Kalmar DCD — Safety and interlocks: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the load capacity, transport, wind, towing, emergency brake, workshop safety and interlocks of the Kalmar DCD heavy forklift truck, one fact per card, each with its source stated in the text. For the overall picture, see the Kalmar DCD technical legacy guide.
Kalmar DCD 200-300: what is the machine intended for?
Lifting and transporting goods within its maximum permissible load, according to the operator's manual (series 2), as recorded by the HIT SRL technical desk. Any other use, or work in hazardous settings such as explosive atmospheres or asbestos dust, calls for special safety rules and equipment suited to that work, according to the same manual, as HIT SRL's technical desk reads it. The manual allows changes to capacity, visibility, guards, brakes, steering or lifting only with the manufacturer's permission. What a given truck may do is set out in its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-intended-use · HIT ref KDCD-162 · fingerprint 98794f · see HIT ref KDCD-163, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-prohibited-operation
Kalmar DCD 200-300: when must the machine not be operated?
When safety or warning equipment such as mirrors or headlights does not work, or brakes, steering or lifting equipment are defective, according to the operator's manual (series 2), the HIT SRL technical desk notes. The manual also forbids operation after repairs or adjustments that the supervisor has not approved, and on tyres not approved by the manufacturer, as set out in the HIT SRL technical cards. The technical handbook (series 3) adds the optional reversing alarm to the equipment that must work. The full list for a given machine is in the manual for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-prohibited-operation · HIT ref KDCD-163 · fingerprint 31b7ca · see HIT ref KDCD-162, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-intended-use
Kalmar DCD 200-300: can the load capacity be exceeded?
No: exceeding the load capacity is prohibited, the limits being on the capacity plate and in the load diagram, according to the operator's manual (series 2), as HIT SRL's technical desk reads it. The manual warns that the stability limit may be exceeded if the overload system is not working, without describing how that system is built, as recorded by the HIT SRL technical desk. The technical handbook (series 3) and the 1997 and 2001 handbooks repeat the ban on exceeding the capacity. The plates and diagram of the individual machine, with its own maintenance manual, set its limits.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-load-capacity-and-overload · HIT ref KDCD-164 · fingerprint c55319 · see HIT ref KDCD-165, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-load-transport-position
Kalmar DCD 200-300: how is a load carried?
With the mast tilted back and the forks raised about 300 mm over even ground, which the operator's manual (series 2) calls the transport position, as set out in the HIT SRL technical cards. Tilting the mast forward with a load is forbidden, and so is turning across a slope, where the load must face uphill, according to the manual, the HIT SRL technical desk notes. When the load blocks the view ahead, the manual has the operator reverse. Carrying rules for a particular truck are written in that machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-load-transport-position · HIT ref KDCD-165 · fingerprint 08a164 · see HIT ref KDCD-164, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-load-capacity-and-overload
Kalmar DCD 200-300: can anyone stand under the raised forks?
No: nobody may stand or walk under the raised forks or attachment, loaded or not, according to the operator's manual (series 2), as logged by the HIT SRL technical desk. The same manual forbids anyone to stand on the forks, as recorded at HIT SRL. The technical handbook (series 3), the 1997 and 2001 handbooks and the DCD 90-180 instruction manual give the same rule, and the manual that comes with the machine is the reference for it.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-no-one-under-forks · HIT ref KDCD-166 · fingerprint cc9dd0 · see HIT ref KDCD-167, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-lifting-people
Kalmar DCD 200-300: can people be lifted with the machine?
Only in an approved lift cage, according to the technical handbook (series 3), as recorded by the HIT SRL technical desk. The handbook prohibits lifting people in any other way. The 1997 and 2001 handbooks and the DCD 90-180 instruction manual give the same rule, and any cage use follows the specific machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-lifting-people · HIT ref KDCD-167 · fingerprint 817ad2 · see HIT ref KDCD-166, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-no-one-under-forks
Kalmar DCD 200-300: what wind limit applies when lifting containers?
Lifting should be avoided in wind stronger than 12 m/s (27 mph), according to the technical handbook (series 3), which tells the operator to allow for the wind when handling containers, the HIT SRL technical desk notes. The operator's manual (series 2) warns against lifting loads in strong wind without giving a figure, as set out in the HIT SRL technical cards. The 1997 and 2001 handbooks and the DCD 90-180 instruction manual give the same 12 m/s. The wind limit binding on a truck is the one in its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-wind-limit · HIT ref KDCD-168 · fingerprint aed2d8 · see HIT ref KDCD-165, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-load-transport-position
Kalmar DCD 280-500: how is the truck driven down a slope?
