This workshop service repair manual covers Kalmar forklifts, including models DCE70-32E3 through DCE180-12. These robust machines are engineered for demanding industrial environments, offering reliable performance and efficiency. They are equipped with powerful engine options such as the Volvo TAD650VE, Volvo TAD750VE, QSB6.7, Volvo TAD660VE, Volvo TAD760VE, and Caterpillar C6.6 diesel engines, paired with advanced transmissions like the Dana-Spicer Off Highway TE13000, TE17000, and ZF 3WG161. The design prioritizes durability and operational excellence, making Kalmar forklifts a trusted choice for material handling needs.
This comprehensive manual provides detailed information essential for the maintenance and repair of your Kalmar forklift. It includes extensive sections covering all major systems, from engine and transmission to hydraulics, brakes, and electrical components. With step-by-step instructions, detailed illustrations, pictures, and diagrams, this resource is designed for both do-it-yourself users and experienced mechanics. It empowers you to perform routine maintenance, diagnose issues, and complete repairs effectively, ensuring your equipment remains in optimal working condition.
KALMAR DCE 90-180, DCE 70-32E3, DCE 70-35E4 FORKLIFT WORKSHOP SERVICE REPAIR MANUAL
APPLICABLE MODEL:
DEC90-6, DCE100-6, DCE120-6, DCE140-6, DCE150-6, DCE100-12, DCE120-12, DCE150-12, DCE160-6, DCE160-9, DCE160-12, DCE180-6, DCE70-32E3, DCE70-35E4
ENGINE COVERED:
6.057L 6-CYLINDER, 4-STROKE, TURBO-INTERCOOLER, VOLVO TAD650VE DIESEL ENGINE
7.145L 6-CYLINDER, 4-STROKE, TURBO-INTERCOOLER, VOLVO TAD750VE DIESEL ENGINE
6.702L 6-CYLINDER, 4-STROKE, TURBO-INTERCOOLER, QSB6.7 DIESEL ENGINE
5.70L 6-CYLINDER IN-LINE, 4-STROKE, VOLVO TAD660VE DIESEL ENGINE
7.15L 6-CYLINDER IN-LINE, 4-STROKE, VOLVO TAD760VE DIESEL ENGINE
6.6L 6-CYLINDER IN-LINE, 4-STROKE, TURBOCHARGED, CATERPILLAR C6.6 DIESEL ENGINE
TRANSMISSION COVERED:
DANA-SPICER OFF HIGHWAY TE13000
DANA-SPICER OFF HIGHWAY TE17000
ZF 3WG161
CONTENTS:
FORWARD
SAFETY DATA
MAINTENANCE
COMPLETE MACHINE
ENGINE CONTROLS
ENGINE INSTRUMENTS
IGNITION SWITCH
ACCELERATOR SYSTEM
FUEL SYSTEM
EXHAUST CLEANING
AIR INTAKE SYSTEM
EXHAUST SYSTEM
INTERCOOLER SYSTEM
PIPE & HOSES
COOLING SYSTEM
CONTROL UNIT ENGINE
START & STOPPING SYSTEM
CLUTCH SYSTEM
TRANSMISSION SYSTEM
LUBRICATION SYSTEM
OIL-COOLER SYSTEM
MANUAL SHIFTING
CALIBRATION SYSTEM
DRIVELINE & AXLE
PROPELLER SHAFT
BRAKE SYSTEM
