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Kalmar DRF 400–450 Workshop Manual VDRF01.01GB – PDF DOWNLOAD
Kalmar DRF 400–450 Workshop Manual VDRF01.01GB – PDF DOWNLOAD
FILE DETAILS:
Kalmar DRF 400–450 Workshop Manual VDRF01.01GB – PDF DOWNLOAD
Language : English
Pages : 612
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Kalmar DRF 400–450 Workshop Manual VDRF01.01GB – PDF DOWNLOAD
A Foreword:
About the Workshop Manual:
General:
Kalmar Industries as your machine supplier. We hope that we’ll meet your expectations.
Workshop manual contents:
The workshop manual contains information for corrective mainte- nance (replacement of components)
and complements the mainte- nance manual. Accompanying the workshop manual is supplier
documentation for engine, transmission and drive axle. Where prac- ticable, please refer from the
workshop manual to the maintenance manual and supplier documentation to avoid duplicated informa-
tion. The workshop manual is divided into the following sections.
References between different information types:
- The maintenance manual and workshop manual are mainly divided into function groups, see Workshop
manual contents page 3. Certain parts are broken out as separate parts to increase usability, e.g.,
“Technical data”. - The basic rule of searching for information is to use function groups to find different types of
information regarding the function or com- ponent in question. As a complement to this, there are
references according to the below.
TABLE OF CONTENTS:
Kalmar DRF 400–450 Workshop Manual VDRF01.01GB – PDF DOWNLOAD
Workshop manual........................................................................ 1 A Foreword............................................................................. 3 A Foreword......................................................................... 5 About the Workshop Manual...................................................... 5 General.................................................................... 5 Workshop manual contents................................................... 5 References between different information types............................. 6 Function group breakdown................................................... 7 Conditions................................................................. 7 Storage.................................................................... 7 About the machine version.................................................. 7 Copyright.................................................................. 8 Reading instructions........................................................... 9 Warning information........................................................ 9 Important information...................................................... 9 Read the operator's manual/maintenance manual.............................. 9 Optional equipment......................................................... 9 Function descriptions...................................................... 10 About the documentation........................................................ 13 Documentation sections..................................................... 13 Ordering of documentation.................................................. 13 Feedback....................................................................... 14 Form for copying........................................................... 14 B Safety............................................................................... 15 B Safety........................................................................... 17 General safety information..................................................... 17 Safety concerns everyone!.................................................. 17 A near-accident is a warning signal!....................................... 17 Safety instructions............................................................ 18 General.................................................................... 18 Service position........................................................... 18 Hydraulic and brake systems, depressurizing................................ 19 Clothing etc............................................................... 20 Several mechanics on the same machine...................................... 20 Working under machine...................................................... 21 Lifting heavy components................................................... 21 Vibrations................................................................. 22 Noise...................................................................... 22 Solvents................................................................... 22 Fire and explosion risks................................................... 23 Fluid or gas under pressure................................................ 24 Coolant.................................................................... 25 Refrigerant................................................................ 26 Air pollution.............................................................. 26 Tensioned springs.......................................................... 27 Electric motors............................................................ 28 Rotating components and tools.............................................. 28 Tyre system................................................................ 29 Environment.................................................................... 30 General.................................................................... 30 C Preventive maintenance............................................................... 31 Preventive maintenance............................................................. 31 0 Complete machine..................................................................... 33 1 Engine............................................................................... 35 1 Engine........................................................................... 37 1.1 Controls and instrumentation............................................... 47 1.1.1 Ignition............................................................. 47 1.1.2 Accelerator.......................................................... 48 1.1.3 Warning light low oil pressure in engine............................. 49 1.1.4 Indicator light preheating........................................... 49 1.1.5 Warning light low coolant level...................................... 49 1.1.6 Warning light high coolant temperature............................... 50 1.1.7 Warning light low fuel level......................................... 50 1.1.8 Operating menu engine and transmission............................... 50 1.1.9 Operating menu engine................................................ 50 1.2 Fuel system................................................................ 