Kalmar DCD — Hydraulics: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the hydraulic pumps, pressures, oils, additive and filters 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: how many hydraulic pumps are there and what do they feed?
Two gear pumps, driven by the engine and mounted on the torque converter, according to the technical handbook (series 3), as HIT SRL's technical desk reads it. In that handbook one pump feeds the lifting function and passes surplus oil to the brake cooling circuit, while the other feeds steering, brakes, the other working functions and the accumulator, as recorded by the HIT SRL technical desk. The maintenance manual (series 1) also gives two fixed-displacement gear pumps, with a priority valve for the steering, and the handbook speaks elsewhere of two or three pumps.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-pumps-200-300 · HIT ref KDCD-089 · fingerprint fecedf · see HIT ref KDCD-092, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-pressures-200-300
Kalmar DCD 200-300: how much oil does the hydraulic tank hold?
The operator's manual (series 2) gives a hydraulic tank of 270 l for the DCD 200, 260 l for the DCD 240 and 320 l for the DCD 250 and DCD 280, as logged by the HIT SRL technical desk. The manual adds 3% of Lubrizol additive to the oil, and the technical handbook (series 3) asks for at least 3% of the same additive, as recorded at HIT SRL. The maintenance manual (series 1) gives 270 l for the DCD 200-220, 260 l for the DCD 240 and 320 l for the DCD 250-300, with the same 3%.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-tank-and-additive-200-300 · HIT ref KDCD-090 · fingerprint 86594b · see HIT ref KDCD-091, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-oil-grades
Kalmar DCD 200-300: which hydraulic oils are approved?
By ambient temperature, ISO-LHV 46 or ISO-LHM 68 to ISO 6743/4, HVLP 46 or HLP 68 to DIN 51524, or AV 32 or AV 46 to SS 155434, according to the operator's manual (series 2), as recorded by the HIT SRL technical desk. Any other choice needs the manufacturer's written approval and may change the service intervals, according to the same manual, as HIT SRL's technical desk reads it. The technical handbook (series 3) and the maintenance manual (series 1) give the same table.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-oil-grades · HIT ref KDCD-091 · fingerprint 1c051a · see HIT ref KDCD-090, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-tank-and-additive-200-300
Kalmar DCD 200-300: which hydraulic pressures does the technical handbook give?
160-170 bar at the accumulator charging valve, at most 175 bar for the steering and 35 bar of servo pressure, according to the technical handbook (series 3), the HIT SRL technical desk notes. The same handbook pre-charges the accumulators with nitrogen to 100 bar and opens the steering shock valves at 280 bar. The handbook puts the pressures of each machine on its own hydraulic plate.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-pressures-200-300 · HIT ref KDCD-092 · fingerprint ae5a9b · see HIT ref KDCD-089, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-pumps-200-300
Kalmar DCD 200-300: how is the main hydraulic pressure set?
Individually on each truck, with both main pressure limiting valves adjusted alike so that the truck can only just lift its rated load at the appropriate load centre, according to the technical handbook (series 3), as recorded at HIT SRL. The handbook seals the adjusting screw after any adjustment, as logged by the HIT SRL technical desk. The DCD 180-250 and DCD 280-500 handbooks set the main pressure in the same way. The setting of a given truck is the one on its hydraulic plate and in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-main-pressure-setting · HIT ref KDCD-093 · fingerprint 669a52 · see HIT ref KDCD-092, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-pressures-200-300
Kalmar DCD 200-300: what is on the pressure plate?
The main hydraulic pressures of the machine, from the maximum brake pressure and the accumulator hydraulic and gas pressures to the load-handling servo, steering, other load-handling and lift pressures, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. The manual places the plate on the right side of the frame in front of the steps, as recorded by the HIT SRL technical desk. It states that the pressures depend on the equipment and are unique to each machine, and that measured pressures should match the plate.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-pressure-plate · HIT ref KDCD-094 · fingerprint 774a92 · see HIT ref KDCD-095, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-pressure-check
Kalmar DCD 200-300: how are the hydraulic pressures checked?
Against the pressure plate with the oil at about 50 °C, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The manual reads the accumulator charging pressure when charging switches over to brake cooling and wants recharging to restart at about 13.5 MPa, the HIT SRL technical desk notes. Steering, lift and tilt, side shift and spreading are read with the function at its end position at about 1100 rpm and at about 1800 rpm, the two readings within ±1.0 MPa, at every service, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-pressure-check · HIT ref KDCD-095 · fingerprint 7475c0 · see HIT ref KDCD-094, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-pressure-plate
Kalmar DCD 320-500: which hydraulic pumps are fitted?
Two single vane pumps on the 32-tonne truck and one single and one double vane pump on the 37-50 tonne trucks, all driven by the engine and fitted on the torque converter, according to the DCD 280-500 technical handbook (2001 edition), as logged by the HIT SRL technical desk. An idling relief valve sends the whole flow back to the tank when no function is in use, according to the handbook, as recorded at HIT SRL. On the DCD 280 the same handbook has two single gear pumps instead, as on the DCD 200-300.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-vane-pumps-320-500 · HIT ref KDCD-096 · fingerprint 7daac2 · see HIT ref KDCD-097, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-lift2-cut-out-320-500
Kalmar DCD 320-500: how do the two lift valve sections work?