POWER ASSISTED BRAKES
PARKING BRAKES
STEERING SYSTEM
POWER STEERING
HYDRAULIC STEERING
SUSPENSION SYSTEM
TIRES AND RIMS
LOAD HANDLING SYSTEM
LIFTING/LOWERING SYSTEM
SIDE SHIFT SYSTEM
SPREADING-TILT-LEVELLING
LOAD CARRER SYSTEM
ECU CONTROL SYSTEM
ELECTRONIC THROTTLE CONTROL
FRAME AND BODY SYSTEM
CAB AND ACCESSORIES
COMMON HYDRAULICS
BATTERY & ALTERNATOR
POWER SUPPLY SYSTEM
ELECTRICAL DISTRIBUTION BOX
COMMUNICATION SYSTEM
HYDRAULIC DIAGRAM
CIRCUIT DIAGRAM
TORQUE SPECIFICATION
KALMAR SMART LINK
THIS MANUAL IS COMPATIBLE WITH THE FOLLOWING COMPUTER OPERATING SYSTEMS:
# ALL WINDOWS VERSION
# ALL MAC VERSION
# YOU NEED THE ADOBE ACROBAT READER TO VIEW THE DOCUMENT AS THE MANUAL IS PDF FORMAT. IF YOUR COMPUTER DON'T HAVE THIS APPLICATION YOU CAN DOWNLOAD AND INSTALL IT FREE FROM ADOBE ACROBAT WEBSITE
# AS THIS MANUAL IS COMING TO YOU IN ZIP FORMAT, YOU NEED TO EXTRACT THE FILE BEFORE USE BY USING WINZIP OR WINRAR SOFTWARE. IF YOUR COMPUTER DON'T HAVE THIS APPLICATION YOU CAN DOWNLOAD AND INSTALL IT FREE FROM WINZIP WEBSITE
THIS IS A VERY COMPREHENSIVE AND INTUITIVE ELECTRONIC PDF FORMAT WORKSHOP MANUAL WHICH HAS DETAILED ILLUSTRATIONS AS WELL AS STEP BY STEP INSTRUCTIONS WITH PICTURES & DIAGRAMS. ALL PAGES ARE PRINTABLE, SO RUN OFF WHAT YOU NEED AND TAKE IT WITH YOU INTO THE GARAGE OR WORKSHOP. THIS MANUAL ARE YOUR NUMBER ONE SOURCE FOR REPAIR AND SERVICE INFORMATION. THEY ARE SPECIFICALLY WRITTEN FOR THE DO-IT-YOURSELF AS WELL AS THE EXPERIENCED MECHANIC. USING THIS REPAIR MANUAL IS AN INEXPENSIVE WAY TO KEEP YOUR MACHINE/VEHICLE WORKING PROPERLY. EACH MANUAL PROVIDES STEP-BY-STEP INSTRUCTIONS BASED ON THE COMPLETE DIS-ASSEMBLY OF THE MACHINE. SO, IT ALLOWING YOU TO STOP WASTING MONEY ON ROUTINE MAINTENANCE, AND GIVE YOU ALL THE SOLID INFORMATION AND GUIDANCE NEEDED TO PERFORM LARGER REPAIRS AND MODIFICATIONS AT HOME.
KALMAR DCE 90-180, DCE 70-32E3, DCE 70-35E4 FORKLIFT WORKSHOP SERVICE REPAIR MANUAL
APPLICABLE MODEL:
DEC90-6, DCE100-6, DCE120-6, DCE140-6, DCE150-6, DCE100-12, DCE120-12, DCE150-12, DCE160-6, DCE160-9, DCE160-12, DCE180-6, DCE70-32E3, DCE70-35E4
ENGINE COVERED:
6.057L 6-CYLINDER, 4-STROKE, TURBO-INTERCOOLER, VOLVO TAD650VE DIESEL ENGINE
7.145L 6-CYLINDER, 4-STROKE, TURBO-INTERCOOLER, VOLVO TAD750VE DIESEL ENGINE
6.702L 6-CYLINDER, 4-STROKE, TURBO-INTERCOOLER, QSB6.7 DIESEL ENGINE
5.70L 6-CYLINDER IN-LINE, 4-STROKE, VOLVO TAD660VE DIESEL ENGINE
7.15L 6-CYLINDER IN-LINE, 4-STROKE, VOLVO TAD760VE DIESEL ENGINE
