Kalmar DCE 90-180 — Safety and interlocks: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the load capacity, transport position, overload protection, emergency equipment and towing 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 permitted load determined?
From the machine plate and the load diagram in the cab, which make capacity depend on the position of the load's centre of gravity, the lift height and the load's size, according to the operator's manual (series 8), as recorded at HIT SRL. That manual prohibits exceeding the load capacity, warning of the risk of tipping, and has a side-heavy load lowered and brought back onto the centre line by side shift, as logged by the HIT SRL technical desk. The same rules appear for the DCF 80-100, and each truck's own operator's manual and load diagram give the capacity that applies.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-load-capacity-and-load-diagram · HIT ref KDCE-101 · fingerprint 94d0b7 · see HIT ref KDCE-102, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-transport-position
Kalmar DCE 90-180: what is the transport position?
Mast tilted back and the load about 300 mm off the ground with its centre of gravity centred sideways, according to the operator's manual (series 8), as set out in the HIT SRL technical cards. Without a load the mast stands vertical and the forks about 300 mm up, side-shifted until one fork tip shows through the mast, and loads are never carried high, according to that manual, the HIT SRL technical desk notes. When the load blocks the view the truck is driven in reverse, and the manual of the specific machine is the reference.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-transport-position · HIT ref KDCE-102 · fingerprint 7542ea · see HIT ref KDCE-103, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-driving-on-gradients
Kalmar DCE 90-180: how is it driven on gradients?
With the lifting equipment facing uphill in either direction of travel, so the truck goes down an incline in reverse, according to the operator's manual (series 8), the HIT SRL technical desk notes. That manual forbids turning on a slope or driving across it, and without a load keeps the equipment lowered and the mast fully back, as set out in the HIT SRL technical cards. Braking on a gradient uses the service brake pedal only, without inching, to retain engine braking, and the gradient rules to follow are those in the machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-driving-on-gradients · HIT ref KDCE-103 · fingerprint 527b8c · see HIT ref KDCE-102, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-transport-position
Kalmar DCE 90-180: can anyone stand under the raised forks?
No, the operator's manual (series 8) bars standing or walking under raised forks or attachments, whether loaded or empty, as recorded at HIT SRL. The same rule is printed on a warning plate on the machine, which also forbids standing on the forks, according to that manual. The warning plates and rules that apply are those in the manual that comes with the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-persons-under-the-load · HIT ref KDCE-104 · fingerprint f63b76 · see HIT ref KDCE-101, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-load-capacity-and-load-diagram
Kalmar DCE 90-180: what does the manual say about wind and tipping over?
Lifting loads in heavy winds is to be avoided and speed adapted when turning, according to the operator's manual (series 8), as HIT SRL's technical desk reads it. In a roll-over the operator keeps hold of the steering wheel and stays in the cab until all movement has stopped, never jumping out, as the same manual and a safety plate in the cab state, as recorded by the HIT SRL technical desk. Wind and stability limits for a given truck are in the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-wind-and-tipping-over · HIT ref KDCE-105 · fingerprint 190674 · see HIT ref KDCE-101, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-load-capacity-and-load-diagram
Kalmar DCE 90-180: what should the operator do near overhead power lines?
Work with extreme care, given the reach of mast and load, according to the operator's manual (series 8), as set out in the HIT SRL technical cards. If the machine touches a line, the operator stays seated in the cab and calls for help, the same manual states, and the operator's manual (series 2) gives the same rule, the HIT SRL technical desk notes. What to do near power lines is set out in the manual issued for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-overhead-power-lines · HIT ref KDCE-106 · fingerprint 75f31a · see HIT ref KDCE-105, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-wind-and-tipping-over
Kalmar DCE 90-180: what happens when the overload protection reacts?
With code 401 the lift and tilt overload set by the calibrated table has been exceeded, speed is limited and lighter loads are to be lifted, according to the error code lists of the workshop manual (series 10, revision 3), as logged by the HIT SRL technical desk. Code 406 reports a fault in the force sensor on the tilt axle, which disables the overload protection, and the machine must not be overloaded until the sensor is replaced, as recorded at HIT SRL. The protection is optional on the DCE 90-180, inching disengages on overload in the operator's manual (series 8), and the overload codes and limits 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/safety-and-interlocks/#hit-dce-overload-protection-codes · HIT ref KDCE-107 · fingerprint c21597 · see HIT ref KDCE-101, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-load-capacity-and-load-diagram
Kalmar DCE 90-180: which emergency equipment does it have?
