Starting from:
$45
Kalmar DRT 450 Reachstackers 45 Tonnes Workshop Manual VDRT02.02GB – PDF DOWNLOAD
Kalmar DRT 450 Reachstackers 45 Tonnes Workshop Manual VDRT02.02GB – PDF DOWNLOAD
FILE DETAILS:
Kalmar DRT 450 Reachstackers 45 Tonnes Workshop Manual VDRT02.02GB – PDF DOWNLOAD
Language : English
Pages : 842
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Kalmar DRT 450 Reachstackers 45 Tonnes Workshop Manual VDRT02.02GB – PDF DOWNLOAD
A Foreword............................................................. 5 A Foreword......................................................... 7 About the Workshop Manual..................................... 7 Reading instructions.......................................... 8 About the documentation....................................... 16 Feedback...................................................... 17 B Safety............................................................... 19 B Safety........................................................... 21 General safety information.................................... 21 Safety instructions........................................... 22 Environment................................................... 37 C Preventive maintenance............................................... 39 C Preventive maintenance........................................... 39 0 Complete machine..................................................... 41 0 Complete machine................................................. 43 1 Engine............................................................... 49 1 Engine........................................................... 51 1.1 Controls and instruments................................... 67 1.1.1 Ignition............................................. 67 1.1.2 Accelerator.......................................... 67 1.2 Fuel system................................................ 68 1.2.1 Fuel tank............................................ 68 1.2.2 Sensor fuel level.................................... 68 1.2.5 Make-contact (closing switch) water in fuel.......... 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 1.7.4 Radiator and expansion tank.......................... 72 1.7.5 Cooling fan.......................................... 73 1.7.7 Coolant.............................................. 74 1.9 Control system, engine..................................... 78 1.9.1 Engine control unit.................................. 78 1.11 Start/stop................................................ 79 1.11.1 Starter motor....................................... 79 1.11.2 Stopping device..................................... 79 2 Transmission......................................................... 81 2 Transmission..................................................... 83 2.1 Controls and instruments................................... 89 2.1.1 Gear selector and multi-function lever............... 89 2.2 Torque converter/Clutch system............................. 90 2.2.1 Flex plates.......................................... 90 2.6 Lubrication system......................................... 93 2.6.3 Oil cooler........................................... 96 2.7 Cooling system............................................. 98 2.7.3 Oil cooler........................................... 98 2.8 Control system, transmission............................... 99 2.8.1 Transmission control unit............................ 99 2.8.2 Break contact (opening switch) declutch.............. 99 2.8.3 Transmission cable harness........................... 99 3 Power transmission...................................................101 3 Power transmission...............................................103 3.2 Propeller shaft............................................103 3.3 Drive axle.................................................104 4 Brakes...............................................................109 4 Brakes...........................................................111 4.1 Controls and instruments...................................111 4.1.1 Brake pedal..........................................111 4.3 Power-assisted brake system................................113 4.3.1 Brake oil pump.......................................114 4.3.2 Brake oil filter.....................................118 4.3.3 Accumulator charging valve...........................119 4.3.4 Accumulator..........................................122 4.3.5 Brake valve..........................................126 4.3.6 Drive axle block.....................................130 4.3.7 Break contact (opening switch) brake oil pressure....131 4.3.8 Make-contact (closing switch) brake lights...........133 4.3.9 Wheel brakes.........................................134 4.3.10 Pipes and hoses.....................................137 4.5 Parking brake system.......................................138 4.5.1 Brake oil pump.......................................139 4.5.2 Brake oil filter.....................................139 4.5.3 Solenoid valve parking brake.........................139 4.5.4 Parking brake unit...................................140 4.5.5 Break contact (opening switch) parking brake.........144 4.5.6 Pipes and