Kalmar DRF450-65A5X Workshop Manual

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DRF 400-450

WORKSHOP MANUAL

Publ. no VDRF03.02GB

Workshop Manual in original

Reachstackers 40-45 tonnes

Workshop

A Foreword

B Safety

C Preventive maintenance

0 Complete machine

1Engine

manual

2 Transmission

3 Driveline/axle

4 Brakes

5 Steering

6 Suspension

7 Load handling

8 Control system

9 Frame, body, cab and accessories

10 Common hydraulics

11 Common electrics

12 Common pneumatics

D Error codes

E Schematics

F Technical data

G Terminologi och Index

A Foreword 1

A Foreword

Table of Contents A Foreword

mm mm mm mm mm mm

Foreword......................................................................................................... 3

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

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

Conditions ......................................................................................................... 3

Storage ..................... .......................... ......................... .......................... ............ 3

About the machine version ................................................................................ 3

Copyright .................. .......................................................... ............................... 3

Reading instructions ...................................... ............................................. 4

Warning information .......................................................................................... 4

Important information ........................................................................................ 4

Read the Operator’s Manual ............................................................................. 4

Read the Maintenance Manual ......................................................................... 4

Workshop manual contents ............................................................................... 5

Function group structure ................................................................................... 6

References between different information types ............................................... 7

Product alternatives and optional equipment .................................................... 8

Machine card ..................................................................................................... 8

Function descriptions ........................................................................................ 9

About the documentation ...................................................... ................... 12

Documentation sections .................................................................................. 12

Ordering of documentation .............................................................................. 12

Feedback .................................................................................................. 13

Form for copying ............................................................................................. 13

Workshop manual DRF 400-450

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2 A Foreword

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Workshop manual DRF 400-450

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A Foreword – Foreword 3

Foreword

About the Workshop Manual

page –

General

Thank you for choosing Car gotec as you r machine s upplier. We ho pe that we will meet your expectations.

Conditions

The instructions are b ased o n the us e of gene rally a vaila ble sta ndard tools. All lifting d evices, such as slings, straps and ratchet blocks, mus t meet governing national standards and regulations for lifting devices.

Cargotec will not accept any responsibility f or modificatio ns performed without permission from Cargotec, or in the event of the use of lifting devices, tools or work methods other than those described in this manual.

Storage

NOTE

The workshop manual s hould be accessible to serv ice personnel.

page –

About the machine version

The information in this publication corresponds to the machine’s design and appearanc e at the time of delivery from Ca rgotec. Due to cu stomisations, there may be variations and/or deviations.

Cargotec r eserves the right to modify specifications and equipment without prior notice. Al l informati on and data in this man ual are val id at the time of publication.

DANGER

External equipment must only be used if it is approved by Cargotec.

Danger to life and property! Only use equipment approved by Cargotec.

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Workshop manual DRF 400-450

Copyright

Cargotec Sweden AB

Duplication of the c ontent in this manual , i n whole or in part , i s st ric tly prohibited without written permission from Cargotec Sweden AB.

Duplication by any means such as copying, p rinting, etc., is prohibite d.

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4 A Foreword – Reading instructions

Reading instructions

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Warning information

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

DANGER

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

WARNING

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

CAUTION

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Read the Operator’s Manual

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Read the Maintenance Manual

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

Important information

Important information ma rked 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

The symbol to the left is used in certain cases on the mach in e an d re fers to important information in the operator’s manual.

000262001128

Read the Maintenance Manual

The symbol to the left is sometim es foun d on the m achin e. It refers to important information in the Maintenance Manual.

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A Foreword – Reading instructions 5

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Workshop manual contents

The Workshop Manual contains information to facilitate maintenance (part replacement) and is a supplement to the Maintenance Manual. Accompanying the Workshop Manual is supplier documentation for engine, transmiss ion and drive axle. If poss ible, the Worksho p Manual provides reference to supplier documentation instead of printing the same information twi ce. Metho ds for pr eventive ma intenanc e and cer tain checks are found in the Maintenance Manual, no references are given. Use the fu nc tion g r oup s to lo cate the information i n t he Ma in te nance Manual.

The workshop manual is divided into the following sections.

A Foreword General information about the workshop manual's purpose, contents and reading

instructions as well as survey for feedback of views and any inaccuracies. B Safety Keep in mind for your safety. C Preventive maintenance Reference to maintenance manual: Preventive maintenance. 0 Complete machine 1 Engine 2 Transmission

3 Driveline/axle 4 Brakes 5 Steering

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, commo n components are described i n several places , but in general 6 Suspension

7 Load handling 8 Cont rol system 9 Frame, body, cab and

accessories

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 fun cti on.

Work instructions for corrective maintenance (replacement of components).

10 Common hydraulics 11 Common electrics 12 Common pneumatics

D Error codes Error code information and instructions for reading error code information. E Schematics Wiring diagrams, hydraulic diagrams and list of electrical components. F Technical data Technical data, conversion tables, information for conversion of units. G Term ino log y and index General terminology and abbr eviations, explanati on of terms and abbreviations that

can appear in the sections, index for headings in the manual.

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6 A Foreword – Reading instructions

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Function group structure

The information in the man ual is divided into a st ructure of functions at different levels based on machine structure and usage. The categories are known as function groups.

The highest level (c alled m ain grou p) indic ates a rea, such as grou p 7 Load handling. The second level (called two-position) indicates func

tion, such as 7.2 Lifting/lowering . The third and fou rth level s are used to break down functions into smaller parts (components).

The main group and two- position group le vel stru cture for t he functi on groups is used for all Cargotec machines, e.g. 4.3 Power-assisted brake system. Machine-specific function group adaptations are done at the third and fourth group le vel, e.g . 4.3 .9 Wheel brake and 4.3.9.1 Disc assembly. Function groups (headings) are only included in the documentation of a machine if the machine has that function or com

ponent. Thus, there may be gaps in function g roup numbering, e.g. th e three-position heading level 4.8.7 Oil cooler is included for some ma

chines but not for others. The function groups are intended as a search term to be able to find

various types of information between different se ctions and manuals. The information of a function group is divided into smaller segments based on type of content, such as description or replacement.

The Maintenance Manual and Workshop Manual contain different information. The Maintenance Manual only contains information required for preventive maintenance and minor troubleshooting. The Workshop Manual contains more in-depth information and repair instructions.

References between se ctions in the sa me manual are i ndicated usin g section and group number, e.g., "see section

Wheel brake

number, e.g., "see

". Reference within a section are indicated with page

Sensor fuel level, description page 24

4 Brakes

, group

4.3.9

There are no references between the Ma intenance Manual and Workshop Manual. If more information on a function group is required, search under the same function group in the other manual. For more in-depth information on where different types of information are locat ed and what referenc es ar e m ade , s ee

information types page 7

References between d iffe rent

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A Foreword – Reading instructions 7

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Function descriptions

(Technical description)

Component descriptions

(Technical description, usu al ly in Worksh op ma nual)

Diagnostics

(Technical description, group 8.4)

References between different information types

The maintenance manual and workshop manual are mainly divided into function groups, see

Workshop manual con tent s page 5

parts are broken out as separate parts to increase usability, e.g., "Technical data".

The basic rule of searching for inf ormation is to use function groups to find different types of informatio n regarding th e function or c omponent in question. As a complement to this, there are references according to the below.

Hydraulic diagrams

(Section E)

Error codes

(Section D)

Wiring diagrams

(Section E)

. Certain

• 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 Diagnostics, to enable fast find ing of the right di agnostic me nu that can be used to check the component (only applies to electrical components).

• From Diagnostics to Wiring diagrams. to en able fast findi ng of the right circuit diagram for further troubleshooting.

• From Diagnostics 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 Diagnostics , 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 fi nding of mo re informat ion about c omponent s or function.

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8 A Foreword – Reading instructions

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Symbol for optional equipment

Product alternatives and optional equipment

The information in the manual is divided into modules. If a product alternative or optional equ ipm en t is fitte d, ha ndl ing may di ffer fro m th at indicated in the modules depending on what is being described. See below.

Special equipment is not described in the manual. If uncertain as to what equipment is fitted to the machine, use the machine card to de termine which information is relevant. See

Product alternative

Product alternative describes options that are fitted instead of a specific piece of standard equipment (e.g. engine alternative).

Equivalent informat ion fo r diffe rent p roduct altern ative s are describ ed consecutively in separate segments within the same function group. To indicate that there are diff erent alternatives, "Product alternat ive" is added to the heading tog ether with a simple descripti on of the alterna tive, e.g. "(Product alternative Climate control system ECC)". In addition, the alternative that is an option is marked with the symbol for optional equipment.

Optional equipment

Optional equipment refers to options that can be added to standard

000264

equipment for more or improved functions. Information on auxil iary equipmen t is described in se parate segment s

together with the standard equipment. The optional equipment de scription covers how the eq uipment affects standard func tion and what components are added.

Machine card page 8

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Machine card

NOTE

If the machine has been modified after delivery, information on the machine card may be incomplete or incorrect.

The machine card indic ate s of wh ic h draw i ngs the mac hi ne co ns is ts, in many cases these can be associated options and product alterna tives. For more inform ation about hand ling of product alternatives an d optional equipment, see

page 8

. The machine card is delivered with the parts catalogue.

Product alternatives and op tion al equ ipm en t

The machine card is divided into the same function groups as the spare parts catalogue, maintenance manual and workshop manual. For reasons of practicality, the machine card only uses the first and second level of the function group register. The function groups are written in groups of four char acters, e.g. group 0107 refers to group 1.7 Cooling system in the manual.

For more information on how the mach ine card is used to order spare parts, see the foreword of the spare parts catalogue.

If the information on the card machine does not help, contact Cargotec.

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A Foreword – Reading instructions 9

NOTE

All documents that accompany the machine are non-registered documents. No notification is made regarding changes.

page –

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 i n a logic al flow from i nput signal to desired output signal. Most functions require that preset con ditions are fulfilled for the fu nctio n to be ac tivat ed. In th ese ca se s, the conditions are listed above the illustration.

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

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10 A Foreword – Reading instructions

Example of function description

1. Hydraulic force (solid double line)

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

3. Flag diagnostic test, indicates that the signal can be checked with diagnostic test, see section

Diagnostics

4. Illustration of function, (apply brake)

5. Reference to description of component

6. Signal description, refer ence va lue for sig nal out from componen t

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)

8 Control system,

group

8.4

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A Foreword – Reading instructions 11

12 34

910

11 12

D790-1

13 14

D797-F

15 16 17 18

˚C

19 20

˚C

21 22

˚C

26 27

Symbol explanation function descriptions

The following symbols are used in function descriptions, the symbols are based on stan dard symbols used in wiring and hy draulic 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 bypass valve

20. Temperature-controlled sw i tch

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

28 29

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12 A Foreword – About the documentation

About the documentation

page –

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 manu al and spare p arts catalogue wi th machine card are supplied with the machine as a separate documentation kit.

Supplementary documentation

Supplementary documentation can be ordered for the machine.

• Workshop manual.

• Supplier documentation for engine, transmission and drive axle.

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Ordering of documentation

Documentation is ordered from your Cargotec dealer. Always specify the publication number when ordering. See the machine card for publication number.

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A Foreword – Feedback 13

Feedback

page –

To: Cargotec Sweden AB

Technical Documentation Torggatan 3 SE-340 10 Lidhult SWEDEN Fax: +46 372 263 93

From:

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

Telephone:

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

Form for copying

Cargotec’s ambition is that you who work with maintenance of a Kalmar machine shall have access to correct information.

Your feedback is important to be able to improve the information. Copy this form, write dow n your views and s end it to us. Tha nk you for

your participation!

Manual information

Suggestions, views, remarks, etc.

E-mail:

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

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

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

Section / page n umber: ....... ................. ................. ................ ............ ................ ................. ................................

