Instruction Manual DRD ContChamp GB

CONTCHAMP DRD 400-450 CONTAINER HANDLING

Publ. no 920935.0389 0206

Contents Safety regulations...................................................................... 2 Introduction................................................................................ 4 Signs.......................................................................................... 6 Operation................................................................................... 8 Instrument and controls........................................................ 8 ECS ................................................................................... ..................................................................................... 16 Module 01, Automatic gear changing............................ 27 Module 04, Lever Steering Steering ............................................ 27 Module 06, Micro Steering ............................................ 28 Module 07, Monitoring................................................... 28 Module 56, Cab lift ........................................................ 29 Module 57, Hydraulic balance ....................................... 30 Module 58, Container counter ....................................... 31 Module 59, Limitation Height/LC-distance..................... 32 Module 61, Support jacks.............................................. 33 Module 70, Printer ......................................................... 34 Heating and air air conditioning system .................................. 35 Operator’s seat, adjustments ............................................. 37 Engine heater ..................................................................... 38 Running-in .......................................................................... 38 Starting the engine ............................................................. 38 Warming up of engine ........................................................ 38 Volvo EDC engine .............................................................. 39 Functional checks............................................................... 40 Stopping of engine, parking................................................ 40 Power steering ................................................................... 40 Lifting technique ................................................................. 41 Special procedures.................................................................. 42 Supervision.............................................................................. 43 Daily supervision ................................................................ 43 Tyres................................................................................... 44 Fuel system ........................................................................ 45 Cooling system................................................................... 45 Engine oil............................................................................ 46 Checking the accumulators ................................................ 46 Hydraulic system ................................................................ 47 Gearbox oil ......................................................................... 47 Air cleaner .......................................................................... 48 Windscreen washer............................................................ 48 Electrical system ................................................................ 49 Technical data.......................................................................... data............ .............................................................. 51 Lubrication chart ...................................................................... 52 Oil and lubricant recommendations ......................................... 58 Detailed technical descriptions with circuit diagrams, periodic supervision, trouble shooting and repairs are dealt with in the Technical Handbook. We reserve the right to alter design and material without notice.

ContChamp DRD420-450

1

Safety regulations

It is important that you read the instruction manual. Incorrect handling can lead to personal injury or damage to products and/or property. Therefore, read the instruction book very carefully before operating the truck. The instruction manual contains important information about your Kalmar truck, about the operation of the truck, about safety during operation and about the truck’s daily maintenance. In addition, you will find useful information that will make operations easier for you in your daily work. The instruction manual must always be kept in the machine. If the manual should be lost, a replacement must be immediately obtained. Never use a machine with a missing instruction manual. Ask your foreman/group leader if there is anything in the manual that you do not understand or if you feel that information is missing in any area. The symbol is used on our products in certain cases and then refers to important information contained in the instruction manual. Make sure that warning and information symbols are always clearly visible and legible. Replace symbols that have been damaged or painted over. In this instruction manual warnings are inserted that apply to your own safety. Warnings point out the risk of accident that can cause personal injury.

WARNING! Warns of the risk of serious personal injury, possible death and/or serious damage to product or property if the regulations are not followed.

For technical warnings, that point out the risk of break down, the word IMPORTANT is used: IMPORTANT! Is used to draw attention to such occurrences that can cause damage to the product or property.

Safety regulations aimed at reducing the risk of personal injury and damage to loads or other property. Intended of use The truck may only be used for the purpose for  which it was intended, namely, to lift and transport goods, the weight of which does not exceed the maximum permitted load capacity of the truck. The truck may not, without specific permission  from Kalmar, be modified or re-built so that its function or performance is altered. The truck may not be driven on public highways if  it has not been adapted to comply with national road safety regulations. Operator requirements The truck may only be driven by operators who  have been specially trained and who have the company’s authority to do so. Laws and other regulations relating to driving li cence, operator ID, log book, etc., must be followed at all times. The operator must be aware of and follow all local  safety regulations. It is always the responsibility of the operator to en sure that the truck has approved fire extinguishing equipment in accordance with currently applicable regulations. Operation of the truck is prohibited: If any of the fitted safety equipment, such as rear  view mirrors, headlights, reversing alarm (optional), does not function correctly. If there is a fault with the brakes, steering or lift  equipment. If it has been repaired, modified or adjusted with out the approval of the work supervisor. If the truck is fitted with tyres not approved by  Kalmar. Continued on next page

For information that facilitates the working process or handling, N.B. is used: N.B. Draws attention to useful information that helps the working process.

Emergency exit If the doors should not open in an emergency, open the rear window for emergency exit. A rear window that can be opened is standard on machines with hydraulically moveable cab. Optional on other machines.

2

KL749


Safety regulations Continued from previous page Operating regulations Before starting, make sure that the cab is locked  in the rear-most position by means of the latches, one on each side. The latches must be secured with spring pins. (Applies to manually moveable cabs). Before starting, always check to ensure that no body is in the way of the truck or its equipment. Make sure that nobody walks or stands under neath raised forks or other equipment, whether they are loaded or not. The operator must always face the direction of op eration and take particular care in areas where persons or other vehicles are likely to appear in the vicinity. If visibility is limited by the load, the operator should operate the truck in reverse. It is prohibited to transport passengers on the  truck outside the cab or on the load. Passengers may be transported inside the cab only on condition that it is equipped with a fixed passenger seat. It is prohibited to lift people if the truck is not  equipped with an approved lift cage. It is prohibited to exceed the load capacity of the  truck. See capacity plate and loading diagram. It is prohibited to transport loads in the raised po sition as this entails a risk of the truck tipping. All transportation shall take place with the load in the transport position. The operator must adapt the speed of the truck to  the character of the load, conditions of visibility, the character of the roadway/surface, etc. The operator shall avoid powerful acceleration  and braking when turning. In addition, the operator shall always moderate the speed of the truck when turning so as to avoid the risk of lateral skidding or tipping. The operator shall take particular care when oper ating in the vicinity of electrical power lines, viaducts, quay-sides, ramps, gates/doors etc. Safety belts must always be worn, if fitted. In the  event of the truck tipping, always remain in the cab and grip the steering wheel securely. Never try to jump out of the cab. The parking brake can also be used as an EMER GENCY BRAKE. However, having been used for emergency braking, the brake linings must be checked and replaced if necessary. If the parking brake has been mechanically released, it must always be reset in order for the truck to regain the parking brake function. Interrupted operation, parking Always check that the gear lever is in the neutral  position before turning the ignition key to restart or to reset an emergency stop. Never leave the operator’s cab without applying  the parking brake (ON position). Always remove the ignition key if the truck is to be  left unattended. Other important points to remember The truck’s hydraulic system includes high pres sure hydraulic accumulators. Always be extremely careful when working with the hydraulic system and avoid being unnecessarily close to the hydraulic equipment, lines and hoses. Before working on the hydraulic system, the accumulators ContChamp DRD420-450

must be emptied into the tank, with the help of the special accumulator evacuation valve. Handle batteries and junction boxes with great  care. The batteries must always be protected over the poles and connections. Always rectify any damage or wear and tear that  can risk personal safety or that can affect the functions of the truck or its service life. Avoid touching oils and greases. Avoid inhaling  exhaust and oil fumes. Always use steps and handrails when entering or  leaving the machine - Never jump! To avoid the risk of slipping, tread only on anti-slip surfaces. If the anti-slip protection has become worn, loose or in any way less effective, it should be replaced. Welding painted steel produces poisonous gas ses. Paint should therefore be stripped before welding, good ventilation ensured and/or face mask with filter used. Mobile phones used in the cab must always have  fixed connections to the machine’s electrical system, with a fixed antenna outside the machine, mounted in accordance with the manufacturer’s instructions. This will avoid interference with the machine’s important electronic functions. Operating with attachments The operator must always take the effect of the  wind into account when handling containers. Avoid lifting with a wind strength in excess of 12 m/s (27 mph/40 feet per second). Always drive carefully so as to avoid attachments  colliding with pillars, cables, etc. Carefully study the "Lift methods" section of the  instruction manual. The tensile strength of the top pane can be seri ously weakened by exposure to elements that contain: Aromatic hydrocarbon, ketone, esters or chlorinated hydrocarbon. Regularly check the surface condition of the top pane and clean only with screen wash or other mild cleaning fluid. After cleaning, rinse thoroughly with warm water. It is prohibited to modify or in any other way make alterations to the top pane. Immediately replace damaged top panes that show signs of cracking or scratching.

CE marking All trucks and equipment (though not thoses fitted on the truck or intended as spare parts) supplied from Kalmar are CE marked, which indicates that they comply with the requirements of the EU Machine Safety Directive. In addition, each truck has a so called, “EU Declaration of Conformity” which is the legal proof that the truck complies with the “health and safety” requirements laid down in the Machine Safety Directive, the EMC directive (electro-magnetic compatibility) and the LVD directive (electrical equipment).

Vibration standard The truck complies with and is below the limits for vibration standard EN 13059.

3

Introduction Kalmar ContChamp, version DRD are specialized machines for container handling. The machines are part of the Kalmar range of forklift trucks, loghandling trucks and various special machines with lifting capacities between 2 and 90 tonnes. The picture on the next page shows the most important units of the truck. The Instruction Manual applies to all container models unless otherwise stated. Since the trucks are delivered with different equipment, minor deviations from the Instruction Manual may occur. Kalmar

Type designation

DRD450-65S5XS Diesel engine Reach Stacker Generation Lift capacity 1:st row, decitonnes Distance between axles, decimetres Top lift spreader Max number of containers at stacking Extra counterweigt Optional Support jacks Optional

IMPORTANT! BEFORE USING THE TRUCK CHECK: – the engine oil – the fuel – the coolant level – the tyre pressures For further information, see the section entitled SUPERVISION.

4


Introduction

2

1

1. Electro-hydraulically activated telescopic boom 2. Top lift frame. Electro-hydraulically operated, 20 – 40' top lift spreader, with ±800 mm sideshifting and +195° / – 105°rotation. 3. Operator’s cab, rubber mounted, moveable longitudinally 4. Drive axle with hub reduction and hydraulic, oil cooled brake system 5. Steered axle with pendulum suspension and double acting steering cylinder. 6. Six cylinder diesel engine with turbo compressor 7. Gearbox, combined with torque converter

3

DRD420-60S5

4 KL595C

5


6

7

5

Signs The information plates on the machine are shown below. The operator shall be aware of and follow the warnings and instructions given on them. Plates that have disappeared, been damaged or become illegible shall be immediately replaced. Spare parts numbers are stated on respective plates. They can also be found in the Spare Parts catalogue. 101

101

A38193.0100A

101

403

109

803 701 103 403

101

103 801

A38193.0100B

403

203 803 113 301

708 110

403

710

A38193.0100C

304 111

302

306 408

104

107 A38193.0100E

A38193.0100D

811

803 101 108

6

112

102


Signs 10 Chassis, cab 101 423049.0100 Lift point. Fixing point for lift equipment when lifting the truck. 102 A26939.0100 Warning! Read the Instruction Manual.