hoses......................................144 4.8 Temperature control, cleaning and oil brake system.........145 4.8.1 Brake oil tank.......................................146 4.8.3 Brake oil pump.......................................146 4.8.4 Accumulator charging valve...........................146 4.8.5 Drive axle block.....................................146 4.8.6 Wheel brakes.........................................146 4.8.7 Oil cooler...........................................147 4.8.8 Cooling fan..........................................148 4.8.9 Thermal bypass valve.................................148 4.8.10 Sensor, oil temperature brake system................149 4.8.11 Breather filter.....................................150 4.8.12 Brake oil filter....................................151 4.8.13 Pipes and hoses.....................................152 4.8.14 Oil, brake system...................................152 5 Steering.............................................................155 5 Steering.........................................................157 5.2 Power assisted system......................................157 5.2.1 Hydraulic oil pump...................................158 5.2.2 Priority valve.......................................158 5.2.3 Steering valve.......................................162 5.2.4 Steering cylinder....................................165 5.2.5 Steering axle cradle.................................167 5.2.6 Link arm.............................................168 5.2.7 Wheel spindle........................................168 5.2.8 Wheel hub............................................168 5.2.13 Pipes and hoses.....................................168 5.2.21 Valve block servo pressure..........................168 6 Suspension...........................................................169 6 Suspension.......................................................171 6.2 Suspension.................................................171 6.2.1 Steering axle cradle.................................173 6.2.2 Wheel spindle........................................175 6.2.3 Wheel hub............................................179 6.3 Tyres and rims.............................................184 6.3.1 Tyres................................................186 6.3.2 Rim..................................................187 6.3.3 Nut, washer and clamp................................188 7 Load handling........................................................191 7 Load handling....................................................193 7.1 Controls and instruments...................................194 7.1.1 Control lever........................................194 7.1.2 Switch, lock twistlocks..............................195 7.2 Lift and lower.............................................196 7.2.1 Hydraulic oil pump...................................199 7.2.2 Servo filter.........................................199 7.2.4 Accumulator servo circuit............................200 7.2.5 Control valve lift, lower and extension..............202 7.2.7 Valve block lift cylinder............................203 7.2.8 Lift cylinder........................................207 7.2.9 Sensor, hydraulic pressure lift cylinder.............211 7.2.10 Lift boom...........................................214 7.2.11 Sensor boom angle...................................214 7.2.12 Pipes and hoses.....................................214 7.2.17 Valve block servo pressure..........................215 7.3 Extension..................................................216 7.3.1 Hydraulic oil pump...................................219 7.3.2 Servo filter.........................................219 7.3.4 Accumulator servo circuit............................219 7.3.5 Control valve lift, lower and extension..............219 7.3.7 Valve block, extension cylinder......................220 7.3.8 Extension cylinder...................................220 7.3.10 Lift boom...........................................225 7.3.11 Sensor boom length..................................227 7.3.12 Pipes and hoses.....................................227 7.3.17 Valve block servo pressure..........................227 7.4 Side shift.................................................228 7.4.1 Hydraulic oil pump...................................229 7.4.3 Control valve, attachment............................230 7.4.5 Side shift cylinder..................................234 7.4.6 Side shift frame.....................................235 7.4.7 Main beam, attachment................................238 7.4.8 Relief valve, attachment.............................239 7.4.9 Pipes and hoses......................................239 7.4.11 Valve block servo pressure..........................239 7.5 Spreading (positioning)....................................240 7.5.1 Hydraulic oil pump...................................242 7.5.3 Control valve, attachment............................242 7.5.5 Valve block spreader motor...........................243 7.5.6 Spreading (positioning) motor........................243 7.5.7 Spreader chains......................................247 7.5.8 Spreader beam........................................254 