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Kalmar DRF 400-450 Reachstackers 40-45 Tonnes Workshop Manual VDRF03.02GB – PDF DOWNLOAD
Kalmar DRF 400-450 Reachstackers 40-45 Tonnes Workshop Manual VDRF03.02GB – PDF DOWNLOAD
FILE DETAILS:
Kalmar DRF 400-450 Reachstackers 40-45 Tonnes Workshop Manual VDRF03.02GB – PDF DOWNLOAD
Language : English
Pages : 1216
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Kalmar DRF 400-450 Reachstackers 40-45 Tonnes Workshop Manual VDRF03.02GB – PDF DOWNLOAD
A Foreword................................................................................................................................. 5 Foreword............................................................................................................................... 7 About the Workshop Manual.......................................................................................................... 7 General........................................................................................................................ 7 Conditions..................................................................................................................... 7 Storage........................................................................................................................ 7 About the machine version...................................................................................................... 7 Copyright...................................................................................................................... 7 Reading instructions............................................................................................................... 8 Warning information............................................................................................................ 8 Important information.......................................................................................................... 8 Read the Operator’s Manual..................................................................................................... 8 Read the Maintenance Manual.................................................................................................... 8 Workshop manual contents....................................................................................................... 9 Function group structure....................................................................................................... 10 References between different information types................................................................................. 11 Product alternatives and optional equipment.................................................................................... 12 Machine card................................................................................................................... 12 Function descriptions.......................................................................................................... 13 About the documentation............................................................................................................ 16 Documentation sections......................................................................................................... 16 Ordering of documentation...................................................................................................... 16 Feedback........................................................................................................................... 17 Form for copying............................................................................................................... 17 B Safety................................................................................................................................... 19 Safety................................................................................................................................. 21 General safety information......................................................................................................... 21 Safety concerns everyone!...................................................................................................... 21 A near accident is a warning!.................................................................................................. 21 Safety instructions................................................................................................................ 22 General........................................................................................................................ 22 Service position............................................................................................................... 22 Hydraulic and brake systems, depressurising.................................................................................... 23 Oils........................................................................................................................... 24 Fuel system.................................................................................................................... 25 Clothing, etc.................................................................................................................. 26 Several mechanics on the same machine.......................................................................................... 27 Working under machine.......................................................................................................... 27 Lifting heavy components....................................................................................................... 28 Vibrations..................................................................................................................... 28 Noise.......................................................................................................................... 29 Solvents....................................................................................................................... 29 Fire and explosion risks....................................................................................................... 30 Fluid or gas under pressure.................................................................................................... 31 Coolant........................................................................................................................ 32 Refrigerant.................................................................................................................... 32 Air pollution.................................................................................................................. 33 Tensioned springs.............................................................................................................. 34 Electric motors................................................................................................................ 34 Rotating components and tools.................................................................................................. 35 Tyres and rims................................................................................................................. 36 Lifting equipment.............................................................................................................. 36 Spare parts.................................................................................................................... 37 Non-ionised radiation.......................................................................................................... 38 Environment........................................................................................................................ 39 General........................................................................................................................ 39 C Preventive maintenance................................................................................................................... 41 The information is found in the Maintenance Manual..................................................................................... 41 0 Complete machine......................................................................................................................... 43 Complete machine....................................................................................................................... 45 Complete machine, description ..................................................................................................... 45 Troubleshooting, general work instructions......................................................................................... 46 Troubleshooting without an error code, example..................................................................................... 47 Troubleshooting with error code, example........................................................................................... 47 Troubleshooting cable harness...................................................................................................... 49 Troubleshooting hydraulic hoses.................................................................................................... 50 1 Engine................................................................................................................................... 51 1 Engine............................................................................................................................... 53 1.1 Controls and instruments....................................................................................................... 73 1.1.1 Ignition switch.......................................................................................................... 73 1.1.2 Accelerator pedal........................................................................................................ 74 1.2 Fuel system.................................................................................................................... 75 1.2.1 Fuel tank................................................................................................................ 75 1.2.2 Sensor, fuel level....................................................................................................... 75 1.6 Air intake and exhaust outlet.................................................................................................. 