Kalmar DCF100-45E7, Operator'S Manual

Page 1: ...S MA MANUAL NUAL Publ no IDCF03 04GB Publ no IDCF03 04GB Operator s Manual in original Operator s Manual in original 8 8 1 10 0 t t o on nn ne es s E Em m p pt t y C y C o on nt t ai ai n ne er rH H...

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Page 3: ...lic Hydraulic control control 9 9 62 62 4 7 4 7 Pedals Pedals 67 67 4 8 4 8 Steering Steering wheel wheel 4 4 68 68 4 9 4 9 Driver s Driver s seat seat 10 10 71 71 4 10 4 10 Heating Heating Air Air co...

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Page 5: ...ways be kept in the machine About machine version The information in this operator s manual corresponds to the ma chine s design and appearance at the time of delivery from Cargotec Due to customer ad...

Page 6: ...fety Read the operator s manual Read the operator s manual maintenance manual The symbol to the left is used in certain cases on the machine and re fers to important information in the operator s manu...

Page 7: ...machine Each de scription of optional equipment in the operator s manual is marked with a symbol and contains an explanatory text The symbol is highly visible and is placed next to the text and figure...

Page 8: ...apply to normal environment and operating conditions Maintenance work described in this operator s manual can be per formed by the operator see chapter 6 Inspection and maintenance This section descri...

Page 9: ...8 1 Foreword 1 3 Inspection and maintenance...

Page 10: ...r s Manual contains important information about your Kalmar machine handling the ma chine safety during operation and daily maintenance of the machine You will also find a lot of valuable information...

Page 11: ...se of higher wind speeds contact Cargotec Operator requirements The machine mayonly be operated by specially trained operators who have the work supervisor s permission to operate the machine Lawsand...

Page 12: ...d with a fire extinguisher it should be of the type ABE according to EN 3 pt 1 2 4 and 5 With such a fire extinguisher it is possible to extinguish fires in both solid organic materials and fluids Ada...

Page 13: ...equipment 9 External rear view mirrors Used to give better visibility when operating 10 Flashing brake lights when reversing 11 Breaker switch for load handling servo circuits Cuts off all power supp...

Page 14: ...outside surface of the roof window at reg ular intervals Clean only with windscreen washer flu id or a mild cleaning agent Rinse thoroughly with plenty of lukewarm water Replace a damaged roof window...

Page 15: ...ad handling equipment is blocked so that it cannot be lowered to its original position contact the Cargotec Service organisation WARNING Cab doors must always be closed when operating Risk of personal...

Page 16: ...e hydrau lic system and avoid standing close to hydraulic components or hoses Before working on the hydrau lic system the accumulators must be drained see Maintenance manual WARNING Handle batteries a...

Page 17: ...aces Hot surfaces 15 15 Filling Filling point point engine engine oil oil A32439 0300 A32439 0300 16 16 Warning Warning Filling Filling point point coolant coolant A57775 0100 A57775 0100 Use only rea...

Page 18: ...when handling wheels when handling wheels The conditions for inflation The conditions for inflation pressure change if factory fitted pressure change if factory fitted tyres are replaced with another...

Page 19: ...et pressures for the machine Information is engraved machine Information is engraved 21 21 Warning Warning A30529 0100 A30529 0100 Pressure Always release the pressure from the Pressure Always release...

Page 20: ...s or other attachments with or without loads are Forks or other attachments with or without loads are easily operated and highly forceful tools easily operated and highly forceful tools Extreme hazard...

Page 21: ...ipment in the machine s cab NOTE Thoroughly read the following chapter about instruments and controls Optional equipment Indicates optional equipment There is a wide range of optional equipment for th...

Page 22: ...wheel 5 Direction indicators 6 Panel for hydraulic functions 7 Control breaker for hydraulics 8 Switch for parking brake 9 Control lever 10 Driver s seat 11 Accelerator 12 Brake pedals 13 Clutch peda...

Page 23: ...work lights carriage and attachment Extra work lights carriage and attachment 21 Switch for work lights mast Extra work lights mast 22 Switch revolving beacon 23 Switch for flashing hazard lights 24...

Page 24: ...direction indication 46 Indicator light parking brake 47 Indicator light locked twistlock lock lugs secured load 48 Indicator light alignment attachment load 49 Indicator light unlocked twistlock lock...

