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Kalmar DRF420-60S5, Maintenance Manual

The maintenance manual for the reliable and efficient Kalmar DRF420-60S5 is now available for free download on manualshive.com. This comprehensive manual provides step-by-step instructions and essential information to ensure optimal performance and longevity of your machine. Get the manual today and enhance your operational efficiency.

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Benämning

Utgåva/Issue

Ritn.nr./ Drawing No.

Name

Klass/Class

H.Grp:

1

234

67

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.

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

 R

E³

A

B

C

D

E

F

Blad/Sheet

Produkt/Product

5

Huvudnr./Project no.

A43032.0100

04

Krets CAN-BUS  KDU

Circuit CAN-BUS KDU

DRFA 400-450

6

FSN

030110

RKO

031210

1

Reference Text Adjustment, Sync. Harnesses.

041478

TKB

040930

1

1

A45209.0100

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1

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2

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3

5

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6

8

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1

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6

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6

4

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1

2

3

3

9

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3

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7

9

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4

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6

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6

5

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CAN

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+

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CAN J1939 -

RS232

TX

RX

Ground

Power 1

Power 2

Power 1

Power 2

K13:1

-D790-1

+CAB

Communication

K13:2

K13:3

K13:4

K13:5

K13:6

K13:7

K13:8

K13:8

K11:7

K11:8

K11:9

K11:10

K13:10

K13:11

K13:12

/A44875.0100/1.B3 /A44875.0200/1.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

/A44875.0100/1.B3 /A44875.0200/1.C2 /A44875.0300/1.D1

4014

/A44875.0100/1.B3 /A44875.0200/1.C2 /A44875.0300/1.D1

4013

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3

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4

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GND

RX

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RS232

K1:13

K1:12

K1:8

K1:11

K1:10

K1:7

K1:9

K1:6

K1:5

K1:4

K1:3

K1:2

K1:1

K1:14

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KID

+

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+

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K4:8

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/A43066.0200/2.C1

CAN-

/A43066.0200/2.C1

CAN+

/A45792.0100/1.B2

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/A45792.0100/1.B2

KID_RX

/A45792.0100/1.C2

GND

1

2

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3

12

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120 Ohm

12

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K2:8

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+

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+

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K2:2

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K2:3

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/A43056.0100/1.D7

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14

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7

7

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/A44879.0100/1.B1 /A44879.0200/1.B4

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A0512A

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A01110B

A01110B

A0118B

A0118B

A0481B

A0482B

A0481A

A0482A

0519

0519

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A0138

A0117

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A0131

A0132

A0135

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0601B

A0134

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0602B

2002

2001

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0613

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A01310

A01311

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2227

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2052

2033

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https://www.forkliftpdfmanuals.com/

Summary of Contents for DRF420-60S5

Page 1: ...iveline 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 F Technical data G Terminology and index Maintenance manual https www forkliftpdfmanuals com ...

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

Page 3: ...ons 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 types 7 Product alternatives and optional equipment 7 Machine card 8 Function descriptions 9 About the documentation 12 Documentation sections 12 Ordering of documentation 12 Feedback 13 Form for co...

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

Page 5: ...ty 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 maintenance manual shall be accessible to service person nel page About the machine version The information in this publication corresponds to the machine s de sign and appearance at the time of deliver...

Page 6: ...r 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 maintenance manual The symbol to the left is used in certain cases on the machine and refers to important information in the maintenance manual DANGER Situation that may result in serious personal inj...

Page 7: ...f 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 description description of the machine s functions with schematic drawings and explanatory texts for the included components Overviews with the components position on the machine Work instructions for preventi...

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 and manu als The information in a function group is divided in smaller sections according to the type of content e g description or change The maintenance manual and Workshop manual contain differen...

Page 9: ...oduct 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 uncertain about the equipment with which the machine is provided use the machine card to decide which information applies see Machine card page 8 Product alternatives Product alternatives are such op...

Page 10: ...ons 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 with the parts cat alogue and shall be kept in the cab The machine card is divided in the same functions groups as the parts catalogue maintenance and Workshop manual For practical reasons the machine c...

Page 11: ...lustration Function descriptions use symbols to illustrate components such as valves sensors etc Example of function description UDRF01 04S Underhållamamual DRF 400 450 2 4 Bromsar 4 3 Servobromssystem Hydraulschema basmaskin Pa D790 2 D797 F D797 R 6 7 8 5 1 2 11 12 3 4 10 9 13 P B ACC P B T D D D C C C Pa 004729 B 1 Bromsoljepump 8 Slutkontakt bromsljus S216 2 Bromsoljefilter 9 Brytkontakt broms...

Page 12: ...e 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 Illustration of function applied brake 5 Component list 6 Position number in illustration reference to component list 7 Electric power solid single line https www forkliftpdfmanuals com ...

Page 13: ...cement 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 18 Electrically controlled servo valve 19 Thermal by pass valve 20 Temperature controlled switch 21 Temperature sensor 22 Pressure sensor 23 Pressure controlled switch 24 Hydraulic cylinder 25 Doubl...

Page 14: ...hine 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 manual The Workshop manual includes supplier documentation for engine transmission and drive axle page Ordering of documentation Extra copies and supplementary documentation is ordered from Ka lmar In...

Page 15: ...on 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 Torggatan 3 SE 340 10 Lidhult SWEDEN Fax 46 372 263 93 From Company Sender Telephone E mail Date Manual informa tion Name Publication number Section page number Sugges tions views re marks etc https www f...

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

Page 17: ...e 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 and explosion risks 9 Fluid or gas under pressure 10 Coolant 11 Refrigerant 12 Air pollution 12 Tensioned springs 13 Electric motors 14 Rotating components and tools 14 Tyre system 15 Environment 16 ...

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 risks that may occur in connection with using as well as service repairs of the machine during normal circumstances That s why it s important that all who work with the machine or re pair service the m...

Page 20: ...e 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 and tools page 14 Tyre system page 15 page Service position General Service position is used for service maintenance and other situa tions when the machine needs to be secured Service position means M...

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 key to position 0 and turn off the main electric power The above illustration shows closed valve 4 Depressurize the attachment Open the relief valve top lift 002269 https www forkliftpdfmanuals com ...

Page 22: ...cs 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 station e g movement of lifting equipment may cause severe personal injuries Safety actions Make sure that the machine s lifting equipment is completely lowered or secured in another way Move battery disco...

Page 23: ...and 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 the component can change during the course of the work and the component may then make unexpected movements which may cause severe personal injuries and material damage A component lifted with lifting...

Page 24: ...tools 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 work position and grip so that the body is not stressed in only one position by the vibrations page Noise Noise louder than 85 dB A that lasts for longer than 8 hours is con sidered harmful to hearing ...

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 aromatic substances This reduces the risk of injuries Avoid skin contact Use protective gloves Make sure that work clothes are solvent resistant page Fire and explosion risks Examples of explosion prone...

Page 26: ...rrents 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 least 10 cm around the welding or cutting point Use gloves breathing protection and protective safety glass es Also welding work must never take place near plastic or rubber materials without first prot...

Page 27: ...ter 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 in the machine s cooling system consists of water anti corrosion compound and when needed anti freeze fluid for exam ple ethylene glycol Coolant must not be drained into the sewer system or directly...

Page 28: ...gulations 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 pollution is the impurities in the air around us and which are re garded as hazardous to health Certain pollution is more prominent in certain environments The following health hazardous air pollution is ...

Page 29: ...ing 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 Tensioned springs Examples of tensioned springs 1 Torque springs in pedals for example 2 Return spring cup springs in parking brake cylinder 3 Lock rings 4 Gas springs Risks If a tensioned spring rele...

Page 30: ...ve 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 cause severe accidents if clothes or hair get caught and are wound up in the machine Safety precautions Do not use gloves when working with a drill Remove loose hanging clothing scarf or tie Never use cl...

Page 31: ...on 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 containers They constitute fatal danger if handled incorrectly Parts can be thrown with explosive force and may cause severe injuries Never repair damaged tyres rims or lock rings Tyre repairs should only b...

Page 32: ...in 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 draining oils or fuel take appropriate action to prevent unnecessary spills Waste oils and fluids must always be taken care of by an authorised disposal company Pay close attention to oil leaks and other...

Page 33: ...m 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 schedule 7 Washing 13 Lubrication 500 hours 14 Lubrication 1000 hours 16 https www forkliftpdfmanuals com ...

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 check in the service log see Check and service log page 4 3 Service at regular intervals shall be performed according to service schedule see Service schedule page 7 The service schedule shall be followe...

Page 36: ...check 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 5500h 500h service 6000h 2000h service 6500h 500h service 7000h 1000h service 7500h 500h service 8000h 2000h service 8500h 500h service 9000h 1000h service 9500h 500h service 10000h 2000h service http...

Page 37: ...ine 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 Driveline axle Mounting propeller shaft check tightening Section 3 Driveline axle group 3 2 Propeller shaft Mounting drive axle inspection Section 3 Driveline axle group 3 3 Drive axle 4 Brakes Powe...

Page 38: ...es 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 hydraulic oil change Section 10 Common hydraulics group 10 6 9 Hydraulic oil fine filter 11 Common electrics Batteries check Section 11 Common electrics group 11 3 1 Start battery https www forkliftpdfman...

Page 39: ...og 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 2500h etc 1000h 3000h 5000h etc 2000h 4000h 6000h etc 0 Complete machine Leakage check C C C Attachments axle pins C C Visual check in connection with lubrication Lubrication 500 hours L L L NOTE on...

Page 40: ...ction 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 ments mountings etc C C C Valve clearance C Only engine alternative Volvo Performed by service shop authorized by Volvo Penta Fuel tank C Clean when needed 2 Transmission Transmission oil filter R R Sect...

Page 41: ...a 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 Suspension Steering axle mounting C C Section 6 Suspension group 6 2 1 Steering axle cradle Wheel spindle checking C C Clearance in wheel sus pension shall be checked Max 1 5 mm Section 6 Suspension group 6 ...

Page 42: ...ta 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 Twistlocks C C R Check for cracks every oth er year or every 5000 oper ating hours Change every 10 000 oper ating hours Section 7 Load handling group 7 9 1 7 Twistlocks Lift shoe combi attach ment C R C Che...

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 lics group 10 6 6 Breather filter hydraulic oil tank Hydraulic oil filter R R Section 10 Common hydrau lics group 10 6 7 Hydraulic oil filter Hydraulic oil filter high pressure filter R R Section 10 ...

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 Any noise NOTE On machines with manual sliding cab the cab must be secured in the rear position with both locks before oper ation After test run Check the following after test run Sealing no leakage F...

Page 45: ...ance 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 control units connectors and sensors https www forkliftpdfmanuals com ...

Page 46: ...t 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 until grease comes out by the seal NOTE Work carefully so that the seal is not damaged Grease points wheel spindle 1 Upper grease point 2 Lower grease point 5 Grease the wheel spindle s upper and lowe...

Page 47: ...ance 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 hinge with grease 10 Wipe off surplus grease 003587 2 1 https www forkliftpdfmanuals com ...

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 check of all attachments that are greased Grease points lubrication grease 1 2 1 10 11 10 5 2 3 3 5 11 9 6 12 10 8 13 14 15 16 17 002263 7 4 18 18 https www forkliftpdfmanuals com ...

Page 49: ...0 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 beam mounting sideshift frame 5 Twistlocks 4 pcs 14 Mounting lift legs combi attachment 4 pcs 6 Chain sliding cab 15 Lift shoe combi attachment 4 pcs 7 Universal joint 2 pcs 16 Mounting lift legs kn...

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: ...ntents 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 example 5 Troubleshooting cable harness 7 Troubleshooting hydraulic hoses 8 https www forkliftpdfmanuals com ...

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

Page 53: ...onents 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 spreading rotation tilt levelling and load carrying Lift and lower is the function to lift and lower the boom Extension is the function to push out and retract the boom Sideshift is to move the atta...

Page 54: ...tion 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 Washer fluid 3 Check if there are error codes 4 If there are error codes use the error code lists as a guide See Troubleshooting with error code example page 5 In the error code lists there are recomme...

Page 55: ...ydraulic 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 indicators of malfunctions detected by the control system Many error codes are connected to electrical mal functions but there are also error codes that interpret associations between one or several ...

Page 56: ...y 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 defective then connect the lead to the control unit NOTE The main electric power shall be turned off with the bat tery disconnector 9 Disconnect the cable harness from the component in question 10 T...

Page 57: ...k 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 in the connector at the control unit or component b The resistance must correspond with the component Oth erwise there may be an open circuit or short circuit in cable harness and or component 5 Chec...

Page 58: ...here 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 pinching damage and leaks Change damaged hoses When removing a hydraulic hose change of O ring is always recommended on the hoses that have these ORFS WARNING Oil under high pressure Personal injury Alway...

Page 59: ...tem 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 1 8 Lubrication 20 1 9 Control system engine 24 1 10 Ignition heating 25 1 11 Start stop 26 https www forkliftpdfmanuals com ...

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

Page 61: ...haust 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 with unit injectors and liquid to air inter cooler 004726 D793 D790 1 D790 2 D795 D797 R D794 P I II III 0 rpm kph bar C 1 8 2 3 M 6 4 5 13 H2O 12 9 11 10 SENSORS 7 1 Ignition S150 8 Accelerator pedal...

Page 62: ...Breather 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 connection inlet 9 Fuel connection return 10 Starter motor 11 Sensor engine rpm 12 Fuel pre filter 13 Drain point condensation water fuel pre filter and sen sor 14 Make contact fuel pressure 15 Fuel ...

Page 63: ...Connection 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 oil cooler 11 Connection radiator inlet 12 Coolant pump 13 Coolant filter 14 Drain plug engine oil 15 Shut off valve coolant 16 Oil filter full flow 17 Oil filter by pass https www forkliftpdfmanuals ...

Page 64: ...0 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 level B759 3 Control unit KIT D790 2 9 Sensor fuel level B757 4 Control unit engine D794 10 Control unit frame rear D797 R 5 Starter motor M654 11 Control unit KID D795 6 Electrical components engine...

Page 65: ...11 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 condensation water fuel filter and sensor water in fuel 8 Fuel filter 9 Sensor fuel pressure 10 Fuel pump 11 Sensor oil pressure and oil temperature 12 Sensor crankshaft position https www forkliftpdfmanuals ...

Page 66: ...ntercooler 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 behind alter nator 13 Connection radiator outlet 14 Inlet intercooler 15 Intercooler 16 Radiator 17 Thermostat 18 Transmission oil cooler 19 Connection radiator inlet 20 Coolant pump 21 Connection expa...

Page 67: ...der 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 end of the hose in the collection container 4 Open the bleeder nipple on the filter bracket 5 Pump up fuel with the hand pump until clean fuel free of air bubbles flows out of the hose NOTE If only the...

Page 68: ...el 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 skin contact with fuel use gloves Fuel on hands may cause rashes and irritation DANGER Pay attention to the fire hazard when working on the fuel system Avoid changing the fuel pre filter when the engin...

Page 69: ...that 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 engine NOTE The fuel pre filter should be drained of water every 50 operating hours Fuel pre filter drain valve and connector for water in fuel sensor NOTE Avoid skin contact with fuel use gloves Fuel ...

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 turn 7 Bleed the fuel system see Fuel system bleeding engine alter native Volvo page 9 8 Turn on the main electrical power and start the engine Check that the fuel filter seals tight 9 Turn off the e...

Page 71: ...l 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 Fit the new fuel filter Tighten the fuel filter to contact and then another half to three quarter turn 10 Turn on the main electrical power and start the engine Check that the fuel filter seals tight ...

Page 72: ...see 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 change as needed The safety car tridge should be changed every other time the filter cartridge is changed 7 Fit a new filter cartridge and fit the cap NOTE The filter cartridge should be changed not cl...

Page 73: ...ental 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 5 Remove the coolant 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 ...

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 004851 B C https www forkliftpdfmanuals com ...

Page 75: ...t 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 the filter holder NOTE Do not forget to open the valve after changing Otherwise the coolant does not pass through the filter and is not cleaned 9 Turn on the main electrical power and start the engi...

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 Cummins The figure shows engine alternative Volvo 5 Check the belt tension and adjust if needed https www forkliftpdfmanuals com ...

Page 77: ...E 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 volume see section F Technical data If glycol is not used then anti corrosion agent must be added However anti corrosion agents do not contain any anti freeze agent and therefore these shall only be us...

Page 78: ...rain 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 under the oil filters 6 Clean the area around the oil filters 7 Remove the oil filters 8 Install new oil filters Lubricate the O rings on the new filters with engine oil Full flow filter tighten to ...

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 section B Safety 3 Remove the protective plates over the oil filling point for the en gine and transmission 4 Place a receptacle underneath the engine 5 Remove the drain plug on the engine and drain ...

Page 80: ...new 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 Tech nical data 13 Start the engine let it idle and check that the drain plug and fil ters do not leak 14 Turn off the engine and check the oil level see Oil level check ing page 23 Top up if needed 1...

Page 81: ...ings 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 section F Technical data 4 The recommendation is that oil is filled when the engine and oil are at operating temperature Fill wait awhile check on the dipstick NOTE Work carefully when filling to prevent...

