Kalmar DCE 90-180 — Electrical and control: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the 24 V system, batteries, KCS control units and diagnostics 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 electrical system does it have?
A 24 V system fed by two 12 V batteries in series and an alternator, with the negative pole to the chassis and the positive through the battery disconnect switch, according to the operator's manual (series 8), the HIT SRL technical desk notes. The specifications of that manual give 2 x 12 V batteries of 140 Ah, as set out in the HIT SRL technical cards. The maintenance manual (series 8) lists alternators of 2240 W for the Volvo engines, 1960 W for the Cummins and 2100 W for the Caterpillar.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-electrical-system-and-batteries · HIT ref KDCE-073 · fingerprint 0d238a · see HIT ref KDCE-074, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-battery-acid-density
Kalmar DCE 90-180: how is the battery charge checked?
Through acid density: the maintenance manual (series 8) expects 1.31 at -20 °C, 1.30 at 0 °C and 1.28 at +20 °C when the battery is fully charged, as recorded by the HIT SRL technical desk. That manual charges the battery below 1.24 at +20 °C and warns that a discharged battery freezes at -5 °C, as HIT SRL's technical desk reads it. It tops up only with distilled water, and the operator's manual (series 8) keeps the electrolyte 10 mm above the cells.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-battery-acid-density · HIT ref KDCE-074 · fingerprint 0da86f · see HIT ref KDCE-073, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-electrical-system-and-batteries
Kalmar DCE 90-180: when is the battery disconnect switch used?
At the end of each shift, during electrical work and before welding, when it cuts the system voltage, according to the operator's manual (series 8), the HIT SRL technical desk notes. Before welding all control unit connectors are unplugged too, and the switch is never opened with the engine running, which the same manual links to possible damage to the voltage regulator, as set out in the HIT SRL technical cards. The maintenance manual (series 8) warns that welding currents can destroy the electronics and cause fires, and the welding precautions to follow are those in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-battery-disconnect-switch-and-welding · HIT ref KDCE-075 · fingerprint 09a8bd · see HIT ref KDCE-073, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-electrical-system-and-batteries
Kalmar DCE 90-180: how is the machine jump-started?
With booster batteries in series giving 24 V and the main power cut first, according to the operator's manual (series 8), as recorded at HIT SRL. Red connects to the positive terminal of the discharged battery and then to the booster's, and black runs from the booster's negative to a point away from the discharged batteries, as that manual describes, as logged by the HIT SRL technical desk. Disconnection follows in reverse order, one cable at a time, the engine then runs at fast idle for about 10 minutes, and the procedure that applies is in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-jump-starting · HIT ref KDCE-076 · fingerprint 27cfdb · see HIT ref KDCE-073, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-electrical-system-and-batteries
Kalmar DCE 90-180: which control units make up the KCS?
ECU 790 for general functions, ECU 792 for steering, ECU 793 for the transmission, ECU 794 for the engine and ECU 796 for the hydraulics, with the display unit EDU 795, according to the maintenance manual (series 8), as HIT SRL's technical desk reads it. A redundant CAN bus links them and survives the loss of one segment, while engine and transmission units share a separate driveline CAN bus, as that manual describes, as recorded by the HIT SRL technical desk. Optional in the earlier operator's manual (series 2), the KCS is standard equipment in the operator's manual (series 8).
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-kcs-control-units · HIT ref KDCE-077 · fingerprint 493549 · see HIT ref KDCE-078, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-control-unit-lamps
Kalmar DCE 90-180: what do the lamps on the control units mean?
On the ECU 790 and ECU 792, green shows battery voltage and the internal 5 V supply, yellow flashes at 0.5 Hz with a valid program and at 5 Hz with none and is steady in set-up mode, and red signals an error, according to the maintenance manual (series 8), as set out in the HIT SRL technical cards. At switch-on all the lamps stay lit for 3 seconds, according to that manual, the HIT SRL technical desk notes. On the ECU 796 a steady green lamp means 22 to 28 V DC, yellow means regular CAN and application, and red flashes when the supply of the PWM board is below 12 V, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-control-unit-lamps · HIT ref KDCE-078 · fingerprint f26ab0 · see HIT ref KDCE-077, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-kcs-control-units
Kalmar DCE 90-180: how are faults of the electric servo controls traced?
Through the error codes, according to the workshop manual (series 10, revision 3), as recorded by the HIT SRL technical desk. A lever signal outside its calibrated range for over 100 ms (codes 610-614) calls for recalibrating or replacing the lever, and a short or open circuit in a function's solenoid (615-624) for checking the connector and the coil resistance, about 20 ohm and not below 15, according to that manual, as HIT SRL's technical desk reads it. With no response at all (601-606) the same manual checks the supplies of the ECU 796, for example code 601 for a supply below 14 V or above 33 V.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-electric-servo-control-faults · HIT ref KDCE-080 · fingerprint 5e4623 · see HIT ref KDCE-078, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/electrical-and-control/#hit-dce-control-unit-lamps