Kalmar DRD450-80S4X Maintenance Manual Download

Page: 469 / 600

Power

2:11

CAN

2:13

2:15

2:16

Pin Number

Drawing

Function

Type

KDU contact K2

-D791-4

+ATTACHMENTA43068.0100/2.B7

A44875.0300/1.D7

+ATTACHMENTA43068.0100/2.B6

+ATTACHMENT

CAN CIRCUIT

POWER SUPPLY

Emergencystop

Power

2:11

CAN

2:13

2:15

2:16

Pin Number

Drawing

Function

Type

KDU contact K2

-D791-3

+ATTACHMENTA43068.0100/2.E7

A44875.0300/1.B7

+ATTACHMENTA43068.0100/2.D6

+ATTACHMENT

CAN CIRCUIT

POWER SUPPLY

Emergencystop

KDU contact K1

1:1

1:3

1:2

1:4

1:5

1:6

1:9

1:8

1:10

1:11

1:12

1:7

1:13

1:14

1:17

1:16

1:18

1:19

1:15

1:20

1:22

1:21

1:23

1:24

1:25

1:28

1:27

1:29

1:30

1:31

1:26

1:32

1:33

1:36

1:35

1:37

1:38

1:39

1:34

1:40

1:41

1:42

Pin Number

Drawing

Function

Type

KDU contact K1

Pin Number

Drawing

Function

Type

-D791-4

+ATTACHMENTA43068.0100/12.B2

A44910.0200/1.B2

+ATTACHMENTA43068.0100/3.C2

+ATTACHMENTA43068.0100/3.A8

+ATTACHMENT

+ATTACHMENTA43068.0100/4.C2

+ATTACHMENTA43068.0100/11.A2

+ATTACHMENTA43068.0100/3.A2

+ATTACHMENTA43068.0100/3.B2

+ATTACHMENTA43068.0100/7.E8

A44910.0200/1.B8

+ATTACHMENTA43068.0100/8.E8

+ATTACHMENTA43068.0100/7.B8

+ATTACHMENTA43068.0100/8.C8

+ATTACHMENTA43068.0100/7.C8

+ATTACHMENTA43068.0100/8.C8

+ATTACHMENTA43068.0100/11.B2

+ATTACHMENTA43068.0100/7.A2

+ATTACHMENTA43068.0100/7.D8

+ATTACHMENTA43068.0100/11.B2

+ATTACHMENTA43068.0100/3.D2

+ATTACHMENTA43068.0100/3.E2

+ATTACHMENTA43068.0100/4.A2

+ATTACHMENTA43068.0100/4.B2

+ATTACHMENTA43068.0100/4.A8

+ATTACHMENTA43068.0100/7.B8

+ATTACHMENTA43068.0100/8.C8

+ATTACHMENTA43068.0100/11.A8

+ATTACHMENTA43068.0100/11.C2

+ATTACHMENTA43068.0100/8.A8

+ATTACHMENTA43068.0100/8.D8

+ATTACHMENTA43068.0100/4.D2

WORK LIGHT

1.5A

TILT OUT

1.5A

TILT IN

1.5A

FRONT KNEE IN

1.5A

FRONT KNEE OUT

0V reference

0V FOR PIN 2, 3, 4, 5, 30, 31

1.5A

LOWERING REAR LEG

1.5A

REAR LEG UP

1.5A

FRONT LEGS UPPER POSITION

In/Output

CLAMPING IN

In/Output

CLAMPING OUT

Input

ALIGNMENT FRONT LEG

PWM

TILT OUT

PWM

TILT IN

Input

ALIGNMENT REAR LEG

Analog Input

FRONT KNEE

Analog Input

REAR LEG

Analog Input

FRONT LEG

Analog Input

REAR LEG

1.5A

FRONT LEGS LOWER POSITION

In/Output

POWER SUPPLY FOR SENSORS

Input

CLAMP FRONT LEG

1.5A

CLAMP POSITION FRONT LEGS

1.5A

REAR KNEE IN

1.5A

REAR KNEE OUT

1.5A

LOWERING FRONT LEG

1.5A

FRONT LEG UP

0V reference

0V FOR PIN 7, 9, 32, 33, 42

0V reference

SENSORS FRONT KNEE AND LEG

0V reference

SENSORS REAR KNEE AND LEG

0V reference

0V FOR INDICATION LAMPS

1.5A

CLAMP POSITION REAR LEGS

In/Output

DRIVING POSITION

Input

CLAMP REAR LEG

DRIVING POSITION

KDU contact K1

1:1

1:3

1:2

1:4

1:5

1:6

1:9

1:8

1:10

1:11

1:12

1:7

1:13

1:14

1:17

1:16

1:18

1:19

1:15

1:20

1:22

1:21

1:23

1:24

1:25

1:28

1:27

1:29

1:30

1:31

1:26

1:32

1:33

1:36

1:35

1:37

1:38

1:39

1:34

1:40

1:41

1:42

Pin Number

Drawing

Function

Type

KDU contact K1

Pin Number

Drawing

Function

Type

-D791-3

+ATTACHMENTA43068.0100/12.C2

A44910.0200/1.D2

A44910.0200/1.E2

+ATTACHMENTA43068.0100/5.C2

+ATTACHMENTA43068.0100/5.A8

+ATTACHMENT

+ATTACHMENTA43068.0100/6.C2

+ATTACHMENTA43068.0100/11.C2

+ATTACHMENTA43068.0100/5.A2

+ATTACHMENTA43068.0100/5.B2

+ATTACHMENTA43068.0100/9.E8

A44910.0200/1.C2

A44910.0200/1.D8

A44910.0200/1.E8

+ATTACHMENTA43068.0100/10.E8

+ATTACHMENTA43068.0100/9.B8

+ATTACHMENTA43068.0100/10.C8

+ATTACHMENTA43068.0100/9.C8

+ATTACHMENTA43068.0100/10.C8

+ATTACHMENTA43068.0100/11.D2

+ATTACHMENTA43068.0100/9.A2

+ATTACHMENTA43068.0100/9.D8

+ATTACHMENTA43068.0100/11.D2

+ATTACHMENTA43068.0100/5.D2

+ATTACHMENTA43068.0100/6.A2

+ATTACHMENTA43068.0100/6.B2

+ATTACHMENTA43068.0100/6.A8

+ATTACHMENTA43068.0100/9.B8

+ATTACHMENTA43068.0100/10.C8

+ATTACHMENTA43068.0100/11.C8

+ATTACHMENTA43068.0100/11.E2

+ATTACHMENTA43068.0100/10.A8

+ATTACHMENTA43068.0100/10.D8

+ATTACHMENTA43068.0100/6.D2

WORK LIGHT

1.5A

LEVELLING REIGHT

1.5A

LEVELLING LEFT

1.5A

FRONT KNEE IN

1.5A

FRONT KNEE OUT

0V reference

0V FOR PIN 2, 3, 4, 5, 30, 31

1.5A

LOWERING REAR LEG

1.5A

REAR LEG UP

1.5A

IND. ALIGNMENT RIGHT FRONT

In/Output

CLAMPING IN

In/Output

CLAMPING OUT

Input

ALIGNMENT FRONT LEG

LEVELLING

PWM

LEVELLING RIGHT

PWM

LEVELLING LEFT

Input

ALIGNMENT REAR LEG

Analog Input

FRONT KNEE

Analog Input

REAR LEG

Analog Input

FRONT LEG

Analog Input

REAR LEG

1.5A

IND. ALIGNMENT RIGHT REAR

In/Output

POWER SUPPLY FOR SENSORS

Input

CLAMP FRONT LEG

1.5A

IND. ALIGNMENT LEFT FRONT

1.5A

REAR KNEE IN

1.5A

REAR KNEE OUT

1.5A

LOWERING FRONT LEG

1.5A

FRONT LEG UP

0V reference

0V FOR PIN 7, 9, 32, 33, 42

0V reference

SENSORS FRONT KNEE AND LEG

0V reference

SENSORS REAR KNEE AND LEG

0V reference

0V FOR ALIGNMENT LAMPS

1.5A

IND. ALIGNMENT LEFT REAR

In/Output

DRIVING POSITION

Input

CLAMP REAR LEG

DRIVING POSITION

Benämning

Utgåva/Issue

Ritn.nr./ Drawing No.

Name

Klass/Class

H.Grp:

234

Godk/Appr

Ritad/Drawn

Konstr/Design

Datum/Date

Sign.

Ref.

Ruta

No.

Ändring

Design change

T=Tillk/Added U=Utgår/Deleted V=Var/Was

Ändring nr

Change No.

Sign.

Datum

Date

Sq.

Denna ritning får ej utan vårt medgivande kopieras.

Den får ej heller delgivas annan eller annars obe-

hörigen användas. Överträdelse härav beivras med

stöd av gällande lag.

This document must not be copied without our

written permission and the contents thereof must

not be imparted to a third party nor be used for any

unauthorized purpose. Contravention will be pro-

secuted.

DRAWING

E³

Blad/Sheet

Produkt/Product

Huvudnr./Project no.

A43044.0500

Krets Korsreferenser Agg Kombi

Circuit Cross References Att Combi

DRFA 400-450

FSN

030218

RKO

031009

Reference Text Adjustment, Sync. Harnesses.

041478

TKB

040930

A45209.0100

Left side

Right side

https://www.forkliftpdfmanuals.com/

Summary of Contents for DRD450-80S4X

Page 1: ...veline axle 4 Brakes 5 Steering 6 Suspension 7 Load handling 8 Control system 9 Frame body cab and accessories 10 Common hydraulics 11 Common electrics 12 Common pneumatics D Error codes E Schematics...

Page 2: ...https www forkliftpdfmanuals com...

Page 3: ...ns 4 Warning information 4 Important information 4 Read operator s manual 4 Read maintenance manual 4 Maintenance manual s content 5 Function group structure 6 References between different information...

Page 4: ...UDRF01 04GB Maintenance manual DRF 400 450 2 AForeword https www forkliftpdfmanuals com...

Page 5: ...y for modifications performed without permission from Kalmar Industries or if other lift ing devices tools or work methods are used other than those de scribed in this manual page Storage NOTE The mai...

Page 6: ...s manual Read the operator s manual The symbol to the left is used in certain cases on the machine and refers to important information in the operator s manual page Read maintenance manual Read the m...

Page 7: ...views and eventual in accuracies B Safety Keep in mind for your safety C Preventive maintenance General information about preventive maintenance of the machine 0 Complete machine Technical descriptio...

Page 8: ...8 7 Oil cooler may be included for some machines but is missing for others The function groups are intended to be used as search terms to find different types of information between different sections...

Page 9: ...duct al ternatives and optional equipment handling of the modules differs depending on if it is the one or the other that is described see be low Special equipment is not described in the manual When...

Page 10: ...ns and product alter natives For more information about handling of product alternatives and optional equipment see Product alternatives and optional equipment page 7 The machine card is delivered wit...

Page 11: ...ustration Function descriptions use symbols to illustrate components such as valves sensors etc Example of function description UDRF01 04S Underh llamamual DRF 400 450 2 4 Bromsar 4 3 Servobromssystem...

Page 12: ...is pressure check connection for checking pressure signal 3 Flag diagnostic test indicates that signal can be checked with diagnostic test see section 8 Control system group 8 4 Diag nostics 4 Illust...

Page 13: ...ement 8 Electric motor 9 Accumulator 10 Disc brake 11 Filter 12 Radiator 13 Bulb 14 Control system two control units with CAN buss 15 Restriction 16 Adjustable restriction 17 Inductive position sensor...

Page 14: ...ine card are supplied with the machine as a separate documentation kit Supplementary documentation There are Supplementary documentation that can be ordered for the machine in the form of a Workshop m...

Page 15: ...n Your feedback is important to be able to improve the information Copy this form write down your views and send it to us Thank you for your participation To Kalmar Industries AB Product Support Torgg...

Page 16: ...UDRF01 04GB Maintenance manual DRF 400 450 14 A Foreword Feedback https www forkliftpdfmanuals com...

Page 17: ...position 4 Hydraulic and brake systems depressurizing 5 Clothing etc 6 Several mechanics on the same machine 6 Working under machine 7 Lifting heavy components 7 Vibrations 8 Noise 8 Solvents 9 Fire...

Page 18: ...UDRF01 04GB Maintenance manual DRF 400 450 2 BSafety https www forkliftpdfmanuals com...

Page 19: ...equipment and tools for the job wear the correct clothes use common sense and work carefully do not take any risks Kalmar Industries has in this publication documented and warned for situations and ri...

Page 20: ...9 Fire and explosion risks page 9 Fluid or gas under pressure page 10 Coolant page 11 Refrigerant page 12 Air pollution page 12 Tensioned springs page 13 Electric motors page 14 Rotating components a...

Page 21: ...start key to position I and activate extension out a dis tinct hissing sound is heard if there is pressure in the hydraulic system Activate lift extension and sideshift several times 3 Turn the start...

Page 22: ...s on the same machine Risks Work with wheels or axle suspension mountings etc may result in components on the other side moving and causing damage injury Movements performed from the operator s statio...

Page 23: ...nd securely Lifting tools should be inspected and type approved for use page Lifting heavy components Risks Unsuitable lift slings straps etc may break or slip The centre of gravity balance point of t...

Page 24: ...ools to hands Especially when fingers are cold Safety actions Use heavy gloves to protect against cold and somewhat against vi brations Switch between work duties to give the body time to rest Vary wo...

Page 25: ...ventilation or wear ing a fresh air mask or respiratory device with a suitable filter for the toxic gases Never leave a solvent container without tight sealing lid Use solvents with low content of aro...

Page 26: ...rents can short circuit the electronics destroy ex pensive equipment and may also cause an explosion or fire Welding work must never be carried out on painted surfaces re move paint by blasting at lea...

Page 27: ...er depressurizing Never use your hands directly to detect a leak A fine high pres sure stream from a hydraulic hose can easily penetrate a hand and causes very severe injuries page Coolant The coolant...

Page 28: ...ulations Use protective gloves and safety glasses if there s a risk of leaks Make sure that heat producing sources or objects are not close by cigarette glow welding flame page Air pollution Air pollu...

Page 29: ...ng with corrosive substances Avoid unnecessary operation of the machine inside the work shop Connect an air extractor to the exhaust pipe so that the exhaust fumes are removed from the workshop page T...

Page 30: ...e belts Propeller shafts Drills Grinders Risks Rotating components for example fans or shafts can cause severe injuries if touched Drills lathes grinders or other machines with rotating parts can caus...

Page 31: ...n the wheel Check that tyres rims and lock rings aren t damaged Never re pair damaged rims or lock rings Use protective screen and safety glasses DANGER Tyres should be regarded as pressurized contain...

Page 32: ...n an envi ronmentally safe manner and according to national regulations Oils and fluids Oils freely discharged cause environmental damage and can also be a fire hazard Therefore when emptying and drai...

Page 33: ...mm mm Table of Contents C Preventive maintenance Preventive maintenance 3 Preventive maintenance general 3 Preventive maintenance work instructions 3 Check and service log 4 50h check 5 Service sched...

Page 34: ...UDRF01 04GB Maintenance manual DRF 400 450 2 C Preventive maintenance https www forkliftpdfmanuals com...

Page 35: ...at an interval of 4 5 operat ing hours up to approx 40 50 operating hours 2 For new machine checking actions shall be performed after 50 hours of operation see 50h check page 5 Note completed 50h chec...

Page 36: ...heck 500h 500h service 1000h 1000h service 1500h 500h service 2000h 2000h service 2500h 500h service 3000h 1000h service 3500h 500h service 4000h 2000h service 4500h 500h service 5000h 1000h service 5...

Page 37: ...ne group 1 2 3 Fuel pre filter 2 Transmission Leakage check Oil level check Section 2 Transmission group 2 6 Lubrication Transmission oil filter changing Section 2 Transmission group 2 6 Lubrication 3...

Page 38: ...s group 9 10 4 Lon gitudinal displacement of cab 10 Common hydraulics Leakage check check tightening as needed Oil level check Section 10 Common hydraulics group 10 6 8 Hydraulic oil Fine filter hydra...

Page 39: ...g see Check and service log page 4 In the column for service below the following abbreviations are used R replace C check or inspection L lubrication Object action Service Comment Reference 500h 1500h...

Page 40: ...tion 1 Engine group 1 6 1 Air cleaning system Air filter safety cartridge C C R C R Changed every other time main cartridge is changed Fan belt C R C R C R Change when needed Bolted joints attach ment...

Page 41: ...Section 4 Brakes group 4 8 14 Oil brake system Breather filter R Section 4 Brakes group 4 8 11 Breather filter 5 Steering Link arms C L C L C L Check bearings Lubrication 500 hours page 14 6 Suspensi...

Page 42: ...a Section 7 Load handling group 7 6 6 Rotation motor unit Oil spreader motor unit R R For volume and quality see section F Technical data Section 7 Load handling group 7 5 6 Positioning mo tor Twistlo...

Page 43: ...9 Humidity filter Lighting and audible sig nals C C C Windshield wipers C C C Incl washer top up when needed 10 Common hydraulics Breather filter C R R R Change at indication Section 10 Common hydrau...

Page 44: ...clean as needed Boom Attachment Hydraulic sliding cab Cab lift and lowering Support jacks Test run Test run the machine and check Instruments Brakes Gearshifting All load handling functions Steering A...

Page 45: ...nce Preventive maintenance 13 page Washing CAUTION When using a high pressure washer to clean the ma chine do not aim the water jet directly at the radia tor or electrical components for example contr...

Page 46: ...where the wheel hangs freely 4 Grease the wheel hub until grease comes out at the seal on the hub s inside Lift the seal ring s lip with a small screwdriver to facilitate pressing out of air Grease u...

Page 47: ...nce 15 Link arms Grease points link arm 1 Outer bearing 2 Inner bearing 8 Grease both link arms outer and inner bearings with grease Brake pedal Grease points brake pedal 9 Grease the brake pedal s hi...