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 injector so that the fuel is injected in the cylinder The fuel volume is calculated based on the signals from the sensors on the engine and CAN message about desired engine rpm from throttle pedal via Co...

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 nent position page 4 page Ignition heating description engine alternative Cummins The engine is equipped with preheating of the inlet air for faster start at low temperatures Preheating is activated ...

Page 84: ...re 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 with the ignition The ignition sends signals to Control unit KIT D790 2 and Control unit cab D790 1 which send messages via CAN buss drivetrain to Control unit frame rear D797 R that activates the s...

Page 85: ...ssion 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 system transmission 11 https www forkliftpdfmanuals com ...

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

Page 87: ...aced 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 converter via power take offs on the transmission Gear positions are selected by pressure modulation with electrical valves that are controlled by Control unit transmission D793 The control unit uses se...

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 Accelerator pedal B690 15 Sensor output shaft speed B758 5 Declutch pedal S220 1 16 Temperature monitor torque converter S221 6 Control unit cab D790 1 17 Oil cooler 7 Control unit transmission D793 18 C...

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 converter 1 Machine in service position see section B Safety 2 Disconnect the breather filter from the transmission 3 Clean the breather filter from dirt https www forkliftpdfmanuals com ...

Page 90: ...WARD 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 REVERSE High modulation that is soft operation intensive slipping between gear positions results in high transmission wear and high oil tem perature The sensor for oil temperature generates a warning w...

Page 91: ...ated 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 page Oil and oil filter changing NOTE The transmission must not be overfilled 1 Operate and warm up the transmission oil 2 Machine in service position see section B Safety Draining transmission oil 3 Pl...

Page 92: ...hrough 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 that the drain plug for transmission oil seals tight 13 Remove the collection container handle the oil and oil filters as environmentally hazardous waste 14 Check the transmission oil level with the...

Page 93: ...and 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 data 3 The recommendation is that oil is filled when the transmission is at operating temperature Fill wait awhile check on the dipstick NOTE Work carefully when filling transmission oil to prevent ...

Page 94: ...sion 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 component position page 4 https www forkliftpdfmanuals com ...

Page 95: ...nected 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 continued operation gears have to be selected using the gear selector In this mode the operator can use the transmission s two first gears in both directions If the malfunction occurs at a higher gear t...

Page 96: ...emperature 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 for 20 seconds C Engage neutral position and apply maximum acceleration for 10 seconds run the engine at idling speed D Repeat steps B and C until the oil is hot The engine speed may be reduced toward...

Page 97: ...h 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 condition if no fault 1 Increase throttle application 2 Reduce throttle application 3 Select neutral position 4 Select travel direction forward 5 Stop the vehicle Press the brake if the machine star...

Page 98: ...ll 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 and PHASE 4 then calibration is complete 12 Turn off the ignition to store the values IMPORTANT Calibration can be aborted at any time by selecting travel direction reverse https www forkliftpdfmanual...

Page 99: ...04GB 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 forkliftpdfmanuals com ...

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

Page 101: ...0 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 reduction https www forkliftpdfmanuals com ...

Page 102: ...ive 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 clearance in universal joints After 1000h Grease universal joints with universal grease EP2 Check tighten attaching bolts at mountings to drive axle and transmission with 200 Nm https www forkliftpdfm...

Page 103: ...ower 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 wheel hubs There are hub reductions at the wheel hubs that change the reduction ratio between wheel and engine to reduce the stress on the drive shaft 1 Hub reduction 2 Drive shaft internal 3 Differenti...

Page 104: ...e 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 draining Both sides shall be drained separately Differential drive axle 1 Breather drive axle inside frame 2 Level and filler plug 3 Drain plug 4 Remove the drain plug in the drive axle at bottom of dri...

Page 105: ...instrumentation 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 and brake fluid 13 4 8 11 Breather filter 15 4 8 12 Brake oil filter 15 4 8 14 Oil brake system 17 https www forkliftpdfmanuals com ...

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

Page 107: ...p 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 system function description page 10 Temperature control cleaning and brake oil function descrip tion page 13 https www forkliftpdfmanuals com ...

Page 108: ...ve 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 set screw to obtain the correct clearance 3 Check that the pedal s travel is smooth Lubrication points brake pedal Illustration shows loose brake pedal 4 Grease the pedal hinges with universal grease...

Page 109: ...discs 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 signal so that the brake lights are activated when the brake cylinder is pressurized When the accumulators are charged the accumulator charging valve controls oil through the drive axle s brake units...

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 Control unit frame rear D797 R 5 Brake valve 12 Brake light H411L H411R 6 Brake cylinders 13 Control unit KIT D790 2 Warning light brake pres sure 7 Wheel brakes https www forkliftpdfmanuals com ...

Page 111: ...r 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 brake system 4 Accumulator charge valve 8 Brake oil filter https www forkliftpdfmanuals com ...

Page 112: ...ng 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 during cooling During cooling the pressure should be max 1 1 5 MPa at max engine rpm 8 Turn off the engine 9 Depressurize the brake and hydraulic systems see section B Safety Hydraulic and brake systems...

Page 113: ...sition 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 apply the brake 8 times before the warning light for low brake pressure is activated If the warning light for low brake pressure is activated one of the brake system s accumulators is probably defecti...

Page 114: ...ith 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 light parking brake is activated when the parking brake is applied D790 1 D790 2 D797 F Pa 004730 9 8 11 12 10 6 5 4 3 1 2 7 P ACC T H P D D D C C 1 Brake oil pump 7 Control unit frame front D797 F 2 ...

Page 115: ...e 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 oil pump 4 Solenoid valve parking brake Y642 2 Accumulator charge valve 5 Parking brake unit 3 Make contact parking brake S200 6 Brake oil filter DANGER The machine may start to roll Risk of crushing B...

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 still when tightening the lock nut 10 Refit the cover to the caliper 11 Test the operation of the parking brake https www forkliftpdfmanuals com ...

Page 117: ...he 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 the cooler back to tank An electric cooling fan increases the air flow through the cooler when the temperature needs to be lowered A thermal by pass valve leads the hydraulic oil past the cooler if ...

Page 118: ...charging 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 4 6 5 8 1 Brake oil filter 5 Tank warmer 2 Brake oil tank 6 Thermal by pass valve 3 Breather filter 7 Oil cooler 4 Sensor brake oil temperature B762 8 Cooling fan M674 https www forkliftpdfmanuals c...

Page 119: ...lder 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 changing the filter NOTE The filter holder is heavy loosen it carefully 1 Machine in service position see section B Safety 2 Depressurize the hydraulic and brake systems see section B Safety NOTE Leave the ...

Page 120: ...rtridge 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 filter cartridge 12 Fit the new filter insert to the filter bracket 13 Fit the filter holder and the drain plug 14 Close the drain valve on the accumulator charging valve 15 Turn on the main electric...

Page 121: ...around 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 oil For volume and grade see section F Technical data 9 Check that the drain plug seals tight 10 Remove the receptacle Handle the oil as environmentally haz ardous waste WARNING Hot pressurized oil Per...

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: ...nction 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 means that the machine is steered electrically with a control on the operator s armrest https www forkliftpdfmanuals com ...

Page 126: ...wheel 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 pumps and the steering valve there s a priority valve which gives priority to oil sup ply to the steering valve before other functions for example load handling The steering cylinder affects the whee...

Page 127: ...rolled 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 D797 O D790 1 D790 3 1 PP P LS T L R C D D D D 2 3 1 Switch joystick or Switch mini wheel 7 Hydraulic oil pump 2 Control unit cab D790 1 Control unit cab option D790 3 machine with mini wheel and combi...

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 Shuttle valve steering 7 Pump working hydraulics 4 3 Shuttle valve mini wheel or joystick steering 8 Control valve mini wheel joystick steering 4 Shuttle valve frame option 9 Priority valve 5 Steering v...

Page 129: ...sion 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 17 6 3 2 Rims 18 https www forkliftpdfmanuals com ...

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

Page 131: ...sion 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 belongs to power transmission see section 3 Driveline axle group 3 3 Drive axle https www forkliftpdfmanuals com ...

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 on journalled shafts The wheel spindle is hinged to enable steering On the wheel spindles there are journalled wheel hubs where the wheels are mounted 6 2 1 Steering axle cradle page Steering axle c...

Page 133: ...the 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 hub cover 3 Wipe grease off the hub cover and the hub nut Handle as envi ronmentally hazardous waste 4 Bend up the lock washer s tabs remove the lock nut and the lock washer https www forkliftpdfmanua...

Page 134: ...again 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 closest groove 8 Fill the bearing casing with grease and fit it 9 Grease the wheel bearing with grease through the grease nip ple Lift the seal ring s lip with a small screwdriver to facilitate the ai...

Page 135: ...ng 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 the tread to release the air Damaged tyres may explode Never stand directly opposite the tyre when deflat ing or inflating The lock ring and lock lugs may re lease and shoot off when the pressure chan...

Page 136: ...he 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 may result When installing drive wheels ensure that the clamps clamp straight on the spacer ring Wheel nuts should be check tightened after 4 5 op erating hours Always follow the tyre manufacturer s...

Page 137: ...ken 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 changing page 18 4 If the tyres and rims have no defects check tighten the wheel nuts Tighten crosswise with torque 400 Nm DANGER Never stand directly opposite the tyre when deflat ing or inflating The...

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 through the valve If the tyre or rim is damaged deflate the tyre by drilling a hole in the tread 3 Loosen the wheel nuts 4 Secure the wheel with lifting equipment 5 Remove nuts washers and clamps 000384 h...

Page 139: ...OTE 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 outer and inner wheel NOTE The spacer ring weighs approx 20 kg 10 Remove the inner wheel Lift away the wheel and place it in a safe manner https www forkliftpdfmanuals com ...

Page 140: ...e 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 2 Deflate the tyre If tyre and rim are in good condition release air through the valve If the tyre or rim is damaged deflate the tyre by drilling a hole in the tread 000384 https www forkliftpdfmanua...

Page 141: ...amps 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 and rim system safety page 7 1 Lift the inner wheel into place with lifting equipment Rotate the wheel so that the guide lug enters the groove on the hub 000383 https www forkliftpdfmanuals com ...

Page 142: ...e 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 Where applicable also washers NOTE Do not forget the retainer for the inner tyre s valve exten sion 6 Remove the lifting equipment 7 Tighten the wheel nuts crosswise 8 Tighten the wheel nuts crosswise w...

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 rim system safety page 7 1 Lift the wheel into place with the lifting equipment Adjust the wheel s position so that the guide pin fits over the groove in the hub and the rim rests up against the hub 0...

Page 144: ...t 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 and remove the jack 7 Test run the machine and check that the wheels are installed securely 8 Check tighten the wheel nuts with torque 400 Nm 000383 000384 https www forkliftpdfmanuals com ...

Page 145: ...sure 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 If the tyre has been completely deflated the tyre must be dismantled and the rim checked for dam age Never fit rim components by striking with a ham mer during inflation Never strike fully or partly 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 work FATAL DANGER Leave tyre work to authorized personnel tyre com pany DANGER Perform the following checks to minimize risks of accidents for all rims that can be dismantled Always use the correct si...

Page 147: ...steps 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 circumference cracks corrosive dam age rust warping and wear Magnetic powder method 1 Blast clean the marked area around the entire rim so that it is completely clean from all paint 2 Test using magnetic powder ...

Page 148: ...hly 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 of cracks 1 Linear crack 2 Pointed crack 6 Visually inspect the lock ring groove If the tested area does not indicate linear or point shaped cracks in the lock ring groove the rim is approved If the c...

Page 149: ...ft 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 unit 30 7 7 Tilt 31 7 8 Levelling 37 7 9 Load carrying 41 7 9 1 Twistlocks 41 7 9 2 Lift legs 46 7 10 Additional functions 56 7 10 1 Support jacks 56 7 10 2 Weight indicator 58 7 10 3 Container counter ...

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 example support jacks Load handling is primarily controlled with the control lever while cer tain functions have separate switches Lift and lower Extension Sideshift Spreading Rotation Tilt Levelling...

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 reduces the con trol current to the solenoid valve for that function Regeneration To increase the speed oil from the rod side 2 is reused to the piston side 1 this is called regeneration Engagement of rege...

Page 153: ...nt 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 side left B768 12 6 Shuttle valve 15 Servo valve regeneration right Y6051 and Servo valve regeneration left Y6052 7 Hydraulic oil pump 16 Position sensor damping B769 1 Mechanical over loading system S...

Page 154: ...el 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 reducer 16 Servo valve blocking Y6001 or Y6002 7 Accumulator servo circuit 17 Pressure sensor rod side C M B768 11 or B768 13 8 Test outlet servo pressure 18 Servo valve regeneration Y6051 or Y6052 9 Ser...

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 cylinder 4 Mounting attachment 9 Rear boom mounting 5 Tilt cylinder left side WARNING Hot pressurized oil Personal injury burn injury rash or irritation Always depressurize the hydraulic systems before sta...

Page 156: ...in 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 the extension cylinder completely in The oil level should be at the top of the level glass Top up as needed for grade see section F Technical data NOTE The hydraulic oil level is checked with the boo...

Page 157: ...ssure 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 hydraulic oil pumps 7 Depressurize the hydraulic and brake systems see section B Safety Hydraulic and brake systems depressurizing 8 Remove the pressure gauge and fit the protective cap on the pressure chec...

Page 158: ...omatical 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 activated the control unit in question reduces the con trol current to the solenoid valve for that function Regeneration To increase the extension speed oil from the rod side 2 is reused to the piston side...

Page 159: ...xtension 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 block pump unloading 17 Servo valve regeneration Y6046 7 Shuttle valve 18 Position sensor damping boom in D796 3 or Posi tion sensor damping boom out D796 4 Mechani cal overloading system Sensor boom le...

Page 160: ...ion 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 signal to hydraulic oil pump 2 3 Valve block top lift hydraulics 4 Tank drain 5 Pressure signal in from shuttle valve 6 Valve block pump unloading 7 Pressure signal to hydraulic oil pump 2 8 Solenoid...

Page 161: ...ness 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 and stop at the leading edge top edge of the boom clearance may be max 3 mm Ad just the glide plates with spacer plates if needed 1 Upper glide plates 2 Side mounted glide plates 3 Lower glide plates...

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 D C C D 1 Control lever S815 T1 1 6 Hydraulic oil pump 2 Control unit cab D790 1 7 Control unit attachment D791 1 3 Control unit frame rear D797 R 8 Servo valve sideshift left Y6020 or Servo valve s...

Page 163: ...shift 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 twistlocks Y6039 and Y6040 3 Relief valve attachment NOTE The illustration shows closed valve The ma chine is delivered with the valve in open posi tion 11 Sideshift frame 12 Sideshift cylinder 13 Main beam...

Page 164: ...ate 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 correct 4 Fit the cover plate 5 Repeat steps 1 4 on the other glide plates 6 Solenoid valve tilt Y6010 and Y6011 17 Sensor twistlocks B7202L R and B7203L R 7 Solenoid valve rotation Y6008 and Y6009 18 Loc...

Page 165: ...r 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 possible and spreading run in so that 40 cm remain to the 20 foot posi tion 2 Turn off the engine and the main electrical power 3 Take the strain off the glide plate in question Take the strain off the lo...

Page 166: ...ates 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 glide plate s guide pin 11 Repeat steps 3 10 on the other glide plates 12 Start the machine and check the spreading function Try lifting a container and check that the spreader beams do not have too much...

Page 167: ...Spreading 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 positions Three seconds after damping is activat ed the function is interrupted This results in less loading of mechanical parts at stops in end positions Position sensors sense when damping should ...

Page 168: ...5 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 unit frame rear D797 R 9 Control valve attachment 4 Solenoid valve engagement of hydraulics for top lift Y6003 10 Valve block spreader cylinder 5 Shuttle valve 11 Hydraulic motor spreading 6 Hydrauli...

Page 169: ...p 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 value Control switch Not activated Twistlocks Unlocked or by pass activated Overloading system Passive D790 1 004864 D791 1 2 3 1 6 4 30 35 D D D D 5 7 1 Control lever S815 T1 2 and S815 T4 5 Control...

Page 170: ...e 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 plate 20 5 Indicator plate 40 2 Sensor damping 20 and 40 Stop 30 B769 6 Spreader motor 3 Sensor damping 30 B777 3 7 Spreader chains 4 Indicator plate 30 or 35 https www forkliftpdfmanuals com ...

Page 171: ...s 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 adjustment page 26 2 Start the engine and run in the spreading to the 20 foot posi tion and turn off the engine 3 Check the C C measurement between the twistlocks C C 20 foot 5853 3 mm Check that both ...

Page 172: ...hat 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 Check the chain tensioner s vertical position so that the chain runs straight toward the chain wheel 7 Start the engine and run out the spreading to the 40 foot posi tion and turn off the engine 8 Check ...

Page 173: ...art 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 9 11 until the chain tension is correct 14 If the machine is equipped with 30 foot or 35 foot stops Start the engine and run out the spreading to the 30 foot or 35 foot position Turn off the engine a...

Page 174: ...hows 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 and bracket 7 Measure the slide plate s thickness change if needed Thickness should be at least 10 mm 8 Place the slide plate in the correct position Check the clearance between the extension beam and...