51 1.2.1 Fuel tank............................................................ 51 1.2.2 Sensor fuel level.................................................... 51 1.2.3 Fuel pre-filter...................................................... 51 1.2.4 Fuel filter.......................................................... 51 1.2.5 Sensor water in fuel................................................. 51 1.2.6 Fuel pump............................................................ 52 1.2.7 Sensor fuel pressure................................................. 52 1.2.8 Injectors............................................................ 52 1.2.9 Breaking contact fuel pressure....................................... 52 1.2.10 Making contact water in fuel........................................ 52 1.5 Mechanical parts........................................................... 53 1.6 Air intake and exhaust outlet.............................................. 54 1.6.1 Air cleaning system.................................................. 54 1.6.2 Turbo................................................................ 54 1.6.3 Exhaust system....................................................... 55 1.6.4 Intercooler.......................................................... 56 1.6.5 Sensor boost pressure................................................ 56 1.6.6 Sensor charge-air temperature........................................ 56 1.7 Cooling system............................................................. 57 1.7.1 Coolant pump......................................................... 57 1.7.2 Coolant filter....................................................... 57 1.7.3 Coolant thermostat................................................... 57 1.7.4 Radiator and expansion tank.......................................... 58 1.7.5 Cooling fan.......................................................... 59 1.7.6 Oil cooler........................................................... 62 1.7.7 Coolant.............................................................. 62 1.7.8 Making contact coolant level......................................... 63 1.7.9 Sensor coolant temperature........................................... 63 1.7.10 Plug-in heater...................................................... 64 1.8 Lubrication................................................................ 65 1.8.1 Oil sump............................................................. 65 1.8.2 Oil pump............................................................. 65 1.8.3 Sensor oil pressure.................................................. 65 1.8.4 Full flow filter..................................................... 65 1.8.5 By-pass filter....................................................... 65 1.8.6 Oil cooler........................................................... 65 1.8.7 Sensor oil temperature............................................... 65 1.9 Control system engine...................................................... 66 1.9.1 Control unit engine.................................................. 66 1.10 Ignition/heating.......................................................... 67 1.10.1 Preheating.......................................................... 67 1.11 Start/stop................................................................ 68 1.11.1 Start motor......................................................... 68 1.11.2 Stop device......................................................... 68 2 Transmission......................................................................... 69 2 Transmission..................................................................... 71 2.1 Controls and instrumentation............................................... 75 2.1.1 Gear and multi-function lever........................................ 75 2.1.2 Clutch pedal......................................................... 75 2.1.3 Switch shifting program A............................................ 75 2.1.4 Switch shifting program 1............................................ 76 2.1.5 Switch shifting program 2............................................ 76 2.1.6 Travel direction indicator forward, neutral, reverse................. 76 2.1.7 Warning light high oil temperature in transmission................... 76 2.1.8 Operating menu engine and transmission............................... 77 2.1.9 Operating menu oil temperature....................................... 77 2.2 Torque converter/clutch system............................................. 78 2.2.1 Flex plates.......................................................... 78 2.2.2 Pump rotor........................................................... 80 2.2.3 Stator............................................................... 80 2.2.4 Turbin rotor......................................................... 80 2.2.5 Sensor engine speed and oil temperature in transmission.............. 80 2.3 Mechanical transmission.................................................... 81 2.3.1 Gear pack............................................................ 81 2.3.2 Power take-off....................................................... 81 2.3.3 Input shaft.......................................................... 81 2.3.4 Valve block transmission control..................................... 81 2.3.5 Sensor turbine speed................................................. 81 2.3.6 Sensor shaft speed................................................... 81 2.3.7 Output shaft......................................................... 81 2.3.8 Sensor output shaft speed............................................ 82 2.6 Lubrication................................................................ 83 2.6.1 Oil pump............................................................. 83 2.6.2 Sensor oil pressure.................................................. 83 2.6.3 Oil cooler........................................................... 84 2.6.4 Oil filter........................................................... 84 2.7 Cooling.................................................................... 85 2.7.1 Cooling oil pump..................................................... 85 2.7.2 Sensor oil temperature............................................... 85 2.7.3 Oil cooler........................................................... 85 2.8 Control system transmission................................................ 86 2.8.1 Control unit transmission............................................ 86 2.8.2 Breaking contact declutch............................................ 86 2.8.3 Cable harness transmission........................................... 87 3 Driveline/axle....................................................................... 89 3 Driveline/axle................................................................... 91 3.2 Drive shaft................................................................ 