Kalmar DCD — Transmission, axles and wheels: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the transmissions, drive axles, tyres, rims and wheel nuts 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 transmission does the operator's manual describe?
A mechanical Dana-Spicer Off Highway HR32000 with torque converter and three forward and three reverse gears, according to the operator's manual (series 2), as recorded at HIT SRL. The manual mounts the pumps of the working hydraulics on it and offers automatic shifting as an option, as logged by the HIT SRL technical desk. The technical handbook (series 3) names it Clark 13,7 HR32312 or Clark 32000, with gears in constant mesh, hydraulically operated disc clutches and disengagement by the inching pedal next to the left brake pedal.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-hr32000 · HIT ref KDCD-045 · fingerprint ac5853 · see HIT ref KDCD-046, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-te17000
Kalmar DCD 200-300: which transmission does the maintenance manual describe?
A Dana-Spicer Off Highway TE17000 with torque converter and three gears in each direction, according to the maintenance manual (series 1), the HIT SRL technical desk notes. In that manual all gears are in constant mesh and are engaged by hydraulically pressurised clutch discs through solenoid valves controlled by the ECU 793 control unit, as set out in the HIT SRL technical cards. The forward and reverse clutches are modulated electro-hydraulically, and the manual allows manual or automatic gear changing.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-te17000 · HIT ref KDCD-046 · fingerprint 0c3c70 · see HIT ref KDCD-045, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-hr32000
Kalmar DCD 200-300: which oil does the transmission take?
ATF DEXRON IID or DEXRON III, 32 l for the HR32000, according to the operator's manual (series 2), as recorded by the HIT SRL technical desk. The technical handbook (series 3) instead assigns DEXRON II to the FT20000, HR28000 and HR32000 and DEXRON III to the TE13000 and TE17000, with 32 l in the whole converter and gearbox system, as HIT SRL's technical desk reads it. The oil to use is the one listed for the transmission actually fitted in the manual of each machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-oil-specification-200-300 · HIT ref KDCD-047 · fingerprint 680f38 · see HIT ref KDCD-048, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-te17000-oil-level
Kalmar DCD 200-300: how is the TE17000 oil level checked?
First at idle, at 600 rpm, in neutral against the low mark, then topped up to the MAX mark with the oil at 60-70 °C, according to the maintenance manual (series 1), the HIT SRL technical desk notes. The manual fills the TE17000 with 35 l of ATF DEXRON III and warns that it must not be overfilled, as set out in the HIT SRL technical cards. The technical handbook (series 3) gives 32 l for the whole converter and gearbox system.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-te17000-oil-level · HIT ref KDCD-048 · fingerprint c05005 · see HIT ref KDCD-047, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-oil-specification-200-300
Kalmar DCD 200-300: what clutch pressure should the transmission show?
17-20 bar in every gear with the oil at 82-93 °C, the engine idling and the parking brake applied, read on the gauge in the cab, according to the technical handbook (series 3), as recorded at HIT SRL. The handbook allows no more than 0.4 bar of difference between the clutches, as logged by the HIT SRL technical desk. It gives a working oil temperature of 82-93 °C and a maximum of 120 °C, according to the same handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-clutch-pressure-200-300 · HIT ref KDCD-049 · fingerprint d4294f · see HIT ref KDCD-050, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-converter-stall-speed-200-300
Kalmar DCD 200-300: what is the converter stall speed?
1990 ± 50 r/min with the TWD731VE, TAD720VE and QSB5.9 engines, according to the technical handbook (series 3), as HIT SRL's technical desk reads it. The handbook forbids holding the stall speed for more than 30 seconds at a time. For the TE17000 the maintenance manual (series 1) gives 1914 rpm with the Volvo TAD750VE and 1879 rpm with the Cummins QSB6.7.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-converter-stall-speed-200-300 · HIT ref KDCD-050 · fingerprint 23b3e8 · see HIT ref KDCD-049, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-clutch-pressure-200-300
Kalmar DCD 200-300: how is the TE17000 transmission calibrated safely?
