Kalmar DCD — Maintenance intervals: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the service schedules, supervision, lubrication and checks 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 does the daily inspection cover?
A walk-round check before every shift for leaks, loose wheel nuts, rims, tyres, mast, chains and lights, plus the fluid levels and the air filter indicator, according to the operator's manual (series 2), as logged by the HIT SRL technical desk. The manual then tests the brakes slowly with at least three applications, the steering and all gears, and runs every hydraulic cylinder to its end positions, as recorded at HIT SRL. The technical handbook (series 3) has its own daily chart, to be done daily or at refuelling.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-daily-inspection-200-300 · HIT ref KDCD-134 · fingerprint 4ed319 · see HIT ref KDCD-135, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-running-in-200-300
Kalmar DCD 200-300: how long is the running-in period?
50 operating hours, with the load increased gradually during that time, according to the operator's manual (series 2), as recorded at HIT SRL. The DCD 90-180 instruction manual gives the same 50 hours without full load and recommends extending running-in to 200 hours. The technical handbook (series 3) also places a warranty service at 50 hours, with oil changes and all filters.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-running-in-200-300 · HIT ref KDCD-135 · fingerprint b0d8ec · see HIT ref KDCD-136, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-check-after-50-hours
Kalmar DCD 200-300: what does the 50-hour check of a new machine include?
A change of the engine oil and oil filter, the transmission oil filter, the drive axle oil and the hydraulic high-pressure filter, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. The same check verifies that no error codes are active and carries out the 500-hour lubrication, according to the manual. The manual schedules it after the first 50 operating hours.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-check-after-50-hours · HIT ref KDCD-136 · fingerprint 218496 · see HIT ref KDCD-137, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-warranty-service-50-hours
Kalmar DCD 180-250 and DCD 280-500: what does the 50-hour warranty service include?
The 200-hour service plus oil changes in the engine, gearbox, rotator reduction gear and top-lift reduction gear, according to the DCD 180-250 technical handbook (1997 edition) and the DCD 280-500 technical handbook (2001 edition), the HIT SRL technical desk notes. Both handbooks change all engine, gearbox and hydraulic filters, wet disc brake and servo filters included, adjust the engine valve clearance and check all bolted joints, as set out in the HIT SRL technical cards. The 1997 handbook also fills in the control chart of the warranty certificate at this service.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-warranty-service-50-hours · HIT ref KDCD-137 · fingerprint d824b8 · see HIT ref KDCD-136, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-check-after-50-hours
Kalmar DCD 200-300: how is the 500-hour service schedule organised?
Into 500-hour, 1000-hour and 2000-hour services, according to the maintenance manual (series 1), as recorded at HIT SRL. In that manual the 500-hour work falls at 500, 1500 and 2500 hours and so on, the 1000-hour work at odd thousands such as 1000, 3000 and 5000 hours, and the 2000-hour work at even thousands, as logged by the HIT SRL technical desk. The operator's manual (series 2) also brings the machine in every 500 hours, while the technical handbook (series 3) schedules supervision at 200, 600 and 1000 hours.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-service-every-500-hours · HIT ref KDCD-138 · fingerprint 4b0f36 · see HIT ref KDCD-139, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-supervision-200-600-1000
Kalmar DCD 200-300: how does the technical handbook schedule periodic supervision?
Every 200, 600 and 1000 operating hours, according to the technical handbook (series 3), as HIT SRL's technical desk reads it. The handbook advises doing a 1000-hour service in the order 1000-hour, 600-hour, then 200-hour work. The DCD 180-250 and DCD 280-500 handbooks give the same intervals and the same order, which also applies to the 600-hour service.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-supervision-200-600-1000 · HIT ref KDCD-139 · fingerprint 07e0ee · see HIT ref KDCD-138, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-service-every-500-hours
Kalmar DCD 200-300: when should the lubrication interval be shortened?
In conditions other than normal handling and environment, for example cold, heat or dust, the maintenance manual (series 1) recommends halving the lubrication interval, as set out in the HIT SRL technical cards. The manual bases the interval on the recommended grades and quantities. It states that the interval must never exceed 12 months.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-lubrication-interval-rule · HIT ref KDCD-140 · fingerprint 56af41 · see HIT ref KDCD-148, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-mast-lubrication-interval
Kalmar DCD 200-300: how often is the engine oil changed?
