Kalmar DCD — Mast, forks, attachments and cab: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the lift mast, chains, forks, side lift and Gantry attachments and cab 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 mast and carriage does the machine use?
A clear-view duplex or triplex mast, with or without free lift, raised by two lifting cylinders on the outer mast, according to the technical handbook (series 3), as logged by the HIT SRL technical desk. The handbook tilts it 5° forward and 10° back, with back-pressure valves in the tilt cylinders, as recorded at HIT SRL. The fork carriage has hydraulic fork positioning and sideshift, and the operator's manual (series 2) mentions forks on rollers with pin or hook fork mounting on request.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-mast-and-carriage-200-300 · HIT ref KDCD-104 · fingerprint a1cf30 · see HIT ref KDCD-105, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-brochure-mast-heights-200-250
Kalmar DCD 200-250: what mast heights does the brochure give?
A lowered height of 3820 mm and an extended height of 5820 mm at a 4000 mm lift height for the standard duplex clear-view mast, rising to 5320 mm and 8820 mm at 7000 mm, according to the manufacturer's DCD brochure, as recorded by the HIT SRL technical desk. The brochure gives the duplex free-lift mast 2000 to 3500 mm of free lift over the same lift heights, as HIT SRL's technical desk reads it. The same table also covers the DCD 280-320, 370-450 and 500.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-brochure-mast-heights-200-250 · HIT ref KDCD-105 · fingerprint 8add6f · see HIT ref KDCD-104, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-mast-and-carriage-200-300
Kalmar DCD 200-300: when is a lifting chain replaced?
When its extension exceeds 3%, measured over the 25 links that run most often over the guide sprocket, according to the technical handbook (series 3), as recorded at HIT SRL. The handbook replaces such a chain whole and never joins or re-rivets it, as logged by the HIT SRL technical desk. Its table gives, for a 1-inch pitch, 635 mm new and 654 mm at 3% over 25 links, and the maintenance manual (series 1) uses the same 3% limit.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-lifting-chain-extension · HIT ref KDCD-106 · fingerprint 38fd76 · see HIT ref KDCD-107, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-fork-wear-and-inspection
Kalmar DCD 200-300: what fork wear is allowed?
No more than 10% of the original dimension, measured 150 mm from the heel, according to the technical handbook (series 3), as HIT SRL's technical desk reads it. The handbook accepts no cracks visible to the naked eye and forbids repairing cracks or wear by welding, as recorded by the HIT SRL technical desk. The same handbook has the forks inspected by specially trained personnel at least once a year.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-fork-wear-and-inspection · HIT ref KDCD-107 · fingerprint ed2462 · see HIT ref KDCD-109, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-damaged-forks
Kalmar DCD 200-300: how far above the ground should the lowered forks stand?
25 mm with the mast vertical and the forks fully lowered, according to the technical handbook (series 3), as set out in the HIT SRL technical cards. The maintenance manual (series 1) gives 10-20 mm with the machine on a level floor, the HIT SRL technical desk notes. Both set the gap by adjusting the two chains equally, and the maintenance manual tightens the chain adjustment nuts to 2000 Nm with new lock washers.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-fork-ground-gap · HIT ref KDCD-108 · fingerprint 3ccd44 · see HIT ref KDCD-106, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-lifting-chain-extension
Kalmar DCD 200-300: can a damaged fork be repaired?
No: damaged lifting forks must be replaced, according to the maintenance manual (series 1), which warns that a repair changes their strength, with the risk of a dropped load and a fatal accident, as logged by the HIT SRL technical desk. A surface crack is ground down about 0.5 mm and, if still visible, tested with magnetic powder by an approved company, according to the same manual, as recorded at HIT SRL. A hot-straightened fork must be heat-treated again by an approved firm, and repairability is decided by the manufacturer or its approved service personnel, according to that manual. The fork rules that apply are those in the specific machine's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-damaged-forks · HIT ref KDCD-109 · fingerprint 961421 · see HIT ref KDCD-107, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-fork-wear-and-inspection
Kalmar DCD 200-300: what do the lights of the lateral lift attachment show?