112 A32442.0100 Warning! Do not jump! Always remain in the truck and firmly grip the steering wheel when there is a risk of tipping. 113 A32653.0200 Type, machine

70 Hydraulic system 701 450203.0100 Hydraulic fluid.

708 A30168.0200 Hydraulic pressure. See Technical Handbook.

MPa

MPa

MP a

MPa

MP a

MPa

103 A26939.0200 Warning! Read the Instruction Manual. MPa

104 A26940.0100 Parking brake ON-OFF. 107 A30536.0300 Warning! No Riders! Passengers may be carried in the cab only if it is equipped with a fixed passenger seat. 108 A30770.0100 Warning! Air conditioning equipment, read the Technical Handbook. Coolant may be topped up only by authorized specialist. 109 A30770.0200 Warning! Air conditioning equipment, see 108. Located on the inside of left hand frame beam. 110 A30770.0300 Warning! Air conditioning equipment, see 108.

MPa

M = Model S/N = Serial number Q = Classified lift capacity of the truck at lift height in accordance with EN1551, EN1459 standards. W = Unloaded weight of machine L = Distance between leading edge of wheel and the load centre H = Classified lift height 20 Electrical system 203 A30537.0100 Main switch. In position 0 the battery’s plus pole is isolated. 30 Engine 301 450202.0100 Fuel.

710 A30529.0100 Warning! High pressure! Always release pressure from the accumulator before working on the hydraulic system. 80 Attachments 801 A30533.0100 Warning! Rotating parts.

803 A32440.0100 Warning! Do not walk under a hanging load.

 

302 A30530.0100 Warning! Rotating fan.

304 A30532.0100 Warning! Hot surface.

811 A33852.0100 Type, attachment

S/N =Serial number

306 A32439.0100 Engine oil. 1 2 3 1 = Refrigerant, type 2 = Amount, kg 3 = Pressure, bar 111 A32441.0100 Warning! Do not step here.

40 Transmission, tyres 403 A32049.0100 Tyre pressure, 1,0 MPa

408 A32439.0200 Transmission oil.


7

OPERATION

3

Instruments and controls

1

4

5

2

6

F 1

2

N

L

3

0

4

R

R 4

5

3

KL1406

7

8

9

1. Gear lever ..............................................................14 FORWARD/NEUTRAL/REVERSE 1/2/3/4 2. Lever DIRECTION INDICATORS/HORN................ 14 FRONT WINDSCREEN WASHER/ FRONT WIPERS/MAIN BEAM 3. Instrument panel .......................................................9 4. Steering wheel panel ................................................9 5. Starting switch.........................................................13 6. Control lever and control panel for .........................10 hydraulic functions

8

10

11

12

13

7. Electrical central unit with fuses and relays...............................................49 8. Brake pedals, normal driving brake .........................15 9. Release clutch.........................................................15 10. Accelerator pedal.....................................................15 11. Steering wheel adjustment ......................................15 12. Servo circuit breaker................................................11 13. Parking brake ..........................................................15


OPERATION


21

23

22

KL581

29 26

27

30

31

32

33

34

35

38 39 36 37 40 41 42 43 44 45 46

52

53

28

25

47 48 49 50 51

24 54 55 56 6059

KL582

66

F 1

2

N

L

3

0

4

R

KL580 R 1

4

57 58 64

21. Pressure gauge, gearbox oil pressure 22. Fuel gauge 23. Temperature gauge, engine coolant temperature 24. Switch, working lights 25. Switch, working lights 26. Switch, working lights 27. Switch, flashing beacon 28. Switch, hazard warning lights 29. Switch, driving lights 30. Spare 31. Spare 32. Spare 33. Spare

34. Switch, compressor air conditioning 1) 35. Control, recirculation/fresh air 36. Control, defrost/cab 37. Switch, fan 38. Control, heat

39. Control, cold 1)

KL675

2

3

5

61

62 63

40. Spare 41. Spare 42. Warning lamp, battery charging 43. Warning lamp, low engine oil pressure 44. Warning lamp, low gearbox oil pressure 45. Warning lamp, low brake pressure (accumulator pressure) 46. Warning lamp, low engine coolant level 47. Indicating lamp, preheating 48. Warning lamp, high engine coolant temperature 49. Warning lamp, high gearbox oil temperature 50. Spare 51. Warning lamp, parking brake ON 52. Spare 53. Spare 54. Spare (Green lamp TWIST-LOCKS LOCKED) 55. Spare (Orange lamp ALIGNMENT) 56. Spare (Red lamp TWIST-LOCKS UNLOCKED) 57. Spare (LOCK/UNLOCK TWIST-LOCKS) 58. Spare (LENGTH ADJUSTMENT 20-40’) 59. Indicating lamp, headlights 60. Indicating lamp, direction indicators 61. ECS terminal 62. Switch, windscreen wiper, rear 63. Switch, windscreen wiper, roof 64. Spare 65. Fuses 66. Hour meter 1)

Optional

65


9

OPERATION


2a 2b

1

3

5

4

6

Joy-stick functions

1. Tilt 1) 2. a. Locking of tilt 1) b. Locking of levelling 1) 3. Rotation 4. Side shift 5. Vertical lift 1) 6. Boom OUT/IN 7. Levelling 1) 8. Length adjustment 20' – 40' 9. Unlocking of twist-locks 10. LIFT/LOWER 1)

7

8

9

Optional

10

Switch functions 13. Rotation limiting 15. AUT = Automatic locking of twist-locks. The parking brake must be OFF MAN = Manual locking of twist-locks (spring-back) Unlocking off twist-locks, see Joy-stick function1 above 17. Stop at 30' and 35' 1) 18. Cab movement horizontal/vertical1) See page 29 19. Support jacks 1) See page 33 20a. Red lamp, the support jacks have left the upper position 1) 20b. Green lamp, support jacks down 1) 1)

Optional

Button 17 for the connection and disconnection of the 30’ and 35’ stops The position gives crawling speed the whole time during extension and retraction. In order to by-pass the 30’ stop press and thereafter . The next stop will be 35’. It is practical to connect in once the 30’ position has been passed.

10

N.B. When operating a machine which is equipped with hydraulically moveable cab, the doors should be closed or the cab in its rear position otherwise all functions will be broken.


OPERATION


A

C

Lamp panel on the boom Container handling A. Twist-locks locked, green B. Alignment, orange C. Twist-locks unlocked, red Lit lamps at container lift: A+B Go out after lift: B

B

Warning! Overriding of the safety system is at one’s own risk and involves a risk of forward tipping.


Engagement and disengagement of servo circuits

KL20

KL 1407

Override (Only in emergency situations) 1. Lower 2. Container coupling

11

OPERATION

Instrument and controls Warning lamps Trucks equipped with ECS System, module 07, are not fitted with warning lamps 43, 44, 46, 48 and 49. All of these lamps should be extinguished when the truck is in operation. A steady light and a buzzer indicate failure.

42

Battery charging lamp (42) If the lamp should light up this indicates that the alternator is not charging. If this should happen, identify the cause and remedy it. Never use the truck when the charging lamp lights.

43

Lubricating oil pressure, engine (43) The lamp will light briefly on starting, and somewhat longer in wintertime when the oil is cold and viscous. If the lamp lights up when the truck is travelling, stop immediately and make sure that the cause is identified and remedied. Oil level? See Supervision.

44

Oil pressure, gearbox (44)

45

The lamp should go out immediately after the engine has started. Pressure is too low if the lamp lights up while the truck is in operation. If this happens, stop the truck immediately and report to the service personnel. 46

Low brake pressure (45)

47

KL598

The lamp will light up if the hydraulic pressure in the accumulator, i.e. the brake system pressure, should drop below 100 bar. After the lamp has lit, sufficient capacity is still available for applying the brakes a number of times. If the pressure is not built up and maintained, check the accumulators for leakage in accordance with the section entitled Supervision.

Engine coolant level (46)

48

The lamp will light momentarily on starting. If the lamp lights up when the truck is travelling, the coolant level is too low. Check the level and top up as necessary. 49

Engine preheating (47) The lamp will lights during the preheating period.

Engine coolant temperature (48) The lamp will light up if the coolant temperature becomes too high. Make sure that the cause is identified and remedied.

50

Oil temperature, gearbox (49) 51

The lamp will light up if the temperature of the gearbox oil exceeds 120°C. Stop the truck and make sure that the cause is identified and remedied.

Spare (50) N.B. Always start in first gear to prevent overheating of the gearbox.

12

Parking brake lamp (51) The lamp will lights while the parking brake is applied.


OPERATION

Instrument and controls Trucks equipped with ECS System, module 07, are not fitted with instruments 21, 22 and 23.

Pressure gauge, gearbox oil pressure (21) The gauge shows the clutch pressure which should be 16.9 – 19.3 bar. Activated parking brake. Idle speed 400 – 600 r/min. Working temperature 82 – 93°C.

21

Fuel gauge (22)

22

The tank is full when the gauge reading is 4/4. The tank is halffull when the pointer is vertical. Always refuel before the gauge reading has dropped to 0. Air may otherwise be drawn into the fuel system, which will then have to be bled.

23

Temperature gauge (23)

KL581

The temperature gauge shows the engine coolant temperature, which should normally be approx. 80°C. This temperature will be reached after the engine has run for about 5 minutes. The temperature may vary between 75 and 97°C. A higher temperature may be an indication that coolant level is low. Check and top up as required, see under Supervision. If the temperature is still too high, the cause must be identified and remedied. Don’t run the engine if the coolant temperature is too high.

Operating hour meter (66) 66

KL1307

The operating hour meter records the number of engine operating hours. Use the meter to determine when the truck is due for periodic service – all service is based on the operating hours of the truck.

Starting switch (5) P 0 I

II

III

All functions switched off, the key can be removed Operating position. All electrical functions are energized. The key may be set to this position to switch on the lighting, for instance, when the engine is not running. Glow position. In this position the glow-plug is energized. The glow mode is indicated by lamp 47. Turn directly to position III if the engine is warm. Starter motor energized.

The truck has an electrical restart guard protecting the starter motor from meshing while the engine is rotating.

WARNING! Risk of explosion. Never use start spray to assist in starting.


13

OPERATION

Instrument and controls Gear lever

– Forward/Neutral/Reverse (1) – 1/2/3/4

The gear-changing mechanism is electrical, gear-changing being effected via solenoid valves. 1

2 3

F – FORWARD N – NEUTRAL R – REVERSE TURN, lever 1, 2, 3, 4

F

4

1

2

3 4

KL676

R

The engine cannot be started unless the gear lever is in neutral. The truck must be stopped completely before changing between forward and reverse, in order to prevent overloading the gearbox and power transmission. 

 

IMPORTANT! The truck must be stopped completely before changing between forward and reverse, in order to prevent overloading the power transmission



Run the engine at idle speed, select the direction of travel with the gear lever and engage first gear, using the rotary control. Never pull away in a higher gear, since this may lead to unnecessary overheating. Release the parking brake, and accelerate carefully. To change up, turn the gear selector handle to second gear, release the accelerator pedal and the second gear will be engaged, accelerate, and so on. Reverse the procedure when changing down. Remember to increase engine speed before engaging a lower gear, since the truck will otherwise brake heavily.

