Kalmar DCF100-45E7 Operator's Manual
  1. Manuals
  2. Brands
  3. Kalmar Manuals
  4. Tractor
  5. DCF100-45E7
  6. Operator's manual
Kalmar DCF100-45E7 Operator's Manual

Kalmar DCF100-45E7 Operator's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

E
E
m
m
p
p
t
t
y C
y C
8
8
-
-
1
1
0
0
t
t
o
o
Publ. no IDCF03.04GB
Publ. no IDCF03.04GB
Operator's Manual in original
Operator's Manual in original
o
o
n
n
t
t
ai
ai
n
n
n
n
n
n
e
e
s
s
e
e
r
r
H
H
and
an
d
l
l
e
e
r
r
OPERATOR'S MA
OPERATOR'S
MANUAL
NUAL

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the DCF100-45E7 and is the answer not in the manual?

Questions and answers

Can los
February 25, 2025

Ottawa yargo tractor ac not working how to repair

0

Subscribe to Our Youtube Channel

Related Manuals for Kalmar DCF100-45E7

Summary of Contents for Kalmar DCF100-45E7

  • Page 1 Publ. no IDCF03.04GB Publ. no IDCF03.04GB OPERATOR'S OPERATOR'S MA MANUAL NUAL Operator's Manual in original Operator's Manual in original...
  • Page 3 Forew Foreword..ord.......................................... 3 3 About About the the operator’s operator’s manual manual ............................3 3 About About the the documentatio documentation n kit kit ........
  • Page 5 1 Foreword   1 Foreword 1 Foreword mm mm mm mmmm mm About the operator’s manual General page  – Thank you for choosing Cargotec as your machine supplier. We hope that we’ll meet your expectations. This Operator’s manual contains information that you must keep in mind for safe handling and optimal use of your new machine.
  • Page 6 1 Foreword – 1.1.1 Reading instructions 1.1.1 Reading instructions Warning information page  – This operator’s manual contains warnings that involve your safety. The warnings provide information on potential dangers that, if not heeded, could lead to personal injury or product damage. D A NG E R Situation that could lead to severe personal injury or death if regulation is not followed.

  • Page 7: Optional Equipment

    1 Foreword – 1.1.1 Reading instructions Optional equipment  – There is a wide range of optional equipment for the machine. Each de-         4 scription of optional equipment in the operator’s manual is marked with         6         2         0         0 a symbol and contains an explanatory text. The symbol is highly visible         0 Indicates optional equipment and is placed next to the text and figure item in question.

  • Page 8: Inspection And Maintenance

    1 Foreword – 1.3 Inspection and maintenance Inspection and maintenance General page  – For satisfactory function of the machine to the lowest cost, mainte- nance must be performed correctly. Intervals for care and lubrication 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.
  • Page 9 1 Foreword – 1.3 Inspection and maintenance...

  • Page 10: Intended Use

    Therefore, read the Operator’s Manual very thorough- ly before starting to use the machine. The Operator’s Manual contains important information about your Kalmar machine, handling the ma-         2 chine, safety during operation, and daily maintenance of the machine.