7.5.9 Main beam, attachment................................256 7.5.10 Position sensor, spreading..........................256 7.5.11 Relief valve, attachment............................256 7.5.12 Pipes and hoses.....................................256 7.5.16 Valve block servo pressure..........................256 7.6 Rotation...................................................257 7.6.1 Hydraulic oil pump...................................258 7.6.3 Control valve, attachment............................259 7.6.5 Valve block rotation motor...........................260 7.6.6 Rotation motor unit..................................261 7.6.7 Rotation bar.........................................264 7.6.8 Ring gear............................................266 7.6.9 Side shift frame.....................................267 7.6.11 Relief valve, attachment............................267 7.6.12 Pipes and hoses.....................................268 7.6.14 Valve block servo pressure..........................268 7.9 Load carrier...............................................269 7.9.1 Twistlocks...........................................269 7.10 Other functions...........................................277 7.10.2 Weight indicator....................................277 7.10.3 Container counter...................................279 7.10.4 Synchronised lift...................................281 8 Control system.......................................................283 8 Control system...................................................285 8.1 Controls and instruments...................................286 8.1.10 Error code menu.....................................286 8.2 Monitoring.................................................289 8.2.1 Overload system......................................289 8.2.2 Bypass...............................................292 8.2.3 Speed limitation.....................................292 8.4 Diagnostics................................................293 8.4.1 CAN/POWER............................................295 8.4.2 LIGHTS...............................................309 8.4.3 CAB..................................................322 8.4.4 CLIMATE..............................................330 8.4.5 HYD..................................................336 8.4.6 ENGINE...............................................341 8.4.7 TRANSM...............................................347 8.4.8 BOOM.................................................354 8.4.9 ATTACH...............................................361 8.4.10 OP..................................................373 8.4.11 EXTRA...............................................377 8.4.13 RMI.................................................377 8.5 Setup......................................................378 8.5.1 Initiation...........................................378 8.5.2 Calibration..........................................392 9 Frame, body, cab and accessories.....................................399 9 Frame, body, cab and accessories.................................401 9.1 Controls and instruments...................................401 9.1.1 Gear selector and multi-function lever...............406 9.1.22 Switch, direction indicators........................407 9.2 Safety and emergency equipment.............................408 9.2.1 Control breaker......................................408 9.2.2 Seat belt............................................408 9.2.3 Fire extinguisher....................................408 9.2.4 Buzzer...............................................408 9.3 Seat.......................................................409 9.3.1 Seat cushion.........................................412 9.3.2 Back rest cushion....................................413 9.3.3 Heating coil.........................................413 9.3.4 Bumper...............................................414 9.3.5 Air suspension.......................................414 9.3.6 Mechanical seat adjustment...........................415 9.3.8 Arm rest.............................................415 9.3.9 Sensor, operator-in-seat.............................415 9.4 Heating, ventilation and air conditioning..................417 9.4.1 Fresh air filter.....................................424 9.4.2 Fresh air and recirculation damper...................425 9.4.3 Cabin fan............................................428 9.4.4 Heat exchanger heat..................................431 9.4.5 Water valve..........................................434 9.4.6 Sensor, engine temperature...........................434 9.4.7 Compressor...........................................435 9.4.8 Condenser............................................438 9.4.9 Receiver drier.......................................440 9.4.10 Pressure switch.....................................440 9.4.11 Expansion valve.....................................442 9.4.12 Sensor, temperature refrigerant.....................443 9.4.13 Heat exchanger, cooling.............................445 9.4.14 Air distributor.....................................446 9.4.15 Defroster nozzles...................................447 9.4.16 Sensor, temperature