Direction indicators/Dip switch/Horn (2) FORWARD/BACKWARDS UPWARDS DOWNWARDS INWARDS, button INWARDS, lever TURN

– Direction indicators – Headlamp flashing – Full beam – Horn – Screen wash – Screen wiper, front 0 = Off/J = Intermittent I = Continuous wiping II = –

 



14


OPERATION

Instrument and controls Brake pedals and release clutch activator (8 and 9)

F 1

2

N

L

3

0

4

R

R 4

3

KL597

8

9

10

The brake pedals operate hydraulically, connected to the hydraulic system of the truck via accumulators which ensure that there will always be sufficient pressure for braking, even in the event of the engine stopping for a brief period. If the accumulator pressure falls below a certain level, lamp 45 on the panel will come on. The brake pedal (8) is used as the ordinary foot brake. The brake pedal is combined with a separate release clutch activator (9). When this pedal is pressed at the same as the brake pedal, the clutch is activated (gearbox disengaged) at a certain brake pressure. The clutch feature is used if hydraulic functions are required while a gear is engaged.

Accelerator (10) The accelerator pedal is mechanical and actuates the fuel injection pump by means of a wire. Options: Some trucks are equipped with hydraulic or electrical accelerator.

Adjusting the steering wheel (11) The slope and height of the steering wheel and instrument panel can be adjusted to the desired driving position. Upper handle upwards: Steering wheel height position Upper handle downwards: Steering wheel angle Lower handle: Steering column angle Loosen the handle anti- clockwise and adjust as required. Tighten the handle firmly after adjustment

11

KL588

Parking brake (13) 13

KL596

WARNING! Never leave the operator ’s seat without applying the parking brake.


The parking brake is applied by a powerful spring in the hydraulic cylinder of the parking brake. The brake is actuated hydraulically by means of lever 13. A warning buzzer will be sound if the operator inadvertently leaves his seat before applying the parking brake. Warning lamp 51 will show a steady light when the parking brake is applied. If the accumulator pressure should drop below a certain level, warning lamp 45 will light up. After that, the parking brake is applied automatically by a heavy spring in the brake cylinder. If the wheels then need to be rotated – the brake must be mechanically released, see page 42. The parking brake may also be used as emergency brake.

IMPORTANT! After any emergency braking the brake pads should be checked and replaced if necessary. Report to service personnel.

15

OPERATION

ECS

1 2 ECU 3



KL621b-c

. ECU 1 1)

ECU 2

ECU 3 1)

01 Automatic Gear Changing 1) 04 Lever Steering 1) 06 Mini Steering 1) 07 MonitoringL 1)

El-Servo 50 Mechanical overload protection Regeneration 51 Vertical lift 1) 52 Balance + vertical lift 1) 53 Tilt locking 1) 57 Hydraulic balance 1) 58 Container Counter 1) 59 Limitation of height/LCdistance 1) 70 PC/Printer 1) 60 Electronic overload protection Regeneration Vertical lift 53 Tilt locking 1) 58 Container Counter 1) 59 Limitation of height/LCdistance 1) 70 PC/Printer 1)

Bottom lift 1) 54 Tilt 1) 55 Pile-slope1) 56 Cab movement

1)

16

1)

61 Support jacks 1)

Kalmar ECS - Electronic Control System - is a modular control and monitoring system to ensure optimum operational security and total economy. It is possible to combine the system’s different modules in a number of different ways. All vital points of the trucks different systems are connected to one or several central computer units, ECUs. A terminal display in the operator’s cab shows current values and generates an alarm if the values exceed the programmed tolerances. DRD Container machines are equipped with ECS as standard. Depending on how respective machines are equipped, one, two or three ECU central units may be fitted. ECU 1 is used for different additional modules, such as 01  Automatic Gear Changing, 04 Lever Steering, 06 Micro Steering, 07 Monitoring. ECU 2 is obligatory and is used to control the El-Servo cir cuits. ECU 2 also functions as overload protection and for the regeneration system. ECU 3 controls the separate bottom lift and other specific  modules The ECS: – provides torque controlled automatic gear changing (Module 01) – provides electro-hydraulic lever steering with or without wheel return (Module 04) – provides electro-hydraulic steering with micro steering wheel (Module 06) – monitors the engine and gearbox to ensure reasonable operating conditions (Module 01) – monitors the components in the system, e.g., sensors, to ensure their correct function (Module 07) – interrupts hydraulic functions with forward overload and when overload of the steering axle occurs (module 50/60) – controls vertical lift and balance (standard el-servo – adapts the speed of movement of the BOOM OUT function in relation to the load and adapts the speed of movement of the LOWER function in relation to boom extension and load (standard el-servo) If a fault occurs: – a red warning lamp blinks on the terminal – an error message appears on the terminal display – The ECS limits the functions of the truck in different ways depending on the seriousness of the fault. Certain functions are monitored on two levels, where level 2 limits the functions of the truck. See the error messages on the terminal display on the following pages.

Optional equipment


OPERATION

ECS Terminal functions 8

1. 2. 3.

7

4. 5. 6.

F N R

KL580B R 1

2

4

5

3

7. 8.

R 1

2

4

5

3

Arrow left is used to scroll between the different menus. Arrow right is used to scroll between the different menus. R is used to reset the display after an error message. All errors, with the exception of certain level 2 errors can be reset by pressing this button. The red warning lamp is then extinguished. The lamp begins to blink again after 3-10 minutes, depending on the fault, if it has not been rectified. - is used to decrease a value. + is used to increase a value. ENTER is used to access the service menus and to save new values when setting up and calibrating the system. Access to the service menus also requires the use of special codes, that are separately obtainable from Kalmar. A red warning light blinks in the event of an error and is extinguished when reset by pressing button 3. The terminal display has 4 lines with space for 20 characters on each line. Graphical presentation of operating menus and error messages

Menu structure There are three types of menus: 1. Operating menus The operating menus are accessible to the operator. The menus that can be selected depend on how the truck is equipped and are determined in SETUP. All operating menus are part of a connected loop. Use arrow RIGHT/LEFT to move around the loop. The loop also contains: 1.a Overload indicator Depends on the selected overload protection, module 50/ 60. 2. Error messages Displayed automatically and have priority over other menus. 3. Service menus The operating menu loop always contains the KALMAR SERVICE main menu.The service sub-menus under this main menu require access to codes that can be found on a special list from Kalmar. If ENTER is pressed by mistake in the service menu and the ENTER CODE menu is displayed, return to the operating menu by pressing ENTER. For further information, refer to the respective headings.

6

1.

1.

1.

1.

KL1409

1. Enter

2. 1. 1a.

1a.


3.

17

OPERATION

ECS Operating menus The menus that are displayed on the terminal depend on the modules with which the truck’s ECS is equipped. The overview below shows the possible combinations. Use either arrow RIGHT/LEFT to switch between menus. All operating menus are in a connected loop. Access to the sub-menus under the service menu requires an access code. If ENTER CODE is displayed by mistake, return to the operating menu by pressing ENTER.

01 Automatic gear changing 07 Monitoring 50 Mechanical overload protection 60 Electronic overload protection

N.B. Additional menus may occur as a result of adaptation to specific customer requirements.

50

6 5 2 1

01.50

6 5 3 1

1

10

07.50 01.07.50 6 5

9

4 7

8

KL1410

Explanations, see next page Operating menus with mechanical overload protection, module 50 18


OPERATION

ECS Operating menus, module 50 1.

Main menu KALMAR INDUSTRIES SERVICE

2.

Normal operating condition, module 50 a. 1750rpm Engine speed, r/min

3.

Normal operating condition, module 50 + module 01 a. 1750rpm Engine speed, r/min b. F3 Current gear c. 14 km/h Current speed

4.

Normal operating condition, module 50 + module 01 + module 07 a. 1750rpm Engine speed, r/min b. F3 Current gear c. 4 km/h Current speed d. Fuel level. The tank is full when the indicator is filled to the right.

1

2 a a 3

b c

a 4

b c d

5

5. Red lamp blinks The steering axle is overloaded. It is not possible to switch to other menus until the overload is rectified.

6

6.

The system interrupts operation. The red warning lamp lights continuously. The machine has forward overload. It is not possible to switch to other menus until the overload is rectified.

7.

a. 75 °C b. 3.8 bar

Engine coolant temperature Engine oil pressure

8.

a. 75 °C b. 3.8 bar

Gearbox oil temperature Gearbox oil pressure

9.

a. 24.5 v b. 75 °C

Battery voltage Hydraulic oil temperature

a 7 b a 8 b a 9

b

a 10

10. a. 28756:21.54h Total operating time, tim: min. sek. b. 130h Time to next service, tim

b


19

OPERATION

ECS

60

2

4

1

01.60

3

1 4

07.60 01.07.60

8

9

7

1

6

5 3

4

KL1411

Explanations, see next page

Operating menus with electronic overload protection, module 60 20


OPERATION

ECS Operating menues, module 60 Modul 60 overload protection function, under normal conditions, functions as a balance and gives a continual reading of the size and position of the load.. 1. Ma Main in menu menu KALM KALMAR AR IND INDUS USTR TRIE IES S SERV SERVICE ICE

1

2.

2

a c d e f

3

a b c d e f

4

5

3.

a b c d

4.

a b c d

Norm No rmal al oper operat atin ing g condit conditio ion, n, modu module le 60. 60. a. 1750 1750 rpm rpm Engi Engine ne spee speed, d, r/mi r/min n c. 3.0 m Distance betw etween een the front ont edge of the wheels and the centre of gravity of the load. d. 25.5 t Current load in tonnes e. Indicator showing steering axle load, fills the display to the left for 95-100% of the permitted load. When the indicator reads full, the system interrupts operation due to overloading of the steering axle. The red warning lamp blinks. It is not possible to switch to other menus until the overload is rectified. f. Load indicator, fills the display to the right for 0-100% loads. When the load indicator reads full, the system interrupts operation due to forward overload. The red warning lamp lights continually. It is not possible to switch to other menus until the overload has been rectified. Norm No rmal al opera operati ting ng condi conditi tion on,, module 60 + module 01 + module 07 a. 1750 1750 rpm rpm Engi Engine ne spee speed d r/m r/min in b. F 3 Current gear c. d. e. f. See menu 2 explanation above. a. 10.38 t Current load in tonnes b. 1.07 m Boom extension c. 3.0 3.08 m Lc-d Lc-dis ista tanc nce. e. Dist Distan anc ce betw betwee een n dri drive ve axl axle centre and load centre. d. 23.0 ° Boom angle

5.

a. 1750 rpm b. F 3 c. 14 km/h d. Fuel level.

Engine speed r/min Current gear Current speed The tank is full when the indicator is filled to the right.

