Kalmar DRF420-60S5 Maintenance Manual
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Kalmar DRF420-60S5 Maintenance Manual

Kalmar DRF420-60S5 Maintenance Manual

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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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Summary of Contents for Kalmar DRF420-60S5

  • Page 1 A Foreword B Safety C Preventive maintenance 0 Complete machine 1 Engine Maintenance 2 Transmission manual 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...
  • Page 2 https://www.forkliftpdfmanuals.com/...

  • Page 3: Table Of Contents

    A Foreword A Foreword Table of Contents A Foreword mm mm mm mm Foreword ....................3 About the Maintenance Manual ..............3 General ......................3 Conditions ......................3 Storage ......................3 About the machine version ................3 Copyright ......................3 Reading instructions ..................
  • Page 4 A Foreword Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 5: Mm Mm Mm Mm

    – The information in this publication corresponds to the machine's de- sign and appearance at the time of delivery from Kalmar Industries. Due to customizations, there may be variations and/or deviations. Kalmar Industries reserves the right to modify specifications and equipment without prior notice.

  • Page 6: Reading Instructions

    A Foreword – Reading instructions Reading instructions Warning information page – Warnings inform on potential dangers which can, if the warnings are not heeded, result in personal injury or product damage. D AN GE R Situation that may result in serious personal injury, possible death, if the instruction is not followed.

  • Page 7: Maintenance Manual's Content

    A Foreword – Reading instructions Maintenance manual's content page – The information in the maintenance manual is divided in function groups (0-12) to facilitate information searches. The manual is divid- ed in 20 sections A-C, 0-12, D-G. The sections with letters contain specific information that applies to several function groups and is not bound to a function, e.g., section "F Technical data".

  • Page 8: Function Group Structure

    (components). The function groups' structure for main group and two-digit group level are common for all machines from Kalmar Industries, e.g., 4.3 Servo brake system. Machine-unique adaptations of functions are done at the third and fourth group level, e.g., 4.3.9 Wheel brake and 4.3.9.1 Disc pack.

  • Page 9: References Between Different Information Types

    A Foreword – Reading instructions References between different information page – types The maintenance manual contains different types of information and is mainly divided in function groups, see section A Foreword. The basic rule of searching for information is to use function groups to find different types of information regarding the function or com- ponent in question.

  • Page 10: Machine Card

    A Foreword – Reading instructions Optional equipment Optional equipment are options that can be added to the standard equipment to obtain additional or improved functions. Symbol indicating optional equipment Information for optional equipment is described in separate sections with standard equipment as the starting point. The description of the optional equipment describes how the standard function is affected by the option as well as which components are added.

  • Page 11: Function Descriptions

    A Foreword – Reading instructions Function descriptions page – Function descriptions are schematic overviews that describe how a function works as well as which components and signals work to- gether. Function descriptions describe the function in a logical flow from in- put signal to desired output signal.
  • Page 12 A Foreword – Reading instructions Hydraulic force (solid double line) Flag pressure check connection (Check point), indicates that there is pressure check connection for checking pressure signal Flag diagnostic test, indicates that signal can be checked with diagnostic test, see section 8 Control system, group 8.4 Diag- nostics Illustration of function, (applied brake) Component list...
  • Page 13 A Foreword – Reading instructions Symbol explanation function descriptions The following symbols are used in function descriptions, the sym- bols are based on standard symbols used in wiring and hydraulic di- agrams. Electric control signal Electric force Hydraulic control signal Hydraulic force Hydraulic motor Hydraulic oil pump with variable displacement...

  • Page 14: About The Documentation

    Ordering of documentation page – Extra copies and supplementary documentation is ordered from Ka- lmar Industries. Kalmar Industries AB SE-341 81 Ljungby, Sweden. NOTE If possible, always indicate publication number when ordering. Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 15: Feedback

    Form for copying page – Kalmar Industries’ ambition is that you who work with maintenance of Kalmar machines shall have access to correct information. Your feedback is important to be able to improve the information. Copy this form, write down your views and send it to us. Thank you...
  • Page 16 A Foreword – Feedback Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 17 B Safety B Safety Table of Contents B Safety mm mm mm mm Safety ....................... 3 General safety information ................ 3 Safety concerns everyone! ................3 A near-accident is a warning signal! ..............3 Safety instructions ..................4 General ......................4 Service position ....................
  • Page 18 B Safety Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 19: Mm Mm Mm Mm

    • use common sense and work carefully, do not take any risks! Kalmar Industries has in this publication documented and warned for situations and risks that may occur in connection with using as well as service/repairs of the machine during normal circumstances.

  • Page 20: Safety Instructions

    B Safety – Safety instructions Safety instructions General page – Read, consider and follow the safety instructions below before start- ing to work in the machine: • Service position page 4 • Hydraulic and brake systems, depressurizing page 5 • Clothing etc.

  • Page 21: Hydraulic And Brake Systems, Depressurizing

    B Safety – Safety instructions Hydraulic and brake systems, depressurizing page – 1 Machine in service position. 2 Depressurize the hydraulic system. Turn the start key to position I and activate extension out, a dis- tinct hissing sound is heard if there is pressure in the hydraulic system.

  • Page 22: Clothing Etc

    B Safety – Safety instructions 5 Depressurize the brake system by opening the drain valve on the accumulator charging valve. NOTE Keep the drain valve open as long as work is in progress. Clothing etc. page – Clothes should be in good condition. Remove loosely hanging cloth- ing (tie, scarf, etc.).

  • Page 23: Working Under Machine

    B Safety – Safety instructions Working under machine page – Working under cab On machines with cab lift the machine shall be secured in raised po- sition with the intended locks. Working under chassis A lifted/raised vehicle may under no circumstances be supported or lifted in parts that belong to the wheel suspension or steering.

  • Page 24: Vibrations

    B Safety – Safety instructions Safety precautions Lift using a lifting device. Use lifting tools or equipment, espe- cially when such equipment is available for specific work operations. See the workshop manual for methods. If lifting must be performed without lifting device: •...

  • Page 25: Solvents

    B Safety – Safety instructions Solvents page – Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax, oil, adhesive, rubber, etc. are called organic solvents. Exam- ples: White (petroleum) spirits, gasoline, thinner, alcohols, diesel, xy- lene, trichloroethylene, toluene. Many solvents are flammable and constitute a fire hazard.

  • Page 26: Fluid Or Gas Under Pressure

    B Safety – Safety instructions Special cases Diesel fuel oil with an additive of petrol has a reduced flash point. Ex- plosion risk even at room temperature. The explosion risk due to warmed diesel fuel oil is greater than for gasoline. When changing oil in the engine, hydraulic system and transmission, keep in mind that the oil may be hot and can cause burn injuries.

  • Page 27: Coolant

    B Safety – Safety instructions Risks There are injury risks in connection with work on: • Hydraulic system (for example, working hydraulics and brake system). • Fuel system. • Tyre repairs. • Air conditioning. Safety precautions • Use safety glasses and protective gloves. •...

  • Page 28: Refrigerant

    B Safety – Safety instructions Refrigerant page – Refrigerant is used in the machine’s air conditioning system. Work on the air conditioning system must be performed by accred- ited/authorised and trained personnel according to national legisla- tion and local regulations. Risks The air conditioning operates at high pressure.

  • Page 29: Tensioned Springs

    B Safety – Safety instructions Risks Sulfuric acid mist is corrosive and injures the respiratory tracts. (Generated when heating certain plastics and paints.) Isocyanates can be released in the form of steam, dust (or may be present in aerosols) when cutting, grinding or welding. Can irritate mucous membranes producing symptoms similar to asthma and im- pairing lung function.

  • Page 30: Electric Motors

    B Safety – Safety instructions Electric motors page – Safety actions Always turn off the battery disconnector when working on electric motors. Always block the machine’s wheels, make sure that the parking brake is activated and that the gear selector is in neutral position be- fore starting any work on the machine.

  • Page 31: Tyre System

    B Safety – Safety instructions Tyre system page – D AN GE R Tyres should be regarded as pressurized containers. They constitute fatal danger if handled incorrectly. Parts can be thrown with explosive force and may cause severe injuries. Never repair damaged tyres, rims or lock rings. Tyre repairs should only be performed by authorized per- sonnel.

  • Page 32: Environment

    B Safety – Environment Environment General page – Ever-increasing industrialisation of our world is having a significant impact on our global environment. Nature, animals and man are sub- jected daily to risks in connection with various forms of chemical handling. There are still no environmentally safe chemicals, such as oils and coolants, available on the market.
  • Page 33 C Preventive maintenance C Preventive maintenance Table of Contents C Preventive maintenance mm mm mm mm Preventive maintenance................3 Preventive maintenance, general ................3 Preventive maintenance, work instructions ............3 Check and service log .................... 4 50h-check ......................5 Service schedule ....................7 Washing ........................
  • Page 34 C Preventive maintenance Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 35: Mm Mm Mm Mm

    It’s very important that preventive maintenance is performed ac- cording to recommended intervals. Preventive maintenance should be performed by Kalmar Industries, or by a service organization authorized by Kalmar Industries. C A U T I O N The warranty is not valid if service intervals are not followed.

  • Page 36: Check And Service Log

    C Preventive maintenance – Preventive maintenance Check and service log page – Model: Serial number: Completed maintenance Oper- Actions Operating Date Signature ating hours hours 50h-check 500h 500h service 1000h 1000h service 1500h 500h service 2000h 2000h service 2500h 500h service 3000h 1000h service 3500h...

  • Page 37: 50H-Check

    C Preventive maintenance – Preventive maintenance 50h-check page – For new machine, checks shall be performed after 50h operating time. Checks are performed to increase the machine’s reliability. 1 Engine Reference Leakage check oil, coolant, exhaust system Coolant level, check Section 1 Engine, group 1.7.7 Coolant Oil and oil filter, change Section 1 Engine, group 1.8 Lubrication...
  • Page 38 C Preventive maintenance – Preventive maintenance 9 Frame, body, cab and accessories Locking of cab (mechanically moveable), check Section 9 Frame, body, cab and accessories, group 9.10.4 Lon- gitudinal displacement of cab 10 Common hydraulics Leakage check, check-tightening as needed Oil level, check Section 10 Common hydraulics, group 10.6.8 Hydraulic oil Fine filter hydraulic oil, change...

  • Page 39: Service Schedule

    C Preventive maintenance – Preventive maintenance Service schedule page – Service shall be performed every 500 operating hours. Actions are divided into 500h, 1000h and 2000h service. Actions for 500h service are performed between 1000h and 2000h service, which means at 500h, 1500h, 2500h, etc. Actions for 1000h service are performed at odd thousands of oper- ating hours: 1000h, 3000h, 5000h, etc.
  • Page 40 C Preventive maintenance – Preventive maintenance Object, action Service Comment Reference 500h, 1000h, 2000h, 1500h, 3000h, 4000h, 2500h 5000h, 6000h etc. etc. etc. Fuel pre-filter Incl. draining of condensa- Section 1 Engine, group 1.2.3 tion water. Fuel pre-filter Radiator External cleaning NOTE! Not high-pressure washer.
  • Page 41 C Preventive maintenance – Preventive maintenance Object, action Service Comment Reference 500h, 1000h, 2000h, 1500h, 3000h, 4000h, 2500h 5000h, 6000h etc. etc. etc. Drive axle oil For volume and quality, Section 3 Driveline/axle, see section F Technical group 3.3 Drive axle data Mounting drive axle Section 3 Driveline/axle,...
  • Page 42 C Preventive maintenance – Preventive maintenance Object, action Service Comment Reference 500h, 1000h, 2000h, 1500h, 3000h, 4000h, 2500h 5000h, 6000h etc. etc. etc. Servo filter Section 7 Load handling, group 7.2.2 Servo filter Cable racks boom and Hose and cable damages. attachment Boom and attachment Damage.
  • Page 43 C Preventive maintenance – Preventive maintenance Object, action Service Comment Reference 500h, 1000h, 2000h, 1500h, 3000h, 4000h, 2500h 5000h, 6000h etc. etc. etc. Service indicator, reset Section 8 Control system, group 8.2.6 Service indicator 9 Frame, body, cab and accessories Hydraulic sliding cab Check and adjust chain tension.
  • Page 44 C Preventive maintenance – Preventive maintenance Object, action Service Comment Reference 500h, 1000h, 2000h, 1500h, 3000h, 4000h, 2500h 5000h, 6000h etc. etc. etc. 11 Common electrics Batteries Section 11 Common electrics, group 11.3.1 Start battery Fuses Check that fuses are in- Section 11 Common tact, change if needed.

  • Page 45: Washing

    C Preventive maintenance – Preventive maintenance Washing page – C A U T I O N When using a high-pressure washer to clean the ma- chine, do not aim the water jet directly at the radia- tor or electrical components, for example, control units, connectors and sensors.

  • Page 46: Lubrication 500 Hours

    C Preventive maintenance – Preventive maintenance Lubrication 500 hours page – 1 Clean the area around each grease cup before greasing. 2 Grease all points with lubrication grease, see section F Techni- cal data. Wheel hub and wheel spindle 3 Raise the right steering wheel with a jack (40 ton) so that wheel bearings and wheel spindle are relieved of stress, do not lift to a height where the wheel hangs freely.
  • Page 47 C Preventive maintenance – Preventive maintenance Link arms 8 Grease both link arms' outer and inner bearings with grease. Brake pedal Grease points link arm 1. Outer bearing 2. Inner bearing 9 Grease the brake pedal's hinge with grease. 10 Wipe off surplus grease. Grease points brake pedal Maintenance manual DRF 400–450 UDRF01.04GB...

  • Page 48: Lubrication 1000 Hours

    C Preventive maintenance – Preventive maintenance Lubrication 1000 hours page – 1 Lower and run out the boom completely and run out the spreader (positioning) completely. 2 Turn off the engine and the main electric power. 3 Grease all grease points on the machine with lubrication grease, see section F Technical data.
  • Page 49 C Preventive maintenance – Preventive maintenance Mounting lift boom (2 pcs.) Wheel spindle (4 pcs.) Mounting attachment (2 pcs.) Wheel hub (2 pcs.) Bearing rotation bar (4 pcs., two per side) + brushing Joint steering axle of ring gear Chain and chain sprocket spreading Glide beam mounting sideshift frame Twistlocks (4 pcs.) Mounting lift legs, combi attachment (4 pcs.)
  • Page 50 C Preventive maintenance – Preventive maintenance I MP O RTAN T Wipe off surplus lubrication paste. Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 51 0 Complete machine 0 Complete machine Table of Contents 0 Complete machine mm mm mm mm Complete machine................... 3 Complete machine, description ................3 Troubleshooting, general work instructions ............4 Troubleshooting without an error code, example ..........5 Troubleshooting with error code, example ............5 Troubleshooting cable harness ................
  • Page 52 0 Complete machine Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 53: Mm Mm Mm Mm

    Complete machine, description page – Kalmar DRF 400-450 is a “Reachstacker” for container handling. The machine has a lift capacity of 40–45 tons depending on version. The engine is a six cylinder four-stroke direct-injected diesel engine. The transmission is hydromechanical with gears in constant mesh.

  • Page 54: Troubleshooting, General Work Instructions

    0 Complete machine – Complete machine Troubleshooting, general work page – instructions When troubleshooting, it’s important that the work is structured and logical. The point of the troubleshooting described in the mainte- nance manual is to exclude components as error source so that the real error source can be pin-pointed.

  • Page 55: Troubleshooting Without An Error Code, Example

    0 Complete machine – Complete machine Troubleshooting without an error page – code, example 1 Choose suitable section 0–12 to find the function and sub-func- tion that have caused the symptom. 2 Read function description for the function in question to get an overall understanding of which components are affected and how these interact 3 Use the function description and check the signals for the func-...
  • Page 56 0 Complete machine – Complete machine 5 Use the function group to find more information if needed. In section 0–12 there is function description, the function's in- cluded components and their position as well as, in certain cas- es, work instructions for how components are checked, cleaned or adjusted.

  • Page 57: Troubleshooting Cable Harness

    0 Complete machine – Complete machine Troubleshooting cable harness page – NOTE Perform troubleshooting for all cables in the same way to avoid damage to control units, components or measuring equipment. 1 Study the circuit diagram in question, check where the suspect- ed cable is connected and if, and if so where, it is spliced.

