Kalmar DRF450 Service Manual

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Workshop manual

I§

AForeword

BSafety

CPreventive maintenance

0Complete machine

1Engine

2Transmission

3Driveline/axle

4Brakes

5Steering

6Suspension

7Load handling

8 Control system

9Frame, body, cab and accessories

10 Common hydraulics

11 Common electrics

12 Common pneumatics

DError codes

ESchematics

FTechnical data

GTerminology and index

A F o r e w o r d 1

A Foreword

Table of Contents A Foreword

A Foreword..............................................................................................3

About the Workshop Manual ..................................................................... 3

General .............................................................................................................. 3

Workshop manual contents .............................................................................. 3

References between different information types ............................................ 4

Function group breakdown .............................................................................. 5

Conditions ......................................................................................................... 5

Storage .............................................................................................................. 5

About the machine version .............................................................................. 5

Reading instructions .................................................................................. 7

Warning information ......................................................................................... 7

Important information ...................................................................................... 7

Read the operator's manual/maintenance manual ......................................... 7

Optional equipment .......................................................................................... 7

Function descriptions ....................................................................................... 8

About the documentation ....................................................................... 11

Documentation sections ................................................................................. 11

Ordering of documentation ............................................................................ 11

Feedback .................................................................................................. 12

Form for copying ............................................................................................. 12

Workshop manual DRF 400–450

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2 A Foreword

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Workshop manual DRF 400–450

A Foreword – A Foreword 3

A Foreword–

A Foreword

About the Workshop Manual

General

Thank you for choosing Kalmar Industries as your machine supplier. We hope that we'll meet your expectations.

Workshop manual contents

The workshop manual contains information for corrective maintenance (replacement of components) and complements the maintenance manual. Accompanying the workshop manual is supplier documentation for engine, transmission and drive axle. Where practicable, please refer from the workshop manual to the maintenance manual and supplier documentation to avoid duplicated information. The workshop manual is divided into the following sections.

AForeword General information about the workshop manual's purpose, contents and

reading instructions as well as survey for feedback of views and any inaccuracies.

BSafety Keep in mind for your safety.

CPreventive maintenance Reference to maintenance manual: Preventive maintenance.

0Complete machine

1Engine

2 Transmission

3Driveline/axle

4Brakes

5Steering

6Suspension

7Load handling

8Control system

9Frame, body, cab and accessories

10 Common hydraulics

11 Common electrics

12 Common pneumatics

DError codes Reference to maintenance manual: Error code information and instructions for

Technical description, comprehensive function descriptions and a description of the function of components included in the machine, divided into function groups.

The components used for each function are described under each subfunction. Consequently, common components are described in several places, but in general under the first function to use the component.

Together with the general description is a detailed description of what is unique about the specific subfunction. The next subfunction to use the same component only has a description what is unique for the new function.

Work instructions for corrective maintenance (replacement of components).

reading error code information.

ESchematics Reference to maintenance manual: Wiring and hydraulic diagrams

F Technical data Technical data, conversion tables, information for conversion of units.

G Terminology and index General terminology and abbreviations, explanation of terms and abbrevia-

tions that can appear in the sections, index for headings in the sections.

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4 A Foreword– About the Workshop Manual

References between different information types

The maintenance manual and workshop manual are mainly divided into function groups, see Workshop manual contents page 3. Certain parts are broken out as separate parts to increase usability, e.g., “Technical data”.

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 references according to the below.

Function descriptions

(Technical description)

Component descriptions

(Technical description, usually in Workshop manual)

Diagnostic test

(Group 8.4)

Hydraulic diagrams

(Section E)

Error codes

(Section D)

Wiring diagrams

(Section E)

•From Function description to Component description, to enable fast finding of more information about the different components that create a function.

•From Function description to Hydraulic diagram, to enable fast finding of the right hydraulic diagram for the function in question.

•From Component description or Function description to Diagnostic test, to enable fast finding of the right diagnostic menu that can be used to check the component (only applies to electrical components).

•From Diagnostic test to Wiring diagrams. to enable fast finding of the right circuit diagram for further troubleshooting.

•From Diagnostic test to Component description or Function description. To enable fast finding of more information about the component's appearance and position when troubleshooting.

•From Error codes to Diagnostic test, to enable fast finding of the right diagnostic menu to troubleshoot component or function in question.

•From Error codes to Function description or Component description, to enable fast finding of more information about components or function.

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A Foreword – About the Workshop Manual 5

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.

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6 A Foreword– About the Workshop Manual

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.

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A Foreword – Reading instructions 7

Reading instructions

Warning information

Warnings inform on p o tential dangers w h ich can, if the warning s 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.

Read the operator’s manual/maintenance manual

Indicates optional equipment

CAUTION

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 the operator's manual/maintenance manual

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

000262

Optional equipment

The symbol to the left is used in the manual to indicate that a function or component is optional equipment. Detailed information on

000264

how the machine is equipped is presented by the machine card enclosed with the spare parts catalogue.

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8 A Foreword– Reading instructions

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.

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000520

Example of function description

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A Foreword – Reading instructions 9

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 compo-

nent

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)

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10 A Foreword – Reading instructions

Symbol explanation function descriptions

9 10

11 12

D790-1

13 14

D797-F

15 16

17 18

˚C

19 20

˚C

21 22

˚C

26 27

28 29

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-bus

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

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A Foreword – About the documentation 11

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.

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12 A Foreword – Feedback

Feedback

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!

To: Kalmar Industries AB

Product Support

Torggatan 3

SE-340 10 Lidhult

SWEDEN

Fax: +46 372 263 93

From:

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

Manual information

Suggestions, views, remarks, etc.

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

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

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

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

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

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

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Workshop manual DRF 400–450

B S a f e t y 1

B Safety

Table of Contents B Safety

B 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 ............................................................................................................ 8

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

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2 B Safety

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B Safety – B Safety 3

B Safety–

B 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.

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4 B Safety– Safety instructions

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

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).

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B Safety – Safety instructions 5

Hydraulic and brake systems, depressurizing

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

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.

The above illustration shows closed valve.

4 Depressurize the attachment.

Open the relief valve top lift.

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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.

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 caref u l when performing w elding 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.

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.

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B Safety – Safety instructions 7

001977

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.

Lock on lift frame for securing cab in raised position.

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.

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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.

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-absorbing materials in roof and on walls.

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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.

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B Safety – Safety instructions 9

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.

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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.

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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.

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

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 heat- ing plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.

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

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B Safety – Safety instructions 13

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 ha zardous g ases 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.

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14 B Safety – Safety instructions

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.

VDRF01.01S

Workshop manual DRF 400–450

B Safety – Safety instructions 15

Tyre system

DANGER

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.

Workshop manual DRF 400–450

VDRF01.01S

16 B Safety – Environment

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, y ou will contribut e 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.

VDRF01.01S

Workshop manual DRF 400–450

C Preventive maintenance 1

C Preventive

maintenance

Preventive maintenance

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

Workshop manual DRF 400–450

VDRF01.01GB

2 C Preventive maintenance

VDRF01.01GB

Workshop manual DRF 400–450

0 Complete machine 1

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.