6.

a. 75 °C b. 3.8 bar

Engine coolant temperature Engine oil pressure

7.

a. 75 °C b. 3.8 bar

Gearbox oil temperature Gearbox oil pressure

8.

a. 24.5 24.5 v b. 75 °C

Batt Batter ery y volt voltag age e Hydraulic oil temperature

9.

a. 28756: 28756:21. 21.54 54 h. Tota Totall operati operating ng time, time, h: h: min. min. sec. sec. b. 130h Time to next service, h

a 6 b a 7 b

8

a b

9

a b


21

OPERATION

ECS Error messages

01 = 01 = Automatic gear changing 04 = = Lever steering 06 = = Micro Steering 07 = = Monitoring 50 = = Mechanical overload protection 60 = = Electronic overload protection

01, 07

01

01, 07

02

01, 07

03

01, 07 04

07

07

07

07

22

05

06

07

08

In order of priority. If two faults occur at the same time, the terminal displays the fault with the highest priority. Error messages always have a higher priority than normal menus. Errors 01-08 are level 2 errors and cannot be reset prior to the fault being rectified. The first two figures show to which module the error message relates. (These figures do not appear on the display)

01. Batter Battery y voltage voltage very very low/high low/high.. Stop as soon as possible and contact service.

02. Faulty signal signal from accelerator accelerator sensor. sensor. Engine speed reduction. Stop as soon as possible and contact service.

03. Faulty signal signal from from injection injection pump pump motor motor sensor. sensor. Engine speed reduction. Stop as soon as possible and contact service.

04. Gear lever lever not func functio tioning ning.. Engine speed reduction. Stop as soon as possible and contact service.

05. Engine oil pressure pressure extremely extremely low low.. Engine speed reduction. Stop as soon as possible and contact service.

06. Coolant Coolant temperat temperature ure extremely extremely high. Engine speed reduction. Stop as soon as possible and contact service.

07. Gearbox Gearbox oil pressure pressure extremely extremely low. low. Engine speed reduction. Stop as soon as possible and contact service.

08. Gearbox Gearbox oil temperature temperature extremely extremely high. high. Engine speed reduction. Stop as soon as possible and contact service.


OPERATION

01, 07 09

ECS

09. Faulty signal from engine rev sensor. Engine speed reduction. Stop as soon as possible and contact service.

07

10

10. Low engine oil pressure. Check oil level and top up as required.

07

11

11. High coolant temperature. Check coolant level and top up as required.

07

12

12. Low gearbox oil pressure. Check oil level and top up as required.

07

13

07

14

14. Fuel level extremely low. Fill the tank to avoid air in the system.

07

15

15. Low coolant level. Top up the coolant fluid.

07

16

07

17

07

18


13. High gearbox oil temperature. Check oil level and top up as required.

16. High hydraulic oil temperature. Operation possible. Contact service.

17. Faulty signal from fuel gauge sensor. Operation possible. Contact service.

18. Faulty signal from gearbox oil pressure sensor. Operation possible. Contact service.

23

OPERATION

07

19

19. Faulty signal from engine oil pressure sensor. Operation possible. Contact service

07

20

20. Faulty signal from coolant temperature sensor. Operation possible. Contact service.

07

21

21. Faulty signal from gearbox oil temperature sensor. Operation possible. Contact service.

07

22

07

23

01, 07 24

24

ECS

04

25

04

26

06

27

07

28

22. Faulty signal from hydraulic oil temperature sensor. Operation possible. Contact service as soon as possible.

23. Service interval exceeded. Contact service as soon as possible.

24. Faulty signal from prop shaft rpm sensor Engine speed reduction. Stop as soon as possible and contact service.

25. Steering lever fault. Switch off the steering system. Contact service as soon as possible.

26. Faulty signal from steering sensor. Switch off the steering system. Contact service as soon as possible.

27. Faulty signal from mini steering sensor. Switch off the steering system. Contact service as soon as possible.

28. Warning! Low brake pressure. Contact service as soon as possible.


OPERATION

ECS

-

31

31. System fault ECU 1. Contact service as soon as possible.

-

32

32. System fault ECU 2. Contact service as soon as possible.

07

50

50. Battery voltage very low/high. Contact service as soon as possible .

60

51

60

52

52. Communication with ECU 1 broken. First try switching off and then re-starting the engine! If the fault remains, contact service as soon as possible.

60

53

53. Faulty signal from angle sensor Stop as soon as possible and contact service.

60

54

50, 60

55

50, 60

56

50, 60

57


51. Communication with ECU 3 broken. Contact service as soon as possible.

54. Faulty signal from length sensor. Stop as soon as possible and check the sensor wire. Contact service if the fault remains.

55. Faulty signal from regeneration sensor. The regeneration is discontinued. Contact service.

56. Faulty signal from hydraulic pressure sensors for left lift cylinder. (There is a sensor in both feed and return lines) Stop as soon as possible and contact service.

57. Faulty signal from hydraulic pressure sensors for right lift cylinder. (There is a sensor in both feed and return lines) Stop as soon as possible and contact service.

25

OPERATION

50

58

50

59

-

60

60

61

60

62

ECS

58. Faulty analog signal from joystick. All boom functions are interrupted. Stop as soon as possible and contact service.

59. Faulty signal from sensor for end position damping Contact service as soon as possible.

60. Faulty signal from twist-locks sensors. Applies to both locked and unlocked position. Stop as soon as possible and contact service.

61. System fault. Load curve is missing. Stop as soon as possible and contact service.

62. Each one of the Module 60 errors will activate error menu 62. When error menu 62 is activated: Warning lamp on the ECS-terminal lights up When pressing RESET: Menu 62 starts blinking, 5 sec ON and 5 sec OFF The hydraulic functions LIFT/LOWER and BOOM OUT/IN are operative but at a lower speed.

26


OPERATION

ECS Module 01, Automatic gear changing Module 01 - Automatic gear changing, is designed for gearboxes with torque converters. The system controls up and down changing of gears, simplifies operation and extends the service life of the transmission equipment.

1

2 3

F

4

1

2

3 4

KL676

R

The system Prevents the gears from being engaged if engine revolutions  exceed 1100 rpm Prevents changing between forward and reverse gears if the  speed of the truck exceeds 3 kpm Locks the gearbox in the current gear if the signal from the  propeller shaft sensor is excessive or if the signal ceases Reduces engine revolutions when changing to a higher gear  so that the speed of the truck remains constant Disengages the gearbox if the operator brakes and the  speed of the truck is lower than 3 kph Provides the required engine revolutions based on the posi tion of the accelerator pedal Continually shows the currently engaged gear on the ECS  terminal display Function The point at which the gearbox changes gear is optimized to the truck’s transmission equipment. The torque in the torque converter initiates the change of gear. The system changes to a lower gear when the torque is higher than a pre-programmed value and vice versa. The operator can limit gear changes from 4 to 3, 2 or 1 by moving the gear selector to the corresponding position. If the selector is in the 2nd gear position, the system changes automatically between 1st and 2nd gears.

Module 04, Lever steering 4ab

2

5

3

1

6

KL1405


The lever steering module is an electrical system for the steering of the truck by means of a steering lever. The steered wheel deflection is inversely proportional to the speed of truck, i.e. at lower speeds, the steered wheel deflection is greater than at higher speeds. The system is available in two versions: Standard: Without wheel return, i.e. when the operator re leases the lever the steered wheels stay in their set position. Optional: With wheel return, i.e. when the operator releases  the lever the steered wheels return to a central position. The ordinary steering wheel is equipped with inductive sensors that sense the movement of the steering wheel. The sensors disconnect the lever steering if the operator is faced with an emergency situation. As soon as the standard steering wheel is used, the lever steering disconnects and the lamp in switch 2, se below, is extinguished. 1. Steering lever 2. Direction switch F/N/R. The lamp in the switch is alight when the lever steering is activated Forwards position = F. Centre position = N Backwards position = R 3. Signal horn 4. Switches for gear changing, a=UP, b=DOWN (Excluded if the truck is equipped with module 01 Automatic gear changing). Press 4a to shift gears 1-2-3-(4) (once for every gear) and 4b to shift down. The gear changing always starts with gear 1 on starting and after the direction switch has passed the N position. 5. Switch for activating lever steering Condition: The truck speed must not exceed 3 kph. If the speed exceeds 3 kph it not possible to activate the lever steering. The lamp in switch 2 is alight when the lever steering is activated 6. Extra function 27

OPERATION

ECS Module 06, Mini steering 3 6

2 b 4 a

1

5

KL1404

The Mini steering module is an electrohydraulical system for comfortable steering of the truck with the arm on the armrest. The steered wheels follow the position of the Mini steering device. If the operator releases the Mini steering device, both the steering device and the steered wheels remain in the set position. The standard steering wheel is equipped with inductive sensors that sense the movement of the steering wheel. The sensors disconnect the Mini steering if the operator is faced with an emergency situation and starts using the standard steering wheel. When the Mini steering is disconnected, the lamp in switch 2, see below, is extinguished. 1. Mini steering device 2. Direction switch F/N/R. The lamp in the switch is alight when the lever steering is activated Forwards position = F. Centre position = N Backwards position = R 3. Signal horn 4. Switches for gear changing, a=UP, b=DOWN (Excluded if the truck is equipped with module 01 Automatic gear changing) Press 4a to shift gears 1-2-3-(4) (once for every gear) and 4b to shift down. The gear changing always starts with gear 1 on starting and after the direction switch has passed the N position. 5. Switch for activating Mini steering Condition: The truck speed must not exceed 3 kph. If the speed exceeds 3 kph it not possible to activate the Mini steering. The lamp in switch 2 is alight when the Mini steering is activated 6. Extra function

Module 07, Monitoring The following signals are monitored: 1. 2. 3. 4. 5. 6.

Battery level, min. <14.4 Volts Engine oil pressure, min. level 1 <1.0 bar Engine oil pressure, min. level 2 <0.5 bar Coolant temperature, max. level 1 >98°C Coolant temperature, max. level 2 >103°C Gearbox oil pressure, min. level 1 <12-15 bar (dependent on selected transmission data kit) 7. Gearbox oil pressure, min. level 2 <10 bar 8. Gearbox oil temperature, max. level 1 >130°C 9. Gearbox oil temperature, max. level 2 >134°C 10. Fuel level, min. 11. Hydraulic fluid temperature, max. >100°C 12. Coolant level, min. 13. Operating time, max. service interval period, shows the time remaining to the next service and generates an alarm when operating time has been exceeded. 14. Brake pressure

28

The monitoring module checks that the engine and gearbox operate within reasonable limits and thereby prevents a major breakdown from occurring. The module also monitors the correct function of the different system components, such as sensors, etc. Values, such as oil pressure and temperature, that are of vital importance when it comes to wear and tear and the risk of breakdown, are monitored in two levels. A read warning lamp lights and an error message appears on the terminal display. If the reason for the fault is not rectified, the system limits the truck’s functions. The most serious faults lead to a reduction in engine revolutions.


OPERATION

ECS Module 56, Cab lift

WARNING! Before operating the cab lift, check to make sure that nobody is in the way of the cab when it moves up or down. 18 1. 2. 3. 4.

KL 1407

Close the doors Fasten the safety chains across both doors. Fasten the safety belt. Operate the cab lift using switch 18.