At every 500-hour service, together with the engine oil filters, on both the Volvo and the Cummins engine of the maintenance manual (series 1), as logged by the HIT SRL technical desk. That manual assumes fuel with no more than 0.5% sulphur for this interval, as recorded at HIT SRL. The technical handbook (series 3) changes the engine oil every 200 hours and allows longer intervals only with regular oil analysis by the oil supplier.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-engine-oil-interval · HIT ref KDCD-141 · fingerprint 3f1871 · see HIT ref KDCD-142, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-engine-oil-filter-interval
Kalmar DCD 200-300: when does the technical handbook change the engine oil filter?
Its lubrication chart places the engine oil filter in the 600-hour column, while the remark on the same line reads filter change every 400 hours, according to the technical handbook (series 3), as recorded by the HIT SRL technical desk. The DCD 180-250 and DCD 280-500 handbooks and the DCD 90-180 instruction manual show the same mismatch between column and remark, as HIT SRL's technical desk reads it. A machine follows the interval printed in its own maintenance manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-engine-oil-filter-interval · HIT ref KDCD-142 · fingerprint 358d98 · see HIT ref KDCD-141, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-engine-oil-interval
Kalmar DCD 200-300: how often are the transmission oil and filter changed?
Both every 1000 hours, at the 1000-hour and 2000-hour services, with the oil checked at the 500-hour service, according to the maintenance manual (series 1), the HIT SRL technical desk notes. That manual also recommends calibrating the transmission every 1000 hours and after every oil change, as set out in the HIT SRL technical cards. The technical handbook (series 3) changes the oil every 1000 hours too but the filter every 600 hours, with the level checked every 200 hours at idle.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-transmission-oil-and-filter-intervals · HIT ref KDCD-143 · fingerprint 79e42f · see HIT ref KDCD-144, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-drive-axle-oil-interval
Kalmar DCD 200-300: how often is the drive axle oil changed?
Every 1000 hours in the differential and both hub reductions, drained at working temperature, according to the lubrication chart of the technical handbook (series 3), as recorded at HIT SRL. The chart checks the level after refilling and every 200 hours, as logged by the HIT SRL technical desk. The maintenance manual (series 1) also changes it every 1000 hours, with the first change at the 50-hour check.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-drive-axle-oil-interval · HIT ref KDCD-144 · fingerprint 51bb57 · see HIT ref KDCD-143, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-transmission-oil-and-filter-intervals
Kalmar DCD 200-300: when are the hydraulic filters changed?
Every 1000 hours for the two high-pressure filters and the hydraulic tank breather filter, according to the technical handbook (series 3), as HIT SRL's technical desk reads it. The handbook also changes the high-pressure filters whenever work has been done on the hydraulic system. The maintenance manual (series 1) gives the same 1000 hours and changes the high-pressure filter at the 50-hour check as well.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-hydraulic-filters-interval · HIT ref KDCD-145 · fingerprint 53a991 · see HIT ref KDCD-146, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-hydraulic-oil-interval
Kalmar DCD 200-300: how often is the hydraulic oil changed?
From 2000 hours the oil is judged by samples and changed at 4000 hours at the latest, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. In that manual a good sample at 2000 hours allows another 1000 hours, and a good sample at 3000 hours a further 1000 hours, with 3% Lubrizol added at each change and a threshold of 18/14 to SS-ISO 4406, the HIT SRL technical desk notes. The technical handbook (series 3) simply changes the hydraulic oil every 2000 hours.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-hydraulic-oil-interval · HIT ref KDCD-146 · fingerprint b1821c · see HIT ref KDCD-145, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-hydraulic-filters-interval
Kalmar DCD 200-300: how often are the steered wheel bearings serviced?
Every 4000 hours the steered wheel bearings and the knuckle pin bearings are dismantled, cleaned, inspected and repacked with grease, according to the technical handbook (series 3), as logged by the HIT SRL technical desk. The DCD 180-250 and DCD 280-500 handbooks and the DCD 90-180 instruction manual give the same 4000 hours.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-wheel-bearings-4000-hours · HIT ref KDCD-147 · fingerprint e021d3 · see HIT ref KDCD-151, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-wheel-nuts-retightening
Kalmar DCD 200-300: how often is the mast lubricated?
