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Home » Technical Resources » Legacy Machine Guides » Kalmar ContChamp » Related models and comparisons

Kalmar ContChamp — Related models and comparisons: technical cards

HIT SRL technical desk · Kalmar ContChamp technical cards · Published 12 October 2026 · Updated 12 October 2026

General guidance only — always follow the operation and maintenance manual for your specific machine.

Short answers to precise questions on the related ContChamp DRD-S and documented differences of the Kalmar ContChamp reach stacker, one fact per card, each with its source stated in the text. For the overall picture, see the Kalmar ContChamp technical legacy guide.

Questions on this page

  1. Kalmar ContChamp DRD-S: what kind of machine is it?
  2. Kalmar ContChamp DRD-S: which marking and declaration does the 2004 handbook mention?
  3. Kalmar ContChamp DRD-S: which engines does the 2004 handbook give?
  4. Kalmar ContChamp DRD-S: which gearbox and drive axle does it have?
  5. Kalmar ContChamp DRD-S: how is the hydraulic system laid out?
  6. Kalmar ContChamp DRD-S: how does the later top lift differ?
  7. Kalmar ContChamp DRD-S: when is the warranty service due?
  8. Kalmar ContChamp DRD-S: how is the top-lift planetary gear oil changed?
  9. Kalmar ContChamp DRD-S: what does the 200-hour service add?
  10. Kalmar ContChamp DRD-S: how often is the cab fresh-air filter changed?
  11. Kalmar ContChamp DRD-S: what are its brake accumulators like, and how are they checked?
  12. Kalmar ContChamp DRD-S: what brake reserve does the 2004 handbook require?
  13. Kalmar ContChamp DRD-S: when are the parking brake linings changed after emergency braking?
  14. Kalmar ContChamp DRD-S: how are the twist-lock lifting pins inspected?
  15. Kalmar ContChamp DRD-S: what tyre pressure does the 2004 handbook give?
  16. Kalmar ContChamp DRD-S: what wind limit does the 2004 handbook set?
  17. Kalmar ContChamp DRD-S: how is a load transported?
  18. Kalmar ContChamp DRD-S: what should the operator do if the truck tips over?
  19. Kalmar ContChamp DRD-S: how is the boom lowered in an emergency?
  20. Kalmar ContChamp DRD-S: who is responsible for the fire extinguisher?
  21. Kalmar ContChamp DRD-S: what is done before work on the hydraulic system?
  22. Kalmar ContChamp DRD-S: how is the truck jacked up to remove a wheel?
  23. Kalmar ContChamp DRD-S: how does the ECS signal a fault?
  24. Kalmar ContChamp DRD-S: what do some ECS messages ask the operator to do?
  25. Kalmar ContChamp DC: how do the engine ratings differ across the documents?
  26. Kalmar ContChamp DC: how do the DC4160RS4 and DC4560RC4 data sheets differ?
  27. Kalmar ContChamp: how do the DC and DRD-S brake systems differ?
  28. Kalmar ContChamp DC: how do the 1995 instruction manual and the 1996 handbook differ on capacities and oils?
  29. Kalmar ContChamp DC: how does the 1990 handbook differ from the 1996 handbook?

Kalmar ContChamp DRD-S: what kind of machine is it?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

The DRD420-450 model S, built for heavy-duty handling of loaded 20-40 ft containers, according to the DRD-S technical handbook (2004 edition), as set out in the HIT SRL technical cards. The handbook illustrates it as the DRD420-60S5 and DRD420-65S5 with a 20-40 ft adjustable top lift. Published sources report that the thousandth ContChamp, a DRD450-60C5X, was described as a third-generation model.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-what-is-the-drd-s · HIT ref KCC-119 · fingerprint 2b72dc · see HIT ref KCC-121, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-engines

Kalmar ContChamp DRD-S: which marking and declaration does the 2004 handbook mention?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

The CE marking and an EU declaration of conformity referring to the EU machine safety directive, the EMC directive and the low-voltage directive, according to the DRD-S technical handbook (2004 edition), as recorded by the HIT SRL technical desk. The handbook states that the truck stays below the limits of the vibration standard EN 13059, as HIT SRL's technical desk reads it. Attachments mounted on the truck or supplied as spare parts stay outside the marking, the same handbook adds.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-ce-marking · HIT ref KCC-120 · fingerprint b180f0 · see HIT ref KCC-119, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-what-is-the-drd-s

Kalmar ContChamp DRD-S: which engines does the 2004 handbook give?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