  • Page 58: Troubleshooting Hydraulic Hoses

    0 Complete machine – Complete machine Troubleshooting hydraulic hoses page – W AR N IN G Oil under high pressure! Personal injury! Always depressurize hydraulic and brake systems before starting to work on the systems. 1 Depressurize the hydraulic and brake systems, see section B Safety.
  • Page 59 1 Engine 1 Engine Table of Contents 1 Engine mm mm mm mm Engine....................... 3 Fuel system ....................9 1.2.3 Fuel pre-filter ..................10 1.2.4 Fuel filter ..................... 12 Air intake and exhaust outlet ..............14 1.6.1 Air cleaning system ................14 Cooling system ..................
  • Page 60 1 Engine Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 61: Mm Mm Mm Mm

    1 Engine – 1 Engine 1 Engine mm mm mm mm Engine, description page – The engine provides power for propulsion and working hydraulics. The following engine alternatives are available: • Volvo TWD1240VE • Cummins QSM11 Both engines are low-emission engines and meet emission stand- ards for USA (California) and Europe.
  • Page 62 1 Engine – 1 Engine Control unit KIT (D790-2) Control unit KID (D795) Starter motor (M654) Control unit transmission (D793) Electrical components engine Engine alternative Volvo, page – component position Engine alternative Volvo, right side (in machine's travel direction) 1. Breather nipple cooling system 11.
  • Page 63 1 Engine – 1 Engine Engine alternative Volvo, left side (in machine's travel direction) 1. Connection cab heat Transmission oil cooler 2. Connection air cleaner 10. Thermostat transmission oil cooler 3. Turbocharger 11. Connection radiator inlet 4. Connection exhaust system 12.
  • Page 64 1 Engine – 1 Engine Engine alternative Cummins, page – function description Engine QSM11 is a straight 6-cylinder, 4-stroke turbocharged low- emission diesel engine with unit injectors and air-to-air intercooler. ˚C <˚ D790-1 D790-2 D795 D793 D794 D797-R SENSORS Ignition (S150) Accelerator pedal (B690) Control unit cab (D790-1) Make-contact (closing switch) coolant level (B759)
  • Page 65 1 Engine – 1 Engine Engine alternative Cummins, page – component position Engine alternative Cummins, right side (in machine's travel direc- tion) Position for compressor climate control unit 7. Drain point condensation water fuel filter and sensor water in fuel 2.
  • Page 66 1 Engine – 1 Engine Engine alternative Cummins, left side (in machine's travel direction) Oil dipstick 13. Connection radiator (outlet) Filling point engine oil 14. Inlet intercooler Connection cab heat 15. Intercooler Connection air cleaner 16. Radiator Turbocharger 17. Thermostat Connection intercooler (outlet) 18.

  • Page 67: Fuel System

    1 Engine – 1.2 Fuel system Fuel system Fuel system, description page – For position of components, see Engine alternative Volvo, compo- nent position page 4 or Engine alternative Cummins, component po- sition page 7. 1. Filling point, fuel 2. Fuel tank 3.

  • Page 68: Fuel Pre-Filter

    1 Engine – 1.2.3 Fuel pre-filter Metal filter supply line, cleaning (engine page – alternative Volvo) 1 Use hose pliers and stop the fuel flow to the fuel filter. 2 Disconnect the hose in its attachments at position 1 and posi- tion 3.
  • Page 69 1 Engine – 1.2.3 Fuel pre-filter 1 Machine in service position, see section B Safety. 2 Place a receptacle under the fuel pre-filter. 3 Clean the area around the fuel pre-filter. 4 Drain the fuel pre-filter of fuel and water. Open the drain valve on the underside, close the valve when the filter is empty.

  • Page 70: Fuel Filter

    1 Engine – 1.2.4 Fuel filter 1.2.4 Fuel filter Fuel filter, changing (Volvo engine) page – D AN GE R Pay attention to the fire hazard when working on the fuel system. Avoid changing the fuel filter when the engine is hot.
  • Page 71 1 Engine – 1.2.4 Fuel filter Fuel filter, changing (Cummins engine) page – D AN GE R Pay attention to the fire hazard when working on the fuel system. Avoid changing the fuel filter when the engine is hot. Fuel may spill on hot surfaces and may ignite. NOTE Avoid skin contact with fuel, use gloves.

  • Page 72: Air Intake And Exhaust Outlet

    1 Engine – 1.6 Air intake and exhaust outlet Air intake and exhaust outlet 1.6.1 Air cleaning system Air filter, changing page – 1 Machine in service position, see section B Safety. 2 Clean the outside of the air filter housing. 3 Remove the cap from the air filter housing.

  • Page 73: Cooling System

    1 Engine – 1.7 Cooling system Cooling system Cooling system, description page – The engine radiator is located together with the Intercooler and transmission oil cooler in a unit, a cooling unit. For position of components, see Engine alternative Volvo, compo- nent position page 4 or Engine alternative Cummins, component po- sition page 7.
  • Page 74 1 Engine – 1.7.2 Coolant filter 12 Check the coolant level in the expansion tank, top up if needed. A. Position of coolant reservoir (expansion tank) B. Filling point C. Level marking, MIN and MAX Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 75 1 Engine – 1.7.2 Coolant filter Coolant filter, changing (Cummins engine) page – NOTE Close the shut-off valve before the filter is loosened. Coolant may run out resulting in environmental damage. 1 Machine in service position, see section B Safety. 2 Close the shut-off valve on the filter holder.

  • Page 76: Cooling Fan

    1 Engine – 1.7.5 Cooling fan 1.7.5 Cooling fan Fan belt, checking page – 1 Place the cab in the front position. 2 Remove the cover plates over the engine and radiator. 3 Wash the engine compartment. 4 Machine in service position, see section B Safety. The figure shows engine alternative Cummins 5 Check the belt tension and adjust if needed.

  • Page 77: Coolant

    1 Engine – 1.7.7 Coolant 1.7.7 Coolant Coolant level, checking page – W AR N IN G The cooling system is pressurized. Steam or hot flu- id may jet out. Risk of scalding and burn injuries! Open the filler cap (position B) very carefully when the engine is warm.

  • Page 78: Lubrication

    1 Engine – 1.8 Lubrication Lubrication Lubrication system, description page – The engine's lubrication system is a completely closed system and has no connections to the machine. For position of components, see Engine alternative Volvo, compo- nent position page 4 or Engine alternative Cummins, component po- sition page 7.
  • Page 79 1 Engine – 1.8 Lubrication Do not tighten the oil plug with higher tightening torque, the threads will be damaged. 10 Fill with engine oil. For volume and grade, see section F Tech- nical data. 11 Start the engine, let it idle and check that the drain plug and fil- ters do not leak.
  • Page 80 1 Engine – 1.8 Lubrication 8 Remove the oil filter. 9 Fill the new filter with new engine oil and lubricate the O-ring on the filter with engine oil. 10 Fit the new filter. Tighten the filter according to the instructions on the filter. 11 When the oil has drained, install the oil plug.
  • Page 81 1 Engine – 1.8 Lubrication Oil level, checking page – W AR N IN G Avoid prolonged skin contact with engine oil. Hazardous to health! Use protective gloves. Engine oil, general The engine's oil filler pipe (position B) and dipstick (position C) are lo- cated under the service hatch in front of the cab.

  • Page 82: Control System Engine

    1 Engine – 1.9 Control system engine Control system engine Control system engine, description page – The engine is controlled by a control system, for which the central unit is a control unit. The control unit controls the amount of fuel to the unit injectors by opening and closing a fuel valve by each injector.

  • Page 83: Ignition/Heating

    1 Engine – 1.10 Ignition/heating 1.10 Ignition/heating Ignition/heating, description (engine page – alternative Volvo) The engine is equipped with preheating of the inlet air, for faster start at low temperatures. Preheating is activated when the start key is in position II. When preheating is activated Indicator light preheat- ing is on.

  • Page 84: Start/Stop

    1 Engine – 1.11 Start/stop 1.11 Start/stop Start/stop, description (engine alternative page – Volvo) The engine is started and stopped with the ignition. The ignition sends signals to Control unit KIT (D790-2) and Control unit cab (D790- 1) which send messages via CAN-buss drivetrain to Control unit en- gine (D794).
  • Page 85 2 Transmission 2 Transmission Table of Contents 2 Transmission mm mm mm mm Transmission .................... 3 Torque converter/clutch system ............... 5 Mechanical transmission ................6 Lubrication ....................7 Cooling ..................... 10 Control system transmission ..............11 Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 86 2 Transmission Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 87: Mm Mm Mm Mm

    2 Transmission – 2 Transmission 2 Transmission mm mm mm mm Transmission, function description page – The transmission converts the engine power to the drive wheels (drive axle) via the propeller shaft and also power to drive the hy- draulic oil pumps for hydraulics and the brake system. The transmission is fully automatic with torque converter.
  • Page 88 2 Transmission – 2 Transmission Mode selector on Control unit KIT (D790-2) Sensor drum speed (B752) Control unit KIT (D790-2) Sensor turbine speed (B751) Accelerator pedal (B690) Sensor output shaft speed (B758) Declutch pedal (S220-1) Temperature monitor torque converter (S221) Control unit cab (D790-1) Oil cooler Control unit transmission (D793)

  • Page 89: Torque Converter/Clutch System

    2 Transmission – 2.2 Torque converter/clutch system Torque converter/clutch system Torque converter/clutch, description page – The torque converter transmits the engine's power to the transmis- sion. For position of components see Transmission, component position page 4. Breather filter, cleaning page –...

  • Page 90: Mechanical Transmission

    2 Transmission – 2.3 Mechanical transmission Mechanical transmission Mechanical transmission, description page – The transmission is built with all gears in constant mesh. It is shifted through hydraulic pressurizing of clutch discs for each one of the gears. The clutch discs connect the input shaft with the main shaft or tubular shaft, depending on which gear has been selected.

  • Page 91: Lubrication

    2 Transmission – 2.6 Lubrication Lubrication Lubrication system, description page – The transmission has its own lubrication system that is used for lu- brication, control and cooling of the transmission. The transmission oil cooler is located at the bottom in the cooler unit behind the en- gine, a thermostat in the cooler enables the oil to reach operating temperature faster.
  • Page 92 2 Transmission – 2.6 Lubrication 5 Place a collection container under the oil filters. 6 Clean the area around the oil filters. 7 Remove the oil filters. 8 Install the new oil filters. Wet the O-ring on the new oil filters with transmission oil. Tight- en to contact and then another two-thirds of a turn.
  • Page 93 2 Transmission – 2.6 Lubrication Oil level, checking page – W AR N IN G Avoid prolonged skin contact with the transmission oil. Hazardous to health! Use protective gloves. The transmission's oil filler pipe and dipstick (position B) are located under the service hatch in front of the cab.

  • Page 94: Cooling

    2 Transmission – 2.7 Cooling Cooling Cooling system, description page – The transmission is cooled by the lubrication system see Lubrication system, description page 7. For position of components see Transmission, component position page 4. Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 95: Control System Transmission

    2 Transmission – 2.8 Control system transmission Control system transmission Control system transmission, description page – The transmission control unit controls shifting based on pressure sensors, temperature sensors and speed sensors. Gear selection takes place by activating solenoid valves that distribute control pres- sure in the transmission, so that selected gear gives the correct speed.
  • Page 96 2 To select the function to calibrate, first navigate to the service menu. Then press Enter. 3 Enter code for calibration. The code is obtained via Kalmar Industries Support. 1 2 3 NOTE The code determines which service menu shall be activat- ed (Diagnostics, Initiation or Calibration).
  • Page 97 2 Transmission – 2.8 Control system transmission 7 Select DRIVE-TRAIN, menu, 3. CALIBR DRIVE-TRN 3(4) GEARBOX TUNING CLUTCH TUNING PHASE SUB-PH Description: Calibration of transmission couplings. CLUTCH STATUS ACTION XXXXrpm PHASE: Indicates current phase in the calibration. 0. Prefilling of coupling 1.
  • Page 98 2 Transmission – 2.8 Control system transmission 10 Calibration starts (takes approx. 15 minutes) and engine speed is raised to approx. 770 rpm. The transmission will activate different gears during calibration. NOTE If the machine starts to move during calibration then use the footbrake to keep the machine stationary.
  • Page 99 3 Driveline/axle 3 Driveline/axle Table of Contents 3 Driveline/axle mm mm mm mm Driveline/axle ................... 3 Propeller shaft .................... 4 Drive axle ....................5 Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 100 3 Driveline/axle Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 101 3 Driveline/axle – 3 Driveline/axle 3 Driveline/axle mm mm mm mm Driveline/axle, description page – The machine's power transmission consists of propeller shaft and drive axle with differential and hub reduction. Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 102 3 Driveline/axle – 3.2 Propeller shaft Propeller shaft Propeller shaft, description page – The propeller shaft transmits the engine power from transmission to the drive axle. Propeller shaft, checking page – • After 50h: Check-tighten attaching bolts at mountings to drive axle and transmission with 200 Nm.
  • Page 103 3 Driveline/axle – 3.3 Drive axle Drive axle Drive axle, description page – The drive axle transmits the engine power to the wheels. After the drive axle's input shaft is a differential which changes the reduction ratio, distributes the power between right and left drive wheels and also makes it possible for the drive wheels to rotate at different speed when cornering.
  • Page 104 3 Driveline/axle – 3.3 Drive axle Drive axle, checking page – 1 Check the drive axle's attachment to the frame so that there is no corrosion on structural elements (e.g., attaching bolts). 2 Check-tighten the drive axle's attaching bolt with 2350 Nm. 3 Check-tighten the wheel nuts with 400 Nm.
  • Page 105 4 Brakes 4 Brakes Table of Contents 4 Brakes mm mm mm mm Brakes....................... 3 Controls and instrumentation ..............4 4.1.1 Brake pedal .................... 4 Service brake system ................. 5 4.3.1 Brake oil pump ..................8 4.3.4 Accumulator ..................9 Parking brake system ................
  • Page 106 4 Brakes Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 107: Mm Mm Mm Mm

    4 Brakes – 4 Brakes 4 Brakes mm mm mm mm Brakes, general page – There are brakes to be able to stop the machine. The brakes act on the drive axle, (the steering axle has no brakes). The brake system is divided into three functions: •...

  • Page 108: Controls And Instrumentation

    4 Brakes – 4.1 Controls and instrumentation Controls and instrumentation 4.1.1 Brake pedal Brake pedal, checking and adjusting page – 1 Clean the floor around the brake pedal and check that nothing blocks movement of the brake pedal. 2 Check that the brake pedal springs back sufficiently and that the clearance between brake pedal and brake valve is 1–1.5 mm.

  • Page 109: Service Brake System

    4 Brakes – 4.3 Service brake system Service brake system Power-assisted brake system, function page – description The power-assisted brake system consists of a brake oil tank, brake oil pump, brake oil filter, accumulator charging valve, accumulators, brake valve, pressure sensors, brake cylinder and wheel brake units. The brake oil pump pumps oil (from tank) which is cleaned in the oil filter.
  • Page 110 4 Brakes – 4.3 Service brake system D790-2 D797-R D797-F Brake oil pump Make-contact, brake lights (S216) Brake oil filter Break-contact brake oil pressure (S204) Accumulator charge valve Control unit frame front (D797-F) Accumulators Control unit frame rear (D797-R) Brake valve Brake light (H411L &...
  • Page 111 4 Brakes – 4.3 Service brake system Power-assisted brake system, component page – position Brake valve Make-contact, brake lights (S216) Brake oil pump Wheel brakes Make-contact brake oil pressure (S204) Accumulators brake system Accumulator charge valve Brake oil filter Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 112: Brake Oil Pump

    4 Brakes – 4.3.1 Brake oil pump 4.3.1 Brake oil pump Brake oil pump, checking page – W AR N IN G Hot, pressurized oil. Personal injury, burn injury, rash or irritation. Always depressurize the hydraulic systems before starting to work in the hydraulic systems. Avoid skin contact with the oil, use protective gloves.

  • Page 113: Accumulator

    4 Brakes – 4.3.4 Accumulator 4.3.4 Accumulator Accumulator, checking page – 1 Start the engine and let it idle for approx. 1 minute (until the ac- cumulator charging valve switches to cooling). 2 Turn off the engine and turn the start key to position I. 3 Apply and release the brake several times, and count the number of times that the brake can be applied before the warn- ing light for low brake pressure is activated.

  • Page 114: Parking Brake System

    4 Brakes – 4.5 Parking brake system Parking brake system Parking brake system, function description page – The parking brake consists of brake oil tank, brake oil pump, brake oil filter, accumulator charging valve, pressure sensors and parking brake unit. The brake oil pump pumps oil (from tank) which is cleaned in the oil filter.

