Kalmar DCD — Troubleshooting and error codes: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the KCS error codes, alarms, warning lights and fault finding 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 levels do the KCS error codes have?
Three, Stop, Warning and Information, each shown by a symbol and a steady red indicator, according to the operator's manual (series 2), as set out in the HIT SRL technical cards. A Stop code is a serious fault that may affect operator safety or damage the machine, and the manual stops work and calls service at once, the HIT SRL technical desk notes. A Warning is dealt with as soon as possible after the shift and an Information covers faults such as a failed bulb, and the technical handbook (series 3) and the maintenance manual (series 1) give the same three levels.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-error-levels · HIT ref KDCD-196 · fingerprint 92df0b · see HIT ref KDCD-197, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-code-return
Kalmar DCD 200-300: when does an acknowledged KCS error code come back?
Within one minute for Stop and within three minutes for Warning or Information while the cause remains, according to the operator's manual (series 2), as logged by the HIT SRL technical desk. The manual clears the display by itself within 30 seconds once the cause has gone, as recorded at HIT SRL. The maintenance manual (series 1) brings an active code back within 1-3 minutes after Reset but shows a deleted Information code again only after a restart, and the technical handbook (series 3) shows Information only once.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-code-return · HIT ref KDCD-197 · fingerprint 226823 · see HIT ref KDCD-196, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-error-levels
Kalmar DCD 200-300: how does a Stop-level error code limit the machine?
By cutting engine speed to 1500 rpm, according to the technical handbook (series 3), as recorded by the HIT SRL technical desk. With the electronic Cummins engine the handbook leaves the reduction to the engine control unit ECU 794. The handbook gives this limit for every Stop-level code.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-stop-level-engine-speed · HIT ref KDCD-198 · fingerprint c5b085 · see HIT ref KDCD-196, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-error-levels
Kalmar DCD 200-300: how are the KCS error codes numbered?
By control unit, 1-299 for the EDU 795 display unit, 300-599 for the ECU 790 and 600-899 for the ECU 796, according to the technical handbook (series 3), the HIT SRL technical desk notes. Faults from the control unit of the Cummins QSB5.9 engine appear as code 1200 with the engine's own fault number, according to the handbook, as set out in the HIT SRL technical cards. The code tables, with the limitation and action for each code, are in the operator's manual (series 2) and in the technical handbook, the Cummins table giving SPN and FMI numbers.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-code-ranges · HIT ref KDCD-199 · fingerprint a200f6 · see HIT ref KDCD-198, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-stop-level-engine-speed
Kalmar DCD 200-300: which temperatures make the KCS warn or stop?
A coolant above 98 °C gives a warning and above 103 °C a stop with engine speed reduction, according to the technical handbook (series 3), as recorded at HIT SRL. For the gearbox oil the same handbook warns above 113 °C and stops above 116 °C, each alarm after 20 seconds, as logged by the HIT SRL technical desk. The operator's manual (series 2) gives a normal coolant temperature of 80-90 °C, varying between 75 and 97 °C.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-temperature-alarms · HIT ref KDCD-200 · fingerprint 5516b5 · see HIT ref KDCD-201, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-other-alarms
Kalmar DCD 200-300: which other alarms does the KCS monitor?
Battery voltage below 23 V for two minutes or above 30 V for ten seconds, fuel below 15%, hydraulic oil above 100 °C or low coolant level for 40 seconds, and low brake pressure for 10 seconds, according to the technical handbook (series 3), as HIT SRL's technical desk reads it. The handbook counts these delays from 60 seconds after engine start, as recorded by the HIT SRL technical desk. An overdue service time also generates a code, according to the same handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-other-alarms · HIT ref KDCD-201 · fingerprint afa4ed · see HIT ref KDCD-200, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-temperature-alarms
Kalmar DCD 200-300: which oil temperatures make the TE17000 warn or disengage?
Above 100 °C the transmission oil temperature sensor gives a warning on the display, with reduced performance, and above 125 °C the transmission is disengaged, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The manual states that high modulation, with heavy slipping between gears, gives strong wear and a high oil temperature, the HIT SRL technical desk notes. The technical handbook (series 3) gives 113 °C for the warning and 116 °C for the stop in its KCS monitoring.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-te17000-oil-temperature · HIT ref KDCD-202 · fingerprint 325202 · see HIT ref KDCD-209, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-transmission-limp-home
Kalmar DCD 200-300: how are the Cummins QSB5.9 fault codes read without KCS?
With the diagnostics switch, the stop-engine light flashing each of the three digits, framed by control flashes of the engine warning light, according to the operator's manual (series 2), as logged by the HIT SRL technical desk. A second switch scrolls through the stored codes, according to the same manual. The technical handbook (series 3) describes the same sequence.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-cummins-flash-codes · HIT ref KDCD-203 · fingerprint c29bfa · see HIT ref KDCD-199, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-code-ranges
Kalmar DCD 200-300: how should the operator react to the warning lights?
By stopping the engine at once if the low engine oil pressure or low transmission oil pressure light comes on while working, according to the operator's manual (series 2), as recorded by the HIT SRL technical desk. If the high transmission oil temperature light comes on, the manual has the machine stopped with the engine idling, as HIT SRL's technical desk reads it. A new shift must not start while the Cummins engine warning light is lit, and the stop engine light of the QSB5.9 means a serious fault that calls for service, according to the manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-operator-warning-lights · HIT ref KDCD-204 · fingerprint 3d175b · see HIT ref KDCD-196, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-error-levels
Kalmar DCD 200-300: what does KCS error code 645 mean?
