Руководство по эксплуатации ричстакера кальмар

Function group breakdown

Breakdown into function groups is common for all machines from Kalmar Industries, down to two-digit heading level (e.g., 4.3 Powerassisted brake system). Machine-unique adaptations of function groups are done at the third and fourth group levels (e.g., 4.3.9 Wheel brake resp. 4.3.9.1 Disc pack).

This results in certain headings (function groups) being omitted in the documentation for certain machines since the machine lacks that particular function. This means that there may be gaps in the function groups’ numbering (e.g., the three-digit heading level 4.8.7 Oil cooler may be included for certain machines, but may be missing for other machines).

References between manual types (of the type «see Workshop manual DFR 400–450») are used since the different manual types have different purposes and thus different information content.

References between sections within the same manual are indicated using section and group number, e.g., «see section 4 Brakes, group 4.3.9 Wheel brake«. A reference within the same section is indicated with page number, e.g., «see Sensor fuel level, description page 24«.

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.

Storage

NOTE

The Maintenance Manual should be accessible to the service personnel.

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.

Copyright

Kalmar Industries AB

Duplication of the content in this manual, in whole or in part, is strictly prohibited without written permission from Kalmar Industries AB.

Duplication by any means such as copying, printing, etc., is prohibited.

Reading instructions

Warning information

Warnings inform on potential dangers which can, if the warnings are not heeded, result in personal injury or product damage.

D A N G E R

Situation that may result in serious personal injury, possible death, if the instruction is not followed.

W A R N I N G

Situation that may result in serious personal injury if the instruction is not followed.

C A U T I O N

Situation that may result in damage to the product if the instruction is not followed.

Important information

Important information marked with NOTE facilitates the work process, operation/handling or increases understanding of the information.

NOTE

Information that is important without being safety related.

Function descriptions

Function descriptions are schematic overviews that describe how a function works as well as which components and signals work together.

Function descriptions describe the function in a logical flow from input signal to desired output signal. Most functions require that preset conditions are fulfilled for the function to be activated. In these cases, the conditions are listed above the illustration.

Function descriptions use symbols to illustrate components such as valves, sensors, etc.

1

10

2

3

9

000520

Example of function description

1.Hydraulic force (solid double line)

2.Flag pressure check connection (Check point), indicates that there is pressure check connection for checking pressure signal

3.Flag diagnostic test, indicates that signal can be checked with diagnostic test, see group “8.4 Diagnostic test”

4.Illustration of function, (applied brake)

5.Reference to description of component

6.Signal description, reference value for signal out from component

7.Description of component’s function

8.Position number, reference to position in illustration

9.Position number in illustration, reference to row in table

10.Electric power (solid single line)

About the documentation

Documentation sections

The documentation to the machine comprises the following sections:

Operator’s manual

The Operator’s manual is supplied with the machine in the cab.

Documentation kit

Maintenance manual and spare parts catalogue with machine card are supplied with the machine as a separate documentation kit.

Supplementary documentation

There are Supplementary documentation that can be ordered for the machine in the form of a Workshop manual. The Workshop manual includes supplier documentation for engine, transmission and drive axle.

Ordering of documentation

Extra copies and supplementary documentation is ordered from Kalmar Industries.

Kalmar Industries AB SE-341 81 Ljungby, Sweden.

NOTE

If possible, always indicate publication number when ordering.

BSafety – Safety

General safety information

Safety concerns everyone!

The safety information concerns everyone who works with the machine! Persons who do not follow the safety instructions given in this manual must make absolutely sure that the work is performed without risks of personal injury and without risk of damage to machine or property!

Remember to:

•follow the instructions in this manual

•be trained for the work in question

•follow local laws, safety rules and regulations

•use the correct equipment and tools for the job

•wear the correct clothes

•use common sense and work carefully, do not take any risks!

In this publication, Kalmar Industries has documented and warned for situations and risks that may occur/exist in connection with operation as well as service/repairs of the truck under normal conditions.

Therefore, its very important that all who work with the truck, or carry out repairs/service work, acquaint themselves with and act according to the information in the maintenance manual and operators manual.

A near-accident is a warning signal!

A near-accident is an unexpected event where neither persons, machine or property are injured or damaged. However, a near-accident indicates that there is an injury risk and actions must be taken to avoid the risk of injuries.