Page 48: ...spreader positioning completely 2 Turn off the engine and the main electric power 3 Grease all grease points on the machine with lubrication grease see section F Technical data Also perform a visual c...

Page 49: ...Wheel spindle 4 pcs 2 Mounting attachment 2 pcs 11 Wheel hub 2 pcs 3 Bearing rotation bar 4 pcs two per side brushing of ring gear 12 Joint steering axle 4 Chain and chain sprocket spreading 13 Glide...

Page 50: ...UDRF01 04GB Maintenance manual DRF 400 450 18 C Preventive maintenance Preventive maintenance IMPORTANT Wipe off surplus lubrication paste https www forkliftpdfmanuals com...

Page 51: ...tents 0 Complete machine Complete machine 3 Complete machine description 3 Troubleshooting general work instructions 4 Troubleshooting without an error code example 5 Troubleshooting with error code e...

Page 52: ...UDRF01 04GB Maintenance manual DRF 400 450 2 0 Complete machine https www forkliftpdfmanuals com...

Page 53: ...nents and functions for handling loads Loads are lifted with an attachment that is mounted on a liftable tel escopic boom Load handling is divided into the functions lift and lower extension sideshift...

Page 54: ...ion 1 Battery voltage should be 22 30 V Fuses check that they are intact 2 Check that all oil and fluid levels are normal Fuel Engine oil Transmission oil Oil for brake system Hydraulic oil Coolant Wa...

Page 55: ...draulic hoses page 8 6 If the leads or hoses between the components seem in order then check the component that receives the signal page Troubleshooting with error code example Error codes are strong...

Page 56: ...troubleshooting electric cabling and hydraulic hoses For electric cabling see Troubleshooting cable harness page 7 For hydraulic hoses see Troubleshooting hydraulic hoses page 8 8 If the cable is not...

Page 57: ...if there is open circuit NOTE Some components cannot be checked without power sup ply to the component In such an event proceed to point 5 a Measure resistance between connections for the compo nent...

Page 58: ...ere it is spliced 3 Locate the hose on the machine Start at one component and follow the hose to the next com ponent 4 Inspect the entire hose and splicing points with respect to chaf ing damage pinch...

Page 59: ...em 9 1 2 3 Fuel pre filter 10 1 2 4 Fuel filter 12 1 6 Air intake and exhaust outlet 14 1 6 1 Air cleaning system 14 1 7 Cooling system 15 1 7 2 Coolant filter 15 1 7 5 Cooling fan 18 1 7 7 Coolant 19...

Page 60: ...UDRF01 04GB Maintenance manual DRF 400 450 2 1Engine https www forkliftpdfmanuals com...

Page 61: ...aust emissions but also the power curve and torque curve page Engine alternative Volvo function description Engine TWD1240VE is a straight 6 cylinder 4 stroke turbocharged low emission diesel engine w...

Page 62: ...reather nipple cooling system 2 Sensor boost pressure and charge air temperature 3 Control unit engine D794 4 Intercooler 5 Sensor coolant temperature 6 Oil dipstick 7 Filling point engine oil 8 Fuel...

Page 63: ...onnection air cleaner 3 Turbocharger 4 Connection exhaust system 5 Connection radiator outlet 6 Connection expansion tank 7 Thermostat 8 Radiator 9 Transmission oil cooler 10 Thermostat transmission o...

Page 64: ...1 D790 2 D795 D797 R D794 P I II III 0 rpm kph bar C 1 7 2 4 M 5 6 3 12 H2O 11 10 9 8 SENSORS 1 Ignition S150 7 Accelerator pedal B690 2 Control unit cab D790 1 8 Make contact closing switch coolant...

Page 65: ...1 10 1 12 2 9 1 Position for compressor climate control unit 2 Fuel connection outlet 3 Control unit engine D794 4 Drain plug engine oil 5 Starter motor 6 Fuel connection inlet 7 Drain point condensat...

Page 66: ...tercooler outlet 7 Connection intercooler inlet 8 Sensor inlet temperature 9 Connection exhaust system 10 Sensor boost pressure 11 Connection expansion tank 12 Alternator sensor coolant temperature be...

Page 67: ...er nipples on the fuel filter s bracket and cylinder head 2 Place a receptacle under the fuel filter 3 Connect a transparent plastic hose to the bleeder nipple on the filter bracket Place the other en...

Page 68: ...l filter 2 Disconnect the hose in its attachments at position 1 and posi tion 3 3 Blow clean the hose with compressed air 1 2 3 Fuel pre filter page Fuel pre filter changing Volvo engine NOTE Avoid sk...

Page 69: ...hat the filter seals tight 12 Turn off the engine and remove the receptacle Handle the fuel as environmentally hazardous and inflammable waste page Fuel pre filter draining condensation water Volvo en...

Page 70: ...fuel filter 4 Remove the fuel filter with filter tool 5 Lubricate the O ring on the new fuel filter with engine oil 6 Fit the new fuel filter Tighten to contact and then another half to three quarter...

Page 71: ...by the filter s threaded connection on the filter holder and lubricate it with engine oil 7 Fill the new fuel filter with pure fuel 8 Lubricate the seal on the new fuel pre filter with engine oil 9 F...

Page 72: ...ee section B Safety 2 Clean the outside of the air filter housing 3 Remove the cap from the air filter housing 4 Remove the filter cartridge 5 Clean the particle outlet 6 Check the safety cartridge ch...

Page 73: ...ntal damage 1 Machine in service position see section B Safety 2 Close the shut off valve on the filter holder 3 Clean the area around the coolant filter 4 Place a receptacle under the coolant filter...

Page 74: ...450 16 1 Engine 1 7 2 Coolant filter A Position of coolant reservoir expansion tank B Filling point C Level marking MIN and MAX 12 Check the coolant level in the expansion tank top up if needed A 0048...

Page 75: ...filter with filter tool 6 Lubricate the O ring on the filter cartridge with engine oil 7 Fit the new filter Tighten to contact and then another half to three quarter turn 8 Open the shut off valve on...

Page 76: ...cab in the front position 2 Remove the cover plates over the engine and radiator 3 Wash the engine compartment 4 Machine in service position see section B Safety The figure shows engine alternative Cu...

Page 77: ...A low coolant level may cause engine damage or may cause the engine to stop 1 Machine in service position see section B Safety 2 If needed top up with water wintertime with at least 40 gly col For vo...

Page 78: ...ain plug engine from underneath 4 Remove the drain plug on the engine and drain the engine of oil Oil filter engine alternative Volvo TWD1240VE 1 By pass filter 2 Full flow filter 5 Place a receptacle...

Page 79: ...container handle the engine oil and fil ters as environmentally hazardous waste page Oil and oil filter change engine alternative Cummins 1 Run the engine until warm 2 Machine in service position see...

Page 80: ...ew filter Tighten the filter according to the instructions on the filter 11 When the oil has drained install the oil plug Torque with 88 Nm 12 Fill with engine oil For volume and grade see section F T...

Page 81: ...ngs MAX and MIN the oil level should be between these markings Wipe off the dipstick before checking NOTE The oil dipstick is long Use gloves 3 Fill engine oil position B as needed for volume see sect...

Page 82: ...controls the amount of fuel to the unit injectors by opening and closing a fuel valve by each injector The unit injectors are activated by an extra cam on the camshaft which presses to gether the inje...

Page 83: ...ing is on The ignition sends signals to Control unit KIT D790 2 which sends messages via CAN buss drivetrain to Control unit en gine D794 For position of components see Engine alternative Volvo compo...

Page 84: ...e the engine can be start ed For position of components see Engine alternative Volvo compo nent position page 4 page Start stop description engine alternative Cummins The engine is started and stopped...

Page 85: ...sion 1 2 Transmission mm mm mm mm Table of Contents 2 Transmission 2 Transmission 3 2 2 Torque converter clutch system 5 2 3 Mechanical transmission 6 2 6 Lubrication 7 2 7 Cooling 10 2 8 Control syst...

Page 86: ...UDRF01 04GB Maintenance manual DRF 400 450 2 2Transmission https www forkliftpdfmanuals com...

Page 87: ...ced between the engine s output shaft and the transmission s in put shaft The hydraulic oil pumps as well as the oil pump for the transmission s control and lubrication are connected to the torque con...

Page 88: ...turbine 10 Sensor rpm drum 11 Sensor rpm output shaft 12 Output shaft 2 Mode selector on Control unit KIT D790 2 13 Sensor drum speed B752 3 Control unit KIT D790 2 14 Sensor turbine speed B751 4 Acce...

Page 89: ...converter transmits the engine s power to the transmis sion For position of components see Transmission component position page 4 page Breather filter cleaning 1 Breather filter on top of torque conve...

Page 90: ...ARD and REVERSE and vice versa while operating at a speed lower than set limit value see sec tion 8 Control system group 8 5 1 5 DRIVETRAIN Modulation also gives smooth shifting between FORWARD and RE...

Page 91: ...ted in Control unit KID D795 and performance is reduced if the oil temperature goes above 125 C the transmission is disengaged For position of components see Transmission component position page 4 pag...

Page 92: ...rough the dipstick s hole to the marking for low level on the dipstick For volume and quality see section F Technical data 11 Start the engine and let the engine idle for at least two minutes 12 Check...

Page 93: ...nd MIN between which the oil level should be Wipe off the dipstick before checking NOTE The dipstick is long Use gloves 2 Fill transmission oil position B as needed for volume see sec tion F Technical...

Page 94: ...ion 2 7 Cooling 2 7 Cooling page Cooling system description The transmission is cooled by the lubrication system see Lubrication system description page 7 For position of components see Transmission c...

Page 95: ...ected to a sensor for engine speed is de tected two of three vehicle speed sensors are defective In case any of the above points occur the transmission will be placed in neutral position To enable con...

Page 96: ...mperature is 61 C If the oil temperature is too low go to DRIVE TRAIN menu 4 A Apply the footbrake so that the machine is stationary B Select travel direction forward and apply maximum accel eration f...

Page 97: ...shall be calibrated F Clutch forward R Clutch reverse 1 Clutch gear 1 2 Clutch gear 2 3 Clutch gear 3 4 Clutch gear 4 ACTION Indicates action from mechanics in the event of a fault 0 No action normal...

Page 98: ...l activate different gears during calibration NOTE If the machine starts to move during calibration then use the footbrake to keep the machine stationary 11 When the engine speed decreases to idling a...

Page 99: ...4GB Maintenance manual DRF 400 450 3Driveline axle 1 3 Driveline axle mm mm mm mm Table of Contents 3 Driveline axle 3 Driveline axle 3 3 2 Propeller shaft 4 3 3 Drive axle 5 https www forkliftpdfmanu...

Page 100: ...UDRF01 04GB Maintenance manual DRF 400 450 2 3Driveline axle https www forkliftpdfmanuals com...

Page 101: ...3 Driveline axle 3 Driveline axle 3 mm mm mm mm 3 Driveline axle page Driveline axle description The machine s power transmission consists of propeller shaft and drive axle with differential and hub...

Page 102: ...ve axle page Propeller shaft checking Grease nipple for universal joint example After 50h Check tighten attaching bolts at mountings to drive axle and transmission with 200 Nm After 500h Clean Check c...

Page 103: ...wer between right and left drive wheels and also makes it possible for the drive wheels to rotate at different speed when cornering The drive shaft transmits the power from the differential to the whe...

Page 104: ...the wheel into the correct posi tion 2 Machine in service position see section B Safety 3 Remove drain plug position 3 on both sides Also remove the level and filler plug position 2 to facilitate dra...

Page 105: ...nstrumentation 4 4 1 1 Brake pedal 4 4 3 Service brake system 5 4 3 1 Brake oil pump 8 4 3 4 Accumulator 9 4 5 Parking brake system 10 4 5 4 Parking brake unit 11 4 8 Temperature control filtration an...

Page 106: ...UDRF01 04GB Maintenance manual DRF 400 450 2 4Brakes https www forkliftpdfmanuals com...

Page 107: ...the machine The brakes act on the drive axle the steering axle has no brakes The brake system is divided into three functions Power assisted brake system function description page 5 Parking brake sys...

Page 108: ...e Illustration shows loose brake pedal 2 Check that the brake pedal springs back sufficiently and that the clearance between brake pedal and brake valve is 1 1 5 mm If needed adjust the brake pedal s...

Page 109: ...iscs The brake valve directs pressure from the accumulators to the brake cylinder The brake cylinder compresses the discs in the brake units that brake the machine Make contact brake pressure gives a...

Page 110: ...004729 B 1 Brake oil pump 8 Make contact brake lights S216 2 Brake oil filter 9 Break contact brake oil pressure S204 3 Accumulator charge valve 10 Control unit frame front D797 F 4 Accumulators 11 Co...

Page 111: ...assisted brake system component position 004893 1 2 3 4 8 7 6 5 1 Brake valve 5 Make contact brake lights S216 2 Brake oil pump 6 Wheel brakes 3 Make contact brake oil pressure S204 7 Accumulators br...

Page 112: ...g the pressure should increase to 19 0 5 MPa before the accumulator charging valve switches to cooling When the accumulator charging valve shifts to cooling the pressure drops 7 Check the pressure dur...

Page 113: ...ition I 3 Apply and release the brake several times and count the number of times that the brake can be applied before the warn ing light for low brake pressure is activated It should be possible to a...

Page 114: ...th pressure from the accumulators by the parking brake valve in the ac cumulator charging valve pressurizing the parking brake caliper Make contact parking brake gives a signal so that the indicator l...

Page 115: ...switches to cooling 2 Turn off the engine and turn the start key to position I 3 Release the parking brake 4 Check that the parking brake caliper can move on the bracket 004894 1 6 5 4 3 2 1 Brake oi...

Page 116: ...7 Adjust the adjustment screw so that the brakes are applied 8 Back off the adjustment screw 3 4 of a turn 9 Tighten the lock nut NOTE To avoid turning the adjustment screw as well it must be held sti...

Page 117: ...e tank which is cleaned in the oil filter When the accumulators are charged the accumulator charging valve controls oil through the drive axle s brake units and cools the brakes The oil passes through...

Page 118: ...harging valve Drive axle block Wheel brake See Power assisted brake system component position page 7 5 By pass valve in distribution block 11 Control unit KID D795 6 Cooler brake system 004895 7 1 3 2...

Page 119: ...der 4 8 12 Brake oil filter page Brake oil filter changing NOTE The filter protects the brake system from impurities It is very important that new impurities do not enter the brake system when changin...

Page 120: ...tridge NOTE Note the position of the O rings 9 Clean the filter holder 10 Fit the O rings on the filter cartridge and filter holder Lubricate the O rings with brake oil 11 Fit the small O ring to the...

Page 121: ...round the drain plug 5 Remove the drain plug and drain the tank 6 Fit the drain plug use a new gasket washer 7 Clean the area around the filling point 8 Remove the filler cap and fill the tank with oi...

Page 122: ...UDRF01 04GB Maintenance manual DRF 400 450 18 4 Brakes 4 8 14 Oil brake system https www forkliftpdfmanuals com...

Page 123: ...UDRF01 04GB Maintenance manual DRF 400 450 5Steering 1 5 Steering mm mm mm mm Table of Contents 5 Steering 5 Steering 3 5 2 Power assisted system 4 https www forkliftpdfmanuals com...

Page 124: ...UDRF01 04GB Maintenance manual DRF 400 450 2 5Steering https www forkliftpdfmanuals com...

Page 125: ...ction steering means to steer the machine during operation The machine is steered with the rear wheels by a power assisted steering system Available options are joystick steering and min wheel which m...

Page 126: ...heel spindles The steering wheel affects via steering wheel shaft the steering valve which in turn directs oil pressure from the hydraulic oil pumps to the steering cylinder Between the hydraulic oil...

Page 127: ...olled by the con trol system Joystick steering and mini wheel function in the same way the dif ference is in the design of the control 001875 8 5 9 11 12 4 13 7 6 10 P LS T CF P LS TP T1 A B D790 2 D7...

Page 128: ...valve joystick steering or mini wheel 12 Sensor steering wheel shaft 6 Shuttle valve 13 Control unit cab D790 1 004900 1 2 3 4 5 6 10 8 9 7 1 Shuttle valve attachment 6 Pump working hydraulics 3 2 Shu...

Page 129: ...ion 1 6 Suspension mm mm mm mm Table of Contents 6 Suspension 6 Suspension 3 6 2 Suspension 4 6 2 1 Steering axle cradle 4 6 2 2 Wheel spindle 5 6 2 3 Wheel hub 5 6 3 Tyre and rim system 7 6 3 1 Tyres...

Page 130: ...UDRF01 04GB Maintenance manual DRF 400 450 2 6Suspension https www forkliftpdfmanuals com...

Page 131: ...ion description The machine s suspension consists of its tyres with associated rims and bolts steering axle with hub wheel spindles and the steering axle s suspension in the frame The drive axle belon...

Page 132: ...axle cradle is attached to the frame with two bushings one at the leading edge and one at the trailing edge of the steering axle cradle In the steering axle cradle there are two wheel spindles mounted...

Page 133: ...he O ring 3 Measure with feeler gauge between thrust bearing and thrust washer Max clearance 1 5 mm 6 2 3 Wheel hub page Wheel hub checking 1 Clean the hub covers on the steering wheels 2 Remove the h...

Page 134: ...gain at least 2 revolutions and then tighten the nut another 45 degrees 6 Fit the lock washer and outer lock nut 7 Tighten with at least 250 Nm or as hard as is needed to bend the lock washer in the c...

Page 135: ...g clips can loosen and shoot out when the pressure is changed With double wheel fitting both tyres must be deflated Do not release air through the valve if the tyre or rim is damaged Drill a hole in t...

Page 136: ...e wheel may release from the hub When removing drive wheels make sure that the wheels are fixed when the spacer rings are re moved If the wheels move they may move the spacer rings and crushing damage...

