Kalmar DRF450-65A5X Workshop Manual

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

page –

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

page –

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

Workshop manual DRF 400-450

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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.

Workshop manual DRF 400-450

VDRF03.02GB

12 B Safety – Safety instructions

page –

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.

VDRF03.02GB

Workshop manual DRF 400-450

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