76 1.6.1 Air cleaning system...................................................................................................... 76 1.6.3 Exhaust system........................................................................................................... 76 1.6.4 Intercooler.............................................................................................................. 77 1.7 Cooling system................................................................................................................. 78 1.7.4 Radiator and expansion tank.............................................................................................. 79 1.7.5 Cooling fan.............................................................................................................. 80 1.7.7 Coolant.................................................................................................................. 82 1.7.10 Engine heater........................................................................................................... 85 1.9 Engine control system.......................................................................................................... 86 1.9.1 Control unit, engine..................................................................................................... 86 1.11 Start/stop.................................................................................................................... 87 1.11.1 Starter motor........................................................................................................... 87 1.11.2 Stopping device......................................................................................................... 87 2 Transmission............................................................................................................................. 89 2 Transmission......................................................................................................................... 91 2.1 Controls and instruments....................................................................................................... 109 2.1.1 Gear selector and multi-function lever................................................................................... 109 2.2 Torque converter/Clutch system................................................................................................. 110 2.2.1 Flex plates.............................................................................................................. 110 2.6 Lubrication system............................................................................................................. 114 2.6.3 Oil cooler............................................................................................................... 117 2.7 Cooling system................................................................................................................. 119 2.7.3 Oil cooler............................................................................................................... 119 2.8 Transmission control system.................................................................................................... 120 2.8.1 Control unit transmission................................................................................................ 120 2.8.2 Normally closed (NC) switch, disengagement............................................................................... 120 2.8.3 Transmission cable harness............................................................................................... 120 3 Driveline/Axle........................................................................................................................... 121 3 Driveline/axle....................................................................................................................... 123 3.2 Propeller shaft................................................................................................................ 123 3.3 Drive axle..................................................................................................................... 124 4 Brakes................................................................................................................................... 129 4 Brakes............................................................................................................................... 131 4.1 Controls and instruments....................................................................................................... 131 4.1.1 Brake pedal.............................................................................................................. 131 4.3 Power-assisted brake system.................................................................................................... 133 4.3.1 Brake fluid pump......................................................................................................... 135 4.3.2 Brake fluid filter....................................................................................................... 140 4.3.3 Accumulator charging valve............................................................................................... 141 4.3.4 Accumulator.............................................................................................................. 144 4.3.5 Brake valve.............................................................................................................. 148 4.3.6 Drive axle block......................................................................................................... 152 4.3.7 NC switch, brake fluid pressure.......................................................................................... 153 4.3.8 NO (normally open) switch, brake lights.................................................................................. 154 4.3.9 Wheel brake.............................................................................................................. 156 4.3.10 Pipes and hoses......................................................................................................... 158 4.5 Parking brake system........................................................................................................... 159 4.5.1 Brake fluid pump......................................................................................................... 160 4.5.2 Brake fluid filter....................................................................................................... 160 4.5.3 M-valve parking brake.................................................................................................... 161 4.5.4 Parking brake unit....................................................................................................... 162 4.5.5 Parking brake NC switch.................................................................................................. 165 4.5.6 Pipes and hoses.......................................................................................................... 165 4.8 Temperature control, cleaning and brake oil.................................................................................... 166 4.8.1 Brake fluid tank......................................................................................................... 167 4.8.2 Tank heater.............................................................................................................. 168 4.8.3 Brake fluid pump......................................................................................................... 168 4.8.4 Accumulator charging valve............................................................................................... 168 4.8.5 Drive axle block......................................................................................................... 168 4.8.6 Wheel brake.............................................................................................................. 168 4.8.7 Oil cooler............................................................................................................... 169 4.8.8 Cooling fan.............................................................................................................. 170 4.8.9 Thermal bypass valve..................................................................................................... 170 4.8.10 Sensor brake oil temperature............................................................................................ 171 4.8.11 Breather filter......................................................................................................... 172 4.8.12 Brake fluid filter...................................................................................................... 173 4.8.13 Pipes and hoses......................................................................................................... 174 4.8.14 Brake system fluid...................................................................................................... 174 5 Steering................................................................................................................................. 175 5 Steering............................................................................................................................. 177 5.1 Controls and instruments....................................................................................................... 177 5.1.2 Mini-wheel............................................................................................................... 177 5.1.3 Joystick................................................................................................................. 178 5.2 Power assisted system.......................................................................................................... 180 5.2.1 Hydraulic oil pump....................................................................................................... 187 5.2.2 Priority valve........................................................................................................... 188 5.2.3 Steering valve........................................................................................................... 194 5.2.4 Steering cylinder........................................................................................................ 