Table of Contents
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Maintenance
manual
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
2 Transmission
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminology and index
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Chapters
Table of Contents
Troubleshooting
Related Manuals for Kalmar DRF450-60S5
Summarization of Contents
A Foreword
About the Maintenance Manual
Information about the manual's purpose, content, and reading instructions.
Reading instructions
Explains how to interpret warnings, important information, and symbols used.
Maintenance manual's content
Overview of manual sections, function groups, and references between information types.
Function group structure
Explains the manual's division into function groups for information search.
References between different information types
Describes how information is linked across different sections and manuals.
Product alternatives and optional equipment
Details how product alternatives and optional equipment are presented.
Machine card
Explains the purpose and use of the machine card for identifying equipment and alternatives.
Function descriptions
Describes schematic overviews of how functions work and interact with components.
B Safety
Safety instructions, General
Read, consider, and follow safety instructions before starting work.
Hydraulic and brake systems, depressurizing
Procedures for safely depressurizing hydraulic and brake systems before maintenance.
Clothing etc.
Guidelines on appropriate clothing and removing jewelry to prevent hazards.
Several mechanics on the same machine
Safety actions and risks when multiple people work on the same vehicle.
Working under machine
Safety precautions for working under a lifted or raised vehicle.
Lifting heavy components
Risks and safety actions associated with handling heavy components.
Vibrations
Safety actions to mitigate risks from prolonged use of vibrating tools.
Noise
Risks of hearing damage from noise and safety precautions.
Solvents
Hazards of solvents and safety precautions for their use.
Fire and explosion risks
Information on explosion-prone substances and ignition causes.
Fluid or gas under pressure
Risks associated with high-pressure fluids or gases and safety precautions.
Coolant
Information about coolant, its risks, and safety precautions.
Refrigerant
Risks associated with refrigerant and safety actions for handling it.
Air pollution
Common air pollutants in workshops and their health hazards.
Tensioned springs
Risks associated with tensioned springs and safety precautions for handling them.
Electric motors
Safety actions to take when working on electric motors.
Rotating components and tools
Risks associated with rotating components and safety precautions for handling them.
Tyre system
Safety precautions and dangers related to tyres and rims.
Environment
General information on environmental impact and protection measures.
C Preventive maintenance
Preventive maintenance, general
Importance of performing preventive maintenance according to recommended intervals.
Preventive maintenance, work instructions
Instructions for new machines, 50h-check, and service at regular intervals.
Check and service log
Log for recording completed maintenance checks and services.
50h-check
Checks performed after 50 hours of operation to increase machine reliability.
Service schedule
Defines service intervals and actions for 500h, 1000h, and 2000h services.
Washing
Cautionary notes regarding the use of high-pressure washers on the machine.
Lubrication 500 hours
Instructions for cleaning and greasing points for wheel hubs and spindles.
Lubrication 1000 hours
Greasing instructions for various points on the machine, including attachments.
0 Complete machine
Complete machine, description
Provides a description of the Kalmar DRF 400-450 reachstacker and its main functions.
Troubleshooting, general work instructions
Describes a structured approach to troubleshooting by excluding components as error sources.
Troubleshooting without an error code, example
Provides an example of troubleshooting steps when no error code is present.
Troubleshooting with error code, example
Explains how to use error code lists and diagnostic menus for troubleshooting.
Troubleshooting cable harness
Instructions for performing troubleshooting on all cables to avoid damage to control units.
Troubleshooting hydraulic hoses
Steps for troubleshooting hydraulic hoses, including inspection for damage and leaks.
1 Engine
Engine, description
Describes the engine's role in propulsion and working hydraulics, and available engine alternatives.
Engine alternative Volvo, function description
Details the Volvo TWD1240VE engine, a 6-cylinder diesel engine with specific features.
Engine alternative Volvo, component position
Illustrates the component positions for the Volvo engine on the right side of the machine.
Engine alternative Cummins, function description
Describes the Cummins QSM11 engine, a 6-cylinder diesel engine with specific features.
Engine alternative Cummins, component position
Illustrates the component positions for the Cummins engine on the right side of the machine.
Fuel system, description
Describes the fuel system, including filling point, fuel tank, and fuel level sensor.
Fuel system, bleeding (engine alternative Volvo)
Step-by-step instructions for bleeding the fuel system on Volvo engines.
Metal filter supply line, cleaning (engine alternative Volvo)
Instructions for cleaning the metal filter supply line on Volvo engines.
Fuel pre-filter, changing (Volvo engine)
Procedure for changing the fuel pre-filter on Volvo engines, with safety warnings.
Fuel pre-filter, draining condensation water (Volvo engine)
Procedure for draining condensation water from the fuel pre-filter on Volvo engines.
Fuel filter, changing (Volvo engine)
Procedure for changing the fuel filter on Volvo engines, with safety warnings.
