Kalmar DCD — Brakes and steering: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the brake circuits, accumulators, parking brake and steering of the Kalmar DCD heavy forklift truck, one fact per card, each with its source stated in the text. For the overall picture, see the Kalmar DCD technical legacy guide.
Kalmar DCD 200-300: what kind of brakes does the machine have?
Wet disc service brakes, oil-cooled and fully sealed, act on the drive wheels through one hydraulic circuit, according to the operator's manual (series 2), as recorded by the HIT SRL technical desk. For parking, that manual uses a spring-applied, hydraulically released disc brake on the input shaft of the drive axle, as HIT SRL's technical desk reads it. The manual applies it automatically if the voltage is lost, and the maintenance manual (series 1) gives the steering axle no brakes.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-service-and-parking-brakes-200-300 · HIT ref KDCD-074 · fingerprint 8a523a · see HIT ref KDCD-078, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-brake-pedal-pressure
Kalmar DCD 280-500: how is the brake system laid out?
In three separate hydraulic circuits, for the foot brake, the brake cooling and the parking brake, all fed by the same pump, according to the DCD 280-500 technical handbook (2001 edition), as set out in the HIT SRL technical cards. According to the handbook, the brake circuits draw on four hydraulic accumulators, while the cooling circuit takes the surplus oil of the main hydraulics from the valve block, the HIT SRL technical desk notes. The handbook limits the brake system with a relief valve at 210 bar.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-brake-circuits-280-500 · HIT ref KDCD-075 · fingerprint 97a2b8 · see HIT ref KDCD-076, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-brake-accumulators-180-250
Kalmar DCD 180-250: how are the brake accumulators set up?
Four membrane-type hydraulic accumulators, pre-charged with nitrogen to 70 bar, feed the brake circuits and the pressure-reducing valve of the servo hydraulics, according to the DCD 180-250 technical handbook (1997 edition), as recorded at HIT SRL. The drawing on the same page of the handbook shows two accumulators, as logged by the HIT SRL technical desk. The handbook limits the brake system with a relief valve at 210 bar and checks or tops up the nitrogen through an upper connection with special equipment.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-brake-accumulators-180-250 · HIT ref KDCD-076 · fingerprint d3bbbe · see HIT ref KDCD-075, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-brake-circuits-280-500
Kalmar DCD 200-300: what is the nitrogen pre-charge of the brake accumulators?
70 bar on the DCD 200-250 and 100 bar on the DCD 280-300, with a maximum accumulator pressure of 165 bar, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. That manual checks the pre-charge at every service. The technical handbook (series 3) gives 100 bar for the whole series, with an accumulator charging valve working at 160-170 bar.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-accumulator-pre-charge-200-300 · HIT ref KDCD-077 · fingerprint f2290c · see HIT ref KDCD-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-accumulator-test-applications
Kalmar DCD 200-300: what brake pressure does the pedal give?
27 bar with the brake pedal half depressed and 100 bar with it fully depressed, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The manual sets the clearance between brake pedal and brake valve to 1-1.5 mm with the set screw of the pedal, the HIT SRL technical desk notes. The same manual checks the brake pressure with the oil at no less than 50 °C, a gauge on the distribution block connection and a comparison with the pressure plate.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-brake-pedal-pressure · HIT ref KDCD-078 · fingerprint 459e26 · see HIT ref KDCD-074, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-service-and-parking-brakes-200-300
Kalmar DCD 200-300: what is the maximum pressure in the brake cooling circuit?
1 bar, on the test-point and valve-block pages of the technical handbook (series 3), as logged by the HIT SRL technical desk. The component list of the hydraulic diagram in the same handbook gives 1.5 bar instead. The DCD 180-250 and DCD 280-500 handbooks show the same two values, 1 bar at the test points and 1.5 bar for the cooling oil pressure valve.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-brake-cooling-pressure · HIT ref KDCD-079 · fingerprint 9c8468 · see HIT ref KDCD-078, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-brake-pedal-pressure
Kalmar DCD 200-300: what clearance does the parking brake need?
0.5 ± 0.1 mm between pads and disc after new pads are fitted, set with the engine idling and the parking brake released, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. The manual cleans the disc with pure denatured alcohol and checks the pad thickness at every service, as HIT SRL's technical desk reads it. The technical handbook (series 3) sets about 1 mm and releases the brake with at least 10 MPa. Each machine takes the clearance given in its own maintenance manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-parking-brake-clearance · HIT ref KDCD-080 · fingerprint 670062 · see HIT ref KDCD-074, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-service-and-parking-brakes-200-300
Kalmar DCD 200-300: how many brake applications must the accumulators allow?
