Operator Dce50-90hm

DCE 50-90HM
Publ. no IDCE06.01GB
1
1 Foreword ........................................................ 3
1.1 About the Operator’s Manual ........................... 3
1.2 About the documentation kit ............................ 6
1.3 Inspection and maintenance ............................ 7
2 Safety ............................................................. 9
2.1 CE marking ...................................................... 11
2.2 ANSI/ASME marking ........................................ 12
2.3 Keep in mind ................................................... 13
3 Summary ...................................................... 19
3.1 Description DCE 50-90HM ............................... 19
3.2 Protection and warning equipment ................ 28
3.3 Plates ............................................................... 30
4 Instruments and controls ............................ 37
4.1 Warning and indicator lamps .......................... 45
4.2 Instruments ..................................................... 47
4.3 Ignition (46) ...................................................... 48
4.4 Switches .......................................................... 49
4.5 Travel direction selector (2) ............................ 53
4.6 Multi-function lever (5) .................................... 54
4.7 Hydraulic control ............................................. 55
4.8 Pedals .............................................................. 59
4.9 Steering wheel (4) ........................................... 61
4.10 Operator’s seat (9) .......................................... 64
4.11 Heating/Air conditioning ................................. 71
4.12 KCS system ..................................................... 76
5 Handling ....................................................... 79
5.1 Running-in ....................................................... 80
5.2 Daily inspection ............................................... 81
5.3 Handling of fault codes ................................... 82
5.4 Operating ......................................................... 95
5.5 Load handling ................................................ 111
6 Inspection and maintenance ..................... 117
6.1 Daily inspection ............................................. 118
6.2 Maintenance ................................................. 121
6.3 Service ........................................................... 142
7 Transporting the vehicle ........................... 143
7.1 Towing ........................................................... 144
7.2 Lifting and securing the vehicle .................... 149
7.3 Service position ............................................. 151
7.4 Long-term storage ......................................... 152
8 Environment and standards ...................... 153
9 Specifications ............................................. 157
10 Terminology ............................................... 165
2
1 Foreword 1 Foreword 3
1 Foreword
1 Foreword
1 Foreword –
1.1 About the Operator’s

Manual
General
Thank you for choosing Kalmar Industries as your machine supplier.
We hope that we’ll meet your expectations.
This operator’s manual contains information that you should keep in
mind for safe handling and optimal use of your new Kalmar machine.
Purpose of the Operator’s Manual

This operator’s manual applies to machine DCE 50-90HM.
The operator’s manual describes how the machine should be oper-
ated and maintained in a correct manner.
Kalmar Industries will not accept any responsibility for machine
modifications without permission from Kalmar Industries as well as
if other lifting devices, tools or work methods are used other than
those described in this manual.
Storage
The operator’s manual should always be kept in the machine.
About the machine version

The information in this operator’s manual corresponds to the ma-
chine’s design and appearance at the time of delivery from Kalmar
Industries. Due to customer adaptations, there may be variations
and/or deviations.
Kalmar Industries reserves the right to change specifications and
equipment without prior notice. All data and information in this man-
ual are valid at the time of publication.
Copyright 2002
Kalmar Industries AB
Duplication of the content in this manual, in whole or in part, is
strictly prohibited without written permission from
Kalmar Industries AB.
Duplication by any means, such as copying, printing, etc., is prohib-
ited.
Operator’s manual DCE 50-90HM IDCE06.01GB

4 1 Foreword – 1.1.1 Reading instructions
1.1.1 Reading instructions

Information about dangerous action
Warning descriptions in this operator’s manual concern your safety.
The warnings point out potential dangers that may lead to personal
injury if the warning instruction isn’t followed.
See examples below.
D AN GE R
Warns for situation that may mean immediate seri-
ous personal injury or death if the instruction isn’t
followed.
What causes the danger.
How to avoid the danger.
W AR N IN G
Warns for situation that eventually may mean risk
of serious personal injury, possible death, and/or
extensive damage to product or property if the in-
struction isn’t followed.
What causes the warning.
How to avoid the situation.
CAUTION
Warns for situation that eventually may mean risk
of lighter personal injury, and/or damage to product
or property if the instruction isn’t followed.
What causes the warning.
How to avoid the situation.
IDCE06.01GB Operator’s manual DCE 50-90HM

1 Foreword – 1.1.1 Reading instructions 5
Important information
NOTE is used to point out information that facilitates the work proc-
ess, operation/handling or increases understanding of information in
the operator’s manual.
See example below.
NOTE
Draws attention to useful information that facilitates work.
Read the operator’s manual/maintenance manual

The symbol to the left is used in certain cases on the machine and
refers to important information in the operator’s manual/mainte-
000262
nance manual.
Read the Operator’s manual/Maintenance manual
Optional equipment
There is a wide range of optional equipment for the machine. Each
000264
description of optional equipment in the operator’s manual is

marked with a symbol and contains an explanatory text. The symbol
Indicates optional equipment is highly visible and is placed next to the text and figure item in ques-
tion.

6 1 Foreword – 1.2 About the documentation kit
1.2 About the documentation

kit
The documentation kit
The following documents are supplied with the machine:
• Operator’s manual DCE 50-90HM (in the cab)
• Maintenance manual DCE 50-90HM
• Spare parts catalogue with machine card
All documentation can be ordered separately from Kalmar Indus-
tries.
Ordering of documentation
Copies of the operator’s manual and maintenance manual can be or-
dered from Kalmar Industries:
Kalmar Industries AB SE-341 81 Ljungby, Sweden.
Always indicate publication number when ordering.

1 Foreword – 1.3 Inspection and maintenance 7
1.3 Inspection and maintenance

General
For satisfactory function of the machine to the lowest cost, mainte-
nance must be performed correctly. Intervals for care and lubrica-
tion refer to normal environment and operating conditions.
Maintenance work described in this operator’s manual can be per-
formed by the operator, see chapter 6 “Inspection and mainte-
nance”. Chapter 6 “Inspection and maintenance” describes the
running checks and actions that the operator should perform in con-
nection with work shifts.
Maintenance
For other maintenance not included in this operator’s manual (serv-
ice and repairs), an authorized service workshop should be contact-
ed.

8 1 Foreword – 1.3 Inspection and maintenance

2 Safety 2 Safety 9
2 Safety
2 Safety
2 Safety –
General
Safety rules are intended to reduce the risk of personal injuries as
well as damage to the load or other property.
Important to read the Operator’s

Manual
Incorrect handling can lead to personal injuries and damages to
product and/or property. Therefore, read the operator’s manual very
thoroughly before starting to use the machine. The operator’s man-
000262 ual contains important information about your Kalmar machine,
about operating the machine, safety during operation, and about
daily maintenance of the machine. You’ll also find a lot of valuable
information that will make your work easier.
The operator’s manual should always be kept in the machine. If it’s
lost, replace it immediately with a new operator’s manual.
NOTE
Never use a machine that doesn’t have an operator’s manual.
Ask your foreman or supervisor if there’s anything in the text you do
not understand or if you feel information is missing in any area.
Intended use
• The machine may only be used for the purpose for which it is de-
signed and adapted, that is, to lift and transport goods (the
weight of which is not to exceed the machine’s maximum rated
load capacity). If it’s used in another way or in potentially dan-
gerous environments (for example, explosive environment, area
with dust containing asbestos), special safety regulations must
be followed and the machine must be equipped for such opera-
tion.
• The machine may not be modified or rebuilt so that its function
or performance is altered without specific permission from Ka-
lmar Industries.
• The machine may not be operated on public roads unless it has
been adapted according to national road safety regulations.
• It is always the machine owner’s responsibility to ensure that
the machine has approved fire-fighting equipment which com-
plies with mandatory regulations.

10 2 Safety – 2 Safety
Operator requirements
• The machine may only be operated by specially trained opera-
tors who have the management’s permission to operate the ma-
chine.
• Laws and regulations regarding driver’s licenses, operator ID,
etc. must always be followed.
• The operator must be aware of and follow all local safety regu-
lations.
Prohibited operation of machine

Operation of the machine is prohibited:
• If safety equipment such as rear-view mirrors and headlamps,
etc. do not function correctly.
• In case of defective brakes, steering or lifting equipment.
• If the machine has been repaired, modified or adjusted without
the supervisor’s/work management’s permission.
• If the machine is fitted with tyres not approved by Kalmar Indus-
tries.
It is not permissible to perform rebuilds or modifications of the de-
sign (CE marking). Any rebuilds and modifications must be approved
by Kalmar Industries.

2 Safety – 2.1 CE marking 11
2.1 CE marking
CE marking
(Declaration of Conformity, only applies to machines sold
within the EU/EEA).
This machine is CE marked. This means that, when delivered, the
machine meets all applicable “Essential Health and Safety Require-
ments”, stipulated in the EU Machinery Directive, 98/37/EG and oth-
er EU directives applicable to this type of machinery.
As proof that the requirements are complied with, an EC Declaration
of Conformity is supplied, issued by Kalmar Industries for each and
every machine. This EC Declaration also applies to appliances and
options manufactured by Kalmar Industries. The documentation is a
valuable document which must be stored securely and saved for at
least 10 years. The documentation must always accompany the ve-
hicle when sold.
Any person who makes any modifications which adversely affect the
safety of the vehicle is responsible for the consequences of his ac-
tions. If the vehicle is used for other purposes, or with other appli-
003555
ances than the ones mentioned in this instruction manual, its safety
Machine plates for machine and attachment must be ensured in each individual case. The vehicle owner is re-
sponsible for ensuring that the vehicle is used in ways specified in
the instruction manual. Other areas of application might require new
CE marking and the issue of a new EC Declaration of Conformance.
For further information, please refer to Standards page 154.

12 2 Safety – 2.2 ANSI/ASME marking
2.2 ANSI/ASME marking

ANSI/ASME marking
(Only applies to vehicles for the North American markets.)
This vehicle is ANSI/ASME marked. This means that when delivered,
it complies with the basic safety requirements in ANSI/ASME B56.1.
Any person who makes any modifications which adversely affect the
safety of the vehicle is responsible for the consequences of his ac-
tions.
If the vehicle is used for other purposes, or with other appliances
than the ones mentioned in this instruction manual, its safety must
be ensured in each individual case. The vehicle owner is responsible
for ensuring that the vehicle is used in ways specified in the instruc-
tion manual.
For further information, see Standards page 154.
003556
Machine plates for machine and attachment

2 Safety – 2.3 Keep in mind 13
2.3 Keep in mind

Interrupted operation and/or parking
W AR N IN G
Always switch the ignition off when the vehicle is
left when parking or at the end of each shift etc.
Danger!
Cut the current with the battery isolator.
NOTE
Always check that no travel direction is engaged before the ig-
nition key is turned.
NOTE
Never leave the operator’s seat without first applying the park-
ing brake (ON position).
NOTE
Always remove the ignition key if the machine is to be left un-
attended.

14 2 Safety – 2.3 Keep in mind
During work shifts
D AN GE R
The machine’s work area is large and visibility from
the operator’s cab is restricted.
Fatal danger! Risk of damage to property and ma-

chine!
Keep in mind:
• Always check that no persons are in the way of

the machine or its equipment.
• The operator must always face in the direction

of travel and should operate with special care
where persons or vehicles may appear.
• The operator shall adjust travel speed according

to the nature of the load, visibility conditions,
road conditions, etc.
• The operator should pay extra attention and op-

erate with special care near electrical power
lines, viaducts, dock sides, ramps, gates/doors,
etc.
• The driver must always wear a seat belt when

driving the vehicle.
• Always operate carefully so that the attachment

does not collide with posts, power lines, etc.
D AN GE R
The machine’s load capacity is limited.
Collapse of lifting cylinders! Fatal danger!
It is prohibited to exceed the machine’s load capac-

ity. See marking plate and load diagram.

D AN GE R
Transport of loads is associated with great risks.
Risk of roll-over and tipping over!
Keep in mind:
• All loads should be carried in the transport posi-

tion.
• The operator should avoid powerful acceleration
and heavy braking when turning.
• The operator should always adjust the speed

when turning to prevent skidding and risk of
roll-over.
In case the machine rolls over or tips, hold on to

the steering wheel and stay in the cab. Do NOT
try to jump out of the cab before all movements
have stopped.
D AN GE R
Forks and other attachments (with or without load)
are easily and forcefully manoeuvred.
Fatal danger and risk of property damage!
Make sure that no persons stand under raised at-

tachment, regardless of if it’s loaded or not.
D AN GE R
Damage and wear can affect the machine’s function
or service life, compromising personal safety.
Always repair all wear and damage.

D AN GE R
The strength of the roof window may be significant-
ly reduced in case of exposure to substances con-
taining: aromatic hydrocarbons, ketones, esters
and chlorinated hydrocarbons.
Low strength! Fatal danger!
Check the outside surface of the roof window at

regular intervals. Only clean with windscreen wash-
er fluid or a mild cleaning agent. Rinse thoroughly
with plenty of lukewarm water. Replace the roof
window immediately if it’s cracked or scratched!
D AN GE R
All reworking of the roof window is prohibited.
Scratches or other damage to the window results in
reduced strength.
Low strength! Fatal danger!
Replace a damaged roof window immediately.
D AN GE R
Lifting loads of large volume in very windy condi-
tions can be associated with great difficulties.
Risk of tipping! Fatal danger!
Avoid lifting loads in heavy wind conditions.
D AN GE R
The machine emits exhaust gas during driving.
Fatal danger in case of poor ventilation!
Avoid driving indoors in poorly ventilated premises.

Use an air extractor.

W AR N IN G
Work position on the machine is located up high.
Risk of falling and body injury!
Always use the steps and handles when you climb

up or down from the machine. Always face the ma-
chine. Do not jump!
W AR N IN G
Cab doors must always be closed or secured in the
“door open position” when operating.
Danger!
Always close the cab door(s) during the work shift.
W AR N IN G
Passengers are only allowed in the cab if there is a
specific passenger seat. It is prohibited to carry pas-
sengers on the machine outside the cab or on the
load.
Danger!
Passengers must use the permanently installed pas-

senger seat.
W AR N IN G
If the parking brake has been released mechanical-
ly, it must always be reset to restore the machine’s
parking brake functions.

W AR N IN G
The machine’s hydraulic system includes accumula-
tors with high pressure.
Danger - risk of injury!
Always be very careful when working with the hy-

draulic system, and avoid standing close to hydrau-
lic components or hoses. Before working on the
hydraulic system, the accumulators must be
drained (this is done by shutting off the engine and
depressing the brake pedal repeatedly until the ac-
cumulator has been emptied).
W AR N IN G
Handle batteries and connectors with great care.
Risk of short-circuiting!
Batteries should always be provided with protective

caps over the terminals and connections.
W AR N IN G
The machine uses oils, lubricants and emits exhaust
gases during operation.
Health hazard during long-term contact!
Avoid contact with oils and lubricants. Use protec-

tive gloves.
NOTE
Mobile phone and communication radio may be used in the
cab. The equipment should not be used while operating or han-
dling loads, as your concentration on operating is reduced.
Kalmar Industries will not assume any responsibility for optional
equipment not installed by Kalmar Industries or by a fitter ap-
proved by Kalmar Industries.

3 Summary 3 Summary 19
3 Summary
3 Summary
3 Summary –
3.1 Description DCE 50-90HM

General
Vehicle DCE 50-90HM is a forklift truck of so-called light capacity for
all types of load handling. It has a lift capacity of 5 up to 9 tonnes.
The vehicle has three alternatives for lift masts (different lift heights):
1. Duplex
2. Duplex free-lift
3. Triplex free-lift
This section provides a short presentation of the vehicle’s compo-
nents, see General page 20.
3.1.1 Identification of the vehicle

Type designation of forklift truck
Each Kalmar vehicle has a type designation. Type designation
DCE 80-6HM (example) indicates the following:
• D - Diesel engine
• C - Counterweight forklift
• E - Generation
• 80 - Lift capacity, decitonne
• 6 - Centre of gravity, distance, decimetre
• H - Hydraulic transmission
• M - Mechanical control of hydraulic transmission
Vehicle card
When ordering and after putting the vehicle into operation, it’s pos-
sible to modify and adapt Kalmar Industries’ vehicles in different
ways with product alternatives and optional equipment. This makes
it possible to satisfy a very broad range of customers.
A vehicle card is delivered together with the spare parts catalogue.
The vehicle card contains a complete specification of the vehicle’s
product alternatives and optional equipment.
The vehicle card shall be updated when the vehicle is modified and
Kalmar Industries shall be informed.

20 3 Summary – 3.1.2 General description
3.1.2 General description

General
This section provides a short presentation of the vehicle’s compo-
nents, which are shown in the illustration below.
003487
1 2 3 4
1. Steering axle
2. Engine
3. Hydraulic transmission
4. Wheel motor (DCE 50-55HM) or drive axle (DCE 60-90HM)
5. Load handling, lift mast
6. Load handling, fork carriage
7. Cab

3 Summary – 3.1.2 General description 21
Engine
The engine is the 4-cylinder turbocharged low emission Perkins
1104C-44T engine. The engine provides power for propulsion and
working hydraulics.
Transmission
The vehicle has continuously variable hydraulic transmission. On the
transmission for the:
• DCE 50-55HM, the gearbox and drive shaft have been replaced
by a transmission pump mounted directly on the diesel engine
output shaft. The power is then transmitted to hydraulically op-
erated wheel motors. The vehicle has front wheel drive.
• On the DCE 60-90HM, the gearbox has been replaced by a trans-
mission pump and a transmission motor. The transmission
pump is directly connected to the diesel engine output shaft,
and the transmission motor is directly connected to the drive
shaft, in its turn. Power transfer consists of a rigid driving axle
with hub reduction gear. The vehicle has front wheel drive.
Drive axle
The drive axle (front axle) is equipped with a differential and hub re-
ductions of the planetary gear type.
Brakes
The vehicle has one brake circuit and is equipped with hydraulically
operated brakes. The brake units consist of fully sealed oil-cooled
disc brakes.
The parking brake is electro-hydraulic operated. The parking brake
for:
• DCE 50-55HM operates the brake friction plates for the drive
wheels’ ordinary service brakes.,
• The DCE 60-90HM brake is a multi-disc brake, and is integrated
with the drive shaft.
The parking brake is applied automatically in case of voltage loss
(with spring force) and is released by hydraulic pressure.
Steering
The vehicle is steered with the rear axle. A double-acting hydraulic
cylinder acts on the wheel pair.
Load handling
The lift mast and fork carriage are used for load handling. The load is
moved vertically and is tilted (angled) forward or back.
The fork carriage is available in different versions. One of the follow-
ing alternatives has been selected for the vehicle:
• Fork carriage with manually moveable forks
• Side shift carriage
• Side shift carriage with fork positioning

The forks are hooked onto the carriage and can be moved manually.
The carriage may be equipped with coil rams, extended forks etc.
Electrical system
The electrical system consists of electrical and electromagnetic
components such as battery, switches, solenoid valves, fuses and
relays.
Control and monitoring system
The vehicle can be equipped with KCS, an electronic control and

monitoring system which monitors and handles certain functions in
the vehicle that require KCS, for example, lever steering, mini-wheel
and electric servo.
Cab
Three different cabs are available. Instrumentation and equipment
(steering wheel, operator’s seat, fresh air system) can be adapted to
customers as well as models.
• Spirit Delta Cab
Spirit Delta is a closed cab constructed of a structural frame to
withstand falling loads. It is equipped with a fresh air system
with filtered inlet and recirculation as well as manual control of
heat or with air conditioning ( ).
The roof window is made of high tensile strength material and
withstands heavy blows, for example, from falling objects.
• FlexGuard Cab:
FlexGuard is an open cab constructed of a structural frame to
withstand falling loads.
• FlexCab Cab:
FlexCab is a closed cab constructed of a structural frame to
withstand falling loads. It is equipped with a fresh air system
with manual control of heat.
Hydraulic system
The hydraulic system includes sub-functions brakes, steering, work-
ing hydraulics and cab. The system consists of a feed circuit with hy-
draulic tank, hydraulic pump (gear wheel pump), filter and
accumulator.