Safety instructions

General

Read, consider and follow the safety instructions below before starting to work in the machine:

•Service position page 4

•Hydraulic and brake systems, depressurizing page 5

•Clothing etc. page 6

•Several mechanics on the same machine page 6

•Working under machine page 7

•Lifting heavy components page 7

•Vibrations page 8

•Noise page 8

•Solvents page 8

•Fire and explosion risks page 9

•Fluid or gas under pressure page 10

•Coolant page 11

•Refrigerant page 12

•Air pollution page 12

•Tensioned springs page 13

•Electric motors page 14

•Rotating components and tools page 14

•Tyre system page 15

Service position

General

Service position is used for service, maintenance and other situations when the machine needs to be secured.

Service position means:

•Machine parked, that is, parking brake applied.

•Boom fully retracted and lowered to horizontal position.

• Engine off.

• Main electric power off (with battery disconnector).

003603

Machine with fully retracted and lowered boom

Hydraulic and brake systems, depressurizing

1Machine in service position, see Service position page 4.

2Depressurize the hydraulic system.

Turn the start key to position I and activate extension out, a distinct hissing sound is heard if there is pressure in the hydraulic system. Activate lift, extension and sideshift several times.

3Turn the start key to position 0 and turn off the main electric power.

4 Depressurize the attachment. Open the relief valve top lift.

002269

The above illustration shows closed valve.

5Depressurize 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.

Clothes should be in good condition. Remove loosely hanging clothing (tie, scarf, etc.). Do not wear clothes with wide sleeves, wide trouser legs, etc.

Remove jewelry as it may conduct electricity and get caught in moving parts.

Long hair must be tied up securely, otherwise it may easily get caught in moving parts. Be careful when performing welding work or work requiring open flames since hair catches fire easily.

Several mechanics on the same machine

W A R N I N G

Be extra careful if several mechanics work on the same vehicle, so that unintentional movements do not injury another person. Communicate so that everyone knows where all are and what they are doing.

Risks

Work with wheels or axle suspension, mountings, etc. may result in components on the other side moving and causing damage/injury.

Movements performed from the operator’s station, e.g., movement of lifting equipment, may cause severe personal injuries.

Safety actions

•Make sure that the machine’s lifting equipment is completely lowered or secured in another way.

•Move battery disconnector to position zero, remove the key.

•Be aware of the risks when several persons work around the vehicle.

•Make your co-workers aware of what you’re working with.

•Do not work with drive wheels on the machine’s both sides at the same time.

Working under machine

Working under cab

On machines with cab lift the machine shall be secured in raised position 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. Always support under the frame or wheel axle.

Risks

Mechanical or hydraulic tools and lifting devices can fall over or accidentally be lowered due to malfunctions or incorrect use.

Lock on lift frame for securing cab in raised position. Safety actions

Use axle stands and supports that stand securely.

Lifting tools should be inspected and type approved for use.

Lifting heavy components

W A R N I N G

Careless handling of heavy components can lead to serious personal injury and material damage.

Use type approved lifting tools or other devices to move heavy components. Make sure that the device is stable and intact.

Risks

Unsuitable lift slings, straps, etc. may break or slip.

The centre of gravity (balance point) of the component can change during the course of the work, and the component may then make unexpected movements which may cause severe personal injuries and material damage.

A component lifted with lifting equipment can start to turn if the equilibrium is upset.

A component lifted using an overhead crane may start to swing back and forth, which can cause severe crushing injuries or material damage.

Safety precautions

Lift using a lifting device. Use lifting tools or equipment, especially when such equipment is available for specific work operations. See the workshop manual for methods.

If lifting must be performed without lifting device:

•Lift near the body.

•Keep your back vertical. Raise and lower with legs and arms, do not bend your back. Do not rotate your body while lifting. Ask for assistance in advance.

•Wear gloves. They’re good protection against minor crushing injuries and cuts to fingers.

•Always use protective shoes.

Vibrations

In case of long-term use of vibrating tools, for example, impact nut runners or grinders, injuries may be sustained as vibrations can be transmitted from tools to hands. Especially when fingers are cold.

Safety actions

Use heavy gloves to protect against cold and somewhat against vibrations.