Page 175: ...Rotation 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 system Passive D790 1 D797 R 004866 D791 1 6 5 3 1 10 9 7 2 8 4 11 P1 T1 A B D D D C C 1 Control lever S815 P3 7 Control unit attachment D791 1 2 Control unit cab D790 1 8 Servo valve rotation clock...

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 engagement of hydraulics for top lift Y6003 10 Valve block hydraulic motor 5 Shuttle valve 11 Rotation motor 6 Hydraulic oil pump Condition Reference value Control switch Not activated Overloading system Pas...

Page 177: ...n 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 position page 15 4 Servo valve rotation clockwise Y6008 or Servo valve rotation counter clockwise Y6009 004903 1 2 3 4 1 2 3 4 5 8 7 6 1 Hydraulic motor rotation 5 Rotation yoke 2 Disc brake 6 Ring ...

Page 178: ...drain 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 disc brake s drain plug pos 4 and lead the oil into the receptacle Remove the disc brake s filler plug pos 2 for faster draining 8 Remove and clean the disc brake s level glass pos 1 while the oil drai...

Page 179: ...ected 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 machine is equipped with tilt lock an electrically controlled blocking valve is used in the damping block If the machine is equipped with controllable tilt the hydraulic cylin ders are supplied from ...

Page 180: ...rosswise 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 cylinders Adjustable restrictions between the connections for piston and rod side in the damping block create re sistance that dampens the tilt movement Hydraulic diagram top lift Hydraulic diagram top l...

Page 181: ...o 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 004911 000462 D790 1 D797 R D791 1 10 9 7 2 5 4 3 1 6 A B C1 C1 C2 C2 8 D D D D 1 Control lever S815 T3 1 6 Hydraulic oil pump 2 Control unit cab D790 1 7 Control unit attachment D791 1 3 Control unit...

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 that the attachment is angled If the machine is equipped with tilt control then tilt lock is also in cluded see Tilt lock function description page 33 Condition Reference value Control switch Not acti...

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 S815 P4 8 Servo valve tilt out Y6010 or Servo valve tilt in Y6011 2 Control unit cab D790 1 9 Control valve attachment 3 Control unit frame rear D797 R 10 Control unit attachment D791 1 4 Solenoid v...

Page 184: ...hment 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 clockwise reduce damping 4 Lift a loaded container test run and brake check that the con tainer does not oscillate uncontrollably If needed adjust the damping according to step 3 5 Start the machine...

Page 185: ...ng 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 locked by blocking the connection to the levelling cylinders Passive levelling means that that an unloaded attachment is in a float position and adapts itself to the angle of the container to be lift ed T...

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 attachment 4 Solenoid valve engagement of hydraulics for top lift Y6003 11 Over centre valve 5 Shuttle valve 12 Valve block levelling cylinder 6 Hydraulic oil pump 13 Levelling cylinder 7 Control unit a...

Page 187: ...om 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 Control switch Not activated 000465 D790 1 D797 F D791 3 D791 2 9 8 7 2 5 4 3 1 6 T1 A B D D D C C P1 1 Control lever S815 T3 1 6 Hydraulic oil pump 2 Control unit cab D790 1 7 Control unit attachme...

Page 188: ...ontrol 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 attachment 2 Rotation yoke 3 Valve block levelling cylinders with Solenoid valve levelling Y6034 4 Over centre valve levelling 5 Levelling cylinder 6 Sideshift frame 7 Sideshift cylinder 4 Solenoid val...

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 cylinder affects a linkage that turns two twistlocks Four position sensors two in each spreader boom sense the posi tion of the linkage and indicates if twistlocks are open or locked In dicator ligh...

Page 190: ...D 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 front 7202R Sensor alignment left rear Y7203L and Sensor alignment right rear Y7203R 10 Hydraulic oil pump 4 Control unit attachment D791 11 Servo valve open twistlocks Y6039 or Servo valve lock twistl...

Page 191: ...k 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 cover for twistlocks check pin link arm and lock nut 4 Clean the area around the sensor for alignment 5 Press in the alignment pin so that the head is flush with the spreader beam s underside Check t...

Page 192: ...the 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 around the grease cup 10 Grease the lift pins bearing with universal grease EP2 11 Repeat steps 1 10 on all four twistlocks M i n 7 0 m m Max 4 mm 002311 https www forkliftpdfmanuals com ...

Page 193: ...rea 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 with new ones 4 Fit approved twistlocks NOTE Use new attaching nut and washers DANGER Material fatigue reduced strength Fatal danger Change twistlocks that shows signs of cracks or other external damag...

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 correct centre of gravity if the machine is driven up to the load with the rear legs lowered until alignment is obtained on the rear legs If the front legs are lowered and clamped around the load in t...

Page 195: ...ng 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 19 20 D790 1 D791 1 D791 4 D D D D D D D C D D D797 R D791 3 21 https www forkliftpdfmanuals com ...

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 Sensor front knee right B7217R 7 Shuttle valve 18 Solenoid valve front leg down right Y6013R or Sole noid valve front leg down right Y6060R 8 Hydraulic oil pump 19 Hydraulic cylinder leg right front 9 Sol...

Page 197: ...of 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 25 24 26 27 28 D790 1 D797 R D791 3 D791 4 D D D D D C D 4 17 20 16 https www forkliftpdfmanuals com ...

Page 198: ...engagement 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 left Y6053L 9 Solenoid valve rear knee out left Y6058L or Sole noid valve rear knee in left Y6059L 23 Solenoid valve clamp in right Y6054R 10 Hydraulic cylinder knee left rear 24 Solenoid valve clamp ...

Page 199: ...17 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 right front 2 Control unit cab D790 1 14 Hydraulic cylinder knee and clamp right rear 3 Control unit attachment right leg pair D791 4 15 Sensor clamping position front leg left B7215L https www forkl...

Page 200: ...rear 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 oil pump 20 Sensor alignment front leg right B7213R 9 Solenoid valve clamp in left Y6054L or Solenoid valve clamp out left Y6055L 21 Sensor alignment rear leg left B7214L 10 Hydraulic cylinder knee ...

Page 201: ...7216 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 Sensor front leg B7219 or Sensor rear lift leg B7220 9 Hydraulic cylinder knee and clamp 5 Sensor front knee B7217 or Sensor rear knee B7218 https www forkliftpdfmanuals com ...

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 that the indicator light for clamping position is activated NOTE The plates for both lift legs right and left must be pressed in to achieve activation of the indicator light Wear limits lift shoe 5 Ch...

Page 203: ...ift 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 cracks within the marked area on the lift shoes without reworking or damaging the part 3 Fit the lift shoes 002314 DANGER Material fatigue reduced strength Fatal danger Change lift shoes that show sign...

Page 204: ...raulic 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 automatic lowering of the support jacks The auto matic function works at both lowering and raising Condition Reference value Control switch Not activated Parking brake Released Transmission Neutral po...

Page 205: ...own 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 12 Control unit engine D794 6 Control valve option frame 13 Indicator light support jacks down H517 7 Shuttle valve 004901 2 1 4 3 5 6 7 8 1 Control valve option frame 5 Support jacks 2 Hydraulic cy...

Page 206: ...o 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 1 7 2 4 5 D D D D 1 Pa Pa 8 6 3 1 Control lever S815 T4 5 Control unit attachment D791 1 2 Control unit cab D790 1 6 Control unit KID D795 3 Boom 7 Sensor hydraulic pressure lift cylinder piston sid...

Page 207: ...shows 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 specified order 1 Park the 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 Industrie...

Page 208: ...tting 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 the boom is raised first and then lowered to the measuring position 10 Scroll to CALIBR SCALE menu 2 11 Enter the weight of the reference load with the and keys Save the setting with ENTER The weight...

Page 209: ...formation 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 D 1 Control unit cab D790 1 5 Control unit frame front D797 F 2 Sensor boom length B777 6 Sensor hydraulic pressure lift cylinder piston side left B768 12 Sensor hydraulic pressure lift cylinder rod...

Page 210: ...the 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 code determines which service menu is activated Di agnostic test Initiation or Calibration 4 Scroll to SCALE with the arrow keys 1 and 2 and press ENTER Every calibration consists of a sequence of men...

Page 211: ...nu 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 machine is lifting PRESENT LOAD 23 If the weight is not quite correct scroll to menu 6 and enter the weight of the reference load with the and keys Save the set ting with ENTER The weight is given in ...

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 Control unit KID D795 and is located on the instrument panel on the right side of the steering wheel The printer is controlled via Operating menu printer in the display where the operator selects which w...

Page 213: ...nsor 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 alignment left front 7202L Sensor alignment right front 7202R Sensor alignment left rear Y7203L and Sensor align ment right rear Y7203R 2 Sensor locked twistlocks left B7205L Sensor locked twistlocks ...

Page 214: ...not 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 front leg right B7215R and Sensor clamping position rear leg right B7216R 4 Control unit attachment right leg pair D791 4 5 Sensor alignment front leg left B7213L and Sensor alignment rear leg left ...

Page 215: ...olled 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 for the function to work well For details on lift and extension see Lift and lower function descrip tion page 4 and Extension function description page 10 Condition Reference value Control switch Not...

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 LIGHTS 19 8 4 3 CAB 20 8 4 4 CLIMATE 21 8 4 5 HYD 21 8 4 6 ENGINE 22 8 4 7 TRANSM 23 8 4 8 BOOM 24 8 4 9 ATTACH 25 8 4 10 OP 26 8 4 11 EXTRA 27 8 5 Setup 31 https www forkliftpdfmanuals com ...

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 functions The software creates the functions in the control system page Control system description A Function keys KIT B Warning and indicator lights C Display KID D Alarm indicator The machine is eq...

Page 220: ...alues 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 Operating menu engine and trans mission is shown on the display This menu is shown until another menu is selected or an event controlled menu is shown e g in case of error code of type WARNING and STOP Othe...

Page 221: ...e 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 limitation at levelling lock or tilt lock Speed limitation at overloading on steering axle Service menu The service menu is the gateway to the machine s diagnostic sys tem By pressing Enter and entering...

Page 222: ...tion 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 to control sideways stability or stability when operating Also it does not take angled ground conditions into ac count NOTE Retract the boom before it is lowered Applies to all load han dling The ove...

Page 223: ...prox 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 overloading system X X X X Mechanical overloading system with analogue position sensors X X X X Electrical overloading system X X X X X X Mechanical overloading system and fixed scale X X X X X X Mechanical ov...

Page 224: ...e 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 sion is less than 1 5 m when the machine operates faster than 10 km h overloading steering axle In case of overloading on the steering axle the control system activates a warning for overloading on th...

Page 225: ...unctions 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 is less than 1 5 m when the machine operates faster than 10 km h overloading steering axle In case of overloading on the steering axle the control system activates a warning for overloading on the s...

Page 226: ...wer 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 Depending on how big the load is on the steering axle the ma chine s speed is limited A bar in the event menu shows the range of the limitation NOTE In case of overloading on the steering axle it is up to...

Page 227: ...nt 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 past limitation for load centre limitation lifting lowering and extension with active error on overloading system 8 2 3 Load centre limitation page Load centre limitation description Load centre limit...

Page 228: ...mitation 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 indicator resetting 1 Machine in service position see section B Safety 2 Navigate first to the service menu and press Enter 3 Enter code for resetting service indicator The code is obtained via Kalmar Ind...

Page 229: ...control 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 flashing red light for control system position 54 and activated Indicator for active error codes position 36 Error code with level WARNING shown automatically on display INFORMATION is indicated with acti...

Page 230: ...he 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 Reset R NOTE If error code isn t included in the error code list it may be due to the following output signal that generated error code is no longer ac tive for example control lever is released or engi...

Page 231: ...t 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 tests are built up of menus The menus are grouped according to logical areas With the diagnostic menus it is possible to read how a control unit interprets input signals as well as what output signals it...

Page 232: ...LIMATE 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 of attachment OP for diagnosis of overloading system EXTRA for diagnosis of optional functions HIST not used 3 2 Number of menu in question menu group CAB contains several menus in a loop 4 10 Total ...

Page 233: ...ow 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 DIAGNOSIS CAN POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH OP EXTRA HIST 000084 https www forkliftpdfmanuals com ...

Page 234: ...V 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 REF XY X XXV DIAG CAN POWER 11 20 797 O FRAME POWER RED POWER EME STOP POWER XX XXV Le X Ri X X DIAG CAN POWER 12 20 797 O FRAME 24V SENSOR SUPPLY 5V REF XY X XXV DIAG CAN POWER 13 20 795 DISPLAY RED P...

Page 235: ...L 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 LIGHTS 7 13 PRESENT OUTPUT SIGNAL HAZARD FLASHER FRONT REAR LE XX RI XX LE XX RI XX DIAG LIGHTS 8 13 ROTATION BEACON SWITCH OUTPUT X XX DIAG LIGHTS 9 13 PRESENT INPUT SIGNAL BRAKE LIGHT SWITCH REVERSE...

Page 236: ...XY 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 DIAG CAB 4 10 HORN SWITCH OUTPUT X XY DIAG CAB 5 10 BUZZER SWITCH SEAT ALARM OP XY X X X DIAG CAB 6 10 FUEL SENSOR VALUE PROC XXXOHM XXX DIAG CAB 7 10 004842 https www forkliftpdfmanuals com ...

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 DIAG CLIMATE 7 8 OUTPUT DRAUGHT VALVE CLOCKWISE ANTI CLOCKWISE XY XY XY XY DIAG CLIMATE 8 8 004843 DIAGNOSIS CAN POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH OP EXTRA HIST HYDRAULIC OIL TEM...

Page 238: ...ORQUE 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 INPUT SIGNAL OIL PRESSURE BOOST PRESSURE XXX XXX DIAG ENGINE 6 10 PRESENT INPUT SIGNAL OIL TEMP COOLANT TEMP INTAKE MAIN TEMP XXX XXX XXX DIAG ENGINE 7 10 PRESENT EDC ERROR SPN FMI 1 SPN FMI 2 SPN FMI...

Page 239: ...PEED 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 15 FWD FEEDBACK REV FEEDBACK 2 4 FEEDBACK 1 3 FEEDBACK XXXX XXXX XXXX XXXX DIAG TRANSM 9 15 PRESENT SENSOR INPUT PRESS FEEDBACK TRANSM TEMP COOLER TEMP XXXX XXXX XXXX DIAG TRANSM 10 15 SERIAL NUMBERS...

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 REQUIRED VALUE FEEDBACK XY XXX XXX DIAG BOOM 5 8 OUTPUT BOOM IN REFERENCE REQUIRED VALUE FEEDBACK XY XXX XXX DIAG BOOM 6 8 OUTPUT BOOM OUT REFERENCE REQUIRED VALUE FEEDBACK XY XXX XXX DIAG BOOM 7 8 PRESENT...

Page 241: ...NLOCKED 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 DIAG ATTACHMENT 11 21 OUTPUT ROTATION C C W REFERENCE REQUIRED VALUE FEEDBACK XY XXX XXX DIAG ATTACHMENT 12 21 OUTPUT SPREADER OUT REFERENCE REQUIRED VALUE FEEDBACK XY XXX XXX DIAG ATTACHMENT 13 21 ...

Page 242: ...RESENT 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 INPUT SIGNAL BOOM ANGLE BOOM EXTENSION X XXV X XXV DIAG OP 4 5 ALLOWED LOAD PRESENT LOAD LOAD STR ANGEL LOAD CENTER XX XX XX XX XX XX XX XX DIAG OP 5 5 004849 https www forkliftpdfmanuals com ...

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 XY DIAG COMBI 8 17 INDICATION LAMPS FRONT LEGS UP FRONT LEGS DOWN XY XY DIAG COMBI 9 17 PRESENT OUTPUT SIGNAL FRONT LEGS DOWN KNEE LEGS LE XY RI XY LE XY RI XY DIAG COMBI 10 17 PRESENT OUTPUT SIGNAL...

Page 244: ...ACH 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 SLID CAB 2 4 OUTPUT FORWARD REFERENCE REQUIRED VALUE FEEDBACK XY XXX XXX DIAG SLID CAB 3 4 OUTPUT REVERSE REFERENCE REQUIRED VALUE FEEDBACK XY XXX XXX DIAG SLID CAB 4 4 https www forkliftpdfmanuals c...

Page 245: ...R 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 LE X RI X LE X RI X DIAG S JACKS 2 4 OUTPUT VALVE S J UP S J DOWN XY XY DIAG S JACKS 3 4 INDICATOR LAMP DOWN XY DIAG S JACKS 4 4 https www forkliftpdfmanuals com ...

Page 246: ...SLIDING 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 SIG 1 STEER WHEEL SIG 2 X X X DIAG STEERING 3 5 OUTPUT STEERING LEFT REFERENCE REQUIRED VALUE FEEDBACK XY XXX XXX DIAG STEERING 4 5 OUTPUT STEERING RIGHT REFERENCE REQUIRED VALUE FEEDBACK XY XXX XXX ...

Page 247: ...formed 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 tolerances variations between different machines Calibration should be performed for optimal use of important func tions Certain functions require calibration in order to work https www forkliftpdfman...

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

Page 249: ...9 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 communication 23 9 9 Glass windows mirrors 24 9 10 Cab structure and suspension 25 9 10 4 Longitudinal displacement of cab 25 9 10 5 Vertically adjustable cab 28 9 11 Cab interior 31 9 12 Frame 32 9 13 Bod...

