Kalmar DCU80-45ES7 Empty Container Handler 2019 Parts Catalogue PDF

Description

Kalmar DCU80-45ES7 Empty Container Handler 2019 Parts Catalogue PDF

The Kalmar DCU80-45ES7 Empty Container Handler 2019 Parts Catalogue PDF is a machine-specific parts reference for the DCU80-45ES7 identified by serial number H30500153. Across 862 pages, the catalogue combines illustrated assembly drawings with corresponding parts lists showing position numbers, part numbers, descriptions, quantities, units and applicable notes. It covers the machine from its QSB6.7 power unit and DANA transmission through the drive axle, braking and steering systems, 16,500 mm mast, lifting carriage, sidelift/twistlock attachment, cab equipment, common hydraulics and electrical installations.

File Details

• Manual type: Parts Catalogue
• Brand: Kalmar
• Model: DCU80-45ES7
• Machine type: Empty Container Handler
• Serial number: H30500153
• Publication date: 2019-07-02
• Language: English
• Page count: 862 pages
• File format: PDF

Illustrated Parts Identification

This Kalmar DCU80-45ES7 parts catalogue is organized around illustration pages and matching parts-list pages. The drawings use numbered positions to identify components, while the following lists provide the corresponding part number, description, required quantity and unit. Assembly and subassembly references are carried throughout the catalogue, making it possible to move from a major machine system down to individual components such as bearings, seals, hoses, valves, sensors, brackets, fasteners and service items.

The catalogue also includes preventive-maintenance parts information. The service-kit section identifies DCU80-100 filter kits for the first 500 h, 500 h, 1000 h and 2000 h intervals, together with associated filters, filter inserts, safety filter, fuel filter/water separator and air-conditioning V-belt. A numerical register is provided toward the end of the catalogue for locating listed parts by number.

Major Machine Components Identified

The machine configuration documented in the Kalmar DCU80-45ES7 Empty Container Handler 2019 Parts Catalogue PDF includes a complete QSB6.7 164kW 3A engine, a complete DANA 3016FTE14310-8 gearbox and a complete Kessler D81 drive axle. The load-handling section identifies mast assembly A67884.0200 with a lifting height of 16500 mm, lifting carriage A65169.0100 with a carriage width of 1600 mm, and attachment 923853.0314 described as sidelift, twistlock, 20′-40′.

The engine section goes well beyond a single installation drawing. It breaks the power unit into fuel-system components, crankshaft and cylinder-block parts, camshaft, cylinder head, crank mechanism, rocker and valve-cover assemblies, air intake, turbocharger and exhaust components, thermostat and cooling parts, lubrication components, control unit, wiring harness, engine heater, starter motor and alternator. This gives parts personnel and technicians a detailed component-level route through the engine installation rather than only a top-level engine reference.

Chapters Covered

• Complete Machine
  • Catalogue instructions and documentation kit
  • Preventive maintenance and DCU80-100 service kits
  • Signs, plates and machine diagrams
• Engine
  • Engine and engine installation
  • QSB6.7 164kW 3A engine assemblies and internal components
  • Fuel system
  • Air intake and exhaust outlet
  • Cooling system
  • Engine control system and electrical installation
• Transmission
  • DANA 3016FTE14310-8 gearbox
  • Torque converter and converter housing
  • Transmission case and drive plate
  • Gear clutch groups and output components
  • Drive and charge pumps
  • Oil filter, speed sensor and control valves
  • Transmission control system
• Driveline / Axle
  • Universal drive shaft and cardan axle
  • Kessler D81 drive axle
  • Drive axle casing and differential
  • Planetary gearing
  • Drive wheel brake and parking brake
• Brakes
  • Power-assisted brake system
  • Brake valve assembly
  • Drive-shaft and frame brake hydraulics
  • Hydraulic pressure filter
• Steering
  • Power-assisted steering system
  • Steering axle and hubs
  • Steering cylinder
  • Servo hydraulics and steering hydraulics
• Suspension
  • Tyres and rims
  • Wheel assembly A21004.6300
• Load Handling
  • Mast, outer mast and inner mast
  • Lifting cylinders and mast hose installation
  • Mast electrical equipment and lubrication
  • Lifting carriage and lift hydraulics
  • Lift accumulator system and cylinder damping
  • Side shift hydraulics
  • Tilt hydraulics and tilt cylinders
  • Load carrier and sidelift/twistlock attachment
• Frame, Body, Cab and Accessories
  • Controls and instruments
  • Safety and emergency equipment
  • Driver’s seat
  • Heating, ventilation and air conditioning
  • Lighting and signalling systems
  • Glass, windows and mirrors
  • Cab structure, suspension and interior
  • Frame, body, counterweight, fuel tank and hydraulic oil tank
  • Central lubrication
• Common Hydraulics
  • Hydraulic pumps
  • Hoses, pipes and valves
  • Cab hydraulics and directional control valve
• Common Electrics
  • Distribution of electricity
  • Cab, lifting-carriage and chassis electrical installations
  • Main power switch and electric cabinet
  • Communication, Smartfleet TelliQ and USB connection
• Numerical Register