Switch between work duties to give the body time to rest.

Vary work position and grip so that the body is not stressed in only one position by the vibrations.

Noise

Noise louder than 85 dB (A) that lasts for longer than 8 hours is considered harmful to hearing. (Limit values may vary between different countries.) High tones (high frequencies) are more damaging than low tones at the same sound level. Impact noise can also be hazardous, e.g. hammer blows.

Risks

At noise levels higher than the limits hearing damage can occur. In more severe cases, hearing damage can become permanent.

Safety precautions

Use hearing protection. Make sure that it is tested and protects against the noise level in question.

Limit noise with noise-absorbing dividers, for example, noise-ab- sorbing materials in roof and on walls.

Solvents

Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax, oil, adhesive, rubber, etc. are called organic solvents. Examples: White (petroleum) spirits, gasoline, thinner, alcohols, diesel, xylene, trichloroethylene, toluene. Many solvents are flammable and constitute a fire hazard.

Risks

Products containing solvents produce vapors that can cause dizziness, headaches and nausea.They may also irritate mucous membranes in the throat and respiratory tracts.

If the solvent comes into direct contact with the skin, this may cause drying and cracking.Risk for skin allergies increases. Solvents may also cause injury if they penetrate through the skin and are absorbed by the blood.

If the body is continuously exposed to solvents, the nervous system may be damaged. Symptoms include sleep disorders, depressions, nervousness, poor memory or general tiredness and fatigue. Continuous inhalation of gasoline and diesel fumes is suspected to cause cancer.

Safety precautions

Avoid inhaling solvent fumes by providing good ventilation, or wearing a fresh-air mask or respiratory device with a suitable filter for the toxic gases.

Never leave a solvent container without tight-sealing lid.

Use solvents with low content of aromatic substances. This reduces the risk of injuries.

Avoid skin contact. Use protective gloves.

Make sure that work clothes are solvent-resistant.

Fire and explosion risks

Examples of explosion-prone substances are oils, petrol, diesel fuel, organic solvents (lacquer, plastic, cleaning agents), rust proofing agents, welding gas, gas for heating (acetylene), high concentration of dust particles of combustible materials. Rubber tyres are highly flammable and cause fires that spread explosively.

Risks

Examples of causes of ignition include welding, cutting, smoking, sparks produced by grinding, inflammable materials coming into contact with hot machine parts, the generation of heat in rags saturated with oil or paint (linseed oil) and oxygen.Oxygen cylinders, lines and valves must be kept free from oil and grease.

Fumes from gasoline, for example, are heavier than air and can thus “run down” a sloping grade, or down into a grease pit, where welding flames, grinding sparks or a burning cigarette can cause an explosion. Evaporated gasoline has a very powerful explosive force.

Special cases

Diesel fuel oil with an additive of petrol has a reduced flash point. Explosion 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.

Welding on or near the machine. If diesel or other oils have leaked out and have been absorbed by rags, absorbing agent, paper or other porous material, glowing welding sparks can cause ignition and an explosive spread of fire.

When a battery is being charged, the battery electrolyte water is divided into oxygen and hydrogen gas. This mixture is very explosive. The risk of explosion is especially high when a booster battery or a rapid-charge unit is used, as these increase the risk of sparks.

The machines nowadays contain a lot of electronic equipment. During welding work, the control units must be disconnected and current turned off using the battery disconnect switch. Otherwise, strong welding currents can short-circuit the electronics, destroy expensive equipment, and may also cause an explosion or fire.

Welding work must never be carried out on painted surfaces (remove paint by blasting at least 10 cm around the welding or cutting point.) Use gloves, breathing protection and protective safety glasses. Also, welding work must never take place near plastic or rubber materials without first protecting them from the heat. Paints, plastics and rubber generate various substances when heated that may be hazardous to health. Be careful with machines that have been exposed to intense heat or a fire.

Safety precautions

Store hazardous substance in approved and sealed container.

Make sure that there is no ignition source near flammable or explosive substances.

Make sure that ventilation is adequate or there is an air extraction unit when handling flammable substances.

Fluid or gas under pressure

High-pressure lines can be damaged during work, and fluid or gas can stream out.

There may be high pressure in a line even if the pump has stopped. Therefore, gas or fluid can leak out when the connection to the hose is loosened.