  • Page 115: Parking Brake Unit

    4 Brakes – 4.5.4 Parking brake unit Parking brake system, component position page – Brake oil pump Solenoid valve parking brake (Y642) Accumulator charge valve Parking brake unit Make-contact parking brake (S200) Brake oil filter 4.5.4 Parking brake unit Parking brake unit, checking and adjustment page –...
  • Page 116 4 Brakes – 4.5.4 Parking brake unit 5 Remove the cover from the brake caliper. 6 Undo the lock nut. 7 Adjust the adjustment screw so that the brakes are applied. 8 Back off the adjustment screw 3/4 of a turn. 9 Tighten the lock nut.

  • Page 117: Temperature Control, Filtration And Brake Fluid

    4 Brakes – 4.8 Temperature control, filtration and brake fluid Temperature control, filtration and brake fluid Temperature control, cleaning and brake oil, page – function description The brake system is cooled with oil that circulates through a cooler. The cooler has a temperature-controlled electric fan that counter- acts overheating.
  • Page 118 4 Brakes – 4.8 Temperature control, filtration and brake fluid By-pass valve in distribution block Control unit KID (D795) Cooler brake system Temperature control, cleaning and brake oil, page – component position Brake oil filter Tank warmer Brake oil tank Thermal by-pass valve Breather filter Oil cooler...

  • Page 119: Breather Filter

    4 Brakes – 4.8.11 Breather filter 4.8.11 Breather filter Breather filter, changing page – 1 Clean the area around the brake tank's breather filter. 2 Remove cover from the filter holder. Remove the screw in the middle and lift away the cover. 3 Remove the old filter cartridge.
  • Page 120 4 Brakes – 4.8.12 Brake oil filter 4 Place a receptacle under the oil filter to collect any oil spills. 5 Clean the outside of the brake oil filter. 6 Remove the drain plug on the underside of the filter. Let the oil drain.

  • Page 121: Oil Brake System

    4 Brakes – 4.8.14 Oil brake system 4.8.14 Oil brake system Oil brake system, changing page – W AR N IN G Hot, pressurized oil. Personal injury, burn injury, rash or irritation. Always depressurize the hydraulic systems before starting to work in the hydraulic systems. Avoid skin contact with the oil, use protective gloves.
  • Page 122 4 Brakes – 4.8.14 Oil brake system Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 123 5 Steering 5 Steering Table of Contents 5 Steering mm mm mm mm Steering ....................3 Power-assisted system ................4 Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 124 5 Steering Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 125 5 Steering – 5 Steering 5 Steering mm mm mm mm Steering, general page – The function steering means to steer the machine during operation. The machine is steered with the rear wheels by a power-assisted steering system. Available options are joystick steering and min- wheel, which means that the machine is steered electrically with a control on the operator's armrest.
  • Page 126 5 Steering – 5.2 Power-assisted system Power-assisted system Power-assisted steering system, function page – description The function power-assisted steering system refers to steering the machine. The machine's steering is power-assisted with pressure from the hydraulic oil pumps. Steering consists of steering wheel, steering wheel shaft, steering valve, hydraulic oil pumps, priority valve, steering cylinder, link arms and wheel spindles.
  • Page 127 5 Steering – 5.2 Power-assisted system Hydraulic diagram base machine Joystick steering/mini-wheel, function page – description Joystick steering or mini-wheel means that the machine is steered with an electric control in the operator seat's left armrest. The elec- tric control sends signals to the control system. The steering cylinder is pressurized by a control valve which also is controlled by the con- trol system.
  • Page 128 5 Steering – 5.2 Power-assisted system Control valve joystick steering or mini-wheel Sensor steering wheel shaft Shuttle valve Control unit cab (D790-1) Power-assisted steering system, component page – position Shuttle valve attachment Pump working hydraulics 3 Shuttle valve steering Pump working hydraulics 4 Control valve mini-wheel/joystick steering Shuttle valve mini-wheel or joystick steering Priority valve...
  • Page 129 6 Suspension 6 Suspension Table of Contents 6 Suspension mm mm mm mm Suspension ....................3 Suspension ....................4 6.2.1 Steering axle cradle ................4 6.2.2 Wheel spindle ..................5 6.2.3 Wheel hub ..................... 5 Tyre and rim system .................. 7 6.3.1 Tyres ....................
  • Page 130 6 Suspension Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 131: Mm Mm Mm Mm

    6 Suspension – 6 Suspension 6 Suspension mm mm mm mm Suspension, description page – The machine’s suspension consists of its tyres (with associated rims and bolts), steering axle with hub, wheel spindles and the steering axle's suspension in the frame. The drive axle belongs to power transmission, see section 3 Driveline/axle, group 3.3 Drive axle.

  • Page 132: Suspension

    6 Suspension – 6.2 Suspension Suspension Suspension, description page – Suspension refers to: • Steering axle cradle • Wheel spindle • Wheel hub The steering axle cradle is attached to the frame with two bushings, one at the leading edge and one at the trailing edge of the steering axle cradle.

  • Page 133: Wheel Spindle

    6 Suspension – 6.2.2 Wheel spindle 6.2.2 Wheel spindle Wheel spindle bearing, checking page – 1 Machine in service position, see section B Safety. 2 Carefully pry up the O-ring. 3 Measure with feeler gauge between thrust bearing and thrust washer.
  • Page 134 6 Suspension – 6.2.3 Wheel hub 5 Torque the bearing nut as follows. A. Lubricate the thread on the spindle and the side of the nut facing the bearing with oil SAE 80W/140. B. Tighten the nut to 250 Nm. C.

  • Page 135: Tyre And Rim System

    6 Suspension – 6.3 Tyre and rim system Tyre and rim system Tyre and rim system, safety page – D AN GE R Always block the wheels on the side of the axle where no work is to be done before positioning the jack.
  • Page 136 6 Suspension – 6.3 Tyre and rim system C A U T I O N When removing wheels, the wheel nuts should be left in place after loosening. If the wheel nuts are re- moved immediately, the wheel may release from the hub.
  • Page 137 Do not exceed the prescribed air pressure. When changing tyre or rim version, another air pressure may apply. Contact Kalmar Industries. 1 Check the rims. • Check that the lock ring and lugs are installed correctly.
  • Page 138 6 Suspension – 6.3 Tyre and rim system Tyre and rim system, removing (drive axle) page – Read the safety instructions before working with the tyre and rim, see Tyre and rim system, safety page 7. 1 Lift the machine under the drive axle by the wheel in question. Support under the drive axle in a safe and adequate manner.
  • Page 139 6 Suspension – 6.3 Tyre and rim system 6 Remove the spacer ring. Pull out the wheel a bit so that the spacer ring comes loose. NOTE The spacer ring weighs approx. 20 kg. 7 Remove the outer wheel. Lift away the wheel and place it in a safe manner. 8 Move the lifting equipment to the inner wheel.
  • Page 140 6 Suspension – 6.3 Tyre and rim system Tyre and rim system, removing (steering axle) page – Read the safety instructions before working with the tyre and rim, see Tyre and rim system, safety page 7. 1 Lift the machine under the steering axle by the wheel in ques- tion.
  • Page 141 6 Suspension – 6.3 Tyre and rim system 3 Loosen the wheel nuts. 4 Secure the wheel with lifting equipment. 5 Remove the wheel. Remove nuts, washers and clamps and pull out the wheel. 6 Lift away the wheel and place it in a safe manner. Tyre and rim system, installing (drive axle) page –...
  • Page 142 6 Suspension – 6.3 Tyre and rim system 2 Fit the inner spacer ring. NOTE The inner ring is not split. 3 Lift the outer wheel into place with lifting equipment. Rotate the wheel so that the guide lug enters the groove on the hub. 4 Fit the outer spacer ring.
  • Page 143 6 Suspension – 6.3 Tyre and rim system 9 Inflate the tyre with air, 1 MPa, see Tyres, inflating page 17. 10 Lower the axle and remove the jack. 11 Test-run the machine and check that the wheels are installed securely.
  • Page 144 6 Suspension – 6.3 Tyre and rim system 2 Place clamps and nuts on the wheel bolts. Where applicable, also washers. 3 Remove the lifting equipment. 4 Fit the wheel. Tighten the wheel nuts crosswise with torque 400 Nm. 5 Inflate the tyre with air, 1 MPa, see Tyres, inflating page 17. 6 Lower the axle and remove the jack.

  • Page 145: Tyres

    Do not exceed the prescribed tyre pressure. Other inflation pressure may apply when changing tyre or rim version, contact Kalmar Industries. Never stand directly in front of the wheel when de- flating or inflating. The conical ring and locking clips can loosen and shoot out when the pressure is changed.

  • Page 146: Rims

    6 Suspension – 6.3.2 Rims Tyres, changing page – D AN GE R Changing tyres is complicated and dangerous work. FATAL DANGER! Leave tyre work to authorized personnel/ tyre com- pany. 6.3.2 Rims Rim, checking page – D AN GE R Perform the following checks to minimize risks of accidents for all rims that can be dismantled.
  • Page 147 Compare the value of the diameter with the specified min. measurement. If the diameter is smaller, the rim, lock ring and the rim bead seat taper must be discarded and replaced with new parts. Information about min. diameter can be obtained from Kalmar Industries. O. Circumference D. Diameter 5 Check for damage in the areas with high stress concentration.
  • Page 148 6 Suspension – 6.3.2 Rims Checking cracks with penetrating fluid 1 Clean the area with cleaning fluid part no. 923626.0668. 2 Spray penetrating fluid part no. 923626.0669 on the cleaned area and let dry 10 min. 3 Wash off penetrating fluid with cleaning fluid part no. 923626.0668.
  • Page 149 7 Load handling 7 Load handling Table of Contents 7 Load handling mm mm mm mm Load handling................... 3 Lifting/lowering ..................4 7.2.2 Servo filter ..................... 7 7.2.3 Pressure reducer ................... 9 Protruding ....................10 7.3.10 Lift boom ..................... 13 Side-shift ....................
  • Page 150 7 Load handling Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 151: Mm Mm Mm Mm

    7 Load handling – 7 Load handling 7 Load handling mm mm mm mm Load handling, general page – The function load handling refers to e.g., to lift, lower, rotate, angle and secure loads. Load handling also includes help functions for han- dling loads, e.g., support jacks.

  • Page 152: Lifting/Lowering

    7 Load handling – 7.2 Lifting/lowering Lifting/lowering Lift and lower, function description page – Lift and lower means to angle the boom up and down so that the at- tachment is lifted and lowered. The lift boom is angled with two lift cylinders that are pressurized by Control valve lift, lower and exten- sion.
  • Page 153 7 Load handling – 7.2 Lifting/lowering D790-1 D797-F D797-F >˚ Control lever (S815-P1) Servo filter Control unit cab (D790-1) Servo valve blocking right (Y6001) and Servo valve blocking left (Y6002) Control unit frame front (D797-F) Valve block lift cylinder Servo valve, lift (Y6005) or Servo valve, lower (Y6004) Lift cylinder Control valve lift, lower and extension Sensor hydraulic pressure lift cylinder piston side left...
  • Page 154 7 Load handling – 7.2 Lifting/lowering Lift and lower, component position page – Shuttle valve attachment Servo valve boom out (Y6006) Shuttle valve steering Servo valve boom in (Y6007) Servo valve boom lower (Y6004) Shuttle valve mini-wheel or joystick steering Servo valve lift (Y6004) Shuttle valve option frame Hydraulic oil pump...

  • Page 155: Servo Filter

    7 Load handling – 7.2.2 Servo filter 1. Outer boom 6. Extension cylinder 2. Inner boom 7. Lift cylinder 3. Tilt cylinder, right side 8. Mounting, lift cylinder 4. Mounting attachment 9. Rear boom mounting 5. Tilt cylinder, left side Sensor boom angle See section 8 Control system, group 8.2.1 Overloading system.
  • Page 156 7 Load handling – 7.2.2 Servo filter 4 Clean the outside of the filter housing and filter holder. 5 Remove the filter holder and remove the cartridge downward. 6 Clean the inside of the filter holder. 7 Place the new cartridge in the filter holder. 8 Check that the O-ring on the filter holder is intact and in place.

  • Page 157: Pressure Reducer

    7 Load handling – 7.2.3 Pressure reducer 7.2.3 Pressure reducer Pressure reducer, checking servo pressure page – W AR N IN G Hot, pressurized oil. Personal injury, burn injury, rash or irritation. Always depressurize the hydraulic systems before starting to work on the hydraulic systems. Avoid skin contact with the oil, use protective gloves.

  • Page 158: Protruding

    7 Load handling – 7.3 Protruding Protruding Extension, function description page – Extension means to push the inner boom in and out in the outer boom. The inner boom is pushed in and out by the extension cylinder which is pressurized by Control valve lift, lower and extension. Ex- tension is controlled with Control lever (S815).
  • Page 159 7 Load handling – 7.3 Protruding D790-1 D797-F D797-R Control lever (S815-P2) Control unit frame rear (D797-R) Control unit cab (D790-1) Servo valve blocking extension (Y6050) Control unit frame front (D797-F) Valve block extension cylinder Servo valve, boom out (Y6006) or Servo valve, boom Extension cylinder in (Y6007) Control valve lift, lower and extension...
  • Page 160 7 Load handling – 7.3 Protruding Extension, component position page – Hydraulic oil pump, Servo filter, Pressure reducer, Ac- cumulator servo circuit, Control valve lift, lower and extension, Shuttle valve, Extension cylinder, Lift boom See Lift and lower, component position page 6. Valve block extension cylinder extension cylinder Connection rod side (C-) Drain (D)

  • Page 161: Lift Boom

    7 Load handling – 7.3.10 Lift boom 7.3.10 Lift boom Glide plates lift boom, checking page – NOTE When adjusting side-mounted glide plates, it is important to check the clearance for the whole boom's stroke. 1 Place the boom in the lowest position (fully retracted). 2 Check wear of the side-mounted glide plates at the leading edge of the lift boom.

  • Page 162: Side-Shift

    7 Load handling – 7.4 Side-shift Side-shift Sideshift, function description page – Sideshift means to move the attachment sideways. The attachment can be sideshifted ± 800 mm from the middle position. Control valve attachment pressurizes the sideshift cylinders which push the attachment's main beam in relation to the lift boom. Side- shift is controlled with Control lever (S815).
  • Page 163 7 Load handling – 7.4 Side-shift Shuttle valve Sideshift cylinder Hydraulic diagram top lift Hydraulic diagram top lift, tilt lock and controllable tilt Hydraulic diagram combi attachment Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic lev- elling Sideshift, component position page –...

  • Page 164: Sideshift Frame

    7 Load handling – 7.4.6 Sideshift frame Sensor twistlocks (B7202L/R and B7203L/R) Solenoid valve tilt (Y6010 and Y6011) Solenoid valve rotation (Y6008 and Y6009) Lock cylinder twistlocks Solenoid valve sideshift (Y6020 and Y6021) Spreader boom 7.4.6 Sideshift frame Glide plates sideshift frame, checking page –...

  • Page 165: Main Beam Attachment

    7 Load handling – 7.4.7 Main beam attachment Lower glide plates sideshift frame, checking page – 1 Place axle stands or similar under the attachment's spreader booms and lower the attachment axle stands so that the side- shift frame's lower glide plates can be accessed. 2 Turn off the engine and the main electrical power.
  • Page 166 7 Load handling – 7.4.7 Main beam attachment 8 Place the glide plate in the correct position. Check the clearance between spreader beam and glide plate. Clearance should be max. 1 mm with all glide plates mounted. Fit/remove spacer plates until the distance is correct. NOTE Excessive clearance may result in damage to the spreader beam when load handling.

  • Page 167: Positioning

    7 Load handling – 7.5 Positioning Positioning Spreading, function description page – Spreading means that the width between the twistlocks is changed. Spreading has two 20-foot and 40-foot stops, as an option there are stops at other distances, e.g., 30-foot stop. Control valve attachment pressurizes valve block spreader motor that directs pressure to the spreader motor.
  • Page 168 7 Load handling – 7.5 Positioning D790-1 D797-R D791-1 Control lever (S815-T1.x and S815-T4) Control unit cab (D790-1) Control unit cab (D790-1) Servo valve spreading out (Y6018) or Servo valve spreading in (Y6019) Control unit frame rear (D797-R) Control valve attachment Solenoid valve, engagement of hydraulics for top lift Valve block spreader cylinder (Y6003)
  • Page 169 7 Load handling – 7.5 Positioning 30-foot stop, function description page – 30-foot stop is an option for spreading that is activated with Switch stop at 30’ or 35’. When the 30-foot stop is activated, spreading stops at 30 feet. Two inductive position sensors indicate the position of the spreader beams and activates damping.
  • Page 170 7 Load handling – 7.5 Positioning Spreading, component position page – Hydraulic oil pump, Shuttle valve See Lift and lower, component position page 6. Valve block top lift hydraulics, Control valve attach- ment, Spreader beam, Main beam attachment, Relief valve attachment See Sideshift, component position page 15.