At every 500-hour lubrication, with the mast raised and securely supported and the engine stopped, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. That manual greases slide plates, support rollers, chain wheels and mast wheels, oils the chains and first relieves the mast anchorage of load, with a jack under the mast or by tilting it back onto a support, as HIT SRL's technical desk reads it. The technical handbook (series 3) puts the tilt cylinder bearings, the chains, the rollers and the relieved mast suspension in its 200-hour column.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-mast-lubrication-interval · HIT ref KDCD-148 · fingerprint eea654 · see HIT ref KDCD-149, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-lifting-chain-check-interval
Kalmar DCD 200-300: how often are the lifting chains checked?
At every 500-hour service, when they are checked for damage and tensioned if necessary, according to the maintenance manual (series 1), the HIT SRL technical desk notes. For the check the manual cleans them along their whole length, checks them with no load on the forks and then greases them. The technical handbook (series 3) inspects the chains at every 1000-hour service instead.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-lifting-chain-check-interval · HIT ref KDCD-149 · fingerprint 156fa4 · see HIT ref KDCD-148, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-mast-lubrication-interval
Kalmar DCD 200-300: how often is the coolant changed?
After 5000 hours with the Volvo TAD750VE and after 2000 hours with the Cummins QSB6.7, according to the maintenance manual (series 1), as recorded at HIT SRL. That manual checks and cleans the cooling system at each change and checks the coolant level and freezing point at every service, as logged by the HIT SRL technical desk. The technical handbook (series 3) changes the coolant and flushes the cooling system once a year.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-coolant-change-intervals · HIT ref KDCD-150 · fingerprint 58da09 · see HIT ref KDCD-141, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-engine-oil-interval
Kalmar DCD 200-300: when are the wheel nuts check-tightened?
On a new machine every 4-5 operating hours during the first working week, up to about 40-50 operating hours, until they stay securely tightened, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. The operator's manual (series 2) check-tightens the nuts of a newly fitted wheel crosswise after 4-5 operating hours. The technical handbook (series 3) retightens the wheel nuts at every 200-hour service.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-wheel-nuts-retightening · HIT ref KDCD-151 · fingerprint 4a7c2b · see HIT ref KDCD-147, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-wheel-bearings-4000-hours
Kalmar DCD 200-300: when is the wet disc brake system checked?
At every 600-hour service, parking brake included, according to the technical handbook (series 3), as set out in the HIT SRL technical cards. The handbook's 200-hour list adds a leak check and a braking test. The DCD 180-250 and DCD 280-500 handbooks give the same 600-hour brake check.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-brake-check-600-hours · HIT ref KDCD-152 · fingerprint 4ace89 · see HIT ref KDCD-151, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-wheel-nuts-retightening
Kalmar DCD 200-300: what fuel system work is due at 1000 hours?
Draining the fuel tank, changing the fuel filter with the fuel system bled and checking the injectors, according to the technical handbook (series 3), as logged by the HIT SRL technical desk. The handbook's 1000-hour list also checks the valve clearances, the cooling system, starter motor, alternator, fuses, belts, batteries and the air conditioning refrigerant level, as recorded at HIT SRL. The maintenance manual (series 1) also changes the fuel filter every 1000 hours.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-fuel-system-1000-hours · HIT ref KDCD-153 · fingerprint e21c98 · see HIT ref KDCD-154, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-valve-clearance-intervals
Kalmar DCD 200-300: how often is the valve clearance checked?
Every 2000 hours on the Volvo TAD750VE, and after 250 hours on a newly reconditioned engine, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. The manual leaves this work, like the injector and turbo checks of the same service, to an authorised Volvo Penta workshop, as HIT SRL's technical desk reads it. On the Cummins QSB6.7 the same manual checks and adjusts the clearance after 5000 hours or every four years, while the technical handbook (series 3) checks it at the 1000-hour service.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-valve-clearance-intervals · HIT ref KDCD-154 · fingerprint e28350 · see HIT ref KDCD-153, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-fuel-system-1000-hours
Kalmar DCD 200-300: how often are the welds checked for cracks?
Every 4000 operating hours or every year for a machine in normal material handling on a flat floor, according to the maintenance manual (series 1), the HIT SRL technical desk notes. The manual shortens the interval for other work, for example on rough ground, as set out in the HIT SRL technical cards. The manual checks most carefully the mast, tilt, drive axle and steering axle anchorages, the forks, the lifting equipment, the counterweight anchorage to the frame and the joint between the frame sides and the rear section.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-weld-crack-check · HIT ref KDCD-155 · fingerprint c0c3fc · see HIT ref KDCD-140, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-lubrication-interval-rule
Kalmar DCD 200-300: how are the belt tensioner and vibration damper of the Cummins QSB6.7 checked?