At least 8 with the engine switched off, before the low brake pressure error code appears, according to the maintenance manual (series 1), the HIT SRL technical desk notes. The technical handbook (series 3) also asks for at least eight, while the operator's manual (series 2) asks for at least six applications with long pedal strokes before the low brake pressure light comes on, as set out in the HIT SRL technical cards. If the code or the light comes sooner, the manuals treat the accumulators as faulty. The count that applies is the one in the manual issued for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-accumulator-test-applications · HIT ref KDCD-081 · fingerprint a26c0e · see HIT ref KDCD-077, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-accumulator-pre-charge-200-300
Kalmar DCD 200-300: how is the brake system checked according to the technical handbook?
With the hydraulics at working temperature, bleeding the brakes at the hub nipples and charging the accumulators, according to the technical handbook (series 3), as recorded at HIT SRL. The handbook stops the engine at once if the accumulator charging pressure exceeds 185 bar and wants the charge to cover at least eight brake applications, as logged by the HIT SRL technical desk. The handbook reads the nitrogen pre-charge as a sharp pressure drop when the evacuating valve is opened, and leaves recharging with nitrogen to special equipment and trained personnel. Workshops apply the brake test given in the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-brake-system-check · HIT ref KDCD-082 · fingerprint 7856fd · see HIT ref KDCD-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-accumulator-test-applications
Kalmar DCD 200-300: how is the steering built?
A single double-acting cylinder under an Orbitrol steering valve moves a rear steered axle that hangs on a pendulum suspension with maintenance-free rubber mountings, according to the technical handbook (series 3), as HIT SRL's technical desk reads it. The handbook runs knuckle pins and wheel axles in taper roller bearings and states that the wheel alignment cannot be adjusted, as recorded by the HIT SRL technical desk. In the same handbook the steering shock valves open at 280 bar.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-steering-200-300 · HIT ref KDCD-083 · fingerprint 4ffc81 · see HIT ref KDCD-084, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-lever-steering-speed-limit
Kalmar DCD 200-300: when can the lever steering or mini-wheel be engaged?
Only below 2 km/h with the steering wheel stationary, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The operator's manual (series 2) gives 3 km/h for the joystick or mini-wheel in the left armrest, the HIT SRL technical desk notes. Both manuals disengage it as soon as the standard steering wheel moves, and the maintenance manual drives it through the ECU 792 control unit and a control valve.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-lever-steering-speed-limit · HIT ref KDCD-084 · fingerprint f6be18 · see HIT ref KDCD-083, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-steering-200-300
Kalmar DCD 200-300: what changes with the reversible operator's seat?
A directional control valve reverses the steering when the seat faces rearwards, keeping the steering wheel angle and the steering angle in agreement, according to the maintenance manual (series 1), as logged by the HIT SRL technical desk. The manual adds a second brake pedal for driving backwards, connected in parallel through a shuttle valve that picks the stronger pressure signal, as recorded at HIT SRL. With this seat, in the Spirit Delta cab, the manual gives electric servo load-handling controls.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-reversible-operator-seat · HIT ref KDCD-085 · fingerprint 4096f7 · see HIT ref KDCD-084, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-lever-steering-speed-limit
Kalmar DCD 200-300: how are the steered wheel bearings adjusted?
To no play and a friction torque of about 19 Nm, with the bearing nut tightened while the hub turns and the lock nut at no less than 250 Nm, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. That manual oils the nut thread with SAE 80W/140 and checks the preload first after 1000 hours and then every 2000 hours, as HIT SRL's technical desk reads it. The technical handbook (series 3) tightens the bearing nuts to 500 Nm while the wheel turns, again after about 100 m of driving, and never loosens them afterwards.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-steered-wheel-bearing-adjustment · HIT ref KDCD-086 · fingerprint eb0481 · see HIT ref KDCD-087, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-wheel-spindle-clearance
Kalmar DCD 200-300: how much play may the steering axle wheel spindle bearings have?
At most 0.25 mm on the DCD 200-250, measured with a feeler gauge before and after lifting the machine under the rear counterweight, according to the maintenance manual (series 1), the HIT SRL technical desk notes. On the DCD 280-300 the manual allows no slack at all when each wheel is jacked up and lowered, as set out in the HIT SRL technical cards. The manual checks the clearance every 1000 hours and calls for new shimming above 0.25 mm.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-wheel-spindle-clearance · HIT ref KDCD-087 · fingerprint 06324d · see HIT ref KDCD-086, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-steered-wheel-bearing-adjustment
Kalmar DCD 180-250: which torques apply to the steering cylinder and knuckle-pin bearings?
386 Nm on the M20 steering cylinder screws of the DCD 180-200 and 670 Nm on the M24 screws of the DCD 220-250, both oiled, according to the DCD 180-250 technical handbook (1997 edition), as recorded at HIT SRL. The handbook tightens the nuts of the upper and lower knuckle-pin bearings to 500 Nm on both size groups, as logged by the HIT SRL technical desk. The handbook locks the cylinder screws with thread-locking compound.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-steering-cylinder-torques-180-250 · HIT ref KDCD-088 · fingerprint 20a26a · see HIT ref KDCD-083, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/brakes-and-steering/#hit-dcd-steering-200-300