A gas cylinder subjected to careless handling can explode, for example, if it falls onto a hard surface. Gas can stream out through damaged valves.

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.

•Never work in on a pressurized system.

•Never adjust a pressure limiting valve to a higher pressure than recommended by the manufacturer.

•A hydraulic hose that swells, for example, at a connection, is about to rupture. Replace it as soon as possible! Check connections thoroughly.

•Use fluid when checking for leaks.

•Never blow clothes clean with compressed air.

•Discarded pressure accumulators must first be punctured before they are deposited as waste (to avoid risk of explosion). Carefully drill a hole with 3 mm diameter after depressurizing.

•Never use your hands directly to detect a leak.A fine high-pres- sure stream from a hydraulic hose can easily penetrate a hand and causes very severe injuries.

Coolant

The coolant in the machine’s cooling system consists of water, anticorrosion compound and (when needed) anti-freeze fluid, for example, ethylene glycol.

Coolant must not be drained into the sewer system or directly onto the ground.

Risks

The cooling system operates at high pressure when the engine is warm. Hot coolant can jet out and cause scalding in case of a leak or when the expansion tank cap (filler cap) is opened.

Ingesting ethylene glycol and anti-corrosion compound is dangerous and hazardous to health.

Safety precautions

•Use protective gloves and safety glasses if there is a risk of splashing or spraying.

•Open the filler cap first, to release the excess pressure. Open carefully.Hot steam and coolant can stream out.

•If possible, avoid working on the cooling system when the coolant is hot.

Refrigerant

Refrigerant is used in the machines air conditioning.

Work on the air conditioning system must be performed by accredited/authorized and trained personnel according to national legislation and local regulations.

Risks

The air conditioning operates at high pressure. Escaping refrigerant can cause freeze burns.

Heated refrigerant (e.g. during the repair of leaks in the A/C system), produces gases that are very toxic if inhaled.

Safety precautions

•Use special instructions and equipment for refrigerant according to the workshop manual when working on the air conditioning system. Special certification and authorization must be held by personnel permitted to do the work. (Follow national legislation and local regulations!)

•Use protective gloves and safety glasses if there’s a risk of leaks.

•Make sure that heat-producing sources or objects are not close by (cigarette glow, welding flame).

Air pollution

Air pollution is the impurities in the air around us and which are regarded as hazardous to health. Certain pollution is more prominent in certain environments.

The following health-hazardous air pollution is especially prominent in workshops:

•Carbon monoxide (fumes) is present in exhaust fumes. Odorless and therefore especially dangerous.

•Nitrogen oxides (nitrous gases) are present in exhaust fumes.

•Welding smoke especially hazardous to health when welding on oily surfaces, galvanized or lacquered materials.

•Oil mist for example, when applying anti-corrosion agent.

•Grinding dust and gases generated when grinding and heating plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.

•Isocyanates are present in certain paints, fillers, adhesives and foam plastics used on machines.

Risks

Sulphuric 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 impairing lung function. Even brief exposure to high concentrations can give problems with persistent high sensitivity.

Safety precautions

•Make sure of adequate ventilation with fresh air when welding, battery charging and other work when hazardous gases are generated.

•Use suitable gloves and breathing protection when there’s a risk of oil mist. Make sure that protective gear is oil-resistant.

•Apply oil-resistant protective lotion to unprotected skin.

•Make sure that an eye-wash station is in the immediate vicinity when working with corrosive substances.

•Avoid unnecessary operation of the machine inside the workshop. Connect an air extractor to the exhaust pipe so that the exhaust fumes are removed from the workshop.

Tensioned springs

Examples of tensioned springs:

1.Torque springs in pedals for example.

2.Return spring (cup springs) in parking brake cylinder.

3.Lock rings

4.Gas springs

Risks

If a tensioned spring releases, it is shot out by the spring force and can also take adjoining parts with it.

Small springs can cause eye injuries.

Parking brake springs are tensioned with high force and can cause very severe accidents if they are accidentally released in an uncontrolled manner.

Gas springs and gas-charged shock absorbers are tensioned with high force and can cause very severe accidents if they are accidentally released in an uncontrolled manner.

Safety precautions

•Use safety glasses.