Page 25: ...automatic manual locking 72 Switch for spreading 20 40 attachment 73 Switch for stop spreading at 30 attachment 74 Spare 75 Switch for automatic manual cab tilt 76 Switch for manual cab tilt 77 Switch...

Page 26: ...valve attachment side shift Side shift attachment not working WARNING 290 Control valve attachment spreading Levelling attachment not working WARNING 291 Indicator light alignment attachment upper no...

Page 27: ...to ground 7 Mechanical problem Incorrect response from mechanical system 8 Mechanical problem or electrical problem Abnormal frequency 9 Communication error Abnormal update rate 10 Mechanical problem...

Page 28: ...e air temperature cable short circuited to ground STOP 105 5 PID105 5 Sensor charge air temperature cable open circuit STOP 106 0 PID102 0 High boost pressure Reduced engine power STOP 106 3 PID102 3...

Page 29: ...in cold weather STOP 629 3 SID254 3 Internal error engine control unit Engine off engine cannot be started Engine running engine misfires STOP 629 8 SID254 8 Internal error engine control unit Engine...

Page 30: ...er STOP 651 4 SID1 4 Electrical problem injector cylinder 1 Engine only runs on 5 cylinders and has reduced power STOP 651 5 SID1 5 Electrical problem injector cylinder 1 Engine only runs on 5 cylinde...

Page 31: ...alfunction or defective injector cylinder 4 Rough running at low rpm and low load STOP 654 12 SID4 12 Electrical problem injector cylinder 4 Engine only runs on 5 cylinders and has reduced power STOP...

Page 32: ...ted to frame STOP 679 13 SID42 13 Governor injection pressure Risk of engine stop STOP 679 0 PSID97 0 Pressure relief valve Engine rpm limited to 1100 rpm STOP 679 7 PSID97 7 Pressure relief valve Eng...

Page 33: ...able short circuited to voltage STOP 2791 4 PPID19 4 EGR status cable short circuited to frame STOP 2791 5 PPID19 5 EGR status cable open circuit STOP 2791 7 PPID19 7 EGR status STOP 520195 5 PPID6 5...

Page 34: ...l Abnormallylow voltageor short circuitingto lower voltage WARNING 100 1 Engine oil pressure low Data valid but higher than normal operating range STOP Very serious 100 18 Engine oil pressure low Data...

Page 35: ...0 16 Coolant temperature engine high Data valid but higher than normal operat ing range WARNING 110 2 Sensor coolant engine defective circuit Defective uneven or rough WARNING 110 3 Sensor coolant eng...

Page 36: ...e STOP Very serious 190 2 Main rpm sensor defective Defective uneven or rough WARNING 190 2 Rpm position sensor Defective uneven or rough WARNING 251 2 Real time clock open circuit power supply Defect...

Page 37: ...Defective uneven or rough WARNING 647 3 Circuit error switch cooling fan Abnormally high voltage or short circuiting to higher voltage WARNING 647 4 Circuit error switch cooling fan Abnormally low vol...

Page 38: ...ti ting ng co coil il ci circ rcui uit t Ab Abno norm rmal ally ly hi high gh vo volt ltag age o e or r sh shor ort t ci circ rcui uiti ting ng to to hi high gher er voltage voltage WARNING WARNING 72...

Page 39: ...voltage WARNING WARNING 11 1172 72 4 4 Tu Turb rboc ocha harg rger p er pre ress ssur ure te e temp mper erat atur ure s e sen enso sor c r cir ircu cuit it Ab Abno norm rmal ally lylo low v w vol olt...

Page 40: ...ran ansm smis issi sion in on in locked neutral position shutdown locked neutral position shutdown STOP STOP 00 00 5 53 3 Me Memo mory e ry err rror i or in co n cont ntro rol uni l unit tr t tran ans...

Page 41: ...in 50 50 00 00 Sen Sensor sor oil oil pre press ssure ure sho short rt cir circui cuitin ting g to to gro ground und Con Contro trol l uni unit t transmission activates limp home transmission activate...

Page 42: ...trol unittransmissionactivates limp home STOP Stop the machine and shift to neutral Select reverse gear 71 00 Solenoid valve VFS 2 Control unit transmission activates limp home STOP Stop the machine a...