Other equipment Spirit Delta

16 34 13 21,22 14 30 36 5,6,12,28,41 1,2,23 8,11
34
20,24
25
3
33
42
43
38,39,40
44
3,27
19
16
003488
19 37 7 4 31 32 17 15,16 35 26,29
1 Rear view mirror
2 Extra rear view mirror (in cab)
3 External rear view mirrors

4 Horn
Placed under cab.
5 Electrically operated loud horn

Placed on the left of the roof side.
6 Roof pane extra strong (12 mm)

Standard roof pane is 6 mm.
7 Passenger seat
8 Laminated windscreen
9 Tinted windows
(Not marked in the figure).
10 Sliding pane left door


11 Sun visor windscreen

Window blind for vertical movement with a string on the right.
Blind stays in chosen position.
12 Sun visor roof pane

Window blind for attaching in the front of the roof window (2
hooks).
13 Sun visor rear pane

Can be pulled down and fixed on two hooks at the lower edge
of the rear window.
14 Stereo, 24 VDC
Directions for use is enclosed.
15 Writing desk with lamps

For handling paperwork in the cab. The writing desk and its
lamps are placed inside the cab on the right.
16 TV-camera with monitor

For improving the view during load handling or reversing. The
camera is placed on counterweight and/or lifting equipment.
The monitor is placed inside the cab on the left.
17 Outlet 24 VDC
Outlet is placed at right door and has a fuse.
18 Handle for cab footstep

19 Splash guard for drive wheels and steering wheels
20 Protection grating for working lamps mast

21 Working lamps cab roof (rear), 2 lamps
22 Extra working lamps cab roof (rear), 2, 4 or 6 lamps
23 Extra working lamps cab roof (front), 2 lamps

24 Working lamps mast, 2 lamps
25 Extra working lamps mast, 2 lamps
26 Headlamps on driving wheel mudguards.
27 Extra working lamps between the tilt cylinders, 1 lamp
28 Manoeuvrable working lamp

29 Extra working lamps on driving wheel mudguards
30 Door stop
31 Auxiliary start connector

Connector for starting the vehicle with help start batteries, or
to be used as a start aid for another vehicle.
32 Engine room lighting
33 Protective screen in front of windscreen
34 Lifting lug
35 Compartment for A4 papers
36 Head restraint
37 Left-hand armrest
38 Indicators with side lamps
39 Extra working lamps, centrally located on cab, 2 lamps
40 Headlamps centrally located on cab
41 Wiper, roof, including washer
42 Mechanical tilt indication
43 Hydraulic weight indication
44 Secondary filter
45 Toolkit
46 Piling carrier (Not marked in the figure).
47 Heater: (Not marked in the figure)

A: 230 V for connection of engine heater with or without cab
heater (located at cab footstep on left side)
B: Outlet for cab heater
C: Cab heater
D: Oil heater hydraulic tank
48 Extra exhaust gas filter systems: (Not marked in the figure)

A: Catalyst, replaces the standard silencer
B: Combi filter, filter system placed on the left side (replaces the
silencer and end pipe)

Other equipment FlexGuard/FlexCab
18 8 13,14 5,20 6 12,15 1,2 21 3
18
19,22
23
27
10,11
8
25,26
24
003491
16 17 9 4 17 7 16
The figure shows a vehicle with FlexGuard.
1 Rear view mirror
2 Extra rear view mirror (in cab)
3 External rear view mirrors

4 Horn
Placed under cab.
5 Electrically operated loud horn

Placed on the left of the roof side.
6 Stereo, 24 VDC
Directions for use is enclosed.
7 Outlet 24 VDC
8 TV-camera with monitor

For improving the view during load handling or reversing. The
camera is placed on counterweight and/or lifting equipment.
The monitor is placed inside the cab on the left.
9 Hydraulic weight indication
10 Windscreen for FlexGuard

11 Windscreen wiper and washer for FlexGuard
12 Roof window for FlexGuard
13 Rear window for FlexGuard
14 Rear window wiper and washer for FlexGuard
15 Wiper, roof, including washer
16 Splash guard for drive and steering wheels
17 Electric cab tipping with manual cab tipping pump
18 Lifting lugs
19 Protective grating for working lamps, mast

20 Working lamps, cab roof, rear edge, 2 lamps
21 Extra working lamps for cab roof front edge, 2 lamps

22 Working lamps, mast, 2 lamps
23 Extra working lamps, mast, 2 lamps
24 Indicators with side lamps
25 Extra working lamps, centrally located on cab, 2 lamps
26 Headlamps centrally located on cab
27 Mechanical tilt indication
28 Door stop (Not marked in the figure)
29 Tool kit (Not marked in the figure)
30 Piling carrier (Not marked in the figure)
31 Heater: (Not marked in the figure)

230 V for connecting engine heater, with or without cab heater
(located at cab footstep on left side).
32 Extra emission control: (Not marked in the figure)

A: Catalyst, replaces standard silencer
B: Combi filter, filter system placed on the right side (replaces
the silencer and end pipe)

28 3 Summary – 3.2 Protection and warning equipment
3.2 Protection and warning

equipment
General
A good working environment has protection and warning equipment
to make the operator’s work easier and safe.
The vehicle may be equipped with the following protection and
warning equipment:
1. Reversing alarm
2. Rotating beacon/flashing warning lamp

The rotating beacon may be vertically adjustable.
3. Horn
4. Electrically operated loud horn
5. Fire extinguisher
The fire extinguisher is generally placed on the bonnet or coun-
terweight, but can also be located inside the cab.
If the vehicle is provided with a fire extinguisher, it should be of
the type ABE according to EN 3 pt. 1, 2, 4 and 5. With such a fire
extinguisher, it is possible to put out fires in both solid organic
materials and fluids. Suitable fire extinguishing equipment can
be ordered from Kalmar Industries.
6. Seat belt
7. Buzzer in cab to indicate alarm/forgotten action, for example,
leaving cab without applying the parking brake.
8. TV-camera with monitor :

Is used for improving the rear view when manoeuvring and/or
load handling with the vehicle. The monitor is placed inside the
cab on a stand on the left or right side.
9. Slow moving vehicle sign .
10. Protective grating for roof window .
11. Flashing brake lamp for reversing .

3 Summary – 3.2 Protection and warning equipment 29
10 2 4,11 5 1 2
003513
3 6 8 9

30 3 Summary – 3.3 Plates
3.3 Plates
Product plates
The following shows the product plates that should be fitted on the
vehicle. When ordering spare parts and when enquiring per tele-
phone or correspondence, the model designation shall be given ac-
cording to the plates. The plates’ spare part numbers are indicated
on each plate.
003514
4 1,2,5
1 Vehicle plate, A33806.0200

M= Vehicle model
S/N= Serial number / Year of manufacture
Q, D, H = Gives the classed lifting capacity (Q) according to
EN1726 at centre of gravity distance (D) up to lift height (H).
W = Vehicle’s operating weight (without load)
Q, D, C, H = Approved load at lift height (H) for each distance
(so-called load centre) horizontally and vertically from the lift
mast and forks (D and C).
003557
Vehicle plates can only be ordered with complete engraving.

2 Additional plate for attachment, A33807.XXXX
Specifications about the vehicle’s attachment.
NOTE
The plate’s design depends on attachment type.
S/N= Serial number / Year of manufacture
A= Identification number for attachment
H= Lift height
D= Centre of gravity, distance
Q= Lift capacity
003558
C= Centre of gravity, height. Distance from forks/underneath

the load up to the load’s centre of gravity.
Plates can only be ordered with complete engraving.

3 Summary – 3.3 Plates 31
3 Decal for attachment, A33808.XXXX

Specifications for the vehicle’s approved lifting equipment. The
plate is also found in the cab for driver information. Corre-
sponds with plates items 1 and 2.
NOTE
The plate’s design depends on attachment type.
S/N= Serial number
H= Lift height
D= Centre of gravity, distance
003559
Q= Maximum load
C= Centre of gravity, height. Distance from forks/underneath
the load up to the load’s centre of gravity
4 Type plate attachment, A45809.0100
S/N= Serial number
Right field indicates year of manufacture
H= Maximum hydraulic pressure to attachment
003560
Q= Maximum load
D= Approved centre of gravity distance from leading edge of
fork/attachment for maximum load
COG= Centre of gravity for dead weight of mast (without load)
LLC= Lost load distance
W= Dead weight of mast (without load)
5 Plate for certified sound level, A42483.XXXX
L(WA)= Identification number for attachment
L WA
106 dB
001834
A42483.0300

Warning and information plates

The following figures show the warning texts and information texts
that are located on the vehicle. The operator shall be aware of the
warnings and should also follow the instructions and information
given on decals (stickers) and plates.
Make sure warning and information symbols on the vehicle and its
components always are easy to see and legible. Symbols that have
been damaged or painted over must be replaced immediately.
1 1
4 2
003515
1 5 2 3 5 1
Chassis, cab
1 Lift point, 423049.0100
Attaching point for lifting device when lifting the vehicle. Lift
points are found:
• lift mast
000276
• rear
2 Warning! A26939.0100
Warning! Read the operator’s manual for information.
000277

3 Warning! A30770.0400
Air conditioning. Filling of refrigerant or other work in the air
conditioning circuit requires special authorization (observe na-
tional legislation and local regulations).
1= Refrigerant, type
2= Amount, kg
1 3= Pressure, bar
2
The plate is also found on condenser, compressor and by the air
3
inlet (leading edge, cab) as plate A30770.0200.
003561
Safety
4 Warning! A36203.0100
- No passengers allowed. Passengers may only ride in the cab
if it’s equipped with a permanently mounted passenger seat.
- Do not jump. Always stop the vehicle in case of risk of tipping
over/roll-over, and hold on to the steering wheel.
000847
5 Fire extinguisher, A43461.0100

Indicates where extinguishing should take place in case of fire
in engine compartment. Nozzle for fire extinguisher is pressed
through the plate.
001833
A43461.0100

003775
9 6 7,8 10 9 9 7,8 9
Engine
6 Filling point, fuel, 450202.0100
D
000286
450202.0100
7 Warning! A30530.0100
Rotating fan.
000287
8 Warning! A30532.0200
Hot surfaces.
000850
Wheels
9 Air pressure, factory-mounted tyres
A32049.0500 0.8 MPa
A32049.1000 0.85 MPa
003562
A32049.0700 0.9 MPa

A32049.0100 1.0 MPa
NOTE
Read chapter 6 “Inspection and maintenance” for safety
when handling wheels.
If factory-installed tyres are replaced by another tyre
brand, the specified tyre pressures may change!

Electrical system
10 Battery isolator, A30537.0100
003749
12 13 14 11
12
003776
Hydraulic system
11 Filling point, hydraulic oil, 450203.0100
000292
12 Warning! A36163.0100
Pressure. Always release the pressure from the accumulator
before working on the hydraulic system.
002497

13 Pressure hydraulics, A43462.0300

Gives the vehicle’s hydraulic pressures. The specifications are
engraved.
003349
Lift mast and attachment

14 Warning! A30771.0100
Never walk under loads and never stand on the forks.
D AN GE R
Forks and other attachments (with or without load)
are easily and forcefully manoeuvred.
Make sure that nobody stands under a raised

attachment, regardless of whether it is loaded or
000858
not.

4 Instruments and controls 4 Instruments and controls 37
4 Instruments and controls
4 Instruments and
4 Instruments and controls –
controls
General
Do not operate the vehicle before you know the position and func-
tion of instruments and controls, and completely understand how
they are used!
This chapter gives general information about instruments, switches,
controls and other equipment in the vehicle’s cab.
NOTE
Thoroughly read the following chapter about instruments and
controls.

38 4 Instruments and controls – 4 Instruments and controls
Summary Spirit Delta

1 2 3 4 5 6
4 3 2 1
L 0
1
14 2
13 A
004060
12 11 10 9 8
Summary
1 Left instrument panel
2 Travel direction selector
3 Steering wheel panel
4 Steering wheel
5 Multi-function lever
6 Right instrument panel
7 Hydraulic controls with four levers (4-lever, 5-lever, electric ser-
vo or joystick)
8 Armrest
9 Operator’s seat
10 Accelerator
11 Brake pedal
12 Electrical distribution box with fuses and relays
13 Steering joystick or mini steering wheel

14 Hours counter (operating hours)
A Hydraulic controls with electric servo

4 Instruments and controls – 4 Instruments and controls 39
Left Instrument panel

15 Control for heat
30 31 32
16 Control for fan
17 Control for defroster/cab
18 Control for AC cooling
19 Switch for recirculation/fresh air

27 28 29
19 .. 26 20 Switch for air condition AC
21 Switch for extra working lamps

18
17 22 Switch for working lamps
16
15 000882 23 Switch for extra working lamps
Left instrument panel on vehicle equipped with a
Switch for switching off reversing alarm
heating unit
30 31 32 24 Switch for rotating beacon

25 Switch for flashing hazard warning lamps
26 Switch for headlamps
27 Switch for seat heating
27 28 29 28 Switch for central lubrication

19 .. 26
Switch for pause heater
TO DE
AU MO
29 Spare
75 30 Spare
003704
31 Gauge for fuel level (not for KCS controlling)
Left instrument panel on vehicle equipped with ECC Switch for electrically adjustable rear-view mirrors
climate unit . 32 Gauge for coolant temperature
75 Climate control system ECC

Steering wheel panel
33 Switch for reversible operator’s seat

42 43 44 45 46
41 Switch for electrically heated rear-view mirrors
40
34 Switch for activation/deactivation of alternative travel direction
39
selector
35 Switch for parking brake
36 Function keys for control and monitoring system, KCS

F
N
37 Switch for windscreen wiper rear
R
38 Switch for windscreen wiper roof

R
1 2 3
39 Spare
4 5
40 Spare
41 Spare
000883
33 34 35 36 37 38 42 Indicator lamp for indicators
Steering wheel panel 43 Indicator lamp for high beams
44 Display control and monitoring system, KCS
45 Indicator control and monitoring system, KCS

46 Ignition
Right instrument panel
47 .. 53 54 55
47 Spare
48 Spare
49 Warning lamp for low battery charging
50 Warning lamp for low oil pressure engine
51 Spare
52 Warning lamp for low brake pressure
002486
56 .. 62 53 Warning lamp for low coolant level engine

Right instrument panel 54 Spare
55 Spare
56 Spare
57 Spare
58 Indicator lamp for pre-heating
59 Warning lamp for high coolant temperature engine
60 Spare
61 Warning lamp for air filter change
Warning lamp for combifilter change
Warning lamp for by-pass

62 Indicator lamp for parking brake

Hydraulic functions
63 64 65 66 67 68
63 Travel direction, forward/neutral/reverse
64 Lift/lower
65 Tilt
66 Side shift
67 Fork positioning
68 Lever for fork levelling

Other combinations may occur.
Hydraulic functions 000885

Summary FlexGuard and FlexCab
Summary applies to FlexGuard and FlexCab.
2 3 4 5
4 3 2 1
N
L 0
R
R
1 4 5
2 3
003796
13 11 11 10 9 6
Summary
2 Travel direction selector
3 Steering wheel panel
4 Steering wheel
5 Multi-function lever
6 Instrument panel
7 Hydraulic functions (4-lever, 5-lever or joystick)
9 Operator’s seat
10 Accelerator
Accelerator pedal with direction of travel selection function

11 Brake pedal
13 Electrical distribution box with fuses and relays


42 43 46 35 Switch for parking brake
49
58 42 Indicator lamp for indicators
43 Indicator lamp for high beams

46 Ignition
49 Warning lamp for low battery charging
50 Warning lamp for low oil pressure
50 51 Spare
52 Warning lamp for low brake pressure
P
53 Warning lamp for low coolant level engine
58 Indicator lamp for pre-heating
60 Spare
51 60 52 61 53 62 35
003483
61 Warning lamp for air filter change

Warning lamp for combifilter change
Warning lamp for by-pass

62 Indicator lamp for parking brake

Instrument panel
31 32 14 15
14 Hours counter (operating hours)
15 Control for heat
22 Switch for working lamps
23 Switch for extra working lamps
24 Switch for rotating beacon

25 Switch for flashing hazard warning lamps
26 Headlamp switch
37 38 26 22 23 25 24 27 76 003484 27 Switch for seat heating

Instrument panel 31 Gauge for fuel level
32 Gauge for coolant temperature
37 Switch for windscreen wiper rear
38 Switch for windscreen wiper roof
76 Switch for fan

Hydraulic functions
64 65 66 67 68 64 Lift/lower
65 Tilt
66 Side shift
67 Fork positioning
68 Lever for fork levelling

001835
Hydraulic functions

4 Instruments and controls – 4.1 Warning and indicator lamps 45
4.1 Warning and indicator lamps

General
This section describes the warning and indicator lamps in the cab.
The lamps indicate status of sub-systems/systems. An activated
warning lamp should be attended to immediately. An activated indi-
cator lamp informs of imminent action.
Warning and indicator lamps are grouped in the right instrument
panel and on the steering wheel panel.
Numbers in brackets refer to the positions in the section Summary
Spirit Delta page 38 and Summary FlexGuard and FlexCab page 42.
Indicator lamp for indicators (42)

The lamp (green) flashes when indicators indicator or flashing hazard
warning lamps are on.
000310
Indicator lamp for high beams (43)

The lamp (blue) is activated when the high beams are on.
000309
Indicator for control and monitoring system,

KCS (45)
The indicator lamp (red) flashes when an alarm is shown on the dis-
play for the control and monitoring system (KCS).
See section 4.12 “KCS system” for detailed information.
001458
Warning lamp for low battery charging (49)

The lamp (red) warns in case of missing charge to the batteries. The
lamp is activated if the voltage from the alternator is lower than the
000297
battery voltage.
NOTE
Do not operate when the Low Battery Charge lamp lights up.

46 4 Instruments and controls – 4.1 Warning and indicator lamps
Warning lamp for low oil pressure engine (50)

If the lamp (red) lights up during driving, the pressure is very low.
Stop the engine at once. Make sure that the reason is diagnosed and
000303
rectified. Contact service.
An audible warning in the cab instrument panel is activated at the
same time as this lamp.
Warning lamp for low brake pressure (52)

The lamp (red) is activated when the pressure in the accumulator,
that is, brake pressure is too low. After the lamp has been activated,
000298
the service brake’s capacity is limited.
Check the accumulators’ sealing if the pressure does not build up
and isn’t maintained, see chapter 6 “Inspection and maintenance”.
Warning lamp for low coolant level engine (53)

If the lamp (red) is activated while operating, the coolant level is too
low. Check and top up, if needed. See chapter 6 “Inspection and
Maintenance”.
000305
Indicator lamp for pre-heating (58)

The lamp (green) is active during the engine’s pre-heating period.
000304
Warning lamp for high coolant temperature

(59)
The lamp (red) is activated if the engine’s coolant temperature
should become too high. Determine the cause and take appropriate.
For action, see chapter 6 “Inspection and Maintenance”.
000302
Warning lamp for air filter replacement (61)
The lamp (red) is activated when the air filter needs to be replaced.
The warning lamp has no symbol.
Warning lamp for by-pass (61)
The lamp (red) indicates when the hydraulic functions are bypassed.
The warning lamp has no symbol.
Indicator lamp for parking brake (62)

The lamp (red) is activated when the parking brake is applied.
000311

4 Instruments and controls – 4.2 Instruments 47
4.2 Instruments
General
This section describes the analogue instruments in the cab. The
gauges or digits indicate levels/status of sub-systems/systems.
Numbers in brackets refer to positions in Summary Spirit Delta page
38 and Summary FlexGuard and FlexCab page 42.
Hours counter (14)

The hours counter shows the number of hours that the engine has
been running.
The meter is used to determine when the vehicle is due for periodic
maintenance. All times in periodic maintenance are based on the ve-
hicle’s operating time in hours.
001342
Fuel level gauge (31)

The tank is full when the gauge shows 4/4, half tank when the indi-
cator points straight up. For action, see chapter 6 “Inspection and
maintenance”.
NOTE
Fill fuel before the gauge shows 0! Otherwise there’s a risk of
air entering the fuel system.
001338
Gauge for coolant temperature (32)

The temperature gauge shows the engine’s coolant temperature,
which normally should be approx. 80 °C. Time to reach operating
temperature is approx. 5-10 minutes, but may be longer depending
on load and weather conditions. The temperature can vary within
the interval 75-110 °C.
Higher temperature may indicate low coolant level. Check and top
up, if needed. See chapter 6 “Inspection and Maintenance”.
If the temperature remains too high, the cause must be determined
001339
and repaired.
NOTE
The engine may not be run with too high coolant temperature!

