear selector
Connected system: Gear changing as below.

R Forward: Press down the left change-over switch simultaneously

Option with the accelerator pedal
Reverse: Press down the right change-over switch simultaneous-
ly with the accelerator pedal
KL1446 Neutral: No change-over switch pressed down.

14 DCD90-180
OPERATION Instrument and controls
Adjusting the steering wheel (11)
The angle and height of the steering wheel and instrument panel
can be adjusted to the desired driving position.
Upper handle upwards: Steering wheel height position
Upper handle downwards: Steering wheel angle
Lower handle: Steering column angle
Loosen the handle clockwise and
adjust as required.
Tighten the knob firmly after
adjustment
11

KL588

Stop control (12), mechanical

This control affects the injection pump and is used to stop the en-
gine.
12 To stop, pull out the stop knob, and then turn the ignition key to 0.
Make a habit of leaving the stop knob in the pulled out mode
when parking the truck.

Parking brake (13)

The parking brake consists of a disc brake on the input shaft of
the drive axle and is applied by a powerful spring in the hydraulic
cylinder of the parking brake. The brake is actuated hydraulically
by means of lever 13.
A warning buzzer will be sound if the operator inadvertently
leaves his seat before applying the parking brake.
Warning lamp 51 will show a steady light when the parking brake
KL744 is applied.
13 If the accumulator pressure should drop below a certain level,
warning lamp 45 will light up. But sufficient capacity will still be
available for releasing the parking brake. After that, the parking
brake is applied automatically by a heavy spring in the brake cyl-
inder. If the wheels then need to be rotated – deactivate the
brake, see section Mechanical disengagement of the parking
brake, page 27.
The parking brake may also be used as emergency brake. If the
parking brake has been used for emergency braking, the brake
pads should be inspected and replaced if needed.

WARNING!

Never leave the operator’s seat with-

out applying the parking brake

DCD90-180 15
OPERATION Heating and air conditioning system
Heating and air conditioning system
The standard version of the truck is equipped with heater and de-
froster only.
The heating system is connected to the engine coolant system
and starts delivering heat after the engine has warmed up.
The fan is controlled in steps 0-I-II-II by switch 37. The air condi-
34 tioning system can be switched on and off by means of switch 34.
35 NOTE. The air conditioner is optional equipment.

34. Switch, compressor air conditioner

35. RECIRCULATION switch
Closed – 100% air from outside of cab
36 39 Open – 20% air from outside of cab
KL599 37 36. Control DEFROSTER/CAB
37. Fan control
38 38. HEAT control
39. COOLING control (Optional)

Setting the heating mode

z Close the recirculation control 35. Open if the weather is very
cold.
z Switch off the air conditioner, switch 34.
z Set the heater control 38 and the fan 37 as required.

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

Setting the cooling mode

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

16 DCD90-180
OPERATION Heating and air conditioning system
Thermostatically controlled Air Conditioning unit
As an optional extra, a thermostatically controlled system for air
conditioning, cooling, demisting/dehumidifying and heating, is
available.
The system is equipped with a sensor that senses both inner and
outer temperatures and automatically regulates the temperature
to the pre-set level, either by heating or by cooling.
33 33. Switch DEMIST/DEHUMIDIFYING FUNCTION.
34. Switch COOLING FUNCTION OFF.
34 35. Switch RE-CIRCULATION.
Switch forwards - air from outside.
35 Switch backwards - air from inside.
36. Control DEMIST/CAB.
37. Control FAN. Infinitely variable setting of fan speed.
38. Control TEMPERATURE. Infinitely variable setting of cab
temperature from 16-26°C.
36 39 Control fully clockwise: Full heating effect = heating valve
KL599A continuously open.
37 Control fully anti-clockwise: Full cooling effect = cooling func-
tion running continuously.
38 N.B. When the controls are in respective full positions, pre-
cise temperature regulation cannot be achieved.
39. Cover. The climate equipment’s demist thermostat is located
under this cover. The thermostat must always be set in the
max. clockwise position.
Normal operation
N.B. Run the compressor from time 1. Set controls 37 FAN and 38 TEMPERATURE to the required
to time, even during the winter, in fan speed and temperature.
order to lubricate and ensure The fan must be running for cooling to function. (If the fan is
correct function. switched off, the compressor and condenser stop.)
2. The system then operates automatically, as follows:
N.B. The cooling is not operative at – When heat is required:
temperatures below 0 °C. The system operates in 10 second cycles. The water valve
opens for heating at intervals from 0 seconds, extending
to 4 seconds. Thereafter, the valve is open for continual
heating.
– When cooling is required:
The system operates in 2 minute cycles. The compressor
operates at intervals from 30 seconds, extending to con-
tinual operation. The condenser operates continuously as
long as cooling is required.
Demisting/Dehumidifying the air in the cab
1. This function is used when the windscreen/windows mist up.
2. Start demisting by pressing switch 33.
The fan then runs at full speed for 3 minutes, the compressor
and condenser run continuously. The switch lamp lights.
N.B. The cooling system is used for dehumidifying air.
3. After 3 min. the fan speed returns automatically to the previ-
ously set level. Control 37 can be used to select a lower fan
speed at any time.
4. Press switch 33 again to switch off the demisting function.
The switch lamp extinguishes.
Operating without automatic cooling
1. Press switch 34 to the OFF position.
The compressor and condenser then stop. The switch lamp
lights. the cooling function is thereby de-selected in all posi-
tions and does not start even when control 38 TEMPERA-
TURE is set to the MIN. position.
2. Set control 38 to the required temperature.

