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Kalmar DRF 400-450 Workshop Manual VDRF03.01GB – PDF DOWNLOAD
Kalmar DRF 400-450 Workshop Manual VDRF03.01GB – PDF DOWNLOAD
FILE DETAILS:
Kalmar DRF 400-450 Workshop Manual VDRF03.01GB – PDF DOWNLOAD
Language : English
Pages : 1040
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Kalmar DRF 400-450 Workshop Manual VDRF03.01GB – PDF DOWNLOAD
Worshop manual.................................................................................. 1 A Foreword.................................................................................. 3 Foreword................................................................................ 5 About the Workshop Manual........................................................... 5 General......................................................................... 5 Conditions...................................................................... 5 Storage......................................................................... 5 About the machine version....................................................... 5 Copyright....................................................................... 5 Reading instructions................................................................ 6 Warning information............................................................. 6 Important information........................................................... 6 Read operator's manual.......................................................... 6 Read maintenance manual......................................................... 6 Workshop manual contents........................................................ 7 Function group structure........................................................ 8 References between different information types.................................. 9 Product alternatives and optional equipment..................................... 10 Machine card.................................................................... 11 Function descriptions........................................................... 11 About the documentation............................................................. 14 Documentation sections.......................................................... 14 Ordering of documentation....................................................... 14 Feedback............................................................................ 15 Form for copying................................................................ 15 B Safety.................................................................................... 17 Safety.................................................................................. 19 General safety information.......................................................... 19 Safety concerns everyone!....................................................... 19 A near-accident is a warning signal!............................................ 19 Safety instructions................................................................. 20 General......................................................................... 20 Service position................................................................ 20 Hydraulic and brake systems, depressurizing..................................... 21 Oils............................................................................ 22 Fuel system..................................................................... 23 Clothing etc.................................................................... 24 Several mechanics on the same machine........................................... 24 Working under machine........................................................... 25 Lifting heavy components........................................................ 25 Vibrations...................................................................... 26 Noise........................................................................... 26 Solvents........................................................................ 27 Fire and explosion risks........................................................ 27 Fluid or gas under pressure..................................................... 28 Coolant......................................................................... 29 Refrigerant..................................................................... 30 Air pollution................................................................... 30 Tensioned springs............................................................... 31 Electric motors................................................................. 31 Rotating components and tools................................................... 32 Tyre system..................................................................... 33 Lifting equipment............................................................... 33 Environment......................................................................... 34 General......................................................................... 34 C Preventive maintenance.................................................................... 37 The information is found in the Maintenance manual...................................... 37 0 Complete machine.......................................................................... 39 Complete machine........................................................................ 41 Complete machine, description ...................................................... 41 Troubleshooting, general work instructions.......................................... 42 Troubleshooting without an error code, example...................................... 43 Troubleshooting with error code, example............................................ 43 Troubleshooting cable harness....................................................... 45 Troubleshooting hydraulic hoses..................................................... 46 1 Engine ................................................................................... 47 1 Engine................................................................................ 49 Engine, general..................................................................... 49 Engine alternative Volvo, function description...................................... 50 Engine alternative Volvo TWD1240VE, component position.............................. 53 Engine alternative Volvo TAD1250VE, component position.............................. 55 Engine and gearbox, separation (Volvo engine)....................................... 57 Engine alternative Cummins QSM11, function description.............................. 