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Kalmar DRF 400-450 Maintenance Manual UDRF01.04GB – PDF DOWNLOAD
Kalmar DRF 400-450 Maintenance Manual UDRF01.04GB – PDF DOWNLOAD
FILE DETAILS:
Kalmar DRF 400-450 Maintenance Manual UDRF01.04GB – PDF DOWNLOAD
Language : English
Pages : 600
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Kalmar DRF 400-450 Maintenance Manual UDRF01.04GB – PDF DOWNLOAD
About the Workshop Manual:
General:
- Thank you for choosing Cargotec as your machine supplier. We hope
that we’ll meet your expectations. - This maintenance manual contains information about how the ma- chine should be maintained for
maximal operating reliability and service life as well as troubleshooting information for fast
correction of any malfunctions.
Conditions:
- The instructions are based on the use of generally available standard
tools. All lifting devices, for example, slings, straps, ratchet blocks,
etc., must meet governing national standards and regulations for lifting
devices. - Cargotec will not accept any responsibility for modifications performed
without permission from Cargotec or if other lifting devices, tools or
work methods are used other than those described in this manual.
About the machine version:
- The information in this publication corresponds to the machine’s design
and appearance at the time of delivery from Cargotec. Due to customizations,
there may be variations and/or deviations. - Cargotec reserves the right to modify specifications and equipment
without prior notice. All information and data in this manual are valid at
the time of publication.
TABLE OF CONTENTS:
Kalmar DRF 400-450 Maintenance Manual UDRF01.04GB – PDF DOWNLOAD
Maintenance manual.......................................................................... 1 A Foreword.................................................................................. 3 Foreword................................................................................ 5 About the Maintenance Manual........................................................ 5 General......................................................................... 5 Conditions...................................................................... 5 Storage......................................................................... 5 About the machine version....................................................... 5 Copyright....................................................................... 5 Reading instructions................................................................ 6 Warning information............................................................. 6 Important information........................................................... 6 Read operator's manual.......................................................... 6 Read maintenance manual......................................................... 6 Maintenance manual's content.................................................... 7 Function group structure........................................................ 8 References between different information types.................................. 9 Product alternatives and optional equipment..................................... 9 Machine card.................................................................... 10 Function descriptions........................................................... 11 About the documentation............................................................. 14 Documentation sections.......................................................... 14 Ordering of documentation....................................................... 14 Feedback............................................................................ 15 Form for copying................................................................ 15 B Safety.................................................................................... 17 Safety.................................................................................. 19 General safety information.......................................................... 19 Safety concerns everyone!....................................................... 19 A near-accident is a warning signal!............................................ 19 Safety instructions................................................................. 20 General......................................................................... 20 Service position................................................................ 20 Hydraulic and brake systems, depressurizing..................................... 21 Clothing etc.................................................................... 22 Several mechanics on the same machine........................................... 22 Working under machine........................................................... 23 Lifting heavy components........................................................ 23 Vibrations...................................................................... 24 Noise........................................................................... 24 Solvents........................................................................ 25 Fire and explosion risks........................................................ 25 Fluid or gas under pressure..................................................... 26 Coolant......................................................................... 27 Refrigerant..................................................................... 28 Air pollution................................................................... 28 Tensioned springs............................................................... 29 Electric motors................................................................. 30 Rotating components and tools................................................... 30 Tyre system..................................................................... 31 Environment......................................................................... 32 General......................................................................... 32 C Preventive maintenance.................................................................... 33 Preventive maintenance.................................................................. 35 Preventive maintenance, general..................................................... 35 Preventive maintenance, work instructions........................................... 35 Check and service log............................................................... 36 50h-check........................................................................... 37 Service schedule.................................................................... 39 Washing............................................................................. 45 Lubrication 500 hours............................................................... 46 Lubrication 1000 hours.............................................................. 48 0 Complete machine.......................................................................... 51 Complete machine........................................................................ 53 Complete machine, description....................................................... 53 Troubleshooting, general work instructions.......................................... 54 Troubleshooting without an error code, example...................................... 55 Troubleshooting with error code, example............................................ 55 Troubleshooting cable harness....................................................... 57 Troubleshooting hydraulic hoses..................................................... 58 1 Engine.................................................................................... 59 1 Engine............................................................................... 61 1.2 Fuel system.................................................................... 67 1.2.3 Fuel pre-filter.......................................................... 68 1.2.4 Fuel filter.............................................................. 70 1.6 Air intake and exhaust outlet.................................................. 72 1.6.1 Air cleaning system...................................................... 72 1.7 Cooling system................................................................. 73 1.7.2 Coolant filter........................................................... 73 1.7.5 Cooling fan.............................................................. 76 1.7.7 Coolant.................................................................. 77 1.8 Lubrication.................................................................... 78 1.9 Control system engine.......................................................... 82 1.10 Ignition/heating.............................................................. 83 1.11 Start/stop.................................................................... 84 2 Transmission.............................................................................. 85 2 Transmission......................................................................... 87 2.2 Torque converter/clutch system................................................. 89 2.3 Mechanical transmission........................................................ 90 2.6 Lubrication.................................................................... 91 2.7 Cooling........................................................................ 94 2.8 Control system transmission.................................................... 