DRF 400 450 instruction 5GB

This Operator’s manual contains information that you must keep in mind for safe handling and optimal use of your new machine.. – About the machine version The information in this Operato

DRF 400-450

1

1 Foreword 3

1.1 About the Operator’s manual 3

1.2 About the documentation kit 6

1.3 Inspection and maintenance 7

2 Safety 9

2.1 Safety and emergency equipment 11

2.2 CE-marking 13

2.3 ANSI/ASME-marking 14

2.4 Keep in mind 15

3 Overview 23

3.1 Description DRF 400-450 23

3.2 Plates 29

4 Instruments and controls 37

4.1 Warning and indicator lights 42

4.2 Instruments 46

4.3 Ignition 47

4.4 Switches 48

4.5 Gear selector and multi-function lever 55

4.6 Control lever 57

4.7 Pedals 60

4.8 Steering wheel 61

4.9 Operator’s seat 64

4.10 Heating/Air conditioning 67

4.11 Control and monitoring system 70

5 Handling 81

5.1 Running-in 83

5.2 Daily inspection 84

5.3 Handling error codes 85

5.4 Operating 127

5.5 Load handling 138

6 Inspection and maintenance 157

6.1 Daily inspection 158

6.2 Maintenance 161

6.3 Service 186

7 Transport of machine 187

7.1 Towing 188

7.2 Lifting and transporting machine 190

7.3 Service position 204

7.4 Long-term storage 205

8 Environment and standards 207

9 Specifications 209

10 Terminology 217

2

Thank you for choosing Kalmar Industries as your machine supplier

We hope that we’ll meet your expectations

This Operator’s manual contains information that you must keep in mind for safe handling and optimal use of your new machine

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Purpose of the Operator’s manual

This Operator’s manual applies to machine DRF 400-450

The Operator’s manual describes how the machine should be rated and maintained in a correct manner

ope-–

Storage

The Operator’s manual should always be kept in the machine

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About the machine version

The information in this Operator’s manual corresponds to the ine’s design and appearance at the time of delivery from Kalmar In-dustries Due to customer adaptations, there may be variations and/

mach-or deviations

Kalmar Industries reserves the right to modify specifications and equipment without prior notice All information and data in the manual are valid at the time of publication

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Copyright

Kalmar Industries ABDuplication of the content in this manual, in whole or in part, is strictly prohibited without written permission from

Kalmar Industries AB

Duplication by any means, such as copying, printing, etc., is strictly prohibited

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Manufacturer

This machine is manufactured by Kalmar Industries AB,Torggatan 3, SE-340 10 Lidhult, Sweden

4 1 Foreword – 1.1.1 Reading Instructions

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Important information

Important information is denoted with NOTE and is intended to litate the work process, handling or to increase understanding of the information

regu-1 Foreword – regu-1.regu-1.regu-1 Reading Instructions 5

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Read operator’s manual

Read the operator’s manual

The symbol to the left is used in certain cases on the machine and refers to important information in the Operator’s manual

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Read maintenance manual

Read the maintenance manual

The symbol to the left is used in certain cases on the machine and refers to important information in the maintenance manual

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Optional equipment

Indicates optional equipment

There is a wide range of optional equipment for the machine Each description of optional equipment in the Operator’s manual is marked with a symbol and contains an explanatory text The symbol

is highly visible and is placed next to the text and figure item in question

See the machine card for complete specifications of the machine’s product alternatives and optional equipment

6 1 Foreword – 1.2 About the documentation kit

kit

page –

The documentation kit

The following documentation is supplied with the machine:

• Operator’s manual DRF 400-450 (in cab with machine)

• Maintenance manual DRF 400-450

• Spare parts catalogue with machine cardThere is supplementary documentation that can be ordered for the machine The following is included:

• Workshop manual DRF 400-450 and supplier documentationfor engine, transmission and drive axle

All documentation can be ordered from Kalmar Industries

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Ordering of documentation

Copies of the Operator’s manual and maintenance manual can be ordered from Kalmar Industries:

Kalmar Industries AB, SE-341 81 Ljungby, Sweden

Always indicate publication number when ordering

1 Foreword – 1.3 Inspection and maintenance 7

page –

General

For satisfactory function of the machine to the lowest cost, nance must be performed correctly Intervals for care and lubrica-tion refer to normal environment and operating conditions

mainte-Maintenance work described in this Operator’s manual can be

per-formed by the operator, see chapter 6 Inspection and maintenance

This section describes the running checks and actions that the rator should perform in connection with work shifts

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Maintenance

For other maintenance not included in this Operator’s manual (service and repairs), contact an authorized brand name workshop

8 1 Foreword – 1.3 Inspection and maintenance

pro-ce of the machine You’ll also find a lot of valuable information that will make your work easier.

