Kalmar Reachstacker DRG420-450 Workshop Manual VDRG03.01GB

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Kalmar Reachstacker DRG420-450 Workshop Manual VDRG03.01GB
Size: 108.12 MB
Format: PDF
Language: English
Brand: Kalmar
Type of Machine: Reachstacker
Type of Manual: Workshop Manual, Electric and Hydraulic Diagrams
Model: Kalmar DRG420-450 Reachstacker
Part Number: VDRG03.01GB
Number of Pages: 1286 Pages

Contents:
A Foreword

About the Workshop Manual​

Reading instructions​

About the documentation​

B Safety

General safety information​

Safety instructions​

Environment​

C Preventive maintenance
0 Complete machine
1 Engine

1.1 Controls and instruments​

1.1.1 Ignition​

1.1.2 Accelerator pedal​

1.1.10 Start button​

1.2 Fuel system​

1.2.1 Fuel tank​

1.2.2 Sensor fuel level​

1.2.12 AdBlue tank​

1.6 Air intake and exhaust outlet​

1.6.1 Air cleaning system​

1.6.3 Exhaust system​

1.6.4 Intercooler​

1.6.8 After-treatment system​

1.6.9 Pipes and hoses​

1.6.10 Cooling fans intercooler​

1.7 Cooling system​

1.7.4 Radiator and expansion tank​

1.7.5 Cooling fan​

1.7.8 Coolant level sensor​

1.7.10 Engine heater​

1.9 Control system, engine​

1.9.1 Engine control unit​

1.10 Ignition/heating​

1.11 Start/stop​

1.11.1 Starter motor​

1.11.2 Stopping device​

1.11.3 Automatic stop of the engine a specific time after leaving the operator's station​

1.11.4 Automatic stop function​

1.11.5 Automatic start and stop function​

2 Transmission

2.1 Controls and instruments​

2.1.1 Gear selector and multi-function lever​

2.2 Torque converter/Clutch system​

2.2.1 Flex plates​

2.3 Mechanical transmission​

2.6 Lubrication system​

2.6.3 Oil cooler​

2.7 Cooling system​

2.7.3 Oil cooler​

2.7.4 Cooling fan​

2.8 Control system, transmission​

2.8.1 Transmission control unit​

2.8.2 Brake pressure sensor​

2.8.3 Transmission cable harness​

3 Driveline/Axle

3.2 Propeller shaft​

3.3 Drive axle​

4 Brakes

4.1 Controls and instruments​

4.1.1 Brake pedal​

4.1.2 Switch parking brake​

4.3 Power-assisted brake system​

4.3.1 Oil pump brake system​

4.3.2 Oil filter brake system​

4.3.3 Accumulator charging valve​

4.3.4 Accumulator​

4.3.5 Brake valve​

4.3.6 Drive axle block​

4.3.9 Wheel brakes​

4.3.10 Pipes and hoses​

4.3.11 Accumulator pressure sensor​

4.3.12 Brake pressure sensor​

4.5 Parking brake system​

4.5.1 Oil pump brake system​

4.5.2 Oil filter brake system​

4.5.3 Solenoid valve parking brake​

4.5.4 Parking brake unit​

4.5.6 Pipes and hoses​

4.5.10 Sensor parking brake pressure​

4.8 Temperature control, cleaning and oil brake system​

4.8.1 Oil tank brake system​

4.8.2 Tank heater​

4.8.3 Oil pump brake system​

4.8.4 Accumulator charging valve​

4.8.5 Drive axle block​

4.8.6 Wheel brakes​

4.8.7 Oil cooler​

4.8.8 Cooling fan​

4.8.9 Thermal bypass valve​

4.8.10 Sensor, oil temperature brake system​

4.8.11 Breather filter​

4.8.12 Oil filter brake system​

4.8.13 Pipes and hoses​

4.8.14 Oil, brake system​

