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Kalmar DRF450-60S5 - User Manual

Kalmar DRF450-60S5
600 pages
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AForeword
BSafety
C Preventive maintenance
0 Complete machine
1Engine
2 Transmission
3 Driveline/axle
4Brakes
5Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
DError codes
ESchematics
F Technical data
G Terminology and index
Maintenance
manual
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Table of Contents

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Summary

B Safety

Safety instructions

Provides general safety instructions to be followed before starting work on or with the machine.

Hydraulic and brake systems, depressurizing

Details the procedure for safely depressurizing hydraulic and brake systems before maintenance.

Working under machine

Provides safety instructions for working under a lifted or raised vehicle, emphasizing secure support.

Lifting heavy components

Warns about risks associated with careless handling of heavy components and advises on safe lifting practices.

Fire and explosion risks

Identifies explosion-prone substances and causes of ignition, with safety precautions.

Fluid or gas under pressure

Warns about dangers of high-pressure fluids or gas leaks and provides safety precautions.

Tyre system

Warns about dangers of handling pressurized tyres and provides safety actions for tyre and rim maintenance.

C Preventive maintenance

Preventive maintenance, general

Emphasizes the importance of performing preventive maintenance according to recommended intervals.

Preventive maintenance, work instructions

Details specific work instructions for preventive maintenance tasks on new and existing machines.

Service schedule

Outlines the service intervals and actions required for 500h, 1000h, and 2000h services.

Lubrication 500 hours

Details the lubrication points and procedures for the 500-hour service interval.

Lubrication 1000 hours

Details the lubrication points and procedures for the 1000-hour service interval.

0 Complete machine

Troubleshooting, general work instructions

Offers a structured approach to troubleshooting by systematically excluding components as error sources.

Troubleshooting without an error code, example

Provides a step-by-step guide for troubleshooting when no specific error code is displayed.

Troubleshooting with error code, example

Explains how to use error code lists and diagnostic menus to troubleshoot malfunctions.

Troubleshooting cable harness

Details the procedure for troubleshooting all cables to avoid damage to control units and measuring equipment.

Troubleshooting hydraulic hoses

Provides instructions for troubleshooting hydraulic hoses, including inspection for damage and leaks.

1 Engine

Fuel system, bleeding (engine alternative Volvo)

Provides instructions for bleeding the fuel system on Volvo engines to remove air from the fuel filter and cylinder head.

Fuel pre-filter, changing (Volvo engine)

Details the procedure for changing the fuel pre-filter on Volvo engines, including safety precautions.

Fuel filter, changing (Volvo engine)

Details the procedure for changing the fuel filter on Volvo engines, including safety precautions.

Fuel filter, changing (Cummins engine)

Details the procedure for changing the fuel filter on Cummins engines, including safety precautions.

Air cleaning system

Describes the air cleaning system, including the procedure for changing the air filter cartridge.

Coolant filter, changing (Volvo engine)

Details the procedure for changing the coolant filter on Volvo engines, including safety precautions.

Coolant filter, changing (Cummins engine)

Details the procedure for changing the coolant filter on Cummins engines, including safety precautions.

Fan belt, checking

Describes how to check and adjust the fan belt tension on both Cummins and Volvo engine alternatives.

Coolant level, checking

Provides instructions and warnings for checking the coolant level in the expansion tank.

Oil and oil filter, change (engine alternative Volvo)

Details the procedure for changing engine oil and filters on Volvo engines, including safety precautions.

Oil and oil filter, change (engine alternative Cummins)

Details the procedure for changing engine oil and filters on Cummins engines, including safety precautions.

2 Transmission

Oil and oil filter, changing

Provides procedures and warnings for changing transmission oil and filters.

Oil level, checking

Details the procedure for checking the transmission oil level, including warnings and notes.

Transmission, calibrating

Provides instructions for calibrating the transmission, including safety precautions.

3 Driveline;axle

Propeller shaft, checking

Details the checks and maintenance procedures for the propeller shaft, including tightening bolts and greasing universal joints.

Drive axle, checking

Provides instructions for checking the drive axle attachment, wheel nuts, brake caliper joint, and seals.

Drive axle oil, changing

Details the procedure for changing the drive axle oil, including positioning, draining, and filling.

4 Brakes

Brake pedal, checking and adjusting

Provides instructions for checking and adjusting the brake pedal, including clearance and smooth travel.

Power-assisted brake system, function description

Describes the components and function of the power-assisted brake system.

Brake oil pump, checking

Details the procedure for checking the brake oil pump pressure, including warnings and operating steps.

Accumulator, checking

Explains how to check the brake system's accumulators and identify potential defects.

Parking brake system, function description

Describes the components and function of the parking brake system.

Parking brake unit

Provides the component position and checking/adjustment procedures for the parking brake unit.

Breather filter, changing

Details the procedure for changing the breather filter, including safety precautions and notes.

Brake oil filter, changing

Details the procedure for changing the brake oil filter, emphasizing cleanliness and safety.

5 Steering

Power-assisted system, function description

Describes the power-assisted steering system, its components, and how it operates with hydraulic oil pumps.

6 Suspension

Steering axle cradle, checking

Provides instructions for checking the steering axle cradle bushings for intactness.

Wheel spindle bearing, checking

Details the procedure for checking the wheel spindle bearing clearance.