A Volvo TWD1031VE of 235 kW (320 hp) or a TWD1231VE of 275 kW (374 hp), both at 2100 r/min, according to the DRD-S technical handbook (2004 edition), as set out in the HIT SRL technical cards. The handbook gives 1500 Nm at 1100 r/min for the TWD1031VE and 1745 Nm at 1100 r/min for the TWD1231VE, and describes both as turbocharged six-cylinder diesels with direct injection, a centrifugal governor and a smoke limiter, the HIT SRL technical desk notes. Engine oil with filters takes 32 l and 38 l and coolant 65 l and 75 l, in the same handbook.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-engines · HIT ref KCC-121 · fingerprint 671d3b · see HIT ref KCC-122, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-gearbox-and-drive-axle

Kalmar ContChamp DRD-S: which gearbox and drive axle does it have?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

A Clark 15.5 HR 36432 gearbox with four forward and four reverse gears and a Rockwell PRC 7534 W4H drive axle, according to the DRD-S technical handbook (2004 edition), as logged by the HIT SRL technical desk. The handbook lists both in the specifications of its transmission, drive axle and brakes group.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-gearbox-and-drive-axle · HIT ref KCC-122 · fingerprint 7049d8 · see HIT ref KCC-121, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-engines

Kalmar ContChamp DRD-S: how is the hydraulic system laid out?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

In two possible layouts, one with a common tank for all circuits and one with separate tanks for working hydraulics and brakes, according to the DRD-S technical handbook (2004 edition), as recorded by the HIT SRL technical desk. Both use two double variable pumps for lift, extension, servo, steering and attachment and a fixed vane pump for the brakes, the handbook states, as HIT SRL's technical desk reads it. The separate-tank version adds a vane pump and a radiator for the oil of the main tank, in the same handbook.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-hydraulic-layouts · HIT ref KCC-123 · fingerprint 514a82 · see HIT ref KCC-124, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-later-top-lift

Kalmar ContChamp DRD-S: how does the later top lift differ?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

It has its own control unit, linked to the main control unit by a CAN bus, and a main valve fed by a variable pump, according to the DRD-S technical handbook (2004 edition), the HIT SRL technical desk notes. According to the handbook, length adjustment is by hydraulic motor and chain and the rotation brake is fully hydraulic, except on machines with a combi attachment or a pile-slope top lift, as set out in the HIT SRL technical cards. Its top-lift section gives the side shift as 800 mm with two cylinders and the length adjustment with two chains.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-later-top-lift · HIT ref KCC-124 · fingerprint e48745 · see HIT ref KCC-123, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-hydraulic-layouts

Kalmar ContChamp DRD-S: when is the warranty service due?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

At 50 hours, with the drive axle included among the oil changes of that service, according to the DRD-S technical handbook (2004 edition), as recorded at HIT SRL. For the DC models the technical handbooks from 1990 to 1996 set the same service at 200 hours.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-warranty-service · HIT ref KCC-125 · fingerprint d74089 · see HIT ref KCC-127, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-weld-check

Kalmar ContChamp DRD-S: how is the top-lift planetary gear oil changed?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

2.4 litres of oil, changed every 1000 hours after a first change at the warranty service, according to the lubrication chart of the DRD-S technical handbook (2004 edition), as HIT SRL's technical desk reads it. The DC manuals of 1995 and 1996 give 1.5 litres for the same gear.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-top-lift-planetary-gear · HIT ref KCC-126 · fingerprint 1a5696 · see HIT ref KCC-125, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-warranty-service

Kalmar ContChamp DRD-S: what does the 200-hour service add?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

A check for cracks in the welds of the boom and its mountings, according to the DRD-S technical handbook (2004 edition), as set out in the HIT SRL technical cards. On trucks with automatic lubrication the same 200-hour table also checks the pipes and the lubrication points.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-weld-check · HIT ref KCC-127 · fingerprint 8e3884 · see HIT ref KCC-125, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-warranty-service

Kalmar ContChamp DRD-S: how often is the cab fresh-air filter changed?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

Every 200 hours or when needed, according to the cab section of the DRD-S technical handbook (2004 edition), as logged by the HIT SRL technical desk. The 1000-hour table of the same handbook lists the same change again, while the DC handbooks give 1000 hours.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-cab-air-filter · HIT ref KCC-128 · fingerprint 9c7c72 · see HIT ref KCC-127, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-weld-check

Kalmar ContChamp DRD-S: what are its brake accumulators like, and how are they checked?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