On level ground, in neutral, with the parking brake applied and the oil above 60 °C but no hotter than 90 °C, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The calibration lasts about 15 minutes, and the manual forbids anyone to leave the machine while it runs, warning that the machine may start to move, the HIT SRL technical desk notes. In that case the manual holds it with the foot brake, and moving the shift lever to reverse stops the calibration at any moment. The calibration procedure to apply is the one in the specific machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-calibration · HIT ref KDCD-051 · fingerprint 7b9eda · see HIT ref KDCD-046, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-te17000
Kalmar DCD 200-300: which drive axle is fitted?
A Kessler D91 with two reduction stages, a hypoid differential and planetary hub reductions, according to the technical handbook (series 3), as logged by the HIT SRL technical desk. The handbook gives type D91 PL488 on the DCD 200-250 and D91 PL408 on the DCD 280-300, as recorded at HIT SRL. The operator's manual (series 2) and the maintenance manual (series 1) name the Kessler D91 without those type letters.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-kessler-d91-drive-axle · HIT ref KDCD-052 · fingerprint 2d705e · see HIT ref KDCD-053, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-drive-axle-oil-200-300
Kalmar DCD 200-300: how much oil does the drive axle take?
30 l in the Kessler D91 differential on the DCD 200-250 and 38 l on the DCD 280-300, with 4 l and 3.5 l in each hub reduction, according to the operator's manual (series 2), as recorded by the HIT SRL technical desk. The oil is hypoid oil to API GL-5 and MIL-L-2105B in SAE 80W140, 80W90, 90 or 85W140 by ambient temperature, according to the same manual, as HIT SRL's technical desk reads it. In its oil change procedure the maintenance manual (series 1) speaks of about 44 l and a 50 l receptacle, while its data section repeats the quantities of the operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-drive-axle-oil-200-300 · HIT ref KDCD-053 · fingerprint 09dabe · see HIT ref KDCD-052, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-kessler-d91-drive-axle
Kalmar DCD 200-300: which torques apply to the drive axle?
1350 Nm (138 kpm) for the drive axle mounting bolts and 350 Nm (36 kpm) for the rim clamp nuts, according to the technical handbook (series 3), the HIT SRL technical desk notes. The same handbook tightens the propeller shaft joints to 98 Nm on M12 screws, except at the drive axle end of the DCD 280-300, where it gives 133 Nm on M14, as set out in the HIT SRL technical cards. The maintenance manual (series 1) gives the same 1350 Nm and 350 Nm.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-drive-axle-torques-200-300 · HIT ref KDCD-054 · fingerprint 643cec · see HIT ref KDCD-052, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-kessler-d91-drive-axle
Kalmar DCD 200-300: what torque do the wheel nuts take?
350 Nm on both axles, tightened alternately in rounds of increasing torque, according to the maintenance manual (series 1), as recorded at HIT SRL. On the twin drive wheels that manual starts at the guide heels and works outwards, and it check-tightens to 350 Nm after a test run and at every service, as logged by the HIT SRL technical desk. The technical handbook (series 3) gives 400 Nm (41 kpm) for the wheel nuts on the steered axle instead.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-wheel-nut-torques-200-300 · HIT ref KDCD-055 · fingerprint 155412 · see HIT ref KDCD-054, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-drive-axle-torques-200-300
Kalmar DCD 200-300: which tyres and pressure does the operator's manual give?
14.00x24/24 on the DCD 200-250 and 16.00x25/28 on the DCD 280-300, air-inflated front and rear to 1.0 MPa, according to the operator's manual (series 2), as HIT SRL's technical desk reads it. The manual requires spare and replacement tyres of a brand approved by the manufacturer, as recorded by the HIT SRL technical desk. It notes that a tyre of another brand may need another pressure and a new pressure plate, and the technical handbook (series 3) also gives 1.0 MPa.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-tyres-200-300 · HIT ref KDCD-056 · fingerprint 2852fe · see HIT ref KDCD-055, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-wheel-nut-torques-200-300
Kalmar DCD 280-500: which transmissions does the handbook give?