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

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14 A Foreword – Feedback

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Workshop manual DRF 400-450

B Safety 1

B Safety

Table of Contents B Safety

mm mm mm mm mm mm

Safety .............................................................................................................. 3

General safety information ......................................................................... 3

Safety concerns everyone! ................................................................................ 3

A near accident is a warning! ............................................................................ 3

Safety instructions ...................................................................................... 4

General ............................................................................................................. 4

Service position ................................................................................................. 4

Hydraulic and brake systems, depressurising ................................................... 5

Oils .................................................................................................................... 6

Fuel system ....................................................................................................... 7

Clothing, etc. ..................................................................................................... 8

Several mechanics on the same machine ......................................................... 9

Working under machine .................................................................................... 9

Lifting heavy components ............................................................................... 10

Vibrations ........................................................................................................ 10

Noise ............................................................................................................... 11

Solvents .......................................................................................................... 11

Fire and explosion risks ................................................................................... 12

Fluid or gas under pressure ............................................................................ 13

Coolant ..................... .......................................................... ............................. 14

Refrigerant ...................................................................................................... 14

Air pollution ..................................................................................................... 15

Tensioned springs ........................................................................................... 16

Electric motors ................................................................................................. 16

Rotating components and tools ....................................................................... 17

Tyres and rims ............................. ....... ...... ...... ....... ...... ....... ...... ....... ...... ....... ... 18

Lifting equipment ......................... ....... ...... ...... ....... ...... ....... ...... ....... ...... ....... ... 18

Spare parts .. ...... ....... ...... ....... ...... .................................................................... 19

Non-ionised radiation ......................... ...... ...... ................................................. 20

Environment ............................................................................................. 21

General ........................................................................................................... 21

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2B Safety

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Workshop manual DRF 400-450

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B Safety – Safety 3

Safety

General safety information

page –

Safety concerns everyone!

The safety information concerns everyone who works with the machine! Persons who do not follow the safety instructions given in this manual must make abs olutely s ure that the work is perf ormed wi thout risks of personal injury and without risk of damage to machine or ma chine property!

Remember to:

• follow the instructions in this ma nual

• 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!

Cargotec has in this publication docum ented and warned f or situations and risks that may occu r in connection w ith using as we ll as service or repairs of the machine during normal circumstances.

That is why it is importa nt that all who work with the machi ne, or repair or service the machine, read and follow the information in the Workshop Manual and Operator’s Manual.

A near accident is a warning!

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 ri sk and acti ons must be ta ken to avoi d the risk of injuries.

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4 B Safety – Safety instructions

Safety instructions

page –

General

Read, consider a nd follow the safety instructi ons below before starting to work in the machine:

•

Service position page 4

•

Hydraulic and brake systems, depressurising page 5

•

Oils page 6

•

Fuel system page 7

•

Clothing, etc. page 8

•

Several mechanics on the same machine page 9

•

Working under machine page 9

•

Lifting heavy components page 10

•

Vibrations page 10

•

Noise page 11

•

Solvents page 11

•

Fire and explosion risks page 12

•

Fluid or gas under pressure page 13

•

Coolant page 14

•

Refrigerant page 14

•

Air pollution page 15

•

Tensioned springs page 16

•

Electric motors page 16

•

Rotating components and tools page 17

•

Tyres and rims page 18

•

Lifting equipment page 18

•

Spare parts page 19

•

Non-ionised radiation page 20

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Machine with a fully retracted and lowered boom

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Service position

General

Service position is us ed for servic e, mainten ance and ot her 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 disconnec tor).

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B Safety – Safety instructions 5

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Hydraulic and brake systems, depressurising

1 Machine in service position. 2 Depressurise the hydraulic system.

Turn the start key to position I and activate extension out, a strong hissing sound is heard if there is pressure in the hy draulic system. Activate lift, extension and side shift several times.

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

power.

4 Depressurise the attachment.

Open the relief valve for top lift.

The illustration above shows closed valve.

CAUTION

Hydraulic oil may be directed the wrong way. Risk of damage to the fine filter for hydraulic oil. Check that the relief valve top lift is closed before the

engine is started after the completion of work.

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6 B Safety – Safety instructions

5 Depressurise the brake system by o pening the drain va lve on the

accumulator charging valve.

NOTE

Keep the drain valve open as long as work is in progress.

NOTE

After work is finished, c lose drain valv e and t ighten the loc k ring.

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Oils

The following safety instructions shall be followed for work when handling oils.

WARNING

Warm and pressurised oil. Always depressurise hydraulic and brake systems

completely before starting to work in the systems. Hydraulic and brake systems are pressurised and the oil may cause personal injuries.

Avoid skin contact with the oil, use protective gloves. Warm oil can cause burn injuries, rashes and irritation! The oil may also be corrosive to mucous membranes in, e.g., the eyes, skin and throat.

IMPORTANT

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Always clean the area around components and connections before they are loosened. Dirt in oil systems causes increased wear, resulting in subsequent material damages.

Always take action to avoid spills. In places where drain containers cannot be used, u se a pump or ho se for safe handling.

Always check that plugs seal tight before collection containers are moved.

Handle all oil as environmentally hazardous waste. Oils freely released cause damage to the environment and may also cause fires. Waste oils/fluids shall always be handled by an authorised company.

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B Safety – Safety instructions 7

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Fuel system

The following safety instructions shall be followed for work when handling fuel.

DANGER

Pay attention to the risk of fire when working on the fuel system.

Work on the fuel system shall be avoided when the engine is warm since fuel can spill on hot surfaces and may ignite.

Ensure that naked flames, sparks or glowing objects have been removed before work begins on or near the fuel system.

Do not smoke in the vicinity of the machine when working on the fuel system.

WARNING

Use protective gloves and protective goggles. If a component is to be disconnected, hold a rag over the connection as protection and to collect fuel. The engine’s fuel system operates at very high pressure. The pressure is so high that the jet can injure the skin, resulting in severe injuries. Risk of personal injuries.

Avoid skin contact with fuel, use protective gloves. Fuel is corrosive to mucous membranes in, e.g., eyes, skin and throat.

CAUTION

Always clean the area around components and connections before they are loosened. Dirt in the fuel may cause malfunctions and engine stop in undesirable situations as well as increase wear, resulting in subsequent material damages.

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8 B Safety – Safety instructions

IMPORTANT

Always take action to avoid spills. In places where drain containers cannot be used, u se a pump or ho se for safe handling.

Always check that plugs and connections seal tight before moving collection containers.

Handle the fuel as environmentally hazardous waste. Fuel freely released causes damage to the environ ment and may also cause fires. Fuel shall always be handled by an authorised company.

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Clothing, etc.

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

Remove jeweller y as it m ay con duct e lectric ity an d get ca ugh t in moving parts.

Long hair should be adequately gathered since it can easily ge t caught in moving parts. Be careful when working with welding or an open flame since hair easily catches on fire.

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B Safety – Safety instructions 9

001977

page –

Several mech anics on the same machine

WARNING

If several mechanics are working on the same vehicle, take extra care so that unintentional movements do not injury another person. Communicate so that eve ryone 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 s tati on, e.g., movement o f lifting equipment, may cause severe personal injuries.

Safety precautions

• 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 wi th.

• Do not work with drive wheels on the ma ch ine's both sides at the same time.

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Locks on lift mast for securing the liftable cab in the raised position.

Working under machine

Working under cab

On machines with liftable cab, the cab must be secured in the raised position with the locks designed for this purpose.

Working under the frame

A raised vehicle may not, for an y reason, be supported or li fted in parts that belong to the wheel sus pension or steering. Alway s support under the frame or wheel axle.

Risks

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

Safety precautions

Use axle stands and supports that stand securely. Lifting tools should be inspected and type approved for use.

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10 B Safety – Safety instructions

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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 tha t 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 co mpone nt may t hen make unexpected movements which may cause severe personal injuries and material damage.

A component lifted w ith lifti ng equipmen t can start to turn if the equi librium is upset.

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

Safety precautions

Lifting with lifting device. Use lifting tools or other tools, especially

when there are such adapted for certain work. See worksh op manu al for methods.

If lifting must be performed without lifting device:

• Lift near the body.

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

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

• Always use protective shoes.

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Vibrations

In case of long-term use of vibra ting tools, for exampl e, impact nut runners or grinders, injurie s may be sust ained a s vibr ations can be t ransmitted from tools to hands. Especially when fingers are cold.

Safety precautions

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 a nd grip so that the body is not stres sed in only one

position by the vibrations.

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B Safety – Safety instructions 11

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Noise

Noise louder than 85 dB (A) that lasts for longer than 8 hours is considered harmful to hearing. (Limit values may vary between different countries.) High tones (hig h frequencies) are more damaging th an 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 protecti on. Make sure that it is tested and p rotects 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 opp osed to w ater) dissolve grease, paint, lacque r, 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 consti tute a fire hazard.

Risks

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

If the solvent en ds up directl y on the skin it may dry o ut and crack . Risk of skin allergies incre ases. Solv ents ma y also cause in jury if the y 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 gene ral tire dness and fat igue. C ontin u ous inhalation of gasoline and diesel fumes is suspected to cause cancer.

Safety precautions

Avoid inhaling sol vent fumes by providing go od ventil ation, or wearin g a fresh-air mask or respiratory de vice with a sui table filter for the toxic gases.

Never leave a solvent container without tight-sealing lid. Use solvents with a low content o f aromatic substan ces. It reduces th e

risk of injury. Avoid skin contact. Use protective gloves. Make sure that work clothes are solvent-resistant.

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Fire and explosion risks

Examples of flammable and explosive substances are oils, gasoline, diesel fuel oil, organic solvents (lacquer, plastics, cleaning agents), rustproofing agents, welding gas, gas for heating (acetylene), high concentration of dust particles consisting of combustible materials. Rubber tyres are flammable and cause explosive fires.

Risks

Examples of cause of ignition is welding, cutting, smoking, sparks when working with grinders, contact between hot machine parts and flammable materials, heat development in rag drenched with oil or paint (linseed oil) and oxygen. Oxygen cylinders , lines and val ves shall be kept free from oil and grease.

Fumes from, e.g., gasoline are heavier than air and may "run" down into a sloping plane, or down in a grease pit, where welding flames, grinding sparks or cigarette embers may cause an explosion. Evapo

rated gasoline explodes very forcefully.

Special cases

Diesel fuel oil with added gasoline has a lower ignition point. Risk of explosion already at room temper ature. The expl osion risk for warm ed diesel fuel oil is higher 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 machine . If diesel and or other oil s have leake d out and been absorbed b y rags , absorb ent age nts, p aper o r other porous material, hot welding sparks can cause ignition and explosive fires.

When a battery is charged, the battery fl uid is d ivided i nto oxyg en and hydrogen gas. This mix ture is ve ry ex pl os iv e. The risk of explosion is especially high when using a boo ster b atte ry or q uick-c harger , as th is increases the risk of sparks.

Today’s machines contain a lot of electronic equipment. When welding, the control units must be disconnected and the electric power must be turned off with the batte ry disconnector. Powe rful welding currents may otherwise short-circuit the electronics, destroy expensive equipment or cause an explosion or fire.

Never weld on pai nted s urfaces (re mo ve pai nt, by bla sting a t leas t 10 cm around the weldi ng or c utting poi nt). Us e gloves , br eathin g protec tion and protect ive g lass es. Als o, w eldin g work may not b e done near plastic or rubber mat eria ls with out firs t pro tec tin g t hem fro m th e h eat . Paints, plastics, a nd rubber deve lop a numbe r of substanc es that may be hazardous to health when heated. Be careful with machines that have been exposed to intense heat or fire.

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B Safety – Safety instructions 13

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 ven tilation is adequ ate or there is an ai r extraction unit

when handling flammable substances.

page –

Fluid or gas under pressure

High-pressure lines can b e damaged during w ork, and fluid or gas c an stream out.

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

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

Risks

Risk of damage/injuries in connection with work on:

• Hydraulic systems (e.g., working hydraulics and brake system).

• Fuel system.

• Tyre repairs.

• Air conditioning.

Safety precautions

• Use safety glasses and protective gloves.

• Never work on a pressurised 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 a ccum ula tor s ha ll first be depressurised an d then punctured before it is discarded (to avoid risk of explosion). Carefully, drill a hole with 3 mm diameter after depressurising.

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

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Coolant

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

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

Risks

The cooling system operates at high pressure when the engine is warm. Hot coolant c an j et ou t an d ca us e sc al din g in case of a leak or when the expansion tank cap (filler cap) is opened.

Ingesting ethylene glyco l and anti - co rros io n com pou nd is danger ous 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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Refrigerant

Refrigerant is used in the machine’s air conditioning system. Work on the air cond itioning system must be performed by accredi ted/

authorised and traine d personnel a ccording to national leg islation and local regulations.

Risks

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

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

Safety precautions

• Use special instructions and equipment for refrigerant according to the manual when working on the air conditioning system. Spe cial certification and authorisation is often required of the person who may do the work. (Note national legislation and local regulations!)

• Use protective glov es and s afety glasses if there’s a ri sk of leaks.

• Make sure that heat-p roducing sources o r objects are not cl ose by (cigarette glow, welding flame).

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B Safety – Safety instructions 15

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Air pollution

Air pollution is the impurities in t he air arou nd us and whic h are regarded as hazardous to health. Certain pollution is more prominent in certain environments.