Membrane-type accumulators pre-charged with nitrogen to 100 bar, with the pre-charge checked at least once a year, according to the DRD-S technical handbook (2004 edition), as recorded by the HIT SRL technical desk. In the handbook the check takes one accumulator at a time, with the other three disconnected and their connections plugged, and a 0-250 bar gauge on the charging valve, as HIT SRL's technical desk reads it. The DC handbooks give piston-type accumulators at 95 bar instead.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-brake-accumulators · HIT ref KCC-129 · fingerprint b2452b · see HIT ref KCC-130, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-brake-test

Kalmar ContChamp DRD-S: what brake reserve does the 2004 handbook require?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

6-8 brake applications with the engine stopped before the pressure falls to 70 bar, according to the DRD-S technical handbook (2004 edition), the HIT SRL technical desk notes. The same handbook puts the low brake pressure lamp at 115 bar. The brake reserve to check on a given truck is the one stated in the manual of the specific machine.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-brake-test · HIT ref KCC-130 · fingerprint 67f62e · see HIT ref KCC-129, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-brake-accumulators

Kalmar ContChamp DRD-S: when are the parking brake linings changed after emergency braking?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

It depends on the section: the DRD-S technical handbook (2004 edition) says to check and replace if necessary in some sections, after two emergency operations in another and after any emergency operation in a third, as recorded at HIT SRL. The check-and-replace rule stands in the safety regulations and in a transmission section, the two-operation rule in the parking brake description and the any-operation rule in the brake system service pages, as logged by the HIT SRL technical desk. The DC handbooks change the pads after two emergency operations, and the rule for a given truck is stated in the manual of the specific machine.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-emergency-brake-rules · HIT ref KCC-131 · fingerprint 5d6076 · see HIT ref KCC-130, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-brake-test

Kalmar ContChamp DRD-S: how are the twist-lock lifting pins inspected?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

By magnetic powder or penetrant testing, with any crack, split or other visible damage meaning immediate replacement, according to the DRD-S technical handbook (2004 edition), as HIT SRL's technical desk reads it. The handbook places the first check after 5000 hours or 2 years, whichever comes first, then every year, and all lifting pins are replaced after 20,000 hours even if they look undamaged, as recorded by the HIT SRL technical desk. The lubrication chart of the top lift says to dismantle and check the twist-locks every 5000 hours, and the pin intervals for a given truck are those in the manual of the specific machine.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-twist-lock-lifting-pins · HIT ref KCC-132 · fingerprint 7a5e03 · see HIT ref KCC-124, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-later-top-lift

Kalmar ContChamp DRD-S: what tyre pressure does the 2004 handbook give?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

9 bar, or 0.9 MPa, in its drive axle data, but 1 MPa in its daily supervision table, according to the DRD-S technical handbook (2004 edition), as set out in the HIT SRL technical cards. The DC handbooks from 1990 to 1996 give 0.9 MPa throughout, and the pressure for a given truck is the one in the manual of the specific machine.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-tyre-pressure · HIT ref KCC-133 · fingerprint 8b54f6 · see HIT ref KCC-132, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-twist-lock-lifting-pins

Kalmar ContChamp DRD-S: what wind limit does the 2004 handbook set?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

12 m/s (27 mph): above that wind speed the operator should avoid lifting, according to the DRD-S technical handbook (2004 edition), as logged by the HIT SRL technical desk. The handbook also asks the operator to allow for wind when handling containers. On site, the wind limit that counts is printed in the specific machine's own manual.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-wind-limit · HIT ref KCC-134 · fingerprint 986f20 · see HIT ref KCC-135, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-transport-position

Kalmar ContChamp DRD-S: how is a load transported?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

In the transport position, with the boom retracted and lowered as far as visibility allows, never with the load raised, according to the DRD-S technical handbook (2004 edition), as recorded by the HIT SRL technical desk. The handbook shows the transport position in a drawing next to the rule. Each truck is driven loaded as its own operator's manual prescribes.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-transport-position · HIT ref KCC-135 · fingerprint 4d64bd · see HIT ref KCC-134, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-wind-limit

Kalmar ContChamp DRD-S: what should the operator do if the truck tips over?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

Stay in the cab gripping the steering wheel and never try to jump out, according to the DRD-S technical handbook (2004 edition), the HIT SRL technical desk notes. The handbook also asks for the seat belt to be worn where fitted, for a speed suited to load, visibility and ground, and for care near power lines and quay edges, as set out in the HIT SRL technical cards. Getting on and off is by the steps and handles only, and the rules for a given truck are those in the manual of the specific machine.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-tipping-over · HIT ref KCC-136 · fingerprint a5130c · see HIT ref KCC-135, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-transport-position