91 3.3 Drive axle................................................................. 92 3.3.1 Differential......................................................... 92 3.3.2 Drive shaft.......................................................... 92 3.3.3 Hub reduction........................................................ 92 4 Brakes............................................................................... 93 4 Brakes........................................................................... 95 4.1 Controls and instrumentation............................................... 95 4.1.1 Brake pedal.......................................................... 95 4.1.2 Switch parking brake................................................. 97 4.1.3 Warning light low brake pressure..................................... 97 4.1.4 Indicator light parking brake........................................ 97 4.1.5 Event menu high oil temperature...................................... 98 4.3 Service brake system....................................................... 99 4.3.1 Brake oil pump.......................................................101 4.3.2 Brake oil filter.....................................................103 4.3.3 Accumulator charging valve...........................................104 4.3.4 Accumulator..........................................................108 4.3.5 Brake valve..........................................................111 4.3.6 Drive axle block.....................................................115 4.3.7 Making contact brake pressure........................................116 4.3.8 Making contact brake light...........................................117 4.3.9 Wheel brakes.........................................................119 4.3.10 Pipes and hoses.....................................................122 4.5 Parking brake system.......................................................123 4.5.1 Brake oil pump.......................................................124 4.5.2 Brake oil filter.....................................................125 4.5.3 Solenoid valve parking brake.........................................125 4.5.4 Parking brake unit...................................................126 4.5.5 Making contact parking brake.........................................129 4.5.6 Pipes and hoses......................................................129 4.8 Temperature control, filtration and brake fluid............................130 4.8.1 Brake oil tank.......................................................131 4.8.2 Tank heater..........................................................132 4.8.3 Brake oil pump.......................................................132 4.8.4 Accumulator charging valve...........................................132 4.8.5 Drive axle block.....................................................132 4.8.6 Wheel brake..........................................................133 4.8.7 Oil cooler...........................................................133 4.8.8 Cooling fan..........................................................133 4.8.9 Thermal by-pass valve................................................134 4.8.10 Sensor brake oil temperature........................................135 4.8.11 Breather filter.....................................................135 4.8.12 Brake oil filter....................................................136 4.8.13 Pipes and hoses.....................................................136 4.8.14 Oil brake system....................................................136 5 Steering.............................................................................137 5 Steering.........................................................................139 5.1 Controls and instrumentation...............................................139 5.1.1 Steering wheel and steering column...................................139 5.1.2 Mini-wheel...........................................................140 5.1.3 Steering lever.......................................................141 5.1.4 Indicator light mini-wheel/steering lever............................142 5.2 Power-assisted system......................................................143 5.2.1 Hydraulic oil pump...................................................147 5.2.2 Priority valve.......................................................147 5.2.3 Steering valve.......................................................150 5.2.4 Steering cylinder....................................................152 5.2.5 Steering axle cradle.................................................153 5.2.6 Link arm.............................................................153 5.2.7 Wheel spindle........................................................153 5.2.8 Wheel hub............................................................153 5.2.9 Shuttle valve........................................................153 5.2.10 Manoeuvre valve mini-wheel/lever steering...........................154 5.2.11 Shuttle valve mini-wheel/lever steering.............................155 5.2.12 Sensor steering wheel angle.........................................156 5.2.13 Pipes and hoses.....................................................156 6 Suspension...........................................................................157 6 Suspension.......................................................................159 6.2 Suspension.................................................................159 6.2.1 Steering axle cradle.................................................159 6.2.2 Wheel spindle........................................................161 6.2.3 Wheel hub............................................................165 6.3 Tyre and rim system........................................................170 6.3.1 Tyres................................................................172 6.3.2 Rims.................................................................173 6.3.3 Nut, washer and clamp (wedge)........................................174 7 Load handling........................................................................175 7 Load handling....................................................................179 7.1 Controls and instrumentation...............................................181 7.1.1 Control lever........................................................181 7.1.2 Switch lock twistlocks...............................................183 7.1.4 Switch rotation stop.................................................183 7.1.5 Switch stop at 30' or 35'............................................184 7.1.6 Switch support jacks.................................................184 