Kalmar DCE 90-180 — Mast, forks, attachments and cab: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the lift mast, chains, forks, carriages, side lift attachment and cab 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 masts and fork carriages are offered?
Duplex, duplex free-lift or triplex free-lift masts, carrying a fixed carriage with manually moved forks, a side shift carriage, side shift with fork spreading or side shift with spreading and centre levelling, according to the operator's manual (series 8), as recorded by the HIT SRL technical desk. The same manual fits the carriage with a coil ram, extended forks or an attachment for empty containers, as HIT SRL's technical desk reads it. The operator's manual (series 2) lists the same carriages, and the maintenance manual (series 8) splits load handling into lifting and lowering, tilting, side shift, fork spreading, levelling and load gripping.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-masts-and-fork-carriages · HIT ref KDCE-061 · fingerprint 5de9fa · see HIT ref KDCE-064, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-side-lift-attachment
Kalmar DCE 90-180: when must the lifting chains be replaced?
Beyond 3% of stretch, measured over the 25 links that pass first and most often over the chain wheel, according to the maintenance manual (series 8), the HIT SRL technical desk notes. For a 1-inch pitch the table of that manual gives 635 mm over 25 links on a new chain and 654 mm at most, as set out in the HIT SRL technical cards. The chains are adjusted so that the lowered forks stand 10-20 mm above the ground with the mast vertical, and the limits to apply 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/mast-and-forks/#hit-dce-lifting-chains · HIT ref KDCE-062 · fingerprint d4e9ac · see HIT ref KDCE-063, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-fork-wear-limits
Kalmar DCE 90-180: how much fork wear is allowed?
No more than 10% of the original blade thickness, measured 150 mm from the fork heel, and no visible cracks, according to the maintenance manual (series 8), as set out in the HIT SRL technical cards. Surface cracks are ground off by about half a millimetre and checked with magnetic powder by an approved firm, while cracks or wear are never repaired by welding, according to that manual, the HIT SRL technical desk notes. A fork straightened hot has to be heat-treated again by an approved firm, and the limits 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/mast-and-forks/#hit-dce-fork-wear-limits · HIT ref KDCE-063 · fingerprint fcac2f · see HIT ref KDCE-062, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-lifting-chains
Kalmar DCE 90-180: how is the side lift attachment for containers built?
With telescopic corner pieces hung on springs that allow 195 mm of levelling to either side, a hydraulic cylinder for 600 mm of side shift each way and twistlocks locked both hydraulically and mechanically, according to the maintenance manual (series 8), as logged by the HIT SRL technical desk. A lamp panel shows alignment, locked and released, according to that manual, as recorded at HIT SRL. The same manual explains that the springs allow the connection to leaning containers, and the operator's manual (series 8) describes the same attachment.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-side-lift-attachment · HIT ref KDCE-064 · fingerprint 127d89 · see HIT ref KDCE-065, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-twistlock-interlocks
Kalmar DCE 90-180: what do the twistlock interlocks prevent?
Twistlock movement without correct seating on the container, and lifting without twistlocks fully locked or fully released, are blocked by an electrical safety system in the maintenance manual (series 8), as recorded by the HIT SRL technical desk. Wrong or failed indicator lamps bar the use of the attachment in the operator's manual (series 8), which has the machine taken out of service and repaired, as HIT SRL's technical desk reads it. Its daily test lifts an empty container until the alignment lamp goes out, when the twistlocks must not release, and the interlock checks 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/mast-and-forks/#hit-dce-twistlock-interlocks · HIT ref KDCE-065 · fingerprint f7320d · see HIT ref KDCE-066, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-working-on-the-twistlocks
Kalmar DCE 90-180: what precautions apply to work on the twistlocks?
The engine must be off, according to the maintenance manual (series 8), the HIT SRL technical desk notes. That manual warns that the twistlocks can lock by themselves when every alignment sensor is pressed by hand, and the operator's manual (series 8) repeats the warning in its daily check. Work on the attachment follows the instructions in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-working-on-the-twistlocks · HIT ref KDCE-066 · fingerprint 99c1e7 · see HIT ref KDCE-065, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-twistlock-interlocks
Kalmar DCE 90-180: how often are the twistlocks checked and replaced?