197 5.2.5 Steering axle cradle..................................................................................................... 200 5.2.6 Link arm................................................................................................................. 201 5.2.7 Wheel spindle............................................................................................................ 201 5.2.8 Wheel hub................................................................................................................ 201 5.2.9 Shuttle valve............................................................................................................ 201 5.2.10 Control valve mini-wheel/joystick control............................................................................... 202 5.2.11 Shuttle valve, mini-wheel/lever steering................................................................................ 205 5.2.12 Steering angle sensor................................................................................................... 206 5.2.13 Pipes and hoses......................................................................................................... 206 6 Suspension............................................................................................................................... 207 6 Suspension........................................................................................................................... 209 6.2 Suspension..................................................................................................................... 209 6.2.1 Steering axle cradle..................................................................................................... 211 6.2.2 Wheel spindle............................................................................................................ 213 6.2.3 Wheel hub................................................................................................................ 217 6.3 Tyres and rims................................................................................................................. 222 6.3.1 Tyres.................................................................................................................... 224 6.3.2 Rims..................................................................................................................... 225 6.3.3 Nut, washer and clamp.................................................................................................... 226 7 Load handling............................................................................................................................ 229 7 Load handling........................................................................................................................ 233 7.1 Controls and instruments....................................................................................................... 235 7.1.1 Control lever............................................................................................................ 235 7.1.2 Switch, lock twistlocks.................................................................................................. 237 7.1.3 Switch, automatic spreading.............................................................................................. 238 7.1.5 Switch, stop at 30' or 35'............................................................................................... 238 7.2 Lifting/lowering............................................................................................................... 239 7.2.1 Hydraulic oil pump....................................................................................................... 243 7.2.2 Servo filter............................................................................................................. 244 7.2.3 Pressure reducer......................................................................................................... 244 7.2.4 Accumulator servo circuit................................................................................................ 246 7.2.5 Control valve lift, lower and extension.................................................................................. 248 7.2.6 Shuttle valve............................................................................................................ 250 7.2.7 Valve block lift cylinder................................................................................................ 251 7.2.8 Lift cylinder............................................................................................................ 255 7.2.9 Sensor hydraulic pressure lift cylinder.................................................................................. 260 7.2.10 Lift boom............................................................................................................... 263 7.2.11 Sensor, boom angle...................................................................................................... 263 7.2.12 Pipes and hoses......................................................................................................... 263 7.2.16 Sensor, attachment damping.............................................................................................. 264 7.3 Extension...................................................................................................................... 265 7.3.1 Hydraulic oil pump....................................................................................................... 272 7.3.2 Servo filter............................................................................................................. 272 7.3.3 Pressure reducer......................................................................................................... 272 7.3.4 Accumulator servo circuit................................................................................................ 273 7.3.5 Control valve lift, lower, extension..................................................................................... 273 7.3.6 Shuttle valve............................................................................................................ 274 7.3.7 Valve block, extension cylinder.......................................................................................... 275 7.3.8 Extension cylinder....................................................................................................... 275 7.3.9 Valve block, pump relief................................................................................................. 279 7.3.10 Lift boom............................................................................................................... 281 7.3.11 Sensor, boom length..................................................................................................... 283 7.3.12 Pipes and hoses......................................................................................................... 283 7.4 Side shift..................................................................................................................... 284 7.4.1 Hydraulic oil pump....................................................................................................... 285 7.4.2 Valve block, top lift hydraulics......................................................................................... 286 7.4.3 Control valve attachment................................................................................................. 287 7.4.4 Shuttle valve............................................................................................................ 291 7.4.5 Side shift cylinder...................................................................................................... 292 7.4.6 Side shift frame......................................................................................................... 293 7.4.7 Main beam, attachment.................................................................................................... 297 7.4.8 Relief valve, attachment................................................................................................. 297 7.4.9 Pipes and hoses.......................................................................................................... 298 7.5 Spreading...................................................................................................................... 299 7.5.1 Hydraulic oil pump....................................................................................................... 306 7.5.2 Valve block, top lift hydraulics......................................................................................... 306 7.5.3 Control valve attachment................................................................................................. 306 7.5.4 Shuttle valve............................................................................................................ 306 7.5.5 Valve block, spreading motor............................................................................................. 307 7.5.6 Spreading motor.......................................................................................................... 307 7.5.7 Spreader chains.......................................................................................................... 311 7.5.8 Spreader beam............................................................................................................ 319 7.5.9 Main beam, attachment.................................................................................................... 321 7.5.10 Position sensor, spreading.............................................................................................. 321 7.5.11 Relief valve, attachment................................................................................................ 321 7.5.12 Pipes and hoses......................................................................................................... 321 7.5.13 Buzzer, automatic spreading 20'-40'..................................................................................... 322 7.6 Rotation....................................................................................................................... 