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Kalmar DRF450-60S5X - User Manual

Kalmar DRF450-60S5X
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

Safety

General safety information

Emphasizes safety concerns for everyone and the importance of heeding warnings.

Safety instructions

Provides general safety instructions to follow before starting work, covering various aspects like service position and clothing.

Hydraulic and brake systems, depressurizing

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

Working under machine

Covers safety precautions for working under the machine, including securing the cab and chassis.

Lifting heavy components

Addresses risks and safety precautions for handling heavy components, emphasizing approved lifting tools.

Fire and explosion risks

Lists explosion-prone substances and ignition causes, with safety precautions for handling flammable materials.

Fluid or gas under pressure

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

Tyre system

Emphasizes the danger of pressurized tires and safety actions for dismantling, inflating, and handling them.

Preventive maintenance

Preventive maintenance, work instructions

Provides step-by-step instructions for new machine checks, 50h checks, and regular service as per schedule.

Complete machine

Troubleshooting, general work instructions

Provides a structured and logical approach to troubleshooting, focusing on isolating component errors.

Troubleshooting without an error code, example

Guides on how to troubleshoot symptoms by identifying functions, reading function descriptions, and checking signals.

Troubleshooting with error code, example

Explains how to use error codes from the display and error code lists to identify and resolve malfunctions.

Troubleshooting cable harness

Details procedures for troubleshooting all cables, including checking for open circuits and short circuits to the frame.

Troubleshooting hydraulic hoses

Provides instructions for troubleshooting hydraulic hoses, including depressurizing systems and inspecting for damage.

Engine

Fuel pre-filter, changing (Volvo engine)

Details the procedure for changing the fuel pre-filter, including safety warnings about fire hazards and hot engines.

Fuel filter, changing (Volvo engine)

Provides steps for changing the fuel filter, including safety warnings and notes on filling with fuel before installation.

Fuel filter, changing (Cummins engine)

Outlines the procedure for changing the fuel filter on Cummins engines, including safety warnings and proper waste handling.

Coolant filter, changing (Volvo engine)

Provides steps for changing the coolant filter, including safety warnings about coolant loss and proper handling.

Coolant filter, changing (Cummins engine)

Details the procedure for changing the coolant filter on Cummins engines, including safety warnings and proper waste handling.

Oil and oil filter, change (engine alternative Volvo)

Provides instructions for changing engine oil and filters for Volvo engines, including safety warnings.

Oil and oil filter, change (engine alternative Cummins)

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

Transmission

Oil and oil filter, changing

Provides instructions for changing transmission oil and filters, with warnings about hot oil and overfilling.

Transmission, calibrating

Provides instructions for calibrating the transmission, including parking the machine, entering a code, checking oil temperature, and performing steps B and C until oil is hot.

Driveline;axle

Drive axle oil, changing

Provides a step-by-step procedure for changing the drive axle oil, including positioning the machine, removing drain plugs, and filling hubs and differential.

Brakes

Power-assisted brake system, function description

Explains the components and function of the power-assisted brake system, including the oil tank, pump, filter, accumulators, and brake units.

Brake oil pump, checking

Details the procedure for checking the brake oil pump, including operating temperature, depressurizing systems, and checking pump pressure during charging and cooling.

Parking brake system, function description

Describes the parking brake system components and how it is released with pressure from accumulators via the parking brake valve.

Parking brake unit, checking and adjustment

Provides steps for checking and adjusting the parking brake unit, including a danger warning about the machine possibly rolling.

Brake oil filter, changing

Provides instructions for changing the brake oil filter, emphasizing cleanliness and safety warnings about hot, pressurized oil.

Steering

Suspension

Tyre and rim system, safety

Emphasizes safety measures for tyre and rim systems, including dangers of blocking wheels, deflating tires, and handling damaged tires or rims.

Tyre and rim system, checking

Advises reading safety instructions before working with tyres and rims, and provides cautions for wheel nut tightening and tyre changing.

Tyre and rim system, removing (drive axle)

Details the procedure for removing wheels from the drive axle, including lifting the machine, deflating the tyre, and removing nuts, washers, and clamps.

Tyre and rim system, installing (drive axle)

Guides on installing drive axle wheels, including lifting the inner wheel, rotating it, and tightening wheel nuts.

Tyres, inflating

Provides safety instructions for inflating tyres, emphasizing approved rim components and proper air pressure.

Load handling

Lifting;lowering

Describes lifting and lowering the boom using two hydraulic cylinders pressurized by a control valve.

Load carrying

Refers to holding any load, with mentions of twistlocks and lift legs.

Twistlocks

Explains that the container is held by four twistlocks controlled by the control lever and switch.

Lift legs

Describes lift legs designed to lift objects using four legs, with front and rear legs controllable separately.

Weight indicator, function description (product alternative fixed scale)

Describes the weight indicator's function for weighing loads at specific boom and extension positions using pressure sensors.