Page 137: ...en care of immediately Remove penetrating objects such as crushed glass pieces of wood metal filings etc If the tyre is damaged the wheel shall be dismantled and the tyre shall be changed see Tyres ch...

Page 138: ...7 1 Lift the machine under the drive axle by the wheel in question Support under the drive axle in a safe and adequate manner 2 Deflate the tyre If tyre and rim are in good condition release air throu...

Page 139: ...TE The spacer ring weighs approx 20 kg 7 Remove the outer wheel Lift away the wheel and place it in a safe manner 8 Move the lifting equipment to the inner wheel 9 Remove the spacer ring between the o...

Page 140: ...and rim system safety page 7 1 Lift the machine under the steering axle by the wheel in ques tion Support under the steering axle in a secure manner Example The figure shows inflation of drive wheel...

Page 141: ...mps and pull out the wheel 6 Lift away the wheel and place it in a safe manner page Tyre and rim system installing drive axle Read the safety instructions before working with the tyre and rim see Tyre...

Page 142: ...groove on the hub 4 Fit the outer spacer ring NOTE The outer ring is split Rotate the ring so that the opening ends up in front of the groove on the hub 5 Place clamps and nuts on the wheel bolts Whe...

Page 143: ...installed securely 12 Check tighten the wheel nuts with torque 400 Nm page Tyre and rim system installing steering axle Read the safety instructions before working with the tyre and rim see Tyre and r...

Page 144: ...4 Fit the wheel Tighten the wheel nuts crosswise with torque 400 Nm Example The figure shows inflation of drive wheel 5 Inflate the tyre with air 1 MPa see Tyres inflating page 17 6 Lower the axle an...

Page 145: ...ure may apply when changing tyre or rim version contact Kalmar Industries 000384 DANGER Always follow the instructions for inflating tyres to avoid risk of accidents Only use approved rim components I...

Page 146: ...steel ruler and sliding calipers If wear exceeds 0 5 mm the rim lock ring and the rim bead seat taper must be discarded and replaced with new parts DANGER Changing tyres is complicated and dangerous w...

Page 147: ...teps 1 The magnetic powder method is used to determine if there s a crack or not and where it is 2 Confirmed cracks are investigated further with penetrating fluid Typical rim damages are circumferenc...

Page 148: ...ly wipe off the cleaning fluid with a drying cloth and let any remaining cleaning fluid evaporate 4 Spray detection fluid part no 923626 0670 on the area 5 Let the sprayed area dry 1 2 hours Example o...

Page 149: ...t 14 7 4 6 Sideshift frame 16 7 4 7 Main beam attachment 17 7 5 Positioning 19 7 5 6 Positioning motor 23 7 5 7 Positioning chains 23 7 5 8 Positioning beam 26 7 6 Rotation 27 7 6 6 Rotation motor uni...

Page 150: ...UDRF01 04GB Maintenance manual DRF 400 450 2 7 Load handling https www forkliftpdfmanuals com...

Page 151: ...g support jacks Load handling is divided into different sub functions Lift and lower Extension Sideshift Spreading Rotation Tilt Levelling Securing load for example twistlocks and lift legs Other for...

Page 152: ...results in less stress on the mechan ical parts when stopping in the end positions Position sensors sense when damping should be activated When damping is activated the control unit in question reduce...

Page 153: ...t D797 F 12 Valve block lift cylinder 4 Servo valve lift Y6005 or Servo valve lower Y6004 13 Lift cylinder 5 Control valve lift lower and extension 14 Sensor hydraulic pressure lift cylinder piston si...

Page 154: ...l or joystick steering 13 Servo valve boom lower Y6004 4 Shuttle valve option frame 14 Servo valve lift Y6004 5 Hydraulic oil pump 15 Pressure sensor piston side C M B768 10 or B768 12 6 Pressure redu...

Page 155: ...start key to position 0 and turn off the main electric power 001239 9 8 6 5 4 3 1 2 8 7 1 Outer boom 6 Extension cylinder 2 Inner boom 7 Lift cylinder 3 Tilt cylinder right side 8 Mounting lift cylind...

Page 156: ...n the filter holder 8 Check that the O ring on the filter holder is intact and in place 9 Fit the filter and filter holder 10 Check the hydraulic oil level with the lift cylinders completely down and...

Page 157: ...sure Compare with pressure plate Turn the steering wheel or activate a load handling function to activate the hydraulic oil pumps The servo pressure is higher than the stand by pressure of the hydraul...

Page 158: ...matical ly near the end positions This results in less stress on the mechan ical parts when stopping in the end positions Position sensors sense when damping should be activated When damping is activa...

Page 159: ...tension cylinder 4 Servo valve boom out Y6006 or Servo valve boom in Y6007 15 Extension cylinder 5 Control valve lift lower and extension 16 Sensor hydraulic pressure lift cylinder B768 12 6 Valve blo...

Page 160: ...on control valve VB 5 Connection control valve VA 6 Connection control valve VA 7 Servo valve blocking Y6050 Valve block pump unloading 1 Solenoid valve engagement hydraulic pressure Y6003 2 Pressure...

Page 161: ...ess of the lower glide plates at the leading edge of the lift boom If needed remove the glide plate and measure the thickness Thickness should be at least 15 mm 5 Check the clearance between the boom...

Page 162: ...in relation to the lift boom Side shift is controlled with Control lever S815 001113 Condition Reference value Control switch Not activated D790 1 D797 R 000458 D791 1 10 9 7 6 5 4 3 2 1 P1 T1 A B 8 D...

Page 163: ...hift cylinder 16 15 12 18 19 13 11 1 2 3 4 5 6 7 8 9 10 17 14 004905 1 Valve block top lift hydraulics 9 Solenoid valve spreading Y6018 and Y6019 2 Valve block pump unloading 10 Solenoid valve twistlo...

Page 164: ...te 3 Check the glide plate s clearance by measuring the distance be tween the glide plate and the edge for the cover plate Clearance should be 1 mm Fit remove spacer plates until the distance is corre...

Page 165: ...and start the engine 7 Lift the attachment and remove the stands 7 4 7 Main beam attachment page Glide plates main beam attachment checking 1 Park the machine with the attachment as far down as possi...

Page 166: ...tes mounted Fit remove spacer plates until the distance is correct NOTE Excessive clearance may result in damage to the spreader beam when load handling 9 Fit the glide plate s bracket 10 Fit the glid...

Page 167: ...preading is controlled with Control lever S815 Inductive position sensors indicate the spreader units position Damping Damping means that the speed of functions are reduced automati cally close to end...

Page 168: ...6 4 12 7 P1 T1 A B D D D C C D 1 Control lever S815 T1 x and S815 T4 7 Control unit cab D790 1 2 Control unit cab D790 1 8 Servo valve spreading out Y6018 or Servo valve spreading in Y6019 3 Control...

Page 169: ...lift Hydraulic diagram top lift tilt lock and controllable tilt Hydraulic diagram combi attachment Hydraulic diagram top lift tilt lock controllable tilt and hydraulic lev elling Condition Reference...

Page 170: ...6 Valve block top lift hydraulics Control valve attach ment Spreader beam Main beam attachment Relief valve attachment See Sideshift component position page 15 M 004904 1 2 3 4 5 6 7 1 Indicator plat...

Page 171: ...checking 1 Before adjustment the clearance between the slide plates and extension beams must be checked otherwise the chain s mountings will be damaged see Slide plates extension beam checking and ad...

Page 172: ...at it is possible to move the washers 5 Remove the cover plates on the attachment s main beam 6 If the 20 foot stops have been adjusted the spreader chains should be adjusted equally as much NOTE Chec...

Page 173: ...rt the engine and run out the spreading until the chain ten sioner is visible in the inspection hole Adjust the chains NOTE Adjust the chain max 2 mm at a time on the chain tension er 13 Repeat steps...

Page 174: ...ows the inner slide plates in the at tachment s main beam 4 Remove the attaching bolts for the slide plate s bracket 5 Remove the guide plate s guide pin 6 Pull out the slide plate with spacer plate a...

Page 175: ...otation is controlled with Control le ver S815 The voltage signal controls direction and speed clock wise or counter clockwise 001115 Condition Reference value Control switch Not activated Overloading...

Page 176: ...more the function must be by passed with Switch rotation stop S1014 Rotation stop uses a position sensor that indicates when rotation is 25 this is used to interrupt rotation 4 Solenoid valve engageme...

Page 177: ...Hydraulic oil pump Shuttle valve See Lift and lower component position page 6 Valve block top lift hydraulics Control valve attach ment Sideshift frame Relief valve attachment See Sideshift component...

Page 178: ...rain plug 6 Fill the planetary gear with new oil through the filling point pos 3 until the level is in the middle of the level glass For volume and quality see section F Technical data 7 Remove the di...

Page 179: ...cted with a damping block There are four versions of tilt Damping Damping with tilt lock Tilt lock Damping with controllable tilt Controllable tilt Damping with controllable tilt and tilt lock If the...

Page 180: ...osswise to damping block tilt Damping block tilt is supplied with servo pressure from Control valve attach ment that is controlled to the tilt cylinders and generates an over pressure in the tilt cyli...

Page 181: ...pressure from Control valve attachment Tilt lock is activated with a switch on Control lever S815 When tilt lock is activated the machine s speed is limited to max 5 km h Hydraulic diagram top lift 0...

Page 182: ...controlled min 2 regardless of boom angle Tilt control is controlled with Control lever S815 An extra section in Control valve attachment pressurizes the tilt cylinders through damping block tilt so t...

Page 183: ...component position page 15 Damping block tilt Tilt cylinder 1 Damping block tilt and Solenoid valve tilt lock Y6012 2 Tilt cylinder Rotation yoke Se Rotation component position page 29 1 Control lever...

Page 184: ...ment hangs horizontally during the whole lifting movement 3 Adjust the tilt damping as needed by adjusting the screws on the damping block Adjust both screws equally Clockwise increase damping Counter...

Page 185: ...g increases mobility of the attachment The hydraulic levelling has a passive position where the attachment floats freely and an active position where the angle can be controlled Levelling can be locke...

Page 186: ...P1 and S815 T4 8 Solenoid valve levelling Y6034 2 Control unit cab D790 1 9 Servo valve levelling right Y6035 or Servo valve lev elling left Y6036 3 Control unit frame rear D797 R 10 Control valve att...

Page 187: ...m the levelling cylinders Levelling lock is activated with a switch on Control lever S815 When levelling lock is activated the machine s speed is limited to max 5 km h 004912 Condition Reference value...

Page 188: ...ntrol valve attach ment Relief valve attachment See Sideshift component position page 15 Over centre valve levelling Valve block levelling cylin ders Levelling cylinders Sideshift frame 1 Main beam at...

Page 189: ...are controlled with the control lever and Switch twist locks One section in Control valve attachment pressurizes two hy draulic cylinders connected in parallel one in each spreader boom Each hydraulic...

Page 190: ...D 14 1 Switch lock twistlocks S1003 8 Solenoid valve engagement of hydraulics for top lift Y6003 2 Control lever S815 T2 9 Shuttle valve 3 Sensor alignment left front 7202L Sensor align ment right fr...

Page 191: ...guide 1 Check that the twistlocks function correctly Lock and open the twistlocks check that the indicator lights work both in cab and on boom 2 Clean the twistlocks from any dirt 3 Under the rubber...

Page 192: ...he lock guide pos 5 and check the clearance max clearance 1 1 5 mm Wear limits lift pin 8 Turn the twistlocks to locked position and check lift pin wear Change the lift pin if needed 9 Clean the area...

Page 193: ...ea for checking for cracks on lift shoe 2 Test for cracks within the marked area on the pins without re working or damaging the part 3 If the lift pins show signs of cracking they shall be replaced wi...

Page 194: ...be checked from the diagnostic menu see section 8 Control system group 8 4 11 1 Combi menu 14 Operating position Operating position is a predefined position of the rear lift legs that gives the load c...

Page 195: ...g of front lift legs function description Condition Reference value Control switch Not activated 4 2 004870 10 P1 T1 1 7 6 8 A B A B A B A B A B 5 11 9 12 13 14 3 16 17 P1 T1 A B A B A B A B A B 18 15...

Page 196: ...right Y6056R or So lenoid valve front knee in right Y6057R 5 Control unit frame rear D797 R 16 Hydraulic cylinder knee right front 6 Solenoid valve engagement of hydraulics for top lift Y6003 17 Senso...

Page 197: ...f rear lift legs function description Condition Reference value Control switch Not activated 2 004872 10 11 P1 T1 1 7 6 8 A B A B A B A B A B 5 12 9 13 14 3 P1 T1 A B A B A B A B A B 15 18 19 21 22 23...

Page 198: ...ngagement of hydraulics for top lift Y6003 20 Sensor rear leg right B7220R 7 Shuttle valve 21 Solenoid valve operating position right Y6053R 8 Hydraulic oil pump 22 Solenoid valve operating position l...

Page 199: ...7 21 P1 T1 1 7 6 8 A B A B A B A B A B 5 15 19 3 14 16 20 P1 T1 A B A B A B A B A B 18 22 12 13 D790 1 D797 R D791 3 D791 4 9 23 1 Switch clamp release legs S1008 13 Hydraulic cylinder knee and clamp...

Page 200: ...ear leg left B7216L 6 Solenoid valve engagement of hydraulics for top lift Y6003 18 Sensor clamping position rear leg right B7216R 7 Shuttle valve 19 Sensor alignment front leg left B7213L 8 Hydraulic...

Page 201: ...216 2 Solenoid valve operating position Y6053 7 Sensor alignment B7213 or B7214 3 Sensor operating position left B7212L or Sensor op erating position right B7212R 8 Hydraulic cylinder lift leg 4 Senso...

Page 202: ...activated NOTE The alignment pin should move easily and spring back completely 4 Press in the plate for clamping position and check that the plate moves easily and springs back completely as well as t...

Page 203: ...ft shoe NOTE Crack checks shall take place every other year or every 5000 operating hours 1 Remove the lift shoes from the lift legs NOTE The lift shoes are heavy Take care when removing 2 Test for cr...

Page 204: ...aulic cylinders one cylinder per support jack The support jacks are located on the frame between the drive wheels If the engine speed is increased to above 1000 rpm when the switch is activated then a...

Page 205: ...wn B7221L and B7221R 10 Hydraulic cylinder support jacks 4 Control unit frame option D797 O 11 Control unit KID D795 5 Solenoid valve support jacks down Y6064 or Sole noid valve support jacks up Y6063...

Page 206: ...calculate the load For more information about sensors see section 8 Control system group 8 2 1 Overloading system Condition Reference value Control switch Not activated 004886 D795 D790 1 D797 F D791...

Page 207: ...hows the correct weight 0 5 ton If the deviation is greater calibrate the weight indicator page Fixed scale calibration NOTE It is very important for accuracy that all steps are performed in the speci...

Page 208: ...ting with ENTER 7 Lift a known reference load and centre the attachment 8 Park the machine on level ground 9 Move the boom to measuring position see step 5 NOTE It is very important for accuracy that...

Page 209: ...ormation about sensors see section 8 Control system group 8 2 1 Overloading system Condition Reference value Control switch Not activated 005118 D795 D790 1 D797 F D797 R 1 3 4 D Pa Pa Pa Pa 6 7 m 2 5...

Page 210: ...he machine on level ground without load and centre the attachment 2 Navigate to the service menu and press ENTER 3 Enter code for calibration Code is obtained from Kalmar Industries Support NOTE The c...

Page 211: ...u 6 and save the setting with EN TER Checking calibration 21 Scroll to CALIBR SCALE menu 7 22 Lift a reference weight and check that the control system cal culates the correct weight of the load the m...

Page 212: ...R key page Printer description Position printer Printer is an option the function for scale that makes it possible to save weights and print out lists of saved weights The printer is connected to Cont...

Page 213: ...sor twistlocks to decide when a container is lifted The container counter counts lifts when alignment disappears with locked twistlocks and twist locks are not opened again within 8 seconds 1 Sensor a...

Page 214: ...ot ac tivated within 10 seconds 1 Sensor clamping position front leg left B7215L and Sensor clamping position rear leg left B7216L 2 Control unit attachment left legs D791 3 3 Sensor clamping position...

Page 215: ...lled by the control system with signals from Sensor boom angle and Sensor boom length NOTE The synchronized lift uses preset variables for the speed The hydraulic oil pumps must be adjusted correctly...

Page 216: ...UDRF01 04GB Maintenance manual DRF 400 450 68 7 Load handling 7 10 4 Synchronous lift https www forkliftpdfmanuals com...

Page 217: ...6 8 2 2 By passing 11 8 2 3 Load centre limitation 11 8 2 4 Height limitation 12 8 2 5 Speed limitation 12 8 2 6 Service indicator 12 8 3 Error codes 13 8 4 Diagnostics 15 8 4 1 CAN POWER 18 8 4 2 LIG...

Page 218: ...UDRF01 04GB Maintenance manual DRF 400 450 2 8 Control system https www forkliftpdfmanuals com...

Page 219: ...when malfunctions have been detected Diagnostic test is tool for performing service and troubleshooting with menus in the machine s display Settings is the tool for setting and adapting the machine s...

Page 220: ...lues in operating menus Function key 6 Return Confirm selection of menu and sub menu as well as confirm entered value Example of operating menus Operating menus When the machine is started the Operati...

Page 221: ...Overloading forward Overloading on steering axle Alignment top lift attachment Alignment bottom lift attachment Twistlock Support jacks Height limitation Fixed scale Open door Rotation stop Speed lim...

Page 222: ...ion to operator boom movement is interrupted In this position the boom and thus the load can only be retract ed until the buzzer stops sounding and the display figure disap pears LLMC is not intended...

Page 223: ...rox 1 m 2 Run out the boom and check that the overloading system is ac tivated B768 10 B768 11 B768 12 B768 13 Ana logue R777 Ana logue R771 Digital B777 Digital B771 B7221 B7224 Mechanical overloadin...

Page 224: ...functions lift and lower as well as extension Using the by pass lower and extension can be activated to get out of the overload ing situation The boom angle exceed 35 at the same time as boom exten s...