DCD90-180 17
OPERATION Operator’s seat
Operator’s seat adjustments
The operator’s seat is provided with the following adjustment
facilities:
A Distance from the pedals.
Release the seat by means of the lever and move it forward or to-
wards the rear.
B Height of the seat cushion.
Turn the knob until the desired height is achieved.
The springing will automatically correspond to the operator’s weight.
C Backrest rake
Turn the knob.
D Armrest slope
E Tilt – simultaneous sloping of seat and backrest.
F Adjustment of cushioning in three steps.
1. Normal position – lever pulled out. Used in normal
operation.
2. Restricted – lever pushed in to the intermediate position.
Used in operation on rough surfaces and restricts the spring travel to
25 mm.
3. Locked position – lever pushed in fully. Used when springing is not
required.

Rotatable seat (Optional)

Some trucks are equipped with a manually or hydraulically rotat-
able frame with integrated seat and steering wheel. These trucks
G have double sets of pedals.

Manual seat rotation

1. Stop the truck.
2. Pull the lever G backwards to release the seat frame.
KL1251 This also applies the parking brake and locks the steering
valve.
3. Turn the steering wheel half a turn counter-clockwise, use
the feet to support the rotation.
4. When the seat is rotated to the opposite position, release the
lever G to lock the seat frame in the new position.

Hydraulic seat rotation

F
1. Stop the truck and fold the armrests down.
4 3 2 1

N
L 0

1 2 3
R
2. Put both feet on the rotatable seat frame and check to make
4 5
sure that there is no hindrance for the frame rotation.
KL580A

3. Pull the lever G backwards to release the seat frame.

This also applies the parking brake and locks the steering
H valve.
4. Press the switch H on the instrument panel, see picture.
The seat now rotates to the opposite direction.
G
5. When the seat is rotated to the opposite position, release the
lever G to lock the seat frame in the new position.

KL1251
WARNING!

Never attempt to rotate the seat while the truck is in

motion. The parking brake will be applied.

18 DCD90-180
OPERATION Tilting the cab
Tilting the cab, preparatory steps
z Set the gear lever to neutral.
z Tilt the upright forward.
z Apply the parking brake.
z Check the there are no loose objects in the cab.
z Close the doors.
z Open the cover behind the hydraulic reservoir on the right-
hand side.
z Turn the two latches C upwards to release the cab from the
chassis.
●
● Manual tilting
z Use the end of the pump rod A to set pump valve B to the
right-hand setting.
A z Pump until the cab has reached the end position.

Electrical tilting (Optional)

z Press button D until the cab has reached the end position.

B
Retracting

Manual retracting
z Use the end of the pump rod A to set pump valve B to the
left-hand setting.
z Pump continually until the cab is in position against the
chassis.
z Turn the two latches C downwards to secure the cab to the
chassis.

Electrical retracting (Optional)

z Press button D until the cab is in position against the chassis.
C z Turn the two latches C downwards to secure the cab to the
KL1435a
chassis.

WARNING!

The cab must always be tipped over the point of balance.

If there is insufficient lateral space the cab must always be
secured against accidental lowering with a brace or similar.

