Kalmar DCD — Engine and power: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the engines, engine oils, coolant, fuel, air cleaner and exhaust cleaning 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: which engines does the operator's manual list?
Four straight six-cylinder turbocharged low-emission diesels, the Volvo TAD720 (174 kW), the Volvo TWD731 (167 kW) and the Cummins QSB5.9 and CT8.3 (160 kW each), according to the operator's manual (series 2), the HIT SRL technical desk notes. The same manual gives every one of them an intercooler except the CT8.3, as set out in the HIT SRL technical cards. The technical handbook (series 3) treats the same four engines in its group 30.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-options-200-300 · HIT ref KDCD-019 · fingerprint 3afb10 · see HIT ref KDCD-020, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-ratings-tad720-cummins
Kalmar DCD 200-300: what are the net ratings of the TAD720VE and the Cummins engines?
174 kW at 2300 rpm with 854 Nm at 1400 rpm for the Volvo TAD720VE, net to ISO 3046, according to the operator's manual (series 2), as HIT SRL's technical desk reads it. The same manual rates both Cummins engines at 160 kW at 2200 rpm, as recorded by the HIT SRL technical desk. Their torques in that manual are 938 Nm at 1300-1500 rpm for the QSB5.9 and 871 Nm at 1500 rpm for the CT8.3.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-ratings-tad720-cummins · HIT ref KDCD-020 · fingerprint 907526 · see HIT ref KDCD-019, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-options-200-300
Kalmar DCD 200-300: what is the rating of the Volvo TWD731VE?
167 kW at 2200 rpm net to ISO 3046, with 893 Nm at 1300-1400 rpm, according to the operator's manual (series 2), as set out in the HIT SRL technical cards. The technical handbook (series 3) prints a different rating, 175 kW (238 hp) at 2400 r/min with 949 Nm at 1300 r/min, the HIT SRL technical desk notes. The DCD 280-500 technical handbook (2001 edition) agrees with 167 kW, and the DCD 180-250 technical handbook (1997 edition) gives 167 kW at 2200 r/min with the torque at 1200 r/min.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd731ve-rating · HIT ref KDCD-021 · fingerprint 643997 · see HIT ref KDCD-019, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-options-200-300
Kalmar DCD 280-500: what data does the handbook give for the Volvo TWD731VE?
An idle speed of 650 ± 25 r/min, valve clearances of 0.40 mm inlet and 0.55 mm exhaust when cold and 25 l of coolant for a six-cylinder of 6.73 litres, according to the DCD 280-500 technical handbook (2001 edition), as logged by the HIT SRL technical desk. The same handbook has the thermostat start to open at 75 °C and be fully open at 88 °C, as recorded at HIT SRL. It rates the engine at 167 kW (231 hp) at 2200 r/min with 893 Nm at 1300-1400 r/min, according to that handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd731ve-data-280-500 · HIT ref KDCD-022 · fingerprint 4fdb0f · see HIT ref KDCD-021, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd731ve-rating
Kalmar DCD 200-300: how much engine oil do the engines take?
20 l for the Volvo TAD720VE, 29 l for the TWD731, 14 l for the Cummins QSB5.9 and 19 l for the CT8.3, according to the operator's manual (series 2), as recorded by the HIT SRL technical desk. For the QSB5.9 the technical handbook (series 3) gives 15 l instead. That handbook confirms 20 l for the TAD720VE and 29 l for the TWD731VE.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-oil-capacities-200-300 · HIT ref KDCD-023 · fingerprint 1e2f18 · see HIT ref KDCD-024, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-coolant-capacities-200-300
Kalmar DCD 200-300: how much coolant does the cooling system hold?
41 l with the Volvo TWD731VE, 40 l with the TAD720VE and 33 l with the Cummins QSB5.9, according to the technical handbook (series 3), the HIT SRL technical desk notes. For the Cummins 6CT8.3 the handbook refers to the manufacturer instead of giving a figure. The DCD 90-180 instruction manual gives the same 41 l and 40 l for the two Volvo engines.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-coolant-capacities-200-300 · HIT ref KDCD-024 · fingerprint d14cf4 · see HIT ref KDCD-023, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-oil-capacities-200-300
Kalmar DCD 200-300: which engine oil grades are specified?