Page 225: ...nctions lift and lower as well as extension Using the by pass lower and extension can be activated to get out of the overload ing situation The boom angle exceed 35 at the same time as boom exten sion...

Page 226: ...er and extension can be activated to get out of the overload ing situation In case of overloading on the steering axle the control system activates a warning for overloading on the steering axle Depen...

Page 227: ...t manual control of recirculation damper for ECC or EHC release of parking brake in case of malfunction of switch parking brake lift above height limitation rotation past rotation stop load handling p...

Page 228: ...itation page Speed limitation description Speed limitation prevents the machine s speed from exceeding pre set value by limiting gear position and engine rpm 8 2 6 Service indicator page Service indic...

Page 229: ...ontrol system position 54 and activated Indicator for active error codes position 36 Error code with level STOP shown automatically on display WARNING is indicated on the display together with a flash...

Page 230: ...e error code list by pressing in function key Enter for two seconds Navigate in the error code list with function keys arrow right and arrow left Leave the error code list by pressing function key Res...

Page 231: ...used page Diagnostic menu description 1 DIAG Diagnostic menus 2 Menu group CAB cab functions 3 Menu number 4 Total number of menus in loop 5 Signal value 6 Variable 7 Menu heading The diagnostic test...

Page 232: ...IMATE for diagnosis heating and ventilation system HYD for diagnosis of common hydraulics and brakes ENGINE for diagnosis of engine BOOM for diagnosis of lift lower and extension ATTACH for diagnosis...

Page 233: ...w keys 1 and 2 and con firm with Enter Each group consists of a sequence of numbered menus The first menu for selected diagnostic menu is shown on the dis play use arrow keys 1 and 2 to change menu DI...

Page 234: ...Le X Ri X X DIAG CAN POWER 8 20 797 F FRAME 24V SENSOR SUPPLY 5V REF XY X XXV DIAG CAN POWER 9 20 797 R FRAME POWER RED POWER XX XXV Le X Ri X DIAG CAN POWER 10 20 797 R FRAME 24V SENSOR SUPPLY 5V RE...

Page 235: ...SIDE F SIDE R REAR LE XX RI XX LE XX RI XX LE XX RI XX DIAG LIGHTS 5 13 HEAD LIGHTS SWITCH HEAD DIMMED X LE XX RI XX XX DIAG LIGHTS 6 13 PRESENT INPUT SIGNAL HAZARD SWITCH FLASH SW X LE X RI X DIAG L...

Page 236: ...Y X DIAG CAB 2 10 DIAGNOSIS CAN POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH OP EXTRA HIST REAR WIPER SWITCH OUTPUT FEEDBACK X XY X DIAG CAB 3 10 ROOF WIPER SWITCH OUTPUT FEEDBACK X XY X DIA...

Page 237: ...DRAUGHT REQ FAN SPEED XX XXV XX XXV XX XXV DIAG CLIMATE 5 8 PRESENT OUTPUT SIGNAL FAN SPEED RECIRKULATION COMPRESSOR XXX XY XY DIAG CLIMATE 6 8 OUTPUT WATER VALVE CLOCKWISE ANTI CLOCKWISE XY XY XY XY...

Page 238: ...RQUE REQUIRED TORQUE XXX XXX DIAG ENGINE 3 10 PRESENT INPUT SIGNAL PREHEAT SWITCH CRANK ENGINE SWITCH D X X X DIAG ENGINE 4 10 PRESENT OUTPUT SIGNAL PREHEAT CRANK ENGINE X X DIAG ENGINE 5 10 PRESENT I...

Page 239: ...EED XXXXHz XXXXHz XXXXHz XXXXHz DIAG TRANSM 6 15 OUTPUT STATUS RSP DRIVE 2 4 VFS SELECTION 1 3 VFS SELECTION X X X X DIAG TRANSM 7 15 FWD SUPPLY REV SUPPLY 2 4 SUPPLY 1 3 SUPPLY X X X X DIAG TRANSM 8...

Page 240: ...PRESS IN LE XY RI XY XY XY DIAG BOOM 2 8 BOOM HIGH SPEED UP OUT LE XY RI XY XY DIAG BOOM 3 8 OUTPUT BOOM UP REFERENCE REQUIRED VALUE FEEDBACK XY XXX XXX DIAG BOOM 4 8 OUTPUT BOOM DOWN REFERENCE REQUIR...

Page 241: ...LOCKED TW IND ALIGNMENT XY XY XY DIAG ATTACHMENT 10 21 PRESENT INPUT SIGNALS LOCK TW UNLOCK TW BY PASS HEIGHT X X X DIAG ATTACHMENT 3 21 OUTPUT ROTATION C W REFERENCE RQUIRED VALUE FEEDBACK XY XXX XXX...

Page 242: ...ESENT INPUT SIGNAL STEERING AXLE BOOM ANGLE EXTENSION X X X DIAG OP 1 5 PRESENT INPUT SIGNAL BY PASS X DIAG OP 2 5 PRESENT INPUT SIGNAL LIFT CYL C C LE RI X XXV X XXV X XXV X XXV DIAG OP 3 5 PRESENT I...

Page 243: ...DIAG COMBI 5 17 PRESENT INPUT SIGNAL LEGS IN DRIVE POSITION LE X RI X DIAG COMBI 6 17 INDICATION LAMPS ALIGNMENT FRONT REAR LE XY RI XY LE XY RI XY DIAG COMBI 7 17 INDICATION LAMPS CLAMP FRONT REAR XY...

Page 244: ...CH OP EXTRA HIST 004858 DIAGNOSIS EXTRA COMBI SLIDING CAB SUPPORT JACKS EL STEERING SWITCHES FORWARD REVERSE OPENED DOORS X X X DIAG SLID CAB 1 4 PRESENT INPUT SIGNAL LOW SPEED CAB DOWN X LIFT X DIAG...

Page 245: ...LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH OP EXTRA HIST 004859 DIAGNOSIS EXTRA COMBI SLIDING CAB SUPPORT JACKS EL STEERING SWITCHES UP DOWN X X DIAG S JACKS 1 4 PRESENT INPUT SIGNALS UP DOWN L...

Page 246: ...LIDING CAB SUPPORT JACKS EL STEERING PRESENT INPUT SIGNAL SIGNAL 1 SIGNAL 2 X XXV X XXV DIAG STEERING 1 5 SWITCHES ON OFF FORWARD REVERSE X X X DIAG STEERING 2 5 PRESENT INPUT SIGNAL HORN STEER WHEEL...

Page 247: ...ormed via menus on the display The settings are split up as Initiation and Calibration Initiation is performed before the machine is used for work This is to compensate for mechanical and electrical t...

Page 248: ...UDRF01 04GB Maintenance manual DRF 400 450 32 8 Control system 8 5 Setup https www forkliftpdfmanuals com...

Page 249: ...3 Seat 11 9 4 HVAC 12 9 4 1 Fresh air filter 17 9 4 8 Condenser 18 9 4 9 Humidity filter 18 9 5 Wiper washer system 20 9 6 Lighting system 21 9 7 Communication systems 22 9 8 Entertainment and commun...

Page 250: ...UDRF01 04GB Maintenance manual DRF 400 450 2 9 Frame body cab and accessories https www forkliftpdfmanuals com...

Page 251: ...el The body comprises wings engine cover tanks and other parts mounted on the frame The cab is built separately and isolated from the frame using heavy duty rubber dampers The operator s seat steering...

Page 252: ...3 Steering wheel panel 4 Steering wheel 5 Switch direction indicators S161 6 Panel for load handling functions 7 Switch control breaker S250 8 Switch parking brake S107 9 Control lever S815 10 Operat...

Page 253: ...ir distribution S117 19 Switch work lights cab roof S105 1 20 Switch work lights attachment S105 2 21 Switch work lights boom S105 3 22 Switch rotating beacon S110 23 Switch hazard flashers S109 24 Sw...

Page 254: ...tor light high beams 47 Indicator light direction indicators 48 Indicator light parking brake 49 Indicator light locked twistlocks 50 Indicator light alignment 51 Indicator light unlocked twistlocks 5...

Page 255: ...op S1014 Switch by pass height limitation S1015 Switch by pass LC limitation load centre S1015 70 Spare 71 Switch lock twistlocks S1003 72 Switch clamp release clamping position legs S1008 73 Switch s...

Page 256: ...dynamic scale 3 Operating menu engine 11 Operating menu service 4 Operating menu transmission and hydraulics 12 Operating menu heating and air conditioning 5 Operating menu electrical system 13 Opera...

Page 257: ...nu support jacks 2 Event menu overload forward 9 Event menu height limitation 3 Event menu overload on steering axle 10 Event menu fixed scale 4 Event menu overload on steering axle 11 Event menu open...

Page 258: ...ipped with a fire extinguisher it should be of the type ABE acc to EN 3 part 1 2 4 and 5 With such a fire extinguisher it is possible to extinguish fires in both solid organic materials and fluids Ada...

Page 259: ...lowing alternative operator seats with equipment are availa ble Operator s seat Bege The seat is equipped with mechanical adjustment air suspension with integral compressor seat belt head restraint ar...

Page 260: ...ses heat from the engine s cool ing system via a heating coil to warm the outside air Outside air is forced by the fan through the heating coil and on through channels in the cab s interior to be aime...

Page 261: ...evaporates in the evaporator in the cab When the refrigerant evaporates cold is generated in the evaporator When the cab air is forced through the evaporator by the cab fan the air is cooled Then the...

Page 262: ...ear D797 R 4 Sensor cab temperature B775 1 17 Magnet clutch M645 5 Sensor temperature outlet fan B775 2 18 Compressor 6 Sensor outdoor temperature B774 19 Condenser 7 Control unit cab D790 1 20 Humidi...

Page 263: ...T D790 2 10 Cab fan M657 3 Sensor outdoor temperature B774 11 Fresh air and recirculation damper M612 4 Control unit cab D790 1 12 Fresh air filter 5 Sensor cab temperature B775 1 inside the left con...

Page 264: ...manual DRF 400 450 16 9 Frame body cab and accessories 9 4 HVAC 004862 2 3 6 1 5 4 1 Condenser 4 Humidity filter 2 Water valve Y673 5 Compressor 3 Pressure monitor S246 6 Magnet clutch M645 https www...

Page 265: ...electrically driven water pump pumps the coolant through the heating system when the engine is off The cab fan pumps air into the cab The pause heater is turned off automatically when the temperature...

Page 266: ...condenser cooler clean using compressed air 9 4 9 Humidity filter page Humidity filter checking Indicator humidity filter 1 Machine in service position see section B Safety 2 Start the engine and let...

Page 267: ...Remove the humidity filter pressure switch from the humidity filter 5 Change the humidity filter 6 Fit the pressure switch and connect the hoses to the humidity filter 7 Check for leaks and refill th...

Page 268: ...or and reservoir E Wiper front The wiper arm is attached to the wiper motor s shaft over a splined cone The shaft is made of hardened steel and the wiper arm s at tachment is made of mild die cast mat...

Page 269: ...ng overview 1 Rear light red 2 Brake lights 3 Direction indicators 4 Running lights 5 Headlights 6 Reversing light white 7 Work lights for cab roof attachment and boom 8 Rotating beacon 9 Interior lig...

Page 270: ...ation and load handling This can be via light and sound The following signal systems are fitted to the machine Communication system overview 1 Horn 2 Air horn 3 Warning light flashing hazard lights 4...

Page 271: ...accessories 9 8 Entertainment and communication 23 9 8 Entertainment and communication page Entertainment and communication general For information and description of equipment see supplier s docu me...

Page 272: ...windows front The function of the glass panes is to enclose the cab and to give the operator good visibility the panes are tinted The rear view mirrors are of the type convex mirror External rear view...

Page 273: ...n page 26 Cab lift and lowering function description page 28 NOTE Cab mounting does not affect the cab s version 9 10 4 Longitudinal displacement of cab page Manual movement of cab description A Posit...

Page 274: ...cab s position is blocked automatically by the hydraulic motor when cab movement is not in use Damping Damping means that the speed of functions is reduced automatical ly near the end positions This...

Page 275: ...S197 7 Shuttle valve 2 Contact closed door one sensor for each door 8 Main pumps 3 Control unit cab D790 1 9 Valve block cab movement sliding cab 4 Control unit frame option D797 O 10 Hydraulic motor...

Page 276: ...b can be raised or lowered hydraulically during operation to improve the operator s visibility The cab s height is adjusted with a hydraulic cylinder in a frame that secures the cab The cab can be sec...

Page 277: ...2 13 8 P1 T1 T3 TP LS A B 2 3 4 5 9 10 11 6 1 Switch cab lift and lowering S 8 Main pumps 2 Contact closed door one sensor for each door 9 Accumulator 3 Control unit cab D790 1 10 Load control valve 4...

Page 278: ...wered cab B777 2 2 Sensor damping end position B769 2 3 Frame cab lift and lowering 4 Hydraulic cylinder cab lift and lowering 5 Cab undercarriage cab lift and lowering 6 Safety lock 1 Load signal LS...

Page 279: ...The cab is designed for optimal operator comfort Switches con trols warning and indicator lights are grouped on the instrument panels to give the operator a good operating environment Recyclable mate...

Page 280: ...o be the structural part for the ma chine s components 1 Frame s front part with drive axle mounting 2 Cab mounts 4 points 3 Steering axle mounting 4 Frame s rear part with counterweights 5 Boom mount...

Page 281: ...a part of the chassis There are fenders to de flect dirt footsteps and handrail to facilitate access on the chassis hood to deflect dirt and objects from the engine compartment as well as a counterwei...

Page 282: ...it with lubricant reservoir Distribution block with restrictions that distribute and dose grease between the different grease points The distribution block s restrictions ensure that all points receiv...

Page 283: ...450 9 Frame body cab and accessories 9 15 Paint coatings 35 9 15 Paint coatings page Paint coatings description Single layer paint thickness 120 my For paint code of current ma chine RAL see machine...

Page 284: ...UDRF01 04GB Maintenance manual DRF 400 450 36 9 Frame body cab and accessories 9 15 Paint coatings https www forkliftpdfmanuals com...

Page 285: ...curity valves 5 10 3 Tanks and accumulators 6 10 4 Pumps 7 10 4 2 Axial piston pump with variable displacement 8 10 5 Hoses pipes and valves 11 10 6 Temperature control cleaning and hydraulic oil 12 1...

Page 286: ...UDRF01 04GB Maintenance manual DRF 400 450 2 10 Common hydraulics https www forkliftpdfmanuals com...

Page 287: ...Under the function common hydraulics there are hydraulic functions that are common for several of the machine s main functions For example the hydraulic oil pumps that supply load handling steering a...

Page 288: ...ment and are therefore unique for each machine When checking pressure the pressures shall match the pressure plate MPa MPa MPa MPa MPa MPa MPa MPa MPa 920643 0024 000441 5 6 7 8 9 1 2 3 4 1 Gas pressu...

Page 289: ...450 10 Common hydraulics 10 2 Security valves 5 10 2 Security valves page Security valves component position 1 Relief valve attachment illustration shows closed valve 2 Accumulator drain valve 004896...

Page 290: ...ors 10 3 Tanks and accumulators page Tanks and accumulators component position Tank 1 Filler plug hydraulic oil 2 Cap for hydraulic oil filter 3 Level glass hydraulic oil 4 Breather filter hydraulic o...

Page 291: ...considered as one pump hydraulic oil pump unit Non return valves make sure that the pumps don t interfere with each other The left hydraulic oil pump unit position 1 and 2 supplies the control valve f...

Page 292: ...004892 D790 1 D797 R 5 4 9 12 10 1 2 3 6 7 No 1 No 2 No 3 No 4 11 8 P LS P P1 LS LS P CF EF P C C D D C C C 1 Control valve lift and extension 7 Hydraulic oil pump 1 2 Shuttle valve 8 Control unit fra...

Page 293: ...oil pump 2 2 1 MPa Hydraulic oil pump 3 2 9 MPa Hydraulic oil pump 4 3 1 MPa Settings apply to standard machine certain machines may have higher stand by pressure For correct stand by pressure see pr...

Page 294: ...the pressure should match the value on the pressure plate All pumps should give the same pressure The order in which the pumps are tested is not of any importance 8 Turn off the engine 9 Transfer the...

Page 295: ...page Hoses pipes and valves component position 1 2 4 7 3 004897 6 5 1 Shuttle valve attachment 5 Collecting block unfiltered returns 2 Shuttle valve steering 6 Collecting block filtered returns 3 Shu...

Page 296: ...s valve The hydraulic oil pump pumps oil from the tank that is cooled in the hydraulic oil cooler and is cleaned by the oil filters in the tank Some of the oil is filtered by the fine filter An electr...

Page 297: ...e control cleaning and hydraulic oil component position 1 2 6 5 7 4 3 004898 1 Cooling fan and cooler hydraulic oil 5 Breather filter hydraulic oil tank 2 Hydraulic oil filter 6 Tank heater 3 Fine fil...

Page 298: ...ntally hazardous waste 5 Fit the filter housing Press down and turn approx 1 8 turn counter clockwise 6 Reset the filter indicator by pressing down the button in the middle on the glass centered on th...

Page 299: ...acle Let the hy draulic oil drain 6 Part the filter unit and remove the filter cartridge Handle the fil ter cartridge as environmentally hazardous waste Note place ment of the parts 7 Clean the filter...

Page 300: ...er brackets 8 Remove the filter inserts NOTE Note position of the O rings 9 Fit the O rings on the filter inserts and filter brackets Lubricate the O rings with hydraulic oil 10 Fit the new filter ins...

Page 301: ...nto the receptacle 4 Fit the drain plug when the oil has drained NOTE Make sure that the seal washer is installed as well 5 Handle the spent oil as environmentally hazardous waste 6 If the hydraulic o...