Workshop manual DRF 400–450

VDRF01.01GB

2 0 Complete machine

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

VDRF01.01GB

Workshop manual DRF 400–450

1 E n gi n e 1

1 Engine

Table of Contents 1 Engine

1 Engine....................................................................................................... 3

1.1 Controls and instrumentation .................................................................. 13

1.1.1 Ignition ................................................................................................. 13

1.1.2 Accelerator .......................................................................................... 14

1.1.3 Warning light low oil pressure in engine ............................................. 15

1.1.4 Indicator light preheating .................................................................... 15

1.1.5 Warning light low coolant level ........................................................... 15

1.1.6 Warning light high coolant temperature ............................................. 16

1.1.7 Warning light low fuel level ................................................................. 16

1.1.8 Operating menu engine and transmission .......................................... 16

1.1.9 Operating menu engine ....................................................................... 16

1.2 Fuel system .............................................................................................. 17

1.2.1 Fuel tank .............................................................................................. 17

1.2.2 Sensor fuel level .................................................................................. 17

1.2.3 Fuel pre-filter ....................................................................................... 17

1.2.4 Fuel filter ............................................................................................. 17

1.2.5 Sensor water in fuel ............................................................................ 17

1.2.6 Fuel pump ........................................................................................... 18

1.2.7 Sensor fuel pressure ........................................................................... 18

1.2.8 Injectors ............................................................................................... 18

1.2.9 Breaking contact fuel pressure ........................................................... 18

1.2.10 Making contact water in fuel .............................................................. 18

1.5 Mechanical parts ..................................................................................... 19

1.6 Air intake and exhaust outlet .................................................................. 20

1.6.1 Air cleaning system ............................................................................. 20

1.6.2 Turbo ................................................................................................... 20

1.6.3 Exhaust system ................................................................................... 21

1.6.4 Intercooler ........................................................................................... 22

1.6.5 Sensor boost pressure ........................................................................ 22

1.6.6 Sensor charge-air temperature ........................................................... 22

1.7 Cooling system ......................................................................................... 23

1.7.1 Coolant pump ...................................................................................... 23

1.7.2 Coolant filter ........................................................................................ 23

1.7.3 Coolant thermostat ............................................................................. 23

1.7.4 Radiator and expansion tank .............................................................. 24

1.7.5 Cooling fan .......................................................................................... 25

1.7.6 Oil cooler ............................................................................................. 28

1.7.7 Coolant ................................................................................................ 28

1.7.8 Making contact coolant level .............................................................. 29

1.7.9 Sensor coolant temperature ............................................................... 29

1.7.10 Plug-in heater ...................................................................................... 30

1.8 Lubrication ............................................................................................... 31

1.8.1 Oil sump .............................................................................................. 31

1.8.2 Oil pump .............................................................................................. 31

Workshop manual DRF 400–450

VDRF01.01GB

2 1 Engine

1.8.3 Sensor oil pressure .............................................................................. 31

1.8.4 Full flow filter ....................................................................................... 31

1.8.5 By-pass filter ........................................................................................ 31

1.8.6 Oil cooler .............................................................................................. 31

1.8.7 Sensor oil temperature ........................................................................ 31

1.9 Control system engine ............................................................................. 32

1.9.1 Control unit engine .............................................................................. 32

1.10 Ignition/heating ......................................................................................... 33

1.10.1 Preheating ............................................................................................ 33

1.11 Start/stop .................................................................................................. 34

1.11.1 Start motor ........................................................................................... 34

1.11.2 Stop device .......................................................................................... 34

VDRF01.01GB

Workshop manual DRF 400–450

1 Engine – 1 Engine 3

1 Engine–

1 Engine

Engine alternative Volvo, function description

Condition Reference value Reference

Engine heater

2, 11

20, 22

Disconnected (when cable is in start lock-out is activated) Engine heater, description page 30

˚C

bar

rpm kph

18, 21

III

<˚

1, 5

6, 15

D790-1 D790-2 D795

D793

3, 7, 12

D794

SENSORS

14, 23

H2O

D797-R

003161

Pos Explanation Signal description Reference

1 The ignition sends voltage signal to

Control unit cab (D790-1) when the start key is turned to position 1 or preheating position.

2Control unit cab (D790-1) sends ig-

nition on via CAN-bus. If the key is turned to preheating position then preheating is also sent on the CANbus.

3If preheating has been activated

with start key, then control unit engine (D794) feeds voltage to the preheating coil.

U = 24 V Ignition, description page 13

Diagnostic menu, see Maintenance manual

DRF 400–450, section 8 Control system, group

8.4.1.4 CAN/POWER, menu 4 and 8.4.6.4 EN- GINE, menu 4

Checked by control system, error shown with error code.

U = 24 V Preheating coil, description page 33

Workshop manual DRF 400–450

Section 11 Common electrics, group 11.6

Communication

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.6.5 ENGINE, menu 5

VDRF01.01GB

4 1 Engine– 1 Engine

Pos Explanation Signal description Reference

4 The preheating coil warms the inlet

air for the engine.

- Preheating coil, description page 33

Diagnostic menu, see Maintenance manual

DRF 400–450, section 8 Control system, group

8.4.6.5 ENGINE, menu 5

5 The ignition sends voltage signal to

Control unit KIT (D790-2) when the start key is turned to start position.

U = 24 V Ignition, description page 13

Diagnostic menu, see Maintenance manual

DRF 400–450, section 8 Control system, group

8.4.1.4 CAN/POWER, menu 4 and 8.4.6.4 ENGINE, menu 4

6Control unit KIT (D790-2) sends start

signal on the CAN-bus.

7Control unit engine (D794) feeds

U = 24 V Starter motor, description (Volvo engine) page

voltage to starter motor.

Section 11 Common electrics, group 11.6

Communication

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.6.5 ENGINE, menu 5

8Starter motor rotates engine. - Starter motor, description (Volvo engine) page

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.6.5 ENGINE, menu 5

9 The engine's sensors send signals

to Control unit engine (D794) which controls the injectors so that the engine starts.

10 Throttle pedal sends voltage signal

proportional to downward pressing to Control unit cab (D790-1).

11 Control unit cab sends message

with rpm request on CAN-bus.

12 Control unit engine increases en-

gine rpm.

13 Make-contact coolant level sends

voltage signal to Control unit engine (D794) if coolant level is low in expansion tank.

-Section 11 Common electrics, group 11.5.3.10

Control unit engine

U = 0.5–4.5 V

Lower voltage than 0.5 V and higher voltage than

4.5 V used to detect mal-

Accelerator pedal, description page 14

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.6.1 ENGINE, menu 1

function in cable harnesses and controls.

Checked by control system, error shown with

Section 11 Common electrics, group 11.6

Communication

error code.

-Section 11 Common electrics, group 11.5.3.10

Control unit engine

U = 24 V Cooling system, description page 23

VDRF01.01GB

Workshop manual DRF 400–450

1 Engine – 1 Engine 5

Pos Explanation Signal description Reference

14 Control unit engine sends engine

data and warning messages on CAN-bus.

15 Control unit KID (D795) shows en-

gine data via display figures.

16 Sensor fuel level (B757) sends volt-

age signal proportional to fuel level in tank to Control unit frame rear (D797-R).

17 Control unit frame rear (D797-R)

sends fuel level on CAN-bus.

18 Control unit KID (D795) shows fuel

level in operating menu for engine.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.6

Communication

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.6.6 ENGINE, menu 6 and 8.4.6.7 ENGINE, menu 7

- Operating menu engine and transmission, description page 16Operating menu engine, description page 16

U = 0.5–4.5 V

Lower voltage than 0.5 V and higher voltage than

4.5 V used to detect mal-

Sensor fuel level, description page 17

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.3.7 CAB, menu 7

function in cable harnesses and controls.

Checked by control system, error shown with

Section 11 Common electrics, group 11.6

Communication

error code.

- Operating menu engine, description page 16

19 Sensor output shaft (B758) sends

pulses with frequency proportional to rpm on output shaft to control unit transmission (D793).

20 Control unit transmission (D793)

sends speed on CAN-bus.

21 Control unit KID (D795) shows the

machine's speed.

22 If the rpm on the output shaft is so

high that it matches the limit for the machine's speed limitation, then Control unit transmission (D793) sends reduce engine rpm on the CAN-bus.

23 Control unit engine (D794) restricts

engine rpm.

-Section 2 Transmission, group 2.3.8 Sensor

output shaft

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.7.6 TRANSM, menu 6

Checked by control system, error shown with

Section 11 Common electrics, group 11.6

Communication

error code.

Section 11 Common electrics, group 11.5.3.12

Control unit KID

Section 11 Common electrics, group 11.6 Communication

-Section 11 Common electrics, group 11.5.3.10 Control unit engine

Workshop manual DRF 400–450

VDRF01.01GB

6 1 Engine– 1 Engine

Engine and gearbox, separation (Volvo engine)

Separation

1 Machine in service position, see section B Safety.

2 Detach relevant hoses and cables before separatin g 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.

5 Remove the plugs ahead of the flywheel.

The outer hole is used for turning the engine over.

6 Remove 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.

7 Take up the slack in the hoisting equipment.

NOTE

Do not raise the engine or gearbox.

VDRF01.01GB

Workshop manual DRF 400–450

1 Engine – 1 Engine 7

8 Remove the screws between engine and gearbox.

9 Remove the engine or gearbox brackets and separate engine

and gearbox.

Assembly

10 Check that the holes for securing the flexible plate to the fly-

wheel 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.

11 Fit the engine or gearbox brackets.

Tighten to a torque of 168 Nm.

12 Connect the engine to the gearbox.

13 Insert the screws between engine and gearbox. Tighten to a

torque of 40 Nm.

14 Fit 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.

15 Fit the plugs ahead of the flywheel.

16 Remove the hoisting equipment from the engine.

17 Remove the jack from underneath the gearbox.

18 Attach relevant hoses and cables to engine and gearbox. Check

fluid levels and top up as necessary.

Workshop manual DRF 400–450

VDRF01.01GB

8 1 Engine– 1 Engine

Engine alternative Cummins, function description

Condition Reference value Reference

Engine heater

<˚

2, 9

18, 20

Disconnected (when cable is in start lock-out is activated) Engine heater, description page 30

˚C

bar

rpm kph

III

1, 3

D794

4, 13

12, 21

D797-R

D790-1 D790-2 D795

D793

H2O

5, 10

SENSORS

16, 19

003162

Pos Explanation Signal description Reference

1 The ignition sends voltage signal to

Control unit cab (D790-1) when the start key is turned to position 1.

2Control unit cab (D790-1) sends ig-

nition on start message on CANbus.

3 The ignition sends voltage signal to

Control unit KIT (D790-2), when the start key is turned to start position.

4Control unit KIT (D790-2) sends start

signal on the CAN-bus.

U = 24 V Ignition, description page 13

Diagnostic menu, see Maintenance manual

DRF 400–450, section 8 Control system, group

8.4.1.4 CAN/POWER, menu 4 and 8.4.6.4 ENGINE, menu 4

Checked by control system, error shown with

Section 11 Common electrics, group 11.6

Communication

error code.