59 Engine alternative Cummins QSM11, component position................................ 62 Engine and transmission, separating (engine alternative Cummins QSM11).............. 64 1.1 Controls and instrumentation.................................................... 66 1.1.1 Ignition.................................................................. 66 1.1.2 Accelerator............................................................... 67 1.2 Fuel system..................................................................... 68 Fuel system, description........................................................ 68 1.2.1 Fuel tank................................................................. 68 1.2.2 Sensor fuel level......................................................... 68 1.6 Air intake and exhaust outlet................................................... 69 1.6.1 Air cleaning system....................................................... 69 1.6.3 Exhaust system............................................................ 69 1.6.4 Intercooler............................................................... 70 1.7 Cooling system.................................................................. 71 Cooling system, description..................................................... 71 1.7.4 Radiator and expansion tank............................................... 72 1.7.5 Cooling fan............................................................... 73 1.7.7 Coolant................................................................... 75 1.7.10 Plug-in heater........................................................... 78 1.9 Control system engine........................................................... 79 1.9.1 Control unit engine....................................................... 79 1.11 Start/stopp.................................................................... 80 1.11.1 Start motor.............................................................. 80 1.11.2 Stop device.............................................................. 80 2 Transmission.............................................................................. 81 2 Transmission.......................................................................... 83 2.1 Controls and instrumentation.................................................... 92 2.1.1 Gear and multi-function lever............................................. 92 2.2 Torque converter/clutch system.................................................. 93 2.2.1 Flex plates............................................................... 93 2.6 Lubrication..................................................................... 97 2.6.3 Oil cooler................................................................ 100 2.7 Cooling......................................................................... 102 2.7.3 Oil cooler................................................................ 102 2.8 Control system transmission..................................................... 103 2.8.1 Control unit transmission................................................. 103 2.8.2 Breaking contact declutch................................................. 103 2.8.3 Cable harness transmission................................................ 103 3 Driveline/axle............................................................................ 105 3 Driveline/axle........................................................................ 107 3.2 Propeller shaft................................................................. 107 3.3 Drive axle...................................................................... 108 4 Brakes.................................................................................... 113 4 Brakes................................................................................ 115 4.1 Controls and instrumentation.................................................... 115 4.1.1 Brake pedal............................................................... 115 4.3 Service brake system............................................................ 117 4.3.1 Brake oil pump............................................................ 119 4.3.2 Brake oil filter.......................................................... 123 4.3.3 Accumulator charging valve................................................ 123 4.3.4 Accumulator............................................................... 126 4.3.5 Brake valve............................................................... 130 4.3.6 Drive axle block.......................................................... 133 4.3.7 Breaking contact brake pressure........................................... 134 4.3.8 Making contact brake light................................................ 135 4.3.9 Wheel brakes.............................................................. 137 4.3.10 Pipes and hoses.......................................................... 139 4.5 Parking brake system............................................................ 140 4.5.1 Brake oil pump............................................................ 141 4.5.2 Brake oil filter.......................................................... 141 4.5.3 Solenoid valve parking brake.............................................. 142 4.5.4 Parking brake unit........................................................ 143 4.5.5 Breaking contact parking brake............................................ 146 4.5.6 Pipes and hoses........................................................... 146 4.8 Temperature control, filtration and brake fluid................................. 147 4.8.1 Brake oil tank............................................................ 148 4.8.2 Tank heater............................................................... 149 4.8.3 Brake oil pump............................................................ 149 4.8.4 Accumulator charging valve................................................ 149 4.8.5 Drive axle block.......................................................... 149 4.8.6 Wheel brake............................................................... 149 4.8.7 Oil cooler................................................................ 150 4.8.8 Cooling fan............................................................... 151 4.8.9 Thermal by-pass valve..................................................... 151 4.8.10 Sensor brake oil temperature............................................. 152 4.8.11 Breather filter.......................................................... 153 4.8.12 Brake oil filter......................................................... 154 4.8.13 Pipes and hoses.......................................................... 