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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 : 300
Downloadable : Yes
File Type : PDF
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.
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
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