N.B. When the cab is lifted from its lower position, the machine can be driven in 1st or 2nd gears only. Conversely, the cab lift is operative in 1st or 2nd gears only

A WARNING! If work must be carried out under the cab when lifted, the hinged mechanical safety latches on both sides must be placed in position under the cab. See A on the adjacent illustration

KL1089

N.B. If the cab gets stuck in its upper position, it can be lowered by means of an emergency lowering valve. This is fitted under the front cover in front of the main hydraulic valves. See B on the adjacent illustration

A Hinged safety latch B Emergency lowering valve

B

KL1090


29

OPERATION

ECS Module 57 Hydraulic Balance The hydraulic balance is included in the ECU 2 el-servo system. Calibration of the balance must be carried out in accordance with the instructions in Technical Handbook ECS SERVICE, ECU 2 SETUP, points 20 and 21.

A

1. 2. 3.

B

Connect a loaded container to the machine Extend the boom until the red lamp A lights. Lift the boom approx. 20 cm over the position where the red flags B on the left lift cylinder are aligned with each other. Lower the boom until the red flags are exactly aligned with each other. (By first lifting the boom too high and then lowering it to the correct position, the regeneration system is prevented from building up pressure that can affect the measurement)

4.

Press the button for weighing = the vertical lift button on the control lever

5.

The result is shown on the ECS terminal display 25 t = The actual weight in tonnes.



30


OPERATION

ECS Module 58, Container counter

ENTER

RESET C1 ENTER

RESET C2

Module 58, Container counter contains two separate counters, C1 and C2. Of these, C1 is most suitable for use for shorter working periods, for example, with a change of operator, per hour or similar. C2 is a total counter, suitable to be used, for example, per week, per assignment or similar. The conditions necessary for a container lift to be registered are: The twist-locks must be locked.  The container must be lifted, at least to that point where the  ALIGNMENT light is extinguished. The twist-locks must not be released for at least 10 seconds.  Resetting the counters Counter C1: 1. Press ENTER when the CONTAINER COUNTER main menu is displayed. 2. Press the right/left arrow keys until the RESET C1 menu is displayed. 3. Press ENTER, and C1 is reset.

ENTER 4 SEC

RETURN TO MENU ENTER

ENTER


Counter C2: 1. Press ENTER when the CONTAINER COUNTER main menu is displayed. 2. Press the right/left arrow keys until the RESET C2 menu is displayed. 3. Press ENTER for at least 4 seconds and C2 is reset. Returning to the main menu 1. Press the right/left arrow keys until RETURN TO MAIN MENU is displayed. 2. Press ENTER to return to the CONTAINER COUNTER main menu. 3. Use the right/left arrow keys to move on through the operating menus.

31

OPERATION

ECS Module 59, Limitation Height/LC-distance In certain cases it may be necessary to limit how high the boom can be lifted, for example, for operations in areas with overhead power lines, bridges, traverses, etc., or how close to the cab the load can be moved. Limitation Height When measure A1 is reached: The boom stops and the menu for height limitation shows the set max height. The pre-set limitation of height, A1 on the adjacent illustration, can be by-passed using the switch D on the hydraulic control panel. The switch D must be continually pressed in whilst the boom moves through the area B (700 mm). In parallel with switch D, the switch E for by-passing the safety system (located on the side of the hydraulic control panel) can also be used. Above height C the system functions as normal. Limitation LC-distance When measure A2 is reached: LIFT - The lifting movement becomes VERTICAL LIFT BOOM IN - The boom stops The pre-set limitation of LC-distance, A2 on the adjacent illustration, can be by-passed using the switch D on the hydraulic control panel. The switch D must be continually pressed in whilst the load moves inside limitation A2. In parallel with switch D, the switch E for by-passing the safety system (located on the side of the hydraulic control panel) can also be used. In front of limitation of LC-distance A2 the system functions as normal.

C

D

E



32


OPERATION

ECS Module 61, Support jacks The upper and lower positions of the support jacks are controlled by inductive sensors, which in turn are connected to the overload protection system. The support jacks can be lowered at overload. The support jacks cannot be raised until the overload is neutralized by disengaging the load or retracting the boom.

20a

20b

Support jacks down Release the parking brake.  Press switch 19 – SUPPORT JACKS DOWN.  When the support jacks have left the upper position, the red  lamp 20a will light and the transmission will be disengaged. When the support jacks have reached the lower position,  green lamp 20b will light. The overload protection system will change parameter curve. The additional capacity for container row 3 (+7 tons) can be utilized.

KL 1407

19

Support jacks up Disengage the load or retract the boom to prevent the over load protection system from interrupting the functions. Press switch 19 – SUPPORT JACKS UP.  When the support jacks have left the lower position, red lamp  20a will light (Green 20b is extinguished). When the support jacks have reached the upper position, red  lamp 20a is extinguished. The overload protection system shifts to the normal parameter curve. Ready for normal operation.

Support jacks

19. Switch, support jacks UP/DOWN 20a. Red indicating lamp – the support jacks have left the upper position 20b. Green indicating lamp – the support jacks have reached the lower position


33

OPERATION

ECS Module 70, Printer

C

(-)

(+)

A

(-) (+)

B

Save current weight 1. Press - to access the SAVE WEIGHT menu. 2. Press ENTER to save the current weight, the rectangle in front of the word ENTER will then be filled in, to confirm that the command has been executed. 3. Press + to return to the main PRINTOUT WEIGHT menu. Printout of current weight 1. Press ENTER, the rectangle in front of the word ENTER will then be filled in, to confirm that the command has been executed. Printout of latest weights 1. Press + to access the PRINTOUT LATEST XX WEIGHTS menu. 2. Use the +/- keys to register the required number of latest weights to be printed out. The system also calculates the total weight. 3. Press ENTER, the rectangle in front of the word ENTER will then be filled in, to confirm that the command has been executed. 4. Press - to return to the main PRINTOUT WEIGHT menu. Return to operating menus To return to the operating menus from any of the three printout menus, press the arrow right/left keys.

KALMAR WEIGHT IS

The printer Module 70 contains three menus (see illustration). A = PRINTOUT WEIGHT is the main menu and is accessed via the normal operating menus. B = SAVE WEIGHT C = PRINTOUT LATEST XX WEIGHTS

28,5T

Example of PRINTOUT WEIGHT

KALMAR

34

1. 2. 3. 4. 5,

10,5T 9,5T 1,0T 5,0T 8,0T

TOTAL WEIGHT

48,0T


OPERATION

Heating and air conditioning system Heating and air conditioning system The standard version of the truck is equipped with heater and defroster only. The heating system is connected to the engine cooling system and starts delivering heat after the engine has warmed up. The fan is controlled by switch 37. The air conditioning system can be switched on and off by means of switch 34. NOTE. The air conditioner is optional equipment.

34 35

36

39 37

KL599

38

34. Switch, compressor air conditioner (Optional) 35. RECIRCULATION switch Closed – 100% air from outside of cab Open – 20% air from outside of cab (The lamp in the switch lights up) 36. Control DEFROSTER/CAB 37. Fan control 38. HEAT control 39. COOLING control (Optional)

Setting the heating mode 

 

KL1452

A

A

Close the recirculation control 35. Open if the weather is very cold. Switch off the air conditioner, switch 34. Set the heater control 38 and the fan 37 as required.

During the autumn and early winter when high air humidity causes misting of the windows Switch on the air conditioner, switch 34.  Open the recirculation control 35.  Set the COOLING control 39 to MAX:  Increase the temperature as required with 38.  Set the fan to maximum speed with 37.  When the windows have been demisted, set the cooling con trol 39 so that the cooling thermostat will trip at regular intervals for defrosting the cooling element. Close recirculation with 35.  Note that the cooling is used for dehumidifying the air in the cab.

Setting the cooling mode Close the recirculation control with 35. Open during hot  weather and high humidity. Set the heater control 38 to COOL.  Switch on the air conditioner, switch 34.  Adjust the cooling control 39 as required.  Open and direct the panel nozzles A towards the roof. 


35

OPERATION

Heating and air conditioning system Thermostatically controlled Air Conditioning unit

33 34 35

39

36 KL599A

37 38

N.B. Run the compressor from time to time, even during the winter, in order to lubricate and ensure correct function. N.B. The cooling is not operative at temperatures below 0 °C.

As an optional extra, a thermostatically controlled system for air conditioning, cooling, demisting/dehumidifying and heating, is available. The system is equipped with a sensor that senses both inner and outer temperatures and automatically regulates the temperature to the pre-set level, either by heating or by cooling. 33. Switch DEMIST/DEHUMIDIFYING FUNCTION. 34. Switch COOLING FUNCTION OFF. 35. Switch RE-CIRCULATION. Switch forwards - air from outside. Switch backwards - air from inside. 36. Control DEMIST/CAB. 37. Control FAN. Infinitely variable setting of fan speed. 38. Control TEMPERATURE. Infinitely variable setting of cab temperature from 16-26°C. Control fully clockwise: Full heating effect = heating valve continuously open. Control fully anti-clockwise: Full cooling effect = cooling function running continuously. N.B. When the controls are in respective full positions, precise temperature regulation cannot be achieved. 39. Cover. The climate equipment’s demist thermostat is located under this cover. The thermostat must always be set in the max. clockwise position. Normal operation 1. Set controls 37 FAN and 38 TEMPERATURE to the required fan speed and temperature. The fan must be running for cooling to function. (If the fan is switched off, the compressor and condenser stop.) 2. The system then operates automatically, as follows: – When heat is required: The system operates in 10 second cycles. The water valve opens for heating at intervals from 0 seconds, extending to 4 seconds. Thereafter, the valve is open for continual heating. – When cooling is required: The system operates in 2 minute cycles. The compressor operates at intervals from 30 seconds, extending to continual operation. The condenser operates continuously as long as cooling is required. Demisting/Dehumidifying the air in the cab 1. This function is used when the windscreen/windows mist up. 2. Start demisting by pressing switch 33. The fan then runs at full speed for 3 minutes, the compressor and condenser run continuously. The switch lamp lights. N.B. The cooling system is used for dehumidifying air. 3. After 3 min. the fan speed returns automatically to the previously set level. Control 37 can be used to select a lower fan speed at any time. 4. Press switch 33 again to switch off the demisting function. The switch lamp extinguishes. Operating without automatic cooling 1. Press switch 34 to the OFF position. The compressor and condenser then stop. The switch lamp lights. the cooling function is thereby de-selected in all positions and does not start even when control 38 TEMPERATURE is set to the MIN. position. 2. Set control 38 to the required temperature.

36


OPERATION

Operator’s seat Operator’s seat adjustments The operator’s seat is provided with the following adjustment facilities: A Distance from the pedals. Release the seat by means of the lever and move it forward or towards the rear.


B

Height of the seat cushion. Turn the knob until the desired height is achieved. The springing will automatically correspond to the operator’s weight.

C

Backrest rake Turn the knob.

D

Armrest slope

E

Tilt – simultaneous sloping of seat and backrest.

F

Adjustment of cushioning in three steps. 1. Normal position – lever pulled out. Used in normal operation. 2. Restricted – lever pushed in to the intermediate position. Used in operation on rough surfaces and restricts the spring travel to 25 mm. 3. Locked position – lever pushed in fully. Used when springing is not required.

37

OPERATION

Engine heater, running-in, start, warming-up Engine heater The truck can be equipped with an engine heater to facilitate starting at temperatures below 0°C. The engine heater consists of a heater cartridge fitted into the engine block and is designed to heat the engine coolant. The engine heater must be connected to a 220 V a.c. earthed outlet.