155 4.8.14 Oil brake system......................................................... 155 5 Steering.................................................................................. 157 5 Steering.............................................................................. 159 5.1 Controls and instrumentation.................................................... 159 5.1.2 Mini-wheel................................................................ 159 5.1.3 Steering lever............................................................ 160 5.2 Power-assisted system........................................................... 162 5.2.1 Hydraulic oil pump........................................................ 165 5.2.2 Priority valve............................................................ 166 5.2.3 Steering valve............................................................ 168 5.2.4 Steering cylinder......................................................... 170 5.2.5 Steering axle cradle...................................................... 172 5.2.6 Link arm.................................................................. 172 5.2.7 Wheel spindle............................................................. 173 5.2.8 Wheel hub................................................................. 173 5.2.9 Shuttle valve............................................................. 173 5.2.10 Manoeuvre valve mini-wheel/lever steering................................ 173 5.2.11 Shuttle valve mini-wheel/lever steering.................................. 176 5.2.12 Sensor steering wheel angle.............................................. 177 5.2.13 Pipes and hoses.......................................................... 177 6 Suspension................................................................................ 179 6 Suspension............................................................................ 181 6.2 Suspension mounting............................................................. 181 6.2.1 Steering axle cradle...................................................... 183 6.2.2 Wheel spindle............................................................. 185 6.2.3 Wheel hub................................................................. 189 6.3 Tyre and rim system............................................................. 194 6.3.1 Tyres..................................................................... 196 6.3.2 Rims...................................................................... 197 6.3.3 Nut, washer and clamp (wedge)............................................. 198 7 Loadhandling.............................................................................. 199 7 Load handling......................................................................... 203 7.1 Controls and instrumentation.................................................... 205 7.1.1 Control lever............................................................. 205 7.1.2 Switch lock twistlocks.................................................... 207 7.1.3 Switch automatic spreading................................................ 207 7.1.5 Switch stop at 30' or 35'................................................. 208 7.2 Lifting/lowering................................................................ 209 7.2.1 Hydraulic oil pump........................................................ 212 7.2.2 Servo filter.............................................................. 213 7.2.3 Pressure reducer.......................................................... 213 7.2.4 Accumulator servo circuit................................................. 215 7.2.5 Manoeuvre valve lift, lower, protrude..................................... 217 7.2.6 Shuttle valve............................................................. 218 7.2.7 Valve block lift cylinder................................................. 219 7.2.8 Lift cylinder............................................................. 222 7.2.9 Sensor hydraulic pressure lift cylinder................................... 226 7.2.10 Lift boom................................................................ 228 7.2.11 Sensor boom angle........................................................ 228 7.2.12 Pipes and hoses.......................................................... 229 7.3 Protruding...................................................................... 230 7.3.1 Hydraulic oil pump........................................................ 233 7.3.2 Servo filter.............................................................. 233 7.3.3 Pressure reducer.......................................................... 234 7.3.4 Accumulator servo circuit................................................. 234 7.3.5 Manoeuvre valve lift, lower, protrude..................................... 234 7.3.6 Shuttle valve............................................................. 234 7.3.7 Valve block protrude cylinder............................................. 235 7.3.8 Extension cylinder........................................................ 235 7.3.9 Valve block pump unloading................................................ 238 7.3.10 Lift boom................................................................ 239 7.3.11 Sensor boom length....................................................... 241 7.3.12 Pipes and hoses.......................................................... 241 7.4 Side-shift...................................................................... 242 7.4.1 Hydraulic oil pump........................................................ 243 7.4.2 Valve block top lift hydraulics........................................... 244 7.4.3 Control valve attachment.................................................. 245 7.4.4 Shuttle valve............................................................. 250 7.4.5 Sideshift cylinder........................................................ 250 7.4.6 Sideshift frame........................................................... 251 7.4.7 Main beam attachment...................................................... 254 7.4.8 Unloading valve attachment................................................ 255 7.4.9 Pipes and hoses........................................................... 255 7.5 Positioning..................................................................... 256 7.5.1 Hydraulic oil pump........................................................ 262 7.5.2 Valve block top lift hydraulics........................................... 262 7.5.3 Control valve attachment.................................................. 262 7.5.4 Shuttle valve............................................................. 