Kalmar DCE 90-180 — Maintenance intervals: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the service intervals, checks and lubrication 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: how is the service schedule organised?
In services every 500 operating hours at three levels, the 500-hour actions at 500, 1500 and 2500 h, the 1000-hour actions at 1000, 3000 and 5000 h and the 2000-hour actions at 2000, 4000 and 6000 h, according to the maintenance manual (series 8), as set out in the HIT SRL technical cards. The check and service log records every service, as the same manual requires, the HIT SRL technical desk notes. The operator's manuals (series 2 and series 8) also call for a service every 500 hours, and the manufacturer's technical information states that the intervals were extended to 500 hours.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-service-levels · HIT ref KDCE-081 · fingerprint 2f1d00 · see HIT ref KDCE-082, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-fifty-hour-check
Kalmar DCE 90-180: what does the 50-hour check of a new machine include?
Changes of engine oil and filter, transmission oil filter, drive axle oil and high-pressure hydraulic filter, plus the transmission oil on machines with a ZF gearbox, according to the maintenance manual (series 8), the HIT SRL technical desk notes. In the same manual the check also covers tightening, leaks, belt tension, levels, brakes, steering, suspension, wheel nuts and batteries, and lubrication as at the 500-hour service, as set out in the HIT SRL technical cards. The check takes place after the first 50 operating hours, as that manual prints it.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-fifty-hour-check · HIT ref KDCE-082 · fingerprint d3db5b · see HIT ref KDCE-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-service-levels
Kalmar DCE 90-180: how often are the wheel nuts checked on a new machine?
Every 4-5 operating hours during the first working week, up to about 40-50 operating hours, until they stay tight, according to the maintenance manual (series 8), as recorded by the HIT SRL technical desk. The DCT 80-90 maintenance manual (series 1) gives the same rule, and the tightening torque of the DCE is 650 Nm in the technical data, as HIT SRL's technical desk reads it. The manual that comes with the machine gives the routine to follow.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-wheel-nuts-on-a-new-machine · HIT ref KDCE-083 · fingerprint bbc1e0 · see HIT ref KDCE-091, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-first-drive-axle-oil-change
Kalmar DCE 90-180: how long is the running-in period?
50 operating hours, with the load increased gradually and the oil pressure and temperature checked regularly, according to the operator's manual (series 8), the HIT SRL technical desk notes. According to the same manual, running-in gives the bearings hard and polished surfaces. The operator's manual (series 2) recommends the same running-in.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-running-in · HIT ref KDCE-084 · fingerprint b0c5e1 · see HIT ref KDCE-082, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-fifty-hour-check
Kalmar DCE 90-180: what rules govern the lubrication intervals?
They assume normal handling and environment with the recommended grades and quantities, are halved in cold, hot or dusty conditions and never exceed 12 months, according to the maintenance manual (series 8), as recorded at HIT SRL. The 500-hour lubrication of that manual covers the cab locks, hinges, brake pedal, chain wheels, chains with chain oil, the mast with glide grease, rollers, side shift, mast anchorages, arms, tilt cylinders and the side lift attachment, as logged by the HIT SRL technical desk. At 1000 hours the same manual adds hose wheels, spindle pins, steering axle wheel bearings, the reversible seat and connectors.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-lubrication-intervals · HIT ref KDCE-085 · fingerprint 03f957 · see HIT ref KDCE-099, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-grease-specification
Kalmar DCE 90-180: how often are the engine oil and filter changed?
At every 500-hour service, on all engine alternatives, according to the maintenance manual (series 8), as HIT SRL's technical desk reads it. The technical data of that manual make this interval conditional on fuel with a sulphur content not above 0.5%, and the operator's manual (series 8) states the same condition, as recorded by the HIT SRL technical desk. The schedule of that manual marks the change in all three service columns for the Volvo, Cummins and Caterpillar engines.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-engine-oil-and-filter-interval · HIT ref KDCE-086 · fingerprint 16e5bf · see HIT ref KDCE-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-service-levels
Kalmar DCE 90-180: when is the coolant changed?