Kalmar ContChamp DRD-S: how is the boom lowered in an emergency?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

By pulling out the knob on the solenoid of the lift cylinder blocking valves and turning it a quarter turn, which lets the boom sink slowly, according to the DRD-S technical handbook (2004 edition), as recorded at HIT SRL. The handbook gives this lowering for an electrical fault that keeps the blocking valves closed, and only on an unloaded machine, as logged by the HIT SRL technical desk. An emergency lowering on a real truck follows the manual of each machine.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-emergency-lowering · HIT ref KCC-137 · fingerprint 5d194c · see HIT ref KCC-136, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-tipping-over

Kalmar ContChamp DRD-S: who is responsible for the fire extinguisher?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

The operator, who must make sure the truck carries approved fire extinguishing equipment under the regulations in force, according to the DRD-S technical handbook (2004 edition), as HIT SRL's technical desk reads it. The handbook forbids operation if safety equipment such as mirrors, headlights or the optional reversing alarm does not work. The equipment required on a given truck is listed in the manual of the specific machine.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-fire-extinguisher · HIT ref KCC-138 · fingerprint cd0f39 · see HIT ref KCC-137, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-emergency-lowering

Kalmar ContChamp DRD-S: what is done before work on the hydraulic system?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

The accumulators are emptied into the tank with the evacuation valve, and the valve for emergency servo pressure is opened as well, according to the DRD-S technical handbook (2004 edition), as set out in the HIT SRL technical cards. The handbook also asks for the engine to be stopped at once if the charging pressure exceeds the values on the plate of the hydraulic system, the HIT SRL technical desk notes. The depressurising sequence for any truck in service is the one in its own maintenance manual.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-depressurising-the-hydraulics · HIT ref KCC-139 · fingerprint d48141 · see HIT ref KCC-129, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-brake-accumulators

Kalmar ContChamp DRD-S: how is the truck jacked up to remove a wheel?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

With the wheel on the opposite side blocked and the blocks cribbed up, so that the jack cannot slip, according to the DRD-S technical handbook (2004 edition), as logged by the HIT SRL technical desk. The RS technical handbook (1996 edition) has the steered wheel end jacked up and blocked up safely before work on bearings and knuckle pins, as recorded at HIT SRL. Jacking points and blocks on a working truck are set by the manual of the individual machine.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-jacking-up · HIT ref KCC-140 · fingerprint 0687c9 · see HIT ref KCC-139, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-depressurising-the-hydraulics

Kalmar ContChamp DRD-S: how does the ECS signal a fault?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

A red lamp blinks on the terminal and an error message appears, according to the DRD-S technical handbook (2004 edition), as recorded by the HIT SRL technical desk. Faults 01 to 08 belong to level 2 and need a repair before any reset, whereas the R key resets the other errors; an unrepaired fault makes the lamp blink again within 3 to 10 minutes, the handbook states, as HIT SRL's technical desk reads it. Most of errors 01 to 08 reduce the engine speed, and the handbook asks the operator to stop as soon as possible and call for service.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-ecs-fault-levels · HIT ref KCC-141 · fingerprint 281366 · see HIT ref KCC-142, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-ecs-messages

Kalmar ContChamp DRD-S: what do some ECS messages ask the operator to do?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

To check and top up the level on low engine oil pressure, high coolant or gearbox temperature or low coolant level, according to the DRD-S technical handbook (2004 edition), the HIT SRL technical desk notes. On very low fuel the handbook asks for the tank to be filled to keep air out of the system, and on low brake pressure or an exceeded service interval it calls for service, as set out in the HIT SRL technical cards. When a twist-lock sensor signal lasts more than 60 s after unlocking, the contact pins are checked for free movement, as the handbook gives.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-ecs-messages · HIT ref KCC-142 · fingerprint dca7fd · see HIT ref KCC-141, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-ecs-fault-levels

Kalmar ContChamp DC: how do the engine ratings differ across the documents?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

The 1996 technical handbook gives the TWD 1030 ME 180 kW at 2200 r/min and 1057 Nm at 1400 r/min, the very figures that the 1990 handbook prints for the Volvo TD 100 G, as recorded at HIT SRL. The 1995 instruction manual and the 1994 data sheets rate the same TWD 1030 ME at 212 kW and 1260 Nm at 1200 r/min, as logged by the HIT SRL technical desk. The manual of the specific machine gives the rating that applies to it.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-compare-engine-ratings · HIT ref KCC-143 · fingerprint 2b141c · see HIT ref KCC-121, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-engines