5 Steering

5.1 Controls and instruments​

5.1.1 Steering wheel​

5.1.2 Mini-wheel​

5.1.3 Joystick​

5.2 Power assisted system​

5.2.1 Hydraulic oil pump​

5.2.2 Priority valve​

5.2.3 Steering valve​

5.2.4 Steering cylinder​

5.2.5 Steering axle cradle​

5.2.6 Link arm​

5.2.7 Wheel spindle​

5.2.8 Wheel hub​

5.2.12 Sensor, steering wheel angle​

5.2.13 Pipes and hoses​

5.2.14 Control valve steering​

5.2.21 Arm rest in position sensor​

5.2.22 Valve block servo pressure, general​

6 Suspension

6.2 Suspension​

6.2.1 Steering axle cradle​

6.2.2 Wheel spindle​

6.2.3 Wheel hub​

6.3 Tyres and rims​

6.3.1 Tyres​

6.3.2 Rim​

6.3.3 Nut, washer and clamp​

6.3.4 Tyre pressure monitoring​

7 Load handling

7.1 Controls and instruments​

7.1.1 Control lever​

7.1.2 Switch lock twistlocks​

7.1.3 Switch, automatic spreading​

7.1.5 Switch stop at 30' or 35'​

7.1.6 Switch support jacks​

7.1.7 Switch lowering front legs​

7.1.8 Switch lowering rear legs​

7.1.9 Switch clamp/release legs​

7.1.31 Switch overheight-legs​

7.2 Lifting/lowering​

7.2.1 Hydraulic oil pump​

7.2.2 Servo filter​

7.2.4 Accumulator servo circuit​

7.2.5 Control valve lift, lower and extension​

7.2.7 Valve block lift cylinder​

7.2.8 Lift cylinder​

7.2.9 Sensor hydraulic pressure lift cylinder​

7.2.10 Lift boom​

7.2.11 Sensor boom angle​

7.2.12 Pipes and hoses​

7.2.16 Sensor damping attachment​

7.2.17 Valve block servo pressure​

7.3 Extension​

7.3.1 Hydraulic oil pump​

7.3.2 Servo filter​

7.3.4 Accumulator servo circuit​

7.3.5 Control valve lift, lower, and extension​

7.3.7 Valve block extension cylinder​

7.3.8 Extension cylinder​

7.3.10 Lift boom​

7.3.11 Sensor boom length​

7.3.12 Pipes and hoses​

7.3.17 Valve block servo pressure​

7.4 Side shift​

7.4.1 Hydraulic oil pump​

7.4.3 Control valve, attachment​

7.4.5 Side shift cylinder​

7.4.6 Side shift frame​

7.4.7 Main beam, attachment​

7.4.8 Relief valve top lift​

7.4.9 Pipes and hoses​

7.4.11 Valve block servo pressure​

7.5 Spreading (positioning)​

7.5.1 Hydraulic oil pump​

7.5.3 Control valve, attachment​

7.5.5 Valve block spreader motor​

7.5.6 Spreader motor​

7.5.7 Spreader chains​

7.5.8 Spreader beam​

7.5.9 Main beam, attachment​

7.5.10 Position sensor, spreading​

7.5.11 Relief valve top lift​

7.5.12 Pipes and hoses​

7.5.13 Buzzer, automatic spread 20'-40'​

7.5.16 Valve block servo pressure​

7.6 Rotation​

7.6.1 Hydraulic oil pump​

7.6.3 Control valve, attachment​

7.6.5 Valve block rotation motor​

7.6.6 Rotation motor unit​

7.6.7 Rotation yoke​

7.6.8 Ring gear​

7.6.9 Side shift frame​

7.6.10 Sensor rotation stop​

7.6.11 Relief valve top lift​

7.6.12 Pipes and hoses​

7.6.14 Valve block servo pressure​

7.7 Tilt​

7.7.1 Hydraulic oil pump​

7.7.3 Damping block tilt​

7.7.4 Lock valve tilt​

7.7.5 Control valve, attachment​

7.7.7 Tilt cylinder​

7.7.8 Lift boom​

7.7.9 Rotation yoke​

7.7.10 Relief valve top lift​

7.7.11 Pipes and hoses​