The following hea lth-hazard ous air pollutio n is e special ly promi nent in workshops:

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

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

• Welding smoke espec ially h azardous to health when wel ding on oily surfaces, galvanised or lacquered materials.

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

• Grinding dust and gases ge nera ted wh en g rin ding and heating plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.

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

Risks

Sulphuric acid mist is corrosive and injures the respiratory tracts. (Generated when heating certain plastics and paints.)

Isocyanates can be released in the form of steam, dust (or may be present in aerosols) when cut ting, grinding or w elding. Can irrit ate mu cous membranes producing symptoms similar to asthma and impairing lung function . Even bri ef exposure to high concen trations can give problems with persistent high sensitivity.

Safety precautions

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

• Use suitable protective gloves and breathing protection when there is a risk of oil m ist. Make sure tha t the protec tion is oil-pro of.

• 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 machin e inside the works hop. Connect an air extractor to the exhaust pipe so that the exhaust fumes are removed from the workshop.

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Tensioned springs

Examples of tensioned springs:

1. Torque springs in pedals for example

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

3. Lock rings

4. Gas springs

Risks

If a tensioned spring releases, it is sho t 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 uncon

trolled manner. Gas springs and gas-charged shock absorbers are tensioned with

high force and c an cause very seve re accidents if th ey 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 instruct i ons in th is and other manual when perf orm ing maintenance and changing parts and components.

• Always use recommended tools.

page –

Electric motors

Safety precautions

Always turn off the battery disconnector when working on electric motors.

Always block the machine’s wheels and make sure that the parking brake is activated and that the gear selector is in neutral position before starting any work on the machine.

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B Safety – Safety instructions 17

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Rotating components and tools

Examples of rotating components and tools:

• Cooling fan

•Drive belts

• Propeller shafts

•Drills

• Grinders

Risks

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

Drills, lathes, grind ers or other ma chines with ro tating par ts can cause severe accidents if clot hes or hair get caught and are wound up in the machine.

Safety precautions

• Do not use gloves when workin g 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.

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18 B Safety – Safety instructions

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Tyres and rims

DANGER

Tires shall be regarded as pressure reservoirs. If handled incorrectly, they constitute a fatal danger

Parts can be thrown with explosive force and may cause severe injuries.

Never repair damaged tyres, rims or lock rings. Tyre changes shall be performed by authorised personnel.

Risks

Dismantling wheels: Tyres, rims or lock rings can be thrown. Inflating of wheels: Tires, rims or lock rings may be ejected.

Safety precautions

• Always 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.

• Wheels shall be infla ted on the machi ne or in a pro tective devic e, designed and dimensioned so that it can handle or dissipate a shock wave from a tyre explosion as well as catch the ejected parts.

• Use protective screen and safety glasses.

page –

Lifting equipment

When working on the machine in general, and with the machine’s lifting equipment in particular, the greatest caution must be exercised with respect to securing the boom and attachment.

For this reason, always be in the ha bit of having the boom fully lowered and fully retracted during work on the machine.

Risks

Risk of crushing if the machine’ s lif ting equipment is not lowered or secured.

Risk of crushing is extra high when depressurising the hydraulic system, see

Hydraulic and brake systems, depressurising page 5

Safety precautions

• Do not start work until the boom is lowered and fully retracted if possible.

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B Safety – Safety instructions 19

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Spare parts

WARNING

The following parts must, for safety reasons, only be replaced with original spare parts:

• Brake valve

• Drive axle

• Valve for mini-wheel/lever steering

• Steering valve (Orbitrol)

• Steering valve incl. priority valve

• Steering axle

• Steering cylinder

•Rims

• Lift boom

• Boom nose extension

• Lift cylinder

• Valve block lift

• Extension cylinder

• Valve block extension

• Rotation motor unit

• Tilt cylinder

• Twistlocks, lifting shoe

• Safety switch (for hydraulic function)

• Emergency switch

•Frame

• Accumulator

• Main valve load handling

• Accumulator charging valve

• All control units

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Non-ionised radiation

WARNING

Extra equipment such as communication radio, RMI, phone, etc. can emit non-ionised radiation.

Danger of disruption to active or inactive medical products.

Use communication radio, RMI, phone, etc. when there are no people with active or inactive medical products in the vicinity.

NOTE

When there are no people wit h act iv e or ina cti ve pr odu ct s in th e vicinity the phone and communication radio in the cab may be used.

Equipment should not be used durin g ope ration or l oad h andlin g as your concentration as operator is reduced.

Cargotec accepts no re sponsibili ty for equipment n ot installed by Cargotec or with Cargotec approved installation.

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B Safety – Environment 21

Environment

page –

General

Ever-increasing indust rialisation o f our world is ha ving a sign ificant impact on our global environ ment. Nature , animals and man are sub jected daily to risks in conn ection with various forms of chemical h andling.

There are still no environmentally safe chemicals, such as oils and coolants, available on the market. Therefore, al l w h o h and le , pe rform service on or repair machines must use the tools, assisting devices and methods necess ary to pro tect the enviro nment in an environ men tally sound manner.

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

Recycling

Well-thought out re cycling o f the mach ine is the cornerstone of ending its life cycle and being able to re-use materials in new products. Ac cording to calculations by Cargotec, the machine can be recycled to more than 90% by weight.

Environmentally hazardous waste

Components such as batteries , plastics , and other materi als that may be considered as enviro nm enta ll y ha za rdous waste must be handl ed in an environmentally correct manner.

Discarded batteries c ontain subs tances h azardous to p ersonal he alth and the environment. Th erefore, handle batteries in an e nvironmental ly safe manner and according to national regulations.

Oils and fluids

Oils freely discharged cause environmental damage and can also be a fire hazard. Therefor e, when e mptying and draini ng 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 unit

The refrigerant in the air conditioning unit for the cab contributes to the greenhouse effect and may not be i ntentionally released in to the open air. Special training is required for al l servic e work on the air condi tion ing unit. Many coun tries d emand certi fication by a gov erning au thority for such work.

Working in a contaminated area

The machine shall be equipped for work within a contaminated area (environmental contam ina t io n o r hea lth - haz ard ous ar ea) b efo re w ork is started. Also, special loc al regulations appl y to such handling and to service work on such a machine.

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22 B Safety – Environment

Declarations

The machine does not contain asbestos. The machines contains lead in batteries and in electric cabling. In cer-

tain models, there are lead castings as counterweight. If the machine is equ ipped with air con ditioning , then re frigerant o f the

type R134a is used, in an amount between 1-3 kg.

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mm mm mm mm mm mm

C Preventive maintenance – C Preventive maintenance 1

C Preventive maintenance

page –

The information is found in the Maintenance Manual

The information is found in the Maintenance Manual. For information on how to order the Maintenance Manual, see the

section

A Foreword

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0 Complete mach ine 1

0 Complete machine

Table of Contents 0 Complete machine

mm mm mm mm mm mm

Complete machine......................................................................................... 3

Complete machine, description ....... ....... ...... ...... ....... ...... ....... ............................... 3

Troubleshooting, general work instructions ............................................................ 4

Troubleshooting without an error code, example ................................................... 5

Troubleshooting with error code, example ............................................................. 5

Troubleshooting cable harness .............................................................................. 7

Troubleshooting hydraulic hoses ............................................................................ 8

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0 Complete machine – Complete machine 3

Complete machine

page –

Complete machine, description

The Kalmar DRF 400–450 is a "Re achstacker" for co ntainer handli ng. The machine a liftin g capaci ty of 40–4 5 tonnes d epending on versio n.

The drive source is a six-c ylinder, four-strok e diesel engin e with direct injection.

The transmission is hydromechanical, with constant mesh gears. It has four speeds forwards and fou r speeds in reverse. Engi ne power is transmitted by a torque converter.

The driveline/axle comprises a propeller shaft and a rigid drive axle with hub reduction. Drive is via the front wheels.

The service brake is of wet disc type, built together with drive wheel hubs. The parking brake is a disc brake and acts on the drive axle in put shaft.

Steering is via the rear wheels and a dou ble acting hydrau lic cylin der. The steering axle is pendulum-suspended in the frame.

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

Load handling comprises components and functions for managing loads. Loads are lifted with and attachment that is fitted on a liftable telescopic boom. Load handling is divided into lifting/lowering, exten sion, side shift, spreading, rotation, tilt, levelling and load carri er fun ctions.

• Lifting/lowering is the function used to raise and lower the boom.

• Extension is the function to extend the boom in and out.

• Side shift is used to move th e lift attachment laterally in relati on to the machine.

• Spreading is used to adjust the width between the attachment’s lifting points.

• Rotation is rotating the load in relation to the machine.

• Tilt is angling the load in the longitudinal direction of the truck.

• Levelling is angling the load in the lateral direction of the truck.

• The load carriers are designed to hold a fixed load.

The control system is functions for warni ng the opera tor of dange rous situations and machine faults. The control system has diagnostic re sources that simplify troubleshooting.

The frame supports the machine. Mounted in the frame are the engine, transmission, drive axle and steering. The side of the frame houses tanks for fuel, hydrauli c oil and oil for the brake system. T he cab is cen trally located and can be tilted longitudinally. As an option the cab is available in a side-mounted version that can be raised and lowered.

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Troubleshooting, general work instructions

When troubleshooting, it is important that the work is structured and logical. The point of the troubleshoo ting describe d in the mainten ance manual is to exclude components as error so urce so that the real e rror source can be pin-po inted. A suggest ed structured w ork method is de scribed below.

When troubleshoo ting , i t is i mp orta nt t o un derstand how the mach ine functions. Certain m alfun ctions can be pi n-p ointed directl y using f unction descriptions. Sections

0–12

contain descriptions of the various

functions of the machine.

Troubleshooting procedure

1 Check that there is battery voltage available.

• Battery disconnector, must be in position 1.

• Battery voltage, should be 22–30 V.

• Fuses, check that they are intact.

2 Check that all oil and fluid levels are normal.

•Fuel

• Engine oi l

• Transmission oil

• Brake system fluid

• Hydraulic oil

• Coolant

• Washer fluid 3 Check if there are error codes. 4 If there are error codes, use the error code lists as a guide. See

Troubleshooting with error code, example page 5

In the error code lists there are recommended actions for every error code. Error code lists are found in section

5 If there is no error code or the problem persis ts, use the functio n

description for the function in question in section The function description contains information on which compo-

nents are involved in the function and how these components work together. In some cases, there is information on what con ditions are required in order for it to be possible to activate the function. Measureme nt points a re marked wi th flags (C fo r meas uring outlet, D for diagnostic me nu).

D Error codes

0–12

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Troubleshooting without an error code, example

1 Choose suitable section

tion that have caused the symptom.

2 Read the function description for the function in question to get

an overall understanding of which components are affected and how these interact.

3 Use the function description and check the signals for the func-

tion in question to find where in the function chain that signal or reaction is incorrect.

4 The fault is probably between the two units where the signal is

failing. Start by checking the component that should send the signal.

5 If the component that is to send the signal seems to be correct,

check transmission of the signal (electric wiring or hydraulic hoses).

For electric cabling, see For hydraulic hoses,

see

Troubleshooting hydraulic hoses page 8

6 If the leads or hoses between the components seem in order,

then check the component that receives the signal.

0–12

to find the function and sub-func-

Troubleshooting cable harness page 7

page –

Troubleshooting with error code, example

Error codes are strong i ndica tors of mal functi ons de tected by the control system. Many error codes are connected to elec trical malfunctio ns but there are also error codes that inte rpret associati ons between one or several signals th at ind icate a n on- electri cal mal functi on. It’ s imp or tant to not draw conclusions too fast based on an error code.

1 Read out error codes from the display, e.g., error code 34. 2 Use the error code lists and search information about the error

code, see "Example of error code information in error code list" below.

Error code lists are found in section

D Error codes

For detailed instructi on o n re adi ng o ut e rror c od e, s ee s ec tio n

Error codes

. 3 Follow the instructions in the field “Action”. 4 Use diagnostic menus and circuit dia grams to dete rmine if the in-

put signal to the control unit is correct; see section

system

, group

8.4 Diagnostics

as well as section

8 Control

E Schematics

5 Use the function group to find more information if needed.

In section

0–12

there is functio n descriptio n, the functi on's included components and their position as well as, in certain cases, work instructions for how components are checked, cleaned or adjusted.

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6 0 Complete machine – Complete machine

6 If possible, eliminate component fault by testing the component

individually. Electric componen ts can s ometi mes be chec ked w ith resi stanc e

measurements using a multimeter. Hydraulic componen ts are often checked by meas uring pressure

(then described in the function group and indicated in the section activated mechanica ll y to d eterm in e if th e ma lfunction is electric or hydraulic.