  • Page 171: Positioning Motor

    7 Load handling – 7.5.6 Positioning motor 7.5.6 Positioning motor Oil spreader motor unit, changing page – W AR N IN G Hot, pressurized oil. Personal injury, burn injury, rash or irritation. Always depressurize the hydraulic systems before starting to work on the hydraulic systems. Avoid skin contact with the oil, use protective gloves.
  • Page 172 7 Load handling – 7.5.7 Positioning chains 4 If needed, adjust the distance by moving washers between the right and left 20-foot stop. The quantity of washers may not be changed. NOTE Note the distance that the stop is adjusted. Run out the spreading slightly so that it is possible to move the washers.
  • Page 173 7 Load handling – 7.5.7 Positioning chains 9 If needed, adjust the 40-foot stops. 10 Start the engine and run in the spreading to the 40-foot posi- tion. 11 Wait 2 minutes and then check the tension of the chains. Measure how much the chain can be pushed in at the hole clos- est to the centre of the attachment.

  • Page 174: Positioning Beam

    7 Load handling – 7.5.8 Positioning beam 7.5.8 Positioning beam Slide plates, extension beam, checking and page – adjustment 1 Park the machine with the attachment as far down as possible and spreading fully run in. 2 Turn off the engine and the main electrical power. 3 Take the strain off the slide plate in question.

  • Page 175: Rotation

    7 Load handling – 7.6 Rotation Rotation Rotation, function description page – The attachment can be rotated +195° -105° in relation to the ma- chine. Control valve attachment pressurizes Valve block rotation motor. Valve block rotation motor controls pressure to the rotation motors, which rotate the attachment.
  • Page 176 7 Load handling – 7.6 Rotation Solenoid valve, engagement of hydraulics for top lift Valve block hydraulic motor (Y6003) Shuttle valve Rotation motor Hydraulic oil pump Hydraulic diagram top lift Hydraulic diagram top lift, tilt lock and controllable tilt Hydraulic diagram combi attachment Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic lev- elling Rotation stop, function description...
  • Page 177 7 Load handling – 7.6 Rotation Servo valve rotation clockwise (Y6008) or Servo valve rotation counter-clockwise (Y6009) Hydraulic diagram top lift Hydraulic diagram top lift, tilt lock and controllable tilt Hydraulic diagram combi attachment Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic lev- elling Rotation, component position page...

  • Page 178: Rotation Motor Unit

    7 Load handling – 7.6.6 Rotation motor unit 7.6.6 Rotation motor unit Oil rotation motor unit, changing page – W AR N IN G Hot, pressurized oil. Personal injury, burn injury, rash or irritation. Always depressurize the hydraulic systems before starting to work on the hydraulic systems.

  • Page 179: Tilt

    7 Load handling – 7.7 Tilt Tilt Tilt, description page – The rotation yoke's suspension is hinged and is provided with two cross-connected hydraulic cylinders that reduce oscillations. The cylinders are pressurized by the hydraulic system and is connected with a damping block. There are four versions of tilt: •...
  • Page 180 7 Load handling – 7.7 Tilt Tilt damping, function description page – Tilt means that the attachment can swing back and forth in the sus- pension to the boom so that the load hangs straight during the entire lift movement. Tilt damping means that the tilt movement is coun- ter-acted.
  • Page 181 7 Load handling – 7.7 Tilt Tilt lock, function description page – Tilt lock is an option for tilt damping which means that the tilt move- ment can be locked. Tilt lock uses two solenoid valves in the damping block. One blocks the connection between the tilt cylinders and the damping block Event menu tilt lock while the other blocks the supply of servo pressure from Control...
  • Page 182 7 Load handling – 7.7 Tilt Hydraulic diagram top lift, tilt lock and controllable tilt Hydraulic diagram combi attachment Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic lev- elling Tilt control, function description page – Tilt control is an option for tilt damping and means that tilting of the attachment can be controlled min.
  • Page 183 7 Load handling – 7.7 Tilt Control lever (S815-P4) Servo valve tilt out (Y6010) or Servo valve tilt in (Y6011) Control unit cab (D790-1) Control valve attachment Control unit frame rear (D797-R) Control unit attachment (D791-1) Solenoid valve engagement of hydraulics for top lift Solenoid valve tilt lock (Y6012) (Y6003) Shuttle valve...
  • Page 184 7 Load handling – 7.7 Tilt Tilt damping, adjusting page – NOTE The tilt damping may have to be adjusted after run-in due to mechanical tolerances. 1 Engine at idle. 2 Lift the boom without load and check that the attachment hangs horizontally during the whole lifting movement.

  • Page 185: Levelling

    7 Load handling – 7.8 Levelling Levelling Mechanical levelling, function description page – Mechanical levelling means that the attachment is angled in horizon- tal direction. This enables the machine to handle loads on uneven surfaces. The attachment's main beam is located in the sideshift frame. The clearance between the sideshift frame and the attachment's main beam allows a movement of approx.
  • Page 186 7 Load handling – 7.8 Levelling D790-1 D791-2 D797-R D791-3 Control lever (S815-P1 and S815-T4) Solenoid valve levelling (Y6034) Control unit cab (D790-1) Servo valve levelling right (Y6035) or Servo valve lev- elling left (Y6036) Control unit frame rear (D797-R) Control valve attachment Solenoid valve, engagement of hydraulics for top lift Over-centre valve...
  • Page 187 7 Load handling – 7.8 Levelling Levelling lock, function description page – Levelling lock is an option for hydraulic levelling which means that the levelling movement can be locked. Levelling lock uses two solenoid valves in the valve block levelling cylinder which block pressure to and from the levelling cylinders.
  • Page 188 7 Load handling – 7.8 Levelling Solenoid valve engagement of hydraulics for top lift Levelling cylinders (Y6003) Shuttle valve Hydraulic diagram combi attachment Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic lev- elling Levelling, component position page – Hydraulic oil pump, Shuttle valve See Lift and lower, component position page 6.

  • Page 189: Load Carrying

    7 Load handling – 7.9 Load carrying Load carrier Load carrier, description page – Load carrier refers to holding on to any load. There are several ways to hold loads. • Twistlocks, rotation lift pins that hold the load in oval holes in the corners of the load.
  • Page 190 7 Load handling – 7.9.1 Twistlocks Condition Reference value Control switch Not activated Alignment Full alignment or by-pass activated Overloading system Passive D790-1 D790-2 D797-R D791-1 Switch lock twistlocks (S1003) Solenoid valve, engagement of hydraulics for top lift (Y6003) Control lever (S815-T2) Shuttle valve Sensor alignment left front (7202L), Sensor align- Hydraulic oil pump...
  • Page 191 7 Load handling – 7.9.1.7 Twistlocks Control unit cab (D790-1) Lock cylinder Control unit frame rear (D797-R) Sensor unlocked twistlocks (B7204) or Sensor locked twistlocks (B7205) Hydraulic diagram top lift Hydraulic diagram top lift, tilt lock and controllable tilt Hydraulic diagram combi attachment Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic lev- elling Twistlocks, component position...
  • Page 192 7 Load handling – 7.9.1.7 Twistlocks 6 Check that the lock guide and lift pin can move freely. 7 Fit a pry bar between the lift pin (pos. 4) and the lock guide (pos. 5) and check the clearance max. clearance: 1–1.5 mm. 8 Turn the twistlocks to locked position and check lift pin wear.
  • Page 193 7 Load handling – 7.9.1.7 Twistlocks Twistlock, checking for cracks page – D AN GE R Material fatigue, reduced strength. Fatal danger! Change twistlocks that shows signs of cracks or other external damage, or twistlocks with more than 10 000 operating hours. NOTE Crack checks shall take place every other year or every 5000 operating hours.

  • Page 194: Lift Legs

    7 Load handling – 7.9.2 Lift legs 7.9.2 Lift legs Lift legs, general page – The lift legs are designed to lift objects at the lower edge by gripping around the object with four legs. To facilitate loading and transport the front and rear legs can be controlled separately.
  • Page 195 7 Load handling – 7.9.2 Lift legs Raising/lowering of front lift legs, function page – description Condition Reference value Control switch Not activated D791-1 D790-1 D791-4 D797-R D791-3 Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 196 7 Load handling – 7.9.2 Lift legs Switch lowering front legs (S1006) Solenoid valve front leg down left (Y6013L) or Sole- noid valve front leg down left (Y6060L) Control unit cab (D790-1) Hydraulic cylinder leg left front Control unit attachment right leg pair (D791-4) Sensor front leg left (B7219L) Control unit attachment left legs (D791-3) Solenoid valve front knee out right (Y6056R) ) or So-...
  • Page 197 7 Load handling – 7.9.2 Lift legs Raising/lowering of rear lift legs, function page – description Condition Reference value Control switch Not activated D790-1 D791-4 D797-R D791-3 Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 198 7 Load handling – 7.9.2 Lift legs Switch rear legs (S1007) Solenoid valve rear knee out right (Y6058R) or Sole- noid valve rear knee in right (Y6059R) Control unit cab (D790-1) Hydraulic cylinder knee right rear Control unit attachment right leg pair (D791-4) Sensor rear knee right (B7218R) Control unit attachment left legs (D791-3) Solenoid valve rear leg down right (Y6014R) or Sole-...
  • Page 199 7 Load handling – 7.9.2 Lift legs Clamp with left legs, function description page – Condition Reference value Control switch Not activated Lift legs Lowered 16 20 D790-1 D791-4 D797-R D791-3 15 19 Switch clamp/release legs (S1008) Hydraulic cylinder knee and clamp right front Control unit cab (D790-1) Hydraulic cylinder knee and clamp right rear Control unit attachment right leg pair (D791-4)
  • Page 200 7 Load handling – 7.9.2 Lift legs Control unit attachment left legs (D791-3) Sensor clamping position front leg right (B7215R) Control unit frame rear (D797-R) Sensor clamping position rear leg left (B7216L) Solenoid valve, engagement of hydraulics for top lift Sensor clamping position rear leg right (B7216R) (Y6003) Shuttle valve...
  • Page 201 7 Load handling – 7.9.2 Lift legs Control valve lift legs Sensor clamping position (B7215 or B7216) Solenoid valve operating position (Y6053) Sensor alignment (B7213 or B7214) Sensor operating position left (B7212L) or Sensor op- Hydraulic cylinder lift leg erating position right (B7212R) Sensor front leg (B7219) or Sensor rear lift leg Hydraulic cylinder knee and clamp (B7220)
  • Page 202 7 Load handling – 7.9.2.14 Lifting shoe 7.9.2.14 Lifting shoe Lift shoe, checking page – 1 Lower all lift legs. 2 Check that the plate for clamping position and pin for alignment move freely and spring back to the basic position. 3 Press in the alignment pin so that the head is flush with the spreader beam's underside and check that the indicator light is activated.
  • Page 203 7 Load handling – 7.9.2.14 Lifting shoe 6 Clean the area around the grease cup. 7 Grease the bearings for the plate for clamping position with uni- versal grease "EP2" 8 Repeat steps 2–7 on all lift legs. Lift shoe, checking for cracks page –...

  • Page 204: Additional Functions

    7 Load handling – 7.10 Additional functions 7.10 Additional functions 7.10.1 Support jacks Support jacks, function description page – Support jacks increase the stability forward and thus the load capac- ity in the third container row or track two for railway goods. The sup- port jacks are raised and lowered with hydraulic cylinders one cylinder per support jack.
  • Page 205 7 Load handling – 7.10.1 Support jacks Switch support jacks (S1013) Hydraulic oil pump 1 & 2 Control unit cab (D790-1) Valve block support jack cylinder Sensor support jacks up (B7222L and B7222R) or Hydraulic cylinder support jacks Sensor support jacks down (B7221L and B7221R) Control unit frame option (D797-O) Control unit KID (D795) Solenoid valve support jacks down (Y6064) or Sole-...

  • Page 206: Weight Indicator

    7 Load handling – 7.10.2 Weight indicator 7.10.2 Weight indicator Weight indicator, function description (product page – alternative fixed scale) The fixed scale makes it possible to weigh the load with boom and extension in a certain position. The weight indicator uses Sensor hydraulic pressure lift cylinder (B768-10 and B768-12) to calculate the load.
  • Page 207 1 Park the machine on level ground without load and centre the attachment. 2 Navigate to the service menu and press ENTER. 3 Enter code for calibration. Code is obtained from Kalmar Industries Support. 1 2 3 NOTE The code determines which service menu is activated (Di- agnostic test, Initiation or Calibration).
  • Page 208 7 Load handling – 7.10.2 Weight indicator 5 Move the boom to measuring position. A. Lift the boom so that the colour marking on the rod (pos A) disappears in the pipe. B. Lower the boom until the colour marking can be seen at the pipe end (pos B).
  • Page 209 7 Load handling – 7.10.2 Weight indicator Weight indicator, function description (product page – alternative dynamic scale) The weight indicator shows the weight of the lifted load. The dynam- ic scale shows the load, regardless of position of boom and exten- sion.
  • Page 210 1 Park the machine on level ground without load and centre the attachment. 2 Navigate to the service menu and press ENTER. 3 Enter code for calibration. Code is obtained from Kalmar Industries Support. 1 2 3 NOTE The code determines which service menu is activated (Di- agnostic test, Initiation or Calibration).
  • Page 211 7 Load handling – 7.10.2 Weight indicator 8 Scroll to CALIBR SCALE, menu 2 and save the setting with EN- CALIBR SCALE 2(7) TER. MAXIMUM BOOM ANGLE 9 Retract the boom completely. CALIBR VALUE X.XXV PRESENT VALUE X.XXV 10 Scroll to CALIBR SCALE, menu 3 and save the setting with EN- CALIBR SCALE 3(7) TER.
  • Page 212 7 Load handling – 7.10.2 Weight indicator 24 Operate the machine without load, stop the machine and check that PRESENT LOAD = 00000 ± 250 kg. NOTE Check when stationary. (Operating generates dynamic forces.) 25 Scroll back from the calibration with the R-key. Printer, description page –...

  • Page 213: Container Counter

    7 Load handling – 7.10.3 Container counter 7.10.3 Container counter Container counter, function description (product page – alternative top lift) The container counter counts the number of lifts performed with the machine. The counter has two separate counters that can be reset to zero separately.
  • Page 214 7 Load handling – 7.10.3 Container counter Container counter, function description (product page – alternative bottom lift) The container counter counts the number of lifts performed with the machine. The counter has two separate counters that can be reset to zero separately. The container counter counts lift when the clamping function is ac- tivated and lift is started, and release of clamping position is not ac- tivated within 10 seconds.

  • Page 215: Synchronous Lift

    7 Load handling – 7.10.4 Synchronous lift 7.10.4 Synchronous lift Synchronous lift, function description page – Synchronized lift means that lift and extension are activated at the same time so that the lift is completely vertical. Synchronized lift is activated by pressing in the pistol trigger on the control lever at the same time as lift is activated.
  • Page 216 7 Load handling – 7.10.4 Synchronous lift Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 217 8 Control system 8 Control system Table of Contents 8 Control system mm mm mm mm Control system..................3 Monitoring ....................6 8.2.1 Overloading system ................6 8.2.2 By-passing ................... 11 8.2.3 Load centre limitation ................. 11 8.2.4 Height limitation .................. 12 8.2.5 Speed limitation ..................
  • Page 218 8 Control system Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 219: Mm Mm Mm Mm

    8 Control system – 8 Control system 8 Control system mm mm mm mm Control system, general page – Many of the machines functions are controlled electrically. The sig- nals that control the machine are monitored to warn the operator or limit the machine's functions in certain dangerous situations or in case of machine malfunctions.
  • Page 220 8 Control system – 8 Control system Function keys The function keys (A) are used to navigate in the menu system. Also used to enter values in the system, change light contrast in keys/in- dicator panel and to confirm alarms. •...
  • Page 221 8 Control system – 8 Control system Event-controlled information Under certain conditions the control system draws the operator's at- tention to important information with figures on the display. Exam- ples of warnings is warning for overloading when the overloading system is activated. Warnings are described in connection with respective function.