95 3 Driveline/axle............................................................................ 99 3 Driveline/axle.......................................................................101 3.2 Propeller shaft................................................................102 3.3 Drive axle.....................................................................103 4 Brakes....................................................................................105 4 Brakes...............................................................................107 4.1 Controls and instrumentation...................................................108 4.1.1 Brake pedal..............................................................108 4.3 Service brake system...........................................................109 4.3.1 Brake oil pump...........................................................112 4.3.4 Accumulator..............................................................113 4.5 Parking brake system...........................................................114 4.5.4 Parking brake unit.......................................................115 4.8 Temperature control, filtration and brake fluid................................117 4.8.11 Breather filter.........................................................119 4.8.12 Brake oil filter........................................................119 4.8.14 Oil brake system........................................................121 5 Steering..................................................................................123 5 Steering.............................................................................125 5.2 Power-assisted system..........................................................126 6 Suspension................................................................................129 6 Suspension...........................................................................131 6.2 Suspension.....................................................................132 6.2.1 Steering axle cradle.....................................................132 6.2.2 Wheel spindle............................................................133 6.2.3 Wheel hub................................................................133 6.3 Tyre and rim system............................................................135 6.3.1 Tyres....................................................................145 6.3.2 Rims.....................................................................146 7 Load handling.............................................................................149 7 Load handling........................................................................151 7.2 Lifting/lowering...............................................................152 7.2.2 Servo filter.............................................................155 7.2.3 Pressure reducer.........................................................157 7.3 Protruding.....................................................................158 7.3.10 Lift boom...............................................................161 7.4 Side-shift.....................................................................162 7.4.6 Sideshift frame..........................................................164 7.4.7 Main beam attachment.....................................................165 7.5 Positioning....................................................................167 7.5.6 Positioning motor........................................................171 7.5.7 Positioning chains.......................................................171 7.5.8 Positioning beam.........................................................174 7.6 Rotation.......................................................................175 7.6.6 Rotation motor unit......................................................178 7.7 Tilt...........................................................................179 7.8 Levelling......................................................................185 7.9 Load carrying..................................................................189 7.9.1 Twistlocks...............................................................189 7.9.2 Lift legs................................................................194 7.10 Additional functions..........................................................204 7.10.1 Support jacks...........................................................204 7.10.2 Weight indicator........................................................206 7.10.3 Container counter.......................................................213 7.10.4 Synchronous lift........................................................215 8 Control system............................................................................217 8 Control system.......................................................................219 8.2 Monitoring.....................................................................222 8.2.1 Overloading system.......................................................222 8.2.2 By-passing...............................................................227 8.2.3 Load centre limitation...................................................227 8.2.4 Height limitation........................................................228 8.2.5 Speed limitation.........................................................228 8.2.6 Service indicator........................................................228 8.3 Error codes....................................................................229 8.4 Diagnostics....................................................................231 8.4.1 CAN/POWER................................................................234 8.4.2 LIGHTS...................................................................235 8.4.3 CAB......................................................................236 8.4.4 CLIMATE..................................................................237 8.4.5 HYD......................................................................237 8.4.6 ENGINE...................................................................238 8.4.7 TRANSM...................................................................239 8.4.8 BOOM.....................................................................240 8.4.9 ATTACH...................................................................241 8.4.10 OP......................................................................242 8.4.11 EXTRA...................................................................243 8.5 Setup..........................................................................247 9 Frame, body, cab and accessories..........................................................249 9 Frame, body, cab and accessories.....................................................251 9.1 Controls and instrumentation...................................................252 9.2 Protection and emergency equipment.............................................258 9.3 Seat...........................................................................259 9.4 HVAC...........................................................................260 9.4.1 Fresh air filter.........................................................265 9.4.8 Condenser................................................................266 9.4.9 Humidity filter..........................................................266 9.5 Wiper/washer system............................................................268 9.6 Lighting system................................................................269 9.7 Communication systems..........................................................270 9.8 Entertainment and communication................................................271 9.9 Glass/windows/mirrors..........................................................272 9.10 Cab structure and suspension..................................................273 9.10.4 Longitudinal displacement of cab........................................273 9.10.5 Vertically adjustable cab...............................................276 9.11 Cab interior..................................................................279 9.12 Frame.........................................................................280 9.13 Body..........................................................................281 9.14 Central lubrication...........................................................282 9.15 Paint/coatings................................................................283 10 Common hydraulics........................................................................285 10 Common hydraulics...................................................................287 10.2 Security valves...............................................................289 10.3 Tanks and accumulators........................................................290 10.4 Pumps.........................................................................291 10.4.2 Axial piston pump with variable displacement............................292 10.5 Hoses, pipes and valves.......................................................295 10.6 Temperature control, cleaning and hydraulic oil...............................296 10.6.6 Breather filter hydraulic oil tank......................................298 10.6.7 Hydraulic oil filter....................................................298 10.6.8 Hydraulic oil...........................................................301 10.6.9 Hydraulic oil fine-filter...............................................302 11 Common electrics.........................................................................303 11 Common electrics....................................................................305 11.2 Electric protection...........................................................306 11.2.2 Fuses...................................................................307 11.3 Batteries.....................................................................310 11.3.1 Start battery...........................................................310 11.4 Alternator....................................................................311 11.5 Distribution of electricity...................................................312 11.5.1 Voltage feed............................................................312 