48 4 Instruments and controls – 4.3 Ignition (46)
4.3 Ignition (46)

General
This section describes the ignition.
Ignition’s function
P No function.
0 Stop position. Everything is off, key can be removed.
I Operating position.
Electric power (current) to all electrical functions.
II Pre-heating position
F
N
In cold weather, pre-heating, i.e. starting heater is used..
R
III Start position.

R
1 2 3
Engagement of starter motor for engine start.
4 5
The engine should not be started (key moved to start po-

sition) until the warning and indication lamps have left
their initial positions (light up then go out again). Note that
some lamps can continue to be illuminated, to indicate
0 states.
P I The lamps are lit one after one, and then are extinguished
(lamp check).
II NOTE
The vehicle is equipped with an electric restarting in-
terlock, which prevents engagement of the starter
motor when the engine is rotating.
000388
III
The condition for the starter motor to engage is that
travel direction selector is in neutral position, that
the parking brake is applied and that the engine isn’t
already running.

4 Instruments and controls – 4.4 Switches 49
4.4 Switches
General
This section describes the switches in the cab. Each switch controls
a function.
Switch for extra working lamps (21)
Switch (green) for extra working lamps.

Position 0 - Lamps off.
Position 1 - Lamps on.
000319
0 1
Switch for working lamps (22)

Switch (green) for working lamps on the cab roof and lift mast.
000318
0 1
Switch for extra working lamps (23)
Switch (green) for extra working lamps on the mast.

000319
0 1
Switch for switching off reversing alarm (23)
Switch (green), reversing alarm cutout (position 23)

Position 0 - Reversing alarm on.
002899
0 1
Position 1 - Reversing alarm off.
Switch for rotating beacon (24)
Switch (green) for rotating beacon, used to draw attention to vehicle

and to warn for potential hazards or dangers.
Position 0 - Rotating beacon off.
000321
0 1 Position 1 - Rotating beacon on.

50 4 Instruments and controls – 4.4 Switches
Switch for flashing hazard warning lamps (25)

Switch (red) for flashing hazard warning lamps, used to draw atten-
tion to vehicle in connection with parking hazard.
Position 0 - Flashing hazard warning lamps off.
000322
0 1 Position 1 - Flashing hazard warning lamps on.
Switch for headlamps (26)
Switch (green) for headlamps. Also activates rear lamps and side
running lamps.
000323 Position 0 - Headlamps off.
0 1 Position 1 - Headlamps on.
Switch for seat heating (27)
Switch (green) for heat in seat.

Position 0 - Heat off.
Position 1 - Heat on.
000324
0 1
Switch for central lubrication (28)
Switch (green) for central lubrication of vehicle. Rocker switch.

Position 0- Central lubrication is done at a pre-determined interval.
Position 1 - Central lubrication on. The pump for central lubrication
000325
0 1 performs one extra lubricating cycle in addition to ordinary lubrica-

tion. The lamp is lit during the cycle.
Switch for pause heater (28)
Switch to activate the pause heater function (position 28).

Position 0 - Pause heater on.
002900
0 1
Position 1 - Pause heater off.
Switch for electrically adjustable rear-view

mirrors (31)
Multi-function joystick switch (position 31). Can select one of two

mirrors to be adjusted. Controlled by the joystick, up-down-side-
ways.
002902

4 Instruments and controls – 4.4 Switches 51
Switch for reversible operator’s seat (33)
Switch (green) for reversible operator’s seat.

Position 0 - Standby.
Position 1 - Turning left.
001279
1 0 2 Position 2 - Turning right.
Switch for electrically heated rear-view mirrors

(33)
Switch (green) for electric heating of the rear-view mirrors (position

001634 33).
0 1 Position 0 – Rear-view mirror heating off.
Position 1 – Rear-view mirror heating on (symbol illuminated).
Switch for activation/deactivation of

alternative travel direction selector (34)
2-position switch
Switch (green) for activation/deactivation of alternative travel direc-
tion selector.
Position 0 - Ordinary travel direction selector is engaged, that is, al-
001635
ternative travel direction selector is disengaged. The lamp in the

0 1
switch is off.
Position 1 - Alternative travel direction selector is engaged. The or-
dinary travel direction selector is disengaged. The lamp in the switch
is on.
Switch for activation/deactivation of

alternative travel direction selector (34)
3-position switch
Switch (green) for activation/deactivation of alternative travel direc-
tion selector.
Position 0 - Ordinary travel direction selector is engaged, that is, al-
001636
ternative travel direction selector is disengaged. The lamp in the

0 1 2
switch is off.
Position 1 - Alternative travel direction selector on hydraulic control
or in accelerator pedal is engaged. The ordinary travel direction se-
lector is disengaged. The lamp in the switch is on.
Position 2 - Alternative travel direction selector on steering joystick
or mini-wheel is engaged. The ordinary travel direction selector is
disengaged. The lamp in the switch is on.

52 4 Instruments and controls – 4.4 Switches
Switch for parking brake (35)

Switch (red) for applying parking brake.
Position 0 - Parking brake off.
Position 1 - Parking brake on.
000331
0 1
Switch for windscreen wiper rear (37)

Switch (green) for windscreen wiper on rear window.
Position 0 - Wiper off.
Position 1 – Interval wiper on (symbol illuminated)

0 1 2 001277
Position 2 – Continuous wiper action on (symbol illuminated).
Switch for windscreen wiper roof (38)
Switch (green) for windscreen wiper on roof window (position 38).

Position 0 - Wiper off.
001278
0 1 2
Position 1 – Interval wiper on (symbol illuminated)
Position 2 –Continuous wiper action on (symbol illuminated).
NOTE
The wiper should not be run when the polycarbonate plastic
roof window is dry.
Switch for fan (76)
Switch (green) for setting fan speed.

Position 0 - Fan shut off.
Position 1 - Low fan speed
003549
0 1 2 Position 2 - High fan speed.

4 Instruments and controls – 4.5 Travel direction selector (2) 53
4.5 Travel direction selector (2)

General
This section describes the functions of the multi-function lever.
F There are two alternative travel direction selectors:
3 21 • Travel direction selector
002436
R
• RMH control
000898
Travel direction
Travel direction are selected with the travel direction selector.
Selection of travel direction:
• F – Forward
• N – Neutral
• R – Reverse (option: audible back-up warning signal)

54 4 Instruments and controls – 4.6 Multi-function lever (5)
4.6 Multi-function lever (5)

General
This section describes the functions of the multi-function lever.
Windscreen wiper and washer

The windscreen wipers and washer are controlled by the multi-func-
tion lever (position 5). Turn the control to the following positions:
• 0 – No wiper action
• J – Interval wiper
• I – Continuous wiper action
0 J
• II – Continuous wiper action

• Push the control left for washing of windscreen, roof window
and rear window.
000896
Headlamp control, horn and direction

indicators
Headlamps and horn are controlled with the multi-function lever (po-
sition 5). Turn the control to the following positions:
• With headlamps on: Multi-function lever is used to switch be-
tween high and low beams. Move the control towards yourself
to switch between high and low beams, and back.
• With headlamps off: Multi-function lever is used to flash with the
0 J
headlamps (high beams). Move the control away from yourself

for high beam flash, return is automatic.
• Press the button for horn.
• Move the lever backward or forward for left respective right di-
000896
rection indication.

4 Instruments and controls – 4.7 Hydraulic control 55
4.7 Hydraulic control

General
This section describes the functions of the hydraulic control.
The control levers control the fork carriage and forks hydraulically.
There are five alternatives for the hydraulic control:
• Hydraulic control with four levers
• Hydraulic control with five levers
• Electric Servo with 4 levers
• Electric Servo with 5 levers
• Joystick
It’s possible to vary the speed of the different hydraulic functions
Lift, tilt, etc.) by varying the amplitude of the lever stroke. It’s also
possible to vary the speed of the hydraulic functions with engine
speed.
Extra hydraulic function can be manoeuvred from switch on the hy-
draulic control.

56 4 Instruments and controls – 4.7 Hydraulic control
Hydraulic control with levers

a. Travel direction forward/neutral/reverse.
FORWARD - move switch forward.
NEUTRAL - set switch in the middle.
REVERSE - move switch back.
b. Lift/lower (position 64).
LIFT - pull lever back.
LOWER - move lever forward.
Lowering speed can only be varied with the lever stroke - it
is not influenced by engine speed.
c. Tilt (position 65).
BACK - pull lever back.
FORWARD - move lever forward.
a b c d e f d. Side shift (position 66).
LEFT - move lever forward.
RIGHT - pull lever back.
Forks cannot be side shifted if fork positioning is at max.
out.
e. Fork positioning (position 67).
OUT - move lever forward.
IN - pull lever back.
Positioning locks when one fork runs against the end-posi-
tion. Side shift to centre - position again.
f. Fork levelling (position 68)

FORK UP - pull lever back.
FORK DOWN - move lever forward.
Fork levelling acts on right or left fork.
000894

4 Instruments and controls – 4.7 Hydraulic control 57
Hydraulic control with electric servo
The electric servo makes it possible to use small fingertip-controlled

linear levers for all the functions of the working hydraulics.
a. Travel direction forward/neutral/reverse.

NEUTRAL - set switch in the middle.
b. Lift/lower.
LIFT - pull lever back.
LOWER - move lever forward.
Lowering speed can only be varied with the lever stroke - it is
not influenced by engine speed.
c. Tilt.
BACK - pull lever back.
FORWARD - move lever forward.
a b c d e f g
d. Side shift.
LEFT - move lever forward.
RIGHT - pull lever back.
Forks cannot be side shifted if fork positioning is at max. out.
e. Fork positioning.
OUT - move lever forward.
IN - pull lever back.
Positioning locks when one fork runs against the end-position.
Side shift to centre - position again.
f. Fork levelling.
FORK UP - pull lever back.
FORK DOWN - move lever forward.
Fork levelling acts on right or left fork.
g. Emergency switch for servo circuits.
004070

58 4 Instruments and controls – 4.7 Hydraulic control
Hydraulic control with joystick
Hydraulic control with the joystick makes it possible to control all the
functions of the working hydraulics with one control.
• Travel direction forward/neutral/reverse (position 63).

63 NEUTRAL - set switch in the middle.
• The joystick can be configured as required (19 configuration op-
tions).
001846

4 Instruments and controls – 4.8 Pedals 59
4.8 Pedals
General
This section describes the vehicle’s foot-operated functions.
4 3 2 1
L 0
4
004069
11 10
10. Accelerator
11. Brake pedals
Accelerator (10)
The accelerator is mechanical and is connected to the injection
pump with a wire cable. Certain vehicles are equipped with elec-
tronic throttle (in case of control and monitoring system, KCS).
Accelerator with function for selecting travel

direction (10)
The accelerator has the same function as above. Travel direction can
be selected with the accelerator. Two switches are placed in the up-
per part of the pedal for selecting travel direction forward (left side)
or reverse (right side).
001840

60 4 Instruments and controls – 4.8 Pedals
Brake pedals (11)

The brake pedals (position 11) are hydraulic and are connected to
the vehicle’s hydraulic system. The brake pedals are used for the
service brake.
The accumulators ensure that there is always brake pressure, even
in case of a temporary engine stop. If the accumulator pressure
drops too low, the warning lamp for low brake pressure (position 52)
is activated.

4 Instruments and controls – 4.9 Steering wheel (4) 61
4.9 Steering wheel (4)

General
This section describes the control devices for steering. The following
alternatives are available for steering the vehicle:
• steering wheel with fixed or adjustable steering column ( ).
• steering joystick (Only for cab alternative Spirit Delta )
• mini-wheel (Only for cab alternative Spirit Delta )

Steering wheel
The steering wheel’s (position 4) and instrument panel’s angle and
height can be adjusted to the required operating position.
1. Steering wheel’s height.
To adjust: Move upper lever upward.
2. Steering wheel panel’s angle.
1
To adjust: Move upper lever downward.
3. Steering column’s angle.

To adjust: Loosen the lower handle and adjust to the required
position. Tighten the handle securely after adjusting.
2
NOTE
Adjustment possibilities only applicable to cab alternative
Spirit Delta.
3
001637

62 4 Instruments and controls – 4.9 Steering wheel (4)
Steering joystick
Only for cab alternative Spirit Delta.
The steering joystick is an electro-hydraulic system, mounted in the
3a 3b 4 left armrest, to steer the vehicle using a linear joystick. The steering
angle is inversely proportional to the vehicle’s speed, that is, low
speed gives greater wheel angle, and vice versa. The system uses
2 5 feedback of the wheels’ position, that is, when the joystick is re-
leased to the middle position, the wheels return to middle position.
1 The standard steering wheel is equipped with a sensor that detects
eventual steering wheel movements in case of an emergency situa-
tion. As soon as the operator starts to steer with the standard steer-
ing wheel, the joystick is disconnected and the lamp in the travel
6 direction selector (position 2) goes off.
1. Steering joystick.
2. Travel direction selector F/N/R.
forward = F
middle position = N
7 reverse = R
3. Not used.
4. Button for engaging joystick steering.
Condition: Speed below 3 km/h. If speed is over 3 km/h, joystick
steering cannot be engaged. The lamp in the travel direction se-
lector (position 2) is constantly illuminated when joystick steer-
ing is engaged.
001448
5. Audible signal.
6. For optional equipment.
7. Armrest.

4 Instruments and controls – 4.9 Steering wheel (4) 63
Mini steering wheel

Only for cab alternative Spirit Delta.
Mini steering wheel (mini-wheel) is an electro-hydraulic system,
mounted in the left armrest, to steer the vehicle using a small steer-
ing wheel. The ground wheels always follow the mini-wheel’s posi-
tion. If the mini-wheel is released, the ground wheels and the mini-
wheel remain in the current position.
The standard steering wheel is equipped with a sensor that detects
eventual steering wheel movements in case of an emergency situa-
tion. As soon as the operator starts to steer with the standard steer-
ing wheel, the mini steering wheel is disconnected and the lamp in
the travel direction selector (position 2) goes off.
1. Mini steering wheel.
Steering wheel’s position on armrest is adjustable.
2. Travel direction selector F/N/R.
forward = F
middle position = N
reverse = R
3. Audible signal.
4. For optional equipment.
5. Not used.
6. Button for engaging mini-wheel.
Condition: Speed below 3 km/h. If speed is over 3 km/h, mini-
wheel steering cannot be engaged. The lamp in the travel direc-
tion selector (position 2) is activated with a fixed glow when
mini-wheel steering is engaged.
7. Armrest.
8. Arm for adjusting the mini wheel position.

64 4 Instruments and controls – 4.10 Operator’s seat (9)
4.10 Operator’s seat (9)

General
This section describes the operator’s seat. The following alternative
seats are available:
• Operator’s seat Bege for the Spirit Delta cab. Available with:
• mechanical adjustment
• air suspension
• integrated horizontal suspension (can be switched off)
• can be rotated 40 °
• can be rotated right and left for easier exit from the cab
• hydraulic reversible 180 °

• Mechanically adjustable lumbar support
• seat belt, 2-point
• head restraint
• adjustable armrest, right
• adjustable armrest, left
• seat heater
• ventilated seat and backrest cushions (air-vent). Also
equipped with an external compressor
• Operator’s seat Isringhausen 6500 for cab Spirit Delta. Available
with:
• air suspension
• air adjustable lumbar support
• head restraint

• seat heater
• integrated compressor

4 Instruments and controls – 4.10 Operator’s seat (9) 65
• Operator’s seat Grammer Actimo XXL for cab Spirit Delta. Avail-
able with:
• air suspension
• head restraint

• seat heater
• Operator’s seat Grammer MSG 20 for cab FlexGuard and Flex-
Cab. Available with:
• adjustable angle
• seat belt
• Operator’s seat Isringhausen 6000 for cab FlexGuard and Flex-
Cab. Available with:
• head restraint

• Operator’s seat Grammer Maximo XXL for cab FlexGuard and
FlexCab. Available with:
• air suspension
• head restraint

• seat heater

Operator’s seat Bege

Only applies to vehicles equipped with a Spirit Delta cab.
The operator’s seat (position 9) is equipped with several controls for
adjustment as follows (adjusting is easier when the seat is unload-
ed):
7 4
1. Distance to pedals.
Release the seat with the lever and move the seat forwards or
backwards.
2. Height of seat.
With mechanical elevation of seat height:
Turn the knob clockwise or counter-clockwise until the required
height is obtained.
With air suspension elevation of seat height:

Turn the knob counter-clockwise to lower seat height. Turn the
knob clockwise to elevate seat height. The suspensions corre-
6 sponds automatically to the operator’s body weight.
Leaving the cab is facilitated if the suspension is evacuated by
pulling the control (position 6) to the outer end-position (seat
lowers to lowest level). When entering the cab, push in the con-
trol to the inner end-position (the seat elevates to the set posi-
5 tion).
1 2 3
3. Backrest angle.
Turn the knob until the required position is obtained.
000342
4. Adjustment armrest angle right.
Operator’s seat with adjustment possibilities Adjustment armrest angle left.

5. Variable angling of seat and backrest.
Turn the knob until the required position is obtained.
6. Adjustment of suspension travel in two steps (lever located on
back of seat):
Suspension active - Lever against seat’s centre line. Used during
normal operation.
Suspension locked - Lever against seat’s outside. Can only be
performed when the seat height reaches a lock position. Used
when suspension is not wanted.
7. Lumbar support.
Turn knob until the required firmness in lumbar support is ob-
tained.

Operator’s seat Isringhausen 6500

The operator’s seat (position 9) is equipped with controls for adjust-
ment as follows (adjusting is easier when the seat is unloaded):
1. Distance to pedals
Release the seat with lever (1) and move the seat forwards or
backwards. Release the lever to lock the seat.
2. Raising/lowering operator’s seat
Lift the control (2) to raise/lower the seat.
8
When the required height has been set, release the control.
3. Seat angle.
Lift control (3) and adjust the angle by loading/unloading the
front of the seat.
4. Backrest angle.
backrest.
5. Damping adjustment.
003712
Press “+” for more damping.

2 3 6 1 5 7 4 9
Press “–” for less damping.
6. Seat heating.
Thermostatically controlled heating for seat cushion and back-
rest.
Press the button to activate / turn off. The indication lamp is il-
luminated when seat heating is activated.
7. Lumbar support. Integrated pneumatic system.
Press buttons (7) to fill up or empty the air chambers to adjust
the backrest for best comfort.
8. Armrest angle can be continuously adjusted with the knurled
knob.
9. Armrest left

Operator’s seat Grammer Actimo XXL

8 ment as follows (adjusting is easier when the seat is unloaded):
9 2. Seat cushion adjustment.

Lift control (2) and adjust the seat cushion forwards or back-
wards.
10 3. Raising/lowering operator’s seat
2 Lift the control (3) to raise the seat.

5
4 Press control (3) down to lower the seat.
6 When the required height has been set, release the control.
4. Seat angle.
003710
front of the seat.

3 1 7
5. Backrest angle.
backrest.
Turn control (6) forwards in stages, for harder damping.
Turn control (6) backwards in stages, for softer damping.
7. Plane damping.
Turn control (7) to the rear-facing position to permit damping.
Turn control (7) to the forwards-facing position to prevent damp-
ing.
Press the buttons to fill up or empty the air chambers to adjust
knob.
10. Armrest left

Operator’s seat Grammer MSG20

Only applies to vehicles equipped with a FlexGuard/FlexCab opera-
tor’s cab.
1. Backrest angle.
2. Distance to pedals.
Release the seat with the lever (2) and move the seat fore or aft.
3. Seat height is adjusted with the control (3).
Use the control to adjust seat height. Move the control down-
ward to elevate seat. Move the control downward until it stops
and the seat height returns to the lowest level.
The suspensions corresponds automatically to the operator’s
000540
1 2 3 body weight.
Operator’s seat Isringhausen 6000
Only applies to vehicles equipped with a FlexGuard/FlexCab opera-

tor’s cab.
2. Raising/lowering operator’s seat
6 Lift the control (2) to raise/lower the seat.
3. Seat angle.
front of the seat.
4. Backrest angle.
backrest.
003713
5. Damping adjustment/weight setting.

2 3 1 5 4 7
Turn the knob to set the required damping level.
knob.
7. Armrest left

Operator’s seat Grammer Maximo XXL
11 Only applies to vehicles equipped with a FlexGuard/FlexCab opera-

tor’s cab.
8
9 10 2. Seat cushion adjustment.
Lift control (2) and adjust the seat cushion forwards or back-
wards.
5 3. Raising/lowering operator’s seat

Lift the control (3) to raise/lower the seat.
1
2
4. Seat angle.
4
003711
front of the seat.