  • Page 222: Monitoring

    8 Control system – 8.2 Monitoring Monitoring Monitoring functions, general page – The machine is equipped with a number of control functions to in- crease safety during load handling: • Overloading system • By-passing • Load-centre limitation • Height limitation •...
  • Page 223 8 Control system – 8.2.1 Overloading system The different overloading systems use different combinations of sensors. The number of sensors is also controlled by the option weight indicator, see section 7 Load handling, group 7.10.2 Weight indicator. Ana- Ana- B768 B768 B768 B768...
  • Page 224 8 Control system – 8.2.1.1 Mechanical overloading system 8.2.1.1 Mechanical overloading system Mechanical overloading system, function description page – This is the basic alternative for overloading system and it uses open- ing sensors to sense the load. The mechanical overloading system is activated when: •...
  • Page 225 8 Control system – 8.2.1.2 Mechanical overloading system with analogue sensors 8.2.1.2 Mechanical overloading system with analogue sensors Mechanical overloading system with analogue position page – sensors, function description This alternative for overloading system uses an opening sensor (on steering axle) to sense the load and also analogue sensors to sense boom length and angle.
  • Page 226 8 Control system – 8.2.1.3 Electrical overloading system 8.2.1.3 Electrical overloading system Electrical overloading system, function description page – This overloading system is a part of the control system and performs calculations of the load with sensor values for boom length, boom angle and cylinder pressure in the lift cylinders.

  • Page 227: By-Passing

    8 Control system – 8.2.2 By-passing 8.2.2 By-passing By-passing, description page – When the overloading system is activated and turns off the hydrau- lics it may be in a situation where it is necessary to by-pass the safe- ty system. By-pass is activated with a switch, there is one to three switches de- pending on the machine's equipment: •...

  • Page 228: Height Limitation

    1 Machine in service position, see section B Safety. 2 Navigate first to the service menu and press Enter. 3 Enter code for resetting service indicator. The code is obtained via Kalmar Industries Support. 1 2 3 NOTE The code determines which service menu shall be activat- ed (Service, Diagnostic test, Initiation or Calibration).

  • Page 229: Error Codes

    8 Control system – 8.3 Error codes Error codes Error codes, description page – When a malfunction occurs in the machine error messages (error codes) are generated by the control unit in question that is sending the error code via the CAN-bus to Control unit KID (D795) that shows the error codes on the display and stores the error codes.
  • Page 230 8 Control system – 8.3 Error codes • In the error code list under operating menu for service. Active error codes are stored in the error code list. Navigate to the operating menu for service. Display the error code list by pressing in function key Enter for two seconds.

  • Page 231: Diagnostics

    8 Control system – 8.4 Diagnostics Diagnostics Diagnostic test, general page – The machine has built-in functions for troubleshooting called diag- DIAGNOSIS nostic test. The diagnostic test consists of several menus that are CAN/POWER LIGHTS CAB shown on the display. The menus are grouped for faster access. CLIMATE HYD ENGINE The following pages contain compilations of diagnostic menus.
  • Page 232 To select diagnostic test, proceed as follows: 1 Navigate to the service menu. 2 Press Enter. 3 Enter code for diagnostic test. Code is obtained from Kalmar Industries Support. 1 2 3 NOTE The code determines which service menu is activated (Di- agnostic test, Initiation or Calibration).
  • Page 233 8 Control system – 8.4 Diagnostics 4 Select group by scrolling with the arrow keys (1 and 2) and con- DIAGNOSIS firm with Enter. CAN/POWER LIGHTS CAB Each group consists of a sequence of numbered menus. The CLIMATE HYD ENGINE first menu for selected diagnostic menu is shown on the dis- TRANSM BOOM ATTACH play, use arrow keys (1 and 2) to change menu.

  • Page 234: Can/Power

    8 Control system – 8.4.1 CAN/POWER 8.4.1 CAN/POWER CAN/POWER, menu overview page – DIAGNOSIS CAN/POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH OP EXTRA HIST DIAG CAN/POWER 1(20) DIAG CAN/POWER 2(20) DIAG CAN/POWER 3(20) PRESENT REDCAN STATUS PRESENT REDCAN STATUS PRESENT DRIVE-TRAIN COMMUNICATION MODE RED.CON.CITIES...

  • Page 235: Lights

    8 Control system – 8.4.2 LIGHTS 8.4.2 LIGHTS LIGHTS, menu overview page – DIAGNOSIS CAN/POWER LIGHTS CLIMATE HYD ENGINE TRANSM BOOM ATTACH OP EXTRA HIST DIAG LIGHTS 1(13) DIAG LIGHTS 2(13) DIAG LIGHTS 3(13) WORKING LIGHT CAB WORKING LIGHT ATTACH WORKING LIGHT BOOM SWITCH SWITCH...

  • Page 236: Cab

    8 Control system – 8.4.3 CAB 8.4.3 CAB, menu overview page – DIAGNOSIS CAN/POWER LIGHTS CLIMATE HYD ENGINE TRANSM BOOM ATTACH OP EXTRA HIST DIAG CAB 1(10) DIAG CAB 2(10) DIAG CAB 3(10) WASHER FRONT WIPER REAR WIPER SWITCH SWITCH (1-3) SWITCH OUTPUT OUTPUT...

  • Page 237: Climate

    8 Control system – 8.4.4 CLIMATE 8.4.4 CLIMATE CLIMATE, menu overview page – DIAGNOSIS CAN/POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH OP EXTRA HIST DIAG CLIMATE 1(8) DIAG CLIMATE 2(8) DIAG CLIMATE 3(8) PRESENT INPUT SIGNAL TEMP COIL PRESENT INPUT SIGNAL REQUIRED TEMP...

  • Page 238: Engine

    8 Control system – 8.4.6 ENGINE 8.4.6 ENGINE ENGINE, menu overview page – DIAGNOSIS CAN/POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH OP EXTRA HIST DIAG ENGINE 1(10) DIAG ENGINE 2(10) DIAG ENGINE 3(10) PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL ACCELERATOR X.XXV...

  • Page 239: Transm

    8 Control system – 8.4.7 TRANSM 8.4.7 TRANSM TRANSM, menu overview page – DIAGNOSIS CAN/POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH OP EXTRA HIST DIAG TRANSM. 1(15) DIAG TRANSM. 2(15) DIAG TRANSM. 3(15) PRESENT INPUT SIGNAL SWITCHES PRESENT VALUE BRAKE PEDAL X.XXV FORWARD...

  • Page 240: Boom

    8 Control system – 8.4.8 BOOM 8.4.8 BOOM BOOM, menu overview page – DIAGNOSIS CAN/POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH OP EXTRA HIST DIAG BOOM 1(8) DIAG BOOM 2(8) DIAG BOOM 3(8) PRESENT INPUT SIGNALS BLOCK VALVES BOOM HIGH SPEED BOOM UP/DOWN XX.XXV...

  • Page 241: Attach

    8 Control system – 8.4.9 ATTACH 8.4.9 ATTACH ATTACH, menu overview page – DIAGNOSIS CAN/POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH OP EXTRA HIST DIAG ATTACHMENT 2(21) DIAG ATTACHMENT 3(21) DIAG ATTACHMENT 1(21) PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS ROT CW/CCW XX.XXV...
  • Page 242 8 Control system – 8.4.10 OP 8.4.10 OP, menu overview page – DIAGNOSIS CAN/POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH EXTRA HIST DIAG OP 1(5) DIAG OP 2(5) DIAG OP 3(5) PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL STEERING AXLE LIFT CYL BOOM ANGLE...

  • Page 243: Extra

    8 Control system – 8.4.11 EXTRA 8.4.11 EXTRA 8.4.11.1 COMBI COMBI, menu overview page – DIAGNOSIS CAN/POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH EXTRA HIST DIAGNOSIS EXTRA COMBI SLIDING-CAB SUPPORT-JACKS EL-STEERING DIAG COMBI 1(17) DIAG COMBI 2(17) DIAG COMBI 3(17) SWITCHES PRESENT INPUT SIGNAL...
  • Page 244 8 Control system – 8.4.11.2 SLIDING-CAB 8.4.11.2 SLIDING-CAB SLIDING-CAB, menu overview page – DIAGNOSIS CAN/POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH EXTRA HIST DIAGNOSIS EXTRA COMBI SLIDING-CAB SUPPORT-JACKS EL-STEERING DIAG SLID-CAB 1(4) DIAG SLID-CAB 2(4) DIAG SLID-CAB 3(4) SWITCHES PRESENT INPUT SIGNAL OUTPUT FORWARD...
  • Page 245 8 Control system – 8.4.11.3 SUPPORT-JACKS 8.4.11.3 SUPPORT-JACKS SUPPORT-JACKS, menu overview page – DIAGNOSIS CAN/POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH EXTRA HIST DIAGNOSIS EXTRA COMBI SLIDING-CAB SUPPORT-JACKS EL-STEERING DIAG S-JACKS 1(4) DIAG S-JACKS 2(4) DIAG S-JACKS 3(4) SWITCHES PRESENT INPUT SIGNALS OUTPUT VALVE...
  • Page 246 8 Control system – 8.4.11.4 EL-STEERING 8.4.11.4 EL-STEERING EL-STEERING, menu overview page – DIAGNOSIS CAN/POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM BOOM ATTACH EXTRA HIST DIAGNOSIS EXTRA COMBI SLIDING-CAB SUPPORT-JACKS EL-STEERING DIAG STEERING 1(5) DIAG STEERING 2(5) DIAG STEERING 3(5) PRESENT INPUT SIGNAL SWITCHES PRESENT INPUT SIGNAL...

  • Page 247: Setup

    8 Control system – 8.5 Setup Setup Settings, general page – Settings are the possibilities to adapt the functions' features to each unique machine. Settings are performed via menus on the display. The settings are split up as Initiation and Calibration Initiation is performed before the machine is used for work.
  • Page 248 8 Control system – 8.5 Setup Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 249 9 Frame, body, cab and accessories 9 Frame, body, cab and accessories Table of Contents 9 Frame, body, cab and accessories mm mm mm mm Frame, body, cab and accessories ............3 Controls and instrumentation ..............4 Protection and emergency equipment ............ 10 Seat ......................
  • Page 250 9 Frame, body, cab and accessories Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 251: Mm Mm Mm Mm

    9 Frame, body, cab and accessories – 9 Frame, body, cab and accessories 9 Frame, body, cab and mm mm mm mm accessories Frame, body, cab and accessories, page – description The machine consists of frame, body and cab. The frame (chassis) is the machine's structural part and is made of high strength steel.

  • Page 252: Controls And Instrumentation

    9 Frame, body, cab and accessories – 9.1 Controls and instrumentation Controls and instrumentation Controls and instruments, overview page – Overview 1 Left instrument panel 2 Gear and multi-function lever (S162) 3 Steering wheel panel 4 Steering wheel 5 Switch direction indicators (S161) 6 Panel for load handling functions 7 Switch control breaker (S250) 8 Switch parking brake (S107)
  • Page 253 9 Frame, body, cab and accessories – 9.1 Controls and instrumentation Left instrument panel 16 Switch fan (S118) 17 Switch temperature (S139) 18 Switch air distribution (S117) 29 30 31 19 Switch work lights cab roof (S105-1) 24..28 20 Switch work lights attachment (S105-2) 19..23 21 Switch work lights boom (S105-3) 22 Switch rotating beacon (S110)
  • Page 254 9 Frame, body, cab and accessories – 9.1 Controls and instrumentation Steering wheel panel 34 Warning light low battery charging 35 Warning light low brake pressure 36 Indicator active error codes 37 Warning light by-pass of hydraulic functions 38 Indicator light activated steering with joystick or mini-wheel 37..41 39 Warning light high coolant temperature 40 Warning light low oil pressure in engine...
  • Page 255 9 Frame, body, cab and accessories – 9.1 Controls and instrumentation Panel for load handling functions 67 Switch lowering front legs (S1006) 67 68 69 70 68 Switch lowering rear legs (S1007) 69 Switch by-pass rotation stop (S1014) 71..74 Switch by-pass height limitation (S1015) Switch by-pass LC-limitation (load-centre) (S1015) 70 Spare 71 Switch lock twistlocks (S1003)
  • Page 256 9 Frame, body, cab and accessories – 9.1 Controls and instrumentation Operating menus, overview Operating menu engine and transmission Operating menu printer Operating menu dynamic scale Operating menu checking dynamic scale Operating menu engine Operating menu service Operating menu transmission and hydraulics Operating menu heating and air conditioning Operating menu electrical system Operating menu statistics, operating hours...
  • Page 257 9 Frame, body, cab and accessories – 9.1 Controls and instrumentation Event menus, overview Event menu start interlock Event menu support jacks Event menu overload forward Event menu height limitation Event menu overload on steering axle Event menu fixed scale Event menu overload on steering axle Event menu open door Event menu alignment top lift...

  • Page 258: Protection And Emergency Equipment

    Adapted fire fighting equipment is available for order from Kalmar Industries. Seat belt For a cab with cab lift and lower, there is always a seat belt as well as safety chains by the doors.

  • Page 259: Seat

    9 Frame, body, cab and accessories – 9.3 Seat Seat Seats, description page – The seat's function is to give the operator a good sitting position and contribute to a good work environment. The cab's seat has several adjustment possibilities and meets high comfort standards. For ad- justment possibilities, see Operator's manual DRF 400–450.

  • Page 260: Hvac

    9 Frame, body, cab and accessories – 9.4 HVAC HVAC Heating and ventilation system, function page – description (product alternative EHC) The heating and ventilation system (EHC) handles heating and venti- lation. (The heating and ventilation system cannot perform cooling.) The temperature in the cab is thermostat-controlled by control unit, cab (D790-1).
  • Page 261 9 Frame, body, cab and accessories – 9.4 HVAC Sensor cab temperature (B775-1) Actuator recirculation (M612) Sensor temperature outlet fan (B775-2) Fan motor heat (M657) Sensor outdoor temperature (B774) Damper motor (Y672) Sensor engine temperature Switch defroster on Control unit KIT (D790-2) Control unit cab (D790-1) Operating menu on Control unit KID (D795) Sensor temperature in refrigerant circuit (B775-3)
  • Page 262 9 Frame, body, cab and accessories – 9.4 HVAC ˚C ˚C D790-1 D790-2 D795 D797-R D794 ˚C ˚C ˚C Switch temperature (S139) Fan motor heat (M657) Switch fan (S118) Damper motor (Y672) Switch air distribution (S117) Control unit frame rear (D797-R) Sensor cab temperature (B775-1) Magnet clutch (M645) Sensor temperature outlet fan (B775-2)
  • Page 263 9 Frame, body, cab and accessories – 9.4 HVAC Heating, ventilation and air conditioning, page – component position Operating menu on Control unit KID (D795) Expansion valve Switch defroster on Control unit KIT (D790-2) Cab fan (M657) Sensor outdoor temperature (B774) Fresh air and recirculation damper (M612) Control unit cab (D790-1) Fresh air filter...
  • Page 264 9 Frame, body, cab and accessories – 9.4 HVAC Condenser Humidity filter Water valve (Y673) Compressor Pressure monitor (S246) Magnet clutch (M645) Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 265: Fresh Air Filter

    9 Frame, body, cab and accessories – 9.4.1 Fresh air filter Pause heater, description page – Pause heater is an option for the heating system that uses the sur- plus heat in the engine's cooling system to keep the cab warm. An extra electrically driven water pump pumps the coolant through the heating system when the engine is off.

  • Page 266: Condenser

    9 Frame, body, cab and accessories – 9.4.8 Condenser 9.4.8 Condenser Condenser, cleaning page – 1 Machine in service position, see section B Safety. 2 Blow the condenser cooler clean using compressed air. 1. Cooler 2. Condenser 9.4.9 Humidity filter Humidity filter, checking page –...
  • Page 267 9 Frame, body, cab and accessories – 9.4.9 Humidity filter Humidity filter, changing page – W AR N IN G Personal injury, environmental damage Read the safety instructions for refrigerant, see sec- tion B Safety. 1 Machine in service position, see section B Safety. 2 Drain the air conditioning of refrigerant R134a, with the intend- ed draining equipment.

  • Page 268: Wiper/Washer System

    9 Frame, body, cab and accessories – 9.5 Wiper/washer system Wiper/washer system Wiping/cleaning of windows, description page – On the cab, there are wipers for front and rear windshields as well as the roof windows. Its function is to clean the windows and to maintain good visibility from the cab.

  • Page 269: Lighting System

    9 Frame, body, cab and accessories – 9.6 Lighting system Lighting system Lighting system, description page – The function of the lighting is to increase safety during operation and load handling. The following lighting is fitted to the machine: 1, 2, 3, 4, 6 7, 10 3, 4, 5 12 7, 11...

  • Page 270: Communication Systems

    9 Frame, body, cab and accessories – 9.7 Communication systems Communication systems Communication systems, description page – The function of the signals is to increase safety during operation and load handling. This can be via light and sound. The following signal systems are fitted to the machine: 3, 6 5, 6...

