Description

Kalmar DC 4160, DC 4560 Parts Catalog – The Only OEM Source for Spare Parts

You’re staring at a machine that won’t move because a hydraulic fitting cracked, and the aftermarket catalog you bought online shows a drawing that doesn’t match the part in your hand. That’s the frustration that keeps a lift truck down for a day. The Kalmar DC 4160, DC 4560 Parts Catalog fixes that. It’s the exact same binder Kalmar dealers used when you call them up – 1829 pages of exploded diagrams, part numbers, and cross-references that come straight from the factory. No swiped PDFs, no reprints. Just the original OEM file.

This catalog covers the DC 4160 and DC 4560 in RS and RC variants. Every bolt, seal, sensor, and hose is listed with its Kalmar part number. You’ll find the machine card instructions on pageu202f1 (the note says it all: “Always check the machine card before using this spare parts catalogue”). That’s the first thing you do – not guess.

Machine Card and Catalog Instructions – Your Starting Point

Before you order a single part, you read the machine card that shipped with your truck. Pageu202f1 tells you to check it. The catalog instructions (group 00) explain how to read the exploded views and text pages. Each group has its own numbering. If you skip this, you’ll order the wrong hydraulic cylinder for the wrong serial number range.

7 Major System Groups in This Catalog

The catalog is split into 10 main groups, but the ones you’ll use most are the seven that cover the guts of the machine:

• 10 – Truck Body and Cab
• 20 – Electrical System
• 30 – Engine and Exhaust System
• 40 – Power Transmission (brakes and driveline)
• +50 – Compressed Air System
• 60 – Steering System
• +70 – Hydraulic System

Each group starts with a table of contents specific to that section. The electrical group alone runs over 50 pages in the original Swedish-English layout. That’s not a typo – Kalmar designed this catalog for global distribution, so labels are in both languages.

What Does the Electrical Section Cover?

Group 20 – Elsystem. You’ll see alternator wiring, starter motor components, fuse boxes, and harness connectors. Every electrical part gets a position number and an article number. Cross-reference that number in the Numerical Register (group 99) to confirm it fits your machine’s serial number. The same goes for the engine group (30) – valve covers, injectors, gaskets, you name it.

Power Transmission: 40 – Brakes and Driveline

Group 40 covers the torque converter, axle shafts, brake discs, and seals. The exploded views show every shim and washer. Need a brake piston seal for the DC 4560? Look up the group 40 page for your model variant – the part numbers are listed per issue (the catalog shows edition 101/91).

Understand the Numerical Register Before You Order

Group 99 is a numerical index of every part number in the catalog. If you have an old part number from a previous repair, look it up here to see which group and position it belongs to. That’s how you avoid ordering a part that supersedes to a different design. Pageu202f3 (the ordering instructions) tells you to include the machine model, serial number, and engine/transmission numbers when you’re unsure. You’ll find the engine and transmission specs on the truck’s nameplates.

Why OEM Matters – This Is Not an Aftermarket Reprint

Aftermarket catalogs guess at part numbers. Kalmar’s own production engineers wrote this one. The part numbers on the exploded views match what comes in the factory box. If a part is listed under “Engine” and “Exhaust,” it’s because it belongs in both assemblies – the catalog shows you exactly where it goes. Kalmar DC 4160, 4560 1990 Technical Manual – Factory Specs works alongside this parts catalog for repair procedures. For similar forklifts, check Kalmar DRF 100 Spare Parts Catalogue or Kalmar DRS4527-S5 2000 Parts Catalog.

External context: the heavy equipment industry has long standardized on OEM documentation for liability reasons. Automotive Industry Overview explains why factory data reduces errors. Same link applies for sourcing: Automotive Industry Overview.

Short paragraph: This catalog doesn’t show torque specs. It’s for parts ordering only.

Long paragraph: The 1829 pages sound overwhelming, but the layout is logical. Open the PDF and go to group 80 if you need mast rollers or carriage parts. Group 90 covers miscellaneous equipment like lights and mirrors. The published issue date is 101/91 – that’s still the active official catalog for these models. Kalmar has not released a newer edition for the DC 4160/4560 because the parts haven’t changed. That’s reliability you can’t get from a third-party rebuild guide.

Frequently Asked Questions

Does this catalog include torque specs for reassembly?

No. This is a parts catalog, not a service manual. Use the technical manual for torque values.

Can I use this catalog for the DC 4160 only, or does it also cover the DC 4560?

It covers both models in a single book. Each section lists parts for the DC 4160 and DC 4560 separately. The machine card on page 1 tells you which serial number range applies to your truck. If your truck is a DC 4160 RS, you’ll see a code like “RS” in the part listing. Pay attention to the variant – the 4160 and 4560 share many engine parts but differ in transmission components. The catalog clearly marks the differences with separate position numbers. I’ve seen guys order a brake kit for a 4160 and try to bolt it on a 4560 – it won’t fit. That’s why you verify the machine card and then flip to group 40 for your specific model code. The exploded drawing will have a note like “DC 4160 RS / DC 4560 RC” next to the part number callout. This is exactly how Kalmar engineers intended the catalog to be read.

How do I find the correct part number for a hydraulic pump on my truck?

Go to group +70 (Hydraulic System). Find the main pump assembly drawing. Note the position number, then look up the article number on the adjacent text page. If uncertain, use the Numerical Register (group 99) and search by the part number you already have.

Is this the same as a service repair manual?

No. This catalog lists parts and part numbers only. You need the separate technical manual for disassembly and reassembly procedures. However, having the correct part number is half the battle – you cannot fix a machine if you order the wrong seal.

Bottom line: if you work on Kalmar DC 4160 or DC 4560 forklifts, this catalog pays for itself the first time you avoid a wrong part. Access the Factory Manual and keep it on your shop tablet or print the pages you need. No fluff, no filler – just OEM data.