A Clark torque converter with a constant-mesh gearbox, type 13,7 HR32312 with three forward and three reverse gears, or 15,5 HR36432 and 15,7 HRT40432 with four in each direction, according to the DCD 280-500 technical handbook (2001 edition), as set out in the HIT SRL technical cards. The gears are engaged by oil-cooled hydraulic multiple-disc clutches with automatic wear compensation, selected through solenoid valves from the gear selector in the cab, according to the handbook, the HIT SRL technical desk notes. The handbook disengages the drive with a separate inching pedal.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-280-500 · HIT ref KDCD-057 · fingerprint 1c0909 · see HIT ref KDCD-058, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-gearbox-oil-280-500
Kalmar DCD 280-500: how much oil do the gearboxes take?
21 l for the Clark 13,7 HR32312, 42 l for the 15,5 HR36432 and 56 l for the 15,7 HRT40432 in the whole system, according to the DCD 280-500 technical handbook (2001 edition), as logged by the HIT SRL technical desk. The handbook fills the Clark 32000 with ATF DEXRON II and the Clark 36000 and 40000 with oil to MIL-L-2410 C/D, C-2, C-3 in SAE 10, as printed, as recorded at HIT SRL. The handbook forbids DEXRON oils in those two gearboxes and checks the level every day at idle with the oil at 82-93 °C.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-gearbox-oil-280-500 · HIT ref KDCD-058 · fingerprint 699d27 · see HIT ref KDCD-057, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-280-500
Kalmar DCD 280-500: what converter stall speeds does the handbook give?
1990 ± 50 r/min for the Volvo TWD731VE with the Clark 13,7 HR32312, according to the DCD 280-500 technical handbook (2001 edition), as recorded by the HIT SRL technical desk. With the 15,5 HR36432 the TWD1031VE stalls at 1782 ± 50 r/min, and the handbook prints 1927 ± 50 r/min for the TWD1031VE with the 15,7 HRT40432, as HIT SRL's technical desk reads it. Each stall test lasts 30 seconds at most in the 2001 handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-converter-stall-speeds-280-500 · HIT ref KDCD-059 · fingerprint d25938 · see HIT ref KDCD-057, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-280-500
Kalmar DCD 280-500: which drive axles are fitted?
A Rockwell (Meritor) PRC 3805 W4H or PRC 5324 W4H or a Kessler D102, according to the DCD 280-500 technical handbook (2001 edition), the HIT SRL technical desk notes. Each has two reduction stages, a hypoid differential, planetary hub reductions and oil-cooled wet disc service brakes, with a spring-applied parking disc brake on the axle input shaft, according to the handbook, as set out in the HIT SRL technical cards. No size is tied to a particular axle in the handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-drive-axles-280-500 · HIT ref KDCD-060 · fingerprint bdc272 · see HIT ref KDCD-061, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-axle-oil-280-500
Kalmar DCD 280-500: how much oil do the drive axles take?
28 l in the differential and 9.5 l in each hub for the Rockwell PRC 3805 W4H, 50 l and 12 l for the PRC 5324 W4H and 63 l and 15 l for the Kessler D102, according to the DCD 280-500 technical handbook (2001 edition), as recorded at HIT SRL. The handbook uses hypoid oil to API GL5 and MIL-L-2105B in SAE 75W 140, 80W 90, 90 or 85W 140 by outside temperature, as logged by the HIT SRL technical desk. The handbook fills each hub reduction directly before the truck goes back into service, never only through the differential.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-axle-oil-280-500 · HIT ref KDCD-061 · fingerprint 903b27 · see HIT ref KDCD-060, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-drive-axles-280-500
Kalmar DCD 280-500: which torques apply to the drive axle mounting and rims?