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

Page 251: ...eel 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 wheel and con trol lever for hydraulics can be adjusted for optimal individual oper ating position Effective insulation results in minimal vibrations and a low sound level The machine is equipped wi...

Page 252: ...2 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 Operator s seat 11 Accelerator pedal B690 12 Brake pedal 13 Declutch pedal S220 1 14 Electrical distribution box with fuses 15 Hour meter P708 A Steering joystick or mini wheel 1 2 3 4 5 12 13 12 11 10 9 7...

Page 253: ...air 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 Switch headlights S100 25 Switch seat heating S143 26 Spare 27 Spare 28 Switch pause heater 29 Spare 30 Spare 31 Socket 24 VDC 32 Spare 33 Spare 16 17 18 19 23 24 28 29 30 31 004661 https www forkliftp...

Page 254: ...ator 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 52 Panel warning and indicator lights 53 Display control and monitoring system 54 Indicator control and monitoring system 55 Ignition S150 56 Switch defroster 57 Switch windshield wiper roof interval ...

Page 255: ...top 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 stop at 30 or 35 S1004 74 Switch hydraulic sliding cab S177 Switch hydraulic cab lift and lowering S177 75 Indicator light support jacks down H517 76 Switch support jacks S1013 77 Spare 78 Switch by p...

Page 256: ...g 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 Operating menu statistics operating hours 6 Operating menu container counter 14 Operating menu statistics fuel consumption 7 Operating menu service interval 15 Operating menu statistics travelled distance...

Page 257: ...enu 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 door 5 Event menu alignment top lift 12 Event menu rotation stop 6 Event menu alignment bottom lift 13 Event menu tilt lock 7 Event menu twistlocks 14 Event menu levelling lock https www forkliftpdf...

Page 258: ...uipped 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 Adapted fire fighting equipment is available for order from Kalmar Industries 6 Seat belt For a cab with cab lift and lower there is always a seat belt as well as safety chains by the doors 7 Buzzer to ...

Page 259: ...llowing 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 armrest left seat heating Operator s seat Isringhausen The seat is equipped with head restraint armrest air suspension with external compressor air adjusted lower back lumbar support seat belt seat hea...

Page 260: ...uses 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 aimed at e g the windshield defroster or at the feet At the air inlet before the cab fan there is a filter that cleans the air before it is forced into the machine The heating and ventilation system can ...

Page 261: ...t 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 air can be controlled in the same way as for the heating system The air conditioning system adds the following functions to the heat ing and ventilation system dehumidification of the air when it is...

Page 262: ...rear 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 Humidity filter 8 Engine 21 Pressure monitor S246 9 Water valve Y673 22 Expansion valve 10 Sensor engine temperature 23 Sensor temperature in refrigerant circuit B775 3 11 Heat exchanger 24 Heat exchanger ...

Page 263: ...IT 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 trol panel behind a grating 13 Heat exchanger cold and heat 6 Switch air distribution R8084 14 Sensor refrigerant temperature B775 3 7 Switch temperature R8083 15 Air distributor Y672 8 Switch fan R8...

Page 264: ...e 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 forkliftpdfmanuals com ...

Page 265: ...a 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 in the cab is six degrees below the set value on the air conditioning system The pause heater is activated with Switch pause heater when the ignition is on 9 4 1 Fresh air filter page Fresh air filt...

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 it idle 3 Check the colour of the indicator on the humidity filter Blue indication humidity filter ok Grey or pink indication change humidity filter see Humidity filter changing page 19 https www for...

Page 267: ...4 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 the machine with refrigerant R134a with the intended equipment For volume see section section F Technical data WARNING Personal injury environmental damage Read the safety instructions for refrigerant ...

Page 268: ...tor 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 material When installing it s very important to make sure that the splines are free from metal filings and similar Also the nuts shall be tightened so hard that the splines are pressed into the attachme...

Page 269: ...ing 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 lighting 10 Extra work lights boom 11 Extra work lights attachment 12 Extra work lights front fenders 20 40 NOTE It is important that the right type of lamp is used for each re spective area See section...

Page 270: ...ration 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 Rotating warning light 5 Warning parking brake 6 Back up alarm NOTE It is important that the right type of lamp is used for each re spective area See section F Technical data 3 4 1 5 6 005114 3 6 2 h...

Page 271: ...d 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 mentation for respective product https www forkliftpdfmanuals com ...

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 mirrors are located on the chassis and the internal rear view mirror is located in the cab The following panes may be of laminated glass Side windows front position E Windshield front window positio...

Page 273: ...on 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 Position lock handle B Lock pin C Lock catch for securing cab Manual cab movement means that the cab can be moved forward to facilitate access for service and maintenance in the engine com partment The ca...

Page 274: ...e 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 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 reduc...

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 cab movement sliding cab 5 Servo valve sliding cab forward and servo valve slid ing cab backward 11 Sensor end position B769 2 6 Control valve option frame https www forkliftpdfmanuals com ...

Page 276: ...ab 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 secured in raised position with two safety locks For safety reasons the machine s speed is reduced and the trans mission is blocked in second gear when the cab is lifted Damping Damping means that the s...

Page 277: ...12 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 Control unit frame option D797 O 11 Hydraulic cylinder cab lift and lowering 5 Servo valve raise cab Y6016 and servo valve lower cab Y6017 12 Sensor lowered cab B777 2 6 Control valve option frame 1...

Page 278: ...owered 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 2 Pressure supply P 3 Tank return T1 4 Connection hydraulic motor B 5 Tank return TP 6 Connection hydraulic motor A 005110 5 4 6 1 2 3 000624 1 6 5 2 3 4 https www forkliftpdfmanuals com ...

Page 279: ...n 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 materials are used for all parts Instrument panels Interior plastic parts Interior textile fabric parts Insulation https www forkliftpdfmanuals com ...

Page 280: ...to 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 mounting 6 Engine compartment with mounts for engine and transmission 7 Member pair 8 Mounts front fenders 001511 6 3 4 7 8 1 5 2 https www forkliftpdfmanuals com ...

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 counterweight to balance the machine s lifting capacity 1 Fenders 2 Hood engine compartment 3 Counterweight 002213 2 3 1 https www forkliftpdfmanuals com ...

Page 282: ...nit 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 receive the right amount of grease Lines between main unit and distribution block as well as distri bution block and grease nipples Grease nipples at grease points On the pump unit it is possible to adjust...

Page 283: ...0 450 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 card https www forkliftpdfmanuals com ...

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: ...ecurity 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 10 6 6 Breather filter hydraulic oil tank 14 10 6 7 Hydraulic oil filter 14 10 6 8 Hydraulic oil 17 10 6 9 Hydraulic oil fine filter 18 https www forkliftpdfmanuals com ...

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

Page 287: ...n 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 and certain cab functions with hydraulic pressure The brake system is completely separate and is found in section 4 Brakes https www forkliftpdfmanuals com ...

Page 288: ...pment 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 pressure servo accumulator 2 Control pressure 3 Hydraulic oil pressure accumulators brake system 4 Gas pressure brake accumulators 5 Feed pressure control valve attachment 6 Feed pressure control valve lif...

Page 289: ...0 450 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 1 2 https www forkliftpdfmanuals com ...

Page 290: ...tors 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 oil tank 5 Drain plugs hydraulic oil 3 1 4 1 2 5 5 001457 https www forkliftpdfmanuals com ...

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 for lift and extension pump 2 also supplies the attachment s control valve At boom in pump 1 and 2 are disconnected The right hydraulic oil pump unit position 3 and 4 supplies the steer ing system and...

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 frame rear D797 R 3 Hydraulic oil pump 3 and 4 9 Solenoid valve top hydraulics Y6003 4 Solenoid valve unloading main pump Y6062 10 Tank 5 Shuttle valve 11 Steering valve 6 Hydraulic oil pump 2 12 Priori...

Page 293: ...c 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 pressure plate However the pressure difference between the pumps must always be maintained 6 Increase engine speed to approx 1100 r min and run extension function against end position overflow Run out ...

Page 294: ...1 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 pressure gauge to the next pump and repeat steps 3 8 on all four pumps MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa 920643 0024 001028 https www forkliftpdfmanuals com ...

Page 295: ...s 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 Shuttle valve joystick steering or mini wheel 7 Priority valve 4 Shuttle valve option frame https www forkliftpdfmanuals com ...

Page 296: ...ss 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 electric cooling fan increased the air flow through the cooler when the temperature needs to be lowered A by pass valve leads the hydraulic oil past the cooler di rectly to the tank if the resistance throu...

Page 297: ...re 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 filter hydraulic oil 7 Sensor hydraulic oil temperature B776 4 Hydraulic oil filter high pressure filter https www forkliftpdfmanuals com ...

Page 298: ...entally 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 the filter cartridge 10 6 7 Hydraulic oil filter page Hydraulic oil filter changing 1 Clean the area around the cover plates on the hydraulic oil tank 2 Turn off the engine and the main electrical powe...

Page 299: ...tacle 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 holder s parts Be especially thorough with the magnetic rod 8 Fit the new filters and assemble the filter units 9 Fit the filter units and the cover plates Tighten the bolts cross wise 10 Check the ...

Page 300: ...ter 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 inserts on the filter bracket 11 Fit the filter bracket and the drain plug 12 Close the drain valve on the accumulator charging valve 13 Turn on the main electric power and start the engine 14 Check tha...

Page 301: ...into 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 oil filters are to be changed replace them be fore the tank is filled with oil see Hydraulic oil filter changing page 14 7 Fill oil through the filling holes on the filters cover plates This means the...

Page 302: ...ft 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 injury burn injury rash or irritation Always depressurize the hydraulic systems before starting to work in the hydraulic systems Avoid skin contact with the oil use protective gloves IMPORTANT Ensure c...

Page 303: ...s 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 units 15 11 6 Communication 16 11 6 1 CAN bus 16 11 6 2 Redundant CAN bus 16 11 6 3 CAN bus driveline 16 https www forkliftpdfmanuals com ...

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

Page 305: ...n 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 For ex ample voltage feed and CAN bus https www forkliftpdfmanuals com ...

Page 306: ...t 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 distribution box frame 7 Battery disconnector F54 K3 F 5 8 3 F 5 8 2 F 5 8 1 K1 K2 K4 D793 X168 004885 2 3 4 5 6 7 1 https www forkliftpdfmanuals com ...

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 control units on frame en gine and transmission 50 A The main fuses divide the machine s voltage feed into smaller parts to maintain as many functions as possible in case of damage to ca bles harness...

Page 308: ...t 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 ATTACHMENT F58 3 15E SUPPLY POWER EMERGENCY 10A KDU FRONT KALMAR DISTRIBUTION UNIT 10A KDU OPT KALMAR DISTRIBUTION UNIT H8 G7 F6 E5 D4 C3 B2 A1 25A KDU FRONT KALMAR DISTRIBUTION UNIT F58 2 15 SUPPLY POWER ...

Page 309: ...hanging 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 harnesses Always use fuses with the correct ampere rating https www forkliftpdfmanuals com ...

Page 310: ...r 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 electrolyte level should be 10 mm above the cells NOTE Only use distilled water for topping up WARNING Battery electrolyte contains corrosive sulphuric ac id Risk of corrosive injuries health hazard ...

Page 311: ...intenance 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 forkliftpdfmanuals com ...

Page 312: ...d 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 redundant voltage feed for control units and then establish CAN bus communication to administer control signals for functions Control units establish communication when Operator s door is opened Inte...

Page 313: ...wing 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 D790 1 cuts off ignition voltage 15 See Ignition voltage 15 description page 13 3 Redundant voltage feed to control units is cut off 4 Control unit cab D790 1 disconnects the redundant CAN bus See Redun...

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 voltage feed is activated the following takes place 1 Start up signal is sent to Control unit cab D790 1 see A in illus tration 2 A hold circuit is activated in Control unit cab D790 1 which ac tivates th...

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 start up signal gives pulse to Control unit cab D790 1 CAN bus communication is established not drivetrain 3 Start key in position I or flashing hazard lights activated 4 Control unit cab D790 1 suppl...

Page 316: ...cted 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 distribution box frame 3 15E feed sends a voltage signal to Control unit cab D790 1 and verifies that relay K2 is active but that relay K3 is inactive This verifies that the operation breaker is working 4...

Page 317: ...2 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 Control unit transmission D793 4 Control unit frame front D797 F 11 Control unit engine D794 5 Control unit frame option D797 O 12 Control unit frame rear D797 R 6 Control unit attachment D791 1 13 Contro...

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 a segment If several segments are lost some control unit s lose contact with the network and work independently often with limited capacity to perform its task The signals can be checked with diagnos...

Page 319: ...tents 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 codes transmission 39 8 Control system 54 Error codes machine 54 https www forkliftpdfmanuals com ...

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

Page 321: ...formation 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 description of the diagnostic menus there are in addition to the explanation of the display figure reference to circuit dia grams that are found in section E Diagrams and reference to function group for furth...

Page 322: ...menu 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 X shows sequence number for shown error code and Y shows number of active error codes Scroll between error codes with key 1 and 2 arrow function Error codes disappear from list when the cause has be...

Page 323: ...he 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 engine alternative Volvo page 6 Error codes engine alternative Cummins page 23 Error codes transmission page 39 Error codes machine page 54 7 After action check that no active error codes remain for the...

Page 324: ...r 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 pedal 91 4 24 DTC 2 7 Throttle pedal con nected to the en gine s con trol unit cable short circuited to ground Engine goes to idle If the throttle pedal is re leased and thenpressed down again the e...

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 control unit and compo nent Check that sensor is in stalled correctly Check connection 14 in the black connector on the en gine s control unit D794 Black 14 ENGINE menu 6 1 8 3 Sensor oil pressure 102 0 ...

Page 326: ...rol 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 in coolant system Check the cap on the ex pansion tank Check sensor coolant tem perature Check thermostat ENGINE menu 7 1 7 Cooling system 105 3 25 DTC 3 2 Sensor charge air tempera ture cable short...

Page 327: ...able 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 unit and compo nent Check sensor coolant tem perature D794 Black 25 ENGINE menu 7 1 7 9 Sensor coolant tem perature 110 4 28 DTC 3 3 Sensor coolant tempera ture cable short circuited to ground Preheati...

Page 328: ...n 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 connected cor rectly Check connection 1 in the black connector on the en gine s control unit D794 Black 1 ENGINE menu 7 1 8 7 Sensor oil tempera ture 175 4 185 DTC 3 7 Sensor oil tempera ture cable short cir...

Page 329: ...or 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 626 3 76 DTC 5 4 Preheat ing relay cable short circuited to voltage Preheating cannot be activated Check cabling between control unit and compo nent Check relay s function D794 Red 36 ENGINE menu 5 1 ...

Page 330: ...629 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 Engine doesn t start Change control unit engine D794 11 5 3 10 Con trol unit engine 629 13 186 DTC 9 9 Memory error in control unitengine D794 Engine doesn t start Change control unit engine D794 11...

Page 331: ...nsor 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 correctly and con nected Check cabling between control unit and compo nent Check the sensor D794 Black 7 D794 Black 18 1 9 3 Sensor camshaft rpm 637 2 101 DTC 2 4 Sensor en gine rpm flywheel Irregular sign...

Page 332: ...ngine 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 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 639 12 38 DTC 6 5 Communi c...

Page 333: ...connection 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 Electric malfunc tion injec tor cylinder 1 Engine runs on 5 cylin ders sounds rough and has reduced power Check cabling between control unit and compo nent Check unit injector con nected correctly D...

Page 334: ...le 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 2 Engine runs on 5 cylin ders sounds rough and has reduced power Check cabling between control unit and compo nent Check unit injector con nected correctly D794 Black 22 Black 12 1 2 8 Injectors 652 ...

Page 335: ...le 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 3 Engine runs on 5 cylin ders sounds rough and has reduced power Check cabling between control unit and compo nent Check unit injector con nected correctly D794 Black 23 Black 12 1 2 8 Injectors 653 ...

Page 336: ...le 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 4 Engine runs on 5 cylin ders sounds rough and has reduced power Check cabling between control unit and compo nent Check unit injector con nected correctly D794 Black 34 Black 24 1 2 8 Injectors 654 ...

Page 337: ...le 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 5 Engine runs on 5 cylin ders sounds rough and has reduced power Check cabling between control unit and compo nent Check unit injector con nected correctly D794 Black 35 Black 24 1 2 8 Injectors 655 ...

Page 338: ...ions 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 tor cylinder 6 Engine runs on 5 cylin ders sounds rough and has reduced power Check cabling between control unit and compo nent Check unit injector con nected correctly D794 Black 36 Black 24 1 2 8 In...

Page 339: ...norunit 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 test and check cylinder 6 D794 Black 36 Black 24 1 2 8 Injectors 1 5 Engine me chanical parts 677 3 41 DTC 4 6 Start relay on starter motor ca ble short circuited to voltage Engine doesn t start Check ...

Page 340: ...to 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 on the en gine s control unit R31 1 11 1 Starter motor Descrip tion Limitation Action Con nec tion and com ponent Diag nostic menu Function group Code Volvo code https www forkliftpdfmanuals com ...

Page 341: ...tion 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 3 131 Electric mal function throt tle pedal cable short circuited to voltage Engine doesn t respond to throttle appli cation Check cabling between Control unit and compo nent Check component 1 1 2 Th...