After 5000 h with the Volvo engines, after 2000 h with the Cummins and after 3000 h or every second year with the Caterpillar, according to the maintenance manual (series 8), as set out in the HIT SRL technical cards. For the Volvo and Cummins engines that manual adds a check or cleaning of the cooling system at each change, the HIT SRL technical desk notes. Level and freezing point are checked at every service, the same manual states.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-coolant-change-intervals · HIT ref KDCE-087 · fingerprint d2d527 · see HIT ref KDCE-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-service-levels
Kalmar DCE 90-180: when is the valve clearance checked?
After 5000 h or every four years on the Cummins engine and first after 500 h on the Caterpillar, according to the maintenance manual (series 8), as logged by the HIT SRL technical desk. On a newly overhauled Volvo engine the same manual adjusts it after 250 h and reserves Volvo work to an authorised Volvo Penta workshop, as recorded at HIT SRL. For the Caterpillar that manual asks for a service technician authorised by the machine manufacturer.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-valve-clearance-intervals · HIT ref KDCE-088 · fingerprint f05b30 · see HIT ref KDCE-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-service-levels
Kalmar DCE 90-180: when are the air filter cartridges changed?
The main cartridge when the restriction indicator shows, after a check at every service, and the safety cartridge at every second change of the main one, according to the maintenance manual (series 8), as recorded by the HIT SRL technical desk. The rule is the same for the Volvo, Cummins and Caterpillar engines in that manual, as HIT SRL's technical desk reads it. In the operator's manual (series 8) the operator checks the indicator and calls service when it turns red, the filter itself being changed by a technician.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-air-filter-cartridges · HIT ref KDCE-089 · fingerprint 92b5d9 · see HIT ref KDCE-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-service-levels
Kalmar DCE 90-180: how often is the transmission oil changed?
Every 1000 h or every year, with the filter changed at each oil change, according to the maintenance manual (series 8), the HIT SRL technical desk notes. On a ZF transmission the filter is also changed when its filter monitor gives an indication, and the same manual recommends calibrating the transmission every 1000 h, as set out in the HIT SRL technical cards. During the calibration of a Dana transmission that manual forbids leaving the machine, which can move.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-transmission-oil-interval · HIT ref KDCE-090 · fingerprint 01cc12 · see HIT ref KDCE-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-service-levels
Kalmar DCE 90-180: when is the drive axle oil first changed?
At the 50-hour check of a new machine, according to the maintenance manual (series 8), as recorded at HIT SRL. The driveline section of the same manual gives the axle about 23 l of oil. The later intervals that apply 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/maintenance-intervals/#hit-dce-first-drive-axle-oil-change · HIT ref KDCE-091 · fingerprint b3fcba · see HIT ref KDCE-082, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-fifty-hour-check
Kalmar DCE 90-180: when are the steering axle hub bearings checked?
First after 1000 h and then every 2000 h for the bearing pre-load, according to the maintenance manual (series 8), as HIT SRL's technical desk reads it. The same manual allows no more than 0.25 mm of clearance at the wheel spindle of the wheel suspension, and gives the checking procedure for the hub in its suspension group.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-steering-axle-hub-bearings · HIT ref KDCE-092 · fingerprint 843bb1 · see HIT ref KDCE-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-service-levels
Kalmar DCE 90-180: how often are the rims checked?
When the tyres are changed or every 12 months, according to the maintenance manual (series 8), as set out in the HIT SRL technical cards. At every service the same manual also checks tyres, rims and wheel nuts for damage, wear, pressure and tightness, the HIT SRL technical desk notes. The rim check of that manual limits the wear of the lock ring to half a millimetre, refers to a minimum diameter given by the manufacturer and looks for cracks with magnetic powder.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-rim-checks · HIT ref KDCE-093 · fingerprint 08e652 · see HIT ref KDCE-083, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-wheel-nuts-on-a-new-machine
Kalmar DCE 90-180: how often are the welds checked for cracks?