In bottom gear, for maximum engine braking, according to the DCD 280-500 technical handbook (2001 edition), as recorded at HIT SRL. The handbook forbids using the release clutch pedal together with the brake pedal, stating that the engine then gives no braking effect. Driving on slopes follows the manual issued for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-slope-and-low-gear-280-500 · HIT ref KDCD-169 · fingerprint 7c56c7 · see HIT ref KDCD-170, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-turning-stability-280-500
Kalmar DCD 280-500: what does the handbook say about turning?
Avoid powerful acceleration and braking when turning and always slow down in turns, according to the DCD 280-500 technical handbook (2001 edition), which names the risk of lateral skidding or tipping, as HIT SRL's technical desk reads it. The handbook asks for particular care near electrical power lines, viaducts, quay sides, ramps and gates, as recorded by the HIT SRL technical desk. The same handbook requires the load to travel lowered with the mast fully back. Turning speeds for a given truck come from the manual of each machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-turning-stability-280-500 · HIT ref KDCD-170 · fingerprint f2d870 · see HIT ref KDCD-169, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-slope-and-low-gear-280-500
Kalmar DCD 200-300: what should the operator do if the machine tips over?
Stay in the cab, hold the steering wheel and never try to jump out before the machine has stopped moving, according to the operator's manual (series 2), as set out in the HIT SRL technical cards. The technical handbook (series 3) adds that seat belts, where fitted, must always be worn, the HIT SRL technical desk notes. A warning plate in the cab shows the same instruction, according to the operator's manual. Rollover behaviour on a particular truck follows the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-rollover · HIT ref KDCD-171 · fingerprint 19e913 · see HIT ref KDCD-172, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-overhead-power-lines
Kalmar DCD 200-300: what should the operator do after touching an overhead power line?
Stay in the operator's seat and call for help, according to the operator's manual (series 2), as logged by the HIT SRL technical desk. The DCD 90-180 instruction manual gives the same instruction. Near overhead lines, the manual that comes with the machine sets the precautions.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-overhead-power-lines · HIT ref KDCD-172 · fingerprint ce3550 · see HIT ref KDCD-171, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-rollover
Kalmar DCD 200-300: which emergency features does the operator's manual describe?
The right-hand cab door is the emergency exit, opened with its inside handle, according to the operator's manual (series 2), as recorded by the HIT SRL technical desk. On machines with electric servo load-handling controls, the manual describes a breaker switch that stops all load-handling functions when pressed down and is reset by turning it clockwise, as HIT SRL's technical desk reads it. The technical handbook (series 3) calls it the emergency stop. Emergency equipment on a given truck is described in the specific machine's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-emergency-equipment · HIT ref KDCD-173 · fingerprint 583555 · see HIT ref KDCD-171, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-rollover
Kalmar DCD 200-300: can the machine roll downhill with the engine stopped?
No, the operator's manual (series 2) forbids it and tells the operator to keep the engine running, the HIT SRL technical desk notes. The manual notes that with the engine stopped there is no hydraulic pressure and no steering capacity. The DCD 90-180 instruction manual adds that without hydraulic pressure the steering is very limited. Descending with a dead engine is covered by the manual for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-engine-off-rolling · HIT ref KDCD-174 · fingerprint 1334df · see HIT ref KDCD-175, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-towing-200-300
Kalmar DCD 200-300: how is the machine towed?
With a tow bar if the engine cannot run, a towing vehicle heavier than the machine and the engine kept running where possible so that brakes and steering work, according to the operator's manual (series 2), as recorded at HIT SRL. The manual disconnects the propeller shaft from the transmission, allows only very short distances and forbids starting the machine by towing, as logged by the HIT SRL technical desk. The manual adds that the brakes work only while pressure remains in the accumulator, after which the parking brake applies by itself. Towing a particular truck follows its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-towing-200-300 · HIT ref KDCD-175 · fingerprint 99dd0b · see HIT ref KDCD-176, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-parking-brake-release-200-300
Kalmar DCD 200-300: how is the spring parking brake released to move the machine?