  • Page 271: Entertainment And Communication

    9 Frame, body, cab and accessories – 9.8 Entertainment and communication Entertainment and communication Entertainment and communication, general page – For information and description of equipment, see supplier's docu- mentation for respective product. Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 272: Glass/Windows/Mirrors

    9 Frame, body, cab and accessories – 9.9 Glass/windows/mirrors Glass/windows/mirrors Glass/windows/mirrors, component position page – The function of the glass panes is to enclose the cab and to give the operator good visibility, the panes are tinted ( The rear-view mirrors are of the type convex mirror. External rear- view mirrors are located on the chassis and the internal rear-view mirror is located in the cab.

  • Page 273: Cab Structure And Suspension

    9 Frame, body, cab and accessories – 9.10 Cab structure and suspension 9.10 Cab structure and suspension Cab structure and suspension, description page – The cab has a level floor with a bracket for the operator's seat. It is suspended in a cab undercarriage via heavy-duty rubber pads locat- ed on the bottom of the cab.
  • Page 274 9 Frame, body, cab and accessories – 9.10.4 Longitudinal displacement of cab W AR N IN G It is important that the lock catches are intact! They should be checked regularly. However, it is not in- cluded as part of the service schedule in preventive maintenance! Hydraulic sliding cab, function description page...
  • Page 275 9 Frame, body, cab and accessories – 9.10.4 Longitudinal displacement of cab D790-1 D797-O Switch (S197) Shuttle valve Contact closed door (one sensor for each door) Main pumps Control unit cab (D790-1) Valve block cab movement (sliding cab) Control unit frame option (D797-O) Hydraulic motor cab movement (sliding cab) Servo valve sliding cab forward and servo valve slid- Sensor end-position (B769-2)

  • Page 276: Vertically Adjustable Cab

    9 Frame, body, cab and accessories – 9.10.5 Vertically adjustable cab Hydraulic cab movement (sliding cab), component page – position 1. Sensor damping (trailing edge of cab on left side) 2. Indicator plate damping 3. Chain sliding cab 4. Hydraulic motor sliding cab 5.
  • Page 277 9 Frame, body, cab and accessories – 9.10.5 Vertically adjustable cab Condition Reference value Parking brake Applied Doors Closed If the door is open with raised cab then lifting and lowering of the boom is lim- ited. D790-1 D797-O Switch cab lift and lowering (S) Main pumps Contact closed door (one sensor for each door) Accumulator...
  • Page 278 9 Frame, body, cab and accessories – 9.10.5 Vertically adjustable cab Cab lift and lowering, component position page – 1. Load signal (LS) 2. Pressure supply (P) 3. Tank return (T1) 4. Connection hydraulic motor (B) 1. Sensor cab end-position lowered cab (B777-2) 2.

  • Page 279: Cab Interior

    9 Frame, body, cab and accessories – 9.11 Cab interior 9.11 Cab interior Cab interior, description page – The cab is designed for optimal operator comfort. Switches, con- trols, warning and indicator lights are grouped on the instrument panels to give the operator a good operating environment. Recyclable materials are used for all parts.

  • Page 280: Frame

    9 Frame, body, cab and accessories – 9.12 Frame 9.12 Frame Chassis, description page – The function of the chassis is to be the structural part for the ma- chine's components. Frame's front part with drive axle mounting Cab mounts (4 points) Steering axle mounting Frame's rear part with counterweights Boom mounting...

  • Page 281: Body

    9 Frame, body, cab and accessories – 9.13 Body 9.13 Body Body, description page – The body's function is a part of the chassis. There are fenders to de- flect dirt, footsteps and handrail to facilitate access on the chassis, hood to deflect dirt and objects from the engine compartment as well as a counterweight to balance the machine's lifting capacity.

  • Page 282: Central Lubrication

    9 Frame, body, cab and accessories – 9.14 Central lubrication 9.14 Central lubrication Central lubrication, description page – Central lubrication automatically lubricates the machine's grease points during operation according to scheduled intervals and replac- es the greasing work during preventive maintenance. The machine has two separate central lubrication systems, one for the machine and one for the attachment.

  • Page 283: Paint/Coatings

    9 Frame, body, cab and accessories – 9.15 Paint/coatings 9.15 Paint/coatings Paint/coatings, description page – Single layer paint, thickness 120 my. For paint code of current ma- chine (RAL), see machine card. Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 284 9 Frame, body, cab and accessories – 9.15 Paint/coatings Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 285 10 Common hydraulics 10 Common hydraulics Table of Contents 10 Common hydraulics mm mm mm mm Common hydraulics ................. 3 10.2 Security valves ................... 5 10.3 Tanks and accumulators ................6 10.4 Pumps ......................7 10.4.2 Axial piston pump with variable displacement ........8 10.5 Hoses, pipes and valves ................
  • Page 286 10 Common hydraulics Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 287: Mm Mm Mm Mm

    10 Common hydraulics – 10 Common hydraulics 10 Common hydraulics mm mm mm mm Common hydraulics, description page – Under the function common hydraulics there are hydraulic functions that are common for several of the machine's main functions. For example, the hydraulic oil pumps that supply load handling, steering and certain cab functions with hydraulic pressure.
  • Page 288 10 Common hydraulics – 10 Common hydraulics Pressure plate On the machine there is a pressure plate which is stamped with the most important pressure information. The pressure plate is located on the left side of the frame in front of the cab steps. The pressure levels vary with the equipment and are therefore unique for each machine.

  • Page 289: Security Valves

    10 Common hydraulics – 10.2 Security valves 10.2 Security valves Security valves, component position page – 1. Relief valve attachment (illustration shows closed valve) 2. Accumulator drain valve Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 290: Tanks And Accumulators

    10 Common hydraulics – 10.3 Tanks and accumulators 10.3 Tanks and accumulators Tanks and accumulators, component position page – Tank 1. Filler plug hydraulic oil 2. Cap for hydraulic oil filter 3. Level glass hydraulic oil 4. Breather filter hydraulic oil tank 5.

  • Page 291: Pumps

    10 Common hydraulics – 10.4 Pumps 10.4 Pumps Pumps, general page – The machine's hydraulics are supplied from six pumps. Four of them for the working hydraulics, one for cooling and filtering of the hy- draulic oil and one for the brake system. The pumps are assembled to 2 pump banks.

  • Page 292: Axial Piston Pump With Variable Displacement

    10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement 10.4.2 Axial piston pump with variable displacement Axial piston pump with variable displacement, page – function description D790-1 D797-R No 1 No 2 No 3 No 4 Control valve lift and extension Hydraulic oil pump 1 Shuttle valve Control unit frame rear (D797-R)
  • Page 293 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement Hydraulic oil pump, checking page – W AR N IN G Hot and pressurized oil. Personal injury, burn injury, rash or irritation. Always depressurize the hydraulic systems before starting to work in the hydraulic systems. Avoid skin contact with the oil, use protective gloves.
  • Page 294 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement 7 Check max. pressure on hydraulic oil pump 1, the pressure should match the value on the pressure plate. All pumps should give the same pressure. The order in which the pumps are tested is not of any importance.

  • Page 295: Hoses, Pipes And Valves

    10 Common hydraulics – 10.5 Hoses, pipes and valves 10.5 Hoses, pipes and valves Hoses, pipes and valves, component position page – Shuttle valve attachment Collecting block unfiltered returns Shuttle valve steering Collecting block filtered returns Priority valve Shuttle valve joystick steering or mini-wheel Shuttle valve option frame Maintenance manual DRF 400–450 UDRF01.04GB...

  • Page 296: Temperature Control, Cleaning And Hydraulic Oil

    10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil 10.6 Temperature control, cleaning and hydraulic oil Temperature control, cleaning and hydraulic page – oil, function description The hydraulic system's oil is cooled and cleaned by a separate pump circulating the oil through cooler and filter.
  • Page 297 10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil Temperature control, cleaning and hydraulic page – oil, component position Cooling fan and cooler hydraulic oil Breather filter hydraulic oil tank Hydraulic oil filter Tank heater Fine filter hydraulic oil Sensor hydraulic oil temperature (B776) Hydraulic oil filter (high pressure filter) Maintenance manual DRF 400–450...
  • Page 298 10 Common hydraulics – 10.6.6 Breather filter hydraulic oil tank 10.6.6 Breather filter hydraulic oil tank Breather filter hydraulic oil tank, changing page – 1 Turn off the engine and the main electrical power. 2 Clean the area around the filter housing. 3 Remove the filter housing.

  • Page 299: 5. Breather Filter, Hydraulic Oil Tank

    10 Common hydraulics – 10.6.7 Hydraulic oil filter 3 Remove the cover plates (position 1) over the hydraulic oil fil- ters. 4 Have a receptacle ready to collect any oil spills. 5 Lift up the filter unit and place it in the receptacle. Let the hy- draulic oil drain.

  • Page 300: Hydraulic Oil Filter

    10 Common hydraulics – 10.6.7 Hydraulic oil filter Hydraulic oil filter (high pressure filter), changing page – W AR N IN G Hot and pressurized oil. Personal injury, burn injury, rash or irritation. Always depressurize the hydraulic systems before starting to work in the hydraulic systems. Avoid skin contact with the oil, use protective gloves.

  • Page 301: Hydraulic Oil

    10 Common hydraulics – 10.6.8 Hydraulic oil 15 Remove the receptacle, handle filters and oil as environmental- ly hazardous waste. 16 Check the oil level in the hydraulic oil tank. The oil level should be at the top of the level glass. Top up if needed. NOTE The hydraulic oil level is checked with the boom complete- ly lowered and retracted.

  • Page 302: Hydraulic Oil Fine-Filter

    10 Common hydraulics – 10.6.9 Hydraulic oil fine-filter 10.6.9 Hydraulic oil fine-filter Fine filter hydraulic oil, changing page – W AR N IN G Hot and pressurized oil. Personal injury, burn injury, rash or irritation. Always depressurize the hydraulic systems before starting to work in the hydraulic systems.
  • Page 303 11 Common electrics 11 Common electrics Table of Contents 11 Common electrics mm mm mm mm Common electrics ..................3 11.2 Electric protection ..................4 11.2.2 Fuses ..................... 5 11.3 Batteries ..................... 8 11.3.1 Start battery ..................8 11.4 Alternator ....................9 11.5 Distribution of electricity .................
  • Page 304 11 Common electrics Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 305: Mm Mm Mm Mm

    11 Common electrics – 11 Common electrics 11 Common electrics mm mm mm mm Common electrics, general page – Under the function common electrics one finds electrical functions that are common to several of the machine's main functions. For ex- ample, voltage feed and CAN-bus.

  • Page 306: Electric Protection

    11 Common electrics – 11.2 Electric protection 11.2 Electric protection Electric protection, component position page – 1. Main fuse, boom top 2. Control breaker 3. Circuit fuses, electrical distribution box cab 4. Main fuses, boom attachment 5. Main fuses, electrical distribution box frame 6.

  • Page 307: Fuses

    11 Common electrics – 11.2.2 Fuses 11.2.2 Fuses Fuses, description page – I MP O RTAN T Risk of cable damage and fire in cable harnesses! Always use fuses with the correct ampere rating. The electrical system has three main circuits (30, 15 and 15E volt- age), see Distribution of electricity, description page 10.
  • Page 308 By the fuse holders there are fuse plates with information about fused function and fuse rating. Circuit fuses electrical distribution box cab A42174.0200 ENGINE ENGINE TRANSMISSION KDU,FRONT (KALMAR DISTRIBUTION UNIT) ENGINE,ECC KDU,REAR (KALMAR DISTRIBUTION UNIT) KDU,OPT (KALMAR DISTRIBUTION UNIT) TRANSMISSION ENGINE ATTACHMENT...
  • Page 309 11 Common electrics – 11.2.2 Fuses Fuses, changing page – I MP O RTAN T Risk of cable damage and fire in cable harnesses! Always use fuses with the correct ampere rating. 1 Turn off the main electric power (battery disconnector). 2 Remove the cover from the fuse holder.

  • Page 310: Batteries

    11 Common electrics – 11.3 Batteries 11.3 Batteries 11.3.1 Start battery Start battery, checking page – W AR N IN G Battery electrolyte contains corrosive sulphuric ac- Risk of corrosive injuries, health hazard! Electrolyte on skin should be removed immediately. Wash with soap and plenty of water.

  • Page 311: Alternator

    11 Common electrics – 11.4 Alternator 11.4 Alternator Alternator, component position page – Alternator, changing page – See supplier documentation engine. Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 312: Distribution Of Electricity

    11 Common electrics – 11.5 Distribution of electricity 11.5 Distribution of electricity Distribution of electricity, description page – This section describes the distribution of electric power and commu- nication between the control units. The distribution of electric pow- er describes the basics of the electrical system and the network of control units.
  • Page 313 11 Common electrics – 11.5.1.1 Battery voltage (30) Control unit cab (D790-1) establishes of redundant CAN-bus. KDU Attachment (option) See Redundant CAN-bus, description page 16. Control unit cab (D790-1) activates ignition voltage (15). See Ig- KDU Attachment nition voltage (15), description page 13. D790-1 D790-2 D795...
  • Page 314 11 Common electrics – 11.5.1.2 Redundant voltage feed of control units 11.5.1.2 Redundant voltage feed of control units Redundant voltage feed of control units, description page – The redundant voltage feed only supplies the control units' control logic and buses, and is completely controlled by Control unit cab D791-2 (D790-1).
  • Page 315 11 Common electrics – 11.5.1.3 Ignition voltage (15) 11.5.1.3 Ignition voltage (15) Ignition voltage (15), description page – The ignition voltage feeds the power electronics. The ignition voltage is activated by: Startup • Start key in position I • Flashing hazard lights (Hazard) activated D790-1 When ignition voltage is activated the following takes place.
  • Page 316 11 Common electrics – 11.5.1.4 Manoeuvre switch voltage 11.5.1.4 Manoeuvre switch voltage Manoeuvre switch voltage (15E), description page – The manoeuvre switch voltage supplies functions which require a control switch, e.g. working hydraulics. The control breaker is activated with Switch control breaker. D790-1 Condition to activate control breaker voltage is that Switch control breaker is not pressed in.

  • Page 317: Control Units

    11 Common electrics – 11.5.3 Control units 11.5.3 Control units Control units, general page – The control units are allotted responsibility for parts of functions. Therefore, a certain function cannot be connected to a special con- trol unit, instead it is created in cooperation between control units, sensors, valves, etc.

  • Page 318: Communication

    11 Common electrics – 11.6 Communication 11.6 Communication Communication, general page – The machine’s communication is handled by a so-called CAN-bus system. The CAN-bus system consists of control units connected to form a network. D791-2 The idea with a network is to share information. Signal values are sent out by the control unit that, e.g., is connected to a sensor, other D791 controls units can use the signal for their functions.
  • Page 319 D Error codes D Error codes Table of Contents D Error codes mm mm mm mm Error codes ....................3 Error codes, explanation ..................3 Reading out error code ..................4 Engine....................... 6 Error codes engine alternative Volvo ..............6 Error codes engine alternative Cummins ............
  • Page 320 D Error codes Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 321: Mm Mm Mm Mm

    D Error codes – Error codes Error codes mm mm mm mm Error codes, explanation page – The error codes are explained in table form for Engine, Transmission as well as Control system. They are sorted according to error code number.

  • Page 322: Reading Out Error Code

    D Error codes – Error codes Reading out error code page – NOTE In case of an error code, perform the recommended actions ac- cording to the error code table to find the problem. Error codes are stored as active or inactive. Active errors are shown in the error code menu.
  • Page 323 D Error codes – Error codes 5 Note error code number (field C) to not forget. • Error code level is shown with a symbol in field B • Error code is shown in field C • Error cause is shown with a symbol in field D •...