Every 4000 h or every year, more often on rough ground, according to the maintenance manual (series 8), as logged by the HIT SRL technical desk. That manual gives extra attention to the mast, tilt, drive axle and steering axle anchorages, the forks, the lifting equipment, the counterweight box and the frame-to-rear joints, and looks for cracks with magnetic powder and then penetrant liquids, as recorded at HIT SRL. The interval assumes normal use on a level floor, the same manual states, and the inspection routine to follow 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/maintenance-intervals/#hit-dce-weld-crack-checks · HIT ref KDCE-094 · fingerprint f612e4 · see HIT ref KDCE-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-service-levels
Kalmar DCE 90-180: what is checked at every service?
The service brake function, brake pedal and brake pressure, the parking brake pad thickness, the accumulator pre-charge, the hydraulic working pressures and the lifting chains, according to the maintenance manual (series 8), as recorded by the HIT SRL technical desk. The brake pressure readings to compare are 27 bar with the pedal half depressed and 100 bar fully depressed, in the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-checks-at-every-service · HIT ref KDCE-095 · fingerprint 952953 · see HIT ref KDCE-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-service-levels
Kalmar DCE 90-180: what does the daily check before each shift include?
A walk-round for leaks, loose wheel nuts, rim damage, tyre wear and pressure and cracks on chains, forks, mast and tilt cylinder mounts, then the fluid levels, the air filter indicator and the fuel pre-filter, according to the operator's manual (series 8), the HIT SRL technical desk notes. A slow test drive with at least three brake applications follows, and the check goes on with steering both ways, all gears, noises and cylinders run to their end stops, according to that manual, as set out in the HIT SRL technical cards. The same manual also looks at the side lift attachment, the hours left to the next service, the particle filter, central lubrication and any active error codes.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-daily-check · HIT ref KDCE-096 · fingerprint 3ada24 · see HIT ref KDCE-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-service-levels
Kalmar DCE 90-180: which extra checks does the Cummins engine need?
The drive belt tensioner and the fan hub after 1000 h or every year, and the rubber vibration damper after 2000 h or every two years, according to the maintenance manual (series 8), as recorded at HIT SRL. For the Caterpillar engine the same manual checks the belts after 500 h or every year.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-cummins-belt-tensioner-and-damper · HIT ref KDCE-097 · fingerprint a1bd42 · see HIT ref KDCE-088, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-valve-clearance-intervals
Kalmar DCE 90-180: how often is the optional particle filter cleaned?
Every 1500 h, at the same time as the carbon is burned off, after a check at every service, according to the maintenance manual (series 8), as HIT SRL's technical desk reads it. The row stands in the Caterpillar engine part of the schedule of that manual, and the daily regeneration is described in the operator's manual (series 8).
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-particle-filter-cleaning-interval · HIT ref KDCE-098 · fingerprint fee4e1 · see HIT ref KDCE-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-service-levels
Kalmar DCE 90-180: which grease is specified?
Two prescriptions are printed: a universal EP grease to NLGI 2 with 3-5% molybdenum sulphide for all points except the glide plates in the maintenance manual (series 8), and plain EP2 grease everywhere except the lifting equipment and slide plates in the workshop manual (series 10, revision 3), as set out in the HIT SRL technical cards. For the lifting equipment that workshop manual specifies an EP2 grease with 3.5% molybdenum disulphide, while glide and slide plates take a lubricant approved by the manufacturer in both manuals, the HIT SRL technical desk notes. The DCT maintenance manual (series 1) writes 3-5% for the lifting equipment, and both prescriptions stay here as printed.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-grease-specification · HIT ref KDCE-099 · fingerprint cfd694 · see HIT ref KDCE-085, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-lubrication-intervals
Kalmar DCE 90-180: how big is the washer fluid reservoir?
2.5 l in the operator's manual (series 8) and 2.0 l in the maintenance manual (series 8), as logged by the HIT SRL technical desk. The workshop manual (series 10, revisions 2 and 3) also gives 2.0 l, and the operator's manual (series 2) gives 2.5 l. Both figures stay here as printed, and the DCF and DCT manuals give 5 l for their reservoirs.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-washer-fluid-reservoir · HIT ref KDCE-100 · fingerprint a8ecae · see HIT ref KDCE-081, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/maintenance-intervals/#hit-dce-service-levels