Mechanically, by screwing in the nut on the caliper bolt until the pads clear the disc, or hydraulically, with about ten strokes of a hand pump, according to the operator's manual (series 2), as HIT SRL's technical desk reads it. The manual always blocks the wheels first and always resets the brake afterwards, as recorded by the HIT SRL technical desk. The manual warns that the spring is strong and that, if the brake is opened wrongly, parts may fly off violently. The release method for a given truck is in the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-parking-brake-release-200-300 · HIT ref KDCD-176 · fingerprint 12f613 · see HIT ref KDCD-175, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-towing-200-300
Kalmar DCD 180-250: how is the parking brake released when the pressure is lost?
Mechanically, on the Rockwell axle by tightening the adjusting nut against the brake spring and on the Kessler axle by unscrewing the adjusting screw anticlockwise, according to the DCD 180-250 technical handbook (1997 edition), as set out in the HIT SRL technical cards. The handbook states that the spring brake applies itself when the accumulator pressure falls below a certain level, the HIT SRL technical desk notes. Released hydraulically, it needs at least 100 bar on the Rockwell and 10 MPa on the Kessler, and it must always be reset after a mechanical release, according to the handbook. The 1997 handbook has no towing procedure, and a given truck follows the manual that comes with the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-parking-brake-release-180-250 · HIT ref KDCD-177 · fingerprint 38e10b · see HIT ref KDCD-181, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-emergency-brake-180-250
Kalmar DCD 280-500: how is the Kessler parking brake released to move the truck?
By backing off the adjusting screw under the cylinder lid, with the wheels chocked on sloping ground, according to the DCD 280-500 technical handbook (2001 edition), as logged by the HIT SRL technical desk. The handbook states that the brake applies by itself when the hydraulic pressure is too low and must always be reset afterwards, as recorded at HIT SRL. The handbook warns of danger to life from the powerful plate-spring package in the cylinder, whose tension is always released before the cylinder is dismantled. Moving such a truck follows the specific machine's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-kessler-parking-brake-release-280-500 · HIT ref KDCD-178 · fingerprint 01c46c · see HIT ref KDCD-180, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-emergency-brake-280-500
Kalmar DCD 200-300: what happens to the parking brake after an emergency stop with it?
The operator's manual (series 2) allows the parking brake to be used as an emergency brake and then has its pads checked as soon as possible and changed if needed, as recorded by the HIT SRL technical desk. The technical handbook (series 3) changes the linings after a single emergency braking, stating that it subjects them to very heavy wear, as HIT SRL's technical desk reads it. In its general safety group the same handbook asks only for inspection and change if necessary. The lining rule for a particular truck is the one in its own maintenance manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-emergency-brake-200-300 · HIT ref KDCD-179 · fingerprint 0920cb · see HIT ref KDCD-180, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-emergency-brake-280-500
Kalmar DCD 280-500: when are the parking brake linings changed after emergency braking?
After one emergency braking in the brake-system pages of the DCD 280-500 technical handbook (2001 edition), the HIT SRL technical desk notes. In its description of the parking brake on the Meritor (Rockwell) drive axle, the same handbook says after two emergency brake operations, as set out in the HIT SRL technical cards. The warning on that axle page gives one again, according to the handbook. The rule binding on a given truck comes from the manual of each machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-emergency-brake-280-500 · HIT ref KDCD-180 · fingerprint d0f65b · see HIT ref KDCD-181, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-emergency-brake-180-250
Kalmar DCD 180-250: when are the parking brake linings changed after emergency braking?
After two emergency brakings, according to the DCD 180-250 technical handbook (1997 edition), which allows the parking brake to serve as an emergency brake, as recorded at HIT SRL. The handbook prints TWICE in capitals in its safety group and repeats the rule in its brake pages, as logged by the HIT SRL technical desk. A parking brake released mechanically must always be reset before the truck has its parking brake function again, according to the same handbook. The count for a particular unit is in the manual of the specific unit.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-emergency-brake-180-250 · HIT ref KDCD-181 · fingerprint d84884 · see HIT ref KDCD-180, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-emergency-brake-280-500
Kalmar DCD 200-300: how is the machine lifted and secured for transport?
By the lifting eyes on the counterweight and on the mast, with the lifting point through the centre of gravity and lifting gear checked for capacity, according to the operator's manual (series 2), as HIT SRL's technical desk reads it. For transport the manual secures the machine with crossed chains at the mast or front wheels and at the rear towing eye or wheels, as recorded by the HIT SRL technical desk. The machine weight is on its plate, and for public roads the manual allows the mast to be removed if the height exceeds the limits. Lifting a given truck follows the manual issued for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-lifting-the-machine · HIT ref KDCD-182 · fingerprint 588b84 · see HIT ref KDCD-175, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-towing-200-300
Kalmar DCD 200-300: how is the hydraulic system depressurised before work?