Fixed scale, calibration

Guides on calibrating the fixed scale weight indicator, emphasizing the importance of following steps in the specified order.

Weight indicator, function description (product alternative dynamic scale)

Explains the weight indicator's dynamic scale function, showing load weight regardless of boom and extension position using boom length, angle, and pressure sensors.

Dynamic scale, calibration

Provides calibration instructions for the dynamic scale weight indicator, emphasizing accuracy and step-by-step procedures.

Control system

Monitoring functions, general

Lists monitoring functions that increase safety during load handling, including overloading system, by-passing, load centre, height, and speed limitations.

Overloading system

Describes the LLMC warning system for stationary load handling, including buzzer, warning figure, and boom movement interruption.

Overloading system, general

Details the LLMC system's function, limitations, and three versions: mechanical, mechanical with analogue sensors, and electrical.

Mechanical overloading system, function description

Explains the basic mechanical overloading system using opening sensors for load and analogue sensors for boom length and angle.

Mechanical overloading system with analogue sensors, function description

Describes this system variant using opening sensors for load and analogue sensors for boom length and angle, detailing activation conditions.

Electrical overloading system, function description

Explains the electrical overloading system's calculations based on sensor values and its interruption of functions like lift and lower during overload.

By-passing, description

Details how to by-pass the safety system using switches for various functions like lowering load or releasing parking brake.

Load centre limitation, description

Explains how load centre limitation prevents the load from coming too close to the machine, controlled by signals from boom angle and length sensors.

Height limitation, description

Describes height limitation as a control system function preventing lifting higher than a pre-set height, using boom angle and length sensors.

Error codes, description

Explains that error messages are generated by control units and sent via CAN-bus to the display, with explanations in section D Error codes.

Diagnostics

Introduces diagnostic tests as built-in functions for troubleshooting, consisting of several menus grouped by logical areas.

Diagnostic test, general

Lists the groups of diagnostic menus, referring to specific menu overview pages for CAN/POWER, LIGHTS, CAB, CLIMATE, HYD, ENGINE, TRANSM, BOOM, ATTACH, OP, and EXTRA.

Frame, body, cab and accessories

Protection and emergency equipment, description

Discusses protective and warning equipment that enhances operator safety, including back-up alarm, rotating beacon, horn, and fire extinguisher.

Humidity filter, changing

Provides steps for changing the humidity filter, including safety warnings about refrigerant and special authorization requirements.

Error codes

Error codes, explanation

Explains that error codes are generated by control units and sent via CAN-bus to the display, with explanations in section D Error codes.

Error code indication

Details how error codes are indicated using symbols, lights, and display figures, divided into STOP, WARNING, and INFORMATION levels.

1 Engine

Lists error codes for Volvo engines, including code, description, limitation, action, connection, diagnostic menu, and function group.

Error codes engine alternative Volvo

Lists error codes for Volvo engines, including code, description, limitation, action, connection, diagnostic menu, and function group.

Error codes engine alternative Cummins

Lists error codes for Cummins engines, including code, description, limitation, action, connection, diagnostic menu, and function group.

2 Transmission

Explains that control units use two modes (Limp-home, Shut-down) for serious transmission malfunctions and refers to section 2 Transmission for more details.

Error codes transmission

Explains that control units use two modes (Limp-home, Shut-down) for serious transmission malfunctions and refers to section 2 Transmission for more details.

8 Control system

Explains that error codes notify operators and mechanics of detected malfunctions, with explanations available in section D Error codes.

Error codes machine

Explains that error codes notify operators and mechanics of detected malfunctions, with explanations available in section D Error codes.

Common hydraulics

Hydraulic oil pump, checking

Guides on checking hydraulic oil pumps by warming up the machine, turning off the engine, connecting a pressure gauge, and checking stand-by pressure.

Hydraulic oil filter, changing

Provides steps for changing the hydraulic oil filter, emphasizing cleanliness and safety warnings about hot, pressurized oil.

Hydraulic oil filter (high pressure filter), changing

Outlines the procedure for changing the high-pressure hydraulic oil filter, including safety warnings and important notes on cleanliness.

Hydraulic oil, changing

Guides on changing the hydraulic oil, including safety warnings about hot, pressurized oil and checking the oil level.

Hydraulic oil fine-filter, changing

Details the procedure for changing the fine filter hydraulic oil, including safety warnings about hot, pressurized oil and ensuring cleanliness.

Common electrics

Fuses, description

Explains the electrical system's main circuits and how main and circuit fuses divide voltage feeds to maintain functions during cable damage.

Technical data

Kalmar DRF450-60S5X Specifications

General IconGeneral
ModelDRF450-60S5X
CategoryForklifts
Engine TypeDiesel
TransmissionAutomatic
Tyre TypePneumatic
Load Capacity45, 000 kg
Wheelbase6, 000 mm

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