Page 43: ...TOP Stop the machine and shift to neutral Select reverse gear 77 02 All gear packs disengaged Transmission in locked neutral po sition shutdown STOP 80 00 Solenoid valvedrive short circuiting to groun...

Page 44: ...ith special care where persons or vehicles may appear The operator must adapt the speed to the loadand ground conditions visibility and wind conditions etc The operator mustpay extra attention and ope...

Page 45: ...he tank NOTE The fuel indicator should never go down to empty tank that all warning lights are off that horn lighting brake lights and direction indicators function correctly that all hydraulic functi...

Page 46: ...f if preheating is in progress not activated no need or has been finished For engine alternative Cummins QSB6 7 Has automatic preheating without indicator to the operator 4 Turn the start key to start...

Page 47: ...ECC The system is controlled by switches for fan heat and air distribution In addition there are functions for recirculation and defroster WARNING At speeds below 8 km h the parking brake can be used...

Page 48: ...y manual control in 13 steps from off to max Fan speed is shown by the bar s height in the operating menu for heating air conditioning system See position C on display Recommendation Set the fan to au...

Page 49: ...on the function key for Enter when the operating menu is shown See position G 5 Activate defroster position 54 The defroster controls the function fan temperature and damper position to optimally hea...

Page 50: ...chment completely and tilt the mast forward 4 Let the engine run 1 minute at idle speed before stopping the en gine so that the engine cools down slightly and the turbo bearings are lubricated 5 Stop...

Page 51: ...parameters position of load s centre of gravity lifting height load s size The capacity varies between models and versions see the machine and type plates section 3 2 Plates It s important to estimate...

Page 52: ...load in high position since this may cause the machine to roll or tip over Always operate with the load facing uphill on an uphill or downhill grade never operate or turn across a grade Operate the ma...

Page 53: ...eeds 5 km h 2 Adjust load height and tilt angle to transport position seeTrans port position page 143 Transport position When the machine is to be run with or without load assume the trans port positi...

Page 54: ...s there is a greater risk of roll over and tipping over Keep in mind the angle of the ramp NOTE When braking use only the service brake pedal right hand brake pedal Do not operate service brake in com...

Page 55: ...locked 6 Adjust the lifting height to transport position The speed is re duced Operate with extreme care Locking of hook attachment with tightly packed containers After a container is lifted out betw...

Page 56: ...ullywith reduced speed so that the lock holes on both sides are in the clear 6 Set down the container and adjust so that the sidelift has align ment Check that the orange lights go on B2 for lift of o...

Page 57: ...uge piece 1 Fasten the gauge piece position 1 on the attachment 2 Lock the gauge piece with the pin position 2 Working near overhead high voltage power lines Operate with extreme care in all work near...

Page 58: ...ced 6 Open twistlocks lock lugs manually with the switch see Overview Spirit Delta page 44 position 69 When releasing twistlocks lock lugs with activated manual locking of twistlocks lock lugs you mus...

Page 59: ...lly when the attachment at a pre set lifting height For manual cab tilt the cab is tilted with switch position 76 For automatic cab tilt speed must not exceed 5 km h operator doors must be closed and...

Page 60: ...pped and the figure in the display is shown Lower the mast for continued load handling If it is necessary to lift above the height limitation then the function can be by passed Activate the by pass sw...

Page 61: ...uid windows Engine oil Transmission oil 3 Check that the engine s indicator forair filter also check and drain the fuel prefilter as needed Volvo engine and the fuel filter Cummins engine For descript...

Page 62: ...k the lift attachment and that Indicator lights for twistlocks lock lugs and alignment work Alignment pins bytwistlocks lock lugs can move easilyup and down Note that an alignment pin that binds in th...

Page 63: ...by press ing in the override button and checking that warning lamp for by pass of hydraulic functions position 35 is on 8 Check the machine s operating hours notify the foreman super visor if the mach...

Page 64: ...g when maintenance work is to be performed Always turn off the engine during service work Only exception is when service work requires engine power No work may bedone on the machine without the right...

Page 65: ...e again CAUTION High pressure washing of sensitive components may lead to short circuiting and cause malfunction Product damage Do not use a high pressure washer on the battery compartment electric co...