The Operator’s manual should always be kept in the machine If it’s lost, replace it immediately with a new Operator’s manual

NOTE

Never use a machine that doesn’t have an Operator’s manual.

Ask your foreman or supervisor if there’s anything in the text you do not understand or if you feel information is missing in any area

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Intended use

• The machine may only be used for the purpose for which it is signed and adapted, that is, to lift and transport goods (the weight of which is not to exceed the machine’s max allowed load capacity) If it’s used in another way or in potentially dangerous environments (for example, explosive environment, area with dust containing asbestos), special safety regulations must be followed and the machine must be equipped for such operation

de-• The machine may not be modified or rebuilt so that its function

or performance is altered, for example, areas that affect lift pacity, visibility conditions from the cab, protective equipment, brakes, steering or lift equipment, without specific permission from Kalmar Industries When modifications/rebuilds authorized

ca-by Kalmar Industries have been performed, the affected

machi-ne plates and documentation shall be adapted so that they are valid for the modification/rebuild

The machine may only be modified or rebuilt if Kalmar Industries accepts product responsibility (without any other manufacturer assuming the product responsibility) Modifications and rebuilds may only be performed if there is knowledge for implementing and testing modifications and rebuilds Modifications and re-

10 2 Safety

builds shall be documented (date and actions) and the sponsible organization shall be indicated with name and address Plates and decals shall be updated according to the machine’s new version

re-• The machine may not be operated on public roads unless it has been adapted according to national road safety regulations

• It is always the machine owner’s responsibility to ensure that the machine has approved fire-fighting equipment according to governing regulations

• The machine is designed for use in outdoor temperatures -40 °C

to 40 °C, relative humidity 10 to 90% and max wind speed 12.2 m/s In case of higher wind speeds, contact Kalmar Industries

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Operator requirements

• The machine may only be operated by specially trained tors who have the management’s permission to operate the machine

opera-• Laws and regulations regarding driver’s licenses, operator ID, etc must always be followed

• The operator must be aware of and follow all local safety lations

regu-–

Prohibited operation of machine

Machine operation is prohibited:

• If safety and warning equipment such as rear-view mirrors, headlights, etc., do not function correctly

• In case of defective brakes, steering or lifting equipment

• If the machine has been repaired, modified or adjusted without the supervisor’s/work management’s permission

• If the machine is fitted with tyres not approved by Kalmar Industries

• The overload protection system (OP) is non-functional during load handling

2 Safety – 2.1 Safety and emergency equipment 11

A fire extinguisher may also be located externally

If the machine is provided with a fire extinguisher, it should be

of the type ABE according to EN 3 pt 1, 2, 4 and 5 With such a fire extinguisher, it is possible to put out fires in both solid orga-nic materials and fluids Adapted fire extinguishing equipment can be ordered from Kalmar Industries

9 External rear-view mirrorsUsed to give improved visibility when operating and load hand-ling One rear-view mirror on each side

10 Control breaker for hydraulicsCuts off all power supply and control signals to hydraulics

12 2 Safety – 2.1 Safety and emergency equipment

ful-EU directives for the machine type.

As proof that the requirements have been fulfilled, an EU Declaration

of Conformity is supplied, issued by Kalmar Industries for each and every machine This EU Declaration of Conformity also covers at-tachments and options made by Kalmar Industries The documenta-tion is valuable and should be kept in a safe location and saved for

at least 10 years The documentation should always accompany the machine when it is sold

Any person performing modifications or changes affecting the machine’s safety is also responsible for the same Safety must be ensured in each separate case if the machine is used for other pur-poses or with other attachments than described in these instruc-tions The machine owner is responsible for ensuring that the machine is used as described in the Operator’s Manual Areas of use may in certain cases require new CE-marking as well as issuance of

a new EU Declaration of Conformity

For further information, see standards in section 8 Environment and

standards.

0

W S/N

2 Safety – 2.4 Keep in mind 15

16 2 Safety – 2.4 Keep in mind

di-• The operator shall adjust travel speed according

to the nature of the load, visibility conditions, road conditions, etc.

• The operator should pay extra attention and erate with special care near electrical power lines, viaducts, docksides, ramps, gates/doors, etc.

op-• Always operate carefully so that the attachment does not collide with posts, power lines, etc.