7 If the component’s measuremen t values are correct , conti nue by

troubleshooting electric cables and hydraulic hoses. For electric cabling, see For hydraulic hoses, see

8 If the cable is not defective, then connect the lead to the control

unit.

C Preventive maintenance

NOTE

The main electric power shall be turned off with the battery disconnector!

9 Disconnect the cable from the component in question. 10 Turn on the main electric power with the battery disconnector. 11 Turn the ignition key to the operating position. 12 Check that voltage reaches the component.

). Sometimes valves can be

Troubleshooting cab le harn es s p age 7

Troubleshooting hydraulic hoses page

Table 1. Ex ample of error code information in error code list

Code Description Limitation Action

34 Signal error from

parking brake switch, indicates re leased and applied at same time or nothing at all.

Parking brake cannot be

released.

Check cabling between the control unit and the component with diagnostic menu.

Check component.

Connections and components

D791-1/K8:5 S107, K8:13 S107

Diagnostic menu

HYD,

Function group

4.1.2 Parking brake control

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Troubleshooting cable harness

NOTE

Perform troubleshooting for all cabl es in the sam e way to avo id damage to control units, components or measuring equipment.

1 Study the circuit diagram in questi on, check where the suspected

cable is connected and if, and if so where, it is spliced. 2 Turn off the main electric power with the battery disconnector. 3 Unplug the connector at the control unit or component in

question.

CAUTION

Wipe and re-grease the connectors. Risk of corrosion on contact surfaces. Clean all connectors loosened during troubleshoot-

ing using electronic cleaner 923836.0826 and regrease them with connector grease 923836.0552.

4 Check if there is open circuit.

NOTE

Some components ca nnot be checked without p ower supply to the component. In such an event, proceed to point 5.

a. Measure resistance between connection s for the component

in the connector at the control unit or component.

b. The resistance mus t correspond with the c om pon ent . O th er-

wise there may be an open circuit or short circuit in cable harness and/or component.

5 Check if there is short circuit to frame:

a. Unplug the conne ctor at bot h the con trol unit a nd the co mpo-

nent in question.

b. Measure the resistance of one lead at a time. Measure be-

tween the lead and a frame-connected part of the machine.

c. The multimeter should show endless resistance.

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Troubleshooting hydraulic hoses

WARNING

Oil under high pressure! Personal injury! Always depressurise hydraulic and brake systems

before starting to work on the systems.

1 Depressurise the hydraulic and brake systems; see section

Safety

2 Study the relevant hydraulic diagra m, check between w hichever

components the suspec t hose i s conne cted and corres pondingl y where it is spliced.

3 Locate the hose on the machine.

Start at one component and follow the hose to the next component.

4 Inspect the entire hose and splicin g points with res pect to chafing

damage, pinching damage and leaks. Change damaged hoses. When removing a hydraulic hose,

change of O-ring is always recomme nded on the hos es that have these (ORFS).

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1 Engine

Table of Contents1 Engine

mm mm mm mm mm mm

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

1.1 Controls and instruments ............................. ............................................ 23

1.1.1 Ignition switch ...................................................................................... 23

1.1.2 Accelerator pedal ................................................................................. 24

1.2 Fuel system .............................................................................................. 25

1.2.1 Fuel tank .............................................................................................. 25

1.2.2 Sensor, fuel level ................................................................................. 25

1.6 Air intake and exhaust outlet ................ .................................................... 26

1.6.1 Air cleaning system .............................................................................. 26

1.6.3 Exhaust syst em ................................................................ ................... 26

1.6.4 Intercooler ............................................................................................ 27

1.7 Cooling system ......................................................................................... 28

1.7.4 Radiator and expansion tank ............................................................... 29

1.7.5 Cooling fan ........................................................................................... 30

1.7.7 Coolant ................................................................................................ 32

1.7.10 Engine heater ...................................................................................... 35

1.9 Engine control system .............................................................................. 36

1.9.1 Control unit , engine ................................ ....................... .. ..................... 36

1.11 Start/stop .................................................................................................. 37

1.11.1 Starter motor ........................................................................................ 37

1.11.2 Stopping device ................................................................................... 37

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1 Engine 3

1 Engine

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Engine, general

Engine alternative

The machine can be equipped with one of the following engine alternatives:

• Volvo TWD1240VE stage II as per Directive 97/68/EC

• Volvo TAD1250VE (stage III as per Directive 97/68/EC)

• Cummins QSM11 (stage III as per Directive 97/68/EC )

If there are differences between engine alternatives, this is written in brackets after heading s or u nder fi gures to c larify that wh ich i s sho wn.

Volvo engines have many similarities. Descriptions and instructions that are the same for both engine alternatives are denominated "(engine alternative Volvo)". If a description or set of instructions only applies to one engine alternative then the whole engine designation is written out, for instance "(engine alternative Volvo TAD1250VE).

Component supplier documentation

The Workshop manual only describes components and work descriptions that concern installation in the machine . For d esc rip tions and instructions for the engine’s compon ents an d syst ems, refe r to suppl ier documentation.

References to com ponent supplier d ocumentation are only provided in exceptional cases . If information abou t a c om po nen t i s no t f ound, the component supplier documentation should be used.

Workshop manual DRF 400–450

VDRF03.02GB

4 1 Engine

page –

Engine alternative Volvo, function description

Condition Reference value Reference

Engine heater

D10

2, 11

Disconnected (when cable is in start lock-out is activated)

III

<˚

1, 5

6, 15

D790-1 D790-2 D795

Engine heater, description page 35

˚C

bar

rpm kph

18, 21

20, 22

D793

3, 7, 12

D794

14, 23

D14

D797-R

D16

D19

SENSORS

H2O

Pos Explanation Signal description Reference

1 The ignition key lock sends a voltage sig-

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

2 Cab control unit (D 790-1) sends ign ition on

via the CAN bus. If the k ey is tu rned to the preheating position, then preheating is also sent on the CAN bus.

3 If preheating is activat ed with th e start key

then Control unit, engine (D794) supplies power to the preheating element.

U = 24 V

Ignition switch, description page 23

D1: Diagnostic menu , see section

Checked by control sys tem, error shown with

system menu 4

Section

11.5.3.1 Cab control unit

, group

and

11 Common electrics,

error code.

U = 24 V D3: Diagnostic menu , see section

system

, group

008223

8 Control

8.4.1.4 CAN/POWER,

8.4.6.4 ENGINE, menu 4

group

8 Control

8.4.6.5 ENGINE, menu 5

4 The preheating coil warms the engine

intake air.

VDRF03.02GB

- D3: Diagnostic menu , see section

Workshop manual DRF 400–450

system

, group

8 Control

8.4.6.5 ENGINE, menu 5

1 Engine 5

Pos Explanation Signal description Reference

5 The ignition key lock sends a voltage sig-

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

6 Control unit KIT (D790-2) transmits a start

signal on the CAN bus.

7 The engine control unit (D794) supplies

power to the starter motor.

8 The starter motor cranks the engine. -

9 The engine’s sensors send signals to the

engine control unit (D794), w hich regulates the injectors so that the engine starts.

10 The accelerator pedal sends the cab con-

trol unit (D790-1) a voltage signal proportional to the downward press of the pedal.

U = 24 V

Checked by control system, error shown with error code.

U = 24 V

Checked by control system, error shown with error code.

U = 0.5–4.5 V Lower voltage than 0.5

V and higher voltage than 4.5 V used to de tect malfunction i n cable harnesses and contro ls.

Ignition switch, description page 23

D5: Diagnostic menu, see section

system

Section

, group

8.4.6.4 ENGINE, menu 4

11 Common electrics,

8 Control

group

11.5.3.11 Control unit KIT

Starter motor, description (engine alternative Volvo) page 37

D7: Diagnostic menu, see section

system

, group

8.4.6.5 ENGINE, menu 5

8 Control

Starter motor, description (engine alternative Volvo) page 37

D7: Diagnostic menu, see section

system

Section

, group

8.4.6.5 ENGINE, menu 5

11 Common electrics,

8 Control

group

11.5.3.10 Engine control unit

Section

ries,

D10: Diagnostic menu, see section

trol system menu 1

9 Frame, body, cab and accesso-

group

9.1 Controls and instruments

, group

8.4.6.1 ENGINE,

8 Con-

11 The cab control unit (D790-1) transmits a

message with the rpm re quest on the C AN bus

12 The engine control unit (D794) increases

engine speed.

13 The NO switch for coolant level sends a

voltage signal to Control unit, engine (D794) if the coolant level in the ex pansion tank is low.

14 The engine control unit (D794) transmits

engine data and warning m essages on the CAN bus.

15 The KID control unit (D795) shows e ngi ne

data via display figures.

Checked by control system, error shown with error code.

- Section

Section

11.5.3.1 Cab control unit

11.5.3.10 Engine control unit

U = 24 V

Checked by control system, error shown with error code.

Cooling system, description page 28

Section

11.5.3.10 Engine control unit

D14: Diagnostic menu, see section

trol system

6 and 8.4.6.7 ENGINE, menu 7

- Section

11.5.3.12 KID control unit

11 Common electrics,

, group

8.4.6.6 ENGINE,

11 Common electrics,

group

8 Con-

Workshop manual DRF 400–450

VDRF03.02GB

6 1 Engine

Pos Explanation Signal description Reference

16 The fuel level sensor (B757) sends a volt-

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

17 Control unit, frame rear (D797-R) transmits

fuel level on the CAN bus.

18 The KID control unit (D795) displays the

fuel level in the operating menu for engine .

19 The output shaft sensor (B758) sends the

transmission control unit (D793) pulses with frequency proportion al to output sh aft rpm.

20 The transmission control unit (D793)

transmits speed on the CAN bus.

21 The KID control unit (D795) shows the ma-

chine’s speed.

U = 0.5–4.5 V Lower voltage than 0.5

V and higher voltage than 4.5 V used to de tect malfunction in cable harnesses and controls.

Checked by control sys tem, error shown with error code.

- Section

Sensor, fuel level, description page 25

D16: Diagnostic menu, see section

Control system

Section

11 Common electrics,

, group

8.4.3.7 CAB,

11.5.3.3 Control unit, frame rear

11 Common electrics,

group

11.5.3.12 KID control unit

- D19: Diagnostic menu, see section

Control system

Checked by control sys tem, error shown with error code.

- Section

Section

11.5.3.9 Control unit, transmission

, group

11 Common electrics,

8.4.7.6 TRANSM,

group

11.5.3.12 KID control unit

22 If output shaft rpm is so high that it reaches

the limit for the machine’s s peed limitation, the cab control unit (D790-1) transmits a reduce engine rpm request on the CAN bus.

23 Control unit engine (D794) restricts engine

rpm.

Checked by control sys tem, error shown with error code.

- Section

Section

11.5.3.1 Cab control unit

11.5.3.10 Engine control unit

11 Common electrics,

group

VDRF03.02GB

Workshop manual DRF 400–450

1 Engine 7

page –

Engine alternative Cummins QSM11, function description (model

Condition Reference value Reference

Engine heater

<˚

2, 9

Disconnected (wh en cable is in start lock-out i s activated)

III

1, 3

D1 D3

D790-1 D790-2 D795

4, 13

year-2008)

Engine heater, description page 35

˚C

bar

rpm kph

16, 19

18, 20

D793

D794

12, 21

D797-R

5, 10, 15

D12

D17

H2O

SENSORS

Pos Explanation Signal description Reference

1 The ignition switch sends a voltage sig-

nal to the cab control unit (D790-1 ) when the ignition key is turned to position 1.

2 The cab control unit (D790-1) transmits

Ignition on as a start message on the CAN bus.

3 The ignition switch sends a voltage sig-

nal to Control unit KIT (D7 90-2) when the start key is turned to the start position.

U = 24 V

Checked by control system, error shown with error code.

U = 24 V

Ignition switch, description page 23

D1: Diagnostic menu, see section

, group

system

and

8.4.6.4 ENGINE, menu 4

Section

11 Common electrics,

11.5.3.1 Cab control unit

Ignition switch, description page 23

D2: Diagnostic menu, see section

system

, group

D14

008224

8 Control

8.4.1.4 CAN/POWER, menu 4

group

8 Control

8.4.6.4 ENGINE, menu 4

4 The KIT control unit (D790-2 ) transmits a

start signal on the CAN bus.

Workshop manual DRF 400–450

Checked by control system, error shown with error code.

Section

11 Common electrics,

11.5.3.11 Control unit KIT

group

VDRF03.02GB

8 1 Engine

Pos Explanation Signal description Reference

5 Control unit, frame rear (D797-R)

supplies power to the starter motor.

