Kalmar DCD — Related models: safety and service: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the operation, safety and service rules for the related DCD 90-180 and DCD 70 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 90-180: what does the operator's daily supervision cover?
Brakes, steering, direction indicators, horn, brake lights and headlights in operation, the mast chains, links and suspension for damage and every hydraulic function run to its end position, according to the DCD 90-180 instruction manual (2002 edition), the HIT SRL technical desk notes. The manual also checks engine, gearbox, drive axle and hoses for noise and leaks, drains water from the fuel filter water separator where fitted and checks the fuel and engine oil levels, as set out in the HIT SRL technical cards. The air cleaner indicator, the coolant, hydraulic oil, gearbox oil and washer fluid levels and the tyre pressures may be checked daily or at refuelling, according to the manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-daily-supervision · HIT ref KDCD-239 · fingerprint e4e08c · see HIT ref KDCD-240, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-service-interval
Kalmar DCD 90-180: how often does the truck go in for service?
Every 200 operating hours counted on the hour meter, according to the DCD 90-180 instruction manual (2002 edition), as recorded at HIT SRL. The manual leaves periodic supervision to specially trained service personnel and makes the operator responsible for having the truck available. The periodic programme itself is not in this manual, which refers to the technical handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-service-interval · HIT ref KDCD-240 · fingerprint b6406e · see HIT ref KDCD-239, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-daily-supervision
Kalmar DCD 90-180: how is a new truck run in?
Without full load during the first 50 hours and with the load increased gradually after that, according to the DCD 90-180 instruction manual (2002 edition), as recorded by the HIT SRL technical desk. The manual recommends extending running-in to 200 hours and calls for a guarantee service after 50 hours by the manufacturer or by personnel it authorises, as HIT SRL's technical desk reads it. During running-in the wheel nuts and propeller shaft nuts are tightened after 8, 16 and 24 operating hours, the wheel nuts in a zig-zag sequence, and again every time a wheel has been changed, according to the manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-running-in · HIT ref KDCD-241 · fingerprint aa8e96 · see HIT ref KDCD-240, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-service-interval
Kalmar DCD 90-180: how often are the engine oil and filter changed?
The oil every 200 hours on the Volvo and Perkins engines and every 250 hours on the Cummins, according to the lubrication chart of the DCD 90-180 instruction manual (2002 edition), the HIT SRL technical desk notes. The chart changes the filter every 200 hours on the Perkins, every 250 hours on the Cummins and every 400 hours on the Volvo, whose mark nevertheless sits in the 600-hour column, as set out in the HIT SRL technical cards. Intervals longer than 200 hours need regular oil tests by the company making the oil, according to the chart.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-engine-oil-and-filter · HIT ref KDCD-242 · fingerprint 12f393 · see HIT ref KDCD-243, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-drive-axle-first-oil
Kalmar DCD 90-180: when is the drive axle oil first changed?
At most 200 hours after the truck is first put into operation, according to the lubrication chart of the DCD 90-180 instruction manual (2002 edition), as recorded at HIT SRL. The chart checks the axle oil level every 200 hours. Later changes come every 1000 hours, according to the same chart.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-drive-axle-first-oil · HIT ref KDCD-243 · fingerprint 96d207 · see HIT ref KDCD-242, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-engine-oil-and-filter
Kalmar DCD 90-180 and DCD 70: how often are the side-lift twist-locks overhauled?
Every 2000 hours the twist-locks are dismantled, checked for wear, cleaned and packed with grease, with worn components changed, according to the side-lift lubrication chart of the DCD 90-180 instruction manual (2002 edition), as HIT SRL's technical desk reads it. The chart does the same whenever damage to the twist-locks is suspected, as recorded by the HIT SRL technical desk. Every 500 hours the same chart greases the sliding surfaces with the attachment fully extended, the length adjustment and locking cylinders, the lifting pinion with its mounting and the contact pin, keeping the sensors clean of grease, and checks the pinion at 1000 hours.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-70-twist-lock-overhaul · HIT ref KDCD-244 · fingerprint 1d1c92 · see HIT ref KDCD-253, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-70-side-lift-pick-up
Kalmar DCD 90-180: how is the engine started in cold weather?