  • Page 11: Operator Requirements

    2 Safety  Any modification or rebuild without Cargotec’s permissions can- cels Cargotec’s product responsibility. Modifications and rebuilds may only be done if the knowledge exists to verify and test modi- fications and rebuilds. Modifications and rebuilds shall be docu- mented (dates and actions) and responsible organisation shall b e stated with name and address.
  • Page 12 2 Safety – 2.1 Safety and emergency equipment Safety and emergency equipment General page  –  A good work environment has safety and emergency equipment to fa- cilitate and make the operator’s work safe. The machine shall be equipped with the following equipment. 6,7,11         2         1...
  • Page 13 2 Safety – 2.1 Safety and emergency equipment 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 supply and control signals to hydraulics.
  • Page 14 2 Safety – 2.4 Keep in mind W A RN I N G The machine’s load capacity is limited. Risk of roll-over and tipping over! Fatal danger! It is prohibited to exceed the machine’s load capacity. See marking plate and load diagram. W A RN I N G The strength of the roof window may be significantly reduced in the event of exposure to substances con-...
  • Page 15 2 Safety – 2.4 Keep in mind W A RN I N G Work position on the machine is located up high. Risk of falling and bodily injury! Always use the steps and handles when you climb up or down from the machine. Always face the machine. Do not jump! W A RN I N G No lowering of load handling equipment when contro l...
  • Page 16 2 Safety – 2.4 Keep in mind W A RN I N G Be careful with a lateral sliding cab. Before the cab i s moved, make sure that no person is in the risk area outside the cab – risk of crushing. It is forbidden to operate the forklift with open doors when the cab is outside the middle position.
  • Page 17 3 3 O O v v e e r r v v i i e e w w – – 3 3 . . 2 2 P P l l a a t t e e s s 3 3 9 9 13 Warning! Warning! A30530.0200 A30530.0200...
  • Page 18 4 4 0 0 3 3 O O v v e e r r v v i i e e w w – – 3 3 . . 2 2 P P l l a a t t e e s s Power transmission, wheels Power transmission, wheels 17 Filling...
  • Page 19 3 3 O O v v e e r r v v i i e e w w – – 3 3 . . 2 2 P P l l a a t t e e s s 4 4 1 1         9         9         4...
  • Page 20 4 4 2 2 3 3 O O v v e e r r v v i i e e w w – – 3 3 . . 2 2 P P l l a a t t e e s s Lifting mast and attachment Lifting mast and attachment 22 Warning!

  • Page 21: Instruments And Controls

    4 Instruments and controls  4 Instrumentsandcontrols 4 Instruments and mm mm mm mmmm mm controls General page  – Do not operate the machine before you know the position and function of instruments and controls, and completely understand how they are used! This chapter gives general information about instruments, switches, controls and other equipment in the machine’s cab.
  • Page 22 4 Instruments and controls Overview Spirit Delta  –         8         0         1         8         0         0 Overview 1 Left instrument panel 2 Gear selector and multi-function lever  3 Steering wheel panel 4 Steering wheel 5 Direction indicators 6 Panel for hydraulic functions 7 Control breaker for hydraulics 8 Switch for parking brake 9 Control lever ...
  • Page 23 4 Instruments and controls Left instrument panel 16 Switch for fan 17 Switch for heat 18 Switch for air distribution 24..28  29 30 31 19 Switch, work lights cab roof 19..23 Extra work lights front fender 20 Switch work lights carriage and attachment         6         6         9...
  • Page 24 4 Instruments and controls Steering wheel panel 32 Warning light, low battery charging 33 Warning lamp for low brake pressure 34 Indicator for active error codes 35 Warning lamp, by-pass of hydraulic functions 36 Indicator light, activated steering with joystick or mini-wheel 37 Warning lamp, high coolant temperature 37..41 38 Warning lamp for low oil pressure engine...
  • Page 25 4 Instruments and controls Panel for hydraulic functions 65 Lift/lower  66 Tilt 67 Side shift 68 Levelling 69 Opening of twistlock / Opening and locking of lock lugs (attachment) 70 Switch for horn 71 Switch for twistlocks / lock lugs, automatic / manual locking 72 Switch for spreading 20’-40’...

