Kalmar DCE 90-180 — Related models and comparisons: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the related DCF 80-100 and DCT 80-90 and documented differences 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 DCF 80-100: what kind of machine is it?
A forklift for handling empty containers, with a maximum lift capacity of 8 to 10 tonnes and a duplex or triplex mast carrying a sidelift attachment, according to the DCF 80-100 operator's manual (series 3), the HIT SRL technical desk notes. Published sources state that the DCF100 was designed to move empty containers two at a time.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-what-is-the-dcf-80-100 · HIT ref KDCE-132 · fingerprint 97b194 · see HIT ref KDCE-133, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dcf-80-100-designation
Kalmar DCF 80-100: how is a designation such as DCF 100-45E7 read?
Letter by letter: D diesel engine, C counterweight forklift, F generation; then 100 decitonnes of lift capacity, 45 for the wheelbase, E for empty container and 7 containers of stacking height, according to the DCF 80-100 operator's manual (series 3), as logged by the HIT SRL technical desk. The designation key of the DCE operator's manual gives no such reading for E3 and E4.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dcf-80-100-designation · HIT ref KDCE-133 · fingerprint e1098b · see HIT ref KDCE-132, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-what-is-the-dcf-80-100
Kalmar DCF 80-100: which engine and driveline does it have?
Either a 180 kW, 1100 Nm Volvo TAD760VE or a 164 kW, 949 Nm Cummins QSB6.7, driving through a fully automatic three-speed Dana TE17 to a Kessler D81 or D91 axle, according to the DCF 80-100 operator's manual (series 3), as recorded by the HIT SRL technical desk. Both engines reach their power at 2200 rpm and their torque at 1500 rpm in that manual, as HIT SRL's technical desk reads it. In the same manual the steering is linear, so the steering angle depends on the number of turns of the steering wheel, and the alternators are 1920 W and 1680 W.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dcf-80-100-engines-and-driveline · HIT ref KDCE-134 · fingerprint e2bac8 · see HIT ref KDCE-132, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-what-is-the-dcf-80-100
Kalmar DCF 80-100: how does its sidelift attachment work?
Twistlocks or hooks with lock lugs hold the container, the width adjusts from 20 to 40 feet and a sensor slows the lift automatically in the last metre below the upper end position, according to the DCF 80-100 operator's manual (series 3), the HIT SRL technical desk notes. The same manual also covers 45-foot containers lifted with the hook attachment set to 40 feet.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dcf-80-100-sidelift-attachment · HIT ref KDCE-135 · fingerprint 479cdc · see HIT ref KDCE-138, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dcf-80-100-lamp-rules
Kalmar DCF 80-100: what are its fluid capacities and tyres?
A 450 l fuel tank, a 450 l hydraulic system with a 360 l tank, 37 l of transmission oil and 14.00x24 tyres at 1.0 MPa, according to the DCF 80-100 operator's manual (series 3), as recorded at HIT SRL. The differential takes 42 l with the Kessler D81 or 54 l with the D91, plus 2 x 4 l in the hub reductions, according to that manual, as logged by the HIT SRL technical desk. The coolant is 22 l with the Volvo or 29 l with the Cummins, the engine oil 23 l or 20 l and the washer reservoir 5 l, in the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dcf-80-100-capacities · HIT ref KDCE-136 · fingerprint 4b3da6 · see HIT ref KDCE-137, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dcf-80-100-oils
Kalmar DCF 80-100: which oils does it use?
The brake system has its own oil, meeting GM Allison C-4, John Deere J20 C or D or Caterpillar TO-4, or an SAE 5W-30 transmission oil, according to the DCF 80-100 operator's manual (series 3), as HIT SRL's technical desk reads it. In that manual the hydraulics take DIN 51524 part 3 HVLP oil in ISO VG 68, 46 or 32 and the transmission ATF Dexron III, as recorded by the HIT SRL technical desk. The engine oil is Volvo VDS-3 or Cummins API CH-4 / ACEA E5, and the axle oil API GL-5 in SAE 80W-140 or 75W-90, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dcf-80-100-oils · HIT ref KDCE-137 · fingerprint 1143b0 · see HIT ref KDCE-136, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dcf-80-100-capacities
Kalmar DCF 80-100: when may a lift not be started?
While the unlocked lamp is lit or the locked or alignment lamps are off, according to the DCF 80-100 operator's manual (series 3), as set out in the HIT SRL technical cards. With incorrect locking, speed and hydraulic movement are reduced, and a machine with faulty indicator lights must be stopped and repaired, the same manual states, the HIT SRL technical desk notes. These rules apply to the hook attachment, with similar ones for the twistlocks, and the lamp rules that apply are those in the specific machine's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dcf-80-100-lamp-rules · HIT ref KDCE-138 · fingerprint 309a4d · see HIT ref KDCE-135, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dcf-80-100-sidelift-attachment
Kalmar DCT 80-90: what kind of machine is it?