Page 342: ...trol 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 between Control unit and compo nent Check component D794 Sen sor 09 1 2 10 Make contact wa ter in fuel 100 1 415 Low engine oil pressure Engine power is reduced suc cessively en gine shuts off after 30 ...

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 and compo nent Check sensor boost pres sure D794 Sen sor 39 EN GINE menu 7 1 6 5 Sensor boost pres sure 102 3 122 Sensor boost pressure ca ble short circuited to voltage Reduced en gine power Check ...

Page 344: ...rcuited 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 installed correctly and connected Check sensor charge air temperature D794 Sen sor 38 EN GINE menu 7 1 6 6 Sensor charge air temperature 108 2 295 Electric mal function air pressure data error Reduced en ...

Page 345: ...145 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 correctly Check sensor coolant tem perature D794 Sen sor 02 EN GINE menu 7 1 7 9 Sensor coolant tem perature 111 1 235 Low coolant level Engine power is reduced suc cessively en gine shuts off after 3...

Page 346: ...ow 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 voltage Warning active until voltage is correct engine runs at high idle to increase voltage Check batteries and alter nator D794 OEM 7 OEM 8 OEM 17 OEM 18 OEM 28 11 5 1 3 Igni tion voltage 15 168 16 442 V...

Page 347: ...em 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 oil temperature cable short circuited to ground No display of engine oil tem perature Check cabling between Control unit and compo nent Check component D794 Sen sor 42 EN GINE menu 7 1 8 7 Sensor oil t...

Page 348: ...function 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 function sen sor throttle pedal idle switch data error No limitation Check cabling between Control unit and compo nent Check component 1 1 2 Throt tle pedal 558 4 551 Electric mal function sen sor thro...

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 and compo nent Check component D794 Actua tor 34 EN GINE menu 5 1 10 1 Pre heating 627 2 434 Voltage feed to control unit disappears without igni tion off Reduced en gine power engine difficult to st...

Page 350: ...sys 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 Communica tion error with Control unit engine D794 Functions via CAN bus not working Use diagnostic menu to lo calize incorrect segment CAN POWER menu 2 1 9 Control system en gine 639 9 427 Communica tion ...

Page 351: ...nds 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 circuit 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 7 Actua tor 8 1 2 8 Injec tors 652 6 315 El...

Page 352: ...t 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 Electric mal function injec tor cylinder 5 cable short circuited to ground Engine runs on 5 cylinders sounds rough and has re duced power Check cabling between Control unit and compo nent Check component...

Page 353: ...ment 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 between Control unit and compo nent Check component 1 1 2 Throt tle pedal 974 4 134 Electric mal function extra throttle ped al cable short circuited to ground Engine doesn t respond to throttle appli c...

Page 354: ...uited 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 sensor tem perature ca ble short circuited to voltage No protection for tempera ture custom er specific option Check cabling between Control unit and compo nent Check component 1 9 Control system en gine...

Page 355: ...l 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 Reduced en gine power Check component D794 Sen sor 09 1 6 5 Sensor boost pres sure 1380 1 219 Low oil level engine No limitation Check the oil level in the engine top up if needed 1 8 Lubrica tion s...

Page 356: ...o 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 other control units No limitation Check error codes in other control units on the ma chine especially Control unit cab D790 1 and Con trol unit transmission D793 8 3 Error codes Descrip tion Limitatio...

Page 357: ...rmation 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 information 11 5 3 9 Con trol unit trans mission 00 53 00 53 Memory errorin control unit transmission Transmission in locked neutral po sition Shut down mode Contact Kalmar In dustries AB for more informatio...

Page 358: ...d 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 re ceives reduced proportional con trol precision de pending on reduced PWM work cycle Check voltage feed If auxiliary start equipment is con nected discon nect it 11 5 1 3 Igni tion voltage 15 31 00...

Page 359: ...pose 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 oil temperature transmission outside valid range Control unit indi cates the error Check cabling to sensor tempera ture torque con verter Check sensor tem perature torque converter D793 H3 B758 766 T...

Page 360: ...ressure 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 pressure B253 Check sensor oil pressure B253 D793 A 2 B253 TRANSM menu 10 2 6 2 Sensor oil pressure 51 00 51 00 Sensor engine rpm and oil temperature transmission short circuited to ground The control ...

Page 361: ...e 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 S221 TRANSM menu 10 2 7 2 Sensor oil tempera ture 52 01 52 01 Sensor oil tem perature short circuited to ground The control unit limits the trans mission s temper ature measurement to the highest val...

Page 362: ...circuited 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 correct 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 co...

Page 363: ...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 component Check component D793 D3 B758 TRANSM menu 6 2 3 8 Sensor rpm output shaft 61 01 61 01 Sensor rpm out put shaft not connected When only one rpm signal which isn t the engine rpm signal is in correct the con tr...

Page 364: ...ct 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 component Check component D793 F3 B758 766 TRANSM menu 6 2 2 5 Sensor engine rpm and oil tem perature transmission 63 00 63 00 Sensor rpm tur bine short circuited to ground When only one rpm signal which is...

Page 365: ...it 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 forward or short circuited voltage Control unit acti vates Limp home mode Check cabling to solenoid valve for ward Y630 Check solenoid valve forward Y630 D793 B1 Y630 C1 Y630 TRANSM menu 8 2 3 4 Valv...

Page 366: ...circuit 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 Valve block trans mission con trol 71 02 71 02 Electric mal function gear 2 4 control cur rent above 1400mA Control unit acti vates Limp home mode Check cabling to solenoid valve gear 2 4 Y6069 Check...

Page 367: ...e 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 vates Limp home mode Check cabling to solenoid valve re verse Y631 Check solenoid valve reverse Y631 D793 F1 Y631 G1 Y631 TRANSM menu 9 2 3 4 Valve block trans mission con trol 72 03 72 03 Electric mal f...

Page 368: ...J1 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 Check solenoid valve gear 1 3 Y6067 D793 H1 Y6067 J1 Y6067 TRANSM menu 9 2 Transmis sion 73 03 73 03 Electric mal function sole noid valve gear 1 3 control cur rent outside ap proved interval incorrect ...

Page 369: ...rect 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 voltage D793 B03 75 02 75 02 Analogue out put signal 5 control current above 1400mA D793 B03 75 03 75 03 Analogue out put signal 5 control current outside ap proved interval incorrect im pedance D79...

Page 370: ...ation 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 ground Transmission in locked neutral po sition Shut down mode Check cabling to solenoid valve drive Y6066 Check solenoid valve drive Y6066 D793 K1 Y6066 TRANSM menu 7 2 3 4 Valve block trans mission ...

Page 371: ...to 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 short circuited to ground Transmission in locked neutral po sition Shut down mode Check cabling to solenoid valve drive Check solenoid valve drive D793 K2 Y6066 TRANSM menu 7 2 3 4 Valve block trans mi...

Page 372: ...i 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 unit attachment right leg pair D791 4 Right side of combi 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...

Page 373: ...con 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 figuration CAN POWER menu 2 11 6 2 Redun dant CAN bus 13 Cable harness error CAN net segment 3 No limita tion Use diagnostic menu to lo calise incorrect segment Varies de pending on ma chine con figura...

Page 374: ...l 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 diagnostic menu to check communication Check the wiring between control unit cab D790 1 and control unit engine D794 D790 1 K13 1 K13 2 CAN POWER menu 3 11 6 3 CAN bus drivetrain 23 No set up file in cont...

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 component with diagnostic menu Check component D790 1 K4 5 K 5 1 K17 2 K 9 7 K10 3 CAN POWER menu 6 11 5 3 1 Con trol unit cab 33 No feed of control breaker voltage to control unit cab from battery Contr...

Page 376: ...n 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 Turn the ignition off and on Perform software down load again D793 11 5 3 9 Con trol unit trans mission 39 Interference during software download Buffer for error codes from trans mission some transmis...

Page 377: ...ights 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 due to short circuit or open circuit in circuit for Wiper motor front M650 Windshield wiper front not working Check cabling between the control unit and component with diagnostic menu Check component...

Page 378: ...oning 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 distribu tion cannot be changed Check cabling between the control unit and component with diagnostic menu Check component D790 1 K4 7 Y672 CLI MATE menu 4 9 4 6 Fresh air and recircula tion damper 82...

Page 379: ...P4 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 menu Check component D790 1 K9 8 R825 1 STEER ING menu 1 5 1 Controls and instru ments 93 Signal error from joystick or mini wheel R825 2 Joystick steering or mini wheel not working Check cabling bet...

Page 380: ...ostic 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 1 change if needed Check cabling between the control unit and component with diagnostic menu D797 F K2 1 9 10 CAN POWER menu 8 11 5 1 3 Igni tion voltage 15 104 Incorrect control breaker voltage to ...

Page 381: ...diagnostic 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 1 Central lubri cation ma chine not working Check cabling between the control unit and component with diagnostic menu Check component D797 F K1 28 M693 1 CAB menu 9 9 14 1 Pump unit 114 Transistor h...

Page 382: ...D797 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 Y6002 Lift and low er not work ing Check cabling between the control unit and component with diagnostic menu Check component D797 F K1 30 Y6002 BOOM menu 2 7 2 7 Valve block lift cylin der 120 Transisto...

Page 383: ...422 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 front right not working Check light Check cabling between the control unit and component with diagnostic menu Check bulb socket D797 F K1 10 H423 LIGHTS menu 8 9 6 7 Direc tion indicators 126 Transi...

Page 384: ...ons 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 pressure lift cylinder 134 Signal error from Sensor hydraulic pressure lift cylin der left B768 13 Overload system not working All lift functions operate at reduced speed Error code 150 ac tivated Chec...

Page 385: ...circuit 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 Control valve lift low er and exten sion 139 Transistor has been triggered due to short circuit or open circuit in cir cuit for solenoid valve boom out Y6006 Extension out not working Check cabling be...

Page 386: ...ad 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 control unit and component with diagnostic menu Check component D797 R K2 7 CAN POWER menu 8 11 5 1 2 Re dundant volt age feed of control units 152 Redundant voltage feed right to control unit frame...

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 cir cuit for light work light boom right H406R 1 Work light boom right not working Check light Check cabling between the control unit and component with diagnostic menu Check bulb socket D797 R K1 1...

Page 388: ...c 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 Attachment functionsnot working Check cabling between the control unit and component with diagnostic menu Check component D797 R K1 31 Y6003 HYD menu 6 7 4 2 Valve block top lift hydraulics 171 Transis...

Page 389: ...cket 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 Check light Check cabling between the control unit and component with diagnostic menu Check bulb socket D797 R K1 25 H412R LIGHTS menu 5 9 6 4 Rear light 177 Transistor has been triggered due to short c...

Page 390: ...cuit 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 menu Check component D797 R K1 40 Y6062 BOOM menu 2 7 3 8 Valve block pump unloading 183 Abnormal signal from Sensor boom angle 771 Overload system not working Check cabling between the control unit an...

Page 391: ...component 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 32 V Check fuse F58 2 4 change if needed Check cabling between the control unit and component with diagnostic menu D797 O K2 1 9 10 CAN POWER menu 8 11 5 1 3 Igni tion voltage 15 204 Incorrect contr...

Page 392: ...h 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 cuit for solenoid valve support jacks up Y6053 Support jacks not working Check cabling between the control unit and component with diagnostic menu Check component D797 O K1 30 Y6063 SUP PORT JACKS me...

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 down Y6017 Hydraulic sliding cab or cab lift not working Check cabling between the control unit and component with diagnostic menu Check component D797 O K1 17 Y6017 SLIDING CAB menu 4 9 10 Cab structu...

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 circuit in cir cuit for central unit central lubrication M693 2 Central lubri cation at tachment not working Check cabling between the control unit and component with diagnostic menu Check component D7...

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 for solenoid valve rotation coun ter clockwise Y6009 Rotation of attachment not working Check cabling between the control unit and component with diagnostic menu Check component D791 1 K1 3 Y6009 ATTAC...

Page 396: ...with 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 valve open twist lock Y6039 Twistlock not working Check cabling between the control unit and component with diagnostic menu Check component D791 1 K1 33 Y6039 ATTACH menu 7 7 9 1 3 Con trol valve at ...

Page 397: ...ent 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 rotation clockwise Y6008 Rotation of attachment not working Check cabling between the control unit and component with diagnostic menu Check component D791 1 K1 16 Y6008 ATTACH menu 9 7 6 3 Control va...

Page 398: ...ly 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 Check that Sensors align ment are clean and correct ly adjusted Check that alignment pin runs smoothly Check cabling between the control unit and component with diagnostic menu ATTACH menu 8 7 9 1 8 ...

Page 399: ...th 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 levelling left Y6036 Levelling not working Check cabling between the control unit and component with diagnostic menu Check component D791 2 K1 3 Y6036 ATTACH menu 18 7 8 3 Control valve attach ment ...

Page 400: ...heck 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 Y6036 Levelling not working Check cabling between the control unit and component with diagnostic menu Check component D791 2 K1 17 Y6036 ATTACH menu 18 7 8 3 Control valve attach ment 339 Transistor has...

Page 401: ...ch 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 needed Check cabling between the control unit and component with diagnostic menu D791 3 K2 11 CAN POWER menu 8 11 5 1 4 Con trol switch voltage 15E 361 Transistor has been triggered due to short circuit o...

Page 402: ...k 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 Left lift leg not working Check cabling between the control unit and component with diagnostic menu Check component D791 3 K1 4 Y6057L COMBI menu 11 7 9 2 3 Con trol valve lift leg 368 Transistor has ...

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 lift leg not working Check cabling between the control unit and component with diagnostic menu Check component D791 3 K1 7 Y6014L COMBI menu 12 7 9 2 3 Con trol valve lift leg 374 Transistor has been t...

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 Solenoid valve clamp close Y6054L Left lift leg not working Check cabling between the control unit and component with diagnostic menu Check component D791 3 K1 11 Y6054L COMBI menu 15 7 9 2 3 Con tr...

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 Check cabling between the control unit and component with diagnostic menu D791 4 K2 1 9 10 CAN POWER menu 8 11 5 1 3 Igni tion voltage 15 404 Incorrect control breaker voltage to Control unit combi ...

Page 406: ...t 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 Solenoid valve clamp closed Y6054R Right lift leg not working Check cabling between the control unit and component with diagnostic menu Check component D791 4 K1 2 Y6054R COMBI menu 15 7 9 2 3 Con trol valv...

Page 407: ...ponent 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 Right lift leg not working Check cabling between the control unit and component with diagnostic menu Check component D791 4 K1 32 Y6013R COMBI menu 10 7 9 2 3 Con trol valve lift leg 422 Transistor h...

Page 408: ...dicator 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 Light panel boom 428 Transistor has been triggered due to short circuit or open circuit in cir cuit for Indicator light H579 Indicator light clamp ing position lift leg rear not working Check light ...

Page 409: ...u 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 service schedule reset the service indicator Preventive maintenance Code Description Limitation Action Connec tionand compo nent Diag nostic menu Function group https www forkliftpdfmanuals com ...

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

Page 411: ...tilt 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 cab and support jacks 18 Hydraulic diagram combi attachment part 1 of 3 20 Hydraulic diagram combi attachment part 2 of 3 22 Hydraulic diagram combi attachment part 3 of 3 24 11 Common electrics 26 C...

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

Page 413: ...diagram 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 Hydraulic diagram cab lift and support jacks page 16 A43276 0100 Hydraulic diagram sliding cab and support jacks page 18 A40854 0100 Hydraulic diagram combi attachment part 1 of 3 page 20 A41791 0100 Hydra...

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 26 27 28 29 30 21 22 31 32 35 33 33 33 33 33 36 34 39 38 37 41 43 44 45 46 40 47 23 10 5 14 42 003183 A40740 0100 ver 8 https www forkliftpdfmanuals com ...

Page 415: ...nk 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 pass valve hydraulic oil cooler 30 Fine filter hydraulic oil 31 Priority valve 32 Pump cooling and filtering of hydraulic oil 33 Non return valve 34 Pressure feed to attachment 35 Hydraulic oil pump...

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 8 11 9 10 12 13 14 5 1 2 https www forkliftpdfmanuals com ...

Page 417: ...lve 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 pressure filter 12 Solenoid valve engagement hydraulic pressure 13 Shuttle valve 14 Hydraulic oil pump 1 and 2 https www forkliftpdfmanuals com ...

Page 418: ...aulics 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 1 1 2 3 3 4 5 5 6 7 8 8 9 10 11 13 14 15 https www forkliftpdfmanuals com ...

Page 419: ...lve 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 pressure filter 12 Solenoid valve engagement hydraulic pressure 13 Shuttle valve 14 Hydraulic oil pump 1 and 2 https www forkliftpdfmanuals com ...

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 14z 14 15 16 8 9 10 11 13 12 003186 A431213 0100 ver 3 https www forkliftpdfmanuals com ...

Page 421: ...tor 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 oil filter 13 Hydraulic oil pump 1 and 2 14 Levelling cylinders 15 Valve block levelling cylinders 16 Over centre valve levelling https www forkliftpdfmanuals com ...

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 https www forkliftpdfmanuals com ...

Page 423: ...0 450 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 and 4 https www forkliftpdfmanuals com ...