7.1.7 Switch to lower front legs...........................................184 7.1.8 Switch to lower rear legs............................................185 7.1.9 Switch clamp/loose leg...............................................185 7.1.10 Indicator light alignment...........................................186 7.1.11 Indicator light locked twistlocks...................................186 7.1.12 Indicator light unlocked twistlocks.................................187 7.1.13 Indicator light alignment left front leg............................187 7.1.14 Indicator light alignment right front leg...........................188 7.1.15 Indicator light alignment left rear leg.............................188 7.1.16 Indicator light alignment right rear leg............................189 7.1.17 Indicator light clamping position front legs........................189 7.1.18 Indicator light clamping position rear legs.........................190 7.1.19 Indicator light front legs raised...................................190 7.1.20 Indicator light front legs lowered..................................191 7.1.21 Indicator light support jacks down..................................191 7.1.22 Event menu support jacks............................................191 7.1.23 Event menu rotation stop............................................191 7.1.24 Event menu alignment................................................192 7.1.25 Event menu lift legs................................................192 7.1.26 Operating menu fixed scale..........................................192 7.1.27 Operating menu dynamic scale........................................192 7.1.28 Operating menu control of dynamic scale.............................193 7.1.29 Operating menu container counter....................................193 7.1.30 Event menu twistlocks...............................................193 7.2 Lifting/lowering...........................................................194 7.2.1 Hydraulic oil pump...................................................197 7.2.2 Servo filter.........................................................197 7.2.3 Pressure reducer.....................................................198 7.2.4 Accumulator servo circuit............................................198 7.2.5 Manoeuvre valve lift, lower, protrude................................200 7.2.6 Shuttle valve........................................................200 7.2.7 Valve block lift cylinder............................................201 7.2.8 Lift cylinder........................................................205 7.2.9 Sensor hydraulic pressure lift cylinder..............................206 7.2.10 Lift boom...........................................................208 7.2.11 Sensor boom angle...................................................209 7.2.12 Pipes and hoses.....................................................209 7.3 Protruding.................................................................210 7.3.1 Hydraulic oil pump...................................................213 7.3.2 Servo filter.........................................................213 7.3.3 Pressure reducer.....................................................213 7.3.4 Accumulator servo circuit............................................213 7.3.5 Manoeuvre valve lift, lower, protrude................................214 7.3.6 Shuttle valve........................................................214 7.3.7 Valve block protrude cylinder........................................215 7.3.8 Protrude cylinder....................................................215 7.3.9 Valve block pump unloading...........................................216 7.3.10 Lift boom...........................................................216 7.3.11 Sensor boom length..................................................216 7.3.12 Pipes and hoses.....................................................216 7.4 Side-shift.................................................................217 7.4.1 Hydraulic oil pump...................................................218 7.4.2 Valve block top lift hydraulics......................................219 7.4.3 Manoeuver valve attachment...........................................220 7.4.4 Shuttle valve........................................................223 7.4.5 Sideshift cylinder...................................................224 7.4.6 Sideshift frame......................................................225 7.4.7 Main beam attachment.................................................227 7.4.8 Unloading valve attachment...........................................228 7.4.9 Pipes and hoses......................................................228 7.5 Positioning................................................................229 7.5.1 Hydraulic oil pump...................................................233 7.5.2 Valve block top lift hydraulics......................................233 7.5.3 Manoeuver valve attachment...........................................234 7.5.4 Shuttle valve........................................................234 7.5.5 Valve block positioning motor........................................235 7.5.6 Positioning motor....................................................235 7.5.7 Positioning chains...................................................239 7.5.8 Positioning beam.....................................................244 7.5.9 Main beam attachment.................................................245 7.5.10 Position sensor positioning.........................................246 7.5.11 Unloading valve attachment..........................................246 7.5.12 Pipes and hoses.....................................................246 7.6 Rotation...................................................................247 7.6.1 Hydraulic oil pump...................................................250 7.6.2 Valve block top lift hydraulics......................................250 7.6.3 Manoeuver valve attachment...........................................251 7.6.4 Shuttle valve........................................................251 7.6.5 Valve block rotation motor...........................................252 7.6.6 Rotation motor unit..................................................253 7.6.7 Rotation yoke........................................................255 7.6.8 Ring gear............................................................258 7.6.9 Sideshift frame......................................................259 7.6.10 Sensor rotation stop................................................260 7.6.11 Unloading valve attachment..........................................260 7.6.12 Pipes and hoses.....................................................260 7.7 Tilt.......................................................................261 