Kalmar DRD450-80S5XS Manuals

Manuals and User Guides for Kalmar DRD450-80S5XS. We have 1 Kalmar DRD450-80S5XS manual available for free PDF download: Maintenance Manual

Kalmar DRD450-80S5XS Maintenance Manual

Kalmar DRD450-80S5XS Maintenance Manual (600 pages)

Brand: Kalmar | Category: Forklifts | Size: 15.58 MB

Table of Contents

A Foreword

3
- Table of Contents
  3
- Storage
  5
- Copyright
  5
- About the Machine Version
  5
- MM MM MM MM
  5
- Conditions
  5
- Foreword
  5
- General
  5
- About the Maintenance Manual
  5
- Reading Instructions
  6
- Warning Information
  6
- Important Information
  6
- Read Operator's Manual
  6
- Read Maintenance Manual
  6
- Maintenance Manual's Content
  7
- Function Group Structure
  8
- References between Different Information Types
  9
- Product Alternatives and Optional Equipment
  9
- Machine Card
  10
- Function Descriptions
  11
- About the Documentation
  14
- Documentation Sections
  14
- Ordering of Documentation
  14
- Feedback
  15
- Form for Copying
  15
B Safety

17
- A Near-Accident Is a Warning Signal
  19
- General Safety Information
  19
- MM MM MM MM
  19
- Safety
  19
- Safety Concerns Everyone
  19
- General
  20
- Safety Instructions
  20
- Service Position
  20
- Hydraulic and Brake Systems, Depressurizing
  21
- Clothing Etc
  22
- Several Mechanics on the same Machine
  22
- Lifting Heavy Components
  23
- Working under Machine
  23
- Noise
  24
- Vibrations
  24
- Fire and Explosion Risks
  25
- Solvents
  25
- Fluid or Gas under Pressure
  26
- Coolant
  27
- Air Pollution
  28
- Refrigerant
  28
- Tensioned Springs
  29
- Electric Motors
  30
- Rotating Components and Tools
  30
- Tyre System
  31
- Environment
  32
- General
  32
C Preventive Maintenance

33
- MM MM MM MM
  35
- Preventive Maintenance
  35
- Preventive Maintenance, General
  35
- Preventive Maintenance, Work Instructions
  35
- Check and Service Log
  36
- 50H-Check
  37
- Service Schedule
  39
- Washing
  45
- Lubrication 500 Hours
  46
- Lubrication 1000 Hours
  48
Complete Machine

51
Engine

59
- Engine
  61
- MM MM MM MM
  61
- Fuel System
  67
- Fuel Pre-Filter
  68
- Fuel Filter
  70
- Air Cleaning System
  72
- Air Intake and Exhaust Outlet
  72
- Coolant Filter
  73
- Cooling System
  73
- Cooling Fan
  76
- Coolant
  77
- Lubrication
  78
- Control System Engine
  82
- Ignition/Heating
  83
- Start/Stop
  84
Transmission

85
- MM MM MM MM
  87
- Transmission
  87
- Torque Converter/Clutch System
  89
- Mechanical Transmission
  90
- Lubrication
  91
- Cooling
  94
- Control System Transmission
  95
Brakes

105
- Brakes
  107
- MM MM MM MM
  107
- Brake Pedal
  108
- Controls and Instrumentation
  108
- Service Brake System
  109
- Brake Oil Pump
  112
- Accumulator
  113
- Parking Brake System
  114
- Parking Brake Unit
  115
- Temperature Control, Filtration and Brake Fluid
  117
- Brake Oil Filter
  119
- Breather Filter
  119
- Oil Brake System
  121
Suspension

129
- MM MM MM MM
  131
- Suspension
  131
- Steering Axle Cradle
  132
- Suspension
  132
- Wheel Hub
  133
- Wheel Spindle
  133
- Tyre and Rim System
  135
- Tyres
  145
- Rims
  146
Load Handling