7 3 6 5. Backrest angle.
backrest.
Turn control (6) forwards in stages, for harder damping.
Turn control (6) backwards in stages, for softer damping.
7. Plane damping.
Turn control (7) to the rear-facing position to permit damping.
Turn control (7) to the forwards-facing position to prevent damp-
ing.
Press the buttons to fill up or empty the air chambers to adjust
knob.
10. Armrest left

11. Seat backrest.
Adjust the seat backrest to the required position.

4 Instruments and controls – 4.11 Heating/Air conditioning 71
4.11 Heating/Air conditioning

General
This section describes the functions of:
• Cab Spirit Delta.
• Cab FlexCab.
4.11.1 Cab Spirit Delta

General
• Heating system
• Climate control system, AC (manual control of cooling and heat)
• Climate control system, ECC (electronic control of temperature,

air distribution and fan speed)
NOTE
The operator’s door and all windows should be closed for
satisfactory function of heating/AC.
001839
Air inlets to cab
4.11.1.1 Heating system/Climate control

system with AC
General
The heating system is connected to the engine’s cooling system and
A
provides heat when the engine is warm.
The system’s fan is controlled in steps 0-I-II-III with the control for fan
(position 16). The air intake is equipped with a filter and may be
equipped with a fine-textured filter for pollen ( ).
Heat is controlled with the heat control (position 15).
The installation can also be equipped with AC .

21
20
19 NOTE
18 The operator’s door and all windows should be closed for satis-
17 factory function of heating/AC.
16 Numbers in brackets refer to positions in Summary Spirit Delta page
000541
15 38 and Summary FlexGuard and FlexCab page 42.

A. Panel nozzle

72 4 Instruments and controls – 4.11.1.1 Heating system/Climate control system with AC
Control for heating (15)

The rotating knob (position 15) provides continuous adjustment of
heat supply. Turn clockwise for more heating, anti-clockwise to re-
duce or shut off the heating.
000547
Control for fan (16)
Infinitely variable control handles (position 16) inlet of fresh air to the
cab. Turn clockwise to increase fan speed, thus increasing fresh air
into the cab, counter-clockwise to reduce inlet of fresh air.
The system’s fan is controlled in steps 0-I-II-III with the control for
fan.
000545
Control for defroster/cab (17)

Infinitely variable control (position 17) handles the distribution of
fresh air to the cab. Air is distributed to the lower cab space (legs)
and defroster (window). Left position for lower cab space, middle
position for cab space and right position for defroster.
000546

4 Instruments and controls – 4.11.1.2 Climate control system ECC (75) 73
Control for cooling AC (18)
The control (position 18) handles setting of the cooling performance.

Turn clockwise to increase cooling, counter-clockwise to reduce/
turn off cooling.
000548
Switch for recirculation/fresh air(19)
Switch (green) to handle air circulation in the cab.

Position 0 - Fresh air inlet open.
Position 1 - Fresh air inlet closed, cab air in recirculation.
000542
0 1
Switch for AC (20)
Switch (green) to handle cooling function. Rocker switch.

Position 0 - Cooling function off,
Position 1 - Cooling function on. The air conditioning’s cooling func-
001837
0 1 tion does not start if the fan control (position 16) is at position zero.
4.11.1.2 Climate control system ECC (75)
General
The climate unit constantly controls the interior temperature, to pro-

vide the required temperature irrespective of ambient conditions.
The installation is always set to AUTO mode and 21°, irrespective of
the setting when last shut off.
The climate unit functions are controlled by the function buttons.
AUTO
MODE
The system can be equipped with a pollen filter ( ).

003564
75
AUTO mode
The temperature, air distribution and fan speed are adjusted auto-
matically in AUTO mode. The selected temperature and AUTO are
003702
shown on the display.

74 4 Instruments and controls – 4.11.1.2 Climate control system ECC (75)
Temperature
Set the required temperature with the buttons.
003565
Fan
Set the required fan speed with the buttons. Speed can be adjusted
between 0-100%.
003566
Air distribution
Select the required function with the buttons. The selected air distri-
bution is indicated with a square underneath the relevant symbol.
003567
Air to floor.
003568
Air to both floor and ventilation nozzles.

003569
Air to windscreen.
003570
Max defroster.
003571
Recirculation
Cabin air is recirculated, i.e. no fresh air is drawn into the driver’s
cab. REC is shown on the display when the function is activated.
003572
Shut off recirculation by pressing the button again.

4 Instruments and controls – 4.11.2 FlexCab Cab 75
4.11.2 FlexCab Cab

General
31 32 14 15
• heating system
The heating unit is connected to the engine cooling system and pro-
vides heat when the engine is warm.
The fan in the unit is controlled in stages 0-I-II with the fan switch
(position 76).
The heating is controlled with the heating control (position 15).
NOTE
003484 The operator’s door and all windows should be closed for satis-
factory function of heating.
37 38 26 22 23 25 24 27 76
Control for heating (15)

The rotating knob (position 15) provides continuous adjustment of
heat supply. Turn clockwise for more heating, anti-clockwise to re-
duce or shut off the heating.
000547
Switch for fan (76)
Switch (green) for fan (position 76).

Position 0 - Fan shut off.
003309
0 1 2
Position 1 - Low fan speed.
Position 2 - High fan speed.

76 4 Instruments and controls – 4.12 KCS system
4.12 KCS system

General
This section describes the control and monitoring system.

44 45
The vehicle is then equipped with an electronic system for control
and monitoring of the vehicle’s functions.
The system gives the operator information in the form of error code
information and operating information. The information is presented
on the steering wheel panel’s display (position 44) and can consist
of three error code levels as well as operating information in the
F
N
form of speed, engine rpm, fuel level, etc. In case of an error code,
R the indicator control and monitoring system (position 45) is lit.
R
The function keys (position 36) are used to navigate in the display
1 2 3
menus for service and troubleshooting, for example.
4 5

38.
000549
36
36. Function keys for control and monitoring system,
KCS
44. Display control and monitoring system, KCS
45. Indicator control
4.12.1 Information menus

General
After the vehicle is started, an engine and transmission menu or a
service menu is shown in the display. Menus are selected with the
right arrow and left arrow function keys. Each time a key is pressed,
the display changes to the next menu. To return quickly to the orig-
inal display, press and hold in the Reset (R) function.
The following describes the information that can be obtained from
each information menu. Figures are indicated with example data.
004071
Example of information menus for vehicle

4 Instruments and controls – 4.12.1.1 Information menu for engine and transmission 77
4.12.1.1 Information menu for engine and

transmission
Description
a. Shows current engine speed (rpm).
a 1240 b. Shows current speed in km/h.
b 4 c. Shows current travel direction.
c F d F – forward, N – neutral, R – reverse.
002477
d. Shows current fuel level.
4.12.1.3 Information menu for scales
Description
a. Shows dead weight (tare) in tonnes.
(+/-) 0000 a Value shown on the row (b) can be reset to zero (off-set) with the
function keys for minus and plus. Set value is shown on row (a).
9.0 t b
Shows 0-3.0 tonnes.
Σ 35.2 t c
000697
b. Current weight in tonnes (net weight).

c. Total weight in tonnes (gross weight).
Value shown on the row (b) can be added to the row (c) with the
function key for Return. The value on the row (c) can be reset by
pressing in function keys Reset and Return at the same time.
4.12.1.4 Information menu for engine
Description
a. Shows engine’s current coolant temperature in °C.
85 ˚C a b. Shows engine’s current oil pressure in bar.
6.2 bar b
000698
4.12.1.6 Information menu for electrical

system and hydraulics
Description
a. Shows current battery voltage in Volt.
b. Shows current temperature of hydraulic oil in °C.
28.7 V a
53 ˚C b
000700

78 4 Instruments and controls – 4.12.1.7 Information menu for operating time
4.12.1.7 Information menu for operating time
Description
a. Shows total distance in km.
1 430 a b. Shows total operating time in hours.
c. Shows time (in hours) to next service.
210 b
200
003486
c
4.12.1.8 Information menu for mini steering

wheel/steering joystick
Description
This menu is for the “Steering joystick” or “Mini steering wheel”

functions and sets the steering sensitivity (1-9).
-/+ Change the sensitivity with the function keys “-/4” and “+/5”.
With one mark in the display, the steering is very slow (forgiving).
001348
With nine marks, the steering is very fast (sensitive).

A default setting is pre-defined and set when the ignition is turned
(position I). The pre-defined value may be changed via the informa-
tion menu for service.
4.12.1.9 Information menu for service
Description
This menu is only used by service personnel.
000557

5 Handling 5 Handling 79
5 Handling
5 Handling
5 Handling –
General
The vehicle is intended to be used in the way that is described in the
operator’s manual. If the vehicle is used in another way or in
potentially dangerous or hazardous conditions, for example, an
explosive environment, special safety regulations must be followed
and the vehicle must be equipped for such conditions and
environments.
NOTE
It is the operator’s responsibility to make sure that the vehicle
is brought in for service every 250th operating hour. The actions
are described in the maintenance manual.
Safety
The information in the chapter for handling the vehicle does not
relieve the operator of the responsibility of following laws or other
national regulations for road safety and work safety.
Awareness, alertness, good judgement and respect for governing
safety regulations are prerequisites for avoiding accident risks of
accidents.
The following safety equipment should be on the vehicle:
• Emergency exit, right door.
In an emergency:
1. Open the emergency exit right door with handle on inside.
• Seat belts.
• Emergency stop hydraulics (only for hydraulic control electric
A servo)
In an emergency:
1. Press down the emergency switch for working hydraulics
(position A) immediately.
All power transmission and control signals stop to working
hydraulics on the mast.
• Fire extinguisher
001403
The fire extinguisher is located on the bonnet or counterweight,

but can also be located inside the cab.
In case of an engine fire, press in the fire extinguisher through
the perforation in the plate for fire extinguisher on the side of
the engine hood.

80 5 Handling – 5.1 Running-in
5.1 Running-in
General
The vehicle should be operated with great care during the run-in
period. The purpose is to give bearing surfaces hard and polished
surfaces, which considerably extends the service life.
Recommended run-in period is 50 operating hours. This gives fewer
malfunctions. Increase the load successively during these 50 hours.

5 Handling – 5.2 Daily inspection 81
5.2 Daily inspection

General
Daily inspection of the vehicle is extremely important in order to
ensure that it is safe both for the operator and its surroundings.
Every operator should perform checks before a new work shift. In
this way, operators can avoid running defective vehicles with
malfunctions that have been generated or caused during an earlier
work shift.
CAUTION
Never operate a defective vehicle.
Report immediately to the foreman/supervisor if

defects are found on the vehicle during daily
inspection!
For work instructions, see section 6.1 “Daily inspection”.

82 5 Handling – 5.3 Handling of fault codes
5.3 Handling of fault codes

General
fault code indication depends on the vehicle’s version:
• equipped with Kalmar Control System (KCS)

• not equipped with Kalmar Control System (KCS)
5.3.1 fault codes

General
An fault code indicates that there is some malfunction in the vehicle.
44 45 The fault codes should be used by operators and service technicians
to identify the cause(s) and take measures.
fault codes are shown automatically in the display for as long as they
are active. The display is discontinued when the cause of the fault
code no longer exists (after 30 seconds).
B The control and monitoring system gives three levels of fault code
information which are indicated by a symbol in the lower left corner
(B) on the display unit (position 44).
The fault code levels are:
• “Stop”, shown automatically on display.
Indication: An fault code is indicated with a STOP sign on the
display, together with continuous red light from the indicator
control and monitoring system (position 45).
Description: Indicates serious malfunction that may be
hazardous to operator’s safety or may cause breakdown of the
vehicle. fault code of this level should be attended to
000559
immediately. Stop working with the vehicle immediately and call

a service technician.
45. Indicator control and monitoring system, KCS • “Warning”, shown automatically on display.
Indication: An fault code is indicated with a warning triangle on
the display, together with continuous red light from the
indicator control and monitoring system (position 45).
Description: Indicates malfunction in vehicle that should be
attended to as soon as possible. Service technician should be
called as soon as possible after finished work shift.
• “Information”, shown automatically on display.
Indication: An fault code is indicated with an adjustable wrench
on the display, together with continuous red light from the
Description: Information for the operator that something should
be attended to, for example, low fuel level. Take appropriate
action to eliminate fault code condition as soon as possible. See
chapter 6 “Inspection and maintenance”.

5 Handling – 5.3.2 fault code indication with KCS 83
fault code information on display

Every fault code gives information to warn the operator of a problem
C and to give a possible solution to the problem. The control and
monitoring system system’s display is divided into four fields where
D E the information is shown (see figure to the left).
B • Field B: fault code level is shown with a symbol.
000389
• Field C: Shows fault code.
• Field D: Indicates cause of fault code.
• Field E: Indicates which function is affected by the fault code.
• Book symbol means that information is available in the
operator’s manual.
Navigate in display
The control and monitoring system can handle several fault codes at
the same time. If several fault codes are generated, the fault code
R that was generated last is shown. The fault code that is displayed
1 2 3 can be confirmed (acknowledged) with the function key for Reset (R).
36 The display of the fault code disappears and the next fault code is
displayed. If the cause of an fault code is eliminated, the fault code
000558
4 5 display disappears after 30 seconds.

KCS
5.3.2 fault code indication with KCS

Description fault code indication with KCS
KCS gives fault code indication from the functions that KCS controls
and monitors. fault code indication is shown on the display.
When an fault code indication is generated, it is extremely important
to identify the fault code and perform appropriate actions to correct
the problem.
fault codes are shown automatically on the display:

84 5 Handling – 5.3.2 fault code indication with KCS
• Indicator control and monitoring system (position 45) is lit.

44 45
• fault codes are shown on the display (position 44).
The fault code that is displayed can be confirmed
(acknowledged) with the function key for Reset (R). The fault
code display disappears and the next fault code is displayed. If
the cause of an fault code is eliminated, the fault code display
B disappears after 30 seconds.
000559

45. Indicator control and monitoring system, KCS
fault code information on display
C
Each fault code gives information to warn the operator of a problem
D E and to give a possible solution to the problem. The control and
monitoring system’s display is divided into four fields where the
B information is shown (see figure to the left):
000389
• Book symbol means that further information is available in the

• Field B: fault code level is shown with a symbol.
• Field C: Shows fault code.
000390
1 2 3
1 “Stop”, 2 “Warning”, 3 “Information”

• Field D: Indicates cause of fault code.
1 2 3
1. Too high/too low temperature.
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure
4. Incorrect sensor signal.
4 5 6
5. Incorrect signal from control.
6. Incorrect level.
000879

• Field E: Indicates which function is affected by the fault code.

1 2 3
1. Battery voltage.
2. Hydraulic functions.
3. Communication.
4 5 6
4. ECU hardware defect.
5. Lift up/down.
6. Forks tilt.
7 8 9 7. Forks side shift.
8. Forks positioning.
9. Levelling.
10 11 12 10. Engine.
11. Coolant engine.
12. Engine oil.
13 14 15 13. Oil pressure engine.

14. Transmission.
15. Oil pressure transmission.
16 17 18 16. Hydrostatic transmission.

17. Pedal.
18. Brake system.
19. Time.
19 20 21
20. Electronic scale.
21. Fuel.
22. Steering.
22 23 24 23. Clamping unit.
24. Emergency stop.
25. Reversible driver’s seat.
25 26 26. Filter.
003748

Instructions fault code indication with KCS

Proceed as follows in case of fault code indication:
1 Stop and park the vehicle.
With fault code level STOP: Identify the fault code according to
this instruction and turn off the engine.
With fault code level Warning or Information: Identify the fault
code according to this instruction and leave the engine running.
2 Identify the fault code in the fault code table:
C
The control and monitoring system generates fault codes from
D E three sub-systems:
• Control unit EDU 795:
B
000389
Shown with fault code number 1-299 (position C) and fault

code level (position B) on display. For fault code table, see
fault codes Control unit EDU 795 (KCS display) page 89.
• Control unit ECU 790:
Shown with fault code number 300-599 (position C) and
fault code level (position B) on display. For fault code table,
see fault codes Control unit ECU 790 page 89.
• Control unit ECU 796:

Shown with fault code number 600-899 (position C) and
fault code level (position B) on display. For fault code table,
see fault Codes Control unit ECU 796 page 92.
1200
B
000584

3 Identify fault code level:

fault code level: The control and monitoring system gives three
levels of fault code information which are indicated by a symbol
in the lower left corner (B) on the display unit (position 44):
• “Stop”, shown automatically on display.
C Indication: fault code is indicated with a STOP sign on the
display, together with continuous red light from the
D E
Turn off the engine after identifying the fault code!
000350
• “Warning”, shown automatically on display.
C Indication: fault code is indicated with a warning triangle on
the display, together with continuous red light from the
D E
000351
• “Information”, shown automatically on display.

C Indication: An fault code is indicated with an adjustable
wrench on the display, together with continuous red light
D E from the indicator control and monitoring system (position
45).
000352
4 Perform action according to fault code table and fault code

C level.
See actions in fault code table.
D E
Identify data about the fault code. fault code level (position B),
B cause (position D) and affected function (position E). For
000389
detailed information about fault code information on display,

see Description fault code indication with KCS page 83.
• In case of STOP:
Contact service and follow instructions.
If the fault code is confirmed with the function key for Reset
(R), the fault code reappears within one minute if the cause
of the malfunction remains.
W AR N IN G
STOP fault codes indicate a malfunction in the
vehicle which may affect safety of the operator/
others in vicinity or may cause a breakdown.
Risk of serious vehicle damage!

Stop work immediately and contact service.

• In case of Warning:
Contact service and drive the vehicle to service.
If the fault code is confirmed with the function key for Reset
(R), the fault code reappears within three minutes if the
cause of the malfunction remains.
NOTE
Malfunctions are not of such a character that work
needs to be stopped. The vehicle’s capacity may be
limited by malfunctions and therefore, it is
recommended that defects are corrected as soon as
possible.
• In case of Information:
Perform action according to fault code table.

5 Handling – 5.3.4 fault code tables 89
5.3.4 fault code tables

General
fault codes are arranged in numerical order. The fault code tables
contain the following information:
• fault code (Code).
• Description of fault code.
• Limitation that may occur in the vehicle for the fault code in
question (Limitation).
• Operator action in case of fault code (Recommended action).
If the fault code is not in the tables, contact service.
fault codes Control unit EDU 795 (KCS display)

Only for KCS.
Table 1. fault codes for EDU 795
fault Description Limitation Recommended action

code
1 Time for service interval has been Contact service.

exceeded.
10 Communication fault ECU 790. Contact service.
11 Communication, defective cable Contact service.

ECU 790 - EDU 795.
14 Communication ECU 796, no reply. Contact service.

EDU 795 - ECU 796.

ECU 796 - ECU 790.
17 Memory fault, check sum EDU 795. Display not functioning Contact service.
fault codes Control unit ECU 790

Only for KCS.
Table 2. fault codes for ECU 790

code
301 Voltage feed fault ECU 790. Reduction of engine rpm. Contact service.
303 Reference voltage fault, 5V, ECU Reduction of engine rpm. Contact service.
790.
304 Sensor malfunction electric scale. Contact service.