D
E

DCD90-180 19
OPERATION
IMPORTANT!
IF THE ENGINE DOES NOT START
Make a new attempt after 15 to 20
seconds.
Do not run the starter motor for more
than 10 seconds at each
attempt.
If the engine still refuses to start, the
cause should be determined and
remedied.
Air in the fuel system? – see page 30.
IMPORTANT!
In extremely cold conditions the
machine must not be used under hard
load until the working temperatures
have been reached.
In extremely cold conditions the auxil-
iary electrical heater should be con-
nected even when the machine is not in
use.
20
Engine heater, running-in, start, warming-up
Engine heater
The truck can be equipped with an engine heater to facilitate
starting at temperatures below 0°C.
The engine heater consists of a heater cartridge fitted into the en-
gine block and is designed to heat the engine coolant.
The engine heater must be connected to a 220 V a.c. earthed
outlet.
IMPORTANT! In extremely cold conditions the auxiliary
electrical heater should be connected even when the ma-
chine is not in use.
Running-in
A new engine should always be treated with care during a certain
running-in period. During this period, the surfaces of the bores,
gears and bearings will become hard and polished, and this will
ensure a long useful life of the engine.
Avoid running the engine at full load during the first 50 hours. The
load can then be gradually increased.
Try to extend the running-in period to 200 hours. This will pay in
the long run – the stoppages and breakdowns will be fewer.
Start
See also section Warming up
WARNING!
Never use a starting spray to facilitate starting, since
this may cause an explosion.
z Set the gear lever to NEUTRAL.
z Turn the starter key directly to position II. Then:
Below +5°C
Hold the key in position II, the pre-heater position, for
approximately 50 seconds.
Turn the key further to position III – the starting position – and
release it as soon as the engine has fired.
Above +5°C
Turn the key directly to position III – the starting position –
and release it as soon as the engine has fired.
Warming-up
Never race a cold engine. Run the engine at 1400–1500 r/min un-
til it starts to warm up. It is essential that the engine oil be warm
and that it is circulating correctly before the turbocharger starts
running at high speeds. Nor should the engine be run at critically
low speeds. Start using the truck only when the engine has
reached normal working temperature, i.e. when the temperature
gauge on the instrument panel reads about 80°C.
Starting in extremely cold conditions
Before starting the engine, heat up the engine, diesel oil and hy-
draulic fluid with the auxiliary electrical heater. When the engine
is started, run at low engine revolutions and low load until the oil
in the engine and transmission and the hydraulic fluid in the hy-
draulic system has heated up and flows freely.
DCD90-180
OPERATION
WARNING!
If results of the functional checks are
in any way doubtful, report
immediately to the supervisor.
WARNING!
If mirrors or CC TV cameras are used
to aid vision, the speed of the ma-
chine must be adapted to the limited
vision.
N.B.
As an optional extra, certain machines
are equipped with an automatic engine
stop:
z When coolant temperature is too
high
z When oil pressure is too low
z If the operator leaves the truck for a
certain time, without switching off
the engine, normally 5 minutes.
IMPORTANT!
Remember to carry out the daily
supervision.
See page 28.
DCD90-180
Functional checks, stopping, steering
Functional checks
When starting the truck and from time to time when using it, make
a habit of checking:
z that the engine temperature gauge reading is about 80°C.
z that the reading on the fuel gauge is sufficiently above 0.
N.B. The reading should never be allowed to drop to 0.
z that all warning lamps are extinguished.
z that the horn, lighting, brake lights and direction indicators
operate correctly.
z that all hydraulic functions operate correctly.
Stopping the engine, parking
z Apply the parking brake.
z Tilt the upright slightly forward and lower the forks onto the
ground.
z Set the gear lever in NEUTRAL.
z Allow the engine to run for 1/2–1 minute while at idling speed
before stopping it.
z Stop the engine:
– Volvo 6-litre engine with manual stop. First pull out the
stop control and then turn the ignition key to position 0.
– Volvo 6-litre engine with fuel cut-off valve:
Turn the ignition key to position 0.
– Volvo 7-litre engine: Turn the ignition key to 0.
– Perkins engines: Turn the ignition key to 0.
– Cummins engine: Turn the ignition key to 0.
z If the truck will not be used for a longer period, turn the main
switch to the OFF position.
IMPORTANT!
Never turn the main switch to OFF when the engine is
running – the voltage regulator may be damaged.
Power steering
The truck has pure power assisted steering, and there is thus no
mechanical connection between the steering column and the
steered wheels. Movements of the steering wheel is transmitted
hydraulically to the steered wheels.
Never let the truck run downhill when the engine is not running,
since no hydraulic pressure will then be available and the
steering of the truck will be very restricted.
21
OPERATION
WARNING!
Heavy loads must not be driven in
highly hoisted positions because this
is detri-mental to lateral stability and
may also cause forward tipping.
Never handle unstable or loosely load-
ed goods. Take extra care when han-
dling long, high or wide loads to
prevent them from falling off, being
damaged or causing the truck to tip.
Always ensure that the load is securely
in place before lifting and transporting.
In all lifting operations, remember not
to exceed maximum lifting capacity,
see the rating plate. If necessary, esti-
mate the location of the load centre
and determine the maximum lifting ca-
pacity, using the load diagram located
in the operator’s cab.
If the load obscures visibility – operate
in reverse.
Never tilt the mast forwards when
loaded.
Capacity, tonnes
KL1073
Load centre, mm
Load diagram
22
Lifting technique
Lifting, lifting technique
When lifting and transporting loads:
z Drive the truck up to the object to be lifted and tilt the mast
slightly forward.
z Lower the forks and insert them under the load, tilt the mast
slightly backward and lift the load.
z If the truck seems to lean to one side, lower the load and ad-
just the lifting point by sideshifting the forks, so that the cen-
tre of gravity of the load coincides with the centre line of the
truck.
Stacking:
z Stop the truck directly in front of the stack and lift the load no
higher than necessary to carry out the stacking operation.
z Drive carefully forwards until the load is in the correct posi-
tion.
z Carefully lower the load and ensure that it is securely
stacked.
z Carefully reverse away from the stack and lower the forks to
the transport position.
Remember the following basic rules when transporting the
load:
z The mast should be tilted backwards – this will prevent the
load from moving or sliding off when the truck is braked.
z The forks should be lifted about 30 cm above ground level
when the truck is driven on a level surface. If the truck is driv-
en on uneven ground or steep inclines, increase the ground
clearance accordingly.
Operations close to high tension power lines
Extreme care must be taken when working in close proximity to
overhead, high tension power lines, particularly in respect of the
reach of the mast, forks and any attachment.
WARNING!
If the machine comes into contact with overhead high
tension power lines - remain seated in the cab and call for
help!
It is extremely dangerous to leave the cab as you will be
earthed when you come into contact with the ground.
DCD90-180
OPERATION Side-lift for empty containers
Safety regulations
See also standard EN 1551.

MAX

WARNING!

1. Before starting work with the machine, check to

ensure that the side-lift indicator lamps are
functioning correctly.

2. It is strictly prohibited to use the side-lift if the

lamps indicate a fault or are not functioning
correctly.

3. Using the side-lift when the indicator lamps are not

functioning correctly entails a major safety risk.

4. It is prohibited to drive the truck with the load higher

than in the position indicated in illustration 1.

5. The brakes should always be operated smoothly

and with great care, taking the prevailing conditions
into consideration.
KL1468

6. For all phases of driving, the mast shall be tilted

1. Driving position under load backwards to the maximum.

7. The side-lift, with or without load, may only be lifted

higher than shown in illustration 1 when stacking.

8. When driving unloaded, the side-shift shall be in the

MAX lowered position, as shown in illustration 2.

9. If forward visibility is obscured by the load, the

operator shall reverse the machine.

10. After stacking, the side-lift, with or without load,

must be returned to its “driving” position, see
illustrations 1 and 2, before the truck can again be
driven.

