KALMAR DRF 400 450 Full Service & Repair 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 Maintenance manual

UDRF01.04GB Maintenance manual DRF 400–450 A Foreword 1 A Foreword mm mm mm mm Table of Contents A Foreword Foreword .................................................................................................. 3 About the Maintenance Manual ................................................................ 3 General .............................................................................................................. 3 Conditions ......................................................................................................... 3 Storage .............................................................................................................. 3 About the machine version .............................................................................. 3 Copyright ........................................................................................................... 3 Reading instructions .................................................................................. 4 Warning information ......................................................................................... 4 Important information ...................................................................................... 4 Read operator's manual ................................................................................... 4 Read maintenance manual ............................................................................... 4 Maintenance manual's content ........................................................................ 5 Function group structure .................................................................................. 6 References between different information types ............................................ 7 Product alternatives and optional equipment .................................................. 7 Machine card .................................................................................................... 8 Function descriptions ....................................................................................... 9 About the documentation ....................................................................... 12 Documentation sections ................................................................................. 12 Ordering of documentation ............................................................................ 12 Feedback .................................................................................................. 13 Form for copying ............................................................................................. 13

UDRF01.04GB Maintenance manual DRF 400–450 2 A Foreword

UDRF01.04GB Maintenance manual DRF 400–450 A Foreword – Foreword 3 mm mm mm mm Foreword About the Maintenance Manual page – General Thank you for choosing Kalmar Industries as your machine supplier. We hope that we'll meet your expectations. This maintenance manual contains information about how the machine should be maintained for maximal operating reliability and service life as well as troubleshooting information for fast correction of any malfunctions. page – Conditions The instructions are based on the use of generally available standard tools. All lifting devices, for example, slings, straps, ratchet blocks, etc., must meet governing national standards and regulations for lifting devices. Kalmar Industries will not accept any responsibility for modifications performed without permission from Kalmar Industries or if other lifting devices, tools or work methods are used other than those described in this manual. page – Storage NOTE The maintenance manual shall be accessible to service person- nel. page – About the machine version The information in this publication corresponds to the machine's design 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. All information and data in this manual are valid at the time of publication. page – Copyright Kalmar Industries AB Duplication of the content in this manual, in whole or in part, is strictly prohibited without written permission from Kalmar Indus- tries AB. Duplication by any means such as copying, printing, etc., is prohibited.

UDRF01.04GB Maintenance manual DRF 400–450 4 A Foreword – Reading instructions Reading instructions page – Warning information Warnings inform on potential dangers which can, if the warnings are not heeded, result in personal injury or product damage. page – Important information Important information marked with NOTE facilitates the work proc- ess, operation/handling or increases understanding of the information. NOTE Information that is important without being safety related. page – Read operator's manual Read the operator's manual The symbol to the left is used in certain cases on the machine and refers to important information in the operator’s manual. page – Read maintenance manual Read the maintenance manual The symbol to the left is used in certain cases on the machine and refers to important information in the maintenance manual. DANGER Situation that may result in serious personal injury, possible death, if the instruction is not followed. WARNING Situation that may result in serious personal injury if the instruction is not followed. CAUTION Situation that may result in damage to the product if the instruction is not followed. 000262 001128

UDRF01.04GB Maintenance manual DRF 400–450 A Foreword – Reading instructions 5 page – Maintenance manual's content The information in the maintenance manual is divided in function groups (0-12) to facilitate information searches. The manual is divided 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". This is described in greater detail in the table below. For more information on function groups, see Function group structure page 6. The function group is intended to function together with references as search key between different types of information, see References between different information types page 7. A Foreword General information about the maintenance manual's purpose, content and reading instructions as well as survey for feedback of views and eventual in- accuracies. B Safety Keep in mind for your safety. C Preventive maintenance General information about preventive maintenance of the machine. 0 Complete machine Technical description, description of the machine's functions with schematic drawings and explanatory texts for the included components. Overviews with the components' position on the machine. Work instructions for preventive maintenance. Work instructions for checking and adjusting. 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 Error code information and instructions for reading error code information. E Schematics Wiring and hydraulic diagrams F Technical data Technical data, conversion tables, information for conversion of units. G Terminology and index General terminology and abbreviations, explanations of terms and abbreviations that may appear in the manual, index for headings in the manual.