90 5 Handling – 5.3.4 fault code tables

code
305 Speed sensor malfunction. Reduction of engine rpm. Contact service.
306 Engine rpm sensor malfunction. Reduction of engine rpm. Contact service.
307 Gear selector malfunction. Reduction of engine rpm. Contact service.
320 Sensor malfunction hydrostatic Reduction of engine rpm. Contact service

operating pressure (forward).
321 Sensor malfunction hydrostatic Reduction of engine rpm. Contact service

operating pressure (reverse).
322 Malfunction of lift lever’s hydraulic Engine rpm does not increase Contact service.
pressure sensor. when using lift lever.
323 Short-circuit or open circuit, output Reduction of engine rpm. Contact service.
signal EDC valve pump (forward).
signal EDC valve pump (reverse).
signal PDC valve hydraulic motor.
340 Sensor malfunction, steering with Steering turns off automatically. Use ordinary steering wheel.
feedback. Reduction of engine rpm. Contact service.
341 Malfunction of joystick. Steering turns off automatically. Use ordinary steering wheel.
Reduction of engine rpm. Contact service.
342 Malfunction of pulse sensor mini- Steering turns off automatically. Use ordinary steering wheel.
wheel. Reduction of engine rpm. Contact service.
343 Short-circuit or open circuit, output Steering turns off automatically. Use ordinary steering wheel.
signal for right steering valve. Reduction of engine rpm. Contact service.
344 Short-circuit or open circuit, output Steering turns off automatically. Use ordinary steering wheel.
signal for left steering valve. Reduction of engine rpm. Contact service.
350 Battery voltage low. Contact service
351 Battery voltage high. Contact service.
352 Fuel level low. Possible to continue operation. Fill fuel.
353 Sensor malfunction fuel level. Possible to continue operation. Contact service.
354 Coolant level low. Reduction of engine rpm. Fill refrigerant.
355 Hydraulic oil temperature high. Do not use hydraulic functions

until temperature has dropped
below 70°C.
356 Sensor malfunction hydraulic oil Possible to continue operation. Contact service.
temperature.
357 Brake system, accumulator Reduction of engine rpm. Stop the vehicle! Contact service.
pressure low.


code
358 Temperature transmission high. Contact service.
359 Temperature transmission Reduction of engine rpm. Contact service.

extremely high.
360 Sensor malfunction temp transm. Possible to continue operation. Contact service.
361 Oil pressure transmission low. Contact service.
362 Oil pressure transmission extremely Reduction of engine rpm. Contact service.
low.
363 Sensor malfunction pressure Possible to continue operation. Contact service.

transmission oil.
364 Engine temperature high. Contact service.
365 Engine temperature extremely high. Reduction of engine rpm Contact service.
366 Sensor malfunction coolant Possible to continue operation. Contact service.

temperature.
367 Engine oil pressure low. Contact service.
368 Engine oil pressure extremely low. Reduction of engine rpm. Contact service.
369 Sensor malfunction engine oil Possible to continue operation. Contact service.
pressure.
370 30 minutes remain until the Burn the Combifilter clean in 30

Combifilter will be burned clean. minutes time.
371 Time to burn the Combifilter clean. Reduction of engine rpm. Burn the Combifilter clean.
372 High pressure in Combifilter. Reduction of engine rpm. Burn the Combifilter clean.
380 Malfunction accelerator pedal LF. Reduction of engine rpm. Contact service.
381 Malfunction accelerator pedal RF. Reduction of engine rpm. Contact service.
382 Malfunction accelerator pedal LR. Reduction of engine rpm. Contact service.
383 Malfunction accelerator pedal RR. Reduction of engine rpm. Contact service.
384 Malfunction servo motor for injector Reduction of engine rpm. Contact service.
pump engine.
390 Fault in the valve for variable pump Contact service.

for Optimum Speed/Optimum Rev,
short circuit or open circuit at
terminal.
400 Fault in sensor for reversible driver’s Only movement forwards is Contact service.
seat. possible.

fault Codes Control unit ECU 796

Only for KCS.
Table 3. fault codes for ECU 796

code
601 Voltage feed fault, ECU 796. Contact service.
602 Memory fault, check sum ECU 796. Contact service.
603 Reference voltage 10 V fault, ECU Contact service.

796.
604 Voltage feed fault PWM outputs, Hydraulics not functioning. Turn off hydraulic functions.
ECU 796. Contact service.
605 Communication fault XA-PWM, K2. Hydraulic functions not Contact service.
functioning.
606 Communication fault XA-PWM, K3. Hydraulic functions not Contact service.
functioning.
610 Input signal from lever for hydraulic Hydraulic function 1 not Do not use hydraulic function 1.
function 1 fault. functioning. Contact service.
615 Short-circuit or open circuit for Hydraulic function 1 not Do not use hydraulic function 1.
control valve hydraulic function 1 at functioning. Contact service.
terminal K2:3.
terminal K2:11.
terminal K2:4.
terminal K2:12.
terminal K2:5.


code
terminal K2:13.
terminal K2:6.
terminal K2:14.
terminal K2:7.
terminal K2:15.
625 Sensor malfunction for electric Scale not functioning. Contact service.
scale.
626 Sensor malfunction for vertical hold. Vertical hold not functioning. Turn off vertical hold. Contact
service.
627 Sensor malfunction for pre-selected Pre-selected lift height not Turn off pre-selected lift height.
lift height. functioning. Contact service.
628 CTX Communication fault. Clamping Only manual clamping function CTX clamping unit not
control not responding. possible. functioning. Select manual
clamping control. Contact
service.
630 Fault in pressure sensor P1 for Clamping pressure is estimated Contact service.
automatic clamping unit to be the set value. WARNING!
There is no automatic increase in
clamping pressure.
631 Fault in pressure sensor P2 for Clamping pressure is estimated Contact service.
automatic clamping unit to be the set value. WARNING!
There is no automatic increase in
clamping pressure.
632 Short circuit or open circuit in Clamping prevented. Contact service.

hydraulic valve at terminal K3:3.
633 Short circuit or open circuit in Clamping prevented. Contact service.

clamping pressure valve on/off.
634 Short circuit or open circuit in lower Not possible to shut off lower left Contact service.
left clamping arm valve on/off. side.
635 Short circuit or open circuit in lower Not possible to shut off lower Contact service.
right clamping arm valve on/off. right side.


code
636 Short circuit or open circuit in upper Not possible to shut off upper left Contact service.
left inner clamping arm valve on/off. side.
637 Short circuit or open circuit in upper Not possible to shut off upper Contact service.
right inner clamping arm valve on/ right side.
off.
638 Short circuit or open circuit in upper Not possible to shut off upper left Contact service.
left outer clamping arm valve on/off. side.
639 Short circuit or open circuit in upper Not possible to shut off upper Contact service.
right outer clamping arm valve on/ right clamping arm.
off.
640 Fault in left clamping pressure Not possible to use left side. Contact service.
sensor.
641 Fault in right clamping pressure Not possible to use right side. Contact service.
sensor.
642 Fault in pressure sensor for opening Clamping prevented. Contact service.
clamping unit.
643 Fault in pressure sensor for closing Clamping prevented. Contact service.
clamping unit.
644 Switch for selecting left or right Not possible to shut off left or Contact service.
clamping arm does not work. right clamping arm.
645 Overload. Speed reduction to max 1 km/h. Contact service.

5 Handling – 5.4 Operating 95
5.4 Operating
5.4.1 While operating
General
D AN GE R
Never use a vehicle without first performing the
daily inspection.
For work instruction, see 6.1 “Daily inspection”.

Notify the foreman/supervisor if defects are found
on the vehicle during daily inspection!
D AN GE R
Never drive a vehicle without using the seat belt.
Mortal danger!
Always use the seat belt when operating the

vehicle.
W AR N IN G
Don’t let the engine idle for a long time.
Risk of engine damage!
Turn off the engine during breaks in operation and

load handling.
NOTE
If vision aids such as mirrors and TV cameras, etc. are used to
improve visibility, the speed of the vehicle must be suitable for
the limited visibility.

96 5 Handling – 5.4.1 While operating
Instructions
Make a habit of checking the following at regular intervals while
operating:
• that the coolant temperature is within approved interval
44 45 (approx. 80 °C).
• that the fuel gauge shows that there is fuel in the tank.
NOTE
The tank should never be run dry.
F
• that all warning lamps are off.
N
• that horn, lighting, brake lamps and indicators function
R
correctly.
1 2
R
3
• that all hydraulic functions function correctly.
4 5
• that no fault codes have been generated (shown on operator’s
display with fault code indication and symbol). Se chapter 5.3
“Handling of fault codes”.
000549
36
• If extra exhaust gas filter systems exists (combi filter):
KCS that the combi filter indicator lamp is not continuously lit or the
44. Display control and monitoring system, KCS Combi filter pressure gauge does not indicate in the red area
(150 mbar). The exhaust filter system then needs to be burned
45. Indicator control and monitoring system, KCS off.
The lamp may flash at high engine load.

5 Handling – 5.4.2 Starting engine 97
5.4.2 Starting engine

General
W AR N IN G
If it’s difficult to start the engine, do not use start
spray.
Risk of explosion!
In case of start problems, contact service.
Instructions
1. Set the travel direction selector in neutral position.
Travel direction selector must be in neutral in order for the
engine to start.
NOTE
If extra exhaust gas filter systems exists (combi filter) :
Check that the vehicle is not connected to the burn off
equipment.
2. Turn the ignition key to the operating position, position I.
Current is now supplied to all electrical functions.
3. In case of cold weather: Turn the ignition key to the pre-heat
position, position ll.
4. When the warning and indicator lamps have gone out, turn to
start position, position III.
Note that not every lamp has to go out.
5. Let the starter motor crank the engine, release the key
immediately when the engine fires.
The vehicle has an electrical restart interlock that protects the
starter motor from engaging when the engine is rotating.
NOTE
IF THE ENGINE DOESN’T START, try again after 15-20
seconds. Don’t run the starter motor for longer than 10
seconds at each start attempt.
If the engine still doesn’t start, this indicates that there is a
malfunction which has to be located and repaired.

98 5 Handling – 5.4.2 Starting engine
Indication lamps for engine status

Before starting - bulb check
1. Turn the ignition key to position I. The function of the starter
switch is described in detail, please refer to Ignition’s function
page 48.
2. Check that the lamps light up for two seconds, or until the
engine has started.
Before starting - pre-heating
1. Turn the ignition key to position I. If pre-heating is needed, the
lamp (58) lights up. The function of the starter switch is
described in detail, see Ignition’s function page 48.
During the starting sequence
1. If lamp (50) lights up, the engine oil pressure is too low.
2. Stop the engine and contact a service technician.
When the engine is running
1. If lamp (50) lights up, the oil pressure is low.
If lamp (59) lights up, the coolant temperature is high.
2. Contact a service technician.

5 Handling – 5.4.3 Warming up 99
5.4.3 Warming up
General
W AR N IN G
Never rev a cold engine at high engine speeds.
Run the engine at 1400-1500 rpm until it starts to

get warm.
W AR N IN G
Don’t let the engine idle for a long time.
Turn off the engine during breaks in operation and

load handling.
Instructions
In case of extremely cold weather, the vehicle must not used in
tough work before operating temperature has been reached.
• It’s very important that the engine oil is warmed up and
circulates well before the turbocharger starts to operate at high
rpm.
• Load the engine carefully until the coolant has reached normal
operating temperature (approx. 80 °C).
• Warm up the hydraulic oil. Run hydraulic functions without load
for a short time before starting to work.

100 5 Handling – 5.4.4 Select travel direction
5.4.4 Select travel direction

General
Turning the handle gives drive forwards or reverse If the RMH control
F is used, move the lever forwards or backwards.
1 Let the engine idle. Travel direction can be selected in four
ways:
21
4 3
NOTE
Switch for the control that controls travel direction must
R
be selected with switch (position 34).
• Travel direction selector
• Accelerator pedal with function for selecting travel
direction
Press down the right upper part of the pedal for reverse
travel direction and left upper part for travel direction
forward.
002478
• Travel direction selector on hydraulic control (electric

servo, joystick,4-lever, 5-lever)
Move lever forward for travel direction forward and back
for reverse travel direction.
• Travel direction selector on mini steering wheel or joystick
Move switch forward for travel direction forward and back

for reverse travel direction.
2 Select travel direction and select drive D, with the rotation
handle (lift the lever to engage drive, D).
3 Release the parking brake, increase throttle carefully and the
vehicle starts to move.
The vehicle’s speed is adjusted completely with the accelerator
pedal.

5 Handling – 5.4.5 Steering 101
5.4.5 Steering
General
The vehicle is equipped with servo steering, which means that there
is no mechanical connection between the steering wheel column
and the ground wheels.
The steering wheel movements are transferred hydraulically to the
steering wheels on the ground.
NOTE
The vehicle must not roll on a downhill grade if the engine is not
running. There is no hydraulic pressure or steering capacity.
5.4.6 Service brake

General
The brake pedal (position 11) is used as service brake.
Use brakes smoothly yet firmly. There is brake pressure for some
time after the engine has been turned off, the pressure has been
accumulated during operation. If the accumulator pressure drops
below a certain level, the indicator lamp for low brake pressure
(position 52) is activated on the panel. Check the accumulator if the
4 3 2 1
pressure is not generated and kept, see chapter 6 “Inspection and

L 0
Maintenance”.
4
The service brake can be combined with an inching function

(disengagement). When the brake is applied, forward drive is
reduced at the same time. At a certain pressure, drive is
disconnected completely .
004069
11 10
10. Accelerator pedal
11. Brake pedals
5.4.7 Parking brake

General
NOTE
Never leave the operator’s seat without first applying the
parking brake.
The parking brake is operated with the switch (position 35) on the
instrument panel. The indicator lamp for parking brake (position 62)
is activated with a red light when the parking brake is applied.

102 5 Handling – 5.4.7 Parking brake
Instructions
The parking brake is applied:
• When the switch for parking brake is pressed down (indicator
lamp for parking brake is lit with a red light).
• Automatically when the engine is stopped.
An audible signal is activated if the operator gets up from the
operator’s seat without first applying the parking brake.
L 0
If the accumulator pressure drops below a certain level, the warning

1
2
lamp for low brake pressure (position 52) is activated. When the
lamp is on, the service brake’s capacity is limited. Finally, the parking
brake is applied automatically by a powerful spring in the brake
cylinder. Check the accumulator if the pressure is not generated and
kept, see chapter 6 “Inspection and Maintenance”.
If the vehicle has to be moved, see chapter 7 “Transporting the
002440
vehicle”.
35 52 62
35. Switch for parking brake

52. Warning lamp for low brake pressure
62. Indicator lamp for applied parking brake
Emergency brake
The parking brake can be used as an emergency brake in emergency
situations.

5 Handling – 5.4.8 Heating / climate control system 103
5.4.8 Heating / climate control system

General
This section describes operation in:
• Cab Spirit Delta with:
– heating system
– Climate control system, AC (manual control of cooling and
heating)
– Climate control system, ECC electronic control of
temperature, air distribution and fan speed)
• Cab FlexCab with:
– heating system
NOTE
The operator’s door and all windows should be closed for
satisfactory function of heating/air condition.
5.4.8.1 Cab Spirit Delta with heater unit / AC
General
The heating system is connected to the engine’s cooling system and
A
The system’s fan is controlled with the control (position 16).
Air conditioning, AC, has manual control of cooling and heating but
lacks automatic dryer function.
Air conditioning, AC, is turned on and off with a switch (position 20).
Heating is controlled with the control (position 15).
21
20 NOTE
19
Use the air conditioning compressor (position 20) every now
18
and then during the winter as well, to ensure lubrication and
17
continued good function.
16
002439
15
A. Panel nozzle
Warm weather
1 Set the desired fan speed (position 16).
Use fresh air inlet (position 19).

2 Set temperature (position 15).
3 Set control for defroster/cab (position 17) in defroster position.
4 ¨Open the panel nozzles, if needed.

104 5 Handling – 5.4.8.1 Cab Spirit Delta with heater unit / AC
Very warm weather or mist on windows

Use recirculation (position 19).
3 Set control for defroster/cab (position 17) in defroster position
and aim the panel nozzles at the upper part of the cab.
Cold weather
Use fresh air inlet (position 19).

3 Set control for defroster/cab (position 17) in defroster position
or floor.
Air conditioning (AC)
Air conditioning has manual setting of cooling, heating and fan.

1. Close the recirculation control (position 19).
Open in case of very warm weather or high humidity.
2. Set temperature to cool (position 15).
3. Turn on air conditioning (position 20).
4. Set the cooling control (position 18) as needed.
5. Open the panel nozzles aimed at the roof.
Air dryer (AC)
Air dryer dries (dehumidifies) the air, for example, in case of mist on
the windows.
1. Open the recirculation (position 19).
2. Start cooling function (position 20).
3. Set the control for cooling to max. cooling performance (position
18).
4. Set the control for defroster/cab (position 17) in defroster
position.
5. Set max. fan speed (position 16).
6. Set temperature to max. heat flow (position 15).
7. Aim the panel nozzles at the roof.
When the windows are mist-free, set the desired temperature
(position 15), desired fan speed and aim the panel nozzles.
NOTE
In weather conditions below -3 °C, the cooling functions
will not operate if the cooling circuit is cooled down.

5 Handling – 5.4.8.2 Cab Spirit Delta with ECC climate unit 105
5.4.8.2 Cab Spirit Delta with ECC climate unit
General
A B I C D
The climate unit constantly controls the interior temperature, to
provide the required temperature irrespective of ambient
conditions. The installation is always set to AUTO mode and 21°,
irrespective of the setting when last shut off.
AUTO
MODE
003703
E F G H
A. Raising the temperature
B. Reducing the temperature
C. Lowering the fan speed
D. Raising the fan speed
E. Auto mode
F. Choosing air distribution
G. Choosing air distribution
H. Recirculation
I. Air distribution
Setting the temperature

The required temperature is increased or reduced by means of the
temperature setting buttons. The temperature can be controlled
between 17°C and 27°C. The end positions give max and min
temperature where no control takes, place, the unit then just gives
max or min heating.
003565
Setting the fan speed

The fan speed can be adjusted manually between 0-100%, using the
buttons. At 0%, the fan is completely shut off and the compressor is
disconnected. The graph in the display shows that the fan speed has
been manually selected.
003566
Choosing air distribution

Air distribution can be adjusted manually, using the buttons. An
arrow ( ^ ) in the display indicates the air distribution selected. Floor
003567
position can only be selected manually, the automatic unit selects

between the windscreen and floor/ventilation nozzles.
The following choices of air distribution can be made:

106 5 Handling – 5.4.8.2 Cab Spirit Delta with ECC climate unit
Air to floor.
003568
Air to both floor and ventilation nozzles.
003569
Air to windscreen.
003570
Max defrost.
003571
Start max defroster
Max defroster is started by moving the arrow ( ^ ) furthest right, by
003571
using the air distribution selection buttons.

In this position, the unit gives full heat and there is no temperature
control, the AC is on and the fans give 100%.
The unit automatically returns to auto mode after 9 minutes. For
manual shut-off, press the auto button briefly.
Air recirculation
Air recirculation can be ordered manually by pressing the
recirculation button. When recirculation is activated “REC” is shown
003572
on the display. To de-activate, press the recirculation button again.
Return to auto mode

Auto mode is regained by pressing the auto button briefly. Note,
there is a short time delay before the display changes - do not press
003702
again.
NOTE
There is a short time delay before Auto is shown on the display.
Do not press again.
Auto/menu function
A brief press on the auto button scrolls through the following
functions:
003702
1. Auto
2. Cool - economy mode The compressor only runs when
necessary. No heating.
3. Heat - economy mode. No compressor operation, just heating.

5 Handling – 5.4.8.2 Cab Spirit Delta with ECC climate unit 107
Adjusting the display

The display adjustment menu can be accessed by pressing the auto
A B C D
button (position E) for several seconds. The following can be
adjusted in this menu:
1. Illumination
2. Contrast.
3. Switch between °C and °F.
AUTO 4. Language.
MODE
Scroll through the menu choices, using the temperature buttons
003707
(positions A and B) and adjust with the fan buttons (positions C and
E D).
A. Scrolling in the menu Return by briefly pressing the auto button (position E).
B. Scrolling in the menu
C. Adjusting values
D. Adjusting values
E. Auto mode
Fault indication
If there is a fault in any sensor, or if the pressure monitor has tripped,
A B C
“fault” will be flashed on the display.
Keep the auto button (position E) depressed for a few seconds to
show the current fault(s) as text on the display.
Scroll between fault messages, using the temperature buttons
(positions A and B). The selected fault message is indicated with an
arrow on the display.
AUTO
MODE
The fault cause is indicated with a left arrow (position F).
003708
The pressure monitor is re-set with the button for reducing fan
speed (position C). Keep the button depressed for several seconds
E F
to reset.
A. Scrolling between fault messages
Return by briefly pressing the auto button (position E).
B. Scrolling between fault messages
C. Resetting the pressure monitor
D. -
E. Auto mode
F. Fault cause

108 5 Handling – 5.4.8.3 FlexCab Cab
5.4.8.3 FlexCab Cab
General
The heating unit is connected to the engine cooling system and

31 32 14 15
The fan in the unit is activated by a switch (position 76).
Heating is adjusted by a control (position 15).
003484
37 38 26 22 23 25 24 27 76
Warm weather
2 Set control for heating (position 15) in position 0.
Very warm weather or mist on windows

2 Set control for heating (position 15) in position 0.
3 Close the panel nozzles, so that all the air will be blown on to
the windscreen.
Cold weather
2 Set control for heating (position 15) in desired position.
3 Open any panel nozzles, so that all air flows down onto the
floor.