• Use available visibility equipment such as

reversing.

2 Safety – 2.4 Keep in mind 17

WARNING

Transport of loads is associated with great risks Risk of roll-over and tipping over! Risk of load dam- age to property!

Respect the machine’s lift capacity and operate with great care during load handling:

• The machine shall only be operated on even faces, intended for the machine’s total weight and ground pressure.

sur-• All loads should be carried in the transport tion Always operate carefully, keep in mind the width and height, so that the boom or attach- ment does not collide with posts, power lines, etc.

posi-• Do not transport the load in high position since this may cause the machine to roll or tip over.

• Always operate with the load facing uphill on an uphill or downhill grade, never operate or turn across a grade.

• Operate the machine in reverse if the

transport-ed load obscures visibility to the front.

• No personnel may enter/stand under a raised load.

• The operator should avoid powerful acceleration and braking.

• The operator should always adjust the speed when turning to prevent skidding and risk of roll-over or tipping over.

In case the machine rolls over or tips, always stay in the cab Do NOT try to jump out of the cab until the machine has stopped moving.

18 2 Safety – 2.4 Keep in mind

WARNING

The machine’s load capacity is limited.

Risk of roll-over and tipping over!

It is prohibited to exceed the machine’s load ity See marking plate and load diagram The ma- chine’s stability limit may be exceeded if the overload protection system is not working.

capac-WARNING

The strength of the roof window may be

significant-ly reduced in case of exposure to substances taining: aromatic hydrocarbons, ketones, esters and chlorinated hydrocarbons.

con-Low strength! Danger!

Check the outside surface of the roof window at regular intervals Clean only with windshield wash-

er fluid or a mild cleaning agent Rinse thoroughly with plenty of lukewarm water Replace a damaged roof window immediately if it’s cracked or

scratched!

WARNING

Lifting loads in very windy conditions is associated with great difficulties.

Risk of roll-over and tipping over!

Avoid lifting loads when wind speeds exceed 12.2 metres per second.

WARNING

The machine emits exhausts during operation Health hazards in poorly ventilated facilities!

2 Safety – 2.4 Keep in mind 19

WARNING

Work position on the machine is located up high Risk of falling and body injury!

Always use the steps and handles when you climb

up or down from the machine Always face the chine Do not jump!

ma-WARNING

Cab doors must always be closed when operating Risk of personal injury and crushing in case of roll- over and tipping!

Always close the operator door(s) during the work shift.

WARNING

Passengers are only allowed in the cab if there is a specific passenger seat It is prohibited to carry pas- sengers on the machine outside the cab or on the load.

Risk of personal injury!

Passengers in the cab must use the permanently stalled passenger seat.

in-20 2 Safety – 2.4 Keep in mind

WARNING

The cab has the sliding cab feature, manual or

rear-most position when operating.

Warning - risk of crushing!

For manual sliding cab, always make sure that the cab is locked in its rearmost position before operat- ing, and that the locks are secured with the lock pins.

For hydraulic longitudinal displacement, the cab may be positioned as desired (locking is automatic) during stationary load handling.

WARNING

The machine’s hydraulic system includes tors with high pressure.

accumula-Risk of personal injury!

Always be very careful when working with the draulic system, and avoid standing close to hydrau- lic components or hoses Before working on the hydraulic system, the accumulators must be drained (see Maintenance manual).

hy-WARNING

Handle batteries and connectors with great care during charging and boosting (auxiliary start) Risk of short-circuiting and generation of hydrogen gas!

Batteries should always be provided with protective caps over the terminals and connections Connect the positive (plus) terminals first Then connect the negative (minus) terminals to prevent sparks that may ignite the hydrogen gas.

2 Safety – 2.4 Keep in mind 21

NOTE

Mobile phone and communication radio may be used in the cab The equipment should not be used while operating or handling loads, as your concentration on operating is reduced Kalmar Industries will not assume any responsibility for optional equipment not installed by Kalmar Industries Further, no re- sponsibility will be assumed for installations performed by oth- ers who are not approved by Kalmar Industries.

WARNING

The machine uses oils and lubricants.

Health hazard in case of long-term skin contact! Avoid skin contact with oils and lubricants Wear protective gloves.

perform-If the parking brake has been released

mechanical-ly, it must always be reset to restore the machine’s parking brake functions.