outlet fan......................448 9.4.17 Sensor cab temperature..............................449 9.4.18 Sensor, ambient temperature.........................450 9.5 Wiper/washer system........................................451 9.5.1 Wiper front..........................................451 9.5.2 Wiper roof...........................................451 9.5.3 Wiper rear...........................................451 9.5.4 Washer motor and reservoir...........................451 9.5.5 Wiper motor front....................................452 9.5.6 Wiper motor roof.....................................453 9.5.7 Wiper motor rear.....................................454 9.6 Lighting system............................................455 9.6.1 Headlights...........................................459 9.6.2 Running lights.......................................459 9.6.3 Tail lights..........................................460 9.6.4 Brake lights.........................................460 9.6.5 Back-up lights.......................................460 9.6.6 Direction indicators.................................461 9.6.7 Flashing hazard lights...............................461 9.6.8 Revolving beacon.....................................461 9.6.9 Working lights, cab..................................462 9.6.10 Work light boom.....................................462 9.6.11 Working lights, attachment..........................463 9.6.12 Interior lighting...................................463 9.7 Signalling system..........................................464 9.7.1 Horn.................................................466 9.7.2 Flashing hazard lights...............................466 9.7.3 Revolving beacon.....................................466 9.7.4 Warning parking brake................................467 9.7.5 Back-up alarm........................................467 9.8 Entertainment and communication............................468 9.9 Glass/windows/mirrors......................................469 9.9.1 Windscreen...........................................470 9.9.2 Side window..........................................473 9.9.3 Roof window..........................................475 9.9.4 Rear window..........................................476 9.9.5 Rear view mirror.....................................476 9.10 Cab structure and suspension..............................477 9.10.1 Cab frame...........................................477 9.10.2 Doors...............................................477 9.10.3 Cab substructure....................................478 9.10.4 Sliding cab.........................................478 9.11 Cab interior..............................................479 9.11.1 Instrument and control panels.......................479 9.11.2 Interior fittings, plastic..........................480 9.11.3 Interior fittings, textile..........................480 9.11.4 Floor covering......................................480 9.11.5 Insulation..........................................480 9.12 Chassis...................................................481 9.13 Body structure............................................482 9.13.1 Wings...............................................482 9.13.2 Hood engine compartment.............................482 9.13.3 Footsteps and hand rail.............................482 9.13.4 Counterweights......................................483 9.15 Paint/coatings............................................484 10 Common hydraulics...................................................485 10 Common hydraulics...............................................487 10.2 Safety valves.............................................487 10.2.1 Accumulator drain valve.............................487 10.2.2 Relief valve, attachment............................487 10.2.3 Pipes and hoses.....................................488 10.2.4 Pressure limiting valve.............................488 10.3 Tanks and accumulators....................................489 10.3.1 Tank................................................489 10.3.2 Pipes and hoses.....................................489 10.4 Pumps.....................................................490 10.4.1 Gear pump with fixed displacement...................490 10.4.2 Axial piston pump with variable displacement........494 10.4.3 Pipes and hoses.....................................504 10.5 Hoses, pipes and valves...................................505 10.5.1 Pipes and hoses.....................................505 10.5.2 Priority valve......................................505 10.5.7 Valve block servo pressure..........................506 10.6 Temperature control, cleaning and hydraulic oil...........509 10.6.2 Hydraulic oil cooler................................510 10.6.3 Cooling fan.........................................511 10.6.4 Sensor hydraulic oil temperature....................511 10.6.5 Bypass valve, cooler................................513 10.6.6 Breather filter hydraulic oil tank..................514 10.6.7 Hydraulic oil filter................................515 10.6.8 Hydraulic oil.......................................517 10.6.9 Fine filter hydraulic oil...........................517 