5 Handling – 5.4.9 Stopping engine - parking 109
5.4.9 Stopping engine - parking

General
NOTE
Never disconnect the main electric power with the battery
isolator when the engine is running! The voltage regulator may
be damaged.
W AR N IN G
Always switch the ignition off when the vehicle is
left when parking or at the end of each shift etc.
Danger!
Cut the current with the battery isolator.
Instructions
1. Stop the vehicle and move the travel direction selector to
neutral position (N).
2. Apply the parking brake.
3. Tilt the mast slightly forward so that the bottom of the forks rest
on the ground. Lower the forks to the ground.
4. Let the engine run 1 minute at idle speed before stopping the
engine so that the engine cools down slightly and the turbo
bearings are lubricated.
5. Stop the engine by turning the start key to position 0.
During longer stoppages, such as parking or at the end of the
shift, the battery isolator should be moved to the OFF (0)
position.
Certain vehicles are equipped with automatic engine Stop

in case:
• coolant temperature is too high.
• lubrication oil pressure is too low.
• the operator leaves the vehicle for some time without
stopping the engine, normally 5 minutes.

110 5 Handling – 5.4.9 Stopping engine - parking
6. If extra exhaust gas filter systems exists (combi filter):

Connect the burn off equipment, on the vehicle or at the vehicle
parking site.
Connect the cabling, electric and pneumatic. Power on to
activate the burn off.
Burn off is ready:
• after 8 hours, the ammeter shall indicate zero Ampere.
• after 8 hours, indication lamp shall be lit green.
• after 40 minutes, indication lamp shall be lit green.
W AR N IN G
During burn off, heating air flows out of the exhaust
pipe that can ignite flammable material.
Fire danger!
Do not cover the filter or have flammable material

near the filter.

5 Handling – 5.5 Load handling 111
5.5 Load handling

General
During all lifting work, make sure that the max. lift capacity is not
exceeded.
The forklift’s capacity is indicated by three parameters:
• position of load’s centre of gravity
• lift height
300 mm
• size of the load
003494
The capacity varies between different models and versions, see
vehicle and type plates, chapter 3.3 “Plates”.
Transport position
It’s important to estimate the position of the centre of gravity. If the
vehicle appears to be side-heavy, the load should be lowered and
adjusted with side shift so that the load’s centre of gravity is moved
to a position along the vehicle’s centre line.
Scales
Only for KCS
The loads weights is approximated with the information menu for
1. 2 a scales.
1 Perform load handling, for example lift/lower load.
7 .2 b
2 Select information menu for scales.
1 5 .8 c
000552
a. Shows dead weight (tare) in tonnes.

Value shown on the row (b) can be reset to zero (off-set)
with the function keys for minus and plus. Set value is
shown on row (a). Shows 0-3.0 tonnes.
b. Current weight in tonnes (net weight).
c. Total weight in tonnes (gross weight).
Value shown on the row (b) can be added to the row (c)
with the function key for Return. The value on the row (c)
can be reset by pressing in function keys Reset and Return
at the same time.

112 5 Handling – 5.5.1 Lifting a load
5.5.1 Lifting a load

General
There are various types of lifting devices for load handling, such as
forks, pike booms and paper grapples.
D AN GE R
Respect the lifting capacity of the vehicle and
observe the greatest care when handling loads:
• Never handle unstable or loosely loaded goods.

Be extra careful when handling long, high or
wide goods, to prevent the goods from falling
off, being damaged or tipping the vehicle over.
• Remember to avoid exceeding the maximum

lifting capacity, please refer to the type plate.
Estimate the position of the centre of gravity,
when necessary, and estimate the loading
capacity using the loading diagram in the cab.
• Never tilt the mast forwards with a load on.
• Nobody must ever stay underneath a lifted load.
There is a risk that the load can tip over, be

dropped, or there could be property damage or
danger to life!
Always ensure that the load rests securely before

lifting.
Instructions
1 Run the vehicle towards the load, as close as possible.
• Try to line up the vehicle’s centre with the load’s centre of
gravity.
• Approach angle towards load should be as straight as
possible.
• Tilt the mast slightly forward.
• Lower the forks as low as possible, adjust the fork
003495
positioning and move the forks in under the load.

• tilt the mast backwards to make the forks horizontal.

5 Handling – 5.5.1 Lifting a load 113
2 Hold the vehicle stationary with the service brake.

Alternatively, apply the parking brake if desired and/or move
the travel direction selector to neutral position. If necessary,
put chocks under the driving wheels
D AN GE R
The operator should pay extra attention and
operate with special care near electrical power
lines, viaducts, docksides, ramps, gates/doors, etc.
Fatal danger!
Apply the parking brake and use stop blocks.
3 Lift the load and tilt back the mast slightly.

If the vehicle appears to be side-heavy - the load should be
lowered and adjusted with side shift so that the load’s centre
of gravity is moved to a position along the vehicle’s centre line.

114 5 Handling – 5.5.2 Transporting load
5.5.2 Transporting load

General
D AN GE R
Respect the vehicle’s lift capacity and be very
careful when handling all loads:
• The mast should be tilted back - prevents load

from being displaced or sliding off when
braking.
• Never tilt the mast forward when carrying loads.
• The vehicle should only be operated on even

surfaces which are intended for the vehicle’s
gross weight and ground loading.
• Always operate with the load against the grade

on uphill or downhill grades, never turn or run
across a grade.
• Operate the vehicle in reverse if the transported

load is stacked so high that it obscures forward
visibility.
• The forks should be raised approx. 300 mm

above the ground level or sufficiently for good
clearance on uneven surfaces or steep grades.
• Heavy loads may not be transported in a high

position since this may cause the vehicle to tip
over.
• No persons may stand under a lifted load.
Risk of load tipping over or falling, as well as

property damage and fatal danger!
Always make sure that the load is placed securely

during transport.
Instructions
1 Lift the load a short distance off the ground. Back away from
the loading site.
2 Adjust the mast and load height to transport position.
Correct transport position is with the load as far down and in as
possible without obstructing visibility, see Transport position
page 115. The load’s centre of gravity should be centred
sideways (laterally).

5 Handling – 5.5.2 Transporting load 115
Transport position
The transport position should be assumed when the vehicle is to be
operated with a load, which minimizes the risk of tipping/rolling over
and imbalance while operating. In transport position, the mast is
tilted back and the load is lifted for good forward visibility (see figure
to the left).
300 mm
003494
Transport position
Operating on grades
It is important to operate with extreme care on grades since there’s
an increased risk of tipping and rolling over.
NOTE
To brake, first release the accelerator to obtain motor braking.
Move the direction of movement selector to the opposite
direction and press the accelerator, for more powerful braking.
Use the service brake pedal if the motor brake is not sufficient.
• When operating with a load.
Lower the load as low as possible without compromising
visibility. Tilt in the mast as far as possible.
Always operate with the load against the grade (see figure),
regardless of travel direction.
• When operating without a load.
Lower the attachment and tilt back the mast as far as possible.
Always operate with the attachment leaning forward (down),
003496
regardless of travel direction.
Operating with load on grade

116 5 Handling – 5.5.3 Unloading
Working near overhead high voltage power lines

Operate with extreme care in all work near overhead high voltage
power lines, keeping in mind the extensive reach capacity of the
mast and load.
D AN GE R
Vehicle comes into contact with overhead high
voltage power lines.
Fatal danger!
Sit down in the operator’s seat and call for help!
5.5.3 Unloading
General
There are different types of attachments for load handling, for
example, forks, coil rams and paper grapple.
Instructions
1 Operate forward and stop in front of the unloading site.
• When needed, lift the load sufficiently (but not higher) for
unloading.
• Approach angle towards load should be as straight as
possible.
• Tilt the mast to vertical position.
003497
2 Operate forward slowly until the load is in position above the

unloading surface.
3 Hold the vehicle stationary with the service brake.
Alternatively, apply the parking brake if desired and/or move
the travel direction selector to neutral position.
4 Lower the load slowly and make sure that it stands securely on
the unloading surface, for example, level ground or a stack.
5 Back away from the stack slowly and lower the forks to
transport position.

6 Inspection and maintenance 6 Inspection and maintenance 117
6 Inspection and maintenance
6 Inspection and
6 Inspection and maintenance –
maintenance
General
This chapter describes:
• DAILY INSPECTION– performed by the operator.
Daily inspection describes the routine inspection that
significantly contributes to making the machine a safe and
reliable work place.
• MAINTENANCE – performed by the operator.
Maintenance describes some simple maintenance actions.
• SERVICE – performed by trained service technician.
Advanced maintenance is performed according to a service
schedule and by trained service technicians. Advanced
maintenance is described in the service manual.
It is the operator’s responsibility to ensure that the machine is
brought in for service every 250 operating hours. Actions are
described in the maintenance manual.
• ERROR CODE INFORMATION – read off by the operator.
Error code information is read off by the operator from the
system’s display in the cab. Depending on the type of error
code, it is handled by the operator or a service technician.
NOTE
All time information refers to operating time, that is, the time
that is shown by the hour meter on the panel.
W AR N IN G
Only genuine spare parts from Kalmar Industries
may be used.
Warranty and service contracts are not fulfilled!
Use spare parts and fluids approved by Kalmar In-

dustries to fulfil warranty terms.

118 6 Inspection and maintenance – 6.1 Daily inspection
6.1 Daily inspection

General
Daily inspection of the machine is extremely important in order to
ensure that it is safe both for the operator and its surroundings.
It is recommended that every operator performs checks before a
new work shift. In this way, operators can avoid running defective
machines with malfunctions that have been generated or caused
during an earlier work shift.
D AN GE R
Never use a machine without first performing the
daily inspection.
Notify the foreman/supervisor if defects are found

on the machine during daily inspection!
Instructions
Perform the following checks:
1. Visual external check of the machine. Walk around the machine
and check the following:
• Leakage from engine, transmission, wheel motors (DCE 50-
55HM), drive axle (DCE 60-90HM), steer cylinder, hydraulic
hoses and hydraulic cylinders
• Loose wheel nuts
After changing the wheels, it is important to check the
wheel nuts (within 4-5 hours operating time).
• Damage to rims
• Uneven tyre wear - remove any glass, metal filings, etc.
from the tyres
• Tyre pressure
• Damage to links, suspension and attachments for mast, lift
cylinders and lift chains
• Communication equipment - indicators, brake lamps,
headlamps and reflectors with regards to damage
• Cab with regards to damage and dirty windows

6 Inspection and maintenance – 6.1 Daily inspection 119
2. Check fluid levels for the following fluids according to

description, see chapter 6.2 “Maintenance”. Top up, if needed,
with the correct fluid:
• Hydraulic oil
• Batteries’ electrolyte level
• Washer fluid - windows
• Engine oil
3. Check the engine’s air filter’s indicator according to description,
see chapter 6.2 “Maintenance”.
4. Start the machine according to instructions and check:
• Instruments - warning lamps, indicators, any error codes on
display
• Fuel level - the gauge must not show empty tank
• Lighting, indicators, horn, brake lamps, flashing hazard
lamps
• Windscreen wipers
• Cooling function of AC and ECC
5. Operate the machine carefully and check the following
functions:
• Brakes - check-brake at least three times
• Steering - in both directions
• Noise from engine, transmission, wheel motors (DCE 50-
55HM) or drive axle (DCE 60-90HM)
6. Run all functions with hydraulic cylinders (lift, tilt, side shift and
fork positioning) to their end-positions for lubrication of cylinder
barrels and piston rods.
7. Check the machine’s operating hours - notify the foreman/
supervisor if the machine is getting close to a service interval.
8. Notify the foreman/supervisor immediately if a machine defect
has been detected.
9. In cold weather:
• check wiper blades
• remove snow from air inlets and cooling fins
• anti-freeze in washer fluid
• connect heater for cab and engine

120 6 Inspection and maintenance – 6.1 Daily inspection
10. If extra exhaust gas filter systems exists (combi filter):

Short-circuit the pin on the pressure indicator and check if the
indicator lamp for the combi filter is lit.
Seal the exhaust pipe momentarily and check if the indicator
lamp indicates high back pressure. If not, clean the exhaust
pipes from soot.
11. Check for any active error codes.
See chapter 5.3 “Handling of error codes”.

6 Inspection and maintenance – 6.2 Maintenance 121
6.2 Maintenance
General
The following maintenance is described in this chapter:
– Cleanliness, general page 123
– Fuel system, general page 124
– Windscreen washer, general page 125
– Air filter engine, general page 126
– Cooling system, general page 127
– Engine oil, general page 128
– Hydraulic system, general page 129
– Tyres, general page 130
– Accumulators, general page 133
– Central lubrication, general page 134
– Battery and battery isolator, general page 135
– Main fuses for electrical system, general page 137
– Fuses for electrical system, general page 138
– Lighting, general page 141
Safety during maintenance

Observe the following when maintenance work is to be performed:
• Always turn off the engine during service work. Only exception
is when service work requires engine power.
• Use stop blocks by the wheels.
• No work may be done on the machine without the right
knowledge and skills to do the work correctly. Service
performed incorrectly may be dangerous.
• Always use a hard hat, protective glasses, gloves, work shoes
and other protective items as required by the work situation.
• Read all plates and instructions on the machine and in the
operator’s manual before doing any maintenance. Each one
contains important information about handling and service.
• Avoid spills when draining/filling oils and fuel. Use reservoirs/
tanks, pump, hose, etc. for safe handling. Oils and fuels cause
environmental damage and should be taken care of by an
authorized company.
• The accumulators must always be depressurized before work
on the hydraulic system.

122 6 Inspection and maintenance – 6.2 Maintenance
Tilting the cab

The cab shall always be tilted past the balanced position. If the space
to the side is insufficient, always secure the cab with a stay to
prevent accidental lowering.
D
Preparations:
• Set the travel direction selector in neutral position.
• Tilt the mast forward and lower the forks.
• Apply the parking brake.
• Check the cab for any loose items.
A B C D
• Close the doors.
Tilting
1. Turn both lock handles (position D) so that they end up in their
D
outer position to loosen the cab from the frame.
2. Set the pump valve (position C) in right position.
3. Fit the pump rod in its bracket (position B).
4. Pump until the cab is in end-position.
Lowering
1. Set the pump valve (position C) in left position.
2. Fit the pump rod in its bracket (position B).
3. Pump all the way until the cab rests on the frame.
outer position to lock the cab to the frame.
Electric tilting
1. Open the cover for cab tilting.

outer position to loosen the cab from the frame.
B C
3. Set the pump valve (position C) in right position.
4. Use the control buttons (position A) to raise the cab to end-
A
position. Press in both buttons at the same time.
Electric lowering
1. Set the pump valve (position C) in left position.

2. Use the control buttons (position A) to lower the cab until it rests
on the frame. Press in both buttons at the same time
003498
outer position to lock the cab to the frame.

4. Close the cover.
A. Button for electric tilting
B. Pump rod bracket
C. Pump valve
D. Lock handle (illustration shows open position)

6 Inspection and maintenance – 6.2.1 Cleanliness 123
6.2.1 Cleanliness
Cleanliness, general
Impurities have a negative impact on performance (heat problems).
Experience shows that clean machines have fewer malfunctions.
The machine should be washed regularly for optimal function. Keep
the following in mind when washing the machine:
• Use mild cleaning agents.
Use a de-greaser when needed. Scrub when needed.
• Use a high-pressure washer, wide water jet.
Do not use a high-pressure washer on the battery compartment,
electrical components, control units, connectors, cabling joints,
cylinder seals, stub axles and chains.
NOTE
Do not wash the combi filter on the exhaust system. Toxic
waste may be released and be rinsed into the sewer.
NOTE
After washing with de-greaser, the hydraulic cylinders should
be run in and out a few times to obtain satisfactory lubrication
once again.
D AN GE R
The strength of the roof window may be severely re-
duced in case of exposure to substances containing:
aromatic hydrocarbons, ketones, esters and chlo-
rinated hydrocarbons.
Fatal danger!
Check the roof window’s surface at regular inter-

vals. Only clean using water with an anti-freeze fluid
or mild cleaning agents. Rinse with plenty of luke-
warm water. Replace a damaged roof window im-
mediately if it’s cracked or scratched!

124 6 Inspection and maintenance – 6.2.2 Fuel system
6.2.2 Fuel system

Fuel system, general
The filler pipe is located on the machine’s right side.
NOTE
Make sure that the area around the tank cap is clean when
refuelling.
• Always fill up with diesel fuel.
• Never use additives in the diesel fuel.
• In wintertime, try to fill up immediately after finished operation.
This prevents formation of condensation in the fuel tank.
• Never pour anti-condensation agents, for example, alcohol, in
the fuel!
A • For tank volume, see chapter 9 “Specifications”.
D
450202.0100
003499
A. Refuelling point

6 Inspection and maintenance – 6.2.3 Windscreen washer 125
6.2.3 Windscreen washer

Windscreen washer, general
W AR N IN G
Only use clean water with an anti-freeze agent, for
example, anti-freeze fluid.
The strength of the roof window may be affected!

Danger!
A The strength of the roof window may be severely re-

duced in case of exposure to substances containing:
aromatic hydrocarbons, ketones, esters and chlo-
rinated hydrocarbons.
The washer fluid reservoir (position A) is located under the engine

hood on the right side of the machine.
Instructions
Check that the reservoir contains enough washer fluid. Top up, if
needed. For volume, see chapter 9 “Specifications”.
Use anti-freeze fluid in wintertime. Choose a suitable concentration
(mix of water/anti-freeze fluid) according to the winter conditions
003500
and outdoor temperatures.

A. Washer fluid reservoir

126 6 Inspection and maintenance – 6.2.4 Air filter engine
6.2.4 Air filter engine

Air filter engine, general
NOTE
Poorly filtered induction air quickly results in serious engine
damage.
The filter is changed by the service technician during routine
inspections and service. When the machine is used in dusty air, the
filter may be clogged after a relatively short time.
In the induction system, between the engine and air filter (position
A), there’s an indicator (position B) which shows red when the air
A filter is clogged.
The air filter has a dust reservoir (position C) which is emptied by
shaking it. It is partly emptied by induction air pulsations during
operation.
B Instructions
Check the indicator regularly and contact a service technician as
soon as the indicator shows red marking.
003501
C
A. Position of air filter container
B. Indicator for change
C. Dust reservoir

6 Inspection and maintenance – 6.2.5 Cooling system 127
6.2.5 Cooling system

Cooling system, general
Coolant is filled in the system’s expansion tank (position B). The
coolant level should be between the MIN and MAX markings
(position C) on the expansion tank.
In case the coolant temperature is too high, the high pressure
escapes through the opening in the pressure cap (position B).
NOTE
Do not open the pressure cap until the coolant temperature has
dropped. Hot coolant may jet up and out!
Low coolant level can be indicated in two ways:
A
• Warning lamp for low coolant level engine (position 53) is
B
activated on the instrument panel.
• Error code is generated in the control and monitoring system’s
display (position 44).
NOTE
The coolant may boil and cause severe engine damage if the
coolant level is too low.
C Instructions
W AR N IN G
Open the pressure cap (position B) very carefully
when the engine is warm.
Steam or hot coolant may jet out and cause scald-

003502
ing/burn injuries.
A. Position of expansion tank Open the pressure cap carefully and let stand for
B. Pressure cap for filling awhile before filling.
C. Level marking, MIN and MAX
If needed, top up with water (wintertime with at least 40% glycol).

For volume, see chapter 9 “Specifications”.
Anti-corrosion agent must always be added if glycol isn’t used.
However, anti-corrosion agents do not contain anti-freeze and may
only be used if the outdoor temperature always is above 0° C.