Page 302: ...t up the filter cartridge and place it in the receptacle and let the hydraulic oil drain 6 Fit the new filter cartridge and fit the cover on the fine filter WARNING Hot and pressurized oil Personal in...

Page 303: ...11 Common electrics 3 11 2 Electric protection 4 11 2 2 Fuses 5 11 3 Batteries 8 11 3 1 Start battery 8 11 4 Alternator 9 11 5 Distribution of electricity 10 11 5 1 Voltage feed 10 11 5 3 Control uni...

Page 304: ...UDRF01 04GB Maintenance manual DRF 400 450 2 11 Common electrics https www forkliftpdfmanuals com...

Page 305: ...electrics 3 mm mm mm mm 11 Common electrics page Common electrics general Under the function common electrics one finds electrical functions that are common to several of the machine s main functions...

Page 306: ...position 1 Main fuse boom top 2 Control breaker 3 Circuit fuses electrical distribution box cab 4 Main fuses boom attachment 5 Main fuses electrical distribution box frame 6 Circuit fuses electrical...

Page 307: ...power to ig nition voltage 15 50 A 4 Battery voltage 30 to cab engine and transmis sion 50 A 5 Electric power feed relay K2 electric power to control breaker voltage 15E 50 A 6 Ignition voltage 15 to...

Page 308: ...fuses electrical distribution box cab Circuit fuses electrical distribution box frame F54 K3 F 5 8 3 F 5 8 2 F 5 8 1 K1 K2 K4 D793 X168 000271 A D C B 004928 005112 H8 G7 F6 E5 D4 C3 B2 A1 25A ATTACH...

Page 309: ...anging 1 Turn off the main electric power battery disconnector 2 Remove the cover from the fuse holder 3 Check that fuses are intact Change when needed IMPORTANT Risk of cable damage and fire in cable...

Page 310: ...3 Check that the battery terminals are free from dirt If needed grease the battery terminals with terminal grease 4 Check the fluid level in the battery cells Top up with battery water if needed The...

Page 311: ...ntenance manual DRF 400 450 11 Common electrics 11 4 Alternator 9 11 4 Alternator page Alternator component position page Alternator changing See supplier documentation engine 001905 https www forklif...

Page 312: ...is activated and the redundant CAN bus is initiated Start up is handled by control unit cab D790 1 The first pre requisite for the machine to be able to perform any ac tion is to first establish the...

Page 313: ...ing takes place when the system goes down in powerless mode 1 Control unit cab D790 1 cuts off manoeuvre switch volt age 15E See Manoeuvre switch voltage 15E description page 14 2 Control unit cab D79...

Page 314: ...interfere with the voltage feed to the other control units When all control units have redundant voltage feed and bus commu nication the system is ready to receive process signals When redundant volta...

Page 315: ...activated the following takes place 1 Battery disconnector in position 1 Voltage feed to Control unit cab D790 1 ignition switch flashing hazard lights door switch and interior lighting 2 Switch for s...

Page 316: ...ted to Control unit cab D790 1 2 Control unit cab D790 1 activates power relay K2 in electrical distribution box frame and control breaker voltage 15E feeds the circuit to relay K3 in electrical distr...

Page 317: ...11 1 4 5 8 003168 9 6 7 1 Control unit cab D790 1 8 Control unit attachment left legs D791 3 2 Control unit KID D795 9 Control unit attachment right leg pair D791 4 3 Control unit KIT D790 2 10 Contr...

Page 318: ...bus Redundant CAN bus means that every control unit has two connec tions for communication The CAN bus is connected in series be tween the control units This means that the CAN bus can handle loss of...

Page 319: ...ents D Error codes Error codes 3 Error codes explanation 3 Reading out error code 4 1 Engine 6 Error codes engine alternative Volvo 6 Error codes engine alternative Cummins 23 2 Transmission 39 Error...

Page 320: ...UDRF01 04GB Maintenance manual DRF 400 450 2 D Error codes https www forkliftpdfmanuals com...

Page 321: ...ormation of what should be checked to find the cause of the error code Diagnostic menu reference to suitable diagnostic menu to fix the problem read signal value or check the function In the descripti...

Page 322: ...enu is shown Hold Enter pressed in for at least two seconds 4 The error code list is shown on the display Active error code is shown on display where field C shows error code number to gether with X Y...

Page 323: ...e error shown with a symbol in field E The book symbol encourages the operator to read the op erator s manual 6 Use the error code tables to find more information about the er ror code Error codes eng...

Page 324: ...Check that the 23 pin connector is installed correctly Check pin C and socket C in the 23 pin connector Check connection 3 in the red connector on the en gine s control unit D794 Red 3 1 1 2 Throttle...

Page 325: ...is in stalled correctly D794 Black 14 ENGINE menu 6 1 8 3 Sensor oil pressure 100 4 182 DTC 3 1 Sensor oil pressure open cir cuit or short circuited to ground No limita tion Check cabling between cont...

Page 326: ...ol unit D794 Black 3 ENGINE menu 7 1 6 5 Sensor boost pressure 105 0 31 DTC 6 1 High cool ant tem perature Engine is shut off Check coolant level Check that radiator is clean Check that there s no air...

Page 327: ...ble short circuited to voltage or open circuit Preheating activated even when engine is warm Check that sensor coolant temperature is installed correctly and connected Check cabling between control un...

Page 328: ...system 175 3 184 DTC 3 7 Sensor oil tempera ture cable short circuited to voltage or open circuit None Check cabling between control unit and compo nent Check that sensor oil tem perature is connecte...

Page 329: ...r on the en gine s control unit D794 Black 4 1 6 5 Sensor boost pressure 1 6 6 Sensor charge air temperature 1 7 9 Sensor coolant tem perature 1 8 3 Sensor oil pressure 1 8 7 Sensor oil tempera ture 6...

Page 330: ...29 11 186 DTC 9 9 Memory error in control unitengine D794 Engine doesn t start Change control unit engine D794 11 5 3 10 Con trol unit engine 629 12 187 DTC 9 9 Memory error in control unitengine D794...

Page 331: ...sor camshaft rpm 636 8 103 DTC 2 5 Sensor en gine rpm camshaft Abnormal frequency Engine takes longer time to start than normal En gine runs normal when start ed Check that sensor is in stalled correc...

Page 332: ...gine goes to idle and can only be stoppedwith emergency stop Check that the 8 pin con nector isn t damaged Check that cables between CIU and engine s control unit aren t damaged Check that connection...

Page 333: ...onnection 11 and 12 in CIU connector are intact Check connection 1 and 2 in the red connector on the engine s control unit D794 Red 1 Red 2 CAN POWER menu 2 1 6 3 CAN bus drivetrain 651 11 113 DTC 7 1...

Page 334: ...e harness aren t dam aged Perform compression test and check cylinder 1 D794 Black 11 Black 12 1 2 8 Injectors 1 5 Engine me chanical parts 652 11 123 DTC 7 2 Electric malfunc tion injec tor cylinder...

Page 335: ...e harness aren t dam aged Perform compression test and check cylinder 2 D794 Black 22 Black 12 1 2 8 Injectors 1 5 Engine me chanical parts 653 11 133 DTC 7 3 Electric malfunc tion injec tor cylinder...

Page 336: ...e harness aren t dam aged Perform compression test and check cylinder 3 D794 Black 23 Black 12 1 2 8 Injectors 1 5 Engine me chanical parts 654 11 143 DTC 7 4 Electric malfunc tion injec tor cylinder...

Page 337: ...e harness aren t dam aged Perform compression test and check cylinder 4 D794 Black 34 Black 24 1 2 8 Injectors 1 5 Engine me chanical parts 655 11 153 DTC 7 5 Electric malfunc tion injec tor cylinder...

Page 338: ...ons to unit injectors aren t dam aged Perform compression test and check cylinder 5 D794 Black 35 Black 24 1 2 8 Injectors 1 5 Engine me chanical parts 656 11 163 DTC 7 6 Electric malfunc tion injec t...

Page 339: ...orunit injector on cylinder 6 Rough run ning at low rpms and low load Check fuel feed pressure Check valve s clearance Check that unit injector and cable harness aren t dam aged Perform compression te...

Page 340: ...o starter motor yellow black is con nected correctly Check that cable to starter motor yellow black isn t damaged Check that relay on starter motor is intact Check connection 31 in the red connector o...

Page 341: ...ion error with Control unit cab D790 1 electric mal function throt tle pedal Engine only runs at idle Use diagnostic menu to lo calize incorrect segment CAN POWER menu 2 1 9 Control system en gine 91...

Page 342: ...rol unit and compo nent Check component D794 Sen sor 09 1 2 10 Make contact wa ter in fuel 97 4 429 Electric mal function wa ter in fuel cable short circuited to ground No limitation Check cabling bet...

Page 343: ...Sensor oil pressure 102 2 433 Sensor boost pressure indi cates heard boost pres sure but other engine data indicate that pressure should be low Reduced en gine power Check cabling between control unit...

Page 344: ...cuited to ground or open circuit Risk of white exhaust smoke No warning for hear coolant temperature Check cabling between control unit and compo nent Check that sensor charge air temperature is insta...

Page 345: ...45 Sensor cool ant tempera ture cable short circuited to ground No display of engine temper ature Check cabling between control unit and compo nent Check that sensor coolant temperature is connected c...

Page 346: ...w battery voltage Warning active until voltage is correct Check fuses Check batter ies and alternator D794 OEM 7 OEM 8 OEM 17 OEM 18 OEM 28 11 5 1 3 Igni tion voltage 15 167 18 597 High battery voltag...

Page 347: ...m perature Check cabling between control unit and compo nent Check that sensor oil tem perature is connected cor rectly D794 Sen sor 42 EN GINE menu 7 1 8 7 Sensor oil tempera ture 175 4 213 Sensor oi...

Page 348: ...unction sen sor throttle pedal idle switch cali bration error Engine only runs at idle Check cabling between Control unit and compo nent Check component 1 1 2 Throt tle pedal 558 2 431 Electric mal fu...

Page 349: ...1 8 3 Sensor oil pressure 1 8 7 Sensor oil tempera ture 626 11 381 Electric mal function of control of re lay preheat ing Preheating not working Risk of white smoke Check cabling between Control unit...

Page 350: ...ys tem 639 13 286 Communica tion error with Control unit engine D794 configuration error Use diagnostic menu to lo calize incorrect segment CAN POWER menu 2 1 9 Control system en gine 639 2 426 Commun...

Page 351: ...ds rough and has re duced power Check cabling between Control unit and compo nent Check component D794 Actua tor 10 Actua tor 9 1 2 8 Injec tors 652 5 331 Electric mal function cylin der 2 open circui...

Page 352: ...on ca ble Engine runs on 5 cylinders sounds rough and has re duced power Check cabling between Control unit and compo nent Check component D794 Actua tor 3 Actua tor 4 1 2 8 Injec tors 655 6 312 Elec...

Page 353: ...ent CAN POWER menu 2 1 9 Control system en gine 974 3 133 Electric mal function extra throttle ped al cable short circuited to voltage Engine doesn t respond to throttle appli cation Check cabling bet...

Page 354: ...ited to ground Reduced en gine power Check cabling between Control unit and compo nent Check component D794 Sen sor 17 Sen sor 37 1 9 Control system en gine 1083 3 293 Electric mal function extra sens...

Page 355: ...burn cable short circuited to ground No limitation Check cabling between Control unit and compo nent Check component 1 9 Control system en gine 1319 2 419 Electric mal function sen sor boost pressure...

Page 356: ...limitation Turn off the engine with start key 1384 31 299 Engine shut off in another way than via start key with for load No limitation Turn off the engine with start key 1484 31 211 Error codes in o...

Page 357: ...mation 11 5 3 9 Con trol unit trans mission 00 52 00 52 Memory errorin control unit transmission Transmission in locked neutral po sition Shut down mode Contact Kalmar In dustries AB for more informat...

Page 358: ...restarts to clear memory Check cabling to control unit Check alternator battery and cabling between battery and alternator 11 5 1 3 Igni tion voltage 15 30 05 30 05 High battery voltage Control unit...

Page 359: ...ose to understand if and if that is the case which clutch is slipping Check the set transmission ratio for the control unit 2 3 Mechani cal transmis sion 43 03 43 03 Signal from Sensor engine rpm and...

Page 360: ...essure B253 D793 A 2 B253 TRANSM menu 10 2 6 2 Sensor oil pressure 50 01 50 01 Sensor oil pres sure not con nected or open circuit Control unit acti vates Limp home mode Check cabling to sensor oil pr...

Page 361: ...measurement to the highest value in its settings which results in poor tempera ture compensa tion Check cabling to sensor oil sump temperature trans mission Check Sensor oil temperature S221 D793 J3...

Page 362: ...ircuited to ground D793 S1 56 01 56 01 Analogue input 6 not connect ed D793 S1 60 00 60 00 Sensor drum rpm short circuited to ground When only one rpm signal which isn t the engine rpm signal is in co...

Page 363: ...rol unit calculates the missing rpm If several rpm sig nals or the engine rpm signal is in correct the con trol unit activates Limp home mode Check cabling be tween Control unit and component Check co...

Page 364: ...t the con trol unit calculates the missing rpm If several rpm sig nals or the engine rpm signal is in correct the con trol unit activates Limp home mode Check cabling be tween Control unit and compone...

Page 365: ...t acti vates Limp home mode Check cabling to solenoid valve for ward Y630 D793 B1 Y630 C1 Y630 TRANSM menu 8 2 3 4 Valve block trans mission con trol 70 01 70 01 Electric mal function sole noid valve...

Page 366: ...ircuit or short circuited volt age Control unit acti vates Limp home mode Check cabling to solenoid valve gear 2 4 Y6069 Check solenoid valve gear 2 4 Y6069 D793 D1 Y6069 E1 Y6069 TRANSM menu 8 2 3 4...

Page 367: ...reverse Y631 D793 F1 Y631 G1 Y631 TRANSM menu 8 2 3 4 Valve block trans mission con trol 72 02 72 02 Electric mal function sole noid valve reverse con trol current above 1400mA Control unit acti vate...

Page 368: ...1 Y6067 TRANSM menu 8 2 Transmis sion 73 02 73 02 Electric mal function gear 1 3 control cur rent above 1400mA Control unit acti vates Limp home mode Check cabling to solenoid valve gear 1 3 Y6067 Che...

Page 369: ...ect im pedance D793 B01 75 00 75 00 Analogue out put signal 5 out put signal short circuited to ground D793 B03 75 01 75 01 Analogue out put signal 5 out put signal not connected or short circuited to...

Page 370: ...tion Check cabling to solenoid valve brake Y602 Check solenoid valve brake Y602 D793 R1 Y602 2 3 4 Valve block trans mission con trol 80 00 80 00 Electric mal function drive cable short circuited to g...

Page 371: ...o solenoid valve gear selection 1 3 Y6075 Check solenoid valve 1 3 selection Y6075 D793 F2 Y6075 TRANSM menu 7 2 3 4 Valve block trans mission con trol 83 00 83 00 Electric mal function drive cable sh...

Page 372: ...at tachment not working Use diagnostic menu to lo calise incorrect segment Varies de pending on ma chine con figuration CAN POWER menu 2 11 6 2 Redun dant CAN bus 4 Communication er ror with control...

Page 373: ...on figuration CAN POWER menu 2 11 6 2 Redun dant CAN bus 12 Cable harness error CAN net segment 2 No limita tion Use diagnostic menu to lo calise incorrect segment Varies de pending on ma chine con fi...

Page 374: ...unit transmis sion D793 D790 1 K13 1 K13 2 CAN POWER menu 3 11 6 3 CAN bus drivetrain 22 Communication er ror with Control unit engine D794 Engine does not respond to com mands from the cab Use diagn...

Page 375: ...3 K1 4 CAN POWER menu 6 11 5 1 3 Igni tion voltage 15 32 5 V feed voltage to control below 4 9 V or above 5 1 V Certain con trols in the cab do not work Check cabling between the control unit and comp...

Page 376: ...Perform software down load again D793 11 5 3 9 Con trol unit trans mission 38 Interference during software download Buffer for error codes from trans mission some transmission error has been active T...

Page 377: ...ghts cab not working Check cabling between the control unit and component with diagnostic menu Check component D790 1 K2 7 H404 2 LIGHTS menu 1 9 6 10 Work lights cab 45 Transistor has been triggered...

Page 378: ...ning is activated Check signals and cabling with diagnostic menu D797 R K1 23 S246 CLI MATE menu 3 and CLI MATE menu 2 9 4 10 Pres sure monitor 81 Incorrect position signal from Damper motor Y672 Air...

Page 379: ...4 ATTACH menu 1 7 1 1 Control lever 92 Signal error from joystick or mini wheel R825 1 Joystick steering or mini wheel not working Check cabling between the control unit and component with diagnostic...

Page 380: ...stic menu Check component D797 F K2 8 CAN POWER menu 8 11 5 1 2 Re dundant volt age feed of control units 103 Voltage feed to Control unit frame front D797 F be low 18 V or above 32 V Check fuse F58 2...

Page 381: ...iagnostic menu Check bulb socket D797 F K1 15 H402R LIGHTS menu 6 9 6 2 High beams 113 Transistor has been triggered due to short circuit or open circuit in cir cuit for central lu brication unit M693...

Page 382: ...797 F K1 5 Y6007 BOOM menu 8 7 3 3 Control valve lift low er and exten sion 119 Transistor has been triggered due to short circuit or open circuit in cir cuit for solenoid valve blocking lift left Y60...

Page 383: ...22 LIGHTS menu 8 9 6 7 Direc tion indicators 125 Transistor has been triggered due to short circuit or open circuit in cir cuit for light for di rection indicator right front H423 Direction in dicator...

Page 384: ...ns operate at reduced speed Error code 150 ac tivated Check cabling between the control unit and component with diagnostic menu Check component D797 F K1 21 B768 12 OP menu 3 7 2 9 Sensor hydraulic pr...

