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An overview of the structure and content of the maintenance manual.
General safety information concerning everyone working with the machine.
Instructions and guidelines to follow before starting work on the machine.
Importance of performing preventive maintenance according to recommended intervals.
Work instructions and checks to be performed for preventive maintenance.
Checks to be performed after 50 hours of operating time for new machines to increase reliability.
Schedule outlining service actions based on operating hours (500h, 1000h, 2000h).
Specific lubrication points and procedures for the 500-hour service interval.
Lubrication points and procedures for the 1000-hour service interval.
Description of the Kalmar DRF 400-450 Reachstacker for container handling.
Guidelines for a structured and logical troubleshooting process to identify and resolve errors.
Example of troubleshooting procedure when error codes are detected by the control system.
Procedure for troubleshooting cable harnesses to avoid damage to control units and components.
Procedure for inspecting and troubleshooting hydraulic hoses for chafing, pinching, and leaks.
Description of the engine's function and available alternatives (Volvo TWD1240VE, Cummins QSM11).
Step-by-step instructions for changing the fuel pre-filter on the Volvo engine.
Step-by-step instructions for changing the fuel filter on the Volvo engine.
Step-by-step instructions for changing the fuel filter on the Cummins engine.
Step-by-step instructions for changing the coolant filter on the Volvo engine.
Step-by-step instructions for changing the coolant filter on the Cummins engine.
Instructions for changing engine oil and filters for the Volvo engine alternative.
Instructions for changing engine oil and filters for the Cummins engine.
Explanation of how the transmission converts engine power to drive wheels and hydraulic pumps.
Description of the mechanical transmission, including gear shifting and clutch operation.
Instructions for changing transmission oil and oil filter.
Description of the transmission control unit's functions and modes (Limp-home, Shut-Down).
Description of the machine's power transmission system, including propeller shaft and drive axle.
Description of the drive axle's function in transmitting engine power to the wheels.
General information about the machine's brakes and their function on the drive axle.
Function description of the power-assisted brake system.
Detailed explanation of how the power-assisted brake system components work together.
Procedure for checking the brake oil pump's pressure output.
Steps to check the brake oil pump pressure at operating temperature.
Function description of the parking brake system and its components.
Explanation of how the parking brake system operates, including pressure signals and activation.
Checking and adjustment procedure for the parking brake unit.
Steps to ensure the parking brake caliper moves freely and applies the brakes correctly.
Function description of the brake system's temperature control, cleaning, and brake fluid.
Explanation of how the brake system oil is cooled and cleaned via a cooler and filters.
Instructions for changing the brake oil filter, emphasizing cleanliness.
Procedure for changing the hydraulic oil in the tank, including checking the oil level.
General information about the steering function and available options like joystick or mini-wheel.
Function description of the power-assisted steering system, including components and operation.
Explanation of how the power-assisted steering system functions using hydraulic oil pressure.
Description of the suspension system, referring to axle cradles, spindles, and hubs.
Safety instructions and DANGER warnings related to tyre and rim handling, especially during deflation/inflation.
Procedure for safely lifting and removing wheels from the drive axle.
Procedure for safely lifting and removing wheels from the steering axle.
Procedure for installing wheels onto the drive axle, including aligning guide lugs.
Procedure for installing wheels onto the steering axle, including aligning guide pins.
General information about load handling functions like lifting, lowering, and securing loads.
Function description of lift and lower operations, including damping and regeneration.
Explanation of how the boom is angled and controlled by the lift cylinder and control lever.
Procedure for changing the servo filter, including safety precautions.
Step-by-step instructions for changing the servo filter, emphasizing safety and oil levels.
Procedure for checking servo pressure on the pressure reducer.
Steps to check the servo pressure by comparing it to the pressure plate value.
Description of the tilt function, including its connection to hydraulic cylinders and damping block.
Explanation of the rotation yoke's suspension and how hydraulic cylinders dampen oscillations.
General information about the machine's electrically controlled functions and monitoring.
General overview of monitoring functions that increase safety during load handling.
List of control functions to increase safety during load handling.
Information about the warning system (LLMC) for stationary load handling.
Details on the Longitudinal Load Moment Control (LLMC) warning system and its activation.
Function description of the basic overloading system which uses opening sensors.
Explanation of how the mechanical overloading system is activated and its effects on machine functions.
Function description of the electrical overloading system, which calculates load using sensor values.
Explanation of how the system calculates load and measures distance to activate overloading system.
Description of how to bypass the safety system when the overloading system is activated.
Explanation of the by-pass switch function and its capabilities.
Explanation of error codes generated by the control unit when a malfunction occurs.
Detailed explanation of error codes, including code, description, limitation, action, and function group.
Procedure for reading out error codes from the machine, including recommended actions.
List of error codes specific to the Volvo engine alternative.
List of error codes specific to the Cummins engine alternative.
List of error codes related to the transmission system and their troubleshooting actions.
General error codes related to various machine functions and systems.
Information on built-in diagnostic test functions for troubleshooting.
Overview of the diagnostic test menus and how they are grouped for access.
Description of the machine's components: frame, body, and cab.
Description of the operator's seat, including adjustment possibilities and available equipment.
Description of the operator's seat, focusing on comfort and adjustment features.
Description of the heating and ventilation system (EHC).
Explanation of how the heating and ventilation system operates, including temperature control.
Instructions for changing the humidity filter, including refrigerant draining and refilling.
Description of the cab structure and suspension system.
Details on the cab's level floor, suspension via rubber pads, and types of cab suspensions.
Schematic illustrating the basic hydraulic system of the machine.
Schematic illustrating the hydraulic system for the top lift function.
Schematic showing the hydraulic system for top lift with tilt lock and controllable tilt.
Schematic showing the hydraulic system for top lift with tilt lock, controllable tilt, and hydraulic levelling.
Schematic illustrating the hydraulic system for joystick steering.
Schematic illustrating the hydraulic system for the sliding cab.
Schematic illustrating the hydraulic system for cab lift and support jacks.
Schematic illustrating the hydraulic system for sliding cab and support jacks.
Part 1 of 3 for the hydraulic diagram of the combi attachment.
Part 2 of 3 for the hydraulic diagram of the combi attachment.
Part 3 of 3 for the hydraulic diagram of the combi attachment.
Circuit diagram for the joystick steering system.
Circuit diagram for the tilt and levelling functions with combi attachment.
Circuit diagram for the boom up/down function, including sensors and solenoid valves.
Technical data and volume specifications for various machine components.
Technical specifications for lift capacity, dimensions, and tyre pressure.
Recommended oils and lubricants for various machine systems based on ambient temperature.
Recommended tightening torques for bolts and nuts, including surface treatment and lubrication.
Definitions of terms used in the manual, covering various machine components and functions.
General| Manufacturer | Kalmar |
|---|---|
| Model | DRF450-65S5X |
| Category | Forklifts |
| Power Type | Diesel |
| Transmission | Automatic |
| Tyre Type | Pneumatic |
| Mast Type | Telescopic |
| Overall Height | 4300 mm |
