Kalmar DCE 90-180 — Brakes and steering: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the brake system, accumulator, parking brake and steering of the Kalmar DCE 90-180 heavy forklift truck, one fact per card, each with its source stated in the text. For the overall picture, see the Kalmar DCE 90-180 technical legacy guide.
Kalmar DCE 90-180: what kind of service brakes does it have?
Wet discs inside the hubs of the drive wheels, braking the drive axle alone through one hydraulic circuit, according to the maintenance manual (series 8), as recorded at HIT SRL. The steering axle is unbraked in that manual, and its accumulator charging valve routes the pump oil to the accumulator or through the brakes for cooling, as logged by the HIT SRL technical desk. The operator's manual (series 8) speaks of fully enclosed wet disc brakes with external cooling, and the workshop manual (series 10, revision 3) credits their long life to efficient cooling.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-service-brakes · HIT ref KDCE-043 · fingerprint 5469f9 · see HIT ref KDCE-048, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-brake-accumulator-pressures
Kalmar DCE 90-180: how does the parking brake work?
A spring applies a calliper on a disc on the drive axle input shaft and hydraulic pressure releases it, so the brake comes on if the brake system loses pressure, according to the workshop manual (series 10, revision 3), as HIT SRL's technical desk reads it. With the parking brake on, the same manual prevents a travel direction from being engaged, as recorded by the HIT SRL technical desk. The operator's manual (series 8) adds that the brake also applies when voltage is lost.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-parking-brake · HIT ref KDCE-044 · fingerprint bdf809 · see HIT ref KDCE-051, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-parking-brake-as-emergency-brake
Kalmar DCE 90-180: how does the steering work?
A double-acting hydraulic cylinder on the rear wheel pair steers the machine progressively, so a quick turn of the wheel gives more steering per revolution, according to the operator's manual (series 8), as recorded at HIT SRL. The steering valve is closed-centre with load signal and shock valves opening at 200 bar, and the through-rod cylinder on link arms is fixed at 600 Nm with oil, according to the workshop manual (series 10, revision 3), as logged by the HIT SRL technical desk. Joystick and mini-wheel steering are options for the Spirit Delta cab, while the DCF 80-100 has linear steering, according to their operator's manuals.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-steering · HIT ref KDCE-045 · fingerprint eb0c72 · see HIT ref KDCE-052, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-lever-and-mini-wheel-steering
Kalmar DCE 90-180: what makes up the suspension?
The tyres, the steering axle with its hubs and wheel spindles, and the steering axle cradle, according to the workshop manual (series 10, revision 3), as HIT SRL's technical desk reads it. In that manual the cradle is pendulum-mounted in the frame on two bushings and the tyres themselves act as suspension. The maintenance manual (series 8) describes the suspension in the same way.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-suspension · HIT ref KDCE-046 · fingerprint df5036 · see HIT ref KDCE-045, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-steering
Kalmar DCE 90-180: what brake pressure should the pedal give?
27 bar with the pedal half depressed and 100 bar with the pedal fully depressed, according to the maintenance manual (series 8), as set out in the HIT SRL technical cards. That manual takes the reading at the distribution block with the oil at 50 °C or more and compares it with the pressure data plate of the machine, the HIT SRL technical desk notes. Revisions 2 and 3 of the workshop manual (series 10) print these two pressures too.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-brake-pressure-at-the-pedal · HIT ref KDCE-047 · fingerprint 066fc5 · see HIT ref KDCE-048, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-brake-accumulator-pressures
Kalmar DCE 90-180: what are the brake accumulator pressures?
A nitrogen pre-charge of 70 bar and a maximum pressure of 165 bar, according to the maintenance manual (series 8), as logged by the HIT SRL technical desk. The workshop manual (series 10, revision 3) gives a charging range of 13.0-16.5 MPa and sets the low brake pressure switch at 11.5 MPa, and revision 2 of the same manual has the same values.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-brake-accumulator-pressures · HIT ref KDCE-048 · fingerprint fe121b · see HIT ref KDCE-049, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-brake-accumulator-test
Kalmar DCE 90-180: how many brake applications should the accumulator allow?
At least six with the engine stopped in the operator's manual (series 8), while the maintenance manual (series 8) asks for 8 before the low brake pressure error code appears, as recorded by the HIT SRL technical desk. The operator's manual charges the accumulator, stops the engine and pumps the pedal with long strokes, and calls the accumulator faulty if fewer applications are possible, as HIT SRL's technical desk reads it. The workshop manual (series 10, revision 3) checks at least 8 applications before the pressure falls to 7.0 MPa, and the figure to apply is the one in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-brake-accumulator-test · HIT ref KDCE-049 · fingerprint 30bdeb · see HIT ref KDCE-048, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-brake-accumulator-pressures
Kalmar DCE 90-180: when does the brake pedal disengage the drive?
Two thresholds are printed: more than 70% of pedal travel on machines with inching in the operator's manual (series 8), and neutral from about 55% below 10 km/h in the workshop manual (series 10), the HIT SRL technical desk notes. Revision 2 of that workshop manual re-engages the drive smoothly below 70% and credits the de-clutch function with better braking and protection against transmission overheating, as set out in the HIT SRL technical cards. With inching switched on, the operator's manual lets the drive slip progressively before the 70% point, and both thresholds stay here as printed.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-brake-pedal-and-drive-disengagement · HIT ref KDCE-050 · fingerprint 5fd245 · see HIT ref KDCE-047, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-brake-pressure-at-the-pedal
Kalmar DCE 90-180: can the parking brake be used as an emergency brake?
Yes, the operator's manual (series 8) allows the parking brake to be used as an emergency brake, as recorded at HIT SRL. The same manual warns that the pads then wear and can lose braking performance, and asks for them to be checked as soon as possible after any emergency stop with the parking brake, as logged by the HIT SRL technical desk. A parking brake released by hand must always be reset, according to that manual, and the way to check the pads is set out in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-parking-brake-as-emergency-brake · HIT ref KDCE-051 · fingerprint 97411c · see HIT ref KDCE-044, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-parking-brake
Kalmar DCE 90-180: when can lever or mini-wheel steering be switched on?
Only with no active steering alarm and below 3 km/h, according to the workshop manual (series 10, revision 3), as HIT SRL's technical desk reads it. The same manual shuts it off for safety when one of its alarms is active or when the sensor on the standard steering wheel detects movement, as recorded by the HIT SRL technical desk. Jerky steering points to a minimum valve current set too high and slow steering to one set too low, and the operator's manual (series 8) gives the same 3 km/h limit for the joystick.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-lever-and-mini-wheel-steering · HIT ref KDCE-052 · fingerprint 7b6b84 · see HIT ref KDCE-045, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/brakes-and-steering/#hit-dce-steering