By opening the accumulator drain valve, checking the release with a pressure gauge on the test point by the accumulator charging valve and keeping the valve open until the work is finished, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The technical handbook (series 3) empties the high-pressure accumulators into the tank through the evacuating valve before any work on the hydraulic system, the HIT SRL technical desk notes. The maintenance manual drills discarded accumulators with a 3 mm hole after depressurising, and its danger notice calls work on pressurised hydraulics fatal. Depressurising a particular truck follows that machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-accumulator-pressure-release · HIT ref KDCD-183 · fingerprint ece32d · see HIT ref KDCD-187, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-service-position
Kalmar DCD 200-300: which fire extinguisher does the machine carry?
One of type ABE to EN 3, normally on the left front wing, according to the operator's manual (series 2), as logged by the HIT SRL technical desk. For an engine fire the manual pushes its nozzle through the marked perforation on the side of the bonnet and makes the owner responsible for approved fire-fighting equipment, as recorded at HIT SRL. The maintenance manual (series 1) also allows it on the right wing or in the cab, and the operator's manual warns of hot air from the exhaust during particle filter regeneration, with a fire risk. The fire equipment of a given truck is listed in its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-fire-extinguisher · HIT ref KDCD-184 · fingerprint f0688a · see HIT ref KDCD-173, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-emergency-equipment
Kalmar DCD 200-300: how should the operator get on and off the machine?
Facing the machine and using the steps and handles, never jumping, according to the operator's manual (series 2), as recorded by the HIT SRL technical desk. The manual keeps the doors closed while operating and lets passengers ride only inside the cab on a fixed passenger seat, as HIT SRL's technical desk reads it. The technical handbook (series 3) asks for worn anti-slip surfaces to be replaced. Access to a given truck follows the manual of each machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-cab-access · HIT ref KDCD-185 · fingerprint 0aa787 · see HIT ref KDCD-186, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-parking-the-machine
Kalmar DCD 200-300: how is the machine parked?
In neutral with the parking brake applied, the forks lowered to the ground and the mast slightly tilted, according to the operator's manual (series 2), the HIT SRL technical desk notes. The manual lets the engine idle for one minute before switching it off and removes the key whenever the machine is left unattended, as set out in the HIT SRL technical cards. For long stops the manual sets the battery disconnector to OFF, and a signal sounds if the operator leaves the seat without the parking brake. Parking a particular truck follows the manual that comes with the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-parking-the-machine · HIT ref KDCD-186 · fingerprint e24a02 · see HIT ref KDCD-185, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-cab-access
Kalmar DCD 200-300: what is the service position?
The machine parked with the parking brake applied, forks and lifting carriage fully lowered, engine switched off and main circuit cut with the battery disconnect switch, according to the maintenance manual (series 1), as recorded at HIT SRL. If a job needs the carriage raised, the manual has it secured, as logged by the HIT SRL technical desk. The manual notes that the pinch risk is much greater while the hydraulic pressure is being released. Service work on a given truck starts from the position its own maintenance manual defines.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-service-position · HIT ref KDCD-187 · fingerprint 0a1817 · see HIT ref KDCD-183, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-accumulator-pressure-release
Kalmar DCD 200-300: where may a raised machine be supported?
Only under the frame or the drive axle, on axle stands that stand steadily, never at parts of the wheel suspension or the steering, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. For the steering axle checks the manual lifts the machine under the counterweight, and for the drive axle bearing check under the mast member with supports under the drive axle, as recorded by the HIT SRL technical desk. To remove a steering axle wheel, however, the same manual places the jack under the steering axle. Jacking points for a given truck are those in the specific machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-jacking-and-support · HIT ref KDCD-188 · fingerprint 27995a · see HIT ref KDCD-187, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-service-position
Kalmar DCD 200-300: what happens if a weld is cracked?
The machine is taken out of service immediately and the manufacturer's service is contacted, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The manual checks doubtful welds with magnetic powder after grit blasting the area free of paint, the HIT SRL technical desk notes. Any crack indication is investigated further with penetrating fluid, according to the same manual. Crack checks on a particular truck follow the manual for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-weld-crack-stop · HIT ref KDCD-189 · fingerprint 876c70 · see HIT ref KDCD-190, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-counterweight
Kalmar DCD 200-300: can the counterweight be changed?