Below +5 °C the key is held in the preheat position for about 50 seconds before starting, according to the DCD 90-180 instruction manual (2002 edition), as set out in the HIT SRL technical cards. The manual limits each starting attempt to 10 seconds, with 15 to 20 seconds between attempts, and forbids starting spray, naming a risk of explosion, the HIT SRL technical desk notes. The manual warms the engine at 1400-1500 r/min, uses the truck only at about 80 °C of coolant and starts it only with the gear lever in neutral.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-starting · HIT ref KDCD-245 · fingerprint eda392 · see HIT ref KDCD-246, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-fuel-bleeding
Kalmar DCD 90-180: how is the fuel system bled after running dry?
On the Volvo and Cummins engines the filter bleed screw is backed off half a turn and the hand pump worked until the fuel runs free of air, according to the DCD 90-180 instruction manual (2002 edition), as logged by the HIT SRL technical desk. The manual then runs the starter in bursts of 20-30 seconds with short pauses, and the engine starts after 2-3 minutes, as recorded at HIT SRL. On the Perkins engines the starter runs in 10-second bursts after pumping, and on the TWD engines the hand pump lever is unlocked before and tightened after, according to the manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-fuel-bleeding · HIT ref KDCD-246 · fingerprint 225026 · see HIT ref KDCD-245, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-starting
Kalmar DCD 90-180: how should the operator react to the warning lamps?
A lamp shows a fault with a steady light and a buzzer, and the truck must never be used with the charging lamp lit, according to the DCD 90-180 instruction manual (2002 edition), as recorded by the HIT SRL technical desk. The manual stops the truck at once if the engine oil pressure lamp lights while travelling or the gearbox oil pressure lamp lights in operation, and stops it if the gearbox oil temperature lamp shows oil above 120 °C, as HIT SRL's technical desk reads it. The low brake pressure lamp lights below 100 bar of accumulator pressure, with braking capacity left for a number of applications, according to the manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-warning-lamps · HIT ref KDCD-247 · fingerprint 91fbbb · see HIT ref KDCD-245, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-starting
Kalmar DCD 90-180: how should the truck be driven in turns?
Always slowing down, never accelerating or braking hard, according to the DCD 90-180 instruction manual (2002 edition), which links this to the risk of lateral skidding or tipping, the HIT SRL technical desk notes. The manual adapts the speed to the load, the visibility and the ground, and with mirrors or cameras to the reduced visibility, as set out in the HIT SRL technical cards. Cornering rules for a given truck sit in its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-turning-speed · HIT ref KDCD-248 · fingerprint 2362d1 · see HIT ref KDCD-249, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-high-loads
Kalmar DCD 90-180: what does the manual say about raised heavy loads?
Heavy loads must not be driven in highly raised positions, which the DCD 90-180 instruction manual (2002 edition) says harms lateral stability and may also tip the truck forward, as recorded at HIT SRL. The manual forbids handling unstable or loosely loaded goods, and if the truck leans to one side it has the load lowered and the forks sideshifted until the load's centre of gravity is on the truck's centre line, as logged by the HIT SRL technical desk. Where needed, the maximum capacity is read from the load centre on the load diagram in the cab, according to the manual. Capacity limits for a particular truck come from its load diagram and the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-high-loads · HIT ref KDCD-249 · fingerprint 5b1ff8 · see HIT ref KDCD-248, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-turning-speed
Kalmar DCD 90-180: what does the manual say about overhead power lines?
Extreme care near overhead high-tension lines, particularly with the reach of the mast, forks and any attachment, according to the DCD 90-180 instruction manual (2002 edition), as HIT SRL's technical desk reads it. After contact with a line the manual has the operator stay seated in the cab and call for help, warning that leaving the cab is extremely dangerous with the risk of being earthed on touching the ground, as recorded by the HIT SRL technical desk. The manual adds that the wide side-lift must not strike poles and overhead lines. Precautions near lines on a given truck are those of the manual that comes with the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-power-lines · HIT ref KDCD-250 · fingerprint 1ba09f · see HIT ref KDCD-249, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-high-loads
Kalmar DCD 90-180: how is the cab tilted safely?