Green for twistlocks locked, orange for the attachment aligned with the container corners and red for twistlocks unlocked, according to the operator's manual (series 2), as recorded by the HIT SRL technical desk. The cab panel of the same manual shows the alignment light in yellow, and the DCD 180-250 technical handbook (1997 edition) also gives a yellow alignment lamp, as HIT SRL's technical desk reads it. The light convention to rely on is the one in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-lateral-lift-attachment-lights · HIT ref KDCD-110 · fingerprint 01be41 · see HIT ref KDCD-111, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-side-lift-attachment
Kalmar DCD 200-300: how does the side lift attachment work?
Telescopic corner pieces hang from the main beam on springs, giving 195 mm of levelling to each side, and a hydraulic cylinder gives ±600 mm of side-shift, according to the maintenance manual (series 1), the HIT SRL technical desk notes. Its electrical safety system blocks the locking or release of the twistlocks while the attachment is not seated correctly on the container, according to the manual, as set out in the HIT SRL technical cards. Lifting stays blocked until the twistlocks are fully locked or fully released, according to the same manual. Interlocks and lights are those described in the manual for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-side-lift-attachment · HIT ref KDCD-111 · fingerprint 3f2e8c · see HIT ref KDCD-110, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-lateral-lift-attachment-lights
Kalmar DCD 280-500: how is the Gantry top lift built?
On a carriage built into the mast and hung on four hydraulically damped links with a 200 mm reach that compensate for leaning containers, according to the DCD 280-500 technical handbook (2001 edition), as recorded at HIT SRL. The top lift adjusts for 20 ft to 40 ft containers by a hydraulic motor driving two chains, slowing down automatically over the last 200 mm, and side-shifts ±400 mm, according to the handbook, as logged by the HIT SRL technical desk. The handbook gives no capacities or weights for it.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-gantry-top-lift · HIT ref KDCD-112 · fingerprint f61252 · see HIT ref KDCD-114, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-gantry-twist-lock-overhaul
Kalmar DCD 280-500: how is the planetary gear of the Gantry top lift serviced?
It holds 2.4 litres of oil, checked every 200 hours up to the red spot on its sight glass, according to the DCD 280-500 technical handbook (2001 edition), as HIT SRL's technical desk reads it. The handbook changes the oil first at the warranty service and then every 1000 hours. The gear belongs to the hydraulic motor of the length adjustment, according to the same handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-gantry-planetary-gear-oil · HIT ref KDCD-113 · fingerprint 357333 · see HIT ref KDCD-112, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-gantry-top-lift
Kalmar DCD 280-500: how often are the Gantry twist-locks overhauled?
Every 2000 hours the twist-locks of the Gantry top lift are dismantled, checked for wear, cleaned and packed with grease, according to the DCD 280-500 technical handbook (2001 edition), as set out in the HIT SRL technical cards. The handbook does the same whenever damage to them is suspected, the HIT SRL technical desk notes. The handbook greases the locking cylinders and contact pins every 200 hours, keeping the sensors free of grease, and greases the slide pads every 200 hours with graphite grease.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-gantry-twist-lock-overhaul · HIT ref KDCD-114 · fingerprint 57c2b3 · see HIT ref KDCD-115, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-gantry-sensors
Kalmar DCD 280-500: how are the sensors of the Gantry top lift set?
With a 2-3 mm gap to the activator, according to the DCD 280-500 technical handbook (2001 edition), as logged by the HIT SRL technical desk. The handbook uses inductive NPN sensors that switch when a magnetic object comes nearer than 8 mm, with a yellow LED that must light when the sensor is connected to the 24 V system, as recorded at HIT SRL. Grease on a sensor can activate it, and the alignment sensors are set to signal when the contact pin is pressed in 3-4 mm, according to the same handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-gantry-sensors · HIT ref KDCD-115 · fingerprint 62cc16 · see HIT ref KDCD-114, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-gantry-twist-lock-overhaul
Kalmar DCD 180-250: what are the sliding plates of the empty container truck?