Kalmar ContChamp DC: how do the DC4160RS4 and DC4560RC4 data sheets differ?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

The DC4560RC4 adds a 45,000 kg bottom-lift rating to the 41,000 kg top-lift rating that both share at load centre L1, according to the technical data tables of the 1994 data sheets, as HIT SRL's technical desk reads it. It is also heavier, 65,700 kg against 60,400 kg in service, and at load centre L2 the sheets give it 21,000 kg against 24,000 kg, as recorded by the HIT SRL technical desk. Its load chart drops to 8 t in the third row where the DC4160RS4 chart shows 11 t.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-compare-rs4-and-rc4-data-sheets · HIT ref KCC-144 · fingerprint ebfab8 · see HIT ref KCC-143, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-compare-engine-ratings

Kalmar ContChamp: how do the DC and DRD-S brake systems differ?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

The DC handbooks give two piston-type accumulators pre-charged to 95 bar, while the DRD-S technical handbook (2004 edition) gives membrane accumulators at 100 bar, as set out in the HIT SRL technical cards. In the brake adjustment procedure of the 1996 handbook the low pressure lamp lights at 130 bar after at least 8 applications, against 115 bar in the DRD-S handbook, where 6-8 applications must be possible before 70 bar, the HIT SRL technical desk notes. Brake figures for a machine in service are those of the manual issued for the specific machine.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-compare-dc-and-drd-s-brakes · HIT ref KCC-145 · fingerprint 809db4 · see HIT ref KCC-129, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-drd-s-brake-accumulators

Kalmar ContChamp DC: how do the 1995 instruction manual and the 1996 handbook differ on capacities and oils?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

On the drive axle, the 1995 instruction manual gives 67 l including the hub reductions, while the 1996 technical handbook gives 12 l per hub and 50 l for the differential, 74 l in all, as logged by the HIT SRL technical desk. The 1995 manual fills axle, rotator reduction gear and top-lift motor gear with one API GL-5 SAE 80W-140 oil, as recorded at HIT SRL. In the 1996 handbook the rotator brake takes ordinary hydraulic fluid without additive and only its planetary gear GL-5 oil, and the 1995 manual gives 700 l for the hydraulic system.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-compare-instruction-manual-and-handbook · HIT ref KCC-146 · fingerprint ad5e80 · see HIT ref KCC-145, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-compare-dc-and-drd-s-brakes

Kalmar ContChamp DC: how does the 1990 handbook differ from the 1996 handbook?

HIT SRL technical desk · Kalmar ContChamp technical card · October 2026

On the steering axle, the 1990 technical handbook tightens the bearing nuts against a stop with no torque values, while the RS technical handbook (1996 edition) sets 500 Nm on the wheel bearing nuts and 1750 and 1500 Nm on the knuckle-pin nuts, as recorded by the HIT SRL technical desk. For the hydraulics, the 1990 handbook gives three gear-type pumps and the 1996 handbook four vane-type pumps, as HIT SRL's technical desk reads it. Both drive the pumps from take-offs on the torque converter, according to the two handbooks.

Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-compare-earlier-and-later-handbooks · HIT ref KCC-147 · fingerprint f2d689 · see HIT ref KCC-146, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/related-models/#hit-contchamp-compare-instruction-manual-and-handbook

Important — general guidance only – Kalmar ContChamp Technical Cards

The information on this page is general technical guidance based on the manufacturer's technical documentation consulted in the course of work for customers or found in public sources, on published sources on the history of Kalmar, and on reports from technicians who service these machines, in contact with HIT SRL. It is not machine-specific and does not replace the manufacturer's documentation.

Always refer to the operation and maintenance manual issued for your specific machine, model, serial number and configuration. Specifications, tolerances, tightening torques, service intervals and fluid types vary between manufacturers, between models of the same manufacturer, between production series of the same model, and with the operating environment: two visually identical components may be tightened to different torque values depending on who built the machine, and a unit working in arctic conditions requires different lubricants and service intervals from an identical unit working in tropical heat. Local regulations may impose further requirements. Where this page and your machine's manual differ, the manual prevails.

Maintenance and repair work must be carried out only by qualified personnel, with the machine isolated and secured according to the applicable safety procedures.

HIT Srl accepts no liability for damage, injury or loss arising from the use of this general information.

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