10.6.10 Pipes and hoses....................................518 10.7 Other.....................................................519 10.7.1 Hydraulic cylinders.................................519 11 Common electrics....................................................529 11 Common electrics................................................531 11.2 Electric protection.......................................531 11.2.1 Battery disconnector................................531 11.2.2 Fuses...............................................531 11.2.3 Control breaker.....................................531 11.3 Batteries.................................................532 11.3.1 Start battery.......................................532 11.4 Alternator................................................534 11.4.1 Alternator..........................................534 11.5 Distribution of electricity...............................535 11.5.1 Voltage feed........................................535 11.5.2 Electronic box......................................542 11.5.3 Control units.......................................544 11.5.5 Cable harness.......................................553 11.6 Communication.............................................560 11.6.1 CAN bus.............................................560 11.6.2 Redundant CAN bus...................................562 11.6.3 CAN bus drive-train.................................564 11.6.4 Communication between PC and machine................565 D Error codes..........................................................567 D Error codes......................................................569 Engine........................................................574 Transmission..................................................618 Control system................................................653 E Schematics...........................................................675 E Schematics.......................................................677 Common hydraulics.............................................677 Common electrics..............................................682 A50001.0100................................................687 0 | Wiring DRFC 400-450................................687 0.0_1 | Wiring Cross References........................688 0.0_2 | Wiring Cross References........................689 0.0_3 | Wiring Cross References Opt....................690 0.0_4 | Wiring Cross References Att....................691 0.0_5 | Wiring Cross References Att....................692 0.0_6 | Wiring Cross References Att Combi..............693 1.0_1 | Wiring Motor Volvo 1240&1250...................694 1.0_2 | Wiring Motor Cummins...........................695 1.0_3 | Wiring Motor Cummins...........................696 1.0_4 | Wiring Motor Volvo D13.........................697 1.1_1 | Wiring Drivetrain..............................698 2.0_1 | Wiring Dana TE 32000...........................699 2.0_2 | Wiring Dana TE 32000...........................700 2.0_3 | Wiring Dana TE 32000...........................701 2.0_1A1 | Wiring Dana TE 32000FF.......................702 2.0_1A2 | Wiring Dana TE 32000FF.......................703 2.0_1A3 | Wiring Dana TE 32000FF.......................704 2.0_1B1 | Wiring diagram gear ZF.......................705 2.1_1 | Wiring Drivetrain..............................706 4.0_1 | Wiring Brakes..................................707 4.0_2 | Wiring Brakes..................................708 5.2_1 +CAB | Wiring Micro lever/wheel..................709 5.2_2 | Wiring Micro lever/wheel.......................710 5.2_3 | Wiring Micro lever/wheel and Combi Att.........711 5.2_4 | Wiring Micro lever/wheel and Combi Att.........712 7.1_1 | Wiring Joystick................................713 7.2_1 +CHASSIS | Wiring Boom Up/Down...................714 7.3_1 | Wiring Boom in/out.............................715 7.5_1 +ATTACHMENT | Wiring Spreading Valves............716 7.5_2 | Wiring Spreading Auto..........................717 7.5_3 | Wiring Spreading Sensors.......................718 7.6_1 | Wiring Rotation................................719 7.7_1 | Wiring Tilt lock...............................720 7.7_2 | Wiring Tilt + Levelling........................721 7.7_3 | Wiring Tilt + Levelling........................722 7.9_1 +ATTACHMENT | Wiring Twistlock...................723 7.9_2 | Wiring Twistlock...............................724 7.9_3 +CAB | Wiring Combi Att..........................725 7.9_4 +ATTACHMENT | Wiring Combi Att...................726 7.9_5 +ATTACHMENT | Wiring Combi Att...................727 7.9_6 +ATTACHMENT | Wiring Combi Att...................728 7.9_7 +ATTACHMENT | Wiring Combi Att...................729 7.9_8 +ATTACHMENT | Wiring Combi Att...................730 7.9_9 +ATTACHMENT | Wiring Combi Att...................731 7.9_10 +ATTACHMENT | Wiring Combi Att..................732 7.9_11 +ATTACHMENT | Wiring Combi Att..................733 7.9_12 +ATTACHMENT | Wiring Combi Att..................734 7.9_13 +ATTACHMENT | Wiring Combi Att..................735 7.9_14 +ATTACHMENT | Wiring Combi Att..................736 7.9_15 | Wiring Over Height............................737 7.9_16 | Wiring Over Height............................738 