Twelve plastic sliding plates in the mast and twelve in the fork carriage take the place of support rollers on the high-lifting empty container truck, according to the DCD 180-250 technical handbook (1997 edition), which names the material ROBALON, as recorded by the HIT SRL technical desk. The handbook lubricates them every 400 hours with a lubricant of an approved brand or of the same specification, as HIT SRL's technical desk reads it. According to the handbook, each plate must protrude at least 3 mm from its frame and keep at least 8 mm of remaining thickness, with at least 5 mm engaged in the frame.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-sliding-plates-180-250 · HIT ref KDCD-116 · fingerprint ff925c · see HIT ref KDCD-104, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-mast-and-carriage-200-300
Kalmar DCD 200-300: what cab does the machine have?
Only the closed Spirit Delta, built on a structural frame to withstand falling loads, according to the operator's manual (series 2), the HIT SRL technical desk notes. The manual gives it a filtered air inlet, recirculation and heating or air conditioning, with a roof window 6 mm thick as standard and 12 mm in the high-strength version, as set out in the HIT SRL technical cards. The technical handbook (series 3) mounts the cab as a separate structure on rubber dampers.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-spirit-delta-cab · HIT ref KDCD-117 · fingerprint 0e4353 · see HIT ref KDCD-119, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-cab-tipping
Kalmar DCD 200-300: what does the maintenance manual say about the cab roof window?
It is a safety component, always made of polycarbonate, according to the maintenance manual (series 1), as recorded at HIT SRL. The manual warns that its strength can drop sharply, without always showing it, after exposure to substances containing aromatic hydrocarbons, ketones, esters or chlorinated hydrocarbons, as logged by the HIT SRL technical desk. It must never be drilled, cut or have its holes widened, and small cracks around the screw holes indicate reduced strength, according to the same manual. A cracked or scratched window is replaced at once, as the manual of each machine requires.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-roof-window · HIT ref KDCD-118 · fingerprint ca2248 · see HIT ref KDCD-117, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-spirit-delta-cab
Kalmar DCD 200-300: how is the cab tipped?
Sideways over its centre of gravity, pivoting on its left-hand mounting, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. The manual raises it with a hydraulic cylinder from a hand pump whose valve is set to the right for tipping and to the left for lowering, with electric tipping as an option, as recorded by the HIT SRL technical desk. Two lock handles hold the cab to the frame on the right-hand side, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-cab-tipping · HIT ref KDCD-119 · fingerprint 3a3963 · see HIT ref KDCD-120, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-work-under-the-cab
Kalmar DCD 200-300: when may someone work under the cab?
Only when the cab is tipped over its balance point or secured in another way, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. Before tipping, the manual puts the gear selector in neutral, tilts the mast forward with the forks lowered, applies the parking brake, removes loose objects from the cab and closes the doors, the HIT SRL technical desk notes. The cab is then tipped fully and held with a stop device, also needed when it is not tipped to the end position or when its mounting is being worked on, according to that manual. Any work under it follows the specific machine's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-work-under-the-cab · HIT ref KDCD-120 · fingerprint c16fb2 · see HIT ref KDCD-119, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-cab-tipping
Kalmar DCD 180-250 and DCD 280-500: how is a tilting cab secured?
It must always be tipped beyond its point of balance or, where there is not enough room at the side, secured against accidental lowering with a brace or similar support, according to the DCD 180-250 technical handbook (1997 edition) and the DCD 280-500 technical handbook (2001 edition), as logged by the HIT SRL technical desk. Both handbooks give the tilting cab to the versions with low-level tilt cylinders, tipped by a hydraulic cylinder and a hand pump with a reversing valve, as recorded at HIT SRL. The 1997 handbook checks the cab tipping pump every 200 hours. Securing the cab follows the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-tilting-cab-180-500 · HIT ref KDCD-121 · fingerprint 5b55c5 · see HIT ref KDCD-120, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/mast-and-forks/#hit-dcd-work-under-the-cab