Page 66: ...Position the Position the attachment and attachment and carriage on carriage on blocks on blocks on the mast the mast Be Be careful so that the mast and careful so that the mast and its components ar...

Page 67: ...azardous waste NOTE NOTE Plug all connections immediately to protect the hydraulic system Plug all connections immediately to protect the hydraulic system from contaminants from contaminants 6 6 Secur...

Page 68: ...ast is handled 12 12 Close the Close the relief valve relief valve for the attac for the attachment and hment and the drain v the drain valve for alve for brake accumulators brake accumulators 13 13 S...

Page 69: ...e the cables and hoses so that nothing protrudes and the cables and hoses so that nothing protrudes and can be dam can be dam aged during transport aged during transport 20 20 Secure Secure the mast s...

Page 70: ...etween mast and ma chine but not the hydraulic hoses for the lift cylinders Collect the waste oil in containers Oil spills are handled as environmentally hazardous waste NOTE Plug all connections imme...

Page 71: ...that the upper mountings are unloaded 8 Remove the cylinder s shafts Use the threaded holes and a pull er to pull out the shafts 9 Release the tilt cylinders from the mast and then refit the shafts i...

Page 72: ...dous waste 14 Lift away the mast lower the mast onto blocks and angle it down towards the ground being careful that the mast s parts are not damaged during handling 15 Lower the tilt cylinders towards...

Page 73: ...hose retainer s support from the mast Refit the screws 25 Attach the hose roller in the top of the mast 26 Angle the hose retainerup against the mast and attach the hoses and cables along the side of...

Page 74: ...ame from the machine into the frame from the machine 9 9 Lubricate the Lubricate the shafts shafts and bracket and bracket align the s align the shafts in hafts in each respec each respec tive mast br...

Page 75: ...ors valve for brake accumulators 18 18 Remove Remove the plugs o the plugs on the hyd n the hydraulic hoses raulic hoses and connect and connect the hy the hy draulic hoses to the lift draulic hoses t...

Page 76: ...for brake accumulators brake accumulators 24 24 Start Start the engine the engine and tilt and tilt the ma the mast fully st fully forward forward 25 25 Switch o Switch off the ff the engine and engi...

Page 77: ...oltage with the battery battery disconnector disconnector 4 4 Remove Remove the safety the safety catch from catch from the chains the chains in the m in the mast ast 5 5 Start the m Start the machin...

Page 78: ...stem voltage with the battery disconnector 11 Connect the chain to the carriage If necessary lift the attach ment with the lifting equipment 12 Release the lifting equipment from the attachment The fi...

Page 79: ...the attachment and the drain valve for brake accumulators 19 Start the machine and check that the hydraulic connections are sealed 20 Check the mast functions by testing them with the levers in the c...

Page 80: ...ice position is used for service maintenance and other situations when the machine needs to be secured Service position entails The machine is parked i e parking brake applied Trolley and attachment i...

Page 81: ...7 Transporting the machine 7 4 Long term storage 213 7 4 Long term storage page General For long term storage of the machine contact Cargotec...

Page 82: ...218 8 Environment and standards...

Page 83: ...1500 rpm Number of cylinders 6 cylinders 6 cylinders Alternator output 1920 W 1680 W Start battery voltage capacity 2x12 V 140 Ah 2x12 V 140 Ah 2 Transmission Dana Spicer Off Highway TE17 No of gears...

Page 84: ...7 Coolant volume 22 l 29 l Coolant filling point Volvo Penta Coolant VCS ready mixed ES Compleat Premix CAUTION Different types of coolant may not be mixed Risk of engine damage if different types of...

Page 85: ...ccessories Refrigerant air conditioning R134a Volume refrigerant See the plate for air conditioning Lubricant air conditioning ZEXEL PAG oil ZXL100 Washer fluid volume 5 l 10 Common hydraulics Oil qua...

Page 86: ...2 EC Name Position Head Of Counterbalanced Products Place Date of Issue Signature The Electro Magnetic Compatibility Directive 2004 108 EC Engine Year of construction is manufactured in conformity wit...

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Page 88: ...Cargotec improves the ef ciency of cargo ows by offering solutions for the loading and unloading of goods on land and at sea wherever cargo Cargotec Sweden AB Torggatan 3...