•Lock rings should be of a suitable type and in good condition.

•Follow the instructions in this and other manual when performing maintenance and changing parts and components.

•Always use recommended tools.

Electric motors

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 before starting any work on the machine.

Rotating components and tools

Examples of rotating components and tools:

•Cooling fan

•Drive belts

•Drive shafts

•Drills

•Grinders

Risks

Rotating components, for example, fans or shafts, can cause severe injuries if touched.

Drills, lathes, grinders or other machines with rotating parts can cause severe accidents if clothes or hair get caught and are wound up in the machine.

Safety precautions

•Do not use gloves when working with a drill.

•Remove loose, hanging clothing, scarf or tie.

•Never use clothing with wide sleeves or trouser legs.

•Make sure that clothing is intact and in good condition.

•Long hair should be gathered up in a hair-net or similar.

•Remove large or loose hanging jewellery from hands, arms and neck.

Tyre system

D A N G E 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 personnel.

Risks

Dismantling wheels: Tyres, rims or lock rings can be thrown. Inflating tyres: Tyres, rims and lock rings can be thrown.

Safety actions

•Deflate the tyre before starting to work on the wheel.

•Check that tyres, rims and lock rings aren’t damaged. Never repair damaged rims or lock rings.

•Use protective screen and safety glasses.

Environment

General

Ever-increasing industrialisation of our world is having a significant impact on our global environment. Nature, animals and man are subjected 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. Therefore, all who handle, perform service on or repair machines must use the tools, assisting devices and methods necessary to protect the environment in an environmentally sound manner.

By following the simple rules below, you will contribute to protecting our environment.

Recycling

Deposit discarded materials for recycling or destruction.

Environmentally hazardous waste

Components such as batteries, plastics and other items that may constitute environmentally hazardous waste must be handled and taken care of in an environmentally safe and sound manner.

Discarded batteries contain substances hazardous to personal health and the environment. Therefore, handle batteries in an environmentally safe manner and according to national regulations.

Oils and fluids

Oils freely discharged cause environmental damage and can also be a fire hazard. Therefore, when emptying and draining oils or fuel, take appropriate action to prevent unnecessary spills.

Waste oils and fluids must always be taken care of by an authorised disposal company.

Pay close attention to oil leaks and other fluid leaks! Take immediate action to seal the leaks.

Air conditioning system

The refrigerant in the air conditioning system for the cab adds to the greenhouse effect and may never be intentionally released into open air. Special training is required for all service work on the air conditioning system. Many countries require special certification by an authority for such work.

Working in a contaminated area

Used cab and engine air filters from machines operating in conditions with asbestos dust, or other hazardous dust, must be sealed in air-tight plastic bags before being deposited in the designated area. The machine must be equipped for work in a contaminated area (environmentally contaminated or hazardous to personal health) before work is started. In addition, special local regulations apply when handling and servicing such a machine.

C Preventive

maintenance

Preventive maintenance

See Maintenance manual DRF 400–450, section C Preventive maintenance.

0 Complete machine

Complete machine, description

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. It has four forward gears and four reverse gears. The engine power is transmitted with a torque converter.

The driveline/axle consists of a drive shaft and a rigid drive axle with hub reduction. Drive takes place on the front wheels.

The service brake is of the type disc brake in oil which is built together with the drive wheels’ wheel hubs. The parking brake is of the type disc brake and acts on the drive axle’s input shaft.

Steering takes place on the rear wheels with a double-acting hydraulic cylinder. The steering axle is oscillation-mounted in the frame.

The wheels are mounted on the hubs with clamps. Twin wheels are mounted on the drive axle, the steering axle single wheels.

Load handling is components and functions for handling loads. Loads are lifted with an attachment that is mounted on a liftable telescopic boom. Load handling is divided into the functions lift and lower, extension, sideshift, spreading, rotation, tilt, levelling and load carrying. Lift and lower is the function to lift and lower the boom. Extension is the function to push out and retract the boom. Sideshift is to move the attachment sideways in relation to the machine. Spreading is to adjust the width between the attachment’s lifting points. Rotation is to rotate the load in relation to the machine. Tilt is to angle the load in the machine’s longitudinal direction. Levelling is to angle the load in the machine’s lateral direction (sideways). Load carrying is to grab the load.