2. Driving position, no load

DCD90-180 23
OPERATION Side-lift for empty containers
Linear levers

Lever d is used for length adjustment

Lever d forward: Increasing length
20-40’ Lever d back: Decreasing length

Lever e is used for locking and unlocking the twist-locks

Lever e forward: Unlocking
Lever e back: Locking

40-20’

Indicating lamps

A B C On side-lift
Lamp A: Twist-locks locked (green)
Lamp B: Alignment, is extinguished when the container is lifted
(orange)
Lamp C: Twist-locks unlocked (red)

D In cab
AB C Lamp A: Twist-locks locked
Lamp B: Alignment, is extinguished when the container is lifted
Lamp C: Twist-locks unlocked
Lamp D: Lights up when the safety system is by-passed with the
F

key.
4 3 2 1

N
L 0

The by-pass key is fitted adjacent to the parking brake

1 4
R
5
and should be used only in emergency situations.
2 3
KL1097A

24 DCD90-180
OPERATION
WARNING!
Exercise special care when operating
the side-lift.
Always check to make sure that no
person is in the way for the truck or
side-lift.
Remember that the side-lift is wide and
ensure that it does not collide with
posts, overhead lines, etc
Side-lift for empty containers
Lifting technique
1. Set the adjustable length to the appropriate container length.
2. Drive slowly forwards towards the container, sideshift if
necessary.
3. Tilt the mast slightly forwards, about 2°, lower the side-lift to
the container and fit the two twist-locks into the container
lock holes so that both ends of the side-lift are resting on the
container. Check that lamp B lights up.
4. Lock the twist-locks. Check that lamp A lights up.
5. Tilt the mast backwards and lift. Check that lamp B is extin-
guished. Adjust lifting height to driving position before
driving.
6. Adjust lifting height to transport position or lower before driv-
ing. See picture Transport position page 23. Operate in re-
verse if the container obscures vision.
7. Releasing containers:
Position the container on the the required base. Check to en-
sure that lamp B lights up. Release the twist-locks, check to
ensure that lamp C lights up.

Operations close to high tension power lines

Extreme care must be taken when working in close proximity to
overhead, high tension power lines, particularly in respect of the
reach of the mast, forks and any attachment.

WARNING!

If the machine comes into contact with overhead high

tension power lines - remain seated in the cab and call for
help!
It is extremely dangerous to leave the cab as you will be
earthed when you come into contact with the ground.

Key switch for by-passing the safety system

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

WARNING!

It is prohibited to lift or transport load when the safety sys-

KL1585
tem is by-passed.

Key switch for by-passing

the safety system

DCD90-180 25
OPERATION Side-lift for empty containers
Switch functions, machines with “joystick”
15. AUT = Automatic locking of twist-locks. The parking brake
15 17 must be OFF.
MAN = Manual locking of twist-locks (spring-back) Unlocking
off twist-locks, see Joy-stick function below.
17. Stop at 30’ and 35’ (Optional)

A Override
Only in emergency situations
At override, all functions are operative.

KL583 WARNING!

Overriding of the safety system is at one's own risk and

A involves a risk of dropping a container.

B
B Engagement and disengagement of servo circuits
ON = Switch in outer position
OFF = Switch in inner position

Lever functions “Joystick”

1 2 3 4

6 5

1. Tilt forwards
2. Tilt backwards
3. Lower
4. Lift
5. Unlocking of twist-locks
6. Length adjustment, increase
7. Length adjustment, decrease
7 8 9 8. Sideshift right
9. Sideshift left

KL1107

26 DCD90-180
SPECIAL PROCEDURES
WARNING!
If it is not possible to run the engine
running during towing, a tow bar must
be used.
Before preparations for towing begin
and after towing has been completed,
the parking brake must be applied and
the wheels chocked to prevent the ma-
chine rolling. The greatest possible
care must be exercised during towing
operations to prevent personal injury.
IMPORTANT!
The truck cannot be started by
being towed.
Any attempt to start the engine by
towing, will inevitably cause damage
to the tranmission.
WARNING!
Chock the wheels on sloping ground.
If the parking brake has been me-
chanically disengaged it must always
be reset in order to restore the
parking brake function.
DCD90-180
Towing
If possible, the engine should be running during towing in order
to retain braking and steering functions. When the engine is not
running, there is no hydraulic pressure for the steering of the
truck which is then extremely limited. Furthermore, the gearbox
will be insufficiently lubricated.
z Towing may only take place over very short distances.
z If a tow bar is used, it shall be connected to the connection/
towing hitch at the rear of the machine.
z The brakes function as long as there is pressure in the accu-
mulator, thereafter the operating brakes cease to function
and the parking brake is automatically applied. If, thereafter,
it is necessary to move or tow the truck, the parking brake
must be released mechanically (see instructions below).
z The vehicle or machine use to for towing must be at least as
heavy as the machine to be towed and have sufficient engine
and brake capacity.
z For towing over longer distances or at speeds higher than 10
km/h, the propeller shaft must be disconnected.
Fire protection
If the machine is equipped with fire extinguishers these should be
of the ABE type, in accordance with EN 3 parts 1, 2, 4 and 5. With
such a fire extinguisher it is possible to extinguish a fire in both
fixed organic materials and liquids. Furthermore, the medium
used to extinguish fire does not conduct electricity.
Suitable fire extinguishers can be ordered from Kalmar.
WARNING!
If the machine is used in highly inflammable environ-
ments, e.g., in explosive environments, it is a strict re-
quirement that the machine be designed, constructed
and equipped in accordance with EN 1755.
Mechanical disengagement of the parking brake
The parking brake is automatically applied by powerful springs in
the braking cylinders if the pressure of the hydraulic accumulator
drops below a certain level.
If the truck must be moved – disengage the brake by loosening
the locknut at A, and then screw out the adjusting screw anti-
clockwise. Always reset the adjusting screw after remedy.
Lifting the truck
Eyebolts are available as optional equipment, i.e., two eyebolts
on the mast and two on the counterweight.
If the truck is not equipped with eyebolts, it should be lifted as fol-
lows:
z Place a sling around the rear of the chassis, between the
counterweight and the steered axle (shown dotted in the il-
lustration).
z Place two slings in the upper yoke of the mast – one sling in
each of the spaces for the lifting cylinder.
The lifting device must be fitted in such a way that the lifting point
coincides with the centre of gravity of the truck.
WARNING!
Follow existing safety rules
27
SUPERVISION Daily supervision
Supervision
IMPORTANT! Supervision is differentiated as follows:
The following must be carried out in z DAILY SUPERVISION – carried out by the operator
addition to daily and periodic supervi-
sion: z PERIODIC SUPERVISION – carried out by specially trained
service personnel.

