Kalmar DCE 90-180 — Engine and power: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the engines, engine oils, coolant and starting 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: which engines do the machines from 2006 have?
Four straight six-cylinder turbo diesels with intercooler: the Volvo TAD650VE (147 kW), Volvo TAD750VE (181 kW), Caterpillar C6.6 (136 kW) and Cummins QSB6.7 (129 or 164 kW), according to the maintenance manual (series 8), as recorded by the HIT SRL technical desk. Torques of 750 Nm, 1050 Nm, 802 Nm and 949 or 799 Nm go with them, in that order, in the technical data of the same manual, as HIT SRL's technical desk reads it. All four are four-stroke low-emission engines with electronically controlled injection, that manual states.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engine-alternatives-machines-from-2006 · HIT ref KDCE-018 · fingerprint 7aaf56 · see HIT ref KDCE-019, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engine-names-in-the-operators-manual-overview
Kalmar DCE 90-180: do all the manuals name the same engines?
Not quite: the overview of the operator's manual (series 8) lists a Volvo TAD650 of 147 kW, a TAD720 of 181 kW, a Cummins QSB5.9 of 129 and 164 kW and a CAT C6.6 of 136 kW, as HIT SRL's technical desk reads it. The specification pages of the same manual give the TAD650VE, TAD750VE and QSB6.7, like the maintenance manual (series 8). Both lists stay here as printed.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engine-names-in-the-operators-manual-overview · HIT ref KDCE-019 · fingerprint 2c3d3c · see HIT ref KDCE-018, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engine-alternatives-machines-from-2006
Kalmar DCE 90-180: which later Volvo engines does the workshop manual add?
The Volvo TAD660VE and TAD760VE, with 800 Nm and 1100 Nm of torque against 750 Nm and 1050 Nm for the TAD650VE and TAD750VE, according to the workshop manual (series 10, revision 3), as recorded by the HIT SRL technical desk. Revision 2 of the same manual already has all six engines in its table.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-volvo-tad660ve-and-tad760ve · HIT ref KDCE-020 · fingerprint 4e97db · see HIT ref KDCE-018, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engine-alternatives-machines-from-2006
Kalmar DCE 90-180: which engines did the earlier series have?
Volvo TAD620VE at 85 or 145 kW, Volvo TAD720VE at 174 kW, Volvo TAD722VE at 180 kW and Cummins QSB5.9 at 138 kW, all with six cylinders, according to the operator's manual (series 2), the HIT SRL technical desk notes. Torques of 477, 700, 864, 1050 and 780 Nm follow the same order in that manual, as set out in the HIT SRL technical cards. The same manual gives alternators of 1540 W for the Volvo engines and 1960 W for the Cummins.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engines-of-the-earlier-series · HIT ref KDCE-021 · fingerprint fc8ba9 · see HIT ref KDCE-022, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-power-trains-in-the-technical-information
Kalmar DCE 90-180: which power trains does the technical information offer?
Seven combinations of engine and gearbox, all with a Kessler D81 drive axle, in the manufacturer's technical information brochure, as recorded at HIT SRL. The 85 kW Volvo TAD620VE goes with a Dana FT20000 and is listed only for the DCE 90-6, 100-6, 120-6, 140-6 and 100-12, a Dana HR28000 or TE13000 follows the 145 kW TAD620VE and the 138 kW Cummins 6B5.9e, and a Dana HR32000 or TE17000 the 174 kW TAD720VE, according to the same brochure, as logged by the HIT SRL technical desk. The brochure names the Cummins 6B5.9e, where the operator's manual (series 2) writes QSB5.9.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-power-trains-in-the-technical-information · HIT ref KDCE-022 · fingerprint a7c762 · see HIT ref KDCE-021, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engines-of-the-earlier-series
Kalmar DCE 90-180: how much oil does an engine oil change take?
15.5 l on the Volvo TAD650VE, 21.5 l on the TAD750VE, 20 l on the Cummins QSB6.7 and 15.5 l on the Caterpillar C6.6, according to the maintenance manual (series 8), as HIT SRL's technical desk reads it. The same table gives 16 l, 23 l and 17.4 l as the total fill of the TAD650VE, TAD750VE and C6.6, as recorded by the HIT SRL technical desk. The operator's manual (series 2) gives 16 l for the TAD620VE and QSB5.9 and 20 l for the TAD720VE and TAD722VE of the earlier series.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engine-oil-change-quantities · HIT ref KDCE-023 · fingerprint 744297 · see HIT ref KDCE-024, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-coolant-capacities
Kalmar DCE 90-180: how much coolant does the cooling system hold?