U = 24 V Ignition, description page 13

Diagnostic menu, see Maintenance manual

DRF 400–450, section 8 Control system, group

8.4.1.4 CAN/POWER, menu 4 and 8.4.6.4 ENGINE, menu 4

Checked by control system, error shown with

Section 11 Common electrics, group 11.6

Communication

error code.

VDRF01.01GB

Workshop manual DRF 400–450

1 Engine – 1 Engine 9

Pos Explanation Signal description Reference

5 Control unit frame rear (D797-R)

feeds voltage to starter motor.

U = 24 V Starter motor, description (Cummins engine)

page 34

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.6.5 ENGINE, menu 5

6Starter motor rotates engine - Starter motor, description (Cummins engine)

page 34

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.6.5 ENGINE, menu 5

7 The engine's sensors send signals

to Control unit engine (D794) which

-Section 11 Common electr i cs, group 11 .5.3.10

Control unit engine

controls the injectors so that the engine starts.

8 Throttle pedal sends voltage signal

proportional to downward pressing to Control unit cab (D790-1).

U = 0.5–4.5 V

Lower voltage than 0.5 V and higher voltage than

4.5 V used to detect mal-

Accelerator pedal, description page 14

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.6.1 ENGINE, menu 1

function in cable harnesses and controls.

9Control unit cab sends message

with rpm request on CAN-bus.

Checked by control system, error shown with

Section 11 Common electrics, group 11.6

Communication

error code.

10 Control unit engine increases en-

gine rpm.

11 Make-contact coolant level sends

voltage signal to Control unit engine (D794) if coolant level is low in expansion tank.

12 Control unit engine (D794) sends

engine data and warning messages on CAN-bus.

13 Control unit KID (D795) shows en-

gine data via display figures.

14 Sensor fuel level (B757) sends volt-

age signal proportional to fuel level in tank to Control unit frame rear (D797-R).

-Section 11 Common electrics, group 11.5.3.10

Control unit engine

U = 24 V Cooling system, description page 23

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.6

Communication

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.6.6 ENGINE, menu 6 and 8.4.6.7 ENGINE, menu 7

- Operating menu engine and transmission, description page 16Operating menu engine, description page 16

U = 0.5–4.5 V

Lower voltage than 0.5 V and higher voltage than

4.5 V used to detect mal-

Sensor fuel level, description page 17

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.3.7 CAB, menu 7

function in cable harnesses and controls.

Workshop manual DRF 400–450

VDRF01.01GB

10 1 Engine – 1 Engine

Pos Explanation Signal description Reference

15 Control unit frame rear (D797-R)

sends fuel level on CAN-bus.

16 Control unit KID (D795) shows fuel

level in operating menu for engine.

17 Sensor output shaft (B758) sends

pulses with frequency proportional to rpm on output shaft to control unit transmission (D793).

18 Control unit transmission (D793)

sends “reduce engine rpm” on CAN-bus.

19 Control unit KID (D795) shows the

machine's speed.

20 If the rpm on the output shaft is so

high that it matches the limit for the machine's speed limitation, then Control unit transmission (D793) sends reduce engine rpm on the CAN-bus.

Checked by control system, error shown with

Section 11 Common electrics, group 11.6

Communication

error code.

- Operating menu engine, description page 16

-Section 2 Transmission, group 2.3.9 Sensor

output shaft

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.7.6 TRANSM, menu 6

Checked by control system, error shown with

Section 11 Common electrics, group 11.6

Communication

error code.

-Section 11 Common electrics, group 11.5.3.12

Control unit KID

Checked by control system, error shown with

Section 11 Common electrics, group 11.6

Communication

error code.

21 Control unit engine (D794) restricts

engine rpm.

-Section 11 Common electrics, group 11.5.3.10

Control unit engine

VDRF01.01GB

Workshop manual DRF 400–450

1 Engine – 1 Engine 11

Engine and gearbox, separation (Cummins engine)

Separation

1 Machine in service position, see section B Safety.

2 Attach hoisting equipment to the engine.

3 Detach relevant hoses and cables b efore separat ing engine and

gearbox.

NOTE

Drain and collect liquids before detaching hoses.

4 Use a jack to secure the gearbox.

5 Remove the cover plate in front of the flywheel.

6 Remove the flexible plate retaining screws. Turn engine over

until one of the flexible plate screws is visible through the hole.

7 Take up the slack in the hoisting equipment.

NOTE

Do not raise the engine.

8 Remove the screws between engine and gearbox.

9 Remove the engine or gearbox brackets.

10 Withdraw the engine rearwards to separate it from the gear-

box.

Assembly

11 Rotate 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.

12 Fit the screws in the engine bracket.

Tighten to a torque of 168 Nm.

13 Connect the engine to the gearbox.

14 Fit the screws between engine and gearbox. Tighten to a

torque of 52 Nm.

Workshop manual DRF 400–450

VDRF01.01GB

12 1 Engine – 1 Engine

15 Fit 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.

16 Fit the plug in front of the flywheel.

17 Remove the hoisting equipment from the engine.

18 Remove the jack from underneath the gearbox.

19 Attach relevant hoses and cables to engine and gearbox. Check

fluid levels and top up as necessary.

VDRF01.01GB

Workshop manual DRF 400–450

1 Engine – 1.1 Controls and instrumentation 13

1.1 Controls and instrumentation

1.1.1 Ignition

Ignition, description

PNo function.

0Stop position. Everything is off, key can be removed.

IOperating position.

Voltage to all electrical functions. Control units for engine and transmission are now ready for start.

The signal can be checked from the diagnostic menu, see

Maintenance manual DRF 400–450, section 8 Control system, group 8.4.1.4 CAN/POWER, menu 4.

II Preheating position.

In preheating position, the engine's inlet air is preheated with a preheating coil to a suitable temperature. Indicator light for preheating is activated during preheating.

The signal can be checked from the diagnostic menu, see

Maintenance manual DRF 400–450, section 8 Control system, group 8.4.6.4 ENGINE, menu 4.

III Start position.

Engagement of starter motor for engine start.

III

000317

NOTE

The machine is equipped with an electric restart interlock, which prevents engagement of the starter motor when the engine is rotating.

Condition for starter motor to engage is that transmission is in neutral position and that the engine isn’t already running.

The signal can be checked from the diagnostic menu, see

Maintenance manual DRF 400–450, section 8 Control system, group 8.4.6.4 ENGINE, menu 4.

Workshop manual DRF 400–450

VDRF01.01GB

14 1 Engine – 1.1.2 Accelerator

001514

1.1.2 Accelerator

Accelerator pedal, description

The accelerator pedal controls the engine's torque and rpm.

The accelerator pedal acts on a rotary potentiometer which gives a signal to Control unit cab (D790-1). The accelerator pedal's positions are factory calibrated but may need to be recalibrated if the pedal is replaced.

The signal can be checked from the diagnostic menu, see Mainte-

nance manual DRF 400–450, section 8 Control system, group 8.4.6.1 ENGINE, menu 1.

A. Accelerator pedal

1. Brake pedal

2. Throttle pedal

Accelerator pedal, change

1 Machine in service position, see section B Safety.

2 Pull one edge of the cover away to facilitate access to the ac-

celerator pedal.

3 Unplug the cable from the connector.

4 Unscrew the connector from the accelerator pedal.

5 Change the accelerator pedal.

6 Fit in the reverse order.

7 Calibrate the accelerator pedal, see section 8 Control system,

group 8.5.2.3 Calibrate DRIVE-TRAIN.

Accelerator pedal, calibration

See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN.

VDRF01.01GB

Workshop manual DRF 400–450

1 Engine – 1.1.3 Warning light low oil pressure in engine 15

1.1.3 Warning light low oil pressure in

engine

Warning light low oil pressure in engine, description

The warning light is activated when the engine's oil pressure is so low that there is a risk of damage. The warning light is supplied with voltage by Control unit KIT (D790-2) and is located in the light panel.

000303

Volvo engine: If the oil pressure is low, the engine rpm is reduced for three seconds, then the engine is turned off. The engine can be restarted and run for intervals of 30 seconds.

NOTE

Restart may result in engine breakdown.

Low engine oil pressure 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 Infor- mation terminal.

1.1.4 Indicator light preheating

Indicator light preheating, description

Only applies to Volvo engines.

The preheating indicator light is on during the engine's preheating period. The indicator light is supplied with voltage by Control unit KIT

000304

(D790-2) and is located in the light panel.

Preheating indicator lamp, change

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

1.1.5 Warning light low coolant level

Warning light, low engine coolant level, description

The warning light is activated if the coolant level is too low. The indicator light is supplied with voltage by Control unit KIT (D790-2) and is located in the light panel.

000305

Volvo engine: If the coolant level is low, the engine rpm is reduced for three seconds, then the engine is turned off. The engine can be restarted and run for intervals of 30 seconds.

NOTE

Restart may result in engine breakdown.

Low engine coolant 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 Infor- mation terminal.