Wheel hub, checking

Provides instructions for checking wheel hub covers, grease, and nuts, including safety precautions.

Tyre and rim system, safety

Warns about dangers when working with tyres and rims, emphasizing securing the machine and deflating tyres.

Tyre and rim system, checking

Provides instructions for checking tyre and rim condition, wheel nuts, and wear.

Tyre and rim system, removing (drive axle)

Details the procedure for removing tyres and rims from the drive axle, including safety precautions.

Tyre and rim system, removing (steering axle)

Provides instructions for removing tyres and rims from the steering axle, including safety precautions.

Tyre and rim system, installing (drive axle)

Details the procedure for installing tyres and rims on the drive axle.

Tyre and rim system, installing (steering axle)

Provides instructions for installing tyres and rims on the steering axle.

Tyres, inflating

Explains the procedure for inflating tyres, including safety warnings and specifications.

Rims, checking

Details checks for rims, including diameter, wear, and damage, with instructions for magnetic powder testing.

7 Load handling

Servo filter, changing

Provides instructions for changing the servo filter, including safety precautions and oil level checks.

Pressure reducer, checking servo pressure

Details the procedure for checking servo pressure at the pressure reducer, including warnings.

Sideshift frame, glide plates sideshift frame, checking

Details the procedure for checking glide plates on the sideshift frame, including thickness and clearance.

Main beam attachment, glide plates main beam attachment, checking

Provides instructions for checking glide plates on the main beam attachment, including thickness and clearance.

Oil spreader motor unit, changing

Details the procedure for changing the oil spreader motor unit, including safety precautions.

Positioning chains, spreader chains, checking

Provides instructions for checking spreader chains, including clearance and tension adjustment.

Slide plates, extension beam, checking and adjustment

Details the procedure for checking and adjusting slide plates on the extension beam.

8 Control system

Service menu

Provides access to the machine's diagnostic system for error codes, diagnostic tests, and settings.

Overloading system

Describes the Longitudinal Load Moment Control (LLMC) warning system for stationary load handling.

Overloading system, general

Explains the functionality of the overloading system, including warnings and boom movement interruption.

By-passing

Explains how to by-pass the safety system when the overloading system is activated and turns off hydraulics.

Load centre limitation

Describes the load centre limitation, which prevents the load from coming too close to the machine.

Height limitation

Describes the height limitation feature, which prevents lifting higher than a pre-set height.

Speed limitation

Describes speed limitation, which prevents exceeding preset values by limiting gear position and engine rpm.

Service indicator, resetting

Provides instructions for resetting the service indicator using the service menu and a code.

Error codes

Notifies operators and mechanics about detected malfunctions through error messages.

Error codes, description

Explains how error codes are generated by control units and displayed on the screen.

Diagnostics

Provides built-in functions for troubleshooting using diagnostic tests and menus displayed on the screen.

Diagnostic test, general

Explains the diagnostic test function, consisting of several menus grouped for faster access.

9 Frame, body, cab and accessories

Protection and emergency equipment

Outlines the protective and warning equipment provided to enhance operator safety.

Fresh air filter, changing

Details the location and procedure for changing the fresh air filter at the front of the cab.

Humidity filter, checking

Describes how to check the humidity filter indicator color to determine if replacement is needed.

Humidity filter, changing

Details the procedure for changing the humidity filter, including safety precautions and authorization requirements.

10 Common hydraulics

Hydraulic oil pump, checking

Details the procedure for checking hydraulic oil pump pressure, including warnings and operating steps.

Breather filter hydraulic oil tank, changing

Details the procedure for changing the breather filter on the hydraulic oil tank, including safety precautions.

Hydraulic oil filter, changing

Provides instructions for changing the hydraulic oil filter, emphasizing cleanliness and safety.

Hydraulic oil filter (high pressure filter), changing

Details the procedure for changing the high pressure hydraulic oil filter, including safety precautions.

Hydraulic oil, changing

Provides instructions for changing the hydraulic oil, including warnings and notes on proper handling.

Hydraulic oil fine-filter, changing

Details the procedure for changing the fine filter hydraulic oil, including safety precautions.

11 Common electrics

Fuses, changing

Provides instructions for changing fuses, including safety precautions and the correct ampere rating.

Start battery, checking

Details the procedure for checking the start battery voltage, terminals, and fluid level.

D Error codes

Error codes

Provides an explanation of error codes in table form, sorted by error code number.

Error codes, explanation

Explains error codes in a table format, providing code, description, limitation, action, and connection details.

Error codes transmission

Provides a table of error codes for the transmission system, including descriptions and actions.

Error codes machine

Provides a table of error codes for the machine's control system, including descriptions and actions.

F Technical data

Technical data

Provides technical specifications for data and volume, covering engine, transmission, and hydraulics.

Specifications for lift capacity and dimensions

Provides specifications for lift capacity and dimensions of various machine models.

Oils and lubricants, recommendation

Recommends specific oil types and qualities based on ambient temperature for various machine systems.

Tightening torques, recommendations

Provides recommended tightening torques for bolts and nuts, including notes on surface treatment and lubrication.

Tightening torques, ORFS-couplings

Details tightening torques for pipe and hose couplings based on pipe diameter and thread type.

Kalmar DRF450-60S5 Specifications

General IconGeneral
BrandKalmar
ModelDRF450-60S5
CategoryForklifts
LanguageEnglish

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