The control system are functions for warning the operator of dangerous situations and malfunctions. The control system has diagnostic possibilities that facilitate troubleshooting.

The frame supports the machine. The engine, transmission, drive axle and steering axle are mounted in the frame. On the frame’s sides there are tanks for fuel, hydraulic oil and oil for the brake system. The cab is located in the centre and can be moved fore-aft. As an option the cab is available in a side-mounted version that can be raised and lowered.

Troubleshooting instructions, general

For instructions, see Maintenance manual DRF 400–450. There are following instructions:

•Troubleshooting, general work instructions

•Troubleshooting without error code, example

•Troubleshooting with error code, example

•Troubleshooting cable harnesses

•Troubleshooting hydraulic hoses

1 Engine

Table of Contents 1 Engine

1Engine – Engine

Engine alternative Volvo, function description

III

003161

Engine and gearbox, separation (Volvo engine)

Separation

1Machine in service position, see section B Safety.

2Detach relevant hoses and cables before separating engine and gearbox.

NOTE

Drain and collect liquids before detaching hoses.

3 Attach hoisting equipment to the engine.

4 Use a jack to secure the gearbox.

5Remove the plugs ahead of the flywheel.

The outer hole is used for turning the engine over.

6Remove the flexible plate retaining screws. Turn the engine over until the flexible plate screws are visible through the inner hole. The flexible plate has eight attachment points that must be undone.

7Take up the slack in the hoisting equipment.

NOTE

Do not raise the engine or gearbox.

8Remove the screws between engine and gearbox.

9Remove the engine or gearbox brackets and separate engine and gearbox.

Assembly

10Check that the holes for securing the flexible plate to the flywheel are in line with the plate retaining nuts.

The flexible plate has eight attachment points that must be connected to the flywheel on the engine.

11Fit the engine or gearbox brackets. Tighten to a torque of 168 Nm.

12Connect the engine to the gearbox.

13Insert the screws between engine and gearbox. Tighten to a torque of 40 Nm.

14Fit the flexible plate retaining screws. Tighten to a torque of 40 Nm.

NOTE

To remove a dropped screw the engine must be detached from the engine brackets and separated from the gearbox. Secure the screw in the sleeve on assembly.

15Fit the plugs ahead of the flywheel.

16Remove the hoisting equipment from the engine.

17Remove the jack from underneath the gearbox.

18Attach relevant hoses and cables to engine and gearbox. Check fluid levels and top up as necessary.

8 1 Engine – 1 Engine

Engine and gearbox, separation (Cummins engine)

Separation

1Machine in service position, see section B Safety.

2Attach hoisting equipment to the engine.

3Detach relevant hoses and cables before separating engine and gearbox.

NOTE

Drain and collect liquids before detaching hoses.

4 Use a jack to secure the gearbox.

5Remove the cover plate in front of the flywheel.

6Remove the flexible plate retaining screws. Turn engine over until one of the flexible plate screws is visible through the hole.

7Take up the slack in the hoisting equipment.

NOTE

Do not raise the engine.

8Remove the screws between engine and gearbox.

9Remove the engine or gearbox brackets.

10Withdraw the engine rearwards to separate it from the gearbox.

Assembly

11Rotate the engine until the holes in the flywheel are in line with the flexible plate attachment points.

The flexible plate has eight attachment points that must be connected to the flywheel on the engine.

12Fit the screws in the engine bracket. Tighten to a torque of 168 Nm.

13Connect the engine to the gearbox.

14Fit the screws between engine and gearbox. Tighten to a torque of 52 Nm.

15Fit the flexible plate retaining screws. Tighten to a torque of 40 Nm.

NOTE

To remove a dropped screw the engine must be detached from the engine brackets and separated from the gearbox. Secure the screw in the sleeve on assembly.

16Fit the plug in front of the flywheel.

17Remove the hoisting equipment from the engine.

18Remove the jack from underneath the gearbox.

19Attach relevant hoses and cables to engine and gearbox. Check fluid levels and top up as necessary.

000317

000303

000304

000305

000302

000307

Low fuel level warning lamp, change

The lamp is part of the Kalmar Information Terminal, KIT. Not changed separately. See section 8 Control system, group 8.1.1 Information terminal.