262 7.5.5 Valve block positioning motor............................................. 263 7.5.6 Positioning motor......................................................... 263 7.5.7 Positioning chains........................................................ 266 7.5.8 Positioning beam.......................................................... 273 7.5.9 Main beam attachment...................................................... 275 7.5.10 Position sensor positioning.............................................. 276 7.5.11 Unloading valve attachment............................................... 276 7.5.12 Pipes and hoses.......................................................... 276 7.5.13 Summer automatic positioning 20'- 40'.................................... 277 7.6 Rotation........................................................................ 278 7.6.1 Hydraulic oil pump........................................................ 281 7.6.2 Valve block top lift hydraulics........................................... 282 7.6.3 Control valve attachment.................................................. 282 7.6.4 Shuttle valve............................................................. 283 7.6.5 Valve block rotation motor................................................ 283 7.6.6 Rotation motor unit....................................................... 284 7.6.7 Rotation yoke............................................................. 286 7.6.8 Ring gear................................................................. 289 7.6.9 Sideshift frame........................................................... 290 7.6.10 Sensor rotation stop..................................................... 291 7.6.11 Unloading valve attachment............................................... 291 7.6.12 Pipes and hoses.......................................................... 291 7.7 Tilt............................................................................ 292 7.7.1 Hydraulic oil pump........................................................ 297 7.7.2 Valve block top lift hydraulics........................................... 297 7.7.3 Damping block tilt........................................................ 298 7.7.4 Lock valve tilt........................................................... 300 7.7.5 Control valve attachment.................................................. 300 7.7.6 Shuttle valve............................................................. 301 7.7.7 Tilt cylinder............................................................. 301 7.7.8 Lift boom................................................................. 301 7.7.9 Rotation yoke............................................................. 301 7.7.10 Unloading valve attachment............................................... 301 7.7.11 Pipes and hoses.......................................................... 301 7.8 Levelling....................................................................... 302 7.8.1 Hydraulic oil pump........................................................ 306 7.8.2 Valve block top lift hydraulics........................................... 306 7.8.3 Control valve attachment.................................................. 306 7.8.4 Shuttle valve............................................................. 307 7.8.5 Over-centre valve levelling............................................... 307 7.8.6 Valve block levelling cylinders........................................... 308 7.8.7 Levelling cylinders....................................................... 308 7.8.8 Sideshift frame........................................................... 309 7.8.9 Unloading valve attachment................................................ 309 7.8.10 Pipes and hoses.......................................................... 309 7.9 Load carrying................................................................... 310 7.9.1 Twistlocks................................................................ 310 7.9.2 Lift legs................................................................. 322 7.10 Additional functions........................................................... 351 7.10.1 Support jacks............................................................ 351 7.10.2 Weight indicator......................................................... 359 7.10.3 Container counter........................................................ 365 7.10.4 Synchronous lift......................................................... 369 8 Control system............................................................................ 371 8 Control system........................................................................ 373 8.1 Controls and instrumentation.................................................... 374 8.1.4 Switch by-passing of load centre limitation and height limitation......... 374 8.1.10 Error code menu.......................................................... 374 8.2 Monitoring...................................................................... 377 8.2.1 Overloading system........................................................ 377 8.2.2 By-passing................................................................ 385 8.2.3 Load centre limitation.................................................... 385 8.2.4 Height limitation......................................................... 386 8.2.5 Speed limitation.......................................................... 386 8.2.6 Service indicator......................................................... 387 8.4 Diagnostics..................................................................... 388 8.4.1 CAN/POWER................................................................. 390 8.4.2 LIGHTS.................................................................... 409 8.4.3 CAB....................................................................... 420 8.4.4 CLIMATE................................................................... 428 8.4.5 HYD....................................................................... 435 8.4.6 ENGINE.................................................................... 439 8.4.7 TRANSM.................................................................... 446 8.4.8 BOOM...................................................................... 458 8.4.9 ATTACH.................................................................... 464 8.4.10 OP....................................................................... 485 8.4.11 EXTRA.................................................................... 