Air filter, changing
Procedure for changing the air filter cartridge, including notes on replacement.
Cooling system, description
Describes the engine radiator, intercooler, and transmission oil cooler in the cooling unit.
Coolant filter, changing (Volvo engine)
Procedure for changing the coolant filter on Volvo engines, with notes on shut-off valve.
Coolant filter, changing (Cummins engine)
Procedure for changing the coolant filter on Cummins engines, with notes on shut-off valve.
Coolant level, checking
Instructions for checking the coolant level in the expansion tank and topping up if needed.
Fan belt, checking
Procedure for checking and adjusting the fan belt tension.
Lubrication 500 hours
Instructions for cleaning and greasing points for wheel hubs and spindles.
Lubrication 1000 hours
Greasing instructions for various points on the machine, including attachments.
Oil and oil filter, change (engine alternative Volvo)
Procedure for changing engine oil and oil filters for Volvo engines.
Oil and oil filter, change (engine alternative Cummins)
Procedure for changing engine oil and oil filters for Cummins engines.
Oil level, checking
Instructions for checking the engine oil level using the dipstick.
Control system engine, description
Describes the engine control system and how the control unit manages fuel injection.
Ignition/heating, description (engine alternative Volvo)
Describes the preheating system for the inlet air on Volvo engines.
Ignition/heating, description (engine alternative Cummins)
Describes the preheating system for the inlet air on Cummins engines.
2 Transmission
Transmission, function description
Explains how the transmission converts engine power to drive wheels and hydraulic oil pumps.
Transmission, component position
Identifies the location of transmission components on the right and left sides.
Torque converter/clutch system
Describes the function of the torque converter transmitting engine power to the transmission.
Mechanical transmission
Explains the constant mesh gear system and hydraulic clutch disc shifting.
Lubrication
Details the transmission's lubrication system, oil cooler, and oil filter changing.
Cooling
Explains how the transmission is cooled by the lubrication system.
Control system transmission
Describes how the control unit manages shifting based on sensors and solenoid valves.
3 Driveline/axle
Driveline/axle, description
Describes the machine's power transmission components: propeller shaft, drive axle, differential, and hub reduction.
Propeller shaft, description
Explains the function of the propeller shaft transmitting engine power to the drive axle.
Propeller shaft, checking
Instructions for checking propeller shaft bolts, universal joints, and grease points.
Drive axle, description
Describes the drive axle's function in transmitting engine power to wheels and differential.
Drive axle, checking
Instructions for checking drive axle attachment, wheel nuts, brake caliper joint, and seals.
Drive axle oil, changing
Procedure for changing the drive axle oil, including draining and filling instructions.
4 Brakes
Brakes, general
Explains the function of brakes and their division into three main functions.
Controls and instrumentation
Overview of controls and instruments, including brake pedal checking and adjustment.
Service brake system
Function description of the power-assisted brake system.
Brake oil pump
Details on checking the brake oil pump's function and pressure.
Accumulator
Procedure for checking the accumulator's function in the brake system.
Parking brake system
Function description of the parking brake system.
Parking brake unit
Checking and adjustment procedure for the parking brake unit.
Temperature control, filtration and brake fluid
Function description of temperature control, cleaning, and brake oil.
Breather filter
Procedure for changing the breather filter in the brake system.
Brake oil filter
Procedure for changing the brake oil filter.
Oil brake system
Procedure for changing the oil in the brake system.
5 Steering
Steering, general
Explains the function of steering, including rear wheel steering and optional joystick steering.
Power-assisted steering system, function description
Refers to steering the machine, powered by hydraulic oil pumps.
Transmission, component position
Identifies component positions for steering systems, including right and left sides.
Joystick steering/mini-wheel, function description
Describes joystick or mini-wheel steering, controlled by electric signals to the control system.
Power-assisted steering system, component position
Identifies components of the power-assisted steering system.
Sensor steering angle (product alternative mini-wheel/joystick steering)
Explains the sensor steering angle for mini-wheel and joystick steering.
6 Suspension
Suspension, description
Describes the machine's suspension components including tyres, steering axle, and frame.
Steering axle cradle
Checking the bushings in the steering axle cradle mountings.
Wheel spindle
Checking the wheel spindle bearing clearance.
Wheel hub
Checking wheel hub covers, grease, and lock nuts.
Tyre and rim system
Safety precautions, description, checking, and removal/installation of tyres and rims.
Tyres
Safety instructions for inflating tyres.
Rims
Checks for damage on rims and magnetic powder method for crack detection.
7 Load handling
Lifting/lowering
Explains lifting and lowering the boom, including damping and regeneration.
Protruding
Describes the extension function of the boom, including damping and regeneration.
Side-shift
Describes the side-shift function, moving the attachment sideways.