Taken together, these chapters provide a component-identification reference across nearly every major assembly fitted to this particular DCU80-45ES7. The catalogue is especially useful when a technician can identify a system or visible component but needs to trace it to the illustrated assembly, determine its position number and locate the corresponding Kalmar part number and quantity.

Engine, Transmission and Axle Parts Coverage

The QSB6.7 section contains illustrated breakdowns for engine brackets, fuel filters and pipes, injection pump, fuel injectors, crankshaft, cylinder block, camshaft, cylinder head, piston and connecting-rod components, rocker assemblies, turbocharger, exhaust manifold, oil cooler, water pump, oil filter, oil pump, oil sump, sensors, control unit and wiring harness. The catalogue also records engine-installation hardware and related air-filter, exhaust and power-train cooling components.

For the DANA transmission, the parts catalogue identifies the torque converter, converter housing, transmission case, drive plate, clutch groups for 1st, forward/2nd and reverse/3rd functions, output components, gears, turbine shaft, pump assemblies, gearbox oil filter, rear cover, speed sensors, charge pump, control valve and pressure-regulating components. The driveline section continues through the universal drive shaft and the Kessler D81 drive axle, including differential, planetary gearing, wheel-brake components and parking-brake parts.

Load Handling, Cab, Hydraulics and Electrics

The load-handling portion is extensive, covering the tall mast structure, mast wheels and chain components, lifting cylinders, hose routing, mast electrical installation, lubrication equipment, lifting carriage, hydraulic lift circuits, accumulators, side shift, tilt and the container-handling attachment. The mast chain listing specifies a length of 9195 mm (181 links) for one chain. The attachment section continues into electrical equipment, hydraulic assemblies, mechanical mounting, slide plates, sensors, twistlock assemblies and hydraulic cylinders.

Cab and body coverage includes control levers and panels, steering column, ignition components, fire extinguisher, driver’s seat, air-conditioning installations, working lights, warning beacon, horn, reverse alarm, mirrors, windows, wipers, cab structure and interior fittings. Body-related pages identify the counterweight, fuel tank, hydraulic oil tank, fenders and central-lubrication installations. Separate common-hydraulic and common-electric chapters cover pumps, cab hydraulics, control valves, electrical distribution, lifting-carriage and chassis wiring, main power switching, the electric cabinet and communication equipment.

Order Parts with the Correct Machine Reference

The catalogue instructions specify that spare-parts orders should identify the machine model and serial number as well as the required part numbers and quantities. That makes the serial-specific identity of this document important: this catalogue is for Kalmar DCU80-45ES7 S/N H30500153. It should therefore be matched against the machine identification before parts are ordered.

Get the Kalmar DCU80-45ES7 Parts Reference Instantly

The Kalmar DCU80-45ES7 Empty Container Handler 2019 Parts Catalogue PDF gives technicians, parts departments and equipment owners a detailed visual reference for identifying assemblies and individual replacement components across the engine, transmission, axle, brakes, steering, load-handling equipment, cab, hydraulics and electrical systems. Using the illustrated positions together with the listed part numbers and quantities helps reduce uncertainty when identifying the components required for maintenance, repair or parts ordering. After purchase, the catalogue is delivered instantly as a PDF with no physical shipping required. It can be opened on compatible computers, tablets and phones and printed whenever a paper reference is useful in the workshop or parts department.

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