323 7.6.1 Hydraulic oil pump....................................................................................................... 327 7.6.2 Valve block, top lift hydraulics......................................................................................... 327 7.6.3 Control valve attachment................................................................................................. 328 7.6.4 Shuttle valve............................................................................................................ 328 7.6.5 Valve block, rotation motor.............................................................................................. 329 7.6.6 Rotation motor unit...................................................................................................... 330 7.6.7 Rotation yoke............................................................................................................ 333 7.6.8 Ring gear................................................................................................................ 336 7.6.9 Side shift frame......................................................................................................... 337 7.6.10 Sensor, rotation stop................................................................................................... 338 7.6.11 Relief valve, attachment................................................................................................ 338 7.6.12 Pipes and hoses......................................................................................................... 338 7.7 Tilt........................................................................................................................... 339 7.7.1 Hydraulic oil pump....................................................................................................... 344 7.7.2 Valve block, top lift hydraulics......................................................................................... 344 7.7.3 Damping block, tilt...................................................................................................... 345 7.7.4 Lock valve, tilt......................................................................................................... 347 7.7.5 Control valve attachment................................................................................................. 348 7.7.6 Shuttle valve............................................................................................................ 348 7.7.7 Tilt cylinder............................................................................................................ 349 7.7.8 Lift boom................................................................................................................ 349 7.7.9 Rotation yoke............................................................................................................ 349 7.7.10 Relief valve, attachment................................................................................................ 349 7.7.11 Pipes and hoses......................................................................................................... 349 7.8 Levelling...................................................................................................................... 350 7.8.1 Hydraulic oil pump....................................................................................................... 354 7.8.2 Valve block, top lift hydraulics......................................................................................... 354 7.8.3 Control valve attachment................................................................................................. 355 7.8.4 Shuttle valve............................................................................................................ 356 7.8.5 Overcentre valve, levelling.............................................................................................. 356 7.8.6 Valve block, levelling cylinders......................................................................................... 356 7.8.7 Levelling cylinders...................................................................................................... 357 7.8.8 Side shift frame......................................................................................................... 357 7.8.9 Relief valve, attachment................................................................................................. 357 7.8.10 Pipes and hoses......................................................................................................... 357 7.9 Load carrier................................................................................................................... 358 7.9.1 Twistlocks............................................................................................................... 358 7.9.2 Lifting jacks............................................................................................................ 372 7.10 Other functions............................................................................................................... 400 7.10.1 Support jacks........................................................................................................... 400 7.10.2 Weight indicator........................................................................................................ 409 7.10.3 Container counter....................................................................................................... 415 7.10.4 Synchronised lift....................................................................................................... 420 8 Control system........................................................................................................................... 423 8 Control system....................................................................................................................... 425 8.1 Controls and instruments....................................................................................................... 426 8.1.4 Switch, bypass of load centre and height limitation...................................................................... 426 8.1.10 Error code menu......................................................................................................... 426 8.2 Monitoring..................................................................................................................... 429 8.2.1 Overload system.......................................................................................................... 429 8.2.2 Bypass................................................................................................................... 437 8.2.3 Load centre limitation................................................................................................... 438 8.2.4 Height limitation........................................................................................................ 438 8.2.5 Speed limitation......................................................................................................... 439 8.2.6 Service indicator........................................................................................................ 439 8.4 Diagnostics.................................................................................................................... 440 8.4.1 CAN/POWER................................................................................................................ 442 8.4.2 LIGHTS................................................................................................................... 462 8.4.3 CAB...................................................................................................................... 475 8.4.4 CLIMATE.................................................................................................................. 484 8.4.5 HYD...................................................................................................................... 492 8.4.6 ENGINE................................................................................................................... 497 8.4.7 TRANSM................................................................................................................... 504 8.4.8 BOOM..................................................................................................................... 523 8.4.9 ATTACH................................................................................................................... 531 8.4.10 OP...................................................................................................................... 554 8.4.11 EXTRA................................................................................................................... 559 8.4.13 RMI..................................................................................................................... 588 8.5 Setup.......................................................................................................................... 591 8.5.1 Initiation............................................................................................................... 591 8.5.2 Calibration.............................................................................................................. 618 9 Frame, body, cab and accessories......................................................................................................... 629 9 Frame, body, cab and accessories..................................................................................................... 633 9.1 Controls and instruments....................................................................................................... 633 9.1.1 Gear selector and multi-function lever................................................................................... 640 9.1.22 Switch, direction indicators............................................................................................ 641 9.2 Safety and emergency equipment................................................................................................. 642 9.2.1 Safety switch............................................................................................................ 