By ambient temperature, SAE 15W/40 to -15 °C, 10W/30 to -25 °C and 5W/30, according to the operator's manual (series 2), as recorded at HIT SRL. Outside Europe that manual accepts API CG-4 or CH-4 instead of ACEA E3, as logged by the HIT SRL technical desk. The technical handbook (series 3) specifies ACEA E2 or API CF4 instead, in SAE 0W, 5W 20, 10W 30 or 20W 50, and the maintenance manual (series 1) confirms the three viscosities of the operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-oil-grades-200-300 · HIT ref KDCD-025 · fingerprint 055134 · see HIT ref KDCD-023, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-oil-capacities-200-300
Kalmar DCD 200-300: how big is the fuel tank and which fuel is used?
300 l on the DCD 200, 230 l on the DCD 240 and 350 l on the DCD 250 and DCD 280-300, according to the operator's manual (series 2), as HIT SRL's technical desk reads it. The manual asks for diesel to EN 590 and never with additives. The maintenance manual (series 1) gives the same capacities, with 300 l for the DCD 200-220.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-fuel-tank-and-diesel · HIT ref KDCD-026 · fingerprint aca858 · see HIT ref KDCD-023, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-oil-capacities-200-300
Kalmar DCD 200-300: what are the valve clearances of the Volvo TAD720VE?
0.35 mm inlet and 0.55 mm exhaust when cold in the data table of the technical handbook (series 3), as set out in the HIT SRL technical cards. The adjustment procedure of the same handbook gives 0.30 mm and 0.50 mm instead, with the lock nut tightened to 20 ± 2 Nm. The clearances to set on a given engine are those in its own maintenance manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-tad720ve-valve-clearances · HIT ref KDCD-027 · fingerprint 2a2551 · see HIT ref KDCD-020, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-ratings-tad720-cummins
Kalmar DCD 200-300: which engines does the maintenance manual offer?
Two, the Volvo TAD750VE of 182 kW and the Cummins QSB6.7 of 194 kW, according to the maintenance manual (series 1), as logged by the HIT SRL technical desk. The manual describes both as straight six-cylinder four-stroke turbocharged low-emission diesels with unit injectors, air-to-air intercooler and electronic fuel injection control, as recorded at HIT SRL. That manual credits both with the USA (California) and European emission requirements and with EN13059 for noise and vibration.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engines-tad750ve-qsb67 · HIT ref KDCD-028 · fingerprint 4abbc6 · see HIT ref KDCD-029, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-ratings-tad750ve-qsb67
Kalmar DCD 200-300: what ratings does the maintenance manual give the TAD750VE and QSB6.7?
For the Volvo TAD750VE, 181 kW at 2300 rpm and 182 kW at 2200 rpm net to ISO 3046, with 1050 Nm at 1500 rpm, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. The same manual rates the Cummins QSB6.7 at 194 kW at 2200 rpm with 949 Nm at 1500 rpm, as HIT SRL's technical desk reads it. Its engine group gives the two engines simply as 182 kW and 194 kW.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-ratings-tad750ve-qsb67 · HIT ref KDCD-029 · fingerprint 5fcee1 · see HIT ref KDCD-028, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engines-tad750ve-qsb67
Kalmar DCD 200-300: how much oil and coolant do the TAD750VE and QSB6.7 take?
The Volvo TAD750VE takes 23 l of engine oil at first filling and 21.5 l at an oil change with the filter, according to the maintenance manual (series 1), the HIT SRL technical desk notes. The same manual gives 20 l of engine oil for the Cummins QSB6.7. It gives 40 l of coolant for either engine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-fluids-tad750ve-qsb67 · HIT ref KDCD-030 · fingerprint b6053a · see HIT ref KDCD-029, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-ratings-tad750ve-qsb67
Kalmar DCD 200-300: which engine oil specifications apply to the TAD750VE and QSB6.7?
For the Volvo, VDS-2 or VDS-3, API CH-4 or CI-4 and ACEA E4-99 (also synthetic), E5 or E7, according to the maintenance manual (series 1), as recorded at HIT SRL. For the Cummins the same manual lists CES-20071, 20072, 20076, 20077 or 20078, API CH-4/SJ or CI-4/SK and ACEA E5 or E7, as logged by the HIT SRL technical desk. The API grades are approved for markets outside the EU/EEA, according to that manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-oil-specifications-tad750ve-qsb67 · HIT ref KDCD-031 · fingerprint 639bb3 · see HIT ref KDCD-030, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-fluids-tad750ve-qsb67
Kalmar DCD 200-300: which coolant mixture is prescribed?
