Kalmar DCE 90-180 — Transmission, axle and wheels: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the transmission, drive axle, tyres and wheels 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 transmissions do the machines from 2006 use?
Manual or fully automatic transmissions with torque converter and three gears each way, the Dana TE13000, the Dana TE17000 or the ZF 3WG161, in the operator's manual (series 8), as HIT SRL's technical desk reads it. According to the same manual, the pumps of the working hydraulics sit on the transmission, as recorded by the HIT SRL technical desk. In the maintenance manual (series 8) the control unit ECU 793 selects each gear by modulating pressure through solenoid valves.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-transmissions-machines-from-2006 · HIT ref KDCE-031 · fingerprint 102b19 · see HIT ref KDCE-033, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-how-the-transmission-shifts
Kalmar DCE 90-180: which transmissions did the earlier series use?
Five Dana units, the FT20000, HR28000, HR32000, TE13000 and TE17000, all with three gears in each direction, according to the operator's manual (series 2), as recorded at HIT SRL. That manual makes a transmission control unit part of the TE13000 and TE17000 alternatives, as logged by the HIT SRL technical desk. According to the manufacturer's technical information, the Dana 20000 is an improved version of the Clark 20000, and the Dana 13000 and 17000 are new gearboxes with integrated electronic control developed with Kalmar.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-transmissions-of-the-earlier-series · HIT ref KDCE-032 · fingerprint 242363 · see HIT ref KDCE-031, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-transmissions-machines-from-2006
Kalmar DCE 90-180: how does the transmission change gear?
All gears stay in constant mesh and a gear is engaged by pressurising its clutch pack, with the forward and reverse clutches modulated electro-hydraulically, according to the maintenance manual (series 8), as recorded by the HIT SRL technical desk. Warning thresholds of 100 °C for a Dana and 120 °C for the ZF apply to the transmission oil, and 125 °C stops the transmission altogether, according to that manual, as HIT SRL's technical desk reads it. Heavy slipping under high modulation wears the transmission hard and heats its oil, the same manual warns.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-how-the-transmission-shifts · HIT ref KDCE-033 · fingerprint fb1264 · see HIT ref KDCE-037, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-transmission-oil
Kalmar DCE 90-180: which drive axle does it have?
The front wheels drive through a Kessler D81 axle, which carries a differential and hub reductions of the planetary type on all versions in the operator's manual (series 8), the HIT SRL technical desk notes. The operator's manual (series 2) and the manufacturer's technical information name the same Kessler D81.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-kessler-d81-drive-axle · HIT ref KDCE-034 · fingerprint 2ab0c8 · see HIT ref KDCE-035, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-differential-and-hub-reductions
Kalmar DCE 90-180: what do the differential and the hub reductions do?
The differential shares the power between the left and right drive wheels and lets them turn at different speeds in corners, according to the maintenance manual (series 8), as recorded at HIT SRL. The hub reductions change the ratio between wheel and engine, which that manual links to lower stress on the drive shafts.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-differential-and-hub-reductions · HIT ref KDCE-035 · fingerprint a84838 · see HIT ref KDCE-034, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-kessler-d81-drive-axle
Kalmar DCE 90-180: how is the machine laid out?
Front-wheel drive through a propeller shaft to a rigid drive axle with hub reduction and twin wheels, and single wheels on an oscillating steering axle, according to the maintenance manual (series 8), as HIT SRL's technical desk reads it. The same manual places the fuel and hydraulic oil tanks on the sides of the frame, uses split rims and puts the cab in the centre, tipping sideways, as recorded by the HIT SRL technical desk. The workshop manual (series 10, revisions 2 and 3) gives the same description.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-machine-layout · HIT ref KDCE-036 · fingerprint dc138e · see HIT ref KDCE-034, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-kessler-d81-drive-axle
Kalmar DCE 90-180: which oil and how much go into the transmission?
35 l of ATF Dexron III in either Dana transmission and 33 l in the ZF 3WG161, according to the maintenance manual (series 8), as set out in the HIT SRL technical cards. For the ZF the same manual accepts oils of the listed API classes, from CD to CI-4 and from SF to SL, or of ACEA categories A, B or E, in grades from SAE 10W to SAE 30 chosen by ambient temperature, the HIT SRL technical desk notes. The operator's manual (series 2) gives Dexron II or Dexron III depending on the transmission, with 25, 21 or 35 l.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-transmission-oil · HIT ref KDCE-037 · fingerprint b1f942 · see HIT ref KDCE-033, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-how-the-transmission-shifts
Kalmar DCE 90-180: how much oil does the drive axle take?
17.5 l in the differential, 18.5 l on the DCE 70-35E4, plus 2 x 2 l in the hub reductions, according to the maintenance manual (series 8), as logged by the HIT SRL technical desk. The manual asks for a hypoid oil to API GL-5 and MIL-L-2105B in SAE 80W-140, 80W-90, 90 or 85W-140 by ambient temperature, as recorded at HIT SRL. The driveline section of the same manual gives about 23 l for the axle, a figure that does not match the technical data, and both stay here as printed.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-drive-axle-oil · HIT ref KDCE-038 · fingerprint 4966ec · see HIT ref KDCE-034, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-kessler-d81-drive-axle
Kalmar DCE 90-180: which tyres and pressures does it use?
Air-inflated 11.00-20/16PR, 12.00-20/20PR or 12.00-20/20PR HD tyres at 0.9 or 1.0 MPa depending on the version, with Michelin tyres always at 1.0 MPa, according to the operator's manual (series 8), as recorded by the HIT SRL technical desk. The pressure plate on the machine is the reference, and that manual mentions plates for 0.7, 0.8, 0.9 and 1.0 MPa, as HIT SRL's technical desk reads it. The pressure to use is the one on the plate of the specific machine and in its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-tyres-and-pressures · HIT ref KDCE-039 · fingerprint 7f74c3 · see HIT ref KDCE-040, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-wheel-nut-torque
Kalmar DCE 90-180: what torque do the wheel nuts take?
650 Nm, applied alternately with increasing torque and checked again after a test run, according to the maintenance manual (series 8), the HIT SRL technical desk notes. The workshop manual (series 10, revisions 2 and 3) gives the same torque, and revision 3 counts ten nuts per wheel.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-wheel-nut-torque · HIT ref KDCE-040 · fingerprint 08cad3 · see HIT ref KDCE-039, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-tyres-and-pressures
Kalmar DCE 90-180: what torques hold the drive axle and the propeller shaft?
650 Nm for the drive axle mounting and 98 Nm for the propeller shaft mounting, according to the maintenance manual (series 8), as recorded at HIT SRL. The workshop manual (series 10, revision 3) prints the same two values and fixes the steering cylinder at 600 Nm with oil.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-axle-and-propeller-shaft-torques · HIT ref KDCE-041 · fingerprint 21a4dd · see HIT ref KDCE-034, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-kessler-d81-drive-axle
Kalmar DCE 90-180: how fast does it travel and lift?
Up to 30 km/h forward and reverse, laden or unladen, and 28 km/h laden with the 85 kW engine, according to the manufacturer's technical information brochure, as HIT SRL's technical desk reads it. The same brochure gives lifting speeds of 0.40-0.50 m/s unladen and 0.35-0.45 m/s at rated load, a lowering speed of 0.40 m/s and a mast tilt of 5 degrees forward and 10 degrees back.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-travel-and-lifting-performance · HIT ref KDCE-042 · fingerprint feec8e · see HIT ref KDCE-036, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/transmission-and-driveline/#hit-dce-machine-layout