Page 424: ...Maintenance 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 forkliftpdfmanuals com ...

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 pump 1 and 2 https www forkliftpdfmanuals com ...

Page 426: ...DRF 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 https www forkliftpdfmanuals com ...

Page 427: ...on 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 Shuttle valve 10 Shuttle valve option frame 11 Hydraulic oil pump 1 and 2 https www forkliftpdfmanuals com ...

Page 428: ...al 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 https www forkliftpdfmanuals com ...

Page 429: ...ntrol 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 8 Shuttle valve option 9 Hydraulic oil pump 1 and 2 https www forkliftpdfmanuals com ...

Page 430: ...diagram 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 3 5 6 8 7 4 9 10 11 12 13 14 9 1 001207 E 15 001206 B 001206 C https www forkliftpdfmanuals com ...

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 Control valve attachment 13 Solenoid valve engagement hydraulic pressure 14 Shuttle valve 15 Hydraulic oil pump 1 and 2 https www forkliftpdfmanuals com ...

Page 432: ...2 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 2 part 2 3 https www forkliftpdfmanuals com ...

Page 433: ...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 Valve block lowering rear lift leg 9 Valve block lowering rear lift leg 10 Lowering cylinder rear lift leg https www forkliftpdfmanuals com ...

Page 434: ...0 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 part 3 3 https www forkliftpdfmanuals com ...

Page 435: ...ft 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 Valve block lowering rear lift leg 9 Valve block lowering rear lift leg 10 Lowering cylinder rear lift leg https www forkliftpdfmanuals com ...

Page 436: ...s 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 fuse box with 8 fuses An arrow symbol means a reference to another circuit diagram 20015 0001 wiring diagrams item designations K standard K standard 1 norms rules K standard 2 cable harness general ...

Page 437: ...ignals 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 Example indicator light K Relay contactor M Motor Example electric motor P Measuring instrument testing equipment Example operating hour gauge R Resistor Example potentiometer S Electric switch for co...

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 A43044 0100 X X X Circuit cross references opt 0 0 A43044 0200 X X X Circuit cross references attachment 0 0 A43044 0300 X X X Circuit cross references attachment 0 0 A43044 0400 X X X Circuit cross refe...

Page 439: ...heel 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 Circuit CAN bus attachment 11 6 A44875 0100 X X X Circuit CAN bus attachment 11 6 A44875 0200 X X X Circuit CAN bus attachment 11 6 A44875 0300 X X X Circuit engine Volvo 1 0 A44878 0100 X X X Circuit...

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

Page 441: ...75 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 A44875 0100 1 B3 A44875 0200 1 C2 A44875 0300 1 D1 4014 A44875 0100 1 B3 A44875 0200 1 C2 A44875 0300 1 D1 4013 X401f 1 X401f 2 X401f 3 X401f 4 X401f 5 X401f 6 X203m 6 4 2 2 4 X203f 6 1 3 5 5 3 1 X...

Page 442: ...13 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 Power 2 K13 1 A43044 0100 2 E6 D790 1 CAB SUPPLY CAN BUS K13 2 K13 3 K13 4 K13 5 K13 6 K13 7 K13 8 K13 9 K11 7 K11 8 K11 9 K11 10 K13 10 K13 11 K13 12 L CAN L R CAN R 0V REF CAN 2 TX GND RX BUZZER Sh...

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 C2 58 2 8 1 X210m 6 XG660 D 1 1 4 A2 58 2 1 1 4 A2 58 2 1 2 A43033 0200 1 A2 58 3 4 1 A 1 A 2 B 1 B 2 C 1 C 2 D 1 D 2 E 1 E 2 F 1 F 2 G 1 G 2 H 1 H 2 1 1 1 2 2 1 2 2 3 1 3 2 4 1 4 2 5 1 5 2 6 1 6 2 7 ...

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 Benämning Utgåva 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 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 me...

Page 445: ...5 X052f 7 1 2 1 1 2 2 Benämning Utgåva 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 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 h...

Page 446: ... 3 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 Keybord Ind Cluster A43032 0200 1 B4 D790 2 CAB K4 1 Keyb Ind K4 5 X015 1 X015 5 X061Af 5 X061Am 5 X061m 5 X061f 5 2 D6 58 5 2 1 F N R KIT KEYBOARD CABA46089 0100 1 B2 CABA46089 0100 1 B2 CABA46089 010...

Page 447: ... 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 ...

Page 448: ...on 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 Project no A43033 0200 03 Krets Ström KDU OPT Circuit Power KDU OPT DRFA 400 450 6 FSN 010220 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 A43033 0100 1 D8...

Page 449: ...T 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 3Lf 1 XE404 3Rf 2 XE404 3Rf 1 X002 7 X002 6 XE406Rf 1 XE406Lf 1 XE406Rf 2 XE406Lf 2 X080f 1 X080f 2 X006 10 X080f 3 X054f 4 X054f 6 X054f 5 X054f 3 X080m 3 X080m 1 X054m 4 X054m 6 X054m 3 X054m 5 X...

Page 450: ...t 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 Extra Arb bel Agg Circuit Opt Work Light Att DRFA 400 450 6 FSN 010613 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 ATTACHMENT A45209 0100 1 2 E404 4L EXTRA WORKING L...

Page 451: ...r 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 A43036 0100 04 Krets Extra Arb bel Bom Circuit OPT Work Light Boom DRFA 400 450 6 FSN 010830 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 A43033 0100 2 B6 58 4 7 1 E404 5L WORKING LIGHT BOOM BOOM E404 5R WORKING LIGHT BOOM B...

Page 452: ...0 450 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 BOOM 5 1 CAB S100 MAIN LIGHT 1 B4 10 9 0 1 5 1 CAB S110 ROT BEACON 1 C4 10 9 0 1 A43034 0100 1 A2 CHASSIS A43060 0100 1 B1 CHASSIS A43034 0100 1 A2 790 1 5 1 A43033 0100 4 F4 D790 2 CAB Input K3 9 5...

Page 453: ...ONT 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 CHASSIS X270f 2 X271f 2 X270f 1 X270f 5 X271f 1 X271f 5 X270f 6 X271f 6 P S216 CHASSIS 1 2 BRAKE LIGHTS 0 2 MPa X270m 2 X271m 2 X270m 1 X270m 5 X271m 1 X271m 5 X270m 6 X271m 6 A43044 0100 1 B4 D797...

Page 454: ...L BRAKE 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 POSITION RIGHT REAR CHASSIS X221 28 X221 42 X221 32 X221 33 X221 10 X221 25 X221 7 X221 9 X272f 1 X272f 2 X272f 3 X272f 5 X273f 1 X273f 3 X273f 2 X273f 5 X272f 6 X273f 6 X272m 1 X272m 3 X272m 2 X272m...

Page 455: ... 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 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 b...

Page 456: ... 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 A43038 0100 04 Krets Givare Instr Circuit Sensors Instr DRFB 400 450 6 FSN 010329 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 h P708 HOUR METER CAB A43054 0100 1 B2 CHASSIS A43059 0100 2 B2 790 1 10 9 U CHASS...

Page 457: ...ällande 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 R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43039 0100 04 Krets Extra Givare Instr Circuit OPT Sensors Instr DRFB 400 450 6 FSN 011121 RKO 031009 1 Reference...

Page 458: ...A43051 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 17 X815 18 X815 6 X815 9 X815 10 X815 1 X815 11 X815 4 X815 8 X007 3 X007 4 X007 5 X007 6 X007 1 X007 2 X37 D A43044 0100 2 B4 D790 1 CAB GND JOYSTICK 0V reference K7 1 A43044 0100 2 C4 D790 1 CAB J...

Page 459: ...N 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 10 X008 15 X008 6 X008 7 X010 6 XB769 2f 3 X010 1 X010 2 XB769 2f 1 XB769 2f 2 X231 2 X231 3 X231 16 X231 17 XB769 2m 1 XB769 2m 2 XB769 2m 3 XB777 2m 1 XB777 2m 2 XB777 2m 3 X064m 1 X064m 2 X064m 3 ...

Page 460: ... 450 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 00816 A43033 0100 3 B2 00816 10 9 Also indicated in symbol display H0_Cluster A43033 0100 4 E7 T U CHASSIS B762 TEMP BRAKE OIL 1 2 A43057 0100 1 B6 W10 A43041 0100 1 B7 W10 A43046 0100 1 E2 21139 0...

Page 461: ...st 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 Bromssystem Circuit Brakes DRFA 400 450 6 FSN 010308 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 2 2 A45209 0100 1 2 CHASSIS Y642 PARKING BRAKE M 1 2 M674 COOLER FAN BR...

Page 462: ...Bf 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 C B XB7205Lf C B XB7203Lf C X404f 4 X404f 5 X404f 6 X404f 3 2 XB7202Lf A XB7204Lf A XB7205Lf A XB7203Lf A X404f 1 B X411 40 X411 41 X411 24 X411 26 X411 13 X411 22 X411 23 X411 27 XB7202Rm A XB7205R...

Page 463: ...KE 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 2 ATTACHMENT Y6040 LOCK TW A43040 0100 1 D3 Also indicated in symbol display A43033 0100 4 E7 Also indicated in symbol display A43033 0100 4 E7 Y6003 A43050 0100 1 D5 Hydraulic valve A43051 0100 2...

Page 464: ... 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 D797 R CABA43034 0100 1 E1 CHASSISA43045 0100 2 A1 CHASSISA43045 0100 1 A1 A43049 0100 1 E3 A43049 0100 1 E3 CHASSISA43045 0100 1 B7 CHASSIS A43037 0100 3 D1 A43037 0100 3 D1 A43037 0100 3 C1 C...

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 RELEASING LEGS Analog Input CLAMP RELEASING LEGS Analog Input REAR LEGS DOWN Input DAMPING 24V reference DAMPING 0V reference 0 5A WATER VALVE Analog Input 0 5A DAMPING Input SEAT HEATER 0 5A RELAY WORK ...

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 OIL Input RIGHT SUPPORT JACK UPPER POS 1 5A SUPPORT JACKS UP 1 5A SUPPORT JACKS DOWN 1 5A TILT CAB UP 1 5A TILT CAB DOWN 0V reference SUPPORT JACKS UP 0V reference SUPPORT JACKS DOWN 0V reference TILT...

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 C W PWM 20 40 OUT PWM 40 20 IN Input 30 35 STOP Analog Input MEASUREPOINT SCALE Analog Input UNLOCKED TWISTLOCK Analog Input LOCKED TWISTLOCK Analog Input LOCKED TWISTLOCK 1 5A UNLOCKED TW In Output AL...

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 reference LEVELLING Benämning Utgåva 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 Ändring Design...

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 ATTACHMENTA43068 0100 5 C2 ATTACHMENTA43068 0100 5 A8 ATTACHMENT ATTACHMENTA43068 0100 6 C2 ATTACHMENTA43068 0100 6 C2 ATTACHMENTA43068 0100 11 C2 ATTACHMENTA43068 0100 5 A2 ATTACHMENTA43068 0100 5 B2 ATTACHMENTA430...

Page 470: ... 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 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 d...

Page 471: ...2 XB7221m 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 X411 21 XB7224m B A43051 0100 2 B4 24V_D791 10 A43051 0100 2 C5 0V_D791 38 A43044 0100 1 B4 D797 F SENSORS OILPRESSURE 0V reference K1 6 A43044 0100 1 B4 D797 F SUPPLY SENSORS OILPRESSURE Analog refer...

Page 472: ...3033 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 Benämning Utgåva 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 Ändring Design change T Tillk Added U Utgår Deleted V Var Was Ändr...

Page 473: ...e 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 R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project...

Page 474: ...R WIPER 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 X057f 1 XM650 2f 3 X004 14 X004 13 X012 1 X012 2 X057f 3 XM650 2f 4 XM650 2f 1 X057f 4 XM650 2f 2 X057f 2 X012 3 X012 4 X010 14 X010 13 X055f 1 XM650 3f 3 X055f 3 XM650 3f 4 X055f 4 X055f 2 XM650 3...

Page 475: ... BK 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 X211 35 1 2 Y6001 BLOCKING RIGHT X211 31 1 2 Y6005 BOOM LIFT X211 2 X211 16 1 2 Y6004 BOOM LOWER X211 3 X211 17 A43040 0100 1 D3 S1005 A43055 0100 1 A4 OVER RIDE Used with Digital Sensors B771 and B...

Page 476: ... 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 Benämning Utgåva 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 Ändring Design change T Tillk Added U Utgår Deleted V Var Was Ändring nr Change No Sign Datum D...

Page 477: ...ses 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 A43043 0100 2 E4 A43049 0100 1 D5 2783 X411 2 X411 3 X411 16 X411 17 X221 31 X221 35 X278f 4 X278f 3 X278m 4 X278m 3 XY6062 2 B7225 ROTATION STOP BN BK BU XB7225m A X416f A A43051 0100 2 C4 24V_D79...

Page 478: ...1 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 A43055 0100 1 A4 OVER RIDE Y6003 A43050 0100 1 D5 Hydraulic valve 1 2 Y6018 20 40 OUT 1 2 Y6019 40 20 IN 1 2 Y6020 SIDESHIFT LEFT 1 2 Y6021 SIDESHIFT RIGHT X411 4 X411 5 X411 31 X411 30 X411 19 X411 18 ...

Page 479: ...0 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 C2 W10 X411 10 A43043 0100 1 D1 24V_D791 10 XB769f A XB769m A ATTACHMENT B769 DAMPING 20 40 BN BK BU XB769m C XB769f C X411 12 XB769m B XB769f B A43043 0100 1 A8 0V_D791 38 A43043 0100 1 D8 0V_D791 3...

Page 480: ...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 A43053 0100 04 Krets Hydraulik Circuit Hydraulics DRFA 400 450 6 FSN 010327 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 T U CHASSIS B776 1 2 HYDRAULIC TEMPERATURE Also indicated in symbol display...

Page 481: ... DRFB 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 9 X081m 2 X080m 9 X081m 1 X37 D X008 11 A43051 0100 2 A1 00816 A43051 0100 2 B1 W10 X006 7 X080f 7 X080m 7 A43059 0100 1 B2 CHASSIS X080m 8 X080f 8 X006 8 A43059 0100 1 B2 790 1 5 1 A43044 0100 2 C...

Page 482: ...l be 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 Adjustment Sync Harnesses 041478 TKB 040930 2 2 A45209 0100 A43044 0100 1 B6 D797 F CHASSIS OPTION FRONT In Output K1 26 A43044 0100 1 C6 D797 F CHASSIS OPTION FRONT In Output K1 40 X274f 3 X274f 1 X274f ...

Page 483: ...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 A43055 0100 04 Krets Förbikoppling Circuit Override DRFA 400 450 6 FSN 020110 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 0 1 5 1 CAB S1005 OVER RIDE A43042 0100 1 B1 00816 A43041 ...

Page 484: ...43056 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 CABA46089 0100 1 B4 HORN A43033 0100 4 F4 D790 2 CAB Input K3 2 H850 HORN CAB 1 2 2 A2 0621 H853 BUZZER CAB 1 2 1 3 CAB S230 SEAT SWITCH 2 S107 A43042 0100 1 B4 PARKING BRAKE 2 B7 0622 X063f 2 X017...

Page 485: ...t 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 D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43056 0100 04 Krets Larm Ljudsignaler Circuit Alarm Soundsignals DRFA 400 450 6 FSN 010327 RKO 031009 1 Reference Text Adjustment Sync Harnesses 0...

Page 486: ...ext 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 W10 A43055 0100 1 C2 W10 A43041 0100 1 A2 00816 A43055 0100 1 C2 00816 1 2 0 1 2 CHASSIS Y6063 SUPPORT JACKS UP 1 2 CHASSIS Y6064 SUPPORT JACKS DOWN X231 30 X231 31 X233f 1 X233f 2 X231 34 X231 35 X2...

Page 487: ...U 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 9 X231 6 XB7222Lf B XB7223Lf B X233f 5 XB7222Rf A XB7223Rf A XB7222Rf B XB7223Rf B X231 27 X231 41 XB7223Rf C XB7222Lf C XB7223Lf C XB7222Rf C X233f 6 X233f 7 X233f 8 X233f 9 X233f 10 XB7222Lm A XB...

Page 488: ...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 Project no A43058 0100 04 Krets Centralsmörjning Circuit Central lubrication DRFA 400 450 6 FSN 010329 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 M M693 1 CENTRAL L...

Page 489: ...be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43059 0100 05 Krets Hytt Förarstol Circuit Cab Seat OPT DRFA 400 450 6 FSN 010410 RKO 031210 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 2 CAB A45209 0100 K383 SEAT HEATER 85 86 30 87A 87 A43033 0100 2 B6 58 4 6 1 A43054 0100 1 E2 790 1 5 1 A43037 0100 1 B1 790 1 5 1 A43054 0100 1 E2 CHASSIS ...

Page 490: ...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 R E A B C D E F Blad...

Page 491: ...D 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 H423 DIRECTION RIGHT FRONT CHASSIS 1 2 H426 DIRECTION LEFT REAR CHASSIS 1 2 H427 DIRECTION RIGHT REAR CHASSIS 0 1 X039f 2 X081f 7 X081f 5 X081f 6 X005 5 X005 6 X270f 4 X271f 4 X221 29 X221 39 X272f...

