This is Kramer System Manual 1000447714 for the 4507/KT457, 5007/KT507, 5507/KT557, 4209/KT429 and 5509/KT559 telehandlers. It covers the hydrostatic travel drive with the H1P pump and both the ICVD and P370 gearboxes. Test reports cover boost pressure, high pressure, cardan shaft speed and engine droop.
It also covers the Deutz TCD 3.6 and TCD 4.1 engines, DOC, DPF and SCR aftertreatment, the brakes, the four steering modes and the work hydraulics. CAN controllers, the safe load indicator and the cameras are covered as well. It includes full hydraulic circuit diagrams and electrical wiring diagrams.
What's Inside This Kramer 4209–5509, KT429–KT559 Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction, Safety and Tightening Torques | 1-27 | Use of the System Manual, Required Tools and Gauges, Safety Instructions, High-Pressure Fluid and Hose Replacement, Jacking and Parking, Symbols and Abbreviations, Cable Colour Codes, Tightening Torques, Hydraulic Screw Connections |
| Engine: Deutz TCD 3.6 | 28-60 | Technical Data, Type Plates, Lube Oil Circuit, Fuel System, Injectors, High-Pressure Pump, Rail Pressure Relief Valve, Cooling and Thermostat, Turbocharging, EGR, Electric Components |
| Engine: Deutz TCD 4.1 | 61-91 | Technical Data, Type Labels, Lube Oil System, Fuel System, Metering Unit, High-Pressure Pump, Cooling Circuit, Thermostat Check, Turbocharging, EGR, Electric Components |
| Exhaust-Gas Aftertreatment | 92-121 | Emission Stages, SCR Catalytic Converter, DOC and Particulate Filter, Urea Metering Unit, Differential Pressure and Temperature Sensors, NOx Sensors, Urea Fill Level, Tank Heater |
| Engine Starting, Monitoring and EAT Control | 122-132 | Starting with Drive Interlock, Engine Monitoring, Oil Pressure Indicator, Battery Charge Control, Preheating, Air Filter Clogging, EAT Control and Heating Circuit |
| Cooling | 133-154 | Cooling Control, Reversing Fan, Tandem Pump, Fan Motor, Reversing Valve, Fan Valve, Coolant Level Sensor, Engine Speed Check, Fan Speed Test and Adjustment |
| Travel Drive: Control and Components | 155-171 | Drive Control, Variable Displacement Pump, Boost Pressure, Travel Speeds Snail, Tortoise and Hare, Speed Sensor, Proportional Valves, Direction Identification Valve, PCOR Valve |
| Travel Drive: H1P Pump with ICVD Gearbox | 172-213 | ICVD Drive System, Gearbox Swivel, Test Reports, Test Ports, Boost Pressure, Starting Speed, Pressure Cut-Off, High Pressure, Cardan Shaft Speed, Engine Droop, Error Descriptions |
| Travel Drive: H1P Pump with P370 Gearbox | 214-254 | P370 Drive System, Test Reports, Boost Pressure, Starting Speed, High Pressure, Cardan Shaft Speed, Engine Droop, Error Descriptions, PCOR and Speed Valves |
| Brakes | 255-335 | Brake Control, Hydraulic and Compressed-Air Trailer Brake, Pressure Accumulators and Charge Valve, Brake Valve, Compressor and Air Reservoir, Trailer Control Valves, Brake Test Logs |
| Steering System | 336-358 | Steering Function, Double Gear Pump, Hydrostatic Steering Unit, Steering Mode Valve, Steering Sensors, Four Steering Modes, Steering Pressure Switch, Steering Pressure Check |
| Hydraulics: Control Circuits | 359-403 | Lifting Cylinder and Load Stabilizer, Overload Control, Tilt Ram, Bucket Repositioning, 3rd Control Circuit, Tipper and Auto-Hitch, Additional Control Circuits, Oscillating-Axle Interlock |
| Hydraulics: Components | 404-443 | Tandem Pump, Filters, Accumulators, Hose Burst Valves, Quickhitch Lock, Changeover and Relief Valves, Variable Displacement Pump, Control Unit and Secondary Valves, Hydraulic Tank |