1570 Nm (160 kpm) for the axle mounting bolts of the Rockwell PRC 3805 W4H and 2350 Nm (240 kpm) for the PRC 5324 W4H and the Kessler D102, according to the DCD 280-500 technical handbook (2001 edition), as HIT SRL's technical desk reads it. The same handbook gives 402 Nm (41 kpm) for the rim clamp nuts on both Rockwell axles and 370 Nm (37 kpm) on the Kessler, as recorded by the HIT SRL technical desk. It gives the 2350 Nm of the Kessler for oiled bolts.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-axle-torques-280-500 · HIT ref KDCD-062 · fingerprint dfabf4 · see HIT ref KDCD-060, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-drive-axles-280-500
Kalmar DCD 180-250: which transmission is fitted?
A Clark 13.7 HR 32312, a torque converter integrated with a constant-mesh gearbox, according to the DCD 180-250 technical handbook (1997 edition), as set out in the HIT SRL technical cards. The handbook gives three forward and three reverse gears in its specification, oil-cooled multiple-disc clutches that need no adjustment and gears selected through electrically operated solenoid valves, the HIT SRL technical desk notes. Its text, however, speaks of four ratios in each direction, and automatic gear changing is offered as an option, according to the same handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-180-250 · HIT ref KDCD-063 · fingerprint 4f3504 · see HIT ref KDCD-064, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-gearbox-oil-180-250
Kalmar DCD 180-250: which oil goes into the Clark gearbox?
API-CD SAE 10W/30 motor oil, 21 l in the whole converter and gearbox system, according to the DCD 180-250 technical handbook (1997 edition), as logged by the HIT SRL technical desk. The handbook forbids refilling with ATF and asks for the old oil to be drained completely before a change to another recommended oil, as recorded at HIT SRL. Its oil table nevertheless also lists Dexron and Dexron II D, and any oil outside the table needs written approval from the manufacturer's service.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-gearbox-oil-180-250 · HIT ref KDCD-064 · fingerprint 3d44f9 · see HIT ref KDCD-063, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-180-250
Kalmar DCD 180-250: which torques apply to the Rockwell drive axle?
1570 Nm (160 kpm) for the axle mounting bolts and 402 Nm (41 kpm) for the rim clamp nuts, according to the DCD 180-250 technical handbook (1997 edition), as recorded by the HIT SRL technical desk. For the propeller shaft joints the handbook gives 79 Nm on M10 screws at the gearbox and, at the drive axle, 110 Nm on 7/16 in and 59 Nm on 3/8 in UNF screws, all oiled, as HIT SRL's technical desk reads it. It gives axle oil to API GL 5 in 85W-140 or 80W-140.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-rockwell-axle-torques-180-250 · HIT ref KDCD-065 · fingerprint 530617 · see HIT ref KDCD-063, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-transmission-180-250
Kalmar DCD 180-250: what tyre pressure does the handbook give?
0.9 MPa where no other value is specified, according to the daily supervision chart of the DCD 180-250 technical handbook (1997 edition), the HIT SRL technical desk notes. The group 40 data of the same handbook print the tyre pressure as 0.9 bar instead. The handbook asks for the pressure to be checked every day.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-tyre-pressure-180-250 · HIT ref KDCD-066 · fingerprint 8ef1d3 · see HIT ref KDCD-065, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-rockwell-axle-torques-180-250
Kalmar DCD 200-300: what safety rules apply when changing tyres?
Only competent, authorised personnel change tyres, and a tyre is deflated by removing the valve before its wheel comes off, both tyres together on a twin wheel, according to the operator's manual (series 2), as recorded at HIT SRL. The manual forbids inflating a tyre with anyone standing in front of it and pumping it above the prescribed pressure, as logged by the HIT SRL technical desk. Tyre work on each truck follows its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-tyre-change-safety · HIT ref KDCD-067 · fingerprint c745ac · see HIT ref KDCD-068, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-tyre-deflation-and-inflation
Kalmar DCD 200-300: how are tyres deflated and inflated safely?