6 The starter motor cranks the engine. -

7 The engine’s sensors send signals to the

engine control unit (D794), which regulates the injectors so that the engine starts.

8 The accelerator pedal sends the cab

control unit (D790-1) a voltage signal proportional to the downward press of the pedal.

9 The cab control u nit (D790-1) transmits a

message with the rpm request on the CAN bus

10 The engine control unit (D794) controls

engine speed.

U = 24 V

Starter motor, descriptio n (engine alte rnative Cummins) page 37

D5: Diagnostic menu, see section

system Starter motor, descriptio n (engine alte rnative

Cummins) page 37

- Section

11.5.3.10 Engine control unit

U = 0.5–4.5 V Lower voltage than 0.5

V and higher voltage than 4.5 V used to de tect malfunction i n cable harnesses and controls.

Checked by control system, error shown with error code.

- Section

Section group

9.1 Controls and instruments

D8: Diagnostic menu, see section

system

Section

11.5.3.1 Cab control unit

11.5.3.10 Engine control unit

8 Control

, group

8.4.6.5 ENGINE, menu 5

11 Common electrics,

group

9 Frame, body, cab and accessories,

8 Control

, group

8.4.6.1 ENGINE, menu 1

11 Common electrics,

group

11 The NO switch for coolant leve l s en ds a

voltage signal to Control unit, engine (D794) if the coolant level in the expan sion tank is low.

12 The engine control unit (D794) tran smits

engine data and warning messages on the CAN bus.

13 The KID control unit (D795) shows en-

gine data via display figures.

14 The fuel level sensor (B757) sends a

voltage signal to C ontrol un it, frame re ar (D797-R) proportional to the f uel l evel in the tank.

15 Control unit, frame rear (D797-R)

transmits fuel level on the CAN bus.

U = 24 V

Checked by control s y stem, error shown with error code.

- Section

U = 0.5–4.5 V Lower voltage than 0.5

V and higher voltage than 4.5 V used to de tect malfunction i n cable harnesses and controls.

Checked by control system, error shown with error code.

Cooling system, description page 28

Section

11 Common electrics,

group

11.5.3.10 Engine control unit

D12: Diagnostic m enu, see se ction

, group

system

8.4.6.6 ENGINE, menu 6 and

8 Control

8.4.6.7 ENGINE, menu 7 11 Common electrics,

group

11.5.3.12 KID control unit

Sensor, fuel level, description page 25

D14: Diagnostic m enu, see se ction

system

Section

, group

8.4.3.7 CAB, menu 7

11 Common electrics,

8 Control

group

11.5.3.3 Control unit, frame rear

16 The KID control unit (D795) displays the

fuel level in the operating menu for engine.

VDRF03.02GB

- Section

Workshop manual DRF 400–450

11 Common electrics,

11.5.3.12 KID control unit

group

1 Engine 9

Pos Explanation Signal description Reference

17 The output shaft sensor (B758) sends

the transmission control unit (D793) pulses with frequency propor tion al to output shaft rpm.

18 The transmission control unit (D793)

transmits speed i nformatio n on the CA N bus.

19 The KID control unit (D795) shows the

machine’s speed.

20 If t he spe ed is at the machi ne’s speed

limitation limit, the cab control unit (D790-1) transmits an engine speed reduction request on the CAN bus.

21 Control unit engine (D794) restricts

engine rpm.

- D17: Diagnost ic menu, s ee section

system

Checked by control system, error shown with error code.

- Section

Section

11.5.3.9 Control unit, transmission

, group

8.4.7.6 TRANSM, menu 6

11 Common electrics,

group

11.5.3.12 KID control unit

Checked by control system, error shown with error code.

- Section

Section

11 Common electrics,

11.5.3.1 Cab control unit

11 Common electrics,

group

11.5.3.10 Engine control unit

8 Control

Workshop manual DRF 400–450

VDRF03.02GB

10 1 Engine

page –

Engine alternative Cummins QSM11, function description (model

Condition Reference value Reference

Engine heater

2, 9

Disconnected (when ca ble is in start lock-out is activated)

III

1, 3

D1 D3

D790-1

D790-2 D795

4, 14

year 2009-)

Engine heater, description page 35

bar

rpm kph

17, 20

19, 21

D793

D794

13, 22

D797-R

5, 10, 16

D13

D18

H2O

SENSORS

Pos Explanation Signal description Reference

1 The ignition switch sends a voltage sig-

nal to the cab con trol unit (D79 0-1) when the ignition key is turned to position 1.

2 The cab control unit (D790-1) transmits

Ignition on as a start message on the CAN bus.

3 The ignition switch sends a voltage sig-

nal to Control unit KIT (D79 0-2) when the start key is turned to the start position.

U = 24 V

Checked by control s y stem, error shown with error code.

U = 24 V

Ignition switch, description page 23

D1: Diagnostic menu, see section

, group

system

8.4.6.4 ENGINE, menu 4

and Section

11 Common electrics,

11.5.3.1 Cab control unit

Ignition switch, description page 23

D2: Diagnostic menu, see section

system

, group

D15

013025a

8 Control

8.4.1.4 CAN/POWER, menu 4

group

8 Control

8.4.6.4 ENGINE, menu 4

4 The KIT control unit (D79 0-2) transmits a

start signal on the CAN bus.

VDRF03.02GB

Checked by control s y stem, error shown with error code.

Workshop manual DRF 400–450

Section

11 Common electrics,

11.5.3.11 Control unit KIT

group

1 Engine 11

Pos Explanation Signal description Reference

5 Control unit, frame rear (D797-R) sup-

plies power to the starter motor.

6 The starter motor cranks the engine. -

7 The engine’s sens ors send signals to the

engine control unit (D794), which regu lates the injectors so that the engine starts.

8 The accelerator pedal sends the cab

control unit (D790-1) a voltage signal proportional to the downward press of the pedal.

9 The cab control uni t (D790-1) transmits a

message with the rpm request on the CAN bus

10 The engine control unit (D794) controls

engine speed.

U = 24 V

Starter motor, descri ption (eng ine alterna tive Cummins) page 37

D5: Diagnostic menu, see section

system Starter motor, descri ption (eng ine alterna tive

Cummins) page 37

- Section

11.5.3.10 Engine control unit

U = 0.5–4.5 V Lower voltage than 0.5

V and higher voltage than 4.5 V used to de tect malfunction in c able harnesses and contro ls.

Checked by control system, error shown with error code.

- Section

Section group

9.1 Controls and instruments

D8: Diagnostic menu, see section

system

Section

11.5.3.1 Cab control unit

11.5.3.10 Engine control unit

8 Control

, group

8.4.6.5 ENGINE, menu 5

11 Common electrics,

group

9 Frame, body, cab and accessories,

8 Control

, group

8.4.6.1 ENGINE, menu 1

11 Common electrics,

group

11 The NO switch for coolant level grounds

the control terminal of the coolant level relay (K322) if the coolant level is low in the expansion tank.

12 Coolant level relay (K322) breaks the cir-

cuit to Control unit, engine (D794) if the coolant level is low in the expansion tank.

13 The engine control unit (D794 ) transmits

engine data and warning messages on the CAN bus.

14 The KID control unit (D795) shows en-

gine data via display figures.

15 The fuel level sensor (B757) sends a

voltage signal t o Control un it, frame rear (D797-R) proportional to the fue l level in the tank.

Low coolant level: U

= 0 V

K322:85

Checked by control sy s tem, error shown with error code.

Cooling system, description page 28

Section

11.5.3.10 Engine control unit

D13: Diagnostic m enu, see s ection

system

8.4.6.7 ENGINE, menu 7

- Section

11.5.3.12 KID control unit

U = 0.5–4.5 V Lower voltage than 0.5

V and higher voltage than 4.5 V used to de tect malfunction in c able harnesses and contro ls.

Sensor, fuel level, description page 25

D15: Diagnostic m enu, see s ection

system

11 Common electrics,

, group

8.4.6.6 ENGINE, menu 6 and

11 Common electrics,

, group

8.4.3.7 CAB, menu 7

group

8 Control

Workshop manual DRF 400–450

VDRF03.02GB

12 1 Engine

Pos Explanation Signal description Reference

16 Control unit, frame rear (D797-R)

transmits fuel level on the CAN bus.

17 The KID control unit (D795) displays the

fuel level in the operating menu for engine.

18 The output shaft sensor (B758) sends

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

19 The transmission control unit (D793)

transmits speed inform ation on the CAN bus.

20 The KID control unit (D795) shows the

machine’s speed.

21 If the speed is at the machine’s speed

limitation limit, the cab control unit (D790-1) transmits an engine speed reduction request on the CAN bus.

22 Control unit engine (D794) restricts

engine rpm.

Checked by control system, error shown with error code.

- Section

Section

11 Common electrics,

11.5.3.3 Control unit, frame rear

11 Common electrics,

group

11.5.3.12 KID control unit

- D18: Diagnostic m enu, see se ction

system

Checked by control system, error shown with error code.

- Section

Section

11.5.3.9 Control unit, transmission

, group

8.4.7.6 TRANSM, menu 6

11 Common electrics,

group

11.5.3.12 KID control unit

Checked by control system, error shown with error code.

- Section

Section

11 Common electrics,

11.5.3.1 Cab control unit

11 Common electrics,

group

11.5.3.10 Engine control unit

8 Control

VDRF03.02GB

Workshop manual DRF 400–450

1 Engine 13

page –

Engine alternative Volvo TWD1240VE, component location

6 741

8 9

1. Air nipple, cooling system

2. Charge air pressure and charge air temperature sensor

3. Engine control unit (D794)

4. Intercooler

5. Coolant temperature sensor

6. Dipstick

7. Engine oil filling point

8. Fuel connection (intake)

9. Fuel connection (return)

10. Starter motor

15 12

Engine alternative, Volvo TWD1240VE, right side (in machine’s direction of travel)

11. Sensor, engine speed

12. Fuel pre-filter

13. Draining of condensation from fuel filter and water-in-fuel sensor

14. NO switch, fuel pressure

15. Fuel filter

16. Extra coolant pump

17. Oil pressure and oil temperature sensor

18. Compressor, air conditioning

19. Alternator

20. Sensor camshaft rpm

001641

Workshop manual DRF 400–450

VDRF03.02GB

14 1 Engine

32 4

1. Connection cab heat

2. Air cleaner connection

3. Turboc harger

4. Exhaust system connection

5. Radiator connection outlet

6. Expansion tank connection

7. Thermostat

8. Water cooler

16 131415

Engine alternative, Volvo TWD1240VE, left side (in machine’s direction of travel)

9. Transmission oil cooler

10. Thermostat, transmission oil cooler

11. Radiator connection intake

12. Coolant pump

13. Coolant filter

14. Engine oil drain plug

15. Coolant shut-off cock

16. Oil filter (full flow)

17. Oil filter (bypass)

003160

VDRF03.02GB

Workshop manual DRF 400–450

1 Engine 15

page –

Engine alternative Volvo TAD1250VE, component location

006446

Volvo TAD1250VE engine right side (in machine’s direction of travel)

1. Intercooler 12. Water separator

2. Water cooler 13. Sensor, water-in-fuel

3. Transmission oil cooler 14. Fuel filt er

4. Preheating element 15. Engine control unit (D794)

5. Cha rge air pres s ure and charg e air temp erat ure sen so r 16. Oil level sensor

6. Engine oil filling point 17. Crankcase pressure sensor

7. Coolant temperature sensor 18. Engine oil drain plug

8. Starter motor 19. Oil pressure and temperature sensor

9. Sensor, engine speed 20. Dipstick

10. NO switch, fuel pressure 21. Alternator

11. Fuel pre-filter

Workshop manual DRF 400–450

VDRF03.02GB

16 1 Engine

1. Connection cab heat 6. Coolant pump

2. Expansion tank 7. Coolant filter (behind console)

3. Sensor, coolant level 8. Oil filter (full flow)

4. Thermostat 9. Oil filter (bypass)

5. Turbocharger 10. Oil pressure sensor, piston cooling

Volvo TAD1250VE engine, left side (in machine’s direction of travel)

006400

VDRF03.02GB

Workshop manual DRF 400–450

1 Engine 17

page –

Engine alternative Cummins QSM11, component location

11 10

1. Location for air conditioning compressor

2. Fuel connection (outlet)

3. Engine control unit (D794)

4. Engine oil drain plug

5. Starter motor

6. Fuel connection (intake)

8 7 6 5 4

001643

Engine alternative, Cummins, right side (in machine’s direction of travel)

7. Draining of condensation from fuel filter and water -in-fuel sens or

8. Fuel filter

9. Sensor fuel pressure

10. Fuel pump

11. Oil pressure and oil temperature sensor

12. Crankshaft position sensor

Workshop manual DRF 400–450

VDRF03.02GB

18 1 Engine

11 12 14133 621 54 10987

23 22 21 1920

Engine alternative, Cum mins, left side (in machine’s dire ction of travel)

1. Engine oil filling point

2. Dipstick

3. Connection cab heat

4. Air cleaner connection

5. Turboc harger

6. Intercooler connection (out let)

7. Intercooler connection (int ake )

8. Intake temperature sensor

9. Exhaust system connection

10. Boost pressure sensor

11. Expansion tank connection

12. Alternator (coolant temperature sensor behind alternator)

003163

13. Radiator connection (outlet)

14. Intake, intercooler

15. Intercooler

16. Water cooler

17. Thermostat

18. Transmission oil cooler

19. Radiator connection (intake)

20. Coolant pump

21. Expansion tank connection

22. Thermostat housing

23. Oil filter

24. Coolant filter

25. Coolant shut-off cock

VDRF03.02GB

Workshop manual DRF 400–450

1 Engine 19

page –

Engine and transmission, separation (engine alternative Volvo)

Separation

1 Machine in service position, see section 2 Disconnect the requisite hoses and cables before separating

engine and transmissi on.