642 9.2.2 Seat belt................................................................................................................ 642 9.2.3 Fire extinguisher........................................................................................................ 642 9.2.4 Buzzer................................................................................................................... 642 9.3 Seat........................................................................................................................... 643 9.3.1 Seat cushion............................................................................................................. 647 9.3.2 Back cushion............................................................................................................. 647 9.3.3 Electric heater.......................................................................................................... 648 9.3.4 Shock absorbers.......................................................................................................... 649 9.3.5 Air suspension........................................................................................................... 649 9.3.6 Mechanical seat adjustment............................................................................................... 650 9.3.7 Passenger seat........................................................................................................... 650 9.3.8 Armrest.................................................................................................................. 650 9.3.9 Sensor operator in seat.................................................................................................. 651 9.4 Heating, ventilation and air conditioning...................................................................................... 652 9.4.1 Fresh air filter......................................................................................................... 660 9.4.2 Fresh air and recirculation damper....................................................................................... 661 9.4.3 Cab fan.................................................................................................................. 664 9.4.4 Heat exchanger heat...................................................................................................... 667 9.4.5 Water valve.............................................................................................................. 670 9.4.6 Engine temperature sensor................................................................................................ 671 9.4.7 Compressor............................................................................................................... 671 9.4.8 Condenser................................................................................................................ 674 9.4.9 Moisture filter.......................................................................................................... 676 9.4.10 Pressure switch......................................................................................................... 676 9.4.11 Expansion valve......................................................................................................... 677 9.4.12 Sensor temperature refrigerant.......................................................................................... 679 9.4.13 Heat exchanger cooling.................................................................................................. 680 9.4.14 Air distributor......................................................................................................... 681 9.4.15 Air vents............................................................................................................... 682 9.4.16 Sensor temperature outlet fan........................................................................................... 683 9.4.17 Sensor cab temperature.................................................................................................. 684 9.4.18 Sensor outdoor temperature.............................................................................................. 685 9.5 Wiper/washer system............................................................................................................ 686 9.5.1 Wiper front.............................................................................................................. 686 9.5.2 Wiper roof............................................................................................................... 686 9.5.3 Wiper rear............................................................................................................... 686 9.5.4 Washer motor and reservoir............................................................................................... 686 9.5.5 Wiper motor, front....................................................................................................... 687 9.5.6 Wiper motor, roof........................................................................................................ 688 9.5.7 Wiper motor, rear........................................................................................................ 689 9.6 Lighting system................................................................................................................ 691 9.6.1 Headlights............................................................................................................... 696 9.6.2 Running light............................................................................................................ 696 9.6.3 Tail light............................................................................................................... 696 9.6.4 Brake light.............................................................................................................. 697 9.6.5 Reversing light.......................................................................................................... 697 9.6.6 Driving direction indicator.............................................................................................. 697 9.6.7 Flashing hazard lights................................................................................................... 698 9.6.8 Revolving beacon......................................................................................................... 698 9.6.9 Working lights, cab...................................................................................................... 698 9.6.10 Working lights, boom.................................................................................................... 699 9.6.11 Work lights, attachment................................................................................................. 700 9.6.12 Interior lighting....................................................................................................... 700 9.7 Signalling system.............................................................................................................. 701 9.7.1 Horn..................................................................................................................... 704 9.7.2 Flashing hazard lights................................................................................................... 704 9.7.3 Revolving beacon......................................................................................................... 704 9.7.4 Warning parking brake.................................................................................................... 704 9.7.5 Reverse alarm............................................................................................................ 704 9.8 Entertainment and communication................................................................................................ 705 9.9 Glass/windows/mirrors.......................................................................................................... 706 9.9.1 Windscreen............................................................................................................... 707 9.9.2 Side window.............................................................................................................. 709 9.9.3 Roof window.............................................................................................................. 712 9.9.4 Rear window.............................................................................................................. 713 9.9.5 Rearview mirror.......................................................................................................... 713 9.9.6 Reversing camera......................................................................................................... 713 9.9.7 Monitor, reversing camera................................................................................................ 714 9.10 Cab structure and suspension.................................................................................................. 715 9.10.1 Cab frame............................................................................................................... 715 9.10.2 Doors................................................................................................................... 716 9.10.3 Cab undercarriage....................................................................................................... 716 9.10.4 Sliding cab............................................................................................................. 718 9.10.5 Vertically adjustable cab............................................................................................... 729 9.11 Cab interior.................................................................................................................. 741 9.11.1 Instrument and control panels........................................................................................... 741 9.11.2 Interior details, plastic............................................................................................... 742 9.11.3 Interior details, textile............................................................................................... 742 9.11.4 Floor covering.......................................................................................................... 