EasyManua.ls Logo

Kalmar DRF450-65S5 User Manual

Kalmar DRF450-65S5
600 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
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
https://www.forkliftpdfmanuals.com/

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Kalmar DRF450-65S5 and is the answer not in the manual?

Kalmar DRF450-65S5 Specifications

General IconGeneral
BrandKalmar
ModelDRF450-65S5
CategoryForklifts
LanguageEnglish

Summary

A Foreword

Foreword

General information about the maintenance manual, including conditions, storage, and copyright.

B Safety

General safety information

Stresses the importance of safety information for everyone working with the machine.

Safety instructions

Lists and details safety instructions to follow before starting work on the machine.

Working under machine

Provides safety guidelines for working under the machine's chassis or cab.

Lifting heavy components

Details risks and safety precautions when handling heavy components.

C Preventive maintenance

Preventive maintenance, general

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

Preventive maintenance, work instructions

Provides instructions for new machines and regular service schedule adherence.

50h-check

Lists checks to be performed after 50 hours of operating time to increase machine reliability.

Service schedule

Details service intervals and actions for 500h, 1000h, and 2000h services.

0 Complete machine

Troubleshooting, general work instructions

Outlines a structured approach to troubleshooting, including checking basic levels and error codes.

Troubleshooting without an error code, example

Provides a step-by-step example of troubleshooting when no error code is present.

Troubleshooting with error code, example

Guides on how to use error code lists and diagnostic menus for troubleshooting.

1 Engine

Engine, description

Describes the engine's function and available alternatives (Volvo, Cummins).

Fuel pre-filter, changing (Volvo engine)

Step-by-step guide for changing the fuel pre-filter on Volvo engines, including safety warnings.

Fuel filter, changing (Volvo engine)

Step-by-step guide for changing the fuel filter on Volvo engines, including safety warnings.

Fuel filter, changing (Cummins engine)

Step-by-step guide for changing the fuel filter on Cummins engines.

Air filter, changing

Instructions for changing the air filter cartridge and resetting the indicator.

Coolant filter, changing (Volvo engine)

Step-by-step instructions for changing the coolant filter on Volvo engines.

Coolant filter, changing (Cummins engine)

Step-by-step instructions for changing the coolant filter on Cummins engines.

Coolant level, checking

Details how to check and top up the coolant level, including warnings.

Oil and oil filter, change (engine alternative Volvo)

Step-by-step instructions for changing engine oil and filters for Volvo engines.

Oil and oil filter, change (engine alternative Cummins)

Step-by-step instructions for changing engine oil and filters for Cummins engines.

Oil level, checking

Instructions for checking engine oil levels using the dipstick.

2 Transmission

Transmission, function description

Explains how the transmission converts engine power to drive wheels and hydraulic pumps.

Lubrication

Details the transmission's lubrication system and oil/filter change procedure.

3 Driveline/axle

Driveline/axle, description

Describes the machine's power transmission system consisting of propeller shaft and drive axle.

Drive axle oil, changing

Step-by-step instructions for changing the drive axle oil, including proper positioning and filling.

4 Brakes

Brakes, general

Explains that brakes are used to stop the machine and act on the drive axle.

Brake pedal, checking and adjusting

Details checks for the brake pedal, including clearance, spring return, and smooth travel.

Service brake system

Describes the power-assisted brake system components and function.

Parking brake system

Explains the function of the parking brake system, including its components and operation.

Parking brake unit

Provides checking and adjustment procedures for the parking brake unit.

Brake oil filter

Step-by-step instructions for changing the brake oil filter, including important notes.

Oil brake system

Details the procedure for changing the oil in the brake system.

5 Steering

Steering, general

Explains the function of steering for machine operation, including rear wheel steering and optional joystick control.

Power-assisted system

Describes the power-assisted steering system, its components, and function.

Joystick steering/mini-wheel, function description

Explains how joystick steering or mini-wheel functions, controlled by electric signals to the control system.

6 Suspension

Suspension, description

Describes the machine's suspension system, consisting of tyres, steering axle, and frame suspension.

Tyre and rim system, safety

Explains the dangers and safety precautions associated with tyre and rim systems.

Tyre and rim system, removing (drive axle)

Step-by-step guide for removing tyres and rims from the drive axle, including safety precautions.

Tyre and rim system, removing (steering axle)

Step-by-step guide for removing tyres and rims from the steering axle, including safety precautions.

Tyre and rim system, installing (drive axle)

Instructions for installing tyres and rims on the drive axle, including guide lug alignment and torque.

Tyre and rim system, installing (steering axle)

Instructions for installing tyres and rims on the steering axle, including wheel position adjustment.

Tyres, inflating

Safety instructions and procedures for inflating tyres, including warnings about pressure.

7 Load handling

Lifting/lowering

Describes the function of angling the boom up and down using lift cylinders and control lever.

Load carrying

Describes how loads are held using twistlocks or lift legs.

Twistlocks

Explains how containers are held by twistlocks, controlled by the control lever and switch.

Twistlocks, checking

Provides steps to check twistlocks function, including indicator lights and cleaning.

Twistlock, checking for cracks

Details crack checks for twistlocks, including removal of lift pins and testing for cracks.

Lift legs

Describes the design and control of lift legs for gripping and transporting objects.

Fixed scale, calibration

Provides step-by-step instructions for calibrating the fixed scale weight indicator.

Dynamic scale, calibration

Provides step-by-step instructions for calibrating the dynamic scale weight indicator.

8 Control system

Control system, general

Explains that many machine functions are electrically controlled and monitored for safety.

Control system, description

Describes the electronic system used for controlling and monitoring machine functions.

Error codes

Notifies operators and mechanics about detected malfunctions.

Diagnostics

Tool for performing service and troubleshooting using menus in the machine's display.

Diagnostic test, general

Explains the built-in diagnostic test functions for troubleshooting.

Diagnostic test, work instruction

Provides instructions on how to select and proceed with diagnostic tests.

Overloading system

Describes the warning system (LLMC) that functions when the machine approaches the stability limit.

9 Frame, body, cab and accessories

Controls and instrumentation

Provides an overview of the controls and instruments in the machine.

Protection and emergency equipment

Lists the protective and warning equipment fitted to the machine for operator safety.

HVAC

Explains the heating and ventilation system (EHC) and its functions.

Fresh air filter

Instructions for changing the fresh air filter located at the front of the cab.

Humidity filter, changing

Step-by-step instructions for changing the humidity filter, including safety warnings.

Cab structure and suspension

Explains the cab's structure, suspension, and manual or hydraulic movement options.

10 Common hydraulics

Common hydraulics, description

Explains that common hydraulics are functions used in several main machine functions.

Hydraulic oil pump, checking

Provides instructions for checking hydraulic oil pumps, including pressure readings.

Breather filter hydraulic oil tank

Instructions for changing the breather filter on the hydraulic oil tank.

Hydraulic oil filter

Details the procedure for changing the hydraulic oil filter.

11 Common electrics

Fuses

Describes the electrical system's main circuits, main fuses, and circuit fuses.

Start battery, checking

Instructions for checking battery voltage, terminals, and fluid levels.

D Error codes

Error codes, explanation

Explains error codes in table form, sorted by error code number, including description, limitation, and action.

Engine

Lists error codes specific to the engine.

Transmission

Lists and explains error codes related to the transmission system.

Control system

Lists and explains error codes related to the control system.

E Schematics

Common hydraulics

Provides a compilation of hydraulic diagrams common to several main functions.

Hydraulic diagrams, compilation

Lists all hydraulic diagrams included in the manual.

Common electrics

Covers electrical functions common to various machine systems.

Related product manuals