Kalmar DCE 90-180 — Troubleshooting and error codes: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the error code levels, transmission modes and fault finding 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 are the KCS error codes graded?
In three levels: STOP, a serious fault that may affect safety or cause a breakdown, WARNING, to be put right as soon as possible while work may go on, and INFORMATION, such as low fuel, for a suitable moment, according to the operator's manual (series 8), as recorded by the HIT SRL technical desk. With a STOP code the machine is parked at once, the engine stopped and service called, and every level lights the red KCS lamp with its own symbol, a STOP sign, a triangle or a spanner, according to that manual, as HIT SRL's technical desk reads it. The workshop manual (series 10, revision 3) uses the same classification.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-error-code-levels · HIT ref KDCE-123 · fingerprint b43cdc · see HIT ref KDCE-124, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-reset-key
Kalmar DCE 90-180: what does the Reset key do with an error code?
It hides the code from the display, and if the cause remains a STOP code returns within one minute and a WARNING or INFORMATION code within three minutes, according to the operator's manual (series 8), as HIT SRL's technical desk reads it. A code whose cause has gone clears itself within 30 seconds in that manual, and the workshop manual (series 10, revision 3) gives the same times, as recorded by the HIT SRL technical desk. The maintenance manual (series 8) states instead that an INFORMATION code cleared with Reset is not shown again until the system is restarted, and both behaviours stay here as printed.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-reset-key · HIT ref KDCE-124 · fingerprint bfe59a · see HIT ref KDCE-123, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-error-code-levels
Kalmar DCE 90-180: how are machine, engine and transmission faults shown?
Three digits for a machine fault, code 1200 plus an SPN/FMI number to SAE J1939 for the engine, to be quoted to the engine supplier, and code 900 for the transmission, according to the operator's manual (series 8), the HIT SRL technical desk notes. Several engine or transmission codes are shown in turn at intervals of about one second, as that manual describes, as set out in the HIT SRL technical cards. For the Volvo engines SAE J1587 codes can also be read with the diagnostic tool of the engine maker, and the workshop manual (series 10, revision 3) has a table of the FMI meanings from 0 to 31.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-error-code-formats · HIT ref KDCE-125 · fingerprint 3df423 · see HIT ref KDCE-126, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-common-machine-codes
Kalmar DCE 90-180: what do codes 352, 354, 355 and 357 mean?
352 is low fuel level (INFORMATION), 354 low coolant level with reduced engine speed (STOP), 355 high hydraulic oil temperature (WARNING) and 357 low accumulator pressure with limited service brake capacity (STOP), according to the operator's manual (series 8), as recorded at HIT SRL. With code 355 the hydraulic functions are not used until the oil is below 70 °C, the same manual states, as logged by the HIT SRL technical desk. Code 357 is set after 10 seconds of low pressure, with up to 60 seconds tolerated at start-up, in the workshop manual (series 10, revision 3), which then has the machine stopped and the accumulator checked.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-common-machine-codes · HIT ref KDCE-126 · fingerprint d2548e · see HIT ref KDCE-123, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-error-code-levels
Kalmar DCE 90-180: what do codes 43.07 and 43.08 mean on the Dana transmissions?
Converter oil temperature: above 100 °C for 43.07, which calls for stopping or smoother driving, and above 125 °C for 43.08, when the control unit selects neutral and caps engine power at 50%, according to the operator's manual (series 8), as HIT SRL's technical desk reads it. With 43.08 the operator stops, selects neutral and runs the engine at full throttle within that limit until the oil is below 100 °C, according to that manual, as recorded by the HIT SRL technical desk. The operator's manual (series 2) words the 43.08 action differently, with neutral and half throttle until the code disappears.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-torque-converter-temperature-codes · HIT ref KDCE-127 · fingerprint 9a3045 · see HIT ref KDCE-128, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-dana-limp-home-and-shut-down
Kalmar DCE 90-180: what are the limp-home and shut-down modes of the Dana transmissions?
Two protective modes of the Dana control unit, according to the maintenance manual (series 8): limp-home, shown as LH, which leaves the first two gears in both directions after faults such as a failed control output, a failed engine speed sensor or two of three failed vehicle speed sensors, and shut-down, shown as Sd, with the transmission locked in neutral, as set out in the HIT SRL technical cards. In limp-home the transmission first goes to neutral and the gear is selected again, and after a fault in a high gear the operator shifts down by hand to first or second, according to that manual, the HIT SRL technical desk notes. The operator's manual (series 8) describes the same modes, and what to do in each is set out in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-dana-limp-home-and-shut-down · HIT ref KDCE-128 · fingerprint cb00ae · see HIT ref KDCE-129, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-zf-reduced-modes
Kalmar DCE 90-180: which reduced modes does the ZF transmission have?
Four, according to the operator's manual (series 8): substitute clutch control, limp-home, transmission shut-down and control unit shut-down, as logged by the HIT SRL technical desk. Substitute clutch control allows normal use with standard modulation values, and limp-home gives one gear in each direction, sometimes only one direction, reselected after stopping in neutral, according to that manual, as recorded at HIT SRL. In the two shut-down modes the transmission stays in neutral, the machine is parked and the engine switched off, as the maintenance manual (series 8) also describes, and the steps to follow are those in the manual of each machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-zf-reduced-modes · HIT ref KDCE-129 · fingerprint d59440 · see HIT ref KDCE-128, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-dana-limp-home-and-shut-down
Kalmar DCE 90-180: which order does fault finding follow?
Battery disconnect switch on, battery voltage of 22-28.5 V and fuses intact, then fluid levels, then the error codes with the actions of the error code lists, then the function description with its pressure and diagnostic check points, and the wiring and hydraulic hoses last, according to the workshop manual (series 10, revision 3), as recorded by the HIT SRL technical desk. That manual warns against drawing conclusions too fast from an error code, as HIT SRL's technical desk reads it. For wiring it measures resistance and insulation to the frame, and for hoses it depressurises the system and looks for chafing and leaks, as revision 2 of the same manual also does.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-troubleshooting-order · HIT ref KDCE-130 · fingerprint 2d4453 · see HIT ref KDCE-123, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-error-code-levels
Kalmar DCE 90-180: what if the engine does not start?
Retry after 15-20 seconds, never run the starter for more than 10 seconds per attempt, and call service if it still fails, according to the operator's manual (series 8), the HIT SRL technical desk notes. The same manual forbids start spray for the risk of explosion and needs the selector in neutral for the starter to engage, as set out in the HIT SRL technical cards. An electric restart lock in that manual stops the starter from engaging with the engine running, and the operator's manual (series 2) gives the same instructions.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-engine-starting-attempts · HIT ref KDCE-131 · fingerprint c4d313 · see HIT ref KDCE-130, https://www.hitsrl.it/technical-resources/guides/kalmar-dce-90-180/troubleshooting/#hit-dce-troubleshooting-order