  • Page 26: Code Description

    5 Handling – 5.3.3 Error code tables Code Description Action Control valve attachment (spreading). Levelling right attachment WARNING not working. Control valve attachment (side shift). Side shift left attachment not WARNING working. Control valve attachment (side shift). Side shift right attachment not WARNING working.
  • Page 27 5 Handling – 5.3.3 Error code tables Error codes engine  – For contact with engine manufacturers, use Volvo code. • Display indicates error code acc. to SAE J1939 SPN / FMI • J1587 indicates error code acc. to SAE J1587 (for Volvo: Vodia). PID, PPID, SID, PSID / FMI Table 2.
  • Page 28 5 Handling – 5.3.3 Error code tables Table 3. Error codes Volvo TAD760VE Description Action  Display J1587 SPN/FMI 94/1 PID94/1 Sensor fuel pressure, low fuel pressure. STOP 94/3 PID94/3 Sensor fuel pressure, cable short-circuited to voltage. STOP 94/5 PID94/5 Sensor fuel pressure, cable open circuit or short-circuited to STOP ground.
  • Page 29 5 Handling – 5.3.3 Error code tables Description Action  Display J1587 SPN/FMI 158/1 PID158/1 Low battery voltage. Engine may be difficult to start. STOP 164/0 PID164/0 Incorrect pressure fuel injection. STOP 164/2 PID164/2 Pressure fuel injection. Engine rpm limited to 1100 rpm. STOP 164/4 PID164/4...
  • Page 30 5 Handling – 5.3.3 Error code tables Description Action  Display J1587 SPN/FMI 637/8 SID22/8 Sensor rpm flywheel. Abnormal frequency. Engine is extremely STOP difficult to start and runs rough or stops. 639/2 SID231/2 Internal error engine control unit. STOP Engine off: engine cannot be started. Engine on: engine goes to idle mode and can only be stopped by using emergency stop.
  • Page 31 5 Handling – 5.3.3 Error code tables Description Action  Display J1587 SPN/FMI 653/3 SID3/3 Electrical problem, injector cylinder 3. Engine only runs on STOP 5 cylinders and has reduced power. 653/4 SID3/4 Electrical problem, injector cylinder 3. Engine only runs on STOP 5 cylinders and has reduced power.
  • Page 32 5 Handling – 5.3.3 Error code tables Description Action  Display J1587 SPN/FMI 656/7 SID6/7 Compression malfunction or defective injector cylinder 6. STOP Rough running at low rpm and low load. 656/12 SID6/12 Electrical problem, injector cylinder 6. Engine only runs on STOP 5 cylinders and has reduced power.
  • Page 33 5 Handling – 5.3.3 Error code tables Description Action  Display J1587 SPN/FMI 1239/1 PSID96/1 Incorrect fuel pressure injection. Engine rpm limited to STOP 1100 rpm. 1239/4 PSID96/4 Incorrect fuel pressure injection. Engine is turned off or engine STOP rpm limited to 1100 rpm. 1239/7 PSID96/7 Incorrect fuel pressure injection.
  • Page 34 5 Handling – 5.3.3 Error code tables Description Action  Display SPN/FMI 91/19 SAE J1939 multiplexing, system error accelerator pedal sensor - CAN-bus WARNING! data error. 91/2 Position sensor accelerator pedal. WARNING! 91/3 Position sensor accelerator pedal, defective circuit - Abnormally high voltage WARNING! or short-circuiting to higher voltage.
  • Page 35 5 Handling – 5.3.3 Error code tables Description Action  Display SPN/FMI 105/0 Circuit temperature sensor inlet manifold - Data valid, but higher than normal STOP! Very serious operating range. 105/15 Temperature inlet manifold high - Data valid, but higher than normal operating WARNING! range.
  • Page 36 5 Handling – 5.3.3 Error code tables Description Action  Display SPN/FMI 157/3 Measurement injection pressure bank 1, defective circuit - Abnormally high WARNING! voltage or short-circuiting to higher voltage. 157/4 Measurement injection pressure bank 1, defective circuit - Abnormally low WARNING! voltage or short-circuiting to lower voltage.
  • Page 37 5 Handling – 5.3.3 Error code tables Description Action  Display SPN/FMI 627/2 Open circuit power supply despite ignition in position on - Defective, uneven, WARNING! or rough. 627/2 Open circuit power supply despite ignition in position on - Defective, uneven, WARNING! or rough.
  • Page 38 1 1 1 1 4 4 5 5 H H a a n n d d l l i i n n g g – – 5 5 . . 3 3 . . 3 3 E E r r r r o o r r c c o o d d e e t t a a b b l l e e s s D D e e s s c c r r i i p p t t i i o o n n A A c c t t i i o o n n  Display...
  • Page 39 5 5 H H a a n n d d l l i i n n g g – – 5 5 . . 3 3 . . 3 3 E E r r r r o o r r c c o o d d e e t t a a b b l l e e s s 1 1 1 1 5 5 D D e e s s c c r r i i p p t t i i o o n n A A c c t t i i o o n n...
  • Page 40 1 1 1 1 6 6 5 5 H H a a n n d d l l i i n n g g – – 5 5 . . 3 3 . . 3 3 E E r r r r o o r r c c o o d d e e t t a a b b l l e e s s D D e e s s c c r r i i p p t t i i o o n n A A c c t t i i o o n n  Display...
  • Page 41 5 5 H H a a n n d d l l i i n n g g – – 5 5 . . 3 3 . . 3 3 E E r r r r o o r r c c o o d d e e t t a a b b l l e e s s 1 1 1 1 7 7 D D e e s s c c r r i i p p t t i i o o n n A A c c t t i i o o n n...
  • Page 42 5 Handling – 5.3.3 Error code tables Description Action Code 62/00 Sensor engine rpm, short-circuiting to ground. STOP or WARNING If several rpm signals or the engine rpm signal are incorrect, control unit transmission activates "limp home". 62/01 Sensor engine rpm, open circuit. STOP or WARNING If several rpm signals or the engine rpm signal are incorrect, control unit transmission activates "limp home".
  • Page 43 5 Handling – 5.3.3 Error code tables Description Action Code 73/01 Solenoid valve VFS 1/3. Control unit transmission activates STOP: Stop the machine and shift to neutral. "limp home". Select reverse gear. 73/02 Solenoid valve VFS 1/3. Control unit transmission activates STOP: Stop the machine and shift to neutral.