742 9.11.5 Insulation.............................................................................................................. 742 9.11.6 Sun blinds.............................................................................................................. 743 9.11.7 Terminal console........................................................................................................ 743 9.11.8 Writing desk............................................................................................................ 743 9.12 Frame......................................................................................................................... 744 9.13 Body.......................................................................................................................... 745 9.13.1 Wings................................................................................................................... 745 9.13.2 Hood engine compartment................................................................................................. 745 9.13.3 Footstep and rail....................................................................................................... 746 9.13.4 Counterweights.......................................................................................................... 746 9.14 Central lubrication........................................................................................................... 747 9.14.1 Pump unit............................................................................................................... 749 9.14.2 Distribution block...................................................................................................... 750 9.14.3 Lines................................................................................................................... 750 9.15 Paint/coatings................................................................................................................ 751 10 Common hydraulics....................................................................................................................... 753 10 Common hydraulics................................................................................................................... 755 10.2 Safety valves................................................................................................................. 755 10.2.1 Accumulator drain valve................................................................................................. 755 10.2.2 Attachment relief valve................................................................................................. 756 10.2.3 Pipes and hoses......................................................................................................... 756 10.3 Tanks and accumulators........................................................................................................ 757 10.3.1 Tank.................................................................................................................... 757 10.3.2 Pipes and hoses......................................................................................................... 757 10.4 Pumps......................................................................................................................... 758 10.4.1 Gear pump with fixed displacement....................................................................................... 758 10.4.2 Axial piston pump with variable displacement............................................................................ 764 10.4.3 Pipes and hoses......................................................................................................... 782 10.5 Hoses, pipes and valves....................................................................................................... 783 10.5.1 Pipes and hoses......................................................................................................... 783 10.5.2 Priority valve.......................................................................................................... 784 10.5.3 Shuttle valve........................................................................................................... 784 10.5.4 Collection block, filtered returns...................................................................................... 786 10.5.5 Collection block, unfiltered returns.................................................................................... 786 10.6 Temperature control, cleaning and hydraulic oil............................................................................... 787 10.6.1 Tank heater............................................................................................................. 788 10.6.2 Hydraulic oil cooler.................................................................................................... 789 10.6.3 Cooling fan............................................................................................................. 790 10.6.4 Sensor hydraulic oil temperature........................................................................................ 791 10.6.5 Radiator bypass valve................................................................................................... 792 10.6.6 Breather filter hydraulic oil tank...................................................................................... 794 10.6.7 Oil filter.............................................................................................................. 795 10.6.8 Hydraulic oil........................................................................................................... 799 10.6.9 Hydraulic oil fine-filter............................................................................................... 799 10.6.10 Pipes and hoses........................................................................................................ 800 10.7 Auxiliaries................................................................................................................... 801 10.7.1 Hydraulic cylinders..................................................................................................... 801 11 Common electrics........................................................................................................................ 809 11 Common electrics.................................................................................................................... 811 11.2 Electric protection........................................................................................................... 811 11.2.1 Battery disconnector.................................................................................................... 811 11.2.2 Fuses................................................................................................................... 811 11.2.3 Safety switch........................................................................................................... 811 11.3 Batteries..................................................................................................................... 812 11.3.1 Start battery........................................................................................................... 812 11.4 Alternator.................................................................................................................... 814 11.4.1 Alternator.............................................................................................................. 814 11.5 Distribution of electricity................................................................................................... 815 11.5.1 Power supply............................................................................................................ 815 11.5.2 Electronic box.......................................................................................................... 824 11.5.3 Control units........................................................................................................... 826 11.5.5 Cables.................................................................................................................. 841 11.6 Communication................................................................................................................. 851 11.6.1 CAN-bus................................................................................................................. 851 11.6.2 Redundant CAN bus....................................................................................................... 853 11.6.3 CAN bus drivetrain...................................................................................................... 856 11.6.4 Communication between PC and machine.................................................................................... 857 11.6.5 RMI (Remote Machine Interface).......................................................................................... 858 11.6.6 Kalmar CAN Customer Gateway............................................................................................. 859 D Error codes.............................................................................................................................. 861 D Error codes.......................................................................................................................... 863 1 Engine............................................................................................................................... 869 2 Transmission......................................................................................................................... 899 8 Control system....................................................................................................................... 951 E Schematics............................................................................................................................... 995 10 Common hydraulics................................................................................................................... 997 Hydraulic diagrams, compilation.................................................................................................... 997 Hydraulic diagram base machine (hydraulic oil pump alternative Rexroth)............................................................ 