LIFT1 and LIFT2 both feed the lift cylinders, but a solenoid valve cuts out LIFT2 while the truck is driven, according to the DCD 280-500 technical handbook (2001 edition), as recorded by the HIT SRL technical desk. Both sections feed the lift only with the gear selector in neutral, the inching pedal pressed or the parking brake applied, according to the handbook, as HIT SRL's technical desk reads it. Each lift cylinder has a factory-set, non-adjustable lowering brake valve that also limits the flow if a pipe breaks, the same handbook states.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-lift2-cut-out-320-500 · HIT ref KDCD-097 · fingerprint db1a6f · see HIT ref KDCD-096, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-vane-pumps-320-500
Kalmar DCD 280-500: how much hydraulic fluid is used and of which type?
320 l on the DCD 280, 350 l on the DCD 320 and 600 l on the DCD 370-500, according to the DCD 280-500 technical handbook (2001 edition), the HIT SRL technical desk notes. The handbook asks for hydraulic fluid to ISO 6743/4, ISO-L HV32, HV46 or HV68 by outside temperature, with a 6% LUBRIZOL additive, as set out in the HIT SRL technical cards. A footnote of the handbook says that the additive does not apply to all drive axles and refers to the machine card and signs, and any deviation needs the manufacturer's written approval.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-fluid-280-500 · HIT ref KDCD-098 · fingerprint e44745 · see HIT ref KDCD-099, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-checks-320-500
Kalmar DCD 320-500: how are the hydraulic pressures checked?
Against the hydraulic plate on the truck, for the accumulator charging, steering and main pressures, according to the DCD 280-500 technical handbook (2001 edition), as recorded at HIT SRL. The handbook stops the engine at once if the accumulator charging pressure exceeds 200 bar and gives a servo pressure of 35 ± 5 bar that cannot be adjusted, as logged by the HIT SRL technical desk. In the same handbook the safety valves on the steering valve open at 200 bar, while on the DCD 280 the shock valves open at 280 bar and the engine stop limit is 185 bar.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-checks-320-500 · HIT ref KDCD-099 · fingerprint 3f904e · see HIT ref KDCD-098, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-fluid-280-500
Kalmar DCD 280-500: when are the hydraulic return filters changed?
Every 1000 hours of operation, or sooner when the pointer of the contamination indicator nears the red section, according to the DCD 280-500 technical handbook (2001 edition), as HIT SRL's technical desk reads it. The handbook always changes them before the indicator shows red, when the return oil reaches the tank unfiltered. The handbook describes them as fitted to some trucks only, in the hydraulic tank.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-return-filters-280-500 · HIT ref KDCD-100 · fingerprint 07b7f7 · see HIT ref KDCD-098, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-fluid-280-500
Kalmar DCD 180-250: how much hydraulic fluid is used and with what additive?
350 l for the trucks designated 20-25-1200 and 270 l for those printed as 28-1200, according to the DCD 180-250 technical handbook (1997 edition), as set out in the HIT SRL technical cards. The handbook uses a hydraulic fluid for mobile applications in SH 32, SH 46 or SH 68 by operating temperature, the HIT SRL technical desk notes. The handbook requires 6% Lubrizol additive at all times, which it links to satisfactory performance of the brake system, and also allows SAE 10 engine oil.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-fluid-180-250 · HIT ref KDCD-101 · fingerprint 553fdd · see HIT ref KDCD-102, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-high-pressure-filters-180-250
Kalmar DCD 180-250: how are the hydraulic high-pressure filters built?
Two filters sit immediately after the pumps, each with a 25 µ absolute fibreglass cartridge, according to the DCD 180-250 technical handbook (1997 edition), as logged by the HIT SRL technical desk. A valve in the filter head opens at 5 bar, and the filter bowl is tightened to 140 Nm, according to the handbook, as recorded at HIT SRL. The handbook changes the cartridge at 1000 hours, after any work on the hydraulic system and whenever a pump has been exchanged.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-high-pressure-filters-180-250 · HIT ref KDCD-102 · fingerprint 0eb30c · see HIT ref KDCD-101, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-hydraulic-fluid-180-250
Kalmar DCD 180-250: what does the lowering brake valve do?
It keeps the lowering speed constant whatever the load, at a fixed 0.40 m/s, according to the DCD 180-250 technical handbook (1997 edition), as recorded by the HIT SRL technical desk. The handbook fits one preset, non-adjustable, pressure-compensated valve at the bottom of each lifting cylinder, and the valve limits the flow of fluid if a hose fails, as HIT SRL's technical desk reads it. Lowering speeds for a given truck are those printed in the manual of each machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-lowering-brake-valve-180-250 · HIT ref KDCD-103 · fingerprint 69a5a4 · see HIT ref KDCD-102, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/hydraulics/#hit-dcd-high-pressure-filters-180-250