Kalmar DCE70-90E Empty Container Truck Technical Handbook 920937-9345 PDF Workshop Manual

Description

Kalmar DCE70-90E Empty Container Truck Technical Handbook – Publication 920937-9345

This Kalmar DCE70-90E Technical Handbook is the complete workshop-level service documentation for the Kalmar DCE70-90E range of empty container trucks. Published under document number 920937-9345, it covers the design, maintenance, troubleshooting and corrective maintenance of these heavy diesel-powered machines, which are built for handling empty containers in harbours and container terminals with stacking up to eight containers high.

Inside this Kalmar DCE70-90E service manual you will find the full group-by-group structure used by Kalmar’s own technical publications, from general safety and intended use through to periodic supervision schedules. Every chapter is written for the technician working on the truck, not for the operator — operating instructions are handled separately in the Instruction Manual.

File Details

• Manual type: Technical Handbook (Workshop/Service Manual)
• Brand: Kalmar
• Model: DCE70-90E
• Document number: 920937-9345
• Language: English
• Page count: 260 pages
• File format: PDF

Chapters Covered

• Group 00 – General
• Group 10 – Chassis and cab
• Group 20 – Electrical system
• Group 30 – Engine
• Group 40 – Transmission, drive axle, brakes
• Group 60 – Steering axle
• Group 70 – Hydraulic system
• Group 80 – Lifting mast, carriage and side lift attachment
• Group 90 – Periodic supervision

Group 00 – General

Covers safety regulations for operating and servicing the truck, intended use, operator requirements, operating regulations, parking and interrupted operation, tyre handling and the safety instructions that apply when working with tyres. Also includes the replacement system for spare parts, tightening torques for metric and UNC/UNF threads, and the SI system of units with conversion factors for pressure, torque and power.

Group 10 – Chassis and cab

Chassis specifications and description, mounting points for the mast, tilt cylinder, steering cylinder and cab, operator’s cab description with instrument panel layout, steering column and ECS terminal, service procedures for the fresh air filter, brake pedal check and lubrication, windscreen wiper removal and fitting, and the air conditioning unit with compressor, condenser, liquid receiver/filter dryer, expansion valve and evaporator. Includes the air conditioning checking procedure and the weekly maintenance routine.

Group 20 – Electrical system

The 24 V electrical system description, battery electrolyte level checking, main switch location, relay box in the cab with fuse ratings, bulb ratings and bases, relays, sockets in the electrical central, electrical diagram explanations with connector and cable marking conventions, and the list of circuit diagrams used across the DCE70-90E range. Covers the central electrical unit with fuses and relays on the cab’s rear wall.

Group 30 – Engine

The Volvo TD730VE and TWD731VE six-cylinder turbocharged diesel engine. Engine specifications including coolant volume, rating, torque, number of cylinders, swept volume, valve clearances, idle speed, injection pump timing, thermostat opening temperatures, lubricating oil pressure and oil capacity. Descriptions of the cooling system, fuel system, lubrication system and combustion air system, plus service procedures for coolant quality, lubricating oil quality, draining water from the fuel tank, air cleaner inspection and filter element change, oil and oil filter change, V-belt tension check, valve clearance adjustment and fuel filter change. Also includes preventive maintenance on the turbocharger.

Group 40 – Transmission, drive axle, brakes

The Clark 13.7 HR 28000 and 32000 torque converter and gearbox with three forward and three reverse gears, the Kessler D81 drive axle with wet disc brakes and spring-activated disc parking brake. Torque converter description, gearbox description, oil circuit, oil level check, gearbox oil and filter change, pressure checking in the Clark gearbox, differential and hub reduction description, service brake and parking brake system, mechanical release of the parking brake, drive axle oil change, and installation procedures for disc brake, hub reduction and planet gear dismantling.

Group 60 – Steering axle

Steering axle specifications, description of the pendulum-mounted steered axle with double-acting steering cylinder, replacement of steering cylinder, replacement of steered wheel bearings and knuckle pin bearings, inspection of dismountable rims, and the safety test carried out when changing tyres, including magnetic examination and penetrance testing.

Group 70 – Hydraulic system

Hydraulic system specifications and general survey covering main hydraulics, steering system, brake system, parking brake, hydraulic pumps, accumulator, high pressure filter, main valve and hydraulic cylinders. Descriptions of the lifting, tilting, sideshift and length adjustment functions, safety interlock for container handling, lowering brake valve, attachment supply, checking the hydraulic hoses, breather filter, changing the hydraulic fluid, mounting of fittings on hydraulic hoses, checking pressures and settings, steering valve (Orbitrol), WDB brake system, oil cooler and the full hydraulic circuit diagram with components.

Group 80 – Lifting mast, carriage and side lift attachment

Lifting chain specifications with maximum permissible wear, lift mast and carriage description, service procedures for inspection of lifting chains and lifting mast, dismantling the carriage and lift mast, adjusting and replacing support wheels, lubrication of sliding surfaces and plates, checking sliding plates, inserting shims, bleeding lift cylinders, hose stretching and tilt cylinder mounting torque. Side lift attachment description covering twist-lock and hook coupling versions.

Group 90 – Periodic supervision

General survey chart with maintenance intervals at 200, 400, 500 and 1000 hours, full lubrication chart with lubrication points and intervals, daily supervision checklist, every 500 hours and every 1000 hours service schedules, and oil and lubricant recommendations for engine oil, drive axle oil, hydraulic fluid, grease and gearbox oil with ambient temperature ranges.

What This Kalmar DCE70-90E Technical Handbook Gives You

This Kalmar DCE70-90E Technical Handbook is not a generic overview — it is the document Kalmar’s own service network uses to keep these trucks running. Every procedure is written around the actual systems fitted to the DCE70-90E: the Volvo TD730VE/TWD731VE engine, the Clark 13.7 HR transmission, the Kessler D81 drive axle, the wet disc brake system and the twin-pump hydraulic system with accumulator-backed brake and steering circuits.

If you maintain or repair empty container trucks, this manual gives you the tightening torques, pressure settings, oil capacities, valve clearances, chain wear limits and adjustment procedures you need to work to specification. The troubleshooting and corrective maintenance information in Groups 10 through 80 covers the most common faults and the steps to put them right, while Group 90 tells you when each service action is due.

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The Kalmar DCE70-90E workshop manual is delivered as an instant PDF download — no shipping, no waiting. You can open it on any device, print the pages you need for the workshop, and keep the complete manual on hand for the life of the truck.