490 8.4.13 RMI...................................................................... 517 8.5 Setup........................................................................... 520 8.5.1 Initiation................................................................ 520 8.5.2 Calibration............................................................... 546 9 Frame, body, cab and accessories.......................................................... 557 9 Frame, body, cab and accessories...................................................... 561 9.1 Controls and instrumentation.................................................... 561 9.1.1 Gear and multi-function lever............................................. 568 9.1.22 Switch travel direction indicator........................................ 569 9.2 Protection and emergency equipment.............................................. 570 9.2.1 Manoeuvre switch.......................................................... 570 9.2.2 Seat belt................................................................. 570 9.2.3 Fire extinguisher......................................................... 570 9.2.4 Buzzer.................................................................... 570 9.3 Seat............................................................................ 571 9.3.1 Seat cushion.............................................................. 575 9.3.2 Back cushion.............................................................. 575 9.3.3 Heating coils............................................................. 576 9.3.4 Shock absorbers........................................................... 577 9.3.5 Air suspension............................................................ 577 9.3.6 Mechanical seat adjustment................................................ 578 9.3.7 Passenger seat............................................................ 578 9.3.8 Armrest................................................................... 578 9.3.9 Sensor driver in seat..................................................... 579 9.4 HVAC............................................................................ 580 9.4.1 Fresh air filter.......................................................... 589 9.4.2 Fresh air damper or recirculation damper.................................. 590 9.4.3 Cab fan................................................................... 593 9.4.4 Heat exchanger heat....................................................... 596 9.4.5 Water valve............................................................... 599 9.4.6 Sensor engine temperature................................................. 600 9.4.7 AC-compressor............................................................. 600 9.4.8 Condenser................................................................. 603 9.4.9 Humidity filter........................................................... 604 9.4.10 Pressure monitor......................................................... 605 9.4.11 Expansion valve.......................................................... 606 9.4.12 Sensor coolant temperature............................................... 607 9.4.13 Heat exchanger cooling................................................... 609 9.4.14 Air distributor.......................................................... 610 9.4.15 Air vents................................................................ 611 9.4.16 Sensor temperature fan air out........................................... 612 9.4.17 Sensor cab temperature................................................... 613 9.4.18 Sensor outer temperature................................................. 614 9.5 Wiper/washer system............................................................. 615 9.5.1 Wiper front............................................................... 615 9.5.2 Wiper roof................................................................ 615 9.5.3 Wiper rear................................................................ 615 9.5.4 Washer motor and reservoir................................................ 615 9.5.5 Wiper motor front......................................................... 616 9.5.6 Wiper motor roof.......................................................... 617 9.5.7 Wiper motor rear.......................................................... 618 9.6 Lighting system................................................................. 620 9.6.1 Headlights................................................................ 625 9.6.2 Position lights........................................................... 625 9.6.3 Rear lights............................................................... 625 9.6.4 Brake lights.............................................................. 625 9.6.5 Back-up lights............................................................ 626 9.6.6 Travel direction indicators............................................... 626 9.6.7 Warning light Hazard...................................................... 626 9.6.8 Rotating beacon........................................................... 626 9.6.9 Work light cab............................................................ 627 9.6.10 Work light boom.......................................................... 627 9.6.11 Work light attachment.................................................... 628 9.6.12 Interior lighting........................................................ 628 9.7 Communication system............................................................ 629 9.7.1 Horn...................................................................... 632 9.7.2 Warning light Hazard...................................................... 632 9.7.3 Rotating beacon........................................................... 632 9.7.4 Warning parking brake..................................................... 632 9.7.5 Back-up alarm............................................................. 632 9.8 Entertainment and communication................................................. 633 9.9 Glass/windows/mirrors........................................................... 634 9.9.1 Windscreen................................................................ 635 9.9.2 Side window............................................................... 637 9.9.3 Roof window............................................................... 640 9.9.4 Back window............................................................... 641 9.9.5 Rear-view mirror.......................................................... 641 9.9.6 Back-up camera............................................................ 641 9.9.7 Monitor back-up camera.................................................... 