7.7.14 Valve block servo pressure​

7.8 Levelling​

7.8.1 Hydraulic oil pump​

7.8.3 Control valve, attachment​

7.8.5 Overcentre valve levelling​

7.8.6 Valve block levelling cylinders​

7.8.7 Levelling cylinders​

7.8.8 Side shift frame​

7.8.9 Relief valve top lift​

7.8.10 Pipes and hoses​

7.8.12 Valve block servo pressure​

7.9 Load carrier​

7.9.1 Twistlocks​

7.9.2 Lift legs​

7.9.3 Tool changer​

7.10 Other functions​

7.10.1 Support jacks​

7.10.2 Weight indicator​

7.10.3 Container counter​

7.10.4 Synchronised lift​

8 Control system

8.1 Controls and instruments​

8.1.2 Information display​

8.2 Monitoring​

8.2.1 Overload system​

8.2.2 Bypass​

8.2.3 Load centre limitation​

8.2.4 Height limitation​

8.2.5 Speed limitation​

8.2.6 Service indicator​

8.2.11 Load sensors​

8.2.12 Statistics​

8.2.13 Weight indicator​

8.2.14 Container counter​

8.2.15 Synchronised lift​

8.2.16 Personnel proximity system​

8.4 Diagnostics​

8.4.1 Engine​

8.4.2 Transmission​

8.4.4 Brakes​

8.4.5 Steering​

8.4.6 Suspension​

8.4.7 Load handling​

8.4.8 Control system​

8.4.9 Frame, body, cab and accessories​

8.4.10 Common hydraulics​

8.4.11 Common electrics​

8.4.13 Pin diagnostics​

8.5 Setup​

8.5.1 Engine​

8.5.2 Transmission​

8.5.4 Brakes​

8.5.5 Steering​

8.5.6 Suspension​

8.5.7 Load handling​

8.5.8 Control system​

8.5.9 Frame, body, cab and accessories​

8.5.11 Common electrics​

9 Frame, body, cab and accessories

9.1 Controls and instruments​

9.1.1 Multi-function lever​

9.2 Safety and emergency equipment​

9.2.1 Control breaker​

9.2.2 Seat belt​

9.2.3 Fire extinguisher​

9.2.5 Alcolock​

9.3 Seat​

9.3.1 Seat cushion​

9.3.2 Back rest cushion​

9.3.3 Heating coil​

9.3.4 Bumper​

9.3.5 Air suspension​

9.3.6 Compressor air-suspension seat​

9.3.8 Passenger seat​

9.3.11 Arm rest​

9.3.17 Head rest​

9.3.19 Sensor, operator-in-seat​

9.4 Heating, ventilation and air conditioning​

9.4.1 Fresh air filter​

9.4.2 Fresh air/recirculation damper​

9.4.3 Cab fan​

9.4.4 Heat exchanger heat​

9.4.5 Water valve​

9.4.6 Sensor coolant temperature​

9.4.7 Compressor​

9.4.8 Condenser unit​

9.4.9 Receiver drier​

9.4.10 Pressure switch​

9.4.11 Expansion valve​

9.4.12 Temperature deicing sensor​

9.4.13 Heat exchanger, cooling​

9.4.14 Air distributor​

9.4.15 Defroster nozzles​

9.4.16 Fan temperature sensor​

9.4.17 Interior temperature sensor​

9.4.18 Ambient temperature sensor​

9.4.19 Pause heater​

9.4.20 Timer diesel heater​

9.4.21 Diesel heater​

9.4.25 Preparation, cab fan​

9.5 Wiper/washer system​

9.5.4 Washer motor and reservoir​

9.5.5 Wiper motor front​

9.5.6 Wiper motor roof​

9.5.7 Wiper motor rear​

9.5.8 Wiper motor, front and roof​

9.6 Lighting system​

9.6.1 Headlights​

9.6.2 Running lights​

9.6.3 Tail lights​

9.6.4 Brake light​

9.6.5 Back-up lights​

9.6.6 Direction indicators​

9.6.7 Warning lamp, Hazard​

9.6.8 Revolving beacon​

9.6.9 Working lights, cab​

9.6.10 Work light boom​