22 2 Safety – 2.4 Keep in mind

6"-contai-This section provides a short presentation of the machine’s parts,

see General page 24.

page –

Type designation of reachstacker

Each Kalmar machine has a type designation Type designation DRF 450-65S5XS (example) indicates the following:

• D – Diesel engine

• R – Reachstacker

• F – Generation

• 450 – Lift capacity, 1st row, decitonne

• 65 – Axle distance, decimetre

• S – Spreading, adjustable top lift

• 5 – Max no of containers when stacking

pos-it possible to satisfy a very broad range of customers

A machine card is delivered together with the spare parts catalogue The machine card contains a complete specification of the machi-ne’s product alternatives and optional equipment

The machine card shall be updated when the machine is modified and Kalmar Industries shall be informed

24 3 Overview – 3.1.2 Overview description

5 Load handling, attachment

6 Load handling, boom

3 Overview – 3.1.2 Overview description 25

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Engine

The machine has several engine options The engines are straight 6-cylinder, turbocharged low-emission engines with intercooler The engine provides power for propulsion and working hydraulics.The machine is equipped with one of the following engine options:

• Volvo TWD1240VE

• Cummins QSM11

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Transmission

The transmission is fully automatic with a torque converter It has

4 forward gears and 4 reverse gears The hydraulic pumps for working hydraulics are mounted on the transmission

The machine is equipped with Dana TE32000

The parking brake is controlled electro-hydraulically and brakes using a brake disc The disc brake acts on the drive axle’s input shaft.The parking brake is applied automatically in case of voltage-drop from the ignition (by spring force) and is released with hydraulic pressure

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Steering

The machine is steered with the rear axle A double-acting hydraulic cylinder acts on the wheel pair Steering is progressive, that is, a quick movement of the steering wheel gives a greater steering angle per steering wheel turn This makes the machine easier to operate

26 3 Overview – 3.1.2 Overview description

One of the following alternatives is selected for the machine:

• Top lift attachment with sideshift +/- 800 mm

• Top lift attachment with hydraulic levelling (with sideshift+/-800 mm)

• Bottom lift attachment (handles containers and trailers)

• Tool carrier (handles different lifting tools)

• "Over height" top lift attachment

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Electrical system

The electrical system consists of electrical and electromagnetic components such as battery, switches, cable harnesses, solenoid valves, fuses and relays It has a computer-based control and moni-toring system for monitoring and controlling the machine’s functions

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Control and monitoring system

The machine has an electronic control system which handles all tems in the machine, such as power electronics, drivetrain and hy-draulic system The control and monitoring system makes maintenance easier and more efficient

sys-–

Cab

The cab is available in one version Instrumentation and equipment (steering wheel, operator’s seat, fresh air system) are customer-adaptable and model-adapted

• Cab Spirit DeltaSpirit Delta is a closed cab constructed of a structural frame to withstand falling loads in accordance with applicable standards

It is equipped with a fresh air system with filtered inlet, lation as well as heating and air conditioning ( )

recircu-The roof window is made of high-strength material and stands heavy blows, for example, from falling objects

with-The cab can be moved fore-aft, either manually or hydraulically ( ), or vertically adjustable ( )

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Hydraulic system

The hydraulic system includes the sub-functions brakes, steering, load handling and cab The hydraulic system is divided into two sec-tions, working hydraulics and brake system

The working hydraulics consists of hydraulics for steering, load handling and cab functions The working hydraulics are supplied from 4 variable load-sensing axial piston pumps and a fixed gear-pump for filtration and cooling of the hydraulic oil

The brake system is separated from the working hydraulics with its

3 Overview – 3.1.2 Overview description 27

4 Electrically powered loud air horn Located at leading edge cab

5 Back-up alarm

6 Passenger seat

7 Tinted windows(Not positioned in figure)

8 Openable window, left door(Not positioned in figure)

9 Openable window, right door (Not positioned in figure)

10 Sun visor, front windshield Can be moved up-down with string, right side Stays in selected position

11 Sun visor, roof window Pull-out type for securing at leading edge of window in two hooks

13, 14

5, 14

27

28 3 Overview – 3.1.2 Overview description

User’s instructions supplied

13 Writing table with light

14 TV-camera with monitor For improved rearward visibility The camera is located on the counterweight and the monitor is located inside the cab