Service during the running-in period

z Tighten the wheel and prop shaft
nuts after 8, 16 and 24 hours of oper-
ation. Tightening torque in accord-
ance with the Technical Handbook.
Tighten the wheel nuts in a zig-zag
sequence. Tighten the nuts in the
same way every time after changing
a wheel.
Proper supervision contributes to making the truck safe to work
with.
Periodic supervision is described in the Technical Handbook. The
operator must make sure that the truck is available for service
every 200 hours of operation.
All times refer to the hours of operation, i.e., the time recorded by
the hour meter on the panel.

Guarantee service after 50 hours.

The guarantee service is performed by
Kalmar, or by personnel authorized by
Kalmar, and is part of the Kalmar delivery WARNING!
commitments.
The guarantee service is also a condition Only genuine Kalmar spare parts may be used. Spare
for continued validity of the guarantee. tyres and replacement tyres must be of a make approved
by Kalmar.

DAILY SUPERVISION Or when Check Refill as re- More details

refuelling quired on page

Brakes Operation

Steering Operation

All instruments: Operation

Direction indicators, horn,
brake lights, headlights

Lift mast: Damage?

Lifting chains
Links, suspension

All hydraulic functions, e.g.: Operation

Lift, tilt, sideshift, Run every function to its end position in order to lubricate the
fork positioning cylinder and prevent corrosion

Engine, gearbox, drive axle, Noises? Oil leakage?

hydraulic hoses Drain water from the fuel filter water separator (if fitted)
Fuel Amount
The gauge reading • 30
should never drop to

Engine oil Level • 31

Air cleaner • Indicator 32

Coolant • Level • 32

Hydraulic oil • Level • 34

Gearbox oil • Level 34

Windscreen washer • Fluid level • 34

Wheels • Tyre pressure 37

28 DCD90-180
SUPERVISION Tyres
Tyres
WARNING!
Checks
Spare and replacement tyres shall be 1. Check the tyres regularly, if possible, daily.
of a make approved by Kalmar. 2. Remove objects that could penetrate the tyres, such as bro-
ken glass, pieces of wood, metal shvings, etc.
3. Check for uneven and rapid wear. This is caused by mechan-
ical faults such as unevenly acting brakes. Make sure that
such faults are immediately rectified.

Compressor for tyre inflation

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

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

WARNING!

Never stand in front of a tyre being inflated.

Do not exceed the recommended tyre pressure, see Tech-
nical Data.
With a change of tyres or wheel type, another tyre pres-
sure may apply, contact KALMAR.
Always follow the instructions for tyre inflation to avoid
serious accidents.
When changing tyres, see “Safety instructions for work-
ing with tyres” in Technical Handbook.
DCD160-12

Tyre inflation

DCD90-180 29
SUPERVISION Fuel system
Fuel system
Always refuel with ordinary diesel oil.
Never use any additives for the diesel oil.
In the winter, it is advisable to refuel the truck immediately after
the day’s work has been completed, i.e., to avoid moisture con-
densing inside the fuel tank.
Never add water-absorbing agents, such as alcohol, to the fuel.
Tank capacity, see Technical Data.
The filling pipe is on the left-hand side of the truck.
Before refuelling, make sure that the area around the filler cap is
clean.

Bleeding the fuel system

Air will be drawn into the fuel system if the truck is used when the
fuel tank is completely empty. It will then be necessary to bleed
the system after refuelling. This is carried out as follows:

Volvo and Cummins engine

z Back off the bleed screw A on the fuel filter half a turn.
z Release the pump handle B by turning it anti-clockwise
(TWD).
z Pump by means of the hand pump B until the fuel flowing
past the bleed screw is completely free from air. Continue
pumping and tighten screw A.
z Tighten the pump handle (TWD).
VolvoTWD731VE
z Run the starter motor in 20–30 second bursts, with a pause
of a couple of seconds between each run. The engine will
start after 2–3 minutes.
A Bleed screw
B Hand pump

A Perkins engine
z Pump by means of hand pump D until the fuel system is filled
with fuel - a stronger resistance is felt

B N.B. The effective stroke of the hand pump is dependent on

the position in which the engine has stopped. If the pump
KL1603
does not draw satisfactorily, run the starter motor for a brief
period of time and try pumping again. The resistance felt
Volvo TAD720VE when pumping indicates how much fuel the pump is draw-
ing.