1.1.8Operating menu engine and transmission

Operating menu engine and transmission, description

a.Shows current engine rpm.

b.Shows current speed in km/h (in display kilometer per hour, kph).

c.Shows current gear.

Travel direction and shifting program are shown on steering wheel panel.

d.Shows current fuel level.

1.1.9Operating menu engine

Operating menu engine, description

a.Shows coolant temperature in °C.

Volvo engine: If coolant temperature exceeds 100 °C, engine rpm is restricted to approx. 1000 rpm.

b.Shows engine oil pressure in bar.

1. Manuals
2. Brands
3. Kalmar Manuals
4. Forklifts
5. DRF450-65S5

Manuals and User Guides for Kalmar DRF450-65S5. We have 1 Kalmar DRF450-65S5 manual available for free PDF download: Maintenance Manual

In 2007, the company entered the international holding Cargotec (pronounced Kargotek), an international logistics company that unites three brands: Kalmar, Hiab
and MacGREGOR.

• Kalmar offers loaders, reach stackers and cranes
• Hiab — load-lifting equipment for installation on automobile chassis
• MacGREGOR — services for the design, manufacture and maintenance of ship handling devices.

Overhead crane KALMAR:

• KALMAR RTD 3026
• KALMAR 4010335-80-T
• KALMAR 4011135-80-T
• KALMAR 4014135-108-T

Loaders of logs KALMAR:

• KALMAR RTD 1523
• KALMAR RTD 2714
• KALMAR RTD 3026
• KALMAR RTD 9208

Forklift trucks KALMAR:

• KALMAR DC 4,5-500 (LB)
• KALMAR DC 7-600
• KALMAR DC 4-500 (LB)
• KALMAR DC 5.5-600 (LB)
• KALMAR DC 5-600 (LB)
• KALMAR DC 6-600 (LB)
• KALMAR DC 7,5-600 (LB)
• KALMAR DC 7-600
• KALMAR DC 8-600 (LB)
• KALMAR DCB 28RoRo
• KALMAR DCB 32RoRo
• KALMAR DCD 100-12
• KALMAR DCD 100-12
• KALMAR DCD 100-6
• KALMAR DCD 120-12
• KALMAR DCD 120-6
• KALMAR DCD 136-6
• KALMAR DCD 150-12
• KALMAR DCD 160-12
• KALMAR DCD 160-6
• KALMAR DCD 160-9
• KALMAR DCD 180-6
• KALMAR DCD 220-12
• KALMAR DCD 200-12
• KALMAR DCD 200-12LB
• KALMAR DCD 220-12
• KALMAR DCD 220-12LB
• KALMAR DCD 240-6LB
• KALMAR DCD 240-9LB
• KALMAR DCD 250-12
• KALMAR DCD 250-12LB
• KALMAR DCD 280-12
• KALMAR DCD 280-12LB
• KALMAR DCD 320-12
• KALMAR DCD 320-12G
• KALMAR DCD 320-12G
• KALMAR DCD 320-12LB
• KALMAR DCD 370-12
• KALMAR DCD 370-12CS
• KALMAR DCD 370-12CSG
• KALMAR DCD 370-12G
• KALMAR DCD 40-5
• KALMAR DCD 420-12
• KALMAR DCD 420-12CS
• KALMAR DCD 420-12CS
• KALMAR DCD 50-6
• KALMAR DCD 420-12G
• KALMAR DCD 450-12
• KALMAR DCD 450-12CS
• KALMAR DCD 450-12CSG
• KALMAR DCD 450-12G
• KALMAR DCD 45-5
• KALMAR DCD 50-6
• KALMAR DCD 50-6H
• KALMAR DCD 520-12
• KALMAR DCD 520-12CS
• KALMAR DCD 520-12CSG
• KALMAR DCD 520-12G
• KALMAR DCD 55-6
• KALMAR DCD 55-6H
• KALMAR DCD 60-6
• KALMAR DCD 60-6
• KALMAR DCD 60-6H
• KALMAR DCD 70-32E3
• KALMAR DCD 70-32E3XL
• KALMAR DCD 70-35E4
• KALMAR DCD 70-35E4XL
• KALMAR DCD 70-40E5
• KALMAR DCD 70-6
• KALMAR DCD 70-6H
• KALMAR DCD 75-6
• KALMAR DCD 75-6H
• KALMAR DCD 80-45E5
• KALMAR DCD 80-45E5R
• KALMAR DCD 80-45E6
• KALMAR DCD 80-45E6R
• KALMAR DCD 80-45E7
• KALMAR DCD 80-45E8
• KALMAR DCD 80-6
• KALMAR DCD 80-9
• KALMAR DCD 80-9H
• KALMAR DCD 90-6
• KALMAR DCD 90-6L
• KALMAR DCD 90-6LH
• KALMAR DCD8 0-6H
• KALMAR DCE 280Ro
• KALMAR DCE 60-6
• KALMAR DCE 330RoRo
• KALMAR DCE 60-6
• KALMAR DCE 70-6
• KALMAR DCE 75-6
• KALMAR DCE 80-6
• KALMAR DCE 80-9
• KALMAR DCE 90-180
• KALMAR DCE 90-6L
• KALMAR DCF 360CSG
• KALMAR DCF 410CSG
• KALMAR DCF 450CSG
• KALMAR EDC 60-6
• KALMAR EDC 50-6
• KALMAR EDC 55-6
• KALMAR EDC 70-6
• KALMAR EDC 75-6
• KALMAR EDC 80-6
• KALMAR EDC 90-6L
• KALMAR GDC 40-5
• KALMAR GDC 40-5
• KALMAR GDC 45-5
• KALMAR GDC 50-6
• KALMAR GDC 55-6
• KALMAR GDC 60-6
• KALMAR GDC 70-6
• KALMAR GDC 75-6
• KALMAR GDC 80-6
• KALMAR GDC 80-9
• KALMAR GDC 90-6L
• KALMAR TD 1612HS
• KALMAR TD 1712HS
• KALMAR TD 912XS