7.7.1 Hydraulic oil pump...................................................266 7.7.2 Valve block top lift hydraulics......................................266 7.7.3 Damping block tilt...................................................266 7.7.4 Lock valve tilt......................................................268 7.7.5 Manoeuver valve attachment...........................................268 7.7.6 Shuttle valve........................................................269 7.7.7 Tilt cylinder........................................................270 7.7.8 Lift boom............................................................270 7.7.9 Rotation yoke........................................................270 7.7.10 Unloading valve attachment..........................................270 7.7.11 Pipes and hoses.....................................................270 7.8 Levelling..................................................................271 7.8.1 Hydraulic oil pump...................................................274 7.8.2 Valve block top lift hydraulics......................................275 7.8.3 Manoeuver valve attachment...........................................275 7.8.4 Shuttle valve........................................................276 7.8.5 Over-centre valve levelling..........................................276 7.8.6 Valve block levelling cylinders......................................277 7.8.7 Levelling cylinders..................................................277 7.8.8 Sideshift frame......................................................278 7.8.9 Unloading valve attachment...........................................278 7.8.10 Pipes and hoses.....................................................278 7.9 Load carrying..............................................................279 7.9.1 Twistlocks...........................................................279 7.9.2 Lift legs............................................................288 7.10 Additional functions......................................................313 7.10.1 Support jacks.......................................................313 7.10.2 Weight indicator....................................................320 7.10.3 Container counter...................................................323 7.10.4 Synchronous lift....................................................327 8 Control system.......................................................................329 8 Control system...................................................................331 8.1 Controls and instrumentation...............................................332 8.1.1 Information terminal.................................................332 8.1.2 Information display..................................................333 8.1.3 Switch by-passing....................................................333 8.1.4 Switch by-passing of load centre limitation and height limitation....334 8.1.5 Indicator light by-passing activated.................................334 8.1.6 Event menu overload forward..........................................335 8.1.7 Event menu overload steering axle....................................335 8.1.8 Event menu height limitation.........................................335 8.1.9 Event menu open door.................................................335 8.1.10 Error code menu.....................................................336 8.2 Monitoring.................................................................339 8.2.1 Overload protection..................................................339 8.2.2 By-passing...........................................................349 8.2.3 Load centre limitation...............................................349 8.2.4 Height limitation....................................................349 8.2.5 Speed limitation.....................................................349 8.3 Error codes................................................................350 8.4 Diagnostics................................................................351 8.5 Setup......................................................................352 8.5.1 Initiation...........................................................352 8.5.2 Calibration..........................................................372 9 Frame, body, cab and accessories.....................................................385 9 Frame, body, cab and accessories.................................................389 9.1 Controls and instrumentation...............................................389 9.1.1 Gear and multi-function lever........................................390 9.1.2 Indicator light full headlights......................................391 9.1.3 Indicator light direction indicators.................................391 9.1.4 Switch work light cab roof...........................................391 9.1.5 Switch work light attachment.........................................392 9.1.6 Switch work light boom...............................................392 9.1.7 Switch rotating beacon...............................................392 9.1.8 Switch hazard........................................................393 9.1.9 Switch headlights....................................................393 9.1.10 Switch seat heating.................................................393 9.1.11 Switch wiper roof, interval.........................................394 9.1.12 Switch wiper roof, continuous.......................................394 9.1.13 Switch interior lighting............................................394 9.1.14 Switch wiper rear, interval.........................................395 9.1.15 Switch wiper rear, continuous.......................................395 9.1.16 Switch hydraulic longitudinal displacement of cab...................395 9.1.17 Switch hydraulic vertically adjustable cab..........................396 9.1.18 Control fan and recirculation.......................................396 9.1.19 Control heating.....................................................397 9.1.20 Control defroster/cab...............................................398 9.1.21 Hour meter..........................................................398 9.1.22 Switch travel direction indicator...................................398 9.2 Protection and emergency equipment.........................................400 9.2.1 Emergency stop device................................................400 9.2.2 Seat belt............................................................400 9.2.3 Fire extinguisher....................................................400 9.2.4 Seat buzzer..........................................................400 9.3 Seat.......................................................................401 9.3.1 Seat cushion.........................................................401 