Kalmar ContChamp DRD450 Manuals

Manuals and User Guides for Kalmar ContChamp DRD450. We have 1 Kalmar ContChamp DRD450 manual available for free PDF download: Technical Handbook

Kalmar ContChamp DRD450 Technical Handbook

Kalmar ContChamp DRD450 Technical Handbook (298 pages)

Brand: Kalmar | Category: Forklifts | Size: 9 MB

Table of Contents

Table of Contents

3
- Safety Regulations
  5
- General
  8
  - Design - Overview
    8
  - Component Units
    9
  - Supplementary Books
    11
  - Replacement System - Spare Parts
    11
  - Tools
    11
  - Tightening Torques
    12
  - System of Units
    14
Group 10 Chassis and Cab

15
- Chassis
  17
  - Description
    17
    
    Support Jacks
    17
    
    Operator's Cab
    18
    
    Steering Column
    23
    
    Hydraulics Control Unit
    24
  - Service
    25
    
    Changing the Fresh Air Filter
    25
    
    Check and Lubrication of Brake Pedal
    25
    
    Windscreen Wipers
    26
- Air Conditioning Unit
  27
  - Description
    27
  - Service
    30
    
    Checking the Air Conditioning Unit
    30
Group 20 Electrical System

33
- Specifications
  
  34
- Electrical System
  
  35
  - Description
    35
    
    Checking the Electrolyte Level of the Batteries
    37
    
    Relays
    38
    
    Bulbs
    39
    
    Starting from Another Battery
    40
    
    Air Operated Operator's Seat
    40
  - Overview
    41
  - Terminal
    42
    
    Menu Structure
    42
    
    Operating Menues
    46
    
    Error Messages
    47
  - ECU-Processor Unit
    54
    
    Transmission Data Kit
    55
    
    Engine Data Kit
    55
- ECU 1 Functions
  
  56
  - Circuit Board
    58
- 1 - Automatic Gear Changing
  
  59
- 4 Lever Steering
  
  60
- 7 - Monitoring
  
  63
- ECU 2 Functions
  
  65
- ECU 3 Functions
  
  99
  - Circuit Board
    100
  - Module 54 Tilt
    101
  - Module 56 Cab Movement
    102
  - Module 61 Support Jacks
    104
- Diagrams
  
  106
  - Gearchanging Systems
    106
  - Electrical Diagram Explanations
    112
  - Cable Markings
    113
Group 30 Engine

163
- Specifications
  164
- Engine
  165
  - Description
    165
    
    General
    165
    
    Cooling System
    167
    
    Fuel System
    169
    
    Lubrication System
    172
    
    Combusting Air System
    174
  - Service
    176
    
    Coolant Quality
    176
    
    Lubrication Oil Quality
    176
    
    Draining the Water from the Fuel Tank
    176
    
    Inspection of Air Cleaner and Changing the Filter Element
    176
    
    Changing the Oil and Oil Filter
    177
    
    Checking V-Belt Tension
    177
    
    Checking and Adjusting the Valve Clearances
    178
    
    Changing the Fuel Filters
    178
    
    Preventive Maintenance on Turbo-Charger
    179
    
    Maintenance of Exhaust-Gas Cleaner
    179
Group 40 Transmission, Drive Axle, Brakes

181
- Transmission
  183
  - Description
    183
    
    Torque Converter
    183
    
    Gearbox
    183
    
    Oil Circuit
    185
  - Service
    186
    
    Oil Level Check
    186
    
    Changing Gearbox Oil and Filter
    186
    
    Checking Pressures in the Clark 36000 Gearbox
    187
- Drive Axle
  188
  - Description
    188
    
    WDB-System
    191
    
    Parking Brake System
    192
  - Service
    193
    
    Changing the Drive-Axle Oil
    193
    
    Parking Brake - Initial Adjustment
    194
    
    Compensation of Lining Wear
    194
Group 60 Steered Axle

195
- Specifications
  196
- Steered Axle
  197
  - Description
    197
  - Service
    198
    
    Replacement of Steering Cylinder
    198
    
    Replacement of Knuckle Pin Bearings
    198
    
    Replacement of Steering Wheel Bearings
    200
    
    Inspection of Dismountable Rims
    202
    
    Safety Test When Changing Tyres
    204
Group 70 Hydraulic System

205
- Specifications
  206
- Main Hydraulics
  207
  - Description
    207
    
    Overview
    207
    
    Electro-Hydraulic Servo System, Principles
    207
    
    Working Hydraulics, Feed
    208
    
    Servo Circuits
    214
    
    Lift
    215
    
    Boom Extension
    217
  - Service
    219
    
    Hydraulic Fluid
    219
    
    Hydraulic Oil Filter
    219
    
    Breather Filter
    219
- Steering System
  221
  - Description
    221
    
    Steering Valve
    222
    
    Priority Valve
    224
- Brake System
  226
  - Description
    226
    
    Brake System
    227
    
    Cooling Circuit
    227
    
    Main Components of the Brake System
    227
    
    Brake System, Feed
    228
    
    Accumulator Charging Valve
    231
    
    Hydraulic Brake Pedal
    232
    
    Parking Brake
    233
    
    Parking Brake Valve
    233
  - Service
    234
    
    Accumulators, Checking the Pre-Charging Pressure
    234
    
    Hydraulic Oil Cooler
    235
    
    Adjusting the WDB Brake System
    237
- Cab Movement
  238
- Tilt, Attachment
  238
- Hydraulic Pumps
  239
  - Description
    239
    
    Variable Axial Piston Pump
    239
    
    Vane Pump
    240
  - Service
    241
    
    Setting the Variable Pumps
    241
- Main Valve
  243
  - Description
    243
  - Service
    244
- Hydraulic Cylinders
  245
  - Service
    245
    
    Repairs to Leaking Hydraulic Cylinders
    245
    
    Lifting Cylinder
    246
    
    Telescoping Cylinder, Main Boom
    247
    
    Damping Cylinders, Attachment
    248
Table of Contents

253
- Clean Hydraulics
  255
- Measures to Prevent Pollution of the Hydraulic System
  256
- Fault Finding for Leakage
  258
- The Function and Removal of Seals
  259
  - Piston Rod Seals
    259
  - Support Ring and O Ring
    261
  - Wiper
    262
  - Single Action V Type Piston Seals with Support Ring
    263
  - Double Action Piston Seals
    264
- Repairing the Piston Rod Surface
  264
- Lubrication
  265
- Dismantling the Steering Cylinder
  266
Group 80 Telescope-Boom with Rotator, Attachment

269
- Boom with Rotator
  271
  - Description
    271
    
    Telescope Boom
    271
    
    Rotator
    272
    
    Damping/Forward Tilt
    273
  - Service
    274
    
    Checking Lubrication
    274
    
    Checking the Sliding Plates
    274
- Top Lift
  276
  - Description
    276
    
    Twist-Locks
    278
  - Service
    280
    
    Indicating Lamps
    280
    
    Alignment Control
    280
    
    Safety Interlocking System
    280
    
    Checking of ALIGNMENT Indicating Lamps and Electrical Interlocking System
    280
    
    Adjustment and Lubrication of Sliding Plates
    281
    
    Control of Twist-Lock Lifting Pins
    282
    
    Inductive Sensors
    282
    
    Chain Adjustment
    283
    
    Bleeding the Damping Cylinders
    283
    
    Setting the Resistance of the Damping Cylinders
    284
  - General Survey
    289
    
    General Survey Chart
    289
    
    Daily Supervision
    294
    
    Every 600 Hours
    296
    
    Every 1000 Hours
    297

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