Page 385: ...ircuit in cir cuit for solenoid valve boom down Y6004 Lower not working Check cabling between the control unit and component with diagnostic menu Check component D797 F K1 17 Y6004 BOOM menu 5 7 2 3 C...

Page 386: ...d system Check components and wiring with diagnostic menu OP menu 1 5 8 2 1 Over load system 151 Redundant voltage feed left to control unit frame rear D797 R does not arrive Check cabling between the...

Page 387: ...the control unit and component with diagnostic menu Check bulb socket D797 R K1 1 H406L 1 LIGHTS menu 3 9 6 11 Work light boom 162 Transistor has been triggered due to short circuit or open circuit in...

Page 388: ...menu Check component D797 R K1 30 H965 LIGHTS menu 11 9 7 2 Back up alarm 170 Transistor has been triggered due to short circuit or open circuit in cir cuit for Solenoid valve top hydraulics Y6003 At...

Page 389: ...ket D797 R K1 10 H412L LIGHTS menu 5 9 6 4 Rear light 176 Transistor has been triggered due to short circuit or open circuit in cir cuit for light rear light right H421R Rearlight left not working Che...

Page 390: ...uit or open circuit in cir cuit for solenoid valve pump unload ing Y6062 Unloading of hydraulic oil pumps at boom in not working Check cabling between the control unit and component with diagnostic me...

Page 391: ...omponent with diagnostic menu Check component D797 O K2 8 CAN POWER menu 8 11 5 1 2 Re dundant volt age feed of control units 203 Voltage feed to con trol unit frame op tion D797 O below 18 V or above...

Page 392: ...diagnostic menu Check component D797 O K1 5 Y636R EL STEER ING menu 5 5 2 10 Con trol valve joy stick control mini wheel 219 Transistor has been triggered due to short circuit or open circuit in cir...

Page 393: ...component D797 O K1 16 Y6016 SLIDING CAB menu 3 9 10 Cab structure and suspension 238 Transistor has been triggered due to short circuit or open circuit in cir cuit for solenoid valve cab back ward do...

Page 394: ...cabling between the control unit and component with diagnostic menu D791 1 K2 11 CAN POWER menu 8 11 5 1 4 Con trol switch voltage 15E 260 Transistor has been triggered due to short circuit or open ci...

Page 395: ...and component with diagnostic menu Check component D791 1 K1 2 Y6008 ATTACH menu 9 7 6 3 Control valve attach ment 266 Transistor has been triggered due to short circuit or open circuit in cir cuit fo...

Page 396: ...ith diagnostic menu Check component D791 1 K1 32 Y6040 ATTACH menu 7 7 9 1 3 Con trol valve at tachment 272 Transistor has been triggered due to short circuit or open circuit in cir cuit for solenoid...

Page 397: ...nt with diagnostic menu Check bulb socket D791 1 K1 39 H563 ATTACH menu 8 7 1 14 Light panel boom 287 Transistor has been triggered due to short circuit or open circuit in cir cuit for solenoid valve...

Page 398: ...y adjusted Check cabling between the control unit and component with diagnostic menu ATTACH menu 8 7 9 1 9 Sensor twistlock 300 Sensor alignment indicates unreason able distance Twistlock not working...

Page 399: ...h diagnostic menu Check component D791 2 K1 2 Y6035 ATTACH menu 17 7 8 3 Control valve attach ment 316 Transistor has been triggered due to short circuit or open circuit in cir cuit for Solenoid valve...

Page 400: ...eck component D791 2 K1 16 Y6035 ATTACH menu 17 7 8 3 Control valve attach ment 338 Transistor has been triggered due to short circuit or open circuit in cir cuit for Solenoid valve levelling left Y60...

Page 401: ...h voltage 15E 354 Incorrect control breaker voltage to Control unit combi attachment left D791 3 Control breaker can not be re leased All hydraulic functions blocked Check fuse F58 3 1 change if neede...

Page 402: ...component D791 3 K1 3 Y6036 ATTACH menu 18 7 9 2 3 Con trol valve lift leg 367 Transistor has been triggered due to short circuit or open circuit in cir cuit for Solenoid valve front knee in Y6057L L...

Page 403: ...D791 3 K1 33 Y6060L COMBI menu 11 7 9 2 3 Con trol valve lift leg 373 Transistor has been triggered due to short circuit or open circuit in cir cuit for Solenoid valve lowering rear leg Y6014L Left li...

Page 404: ...unit and component with diagnostic menu Check bulb socket D791 3 K1 39 H567L COMBI menu 7 7 1 14 Light panel boom 379 Transistor has been triggered due to short circuit or open circuit in cir cuit for...

Page 405: ...Control breaker voltage to Control unit combi attach ment right D791 4 below 18 V or above 32 V Control breaker can not be re leased All hydraulic functions blocked Check fuse F58 3 1 change if needed...

Page 406: ...with diagnostic menu Check component D791 4 K1 42 Y6053R COMBI menu 16 7 9 2 5 Valve operating po sition 415 Transistor has been triggered due to short circuit or open circuit in cir cuit for Solenoi...

Page 407: ...onent D791 4 K1 31 Y6058R COMBI menu 12 7 9 2 3 Con trol valve lift leg 421 Transistor has been triggered due to short circuit or open circuit in cir cuit for Solenoid valve lowering front leg Y6013R...

Page 408: ...icator light clamp ing position lift leg front not working Check light Check cabling between the control unit and component with diagnostic menu Check bulb socket D791 4 K1 29 H578 COMBI menu 8 7 1 14...

Page 409: ...to check CAN bus CAN POWER menu 1 2 11 6 2 Redun dant CAN bus 500 Service interval reached No limita tion Check that service has been completed If service is performed according to Kalmar Industries...

Page 410: ...UDRF01 04GB Maintenance manual DRF 400 450 92 D Error codes 8 Control system https www forkliftpdfmanuals com...

Page 411: ...ilt lock controllable tilt and hydraulic levelling 10 Hydraulic diagram joystick steering 12 Hydraulic diagram sliding cab 14 Hydraulic diagram cab lift and support jacks 16 Hydraulic diagram sliding...

Page 412: ...UDRF01 04GB Maintenance manual DRF 400 450 2 ESchematics https www forkliftpdfmanuals com...

Page 413: ...iagram top lift tilt lock controllable tilt and hydraulic levelling page 10 A43123 0100 Hydraulic diagram joystick steering page 12 A48056 0100 Hydraulic diagram sliding cab page 14 A40855 0100 Hydrau...

Page 414: ...L2 L4 L3 X1 X2 B T P PP LS T P D B1 A1 B2 A2 T P PSS PS P M T ACC B H M C C VB D VA VA C C VA D T C C VA D T T P PP LS CF EF T P LS L R T P A H H 1 3 2 4 6 7 8 9 11 12 11 15 10 13 16 17 18 19 20 24 25...

Page 415: ...k 21 Brake oil tank 22 Breather filter hydraulic oil tank 23 Steering valve 24 Steering cylinder 25 Oil return from attachment 26 Brake oil filter 27 Hydraulic oil filter 28 Cooler hydraulic oil 29 By...

Page 416: ...10 Common hydraulics page Hydraulic diagram top lift B1 B2 S L1 L2 L4 L3 X1 X2 P C2 C1 C1 C2 T A B P T PP T B A B A B A B A T1 P1 PS TPB P2B T2B T3B LSPB B C A 003184 A40853 0100 ver 4 1 3 3 4 5 6 7 8...

Page 417: ...ve block rotation motor 5 Sideshift cylinders 6 Spreader motor 7 Valve block spreader motor 8 Twistlock cylinders 9 Control valve attachment 10 Filter hydraulic oil 11 Filter hydraulic oil high pressu...

Page 418: ...ulics page Hydraulic diagram top lift tilt lock and controllable tilt B1 B2 S L1 L2 L4 L3 X1 X2 B A B A B A B A T1 P1 PS TPB P2B T2B T3B LSPB B A P PP T T B A P C1 C2 C1 C2 T 003185 A40853 0200 ver 5...

Page 419: ...ve block rotation motor 5 Sideshift cylinders 6 Spreader motor 7 Valve block spreader motor 8 Twistlock cylinders 9 Control valve attachment 10 Filter hydraulic oil 11 Filter hydraulic oil high pressu...

Page 420: ...Hydraulic diagram top lift tilt lock controllable tilt and hydraulic levelling P C2 C1 C1 C2 T A B P T PP T B1 B2 S L1 L2 L4 L3 X1 X2 A B A B B A A B A B A B P1 T1 T2 T3 TP PS 1 1 2 3 3 4 5 5 6 7 8 14...

Page 421: ...or 5 Sideshift cylinders 6 Spreader motor 7 Valve block spreader motor 8 Twistlock cylinders 9 Control valve attachment 10 Solenoid valve engagement hydraulic pressure 11 Shuttle valve 12 Hydraulic oi...

Page 422: ...DRF 400 450 12 E Schematics 10 Common hydraulics page Hydraulic diagram joystick steering B1 B2 S L1 L2 L4 L3 X1 X2 P T LS L R CF EF P T LS PP T1 P LS TP B A 1 2 3 4 5 6 7 7 001986 A40856 0100 ver 2 h...

Page 423: ...450 E Schematics 10 Common hydraulics 13 1 Control valve option frame 2 Steering cylinder 3 Steering valve 4 Priority valve 5 Shuttle valve 6 Shuttle valve joystick steering 7 Hydraulic oil pumps 3 a...

Page 424: ...aintenance manual DRF 400 450 14 E Schematics 10 Common hydraulics page Hydraulic diagram sliding cab B1 B2 S L1 L2 L4 L3 X1 X2 T1 P LS TP B A 1 2 3 4 5 6 002394 A40855 0100 ver 1 https www forkliftpd...

Page 425: ...E Schematics 10 Common hydraulics 15 1 Control valve option frame 2 Hydraulic motor sliding cab 3 Solenoid valve engagement hydraulic pressure 4 Shuttle valve 5 Shuttle valve option 6 Hydraulic oil pu...

Page 426: ...RF 400 450 16 E Schematics 10 Common hydraulics page Hydraulic diagram cab lift and support jacks B1 B2 S L1 L2 L4 L3 X1 X2 T1 P LS TP B A B A T3 001987 A43276 0100 ver 1 2 3 3 4 4 7 8 9 1 5 6 10 11 h...

Page 427: ...n frame 2 Accumulator 3 Hydraulic cylinder support jacks 4 Valve block support jacks 5 Load control valve 6 Hydraulic cylinder cab lift lowering 7 Restriction 8 Valve block top lift hydraulics 9 Shutt...

Page 428: ...l DRF 400 450 18 E Schematics 10 Common hydraulics page Hydraulic diagram sliding cab and support jacks 001985 A40854 0100 ver 1 1 2 2 3 3 4 5 6 7 8 9 B1 B2 S L1 L2 L4 L3 X1 X2 T1 P LS TP B A B A http...

Page 429: ...trol valve option frame 2 Hydraulic cylinder support jacks 3 Over centre valve support jacks 4 Hydraulic motor sliding cab 5 Restriction 6 Solenoid valve engagement hydraulic pressure 7 Shuttle valve...

Page 430: ...iagram combi attachment part 1 of 3 P C2 C1 C1 C2 T A B P T PP T B1 B2 S L1 L2 L4 L3 X1 X2 A B A B B A A B A B A B P1 T1 P2 T2 T3 TP PS 001206 A 001207 D 001207 F 001205 A41791 0100 ver 1 part 1 3 2 1...

Page 431: ...rotation motor 5 Sideshift cylinders 6 Spreader motor 7 Valve block spreader motor 8 Twistlock cylinders 9 Valve block levelling cylinders 10 Over centre valve levelling 11 Levelling cylinders 12 Cont...

Page 432: ...E Schematics 10 Common hydraulics page Hydraulic diagram combi attachment part 2 of 3 P T A B A B A B A B A B A B P1 T3 T2 P2 TP 1 2 5 10 6 7 3 4 8 9 001205 A 001205 B 001205 C 001206 A41791 0100 ver...

Page 433: ...leg 3 Valve block lowering front lift leg 4 Valve block lowering front lift leg 5 Clamping cylinder front lift leg 6 Valve block operating position front lift leg 7 Clamping cylinder rear lift leg 8...

Page 434: ...24 E Schematics 10 Common hydraulics page Hydraulic diagram combi attachment part 3 of 3 A B A B A B A B A B T1 P1 T2 T3 P2 TP 001205 E 001205 D 001205 F 1 2 3 4 8 9 10 5 6 7 001207 A41791 0100 ver 1...

Page 435: ...t leg 3 Valve block lowering front lift leg 4 Valve block lowering front lift leg 5 Clamping cylinder front lift leg 6 Valve block operating position front lift leg 7 Clamping cylinder rear lift leg 8...

Page 436: ...type in the specific dia gram Sensors etc are drawn in resting position on circuit powerless mode Colour cable harness White cable ground signal Grey cable Other cable harness Fuse box e g F58 means...

Page 437: ...gnals or vice versa Example inductive sensor D Binary element delay unit memory Example control unit F Protective device Example fuse G Alternator power supply device Example battery H Signal device E...

Page 438: ...X X Circuit sliding cab vertically adjustable cab 9 10 A43041 0100 X X X Circuit brake system 4 0 A43042 0100 X X X Circuit attachment twistlock 7 9 A43043 0100 X X X Circuit cross references 0 0 A430...

Page 439: ...eel 5 2 A43066 0100 X X X Circuit steering joystick mini wheel and combi attachment 5 2 A43066 0200 X X X Circuit reversing alarm 9 7 A43067 0100 X X X Circuit combi attachment 7 9 A43068 0100 X X X C...

Page 440: ...UDRF01 04GB Maintenance manual DRF 400 450 30 E Schematics 11 Common electrics https www forkliftpdfmanuals com...

Page 441: ...0200 1 C2 A44875 0300 1 D1 4016 A44875 0100 1 B3 A44875 0200 1 D2 A44875 0300 1 D1 4011 A44875 0100 1 C3 A44875 0200 1 C2 A44875 0300 1 D1 4012 A44875 0100 1 B3 A44875 0200 1 C2 A44875 0300 1 D1 4015...

Page 442: ...X401f 1 X401f 2 X401f 3 X401f 4 X401f 5 X401f 6 2 1 X203f 6 5 4 3 X203m 6 5 4 3 2 1 X205m A B 4 X210f 3 L Shield KCU CAN L R Shield CAN R Shield CAN J1939 RS232 TX RX Ground Power 1 Power 2 Power 1 Po...

Page 443: ...100 1 E8 37 200 A43034 0100 1 E8 37 200 A44878 0100 1 B3 A44878 0200 1 B2 58 1 3 1 A44878 0100 1 B3 A44878 0200 1 B2 58 2 2 1 A44879 0100 1 D1 A44879 0200 1 C4 58 2 5 1 A44878 0100 1 B3 A44878 0200 1...

Page 444: ...C2 58 4 3 2 X052m 6 X052f 6 X067f 2 1 3 X37 C 1 A5 0711 1 A5 0711 4 A43063 0200 1 C2 12V 1 Ben mning Utg va Issue Ritn nr Drawing No Name Klass Class H Grp 1 2 3 4 6 7 8 F E D C B A 8 7 6 5 4 3 2 1 G...

Page 445: ...5 X052f 7 1 2 1 1 2 2 Ben mning Utg va Issue Ritn nr Drawing No Name Klass Class H Grp 1 2 3 4 6 7 8 F E D C B A 8 7 6 5 4 3 2 1 Godk Appr Ritad Drawn Konstr Design Datum Date Sign Ref Ruta Nr No ndr...

Page 446: ...2 1 2 A6 58 4 1 1 2 C6 58 5 1 1 2 C6 58 5 1 2 2 D6 58 5 1 2 1 B7 58 2 3 2 1 B7 58 2 3 1 X222 1 X212 12 14 X222 12 14 X222 9 X212 1 X212 9 10 X222 11 X212 11 X001 5 6 X001 1 X001 2 3 4 X37 A X37 A Key...

Page 447: ...Sign Datum Date Sq Denna ritning f r ej utan v rt medgivande kopieras Den f r ej heller delgivas annan eller annars obe h rigen anv ndas vertr delse h rav beivras med st d av g llande lag This documen...

Page 448: ...and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr...

Page 449: ...BOOM BOOM 5 1 S105 1 CAB 1 C4 0 1 E404 3L WORKING LIGHT BOOM BOOM 10 9 A43037 0100 1 C1 CHASSIS A43037 0100 1 C1 790 1 5 1 X006 2 X006 3 X411 15 X411 1 X221 1 X221 15 X202f 7 X202f 8 XE404 3Lf 2 XE404...

Page 450: ...not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43035 0100 04 Krets...

Page 451: ...ny unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43036 0100 04 Krets Extra Arb bel Bom Circuit OPT Work Light Boom DRF...

Page 452: ...450 6 FSN 010702 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 4 A45209 0100 A43060 0100 1 B1 CHASSIS A43059 0100 1 B2 790 1 5 1 A43059 0100 1 B2 CHASSIS M H428 ROT BEACON...

Page 453: ...T CHASSIS 1 2 E400L DIPPED LIGHT LEFT FRONT CHASSIS 1 2 E402L HEAD LIGHT LEFT CHASSIS 1 2 E402R HEAD LIGHT RIGHT CHASSIS 1 2 E400R DIPPED LIGHT RIGHT FRONT CHASSIS 1 2 H417 1 SIDE POSITION RIGHT FRONT...

Page 454: ...RAKE LIGHT LEFT REAR CHASSIS 1 2 H411R BRAKE LIGHT RIGHT REAR CHASSIS 1 2 H412L REAR LIGHT LEFT CHASSIS 1 2 H412R REAR LIGHT RIGHT CHASSIS 1 2 H416 2 SIDE POSITION LEFT REAR CHASSIS 1 2 H417 2 SIDE PO...

