7Factory Service Manual For Kramer Telehandler. Manual Contains Illustrations, Instructions, Diagrams For Step By Step Remove And Install, Assembly And Disassembly, Service, Inspection, Repair, Troubleshooting, Tune-Ups.
Format: PDF
Language: English
Pages: 420
Issued: november 2011
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes
Model
Kramer Telehandler
2506
Contents
-CAB OVERVIEW, USE, OPERATION
Machine Outside View
Inside Of Cab (Overview)
Instrument Panel, Multifunctional Lever, Switch Consoles (Overview)
Fields Of Application And Using A Machine With An Attachment
Legal Regulations Regarding Machine Operation
Type Labels And Component Numbers
Key-Based Drive Interlock (Option)
Drive Interlock With Code Input (Option)
Battery Master Switch (Option)
Avoiding Running The Engine Under Low-Load Conditions
Stopping The Diesel Engine
Jump-Starting The Diesel Engine (External Battery)
Pressure Relief On The Quickhitch Couplers
Overview Of Steering Modes (Option)
Steering Synchronisation (Wheels Front/Rear Axles)
Low-Speed Control (Option)
Rear Hydraulic Additional Control Circuit (Option)
Hydraulic Connection For Tipping Trailer (Option)
Autohitch Trailer Coupling (Option)
Automatic Trailer Coupling (Option)
Hydraulic Trailer Brake Connection (Option)
Fitting Attachments From Other Manufacturers (Option)
Towing The Machine
-SPECIFICATIONS
Model And Trade Names (Overview)
Frame
Diesel Engine
Drive
Axles
Service And Parking Brake (Disc Brake)
Steering System
Work Hydraulics
Electrical System
Tyres
Machine Weight, Axle Loads
Trailer Couplings: Trailer Weight/Drawbar Load
Sound Levels, Noise
Vibrations, Oscillation And Acceleration Values
Coolant Compound Table
Tightening Torques
Standard Bucket Payloads
Pallet Forks Payloads
Dimensions With Standard Bucket
Dimensions With Pallet Forks
-MAINTENANCE AND SERVICE WORK
Explanation Of Symbols On The Maintenance Label
Maintenance Label
Fluids And Lubricants
Maintenance Plan (Overview)
Important Notice Regarding Maintenance Work
Safety Strut For Telescopic Boom
Fuel System
Refuelling
Checking/Cleaning The Additional Fuel Filter (Water Separator, Option)
Bleeding The Fuel System
Replacing The Fuel Filter
Diesel Engine Lubrication System
Filling Up Engine Oil
Change The Engine Oil
Replacing The Engine Oil Filter Cartridge
Diesel Engine And Hydraulics Cooling System
Temperature Gauge: Diesel Engine Coolant
Filling Up Coolant
Cleaning The Radiator Fins
Draining Coolant
Air Filter
Replacing The Filter Cartridge
V-Belts
Hydraulic System
Monitoring The Hydraulic Oil And The Return Filter Indicator Lights
Checking The Hydraulic Oil Level Once A Day
Filling Up Hydraulic Oil
Changing The Filter Insert
Replacing Hydraulic Oil
Important Notices On The Use Of Biodegradable Oil
Checking Hydraulic Pressure Lines
Oil Levels: Rear Axle Transfer Gearbox
Oil Levels: Front And Rear Axle Differentials
Oil Levels: Front And Rear Axle Planetary Drives
Lubrication Work
Lubrication Points On The Telescopic Boom (Overview)
Lubricating With The Central Lubrication System (Option)
Setting The Lubrication And Break Times
Central Lubrication System Diagram
Installing The High-Pressure Hoses On The Central Lubrication System
Instructions For Troubleshooting In Case Of Central Lubrication System Blocking
Repairing A Blocking Distributor Of The Central Lubrication System
Troubleshooting Table For Central Lubrication System
Maintenance Of The Brake System
Tyres
Changing Wheels
Heating/Cab Ventilation
Air Conditioning (Option): Maintenance
Functional And Visual Checks Of The Air Conditioning
Cleaning The Heat Exchanger (Condenser)
Maintenance Of The Electrical System
Maintenance Of The Automatic Trailer Coupling (Option)
General Maintenance And Cleaning Work
Maintenance Of Attachments And Of The Work Equipment
-ENGINE
Diesel Engine Diagrams
Diagnosis/Fuel Preheater (Electrical Diagrams)
Manual Throttle Diagrams
Engine Designation
Fuel Specification
Coolant Specification
Diesel Engine TD 2009 L04 (Overview)
Electric Components On Engine (Overview)
Lube Oil Circuit
