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Содержание DCF100-45E7

Страница 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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Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

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