Workshop manual DRF 400–450

VDRF01.01GB

16 1 Engine – 1.1.6 Warning light high coolant temperature

000355

1.1.6 Warning light high coolant temperature

Warning light high coolant temperature, description

The warning light is activated if the engine's coolant temperature should become too high. The warning light is supplied with voltage by Control unit KIT (D790-2) and is located in the light panel.

000302

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

High coolant temperature 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 Infor- mation terminal.

1.1.7 Warning light low fuel level

Warning light low fuel level, description

The warning light is activated when approx. 17% of the fuel remains, which corresponds to approx. 5 hours operating time. The warning light is supplied with voltage by Control unit KIT (D790-2) and is located in the light panel.

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 Infor- mation terminal.

1.1.8 Operating 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.

000353

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

d. Shows current fuel level.

1.1.9 Operating 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.

VDRF01.01GB

Workshop manual DRF 400–450

1 Engine – 1.2 Fuel system 17

1.2 Fuel system

Fuel system, description

The fuel system distributes fuel to the cylinders and so controls engine output power and rpm.

When the engine starts, the fuel pump sucks fuel from the tank through the fuel filter and feeds it to the unit injectors under pressure. The unit injectors inject the atomized fuel into the engine combustion chambers.

1.2.1 Fuel tank

Fuel tank, description

The fuel tank is located on the left-hand side of the machine behind the brake fluid reservoir.

1.2.2 Sensor fuel level

Sensor fuel level, description

The signal can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control sys tem, group 8.4.3.7 CAB, menu 7.

1 2 3

1. Filling point, fuel

2. Fuel tank

3. Sensor, fuel level (behind air filter)

002289

1.2.3 Fuel pre-filter

Fuel prefilter, general

See Maintenance manual DRF 400–450 and supplier documentation engine (Volvo engine)

1.2.4 Fuel filter

Fuel filter, general

See Maintenance manual DRF 400–450 and supplier documentation engine.

1.2.5 Sensor water in fuel

Sensor water in fuel, description

See supplier documentation engine (Cummins engine).

Workshop manual DRF 400–450

VDRF01.01GB

18 1 Engine – 1.2.6 Fuel pump

1.2.6 Fuel pump

Fuel pump, description

See supplier documentation engine.

1.2.7 Sensor fuel pressure

Sensor fuel pressure, description

See supplier documentation engine (Cummins engine).

1.2.8 Injectors

Injectors, description

See supplier documentation engine.

1.2.9 Breaking contact fuel pressure

Breaking contact fuel pressure, description

See supplier documentation engine (Volvo engine).

1.2.10 Making contact water in fuel

Make-contact water in fuel, description

See Subcontractor documentation, engine (Volvo engine).

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Workshop manual DRF 400–450

1 Engine – 1.5 Mechanical parts 19

1.5 Mechanical parts

Engine's mechanical parts, general

See supplier documentation engine.

Workshop manual DRF 400–450

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20 1 Engine – 1.6 Air intake and exhaust outlet

1.6 Air intake and exhaust

outlet

1.6.1 Air cleaning system

Air cleaning system, description

54321

Air is required for combustion in the engine. Free and unobstructed passages for fresh air and exhaust gases are essential for efficient engine operation.

For location of components, also see Maintenance manual DRF 400– 450, section 1 Engine.

Air cleaning system, overview

1. Intake hose

2. Filter indication

3. Air cleaner

4. Intake

5. Dust receptacle

001357

Air filter, changing

See Maintenance manual DRF 400–450.

1.6.2 Turbo

Turbo, description

See supplier documentation engine.

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Workshop manual DRF 400–450

1 2 3

Exhaust system, overview

1. Turbocharger

2. Flex hose

3. Exhaust pipe

4. End pipe

5. Muffler

1 Engine – 1.6.3 Exhaust system 21

1.6.3 Exhaust system

Exhaust system, description

The exhaust system is mounted to the chassis. A heat shield is mounted between the engine and the exhaust system to protect cable harnesses, etc. A flex hose between the turbo and muffler ab-

sorbs engine movements. On the outside of the machine, there is a heat shield located over the exhaust system.

WARNING

Hot exhaust system!

001356

Risk of burn injuries!

Never touch the turbo or muffler when the machine is running or just after it has been turned off!

Workshop manual DRF 400–450

VDRF01.01GB

22 1 Engine – 1.6.4 Intercooler

1.6.4 Intercooler

Intercooler, description

The charge air is cooled in the upper part of the radiator assembly (only Cummins engine)

For the Volvo engine, see supplier documentation engine.

See also Cooling system, description page 23.

Radiator assembly, Cummins engine

1. Intercooler

2. Radiator, engine

3. Cooler, transmission oil

4. Thermostat, transmission oil

5. Mounting, condenser (for AC)

003215

1.6.5 Sensor boost pressure

Sensor, intercooler, description

The signal can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.6.6 ENGINE, menu 6.

For more information, see supplier documentation engine.

1.6.6 Sensor charge-air temperature

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Sensor charge-air temperature, description

The signal can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.6.7 ENGINE, menu 7.

For more information, see supplier documentation engine.

Workshop manual DRF 400–450

1 Engine – 1.7 Cooling system 23

1.7 Cooling system

Cooling system, description

The engine is water-cooled and has passages through which the coolant from the radiator flows round a closed system.

Main parts of the cooling system:

•Coolant pump

•Expansion tank

• Thermostat

•Cooling fan

•Radiator

•Engine oil cooler

•Intercooler

•Coolant filter

How the engine cooling system works:

1. Coolant is circulated through the cylinder head, engine block and oil cooler by the coolant pump. Coolant is pumped through the intercooler on the Volvo engine by a separate coolant pump.

2. The thermostat directs the heated coolant back to the coolant pump or through the radiator.

3. When the coolant is colder than the thermostat o pening t emperature it is pumped back to the engine.

When the coolant is warmer than the thermostat opening temperature it is pumped through the radiator and then back to the coolant pump.

4. The expansion tank allows the coolant to expand without escaping from the engine.

1.7.1 Coolant pump

Coolant pump, description

See supplier documentation engine.

1.7.2 Coolant filter

Coolant filter, general

See Maintenance manual DRF 400–450 and supplier documentation engine.

1.7.3 Coolant thermostat

Thermostat coolant, description

See supplier documentation engine.

Workshop manual DRF 400–450

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24 1 Engine – 1.7.4 Radiator and expansion tank

1.7.4 Radiator and expansion tank

Radiator and expansion tank, description

The radiator for the engine coolant is mounted in the radiator assembly (made of aluminium) located on one side of the engine.

The purpose of the cooler assembly is to cool:

•Engine coolant

•Gearbox oil (cooled in the lower part of the radiator assembly),

see also section 2 Transmission, group 2.6.3 Oil cooler.

• The charge air (only Cummins engine) is cooled in the upper part

of the radiator assembly, see also Intercooler, description page

22.

See also Cooling system, description page 23.

For more information, see supplier documentation engine.

Radiator assembly, Volvo engine

1. Radiator, engine

2. Cooler, transmission oil

3. Thermostat, transmission oil

4. Mounting, condenser (for AC)

003214

003215

Radiator assembly, Cummins engine

1. Intercooler

2. Radiator, engine

3. Cooler, transmission oil

4. Thermostat, transmission oil

5. Mounting, condenser (for AC)

VDRF01.01GB

Workshop manual DRF 400–450

1 Engine – 1.7.5 Cooling fan 25

1.7.5 Cooling fan

Cooling fan, description

See supplier documentation engine.

Fan belt, change (Volvo engine)

1 Move the cab into its foremost position.

2 Machine in service position, see section B Safety.

3 Remove the cover plates over the engine and radiator.

4 Release the belt catch using the ratchet handle and remove the

fan belt from the belt pulley on the belt tensioner.

5 Remove the fan belt.

The illustration shows the engine without radiator fan.

6 Fit a new fan belt on the fan wheel and crankshaft belt pulley.

Workshop manual DRF 400–450

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26 1 Engine – 1.7.5 Cooling fan

7 Release the belt catch using the ratchet handle and fit the fan

belt on the belt tensioner pulley.

Extra water pump drive belt, change (Volvo engine)

1 Move the cab into its foremost position.

2 Machine in service position, see section B Safety.

3 Remove the cover plates over the engine and radiator.

4 Wash the engine bay.

5 Release the belt catch using the ratchet handle and remove the

drive belt from the belt pulley on the belt tensioner.

6 Remove the drive belt.

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Workshop manual DRF 400–450

1 Engine – 1.7.5 Cooling fan 27

The illustration shows the engine without radiator fan.

7 Fit a new drive belt round the water pump and fuel pump pul-

leys.

8 Release the belt catch using the ratchet handle and fit the fan

belt on the belt tensioner pulley.

Fan belt, change (Cummins engine)

1 Move the cab into its foremost position.

2 Machine in service position, see section B Safety.

3 Remove the cover plates over the engine and radiator.

4 Wash the engine bay.

Workshop manual DRF 400–450

VDRF01.01GB

28 1 Engine – 1.7.6 Oil cooler

5 Remove the belt tensioner.

6 Remove the fan belt.

7 Fit a new fan belt.

8 Use the belt tensioner to tension the fan belt.

1.7.6 Oil cooler

Oil cooler, description

See supplier documentation engine.