UDRF01.04GB Maintenance manual DRF 400–450 6 A Foreword – Reading instructions page – Function group structure The information in the manual is divided in a structure of functions at different levels, based on the machine's design and use, called function groups. The upper level (called main group) determines area, e.g., group 7 Load handling. The second level (called two-digit) determines function, e.g., 7.2 Lift and lower. The third and fourth levels are used to break down functions in smaller parts (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. This means that certain function groups (headings) will be left out in the documentation for certain machines since the machine is missing that specific function or component. In turn, this means that there may be skips in the function groups' numbering (e.g., the three-digit heading level 4.8.7 Oil cooler may be included for some machines, but is missing for others). The function groups are intended to be used as search terms to find different types of information between different sections and manu- als. The information in a function group is divided in smaller sections according to the type of content, e.g., description or change. The maintenance manual and Workshop manual contain different information. The maintenance manual contains only the information needed for preventive maintenance and simpler troubleshooting. The Workshop manual contains more in-depth information and repair instructions. References between sections in the same manual are indicated with section and group number, e.g., see section 4 Brakes, group 4.3.9 Wheel brake". References within a section are indicated with page number, e.g., "see Sensor fuel level, description page 24". References between Maintenance manual and Workshop manual are not given. If more information is desired for a function group, the primary recommendation is to search in the same function group in the other manual. For additional information about where different information types are found and which references are given, see References between different information types page 7.

UDRF01.04GB Maintenance manual DRF 400–450 A Foreword – Reading instructions 7 page – References between different information 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 component in question. As a complement to this, there are written references according to the below. • From Function description to Hydraulic diagram, for hydraulic diagrams of function in question. • From Error codes to Diagnostic test, for diagnostic menu to trou- bleshoot component or function in question. • From Error codes to Function description, for further information about components or function. page – Product alternatives and optional equipment The information in the manual is divided in modules. For product alternatives and optional equipment, handling of the modules differs depending on if it is the one or the other that is described, see below. Special equipment is not described in the manual. When uncertain about the equipment with which the machine is provided, use the machine card to decide which information applies, see Machine card page 8. Product alternatives Product alternatives are such options that exclude certain standard equipment (e.g., engine alternative). Similar information for different product alternatives are described in separate sections following each other in the same function group. To show that there are different alternatives, the added text "Product alternative" is used in the heading, together with a simple description of which alternative is described, e.g., "(Product alternative Air conditioning ECC)". Further, alternatives that are optional equipment are marked with the symbol for optional equipment. Function descriptions (Section 0-12) Hydraulic diagrams (Section E) Error codes (Section D) Diagnostic test (Section 8) Wiring diagrams (Section E)

UDRF01.04GB Maintenance manual DRF 400–450 8 A Foreword – Reading instructions Symbol indicating optional equipment Optional equipment Optional equipment are options that can be added to the standard equipment to obtain additional or improved functions. 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 – Machine card NOTE If the machine has been modified after delivery the information on the machine card may be lacking or incorrect. The machine card indicates of which drawings the machine consists, in many cases these can be connected to options and product alternatives. For more information about handling of product alternatives and optional equipment, see Product alternatives and optional equipment page 7. The machine card is delivered with the parts catalogue and shall be kept in the cab. The machine card is divided in the same functions groups as the parts catalogue, maintenance and Workshop manual. For practical reasons, the machine card uses only the first and second level in the function group register. The function groups are written in groups of four characters, e.g. group 0107 matches group 1.7 Cooling system in the manual. For more information about how the machine card is used for ordering spare parts, see the parts catalogue's foreword. If the information on the machine card does not help, contact Ka- lmar Industries AB. NOTE All documents that accompany the machine are non-registered documents and there will be no notification of changes. 000264

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KALMAR DRF 400 450 Full Service & Repair Manual

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