Kalmar DCE 90-180 — Hydraulics: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the hydraulic pumps, pressures, oil and filters 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 pumps feed the hydraulics?
With a Dana transmission, gear pump 1 serves steering with priority and load handling, pump 2 lifting, lowering and tilting, and pump 3 brake charging, cooling and the load-handling servo circuit, according to the workshop manual (series 10, revision 3), as recorded at HIT SRL. The pumps sit in two banks on the gearbox power take-off, and optional pumps serve lever or mini-wheel steering and OptimumLift, according to that manual, as logged by the HIT SRL technical desk. With the ZF transmission the same manual lists three pumps with the same functions plus one for joystick or mini-wheel steering.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-hydraulic-pumps · HIT ref KDCE-053 · fingerprint 2902f2 · see HIT ref KDCE-054, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-high-pressure-filters-and-oil-cooler
Kalmar DCE 90-180: how is the hydraulic oil filtered and cooled?
Through three high-pressure filters, one after each main pump, and an oil cooler with an electric fan, according to the workshop manual (series 10, revision 3), as HIT SRL's technical desk reads it. Each filter has a valve that lets oil past the element when it is too thick or the element is clogged, and the manual warns that the oil then goes through unfiltered, as recorded by the HIT SRL technical desk. A thermal valve sends all the oil through the cooler core above 65 °C and none below 55 °C, the same limits as in the maintenance manual (series 8).
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-high-pressure-filters-and-oil-cooler · HIT ref KDCE-054 · fingerprint 9fcce9 · see HIT ref KDCE-055, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-hydraulic-oil-grades
Kalmar DCE 90-180: which hydraulic oil does it take?
SS 155434 AV 32 or AV 46 oil, DIN 51524 HVLP 46 or HLP 68 grade oil, or the ISO-LHV 46 and ISO-LHM 68 grades of ISO 6743/4, picked by ambient temperature and dosed with 3% Lubrizol, in the maintenance manual (series 8), as recorded by the HIT SRL technical desk. Brake disc lubrication is the purpose of that additive in the workshop manual (series 10, revision 3), as HIT SRL's technical desk reads it. The operator's manuals (series 2 and series 8) list the same oils, while the DCF 80-100 and DCT 80-90 use DIN 51524 part 3 HVLP oils without additive.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-hydraulic-oil-grades · HIT ref KDCE-055 · fingerprint 550bf7 · see HIT ref KDCE-056, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-hydraulic-oil-change-on-condition
Kalmar DCE 90-180: when is the hydraulic oil changed?
On condition, after oil samples, and at 4000 h at the latest, according to the maintenance manual (series 8), the HIT SRL technical desk notes. In that manual the first sample comes at 2000 h; if the oil is good it runs another 1000 h to a second sample, and if that is good too, a final 1000 h from 3000 h before the change, as set out in the HIT SRL technical cards. Lubrizol is added at 3% at each change, the same manual states.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-hydraulic-oil-change-on-condition · HIT ref KDCE-056 · fingerprint 34e9cb · see HIT ref KDCE-055, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-hydraulic-oil-grades
Kalmar DCE 90-180: how are the hydraulic pressures checked?
With the oil at about 50 °C and the readings compared with the pressure plate of the machine, according to the maintenance manual (series 8), as recorded at HIT SRL. That manual charges the accumulator until it switches over to brake cooling and expects recharging to restart at about 13.5 MPa, as logged by the HIT SRL technical desk. Steering, lift-tilt and side shift-spreading pressures are read at about 1100 rpm, the steering and lift-tilt readings repeated at about 1800 rpm with no more than ±1.0 MPa of difference, and adjustments are left to the workshop manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-hydraulic-pressure-check · HIT ref KDCE-057 · fingerprint 82864c · see HIT ref KDCE-053, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-hydraulic-pumps
Kalmar DCE 90-180: how is the hydraulic system depressurised before work?
With the machine in service position, the accumulator drain valve is opened and a gauge at the test point by the accumulator charging valve must show zero, according to the maintenance manual (series 8), as HIT SRL's technical desk reads it. The valve stays open as long as the work goes on, and the manual calls work on a pressurised hydraulic system a mortal danger, as recorded by the HIT SRL technical desk. A hissing sound means that the pressure is being released, the workshop manual (series 10, revision 3) adds, and the steps to follow are those in the maintenance manual for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-depressurising-the-hydraulic-system · HIT ref KDCE-058 · fingerprint 891559 · see HIT ref KDCE-057, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-hydraulic-pressure-check
Kalmar DCE 90-180: what are the Optimum options?
Three options for load handling and driving, Optimum speed, Optimum rev and Optimum drive, in the operator's manual (series 8), as set out in the HIT SRL technical cards. In that manual Optimum drive allows inching at a higher engine speed for faster lifting, and Optimum rev matches the engine speed to the power load handling needs, the HIT SRL technical desk notes. Optimum speed is an extra load-sensing variable pump next to the fixed pump, worth up to 50% more lifting speed without load according to the same manual. The manufacturer's technical information calls the three options Optispeed, Optirev and Optidrive, and revision 3 of the workshop manual names the extra pump OptimumLift.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-optimum-options · HIT ref KDCE-059 · fingerprint d213ef · see HIT ref KDCE-053, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-hydraulic-pumps
Kalmar DCE 90-180: how big are the fuel and hydraulic tanks?
A fuel tank of 140 l or 200 l and a hydraulic oil tank of 205 l or 225 l, depending on the version, according to the operator's manual (series 8), as logged by the HIT SRL technical desk. The fuel is diesel to EN 590, and the operator's manual (series 2) and the manufacturer's technical information give the same figures, as recorded at HIT SRL. The maintenance manual (series 8) prints the 205 l and 225 l as the figure of the hydraulic system rather than of the tank.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-fuel-and-hydraulic-tanks · HIT ref KDCE-060 · fingerprint 56d486 · see HIT ref KDCE-055, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-hydraulic-oil-grades
Kalmar DCE 90-180: how much oil does the hydraulic system take in each version?
205 l on the DCE 90-6 and 225 l on every other version, DCE 70-32E3 and DCE 70-35E4 included, according to the common hydraulics table of the maintenance manual (series 8), as recorded by the HIT SRL technical desk. In the same table the oil quality refers to the recommended oils, and the oil additive is Lubrizol at 3%.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-hydraulic-system-capacity · HIT ref KDCE-153 · fingerprint 2bc22e · see HIT ref KDCE-060, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/hydraulics/#hit-dce-fuel-and-hydraulic-tanks