128 6 Inspection and maintenance – 6.2.6 Engine oil
6.2.6 Engine oil

Engine oil, general
W AR N IN G
Avoid prolonged contact with engine oil.
Hazardous to health!
Use protective gloves.
B A The engine’s oil filler pipe (position B) and dipstick (position A) are
located under the engine hood on the right side of the machine
Instructions
Check the oil level when the engine is warm. The dipstick has two
markings, MAX. and MIN., the oil level should be between these
markings.
• Wipe off the dipstick before checking.
• Fill engine oil (position B) when needed (for volume, see chapter
9 “Specifications”).
It is recommended that oil is filled when the engine is warm and
the oil flows easily. Fill – wait awhile – check on the dipstick.
NOTE
Fill oil with care to prevent other fluids or particles from
contaminating the oil. Contamination means risk of engine
damage.
003503
A. Dipstick
B. Filling point

6 Inspection and maintenance – 6.2.8 Hydraulic system 129
6.2.8 Hydraulic system

Hydraulic system, general
W AR N IN G
Avoid prolonged contact with hydraulic oil.
Hazardous to health!
Use protective gloves.
A B
The hydraulic oil tank is located on the machine’s left side.
Instructions
Check the oil level (position A) when all hydraulic pistons are in the
B
retracted position. The level should be between the MAX and MIN
positions on the dipstick. Fill oil (position A) when needed (for
volume, see chapter 9 “Specifications”).
A
NOTE
Fill oil with care to prevent other fluids or particles from
contaminating the oil. Contamination means risk of damage to
the transmission, control system, brake system and the
working hydraulics.
003504
A. Filling point and dipstick

B. Breather filter

130 6 Inspection and maintenance – 6.2.9 Tyres
6.2.9 Tyres
Tyres, general
There are two variants of front wheels for the vehicle:
• Twin installation (wheel)
• Single installation (wheel)

The procedure is the same in both cases.
W AR N IN G
Spare and replacement tyres should be of brand
names approved by Kalmar Industries.
This is to comply with warranty and service contract

conditions!
Use tyres approved by Kalmar Industries to comply

with warranty terms.
D AN GE R
Changing tyres is high-risk work.
Fatal danger!
It is recommended that tyre changes are performed
by service personnel, with competence and author-
ity to handle tyres!
Checking tyres
W AR N IN G
Check-tighten the wheel nuts on a new wheel after
4-5 operating hours.
Loose wheel nuts can result in damage to rims,

bolts, nuts and hubs.
Tighten bolted joints alternately. Contact a service

technician as needed.
• Check the tyres at regular intervals.

• Remove embedded foreign objects such as crushed glass,
wood, metal filings, etc.

6 Inspection and maintenance – 6.2.9 Tyres 131
• Check for uneven and fast wear, this is caused by mechanical

defects, such as unevenly applied brakes. Make sure that such
defects are repaired.
Changing wheels
For changing wheels, see Maintenance manual DCE 50-90HM.
Inflating tyres
Care of compressor for inflating tyres:
• An air filter with water separator should be installed in the line
from the compressor used for inflating tyres. The water filter
minimizes the risk of corrosion on rims.
• Drain the water separator regularly.
D AN GE R
Never stand in front of a tyre when inflating it! Do
not exceed the prescribed air pressure. When
changing tyre or rim version, another tyre pressure
may apply. Contact Kalmar Industries.
Fatal danger!
Always follow the instructions for inflating tyres to

003505
avoid serious accidents.

132 6 Inspection and maintenance – 6.2.9 Tyres
1. Before inflating, make sure that the rim’s lock ring (position 1) is
3 in the correct position.
2
1 NOTE
If the tyre has been completely deflated, the rim must be
dismantled and checked with for any damage. Let service
personnel with the right competence and authority
perform tyre changes and tyre handling!
2. Connect the compressor hose with a self-locking chuck to the
tyre nipple.
3. Stand obliquely behind the tyre and remain there during the
entire pumping procedure to avoid being hit by pieces of rim if
there is an explosion.
4. Inflate the tyre to the prescribed pressure, see chapter 9
“Specifications”. When changing tyre or rim version, another
tyre pressure may apply, contact Kalmar Industries.
003770
1. Lock ring
2. Rim edge
3. Tapered rim edge

6 Inspection and maintenance – 6.2.10 Checking accumulators 133
6.2.10 Checking accumulators

Accumulators, general
The function of the accumulator (position A) is to maintain even
brake pressure and also to maintain brake pressure, and thus
braking action, a short time if hydraulic pressure is lost.
The accumulator is pre-charged with nitrogen gas.
Instructions
Check sealing according to the following points if the warning lamp
for low brake pressure (position 52) lights up:
1. Start the engine and let it run until the accumulator is filled.
Warning lamp for low brake pressure (position 52) goes off.
A 2. Stop the engine and then turn the start key to position I.
3. Press down the brake pedal with long pumping brake strokes,
A with a slight delay between each braking action.
003506
It should be possible to brake at least six times before the lamp

for low brake pressure lights up.
A. Accumulator 4. Start the engine, let the accumulators charge and repeat the
test a couple of times.
If it’s not possible to brake six times before the warning lamp for low
brake pressure lights up, there’s some defect in the accumulators.
Contact service for troubleshooting and appropriate action as soon
as possible.

134 6 Inspection and maintenance – 6.2.11 Central lubrication
6.2.11 Central lubrication

Central lubrication, general
Central lubrication (which replaces manual lubrication) is available in

different variants. The alternatives are:
• Manual, hand-pumping of lubricant at a lubrication point which
then branches to all selected lubrication points.
• Automatic, pre-programmed lubrication unit for lubrication of all
selected lubrication points at a set time interval. Extra
lubrication is supplied when the switch in the cab is activated.
Central lubrication consists of the following components:
• Pump unit, with lubricant reservoir.
A • Distribution block.
• Lines, to all selected lubrication points.
A • Grease nipples, at all selected lubrication points
Maintenance of the central lubrication system consists of refilling
lubricant and a check that all connected lubrication points receive
enough lubricant.
B Instructions
NOTE
When working with the central lubrication, cleanness is of
highest importance. Filth and litter may cause system
interruptions. Use naphtha or lamp petrol to clean the system.
003507
Do not use trichlorethane or other organic solvent, for example

alcohol, methanol, acetone etc.
A. Pump unit Function check of central lubrication function:
B. Distribution block
• Check that no indication “Er” is set in display on the container.
This indicates a fault. Contact service.
• Check that no indication “LL” is set in display on the container.
This indicates that lubricant needs to be refilled. See below.
Refilling the lubricant:
• Refill the container to the “Max” marking through the nipple
(position 1).
• The lubricant must be pure and is not allowed to change
consistency as it ages.
001948
1. Refilling nipple
2. Ventilation hole
3. Plate

6 Inspection and maintenance – 6.2.12 Battery and battery isolator 135
Refilling lubricant when the container is empty:

• If the container is empty and then refilled, the pump may have
to work a longer period of time in order to supply all lubrication
points with enough lubricant.
The switch for extra lubrication shall be used (is placed to the
left of the display on the container).
• Check that all air under the plate has disappeared (position 3).
The sealing of the plate shall clean the hole on the top of the
container. A small amount of lubricant shall emerge to indicate
that a thorough venting has been done.
6.2.12 Battery and battery isolator

Battery and battery isolator, general
W AR N IN G
The battery’s electrolyte contains corrosive sulphu-
ric acid.
Risk of corrosive injury! Health hazard!
Immediately remove any electrolyte in contact with

A-C bare skin. Wash with soap and plenty of water. If
electrolyte has splashed into the eyes, rinse imme-
C
diately with plenty of water and seek immediate
medical attention.
The electrical system operates at 24 Volt. The voltage source

consists of two 12 volt batteries, connected in series, charged by an
alternator. The negative terminal is connected to the chassis.
The positive terminal is connected to a battery isolator (position A).
Checking electrolyte level in battery
A W AR N IN G
B
Always turn off the electric power when the vehicle
003508
is left when parking or at the end of each shift etc.,

when working on the electrical system or when
welding on the vehicle.
A. Battery isolator
B. Battery isolator in position on, that is, main current Danger!
is connected.
Turn off the electric power with the battery isolator.
C. Battery isolator in position off that is, main current
is disconnected.

136 6 Inspection and maintenance – 6.2.12 Battery and battery isolator
The batteries (position D) are located under the engine hood on the
machine’s right side.
Checking the electrolyte level is recommended. Fill as needed with
de-ionised water.
1. Open the engine hood on the right side.
2. Turn off the battery voltage (position A).
3. Check level. Fill as needed with de-ionised water.
Electrolyte’s fluid surface should be 10 mm over cells.
Batteries contain substances hazardous to the environment and
personal health. Therefore, discarded batteries must be handled
according to local/national regulations.
D
Starting with booster battery
W AR N IN G
Batteries contain a mixture of oxygen and hydrogen
gas which is highly explosive. A spark, caused if the
booster start cables are connected incorrectly, may
be sufficient to cause a powerful battery explosion
and injuries.
Explosion hazard!
003509
Connect positive (plus) terminals first. Then connect

negative (minus) terminals.
D. Position, batteries
1. Open the engine hood on the right side.
2. Turn off the main electric power.
3. Check that the booster batteries are connected in series so that
they supply 24 V. Do not disconnect the ordinary cables to the
machine’s battery.
4. Connect in the following order:
a. The red booster cable (+) to the booster battery
b. The red booster cable (+) to the discharged battery
c. The black booster cable (–) to the booster battery
d. The black booster cable to a point some distance from the
discharged battery, for example, at the minus cable’s
connection to the frame or directly to the engine block.
5. Start the engine.
Do not move the connections during the start attempt – risk of
sparks. Do not lean over any of the batteries.
6. Disconnect the cables in the reverse order as to when
connecting them.

6 Inspection and maintenance – 6.2.13 Main fuses for electrical system 137
6.2.13 Main fuses for electrical system

Main fuses for electrical system, general
W AR N IN G
Never use fuses with too high ampere rating.
Risk of damage or cable fire!
Follow instructions on the fuse plate for fuse type

and ampere rating.
A
The machine’s electrical system has one position for main fuses:
A. Main fuses in battery compartment on frame, 4 fuses 25 A.
Cuts off all electric power.
Changing main fuse
When checking and changing main fuse:
1. Turn off the main electric power (position A).
2. Tilt the cab, see Tilting the cab page 122.
003510
3. Remove the plastic cover.

4. Check if the fuses are intact. Change as needed.
Fuses are rated at 25 A.

138 6 Inspection and maintenance – 6.2.14 Fuses for electrical system
6.2.14 Fuses for electrical system

Fuses for electrical system, general
The electrical system’s fuses are located in the electrical distribution
box in the cab.
The electrical distribution box in the cab is located behind the
operator’s seat in the cab. There are fuses for control units and
equipment in the cab.
001838
A. Fuse holders in electrical distribution box
NOTE
All fuses are disconnected by the main fuses.
Table 1. Fuse box 58-1
Connection Fuse number / Nominal current Functions
1 1 / 15 A Starter motor, start interlock, pre-heating indication lamp.
2 2 / 10 A Indicator, parking brake pressure, courtesy lamp.
3 3 / 15 A Lighting high and low beams, instruments.
4 4 / 15 A Windscreen wiper front, horn, washer motor.
5 5 / 15 A Wiper roof and rear window, reading lamp.

6 Inspection and maintenance – 6.2.14 Fuses for electrical system 139
6 6 / 15 A Back-up (reverse) lamp, back-up (reverse) alarm, warning lamp,

work lamps mast.
7 7 / 15 A Work lamps roof.
8 8/5A Parking brake.
1 1 / 10 A Brake lamps.
2 2 / 10 A Seat revolving VBFS, travel direction selector, hydraulic

transmission.
3 3 / 15 A Fan heat, control unit AC.
4 4 / 15 A Fan condenser, engine recirculation.
5 5 / 10 A Valves forward/reverse.
6 6 / 10 A High beams.
7 7 / 10 A Low beams.
8 8 / 10 A Rear lamps left, side lamps left.
1 1/5A Converter 12V.
2 2 / 25 A Air compressor seat, seat heating, central lubrication.
3 3/5A Indicator lamps, monitoring, warning lamps, sensor for coolant

level.
4 4 / 10 A Rear lamps right, side lamps right.
5 5 / 15 A Power supply, speed sensor.
6 6 / 15 A Air compressor seat up/down.
7 7/5A Electrical scales.
8 8/5A
1 1 / 15 A Fan hydraulic oil cooler.
2 2 / 15 A Working lamp chassis.
3 3 / 10 A Lift function.
4 4/-
5 5 / 10 A Supply ECU790.

140 6 Inspection and maintenance – 6.2.14 Fuses for electrical system
6 6/5A Supply EDU 795, ECU 790, ECU 796.
7 7 / 10 A Supply ECU 796, clamping pressure sensor.
8 8/5A Extra 12 V-converter, clock.
Table 5. Fuse box 56-5P
A
003745
A. Fuse box for engine
Connection Fuse number / Rating Functions
1 1 / 15A Preheating.
2 2 / 10A Supply for fuel injection pump.
3 3/- -
4 4/- -
5 5/- -
6 6/- -
Instructions
When checking and changing fuses:
1. Turn off the main electric power.
See Battery and battery isolator, general page 135.
2. Remove the cover from the electrical distribution box.
3. Check or change fuses as needed.
The fuse plate gives information about each fuse.

6 Inspection and maintenance – 6.2.15 Lighting 141
6.2.15 Lighting
Lighting, general
It’s important to use the right type of light bulb for each area, see
chapter 9 “Specifications”.
Lamp bulbs can be changed for the following:
• Instruments
• Control lamps
• Interior lighting
• Rear lamps, red
• Brake lamps
• Direction indicators
• Side lamps
• Headlamps (for high and low beams)
• Back-up lamp, white
• Work lamps
• Rotating beacon
Instructions
Changing a bulb in the working lamps:
1 Loosen the rubber strip (position A).
2 Remove the glass (position B).
3 Change bulb.
000579
A B
A. Rubber strip
B. Glass

142 6 Inspection and maintenance – 6.3 Service
6.3 Service
General
It is of the greatest importance that inspection and service is done
at the recommended intervals.
Service is done by Kalmar Industries, or by Kalmar Industries’
authorised service technician.
W AR N IN G
Service intervals must be respected.
This is in order to comply with warranty and service

agreement conditions!
Use Kalmar Industries Approved Spares and fluids

to comply with warranty conditions.
Service shall be done at 250 h intervals and the measures to be

taken are described in the maintenance manual.

7 Transporting the vehicle 7 Transporting the vehicle 143
7 Transporting the vehicle
7 Transporting the
7 Transporting the vehicle –
vehicle
Safety
D AN GE R
The vehicle must be adequately secured during
transport. The vehicle is heavy and can cause
extensive damage in case of a fall and similar.

Follow the instructions in order to secure the
vehicle during transport.
W AR N IN G
Cab doors must always be closed during transport.
Danger!
Always close the cab door(s) during transport.

144 7 Transporting the vehicle – 7.1 Towing
7.1 Towing
General
D AN GE R
The vehicle cannot be manoeuvred or have the
brakes applied when the hydraulic pressure is gone.
Rolling vehicle! Fatal danger!
If possible, tow with kept hydraulic pressure. Tow

only short distances.
W AR N IN G
Do not try to start the vehicle by towing.
Serious damage to engine and power transmission!
Start the engine according to instructions in the

Before taking action and when you have finished towing, the parking
brake must be applied and the wheels blocked to prevent the
vehicle from starting to roll.
Extreme care must be observed during towing work to avoid
personal injuries.
When towing, keep in mind:
• The towing vehicle should be heavier than the vehicle being
towed.
• When towing always use a tow bar.
• If possible, the engine should be running during towing in order
for brakes and steering to function.
When the engine is off, there’s no hydraulic pressure to the
steering function and thus the vehicle’s steering function is
severely limited. Also, transmission lubrication is insufficient.
• The brakes function as long as there’s pressure in the
accumulator, then the service brake stops functioning and the
parking brake is applied automatically. If it’s necessary to move/
tow the vehicle after that, the parking brake must be released
mechanically, see chapter 7.1.1 “Mechanical release of parking
brake” and disconnect the hydraulic transmission, please refer
to chapter 7.1.2 “Disconnecting the hydraulic transmission”.

7 Transporting the vehicle – 7.1.1 Mechanical release of parking brake 145
• Only tow for the shortest possible distances.
7.1.1 Mechanical release of parking brake

Description
The parking brake is applied automatically by a powerful spring in
the brake cylinder if the pressure in the hydraulic accumulator
should drop below a certain level.
If the vehicle has to be moved (towed) without sufficient pressure in
the hydraulic accumulator, the parking brake must be released
manually.
D AN GE R
Before starting to work with the parking brake,
make sure that the vehicle cannot move
accidentally when the braking action is released.
Fatal danger!
Block the wheels to avoid unwanted rolling of the

vehicle.
D AN GE R
The parking brake has high spring force. If the
brakes are opened incorrectly, parts may detach
and fly off with high velocity and force.
Fatal danger!
Follow the instructions below.

146 7 Transporting the vehicle – 7.1.1 Mechanical release of parking brake
DCE 50-55HM
On the DCE 50-55HM, the parking brake acts on the service brake
friction plates.
1. Ensure that the parking brake is released.
2. Place an oil tray for leak oil underneath the wheel motor (the
opening is in connection with the leak oil circuit).
3. Unscrew the plugs (position A) using a hexagonal socket key.
4. Disengage the parking brake by alternately screwing in two
screws M12x30 (position B) on each drive wheel until the
wheels are released. Apply also a washer (position C) to ensure
that the screws are not screwed in too far.
Restoring the parking brake:
1. Screw out the screws (position B) on each drive wheel.
2. Screw in the plugs (position A).
NOTE
If the parking brake has been released mechanically, it must
always be re-set to restore the parking brake function in the
vehicle.
C
B
004074
C
B
A. Plug
B. Screw M12x30
C. Washer

7 Transporting the vehicle – 7.1.1 Mechanical release of parking brake 147
DCE 60-90HM
On the DCE 60-90HM, the parking brake is a multi-disc brake, and is
integrated with the drive shaft.
1. Ensure that the parking brake is released.
2. Unscrew the knob (position A) as far as possible.
3. Screw in the knob (position B and A) as far as possible.
4. Pump about 10 times with the pump rod (position C).
Restoring the parking brake:
1. Screw out the knob (position B) as far as possible.
2. Screw in the knob (position A) as far as possible.
A-C
NOTE
If the parking brake has been released mechanically, it must
always be re-set to restore the parking brake function in the
vehicle.
003778
A B C
A. Knob for manually releasing the parking brake
B. Knob for manually releasing the parking brake
C. Pump rod

148 7 Transporting the vehicle – 7.1.2 Disconnecting the hydraulic transmission
7.1.2 Disconnecting the hydraulic

transmission
Description
If the vehicle needs to be moved (towed), the hydraulic transmission
must be disconnected. Disconnect the transmission by undoing the
screws (position A) on the transmission pump three turns.
NOTE
If the hydraulic transmission is disconnected, it must always be
re-connected for the transmission to function again.
A
004073
DCE 50-55HM
A
004080
DCE 60-90HM
A. Screws for disconnecting the hydraulic
transmission

7 Transporting the vehicle – 7.2 Lifting and securing the vehicle 149
7.2 Lifting and securing the

vehicle
General
The following actions are recommended when the vehicle is to be
transported:
• Remove any fragile equipment, for example, rear-view mirrors.
• If transport is to take place on a public road:
Lift off mast when transporting if the height exceeds the height
restriction.
See maintenance manual for detailed information.
• Apply the parking brake.
• Secure the vehicle for transport with chains, e.g. on a lorry. See
vehicle plate for vehicle weight.
Front: Secure the chains in the mast, alternatively in the front
wheels, left and right side.
NOTE
Cross the chains when securing for optimal stability.
Rear: Secure the chains in the towing eye for vertical
counterweight, alternatively in the rear wheels.
7.2.1 Lifting the vehicle

General
For lifting the vehicle, follow the governing safety regulations.
Instructions, lifting without lifting eyes

If the vehicle isn’t equipped with lifting eyes, the vehicle should be
lifted as follows:
1. Route a lifting sling at the rear around the chassis, between the
counterweight and the steering axle.
2. Route two lifting slings in the lift mast’s two lifting eyes.
3. The lifting device must be adapted so that the lifting point
passes through the vehicle’s centre of gravity.
003511

150 7 Transporting the vehicle – 7.2.1 Lifting the vehicle
Instructions, lifting with lifting eyes
Optional equipment includes two lifting eyes on the counterweight.