  • Page 324: Engine

    D Error codes – 1 Engine 1 Engine mm mm mm mm Error codes engine alternative page – Volvo Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 91/3 23 DTC Throttle Engine goes Check that the control's D794/...
  • Page 325 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 97/3 Water in No limita- Drain water trap. 1.2.3 Fuel pre- DTC - fuel or tion. filter Clean metal filter in feed clogged line's hose connection on...
  • Page 326 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 102/3 67 DTC Sensor Engine Check cabling between D794/ ENGINE, 1.6.5 Sensor boost smokes control unit and compo- Black:3 menu 7 boost pressure...
  • Page 327 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 105/4 26 DTC Sensor No limita- Check cabling between D794/ ENGINE, 1.6.6 Sensor charge-air tion. control unit and compo- Black:2 menu 7 charge-air...
  • Page 328 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 1485/ 43 DTC Main relay, Instrument Check that cables to relay 11.5.3 Power cable panel loses aren't damaged. supply short- voltage...
  • Page 329 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 620/3 63 DTC Voltage Several error Check connection 5 in the D794/ 1.6.5 Sensor feed to codes for de- black connector on the en- Black:5 boost pressure...
  • Page 330 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 626/5 74 DTC Preheat- Preheating Check cabling between D794/ ENGINE, 1.10.1 Pre- ing relay cannot be control unit and compo- Red:36 menu 5 heating...
  • Page 331 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 630/ - DTC - Electric Reduced en- Troubleshoot engine with malfunc- gine power. supplier's troubleshooting tion en- tools gine.
  • Page 332 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 637/3 18 DTC Sensor en- Engine is ex- Check that sensor is in- D794/ 1.9.2. Sensor gine rpm, tremely diffi- stalled correctly and con- Black:30,...
  • Page 333 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 639/2 Communi- Engine off: Check that the 8-pin con- D794/ CAN/ 1.6.3 CAN-bus DTC 6.5 cation er- engine can- nector isn't damaged.
  • Page 334 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 651/4 Electric Engine runs Check cabling between D794/ 1.2.8 Injectors DTC 7.1 malfunc- on 5 cylin- control unit and compo- Black:11, tion, injec- ders, sounds...
  • Page 335 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 652/4 Electric Engine runs Check cabling between D794/ 1.2.8 Injectors DTC 7.2 malfunc- on 5 cylin- control unit and compo- Black:22, tion, injec- ders, sounds...
  • Page 336 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 653/4 Electric Engine runs Check cabling between D794/ 1.2.8 Injectors DTC 7.3 malfunc- on 5 cylin- control unit and compo- Black:23, tion, injec- ders, sounds...
  • Page 337 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 654/4 Electric Engine runs Check cabling between D794/ 1.2.8 Injectors DTC 7.4 malfunc- on 5 cylin- control unit and compo- Black:34, tion, injec- ders, sounds...
  • Page 338 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 655/4 Electric Engine runs Check cabling between D794/ 1.2.8 Injectors DTC 7.5 malfunc- on 5 cylin- control unit and compo- Black:35, tion, injec- ders, sounds...
  • Page 339 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 656/4 Electric Engine runs Check cabling between D794/ 1.2.8 Injectors DTC 7.6 malfunc- on 5 cylin- control unit and compo- Black:36, tion, injec- ders, sounds...
  • Page 340 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Volvo ponent code 677/5 Starter Engine Check that cable to starter 1.11.1 Starter DTC 4.6 motor re- doesn't motor (yellow/black) is con- motor lay, open start.
  • Page 341 D Error codes – 1 Engine Error codes engine alternative page – Cummins Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 84/10 Electric mal- Engine rpm re- Check cabling between 1.9 Control function sen- stricted to max...
  • Page 342 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 91/8 Electric mal- Engine doesn't Check cabling between 1.1.2 Throt- function throt- respond to Control unit and compo- tle pedal tle pedal, throttle appli-...
  • Page 343 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 100/2 Sensor oil No warning for Check sensor oil pressure D794/ 1.8.3 Sensor pressure, data low oil pres- engine.
  • Page 344 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 105/0 Warm inlet air Engine power Check coolant level in the 1.6 Air inlet is reduced suc- engine, top up if needed.
  • Page 345 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 110/0 High coolant Engine power Check coolant level. 1.7 Cooling temperature. is reduced suc- GINE, system Check that radiator is cessively, en- menu 7...
  • Page 346 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 166/2 Power imbal- Rough idling. Check fuel quality. If the 1.2 Fuel sys- ance between fuel system has been tem, 1.5 En- cylinders.
  • Page 347 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 168/ Voltage feed Rough idling. Check fuses. Check batter- D794/ 11.5.1.3 Igni- to control unit ies and alternator. OEM:7, tion voltage low.
  • Page 348 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 190/2 Electric mal- Engine stops Check cabling between D794/ 1.9 Control function rpm/ and cannot be Control unit and compo- Sen- system en-...
  • Page 349 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 620/3 Electric mal- Reduced en- Check cabling between D794/ 1.7.8 Make- function refer- gine power. No Control unit and compo- Sen- contact cool-...
  • Page 350 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 630/2 Software er- Reduced en- Reprogram software in 11.5.3.10 ror control gine power, Control unit engine (D794). Control unit unit engine engine difficult...
  • Page 351 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 644/2 Electric mal- Engine is shut Check cabling between 1.1.2 Throt- function throt- off. Control unit and compo- tle pedal tle pedal, nent.
  • Page 352 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 653/6 Electric mal- Engine runs on Check cabling between D794/ 1.2.8 Injec- function injec- 5 cylinders, Control unit and compo- Actua- tors...
  • Page 353 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 702/3 Electric mal- No limitation. Check cabling between 1.9 Control function extra Control unit and compo- system en- input / output nent.
  • Page 354 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 1043/ Electric mal- Engine only Check cabling between 1.1.2 Throt- function throt- runs at idle. Control unit and compo- tle pedal tle pedal nent.
  • Page 355 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 1084/ Electric mal- No protection Check cabling between 1.9 Control function extra for pressure Control unit and compo- system en- sensor pres- (customer-spe-...
  • Page 356 D Error codes – 1 Engine Descrip- Limitation Action Con- Diag- Function tion nec- nostic group tion menu com- Code Cum- mins nent code 1381/ Electric mal- Check cabling between 1.2.7 Sensor function fuel Control unit and compo- fuel pressure pressure, ca- nent.

  • Page 357: Transmission

    Action nostic group menu Code compo- nent code 00.50 00.50 Memory error in Transmission in Contact Kalmar In- 11.5.3.9 Con- control unit locked neutral po- dustries AB for trol unit trans- transmission. sition (Shut-down more information mission mode). 00.51 00.51...
  • Page 358 D Error codes – 2 Transmission Con- nec- Diag- tion Function Description Limitation Action nostic group menu Code compo- nent code 20.62 20.62 Electric mal- Control unit acti- Performs checks D793/A:2 TRANSM 2.6.2 Sensor function sensor vates, Limp-home acc. to error code - B253 , menu oil pressure...
  • Page 359 D Error codes – 2 Transmission Con- nec- Diag- tion Function Description Limitation Action nostic group menu Code compo- nent code 41.06 41.06 Incorrect gear Control unit Check cabling to 2.1.1 Gear and selection from doesn't allow gear selector with multi-func- gear selector.
  • Page 360 D Error codes – 2 Transmission Con- nec- Diag- tion Function Description Limitation Action nostic group menu Code compo- nent code 43.08 43.08 Torque convert- The control unit Check cabling to D793/H3 TRANSM 2.2.5 Sensor er temperature protects the sensor tempera- - B758/ , menu engine rpm...
  • Page 361 D Error codes – 2 Transmission Con- nec- Diag- tion Function Description Limitation Action nostic group menu Code compo- nent code 51.01 51.01 Sensor engine The control unit Check cabling to D793/H3 TRANSM 2.2.5 Sensor rpm and oil limits the trans- sensor oil sump - B758/ , menu...
  • Page 362 D Error codes – 2 Transmission Con- nec- Diag- tion Function Description Limitation Action nostic group menu Code compo- nent code 54.00 54.00 Analogue input D793/ 2.7.2 Sensor 4 short- M1- S221 oil tempera- circuited to ture ground. 54.01 54.01 Analogue input D793/ 2.7.2 Sensor...
  • Page 363 D Error codes – 2 Transmission Con- nec- Diag- tion Function Description Limitation Action nostic group menu Code compo- nent code 60.01 60.01 Sensor rpm When only one Check cabling be- D793/C3 TRANSM 2.3.6. Sensor drum not con- rpm signal which tween Control unit - B752 , menu 6...
  • Page 364 D Error codes – 2 Transmission Con- nec- Diag- tion Function Description Limitation Action nostic group menu Code compo- nent code 62.00 62.00 Sensor engine When only one Check cabling be- D793/F3 TRANSM 2.2.5 Sensor rpm short- rpm signal which tween Control unit - B758/ , menu 6...
  • Page 365 D Error codes – 2 Transmission Con- nec- Diag- tion Function Description Limitation Action nostic group menu Code compo- nent code 63.01 63.01 Sensor turbine When only one Check cabling be- D793/R2 TRANSM 2.3.5. Sensor not connected. rpm signal which tween Control unit - B751 , menu 6...
  • Page 366 D Error codes – 2 Transmission Con- nec- Diag- tion Function Description Limitation Action nostic group menu Code compo- nent code 70.03 70.03 Electric mal- Control unit acti- Check cabling to D793/B1 TRANSM 2.3.4 Valve function sole- vates, Limp-home solenoid valve for- - Y630, , menu 9 block trans-...
  • Page 367 D Error codes – 2 Transmission Con- nec- Diag- tion Function Description Limitation Action nostic group menu Code compo- nent code 72.00 72.00 Electric mal- Control unit acti- Check cabling to D793/F1 TRANSM 2.3.4 Valve function re- vates, Limp-home solenoid valve re- - Y631, , menu 8 block trans-...
  • Page 368 D Error codes – 2 Transmission Con- nec- Diag- tion Function Description Limitation Action nostic group menu Code compo- nent code 73.00 73.00 Electric mal- Control unit acti- Check cabling to D793/H1 TRANSM 2.3.4 Valve function gear 1/ vates, Limp-home solenoid valve gear - Y6067, , menu 8...
  • Page 369 D Error codes – 2 Transmission Con- nec- Diag- tion Function Description Limitation Action nostic group menu Code compo- nent code 74.01 74.01 Analogue out- D793/ put signal 4 out- put signal not connected or short-circuited to voltage. 74.02 74.02 Analogue out- D793/ put signal 4...
  • Page 370 D Error codes – 2 Transmission Con- nec- Diag- tion Function Description Limitation Action nostic group menu Code compo- nent code 76.00 76.00 Electric mal- Control unit indi- Check cabling to D793/R1 2.3.4 Valve function brake, cates the error, solenoid valve - Y602 block trans- cable short-...
  • Page 371 Check solenoid circuited to valve drive. voltage. 90.xx - 90.xx System error. Transmission in Contact Kalmar In- D793/ 11.5.3.9 Con- 99.xx locked neutral po- dustries AB for A:20 trol unit trans- 99.xx sition (Shut-down more information.

  • Page 372: Control System

    D Error codes – 8 Control system 8 Control system mm mm mm mm Error codes machine page – Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Communication er- Attachment Use diagnostic menu to lo- Varies de- CAN/ 11.6.2 Redun-...
  • Page 373 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Communication er- Hydraulic Use diagnostic menu to lo- Varies de- CAN/ 11.6.2 Redun- ror with Control unit sliding cab, calise incorrect segment.
  • Page 374 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Cable harness error No limita- Use diagnostic menu to lo- Varies de- CAN/ 11.6.2 Redun- CAN-net segment tion. calise incorrect segment. pending POWER, dant CAN bus...
  • Page 375 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Interference during – Turn the ignition off and on. D794 – 11.5.3.10 software download Control unit Perform software down- engine load again.
  • Page 376 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Interference during – Turn the ignition off and on. D793 – 11.5.3.9 Con- software download. trol unit trans- Perform software down- Buffer for error mission load again.
  • Page 377 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Windshield Check cabling between the D790-1/ CAB, 9.5.7 Wiper triggered due to wiper rear control unit and component K2:4 –...
  • Page 378 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Windshield Check the wiring to the D790-1/ CAB, 9.5.4 Washer triggered due to washer not washer motor. K10:13 –...
  • Page 379 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Signal error from Engine rpm Check cabling between the D790-1/ ENGINE, 1.1.2 Throttle accelerator pedal restricted to control unit and component K6:11 –...
  • Page 380 V or above 5.1 V. with diagnostic menu. menu 9 front Check component. Incorrect values for Lift and low- Contact Kalmar Industries – – 7.2 Lift and load curve. er as well as lower 7.3 Ex- extension tension not working.
  • Page 381 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Cooling fan Check light. D797-F/ HYD, 4.8.9 Cooling triggered due to brake oil not K1:14 – menu 2 Check cabling between the short-circuit or...
  • Page 382 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Lower not Check cabling between the D797-F/ BOOM, 7.2.3 Control triggered due to working. control unit and component K1:3 –...
  • Page 383 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Brake light Check light. D797-F/ – 9.6.5 Brake triggered due to front right K1:33 – light Check cabling between the short-circuit or not working...
  • Page 384 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Regenera- Check cabling between the D797-F/ BOOM, 7.2.7 Valve triggered due to tion lift not control unit and component K1:11 –...
  • Page 385 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Signal error from Overload Check cabling between the D797-F/ 7.2.9 Sensor Sensor hydraulic system not control unit and component K1:24 –...
  • Page 386 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent High brake oil tem- Reduced Check that the cooling fan – HYD, 4.8 Tempera- perature. braking per- works. menu 2 ture control, formance.
  • Page 387 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Incorrect control – Check cabling between the D797-R/ CAN/ 11.5.1.4 Con- breaker voltage to control unit and component K2:11 POWER, trol switch Control unit frame...
  • Page 388 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Regenera- Check cabling between the D797-R/ BOOM, 7.3.6 Valve triggered due to tion exten- control unit and component K1:4 –...
  • Page 389 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Running light Check light. D797-R/ LIGHTS, 9.6.3 Running triggered due to left rear not K1:7 – menu 5 lights Check cabling between the...
  • Page 390 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Air condi- Check if error code 181 is D797-R/ CLI- 9.4.8 Com- triggered due to tioning not generated, error code 179 K1:11 –...
  • Page 391 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Abnormal signal Incorrect Check cabling between the D797-R/ HYD, 10.6 Temper- from Sensor hy- temperature control unit and component K2:13 –...
  • Page 392 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Hydraulic Check cabling between the D797-O/ EXTRA / 9.10 Cab triggered due to sliding cab or control unit and component K1:3–...
  • Page 393 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Cab tilt not Check cabling between the D797-O/ SLIDING 9.10 Cab triggered due to working. control unit and component K1:33 –...
  • Page 394 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Redundant voltage – Check cabling between the D791-1/ CAN/ 11.5.1.2 Re- feed left to Control control unit and component K2:7 POWER, dundant volt-...
  • Page 395 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Extra work Check light. D791-1/ LIGHTS, 9.6.12 Work triggered due to light attach- K1:28 – menu 2 light attach- Check cabling between the short-circuit or...
  • Page 396 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Sideshift of Check cabling between the D791-1/ ATTACH, 7.4.3 Control triggered due to attachment control unit and component K1:30 –...
  • Page 397 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Indicator Check light. D791-1/ ATTACH, 7.1.14 Light triggered due to light open K1:25 – menu 8 panel boom Check cabling between the short-circuit or...
  • Page 398 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Spreader not Check cabling between the D791-1/ ATTACH, 7.5.3 Control triggered due to working. control unit and component K1:19 –...
  • Page 399 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Emergency voltage Control Check fuse F58-3:1, change D791-2/ CAN/ 11.5.1.4 Con- to Control unit at- breaker can- if needed. K2:1/9/10 POWER, trol switch...
  • Page 400 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Levelling not Check cabling between the D791-2/ ATTACH, 7.8.6 Valve triggered due to working. control unit and component K1:30 –...
  • Page 401 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Redundant voltage – Check cabling between the D791-3/ CAN/ 11.5.1.2 Re- feed left to Control control unit and component K2:7 POWER, dundant volt-...
  • Page 402 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Left lift leg Check cabling between the D791-3/ COMBI, 7.9.2.5 Valve triggered due to not working. control unit and component K1:42 –...
  • Page 403 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Left lift leg Check cabling between the D791-3/ COMBI, 7.9.2.3 Con- triggered due to not working. control unit and component K1:31 –...
  • Page 404 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Indicator Check light. D791-3/ COMBI, 7.1.14 Light triggered due to light align- K1:25 – menu 7 panel boom Check cabling between the short-circuit or...
  • Page 405 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Levelling not Check cabling between the D791-3/ ATTACH, 7.8.3 Control triggered due to working. control unit and component K1:17 –...
  • Page 406 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Controllable Check cabling between the D791-4/ ATTACH, 7.7.5 Control triggered due to tilt not work- control unit and component K1:15 –...
  • Page 407 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Right lift leg Check cabling between the D791-4/ COMBI, 7.9.2.3 Con- triggered due to not working. control unit and component K1:5 –...
  • Page 408 D Error codes – 8 Control system Code Description Limitation Action Connec- Diag- Function tion and nostic group compo- menu nent Transistor has been Right lift leg Check cabling between the D791-4/ COMBI, 7.9.2.3 Con- triggered due to not working. control unit and component K1:9 –...
  • Page 409 1 – cannot be shown. Service interval No limita- Check that service has – – Preventive reached. tion. been completed. If service maintenance is performed according to Kalmar Industries service schedule, reset the service indicator Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 410 D Error codes – 8 Control system Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 411 E Schematics E Schematics Table of Contents E Schematics mm mm mm mm Common hydraulics ................. 3 Hydraulic diagrams, compilation ................3 Hydraulic diagram basic machine ................. 4 Hydraulic diagram top lift ..................6 Hydraulic diagram top lift, tilt lock and controllable tilt ........8 Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling ..
  • Page 412 E Schematics Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 413: Mm Mm Mm Mm

    E Schematics – 10 Common hydraulics 10 Common hydraulics mm mm mm mm Hydraulic diagrams, compilation page – Designation Drawing number Hydraulic diagram basic machine page 4 A40740.0100 Hydraulic diagram top lift page 6 A40853.0100 Hydraulic diagram top lift, tilt lock and controllable tilt page 8 A40853.0200 Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling page 10 A43123.0100...