The drive belt tensioner and the fan hub after 1000 hours or every year, the viscous vibration damper after 2000 hours or every two years, according to the maintenance manual (series 1), as recorded at HIT SRL. On the damper the manual looks for fluid loss, dents, wobble and any deformation or raising of the damper's cover plate, as logged by the HIT SRL technical desk. The manual also states that the silicone fluid of the damper solidifies after long service.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-qsb67-belt-and-damper · HIT ref KDCD-156 · fingerprint 78c67d · see HIT ref KDCD-154, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-valve-clearance-intervals
Kalmar DCD 200-300: what does the central lubrication system cover?
14 grease points in the basic layout, 8 in the steering and 6 on the mast, which is the only layout for the manual system, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. The automatic system can have 18 points, with 4 more on the vehicle, or 23 points, with 9 more on the vehicle and a centre-levelling carriage, according to the manual, as recorded by the HIT SRL technical desk. The manual leaves out the propeller shaft universal joint, the brake pedal, the fork shanks, the mast wheels and the support rollers, which are still lubricated at preventive maintenance.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-central-lubrication · HIT ref KDCD-157 · fingerprint 67f532 · see HIT ref KDCD-140, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-lubrication-interval-rule
Kalmar DCD 180-250: what does the daily supervision chart include?
Function tests of brakes, steering, instruments, lights and horn, of lift, tilt, sideshift and fork positioning, according to the daily supervision chart of the DCD 180-250 technical handbook (1997 edition), as set out in the HIT SRL technical cards. The chart checks the lifting chains for damage, the hoses for leaks and engine, gearbox and drive axle for noises, and runs all hydraulic functions to their stops for cylinder lubrication, the HIT SRL technical desk notes. The chart also checks the levels of fuel, engine oil, coolant, hydraulic fluid, gearbox oil and washer fluid, the air cleaner indicator and the tyre pressure, some of them also at every refuelling.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-daily-supervision-180-250 · HIT ref KDCD-158 · fingerprint 6b531e · see HIT ref KDCD-159, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-every-200-hours-180-250
Kalmar DCD 180-250: what does the 200-hour service include?
Washing the truck and cleaning the radiator fins with water and detergent, without high pressure on bearings or radiator, according to the DCD 180-250 technical handbook (1997 edition), as logged by the HIT SRL technical desk. The handbook retightens the wheel nuts and the bolted joints of mast, drive axle and propeller shaft, cleans the battery terminals and coats them with petroleum jelly and tests the brakes, as recorded at HIT SRL. The handbook also checks the V-belt tension, the air cleaner indicator, the steering axle play and the inductive sensors, and the exhaust catalyst where fitted.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-every-200-hours-180-250 · HIT ref KDCD-159 · fingerprint 8d1050 · see HIT ref KDCD-158, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-daily-supervision-180-250
Kalmar DCD 180-250: what does the 600-hour service add?
An air cleaner element change if the indicator shows red, on top of the 200-hour work, according to the DCD 180-250 technical handbook (1997 edition), as recorded by the HIT SRL technical desk. The handbook checks turbocharger and exhaust system for leaks, the steered wheels for alignment, deformation and bearing play, and the mast hose guide pulleys, hoses and forks for damage and wear, as HIT SRL's technical desk reads it. The same handbook also has the chains washed, lubricated and adjusted for length, and the wet disc brake tested with the parking brake.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-every-600-hours-180-250 · HIT ref KDCD-160 · fingerprint 509737 · see HIT ref KDCD-161, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-every-1000-hours-180-250
Kalmar DCD 180-250: what does the 1000-hour service add?
A new cab filter element and checks of the engine cooling system, starter motor, alternator and fuses, on top of the 600- and 200-hour work, according to the DCD 180-250 technical handbook (1997 edition), the HIT SRL technical desk notes. The handbook checks the V-belts, batteries, wheels, propeller shaft bolted joints, universal joint play and lifting chains, and cleans the transmission and drive axle breather filters, as set out in the HIT SRL technical cards. The same handbook touches up paint and safety markings, checks the air conditioning refrigerant level and ends with a test drive of all functions.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-every-1000-hours-180-250 · HIT ref KDCD-161 · fingerprint b4e927 · see HIT ref KDCD-160, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/maintenance-intervals/#hit-dcd-every-600-hours-180-250