642 9.10 Cab structure and suspension................................................... 643 9.10.1 Framework cab............................................................ 643 9.10.2 Doors.................................................................... 643 9.10.3 Cab mounting............................................................. 644 9.10.4 Longitudinal displacement of cab......................................... 645 9.10.5 Vertically adjustable cab................................................ 654 9.11 Cab interia.................................................................... 666 9.11.1 Instrument and control panels............................................ 666 9.11.2 Interior details plastic................................................. 667 9.11.3 Interior details textile................................................. 667 9.11.4 Flooring material........................................................ 667 9.11.5 Insulation............................................................... 667 9.11.6 Sunshield curtains....................................................... 668 9.11.7 Terminal table........................................................... 668 9.11.8 Writing-desk............................................................. 668 9.12 Frame.......................................................................... 669 9.13 Body structure................................................................. 670 9.13.1 Fenders.................................................................. 670 9.13.2 Hood engine compartment.................................................. 670 9.13.3 Footstep and rail........................................................ 670 9.13.4 Counterweights........................................................... 671 9.14 Central lubrication............................................................ 672 9.14.1 Pump unit................................................................ 674 9.14.2 Distribution block....................................................... 675 9.14.3 Pipes.................................................................... 675 9.15 Paint/coatings................................................................. 676 10 Common hydrulics......................................................................... 677 10 Common hydraulics.................................................................... 679 10.2 Security valves................................................................ 679 10.2.1 Accumulator drain valve.................................................. 679 10.2.2 Unloading valve attachment............................................... 680 10.2.3 Pipes and hoses.......................................................... 680 10.3 Tanks and accumulators......................................................... 681 10.3.1 Tank..................................................................... 681 10.3.2 Pipes and hoses.......................................................... 681 10.4 Pumps.......................................................................... 682 10.4.1 Gear pump with fixed displacement........................................ 682 10.4.2 Axial piston pump with variable displacement............................. 685 10.4.3 Pipes and hoses.......................................................... 693 10.5 Hoses, pipes and valves........................................................ 694 10.5.1 Pipes and hoses.......................................................... 694 10.5.2 Priority valve........................................................... 695 10.5.3 Shuttle valve............................................................ 695 10.5.4 Collection block filtered return......................................... 696 10.5.5 Collection block unfiltered return....................................... 696 10.6 Temperature control, cleaning and hydraulic oil................................ 697 10.6.1 Tank heater.............................................................. 698 10.6.2 Hydraulic oil cooler..................................................... 699 10.6.3 Cooling fan.............................................................. 700 10.6.4 Sensor hydraulic oil temperature......................................... 700 10.6.5 By-pass valve cooler..................................................... 702 10.6.6 Breather filter hydraulic oil tank....................................... 703 10.6.7 Hydraulic oil filter..................................................... 704 10.6.8 Hydraulic oil............................................................ 707 10.6.9 Hydraulic oil fine-filter................................................ 707 10.6.10 Pipes and hoses......................................................... 708 10.7 Hydraulic aux.................................................................. 709 10.7.1 Hydraulic cylinders...................................................... 709 11 Common electric.......................................................................... 719 11 Common electric...................................................................... 721 11.2 Electric protection............................................................ 721 11.2.1 Battery disconnector..................................................... 721 11.2.2 Fuses.................................................................... 721 11.2.3 Manoeuvre switch......................................................... 721 11.3 Batteries (storage)............................................................ 722 11.3.1 Start battery............................................................ 722 11.4 Alternator (generation)........................................................ 724 11.4.1 Alternator............................................................... 724 11.5 Distribution of electricity.................................................... 725 11.5.1 Voltage feed............................................................. 725 11.5.2 Electrical distribution box.............................................. 733 11.5.3 Control units............................................................ 735 11.5.5 Cable harness............................................................ 750 11.6 Communication.................................................................. 760 11.6.1 CAN-bus.................................................................. 760 11.6.2 Redundant CAN-bus........................................................ 762 11.6.3 CAN-bus driveline........................................................ 765 11.6.4 Communication between PC and machine .................................... 