998 Hydraulic diagram base machine (hydraulic oil pump alternative Sauer-Danfoss)......................................................1000 Hydraulic diagram joystick control (hydraulic oil pump alternative Rexroth)........................................................1002 Hydraulic diagram joystick control (hydraulic oil pump alternative Sauer-Danfoss)..................................................1004 Hydraulic diagram top lift (hydraulic oil pump alternative Rexroth)................................................................1006 Hydraulic diagram top lift (hydraulic oil pump alternative Sauer-Danfoss)..........................................................1008 Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump alternative Rexroth)...............................1010 Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump alternative Sauer-Danfoss).........................1012 Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling (hydraulic oil pump alternative Rexroth)..........1014 Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling (hydraulic oil pump alternative Sauer-Danfoss)....1016 Hydraulic diagram combi yoke (part 1 of 3) (hydraulic oil pump alternative Rexroth)................................................1018 Hydraulic diagram combi yoke (part 1 of 3) (hydraulic oil pump alternative Sauer-Danfoss)..........................................1020 Hydraulic diagram combi yoke (part 2 of 3) ........................................................................................1022 Hydraulic diagram combi yoke (part 3 of 3) ........................................................................................1024 Hydraulic diagram sliding cab (hydraulic oil pump alternative Rexroth).............................................................1026 Hydraulic diagram sliding cab (hydraulic oil pump alternative Sauer-Danfoss).......................................................1028 Hydraulic diagram cab lift and support jacks (hydraulic oil pump alternative Rexroth)..............................................1030 Hydraulic diagram cab lift and support jacks (hydraulic oil pump alternative Sauer-Danfoss)........................................1032 Hydraulic diagram sliding cab and support jacks (hydraulic oil pump alternative Rexroth)...........................................1034 Hydraulic diagram sliding cab and support jacks (hydraulic oil pump alternative Sauer-Danfoss).....................................1036 11 Common electrics....................................................................................................................1038 Circuit diagram, description ......................................................................................................1038 Component designations.............................................................................................................1040 Circuit diagrams, compilation......................................................................................................1040 A50001.0100............................................................................................................................1045 0 | Wiring DRFC 400-450............................................................................................................1045 0.0_1 | Wiring Cross References....................................................................................................1046 0.0_2 | Wiring Cross References....................................................................................................1047 0.0_3 | Wiring Cross References Opt................................................................................................1048 0.0_4 | Wiring Cross References Att................................................................................................1049 0.0_5 | Wiring Cross References Att................................................................................................1050 0.0_6 | Wiring Cross References Att Combi..........................................................................................1051 1.0_1 | Wiring Motor Volvo 1240&1250...............................................................................................1052 1.0_2 | Wiring Motor Cummins.......................................................................................................1053 1.0_3 | Wiring Motor Cummins.......................................................................................................1054 1.0_4 | Wiring Motor Volvo D13.....................................................................................................1055 1.1_1 | Wiring Drivetrain..........................................................................................................1056 2.0_1 | Wiring Dana TE 32000.......................................................................................................1057 2.0_2 | Wiring Dana TE 32000.......................................................................................................1058 2.0_3 | Wiring Dana TE 32000.......................................................................................................1059 2.0_1A1 | Wiring Dana TE 32000FF...................................................................................................1060 2.0_1A2 | Wiring Dana TE 32000FF...................................................................................................1061 2.0_1A3 | Wiring Dana TE 32000FF...................................................................................................1062 2.0_1B1 | Wiring diagram gear ZF...................................................................................................1063 2.1_1 | Wiring Drivetrain..........................................................................................................1064 4.0_1 | Wiring Brakes..............................................................................................................1065 4.0_2 | Wiring Brakes..............................................................................................................1066 5.2_1 +CAB | Wiring Micro lever/wheel..............................................................................................1067 5.2_2 | Wiring Micro lever/wheel...................................................................................................1068 5.2_3 | Wiring Micro lever/wheel and Combi Att.....................................................................................1069 5.2_4 | Wiring Micro lever/wheel and Combi Att.....................................................................................1070 7.1_1 | Wiring Joystick............................................................................................................1071 7.2_1 +CHASSIS | Wiring Boom Up/Down...............................................................................................1072 7.3_1 | Wiring Boom in/out.........................................................................................................1073 7.5_1 +ATTACHMENT | Wiring Spreading Valves........................................................................................1074 7.5_2 | Wiring Spreading Auto......................................................................................................1075 7.5_3 | Wiring Spreading Sensors...................................................................................................1076 7.6_1 | Wiring Rotation............................................................................................................1077 7.7_1 | Wiring Tilt lock...........................................................................................................1078 7.7_2 | Wiring Tilt + Levelling....................................................................................................1079 7.7_3 | Wiring Tilt + Levelling....................................................................................................1080 7.9_1 +ATTACHMENT | Wiring Twistlock...............................................................................................1081 7.9_2 | Wiring Twistlock...........................................................................................................1082 7.9_3 +CAB | Wiring Combi Att......................................................................................................1083 7.9_4 +ATTACHMENT | Wiring Combi Att...............................................................................................1084 7.9_5 +ATTACHMENT | Wiring Combi Att...............................................................................................1085 7.9_6 +ATTACHMENT | Wiring Combi Att...............................................................................................1086 7.9_7 +ATTACHMENT | Wiring Combi Att...............................................................................................1087 7.9_8 +ATTACHMENT | Wiring Combi Att...............................................................................................1088 7.9_9 +ATTACHMENT | Wiring Combi Att...............................................................................................1089 7.9_10 +ATTACHMENT | Wiring Combi Att..............................................................................................1090 7.9_11 +ATTACHMENT | Wiring Combi Att..............................................................................................1091 7.9_12 +ATTACHMENT | Wiring Combi Att..............................................................................................1092 7.9_13 +ATTACHMENT | Wiring Combi Att..............................................................................................1093 7.9_14 +ATTACHMENT | Wiring Combi Att..............................................................................................1094 7.9_15 | Wiring Over Height........................................................................................................1095 7.9_16 | Wiring Over Height........................................................................................................1096 7.9_17 | Wiring Combi Att..........................................................................................................1097 7.9_18 | Wiring