35 l with the Volvo TAD650VE and 40 l with the Volvo TAD750VE, Cummins QSB6.7 and Caterpillar C6.6, according to the maintenance manual (series 8), as set out in the HIT SRL technical cards. The workshop manual (series 10, revision 3) groups the TAD660VE with the TAD650VE and the TAD760VE with the TAD750VE for the same figures, the HIT SRL technical desk notes. In the operator's manual (series 2) the TAD620VE and QSB5.9 take 35 l and the TAD720VE and TAD722VE 40 l.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-coolant-capacities · HIT ref KDCE-024 · fingerprint 9e839d · see HIT ref KDCE-023, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engine-oil-change-quantities
Kalmar DCE 90-180: which engine oils does the maintenance manual list?
Oils to Volvo VDS-2 or VDS-3, API CH-4 or CI-4 and ACEA E4-99, E5 or E7 for the Volvo engines, to Cummins CES 20071-20078, API CH-4/SJ or CI-4/SK and ACEA E5 or E7 for the Cummins, and to EMA DHD-1 for the Caterpillar, according to the maintenance manual (series 8), as logged by the HIT SRL technical desk. The grade is SAE 15W-40, 10W-30 or 5W-30 by ambient temperature, the chart marking -15 °C and -25 °C, as recorded at HIT SRL. The same manual admits API CH-4 and CI-4 oils for the Caterpillar when they meet the Caterpillar ECF-1 specification.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engine-oils-machines-from-2006 · HIT ref KDCE-025 · fingerprint e9fe14 · see HIT ref KDCE-026, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engine-oil-of-the-earlier-series
Kalmar DCE 90-180: which engine oil did the earlier series need?
An oil meeting both ACEA E2 and API CF-4, in grades from SAE 0W to 20W-50 by ambient temperature, according to the operator's manual (series 2), as recorded by the HIT SRL technical desk. Outside Europe the same manual also approves API CG-4 or CH-4. The maintenance manual for the machines from 2006 lists other oils for their engines.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engine-oil-of-the-earlier-series · HIT ref KDCE-026 · fingerprint c6256f · see HIT ref KDCE-025, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engine-oils-machines-from-2006
Kalmar DCE 90-180: how is the coolant mixed according to the maintenance manual?
In a separate clean vessel, from 50% glycol and 50% pure water, according to the maintenance manual (series 8), the HIT SRL technical desk notes. That mixture gives frost protection to about -36 °C and a boiling point up to 108 °C, and the manual never lets the glycol share exceed 60%, about -54 °C, as set out in the HIT SRL technical cards. The glycol is ethylene glycol to ASTM D4985, never mixed with other glycol types, and above 60% the same manual expects lower frost protection and poorer cooling.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-coolant-mixture-maintenance-manual · HIT ref KDCE-027 · fingerprint ab86c7 · see HIT ref KDCE-028, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-coolant-in-the-workshop-manual
Kalmar DCE 90-180: which coolant does the workshop manual ask for?
Only ready-mixed coolant of the type named for each engine, Volvo Penta Coolant VCS, ES Compleat Premix or Cat ELC 50/50 Premix, according to the workshop manual (series 10, revision 3), as recorded at HIT SRL. The same manual tops up only with the type already in the system and never mixes coolant types, warning that mixing them risks engine damage, as logged by the HIT SRL technical desk. The maintenance manual mixes its own 50/50 coolant instead, and both instructions stay here as printed.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-coolant-in-the-workshop-manual · HIT ref KDCE-028 · fingerprint 572cf6 · see HIT ref KDCE-027, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-coolant-mixture-maintenance-manual
Kalmar DCE 90-180: how much glycol is needed when topping up with water?
At least 50% in the operator's manual (series 8) and at least 40% in the operator's manual (series 2), as HIT SRL's technical desk reads it. Both manuals add an anti-corrosion agent when glycol is not used and allow that agent alone, which gives no frost protection, only where the temperature never falls below 0 °C, as recorded by the HIT SRL technical desk. Both percentages stay here with their edition, and the maintenance manual (series 8) prescribes 50% mixtures in any case.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-glycol-when-topping-up · HIT ref KDCE-029 · fingerprint bb14c8 · see HIT ref KDCE-027, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-coolant-mixture-maintenance-manual
Kalmar DCE 90-180: what are the normal operating temperatures?
A coolant temperature of about 82-95 °C depending on load, according to the operator's manual (series 8), as set out in the HIT SRL technical cards. The same manual warms a cold engine at 1400-1500 rpm and checks the transmission oil level at idle in neutral with the oil at about 60-70 °C, the HIT SRL technical desk notes. With code 355 it keeps the hydraulic functions unused until the hydraulic oil is below 70 °C, and the operator's manual (series 2) gives the same values.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-operating-temperatures-and-warm-up · HIT ref KDCE-030 · fingerprint 44078c · see HIT ref KDCE-023, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/engine-and-power/#hit-dce-engine-oil-change-quantities