766 11.6.5 RMI (Remote Machine Interface)........................................... 767 D Error codes............................................................................... 769 Error codes............................................................................. 771 Error codes, explanation............................................................ 771 Error code menu, description........................................................ 771 Reading out error code.............................................................. 775 1 Engine................................................................................ 777 Error codes engine, general......................................................... 777 Error codes engine (engine alternative Volvo)....................................... 778 Error codes engine (engine alternative Cummins QSM11)............................... 796 2 Transmission.......................................................................... 808 Error codes transmission (transmission alternative TE32000)......................... 808 8 Control and monitoring system......................................................... 818 Error codes machine................................................................. 818 E Schematics................................................................................ 859 10 Common hydraulics.................................................................... 861 Hydraulic diagrams, compilation..................................................... 861 Hydraulic diagram basic machine..................................................... 862 Hydraulic diagram top lift.......................................................... 864 Hydraulic diagram top lift, tilt lock and controllable tilt......................... 866 Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling.... 868 Hydraulic diagram joystick steering................................................. 870 Hydraulic diagram sliding cab....................................................... 872 Hydraulic diagram cab lift and support jacks........................................ 874 Hydraulic diagram sliding cab and support jacks..................................... 876 Hydraulic diagram combi attachment (part 1 of 3).................................... 878 Hydraulic diagram combi attachment (part 2 of 3).................................... 880 Hydraulic diagram combi attachment (part 3 of 3).................................... 882 11 Common electric...................................................................... 884 Wiring diagrams, description ....................................................... 884 Component designations.............................................................. 885 Circuit diagrams, compilation....................................................... 886 Wiring.................................................................................. 889 0.0-1 Wiring Cross References....................................................... 890 0.0-2 Wiring Cross References....................................................... 891 0.0-3 Wiring Cross References Opt................................................... 892 0.0-4 Wiring Cross References Att................................................... 893 0.0-5 Wiring Cross References Att................................................... 894 0.0-6 Wiring Cross References Att. Combi............................................ 895 1.0-1 Wiring Engine Volvo 1240 & 1250............................................... 896 1.0-2 Wiring Engine Cummins......................................................... 897 1.0-3 Wiring Engine Cummins......................................................... 898 1.1-1 Wiring Drivetrain............................................................. 899 2.0-1 Wiring Dana TE 32000.......................................................... 900 2.0-2 Wiring Dana TE 32000.......................................................... 901 2.0-3 Wiring Dana TE 32000.......................................................... 902 2.1-1 Wiring Drivetrain............................................................. 903 4.0-1 Wiring Brakes................................................................. 904 4.0-2 Wiring Brakes................................................................. 905 5.2-1 Wiring Micro Lever/Wheel...................................................... 906 5.2-2 Wiring Micro Lever/Wheel...................................................... 907 5.2-3 Wiring Micro Lever/Wheel and Combi Att........................................ 908 5.2-4 Wiring Micro Lever/Wheel and Combi Att........................................ 909 7.1-1 Wiring Joystick............................................................... 910 7.2-1 Wiring Boom Up/Down........................................................... 911 7.3-1 Wiring Boom In/Out............................................................ 912 7.5-1 Wiring Spreading Valves....................................................... 913 7.5-2 Wiring Spreading Auto......................................................... 914 7.5-3 Wiring Spreading Sensors...................................................... 915 7.6-1 Wiring Rotation............................................................... 916 7.7-1 Wiring Tilt lock.............................................................. 917 7.7-2 Wiring Tilt + Levelling....................................................... 918 7.7-3 Wiring Tilt + Levelling....................................................... 919 7.9-1 Wiring Twistlock.............................................................. 920 7.9-2 Wiring Twistlock.............................................................. 921 7.9-3 Wiring Combi Att.............................................................. 922 7.9-4 Wiring Combi Att.............................................................. 923 7.9-5 Wiring Combi Att.............................................................. 924 7.9-6 Wiring Combi Att.............................................................. 925 7.9-7 Wiring Combi Att.............................................................. 926 7.9-8 Wiring Combi Att.............................................................. 927 7.9-9 Wiring Combi Att.............................................................. 928 7.9-10 Wiring Combi Att............................................................. 929 7.9-11 Wiring Combi Att............................................................. 930 7.9-12 Wiring Combi Att............................................................. 931 7.9-13 Wiring Combi Att............................................................. 932 7.9-14 Wiring Combi Att............................................................. 933 7.9-15 Wiring Combi Att............................................................. 934 7.9-16 Wiring Combi Att............................................................. 935 7.9-17 Wiring Combi Att............................................................. 936 7.10-1 Wiring Hyd Support jacks..................................................... 