Fork attachment....................................................................................................1098 7.10_1 | Wiring Hyd Support jacks..................................................................................................1099 7.10_2 | Wiring Hyd Support jacks..................................................................................................1100 7.10_3 | Wiring Printer............................................................................................................1101 8.2_1 +CHASSIS | Wiring OP + Scale.................................................................................................1102 8.2_2 +CHASSIS | Wiring OP + Scale.................................................................................................1103 8.2_3 | Wiring Override............................................................................................................1104 8.2_4 | Wiring RMI.................................................................................................................1105 9.1_1 | Wiring OPT Sensors Instr...................................................................................................1106 9.1_2 | Wiring Option..............................................................................................................1107 9.1_3 | Wiring Option..............................................................................................................1108 9.1_4 | Wiring Sensors Instr.......................................................................................................1109 9.1_5 | Wiring Option Cabin........................................................................................................1110 9.1_6 | Wiring Option, Boom nose...................................................................................................1111 9.1_7 | Wiring Option..............................................................................................................1112 9.3_1 +CAB | Wiring Cab Seat OPT...................................................................................................1113 9.3_2 +CAB | Wiring Cab Seat OPT...................................................................................................1114 9.4_1 +CAB | Wiring Climate Control................................................................................................1115 9.4_2 +CAB | Wiring Climate Control................................................................................................1116 9.5_1 +CAB | Wiring Wiper function.................................................................................................1117 9.6_1 +CAB | Wiring Work Light.....................................................................................................1118 9.6_2 +ATTACHMENT | Wiring Opt. Work Light Att.....................................................................................1119 9.6_3 | Wiring OPT Work Light Boom.................................................................................................1120 9.6_5 | Wiring Lights..............................................................................................................1121 9.6_6 | Wiring Lights..............................................................................................................1122 9.6_7 | Wiring Lights..............................................................................................................1123 9.6_8 | Wiring Lights..............................................................................................................1124 9.6_9 | Wiring Step In Light.......................................................................................................1125 9.6_10 | Wiring Opt. Work Light Chassis............................................................................................1126 9.7_1 | Wiring Alarm, Soundsignals.................................................................................................1127 9.7_2 | Wiring Alarm, Soundsignals.................................................................................................1128 9.7_3 | Wiring Flashing indicator, Hazard..........................................................................................1129 9.7_4 | Wiring Reverse alarm.......................................................................................................1130 9.8_1 | Wiring Radio...............................................................................................................1131 9.9_9 | Wiring Camera..............................................................................................................1132 9.10_1 | Wiring Sliding/Vertically adjustable Ca...................................................................................1133 9.10_2 | Wiring Cab tilt...........................................................................................................1134 9.14_1 | Wiring Central Lubrication................................................................................................1135 10.0_1 | Wiring Hydraulics.........................................................................................................1136 11.5_1 +CHASSIS | Wiring Power.....................................................................................................1137 11.5_2 +CAB | Wiring Power.........................................................................................................1138 11.5_3 +CAB | Wiring Power.........................................................................................................1139 11.5_4 | Wiring Power..............................................................................................................1140 11.5_5 | Wiring Power..............................................................................................................1141 11.5_6 | Wiring Power..............................................................................................................1142 11.5_7 | Wiring 24V................................................................................................................1143 11.5_8 | Wiring 12V + Com. Radio...................................................................................................1144 11.5_9 | Wiring Power Att..........................................................................................................1145 11.5_10 | Wiring Power 230V Inverter...............................................................................................1146 11.6_3 | Wiring CAN-BUS Opt. chassis KDU...........................................................................................1147 11.6_4 | Wiring CAN-BUS Att........................................................................................................1148 11.6_5 | Wiring CAN-BUS Att........................................................................................................1149 11.6_6 | Wiring CAN-BUS Att........................................................................................................1150 List of Components.....................................................................................................................1151 F Technical data...........................................................................................................................1173 Technical data.........................................................................................................................1175 Data and volume....................................................................................................................1175 Lift capacity and dimensions (model year -2008)....................................................................................1179 Lift capacity and dimensions (model year 2009-)....................................................................................1182 Oils and lubricants, recommendation................................................................................................1185 Tightening torques, recommendations................................................................................................1187 Tightening torques, ORFS- couplings................................................................................................1189 Tightening torque, climate control system connections..............................................................................1190 Unit explanations..................................................................................................................1191 Conversion table, SI-units.........................................................................................................1192 Conversion table, length...........................................................................................................1193 Conversion table, area.............................................................................................................1193 Conversion table, volume...........................................................................................................1193 Conversion table, weight...........................................................................................................1194 Conversion table, pressure.........................................................................................................1194 G Terminology and index....................................................................................................................1195 Terminology and index..................................................................................................................1197 Terminology........................................................................................................................1197 Index..............................................................................................................................1200
DESCRIPTION:
Kalmar DRF 400-450 Reachstackers 40-45 Tonnes Workshop Manual VDRF03.02GB – PDF DOWNLOAD
About the Workshop Manual:
General:
- Thank you for choosing Cargotec as your machine supplier. We hope
that we’ll meet your expectations.
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.
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