With the gear lever in neutral, the mast tilted forward, the parking brake applied, loose objects removed, the doors closed and the two cab latches released, according to the DCD 90-180 instruction manual (2002 edition), as set out in the HIT SRL technical cards. The manual tilts the cab with a hand pump or an optional electric pump and always tips it past its point of balance or, with too little room at the side, secures it against accidental lowering with a brace or similar support, the HIT SRL technical desk notes. On return the two latches are turned down to lock the cab to the frame, according to the manual. Before the cab of any truck is raised, the procedure is checked in the manual for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-cab-tilting · HIT ref KDCD-251 · fingerprint ac0ac4 · see HIT ref KDCD-258, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-parking-and-stopping
Kalmar DCD 90-180 and DCD 70: how is the truck driven with the side-lift for empty containers?
With the mast tilted fully back in every phase of driving, according to the DCD 90-180 instruction manual (2002 edition), as logged by the HIT SRL technical desk. The manual allows the side-lift, loaded or empty, above the driving position of its illustration only when stacking, and requires it back in the driving position after stacking before the truck moves again, as recorded at HIT SRL. The manual asks for smooth, careful braking at all times and refers to EN 1551 on that page. Side-lift driving on a given truck follows the specific machine's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-70-side-lift-driving · HIT ref KDCD-252 · fingerprint 14b59a · see HIT ref KDCD-253, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-70-side-lift-pick-up
Kalmar DCD 90-180 and DCD 70: how is an empty container picked up with the side-lift?
By setting the side-lift length, tilting the mast about 2° forward and lowering the side-lift onto the container until the orange alignment lamp lights, according to the DCD 90-180 instruction manual (2002 edition), as recorded by the HIT SRL technical desk. The manual then locks the twist-locks, checks that the green lamp lights, tilts back and lifts until the alignment lamp goes out, as HIT SRL's technical desk reads it. On release the alignment lamp must light before the twist-locks are unlocked and the red lamp after, with the lamps both on the attachment and in the cab, according to the manual. The lamp sequence for a given truck is the one in the manual of each machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-70-side-lift-pick-up · HIT ref KDCD-253 · fingerprint c07bef · see HIT ref KDCD-252, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-70-side-lift-driving
Kalmar DCD 90-180: how is the truck towed?
With the propeller shaft disconnected for longer distances or above 10 km/h and a towing vehicle at least as heavy as the truck, with enough engine and brake capacity, according to the DCD 90-180 instruction manual (2002 edition), the HIT SRL technical desk notes. The manual uses a tow bar on the rear towing hitch when the engine cannot run and applies the parking brake with the wheels chocked before preparations begin and after towing ends, as set out in the HIT SRL technical cards. The manual keeps the engine running where possible, tows only very short distances and never starts the truck by towing. For each truck the towing limits come from its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-towing · HIT ref KDCD-254 · fingerprint 6f0bcb · see HIT ref KDCD-255, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-parking-brake-release
Kalmar DCD 90-180: how is the parking brake released to move the truck?
By loosening the lock nut and screwing the adjusting screw out anticlockwise, according to the DCD 90-180 instruction manual (2002 edition), as recorded at HIT SRL. The manual applies the spring brake automatically when the accumulator pressure drops and has the wheels chocked on sloping ground, as logged by the HIT SRL technical desk. The adjusting screw must always be reset afterwards to restore the parking brake function, according to the manual. On any truck, the brake release follows the steps of the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-parking-brake-release · HIT ref KDCD-255 · fingerprint dcd6d4 · see HIT ref KDCD-254, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-towing
Kalmar DCD 90-180: how is the truck lifted?