Cooling
Adjusting The Cable Pull For Speed Regulation
Fuel System
Replacing The Cylinder Head Gasket
Removing/Installing The Fuel Injection Pump
Mounting The Fuel Injection Pump
Removing/Installing The Fuel Injectors
Sealing The Coolant Pump
Removing/Installing The Thermostat
Checking The Thermostat
Assembly Instructions: Replacing The Visco Clutch
Tightening Torque Table
Diesel Engine Malfunctions
-DRIVE
Drive (Hydraulic Diagram)
Drive Diagrams
Making Settings With The Laptop
Error: Incorrect Tool Key
Importing New Data
Drive Electronics Plus+1 Mode Description
Reading Out/Deleting The Error History
Deleting The Error History
Switching The Inching Potentiometer On/Off
Reading In The Inching Potentiometer Again
Reading In The Inching Potentiometer
Switching The Creep Gear Potentiometer On/Off
Switching On The Creep Gear Potentiometer
Reading In The Creep Gear Potentiometer
Modifying The Load Stabiliser Settings
Error Code Table
Towing And Transporting The Machine
Hydraulic Pump H1 (Model 407 02) Test Ports And HP Valves (Overview)
Hydraulic Pump H1 (Model 407 02) Proportional Valve And Electronics (Overview)
Variable Displacement Motor H1110 Cm3/Rev (Overview)
Variable Displacement Motor H1B (Overview)
Model 407 02 Test Report
Error Description For Test Report Model 407 02
Drive With Hydraulic Pump H1 (Hydraulic Circuit)
Checking The Idling Speed
Checking/Adjusting Starting Speed
Adjusting Boost Pressure
Checking High Pressure
Checking Driving Direction Identification
Checking The Energisation Of The Driving Direction Identification
Checking Engine Droop (Variable Displacement Pump)
Setting The Pump Droop Speed
Setting Engine Droop/Control Initiation Of The Hydraulic Motor
Setting Maximum Speed
Troubleshooting Boost-Pressure Errors (Diagram)
Checking High Pressure (HP Valves)
Checking Pump Engine Droop, Driving Direction Identification, Differential Pressure Measurement
-AXLES
Differential Lock Diagrams
Axle Type Label
Front Axle Screw Connections
Rear Axle Screw Connections
Drain, Fill And Check Plug – Front Axle
Drain, Fill And Check Plug – Rear Axle
Front Axle Tightening Torques (Nm)
Rear Axle Tightening Torques (Nm)
Sealing Work
-BRAKES
Brake Diagrams
Brakes (Hydraulic Diagram)
Brake Circuit
Trailer Brake Valve Circuit
Service Brake Function
Parking Brake Circuit
Service Brake
Sealing The Brake Calliper
Bleeding The Brake System With Bleed Equipment
Setting The Brake Pedal With The Inching Potentiometer
-STEERING SYSTEM
Steering System (Hydraulic Diagram)
Steering Circuit With Final-Position Synchronisation
Steering Circuit With Front, 4 Wheel And Crab Steering
Steering System Adjustment
Hydraulic Ports On Servostat
Pressure Relief Valve: Adjustment
Sealing Steering Rams
Sealing Steering Rams
Checking The Steering Mode Valve
Checking A Steering Ram
Overview Of Steering Ram Setting
How To Check And Set The Steering Rams
Checking The Track Setting (1)
Correcting The Track Setting (2)
Steering Misalignment During Final-Position Synchronisation (3)
Adjustment Work
Checking Steering Synchronisation (4)
-WORK HYDRAULICS
20 Kph 4-Fold Control Valve (Hydraulic Diagram)
30 Kph 5-Fold Control Valve (Hydraulic Diagram)
Hydraulics Legend
Raising/Lowering (Diagrams)
Raising/Lowering The Telescopic Boom (Hydraulic Diagram)
Raising/Lowering The Telescopic Boom, Bad Stabiliser (Hydraulic Diagram)
Dumping In/Out, Tilt Ram Lock (Electrical Diagrams)
Dumping Out (Hydraulic Diagram)
Tilt Ram Lock (Hydraulic Diagram)
Extending/Retracting The Telescopic Boom (Black/White) (Electrical Diagrams)
Extending/Retracting The Telescopic Boom/Proportional (Electrical Diagrams)
Retracting/Extending The Telescopic Boom (Hydraulic Diagram)
Locking/Unlocking The Quickhitch (Black/White) (Electrical Diagrams)
Quickhitch Diagram Designations (Black/White, Lock/Unlock)
Locking/Unlocking The Quickhitch Proportionally (Electrical Diagrams)
Quickhitch Diagram Designations (Proportional, Lock/Unlock)
Locking (Hydraulic Diagram)
Locking/Additional Control Circuit (Hydraulic Diagram)
Locking/Return Without Pressure (Hydraulic Diagram)