z Push in the stop control and run the starter motor in 10

A second bursts, with a pause of about two seconds between
each run. The engine will start after a few attempts.
D Hand pump

KL1586

B
Cummins 6BTA5.9 Perkins engine

30 DCD90-180
SUPERVISION Engine oil
Engine oil
B
The dipstick for the engine oil (B) is on the left-hand side beneath
A the engine cover. (Cummins: right side) The dipstick has two
markings, MIN and MAX, and the oil level should be between
these. Clean the dipstick before checking the oil level.
It is advisable to top up with oil when the engine is warm and the
oil flows easily. Top up – wait a while – check on the dipstick.
A A Oil filler cap (Perkins: On the engine valve cover)
B Oil dipstick

Volvo TWD731VE

A
A

B
KL1604

Volvo TAD720VE

B
A
KL1587
Cummins 6BTA5.9

DCD90-180 31
SUPERVISION Air cleaner, Cooling system
Air cleaner
The dust container is emptied automatically.
The filter element in the air cleaner is replaced by the service per-
sonnel as a routine measure. If the truck is used under dusty con-
ditions, the filter may become clogged after a relatively short
period of time.
An indicator, which turns red when the filter has become clogged,
is located in the air intake system between the air cleaner and the
engine.
Check the indicator regularly and get in touch with the service
personnel as soon as the indicator has turned red.
Time for
filter change
IMPORTANT!
Inadequately filtered intake air may quickly cause seri-
ous damage to the engine.

KL1588

Cooling system
Volvo TWD731VE and Cummins 6BTA5.9
The coolant is topped up via the radiator filling cap accessible
through an aperture in the engine hood.
Volvo TAD720VE
The coolant is topped up via the separate expansion tank.

WARNING!

Do not open the cap when the engine is hot, since steam
or hot water may spray out.
Volvo TWD731VE
Cummins 6BTA5.9 Fill with water containing at least 40% glycol. If glycol is not used,
a corrosion inhibitor must always be added to the coolant. But the
corrosion inhibitor is not an anti-freeze agent, and should therefore
be used only if the ambient temperature is constantly above 0°C.
If the coolant level should drop below the minimum level, warning
lamp 46 on the instrument panel will light up.

IMPORTANT!
Insufficient coolant may impair the coolant circulation
which may cause the coolant to boil and give rise to en-
gine damage.
Do not top up the separate expansion tank, since this
may cause an air-block in the radiator leading to severe
engine damage

KL1605

Volvo TAD720VE

32 DCD90-180
SUPERVISION Accumulator
Checking the brake system accumulator
The accumulator is charged with nitrogen. If lamp 45 for low
brake pressure should light up, check for leakage as follows.

1. Start the engine and let it run until the accumulator is

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

N.B. Equipment for the topping up of nitrogen can be

ordered from KALMAR’s spares department.

A WARNING!

Charging should be made by authorized service person-

nel using approved equipment.

KL748 A. Quick evacuation valve, accumulator.

WARNING!

The brake pressure accumulator has an internal pres-

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

DCD90-180 33
SUPERVISION Hydraulic system, gearbox oil, windscreen washer
Hydraulic system
The hydraulic tank is on the right-hand side of the truck.

A A Refill

A B Sight glass

The fluid level should be in the middle of the sight glass when all
hydraulic cylinders are in bottom position.
The hydraulic fluid must always contain 3% of Lubrizol additive to
ensure satisfactory performance of the oil-cooled brake system.
The additive is not consumed during normal operation and must
B only be added at oil change and refill. Lubrizol may be ordered
from Kalmar Service department.

B
WARNING!

Hydraulic fluid with Lubrizol additive is chemically ag-

gressive. Avoid extended contact with the skin.

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

A Filler pipe
B Dipstick
A Check the level with the engine idling.

Windscreen washer
The windscreen washer container is beneath the left-hand en-
gine cover.
Check that there is sufficient washer fluid in the bottle. Refill if
necessary. Use anti-freeze fluid during the winter, e.g. methylated
spirits or special washer fluid.