Sideshift frame
Checking glide plates on the sideshift frame for wear and clearance.
Main beam attachment
Checking glide plates on the main beam attachment for wear and thickness.
Positioning
Describes the spreading function, including stops and damping.
Positioning motor
Procedure for changing the oil in the spreader motor unit.
Positioning chains
Checking spreader chains for adjustment and tension.
Positioning beam
Checking and adjusting slide plates on the extension beam.
Rotation
Describes the rotation function of the attachment and rotation stop.
Tilt
Describes the tilt function and its different versions: damping, tilt lock, and controllable tilt.
Levelling
Describes mechanical and hydraulic levelling functions, including levelling lock.
Load carrying
Describes methods for holding loads, including twistlocks and lift legs.
Lift legs
Describes the lift legs' design, operating position, and components.
Additional functions
Describes additional functions such as support jacks.
Weight indicator
Describes weight indicator function and calibration for fixed and dynamic scales.
Printer
Describes the printer option for saving and printing weights.
Container counter
Describes the container counter function for tracking lifts.
Synchronous lift
Describes synchronized lift where lift and extension are activated simultaneously.
8 Control system
Control system, general
Explains the electrical control system, its signals, and functions for operator safety.
Control system, description
Describes the electronic system for controlling and monitoring machine functions.
Monitoring functions, general
Lists monitoring functions that enhance safety during load handling.
Overloading system
Describes the warning system (LLMC) for stationary load handling.
By-passing
Explains how to by-pass the safety system when overloading is activated.
Load centre limitation
Prevents the load from coming too close to the machine, controlled by sensor signals.
Height limitation
Prevents the machine from lifting higher than a pre-set height.
Speed limitation
Prevents the machine's speed from exceeding a pre-set value.
Service indicator
Instructions for resetting the service indicator.
Error codes
Notifies operators and mechanics of detected malfunctions.
Diagnostics
Built-in functions for troubleshooting using menus on the machine's display.
Setup
Possibilities to adapt functions' features and settings via display menus.
9 Frame, body, cab and accessories
Controls and instrumentation
Overview of controls and instruments, including the left instrument panel and steering wheel panel.
Protection and emergency equipment
Describes the protective and warning equipment for operator safety.
Seat
Describes operator seats (Bege, Isringhausen) and their adjustment possibilities.
HVAC
Describes the heating, ventilation, and air conditioning system.
Fresh air filter
Procedure for changing the fresh air filter located at the front of the cab.
Condenser
Procedure for cleaning the condenser cooler using compressed air.
Humidity filter
Checking the humidity filter indicator and procedure for changing it.
Wiper/washer system
Describes the function of wipers for front, rear, and roof windows.
Lighting system
Describes the machine's lighting system for safety during operation and load handling.
Communication systems
Describes signals for safety via light and sound, including horn and warning lights.
Entertainment and communication
General information on entertainment and communication equipment.
Glass/windows/mirrors
Describes the function and component position of glass panes and mirrors.
Cab structure and suspension
Describes the cab's structure, suspension, and manual/hydraulic movement.
D Error codes
Error codes, explanation
Explains error codes in table form for Engine, Transmission, and Control system, sorted by error code number.
Reading out error code
Procedure for reading out error codes from the display, including a warning.
Engine
Lists error codes for Volvo and Cummins engine alternatives.
Transmission
Lists error codes for the transmission, including Limp-home and Shut-down modes.
Control system
Lists error codes for the machine's control system, including CAN/POWER, LIGHTS, CAB, etc.
E Schematics
Common hydraulics
Lists all hydraulic diagrams, including basic machine, top lift, and combi attachment.
Common electrics
Covers circuit diagrams, component designations, and circuit diagrams compilation.
F Technical data
Specifications for data and volume
Provides specifications for data and volume, including engine and transmission details.
Specifications for lift capacity and dimensions
Details lift capacity and dimensions for different container sizes and models.
Oils and lubricants, recommendation
Recommends oil types and qualities based on ambient temperature for various systems.
Tightening torques, recommendations
Provides recommended tightening torques for bolts and nuts in Nm.
Tightening torques, ORFS-couplings
Specifies tightening torques for pipe and hose couplings based on UNC thread and pipe diameter.
Unit explanations
Explains units and their abbreviations used in technical data.
Conversion table, SI-units
Provides conversion factors between SI and non-SI units for various measurements.
Conversion table, length
Provides conversion factors for length between different units.
Conversion table, area
Provides conversion factors for area between different units.
Conversion table, volume
Provides conversion factors for volume between different units.
Conversion table, weight
Provides conversion factors for weight between different units.
Conversion table, pressure
Provides conversion factors for pressure between different units.
G Terminology and index
Terminology
Provides definitions for terms related to the machine's functions, components, and systems.
Index
Alphabetical listing of titles, tabs, and function groups for easy navigation.
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