Page 492: ...25 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 X775 2 1 X775 3 1 X775 1 2 X035f 7 X775 2 2 X035f 8 X774 2 X036f 7 X775 3 2 X036f 8 X221 23 X035f 9 X036f 9 X033m 1 X033m 2 X033m 3 X033m 4 X033m 5 X036m 7 X036m 8 X035m 7 X035m 8 X035m 9 X036m 9 2...

Page 493: ...39f 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 2 X039m 6 X039m 5 X036m 1 X278m 1 X034m 7 X034m 9 X034m 8 X657m 1 X657m 2 X039m 8 X036m 2 X036m 3 X37 D X37 D CHASSIS X612m 1 X612f 1 X612f 2 X612f 3 X612m 2 X612m 3 M612 MOTOR RECIRCULATION 12V G...

Page 494: ...en 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 5 Huvudnr Project no A43062 0100 04 Krets Radio Circuit Radio DRFB 400 450 6 FSN 010517 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 X900 1 8 2 8 3 8 4 8 ...

Page 495: ...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 R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43063 0100 04 Krets 24V Circuit 24V DRFA 400 450 6 FSN 030124 RKO 031009 1 Reference T...

Page 496: ...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 R E A B C D E F Blad Sheet Produkt Pro...

Page 497: ... 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 5 Huvudnr Project no A43064 0100 04 Krets Tiltlåsning Circuit Tilt lock DRFA 400 450 6 FSN 010613 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 1 2 ATTACHMEN...

Page 498: ...DRFA 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 CHASSIS Y6048 TILT CAB DOWN 1 2 CHASSIS Y6057 TILT CAB UNLOAD HYDRAULIC OIL XB777 4f A X231 22 XB777 4f C X231 32 X231 33 X231 7 X231 36 X231 25 XB777 4m A XB777 4m C XB777 4m B X231 37 XB777 4f B A...

Page 499: ... D790 1 Analog reference 5V K9 7 Benämning Utgåva 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 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 a...

Page 500: ...ontravention 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 031210 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 2 2 A45209 0100 1 2 CHASSIS Y636L MICRO LEVER STEERING LEFT 1 2 CHASSIS Y636R MICRO LEVER STEERING RIGHT X231 4 X231 5 X231 18 X23...

Page 501: ...CAB Input K1 27 D790 3 CAB Input K1 41 Benämning Utgåva 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 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 e...

Page 502: ...066 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 0100 1 2 CHASSIS Y636L1 MICRO LEVER STEERING LEFT 1 2 CHASSIS Y636R1 MICRO LEVER STEERING RIGHT X231 4 X231 5 X231 18 X231 19 X235f 1 X235m 1 X235f 3 X235m 3 X235f 2 X235f 4 X235m 2 X235m 4 X022 1 X02...

Page 503: ... 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 A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A43067 0100 04 Krets Backlarm Circuit Reverse alarm DRFA 400 450 6 FSN 011121 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 0...

Page 504: ...ombi 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 LEGS DOWN 1 C4 1 2 0 3 1 S1008 7 1 E4 1 2 0 10 9 CLAMPING RELEASING LEGS 1 D4 X009 1 X009 2 X009 3 X009 4 X009 5 X009 6 X009 8 X009 9 X009 10 A43044 0100 2 A6 D790 1 SUPPLY SWITCH LEGS 24V referen...

Page 505: ... Nr 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 ...

Page 506: ...t 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 0100 1 2 Y6054R CLAMPING IN 1 2 Y6055R CLAMPING OUT 1 2 Y6057R FRONT KNEE IN 1 2 Y6056R FRONT KNEE OUT 1 2 Y6059R REAR KNEE IN 1 2 Y6058R REAR KNEE OUT X441 11 X441 12 X441 4 X441 5 X441 30 X441 31 X...

Page 507: ...ING 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 041478 TKB 040930 4 12 ATTACHMENT A45209 0100 1 2 Y6013R LOWERING FRONT LEG 1 2 Y6060R FRONT LEG UP 1 2 Y6014R LOWERING REAR LEG 1 2 Y6061R REAR LEGS UP 1 2 Y6053R DRIVING POSITION X441 32 X441 33 X441 7...

Page 508: ...kt 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 0100 1 2 Y6054L CLAMPING IN 1 2 Y6055L CLAMPING OUT 1 2 Y6057L FRONT KNEE IN 1 2 Y6056L FRONT KNEE OUT 1 2 Y6059L REAR KNEE IN 1 2 Y6058L REAR KNEE OUT X431 4 X431 5 X431 30 X431 31 X431 6 X431 11 X...

Page 509: ...WING 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 041478 TKB 040930 6 12 ATTACHMENT A45209 0100 1 2 Y6060L FRONT LEG UP 1 2 Y6014L LOWERING REAR LEG 1 2 Y6061L REAR LEG UP 1 2 Y6053L DRIVING POSITION 1 2 Y6013L LOWERING FRONT LEG X431 32 X431 33 X431 7...

Page 510: ...12 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 XB7213Rf A X441 21 X441 36 X441 23 X441 27 X441 13 XB7217Rf B XB7217Rf C XB7219Rf B XB7215Rf B XB7213Rf B XB7219Rf C XB7215Rf C XB7213Rf C XB7217Rm A XB7219Rm A XB7215Rm A XB7213Rm A XB7217Rm B XB7217...

Page 511: ... REAR 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 X441 24 X441 41 X441 20 XB7218Rf B XB7216Rf B XB7220Rf B XB7212Rm A XB7212Rm B XB7212Rm C XB7218Rm A XB7220Rm A XB7216Rm A XB7214Rm A XB7218Rm B XB7220Rm B XB7216Rm B XB7214Rm C XB7216Rm C XB7220Rm C...

Page 512: ...12 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 XB7217Lf B XB7213Lf B XB7215Lf B XB7219Lf B X431 26 XB7217Lm A XB7219Lm A XB7215Lm A XB7213Lm A XB7217Lm B XB7219Lm B XB7215Lm B XB7213Lm B XB7217Lm C XB7219Lm C XB7215Lm C XB7213Lm C XB7215Lf C XB721...

Page 513: ...L REAR 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 XB7220Lf A X431 22 X431 37 X431 24 X431 41 X431 20 XB7218Lf B XB7214Lf B XB7216Lf B XB7220Lf B XB7218Lf C XB7220Lf C XB7216Lf C XB7214Lf C XB7212Lm A XB7212Lm B XB7212Lm C XB7218Lm A XB7220Lm A XB7216Lm ...

Page 514: ...L 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 X441 25 X441 29 X441 39 X431 10 X431 25 X431 29 X431 39 X415f 1 X415f 2 X415f 3 X415f 4 X441 38 X431 38 X415f 6 X443m 5 X443m 6 X443m 7 X443m 8 X433m 6 X433m 7 X433m 8 X443m 12 X433m 5 X433m 12 X41...

Page 515: ...ereof 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 04 Krets Kombi Agg Circuit Combi Att DRFA 400 450 6 FSN 020530 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 12 12 ATTACHMENT A45209 0100 1 2 E404 6R WORK LIGHT RIGHT LEG ...

Page 516: ... 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 A44875 0100 03 Krets CAN BUS AGG Circuit CAN BUS ATT DRFA 400 450 6 FSN 030110 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 X412f 2 3 7 X412f 8 4 5 1 2 X401m 3 4 5 X401m 6 L CAN L R CAN R CAN Shiel...

Page 517: ...cuted 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 Harnesses 041478 TKB 040930 1 1 A45209 0100 1 2 3 4 5 X401m 6 X412f 2 3 7 8 4 5 X422 2 3 7 8 4 5 L CAN L R CAN R CAN Shield K2 2 D791 1 BOOM K2 3 K2 7 K2 8 K2 4 K2 5 K2 6 L CAN L R CAN R CAN Shield K...

Page 518: ...SN 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 2 3 4 X401m 5 X401m 6 1 2 3 A43032 0100 1 A2 A43032 0200 1 A2 4015 A43032 0100 1 A2 A43032 0200 1 A2 4014 A43032 0100 1 A2 A43032 0200 1 A2 4013 A43032 0100 1 A2 A43032 0200 1 A2 4016 A43032 0100 ...

Page 519: ...n 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 5 Huvudnr Project no A44878 0100 04 Krets Motor Volvo Circuit Motor Volvo DRFA 400 450 6 FSN 010411 TKB 031204 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 A43033 010...

Page 520: ...121 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 7 50 8 50 9 50 10 50 11 50 12 50 13 50 14 50 15 50 16 50 17 50 18 50 19 50 20 50 21 50 22 50 23 50 24 50 25 50 26 50 27 50 28 50 29 50 30 50 31 50 32 50 33 50 34 50 35 50 36 50 37 50 38 50 39 50 4...

Page 521: ...ent 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 A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A44878 0200 04 Krets Motor Cummins Circuit Motor Cummins DRFB 400 450 6 TKB 030929 RKO 031121 1 Reference Text Adjustment Sync Harnesses...

Page 522: ...rpose 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 031201 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 3 A45209 0100 A43033 0100 1 C5 58 1 5 1 A43033 0100 1 B8 58 2 5 1 A43032 0100 1 C2 A43032 0200 1 C2 CAN_J1939_ A43032 0100 1 C2 A43...

Page 523: ... 4 3 2 1 Godk Appr Ritad Drawn Konstr Design Datum Date Sign Ref Ruta Nr 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...

Page 524: ...ssue 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 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 beivr...

Page 525: ...r 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 F Blad Sheet Produkt Product 5 Huvudnr Project no A44880 0100 03 Krets Ström Agg Circuit Power Att DRFA 400 450 6 FSN 020204 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 X422 1...

Page 526: ...t 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 X421 3 X421 4 X421 5 X421 31 X421 16 X421 17 X421 18 X421 19 X421 6 X421 34 X421 30 A43044 0400 1 D2 D791 2 BOOM LEVELLING RIGHT 1 5A K1 2 A43044 0400 1 D2 D791 2 BOOM LEVELLING LEFT 1 5A K1 3 A43044...

Page 527: ...LEFT PWM K1 17 Benämning Utgåva 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 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 ...

Page 528: ...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 A45043 0100 04 Krets Over Height Circuit Over Height DRFA 400 450 6 FSN 030206 RKO 031009 1 Sync Harness 041583 TKB 041027 1 2 A45209 0100 X009 1 X009 2 XS1007 XS1008 X009 3 X009 4 X009 5 X009 6 X009 8 X009 9 X009 10 XS1006 XS1007 XS1008 XS1006 D790 1 CAB 24V ...

Page 529: ...89f 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 Rm B XB7231 Lm B XB7231 Lf B XB7231 Rf B X421 20 X421 13 1 X421 9 XB7231 Lm A XB7231 Rm A X421 10 X489m 10 X489f 10 XB7231 Lf A XB7231 Rf A X408m 1 X408m 2 X408f 2 X408f 1 A43044 0400 1 D2 D791 2 B...

Page 530: ...ate 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 R E A B C D E...

Page 531: ... 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 secute...

Page 532: ...3 X005 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 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 1 2 R8082 FAN SPEED 3 1 2 R8083 TEMEPERATURE 3 1 2 R808...

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 X062f 9 X062m 9 M645 1 2 MAGNETIC CLUTCH COMPRESSOR X278m 1 CHASSIS A43033 0100 2 D6 58 5 3 2 A43044 0100 2 B6 D790 1 WATER VALVE Analog Input K10 4 Benämning Utgåva Issue Ritn nr Drawing No Name Klass...

Page 534: ...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 A46088 0100 02 Krets Instegsbelysning Circuit Step In Light DRFB 400 450 6 TKB 030901 RKO 031009 1 Reference Text Adjustment Sync Harnesses 041478 TKB 040930 1 1 A45209 0100 A43044 0100 2 C2 D790 1 CAB OPTION STEP IN LIGHT PWM Output K5 3 X005...

Page 535: ...ER 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 X057f 1 X004 14 X004 13 X012 1 X012 2 X057f 3 XM650 2f 4 X057f 4 XM650 2f 2 X057f 2 X012 3 X012 4 X010 14 X010 13 X055f 1 X055f 3 XM650 3f 4 X055f 4 X055f 2 XM650 3f 2 X058f 1 X058f 2 X057m 1 XM65...

Page 536: ...44 0100 1 B6 D797 F REGENERATION RIGHT 1 5A K1 32 A43044 0100 1 B6 D797 F REGENERATION LEFT 1 5A K1 33 Benämning Utgåva 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 Ändring Design change T Tillk Added U Utgår Deleted V Var Was Ändring nr Change No Sign Datum Date Sq Denna ritning får ej ...

Page 537: ...2 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 A43044 0100 2 C2 D790 1 TEMP INDOOR Reostat in K4 8 A43044 0100 2 C2 D790 1 TEMP AMBIENT Reostat in K4 9 A43044 0100 2 C2 D790 1 TEMP FAN AIR Reostat in K4 10 A43044 0100 2 C2 D790 1 DEICING SENSOR Reo...

Page 538: ... 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 X062f 9 X062m 9 M645 1 2 MAGNETIC CLUTCH COMPRESSOR X278m 1 CHASSIS A43033 0100 2 D6 58 5 3 2 1 2 R3 Benämning Utgåva 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 ...

Page 539: ... Schalter Nebelscheinwerfer Interrupteur feux de brouillard 103 S Strömställare fjärrljus Switch distance light Schalter Fernscheinwerfer Interrupteur feux longue porte e 104 S Strömställare lastljus Switch mast lights Schalter Ladescheinwerfer Interrupteur feux de travail 105 S Strömställare arbetsljus Switch working lights Schalter Arbeitsbeleuchtung Interrupteur feux de travail 106 S Strömställ...

Page 540: ... bak Switch power take off rear Schalter Nebenantrieb hinten Interrupteur prise de puissance arrière 130 S Strömställare hög lågväxel Switch high low gear Schalter Rangegetriebe Hoch Niedrig Interrupteur petite grande vitesse 131 S Strömställare färdväljare fram Switch gear selector forward Schalter Fahrtrichtungswähler vorwärts Interrupteur marche avant 132 S Strömställare färdväljare bak Switch ...

Page 541: ...er Kombi Signal Beleuchtung Fern Abblendlicht Waschanlage 2 Intervallwischer vor rückwärts Interupteur avertisseur feux de route et de croisement essuie glace à balayage intermittent 163 S Strömställare start på 2 an Switch start 2nd gear Schalter Start 2 gang Interrupteur démarrage 2 trans 165 S Strömställare stolvärme Switch seat heater Schalter Sitzheizung Interrupteur chauffage du siège 166 S ...

Page 542: ...Schalter Option Interrupteur option 200 S Brytkontakt lampa park broms Contact breaking warning lamp parking brake Unterbrecherkontakt Warnlampe Feststellb remse Contact à ouverture voyant frein de stationnement 201 S Brytkontakt lampa färdbroms Contact breaking warning lamp brake Unterbrecherkontakt Warnlampe Betriebsb remse Contact à ouverture voyant frein de service 202 S Brytkontakt lampa olje...

Page 543: ...ntakt Kabinenverriegelung Contact à fermeture verrouillage de la cabine 229 S Slutkontakt stolslåsning Contact making seat locking Schließkontakt Sitzsperre Contact àfermeture verrouillage du siège 230 S Brytkontakt stol Contact breaking seat Unterbrecherkontakt Sitz Contact à ouverture siège 231 S Slutkontakt fotkontroll stolvändning Contact making seat rotation foot switch Endkontakt Drehen des ...

Page 544: ...t à fermeture écartement des bras de fourche 264 S Slutkontakt sidoföring Contact making sideshift Schließkontakt Seitenverschiebung Contact à fermeture déplacement latéral 265 S Slutkontakt stativ in ut Contact making lifting mast in out Schließkontakt Hubgerüst ein aus Contact à fermeture mat de lev ext ret 266 S Brytkontakt hyttdörr Contact breaking cab door Unterbrecherkontakt Kabinetür Contac...

Page 545: ...ent wiper Relais Intervallwischer Relais balayage intermittent 322 K Relä kylvätskenivå Relay coolant level Relais Kühlflüßigkeitsstand Relais niveau radiateur 323 K Relä blinkers Relay blinkers Relais Blinker Relais clignotants 324 K Relä rangespärr Relay range interlock Relais Rangesperre Relais blocage doubleur 325 K Relä blinkande bromsljus back Relay flashing brake lights reversing Relais bli...

Page 546: ...olvändning ljussignal Relay multifunction seat rotation light signal Relais Multifunktion Sitzdrehen Lichtsignal Relais multifonction siège appel de phare 348 K Relä fläktmotor värmare Relay fan heating Relais Gebläsemotor Heizung Relais chauffage du moteur de ventilateur 349 K Relä fartreglage Relay speed control Relais Geschwindigkeitsregelung Relais commande de vitesse 350 K Relä pumpkontaktor ...

Page 547: ...ing height limiter Relais blinkende Rundumleuchte Höhebegrenzung Relais lampe clignotante limiteur de hauteur 373 K Relä bakljus Relay light Relais beleuchtung Relais feux 375 K Huvudkontaktor reglersystem Main contactor operating control Hauptschütz Regelsystem Contacteur principal système de régulation 376 K Kontaktor fram reglersystem Contactor forward operating control Schütz vom Regelsystem C...