15 Socket 24 VDC The socket is located on the right side behind the operator’s seat and is routed across a fuse

16 Slip-protection on i.e steps and counterweights(Not positioned in figure)

17 Steps with rail by mudguard Located on left side

18 Steps to cab roof

19 Work lights cab roof, 2 lights

20 Work lights front fender, 2 lights

21 Extra work lights front fender, 2 or 4 lights

22 Work lights boom, 2 lights

23 Extra work lights boom, 2 lights

24 Work lights attachment, 2 lights

25 Extra work lights attachment, 2 lights

26 Work lights bottom lift attachment (rear legs), 2 lights

27 Tool kit Located in battery compartment on left side

28 Auxiliary heater: (Not positioned in figure)

Equipment kit 1: engine and cab heaterEquipment kit 2: start interlock, engine and cab heaterEquipment kit 3: start interlock, oil heater hydraulics and brake system, engine and cab heater

Equipment kit 4: start interlock, oil heater hydraulics and brake system, oil sump heater, engine heater and electric or diesel-powered cab heater

29 Pause heater (Not positioned in figure)

3 Overview – 3.2 Plates 29

page –

Product plates Europe

The following shows the product plates that should be fitted on the machine when operating in Europe When ordering spare parts and when enquiring per telephone or correspondence, the model desig-nation and serial number shall be given according to the plates The plates’ spare part number is indicated on respective plate

1 Machine plate (example), A32653

M = Machine modelS/N = Serial number/Year of manufacture

Q = Machine’s classed lift capacity acc to EN1459

W = Machine’s operating weight (without load)

L = Distance between leading edge of wheels and load’s centre

mach-Machine plate can only be ordered with complete engraving

2 Type plate for attachment (example)S/N = Serial number/Year of manufacture

Lower field indicates year of manufacture

Type plate can only be ordered with complete engraving

30 3 Overview – 3.2 Plates

3 Additional plate for optional equipment (example)Plate appearance depends on type of optional equipment.Example plate is for machine with support jacks

S/N = Serial number/Year of manufacture

A = Identification number for attachment

3 Overview – 3.2 Plates 31

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Warning and information plates

The following figures show the warning texts and information texts that are located on the machine The operator shall be aware of the warnings and should also follow the instructions and information gi-ven on the plates

Make sure warning and information symbols on the machine and its components always are easy to see and legible Plates that have been damaged, illegible or painted over must be replaced immediately

Chassis, cab

1 Lift point, 423049.0100Attaching point for lifting device when lifting the machine and boom For lifting machine (1a):

• front part of frame

• rear part of frame by boom mountingFor lifting boom (1b):

• front part of boom

• rear part of boom

1b

7 4

3

8 14

2

19

14 6

20 1a

1b 1b

9

5 Warning! A30770.0200 Air conditioning Located on the inside of the left frame member.

Filling of refrigerant requires special competence and zation (follow national legislation and local rules)

authori-6 Warning! A30770.0300 Air conditioning Filling of refrigerant requires special compe-tence and authorization (follow national legislation and local rules)

1= Refrigerant, type2= Amount, kg3= Pressure, bar

8 Battery disconnector, A30537.0100

In position 0, the battery’s plus terminal is disconnected

9 Plate battery voltage, A30534.0200Turn off the main electric power (with the battery disconnector) when disconnecting or connecting the boom Otherwise sparks and short-circuiting may result

Engine

10 Filling point, fuel, 450202.0100

11 Warning! A30530.0100Rotating fan

12 Warning! A30532.0100Hot surfaces

13 Filling point, engine oil, A32439.0500

34 3 Overview – 3.2 Plates

Power transmission, wheels

14 Air pressure tyres 1.0 MPa, A32049.0100

be replaced with plate which has current pressure!

15 Filling point, transmission oil, A32439.0200

Hydraulic system

16 Filling point, hydraulic oil, 450203.0100

17 Pressure hydraulics, 920643.0024 (plate below)Indicates set pressures for machine Information is engraved

MPa MPa

MPa MPa

MPa

MPa

MPa

36 3 Overview – 3.2 Plates

4 Instruments and controls 37

4 Instruments and controls

func-This chapter gives general information about instruments, switches, controls and other equipment in the machine’s cab

NOTE

Thoroughly read the following chapter about instruments and controls.

38 4 Instruments and controls

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Overview

Overview

1 Left instrument panel

2 Gear selector and multi-function lever

3 Steering wheel panel

4 Steering wheel

5 Direction indicators

6 Panel for hydraulic functions

7 Control breaker for hydraulics

8 Switch for parking brake

14 Electrical distribution box with fuses and relays

15 Hour meter (operating hours)

A Joystick or mini steering wheel

14 15

A

8