149
- Load Handling
  151
- MM MM MM MM
  151
- Lifting/Lowering
  152
- Servo Filter
  155
- Pressure Reducer
  157
- Protruding
  158
- Lift Boom
  161
- Side-Shift
  162
- Sideshift Frame
  164
- Main Beam Attachment
  165
- Positioning
  167
- Positioning Chains
  171
- Positioning Motor
  171
- Positioning Beam
  174
- Rotation
  175
- Rotation Motor Unit
  178
- Tilt
  179
- Levelling
  185
- Load Carrying
  189
- Twistlocks
  189
- Lift Legs
  194
- Additional Functions
  204
- Support Jacks
  204
- Weight Indicator
  206
- Container Counter
  213
- Synchronous Lift
  215
Control System

217
- Control System
  219
- MM MM MM MM
  219
- Monitoring
  222
- Overloading System
  222
- By-Passing
  227
- Load Centre Limitation
  227
- Height Limitation
  228
- Service Indicator
  228
- Speed Limitation
  228
- Error Codes
  229
- Diagnostics
  231
- Can/Power
  234
- Lights
  235
- Cab
  236
- Climate
  237
- Hyd
  237
- Engine
  238
- Transm
  239
- Boom
  240
- Attach
  241
- Extra
  243
- Setup
  247
Frame, Body, Cab and Accessories

249
- Frame, Body, Cab and Accessories
  251
- MM MM MM MM
  251
- Controls and Instrumentation
  252
- Protection and Emergency Equipment
  258
- Seat
  259
- Hvac
  260
- Fresh Air Filter
  265
- Condenser
  266
- Humidity Filter
  266
- Wiper/Washer System
  268
- Lighting System
  269
- Communication Systems
  270
- Entertainment and Communication
  271
- Glass/Windows/Mirrors
  272
- Cab Structure and Suspension
  273
- Longitudinal Displacement of Cab
  273
- Vertically Adjustable Cab
  276
- Cab Interior
  279
- Frame
  280
- Body
  281
- Central Lubrication
  282
- Paint/Coatings
  283
Common Hydraulics

285
- 10 Common Hydraulics
  287
- MM MM MM MM
  287
- Security Valves
  289
- Tanks and Accumulators
  290
- Pumps
  291
- Axial Piston Pump with Variable Displacement
  292
- Hoses, Pipes and Valves
  295
- Temperature Control, Cleaning and Hydraulic Oil
  296
- 5. Breather Filter, Hydraulic Oil Tank
  299
- Hydraulic Oil Filter
  300
- Hydraulic Oil
  301
- Hydraulic Oil Fine-Filter
  302
Common Electrics

303
- 11 Common Electrics
  305
- MM MM MM MM
  305
- Electric Protection
  306
- Fuses
  307
- Batteries
  310
- Start Battery
  310
- Alternator
  311
- Distribution of Electricity
  312
- Voltage Feed
  312
- Control Units
  317
- CAN-Bus
  318
- CAN-Bus Driveline
  318
- Communication
  318
- Redundant CAN-Bus
  318
D Error Codes

319
- Error Codes
  321
- Error Codes, Explanation
  321
- MM MM MM MM
  321
- Reading out Error Code
  322
- Engine
  324
- Error Codes Engine Alternative Cummins
  324
- Error Codes Engine Alternative Volvo
  324
- Error Codes Transmission
  357
- Transmission
  357
- Control System
  372
- Error Codes Machine
  372
E Schematics

411
F Technical Data

571
- MM MM MM MM
  573
- Specifications for Data and Volume
  573
- Technical Data
  573
- Specifications for Lift Capacity and Dimensions
  575
- Oils and Lubricants, Recommendation
  578
- Tightening Torques, Recommendations
  580
- Tightening Torques, ORFS-Couplings
  581
- Unit Explanations
  583
- Conversion Table, SI-Units
  584
- Conversion Table, Area
  585
- Conversion Table, Length
  585
- Conversion Table, Volume
  585
- Conversion Table, Pressure
  586
- Conversion Table, Weight
  586

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