Maximum load exceeded, according to the operator's manual (series 2), the HIT SRL technical desk notes. The manual limits travel speed to 1 km/h until the load is lowered, as set out in the HIT SRL technical cards. The code belongs to the table of the ECU 796, and the technical handbook (series 3) does not list it. What the code does on a given truck is set out in the manual for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-code-645-maximum-load · HIT ref KDCD-205 · fingerprint 3c0677 · see HIT ref KDCD-199, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-code-ranges
Kalmar DCD 200-300: what should be done after a high hydraulic oil temperature alarm?
Keep the hydraulic functions out of use until the oil has cooled below 70 °C, according to the technical handbook (series 3), which lists the alarm as code 355, as recorded at HIT SRL. The operator's manual (series 2) tells the operator only to call service for the same code. The cooling limit for a given truck is the one in its own maintenance manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-hydraulic-oil-too-hot · HIT ref KDCD-206 · fingerprint f32a90 · see HIT ref KDCD-200, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-temperature-alarms
Kalmar DCD 200-300: which reference values does the handbook give for checking KCS sensors?
Oil pressure senders from 0.5 V at 0 bar to 4.5 V at 40 bar and temperature senders of about 8.5 kΩ at 0 °C, 3.67 kΩ at 20 °C and 286-290 Ω at 100 °C, according to the technical handbook (series 3), as HIT SRL's technical desk reads it. The handbook gives the fuel level sender 0-73 Ω and never lets proportional valve coils fall below 15 Ω, as recorded by the HIT SRL technical desk. It gives electric servo valve coils about 20 Ω, the variable pump valve at least 10 Ω and joystick potentiometers 0.5-4.5 V.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-sensor-checks · HIT ref KDCD-207 · fingerprint 1423b2 · see HIT ref KDCD-201, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-kcs-other-alarms
Kalmar DCD 200-300: what are the protective modes of the TE17000 transmission?
Limp-home and Shut-down, according to the maintenance manual (series 1), as logged by the HIT SRL technical desk. Limp-home, shown as LH, starts on a fault in a control output, in the engine-speed sensor or in two of the three vehicle-speed sensors, puts the transmission in neutral and then allows only the first two gears in both directions after reselecting, according to the manual, as recorded at HIT SRL. Shut-down, shown as Sd, releases the oil pressure to all pressure modulators and leaves the transmission permanently in neutral, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-transmission-limp-home · HIT ref KDCD-209 · fingerprint 0a801b · see HIT ref KDCD-202, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-te17000-oil-temperature
Kalmar DCD 200-300: what does the handbook ask for after gearbox damage?
The oil cooler must always be replaced, the handbook noting that a faulty cooler may have caused the damage, according to the technical handbook (series 3), as recorded by the HIT SRL technical desk. Metal particles found in the gearbox suction strainer must be investigated before new oil goes in, according to the same handbook. Both rules appear again in the handbooks of the DCD 180-250 and DCD 280-500.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-gearbox-damage · HIT ref KDCD-210 · fingerprint b1b657 · see HIT ref KDCD-211, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-converter-outlet-pressure
Kalmar DCD 180-250 and DCD 280-500: how is the converter outlet pressure checked?
With the gearbox in neutral and the engine at 2000 r/min, where the pressure must be above 1.7 bar, without exceeding 4.9 bar at top engine speed, according to the DCD 280-500 technical handbook (2001 edition) and the DCD 180-250 technical handbook (1997 edition), the HIT SRL technical desk notes. The 2001 handbook checks it with the oil at 80-95 °C, while its gearbox table and the 1997 handbook give 82-93 °C, as set out in the HIT SRL technical cards. If the clutch pressure is wrong, the 2001 handbook checks the gearbox pressure sensor first.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-converter-outlet-pressure · HIT ref KDCD-211 · fingerprint 7f083e · see HIT ref KDCD-212, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-gear-pump-wear
Kalmar DCD 180-250 and DCD 280-500: what wear limits apply to the gear pumps?
A pump body worn more than 0.13 mm is replaced, and pressure plate wear is limited to 0.05 mm, according to the DCD 280-500 technical handbook (2001 edition) and the DCD 180-250 technical handbook (1997 edition), as recorded at HIT SRL. Both handbooks read wear where the teeth mesh as a sign of impurities in the oil, pitting as cavitation or gas formation and discolouration as overheating, as logged by the HIT SRL technical desk. After fitting, the pump runs unloaded at idle for at least two minutes, and hot oil must never enter a cold pump, according to the 2001 handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-gear-pump-wear · HIT ref KDCD-212 · fingerprint cc9c3d · see HIT ref KDCD-211, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-converter-outlet-pressure
Kalmar DCD 180-250: which gauges and warning lamps does the instrument panel carry?
A gearbox oil pressure gauge, fuel and coolant temperature gauges and warning lamps for battery charging, low engine oil pressure, low gearbox oil pressure, low brake accumulator pressure, low coolant level, high coolant temperature, high gearbox oil temperature, high brake cooling oil temperature (optional) and parking brake applied, according to the DCD 180-250 technical handbook (1997 edition), as HIT SRL's technical desk reads it. The handbook also shows an hour meter and a preheat lamp on the panel, as recorded by the HIT SRL technical desk. The handbook gives no error codes for the DCD 180-250.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-warning-lamps-180-250 · HIT ref KDCD-213 · fingerprint 7ff190 · see HIT ref KDCD-212, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/troubleshooting/#hit-dcd-gear-pump-wear