A tyre is deflated before its wheel is removed, both tyres together on a twin wheel, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. If the tyre or rim is damaged, the manual deflates it through a hole drilled in the tread instead of the valve, and it inflates tyres on the machine or in a protective device built to withstand a bursting tyre, as recorded by the HIT SRL technical desk. The mechanic stands obliquely behind the tyre and checks at 30 kPa that all rim parts are in place, nobody stands in front of it, and the pressure to reach is the one in the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-tyre-deflation-and-inflation · HIT ref KDCD-068 · fingerprint 275b0b · see HIT ref KDCD-067, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-tyre-change-safety
Kalmar DCD 200-300: which tyre and rim rules does the maintenance manual set?
The machine must not be operated with a flat tyre, and rims must never be repaired by welding, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The manual forbids changing tyre size, make or type and rim type or make without the manufacturer's approval, the HIT SRL technical desk notes. The manual adds that too low a tyre pressure impairs stability and reduces the capacity of the machine. The tyre approvals that apply are given in the manual of each machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-tyre-and-rim-rules · HIT ref KDCD-069 · fingerprint 9b98be · see HIT ref KDCD-068, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-tyre-deflation-and-inflation
Kalmar DCD 280-500: what does the handbook say about dual tyres and inflation?
The truck must never run on one tyre of a dual assembly, according to the DCD 280-500 technical handbook (2001 edition), as logged by the HIT SRL technical desk. The handbook forbids welding on an inflated tyre and rim assembly and checks the seating after inflating to about 34 kPa (5 psi) before inflating further, as recorded at HIT SRL. A tyre that has run flat calls for the rim to be dismantled and every part inspected, according to the same handbook. The inflation rules to follow are those of the manual that comes with the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-dual-tyres-and-inflation-280-500 · HIT ref KDCD-070 · fingerprint 32f121 · see HIT ref KDCD-071, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-tyre-pressure-and-stability-280-500
Kalmar DCD 280-500: what does the handbook say about tyre pressure and stability?
Under-inflated tyres seriously affect the stability of the truck and reduce its safe load handling capacity, according to the DCD 280-500 technical handbook (2001 edition), as recorded by the HIT SRL technical desk. The handbook gives 1.0 MPa with every drive axle and in the daily check where no other value is given, as HIT SRL's technical desk reads it. The handbook checks the pressure every day and never over-inflates the tyres. The pressure to use on a given truck is printed in the manual for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-tyre-pressure-and-stability-280-500 · HIT ref KDCD-071 · fingerprint 4f2017 · see HIT ref KDCD-070, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-dual-tyres-and-inflation-280-500
Kalmar DCD 180-250: what tyre safety rules does the handbook give?
No welding on an inflated tyre and rim assembly and no running on one tyre of a dual assembly, according to the DCD 180-250 technical handbook (1997 edition), the HIT SRL technical desk notes. The handbook inflates a tyre only with all side rings and lock rings in place, checks the assembly at about 5 psi (34 kPa, 0.34 bar) and uses a clip-on chuck while staying out of the danger area, as set out in the HIT SRL technical cards. A tyre that has run flat means dismantling the rim and inspecting every part, and the procedure for a given truck is in the specific machine's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-tyre-safety-180-250 · HIT ref KDCD-072 · fingerprint 4dd913 · see HIT ref KDCD-073, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-rim-lock-ring-wear
Kalmar DCD 180-250: when are a dismountable rim and its lock ring discarded?
When the mark that the lock ring wears into the rim bead between its ends exceeds 0.5 mm, measured with a straight edge and feeler gauge, according to the DCD 180-250 technical handbook (1997 edition), as recorded at HIT SRL. In that case the handbook discards the wheel, the lock ring and the bead seat or loose flange, as logged by the HIT SRL technical desk. The handbook inspects the high-stress areas of the rim at every tyre change for circumferential cracks, fretting, corrosion pitting, distortion and wear. The wear limits to apply are those in the manual of the specific unit.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-rim-lock-ring-wear · HIT ref KDCD-073 · fingerprint 19e43b · see HIT ref KDCD-072, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/transmission-and-driveline/#hit-dcd-tyre-safety-180-250