Running-in A new engine should always be treated with care during a certain running-in period. During this period, the surfaces of the bores, gears and bearings will become hard and polished, and this will ensure a long useful life of the engine. Avoid running the engine at full load during the first 50 hours. The load can then be gradually increased. Try to extend the running-in period to 200 hours. This will pay in the long run – the stoppages and breakdowns will be fewer.

Start

WARNING! IMPORTANT! IF THE ENGINE DOES NOT START

Never use a starting spray to facilitate starting, since this may cause an explosion.

Make a new attempt after 15 to 20 seconds. Do not run the starter motor for more than 10 seconds at each attempt. If the engine still refuses to start, the cause should be determined and remedied. Air in the fuel system? – see page 45 .

 

Set the gear lever to NEUTRAL. Turn the starter key directly to position II. Then: Below +5°C Hold the key in position II, the pre-heater position, for approximately 50 seconds. Turn the key further to position III – the starting position – and release it as soon as the engine has fired. Above +5°C Turn the key directly to position III – the starting position – and release it as soon as the engine has fired.

Warming-up Never race a cold engine. Run the engine at 1400 – 1500 r/min until it starts to warm up. It is essential that the engine oil be warm and that it is circulating correctly before the turbocharger starts running at high speeds. Nor should the engine be run at critically low speeds. Start using the truck only when the engine has reached normal working temperature, i.e. when the temperature gauge on the instrument panel reads about 80°C.

38


OPERATION

EDC engine

IMPORTANT! Starting the EDC engine 1. Switch on the ignition. The engine cannot be started before the lamp in the Diagnostic Switch (A) has extinguished. The EDC system first checks all engine systems 2. Turn the ignition key to the start position and immediately release the key again. Depending on the temperature, preheating of the EDC system then starts. Pre-heating times varies from 0 s at +25°C to 50 s at - 20°C. (In emergency situations, the preheater can be by-passed by turning the ignition key to the start position twice) 3. Thereafter, turn the ignition key to the start position again - and the engine starts, but not directly, only after a number of revolutions. This pre-heats the engine combustion chamber which reduces smoking at start up. N.B. On an EDC engine, the starter motor must turn longer than with conven- tional engines. Stopping the EDC engine 1. Stop the engine in the normal way, by turning the ignition key to 0

KL1257

A

Trucks with Volvo EDC engines (Optional extra) Certain Volvo engines are equipped with EDC, an electronic system for the control of the diesel engine’s operation. The system’s central unit receives information relating to a number of parameters, such as, engine revolutions, coolant temperature, fuel temperature, turbo-charge pressure, turbo-charge temperature, etc., and on the basis of the values received, determines the volume of injected fuel. The EDC system also contains a diagnostic system that enables rapid fault finding, if a fault should occur. A diagnostic switch on the instrument panel shows the current fault, by means of different series of blinking of the in-built lamp. Function A = Diagnostic Switch. The switch lamp starts to continually blink if the EDC system receives abnormal values from the engine, or if there is a fault in the EDC system itself. When the switch is pressed for at least one second, the alarm is reset and it is then possible to read off the diagnostic code. The switch lamp shows the diagnostic code by means of twostage blinking. First a series, then a pause, then a further series of blinks. If several diagnostic codes are stored in the system, press the switch again and read off the next code, and so on. When the first code re-appears, all diagnostic codes have been read. The system stores the codes until they are deleted and it possible to check the codes again at any time. Reading off the diagnostic codes 1. Press switch A down for at least one second. When the lamp starts to blink, the first fault is shown For example: 2 blinks - pause - 4 blinks = diagnostic code 2.4 2. Press switch A down again to check if there are further diagnostic codes. Continue until the first code re-appears. Deleting diagnostic codes IMPORTANT! Never delete a diagnostic code before the fault in question has been rectified 1. 2.

3. Diagnostic code 1.3 2.2 2.3 2.4 2.5 2.6 2.7 4.6 5.1 8.1 8.3 9.9

Switch off the ignition. Press switch A down and switch on the ignition whilst the switch is still held down. Keep the switch pressed down for at least 3 seconds. All diagnostic codes are now deleted.

Fault

Result of fault

Action

Incorrectly calibrated throttle Incorrect position of throttle lever Throttle control rod fault Engine speed (rpm) sensor fault Engine speed sensor - incorrect signal Throttle control sensor fault Throttle control sensor - incorrect signal Short circuit or breakdown in start relay Short circuit or breakdown in main relay Fault in the EDC central unit Fault in the EDC central unit EDC program fault

Engine stops Engine stops Engine stops Engine stops Reduced engine revs. 1000 rpm Engine stops -

Contact service -”-”-”-”-”-”-”-”-”-”-”-

IMPORTANT! If the diagnostic system has resulted in reduced engine revs. or engine stop, all diagnostic codes must be deleted before the engine can be restarted. ContChamp DRD420-450

39

OPERATION

Functional checks, stopping of engine, steering Functional checks

WARNING! If results of the functional checks are in any way doubtful, report immediately to the supervisor.

WARNING! If mirrors or CC TV cameras are used to aid vision, the speed of the machine must be adapted to the limited vision.

When starting the truck and from time to time when using it, make a habit of checking: that the engine temperature gauge reading is about 80°C.  that the reading on the fuel gauge is sufficiently above 0.  N.B. The reading should never be allowed to drop to 0. that all warning lamps are extinguished.  that the horn, lighting, brake lights and direction indicators  operate correctly. that all hydraulic functions operate correctly.  that the indicating lamps for the twist-locks and alignment  operate as intended. that the contact pins at the twist-locks can be moved freely  up and down. Note that a pin which binds in the top position will indicate alignment even if the frame is not in contact with the container. that the twist-lock interlock performs satisfactorily. Lift an  empty container sufficiently for the ALIGNMENT lamp to be extinguished. It must then be impossible to release the twistlocks.

Stopping the engine, parking    

 

Apply the parking brake. Set the gear lever in NEUTRAL. Retract the boom and lower it to its lowest position. Allow the engine to run for 1/2 – 1 minute at idling speed before stopping it. This will allow the engine to cool down and the turbo bearings to be lubricated. Stop the engine by turning the key to position 0. If the truck will not be used for a longer period, turn the main switch to the OFF position.

IMPORTANT! Never turn the the main switch to OFF when the engine is running – the voltage regulator may be damaged.

Power steering

IMPORTANT! Remember to carry out the daily supervision. See page 43 .

40

The truck has hydraulic power steering with no mechanical connection between the steering column and the steered wheels. Movements of the steering wheel is transmitted hydraulically to the steered wheels. Never let the truck run downhill when the engine is not running, since no hydraulic pressure will then be available and the steering of the truck will be very restricted.


OPERATION

Lifting technique Lifting technique, container In all lifting operations, remember not to exceed the maximum lifting capacity. See the picture below. Always drive carefully. Remember that the truck is wide and tall, so make sure that the boom or top lift frame will not collide with posts, overhead cables, etc. 1. Adjust length setting to suit the length of the container. 2. Drive up to the container from any angle. Put the gear selector in neutral or disengage the gearbox with brake and clutch pedals. 3. Adjust by rotating, side shifting and rising or lowering the boom. Then lower the top lift onto the container. 4. Align the twist-locks with the container locking holes. 5. Check that the orange ALIGNMENT lamp is alight, which indicates that all four twist-locks are aligned in the locking holes of the container. 6. Lock the twist-locks by means of the TWIST-LOCKS button. If switch 15 (page 10) is in the AUT position, the twist-locks will lock automatically. 7. Check that the green TWIST-LOCKS LOCKED lamp is alight. 8. Ready for lifting. When the container is lifted, the ALIGNMENT lamp should be extinguished. 9. Always start in 1:st gear for all transport operations.

WARNING! All four corners of the top lift must be in contact with the container when locking or releasing the twistlocks. In addition, during release, the container must rest with all corners firmly on the surface supporting it. Heavy loads must not be driven in highly hoisted positions because this is detrimental to lateral stability and may also cause forward tipping.

Transport position

WARNING! KL1103

Great care must always be taken when rotating a container in order to avoid any collision with boom or chassis.

WARNING! WARNING!

The cab MUST ALWAYS be in the rear- most position during ALL transport operations to avoid risk of injury or damage.

If the indicating lamps for the overload indication system are inoperative, the system must immediately be repaired. Safety may be affected if the truck is used when the lamps are defective. Never start lifting a load if the TWIST-LOCKS UNLOCKED (red) lamp is ON or if any of the TWIST-LOCKS LOCKED (green) or ALIGNMENT (orange) lamps is extinguished. The ALIGNMENT lamp is extinguished on lifting.

See rating plate for machine concerned!

Operations close to high tension power lines Extreme care must be taken when working in close proximity to overhead, high tension power lines, particularly in respect of the reach of the boom and attachment.

WARNING! If the machine comes into contact with overhead high tension power lines - remain seated in the cab and call for help! It is extremely dangerous to leave the cab as you will be earthed when you come into contact with the ground.

C


41

SPECIAL PROCEDURES Towing WARNING! If it is not possible to run the engine running during towing, a tow bar must be used. Before preparations for towing begin and after towing has been completed, the parking brake must be applied and the wheels chocked to prevent the machine rolling. The greatest possible care must be exercised during towing operations to prevent personal injury.

IMPORTANT! The truck cannot be started by being towed. Any attempt to start the engine by towing, will inevitably cause damage to the tranmission.

If possible, the engine should be running during towing in order to retain braking and steering functions. When the engine is not running, there is no hydraulic pressure for the steering of the truck which is then extremely limited. Furthermore, the gearbox will be insufficiently lubricated. Towing may only take place over very short distances.  If a tow bar is used, it shall be connected to the connection/  towing hitch at the rear of the machine. The brakes function as long as there is pressure in the accu mulator, thereafter the operating brakes cease to function and the parking brake is automatically applied. If, thereafter, it is necessary to move or tow the truck, the parking brake must be released mechanically (see instructions below). The vehicle or machine use to for towing must be at least as  heavy as the machine to be towed and have sufficient engine and brake capacity. For towing over longer distances or at speeds higher than 10  km/h, the propeller shaft must be disconnected.

Mechanical release of Parking Brake

WARNING! Block the wheels before releasing the parking brake. The parking brake is a disc brake on the in-going axle of the drive axle. The parking brake is automatically spring-applied if the pressure in the hydraulic accumulator should sink below a certain level. If the truck needs to be moved: 1. Note the position of the nut (B) on its bolt and remove the split pin securing the nut. 2. Tighten the nut (B), this compresses the brake spring. Continue tightening until the brake pads are released from the brake disc. 3. Once the fault has been rectified, reset the parking brake function by returning the nut (B) to the same position as in point 1.

B

WARNING! If the parking brake has been mechanically released, it must always be reset in order for the truck to retain its parking brake function. KL1102

Fire protection If the machine is equipped with fire extinguishers these should be of the ABE type, in accordance with EN 3 parts 1, 2, 4 and 5. With such a fire extinguisher it is possible to extinguish a fire in both fixed organic materials and liquids. Furthermore, the medium used to extinguish fire does not conduct electricity. Suitable fire extinguishers can be ordered from Kalmar.