Page 455: ...3 4 6 7 8 F E D C B A 8 7 6 5 4 3 2 1 Godk Appr Ritad Drawn Konstr Design Datum Date Sign Ref Ruta Nr No ndring Design change T Tillk Added U Utg r Deleted V Var Was ndring nr Change No Sign Datum Dat...

Page 456: ...r be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43038 0100 04 Krets Givare Instr Circuit Sensors Instr...

Page 457: ...lande lag This document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be...

Page 458: ...051 0100 1 F3 A43064 0100 1 F2 14 16 20 19 17 18 6 8 4 11 1 10 7 15 5 9 X007 9 X007 12 X007 8 X815 15 X815 7 X815 5 X007 16 X007 15 X007 14 X007 13 X008 1 X008 2 X815 14 X815 16 X815 20 X815 19 X815 1...

Page 459: ...BK BU 1 2 CHASSIS Y6016 CAB FORWARD UP 1 2 CHASSIS Y6017 CAB REVERSE DOWN 1 2 0 CHASSIS B777 2 CAB LOW POSITION BN BK BU X231 38 X231 21 XB777 2f A XB777 2f B XB777 2f C X064f 1 X064f 2 X064f 3 X231 1...

Page 460: ...50 6 FSN 010308 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 2 A45209 0100 5 7 CAB S107 PARKING BRAKE 1 A43043 0100 2 F3 A43046 0100 1 E2 A43056 0100 1 D2 A43055 0100 1 A2...

Page 461: ...not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43042 0100 04 Krets...

Page 462: ...3 2 X403Bf 4 X403Bf 5 X403Bf 6 X403Af 4 X403Af 5 X403Af 6 X403Af 3 2 XB7202Rf C XB7203Rf C XB7204Rf C XB7205Rf C XB7202Rf A XB7203Rf A XB7204Rf A XB7205Rf A X403Bf 1 X403Af 1 B XB7202Lf C B XB7204Lf...

Page 463: ...A43055 0100 1 C2 00816 A43055 0100 1 C2 W10 1 2 H562 UNLOCKED TW BOOM 1 2 H564 ALIGNMENT BOOM 1 2 H563 LOCKED TW BOOM Also indicated in symbol display A43033 0100 4 E7 1 2 ATTACHMENT Y6039 UNLOCK TW 1...

Page 464: ...8 1 19 1 15 1 20 1 22 1 21 1 23 1 24 1 25 1 28 1 27 1 29 1 30 1 31 1 26 1 32 1 33 1 36 1 35 1 37 1 38 1 39 1 34 1 40 1 41 1 42 Pin Number Drawing Function Type KDU contact K1 Pin Number Drawing Functi...

Page 465: ...PPLY SWITCH 24V reference SUPPLY SWITCH LEGS 24V reference SUPPLY SWITCH LEGS 1 5A FRONT LEGS DOWN Input FRONT LEGS DOWN Input REAR LEGS DOWN Input GND SWITCH LEGS 0V reference 24V reference CLAMP REL...

Page 466: ...PWM MICRO LEVER STEERING LEFT PWM MICRO LEVER STEERING RIGHT Input LEFT SUPPORT JACK LOWER POS Analog Input CAB LOW POSITION Analog Input TILT CAB UNLOAD HYDRAULIC OIL 1 5A TILT CAB UNLOAD HYDRAULIC...

Page 467: ...1 5A TILT LOCK 1 5A POWER SUPPLY SENSORS In Output ROTATION STOP In Output DAMPING 20 40 Input ALIGNMENT FRONT 10A CENTRAL LUBRICATION ATT 5A WORKING LIGHT ATTACHMENT PWM ROTATION C W PWM ROTATION C...

Page 468: ...upper position PWM LEVELLING RIGHT PWM LEVELLING LEFT PWM TILT OUT PWM TILT IN Input Over Height Leg upper position 1 5A LEVELLING 1 5A LEVELLING 1 5A Over height down 1 5A Over height up 0V referenc...

Page 469: ...41 1 42 Pin Number Drawing Function Type KDU contact K1 Pin Number Drawing Function Type D791 3 ATTACHMENTA43068 0100 12 C2 A44910 0200 1 D2 A44910 0200 1 E2 ATTACHMENTA43068 0100 5 C2 ATTACHMENTA430...

Page 470: ...s Class H Grp 1 2 3 4 6 7 8 F E D C B A 8 7 6 5 4 3 2 1 Godk Appr Ritad Drawn Konstr Design Datum Date Sign Ref Ruta Nr No ndring Design change T Tillk Added U Utg r Deleted V Var Was ndring nr Change...

Page 471: ...B7221m XB7221f C X221 13 P U B768 10 1 2 3 0 250bar P U B768 11 1 2 3 0 250bar P U B768 12 1 2 3 0 250bar P U B768 13 1 2 3 0 250bar B7224 MEASUREPOINT SCALE BN BK BU XB7224m A XB7224m C XB7224f C X41...

Page 472: ...43033 0100 4 F4 D790 2 CAB MULTI SWITCH GEAR Input K3 12 A43046 0200 1 B5 790 1 5 12 X040f 3 X040f 5 X040f 4 X066f 1 X066f 3 X066f 2 A43046 0200 1 B5 790 1 6 12 Ben mning Utg va Issue Ritn nr Drawing...

Page 473: ...kopieras Den f r ej heller delgivas annan eller annars obe h rigen anv ndas vertr delse h rav beivras med st d av g llande lag This document must not be copied without our written permission and the c...

Page 474: ...IPER KIT_KEYBOARD A43033 0100 4 E6 INT ROOF WIPER 53 53a 31 31b M650 2 REAR WIPER 53b 53 31b 53a 31 M650 1 FRONT WIPER 53 53a 31 31b M650 3 ROOF WIPER X002 4 X002 1 X017 5 X017 4 X017 6 X017 7 X017 8...

Page 475: ...K BU XB769 1m A XB769 1m B XB769 1m C 2024A 2029A XB769 1f C X202m 12 X221 41 X202f 12 1 2 Y6052 REGENERATION LEFT X211 11 X211 34 1 2 Y6002 BLOCKING LEFT X211 30 1 2 Y6051 REGENERATION RIGHT X211 12...

Page 476: ...n Output K1 40 X211f 4 X211f 5 X211f 18 X211f 19 X301 2B A43033 0100 1 D4 37 200 A43044 0100 1 B4 D797 F CHASSIS BOOM OUT 1 5A K1 4 Ben mning Utg va Issue Ritn nr Drawing No Name Klass Class H Grp 1 2...

Page 477: ...041478 TKB 040930 1 1 A45209 0100 A43040 0100 1 D3 1 2 ATTACHMENT Y6008 ROTATION C W 1 2 ATTACHMENT Y6009 ROTATION C C W 1 2 CHASSIS Y6003 ACTIVATION OF TOPLIFT HYDRAULICS ATTACHMENTA43051 0100 1 E4...

Page 478: ...0100 04 Krets Agg funktion Circuit Att function DRFA 400 450 6 FSN 010327 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 2 ATTACHMENT A45209 0100 A43040 0100 1 D3 S1005 A430...

Page 479: ...2 2 A45209 0100 A43043 0100 2 B2 W10 A43043 0100 2 A2 00816 ATTACHMENT B777 3 30 35 STOP BN BK BU X411 20 X779f A X779f B X779f C X008 10 X779m A X779m B X779m C A43054 0100 1 C2 00816 A43054 0100 1 C...

Page 480: ...third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43053 0100 04 Krets Hydraulik Circuit Hy...

Page 481: ...RFB 400 450 6 FSN 010307 RKO 040223 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 2 A45209 0100 A43046 0100 1 D2 790 1 5 1 A43038 0100 1 C7 CHASSIS X005 1 X081f 1 X081f 2 X080f 9 X006...

Page 482: ...e pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43054 0100 05 Krets Extra Utrustning Circuit Option DRFB 400 450 6 TKB 030815 RKO 040223 1 Reference Text Adjustm...

Page 483: ...imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43055 0100 04 Krets F rbi...

Page 484: ...56 0100 04 Krets Larm Ljudsignaler Circuit Alarm Soundsignals DRFA 400 450 6 FSN 010327 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 2 A45209 0100 H CAB S162 MULTI SWITCH...

Page 485: ...e copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E...

Page 486: ...t Adjustment Sync Harnesses 041478 TKB 040930 1 2 A45209 0100 1 2 H574 SUPPORT JACK DOWN CAB A43042 0100 1 B1 W10 3 1 CAB S1013 SUPPORT JACKS 7 1 C4 10 9 1 B4 A43041 0100 1 B2 00815 A43041 0100 1 B7 W...

Page 487: ...CHASSIS B7223L LEFT SUPPORT JACK LOWER POS BN BK BU CHASSIS B7222R RIGHT SUPPORT JACK UPPER POS BN BK BU CHASSIS B7223R RIGHT SUPPORT JACK LOWER POS BN BK BU X231 13 X231 20 XB7222Lf A XB7223Lf A X231...

Page 488: ...tents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A...

Page 489: ...pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43059 0100 05 Krets Hytt F rarstol Circuit Cab Seat OPT DRFA 400 450 6 FSN 010410 RKO 031210 1 Reference Text Adju...

Page 490: ...nna ritning f r ej utan v rt medgivande kopieras Den f r ej heller delgivas annan eller annars obe h rigen anv ndas vertr delse h rav beivras med st d av g llande lag This document must not be copied...

Page 491: ...10 9 A43033 0100 2 B6 58 4 2 2 A43037 0100 1 B1 CHASSIS A43037 0100 1 C1 CHASSIS A43033 0100 4 F4 D790 2 CAB Input K8 8 A43033 0100 4 F4 D790 2 CAB Input K8 9 1 2 H422 DIRECTION LEFT FRONT CHASSIS 1 2...

Page 492: ...C 1 2 TEMP FAN AIR B775 3 10 kOhm at 25 C 1 2 DEICING SENSOR X278f 5 X005 7 X005 8 X005 10 X005 9 X033f 1 X033f 2 X033f 3 X005 11 X033f 5 X033f 4 X004 12 X004 8 X004 9 X004 10 X004 11 X775 1 1 X774 1...

Page 493: ...6 X039f 5 X036f 1 X221 11 X221 26 X645 1 X278f 1 X034f 7 X034f 9 X034f 8 X010 4 X657f 1 X657f 2 X039f 8 X036f 2 X036f 3 X033m 8 X033m 7 X035m 1 X035m 4 X035m 2 X035m 6 X035m 5 X034m 4 X034m 5 X034m 1...

Page 494: ...permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product...

Page 495: ...rav beivras med st d av g llande lag This document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized pur...

Page 496: ...utan v rt medgivande kopieras Den f r ej heller delgivas annan eller annars obe h rigen anv ndas vertr delse h rav beivras med st d av g llande lag This document must not be copied without our writte...

Page 497: ...ermission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5...

Page 498: ...FA 400 450 6 FSN 010731 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 CHASSIS B777 4 TILT CAB UNLOAD HYDRAULIC OIL BN BK BU 1 2 CHASSIS Y6047 TILT CAB UP 1 2...

Page 499: ...2 D790 1 Analog reference 5V K9 7 Ben mning Utg va Issue Ritn nr Drawing No Name Klass Class H Grp 1 2 3 4 6 7 8 F E D C B A 8 7 6 5 4 3 2 1 Godk Appr Ritad Drawn Konstr Design Datum Date Sign Ref Rut...

Page 500: ...ravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43066 0100 05 Krets Styrn spak miniratt Circuit Micro lever wheel DRFA 400 450 6 FSN 011122 RKO 0...

Page 501: ...CAB Input K1 27 D790 3 CAB Input K1 41 Ben mning Utg va Issue Ritn nr Drawing No Name Klass Class H Grp 1 2 3 4 6 7 8 F E D C B A 8 7 6 5 4 3 2 1 Godk Appr Ritad Drawn Konstr Design Datum Date Sign R...

Page 502: ...6 0200 04 Krets Styrn spak miniratt och Kombiagg Circuit Micro lever wheel and Combi Att DRFA 400 450 6 TKB 030428 RKO 031210 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 2 2 A45209 01...

Page 503: ...ot be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C...

Page 504: ...i Att DRFA 400 450 6 FSN 011122 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 12 CAB A45209 0100 3 1 S1006 7 1 A4 1 2 0 10 9 FRONT LEGS DOWN 1 A4 3 1 S1007 7 1 C4 10 9 REAR...

Page 505: ...a Nr No ndring Design change T Tillk Added U Utg r Deleted V Var Was ndring nr Change No Sign Datum Date Sq Denna ritning f r ej utan v rt medgivande kopieras Den f r ej heller delgivas annan eller an...

Page 506: ...Product 5 Huvudnr Project no A43068 0100 04 Krets Kombi Agg Circuit Combi Att DRFA 400 450 6 FSN 020530 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 3 12 ATTACHMENT A45209 0...

Page 507: ...G R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43068 0100 04 Krets Kombi Agg Circuit Combi Att DRFA 400 450 6 FSN 020530 RKO 031009 1 Reference Text Adjustment Sync Harnesses 04147...

Page 508: ...Product 5 Huvudnr Project no A43068 0100 04 Krets Kombi Agg Circuit Combi Att DRFA 400 450 6 FSN 020530 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 5 12 ATTACHMENT A45209 0...

Page 509: ...NG R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43068 0100 04 Krets Kombi Agg Circuit Combi Att DRFA 400 450 6 FSN 020530 RKO 031009 1 Reference Text Adjustment Sync Harnesses 0414...

Page 510: ...ATTACHMENT A45209 0100 8 A2 X44126 B7217R FRONT KNEE BN BK BU B7219R FRONT LEG BN BK BU B7215R CLAMP FRONT LEG BN BK BU B7213R ALIGNMENT FRONT LEG BN BK BU X441 26 XB7217Rf A XB7219Rf A XB7215Rf A XB7...

Page 511: ...AR KNEE BN BK BU B7220R REAR LEG BN BK BU B7216R CLAMP REAR LEG BN BK BU B7214R ALIGNMENT REAR LEG BN BK BU B7212R DRIVING POSITION BN BK BU XB7212Rf A X441 40 XB7212Rf B XB7212Rf C X441 22 X441 37 X4...

Page 512: ...ATTACHMENT A45209 0100 10 A2 X43126 B7217L FRONT KNEE BN BK BU B7219L FRONT LEG BN BK BU B7215L CLAMP FRONT LEG BN BK BU B7213L ALIGNMENT FRONT LEG BN BK BU X431 21 X431 36 X431 23 X431 27 X431 13 XB7...

Page 513: ...EAR KNEE BN BK BU B7220L REAR LEG BN BK BU B7216L CLAMP REAR LEG BN BK BU B7214L ALIGNMENT REAR LEG BN BK BU B7212L DRIVING POSITION BN BK BU X431 40 XB7212Lf B XB7218Lf A XB7214Lf A XB7216Lf A XB7220...

Page 514: ...IND ALIGNMENT LEFT FRONT BOOM 1 2 H567L IND ALIGNMENT LEFT REAR BOOM X415f 7 X415f 8 X415f 9 X415f 10 X415f 12 X443f 5 X443f 6 X443f 7 X443f 8 X433f 6 X433f 7 X433f 8 X443f 12 X433f 5 X433f 12 X441 10...

Page 515: ...eof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43068 0100...

Page 516: ...ird party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A44875 0100 03 Krets CAN BUS AGG Circuit CA...

Page 517: ...ted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A44875 0200 03 Krets CAN BUS AGG Circuit CAN BUS ATT DRFA 400 450 6 FSN 030110 RKO 031009 1 Reference Text Adjustment Sync H...

Page 518: ...030224 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 X442 2 3 7 X442 8 4 5 X432 2 3 7 X432 8 4 5 2 3 4 X412f 5 7 8 1 2 3 X414f 4 5 X414f 6 X414m 4 5 X414m 6 1...

Page 519: ...ermission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5...

Page 520: ...1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 2 A45209 0100 X794 1f 7 8 X794 1f 17 18 X794 1f 28 29 30 X794 1f 37 38 39 40 X794 1f 46 X794 1f 50 X794 1m 1 50 2 50 3 50 4 50 5 50 6 50...

Page 521: ...must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E...

Page 522: ...se Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A44879 0100 04 Krets Dana TE 32000 Circuit Dana TE 32000 DRFA 400 450 6 TKB 030516 RKO 0312...

Page 523: ...5 4 3 2 1 Godk Appr Ritad Drawn Konstr Design Datum Date Sign Ref Ruta Nr No ndring Design change T Tillk Added U Utg r Deleted V Var Was ndring nr Change No Sign Datum Date Sq Denna ritning f r ej ut...

Page 524: ...Issue Ritn nr Drawing No Name Klass Class H Grp 1 2 3 4 6 7 8 F E D C B A 8 7 6 5 4 3 2 1 Godk Appr Ritad Drawn Konstr Design Datum Date Sign Ref Ruta Nr No ndring Design change T Tillk Added U Utg r...

Page 525: ...ritten permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt P...

Page 526: ...Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 1 2 Y6035 LEVELLING RIGHT 1 2 Y6036 LEVELLING LEFT 1 2 Y6010 TILT OUT 1 2 Y6011 TILT IN 1 2 Y6034 1 LEVELLING 1 2 Y6034 2 LEVELLING X421 2 X...

Page 527: ...LEFT PWM K1 17 Ben mning Utg va Issue Ritn nr Drawing No Name Klass Class H Grp 1 2 3 4 6 7 8 F E D C B A 8 7 6 5 4 3 2 1 Godk Appr Ritad Drawn Konstr Design Datum Date Sign Ref Ruta Nr No ndring Des...

Page 528: ...ed for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A45043 0100 04 Krets Over Height Circuit Over Height DRFA 400...

Page 529: ...7 X421 33 B7231 L Over Height Leg upper position BN BK BU B7231 R Over Height Leg upper position BN BK BU 1 2 H5001 Over Height leg upper pos XB7231 Lm C XB7231 Rm C 2 XB7231 Lf C XB7231 Rf C XB7231...