9.3.2 Back cushion.........................................................401 9.3.3 Heating coils........................................................402 9.3.4 Shock absorbers......................................................402 9.3.5 Air suspension.......................................................402 9.3.6 Mechanical seat adjustment...........................................402 9.3.7 Passenger seat.......................................................403 9.3.8 Armrest..............................................................403 9.3.9 Sensor driver in seat................................................403 9.4 HVAC.......................................................................404 9.4.1 Fresh air filter.....................................................410 9.4.2 Fresh air damper or recirculation damper.............................411 9.4.3 Cab fan..............................................................413 9.4.4 Heat exchanger heat..................................................416 9.4.5 Water valve..........................................................419 9.4.6 Sensor engine temperature............................................420 9.4.7 AC-compressor........................................................421 9.4.8 Condenser............................................................422 9.4.9 Humidity filter......................................................423 9.4.10 Pressure monitor....................................................424 9.4.11 Expansion valve.....................................................425 9.4.12 Sensor coolant temperature..........................................425 9.4.13 Heat exchanger cooling..............................................427 9.4.14 Air distributor.....................................................428 9.4.15 Air vents...........................................................429 9.4.16 Sensor temperature fan air out......................................430 9.4.17 Sensor cab temperature..............................................431 9.4.18 Sensor outer temperature............................................432 9.5 Wiper/washer system........................................................433 9.5.1 Wiper front..........................................................433 9.5.2 Wiper roof...........................................................433 9.5.3 Wiper rear...........................................................433 9.5.4 Washer motor and reservoir...........................................433 9.5.5 Wiper motor front....................................................434 9.5.6 Wiper motor roof.....................................................435 9.5.7 Wiper motor rear.....................................................436 9.6 Lighting system............................................................437 9.6.1 Headlights...........................................................439 9.6.2 Position lights......................................................440 9.6.3 Rear lights..........................................................440 9.6.4 Brake lights.........................................................440 9.6.5 Back-up lights.......................................................440 9.6.6 Travel direction indicators..........................................441 9.6.7 Warning light Hazard.................................................441 9.6.8 Rotating beacon......................................................441 9.6.9 Work light cab.......................................................441 9.6.10 Work light boom.....................................................442 9.6.11 Work light attachment...............................................442 9.6.12 Interior lighting...................................................442 9.7 Communication system.......................................................443 9.7.1 Horn.................................................................445 9.7.2 Warning light Hazard.................................................445 9.7.3 Rotating beacon......................................................445 9.7.4 Warning parking brake................................................445 9.7.5 Back-up alarm........................................................446 9.8 Entertainment and communication............................................447 9.9 Glass/windows/mirrors......................................................448 9.9.1 Windscreen...........................................................448 9.9.2 Side window..........................................................448 9.9.3 Roof window..........................................................451 9.9.4 Back window..........................................................452 9.9.5 Rear-view mirror.....................................................452 9.9.6 Back-up camera.......................................................452 9.9.7 Monitor back-up camera...............................................453 9.10 Cab structure and suspension..............................................454 9.10.1 Framework cab.......................................................454 9.10.2 Doors...............................................................455 9.10.3 Cab mounting........................................................455 9.10.4 Longitudinal displacement of cab....................................457 9.10.5 Vertically adjustable cab...........................................463 9.11 Cab interia...............................................................472 9.11.1 Instrument and control panels.......................................472 9.11.2 Interior details plastic............................................473 9.11.3 Interior details textile............................................473 9.11.4 Flooring material...................................................474 9.11.5 Insulation..........................................................474 9.11.6 Sunshield curtains..................................................474 9.11.7 Terminal table......................................................474 9.11.8 Writing-desk........................................................474 9.12 Frame.....................................................................475 9.13 Body structure............................................................476 9.13.1 Fenders.............................................................476 9.13.2 Hood engine compartment.............................................476 9.13.3 Footstep and rail...................................................477 9.13.4 Counterweights......................................................477 9.14 Central lubrication.......................................................478 9.15 Paint/coatings............................................................479 10 Common