  • Page 44: While Operating

    5 Handling – 5.4 Operating Operating 5.4.1 While operating General page  – D A NG E R The machine’s work area is large and visibility from the operator’s cab is restricted. Extreme hazard to personal health and risk of proper- ty damage! Keep in mind: •...
  • Page 45 5 Handling – 5.4.1 While operating W A RN I N G Never operate the machine without wearing the seatbelt. Extreme danger! Always use the seatbelt when operating the machine, even when you expect a short shift. The seatbelt may not be modified.

  • Page 46: Starting Engine

    5 Handling – 5.4.2 Starting engine 5.4.2 Starting engine General page  – W A RN I N G If it’s difficult to start the engine, do not use start spray. Risk of explosion! In case of start problems, contact service. Instructions  –...

  • Page 47: Emergency Brake

    5 Handling – 5.4.8 Heating / Air conditioning Emergency brake  –  At speeds below 8 km/h, the parking brake can be used as an emer- gency brake and in emergencies. W A RN I N G At speeds below 8 km/h, the parking brake can be used as an EMERGENCY BRAKE.
  • Page 48 5 Handling – 5.4.8 Heating / Air conditioning Normal weather conditions  – 1 Set desired temperature (position 17). Set the temperature within temperature range 16 °C to 27 °C. See position B on display. Setting of min. and max. respectively, shuts off automatic climate control (control of fan, temperature and air distribution) and sets the heat valve in min.
  • Page 49 5 Handling – 5.4.8 Heating / Air conditioning Mist on windows  – 1 Set a warm temperature (position 17). 2 Set a fan speed to a faster position (position 16). 3 Set air distribution (position 18) and panel nozzles (position A) at the front windshield to get g ood visibility through the windows.
  • Page 50 5 Handling – 5.4.9 Stopping engine – parking 5.4.9 Stopping engine – parking General page  – NOTE Never disconnect the main electric power with the battery discon- nector when the engine is running! The voltage regulator may be damaged. Instructions  –...

  • Page 51: Load Handling

    5 Handling – 5.5 Load handling Load handling General page  – During all lifting work, it is important to remember to not exceed maxi- mal lift capacity. Load handling also includes lifting tools. The machine’s capacity is indicated by three parameters: •...
  • Page 52 5 Handling – 5.5.2 Transporting load 5.5.2 Transporting load General page  – W A RN I N G Transporting loads is associated with major risks. Risk of roll-over and tipping over! Risk of load dam- age to property! Fatal danger! Respect the lifting capacity of the machine and exer- cise the greatest caution during load handling: •...