9.6.11 Working lights, attachment​

9.6.12 Interior lighting​

9.6.13 Extra working lights frame​

9.7 Signalling system​

9.7.1 Horn​

9.7.2 Warning lamp, Hazard​

9.7.3 Revolving beacon​

9.7.4 Warning parking brake​

9.7.5 Reverse alarm​

9.7.7 Buzzer​

9.8 Entertainment and communication​

9.8.1 Radio with CD​

9.8.7 Voltage converter​

9.9 Glass/windows/mirrors​

9.9.1 Windscreen​

9.9.2 Side window​

9.9.3 Roof window​

9.9.4 Rear window​

9.9.5 Rear view mirror​

9.9.8 Rear view camera and load camera​

9.10 Cab structure and suspension​

9.10.1 Cab frame​

9.10.2 Doors​

9.10.3 Cab substructure​

9.10.4 Sliding cab​

9.10.5 Vertically adjustable cab​

9.11 Cab interior​

9.11.1 Instrument and control panels​

9.11.2 Interior fittings, plastic​

9.11.3 Interior fittings, textile​

9.11.4 Floor covering​

9.11.5 Insulation​

9.11.6 Sun visors​

9.12 Frame​

9.13 Body structure​

9.13.1 Wings​

9.13.2 Hood engine compartment​

9.13.3 Footsteps and hand rail​

9.13.4 Counterweight​

9.13.5 Battery compartment​

9.13.8 Tool kit​

9.13.9 Lifting lugs​

9.14 Central lubrication​

9.14.1 Pump unit​

9.14.2 Distribution block​

9.14.3 Lines​

9.14.4 Lubricant nipples​

9.14.5 Sensor, central lubrication​

9.15 Paint/coatings​

10 Common hydraulics

10.2 Safety valves​

10.2.1 Accumulator drain valve​

10.2.2 Relief valve top lift​

10.2.3 Pipes and hoses​

10.2.4 Pressure relief valve​

10.3 Tanks and accumulators​

10.3.1 Tank​

10.3.2 Pipes and hoses​

10.4 Pumps​

10.4.1 Gear pump with fixed displacement​

10.4.2 Axial piston pump with variable displacement​

10.4.3 Pipes and hoses​

10.5 Hoses, pipes and valves​

10.5.1 Pipes and hoses​

10.5.2 Priority valve​

10.5.5 Collecting block, unfiltered returns​

10.5.7 Valve block servo pressure​

10.5.8 Accumulator servo circuit​

10.6 Temperature control, cleaning and hydraulic oil​

10.6.1 Tank heater​

10.6.2 Hydraulic oil cooler​

10.6.3 Cooling fan​

10.6.4 Sensor hydraulic oil temperature​

10.6.5 Radiator bypass valve​

10.6.6 Breather filter hydraulic oil tank​

10.6.7 Hydraulic oil filter​

10.6.9 Fine filter hydraulic oil​

10.6.10 Pipes and hoses​

10.6.14 Servo filter​

10.7 Other​

10.7.1 Hydraulic cylinders​

11 Common electrics

11.2 Electric protection​

11.2.1 Battery disconnector​

11.2.2 Fuses​

11.2.6 Control breaker​

11.3 Batteries​

11.3.1 Starter battery​

11.4 Alternator​

11.4.1 Alternator​

11.5 Distribution of electricity​

11.5.1 Voltage feed​

11.5.2 Electronic box​

11.5.3 Control units​

11.5.5 Cable harness​

11.6 Communication​

11.6.1 CAN bus​

11.6.2 Redundant CAN bus​

11.6.3 CAN bus drive-train​

11.6.6 Communication between PC and machine​

D Error codes
1 Engine
2 Transmission
8 Control system
E Schematics

Common hydraulics​

Common electrics​

Wiring Diagram​

A55039.1200​

A55039.1500​

A55040.0100​

A56400.0100​

A60822.0100​

A60822.0200​

A60822.0300​

A60822.0400​

A60822.0500​

A60822.0600​

List of Components​

F Technical data
G Terminology and index