WARNING! If the machine is used in highly inflammable environments, e.g., in explosive environments, it is a strict re- quirement that the machine be designed, constructed and equipped in accordance with EN 1755. 42


SUPERVISION

Daily supervision

IMPORTANT! The following must be carried out in addition to daily and periodic supervision: Service during the running-in period Tighten the wheel nuts and propshaft  bolts after 8, 16 and 24 hours of operation. Tightening torque in accordance with the Technical Handbook. Tighten the wheel nuts in a zig-zag sequence. Tighten the nuts in the same way every time after changing a wheel. Guarantee service after 50 hours. The guarantee service is performed by Kalmar, or by personnel authorized by Kalmar, and is part of the Kalmar delivery commitments. The guarantee service is also a condition for continued validity of the guarantee.

DAILY SUPERVISION

Or when refuelling

Supervision Supervision is differentiated as follows:  

DAILY SUPERVISION – carried out by the operator PERIODIC SUPERVISION – carried out by specially trained service personnel.

Proper supervision contributes to making the truck safe to work with. Periodic supervision is described in the Technical Handbook. The operator must make sure that the truck is available for service every 200 hours of operation. All times refer to the hours of operation, i.e., the time recorded by the hour meter on the panel. N.B. Only genuine Kalmar spare parts may be used. Spare tyres and replacement tyres must be of a make approved by Kalmar. Check

Refill as required

More details on page

Brakes

Operation

Steering

Operation

All instruments: Direction indicators, horn, brake lights, headlights

Operation

Lifting boom: Pivot points, slide plates

Damage?

Lift unit and rotator

Operation

Twist-locks

At suspected damage, check the twist-locks immediately

All hydraulic functions

Check all functions. Run every function to its end position in order to lubricate the cylinders and prevent corrosion

Engine, gearbox, drive axle, hydraulic hoses

Noises? Oil leakage?

Fuel

Amount The gauge reading should never drop to 0

•

45

Check that the rear steered axle suspension is free from dirt and that the sensor is free from grease (Mechanical overload safety system)

Coolant

•

Level

•

45

Engine oil

•

Level

•

46

Gearbox oil

•

Level

•

47

Hydraulic oil

•

Level

•

47

Windscreen washer

•

Fluid level

•

48

Wheels

•

Tyre pressure 1,0 MPa


43

SUPERVISION

Tyres Tyres

WARNING! Spare and replacement tyres shall be of a make approved by Kalmar.

Checks 1. Check the tyres regularly, if possible, daily. 2. Remove objects that could penetrate the tyres, such as broken glass, pieces of wood, metal shvings, etc. 3. Check for uneven and rapid wear. This is caused by mechanical faults such as unevenly acting brakes. Make sure that such faults are immediately rectified. Compressor for tyre inflation 1. An air filter with water separator should be fitted in the line from the compressor that is used for tyre inflation. The water separator minimizes the risk of the wheels rusting. 2. Drain the water separator regularly. Tyre inflation 1. Before inflating, make sure that the wheel locking ring is in the correct position, see illustration. N.B. If the tyre has been completely deflated, the wheel must be dismantled and checked for damage. 2. Connect the compressor hose, with a grip-nozzle to the nipple on the tyre. 3. Move away to the side and remain there throughout the entire inflation process. 4. Inflate the tyre to the recommended pressure, see Technical Data. With a change of tyres or wheel type, another tyre pressure may apply, contact KALMAR.

KL1469

Locking ring

WARNING! Never stand in front of a tyre being inflated. Do not exceed the recommended tyre pressure, see Technical Data. With a change of tyre or wheel type, another tyre pressure may apply, contact KALMAR. Always follow the instructions for tyre inflation to avoid serious accidents. When changing tyres, see “ Safety instructions for working with tyres ” in Technical Handbook.

KL1470RS

Tyre inflation 44


SUPERVISION

Fuel system, cooling system Fuel system Always refuel with ordinary diesel oil. Never use any additives for the diesel oil. In the winter, it is advisable to refuel the truck immediately after the day’s work has been completed, to avoid moisture condensing on inside of the fuel tank. Never add water-absorbing agent, such as alcohol, to the fuel. Tank capacity, see Technical Data. The filling pipe is on the left-hand side of the truck. Before refuelling, make sure that the area around the filler cap is clean. KL590

Bleeding the fuel system Air will be drawn into the fuel system if the truck is used when the fuel tank is completely empty. It will be necessary to bleed the system after refuelling. This is carried out as follows: Back off the bleed screw A on the fuel filter half a turn.  Release the pump handle B by turning it anti-clockwise.  Pump by means of the hand pump B until the fuel flowing  past the bleed screws is completely free from air. Continue pumping and tighten screw A. Tighten the pump handle.  Run the starter motor in 20 – 30 second bursts, with a pause  of a couple of seconds between each run. The engine will start after 2 – 3 minutes. A Bleed screw B Hand pump No further bleeding is normally necessary. If the engine fails to start after having been bled as described above or if it stops after a few seconds, the fuel system must be bled again. Back off the fuel pipe at any two injectors and run the starter motor until airfree fuel sprays out. Tighten the coupling immediately. Make a fresh starting attempt.

Cooling system The coolant is topped up via the header on top of the radiator, which is located under the cab.

WARNING! Do not open the cap when the engine is hot, since steam or hot water may spray out.

Fill with water containing at least 40% glycol. If glycol is not used, a corrosion inhibitor must always be added to the coolant. But the corrosion inhibitor is not an anti-freeze agent, and should therefore be used only if the ambient temperature is constantly above 0°C. If the coolant level should drop below the minimum level, warning lamp 46 on the instrument panel will light up. Insufficient coolant may impair the coolant circulation which may cause the coolant to boil and give rise to engine damage.


45

SUPERVISION

Engine oil, accumulators Engine oil The dipstick for the engine oil (B) is beneath the service cover in front of the cab. The dipstick has two markings, MIN and MAX, and the oil level should be between these. Clean the dipstick before checking the oil level. It is advisable to top up with oil when the engine is warm and the oil flows easily. Top up – wait a while – check on the dipstick. A Oil filler cap B Oil dipstick

B A KL950A

Checking the brake system accumulators The accumulators are charged with nitrogen. If lamp 45 for low brake pressure should light up, check for leakage as follows. 1. Start the engine and let it run until the accumulators are charged. 2. Stop the engine and then turn the starting key to position I. 3. Depress the brake pedal repeatedly with long strokes, holding it down in the depressed position for a brief while on every occasion. 4. It should be possible to apply the brakes at least six times before lamp 45 lights up. 5. Start the engine, allow the accumulators to be charged and repeat the test a couple of times. 6. If the brakes cannot be applied six times before lamp 45 lights up, the accumulators are faulty. If so, ensure that the fault receives attention as soon as possible and that the accumulators are charged with nitrogen.

KL591

WARNING! Charging should be made with approved equipment by authorized personnel.

A Quick evacuation valve, accumulators. B Valve for emergency pressure to servo system.

WARNING! RISK OF SERIOUS INJURY. The brake pressure accumulators have an internal pressure of up to 210 bar. Take great care therefore when working on the system and al-ways release pressure from the accumulators before removing any component from the system. Discharge the pressure by opening the quick- evacuation valve A. Open also valve B!

46


SUPERVISION

Hydraulic system, gearbox oil Hydraulic system The hydraulic tank is on the right-hand side of the truck. A Refill B Sight glass The fluid level should be in the middle of the sight glass when all hydraulic cylinders are in bottom position. The hydraulic fluid must always contain 6% of Lubrizol additive to ensure satisfactory performance of the oil-cooled brake system. The additive is not consumed during normal operation and must only be added at oil change and refill. Lubrizol may be ordered from Kalmar Service department.

WARNING! Hydraulic fluid with Lubrizol additive is chemically aggressive. Avoid extended contact with the skin.

Gearbox oil The oil filler cap and dipstick for the gearbox oil are beneath the service cover in front of the cab. A Filler pipe B Dipstick Check the level with the engine idling.

B A

KL950B


47

SUPERVISION

Air cleaner, windscreen washer Air cleaner The dust container is emptied automatically. The filter element in the air cleaner is replaced by the service personnel as a routine measure. If the truck is used under dusty conditions, the filter may become clogged after a relatively short period of time. An indicator, which turns red when the filter has become clogged, is located in the air intake system between the air cleaner and the engine. Check the indicator regularly and get in touch with the service personnel as soon as the indicator has turned red.

IMPORTANT! Inadequately filtered intake air may quickly cause serious damage to the engine. Time to change the filter!

Windscreen washer The windscreen washer container is beneath the service cover in front of the cab. Check that there is sufficient washer fluid in the bottle. Refill if necessary. Use anti-freeze fluid during the winter.

KL592

48


SUPERVISION

Electrical system

IMPORTANT! The starting batteries accompanying the truck are of the maintenance-free type, which implies that it should not be necessary to top-up with electrolyte during the life of the batteries. However, the level of the electrolyte should preferably be checked once or twice a year. Fill as required by add- ing de-ionized water.

Electrical system The electrical system operates at 24 V. The source of power supply are two 12 V batteries which are charged by an alternator. The negative pole is connected to the chassis. The positive pole is connected to a main switch A. When working with the electrical system, when carrying out welding on the truck or at long time parking, always isolate the batteries.

Checking the electrolyte level of the batteries The batteries are fitted behind a cover on the left-hand side of the truck. The electrolyte level should be about 10 mm above the cells. Top up with de-ionized water as necessary. Batteries contain substances dangerous to health and the environment. Discarded batteries must therefore be dealt with in accordance with current local/national regulations.

S1-6 7-12 13-18 19-24

WARNING! The battery electrolyte contains corrosive sulphuric ac- id. Immediately remove any electrolyte that comes into contact with the skin. Wash with soap and lots of water. If electrolyte gets into the eyes, immediately rinse with lots of water and immediately contact a doctor.



WARNING! Never use fuses of a higher amperage than stated on the lid decal. Risk of damage or fire.

Relay box in cab – fuses Fuse No.