NOTE

Drain and collect liquids before detaching hoses.

3 Attach hoisting equipment to the engine.

B Safety

4 Use a jack to se cure the transmission.

5 Remove the plugs in front of the flywheel.

Use the outer hole to turn the engine round.

6 Remove the flex plate’s attaching bolt. Turn the engine until flex

plate’s attaching bolts are visibl e in the inn er hole. Th e flex pl ate has eight attachment points to be loosened.

7 Take up the slack in the hoisting equipment.

NOTE

Do not lift the engine or transmission.

Workshop manual DRF 400–450

VDRF03.02GB

20 1 Engine

8 Remove the bolts between the engine and the transmission. 9 Loosen the engine or transmission attachme nt brackets and sep -

arate the engine and transmission.

Assembly

10 Check that the holes for the flex plate’s mountin g in the flywheel

are just in front of the flex plate’s retaining nuts. The flex plate has eight attachment points to be connected with

the flywheel on the engine.

11 Fit the engine or transmission brackets.

Tighten to a torque of 168 Nm.

12 Connect the engine to the transmission.

13 Fit the bolts between the engine and transmission. Tighten to a

torque of 40 Nm.

14 Fit the flex plate’s attaching bolts. Tighten to a torque of 40 Nm.

NOTE

The engine must be loosened from the engine mounts and separated from the transmiss io n to remov e a drop ped bol t. Secure the bolt in the socket when installing.

15 Fit the plugs in front of the flywheel. 16 Remove the hoisting equipment from the engine. 17 Remove the jack from underneath the transmission. 18 Connect the requisite hose s and cabl es fo r the e ngine an d trans -

mission. Check and fill fluids as needed.

19 Bleed air from the engine’s fuel system before start.

VDRF03.02GB

Workshop manual DRF 400–450

1 Engine 21

page –

Engine and transmission, separation (engine alternative Cummins QSM11)

Separation

1 Machine in service position, see section 2 Attach hoisting equipment to the engine. 3 Disconnect the requisite hoses and cable s before se paratin g en-

gine and transmission.

NOTE

Drain and collect liquids before detaching hoses.

4 Use a jack to se cure the transmission.

B Safety

5 Remove the cover washer.

Workshop manual DRF 400–450

VDRF03.02GB

22 1 Engine

6 Rotate the engine for each bolt in the flex plate that has to be

removed.

7 Remove the screws of the flex plate through the hole under the

cover washer.

8 Take up the slack in the hoisting equipment.

NOTE

Do not lift the engine.

9 Remove the bolts between engine and transmission. 10 Loosen the engine and transmission brackets. 11 Withdraw the engine rearwards to separate it from the

transmission.

Assembly

12 Rotate the engine so that the holes i n the flywheel are j ust in front

of the attachment points on the flex plate. The flex plate has eight attachment points to be connected with

the flywheel on the engine.

13 Fit the bolts to the engine and transmission brackets. Tighten to

a torque of 168 Nm. 14 Connect the engine to the transmission. 15 Fit the bolts between engine and transmission. Tighten to a

torque of 52 Nm. 16 Fit the flex plate’s attaching bolts. Tighten to a torque of 40 Nm.

NOTE

The engine must be loosened from the engine mounts and separated from the transmiss io n to remov e a drop ped bol t. Secure the bolt in the socket when installing.

17 Fit the plug in front of the flywheel. 18 Remove the hoisting equipment from the engine. 19 Remove the jack from underneath the transmission. 20 Connect the requisite hose s and cabl es fo r the e ngine an d trans -

mission. Check and fill fluids as needed.

VDRF03.02GB

Workshop manual DRF 400–450

1 Engine – 1.1 Controls and instruments 23

1.1 Con trols and instrumen ts

1.1.1 Ignition switch

page –

Ignition switch, description

P No function. 0 Stop position. Everything switched off; key can be removed. I Operating pos iti on .

Voltage to all electrical functions. Engine and transmission control units are now ready for start.

The signal can b e checked from the diag nostic menu, see section

8 Control system

II Preheating position.

In the preheating pos ition the en gine’s int ake air is he ated by the electric heater to a suitable temperature. The preheating lamp illuminates during preheating.

The signal can b e checked from the diag nostic menu, see section

8 Control system

III Start position.

Engagement of starter motor for engine start.

, group

8.4.1.4 CAN/POWER, menu 4

8.4.6.4 ENGINE, menu 4

III

000317

NOTE

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

Conditions for starter motor engagement are that transmission is in neutral position and the engine is not already running.

The signal can b e checked from the diag nostic menu, see section

8 Control system

, group

8.4.6.4 ENGINE, menu 4

Workshop manual DRF 400–450

VDRF03.02GB

24 1 Engine – 1.1.2 Accelerator pedal

1.1.2 Accelerator pedal

page –

1. Brake pedal

2. Accelerator pedal

page –

Accelerator pedal, replacement

1 Machine in service position, see section 2 Pull one edge of the cover away to facilitate access to the accel-

erator pedal.

3 Unplug the cable from the connector. 4 Unscrew the connector from the accelerator pedal. 5 Replace the accelerator pedal. 6 Fit in the reverse order. 7 Calibrate the gas pedal, see the s ection

8.5.2.3 Calibrate DRIVE-TRAIN

Accelerator pedal, calibration

See section

8 Control system,

B Safety

8 Control system,

group

8.5.2.3 Calibrate DRIVE-T RAIN

group

VDRF03.02GB

Workshop manual DRF 400–450

1 Engine – 1.2 Fuel system 25

1.2 Fuel system

page –

Fuel system, des cription

The fuel system distributes fuel between the cylinders and thereby controls the engine output power and rpm.

When the engine is started, the fuel pump sucks fuel from the tank through the fuel fil ter and forces it to the unit in jec tio ns . Th e unit injec

tors spray in the fuel and ato mises the fue l to the engine’ s combustion chamber.

1.2.1 Fuel tank

page –

Fuel tank, description

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

1.2.2 Sensor, fuel level

page –

Sensor, fuel level, description

The signal can be checked from the diagnostic menu, see section

Control system

, group

8.4.3.7 CAB, menu 7

1 2 3

1. Fuel filler orifice

2. Fuel tank

3. Sensor, fuel level (behind air filt er)

002289

Workshop manual DRF 400–450

VDRF03.02GB

26 1 Engine – 1.6 Air intake and exhaust outlet

1.6 Air intake and exhaust outlet

1.6.1 Air cleaning system

page –

54321

Air cleaning system, overview

1. Intake hose

2. Filter indicator

3. Air cleaner

4. Intake

5. Dust reservoir

Air cleaning system, description

Combustion in the engine requires air. Free unobstructed flow for fresh air and exhausts is essential for effective engine operation.

001357

page –

1 2 3

Exhaust system overview

1. Turbocharger

2. Flex pipe

3. Exhaust pipe

4. Tail pipe

5. Silencer

1.6.3 Exhaust system

Exhaust system, description

The exhaust system is installed in the chassis. A heat shield is installed between the engine and the exhaust system to protect wiring, etc. A flex-pipe between the turbo and silencer absorbs the engine’s

movements. On the ou tside of the machine, there i s a heat shield fitted 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!

VDRF03.02GB

Workshop manual DRF 400–450

1 Engine – 1.6.4 Intercooler 27

1.6.4 Intercooler

page –

Intercooler, description

Engine alternative Volvo TAD1250VE and Cummins QSM11

The charge air is cooled by an air-air intercooler in the upper part of the cooling unit.

Engine alternative Volvo TWD1240VE

The charge air is cooled by a w ate r-ai r inte rco ol er on the engine, see engine supplier documentation.

Also refer to

Cooling system, description page 28

003215

Cooling unit, engine alternative Volvo TAD1250VE and Cummins QSM11

1. Intercooler

2. Engine cooler

3. Transmission oil cooler

4. Transmission oil thermostat

5. Condenser mounting (to AC)

Workshop manual DRF 400–450

VDRF03.02GB

28 1 Engine – 1.7 Cooling system

1.7 Cooling system

page –

Cooling system, description

The engine is wa ter-cooled and has passage s 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. The coolant pump pumps coolant through the cylinder head, engine block and oil cooler. On the engine alternative Volvo TWD1240VE a separate coo lant pump pumps coola nt through the intercooler.

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

3. When the coolant is cold er than the thermostat opening temperature it is pumped back to the engine.

When the coolant is warm er than th e thermostat opening tem pe rature 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.

VDRF03.02GB

Workshop manual DRF 400–450

1 Engine – 1.7.4 Radiator and expansion tank 29

1.7.4 Radiator and expansion tank

page –

Radiator and expansion tank, description

Radiator for the en gine is loc ated i n the coo ling unit w hic h is fi tted b e-

hind the engine. The purpose of the cooler assembly is to cool:

• Engine coolant

• Transmission oil (cooled in the lower part of the cooling unit), see also section

• The charge air (engine alternative Volvo TAD1250VE and Cummins QSM11) is cooled in the upper cooling unit), see also

2 Transmission,

cooler, description page 27

Engine alternative Volvo TWD1240VE has water-air intercooler mounted directly on the engine .

Also refer to For more information, see

Cooling system, description page 28

group

2.6.3 Oil cooler

supplier documentation, engine

Inter-

003215

Cooling unit, engine alternative Volvo TAD1250VE and Cummins QSM11

1. Intercooler

2. Engine cooler

3. Transmission oil cooler

4. Transmission oil thermostat

5. Condenser mounting (to AC)

003214

Cooling unit, engine alternative Volvo TWD1240VE

1. Engine cooler

2. Transmission oil cooler

3. Transmission oil thermostat

4. Condenser mounting (to AC)

Workshop manual DRF 400–450

VDRF03.02GB

30 1 Engine – 1.7.5 Cooling fan

1.7.5 Cooling fan

page –

Fan belt, replacement (engine alternative Volvo)

1 Position the cab in the front position. 2 Machine in service position, see section 3 Remove the cover plates over the engine and radiator. 4 Release the tension on th e fan b elt an d relea se the fan be lt fr om

belt pulley on the belt tensioner.

5 Remove the fan belt.

B Safety

The figure shows engine without co oli ng fan.

6 Fit the new fan belt as illustrated.

VDRF03.02GB

Workshop manual DRF 400–450

1 Engine – 1.7.5 Cooling fan 31

page –

Drive belt, extra water pump, replacement (engine alternative Volvo TWD1240VE)

1 Position the cab in the front position. 2 Machine in service position, see section 3 Remove the cover plates over the engine and radiator. 4 Release the tension on the fan belt. 5 Remove the drive belt.

B Safety

The figure shows engine without cooling fan.

6 Fit the new drive belt as illustrated.

Workshop manual DRF 400–450

VDRF03.02GB

32 1 Engine – 1.7.7 Coolant

page –

Fan belt, replacement (engine alternative Cummins)

1 Position the cab in the front position. 2 Machine in service position, see section

B Safety

. 3 Remove the cover plates over the engine and radiator. 4 Loosen the belt tensioner. 5 Remove the fan belt. 6 Fit a new fan belt. 7 Tension the fan belt with the belt tensioner.

1.7.7 Coolant

page –

Coolant, changing (engine alternative Volvo)

A. Location, expansion tank B. Filling point C. Level marking

NOTE

Read the safety instruc tions for coolant befo re starting work, see section B Safety.

