Kalmar DRF 400, DRF 450 Maintenance Manual

Maintenance

AForeword

BSafety

C Preventive maintenance

0 Complete machine

1Engine

manual

2 Transmission

3 Driveline/axle

4Brakes

5Steering

6 Suspension

7 Load handling

8 Control system

9 Frame, body, cab and accessories

10 Common hydraulics

11 Common electrics

12 Common pneumatics

DError codes

ESchematics

F Technical data

G Terminology and index

A Foreword 1

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

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

Maintenance manual DRF 400–450

UDRF01.04GB

2 A Foreword

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Maintenance manual DRF 400–450

mm mm mm mm

A Foreword – Foreword 3

Foreword

About the Maintenance Manual

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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.

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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.

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Storage

NOTE

The maintenance manual shall be accessible to service personnel.

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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.

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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.

Maintenance manual DRF 400–450

UDRF01.04GB

4 A Foreword – Reading instructions

Reading instructions

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Warning information

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

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

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Read the operator's manual

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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.

Read 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.

000262001128

Read maintenance manual

The symbol to the left is used in certain cases on the machine and refers to important information in the maintenance manual.

Read the maintenance manual

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Maintenance manual DRF 400–450

A Foreword – Reading instructions 5

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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 struc- ture 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 inaccuracies.

B Safety Keep in mind for your safety.

C Preventive maintenance General information about preventive maintenance of the machine.

0 Complete machine

1Engine

2 Transmission

3 Driveline/axle

4Brakes

5 Steering

6 Suspension

7 Load handling

8 Control system

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.

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 abbrevia-

tions that may appear in the manual, index for headings in the manual.

Maintenance manual DRF 400–450

UDRF01.04GB

6 A Foreword – Reading instructions

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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 manuals. 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.

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Maintenance manual DRF 400–450

A Foreword – Reading instructions 7

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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.

Function descriptions

(Section 0-12)

Diagnostic test

(Section 8)

• From Function description to Hydraulic diagram, for hydraulic diagrams of function in question.

• From Error codes to Diagnostic test, for diagnostic menu to troubleshoot component or function in question.

• From Error codes to Function description, for further information about components or function.

Hydraulic diagrams

(Section E)

Error codes

(Section D)

Wiring diagrams

(Section E)

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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.

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8 A Foreword – Reading instructions

Optional equipment

Optional equipment are options that can be added to the standard

000264

Symbol indicating optional equipment

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.

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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 Kalmar Industries AB.

NOTE

All documents that accompany the machine are non-registered documents and there will be no notification of changes.

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Maintenance manual DRF 400–450

A Foreword – Reading instructions 9

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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.

2 4 Bromsar – 4.3 Servobromssystem

D790-2

D797-R

ACC

D797-F

1. Bromsoljepump 8. Slutkontakt bromsljus (S216)

2. Bromsoljefilter 9. Brytkontakt bromsoljetryck (S204)

3. Ackumulatorladdningsventil 10. Reglerenhet ram fram (D797-F)

4. Ackumulatorer 11. Reglerenhet ram bak (D797-R)

5. Bromsventil 12. Bromsljus (H411L & H411R)

6. Bromscylindrar 13. Reglerenhet KIT (D790-2), Varningslampa bromstryck

7. Hjulbromsar

Hydraulschema basmaskin

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Underhållamamual DRF 400–450

Example of function description

Maintenance manual DRF 400–450

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10 A Foreword – Reading instructions

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 section 8 Control system, group 8.4 Diag-

nostics

4. Illustration of function, (applied brake)

5. Component list

6. Position number in illustration, reference to component list

7. Electric power (solid single line)

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Maintenance manual DRF 400–450

A Foreword – Reading instructions 11

910

11 12

D790-1

13 14

D797-F

15 16

17 18

˚C

19 20

˚C

21 22

˚C

26 27

28 29

000523

Symbol explanation function descriptions

The following symbols are used in function descriptions, the symbols are based on standard symbols used in wiring and hydraulic diagrams.

1. Electric control signal

2. Electric force

3. Hydraulic control signal

4. Hydraulic force

5. Hydraulic motor

6. Hydraulic oil pump with variable displacement

7. Hydraulic oil pump with fixed displacement

8. Electric motor

9. Accumulator

10. Disc brake

11. Filter

12. Radiator

13. Bulb

14. Control system, two control units with CAN-buss

15. Restriction

16. Adjustable restriction

17. Inductive position sensor

18. Electrically controlled servo valve

19. Thermal by-pass valve

20. Temperature-controlled switch

21. Temperature sensor

22. Pressure sensor

23. Pressure-controlled switch

24. Hydraulic cylinder

25. Double-acting hydraulic cylinder

26. Spring brake cylinder

27. Valve block

28. Shuttle valve

29. Non-return valve

Maintenance manual DRF 400–450

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12 A Foreword – About the documentation

About the documentation

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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.