  • Page 414: Hydraulic Diagram Basic Machine

    E Schematics – 10 Common hydraulics Hydraulic diagram basic machine page – Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 415 E Schematics – 10 Common hydraulics Lift cylinder 25. Oil return from attachment Valve block lift cylinder 26. Brake oil filter Extension cylinder 27. Hydraulic oil filter Valve block extension cylinder 28. Cooler hydraulic oil Lift cylinder 29. By-pass valve hydraulic oil cooler Valve block lift cylinder 30.

  • Page 416: Hydraulic Diagram Top Lift

    E Schematics – 10 Common hydraulics Hydraulic diagram top lift page – Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 417 E Schematics – 10 Common hydraulics Tilt cylinder Damping block Rotation motor unit Valve block rotation motor Sideshift cylinders Spreader motor Valve block spreader motor Twistlock cylinders Control valve attachment 10. Filter hydraulic oil 11. Filter hydraulic oil (high pressure filter) 12.

  • Page 418: Hydraulic Diagram Top Lift, Tilt Lock And Controllable Tilt

    E Schematics – 10 Common hydraulics Hydraulic diagram top lift, tilt lock page – and controllable tilt Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 419 E Schematics – 10 Common hydraulics Tilt cylinder Damping block Rotation motor unit Valve block rotation motor Sideshift cylinders Spreader motor Valve block spreader motor Twistlock cylinders Control valve attachment 10. Filter hydraulic oil 11. Filter hydraulic oil (high pressure filter) 12.

  • Page 420: Hydraulic Diagram Top Lift, Tilt Lock, Controllable Tilt And Hydraulic Levelling

    E Schematics – 10 Common hydraulics Hydraulic diagram top lift, tilt lock, page – controllable tilt and hydraulic levelling Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 421 E Schematics – 10 Common hydraulics Tilt cylinder Damping block Rotation motor unit Valve block rotation motor Sideshift cylinders Spreader motor Valve block spreader motor Twistlock cylinders Control valve attachment 10. Solenoid valve engagement hydraulic pressure 11. Shuttle valve 12. Hydraulic oil filter 13.

  • Page 422: Hydraulic Diagram Joystick Steering

    E Schematics – 10 Common hydraulics Hydraulic diagram joystick steering page – Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 423 E Schematics – 10 Common hydraulics Control valve option frame Steering cylinder Steering valve Priority valve Shuttle valve Shuttle valve joystick steering Hydraulic oil pumps 3 and 4 Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 424: Hydraulic Diagram Sliding Cab

    E Schematics – 10 Common hydraulics Hydraulic diagram sliding cab page – Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 425 E Schematics – 10 Common hydraulics Control valve option frame Hydraulic motor sliding cab Solenoid valve engagement hydraulic pressure Shuttle valve Shuttle valve option Hydraulic oil pump 1 and 2 Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 426: Hydraulic Diagram Cab Lift And Support Jacks

    E Schematics – 10 Common hydraulics Hydraulic diagram cab lift and page – support jacks Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 427 E Schematics – 10 Common hydraulics Control valve option frame Accumulator Hydraulic cylinder support jacks Valve block support jacks Load control valve Hydraulic cylinder cab lift/lowering Restriction Valve block top lift hydraulics Shuttle valve 10. Shuttle valve option frame 11. Hydraulic oil pump 1 and 2 Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 428: Hydraulic Diagram Sliding Cab And Support Jacks

    E Schematics – 10 Common hydraulics Hydraulic diagram sliding cab and page – support jacks Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 429 E Schematics – 10 Common hydraulics Control valve option frame Hydraulic cylinder support jacks Over-centre valve support jacks Hydraulic motor sliding cab Restriction Solenoid valve engagement hydraulic pressure Shuttle valve Shuttle valve option Hydraulic oil pump 1 and 2 Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 430: Hydraulic Diagram Combi Attachment (Part 1 Of 3)

    E Schematics – 10 Common hydraulics Hydraulic diagram combi page – attachment (part 1 of 3) Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 431 E Schematics – 10 Common hydraulics Tilt cylinder Damping block Rotation motor unit Valve block rotation motor Sideshift cylinders Spreader motor Valve block spreader motor Twistlock cylinders Valve block levelling cylinders 10. Over-centre valve levelling 11. Levelling cylinders 12. Control valve attachment 13.

  • Page 432: Hydraulic Diagram Combi Attachment (Part 2 Of 3)

    E Schematics – 10 Common hydraulics Hydraulic diagram combi page – attachment (part 2 of 3) 001205:A 001205:B 001205:C Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 433 E Schematics – 10 Common hydraulics Control valve lift leg left Lowering cylinder front lift leg Valve block lowering front lift leg Valve block lowering front lift leg Clamping cylinder front lift leg Valve block operating position front lift leg Clamping cylinder rear lift leg Valve block lowering rear lift leg Valve block lowering rear lift leg...

  • Page 434: Hydraulic Diagram Combi Attachment (Part 3 Of 3)

    E Schematics – 10 Common hydraulics Hydraulic diagram combi page – attachment (part 3 of 3) 001205:D 001205:E 001205:F Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 435 E Schematics – 10 Common hydraulics Control valve lift leg right Lowering cylinder front lift leg Valve block lowering front lift leg Valve block lowering front lift leg Clamping cylinder front lift leg Valve block operating position front lift leg Clamping cylinder rear lift leg Valve block lowering rear lift leg Valve block lowering rear lift leg...

  • Page 436: 11 Common Electrics

    E Schematics – 11 Common electrics 11 Common electrics mm mm mm mm Circuit diagrams, description page – A circuit diagram is divided into circuit name(drawing number) and consists of a number of pages. The following is an explanation of the symbols used in circuit dia- grams: •...

  • Page 437: Component Designations

    E Schematics – 11 Common electrics Component designations page – The components in circuit diagrams have a prefix and number, the prefix describes the type of component, the number which compo- nent. Component list with component number, prefix and designation is provided as an appendix after the circuit diagrams.

  • Page 438: Circuit Diagrams, Compilation

    E Schematics – 11 Common electrics Circuit diagrams, compilation page – Circuit diagrams are included as an appendix in the following order. Designation Group Drawing number 2004 2005 Circuit CAN-BUS KDU 11.6 A43032.0100 Circuit CAN-BUS opt. frame KDU 11.6 A43032.0200 Circuit Current 11.5 A43033.0100...
  • Page 439 E Schematics – 11 Common electrics Designation Group Drawing number 2004 2005 Circuit by-passing A43055.0100 Circuit alarms, audible signals A43056.0100 Circuit hyd. support jacks 7.10 A43057.0100 Circuit central lubrication 9.14 A43058.0100 Circuit operator's seat A43059.0100 Circuit direction indicators, hazard flashers A43060.0100 Circuit climate system A43061.0100...
  • Page 440 E Schematics – 11 Common electrics Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
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  • Page 571 F Technical data F Technical data Table of Contents F Technical data mm mm mm mm Technical data ..................3 Specifications for data and volume ............... 3 Specifications for lift capacity and dimensions ............. 5 Oils and lubricants, recommendation ..............8 Tightening torques, recommendations ...............
  • Page 572 F Technical data Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 573: Mm Mm Mm Mm

    F Technical data – Technical data Technical data mm mm mm mm Specifications for data and volume page – Data 1 Engine Volvo TWD1240VE Cummins QSM11 Power acc. to ISO 3046 (net power) 256 kW at 2000 rpm 280 kW at 2000 rpm Torque ISO 3046 1751 Nm at 1200 rpm 1898 Nm at 1100-1400 rpm...
  • Page 574 F Technical data – Technical data 9.6 Frame, body, cab and accessories, lighting system Rotating beacon PK22s Volumes For oil types see Oils and lubricants, recommendation page 8. 1 Engine Volvo TWD1240VE Cummins QSM11 Engine oil 35 l 34 l Cooling system 68 l 40 l...

  • Page 575: Specifications For Lift Capacity And Dimensions

    Container 8'6'' Container 9'6'' Lifting height top lift attach- ment Row 1 Row 2 Row 3 Row 1 Row 2 Row 3 H4 (mm) H5 (mm) DRF420-60S5 41*/42 40*/42 15100 18100 DRF450-60S5 43*/45 42*/45 15100 18100 DRF450-60S5X 43*/45 42*/45 15200...
  • Page 576 Turning radius Main dimensions (mm) weight (mm) (mm) (kg) A1 - A2 - R1 - R3 - Tyres 20 ft 40 ft 20 ft 40 ft DRF420-60S5 6055- 18.00x25/ 11200 13600 8100 9400 4150 11200 4500 64500 12185 DRF450-60S5 6055- 18.00x25/...
  • Page 577 F Technical data – Technical data Model Service Aisle width Turning radius Main dimensions (mm) weight (mm) (mm) (kg) DRF450-65S6 6055- 18.00x25/ 11900 13900 8500 9450 4150 12000 4500 67800 12185 DRF450-65S5X 6055- 18.00x33/ 11600 13600 8500 9400 4150 11700 4600 76300 12185...

  • Page 578: Oils And Lubricants, Recommendation

    The table indicates recommended viscosity for different oil types and qualities depending on the ambient temperature. Any deviation from this table must be approved in writing by Kalmar Industries, and may mean changed service intervals. °C Oil type, quality °F...
  • Page 579 Gleitmo 805 or equivalent shall be used. Sealant silicone Use Loctite 5972 or Loctite 598 (or equivalent). If uncertain, contact Kalmar Industries. Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 580: Tightening Torques, Recommendations

    F Technical data – Technical data Tightening torques, page – recommendations The tightening torques in the following table are recommendations when tightening bolts and nuts. When torquing using a machine, for example, bolt runner, the tight- ening torque should be reduced by approx. 5%. For mild surfaces (hardness below 200 HB), washer shall be used under both bolt head and nut.

  • Page 581: Tightening Torques, Orfs-Couplings

    F Technical data – Technical data Quality 10.9 12.9 UNC-thread 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm 5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm 7/16 70 Nm 62 Nm...
  • Page 582 F Technical data – Technical data Pipe diameter Tightening torques inch 180-200 1"1/4 200-240 1"1/2 Socket width Tightening torques inch 11/16 23-25 13/16 33-38 15/16 51-57 1 3/8 120-130 1 5/8 150-170 Flange coupling UNF-UN Metric-ISO BSSP Thread (inch) Tightening torques Thread Tightening torques Thread (inch)

  • Page 583: Unit Explanations

    F Technical data – Technical data Unit explanations page – Unit Abbreviation Newton metre Kilo pound metre Kilo pascal Mega pascal Kilowatt kilojoule British termel unit Calorie Inch Feet Yard Mile mile Centimetre Metre Kilometre Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

  • Page 584: Conversion Table, Si-Units

    F Technical data – Technical data Conversion table, SI-units page – SI-unit Recalculation fac- Non-SI Recalculation fac- Torque x 10,2 = kg·cm x 0,8664 = lb·in x 0,74 = lbf·ft x 1,36 = Nm x 0,102 = kg·m x 7,22 = lb·ft Pressure (Pa = N/m x 4,0...

  • Page 585: Conversion Table, Length

    F Technical data – Technical data Conversion table, length page – Unit mile 0,01 0,00001 0,3937 0,03281 0,01094 0,000006 0,001 39,37 3,2808 1,0936 0,00062 100000 1000 39370,7 3280,8 1093,6 0,62137 2,54 0,0254 0,000025 0,08333 0,02777 0,000015 30,48 0,3048 0,000304 0,3333 0,000189 91,44 0,9144...

  • Page 586: Conversion Table, Weight

    F Technical data – Technical data Conversion table, weight page – Unit 0,001 0,000001 0,03527 0,0022 1000 0,001 35,273 2,20459 1000000 1000 35273 2204,59 28,3495 0,02835 0,000028 0,0625 453,592 0,45359 0,000454 1ton (metric) = 1,1023 ton (US) = 0,9842 ton (UK) Conversion table, pressure page –...
  • Page 587 G Terminology and index G Terminology and index Table of Contents G Terminology and index mm mm mm mm Terminology and index ................3 Terminology ......................3 Index ........................6 Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 588 G Terminology and index Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 589 G Terminology and index – Terminology and index Terminology and index mm mm mm mm Terminology page – Term Description Accumulator Reservoir that stores (accumulates) pressure for i.e. hydraulic functions. Anti-corrosion compound Prevents oxidation, in simple terms, rustproofing. Attachment Part of the machine that grabs the load when lifting. Axle distance Distance between drive axle and steering axle.
  • Page 590 G Terminology and index – Terminology and index Term Description Hydraulic system System that uses oil pressure to transfer power to different functions. Indicator Manual “sensor”, for example, shows that a filter is clogged and needs to be changed. Load centre. Levelling Attachment is tilted, for example, if load stands on uneven ground.
  • Page 591 G Terminology and index – Terminology and index Term Description Start up Start procedure for control and monitoring system (from powerless to supplied with voltage). Steering axle Wheel axle with steering. Tilting Load is leaned forward or backward. Torque converter Hydraulic, variable clutch.
  • Page 592 G Terminology and index – Terminology and index Index page – Title Functiongroup 50h-check C Preventive Maintenance A near-accident is a warning signal! B Safety About the documentation A Foreword About the machine version A Foreword About the Maintenance Manual A Foreword Accumulator 4 Brakes...
  • Page 593 G Terminology and index – Terminology and index Title Functiongroup Circuit diagrams, description E Schematics CLIMATE 8 Control system 8.4.4 Clothing etc. B Safety Common electrics 11 Common electrics Common hydraulics 10 Common hydraulics Communication 11 Common electrics 11.6 Communication system 9 Frame, body, cab and accessories Complete machine 0 Complete machine...
  • Page 594 G Terminology and index – Terminology and index Title Functiongroup Documentation sections A Foreword Drive axle 3 Driveline/Axle Driveline/axle 3 Driveline/Axle Electric motors B Safety Electric protection 11 Common electrics 11.2 Engine 1 Engine ENGINE 8 Control system 8.4.6 Entertainment and communication 9 Frame, body, cab and accessories Environment B Safety...
  • Page 595 G Terminology and index – Terminology and index Title Functiongroup General safety information B Safety Glass/windows/mirrors 9 Frame, body, cab and accessories Height limitation 8 Control system 8.2.4 Hoses, pipes and valves 10 Common hydraulics 10.5 Humidity filter 9 Frame, body, cab and accessories 9.4.9 HVAC 9 Frame, body, cab and accessories...
  • Page 596 G Terminology and index – Terminology and index Title Functiongroup Load centre limitation 8 Control system 8.2.3 Load handling 7 Load handling Longitudinal displacement of cab 9 Frame, body, cab and accessories 9.10.4 Lubrication 1 Engine Lubrication 2 Transmission Lubrication 1000 hours C Preventive Maintenance Lubrication 500 hours C Preventive Maintenance...
  • Page 597 G Terminology and index – Terminology and index Title Functiongroup Pumps 10 Common hydraulics 10.4 Read maintenance manual A Foreword Read operator's manual A Foreword Reading instructions A Foreword Reading out error code D Error codes Redundant CAN-bus 11 Common electrics 11.6.2 References between different information types A Foreword...
  • Page 598 G Terminology and index – Terminology and index Title Functiongroup Storage A Foreword Support jacks 7 Load handling 7.10.1 Suspension 6 Suspension Suspension mounting 6 Suspension Synchronous lift 7 Load handling 7.10.4 Tanks and accumulators 10 Common hydraulics 10.3 Technical data F Technical data Temperature control, cleaning and hydraulic oil 10 Common hydraulics...
  • Page 599 G Terminology and index – Terminology and index Title Functiongroup Voltage feed 11 Common electrics 11.5.1 Working under machine B Safety Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...
  • Page 600 G Terminology and index – Terminology and index Maintenance manual DRF 400–450 UDRF01.04GB https://www.forkliftpdfmanuals.com/...

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