  • Page 53: Transport Position

    5 Handling – 5.5.2 Transporting load Instructions for sidelift  – 1 Lift the load slightly. Back away from the stack. When lifting, the middle light, B – Alignment, (orange), is off. Then the function for twistlocks is disengaged. The function for opening lock lugs still works but is disengaged when travel speed exceeds 5 km/h.
  • Page 54 5 Handling – 5.5.2 Transporting load The machine should be run in transport position even without load in order to maximise operator visibility. In transport position without load, the mast shall be vertical and the at- tachment raised for good forward visibility, see figure to the left.         6         2         1...
  • Page 55 5 Handling – 5.5.2 Transporting load Lift of 45’ empty container with hook attachment  – Set length adjustment to 40 foot position. Run slowly toward the container. Adjust sideways. Set the mast vertical. Align the hooks in the container’s lift holes. Run forward until the sidelift has alignment with the container.
  • Page 56 5 Handling – 5.5.2 Transporting load Lift tightly spaced containers with hook attachments  – Set length adjustment to container length in question. Run slowly toward the container. Adjust sideways. Set the mast vertical. Align the hooks in the container’s lift holes. Run forward until the sidelift has alignment with the container.
  • Page 57 5 Handling – 5.5.2 Transporting load Handling standard containers with wide body  – attachment To handle standard containers with machine equipped with wide body attachment, a gauge piece must be installed on the attachment. To install the gauge piece: Fasten the gauge piece (position 1) on the attachment. Lock the gauge piece with the pin (position 2).
  • Page 58 5 Handling – 5.5.3 Unloading 5.5.3 Unloading Instructions for sidelift page  – 1 Run forward towards the stack of containers, as close as possi- ble. Strive to line up the lifted container’s centre line with the cen- tre of the container stack. 2 Lift the load over the stack.
  • Page 59 5 Handling – 5.5.4 Functions for load handling 5.5.4 Functions for load handling Cab tilt page  – Cab tilt facilitates visibility during load handling. The cab is tilted up to obtain a more ergonomic operating position. With switch (position 75) select automatic tilt or manual tilt.
  • Page 60 5 Handling – 5.5.4 Functions for load handling Height limitation  – Height limitation limits how high the mast can be raised. The height limitation can be adjusted in accordance with customer requirements. When the mast reaches a certain preset height (position A), the lifting movement is stopped and the figure in the display is shown.
  • Page 61 6 Inspection and maintenance – 6.1 Daily inspection • Tyre pressure • Damage or cracks in vital components and their mountings such as lifting chains, fork mountings, mast and tilt cylinders D A NG E R Cracks in materials or welds in load bearing struc- tures can reduce the machine’s strength.
  • Page 62 6 Inspection and maintenance – 6.1 Daily inspection Operate the machine slowly/carefully and check the following functions: • Brakes – check-brake at least three times • Steering – in both directions • Transmission – all gears – forward and reverse •...
  • Page 63 6 Inspection and maintenance – 6.1 Daily inspection • Check that the lock lugs are working by moving in towards double containers until the "Alignment" light illuminates. The display for the control and monitoring system, see Overview Spirit Delta, page 44 (position 51), shows by means of sym- bols which ones are aligned.

  • Page 64: Safety During Maintenance

    6 Inspection and maintenance – 6.2 Maintenance Maintenance General page  – The following maintenance actions are described in this chapter:  – Cleanliness, general page 159  – Fuel system, general page 161  – Windscreen washer, general page 163  –  Air filter engine, general page 164  –...
  • Page 65 6 Inspection and maintenance – 6.2.1 Cleanliness 6.2.1 Cleanliness Cleanliness, general page  – Dirt has a negative impact on performance. Experience shows that clean machines have less malfunctions. The machine should be washed regularly for optimal function. Keep the following in mind when washing: •...
  • Page 66 1 1 9 9 2 2 7 7 T T r r a a n n s s p p o o r r t t i i n n g g t t h h e e m m a a c c h h i i n n e – e –...
  • Page 67 7 7 T T r r a a n n s s p p o o r r t t i i n n g g t t h h e e m m a a c c h h i i n n e – e –...
  • Page 68 1 1 9 9 4 4 7 7 T T r r a a n n s s p p o o r r t t i i n n g g t t h h e e m m a a c c h h i i n n e – e –...