937 7.10-2 Wiring Hyd Support jacks..................................................... 938 7.10-3 Wiring Printer............................................................... 939 8.2-1 Wiring OP + Scale............................................................. 940 8.2-2 Wiring OP+ Scale.............................................................. 941 8.2-3 Wiring Override............................................................... 942 8.2-4 Wiring RMI.................................................................... 943 9.1-1 Wiring OPT Sensors Instr...................................................... 944 9.1-2 Wiring Option................................................................. 945 9.1-3 Wiring Option................................................................. 946 9.1-4 Wiring Sensors Instr.......................................................... 947 9.1-5 Wiring Option Cabin........................................................... 948 9.3-1 Wiring Cab Seat Opt........................................................... 949 9.3-2 Wiring Cab Seat Opt........................................................... 950 9.4-1 Wiring Climate Control........................................................ 951 9.4-2 Wiring Climate Control........................................................ 952 9.5-1 Wiring Wiper function......................................................... 953 9.6-1 Wiring Work Light............................................................. 954 9.6-2 Wiring Opt. Work Light........................................................ 955 9.6-3 Wiring Opt. Work Light Boom................................................... 956 9.6-5 Wiring Lights................................................................. 957 9.6-6 Wiring Lights................................................................. 958 9.6-7 Wiring Lights................................................................. 959 9.6-8 Wiring Lights................................................................. 960 9.6-9 Wiring Step In Light.......................................................... 961 9.6-10 Wiring Opt. Work Light Chassis............................................... 962 9.7-1 Wiring Alarm, Soundsignals.................................................... 963 9.7-2 Wiring Alarm, Soundsignals.................................................... 964 9.7-3 Wiring Flashing Indicator, Hazard............................................. 965 9.7-4 Wiring Reverse Alarm.......................................................... 966 9.8-1 Wiring Radio.................................................................. 967 9.9-9 Wiring Camera................................................................. 968 9.10-1 Wiring Sliding/Vertically Ajustable Cab...................................... 969 9.10-2 Wiring Cab Tilt.............................................................. 970 9.14 Wiring Central Lubrication..................................................... 971 10.0-1 Wiring Hydraulics............................................................ 972 11.5-1 Wiring Power................................................................. 973 11.5-2 Wiring Power................................................................. 974 11.5-3 Wiring Power................................................................. 975 11.5-4 Wiring Power................................................................. 976 11.5-5 Wiring Power................................................................. 977 11.5-6 Wiring Power................................................................. 978 11.5-7 Wiring 24 V.................................................................. 979 11.5-8 Wiring 12 V + Com. Radio .................................................... 980 11.5-9 Wiring Power Att............................................................. 981 11.6-3 Wiring CAN-BUSS Opt. Chassis KDU............................................. 982 11.6-4 Wiring CAN-BUSS Att.......................................................... 983 11.6-5 Wiring CAN-BUSS Att.......................................................... 984 11.6-6 Wiring CAN-BUSS Att.......................................................... 985 List of Components...................................................................... 987 F Technical data............................................................................1005 Technical data..........................................................................1007 Data and volume.....................................................................1007 Lift capacity and dimensions........................................................1010 Oils and lubricants, recommendation.................................................1013 Tightening torques, recommendations.................................................1014 Tightening torque, ORFS connections.................................................1016 Unit explanations...................................................................1017 Conversion table, SI-units..........................................................1018 Conversion table, length............................................................1019 Conversion table, area..............................................................1019 Conversion table, volume............................................................1019 Conversion table, weight............................................................1020 Conversion table, pressure..........................................................1020 G Terminology and index.....................................................................1021 Terminology and index...................................................................1023 Terminology.........................................................................1023 Index...............................................................................1026
DESCRIPTION:
Kalmar DRF 400-450 Workshop Manual VDRF03.01GB – 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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