Safe Load Indicator (Electrical Diagrams)
Overload Cutoff (Hydraulic Diagram)
Load Stabiliser (Electrical Diagrams)
Additional Control Circuit/Tipping Trailer (Hydraulic Diagram)
Tipping Trailer (Hydraulic Diagram)
Autohitch (Hydraulic Diagram)
Autohitch/Tipping Trailer (Hydraulic Diagram)
Additbnal Function (Electrical Diagrams)
Autohitch/Additional Control Circuit/Tipping Trailer (Hydraulic Diagram)
Test Report For Hydraulics 407-02 (2506)
Work Hydraulics Oil Supply
Pump Pressure/Work Hydraulics Test Port
Control Valve (Overview)
Control Valve Design
Checking And Setting The Work Hydraulics
7-Fold Pilot Valve (Overview)
4-Fold Pilot Valve (Overview)
Pilot Control Circuit
Load Stabiliser Circuit
Lift Ram Circuit
Tilt Ram Circuit
3Rd Control Circuit
Circuit: Additional Control Circuit And Rear Tipping Trailer
Tilt Ram Lock Circuit
Circuit: Autohitch And Tipping Trailer Ports
Overload Cutoff Circuit
Load Stabiliser
Valve For Tilt Ram Lock
Tipping Trailer And Additional Control Circuit Valve
Work Hydraulics/Steering System Priority Valve
Valves (General Overview)
Lift Ram (Sealing Work)
Tilt Ram (Sealing Work)
Push-Out Ram
Compensating Ram
Control Ram (Quickhitch Frame) (Sealing Work)
Lift, Tilt And Push-Out Rams: Velocity
Usable Consumer Pressure At Additional Control Circuit (Option)
Overload Control (“Smart Handling”)
Overview Of Safe Load Indicator
Setting The Safe Load Indicator (0 % Point)
Setting The Safe Load Indicator (100 % Point Stability)
Inspection Plan For Overload Control (Model 407 Telehandler)
Testing Without Any Load
Testing With Load
Functional Description Of Overload Control (Smart Handling)
Electric Components
Circuit Diagram: Overload Control Enabled
Circuit Diagram: Automatic Retraction Off
Overview Of Valves
Overview Of Valve Connections And Ports
Circuit Diagram: Overload Control
Circuit Diagram Legend
Extend (Solenoid Valve Y102) (Circuit Diagram)
Pallet Forks Mode (Circuit Diagram)
Tip Switch S084 Pressed (Circuit Diagram)
Electric Components
Overload Control Relay
Installation Position: Overload Control Relay
-ELECTRICAL SYSTEM
Lights (Diagrams)
Working Lights (Diagrams)
Turn Indicators/Horn/Rotating Beacon (Diagrams)
Window Heating/Front Socket (Electrical Diagrams)
Wipe/Wash System (Electrical Diagrams)
Seat/Air Conditioning System (Diagrams)
Multimedia/Monitoring/Cigarette Lighter (Electrical Diagrams)
Cab Wiring Harness 1000256306-01
Cab Wiring Harness Legend
Engine Wiring Harness 1000245802
Engine Wiring Harness Legend
Frame Wiring Harness 1000256307
Frame Wiring Harness (Legend)
Cab Wiring Harness (Overload Control)
Cab Wiring Harness Legend
Frame Wiring Harness (Overload Control)
Frame Wiring Harness (Overload Control) (Legend)
Ohm’S Law (Current, Voltage, Resistance); Power
Measuring Equipment, Measuring Methods
Terminal Description
Color Coding Of Electric Lines
Switching Relay Function
Fuse Assignment
Switching Relay Assignment On Board
Switching Relay Assignment On Bracket
Main Fuse Box With Relays In The Engine Compartment
Electric Units
Connector Description
Switch Assignment On Board
Switch Assignment On Instrument Panel (Overview)
Control Lever (Black/White Control)
Joystick (Black/White Function)
Joystick: Retracting/Extending The Telescopic Boom (Black/White)
Joystick: Unlocking/Locking The Telescopic Boom (Black/White)
Control Lever (Proportional Control)
Joystick (Proportional Function)
Joystick: Retracting/Extending The Telescopic Boom (Proportional)
Joystick: Unlocking/Locking The Telescopic Boom (Proportional)
Additional Control Circuit With Potentiometer (Proportional)
Proportional Controls Connector Assignment (Overview)
Proportional Controls (Overview And Connections)
Retrofitting A Rotating Beacon
Retrofitting The Backup Warning System
Retrofitting 2 Front Working Lights
Retrofitting 2 Rear Working Lights
Retrofitting A Rear 7-Pole Socket
Retrofitting A Front 4-Pole Socket
Retrofitting 2 Working Lights On The Telescopic Boom (From Mid 2011)
What you get
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