7.9_17 | Wiring Combi Att..............................739 7.9_18 | Wiring Fork attachment........................740 7.10_1 | Wiring Hyd Support jacks......................741 7.10_2 | Wiring Hyd Support jacks......................742 7.10_3 | Wiring Printer................................743 8.2_1 +CHASSIS | Wiring OP + Scale.....................744 8.2_2 +CHASSIS | Wiring OP + Scale.....................745 8.2_3 | Wiring Override................................746 8.2_4 | Wiring RMI.....................................747 9.1_1 | Wiring OPT Sensors Instr.......................748 9.1_2 | Wiring Option..................................749 9.1_3 | Wiring Option..................................750 9.1_4 | Wiring Sensors Instr...........................751 9.1_5 | Wiring Option Cabin............................752 9.1_6 | Wiring Option, Boom nose.......................753 9.1_7 | Wiring Option..................................754 9.3_1 +CAB | Wiring Cab Seat OPT.......................755 9.3_2 +CAB | Wiring Cab Seat OPT.......................756 9.4_1 +CAB | Wiring Climate Control....................757 9.4_2 +CAB | Wiring Climate Control....................758 9.4_3 | Wiring Climate Control.........................759 9.5_1 +CAB | Wiring Wiper function.....................760 9.6_1 +CAB | Wiring Work Light.........................761 9.6_2 +ATTACHMENT | Wiring Opt. Work Light Att.........762 9.6_3 | Wiring OPT Work Light Boom.....................763 9.6_5 | Wiring Lights..................................764 9.6_6 | Wiring Lights..................................765 9.6_7 | Wiring Lights..................................766 9.6_8 | Wiring Lights..................................767 9.6_9 | Wiring Step In Light...........................768 9.6_10 | Wiring Opt. Work Light Chassis................769 9.7_1 | Wiring Alarm, Soundsignals.....................770 9.7_2 | Wiring Alarm, Soundsignals.....................771 9.7_3 | Wiring Flashing indicator, Hazard..............772 9.7_4 | Wiring Reverse alarm...........................773 9.8_1 | Wiring Radio...................................774 9.9_9 | Wiring Camera..................................775 9.10_1 | Wiring Sliding/Vertically adjustable Ca.......776 9.10_2 | Wiring Cab tilt...............................777 9.14_1 | Wiring Central Lubrication....................778 10.0_1 | Wiring Hydraulics.............................779 11.5_1 +CHASSIS | Wiring Power.........................780 11.5_2 +CAB | Wiring Power.............................781 11.5_3 +CAB | Wiring Power.............................782 11.5_4 | Wiring Power..................................783 11.5_5 | Wiring Power..................................784 11.5_6 | Wiring Power..................................785 11.5_7 | Wiring 24V....................................786 11.5_8 | Wiring 12V + Com. Radio.......................787 11.5_9 | Wiring Power Att..............................788 11.5_10 | Wiring Power 230V Inverter...................789 11.6_3 | Wiring CAN-BUS Opt. chassis KDU...............790 11.6_4 | Wiring CAN-BUS Att............................791 11.6_5 | Wiring CAN-BUS Att............................792 11.6_6 | Wiring CAN-BUS Att............................793 A58687.0100................................................794 1.0_1A1................................................794 1.0_1A2................................................795 1.0_1B1................................................796 2.0_1A1................................................797 2.0_1A2................................................798 List of Components.........................................799 F Technical data.......................................................817 F Technical data...................................................819 G Terminology and index................................................833 G Terminology and index............................................835 Terminology...................................................835 Index.........................................................837
DESCRIPTION:
Kalmar DRT 450 Reachstackers 45 Tonnes Workshop Manual VDRT02.02GB – PDF DOWNLOAD
About the Workshop Manual:
General:
- Thank you for choosing Cargotec as your machine supplier. We hope
that we’ll meet your expectations.
Conditions:
- The instructions are based on the use of generally available standard
tools. All lifting devices, for example, slings, straps, ratchet blocks,
etc., must meet governing national standards and regulations for lifting
devices. - Cargotec will not accept any responsibility for modifications performed
without permission from Cargotec or if other lifting devices, tools or
work methods are used other than those described in this manual.
About the machine version:
- The information in this publication corresponds to the machine’s design
and appearance at the time of delivery from Cargotec. Due to customizations,
there may be variations and/or deviations. - Cargotec reserves the right to modify specifications and equipment
without prior notice. All information and data in this manual are valid at
the time of publication.
IMAGES PREVIEW OF THE MANUAL:
More products