Three items, according to the operator's manual (series 8): the right-hand door as emergency exit, a breaker switch for all load-handling functions on electric servo machines and a fire extinguisher, as recorded by the HIT SRL technical desk. According to that manual, the breaker switch is reset clockwise, and in an engine fire the extinguisher nozzle goes through a marked plate on the engine hood, as HIT SRL's technical desk reads it. The operator's manual (series 2) lists the same items, and each machine's own manual lists its emergency equipment.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-emergency-equipment · HIT ref KDCE-108 · fingerprint 7c80c9 · see HIT ref KDCE-109, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-automatic-engine-stop
Kalmar DCE 90-180: when does the engine stop by itself?
After a serious malfunction, according to the operator's manual (series 8), the HIT SRL technical desk notes. The engine can then be restarted for about 25 seconds to move the machine out of an unsuitable position, the same manual states, as set out in the HIT SRL technical cards. Some machines also stop for high coolant temperature, low oil pressure or when the operator leaves the machine running, normally after 5 minutes, and the restart and stop behaviour of a given truck is described in its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-automatic-engine-stop · HIT ref KDCE-109 · fingerprint 8f161e · see HIT ref KDCE-110, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-engine-stop-controls
Kalmar DCE 90-180: how is the engine stopped?
With the ignition switch on the Caterpillar and Cummins engines, while the Volvo engines also have an AUX STOP button in the engine compartment on the left-hand side for emergency or service use, according to the workshop manual (series 10, revision 3), as recorded at HIT SRL. After more than five minutes with the driver out of the cab the engine stops, a default an authorised technician may change, according to the same manual, as logged by the HIT SRL technical desk. The stop controls of a given machine are described in the manual of each machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-engine-stop-controls · HIT ref KDCE-110 · fingerprint f7d19d · see HIT ref KDCE-109, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-automatic-engine-stop
Kalmar DCE 90-180: which fire extinguisher should it carry?
If one is fitted, an extinguisher of type ABE to EN 3 parts 1, 2, 4 and 5, according to the operator's manual (series 8), as HIT SRL's technical desk reads it. That manual makes the machine owner responsible for approved fire-fighting equipment and has the dry chemical applied from outside an enclosed area, which is then ventilated, as recorded by the HIT SRL technical desk. The extinguisher usually sits on the left front mudguard, or on the right or in the cab, and fire equipment follows the specific machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-fire-extinguisher · HIT ref KDCE-111 · fingerprint deb999 · see HIT ref KDCE-108, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-emergency-equipment
Kalmar DCE 90-180: how is it towed?
Behind a heavier towing vehicle, over the shortest possible distance, with the propeller shaft disconnected and the engine running if it can, or on a tow bar if it cannot, according to the operator's manual (series 8), as set out in the HIT SRL technical cards. The same manual explains that with the engine stopped the steering and the lubrication of the transmission are insufficient, and that the brakes work only while accumulator pressure lasts, after which the parking brake applies, the HIT SRL technical desk notes. The machine is never started by towing, and towing is done only as the manual of the specific machine describes.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-towing · HIT ref KDCE-112 · fingerprint e6aed8 · see HIT ref KDCE-113, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-releasing-the-parking-brake
Kalmar DCE 90-180: how is the parking brake released without accumulator pressure?
Mechanically, by screwing in the nut that compresses the brake spring, or hydraulically with release knobs and about ten strokes of a pump rod, according to the operator's manual (series 8), as logged by the HIT SRL technical desk. The wheels are blocked first and the brake is always restored afterwards, the same manual states, warning that the spring is very strong and that a wrong release can make parts fly, as recorded at HIT SRL. The release method that applies is the one in the manual that comes with the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-releasing-the-parking-brake · HIT ref KDCE-113 · fingerprint ffb4f6 · see HIT ref KDCE-112, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-towing
Kalmar DCE 90-180: why must it not roll down a slope with the engine off?
With the engine stopped there is no hydraulic pressure and no steering capacity, according to the operator's manual (series 8), as recorded by the HIT SRL technical desk. That manual asks to keep the engine running, and notes that brake pressure remains for a while after stopping, stored in the accumulator, as HIT SRL's technical desk reads it. The operator's manual (series 2) gives the same warning, and moving a machine without power follows its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-engine-stopped-on-a-slope · HIT ref KDCE-114 · fingerprint 7f2577 · see HIT ref KDCE-103, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-driving-on-gradients
Kalmar DCE 90-180: what is the service position?
Parking brake applied, forks and carriage fully lowered, engine off and main power cut with the battery disconnect switch, the position the maintenance manual (series 8) requires for any work on the machine, the HIT SRL technical desk notes. Stands or ramps, when used, must suit the weight of the machine, and that manual forbids supporting a raised machine on suspension or steering parts, as set out in the HIT SRL technical cards. The operator's manual (series 8) adds the mast tilted forward, and the service position to use is the one defined in the manual for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-service-position · HIT ref KDCE-115 · fingerprint 192e35 · see HIT ref KDCE-116, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-lifting-and-lashing-the-machine
Kalmar DCE 90-180: how is the machine lifted or lashed for transport?