By optional eyebolts, two on the mast and two on the counterweight, with the lifting point over the centre of gravity of the truck, according to the DCD 90-180 instruction manual (2002 edition), as HIT SRL's technical desk reads it. Without eyebolts the manual uses one sling round the rear of the chassis between counterweight and steered axle and two slings in the upper mast yoke, one in each lifting cylinder space, as recorded by the HIT SRL technical desk. The lifting method for a given truck 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/related-models-safety-and-service/#hit-dcd-dcd-90-180-lifting-the-truck · HIT ref KDCD-256 · fingerprint 706694 · see HIT ref KDCD-254, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-towing
Kalmar DCD 90-180: what does the manual say about the brake accumulator?
It is nitrogen-charged and holds up to 210 bar, according to the DCD 90-180 instruction manual (2002 edition), as set out in the HIT SRL technical cards. The manual always releases its pressure through the quick-evacuation valve before any component of the system is removed, the HIT SRL technical desk notes. Recharging is for authorised service personnel with approved equipment, and the manual gives a test of six brake applications. Accumulator work on a given truck follows that machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-brake-accumulator · HIT ref KDCD-257 · fingerprint d621bc · see HIT ref KDCD-247, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-warning-lamps
Kalmar DCD 90-180: how is the truck parked and stopped?
With the parking brake applied, the mast tilted slightly forward, the forks lowered to the ground and neutral selected, according to the DCD 90-180 instruction manual (2002 edition), as logged by the HIT SRL technical desk. The manual lets the engine idle for 1/2-1 minute before stopping it and turns the main switch off when the truck will stand unused for a longer period, never with the engine running, as recorded at HIT SRL. A buzzer sounds if the operator leaves the seat without the parking brake, and the key comes out when the truck is left unattended, according to the manual. Shutdown details vary from truck to truck and are set out in the manual of each machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-parking-and-stopping · HIT ref KDCD-258 · fingerprint d92a6a · see HIT ref KDCD-251, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-cab-tilting
Kalmar DCD 90-180: what battery safety rules does the manual give?
Batteries are isolated for work on the electrical system, for welding on the truck and for long parking, according to the DCD 90-180 instruction manual (2002 edition), as recorded by the HIT SRL technical desk. The manual warns that batteries give off explosive oxyhydrogen gas and that a spark, for example from wrongly connected starting cables, could make a battery explode, as HIT SRL's technical desk reads it. Electrolyte, which contains sulphuric acid, is washed off the skin at once with soap and plenty of water, with eyes rinsed and a doctor contacted immediately, according to the manual. Battery handling on a particular truck follows the specific machine's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-battery-safety · HIT ref KDCD-259 · fingerprint ac5dc9 · see HIT ref KDCD-258, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-parking-and-stopping
Kalmar DCD 90-180: how is a tyre inflated safely?
With the wheel locking ring checked in its correct position first, according to the DCD 90-180 instruction manual (2002 edition), the HIT SRL technical desk notes. A tyre that has been completely deflated means the wheel is dismantled and checked for damage, and the person inflating connects the hose with a grip nozzle and stands to the side for the whole operation, never exceeding the recommended pressure, according to the manual, as set out in the HIT SRL technical cards. The manual fits a water separator filter on the compressor line, to be drained often. Inflation pressures for a given truck are those in its own maintenance manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-tyre-inflation · HIT ref KDCD-260 · fingerprint 685552 · see HIT ref KDCD-259, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-battery-safety
Kalmar DCD 90-180: which standards does the truck meet?
CE marking with EN1551, ASME B56.1 for the USA on trucks up to 13.6 tonnes and EN12895 for the European EMC test, according to the manufacturer's DCD 90-180 technical information brochure, as recorded at HIT SRL. The brochure's data table answers yes to stability to ISO 1074/10525 for every model, as logged by the HIT SRL technical desk. The DCD 90-180 instruction manual (2002 edition) makes it a strict requirement that a truck used in highly inflammable environments, such as explosive environments, be designed, built and equipped to EN 1755. Use in such settings follows the manual for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-standards · HIT ref KDCD-261 · fingerprint 766900 · see HIT ref KDCD-260, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/related-models-safety-and-service/#hit-dcd-dcd-90-180-tyre-inflation