1.7.7 Coolant

Coolant, description

See supplier documentation engine.

Coolant, changing

1 Machine in service position, see section B Safety.

2 Remove the cap on the expansion tank.

3 Place a receptacle under the radiator and engine. (Cooling sys-

tem capacity is 40 litres.)

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Workshop manual DRF 400–450

1 Engine – 1.7.8 Making contact coolant level 29

4 Drain the cooling system.

Open the drain cock on the lower part of the radiator. Collect the coolant in the receptacle.

5 Open the drain cock on the engine.

6 When all the coolant has run out, close the drain cocks.

7 Fill new coolant through the expansion tank.

The Volvo engine is shown in the illustration.

8 Open the bleed nipple to release air and to accelerate filling.

Close the bleed nipple when clean coolant without air bubbles runs out.

9 Switch on the main circuit and start the engine.

10 Turn heating to max. in the cab.

11 Warm up the engine until the thermostat opens and coolant is

pumped round the whole system.

12 Check the level in the expansion tank, fill if necessary.

13 Check the coolant level again after 10 working hours.

1.7.8 Making contact coolant level

Make-contact coolant level, description

See supplier documentation engine.

1.7.9 Sensor coolant temperature

Sensor coolant temperature, description

The signal can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.6.7 ENGINE, menu 7.

For more information, see supplier documentation engine.

Workshop manual DRF 400–450

VDRF01.01GB

30 1 Engine – 1.7.10 Plug-in heater

1.7.10 Plug-in heater

Engine heater, description

See supplier documentation engine.

Available as an option in conjunction with the engine heater is a start-inhibiting function. It is activated when the heater is in operation.

VDRF01.01GB

Workshop manual DRF 400–450

1 Engine – 1.8 Lubrication 31

1.8 Lubrication

Lubrication system, description

See supplier documentation engine.

Engine oil, change

See Maintenance manual DRF 400–450.

1.8.1 Oil sump

Oil sump, description

See supplier documentation engine.

1.8.2 Oil pump

Oil pump, description

See supplier documentation engine.

1.8.3 Sensor oil pressure

Sensor oil pressure, description

The signal can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.6.6 ENGINE, menu 6.

For more information, see supplier documentation engine.

1.8.4 Full flow filter

Full-flow filter, general

See Maintenance manual DRF 400–450, section 1 Engine, group

1.8.4 Full flow filter and supplier documentation engine.

1.8.5 By-pass filter

By-pass filter, general

See Maintenance manual DRF 400–450, section 1 Engine, group

1.8.4 Full flow filter and supplier documentation engine (Volvo).

1.8.6 Oil cooler

Oil cooler, description

See supplier documentation engine.

1.8.7 Sensor oil temperature

Sensor oil temperature, description

The signal can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.6.7 ENGINE, menu 7.

For more information, see supplier documentation engine.

Workshop manual DRF 400–450

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32 1 Engine – 1.9 Control system engine

1.9 Control system engine

Control system engine, description

See Maintenance manual DRF 400–450 and supplier documentation engine.

1.9.1 Control unit engine

Control unit, general

See section 11 Common electrics, group 11.5.3.10 Control unit engine and supplier documentation engine.

VDRF01.01GB

Workshop manual DRF 400–450

1 Engine – 1.10 Ignition/heating 33

1.10 Ignition/heating

1.10.1 Preheating

Preheating coil, description

The signal can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.6.5 ENGINE, menu 5.

For more information, see supplier documentation engine.

Workshop manual DRF 400–450

VDRF01.01GB

34 1 Engine – 1.11 Start/stop

1.11 Start/stop

1.11.1 Start motor

Starter motor, description (Volvo engine)

The starter motor rotates the engine until fuel combustion begins and the engine starts.

The starter motor is supplied with voltage directly from the start batteries, a relay on the starter motor (solenoid) is activated by control unit engine (D794).

For more information, see supplier documentation engine.

Starter motor, description (Cummins engine)

The starter motor rotates the engine until fuel combustion begins and the engine starts.

The starter motor is supplied with current directly from the starter batteries. A relay on the starter motor (solenoid) is activated by Control unit frame rear (D797-R).

The signal can be checked from the diagnostic menu, Maintenance

manual DRF 400–450, see section 8 Control system, group 8.4.6.5 ENGINE, menu 5.

For more information, see supplier documentation engine.

1.11.2 Stop device

Stop device, description

The engines have unit injectors that stop delivering fuel when the voltage is cut off, which means that the engine stops.

The engine can only be stopped by turning off the ignition.

NOTE

The battery disconnector may not be used for emergency stop!

For more information, see supplier documentation engine.

Automatic motor shutoff after a certain adjustable time is available as an option.

VDRF01.01GB

Workshop manual DRF 400–450

2 T r a n s m i s s i o n 1

2 Transmission

Table of Contents 2 Transmission

2 Transmission ............................................................................................ 3

2.1 Controls and instrumentation .................................................................... 7

2.1.1 Gear and multi-function lever ............................................................... 7

2.1.2 Clutch pedal .......................................................................................... 7

2.1.3 Switch shifting program A ..................................................................... 7

2.1.4 Switch shifting program 1 ..................................................................... 8

2.1.5 Switch shifting program 2 ..................................................................... 8

2.1.6 Travel direction indicator forward, neutral, reverse ............................. 8

2.1.7 Warning light high oil temperature in transmission ............................. 8

2.1.8 Operating menu engine and transmission ............................................ 9

2.1.9 Operating menu oil temperature .......................................................... 9

2.2 Torque converter/clutch system ............................................................. 10

2.2.1 Flex plates ........................................................................................... 10

2.2.2 Pump rotor .......................................................................................... 12

2.2.3 Stator ................................................................................................... 12

2.2.4 Turbin rotor ......................................................................................... 12

2.2.5 Sensor engine speed and oil temperature in transmission ................ 12

2.3 Mechanical transmission ......................................................................... 13

2.3.1 Gear pack ............................................................................................ 13

2.3.2 Power take-off ..................................................................................... 13

2.3.3 Input shaft ........................................................................................... 13

2.3.4 Valve block transmission control ........................................................ 13

2.3.5 Sensor turbine speed .......................................................................... 13

2.3.6 Sensor shaft speed .............................................................................. 13

2.3.7 Output shaft ........................................................................................ 13

2.3.8 Sensor output shaft speed .................................................................. 14

2.6 Lubrication ............................................................................................... 15

2.6.1 Oil pump .............................................................................................. 15

2.6.2 Sensor oil pressure .............................................................................. 15

2.6.3 Oil cooler ............................................................................................. 16

2.6.4 Oil filter ................................................................................................ 16

2.7 Cooling ..................................................................................................... 17

2.7.1 Cooling oil pump ................................................................................. 17

2.7.2 Sensor oil temperature ....................................................................... 17

2.7.3 Oil cooler ............................................................................................. 17

2.8 Control system transmission ................................................................... 18

2.8.1 Control unit transmission .................................................................... 18

2.8.2 Breaking contact declutch .................................................................. 18

2.8.3 Cable harness transmission ................................................................ 19

Workshop manual DRF 400–450

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2 2 Transmission

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Workshop manual DRF 400–450

2 Transmission – 2 Transmission 3

2 Transmission–

2 Transmission

Transmission, function description

<˚

10, 16, 18, 20, 26

6, 23

˚C

D790-1

D793

12 13

˚C

D790-2 D795

2, 7

D794

D797-F

Pos Explanation Signal description Reference

1 The gear selector sends voltage sig-

nal to Control unit KIT (D790-2).

Forward, Conn. F: U = 24 V

Reverse, Conn. R: U = 24 V

Gear and multi-function lever, description page 7

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.7.2, TRANSM, menu 2

002212

2Control unit KIT (D790-2) sends se-

lected travel direction (forward or reverse) on CAN-bus.

3 The transmission's oil pump pumps

oil when the engine is running.

4 The transmission's oil filter cleans

the oil from impurities.

Checked by control system, error shown with error code.

- Oil filter, general page 16

Workshop manual DRF 400–450

Section 11 Common electrics, group 11.6

Communication

Oil pump, description page 15

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4 2 Transmission– 2 Transmission

Pos Explanation Signal description Reference

5 The throttle pedal sends signal to

U = 0.5-4.5 V Section 1 Engine, group 1.1.1 Accelerator

Control unit cab (D790-1).

6Control unit cab (D790-1) sends de-

sired throttle application on CANbus.

7Control unit KIT (D790-2) sends se-

lected shifting program on CANbus.

8Sensor oil pressure sends voltage

signal proportional to oil pressure in Control unit transmission TCU

Checked by control system, error shown with error code.

Checked by Control unit transmission, error shown with error code.

(D793).