1. Use the lifting eyes to secure the lifting device.
2. The lifting device must be adapted so that the lifting point
passes through the vehicle’s centre of gravity.
003512

7 Transporting the vehicle – 7.3 Service position 151
7.3 Service position

General
Service position is used for service, maintenance and other
situations when the vehicle needs to be secured.
Service position means:
• Vehicle parked, that is, applied parking brake.
• Engine off.
• Main electric power off (with battery isolator).
• When needed: Vehicle standing on wooden blocks (approx. 20
cm) for work that requires access from underneath.
Lift up the vehicle or reverse the vehicle up on wooden blocks,
ramps or axle stands.

152 7 Transporting the vehicle – 7.4 Long-term storage
7.4 Long-term storage

General
For long-term storage of the vehicle, contact Kalmar Industries.

8 Environment and standards 8 Environment and standards 153
8 Environment and standards
8 Environment and
8 Environment and standards –
standards
General
Ever-increasing industrialization of our world is having a significant
impact on our global environment. Nature, animals and humans are
exposed daily to great risks in connection with handling of chemicals
in different forms.
There are still no environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle,
operate, perform service on or repair vehicles must use the tools
and aids necessary to protect the environment in an
environmentally sound manner.
By following the simple rules below, you contribute to protecting
and caring for our environment:
Recycling
Deposit discarded materials for recycling or destruction.
Environmentally hazardous waste

Components such as batteries, plastics and other items that may
constitute environmentally hazardous waste shall be taken care of
in an environmentally sound manner.
Discarded batteries contain substances hazardous to personal
health and the environment. Therefore, handle batteries in an
environmentally safe manner and according to national regulations.
Oils and fluids

Freely discharged oil causes environmental damage and can also be
a fire hazard. Therefore, when emptying and draining oils or fuel,
take appropriate action to prevent unnecessary spills.
Waste oils and fluids should always be taken care of by an
authorised disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal the leaks.
Air conditioning
The refrigerant in the air conditioning system for the cab adds to the
greenhouse effect and may never be intentionally released into open
air. Special training is required for all service work on the air
conditioning system. Many countries require special certification by
an authority for such work.

154 8 Environment and standards – 8 Environment and standards
Working in a contaminated area

Used cab filters and engine air filters from vehicles operating in
contaminated conditions, with asbestos or other hazardous dust,
shall be put into tight-sealing plastic bags before being deposited in
the designated area. The vehicle shall be equipped for work in a
contaminated area (environmentally contaminated or hazardous to
personal health) before work is started. In addition, special local
regulations apply when handling and servicing such a vehicle.
Standards
Sound/noise, vibrations, stability, electrical and
visibility, etc.
This vehicle complies with the harmonised standard EN 1726-1
“Industrial trucks - safety - Engine powered trucks with lifting
capacity not exceeding 10 000 kg”.
CE marking
Vehicles for the EU/EEA markets are CE marked. This means that on
delivery, they comply with the applicable “Essential Health and
Safety Requirements” stipulated in the EU Machinery Directive, and
with EU Directives applicable to this type of machinery.
For further information, see CE marking page 11.
ANSI/ASME marking
Vehicles for North American markets are ANSI/ASME marked. This
means that when delivered, it complies with the applicable safety
requirements stipulated in ANSI/ASME B56.1.
For further information, see ANSI/ASME marking page 12.
EMC, electromagnetic interference

The EU EMC directive regarding “Electromagnetic compatibility”, 89/
336/EG, gives a general description of the standards that may be
required of a vehicle from a safety aspect, where the limit values
have been established in international standards. A vehicle or a
device that meets these standards should be CE-marked.
Kalmar’s vehicles have been specially tested with regards to
electromagnetic interference in accordance with harmonised
standard EN 12895. The vehicle’s CE marking and the vehicle’s
declaration of conformity also includes the EMC-directive. If other
electronic equipment is installed on the vehicle, it must be CE
marked and tested on the vehicle with regards to electromagnetic
interference. It must also be approved by Kalmar Industries.

8 Environment and standards – 8 Environment and standards 155
Exhaust emissions
Vehicles for EU/EEA markets comply with the EU Exhaust Emission
Directive 97/68/EG, which means that the exhaust emissions from
the engine have been reduced to comply with the requirements.
Vehicles for North American markets comply with the EPA and
CARB exhaust emission regulations, which means that the exhaust
emissions from the engine have been reduced to comply with the
requirements
Noise emission
Vehicles for the EU/EEA markets comply with the EU Noise Directive
2000/14/EG, which means that the vehicle has been marked with its
measured environmental noise emission.

156 8 Environment and standards – 8 Environment and standards

9 Specifications 9 Specifications 157
9 Specifications
9 Specifications
9 Specifications –
Technical data
Machine weights and dimensions vary depending on the machine’s
equipment. Detailed information on weight and dimension is found
in the product specification and spec. sheet for the specific machine
in question.
1. Engine Perkins 1104C-44T
Fuel Diesel, quality according to EN590
Engine’s operating mode Direct-injected, 4-stroke, turbocharged low-emission engines
Power acc. to ISO 3046 (net power) 74,5 kW at 2200 rpm
Torque ISO 3046 412 Nm at 1400 rpm
No. of cylinders 4 cylinders
Alternator, rating 1540 W
Start battery, voltage – capacity 2x12 V – 75 Ah
2. Transmission Constantly variable hydraulic transmission
3. Power transmission DCE 50-55HM DCE 60-90HM
Drive axle, type Wheel motors Drive axle - D41
4. Brakes DCE 50-55HM DCE 60-90HM
Service brake system – acts on Wet Disc Brake – drive wheels

wheels
Parking brake system – acts on Brake integrated in wheel motors – Brake integrated in driving axle – drive
wheels drive wheels wheels
5. Steering
Steering system Hydraulic servo
6. Wheels DCE DCE DCE DCE DCE DCE DCE DCE

50- 55- 60- 70- 75- 80- 80- 90-
6HM 6HM 6HM 6HM 6HM 6HM 9HM 6HM
Dimension, front 315/70-15 8.25-15
Dimension, rear 28x9-15 8.25-15
Inflation pressure front, also see 1.00 MPa 0.85 MPa 1.00 MPa
machine plate
Inflation pressure rear, also see 0.9 MPa 0.85 MPa

machine plate

158 9 Specifications – 9 Specifications
6. Wheels DCE DCE DCE DCE DCE DCE DCE DCE

50- 55- 60- 70- 75- 80- 80- 90-
6HM 6HM 6HM 6HM 6HM 6HM 9HM 6HM
Tyre type, front and rear Air-inflated. Spare and replacement tyres should be of a brand name approved
by Kalmar Industries.
9. Cab Spirit Delta FlexCab FlexGuard
Equivalent sound pressure level in max 72 dB(A) max 76 dB(A) max 85 dB(A)
cab. Measure with standard engine.
Specifications, oils and fluids

Eventual deviation from this table must be supported with written
approval from Kalmar Industries.
1.2 Engine, fuel system DCE 50-55HM DCE 60-90HM
Fuel tank, volume 90 l 155 l
1.7 Engine, cooling system

Coolant volume approx. 20 l
1.8 Engine, lubricating

system
Oil quality See Oil recommendations page 160.
Oil volume 9l
3.3 Power transmission, drive D41, width=1175 mm D41, width=1482 mm D41, width=1688 mm
axle
Oil quality See Oil recommendations page 160.
Oil volume, differential 8l 12 l 14,5 l
Oil volume, hub 0,9 l/hub
9.4 Air conditioning

Refrigerant R134a
Quantity 1,4 kg
Oil Seltec PAG oil
Volume 0,19 l
10 Common hydraulics DCE 50-55HM DCE 60-90HM
Oil quality See Oil recommendations page 160
Oil additive Lubrizol shall be added when changing hydraulic oil. Concentration 3%.

9 Specifications – 9 Specifications 159
Hydraulic system volume 125 l 150 l
Other
Grease Use a universal grease, type EP acc. to NLGI Grade 2 with 3-5% molybdenum
sulphide for all grease points except for plastic plates.

Oil recommendations
Recommended viscosity for different oil types and qualities at
different ambient temperatures is given in the table below.
Eventual deviation from this table must be supported with written
approval from Kalmar Industries.
°C -30 -20 -10 0 +10 +20 +30 +40 +50

°F -22 -4 +14 +32 +50 +68 +86 +104 +122
Oil type, quality
Engine oil SAE 0W
ACEA: E2 or API: CF4 SAE 5W 20
SAE 10W 30
SAE 20W 50
Drive axle, hypoid oil SAE 80W 140

API GL5 or MIL-L-2105B SAE 80W 90
SAE 90
SAE 85W 140
Hydraulic oil AV 32
SS 155434 AV 46
Hydraulic oil HVLP 46

DIN 51524 HLP 68
Hydraulic oil ISO - LHV 46

ISO 6743/4 ISO - LHM 68

Specifications lamps
Lamp Rating Socket
(W)
Instruments 3 Ba7s
Control lights 1,2 W2x4.6d
Interior lighting 10 S8.5
Rear lights, red 5 BA15s
Brake lights 21 BA15s
Direction indicators 21 BA15s
Running lights 5 SV8,5
Headlights (for high- low beams) 75/70 P43t-38
Back-up light, white 70 PK22s
Work lights 70 PK22s
Rotating beacon 70 PK22s
Unit explanations
Unit Abbreviation
Newton metre Nm
Kilopond metre kpm
Kilopascal kPa
Megapascal MPa
Kilowatt kW
Kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Meter m
Kilometre km

Conversion table SI-units

SI-unit Conversion factor Non-SI Conversion factor SI
Torque
N·m x 10.2 = kg·cm x 0.8664 = lb·in
N·m x 0.74 = lbf·ft x 1.36 = N·m
N·m x 0.102 = kg·m x 7.22 = lb·ft
Pressure (Pa = N / m2 )
kPa x 4.0 = in.H 2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp / cm 2 x 14.22 = psi x 0.070 = kp / cm 2
N/ mm 2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J / s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu / s x 1.055 = kW
W x 0.74 = ft·lb / s x 1.36 =W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 =J
Speed and acceleration
m/s 2 x 3.28 = ft / s 2 x 0.305 = m/s 2
m/s x 3.28 = ft / s x 0.305 = m/s
km / h x 0.62 = mph x 1.61 = km / h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
ºC = (ºF – 32)/1.8 ºF = (ºC x 1.8) + 32
Flow factor
l / min (dm3 / min) x 0.264 = US gal / min x 3.785 = litre/min

Conversion table length

Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm - 1 mm = 0.001 m
Conversion table area

Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000
yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a - 1 mile2 = 259 ha = 2.59 km 2

Conversion table volume

Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
dm3 (l) 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1 gal (US) = 3785.41 cm 3 = 231 in3 = 0.83267 gal (UK)
Conversion table weight

Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)
Conversion table pressure

Unit kp/cm2 bar Pa=N/m2 kPa lbf/in2 lbf/ft2
kp / cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/ m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735.56 Torr (mmHg) = 0.96784 atm

10 Terminology 10 Terminology 165
10 Terminology
10 Terminology
10 Terminology –
Explanations
Term Description
AC Heater unit with manual control of cooling and heating
Accumulator Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions.
Anti-corrosion compound Prevents oxidation, in simple terms, rust proofing.
Attachment Part of the machine that grabs the load when lifting.
Axle distance Distance between drive axle and steering axle.
Bar Unit to express pressure.
Battery disconnector Cuts off power supply from battery.
Buzzer Acoustic alarm to catch the operator’s attention.
Central lubrication More or less automatic system for lubrication of a number of chosen grease
points.
Control valve Valves that can be used to control something, for example, to release pressure
and thus lower a boom or a fork.
Counterweight Balances the machine so that it doesn’t tip when lifting. Adapted to machine’s
capacity.
Daily inspection Actions that should be performed daily to ensure the machine’s functionality
Decitonne Tenth of a tonne, measure of machine’s lift capacity.
Display “Window” showing digital information, i.e. steering wheel panel in cab (for KCS).
Drive axle Driving axle that receives the torque from the drivetrain.
Drivetrain Parts in machine involved in power transmission; engine, torque converter,
transmission and wheel engines alt. drive axle with differential and hub reduc-
tion.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which is emptied
automatically during operation.
ECC Electronic Climate Control. Climate control unit with electronic control of cooling,
dehumidification and heating
Electrolyte level Fluid level in battery cells.
End-positions As far out or away an object can be moved, i.e., end-position for tilt cylinders.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Expansion tank Tank for coolant.
Fixed displacement Pump with fixed pump volume.
Fixed displacement Pump with fixed pump volume.
FlexCab Protective cage with a protective robust frame design. Enclosed.
FlexGuard Protective cage with a protective robust frame design. Open.
Frame member Structural members in the frame.

166 10 Terminology – 10 Terminology
Term Description
Hanging load Lifted load.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases
torque from the drivetrain.
Hydraulic oil Oil for hydraulic system. See specifications in operator’s manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Indicator Manual “sensor”, for example, that a filter is clogged and needs to be changed.
KCS An electronic control and monitoring system which monitors and handles certain
machine systems that require KCS, for example, certain engine and transmission
alternatives.
Levelling Forks are angled, for example, if the load stands on an uneven surface.
Lift capacity Machine’s maximal lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Low-emission engine Engine with low emissions of hazardous substances. Strict regulations about lim-
it values in order for engine to be called low-emission engine.
Lubrication device Automatic lubrication device that greases bearings for mast mounting (mounted
directly on grease point)
Machine model Machine type. Indicated, for example: DCE 50-90HM. See also type designation.
Main fuse Located by battery. Cuts off power to all machine systems.
Maintenance Periodic maintenance actions so that machine functions safely and for long life.
Mast Carrier of attachment and load.
Operating hours Number of hours machine has been in operation, shown on hour meter in cab.
Option Extra equipment selected to supplement machine.
Pilot oil pressure A low control pressure, for example, for a valve.
Piston rod Rod that can be pushed into the piston’s cylinder barrel.
Positioning Positioning of forks, i.e. changing relative distance/position between forks).
Product alternative One of several alternatives is selected for a machine, i.e. engine alternative.
Progressive steering Quick steering movements give larger steering angles.
Proportional valve An electro-magnetically controlled valve. If a voltage is applied, the valve is acti-
vated in proportion to the voltage’s amplitude. In simple terms, infinitely variable
valve, as opposed to on/off valve. For example, on transmission’s valve housing.
Recirculation Circulate over and over again.
Refrigerant Fluid/gas in air conditioning. May only be handled by authorized trained person.
Securing machine for transport Actions before transporting machine.
Serial number Unique machine designation. On machine plate.
Service position How machine should be positioned safely before service may be started.
Servo A small user movement results in a big machine movement, i.e. servo steering.
Servo pressure A low control pressure to control a higher pressure, for example, for a valve.
Sideshift Forks are moved sideways in parallel.
Solenoid valve An electro-magnetically controlled valve. See also proportional valve.

10 Terminology – 10 Terminology 167
Term Description
Spirit Delta Enclosed type of cab.
Steering axle Wheel axle with steering.
Tilting Mast is leaned forward or backward.
Type designation Indicates machine type and capacity. See also machine model.
Valve slide Moveable part in valve. Determines oil’s path.
Wet brakes Brake discs in oil-bath.
Wheel motor Motor directly mounted on the drive wheels. Replaces the driving axle on the
DCE 50-55HM and i used for propulsion of the vehicle.
Working hydraulics All load handling functions, that is, lift and lower, tilt, sideshift, positioning and
levelling.

168 10 Terminology – 10 Terminology

169
11 Index
About the documentation kit 6 Information menu for operating time 78
About the Operator’s Manual 3 Information menu for scales 77
Air filter engine 126 Information menu for service 78
ANSI/ASME marking 12 Information menus 76
Battery and battery isolator 135 Inspection and maintenance 117
Cab Spirit Delta 71 Inspection and maintenance 7
Cab Spirit Delta with ECC climate unit 105 Instruments 47
Cab Spirit Delta with heater unit / AC 103 Instruments and controls 37
CE marking 11 KCS system 76
Central lubrication 134 Keep in mind 13
Checking accumulators 133 Lifting a load 112
Cleanliness 123 Lifting and securing the vehicle 149
Climate control system ECC (75) 73 Lifting the vehicle 149
Cooling system 127 Lighting 141
Daily inspection 118 Load handling 111
Daily inspection 81 Long-term storage 152
Description DCE 50-90HM 19 Main fuses for electrical system 137
Disconnecting the hydraulic transmission 148 Maintenance 121
Engine oil 128 Mechanical release of parking brake 145
Environment and standards 153 Multi-function lever (5) 54
fault code indication with KCS 83 Operating 95
fault code tables 89 Operator’s seat (9) 64
fault codes 82 Parking brake 101
FlexCab Cab 108 Pedals 59
FlexCab Cab 75 Plates 30
Foreword 3 Protection and warning equipment 28
Fuel system 124 Reading instructions 4
Fuses for electrical system 138 Running-in 80
General description 20 Safety 9
Handling 79 Select travel direction 100
Handling of fault codes 82 Service 142
Heating system/Climate control system with AC Service brake 101
71 Service position 151
Heating / climate control system 103 Specifications 157
Heating/Air conditioning 71 Starting engine 97
Hydraulic control 55 Steering 101
Hydraulic system 129 Steering wheel (4) 61
Identification of the vehicle 19 Stopping engine - parking 109
Ignition (46) 48 Summary 19
Information menu for electrical system and hy- Switches 49
draulics 77 Terminology 165
Information menu for engine 77 Towing 144
Information menu for engine and transmission 77 Transporting load 114
Information menu for mini steering wheel/steer- Transporting the vehicle 143
ing joystick 78 Travel direction selector (2) 53
170
Tyres 130
Unloading 116
Warming up 99
Warning and indicator lamps 45
While operating 95
Windscreen washer 125
Kalmar Industries AB
SE-341 81 Ljungby, Sweden
Tel: +46 372 260 00, Fax: +46 372 263 90
www.kalmarind.com

Operator Dce50-90hm

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Operator Dce50-90hm

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DCE 50-90HM

1.1 About the Operator’s

Purpose of the Operator’s Manual

About the machine version

Operator’s manual DCE 50-90HM IDCE06.01GB

1.1.1 Reading instructions

What causes the danger.

How to avoid the danger.

How to avoid the situation.

What causes the warning.

How to avoid the situation.

IDCE06.01GB Operator’s manual DCE 50-90HM

Read the operator’s manual/maintenance manual

Read the Operator’s manual/Maintenance manual

description of optional equipment in the operator’s manual is

Operator’s manual DCE 50-90HM IDCE06.01GB

1.2 About the documentation

IDCE06.01GB Operator’s manual DCE 50-90HM

1.3 Inspection and maintenance

Operator’s manual DCE 50-90HM IDCE06.01GB

IDCE06.01GB Operator’s manual DCE 50-90HM

Important to read the Operator’s

Operator’s manual DCE 50-90HM IDCE06.01GB

Prohibited operation of machine

IDCE06.01GB Operator’s manual DCE 50-90HM

Operator’s manual DCE 50-90HM IDCE06.01GB

2.2 ANSI/ASME marking

Machine plates for machine and attachment

IDCE06.01GB Operator’s manual DCE 50-90HM

2.3 Keep in mind

Cut the current with the battery isolator.

Operator’s manual DCE 50-90HM IDCE06.01GB

During work shifts

Fatal danger! Risk of damage to property and ma-

• Always check that no persons are in the way of

• The operator must always face in the direction

• The operator shall adjust travel speed according

• The operator should pay extra attention and op-

• The driver must always wear a seat belt when

• Always operate carefully so that the attachment

It is prohibited to exceed the machine’s load capac-

IDCE06.01GB Operator’s manual DCE 50-90HM

• All loads should be carried in the transport posi-

• The operator should always adjust the speed

In case the machine rolls over or tips, hold on to

Fatal danger and risk of property damage!

Make sure that no persons stand under raised at-

Fatal danger and risk of property damage!

Always repair all wear and damage.

Operator’s manual DCE 50-90HM IDCE06.01GB

Low strength! Fatal danger!

Check the outside surface of the roof window at

Low strength! Fatal danger!

Replace a damaged roof window immediately.

Risk of tipping! Fatal danger!

Avoid lifting loads in heavy wind conditions.

Avoid driving indoors in poorly ventilated premises.

IDCE06.01GB Operator’s manual DCE 50-90HM

Always use the steps and handles when you climb

Always close the cab door(s) during the work shift.

Passengers must use the permanently installed pas-

Operator’s manual DCE 50-90HM IDCE06.01GB

Always be very careful when working with the hy-

Batteries should always be provided with protective