Page 530: ...e Sq Denna ritning f r ej utan v rt medgivande kopieras Den f r ej heller delgivas annan eller annars obe h rigen anv ndas vertr delse h rav beivras med st d av g llande lag This document must not be...

Page 531: ...Change No Sign Datum Date Sq Denna ritning f r ej utan v rt medgivande kopieras Den f r ej heller delgivas annan eller annars obe h rigen anv ndas vertr delse h rav beivras med st d av g llande lag Th...

Page 532: ...005 11 X033f 5 X033f 4 X004 12 X004 8 X004 9 X004 10 X004 11 X775 1 1 X774 1 X775 2 1 X775 3 1 X775 1 2 X035f 7 X775 2 2 X035f 8 X774 2 X775 3 2 X036f 8 X221 23 X035f 9 X036f 9 X033m 1 X033m 2 X033m 3...

Page 533: ...1 2 R4 2 x 220 Ohm 1 2 R1 82 Ohm A43044 0100 1 E4 D797 R CHASSIS MAGNETIC CLUTCH COMPRESSOR In Output K1 11 A43044 0100 1 D6 D797 R CHASSIS MAGNETIC CLUTCH COMPRESSOR In Output K1 26 X062f 8 X062m 8 X...

Page 534: ...party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A46088 0100 02 Krets Instegsbelysning Circuit...

Page 535: ...KIT_KEYBOARD A43033 0100 4 E6 INT ROOF WIPER M 53 53a 31 31b M650 2 REAR WIPER M 53b 53 31b 53a 31 M650 1 FRONT WIPER M 53 53a 31 31b M650 3 ROOF WIPER X002 4 X002 1 X017 5 X017 4 X017 6 X017 7 X017 8...

Page 536: ...044 0100 1 B6 D797 F REGENERATION RIGHT 1 5A K1 32 A43044 0100 1 B6 D797 F REGENERATION LEFT 1 5A K1 33 Ben mning Utg va Issue Ritn nr Drawing No Name Klass Class H Grp 1 2 3 4 6 7 8 F E D C B A 8 7 6...

Page 537: ...X036f 8 X221 23 X035f 9 X036f 9 X033m 1 X033m 2 X033m 3 X033m 4 X033m 5 X036m 8 X035m 7 X035m 8 X035m 9 X036m 9 A44878 0100 1 D5 A44878 0200 1 B3 246 P S246 CHASSIS 1 2 REFRIGERANT 0 2 MPa X278m 5 A43...

Page 538: ...1 2 R4 2 x 220 Ohm 1 2 R1 82 Ohm A43044 0100 1 E4 D797 R CHASSIS MAGNETIC CLUTCH COMPRESSOR In Output K1 11 A43044 0100 1 D6 D797 R CHASSIS MAGNETIC CLUTCH COMPRESSOR In Output K1 26 X062f 8 X062m 8 X...

Page 539: ...Schalter Nebelscheinwerfer Interrupteur feux de brouillard 103 S Str mst llare fj rrljus Switch distance light Schalter Fernscheinwerfer Interrupteur feux longue porte e 104 S Str mst llare lastljus S...

Page 540: ...k Switch power take off rear Schalter Nebenantrieb hinten Interrupteur prise de puissance arri re 130 S Str mst llare h g l gv xel Switch high low gear Schalter Rangegetriebe Hoch Niedrig Interrupteur...

Page 541: ...ter Kombi Signal Beleuchtung Fern Abblendlicht Waschanlage 2 Intervallwischer vor r ckw rts Interupteur avertisseur feux de route et de croisement essuie glace balayage intermittent 163 S Str mst llar...

Page 542: ...tch option Schalter Option Interrupteur option 200 S Brytkontakt lampa park broms Contact breaking warning lamp parking brake Unterbrecherkontakt Warnlampe Feststellb remse Contact ouverture voyant fr...

Page 543: ...kontakt Kabinenverriegelung Contact fermeture verrouillage de la cabine 229 S Slutkontakt stolsl sning Contact making seat locking Schlie kontakt Sitzsperre Contact fermeture verrouillage du si ge 230...

Page 544: ...tact fermeture cartement des bras de fourche 264 S Slutkontakt sidof ring Contact making sideshift Schlie kontakt Seitenverschiebung Contact fermeture d placement lat ral 265 S Slutkontakt stativ in u...

Page 545: ...t wiper Relais Intervallwischer Relais balayage intermittent 322 K Rel kylv tskeniv Relay coolant level Relais K hlfl igkeitsstand Relais niveau radiateur 323 K Rel blinkers Relay blinkers Relais Blin...

Page 546: ...olv ndning ljussignal Relay multifunction seat rotation light signal Relais Multifunktion Sitzdrehen Lichtsignal Relais multifonction si ge appel de phare 348 K Rel fl ktmotor v rmare Relay fan heatin...

Page 547: ...eight limiter Relais blinkende Rundumleuchte H hebegrenzung Relais lampe clignotante limiteur de hauteur 373 K Rel bakljus Relay light Relais beleuchtung Relais feux 375 K Huvudkontaktor reglersystem...

Page 548: ...uchtung links Eclairage conteneur gauche 406 E G lampa cont belysning h ger Container light right hand Containerbeleuchtung rechts Eclairage conteneur droite 408 E G lampa park ljus v fram Light bulb...

Page 549: ...trichtungsanzeiger rechts vorn Ampoule clignotant avant droite 426 H G lampa k rvisare v bak Light bulb direction indicator left hand rear Gl hlampe Fahrtrichtungsanzeiger links hinten Ampoule clignot...

Page 550: ...e feux stop clingnotant gauche blackout 454 H G lampa bromsljus blackout h ger Light bulb brake light blackout right hand Gl hlampe Bremslicht Ausfall rechts Ampoule feux stop clingnotant droit blacko...

Page 551: ...tre pour les 40 blackout infra rouge 463 H G lampa bak ljus v nster bak blackout Light bulb rear light left hand rear blackout Gl hlampe Rueckfahrtleuchte links hinten Ausfall Ampoule feux de recul ga...

Page 552: ...ue avant directrice 531 H Kont lampa 4 hjuls styrning Indicating lamp 4 wheel steering Kontrollampe Vierradlenkung T moin 4 roues drectrices 532 H Kont lampa crab styrning Indicating lamp crab steerin...

Page 553: ...trolllampe Motor Information Lampe de contr l information moteur 574 H Kontroll lampa st dben nere Indicator lamp support jacks down Kontrollampe Stuetzbein unten Lampe de contr l beqilles abaiss es 5...

Page 554: ...entil fl desbegr nsning Solenoid valve flow restriction Magnetventil Flie begrenzung Electrovanne limiteur de d bit 612 M St llmotor recirkulation Regulating motor re circulation Stellmotor Re zirkula...

Page 555: ...M ventil l sning orbitrol ls Solenoid valve locking LS orbitrol Magnetventil Sperren LS Orbitrol Electrovanne verrouillage de LS Orbitrol 640 Y M ventil gasol Solenoid valve LPG Magnetventil LPG Elect...

Page 556: ...e climatisation 664 M Cirk pump klimatanl ggning Circulating pump air condition Umw lzpumpe Klimaanlage Pompe de circulation climatisation 665 V Diod Diode Diode Diode 666 M Fl ktmotor cirkulation Cir...

Page 557: ...cateur de capacit batterie 710 P Tidur motor kupev rmare Timer engine and cab heater Schaltuhr motor und Kabinenheizung Minuterie chauffage moteur et habitacle 711 P R knare impuls Counter impulse Z h...

Page 558: ...tur Sp lkreis Bremsen Capteur temp circuit refroidiss freins 763 B Givare niv hydraulolja Transmitter hydraulic fluid level Geber Hydraulik lf llstand Capteur niveau huile hydraulique 764 B Givare ser...

Page 559: ...Servo amplifier steering system Servoverst rker Steuerungssystem Amplificateur pour le servo commande du systeme de direction 789 B Givare allm n Transmitter common Geber allgemein Capteur g n ral 790...

Page 560: ...vandlare h ger Signal amplifier right Signalverst rker rechts Amplificateur de signaux droit 824 U Signalomvandlare v nster Signal amplifier left Signalverst rker links Amplificateur de signaux gauche...

Page 561: ...TW Interrupteur deverroulliage TW 1003 S Str mst llare l sa TW Switch locking of TW Schalter Verriegelung der TW Interrupteur verroulliage TW 1004 S Str mst llare stopp vid 30 35 Switch stop at 30 35...

Page 562: ...mst llare Korta Armen av p Switch Short Arm on off 1025 S Str mst llare pappersfunktioner av p Switch paper funktions on off 1026 S Str mst llare omkoppling pappers kl mmagregat Switch switch papper b...

Page 563: ...Relay working light cab shift std blackout Relais Arbeitsbeleuchtung schaltung std Ausfall Relais normal blackout pour l clai ge de la cabine 3013 K Rel arb bel bom 20 vxl std blackout Relay working...

Page 564: ...rol Relais drehbarer Fahrersitz Geschwindigkeitsregelung Relais si ge pivotant commande de vitesse 3404 K Rel VBFS mastljus Relay rotating driver s seat mast light Relais drehbarer Fahrersitz Ladesche...

Page 565: ...Solenoid valve clamping releasing legs Magnetventil Klemmen L sen der Beine Electrovanne serrage deserrage b quilles 6016 Y M ventil Hyttskjutning fram Solenoid valve cab movement forward Elektro Mag...

Page 566: ...rear wheel steering right Magnetventil Hinterrad links Lenkung rechts Electrovanne roue arri re gauche direction droite 6034 Y M ventil skevning Solenoid valve levelling Magnetventil Niveausgleich El...

Page 567: ...ne serrage 6055 Y M ventil kl mma is r Solenoid valve clambing out Magnetventil aufklammern Electrovanne d serrage 6056 Y M ventil fr mre kn ut Solenoid valve front knee out Magnetventil vorderes Knie...

Page 568: ...valve Inching Magnetventil Inching Electrovanne Inching 6078 Y M ventil Avst ngning vre kl marm Solenoid valve upper arm off Magnetventil Electrovanne 7200 S Givare axeltryck h ger Sensor axle pressur...

Page 569: ...position de conduite 7213 S Givare Anliggning fr mre ben Sensor Alignment front legs Geber Anliegen vordere Beine Capteur alignement jambes avants 7214 S Givare Anliggning bakre ben Sensor Alignment r...

Page 570: ...Potentiometer left front wheel Potentiometer vorderrad links Potentiometre roue avant gauche 8079 R Potentiometer h ger bakhjul Potentiometer right rear wheel Potentiometer hinterrad rechts Potentiome...

Page 571: ...Specifications for lift capacity and dimensions 5 Oils and lubricants recommendation 8 Tightening torques recommendations 10 Tightening torques ORFS couplings 11 Unit explanations 13 Conversion table...

Page 572: ...UDRF01 04GB Maintenance manual DRF 400 450 2 F Technical data https www forkliftpdfmanuals com...

Page 573: ...Driveline axle Meritor PRC7534 Kessler D102 4 Brakes Wet Disc Brakes Drive wheels Parking brake Spring brake Drive wheels 5 Steering Hydraulic servo 6 Suspension DRF420 DRF400 450 DRF450 X Dimensions...

Page 574: ...ransmission oil 60 l when changing 80 l total 3 Driveline axle Meritor PRC7534 Kessler D102 Differential 50 l 65 l Hub reduction 2x10 l 2x12 l 4 Brakes Brake system 140 l 7 Load handling Planetary gea...

Page 575: ...0 DRF450 60S5X 43 45 35 18 42 45 35 18 15200 18200 DRF420 65S5 41 42 28 13 40 42 28 13 15100 18100 DRF420 65S6 39 41 42 28 13 40 42 28 13 16200 19250 DRF450 65S5 43 45 30 15 42 45 30 15 15100 18100 DR...

Page 576: ...weight kg A1 20 ft A2 40 ft R1 20 ft R3 40 ft B V L H3 Gro un d cle ara nce Tyres DRF420 60S5 11200 13600 8100 9400 4150 6055 12185 11200 4500 250 18 00x25 36 64500 DRF450 60S5 11200 13600 8100 9400...

Page 577: ...36 65800 DRF450 70S5X 12100 13600 9000 9400 4150 6055 12185 12200 4700 300 18 00x33 36 77800 DRF450 70S5XS 12100 13600 9000 9400 4150 6055 12185 12200 4700 300 18 00x33 36 79300 DRF450 705XS 12500 136...

Page 578: ...changed service intervals Oil type quality C 40 30 20 10 0 10 20 30 40 F 40 22 4 14 32 50 68 86 104 1 8 Engine lubrication system VDS 2 AND ACEA E3 SAE 15W40 engine oil SAE 5W30 engine oil 2 6 Transm...

Page 579: ...one of the quality stand ards as well as be a UTTO oil Universal Tractor Transmission Oil Grease Use a universal grease type EP according to NLGI Grade 2 with 3 5 molybdenum sulphide content for all l...

Page 580: ...to the table below State Bolt Nut Lubrication 1 untreated untreated oil 2 bright galvanized untreated or bright galvanized dry or oil 3 hot galvanized untreated dry or oil Quality 8 8 10 9 12 9 State...

Page 581: ...73 Nm 216 Nm 255 Nm 5 8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm 3 4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm 7 8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm 1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm 1 1 8 1260 Nm 1120 Nm 1...

Page 582: ...mm inch Nm UNF UN Metric ISO BSSP Thread inch Tightening torques Nm Thread mm Tightening torques Nm Thread inch Tightening torques Nm 7 16 20 21 10x1 20 1 8 28 20 1 2 20 27 12x1 5 35 1 4 19 35 9 16 1...

Page 583: ...13 page Unit explanations Unit Abbreviation Newton metre Nm Kilo pound metre kpm Kilo pascal kPa Mega pascal MPa Kilowatt kW kilojoule kJ British termel unit Btu Calorie ca Inch in Feet ft Yard yd Mil...

Page 584: ...bar kp cm 2 x 14 22 psi x 0 070 kp cm 2 N mm 2 x 145 04 psi x 0 069 bar MPa x 145 psi x 0 00689 MPa Power W J s kW x 1 36 hp cv x 0 736 kW kW x 1 34 bhp x 0 746 kW kW x 0 948 Btu s x 1 055 kW W x 0 7...

Page 585: ...1 mm 0 001 mm Unit cm2 m2 km2 a ft2 yd2 in2 cm2 1 0 0001 0 000001 0 001076 0 000012 0 155000 m2 10000 1 0 000001 0 01 10 764 1 1958 1550 000 km2 1000000 1 10000 1076400 1195800 a 0 01 100 0 0001 1 10...

Page 586: ...000028 1 0 0625 lb 453 592 0 45359 0 000454 16 1 1ton metric 1 1023 ton US 0 9842 ton UK Unit kp cm2 bar Pa N m 2 kPa lbf in2 lbf ft2 kp cm2 1 0 98067 98066 5 98 0665 14 2233 2048 16 bar 1 01972 1 10...

Page 587: ...aintenance manual DRF 400 450 G Terminology and index 1 G Terminology and index mm mm mm mm Table of Contents G Terminology and index Terminology and index 3 Terminology 3 Index 6 https www forkliftpd...

Page 588: ...UDRF01 04GB Maintenance manual DRF 400 450 2 G Terminology and index https www forkliftpdfmanuals com...

Page 589: ...enth of a tonne measure of the machine s lift capacity Display Window showing digital information on steering wheel panel in cab Drive axle Driving axle that receives the torque from the drivetrain Dr...

Page 590: ...w control pressure to for example a valve Planetary gear Type of transmission with gears in constant engagement Product alternative One of several alternatives is selected for a machine i e engine alt...

Page 591: ...F Technical da ta Twistlocks Four lock pins one in each corner of the attachment pushed down in corresponding holes in container and twisted to lock the container when lifting Type designation Indica...

Page 592: ...hydraulics 10 4 2 Batteries storage 11 Common electrics 11 3 Body structure 9 Frame body cab and accessories 9 13 BOOM 8 Control system 8 4 8 Brake oil filter 4 Brakes 4 8 12 Brake oil pump 4 Brakes...

Page 593: ...m 8 Control system 8 Control system engine 1 Engine 1 9 Control system transmission 2 Transmission 2 8 Control units 11 Common electrics 11 5 3 Controls and instrumentation 4 Brakes 4 1 Controls and i...

Page 594: ...or codes 1 Error codes machine D Error codes 8 Error codes transmission D Error codes 2 Error codes explanation D Error codes EXTRA 8 Control system 8 4 11 Feedback A Foreword Fire and explosion risks...

Page 595: ...iagram joystick steering E Schematics 10 Hydraulic diagram sliding cab E Schematics 10 Hydraulic diagram sliding cab and support jacks E Schematics 10 Hydraulic diagram top lift E Schematics 10 Hydrau...

Page 596: ...OP 8 Control system 8 4 10 Ordering of documentation A Foreword Overloading system 8 Control system 8 2 1 Paint coatings 9 Frame body cab and accessories 9 15 Parking brake system 4 Brakes 4 5 Parking...

Page 597: ...uctions B Safety Seat 9 Frame body cab and accessories 9 3 Security valves 10 Common hydraulics 10 2 Service brake system 4 Brakes 4 3 Service indicator 8 Control system 8 2 6 Service position B Safet...

Page 598: ...2 2 TRANSM 8 Control system 8 4 7 Transmission 2 Transmission 2 Troubleshooting cable harness 0 Complete machine Troubleshooting hydraulic hoses 0 Complete machine Troubleshooting with error code exam...

Page 599: ...B Maintenance manual DRF 400 450 G Terminology and index Terminology and index 13 Voltage feed 11 Common electrics 11 5 1 Working under machine B Safety Title Tab Functiongroup https www forkliftpdfma...

Page 600: ...UDRF01 04GB Maintenance manual DRF 400 450 14 G Terminology and index Terminology and index https www forkliftpdfmanuals com...

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Kalmar DRD450-80S4X, Maintenance Manual

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