hydraulics...................................................................481 10 Common hydraulics...............................................................483 10.1 Controls and instrumentation..............................................483 10.1.1 Warning light hydraulic oil temperature.............................483 10.1.2 Operating menu hydraulic oil temperature............................483 10.2 Security valves...........................................................484 10.2.1 Accumulator drain valve.............................................484 10.2.2 Unloading valve attachment..........................................484 10.2.3 Pipes and hoses.....................................................485 10.3 Tanks and accumulators....................................................486 10.3.1 Tank................................................................486 10.3.2 Pipes and hoses.....................................................486 10.4 Pumps.....................................................................487 10.4.1 Gear pump with fixed displacement...................................487 10.4.2 Axial piston pump with variable displacement........................490 10.4.3 Pipes and hoses.....................................................498 10.5 Hoses, pipes and valves...................................................499 10.5.1 Pipes and hoses.....................................................499 10.5.2 Priority valve......................................................499 10.5.3 Shuttle valve.......................................................500 10.5.4 Collection block filtered return....................................501 10.5.5 Collection block unfiltered return..................................501 10.6 Temperature control, cleaning and hydraulic oil...........................502 10.6.1 Tank heater.........................................................502 10.6.2 Hydraulic oil cooler................................................503 10.6.3 Cooling fan.........................................................505 10.6.4 Sensor hydraulic oil temperature....................................505 10.6.5 By-pass valve cooler................................................506 10.6.6 Breather filter hydraulic oil tank..................................507 10.6.7 Hydraulic oil filter................................................508 10.6.8 Hydraulic oil.......................................................509 10.6.9 Hydraulic oil fine-filter...........................................509 10.6.10 Pipes and hoses....................................................509 10.7 Hydraulic aux.............................................................510 10.7.1 Hydraulic cylinders.................................................510 11 Common electrics....................................................................521 11 Common electrics................................................................523 11.1 Controls and instrumentation..............................................523 11.1.1 Hour meter..........................................................523 11.1.2 Warning light battery charging......................................523 11.1.3 Switch emergency stop...............................................524 11.1.4 Ignition............................................................524 11.2 Electric protection.......................................................525 11.2.1 Battery disconnector................................................525 11.2.2 Fuses...............................................................525 11.2.3 Switch emergency stop...............................................525 11.3 Batteries.................................................................526 11.3.1 Start battery.......................................................526 11.4 Alternator................................................................528 11.4.1 Alternator..........................................................528 11.5 Distribution of electricity...............................................529 11.5.1 Voltage feed........................................................529 11.5.2 Electrical distribution box.........................................538 11.5.3 Control units.......................................................540 11.5.5 Cable harness.......................................................553 11.6 Communication.............................................................566 11.6.1 CAN-bus.............................................................566 11.6.2 Redundant CAN-bus...................................................568 11.6.3 CAN-bus driveline...................................................571 11.6.4 Communication between PC and machine................................572 D Error codes..........................................................................573 Error codes........................................................................573 E Schematics...........................................................................575 Schematics.........................................................................575 F Technical data.......................................................................577 F Technical data...................................................................579 Specifications for data and volume.............................................579 Specifications for lift capacity and dimensions................................581 Oils and lubricants, recommendation............................................584 Lighting system, technical data................................................585 Tightening torques, recommendations............................................586 Unit explanations..............................................................587 Conversion table, SI-units.....................................................588 Conversion table, length.......................................................589 Conversion table, area.........................................................589 Conversion table, volume.......................................................589 Conversion table, weight.......................................................590 Conversion table, pressure.....................................................590 G Terminology and index................................................................591 G Terminology and index............................................................593 Terminology....................................................................593 Explanations...............................................................593 Index..........................................................................596 General....................................................................596
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