No: the counterweights are fitted at the factory to suit the truck, and their total weight must not be changed, according to the maintenance manual (series 1), as logged by the HIT SRL technical desk. The warning of the manual names the driving characteristics, capacity and safety of the truck, as recorded at HIT SRL. The manual checks the counterweights, their mounting points and welds at the 1000-hour and 2000-hour services. Counterweight data for a given truck stay those of the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-counterweight · HIT ref KDCD-190 · fingerprint 6c9525 · see HIT ref KDCD-189, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-weld-crack-stop
Kalmar DCD 200-300: when must the lateral lift attachment not be used?
When its indicator lights give a wrong indication or do not work, according to the operator's manual (series 2), as recorded by the HIT SRL technical desk. The manual requires the attachment fully lowered when travelling empty and in the transport position when travelling with a container, as HIT SRL's technical desk reads it. The manual raises the attachment above the transport position only for stacking and keeps the mast fully back while driving. Use of the attachment on a given truck follows the manual of each machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-lateral-lift-lights-rule · HIT ref KDCD-191 · fingerprint 3b773f · see HIT ref KDCD-192, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-side-lift-twistlocks
Kalmar DCD 200-300: how are the twistlocks of the side lift attachment handled and checked?
Only with the engine off, according to the maintenance manual (series 1), which warns that the twistlocks can lock automatically if all the alignment sensors are actuated by hand, the HIT SRL technical desk notes. The manual checks them for cracks every other year or every 5000 hours and replaces them when they show cracks or other external damage or have more than 10,000 operating hours, as set out in the HIT SRL technical cards. The same manual gives 5 ± 1 mm between alignment pin and sensor. Twistlock work on a particular attachment follows the specific machine's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-side-lift-twistlocks · HIT ref KDCD-192 · fingerprint 0a8cc3 · see HIT ref KDCD-191, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-lateral-lift-lights-rule
Kalmar DCD 180-250: how does the container handling interlock work?
Two solenoid valves cut the servo supply from the control levers to the main valve, according to the DCD 180-250 technical handbook (1997 edition), as recorded at HIT SRL. In that handbook lifting is stopped unless every twistlock is either open or locked, and twistlock locking is stopped unless the attachment is fully aligned on the container with all its corners close up, as logged by the HIT SRL technical desk. The handbook gives optional twistlock lamps, green for locked, yellow for alignment and red for unlocked. The interlock and lamp convention for a given truck are those of its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-container-interlock-180-250 · HIT ref KDCD-193 · fingerprint e73bce · see HIT ref KDCD-194, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-gantry-twist-lock-interlock
Kalmar DCD 280-500: how are the Gantry twist-locks interlocked?
By a spring-loaded contact pin and an inductive sensor at each twist-lock, according to the DCD 280-500 technical handbook (2001 edition), as HIT SRL's technical desk reads it. The handbook lights the ALIGNMENT lamp only when all four pins are pressed in, and only then may the twist-locks be locked, as recorded by the HIT SRL technical desk. Once the container is lifted the alignment signal ceases and the twist-locks cannot be released, and lifting is blocked while they are neither fully released nor turned 90° in the locking holes, according to the handbook. The interlocks of a given attachment are described in the manual that comes with the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-gantry-twist-lock-interlock · HIT ref KDCD-194 · fingerprint 0ab235 · see HIT ref KDCD-195, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-gantry-lamps-fault
Kalmar DCD 280-500: what if the indicator lamps of the Gantry top lift fail?
The attachment must be taken out of service and repaired, according to the DCD 280-500 technical handbook (2001 edition), which warns that using it with faulty lamps could cause personal injury, as set out in the HIT SRL technical cards. The handbook places a green lamp on the left for twist-locks locked, an orange lamp in the centre for alignment, which goes out when lifting, and a red lamp on the right for twist-locks unlocked, the HIT SRL technical desk notes. The handbook's check makes sure the pins move freely and that the twist-locks cannot be released with an empty container just lifted. The lamp convention of a particular attachment is the one in the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-gantry-lamps-fault · HIT ref KDCD-195 · fingerprint 09c4f9 · see HIT ref KDCD-194, https://www.hitsrl.it/technical-resources/guides/kalmar-dcd/safety-and-interlocks/#hit-dcd-gantry-twist-lock-interlock