34 DCD90-180
SUPERVISION
N.B.
The starting batteries accompanying
the truck are of the maintenance-free
type, which implies that it should not
be necessary to top-up with electro-
lyte during the life of the batteries.
However, the level of the electrolyte
should preferably be checked once or
twice a year. Fill as required by adding
de-ionized water.
Volvo engine
Cummins engine
WARNING!
Batteries emit oxyhydrogen which
is an explosive gas. A spark, for
example from incorrectly connected
starting cables, could cause a battery
to explode and result in serious injury
and damage.
DCD90-180
Electrical system
Electrical system
The electrical system operates at 24 V. The source of power sup-
ply are two 12 V batteries which are charged by an alternator. The
negative pole is connected to the chassis.
The positive pole is connected to a main switch A.
IMPORTANT!
When working with the electrical system, when carrying
out welding on the truck or at long time parking, always
isolate the batteries.
Checking the electrolyte level of the batteries
The batteries are fitted behind a cover on the left-hand side of the
truck. The electrolyte level should be about 10 mm above the
cells. Top up with de-ionized water as necessary.
Batteries contain substances dangerous to health and the envi-
ronment. Discarded batteries must therefore be dealt with in ac-
cordance with current local/national regulations.
WARNING!
The battery electrolyte contains corrosive sulphuric ac-
id. Immediately remove any electrolyte that comes into
contact with the skin. Wash with soap and lots of water.
If electrolyte gets into the eyes, immediately rinse with
lots of water and immediately contact a doctor.
Bulbs
Rating
Description Watts ...................................... Base
Instruments 3 .............................................BA7s
Indicating lamps 1,2 .................................... W2x4,6d
Cab lighting 10 ............................................ S8,5
Rear lights, red 5 ...........................................BA15s
Brake lights 21 ......................................... BA15s
Direction indicators 21 ......................................... BA15s
Position lights 5 ............................................SV8,5
Driving lights 75/70 ..................................P43t-38
(full/dipped beam)
Reversing lights, white 70 ......................................... PK22s
Working lights 70 ......................................... PK22s
Hazard beacon 70 ......................................... PK22s
Main fuse for electrical system
Fitted on the left side of the engine 2 x 50 A
Starting from another battery
z Make sure the auxiliary batteries are connected in series, so
that 24 V will be supplied.
Note: Do not disconnect the truck-battery cables
z Connect the jumper cables in the following order:
1. Red cable (+) to auxiliary battery
2. Red cable (+) to truck battery
3. Black cable (–) to auxiliary battery
4. Black cable (–) to a location some distance away from
the truck battery, such as the negative cable connection on
the chassis.
z Start the engine. Do not disturb the jumper cables while
starting, as sparks may otherwise be caused. Do not lean
over either battery.
z Disconnect the jumper cables in exactly the reverse order.
35
SUPERVISION Electrical system
Relay box in cab – fuses
S1-6 7-12 13-18 19-24
Fuse Rating
No. Circuit protected A
S1 Wiper motor front, direction indicators,
seat buzzer, parking brake sensor ........................... 10
S2 Ignition key, pre-heater, starter motor,
cab lighting (Air conditioner 25 A1)).......................... 15
S3 Container attachment, safety interlock ..................... 15
S4 Electric gear-changing ............................................ 5
B S5 Warning lamps, instrument illumination, relay,
coolant level .............................................................. 5
S6 Brake lights, reversing lights, reversing alarm ......... 15
S7 Fan (Air conditioner1)) .............................................. 25
S8 Spare (Working lights, container 1)) ......................... 15
WARNING!
S9 Working lights (15 A for 4 lamps 1))
Hazard beacon ........................................................ 10
Never use fuses of a higher amperage S10 Working lights, standard (15 A for 4 lamps) ............ 10
than stated on the lid decal. Risk of
damage or fire. S11 Horn, screenwash motor, wiper rear and roof,
wiper front, intermittent relay .................................... 10
S12 Driving lights (main fuse), rear lights
(main fuse), position lights ...................................... 15
S13 Main beam, right-hand (Main beam, front 10A 2)) ...... 5
S14 Main beam, left-hand (Main beam, rear 10A 2)) ......... 5
S15 Dipped beam, right-hand (Dipped beam, front 2)) ...... 5
S16 Dipped beam, left-hand (Dipped beam, rear 2)) ......... 5
S17 Rear light, left-hand (Rear light, front 2)) .................... 5
S18 Rear light, right-hand (Rear light, rear 2)) ................... 5
S19 ECU 1 1) ................................................................... 10
S20 ECU 4 1) ................................................................... 10
S21 Voltage converter 24/12 ............................................. 5
S22-24 Spare........................................................................... -
1) Optional equipment 2) Rotatable operator’s seat

Relays
305 Reversing light
313-1 Brake light (rear-front) 2)
313-3 Direction indicators (right-left) 2)
313-4 Direction indicators (left-right) 2)
313-5 Rear light (rear-front) 2)
313-6 Dipped beam (front-rear) 2)
313-7 Reversing light (rear-front) 2)
313-8 Main beam (front-rear) 2)
313-9 Shifting (rear-front) 2)
313-10 Shifting (front-rear) 2)
314 Parking brake, disengagement
315 High power (Starting switch)
316 Wiper motor, front
320 Electric stop (ECS 07) 1)
322-1 Coolant level
322-2 Coolant level (ECS 07) 1)
323 Pulse relay, direction indicators
328 Lever steering (ECS 04) 1)
330 Starting block
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 block
1) 2)
A Optional equipment Rotatable operator’s seat

36 DCD90-180
TECHNICAL DATA
Truck model, type designation DCD
Forklift trucks 90-6(XL) 100-6(XL) 120-6(XL) 136-6(XL) 160-12
100-12(XL) 180-6
120-12
150-12
160-6
160-9
Empty container trucks 70-32E3(XL)
70-35E4(XL)
70-40E5
Engine
Make – type designation Perkins – Volvo – Volvo – Volvo – Cummins –
1006-60T TD640VE TWD731VE TAD720VE 6BTA5.9
Fuel – type of engine Diesel – 4-stroke
Power ISO3046 1) – at speed kW -r/m 92/125 – 129/175 – 167/227 – 174 – 149 –
2500 2400 2200 2300 2500
Torque ISO3046 – at speed Nm-r/m 414 – 690 – 893 – 854 – 814 –
1300 1400-1500 1300 1400 1500
No. of cylinders – compression ratio 6–16,5:1 6–19,0:1 6–17,7:1 6–18,4:1 6–16,5:1
Alternator, type – capacity W AC-1260 AC-1540 AC-1540 AC-1540 AC-1540
Starting battery, voltage – capacity V-Ah 2x12–140
Fuel consumption l/h 6 8–10 8–10 9–11 9–11
Transmission
Gearbox, make – type designation Clark – 20000 Clark – 28000 Clark – 32000
Clutch, type Torque converter Torque converter Torque converter
Gearbox, principle Powershift Powershift Powershift
No. of gears, forward – reverse 3–3 3–3 3–3
Drive axle, make – type designation Kessler D81 PL478-NLB
Wheels
Wheels, front and rear 2) Pneumatic
Dimension, front and rear 10.00x20 10.00x20 11.00x20 12.00x20 12.00x20
Tyre pressure, front and rear MPa 0,7 0,8 0,9 0,9 1,0
Steering- and brakes
Steering system Hydraulic servo
Driving brake system, type – wheels braked Wet disc brakes – Drive wheels
Parking brake Spring-action brake with hydraulic release – input axle differential
Equivalent noise level in cab
In accordance with machine directive.
Limit 70 dB(A)
with standard engine dB(A) max 73
with noise reduction kit dB(A) 70
Volumes
Fuel, tank volume L 145 205 205 205 205
Hydraulic fluid, tank volume L 180 180 180 220 220
Coolant L 1006-60T=39, TD640VE=35, TWD731VE=41,
TAD720VE=40, 6BTA5.9=36
Engine oil L 1006-60T=13, TD640VE=22, TWD731VE=28,
TAD720VE=20, 6BTA5.9=16,3
Drive axle (incl.hub reductions) L 2 x 2 + 17,5
Gearbox oil, incl. filters L 20000=16, 28000=30, 32000=32
Truck weights and sizes vary depending on how the truck is
equipped and this is shown in detail by the product specification
and data sheets for the truck in question. The combination of en-
gine–gearbox is also specified in the product specification.
1) SO 3046 = Net power
2) Spare and replacement tyres must be of a make approved by
Kalmar.