9Sensor oil pressure and oil temper-

ature sends pulse signal with frequency proportional to engine rpm

Checked by Control unit transmission, error shown

with error code. and voltage signal proportional to transmission oil temperature to Control unit transmission TCU (D793).

pedal

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system,

group 8.4.6.1 ENGINE, menu 1

Section 11 Common electrics, group 11.6

Communication

Section 11 Common electrics, group 11.6 Communication

Sensor oil pressure, description page 15

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.7.10, TRANSM, menu 10

Sensor engine rpm and oil temperature transmission, description page 12

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system,

group 8.4.7.6, TRANSM, menu 6

10 Control unit transmission TCU

(D793) supplies voltage to valve block transmission control to obtain desired function.

11 Solenoid valves for travel direction

and gear position in valve block transmission control activate gears in the transmission and the engine's power is transmitted to the transmission's output shaft.

12 Sensor rpm turbine sends pulse sig-

nal with frequency proportional to turbine's rpm to Control unit transmission TCU (D793).

13 Sensor rpm drum sends pulse sig-

nal with frequency proportional to drum's rpm to Control unit transmission TCU (D793).

14 Sensor rpm output shaft sends

pulse signal with frequency proportional to output shaft's rpm to Control unit transmission TCU (D793).

Checked by Control unit

transmission, error shown

with error code.

Checked by Control unit

transmission, error shown

with error code.

Checked by Control unit

transmission, error shown

with error code.

Checked by Control unit

transmission, error shown

with error code.

Checked by Control unit

transmission, error shown

with error code.

Section 11 Common electrics, group

11.5.4.11 Control unit, transmission

Valve block transmission control, description page 13

Sensor rpm turbine, description page 13

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.7.6, TRANS, menu 6

Sensor rpm drum, description page 13

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.7.6, TRANSM, menu 6

Sensor output shaft, description page 14

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system,

group 8.4.7.6, TRANSM, menu 6

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Workshop manual DRF 400–450

2 Transmission – 2 Transmission 5

Pos Explanation Signal description Reference

15 Temperature monitor torque con-

verter sends voltage signal to Control unit transmission TCU (D793) if oil temperature in torque converter becomes too high.

16 Control unit transmission controls

gearshifting according to selected shifting program.

17 The oil cooler cools the transmis-

sion oil. A thermostat senses the oil temperature and directs the oil back to the transmission if the oil is cold.

18 Control unit transmission TCU

(D793) sends temperature and rpm information on CAN-bus.

19 Control unit KID (D795) shows

transmission information in operating menus.

20 If signal from Sensor output shaft

indicates that the machine's speed exceeds the speed limitation, then Control unit transmission TCU (D793) sends signal for reduced engine rpm on CAN-bus.

Checked by Control unit transmission, error shown with error code.

Sensor engine rpm and oil temperature transmission, description page 12

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system,

group 8.4.7.6, TRANSM, menu 6

Checked by Control unit transmission, error shown

Section 11 Common electrics, group 11.5.4

Control units

with error code.

- Oil cooler, description page 17

Checked by control system, error shown with er-

Section 11 Common electrics, group 11.6

Communication

ror code.

Checked by control system, error shown with error code.

Operating menu engine and transmission, description page 9Operating menu oil temperature, description page 9

- Sensor output shaft, description page 14

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.7.6, TRANSM, menu 6

21 Control unit engine (D794) reduces

engine rpm.

22 If the clutch pedal is pressed down

it sends a voltage signal to Control unit cab (D790-1).

23 Control unit cab (D790-1) sends dis-

engage drive on CAN-bus.

24 Make-contact disengage sends

voltage signal to Control unit frame front (D797-F) if brake pressure is high enough to allow disengagement of drive.

-Section 11 Common electrics, group

11.5.3.10 Control unit, engine

U = 24 V Clutch pedal, description page 7

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.7.1, TRANSM, menu 1

Checked by control system, error shown with er-

Section 11 Common electrics, group 11.6

Communication

ror code.

Brake pressure above

0.2 MPa:

Conn 1, U = 24 V

Conn 2, U = 24 V

Breaking contact disengagement (declutch), description page 18

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system,

group 8.4.7.1, TRANSM, menu 1

Brake pressure below

0.2 MPa:

Conn 1, U = 24 V

Conn 2, U = 0 V

Workshop manual DRF 400–450

VDRF01.01GB

6 2 Transmission– 2 Transmission

Pos Explanation Signal description Reference

25 Control unit frame front (D797-F)

sends disengagement approved on CAN-bus.

26 Control unit transmission (D793)

supplies voltage to valve block transmission control so that drive is disengaged.

Checked by control sys-

tem, error shown with er-

ror code.

Checked by Control unit

transmission, error shown

with error code.

Engine and gearbox, separation

Engine alternative Volvo: see section 1 Engine, group 1 Engine and gearbox, separation (engine alternative Volvo).

Engine alternative Cummins: see section 1 Engine, group 1 Engine and gearbox, separation (engine alternative Cummins).

Section 11 Common electrics, group 11.6 Communication

Section 11 Common electrics, group 11.5.3.9 Control unit, transmission

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Workshop manual DRF 400–450

2 Transmission – 2.1 Controls and instrumentation 7

001515

000413

2.1 Controls and instrumentation

2.1.1 Gear and multi-function lever

Gear and multi-function lever, description

Travel direction is selected with the gear and multi-function lever.

Selection of travel direction:

•F – Forward

•N – Neutral

•R – Reverse

The switch is supplied with voltage by and sends signals to Control unit KIT (D790-2).

The signal can be checked from the diagnostic menu, see Mainte-

002209

nance manual DRF 400–450, section 8 Cont rol system , group 8.4.7.2 TRANSM, menu 2.

A. Clutch pedal

2.1.2 Clutch pedal

Clutch pedal, description

The switch is supplied with voltage by and sends signals toControl unit cab (D790-1).

The signal can be checked from the diagnostic menu, see Mainte-

nance manual DRF 400–450, section 8 Control system, group 8.4.7.1 TRANSM, menu 1.

2.1.3 Switch shifting program A

Switch shifting program A, description

The switch activates shifting program A, which means automatic selection of gear position.

The switch is supplied with voltage by and sends signals to Control unit KIT (D790-2).

The signal can be checked from the diagnostic menu, see Mainte-

nance manual DRF 400–450, section 8 Control system, group 8.4.7.2 TRANSM, menu 2.

Workshop manual DRF 400–450

VDRF01.01GB

8 2 Transmission – 2.1.4 Switch shifting program 1

2.1.4 Switch shifting program 1

Switch shifting program 1, description

The switch activates shifting program 1, which means that gear position is locked to 1st gear.

The switch is supplied with voltage by and sends signals to Control

000414

unit KIT (D790-2).

The signal can be checked from the diagnostic menu, see Mainte-

nance manual DRF 400–450, section 8 Control system, group 8.4.7.2 TRANSM, menu 2.

2.1.5 Switch shifting program 2

Switch shifting program 2, description

The switch activates shifting program 2, which means that gear position is locked to 2nd gear.

The switch is supplied with voltage by and sends signals to Control

000415

unit KIT (D790-2).

The sensor can be checked from the diagnostic menu, see Mainte-

nance manual DRF 400–450, section 8 Control system, group 8.4.7.2 TRANSM, menu 2.

2.1.6 Travel direction indicator forward, neutral, reverse

Travel direction indicator forward, neutral and reverse, description

Indicates selected travel direction with gear and multi-function lever. The letters F (Forward), N (Neutral) or R (Reverse) are lit for each respective travel direction.

000403

2.1.7 Warning light high oil temperature in transmission

Warning light high oil temperature in transmission, description

The warning light is activated if the transmission's oil temperature is too high. Stop the machine and let the engine run at idle speed.

000306

VDRF01.01GB

Workshop manual DRF 400–450

2 Transmission – 2.1.8 Operating menu engine and transmission 9

000356

2.1.8 Operating menu engine and transmission

Operating menu engine and transmission, description

Field c shows current gear.

a. Engine rpm b. Speed c. Current gear d. Fuel level

a. Transmission oil temperature b. Hydraulic oil temperature

000353

2.1.9 Operating menu oil temperature

Operating menu oil temperature, description

Field a shows transmission oil temperature.

Workshop manual DRF 400–450

VDRF01.01GB

10 2 Transmission – 2.2 Torque converter/clutch system

2.2 Torque converter/clutch system

Torque converter, description

See supplier documentation transmission.

2.2.1 Flex plates

Flex plates, description

See supplier documentation transmission.

Flex plates, changing

1 Machine in service position, see section B safety.

2 Remove the flywheel cover plate.

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3 Remove the nuts from the flex plate.

Workshop manual DRF 400–450

2 Transmission – 2.2.1 Flex plates 11

4 Turn the engine for each nut to be removed from the flex plate.

5 Attach the transmission to an overhead crane.

6 Remove the bolts holding together the transmission and en-

gine.

7 Carefully separate the transmission and engine.

Workshop manual DRF 400–450

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12 2 Transmission – 2.2.2 Pump rotor

8 Remove the bolts holding the flex plate to the transmission.

9 Change the flex plate.

10 Fit in the reverse order. Fit the attaching bolts with 40 Nm.

Attachment of flex plate.

2.2.2 Pump rotor

Pump rotor, description

See supplier documentation transmission.

2.2.3 Stator

Stator, description

See supplier documentation transmission.