With slings in the two lifting eyes of the mast and, at the rear, round the chassis between counterweight and steering axle or in the two lifting eyes of the counterweight where fitted, the lifting point passing through the centre of gravity, according to the operator's manual (series 8), as recorded at HIT SRL. On a transport vehicle the same manual crosses the lashing chains and cuts the main power, and it removes the mast if the height exceeds road limits, as logged by the HIT SRL technical desk. Each machine's own manual shows where to sling and lash it.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-lifting-and-lashing-the-machine · HIT ref KDCE-116 · fingerprint 833ed5 · see HIT ref KDCE-115, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-service-position
Kalmar DCE 90-180: what precautions apply when removing a tyre?
Both tyres of a twin pair are deflated and the wheels on the other side blocked before a tyre comes off, under the pressure-vessel rules of the maintenance manual (series 8), as HIT SRL's technical desk reads it. If tyre or rim is damaged, a hole is drilled in the tread instead of using the valve, rims and lock rings are never welded or repaired, and a flat tyre is never driven on, according to that manual, as recorded by the HIT SRL technical desk. Tyre changes are for authorised personnel, and tyre work follows the procedures in the specific machine's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-tyres-as-pressure-vessels · HIT ref KDCE-117 · fingerprint d53da3 · see HIT ref KDCE-118, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-inflating-tyres
Kalmar DCE 90-180: how are the tyres inflated safely?
With the rim lock ring checked for correct seating, a self-locking air chuck and the operator standing obliquely behind the tyre, never in front of it, without exceeding the prescribed pressure, according to the operator's manual (series 8), as set out in the HIT SRL technical cards. The maintenance manual (series 8) checks all parts at 30 kPa first and forbids striking rim components with a hammer during inflation, the HIT SRL technical desk notes. A completely deflated tyre calls for the rim to be dismantled and checked, and inflation pressures and steps are those in the machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-inflating-tyres · HIT ref KDCE-118 · fingerprint ed12e3 · see HIT ref KDCE-117, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-tyres-as-pressure-vessels
Kalmar DCE 90-180: when must the machine not be used?
Without the daily inspection or with defects, according to the operator's manual (series 8), as logged by the HIT SRL technical desk. That manual has defects reported at once to the supervisor and the machine stopped immediately and left for service if welds show damage or cracks, a rule that the operator's manual (series 2) does not have, as recorded at HIT SRL. Faulty brakes, steering or lifting, safety devices not working, unauthorised persons or vehicles in the area and unapproved tyres also rule out use, and the defects that stop a given machine are listed in its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-defective-machine · HIT ref KDCE-119 · fingerprint bb0a01 · see HIT ref KDCE-115, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-service-position
Kalmar DCE 90-180: how is the machine parked?
Selector in neutral, parking brake applied, mast tilted slightly forward and forks on the ground, then one minute at idle before the engine is stopped and the key removed, according to the operator's manual (series 8), as recorded by the HIT SRL technical desk. For longer stops the same manual opens the battery disconnect switch, and it explains the idle minute as cooling the engine and lubricating the turbo bearings, as HIT SRL's technical desk reads it. The operator must never leave the seat without the parking brake, a buzzer sounding otherwise, and parking follows the manual issued for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-parking-the-machine · HIT ref KDCE-120 · fingerprint f46458 · see HIT ref KDCE-115, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-service-position
Kalmar DCE 90-180: how does lift height limit travel speed?
Up to 3 m of lift height speed is limited to 20 km/h, depending on the truck, at maximum height to 5 km/h, and in between in proportion to the height, according to the workshop manual (series 10, revision 3), the HIT SRL technical desk notes. The function belongs to the set-up functions of the KCS and may vary with customer settings, according to that manual, as set out in the HIT SRL technical cards. The maintenance manual (series 8) mentions a speed limitation acting on gear and engine speed without giving values, and the speed settings of a given truck are those recorded in the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-speed-limit-by-lift-height · HIT ref KDCE-121 · fingerprint 82b732 · see HIT ref KDCE-102, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-transport-position
Kalmar DCE 90-180: what precautions apply to cleaning the optional particle filter?
The cleaning unit is connected at the parking place and the burn-off is never interrupted, according to the operator's manual (series 8), as recorded at HIT SRL. During cleaning hot air able to ignite flammable material leaves the exhaust pipe, so that manual keeps the filter uncovered and away from anything flammable, as logged by the HIT SRL technical desk. Depending on the unit, cleaning ends after 8 hours or after 40 minutes, and the cleaning instructions for the filter are those in the manual that comes with the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-particle-filter-burn-off · HIT ref KDCE-122 · fingerprint bf4b92 · see HIT ref KDCE-120, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/safety-and-interlocks/#hit-dce-parking-the-machine