DCD90-180 37
LUBRICATION CHART

23

IMPORTANT!
If the truck is standing unused outdoors, with the
piston rods exposed, all piston rods must be
greased to prevent corrosion.
After they have been washed with degreasing
agent, all pistons should be moved backwards
and forwards several times to obtain a new pro-
tective oil film.

38 DCD90-180
LUBRICATION CHART
Item Description Interval No. of Remarks
No. operating hours lub.
points
200 600 1000
1 Cylinder bearing, tilt cylinders L
2 Hose roller x 1 x) Dismantle, clean, lubricate and
reassemble
3 Chain wheels L 2
4 Lifting chains L 2 Brush or spray with thin engine oil
5 Support rollers, forks L 12
6 Cylinder bearing L 4
7 Support wheels and support rollers, mast L 10
8 Mast suspension L 2 Relieve the mast of load when lubricating
9 Engine oil x 1 x) Volvo, Perkins: oil change every 200
hours 1)
Cummins: oil change every 250 hours 1)
10 Oil filter engine x xx x) Perkins: Filter change every 200 hours
Cummins: Filter change every 250 hours
xx) Volvo: Filter change every 400 hours
11 Steered wheel bearings 2 Dismantle, clean, inspect and pack with
12 King pin bearing 4 grease every 4000 hours

13 Gearbox oil C x 1 x) Oil change. Check level while idling

14 Gearbox oil filter x 1 x) Filter change
15 Drive axle C 3 x) First oil change max 200 hours after first
x xx operation.
xx) Oil change, differential and hubs.
Drain the oil at working temperature.
Check the levels after refill.
16 Propeller shaft L 3
17 Hydraulic fluid filter x 2 x) Filter change
18 Hydraulic fluid C 1 Oil change every 2000 hours
19 Breather filter, hydraulic reservoir x 1 x) Filter change
20 Hydraulic pump, cab tilt C
21 Linkage L 4
22 Hinges, doors and hatches L Dismount doors and hatches
23 Brake pedals CL 2 Check and retighten the pedal axle locking
screws. Lubricate axle nipples

1) The interval is greatly dependent on the fuel and lubricant

quality as well as the operating conditions.
If intervals longer than 200 hours are desired, the condition of the
oil must be checked by the company making the oil, by means of
regular lubricant tests.

Quantities, see Technical Data.

L=Lubricate
C=Check

DCD90-180 39
LUBRICATION CHART, SIDELIFT EMPTY CONTAINER

4
4
4

1 1

6 5

8
7

KL1475

40 DCD90-180
LUBRICATION CHART, SIDELIFT EMPTY CONTAINER
Pos Description Interval No. of Remark
No. lub.
points
500 1000
1 Sliding surfaces, length adjustment L Brush onto all sliding surfaces with the at-
tachment in the fully extended position
4 Cylinders, length adjustment L 4
5 Locking cylinders L 4 Check that the sensors are free from grease
and that the sensor faces are undamaged
6 Lifting pinion twist connection L 4
7 Lifting pinion L C 4 Disassemble the twist-locks every 2000 h.
Check for wear. If needed, change compo-
nents accordingly. Clean and pack with
grease. Same procedure should be used at
suspected damage to the twist-locks.
8 Contact pin L 4 Check that the sensors are free from grease
and that the sensor faces are undamaged

L = Lubricate
C = Check

DCD90-180 41
Oil and lubricant recommendations
IMPORTANT!
Any deviations from the above table
must be supported by written approval
from Kalmar.
42
Grease
Use EP universal grease to NLGI Grade 2 with 3–5% molybde-
num disulphide additive for all lubrication points, including wheel
bearings.
Grease for Plastic plates
Use grease recommended by Kalmar. Ordered from Kalmar’s
Spares department.
0,65 kg cartridge for grease gun Art. no 923110.0360
5 kg can Art. no 923595.0003
Coolant for air conditioning unit
ZXL100 Seltec PAG oil
DCD90-180
Kalmar Industries AB
SE-341 81 Ljungby, Sweden
Tel: +46 372 260 00, Fax: +46 372 263 90
www.kalmarind.com