  • Page 69: Mast, Removal

    7 7 T T r r a a n n s s p p o o r r t t i i n n g g t t h h e e m m a a c c h h i i n n e – e –...
  • Page 70 7 Transporting the machine – 7.2.2 Transporting the machine         8         4         6        5         0         0 3 Depressurise the hydraulic system. Open the relief valve for the attachment and the drain valve for brake accumulators. W A RN I N G Pressurised oil system.
  • Page 71 7 Transporting the machine – 7.2.2 Transporting the machine 6 Connect lifting equipment to outer mast’s lifting eyes. Tension the lifting equipment so that the weight of the mast is held by the lift- ing equipment. D A NG E R Lift in the outer mast, the mast’s parts can be separated.
  • Page 72 7 Transporting the machine – 7.2.2 Transporting the machine 11 Remove the circlips and lock screws and then remove the shafts that attach the mast in the frame. Use the threaded holes and a puller to pull out the shafts. W A RN I N G The mast may swing out when it is loosened from the machine.
  • Page 73 7 Transporting the machine – 7.2.2 Transporting the machine 17 Spray rustproofing on the shafts. 18 Refit the shafts in the frame and lock them with the circlips and lock screws. 19 Close the relief valve for the attachment and the drain valve for brake accumulators.
  • Page 74 2 2 0 0 6 6 7 7 T T r r a a n n s s p p o o r r t t i i n n g g t t h h e e m m a a c c h h i i n n e – e –...
  • Page 75 7 7 T T r r a a n n s s p p o o r r t t i i n n g g t t h h e e m m a a c c h h i i n n e – e –...
  • Page 76 2 2 0 0 8 8 7 7 T T r r a a n n s s p p o o r r t t i i n n g g t t h h e e m m a a c c h h i i n n e – e –...
  • Page 77 7 7 T T r r a a n n s s p p o o r r t t i i n n g g t t h h e e m m a a c c h h i i n n e – e –...
  • Page 78 7 Transporting the machine – 7.2.2 Transporting the machine 9 Start the engine and carefully lower the mast so that the carriage wheels steer into the inner mast. Stop when the chains can be connected to the carriage. If necessary, lift the carriage with the lifting equipment.
  • Page 79 7 Transporting the machine – 7.2.2 Transporting the machine 14 Connect the bracket with the wiring and hydraulic hoses to the carriage. 15 Connect the wiring from the carriage to the mast. 16 Remove the plugs and connect the hydraulic hoses from the car- riage to the mast.

  • Page 80: Service Position

    7 Transporting the machine – 7.3 Service position Service position General page  – Service 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. •...

  • Page 81: Long Term Storage

    7 Transporting the machine – 7.4 Long-term storage Long-term storage General page  – For long-term storage of the machine, contact Cargotec.
  • Page 82 8 Environment and standards...

  • Page 83: Specifications

    9 Specifications   9 Specification s 9 Specifications mm mm mm mmmm mm Technical data page  – The machine’s weights and dimensions vary depending on how the machine is equipped. Detailed information regarding this is given in the product specification and data sheet for the machine in question. 1.
  • Page 84 9 Specifications 9. Cab Spirit Delta with Volvo TAD760VE Spirit Delta with Cummins QSB6.7 Equivalent sound pressure level in cab  69 dB(A)  65 dB(A) according to EN12053 with measure- ment uncertainty  = 2.5 dB. Meas- urement value with standard engine. Whole-body vibrations according to 0,4 - 0,7 m/s EN13059 with measurement uncer-...

  • Page 85: Frame, Body, Cab And Accessories

    9 Specifications 7 Load handling Oil quality See Recommended oils and lubricants page 222  . 9 Frame, body, cab and accessories Refrigerant air conditioning R134a Volume refrigerant See the plate for air conditioning Lubricant air conditioning ZEXEL PAG oil ZXL100 Washer fluid, volume 10 Common hydraulics Oil quality...

  • Page 86: Declaration Of Conformity

    Declaration of Conformity We, Cargotec Sweden AB, SE-340 10 Lidhult, (Registration No. 556014-5418) herewith declare that the machine, Type Containerhandler  DCF100-45E7 Model Serial No A301.XXXXX Year of construction 2010 Engine VOLVO TAD 760VE is manufactured in conformity with the requirements in - The Machinery Directive 2006/42/EC;...
  • Page 88 Cargotec improves the efficiency of cargo flows by offering solutions for Cargotec Sweden AB the loading and unloading of goods on land and at sea – wherever cargo Torggatan 3...

Table of Contents

Save PDF