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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.

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Maintenance manual DRF 400–450

A Foreword – Feedback 13

Feedback

page –

To: Kalmar Industries AB

Product Support

Torggatan 3

SE-340 10 Lidhult

SWEDEN

Fax: +46 372 263 93

From:

Company / Sender: ..........................................................................................................................................

Telephone: ..........................................................................................................................................................

Form for copying

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 for your participation!

Manual information

Suggestions, views, remarks, etc.

E-mail: .................................................................................................................................................................

Date: .................................... - .................. - ..................

Name / Publication number: .............................................................................................................................

Section / page number: ......................................................................................................................................

.............................................................................................................................................................................

Maintenance manual DRF 400–450

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14 A Foreword – Feedback

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Maintenance manual DRF 400–450

B Safety 1

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 ................................................................................................ 4

Hydraulic and brake systems, depressurizing .................................................. 5

Clothing etc. ...................................................................................................... 6

Several mechanics on the same machine ....................................................... 6

Working under machine ................................................................................... 7

Lifting heavy components ................................................................................ 7

Vibrations .......................................................................................................... 8

Noise ................................................................................................................. 8

Solvents ............................................................................................................ 9

Fire and explosion risks .................................................................................... 9

Fluid or gas under pressure ............................................................................ 10

Coolant ............................................................................................................ 11

Refrigerant ...................................................................................................... 12

Air pollution .................................................................................................... 12

Tensioned springs ........................................................................................... 13

Electric motors ................................................................................................ 14

Rotating components and tools ..................................................................... 14

Tyre system ..................................................................................................... 15

Environment ............................................................................................. 16

General ............................................................................................................ 16

Maintenance manual DRF 400–450

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2B Safety

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Maintenance manual DRF 400–450

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B Safety – Safety 3

Safety

General safety information

page –

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 machine 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!

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.

That' s why it's important that all who work with the machine, or repair/service the machine read and follow the information in the manual and operator's 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.

Maintenance manual DRF 400–450

UDRF01.04GB

4 B Safety – Safety instructions

Safety instructions

page –

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 9

• 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

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Machine with fully retracted and lowered boom

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

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B Safety – Safety instructions 5

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Hydraulic and brake systems, depressurizing

1 Machine in service position.

2 Depressurize 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.

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

power.

4 Depressurize the attachment.

Open the relief valve top lift.

The above illustration shows closed valve.

002269

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UDRF01.04GB

6 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.

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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

WARNING

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.

UDRF01.04GB

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.

Maintenance manual DRF 400–450

B Safety – Safety instructions 7

001977

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Lock on lift frame for securing cab in raised position.

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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.

Safety actions

Use axle stands and supports that stand securely.

Lifting tools should be inspected and type approved for use.

Lifting heavy components

WARNING

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.

Maintenance manual DRF 400–450

UDRF01.04GB

8 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:

• 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.

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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.

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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.

UDRF01.04GB

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-absorbing materials in roof and on walls.

Maintenance manual DRF 400–450

B Safety – Safety instructions 9

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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.

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Fire and explosion risks

Examples of explosion-prone substances are oils, petrol, diesel fuel, organic solvents (lacquer, plastic, cleaning agents), rustproofing 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.

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10 B Safety – Safety instructions

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.

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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.

Maintenance manual DRF 400–450

B Safety – Safety instructions 11

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-pressure stream from a hydraulic hose can easily penetrate a hand and causes very severe injuries.

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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.

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12 B Safety – Safety instructions

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Refrigerant

Refrigerant is used in the machine’s air conditioning system.

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

Risks

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

Refrigerant that is heated (e.g., when repairing leaking climate/AC system), generates gases that are very dangerous to inhale.

Safety actions

• Use special instructions and equipment for refrigerant according to the manual when working on the air conditioning system. Special certification and authorization is often required of the person who may do the work. (Note 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).

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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.

UDRF01.04GB

Maintenance manual DRF 400–450

B Safety – Safety instructions 13

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 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.

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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.

Maintenance manual DRF 400–450

UDRF01.04GB

14 B Safety – Safety instructions

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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.

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Rotating components and tools

Examples of rotating components and tools:

• Cooling fan

•Drive belts

• Propeller 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 jewelry from hands, arms and neck.

UDRF01.04GB

Maintenance manual DRF 400–450

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