1 Machine in service position, see section 2 Remove the cap on the expansion tank. 3 Place a receptacle under the radiator and engine. (The cooling

system holds about 40 l.)

004851

B Safety

VDRF03.02GB

Workshop manual DRF 400–450

1 Engine – 1.7.7 Coolant 33

4 Drain the cooling system.

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

5 Open the drain cock on the engine. 6 Once all the coolant has drained ou t, close drain cocks. 7 Fill the new premixed coolant of the correct type in the expans ion

tank. For volume and quality, see section

F Technical data

CAUTION

Different types of coolant cannot be mixed. Risk of engine damage and damage to the

cooling

system if different coolant types are mixed.

When changing and refilling the coolant the coolant must be of the same type as was previously used.

8 Open the bleed nipple to release the air an d speed up the filli ng.

Close the bleed nippl e when clean coolan t without air bubbl es is flowing out.

9 Turn on the main electric power and start the engine. 10 Turn on max. heat in the cab. 11 Run the engine to operating temperature so the thermostat

opens and coolant is pumped around the whole system. 12 Check the level in the expansion tank, fill if required. 13 Check the coolant level again after 10 operating hours.

Workshop manual DRF 400–450

VDRF03.02GB

34 1 Engine – 1.7.7 Coolant

page –

Coolant, changing (engine alternative Cummins QSM11)

NOTE

Read the safety instruc tions for coolant befo re starting work, see section B Safety

1 Machine in service position, see section 2 Remove the cap on the expansion tank. 3 Place a receptacle under the radiator and engine. (The cooling

system holds about 40 l.)

B Safety

A. Location, expansion tank B. Filling point C. Level marking

004851

4 Drain the cooling system.

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

VDRF03.02GB

Workshop manual DRF 400–450

1. Coolant shut-off cock

2. Coolant filter

3. Oil filter

1 Engine – 1.7.10 Engine heater 35

5 Open the drain cock on the engine. 6 Once all the coolant has drained ou t, close drain cocks. 7 Fill the new premixed coolant of the correct type in the expans ion

tank. For volume and quality, see section

F Technical data

CAUTION

Different types of coolant cannot be mixed. Risk of engine damage and damage to the

cooling When changing and refilling the coolant the coolant

must be of the same type as was previously used.

8 Turn on the main electric power and start the engine. 9 Turn on max. heat in the cab.

10 Run the engine to operating temperature so the thermostat

11 Check the level in the expansion tank, fill if required. 12 Check the coolant level again after 10 operating hours.

system if different coolant types are mixed.

opens and coolant is pumped around the whole system.

1.7.10 Engine heater

page –

Engine heater, description

See

supplier documentation, engine

A start-inhibitor functio n is ava il abl e as an op tio n co upl ed w it h the engine heater. The function is activated when the heater is running.

Workshop manual DRF 400–450

VDRF03.02GB

36 1 Engine – 1.9 Engine control system

1.9 Engine control system

1.9.1 Control unit, engine

page –

Engine control unit, general

See section

and

unit

11 Common electrics,

supplier documentation, engine

group

11.5.3.10 Engine control

VDRF03.02GB

Workshop manual DRF 400–450

1 Engine – 1.11 Start/stop 37

1.11 Start/stop

1.11.1 Starter motor

page –

Starter motor, description (engine alterna ti ve Volvo)

The starter motor cranks the engine until fuel combusti on b egi ns and the engine starts.

The starter motor is suppl ied with voltage d irectly from t he start batt eries. A relay on the starter motor (solenoid) is activated by the engine control unit (D794).

For more information, see

supplier documentation, engine

Starter motor, description (engine alterna tive Cummins)

The starter motor cranks the engine until fuel combusti on b egi ns and the engine starts.

The starter motor is suppl ied with voltage d irectly from t he start batt eries. A relay on the starter motor (solenoid ) is activated by Con trol unit, frame rear (D797-R).

The signal can be checked from the diagnostic menu, see section

Control system

For more information, see

, group

8.4.6.5 ENGINE, menu 5

supplier documentation, engine

1.11.2 Stopping device

page –

Stopping device, description

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

The engine can on ly be s topp ed by tu rning off the ignition vi a t he ign ition switch.

NOTE

The battery disconnect switch must not be used for emergency stop!

For more information, see

Automatic engine shut down is available as an option. This mean s that the engine shuts of f automatically after 3-30 min ute s (depending on customer setting) if the machine is stationary and idling.

supplier documentation, engine

Workshop manual DRF 400–450

VDRF03.02GB

38 1 Engine – 1.11.2 Stopping device

VDRF03.02GB

Workshop manual DRF 400–450

2 Transmission 1

2 Transmission

Table of Contents 2 Transmission

mm mm mm mm mm mm

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

2.1 Controls and instruments ............................. ............................................ 21

2.1.1 Gear selector and mu lti-function lever ................................................. 21

2.2 Torque converter/Clutch system .............................................................. 22

2.2.1 Flex plates ........................................................................................... 22

2.6 Lubrication system ................................................................................... 26

2.6.3 Oil cooler .............................................................................................. 29

2.7 Cooling system ......................................................................................... 31

2.7.3 Oil cooler .............................................................................................. 31

2.8 Transmission control system .................................................................... 32

2.8.1 Control unit tra ns mission ............................................ ......................... 32

2.8.2 Normally closed (NC) switch, disengagement ..................................... 32

2.8.3 Transmission cable harness ................................................................ 32

Workshop manual DRF 400–450

VDRF03.02GB

2 2 Transmission

VDRF03.02GB

Workshop manual DRF 400–450

mm mm mm mm mm mm

2 Transmission – 2 Transmission 3

2 Transmission

page –

Transmission, general

Component supplier documentation

The workshop manual only describes components and work descriptions that concern instal lati on in the mac hi ne. F or de sc ript ion s of and instructions for the transmission’s components and systems, refer to the supplier documentation.

References to com ponent supplier d ocumentation are only provided in exceptional cases . If information abou t a c om po nen t i s no t f ound, the component supplier documentation should be used.

Workshop manual DRF 400–450

VDRF03.02GB

4 2 Transmission– 2 Transmission

page –

Transmission, function description (transmission alternative Dana)

D14

2, 7

D790-2 D795

D794

D15

D797-F

D24

D22

6, 23

10, 16, 18, 20, 26

D12

D790-1

D793

12 13

5 D5

D13

Pos Explanation Signal description Reference

1 The gear selector s ends a voltag e sig-

nal to the KIT control unit (D790-2).

2 The KIT control unit (D790-2) trans-

mits the selected direction of travel (forward or reverse) on the CAN bus.

3 The transmiss ion’s oil pump pump s oil

when the engine is running.

4 The transmissi on’s oil filter cle ans the

oil from impurities.

5 The accelerator pedal tran smits a sig-

nal to the cab control unit (D790-1).

Forward, Conn. F: U = 24 V

Reverse, Conn. R: U = 24 V

Checked by control s ystem, error shown with error code.

U = 0.5-4.5 V Section 1 Engine, group 1.1.2

Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments

D1: Diagnostic menu, see section 8 Control system , group 8.4.7.2 TRANSM, menu 2

Section 1 1 Comm on elect rics, group 11.5.3.11

KIT control unit

Accelerator pedal D5: Diagnostic menu, see section 8 Control

system , group 8.4.6.1 ENGINE, menu 1

002212

VDRF03.02GB

Workshop manual DRF 400–450

2 Transmission – 2Transmission 5

Pos Explanation Signal description Reference

6 The cab control unit (D790-1) trans-

mits the desired throttle application on the CAN bus.

7 The KIT control unit (D790-2) trans-

mits the selected shifting program on the CAN bus.

8 The oil pressure sensor sends the

transmission control unit (D793) a voltage signal proportional to oil pressure.

9 The engine speed an d oil temperature

sensor (B758/766) sends the transmission control unit (D793) a pulse signal with frequency proport ion al to engine speed and a voltage signal proportional to the transmission oil temperature.

10 The transmission control unit (D793)

supplies voltage to valve block transmission control to obt ain desire d function.

Checked by contro l s ys tem, error shown with error code.

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

Section 11 Common electrics, group 11.5.3.1

Cab control unit

Section 11 Common electrics, group 11.5.3.11 KIT control unit

D8: Diagnostic menu, see section 8 Control system , group 8.4.7.10 TRANSM, menu 10

D9: Diagnostic menu, See Section 8 Control system , group 8.4.7.6 TRANSM, menu 6 and

8.4.7.10 TRANSM, menu 10

Section 11 Common electrics, group 11.5.3.9 Transmission control unit

11 Solenoid valves for travel direction

and gear position in va lve bl ock tran smission control activate gears in the transmission and the engine’s power is transmitted to the transmission’s output shaft.

12 The turbine speed sensor (B751)

sends the transmission control unit (D793) a pulse signal with frequency proportional to turbine speed.

13 The drum sensor (B752) sends the

transmission control unit (D793) a pulse signal with frequency proportional to drum speed.

14 The output shaft speed senso r (B758)

sends the transmission control unit (D793) a pulse signal with frequency proportional to output shaft speed.

15 The torque converter temperature

switch (S221) sends th e transmis sion control unit (D793) a voltage signal if oil temperature in th e torque converter becomes too high.

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

hecked by Control unit

C transmission, error shown with error code.

D12: Diagnostic menu, see section 8 Control system , group 8.4.7.6 TRANS, menu 6

D13: Diagnostic menu, see section 8 Control system , group 8.4.7.6 TRANSM, menu 6

D14: Diagnostic menu, see section 8 Control system , group 8.4.7.6 TRANSM, menu 6

D15: Diagnostic menu, see section 8 Control system , group 8.4.7.10 TRANSM, menu 10

Workshop manual DRF 400–450

VDRF03.02GB

6 2 Transmission– 2 Transmission

Pos Explanation Signal description Reference

16 The transmission control unit (D793)

controls gear shifting according to selected shifting program.

17 The oil cooler cools the transmission

oil. A thermostat senses the oil’s temperature and directs t he oil back to the transmission if the oil is cold.

18 The transmission control unit (D793)

transmits temperatur e and speed data on the CAN bus.

19 The KID control unit (D795) shows

transmission information in operating menus.

20 If the signal from the output shaft

speed sensor (B758) indicates that machine speed exceeds the speed limitation, the transmission control unit (D793) transmits a engine speed reduction request on the CAN bus.

21 The engine control unit (D794) reduc-

es engine speed.

Checked by Control u nit transmission, error

Section 11 Common electrics, group 11.5.3.9

Transmission control unit

shown with error code.

- Oil cooler, description page 31

Checked by control s ystem, error shown with

Section 11 Common electrics, group 11.5.3.9

Transmission control unit

error code. Checked by control s ys-

tem, error shown with

Section 1 1 Comm on elect rics, group 11.5.3.12

KID control unit

error code.

- D15: Diagnostic menu, see section 8 Control system , group 8.4.7.6 TRANSM, menu 6

-Section 11 Comm on ele ctrics, group 11.5.3.10

Engine control unit

22 If the clutch pedal (S220-1) is de-

pressed, it sends a voltage signal to the cab control unit (D790-1).

23 The cab control unit (D790-1) trans-

mits disengage drive on CAN bus.

24 Normally closed (NC) switch, disen-

gagement (S220-2) s ends the Control unit, frame front (D797-F) a voltage signal if brake pressure is high enough to allow drive dise ngagement.

25 Control unit, frame front (D797-F)

transmits disengagement approved on the CAN bus.

26 The transmission control unit (D793)

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

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

group 9.1 Controls and instruments D22: Diagnostic menu, see section 8 Control

system , group 8.4.7.1 TRANSM, menu 1

Checked by control s ystem, error shown with

Section 11 Common electrics, group 11.5.3.1

Cab control unit

error code. Brake pressure above

0.2 MPa:

Conn 1, U = 24 V Conn 2, U = 24 V

Normally closed (NC) switch, disengagement, description page 32

D24: Diagnostic menu, see 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

Checked by control s ystem, error shown with

Section 11 Common electrics, group 11.5.3.2

Control unit, frame front

error code.

hecked by Control u nit

C transmission, error

Section 11 Common electrics, group 11.5.3.9

Transmission control unit

shown with error code.

VDRF03.02GB

Workshop manual DRF 400–450

2 Transmission – 2 Transmission 7

page –

Transmission, function description (transmission alternative Dana full flow)

12, 24, 26, 28, 34

D13

16 14

D30

6, 31

81020

Pa Pa

17 15

D790-1

D793

D790-2 D795

D794

2, 7

D797-F

D10

D11

D32

010494

Pos Explanation Signal description Reference

1 The gear selector sends a voltage sig-

nal to the KIT control unit (D790-2).