2.2.4 Turbin rotor

Turbine rotor, description

See supplier documentation transmission.

2.2.5 Sensor engine speed and oil

temperature in transmission

Sensor engine rpm and oil temperature transmission, description

The sensor can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.7.6 TRANSM, menu 6.

For more detailed information, see supplier documentation transmission.

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Workshop manual DRF 400–450

2 Transmission – 2.3 Mechanical transmission 13

2.3 Mechanical transmission

Mechanical transmission, description

See Maintenance manual DRF 400–450 and supplier documentation transmission.

2.3.1 Gear pack

Gear pack, description

See supplier documentation transmission.

2.3.2 Power take-off

Power take-off, description

See supplier documentation transmission.

2.3.3 Input shaft

Input shaft, description

See supplier documentation transmission.

2.3.4 Valve block transmission control

Valve block transmission control, description

See supplier documentation transmission.

2.3.5 Sensor turbine speed

Sensor rpm turbine, description

The sensor can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.7.6 TRANSM, menu 6.

For more detailed information, see supplier documentation transmission.

2.3.6 Sensor shaft speed

Sensor rpm drum, description

The signal can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.7.6 TRANSM, menu 6.

For more detailed information, see supplier documentation transmission.

2.3.7 Output shaft

Output shaft, description

See supplier documentation transmission.

Workshop manual DRF 400–450

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14 2 Transmission – 2.3.8 Sensor output shaft speed

2.3.8 Sensor output shaft speed

Sensor output shaft, description

The signal can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.7.6 TRANSM, menu 6.

For more detailed information, see supplier documentation transmission.

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Workshop manual DRF 400–450

2 Transmission – 2.6 Lubrication 15

2.6 Lubrication

Lubrication system, description

The transmission lubricating system has the following function:

•Lubricate gear wheel and bearings

•Apply the clutches in the gearbox

•Cool down the torque converter and gearbox

•Clean the oil of any impurities with two oil filters.

During operation of the engine, the oil pump draws oil from the gearbox oil pan through a strainer, and it then pumps it through two oil filters to a control valve.

The control valve provides oil at the correct pressure to the gearbox valve housing to activate the clutch plates for FORWARD or REVERSE and gear 1, 2, 3, or 4. The clutch plates require just a small amount of the oil flow supplied by the pump. The remainder of the oil is pumped through the torque converter circuit to the oil cooler and returns to the gearbox for lubrication.

See also Maintenance manual DRF 400–450 and supplier documen- tation transmission.

Transmission oil, changing

See Maintenance manual DRF 400–450.

2.6.1 Oil pump

Oil pump, description

See supplier documentation transmission.

2.6.2 Sensor oil pressure

Sensor oil pressure, description

The sensor can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.7.10 TRANSM, menu 10.

For more detailed information see supplier documentation transmission.

Workshop manual DRF 400–450

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16 2 Transmission – 2.6.3 Oil cooler

2.6.3 Oil cooler

Oil cooler, description

The transmission oil is cooled in the lower section of the cooler assembly.

A temperature controlled bypass valve, which only acts on the cool-

ing circuit for transmission oil, is located in a pipe at the lower edge of the radiator (on engine side). The valve closes when oil starts to reach operating temperature. In this way the oil reaches operating temperature more quickly.

For more detailed information see supplier documentation transmis- sion.

Radiator core, engine alternative Volvo

1. Radiator, engine

2. Cooler, transmission oil

3. Thermostat, transmission oil

4. Mounting, condenser (to AC)

003214

003215

Radiator core, engine alternative, Cummins

1. Charge air cooler

2. Radiator, engine

3. Cooler, transmission oil

4. Thermostat, transmission oil

5. Mounting, condenser (to AC)

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2.6.4 Oil filter

Oil filter, general

See Maintenance manual DRF 400–450 and supplier documentation transmission.

Workshop manual DRF 400–450

2 Transmission – 2.7 Cooling 17

2.7 Cooling

Cooling system, description

See supplier documentation transmission.

2.7.1 Cooling oil pump

Oil pump, description

See supplier documentation transmission.

2.7.2 Sensor oil temperature

Sensor oil temperature, description

The signal can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.7.10 TRANSM, menu 10.

For more detailed information see supplier documentation transmission.

2.7.3 Oil cooler

Oil cooler, description

See Oil cooler, description page 16.

Workshop manual DRF 400–450

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18 2 Transmission – 2.8 Control system transmission

2.8 Control system transmission

Control system, transmission, general

See Maintenance manual DRF 400–450 and supplier documentation transmission.

Transmission, calibration

See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN.

2.8.1 Control unit transmission

Control unit, transmission, general

See section 11 Common electrics, group 11.5.3.9 Control unit, trans- mission and supplier documentation transmission.

2.8.2 Breaking contact declutch

Breaking contact disengagement (declutch), description

The break contact for disengagement senses if the wheel brakes are

pressurised. The break contact is located on the distribution block for the brake system, above the drive axle's differential.

The sensor can be checked from the diagnostic menu, see Mainte-

nance manual DRF 400–450, section 8 Control system, group 8.4.7.1

TRANSM, menu 1.

1. Connection brake cooling, return from wheel brake

2. Connection brake cooling, return to radiator and tank

3. Connection brake cooling, to wheel brake

4. Connection brake cooling, from accumulator charging valve

5. Connection brake cylinder, to wheel brake

6. Connection brake pressure, from brake valve

7. Make-contact, declutch (S220)

8. Make-contact, wheel brake (S216)

9. Test outlet, brake pressure

10. Test outlet, back-pressure brake cooling

000439

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Workshop manual DRF 400–450

2 Transmission – 2.8.3 Cable harness transmission 19

2.8.3 Cable harness transmission

Cable harness transmission, description

See section E Diagrams.

Workshop manual DRF 400–450

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20 2 Transmission – 2.8.3 Cable harness transmission

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Workshop manual DRF 400–450

3 D r i v e l i n e / a x l e 1

3 Driveline/axle

Table of Contents 3 Driveline/axle

3 Driveline/axle ........................................................................................... 3

3.2 Drive shaft .................................................................................................. 3

3.3 Drive axle ................................................................................................... 4

3.3.1 Differential ............................................................................................. 4

3.3.2 Drive shaft ............................................................................................. 4

3.3.3 Hub reduction ........................................................................................ 4

Workshop manual DRF 400–450

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2 3 Driveline/axle

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Workshop manual DRF 400–450

3 Driveline/axle – 3 Driveline/axle 3

3 Driveline/axle –

3 Driveline/axle

3.2 Drive shaft

Universal drive shaft, description

The universal drive shaft transfers the engine power from the transmission to the drive axle. The universal drive shaft has two joints which mean that the engine and drive axle can move in relation to each other.

Universal drive shaft, replacement

1 Machine in service position, see section B Safety.

2 Clean the contact surfaces (cross-toothed) on the drive axle

and gearbox.

3 Fit the universal drive shaft in position with the coupling up-

ward.

4 Fit the universal drive shaft attaching bolts.

Tightening torque 200 Nm. Retighten the attaching bolts after 50 hours operating time.

Workshop manual DRF 400–450

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4 3 Driveline/axle– 3.3 Drive axle

3.3 Drive axle

Drive axle, general

See Maintenance manual DRF 400–450 and supplier documentation drive axle.

3.3.1 Differential

Differential, description

See supplier documentation drive axle.

3.3.2 Drive shaft

Drive shaft, description

See supplier documentation drive axle.

3.3.3 Hub reduction

Hub reduction, description

See supplier documentation drive axle.

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Workshop manual DRF 400–450

4 B r ak e s 1

4 Brakes

Table of Contents 4 Brakes

4 Brakes....................................................................................................... 3

4.1 Controls and instrumentation .................................................................... 3

4.1.1 Brake pedal ............................................................................................ 3

4.1.2 Switch parking brake ............................................................................. 5

4.1.3 Warning light low brake pressure ......................................................... 5

4.1.4 Indicator light parking brake ................................................................. 5

4.1.5 Event menu high oil temperature ......................................................... 6

4.3 Service brake system ................................................................................. 7

4.3.1 Brake oil pump ...................................................................................... 9

4.3.2 Brake oil filter ...................................................................................... 11

4.3.3 Accumulator charging valve ................................................................ 12

4.3.4 Accumulator ........................................................................................ 16

4.3.5 Brake valve .......................................................................................... 19

4.3.6 Drive axle block ................................................................................... 23

4.3.7 Making contact brake pressure .......................................................... 24

4.3.8 Making contact brake light ................................................................. 25

4.3.9 Wheel brakes ....................................................................................... 27

4.3.10 Pipes and hoses .................................................................................. 30

4.5 Parking brake system .............................................................................. 31

4.5.1 Brake oil pump .................................................................................... 32

4.5.2 Brake oil filter ...................................................................................... 33

4.5.3 Solenoid valve parking brake .............................................................. 33

4.5.4 Parking brake unit ............................................................................... 34

4.5.5 Making contact parking brake ............................................................ 37

4.5.6 Pipes and hoses .................................................................................. 37

4.8 Temperature control, filtration and brake fluid ....................................... 38

4.8.1 Brake oil tank ....................................................................................... 39

4.8.2 Tank heater ......................................................................................... 40

4.8.3 Brake oil pump .................................................................................... 40

4.8.4 Accumulator charging valve ................................................................ 40

4.8.5 Drive axle block ................................................................................... 40

4.8.6 Wheel brake ........................................................................................ 41

4.8.7 Oil cooler ............................................................................................. 41

4.8.8 Cooling fan .......................................................................................... 41

4.8.9 Thermal by-pass valve ......................................................................... 42

4.8.10 Sensor brake oil temperature ............................................................. 43

4.8.11 Breather filter ...................................................................................... 43

4.8.12 Brake oil filter ...................................................................................... 44

4.8.13 Pipes and hoses .................................................................................. 44

4.8.14 Oil brake system .................................................................................. 44

Workshop manual DRF 400–450

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2 4 Brakes

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Workshop manual DRF 400–450

4 Brakes – 4 Brakes 3

4 Brakes–

4 Brakes

4.1 Controls and instrumentation

4.1.1 Brake pedal

Brake pedal, description

The brake pedal affects the brake valve via a lever. A spring automatically returns the pedal to resting position.