A forklift truck for empty containers lifting 8 or 9 tonnes depending on version, with a side lift attachment on a trolley carried by the mast, according to the DCT 80-90 maintenance manual (series 1), as logged by the HIT SRL technical desk. In that manual the cab sits on the rear section of the frame.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-what-is-the-dct-80-90 · HIT ref KDCE-139 · fingerprint c3c50d · see HIT ref KDCE-141, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dct-80-90-lifting-data
Kalmar DCT 80-90: which engine and driveline does it have?
Either engine, the Yuchai YC6A240-30 or the Cummins QSB6.7, gives 164 kW at 2200 rpm and drives a Kessler D81 or D91 axle through a three-speed Dana HR32000, according to the DCT 80-90 maintenance manual (series 1), as recorded by the HIT SRL technical desk. In that manual the torques are 800 Nm for the Yuchai and 949 Nm for the Cummins at 1500 rpm, and two fixed pumps on the transmission power take-off serve load handling and the brakes, steering and cooling, as HIT SRL's technical desk reads it. The return filters sit in the hydraulic tank, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dct-80-90-engines-and-driveline · HIT ref KDCE-140 · fingerprint e4868d · see HIT ref KDCE-139, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-what-is-the-dct-80-90
Kalmar DCT 80-90: how high does it stack and how much does it weigh?
Five to eight 8 ft 6 in containers high, depending on the version from E5 to E8, with lift heights of 15,220 to 21,280 mm and kerb weights of 35.5 to 40.0 t, according to the DCT 80-90 maintenance manual (series 1), the HIT SRL technical desk notes. With 9 ft 6 in containers the stacks drop to 5, 5, 6 and 7 high, the same manual adds, as set out in the HIT SRL technical cards. In that manual the capacity is 8 t for the DCT 80 and 9 t for the DCT 90 at a 1220 mm load centre, with 600 mm of side shift each way and 3 degrees of tilt forward and back.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dct-80-90-lifting-data · HIT ref KDCE-141 · fingerprint 94dca7 · see HIT ref KDCE-139, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-what-is-the-dct-80-90
Kalmar DCT 80-90: how is its service schedule organised?
In 250, 500, 1000 and 2000-hour services, the 250-hour actions falling at 250, 750 and 1250 h, according to the DCT 80-90 maintenance manual (series 1), as recorded at HIT SRL. The same paragraph also states that service is performed every 500 operating hours, and the Yuchai engine oil and filter are replaced at all four levels.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dct-80-90-service-levels · HIT ref KDCE-142 · fingerprint b9f347 · see HIT ref KDCE-143, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dct-80-90-crack-checks
Kalmar DCT 80-90: how often is it checked for cracks?
Every 1000 h or every year, according to the DCT 80-90 maintenance manual (series 1), as HIT SRL's technical desk reads it. Traces of combustible material in the engine compartment are looked for too, with extra care on hot surfaces such as the exhaust parts and turbo, in the schedule of that manual. The DCE maintenance manual sets the crack check at 4000 h or every year.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dct-80-90-crack-checks · HIT ref KDCE-143 · fingerprint bc2510 · see HIT ref KDCE-142, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dct-80-90-service-levels
Kalmar DCT 80-90: how is the fuel pre-filter of the Yuchai engine serviced?
It is replaced at every service level, with condensation water drained every 50 hours, according to the DCT 80-90 maintenance manual (series 1), as set out in the HIT SRL technical cards. The same manual asks for earlier filter changes if an error code appears.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dct-80-90-yuchai-fuel-pre-filter · HIT ref KDCE-144 · fingerprint 8624bf · see HIT ref KDCE-142, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dct-80-90-service-levels
Kalmar DCT 80-90: what are its fluid capacities and tyres?
12.00x24 or 14.00x24 tyres at 1.0 MPa, a 380 l fuel tank, a 320 l hydraulic tank in a 450 l system, 32 l of transmission oil and 42 l or 54 l of differential oil with 2 x 4 l in the hub reductions, according to the DCT 80-90 maintenance manual (series 1), as logged by the HIT SRL technical desk. In that manual the coolant is 32 l with the Yuchai or 29 l with the Cummins and the engine oil with filter 24 l or 20 l, as recorded at HIT SRL. The same manual accepts diesel to EN 590 or to ASTM D975 grades No 1-D and No 2-D, with a 5 l washer reservoir.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dct-80-90-capacities · HIT ref KDCE-145 · fingerprint 37bf0b · see HIT ref KDCE-146, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dct-80-90-transmission-oil
Kalmar DCT 80-90: which transmission oil does it need?