Checked for cracks every other year or every 5000 h and replaced every 10,000 h, according to the maintenance manual (series 8), as recorded at HIT SRL. The same manual orders their replacement as soon as cracks or external damage appear, warning of mortal danger from material fatigue. Each machine's own manual sets the intervals that apply.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-twistlock-crack-checks-and-replacement · HIT ref KDCE-067 · fingerprint 628f5e · see HIT ref KDCE-065, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-twistlock-interlocks
Kalmar DCE 90-180: how is the electric scale calibrated?
The carriage is run up, lowered slowly to about 1 m and zeroed, and a known weight near the usual or maximum load is then lifted, in the workshop manual (series 10, revision 3), as HIT SRL's technical desk reads it. If code 304 stays on, the summed output of the two load cells in the chain tensioners must not be below 0.2 V, according to that manual, as recorded by the HIT SRL technical desk. The maintenance manual (series 8) gives the scale an accuracy of about ±1% of the maximum capacity with the mast vertical and the carriage centred.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-electric-scale-calibration · HIT ref KDCE-068 · fingerprint c7282e · see HIT ref KDCE-061, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-masts-and-fork-carriages
Kalmar DCE 90-180: which cabs are available?
The closed Spirit Delta, the open FlexGuard and the enclosed FlexCab, all built on a structural frame to withstand falling loads, according to the operator's manual (series 8), as set out in the HIT SRL technical cards. Filtered fresh air, heating or climate control and a 6 mm roof window, 12 mm in the extra-strong version, belong to the Spirit Delta, and a heater with optional air conditioning to the FlexCab, according to that manual, the HIT SRL technical desk notes. The workshop manual (series 10) adds a Spirit Delta Space cab with the same noise level and heating power.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-cab-alternatives · HIT ref KDCE-069 · fingerprint 553ecd · see HIT ref KDCE-070, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-cab-noise
Kalmar DCE 90-180: how loud is it in the cab?
At most 73 dB(A) in the Spirit Delta, 78 dB(A) in the FlexCab and 85 dB(A) in the open FlexGuard, measured to EN 12053, according to the operator's manual (series 8), as logged by the HIT SRL technical desk. The operator's manual (series 2) and the maintenance manual (series 8) give the same values, as recorded at HIT SRL. According to the manufacturer's technical information, the external sound power is 109 dB(A), or 110 dB(A) with the 174 kW Volvo engine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-cab-noise · HIT ref KDCE-070 · fingerprint 902cc7 · see HIT ref KDCE-071, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-whole-body-vibration
Kalmar DCE 90-180: what whole-body vibration does the operator feel?
From 0.4 to 0.7 m/s² with the Spirit Delta cab and from 0.4 to 0.8 m/s² with the FlexGuard or FlexCab, depending on tyres and seat, measured to EN 13059 in the operator's manual (series 8), as recorded by the HIT SRL technical desk. The operator's manual (series 2) only states that the truck stays below the 0.5 m/s² limit value of that standard, as HIT SRL's technical desk reads it. Both figures stay here as printed, each with its edition.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-whole-body-vibration · HIT ref KDCE-071 · fingerprint fabcec · see HIT ref KDCE-070, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-cab-noise
Kalmar DCE 90-180: how is the cab tilted safely?
Selector in neutral, parking brake on, mast tilted forward and forks lowered, with the doors closed and nothing loose in the cab, before tilting, according to the operator's manual (series 8), the HIT SRL technical desk notes. That manual always takes the cab past its balanced position and secures it with a stay when there is not enough room at the side, as set out in the HIT SRL technical cards. The maintenance manual (series 8) tilts it fully every time and always fits the stay, and the procedure 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/mast-and-forks/#hit-dce-tilting-the-cab · HIT ref KDCE-072 · fingerprint c82a4e · see HIT ref KDCE-069, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-cab-alternatives
Kalmar DCE 90-180: how much refrigerant does the cab air conditioning take?
1200 g of R134a refrigerant with the FlexCab and 2200 g with the Spirit Delta cab, according to the maintenance manual (series 8), as recorded at HIT SRL. For both cabs the same table refers to the air-conditioning plate for the quantity.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-air-conditioning-refrigerant · HIT ref KDCE-154 · fingerprint d5c927 · see HIT ref KDCE-069, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/mast-and-forks/#hit-dce-cab-alternatives