2 The KIT control unit (D790-2) tra nsmits

the selected direction of travel (forw ard or reverse) on the CAN bus.

3 The transmissi on’s oi l pump pumps oil

when the engine is running.

4 The transmission’s oil filter cleans the

oil from impurities.

5 The accelerator pedal transmits a sig-

nal to the cab control unit (D790-1).

Forward, Conn. F: U = 24 V Reverse, Conn. R: U = 24 V

Checked by contro l system, error shown with error code.

- -

U = 0.5-4.5 V Section

Section

ries,

group

D1: Diagnostic menu, see se ction

system

Section

11.5.3.11 KIT control unit

D1: Diagnostic menu, see se ction

system

pedal

D5: Diagnostic menu, see se ction

system

9 Frame, body, cab and accesso-

, group

11 Common electrics,

, group

1 Engine,

, group

9.1 Controls and instruments 8 Control

8.4.7.2 TRANSM, menu 2

group

8 Control

8.4.7.2 TRANSM, menu 2

group

1.1.2 Accelerator

8 Control

8.4.6.1 ENGINE, menu 1

Workshop manual DRF 400–450

VDRF03.02GB

8 2 Transmission – 2 Transmission

Pos Explanation Signal description Reference

6 The cab control unit (D790-1) tra nsmits

the desired throttle application on the CAN bus.

7 The KIT control unit (D7 90-2) transmits

the selected shifting program on the CAN bus.

8 Pressure sensor gear 1/3 (B6067)

sends the transmission control unit (D793) a voltage signal proportio nal to oil pressure.

9 Pressure sensor gear 2/4 (B6069)

sends the transmission control unit (D793) a voltage signal proportio nal to oil pressure.

10 Sensor, engine speed (B7530) sends a

pulse signal with frequency proportion al to the engine speed to Control unit, transmission (D793).

11 The oil temperature sensor (B7660)

sends the transmission control unit (D793) a voltage signal proportio nal to transmission oil temper atu re.

Checked by control system, 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

11.5.3.1 Cab control unit

Section

11 Common electrics,

group

11.5.3.11 KIT control unit

D8: Diagnostic menu , see section

system

, group

8.4.7.10 TRANSM,

8 Control

menu 10

D8: Diagnostic menu , see section

system menu

D10: Diagnostic menu, see section

, group

trol system

D11: Diagnostic menu, see section

trol system

8.4.7.10 TRANSM,

, group

8.4.7.6 TRANSM,

8.4.7.10 TRANSM,

8 Control

menu 10

8 Con-

12 The transmission control unit (D793)

supplies voltage to the solenoid and servo valves to obtain the desired func tion.

13 14 15 16 17 18 19

20 The turbine speed sensor (B7510)

Solenoid valve drive fo rward (Y6066F) or Solenoid valve drive reverse (Y6066R) and Servo valve gear for ward/reverse (Y6300) are activated to select the direction of travel.

Solenoid valve gear selection 1/3 (Y6075) and Servo valve gear 1/3 (Y6067) or Solenoid valve gear selec tion 2/4 (Y6074) and Servo valve gear 2/4 (Y6069) are act ivated to select gear position.

The engine’s power is transferred to the transmission’s output shaft.

sends the transmission control unit (D793) a pulse signal with frequency proportional to turbine speed.

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

11.5.3.9 Transmission control unit

D13: Diagnostic menu, See Sect ion

trol system

8.4.7.8 TRANSM, menu 8

, group

8.4.7.7 TRANSM, menu

and

TRANSM, menu 9

D10: Diagnostic menu, see section

trol system

, group

8.4.7.6 TRANS, menu 6

8 Con-

8.4.7.9

8 Con-

VDRF03.02GB

Workshop manual DRF 400–450

2 Transmission – 2 Transmission 9

Pos Explanation Signal description Reference

21 The drum sensor (B7520) sends the

transmission control unit (D793) a pulse signal with frequen cy prop orti on al to drum speed.

22 The output shaft speed sensor (B7580)

sends the transmission control unit (D793) a pulse signal with frequency proportional to output shaft speed.

23 The torque converter temperature

switch (S2210) sends the trans mission control unit (D793 ) a voltage signal if oil temperature in the torque c onverter be comes too high.

24 The transmission control unit (D793)

controls gear shifting according to se lected shif ting program.

25 The oil cooler cools the transmission

oil. A thermostat senses the oil’s tem perature and directs t he oil b ack to the transmission if the oil is cold.

26 The transmission control unit (D793)

transmits temperat ure an d s pe ed data on the CAN bus.

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 contro l system, error shown with error code.

D10: Diagnostic menu, see section

trol system menu

D10: Diagnostic menu, see section

trol system menu

D11: Diagnostic menu, see section

trol system

, group

8.4.7.6 TRANSM,

, group

8.4.7.6 TRANSM,

, group

8.4.7.10 TRANSM,

menu 10

Section

11 Common electrics,

group

11.5.3.9 Transmissi on con trol unit

Oil cooler, description page 31

Section

11 Common electrics,

group

11.5.3.9 Transmissi on con trol unit

8 Con-

27 The KID control unit (D795) shows

transmission information in operating menus.

28 If the signal from the output sha ft speed

sensor (B7580) indicates that machine speed exceeds the speed limitation, the transmission control unit (D793) transmits a engine speed reduction re quest on the CAN bus.

29 The engine control unit (D794) reduces

engine speed.

30 If the clutch pedal (S220-1) is de-

pressed, it sends a v oltage signal to the cab control unit (D790-1).

31 The cab control unit (D790-1) transmits

disengage drive on CAN bus.

Checked by contro l system, error shown with error code.

- D10: Diagnostic menu, see section

- Section

Section

11 Common electrics,

11.5.3.1 2 KID control unit

trol system menu

, group

8.4.7.6 TRANSM,

11 Common electrics,

11.5.3.10 Engine control unit

U = 24 V Section

ries,

D30: Diagnostic menu, see section

trol system menu

Checked by contro l system, error shown with error code.

Section

11.5.3.1 Cab control unit

9 Frame, body, cab and accesso-

group

9.1 Controls and instruments

, group

8.4.7.1 TRANSM,

11 Common electrics,

group

8 Con-

Workshop manual DRF 400–450

VDRF03.02GB

10 2 Transmission – 2 Transmission

Pos Explanation Signal description Reference

32 Normally closed (NC) switch, disen-

gagement (S220-2) sends the Control unit, frame front (D797 -F) a voltage si g nal if brake pres sure is high enough to allow drive disengagement.

33 Control unit, frame front (D797-F)

transmits disengagem ent approved on the CAN bus.

34 The transmission control unit (D793)

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

Brake pressure above

MPa:

0.2

Conn 1, U = 24 V Conn 2, U = 24 V Brake pressure below

MPa:

0.2 Conn 1, U = 24 V Conn 2, U = 0 V

Checked by control system, error shown with error code.

Checked by Control unit

transmission, error shown with error code.

Normally closed (NC ) sw it ch, di sen ga gement, description page 32

D32: Diagnostic menu, see section

trol system menu

Section

, group

8.4.7.1 TRANSM,

11 Common electrics,

group

8 Con-

11.5.3.2 Control unit, frame front

Section

11 Common electrics,

group

11.5.3.9 Transmission control unit

VDRF03.02GB

Workshop manual DRF 400–450

2 Transmission – 2 Transmission 11

page –

Transmission shifting, function description (transmission alternative Dana)

1/3

VFS 1/3

2/4

Rev

RSP

Fwd

91113 15

12 14

19 20

Rev

Fwd

23 24

1/3

2/4

25 26

VFS 2/4

Fwd

2:nd

27 28 29 30 31 32

4:th

Rev

Pos Explanation Signal description Reference

1. Bottom strainer oil sump, separates particles from the oil before the pumps.

2. The transmission’s oil pump 1 feeds the transmission with control pressure for control of the transmission.

3. The oil filter cleans the oil. - -

4. The bypass valve in the filter bracket leads the oil past the filter if the resistance through the filter becomes too high.

5. The pressure governor rele as es pre ssure to the torque converter if the pressure becomes too high.

6. The pressure reducer reduces the feed pr essure to servo pressure.

- -

100.5 l/min at 1973 rpm -

Opening pressure: 410-450 kPa

Opening pressure: 2200 kPa

1200 kPa -

1:st

3:rd

008210

7. Solenoid valve neutral position (RSP) (Y6066) controls Valve spool neutral position.

Workshop manual DRF 400–450

- Diagnostic menu, see section

Control system

, group

TRANSM, menu 7

8.4.7.7

VDRF03.02GB

12 2 Transmission – 2 Transmission

Pos Explanation Signal description Reference

8. Valve spool neutral position opens or closes to allow control pressure to the transmission.

9. Solenoid valve drive forward (Y630) controls Pressure booster drive forward.

10. Pressure booste r forward increases the pressure and pressurises Drive clutch forward.

11. Solenoid valve gear 2/4 (Y6069) controls Pressure booster gear 2/4.

12. Pressure booster gear 2/4 increases the pressure and feeds Valve sli de gear s elect ion 2/4 as well as Valve slide gear 2/4 control.

13. Solenoid valve drive reverse controls Pressure booster drive reverse.

14. Pressure boo ster reverse increases the pressure and pressurises Drive clutch reverse.

- -

0-600 kPa Diagnostic menu, see se cti on

Control system TRANSM, menu 8

, group

and

8.4.7.8

8.4.7.9

TRANSM, menu 9

0-2000 kPa -

0-600 kPa Diagnostic menu, see se cti on

Control system

, group

TRANSM, menu 8

and

8.4.7.8

8.4.7.9

TRANSM, menu 9

0-2000 kPa -

0-600 kPa Diagnostic menu, see se cti on

Control system

, group

TRANSM, menu 8

and

8.4.7.8

8.4.7.9

TRANSM, menu 9

0-2000 kPa -

15. Solenoid valve 1/3 (Y6067) controls Pressure booster gear 1/3.

16. Pressure booster gear 1/3 increases the pressure and feeds Valve sli de gear s elect ion 1/3 as well as Valve slide gear 1/3 control.

17. Contact drive sends signal to the control unit to verify th at drive clutches for travel direction an d gear selection are activated whe n solenoid va lve neutral position (RSP) (Y6066) is activated.

18. The drive control valve compares pressure signals from drive clutches for dir ection of travel and gear selection and sends the p ressure sign al on to the drive contact.

19. The valve spool for reverse drive control opens when the reverse drive clutch is pressurised and leads a pressure signa l to the drive contr ol valve.

20. The valve spool for forward drive control opens when the forward drive clu tch is pressuri sed and leads a pressure signa l to the drive contr ol valve.

0-600 kPa Diagnostic menu, see se cti on

Control system

, group

TRANSM, menu 8

and

8.4.7.8

8.4.7.9

TRANSM, menu 9

0-2000 kPa -

- -

0-2000 kPa

0-2000 kPa -

21. Solenoid valve VFS 2/4 (Y6074) controls servo pressure to Valve slide gear selection 2/4.

VDRF03.02GB

Workshop manual DRF 400–450

1200 kPa Diagnostic menu, see section

Control system

, group

8.4.7.7

TRANSM, menu 7

Kalmar DRF450-65A5X Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

A Foreword

Foreword

About the Workshop Manual

General

Conditions

Storage

About the machine version

Copyright

Reading instructions

Warning information

Read the Operator’s Manual

Read the Maintenance Manual

Important information

Workshop manual contents

Function group structure

References between different information types

Product alternatives and optional equipment

Machine card

Function descriptions

About the documentation

Documentation sections

Ordering of documentation

Feedback

Form for copying

B Safety

Safety

General safety information

Safety concerns everyone!

A near accident is a warning!

Safety instructions

General

Service position

Hydraulic and brake systems, depressurising

Oils

Fuel system

Clothing, etc.

Several mech anics 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

Tyres and rims

Lifting equipment

Spare parts

Non-ionised radiation

Environment

General

C Preventive maintenance

The information is found in the Maintenance Manual

0 Complete machine

Complete machine

Complete machine, description

Troubleshooting, general work instructions

Troubleshooting without an error code, example

Troubleshooting with error code, example

Troubleshooting cable harness

Troubleshooting hydraulic hoses

1 Engine

1 Engine 3

1.1 Con trols and instrumen ts

1.1.1 Ignition switch

1.1.2 Accelerator pedal

1.2 Fuel system

1.2.1 Fuel tank

1.2.2 Sensor, fuel level

1.6 Air intake and exhaust outlet

1.6.1 Air cleaning system