50% glycol to ASTM4985 and 50% pure water in the maintenance manual (series 1), protecting down to about -36 °C with a boiling point up to 108 °C, as HIT SRL's technical desk reads it. That manual keeps the glycol at no less than 40% where the temperature can fall below 0 °C and never above 60%, and forbids mixing ethylene glycol with other glycol types, as recorded by the HIT SRL technical desk. The technical handbook (series 3) prescribes instead a year-round mixture of 60% water and 40% ethylene glycol.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-coolant-mixture · HIT ref KDCD-032 · fingerprint 715c37 · see HIT ref KDCD-024, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-coolant-capacities-200-300
Kalmar DCD 200-300: what valve lash does the Cummins QSB6.7 need?
0.254 mm intake and 0.508 mm exhaust nominal, checked with the coolant below 60 °C, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The same manual allows check limits of 0.152-0.381 mm intake and 0.381-0.762 mm exhaust, and within those limits it asks for no adjustment. Its lock nut is tightened to 24 Nm, according to that manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-qsb67-valve-lash · HIT ref KDCD-033 · fingerprint 3eb1fe · see HIT ref KDCD-030, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-fluids-tad750ve-qsb67
Kalmar DCD 280-500: which engines are named in the handbook?
Volvo TWD731VE, TWD1031VE or TWD1231VE, Scania DI-9 or DI-11 and Cummins 6CT or M11 engines, according to the DCD 280-500 technical handbook (2001 edition), as logged by the HIT SRL technical desk. In the handbook's automatic gear-change diagrams the Clark 32000 serves the TWD731, DI-9 and 6CT, the Clark 36000 the TWD1031, DI-11 and M11, and the Clark 40000 the TWD1231, as recorded at HIT SRL. The handbook does not say which engine goes on which size.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engines-and-gearboxes-280-500 · HIT ref KDCD-034 · fingerprint af5ff7 · see HIT ref KDCD-035, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd1031ve-twd1231ve-ratings
Kalmar DCD 280-500: what are the ratings of the Volvo TWD1031VE and TWD1231VE?
235 kW (320 hp) at 2100 r/min with 1500 Nm at 1100 r/min for the TWD1031VE of 9.60 l, and 275 kW (374 hp) at 2100 r/min with 1745 Nm at 1100 r/min for the TWD1231VE of 12 l, to ISO 3046, according to the DCD 280-500 technical handbook (2001 edition), as recorded by the HIT SRL technical desk. The handbook describes both as six-cylinder in-line four-stroke engines with turbocharger, intercooler and individual cylinder heads, as HIT SRL's technical desk reads it. It gives them a centrifugal RSV governor on the injection pump.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd1031ve-twd1231ve-ratings · HIT ref KDCD-035 · fingerprint 3d59d4 · see HIT ref KDCD-036, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd1031ve-twd1231ve-fluids
Kalmar DCD 280-500: how much coolant and oil do the TWD1031VE and TWD1231VE take?
65 l of coolant and 32 l of engine oil including filters for the TWD1031VE, and 75 l and 38 l for the TWD1231VE, according to the DCD 280-500 technical handbook (2001 edition), the HIT SRL technical desk notes. The same handbook gives both engines cold valve clearances of 0.40 mm inlet and 0.70 mm exhaust, as set out in the HIT SRL technical cards. It gives idle speeds of 675 ± 25 and 600 ± 25 r/min and a thermostat of 82/95 °C as printed.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd1031ve-twd1231ve-fluids · HIT ref KDCD-036 · fingerprint 5f4ec5 · see HIT ref KDCD-035, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd1031ve-twd1231ve-ratings
Kalmar DCD 280-500: which engine oil does the handbook specify?
ACEA E2 or API CF4 oil for the Cummins, Scania and Volvo engines, in SAE 5W 30, 10W 30 or 15W 40 by outside temperature, according to the DCD 280-500 technical handbook (2001 edition), as recorded at HIT SRL. The same handbook changes the engine oil every 200 hours, as logged by the HIT SRL technical desk. For the DCD 200-300 the technical handbook (series 3) lists SAE 0W, 5W 20, 10W 30 and 20W 50 under the same classes.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-oil-280-500 · HIT ref KDCD-037 · fingerprint cc625d · see HIT ref KDCD-034, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engines-and-gearboxes-280-500
Kalmar DCD 280-500: how is the exhaust gas cleaner of the Volvo engines maintained?