11.5.3 Control units...........................................................317 11.6 Communication.................................................................318 11.6.1 CAN-bus.................................................................318 11.6.2 Redundant CAN-bus.......................................................318 11.6.3 CAN-bus driveline.......................................................318 D Error codes...............................................................................319 Error codes.............................................................................321 Error codes, explanation............................................................321 Reading out error code..............................................................322 1 Engine...............................................................................324 Error codes engine alternative Volvo................................................324 Error codes engine alternative Cummins..............................................341 2 Transmission.........................................................................357 Error codes transmission............................................................357 8 Control system.......................................................................372 Error codes machine.................................................................372 E Schematics................................................................................411 10 Common hydraulics...................................................................413 Hydraulic diagrams, compilation.....................................................413 Hydraulic diagram basic machine.....................................................414 Hydraulic diagram top lift..........................................................416 Hydraulic diagram top lift, tilt lock and controllable tilt.........................418 Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling....420 Hydraulic diagram joystick steering.................................................422 Hydraulic diagram sliding cab.......................................................424 Hydraulic diagram cab lift and support jacks........................................426 Hydraulic diagram sliding cab and support jacks.....................................428 Hydraulic diagram combi attachment (part 1 of 3)....................................430 Hydraulic diagram combi attachment (part 2 of 3)....................................432 Hydraulic diagram combi attachment (part 3 of 3)....................................434 11 Common electrics....................................................................436 Circuit diagrams, description.......................................................436 Component designations..............................................................437 Circuit diagrams, compilation.......................................................438 Circuit diagrams....................................................................441 A43032.0100.....................................................................441 A43032.0200.....................................................................442 A43033.0100.....................................................................443 A43033.0200.....................................................................448 A43034.0100.....................................................................449 A43035.0100.....................................................................450 A43036.0100.....................................................................451 A43037.0100.....................................................................452 A43038.0100.....................................................................456 A43039.0100.....................................................................457 A43040.0100.....................................................................458 A43041.0100.....................................................................459 A43042.0100.....................................................................460 A43043.0100.....................................................................462 A43044.0100.....................................................................464 A43044.0200.....................................................................466 A43044.0300.....................................................................467 A43044.0400.....................................................................468 A43044.0500.....................................................................469 A43045.0100.....................................................................470 A43046.0100.....................................................................472 A43046.0200.....................................................................473 A43047.0100.....................................................................474 A43048.0100.....................................................................475 A43049.0100.....................................................................476 A43050.0100.....................................................................477 A43051.0100.....................................................................478 A43053.0100.....................................................................480 A43054.0100.....................................................................481 A43055.0100.....................................................................483 A43056.0100.....................................................................484 A43057.0100.....................................................................486 A43058.0100.....................................................................488 A43059.0100.....................................................................489 A43060.0100.....................................................................491 A43061.0100.....................................................................492 A43062.0100.....................................................................494 A43063.0100.....................................................................495 A43063.0200.....................................................................496 A43064.0100.....................................................................497 A43065.0100.....................................................................498 A43066.0100.....................................................................499 A43066.0200.....................................................................501 A43067.0100.....................................................................503 A43068.0100.....................................................................504 A44875.0100.....................................................................516 A44875.0200.....................................................................517 A44875.0300.....................................................................518 A44878.0100.....................................................................519 A44875.0200.....................................................................520 A44879.0100.....................................................................522 A44880.0100.....................................................................525 A44910.0100.....................................................................526 A44910.0200.....................................................................527 A45043.0100.....................................................................528 A45769.0100.....................................................................530 A45792.0100.....................................................................531 A46087.0100.....................................................................532 A46088.0100.....................................................................534 A46089.0100.....................................................................535 A46090.0100.....................................................................536 A46091.0100.....................................................................537 List of components..................................................................539 F Technical data............................................................................571 Technical data..........................................................................573 Specifications for data and volume..................................................573 Specifications for lift capacity and dimensions.....................................575 Oils and lubricants, recommendation.................................................578 Tightening torques, recommendations.................................................580 Tightening torques, ORFS- couplings.................................................581 Unit explanations...................................................................583 Conversion table, SI-units..........................................................584 Conversion table, length............................................................585 Conversion table, area..............................................................585 Conversion table, volume............................................................585 Conversion table, weight............................................................586 Conversion table, pressure..........................................................586 G Terminology and index.....................................................................587 Terminology and index...................................................................589 Terminology.........................................................................589 Index...............................................................................592
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