Page 548: ...chtung links Eclairage conteneur gauche 406 E G lampa cont belysning höger Container light right hand Containerbeleuchtung rechts Eclairage conteneur droite 408 E G lampa park ljus vä fram Light bulb parking light left hand forward Glühlampe Standlicht links vorn Ampoule feux de stationnement avant gauche 408 E G lampa park ljus hö fram Light bulb parking light right hand forward Glühlampe Standli...

Page 549: ...richtungsanzeiger rechts vorn Ampoule clignotant avant droite 426 H G lampa körvisare vä bak Light bulb direction indicator left hand rear Glühlampe Fahrtrichtungsanzeiger links hinten Ampoule clignotant arrière gauche 427 H G lampa körvisare hö bak Light bulb direction indicator right hand rear Glühlampe Fahrtrichtungsanzeiger rechts hinten Ampoule clignotant arrière droite 428 H G lampa roterand...

Page 550: ...oule feux stop clingnotant gauche blackout 454 H G lampa bromsljus blackout höger Light bulb brake light blackout right hand Glühlampe Bremslicht Ausfall rechts Ampoule feux stop clingnotant droit blackout 456 E G lampa backljus blackout IR vänster Light bulb rear light blackout IR left hand Glühlampe Rueckfahrtleuchte Ausfall IR links Ampoule feux de recul blackout infra rouge gauche 456 E G lamp...

Page 551: ...poutre pour les 40 blackout infra rouge 463 H G lampa bak ljus vänster bak blackout Light bulb rear light left hand rear blackout Glühlampe Rueckfahrtleuchte links hinten Ausfall Ampoule feux de recul gauche blackout 463 H G lampa bak ljus höger bak blackout Light bulb rear light right hand rear blackout Glühlampe Rueckfahrtleuchte rechts hinten Ausfall Ampoule feux de recul droit blackout 464 E G...

Page 552: ...roue avant directrice 531 H Kont lampa 4 hjuls styrning Indicating lamp 4 wheel steering Kontrollampe Vierradlenkung Témoin 4 roues drectrices 532 H Kont lampa crab styrning Indicating lamp crab steering Kontrollampe Diagonal lenkung Témoin dépacement en diagonal 533 H Kont lampa hyd pump Indicating lamp emergency hyd pump Kontrollampe Ackumulatorladepumpe Témoin pompe hydrzulique d urgence 547 H ...

Page 553: ...n Kontrolllampe Motor Information Lampe de contrôl information moteur 574 H Kontroll lampa stödben nere Indicator lamp support jacks down Kontrollampe Stuetzbein unten Lampe de contrôl beqilles abaissées 575 H Kontroll lampa stödben ur arb läge Indicator lamp support jacks out of working pos Kontrollampe Stuetzbein außerhalb Arbeitsposition Lampe de contrôl béquille relevées 576 H Kontroll lampa a...

Page 554: ...ventil flödesbegränsning Solenoid valve flow restriction Magnetventil Fließbegrenzung Electrovanne limiteur de débit 612 M Ställmotor recirkulation Regulating motor re circulation Stellmotor Re zirkulation Moteur de commande re circulation 613 Y M ventil momentförstärkare Solenoid valve torque amplifier Magnetventil Drehmomentwandler Electrovanne convertisseur de couple 614 Y M ventil rangespärr S...

Page 555: ...Y M ventil låsning 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 Electrovanne GPL 641 Y M ventil förångare LPG Solenoid valve evaporator LPG Magnetventil Verdampfer LPG Electrovanne évaporateur GPL 642 Y M ventil park broms Solenoid valve parking brake Magnetventil Fe...

Page 556: ...e climatisation 664 M Cirk pump klimatanläggning Circulating pump air condition Umwälzpumpe Klimaanlage Pompe de circulation climatisation 665 V Diod Diode Diode Diode 666 M Fläktmotor cirkulation Circulation fan Umluftgebläser Moteur du ventilateur circulation 667 M Cirkulationspump värmesystem Circulation pump heating system Wärmetauscher Heizsystem Pompe de circulation circuit de chauffage 668 ...

Page 557: ...cateur de capacité batterie 710 P Tidur motor kupevärmare Timer engine and cab heater Schaltuhr motor und Kabinenheizung Minuterie chauffage moteur et habitacle 711 P Räknare impuls Counter impulse Zähler Impuls Compteur d impulsion 712 P Mätare oljetryck motor Motor oil pressure gauge Maßinstrument Öldruck Motor Minuterie prèssion d huile moteur 714 P Mätare temp Hydraulolja Hydraulic fluidtemper...

Page 558: ...ur Spülkreis Bremsen Capteur temp circuit refroidiss freins 763 B Givare nivå hydraulolja Transmitter hydraulic fluid level Geber Hydraulikölfüllstand Capteur niveau huile hydraulique 764 B Givare servotryck växellåda Transmitter gear box servo pressure Geber Servodruck Getriebe Capteur pression servo de la boîte 765 B Givare oljetryck v låda Transmitter oil pressure gear box Geber Öldruck Getrieb...

Page 559: ...vo amplifier steering system Servoverstärker Steuerungssystem Amplificateur pour le servo commande du systeme de direction 789 B Givare allmän Transmitter common Geber allgemein Capteur général 790 D Elektronisk kontrollenhet ECU hytt Electronic Control Unit ECU cab Elektronische Kontrolleinheit ECU Kabine Unite de control électronique ECU cabine 791 D Elektronisk kontrollenhet aggregat Electronic...

Page 560: ...ignalomvandlare höger Signal amplifier right Signalverstärker rechts Amplificateur de signaux droit 824 U Signalomvandlare vänster Signal amplifier left Signalverstärker links Amplificateur de signaux gauche 825 R Reglage spakstyrning Controls steering with control levers Regler Hebelsteuerung Commande leviers 826 Y Ventil spakstyrning Valve steering with control levers Ventil Hebelsteuerung Distr...

Page 561: ... TW Interrupteur deverroulliage TW 1003 S Strömställare låsa TW Switch locking of TW Schalter Verriegelung der TW Interrupteur verroulliage TW 1004 S Strömställare stopp vid 30 35 Switch stop at 30 35 Schalter Stopp bei 30 35 Interrupteur arrêt á 30 35 1005 S Strömställare förbikoppling av säkerhetssystem Switch overriding of the safety system Schalter ûberbrückung des sicherheitssystem Interrupte...

Page 562: ...mställare Korta Armen av på Switch Short Arm on off 1025 S Strömställare pappersfunktioner av på Switch paper funktions on off 1026 S Strömställare omkoppling pappers klämmagregat Switch switch papper bale clamp 1027 S Strömställare lyfthöjdsförval Switch lift height selection 1028 S Strömställare lyfthöjdsförval öka Switch lift height selection increase 1029 S Strömställare lyfthöjdsförval minska...

Page 563: ...t Relay working light cab shift std blackout Relais Arbeitsbeleuchtung schaltung std Ausfall Relais normal blackout pour l éclai âge de la cabine 3013 K Relä arb bel bom 20 vxl std blackout Relay working light boom20 shift std b out Relais Arbeitsbeleuchtung Ausleger 20 Schaltung std Ausfall Relais normal blackout pour les feux de travail sur la poutre pour les 20 3014 K Relä arb bel bom 40 vxl st...

Page 564: ...ntrol Relais drehbarer Fahrersitz Geschwindigkeitsregelung Relais siège pivotant commande de vitesse 3404 K Relä VBFS mastljus Relay rotating driver s seat mast light Relais drehbarer Fahrersitz Ladescheinwerfer Relais siège pivotant feux de travail 3412 K Relä bak ljus Relay rotating driver s seat rear light Relais drehbarer Fahrersitz Rücklicht Relais siège pivotant feu arrière 3768 K Relä oljet...

Page 565: ...Solenoid valve clamping releasing legs Magnetventil Klemmen Lösen der Beine Electrovanne serrage deserrage béquilles 6016 Y M ventil Hyttskjutning fram Solenoid valve cab movement forward Elektro Magnetventil Kabinenversetzung vorwärts Electrovanne mouvement avant de la cabine 6017 Y M ventil Hyttskjutning bak Solenoid valve cab movement reverse Elektro Magnetventil Kabinenversetzung hinten Electr...

Page 566: ...rear wheel steering right Magnetventil Hinterrad links Lenkung rechts Electrovanne roue arrière gauche direction droite 6034 Y M ventil skevning Solenoid valve levelling Magnetventil Niveausgleich Electrovanne levage 6035 Y M ventil skevning höger Solenoid valve levelling right Magnetventil Niveausgleich rechts Electrovanne levage droit 6036 Y M ventil skevning vänster Solenoid valve levelling lef...

Page 567: ...e serrage 6055 Y M ventil klämma isär Solenoid valve clambing out Magnetventil aufklammern Electrovanne déserrage 6056 Y M ventil främre knä ut Solenoid valve front knee out Magnetventil vorderes Knie ausklappen Electrovanne sortie d articulation avant 6057 Y M ventil främre knä in Solenoid valve front knee in Magnetventil vorderes Knie einklappen Electrovanne rentrée d articulation avant 6058 Y M...

Page 568: ...valve Inching Magnetventil Inching Electrovanne Inching 6078 Y M ventil Avstängning Övre klämarm Solenoid valve upper arm off Magnetventil Electrovanne 7200 S Givare axeltryck höger Sensor axle pressure right Drucksensor Achsdruck rechts Capteur de pression arbre du vérin du levage droit 7201 S Givare axeltryck vänster Sensor axle pressure left Drucksensor Achsdruck links Capteur de pression arbre...

Page 569: ... position de conduite 7213 S Givare Anliggning främre ben Sensor Alignment front legs Geber Anliegen vordere Beine Capteur alignement jambes avants 7214 S Givare Anliggning bakre ben Sensor Alignment rear legs Geber Anliegen hinten Beine Capteur alignement jambes arriéres 7215 S Givare kläm främre ben Sensor Clamp front legs Geber Anliegen Beine vorne Capteur position de vérouillage jambes avants ...

Page 570: ...Potentiometer left front wheel Potentiometer vorderrad links Potentiometre roue avant gauche 8079 R Potentiometer höger bakhjul Potentiometer right rear wheel Potentiometer hinterrad rechts Potentiometre roue arrière droite 8080 R Potentiometer vänster bakhjul Potentiometer left rear wheel Potentiometer hinterrad links Potentiometre roue arrière gauche 8081 R Potentiometer tiltvinkel Potentiometer...

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 SI units 14 Conversion table length 15 Conversion table area 15 Conversion table volume 15 Conversion table weight 16 Conversion table pressure 16 https www forkliftpdfmanuals com ...

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

Page 573: ...3 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 front rear 18 00x25 36 18 00x25 40 18 00x33 36 Tyre pressure also see pressure plate 1 0 MPa 9 6 Frame body cab and accessories lighting system Light Rating W Socket Control lights 1 2 W2x4 6d Inter...

Page 574: ...Transmission 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 gear hydraulic motor attachment 1 6 l Brake hydraulic motor attachment 0 6 l 9 Frame body cab and accessories Volvo TWD1240VE Cummins QSM11 Washer fluid 5 l Air conditioning refrigerant 2000 g R134a Air...

Page 575: ...00 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 DRF450 65S6 42 44 45 30 15 43 45 30 15 16200 19250 DRF450 65S5X 45 36 38 21 43 45 37 38 21 15200 18200 DRF450 65S6X 42 45 35 38 21 43 45 34 36 38 21 16300 19350 DRF420 70S5 41 42 30 15 40 42 30 15 1510...

Page 576: ...e 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 4150 6055 12185 11200 4500 250 18 00x25 40 66400 DRF450 60S5X 11200 13600 8100 9400 4150 6055 12185 11200 4600 300 18 00x33 36 76500 DRF420 65S5 11600 13600 8500 9400 4150 6055 12185 11700 4500 250 1...

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 13600 9400 9400 4150 6055 12185 12700 4750 300 18 00x33 36 82100 DRD450 80S4X 14900 15300 11000 11250 4500 6055 12185 14200 5150 425 21 00x35 36 102600 DRD450 80S4XS 14900 15300 11000 11250 4500 6055 12...

Page 578: ...n 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 Transmission lubrication system ATF DEXRON III DEXRON III 3 3 Power transmission drive axle API GL 5 SAE 80W140 SAE 75W90 4 Brakes UTTO oil GM Allison C 4 John Deere J20 C D Cat epillar TO 4 SAE 5W30 trans...

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 lubrication points except for glide plates where lubrication paste Gleitmo 805 or equivalent shall be used Sealant silicone Use Loctite 5972 or Loctite 598 or equivalent If uncertain contact Kalmar In...

Page 580: ...g 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 1 2 3 1 1 Fine M thread M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm M101 25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm M121 25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm M161 5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm M181 5 330 Nm 294 N...

Page 581: ...173 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 1424 Nm 1780 Nm 2100 Nm 1 1 4 1760 Nm 1565 Nm 1990 Nm 2490 Nm 2940 Nm 1 3 8 2320 Nm 2065 Nm 2620 Nm 3280 Nm 3870 Nm 1 1 2 3060 Nm 2720 Nm 3455 Nm 4320 Nm 5100 Nm Quality 8 8 10 9 12 9 Pipe diameter Ti...

Page 582: ...s 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 18 40 14x1 5 45 3 8 19 70 3 4 16 78 16x1 5 55 1 2 14 100 7 8 14 110 18x1 5 68 3 4 14 190 1 1 16 12 180 20x1 5 80 1 11 300 1 3 16 12 230 22x1 5 98 1 1 4 11 330 1 5 16 12 285 26x1 5 170 1 1 2 11 400 1 5...

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 Mile mile Centimetre cm Metre m Kilometre km https www forkliftpdfmanuals com ...

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 74 ft lb s x 1 36 W Energy J Nm kJ x 0 948 Btu x 1 055 kJ J x 0 239 calorie x 4 19 J Speed and acceleration m s2 x 3 28 ft s 2 x 0 305 m s 2 m s x 3 28 ft s x 0 305 m s km h x 0 62 mph x 1 61 km h Horse...

Page 585: ...m 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 1076 4 119 58 ft2 0 092903 0 000929 1 0 1111 144 000 yd2 0 83613 0 008361 9 1 1296 00 in2 6 4516 0 000645 0 006943 0 000771 1 1ha 100a 1mile2 259ha 2 59km 2 Unit cm3 cc m3 l in3 ft3 yd3 cm3 ml 1 0 0000...

Page 586: ...0 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 100000 100 14 5037 2088 6 Pa N m2 0 00001 0 001 1 0 001 0 00015 0 02086 kPa 0 01020 0 01 1000 1 0 14504 20 886 lbf in2 0 07032 0 0689 6894 76 6 89476 1 144 lbf ft2 0 00047 0 00047 47 88028 0 04788 0 00...

Page 587: ...Maintenance 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 forkliftpdfmanuals com ...

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

Page 589: ...Tenth 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 Drivetrain Parts in machine involved in power transmission engine torque converter transmis sion propeller shaft and drive axle with differential and hub reduction Dust reservoir The air filter collect...

Page 590: ...ow 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 alternative Proportional valve An electro magnetically controlled valve If a current is applied the valve is activated in proportion to the current s amplitude In simple terms infinitely variable valve ...

Page 591: ...n 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 Indicates machine type and capacity See also machine model Valve slide Moveable part in valve Determines oil s path Variable displacement Adjustable volume capacity of a pump Variable pump Pump with adjust...

Page 592: ...n 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 4 3 1 Brake pedal 4 Brakes 4 1 1 Brakes 4 Brakes 4 Breather filter 4 Brakes 4 8 11 Breather filter hydraulic oil tank 10 Common hydraulics 10 6 6 By passing 8 Control system 8 2 2 CAB 8 Control syste...

Page 593: ...em 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 instrumentation 9 Frame body cab and accessories 9 1 Conversion table area F Technical data Conversion table length F Technical data Conversion table pressure F Technical data Conversion table SI unit...

Page 594: ...ror 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 B Safety Fluid or gas under pressure B Safety Foreword A Foreword Form for copying A Foreword Frame 9 Frame body cab and accessories 9 12 Frame body cab and accessories 9 Frame body cab and accessor...

Page 595: ...diagram 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 Hydraulic diagram top lift tilt lock and controllable tilt E Schematics 10 Hydraulic diagram top lift tilt lock controllable tilt and hy draulic levelling E Schematics 10 Hydraulic diagrams compilation E S...

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 brake unit 4 Brakes 4 5 4 Positioning 7 Load handling 7 5 Positioning beam 7 Load handling 7 5 8 Positioning chains 7 Load handling 7 5 7 Positioning motor 7 Load handling 7 5 6 Power assisted syste...

Page 597: ...ructions 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 Safety Service schedule C Preventive Maintenance Servo filter 7 Load handling 7 2 2 Setup 8 Control system 8 5 Several mechanics on the same machine B Safety Side shift 7 Load handling 7 4 Sideshift frame...

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 example 0 Complete machine Troubleshooting without an error code example 0 Complete machine Troubleshooting general work instructions 0 Complete machine Twistlocks 7 Load handling 7 9 1 Tyre and rim syst...

Page 599: ...GB 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 forkliftpdfmanuals com ...

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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