Circuit protected

Rating A

S1

B

A

2

1

KL593A

4

3

6

8 10 12 14 16

7

9 11 13 15

C KL728A

19

Wiper motor front, direction indicators, seat buzzer, parking brake sensor ........................... 10 S2 Ignition key, pre-heater, starter motor, cab lighting (Air conditioner 25 A 1)) ........................ 15 S3 Container attachment, safety interlock ..................... 15 S4 Electric gear-changing .............................................. 5 S5 Warning lamps, instrument illumination, relay, coolant level .............................................................. 5 S6 Brake lights, reversing lights, reversing alarm ......... 15 S7 Fan (Air conditioning 1)) ........................................... 25 S8 Spare (Container lights 1)) ....................................... 15 S9 Working lights (15 A for 4 lamps) 1) Hazard beacon ........................................................ 10 S10 Working lights, standard (15 A for 4 lamps) ............ 10 S11 Horn, screenwash motor, wiper rear and roof, wiper front, intermittent relay .................................... 10 S12 Driving lights (main fuse), rear lights (main fuse), position lights 15 S13 Main beam, right-hand ............................................... 5 S14 Main beam, left-hand ................................................. 5 S15 Dipped beam, right-hand............................................ 5 S16 Dipped beam, left-hand.............................................. 5 S17 Rear light, left-hand.................................................... 5 S18 Rear light, right-hand.................................................. 5 S19 ECU1 1) .................................................................... 10 S20 ECU2 ....................................................................... 10 S21 Voltage converter ....................................................... 5 S22-24 Spare.......................................................................... – 1)

Optional equipment

Miscellaneous fuses

D ContChamp DRD420-450

A B C D

Main switch Main fuse, boom (1x25 A) Top lift fuse (2x10 A) in the attachment electrical central box Main fuse for truck electrical system Fitted on the engine, 2x50 A 49

SUPERVISION

Electrical system Relays 305 314 315 316 320 322-1 322-2 323 328 330 331 332 334 367 399

Reversing light Parking brake, disengagement High power (Starting switch) Wiper motor, front Electric stop (ECS 07) 1) Coolant level Coolant level (ECS 07) 1) Pulse relay, direction indicators Gear shift (ECS 01) 1) Starting block Propulsion forward Propulsion reverse Clutch release (ECS 01) 1) Lever steering (ECS 04) 1) Spare

Miscellaneous 321-1 321-2 960

Intermittent relay wiper front Intermittent relay wiper rear 1) Reversing interlock

1)

Optional equipment

Bulbs Description

Rating Watts ............................. Base

Instruments Indicating lamps Cab lighting Rear lights, red Brake lights Direction indicators Position lights Driving lights (full/dipped beam) Reversing lights, white Working lights Hazard beacon

3 .................................... BA7s 1,2 ........................... W2x4,6d 10 ................................... S8,5 5 .................................. BA15s 21 ................................BA15s 21 ................................ BA15s 5 ...................................SV8,5 75/70 .........................P43t-38 70 ................................PK22s 70 ................................PK22s 70 ................................PK22s



Starting from another battery Make sure the auxiliary batteries are connected in series, so that 24 V will be supplied. N.B. Note: Do not disconnect the truck-battery cables Connect the jumper cables in the following order:  1. Red cable (+) to auxiliary battery 2. Red cable (+) to truck battery 3. Black cable ( – ) to auxiliary battery 4. Black cable ( – ) to a location some distance away from the truck battery, such as the negative cable connection on the chassis. Start the engine  Do not disturb the jumper cables while starting, as sparks may otherwise be caused. Do not lean over either battery. Disconnect the jumper cables in exactly the reverse order.  

WARNING! Batteries emit oxyhydrogen which is an explosive gas. A spark, for example from incorrectly connected starting cables, could cause a battery to explode and result in serious injury and damage.

50


TECHNICAL DATA Truck model, type designation DRD 420-60S5 – 420-70S6 Engine Make – type designation Fuel – type of engine Power ISO 3046 1) – at speed Torque ISO 3046 – at speed No of cylinders – compression Alternator, type – power Starting battery, voltage – capacity

kW -r/m Nm-r/m

V-Ah

Transmission Gearbox, make – type designation Clutch, type Gearbox No. of gears, forward – reverse Drive axle, type Wheels Wheels, front and rear 2) Wheel dimension, front and rear Pressure, front – rear

MPa

L L L

Fuel Hydraulic system,tank volume total volume Brake system tank volume 3) Drive axle (incl. hub reduction)

L L L L L

450-80S4X

Volvo – TWD1031VE Diesel – 4-stroke 235 – 2100 1500 – 1100 6-18,0:1 AC – 1920 W 2x12 – 140

Volvo – TWD1231VE Diesel – 4-stroke 275 – 2100 1753 – 1100 6-18,0:1 AC – 1920 W 2x12 – 140

Clark – 15,5 HR 36432 Torque converter Powershift 4 – 4 Double reduction, planet gear hub

Clark – 15,7 HR 40432 Torque converter Powershift 4 – 4 Double reduction, planet gear hub

Hydraulic servo Hydraulic – drive wheels Spring brake – drive wheels

dB(A) dB(A)

Liquid capacities Cooling system Gearbox oil Engine oil

450-60S5X – 450-70S5XS

Pneumatic See data sheet 1,0

Steering- and brake system Steering system Driving brake system, type – affected wheels Parking brake system, type – affected wheels Equivalent noise level in cab In accordance with machine directive. Limit 70 dB(A) with standard engine with noise reduction kit

450-60S5 – 450-70S5

max 72 68 TWD1031VE/Clark 36000 65 57 32 510 600 880 100 74

TWD1231VE/Clark 40000 75 55 38 510 700 1000 100 222

Truck dimensions and weights vary according to amount of extra equipment on the truck. These changes are explained in the product specification and data sheet. 1)

ISO 3046=Net power. Spare wheels should be of a brand approved by Kalmar. 3) Only machines with separate tank for brake system 2)


51

LUBRICATION CHART 3

2 1

4 5

24

DRD420-60S5

6, 7

KL586C

25

Refill Brake Planetary gear Sight glass

52


LUBRICATION CHART Item Description No.

Interval operating hours 200 600 1000

No. of Remarks lub. points

1 2

Boom mounting Slide plates, boom

L L

2

3 4 5

Rotator mounting Tilt cylinders Rotator reduction gear (Brake and planetary gear)

L L x

2 4 4

6 7 8 9

Rotator bearing Pinion and ring gear Link levers Steered wheel bearing

L L L

10

Knuckle pin bearings

11 12 13

Engine oil Engine oil filter Gearbox oil

14 15 16 17 18 19 20 21 22 23 24

Gearbox oil filter Hydraulic oil filter, working hydraulics Hydraulic oil filter, brake system cooling circuit Hydraulic oil filter, servo system Hydraulic oil filter, top lift Propeller shaft Drive axle Breather filters, hydraulic tank Hydraulic oil Door and panel hinges Brake pedals

25

Hydralic oil, brake system

Manually pump grease while the boom is moved slowly outwards and inwards to its end positions

C

xx

4 3 4 2 4

x x C

x

2 1

x x

2 2 1

x

x x L C

x x x

C

C

1 1 3 3 2

CL

2

x

1

Check the level. Top up the red point on the sight glasses 2) x) First oil change at warranty service xx) Thereafter oil change every 1000 h 2 nipples on each side Brush on with grease Remove, clean, inspect and pack with grease every 4000 h Remove, clean, inspect and pack with grease every 4000 h x) Change the oil every 200 h1) x) Change the filter every 400 h x) Change the oil. Check the level at idling speed x) Change the filters x) Change the filters x) Change the filters x) Change the filters x) Change the filters Change the oil x) Change filters every 2000 h x) Change oil every 2000 h Lift off the doors and panels Check and retighten the pedal axle locking screws. Lubricate axle nipples x) Change the oil. N.B. Only machines with separate tank for brake system

1)

The interval is greatly dependent on the fuel and lubricant quality as well as the operating conditions. If intervals longer than 200 hours are desired, the condition of the oil must be checked by the company making the oil, by means of regular lubricant tests. 2 ) Note! DIfferent oils in brake and planetary gear. (Volume brake: 0.6 l. Volume gear: 1.6 l) For volumes, see Technical Data. For lubricating oil grades, see Oil and lubricant recommendations L=Lubricate C=Check

IMPORTANT! If the truck is standing unused outdoors, with the hydraulic piston rods exposed, all piston rods must be greased to prevent corrosion.


After they have been washed with degreasing agent, all pistons should be moved backwards and forwards several times to obtain a new pro- tective oil film.

53

LUBRICATION CHART TOP-LIFT, cylinder operated extension 1

2

3

3

4

1

4

4

4

5

A3139001B

6

7

6

7

7

8

9

54


LUBRICATION CHART TOP-LIFT, cylinder operated extension Item Description No.

Interval operating hours 200

600

1000

No. of Remark lub. points

1

Sliding surfaces, length adjustment

L

Brush onto all sliding surfaces with the attachment in the fully extended position

2

Sliding surfaces, sideshifting

L

Brush onto all sliding surfaces with the attachment sideshifting to the limit in each direction

3

Cylinders, pile slope

L

8

4

Cylinders, sideshift

L

4

5

Cylinders, length adjustment

L

4

6

Cylinder, twist-locks

L

4

Check that the sensors are free from grease and that the sensor faces are undamaged.

7

Lift pinion twist connection

L

x

4

8

Lift pinion

L

x

4

Disassemble the twist-locks every 2000 h. Check for wear. If needed, change components accordingly. Clean and pack with grease. Same procedure should be used at suspected damage to the twist-locks.

9

Contact pins

C

4

Only top lift with pile slope

Lubricate with grease Check that the sensors are free from grease and that the sensor faces are undamaged.

L=Lubricate C=Check


55

LUBRICATION CHART TOP-LIFT, chain operated extension 1

2

1

  a b

3

4

4

c

 

4

4

5

 

7

6

6

7

7

8



9

56


LUBRICATION CHART TOP-LIFT, chain operated extension Item No. Description

Interval operating hours 200

600

1000

No. of lub. Remarks points

1

Sliding surfaces, length adjustment

L

Brush onto all sliding surfaces with the in the fully extended position

2

Sliding surfaces, side-shift

L

Brush onto all sliding surfaces with the toplift fully side-shifted in both directions

3

Planetary gear a. Venting/Topping up b. Sight glass c. Magnetic plugg, oil drainage

C

4

Cylinders, side-shift

L

4

5

Chains

L

2

6

Locking cylinders, twist-locks

L

4

Check that the sensors are free from grease and that the sensor faces are undamaged

7

Lifting pin twist connection

L

x

4

8

Lifting pin

L

x

4

Dismantle the twist-locks every 2000 h. Check for wear. If necessary, change components accordingly. Clean and pack with grease. Same procedure should be used if damage to the twistlocks is suspected. See group 80.

9

Contact pin

L

x

1

4

Level check, fill to the red spot on the sight glass. Oil volume 2.4 litres. x) First oil change - guarantee service x) Then, oil change every 1000 hours

Lubricate with grease Check that the sensors are free from grease and that the sensor faces are undamaged

L = Lubricate C = Check


57

Oil and lubricant recommendations  

   

       





 





     

  













  

     

  

     

   

    

 

 

  

  

              

 

    

     

         

   



                                  

Oil in rotator reduction gear and top-lift Brake Quality: Planetary gear Quality: Viscosity:

Ordinary hydraulic fluid without additve, API GL-5 SAE 80W-140 Above +30°C or heavy duty: SAE 320

Grease IMPORTANT! Any deviations from the above table must be supported by written approval from Kalmar Service.

Use EP universal grease to NLGI Grade 2 with 3 – 5% molybdenum disulphide additive for all lubrication points, including wheel bearings.

Grease for Plastic plates Use grease recommended by Kalmar. Ordered from Kalmar’s Spares department. 0,65 kg cartridge for grease gun Art. no 923110.0360 5 kg can Art. no 923595.0003

Coolant for air conditioning unit ZXL100 Seltec PAG oil 58


Instruction Manual DRD ContChamp GB

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