6.6L 6-CYLINDER IN-LINE, 4-STROKE, TURBOCHARGED, CATERPILLAR C6.6 DIESEL ENGINE
TRANSMISSION COVERED:
DANA-SPICER OFF HIGHWAY TE13000
DANA-SPICER OFF HIGHWAY TE17000
ZF 3WG161
CONTENTS:
FORWARD
SAFETY DATA
MAINTENANCE
COMPLETE MACHINE
ENGINE CONTROLS
ENGINE INSTRUMENTS
IGNITION SWITCH
ACCELERATOR SYSTEM
FUEL SYSTEM
EXHAUST CLEANING
AIR INTAKE SYSTEM
EXHAUST SYSTEM
INTERCOOLER SYSTEM
PIPE & HOSES
COOLING SYSTEM
CONTROL UNIT ENGINE
START & STOPPING SYSTEM
CLUTCH SYSTEM
TRANSMISSION SYSTEM
LUBRICATION SYSTEM
OIL-COOLER SYSTEM
MANUAL SHIFTING
CALIBRATION SYSTEM
DRIVELINE & AXLE
PROPELLER SHAFT
BRAKE SYSTEM
POWER ASSISTED BRAKES
PARKING BRAKES
STEERING SYSTEM
POWER STEERING
HYDRAULIC STEERING
SUSPENSION SYSTEM
TIRES AND RIMS
LOAD HANDLING SYSTEM
LIFTING/LOWERING SYSTEM
SIDE SHIFT SYSTEM
SPREADING-TILT-LEVELLING
LOAD CARRER SYSTEM
ECU CONTROL SYSTEM
ELECTRONIC THROTTLE CONTROL
FRAME AND BODY SYSTEM
CAB AND ACCESSORIES
COMMON HYDRAULICS
BATTERY & ALTERNATOR
POWER SUPPLY SYSTEM
ELECTRICAL DISTRIBUTION BOX
COMMUNICATION SYSTEM
HYDRAULIC DIAGRAM
CIRCUIT DIAGRAM
TORQUE SPECIFICATION
KALMAR SMART LINK
THIS MANUAL IS COMPATIBLE WITH THE FOLLOWING COMPUTER OPERATING SYSTEMS:
# ALL WINDOWS VERSION
# ALL MAC VERSION
# YOU NEED THE ADOBE ACROBAT READER TO VIEW THE DOCUMENT AS THE MANUAL IS PDF FORMAT. IF YOUR COMPUTER DON'T HAVE THIS APPLICATION YOU CAN DOWNLOAD AND INSTALL IT FREE FROM ADOBE ACROBAT WEBSITE
# AS THIS MANUAL IS COMING TO YOU IN ZIP FORMAT, YOU NEED TO EXTRACT THE FILE BEFORE USE BY USING WINZIP OR WINRAR SOFTWARE. IF YOUR COMPUTER DON'T HAVE THIS APPLICATION YOU CAN DOWNLOAD AND INSTALL IT FREE FROM WINZIP WEBSITE
THIS IS A VERY COMPREHENSIVE AND INTUITIVE ELECTRONIC PDF FORMAT WORKSHOP MANUAL WHICH HAS DETAILED ILLUSTRATIONS AS WELL AS STEP BY STEP INSTRUCTIONS WITH PICTURES & DIAGRAMS. ALL PAGES ARE PRINTABLE, SO RUN OFF WHAT YOU NEED AND TAKE IT WITH YOU INTO THE GARAGE OR WORKSHOP. THIS MANUAL ARE YOUR NUMBER ONE SOURCE FOR REPAIR AND SERVICE INFORMATION. THEY ARE SPECIFICALLY WRITTEN FOR THE DO-IT-YOURSELF AS WELL AS THE EXPERIENCED MECHANIC. USING THIS REPAIR MANUAL IS AN INEXPENSIVE WAY TO KEEP YOUR MACHINE/VEHICLE WORKING PROPERLY. EACH MANUAL PROVIDES STEP-BY-STEP INSTRUCTIONS BASED ON THE COMPLETE DIS-ASSEMBLY OF THE MACHINE. SO, IT ALLOWING YOU TO STOP WASTING MONEY ON ROUTINE MAINTENANCE, AND GIVE YOU ALL THE SOLID INFORMATION AND GUIDANCE NEEDED TO PERFORM LARGER REPAIRS AND MODIFICATIONS AT HOME.