Wheel loaders KALMAR:

• KALMAR DCD 70
• KALMAR DCE 70
• KALMAR DCE80-100

Reachstackers (container loaders) KALMAR:

• KALMAR DRD 100-5258
• KALMAR DRD 100-5258
• KALMAR DRD 100-5286
• KALMAR DRD 200-52B3
• KALMAR DRD 420-60S5
• KALMAR DRD 420-65S5
• KALMAR DRD 420-65S6
• KALMAR DRD 420-70S5
• KALMAR DRD 450-60S5
• KALMAR DRD 450-60S5X
• KALMAR DRD 450-65S5
• KALMAR DRD 450-60S5X
• KALMAR DRD 450-65S5XS
• KALMAR DRD 450-65S6
• KALMAR DRD 450-65S6X
• KALMAR DRD 450-65SX
• KALMAR DRD 450-70S5
• KALMAR DRD 450-70S5X
• KALMAR DRD 450-70S5XS
• KALMAR DRD 450-80S5X (S)
• KALMAR RDS 4227-4CH
• KALMAR RDS 4227-4CH
• KALMAR RDS 4227-4TL
• KALMAR RDS 4227-5TL
• KALMAR RDS 4227-6TL
• KALMAR RDS 4231-4TL
• KALMAR RDS 4231-5TL
• KALMAR RDS 4231-6TL
• KALMAR RDS 4527-4CH
• KALMAR RDS 4531-4TL
• KALMAR RDS 4531-5CH
• KALMAR RDS 4531-5TL
• KALMAR RDS 4531-6TL
• KALMAR RDS 4535-4TL
• KALMAR RDS 4535-5CH
• KALMAR RDS 4535-5TL
• KALMAR RDS 4535-6TL
• KALMAR RDS 4540-5TL
• KALMAR TRX 182
• KALMAR RDS 4540-6TL

Tractor units KALMAR:

• KALMAR TR 161
• KALMAR TR 181
• KALMAR TR 241
• KALMAR TR 618i
• KALMAR TRX 182
• KALMAR TT 131
• KALMAR TT 161
• KALMAR TT 612d
• KALMAR TT 618i

Terminal tractors KALMAR:

• KALMAR RTD 3026
• KALMAR TRX 182
• KALMAR TT 618i
• KALMAR TR 618i
• KALMAR TT 612d

Log loaders KALMAR:

• KALMAR RTD 1623
• KALMAR RTD 3026

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