An oil to GM Allison C-4, John Deere J20 C or D, Caterpillar TO-4 or MIL-PRF-2104G, in a viscosity grade chosen by outdoor temperature, according to the DCT 80-90 maintenance manual (series 1), as recorded by the HIT SRL technical desk. The same manual states that engine oil or GL-5 oil may not be used in the transmission.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dct-80-90-transmission-oil · HIT ref KDCE-146 · fingerprint 4be7a3 · see HIT ref KDCE-145, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dct-80-90-capacities
Kalmar DCT 80-90: what do published sources report on later Kalmar empty container handlers?
The DCG80-100 range, single and double stackers of 8, 9 or 10 tonnes, was presented by Kalmar in November 2016, published sources state, the HIT SRL technical desk notes. The same published sources report that Kalmar had delivered almost ten thousand empty container handlers in the previous 30 years.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dcg80-100-empty-container-range · HIT ref KDCE-147 · fingerprint f2e11f · see HIT ref KDCE-139, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-what-is-the-dct-80-90
Kalmar DCE 90-180: how do the engines and transmissions differ between the two series?
The operator's manual (series 2) lists Volvo TAD620VE, TAD720VE and TAD722VE and Cummins QSB5.9 engines with five Dana transmissions, as recorded at HIT SRL. The maintenance manual (series 8) lists Volvo TAD650VE and TAD750VE, Caterpillar C6.6 and Cummins QSB6.7 engines, and the operator's manual (series 8) Dana TE13000 and TE17000 or ZF 3WG161 transmissions, as logged by the HIT SRL technical desk. The Dana TE13000 and TE17000 appear in both series, while the FT20000, HR28000 and HR32000 belong to the earlier one, according to the same manuals.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-series-2-and-series-8-driveline · HIT ref KDCE-148 · fingerprint bffd3d · see HIT ref KDCE-149, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-grease-and-coolant-two-manuals
Kalmar DCE 90-180: where do the maintenance and workshop manuals differ on grease and coolant?
On grease, the maintenance manual (series 8) puts EP2 with 3-5% molybdenum sulphide on every point except the glide plates, while the workshop manual (series 10, revision 3) keeps 3.5% molybdenum disulphide grease for the lifting equipment and plain EP2 elsewhere, as HIT SRL's technical desk reads it. On coolant, the maintenance manual mixes 50% glycol with 50% water in a separate vessel, while the workshop manual asks for the ready-mixed coolant named for each engine and never mixes types, as recorded by the HIT SRL technical desk. Neither prescription is preferred here: each stays as printed with its edition.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-grease-and-coolant-two-manuals · HIT ref KDCE-149 · fingerprint 43c153 · see HIT ref KDCE-148, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-series-2-and-series-8-driveline
Kalmar DCE 90-180: how do its brakes and steering differ from the DCF 80-100?
The wet brakes of the DCE 90-180 run on the hydraulic oil with its 3% additive, while the DCF 80-100 has a separate brake oil to C-4, J20 or TO-4 specifications, according to their manuals, as set out in the HIT SRL technical cards. The DCE steers progressively, with more steering per turn for a quick movement of the wheel, where the DCF 80-100 steers linearly, its angle depending on the number of wheel turns, according to their operator's manuals, the HIT SRL technical desk notes. The DCF 80-100 also uses DIN 51524 part 3 HVLP hydraulic oil without additive, according to the same manuals.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dce-and-dcf-brakes-and-steering · HIT ref KDCE-150 · fingerprint 834ae4 · see HIT ref KDCE-151, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dce-and-dct-service-levels
Kalmar DCE 90-180: how does its service schedule differ from the DCT 80-90?
The DCT 80-90 maintenance manual (series 1) adds a 250-hour level to the 500, 1000 and 2000-hour services of the DCE 90-180 maintenance manual (series 8), as logged by the HIT SRL technical desk. The crack check comes every 1000 h or every year on the DCT 80-90 against every 4000 h or every year on the DCE 90-180, according to the same manuals.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dce-and-dct-service-levels · HIT ref KDCE-151 · fingerprint 8fc2e4 · see HIT ref KDCE-150, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dce-and-dcf-brakes-and-steering
Kalmar DCE 90-180: how do the Dana and ZF transmissions differ?
35 l of ATF Dexron III go into a Dana unit, which warns above 100 °C, and 33 l of API or ACEA oil into the ZF 3WG161, which warns above 120 °C, according to the maintenance manual (series 8), as recorded by the HIT SRL technical desk. Their protection modes differ too: the Dana control unit has limp-home and shut-down, the ZF four reduced modes from substitute clutch control to control unit shut-down, according to the maintenance and operator's manuals (series 8), as HIT SRL's technical desk reads it. The same maintenance manual stops the transmission at 125 °C.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-dana-and-zf-transmissions · HIT ref KDCE-152 · fingerprint 75e7d9 · see HIT ref KDCE-148, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/related-models/#hit-dce-series-2-and-series-8-driveline