A first top-up of the catalyst after about 50 hours of operation, then a check every 100-300 hours, for the exhaust gas cleaner of the TWD731VE, according to the DCD 280-500 technical handbook (2001 edition), as HIT SRL's technical desk reads it. A small cleaner is emptied and refilled with new catalyst after about 5000 hours, according to the same handbook, as recorded by the HIT SRL technical desk. For the TWD1031VE and TWD1231VE the handbook asks only for a check for carbon deposits about twice a year.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-exhaust-catalyst-280-500 · HIT ref KDCD-038 · fingerprint 3a6a99 · see HIT ref KDCD-039, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-air-cleaner-280-500
Kalmar DCD 280-500: when are the air filter elements changed?
The main element when the restriction indicator shows red, which on the TWD1031VE and TWD1231VE happens at a pressure drop of about 500 mm water column, according to the DCD 280-500 technical handbook (2001 edition), as set out in the HIT SRL technical cards. The safety element is changed after five main element changes, at least every other year, if the indicator still shows red after a main element change or if the engine has run with a damaged main element, according to the same handbook, the HIT SRL technical desk notes. The handbook never allows the safety element to be cleaned and reused.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-air-cleaner-280-500 · HIT ref KDCD-039 · fingerprint b4dca2 · see HIT ref KDCD-038, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-exhaust-catalyst-280-500
Kalmar DCD 180-250: what engine does the handbook describe?
The Volvo TWD 731 VE, a six-cylinder in-line four-stroke low-emission diesel of 6.73 l with overhead valves, according to the DCD 180-250 technical handbook (1997 edition), as logged by the HIT SRL technical desk. The handbook gives it a turbocharger and a water-to-air intercooler. It also lists replaceable wet cylinder liners and two cylinder heads, each covering three cylinders, according to the same handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd731ve-180-250-description · HIT ref KDCD-040 · fingerprint 6ac8d9 · see HIT ref KDCD-041, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd731ve-180-250-capacities
Kalmar DCD 180-250: how much oil and coolant does the TWD 731 VE take?
24 l of engine oil and 33 l of coolant, according to the DCD 180-250 technical handbook (1997 edition), as recorded by the HIT SRL technical desk. The handbook changes the engine oil at operating temperature. It fills the oil filters with oil before fitting and tightens them by hand, according to the same handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd731ve-180-250-capacities · HIT ref KDCD-041 · fingerprint 5da25e · see HIT ref KDCD-042, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd731ve-180-250-settings
Kalmar DCD 180-250: what are the settings of the TWD 731 VE?
Cold valve clearances of 0.40 mm inlet and 0.55 mm exhaust and an idle speed of 650 ± 50 r/min, according to the DCD 180-250 technical handbook (1997 edition), the HIT SRL technical desk notes. The handbook sets the injection pump timing at 10° ± 0.5° before top dead centre, as set out in the HIT SRL technical cards. It gives an oil pressure of 3-5 bar at running speed and at least 1.5 bar at idle, and a thermostat that starts to open at 75 °C and is fully open at 88 °C.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd731ve-180-250-settings · HIT ref KDCD-042 · fingerprint 8854b5 · see HIT ref KDCD-041, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd731ve-180-250-capacities
Kalmar DCD 180-250: which engine oil does the handbook specify?
API-CD oil for turbocharged engines, chosen by ambient temperature, according to the DCD 180-250 technical handbook (1997 edition), as recorded at HIT SRL. The handbook allows SAE 15W/40 down to -15 °C, 10W/30 down to -25 °C, 20W/30 down to -10 °C, SAE 30 down to 0 °C and SAE 40 down to +10 °C, as logged by the HIT SRL technical desk. Below -10 °C it allows only synthetic or semi-synthetic SAE 5W/30, according to the same handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engine-oil-180-250 · HIT ref KDCD-043 · fingerprint 9a46ae · see HIT ref KDCD-042, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-twd731ve-180-250-settings
Kalmar DCD 200-300: how is the particle filter cleaned?
Every year or every 1500 hours, the particle filter of the extra exhaust cleaning device is cleaned of fuel and lubricant residue, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. After a normal burn-off the manual lets it cool for 3-4 hours, removes its centre section and flushes it with water from the outlet side, not at high pressure, until the water runs clean, as recorded by the HIT SRL technical desk. The manual refits it with new gaskets and gives the device as 400 V and 13.5 kW.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-particle-filter · HIT ref KDCD-044 · fingerprint 29ffb7 · see HIT ref KDCD-028, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/engine-and-power/#hit-dcd-engines-tad750ve-qsb67