| Hydraulics: Check and Adjust | 444-458 | Test Report, Engine Speed Check, Circuit Pressure, Working Pressure, Pump Pressure Regulator, LS Pressure, Pilot Control Pressure, Secondary Valve Checks |
| Hydraulic Diagrams | 459-476 | Work Hydraulics Diagram, Control Unit Legend, ICVD and P370 Drive Diagrams, Brake Circuit Diagram, Steering Circuit Diagram, Legends |
| Electrical System: Controllers and Fuses | 477-543 | CAN Signals, Traction Electronics, Frame, Engine and Cab Controllers, Telematics, Drive Interlock, Steering Electronics, Joystick, Display, Fuses and Relays |
| Safe Load Indicator, Calibration and Cameras | 544-571 | Safe Load Indicator, Calibration, Travel Sensor Basic Setting, Front Camera Setup and Display Modes, Rear Camera |
| Electrical Components: Functional Descriptions | 572-635 | Sensors, Buzzer, Relays, Accelerator Pedal, Angle Sensor, Switches, Plug Pin Assignments, Autohitch, Load Stabilizer, DPF Regeneration |
| Electrical Wiring Diagrams | 636-870 | Circuit Diagrams for Deutz 3.6 and Deutz 4.1 Machines, Contents Sheets, Lights, Brake, CAN, Engine Starter and Preheating, Eat, Injectors, Alternator, Item Register |
| Heating and Air Conditioning | 871-888 | Heating and a/C Circuit, Safety, R134a Charge, Compressor, Blower, Heating Switch, Dryer, Evaporator, Condenser |
| Installation Positions | 889-1021 | Hydraulics, Cab Electrical System, Frame Electrical System, Engine Bay Electrics for 3.6 and 4.1 Engines, Compressed Air System |
| Switches, Error Codes and Central Lubrication | 1022-1048 | Switch Assignment and Symbols, Error Code Display and Status Colours, Buzzer Warnings, SPN and FMI, KADIAS Diagnosis, Central Lubrication Pump and Progressive Distributor |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine, Deutz TCD 3.6 L4 (types 416-32/38/39) | 100 kW (134 hp) at 2300 rpm; 500 Nm (369 lbf ft) at 1600 rpm | p. 28 |
| Displacement, TCD 3.6 | 3621 cm³ (221 in³) | p. 28 |
| Engine, Deutz TCD 4.1 L4 (types 416-34/36) | 115 kW (154.2 hp) at 2300 rpm; 609 Nm (449.1 lbf ft) at 1600 rpm | p. 61 |
| Displacement, TCD 4.1 | 4038 cm³ (246.4 in³) | p. 61 |
| Idling speeds | Min. 990 - 1020 rpm; max. 2350 - 2400 rpm | p. 450 |
| Engine oil pressure warning | Below 2 bar (29 psi) | p. 127 |
| Cooling fan speed at max. engine speed | 2190 - 2220 rpm | p. 153 |
| Work hydraulics working pressure | 260 - 275 bar (3774 - 3991 psi) | p. 452 |
| Work hydraulics working pressure, type 416-39 | 200 - 215 bar (2903 - 3120 psi) | p. 452 |
| Pressure regulator, variable displacement pump | 300 bar (4354 psi) | p. 453 |
| Circuit pressure, variable displacement pump | 21 - 23 bar (305 - 334 psi) | p. 451 |
| Pilot control pressure | 30 - 38 bar (435 - 552 psi) for H1P 89; 30 - 35 bar (435 - 508 psi) for H1P 100/130 | p. 455 |
| Steering pressure | 180 - 195 bar (2612 - 2830 psi) | p. 358 |
| Brake accumulator charge valve | 115 - 130 bar switch-on, 145 - 160 bar shutdown | p. 283 |
| Travel drive boost pressure | 27 - 30 bar (392 - 435 psi) | p. 185 |
| Travel drive high pressure, ICVD 416-32 | 470 - 495 bar (6821 - 7184 psi) | p. 186 |
| Maximum travel speed, ICVD i=1.18 | 40 km/h (25mph) | p. 185 |
| Tandem gear pump | 22 ccm/rev (1.34 cu in), 49 L/min (12.94 gal/min) | p. 405 |
| A/C refrigerant charge | R134a 1300 g (45.9 oz) | p. 877 |
| Engine overspeed warning (buzzer B018) | Above 2800 rpm | p. 1030 |