000606

Brake pedal, checking and adjustment

See Maintenance manual DRF 400–450.

Brake pedal, replacement

WARNING

Hot, pressurised oil.

Personal injury, burn injury, rash or irritation

Depressurise the hydraulic and brake systems before starting to work on the brake system. Avoid skin contact with the oil, use protective gloves.

1 Turn off the engine and the main electrical power.

2 Depressurise the brake and hydraulic systems, see section B

Safety, Hydraulic and brake systems, depressurising.

3 Detach the brake valve from the brake pedal

Secure the brake valve on the cab's undersid e and remove the brake valve attaching bolt.

Workshop manual DRF 400–450

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4 4 Brakes– 4.1.1 Brake pedal

4 Remove the panel around the steering wheel shaft.

NOTE

There is a variant available with adjustable steering wheel shaft.

5 Detach the steering valve from the pedal bracket.

Secure t he s teering valve on th e underside of the cab. Remove the steering valve's attaching bolts. Pull the valve down slightly so that the steering shaft releases from the steering valve.

6 Detach the steering wheel shaft from the brake pedal.

Undo the bolts and pull the steering wheel shaft up slightly so that the brake pedal can be removed.

7 Detach the clutch pedal from the brake pedal.

8 Remove the brake pedal

Remove the brake pedal's attaching bolts and lift away the

brake pedal. Mounting of steering wheel shaft and steering valve in pedal bracket.

9 Transfer the pedal rubber to the new pedal.

10 Fit the new brake pedal

Fit the pedal and fit the pedal's attaching bolts.

11 Connect the steering valve to the brake pedal.

12 Connect the brake valve to the brake pedal.

13 Fit the clutch pedal to the brake pedal.

14 Close the drain valve on the accumulator charging valve.

15 Grease and adjust the brake pedal, see Maintenance manual

DRF 400–450, section 4 Brakes, group 4.1.1 Brake pedal.

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Workshop manual DRF 400–450

4 Brakes – 4.1.2 Switch parking brake 5

30-35

4.1.2 Switch parking brake

Switch parking brake, description

The parking brake is activated with Switch parking brake (S107).

The switch sends voltage signals to Control unit, cab (D790-1). The switch sends signals for both off and on position.

3 03

The signals can be checked from the diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group 8.4.5.5 HYD, menu 5.

000002

4.1.3 Warning light low brake pressure

Warning light low brake pressure, description

Warning light low brake pressure is activated in case of pressure loss in the brake system's supply circuit, that is, when the pressure is below 11.5 MPa.

The warning light is supplied with voltage by Control unit KIT (D790-

2).

000003000004

4.1.4 Indicator light parking brake

Indicator light parking brake, description

Indicator light parking brake is activated when the parking brake is applied.

If the operator leaves the seat without applying the parking brake, the parking brake is activated automatically by the control system. The indicator light flashes to indicate that the parking brake is applied despite the switch parking brake is not being on.

The warning light is supplied with voltage by Control unit KIT (D790-

2).

Workshop manual DRF 400–450

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6 4 Brakes– 4.1.5 Event menu high oil temperature

4.1.5 Event menu high oil temperature

Event menu high oil temperature, description

Warning high oil temperature is shown on the display when the oil temperature is too high in the brake oil tank.

Warning is activated by Control unit KID (D795).

000005

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Workshop manual DRF 400–450

4 Brakes – 4.3 Service brake system 7

4.3 Service brake system

Power-assisted brake system, function description

D790-2

D797-R

D797-F

9, 12

ACC

Pos Explanation Signal description Reference

1 The brake oil pump pumps oil from

the brake tank.

2 The brake oil filter cleans the oil. - Brake oil filter, description page 44

3 The accumulator charging valve di-

rects oil to charging of accumulators or through the brake system's cooling circuit.

P = 19±0.5 MPa Brake oil tank, description page 39

Brake oil pump, description page 9

- Accumulator charging valve, description page 12

003164

4 The accumulators store oil pres-

sure.

See pressure plate "Accumulator pressure brake system", on left frame member.

Workshop manual DRF 400–450

Accumulator, description page 16

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8 4 Brakes– 4.3 Service brake system

Pos Explanation Signal description Reference

5 The brake valve directs pressure

from the accumulators to the brake cylinders proportional to pressing of the pedal.

6 The brake cylinders compress the

discs in the brake unit.

7 The wheel brakes brake the ma-

chine.

8Make-contact brake lights (S216)

close the circuit when the brake cylinders are pressurized.

9Control unit frame front (D797-F)

sends brake light request on CANbus.

- Brake valve, description page 19

See pressure plate

Wheel brake, description page 27

"Brake pressure", on left frame member.

- Wheel brake, description page 27

Brake pressure above

0.2 MPa:

Conn 1, U = 24 V

Conn 2, U = 24 V

Make-contact brake lights, description page 25

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.5.4 HYD, menu 4

Brake pressure below

0.2 MPa:

Conn 1, U = 24 V

Conn 2, U = 0 V

Controlled by control system, error shown

Section 11 Common electrics, group 11.6

Communication

with error code.

10 Brake lights are activated by Con-

trol unit frame rear (D797-R).

11 Breaking contact brake oil pressure

(S204) opens the circuit if the pressure in the accumulators is low.

12 Control unit frame front (D797-F)

sends warning about low brake pressure on CAN-bus.

13 Control unit KIT (D790-2) activates

Warning light brake pressure.

U = 24 V Section 9 Frame, body, cab and accessories,

group 9.6.5 Brake lights

Diagnostic menu, see Maintenance manual

DRF 400–450, section 8 Control system, group

8.4.2.11 LIGHTS, menu 11

Brake pressure above

11.5 MPa:

Conn 1, U = 24 V

Conn 2, U = 24 V

Make-contact brake pressure, description page 24

Diagnostic menu, see Maintenance manual DRF 400–450, section 8 Control system, group

8.4.5.4 HYD, menu 4

Brake pressure below

11.5 MPa:

Conn 1, U = 24 V

Conn 2, U = 0 V

Controlled by control system, error shown

Section 11 Common electrics, group 11.6

Communication

with error code.

Controlled by control system, error shown

Warning light low brake pressure, description page 5

with error code.

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Hydraulic diagram A40740.0100

Workshop manual DRF 400–450

Kalmar DRF450 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Workshop manual

A Foreword

A Foreword

About the Workshop Manual

General

Workshop manual contents

References between different information types

Function group breakdown

Conditions

Storage

About the machine version

Copyright

Reading instructions

Warning information

Important information

Read the operator's manual/maintenance manual

Optional equipment

Function descriptions

About the documentation

Documentation sections

Ordering of documentation

Feedback

Form for copying

B Safety

B Safety

General safety information

Safety concerns everyone!

A near-accident is a warning signal!

Safety instructions

General

Service position

Hydraulic and brake systems, depressurizing

Clothing etc.

Several mechanics on the same machine

Working under machine

Lifting heavy components

Vibrations

Noise

Solvents

Fire and explosion risks

Fluid or gas under pressure

Coolant

Refrigerant

Air pollution

Tensioned springs

Electric motors

Rotating components and tools

Tyre system

Environment

General

C Preventive maintenance 1

Preventive maintenance

0 Complete machine

1 Engine

1 Engine

1.1 Controls and instrumentation

1.1.1 Ignition

1.1.2 Accelerator

1.1.4 Indicator light preheating

1.1.5 Warning light low coolant level

1.1.6 Warning light high coolant temperature

1.1.7 Warning light low fuel level

1.1.8 Operating menu engine and transmission

1.1.9 Operating menu engine

1.2 Fuel system

1.2.1 Fuel tank

1.2.2 Sensor fuel level

1.2.3 Fuel pre-filter

1.2.4 Fuel filter

1.2.5 Sensor water in fuel

1.2.6 Fuel pump

1.2.7 Sensor fuel pressure

1.2.8 Injectors

1.2.9 Breaking contact fuel pressure

1.2.10 Making contact water in fuel

1.5 Mechanical parts