Kalmar DRF 400-450 Reach Stacker — Technical Legacy Guide

Summary

The Kalmar DRF 400-450 is a diesel reachstacker for container handling with a lift capacity of 40 to 45 tonnes depending on version, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. The operator's manual (series 1) adds that, with the bottom lift attachment, it also handles trailer goods, and that it lifts up to six 8 ft 6 in containers. According to the manuals, drive goes from a six-cylinder Volvo or Cummins diesel engine through a Dana transmission to a drive axle with hub reductions, while the rear axle steers. The sections below follow the manufacturer's documentation on identification, power unit, brakes and steering, hydraulics, boom and attachment, electrical system, safety and maintenance, and close with key data and the related DRT 450, DRG 420-450 and DRF 100.

Published sources date the first Kalmar reachstacker prototype to 1985 and state that the DRF was introduced in 2002, the HIT SRL technical desk notes. The manuals give the machine a 24 V electrical system, a brake system separate from the working hydraulics with wet disc brakes, and an overload warning system called LLMC that must always be functional.

Model identification

Every DRF designation encodes engine, machine type, generation, first-row capacity and axle distance, according to the type designation key of the operator's manual (series 1), as recorded at HIT SRL. In the example DRF 450-65S5XS, D stands for diesel engine, R for reachstacker, F for generation, 450 for the first-row lift capacity in decitonnes and 65 for the axle distance in decimetres, according to that key. The letters and figure that follow give S for spreading with an adjustable top lift, 5 for the maximum number of containers when stacking, X for extra counterweight and the final S for support jacks, according to the same key.

According to the manufacturer's technical information, the letter X of the same example stands for extended capacity, not extra counterweight, as HIT SRL's technical desk reads it. The technical information gives the 65 of the example as the wheel base in decimetres. The designation key of the operator's manual does not list the letter C found in the C versions.

The capacity table of the maintenance manual (series 1) covers twelve DRF versions, from the DRF420-60S5 to the DRF450-70S5XS, together with two DRD450-80S4 versions, as set out in the HIT SRL technical cards. The list runs through the DRF420-60S5, DRF450-60S5, DRF450-60S5X, DRF420-65S5, DRF420-65S6, DRF450-65S5, DRF450-65S6, DRF450-65S5X, DRF450-65S6X, DRF420-70S5, DRF450-70S5X and DRF450-70S5XS, according to that table. The workshop manual (series 3, revision 1) adds C versions, from the DRF400-60C5 to the DRF450-75C5XS, next to S versions up to the DRF450-75S5XS. The workshop manual (series 3, revision 2) splits its capacity and dimension tables into machines up to model year 2008 and machines from model year 2009, the second adding the DRF450-60S5M and the DRF450-70S5.

The capacity of a DRF depends on the number of containers in height and on the size and centre of gravity of the load, according to the operator's manual (series 1), as logged by the HIT SRL technical desk. For the DRF450-65S5 with 8 ft 6 in containers, the capacity table of the maintenance manual (series 1) prints 43*/45 tonnes in the first row, 30* in the second and 15* in the third, with top lift heights H4 of 15,100 mm and H5 of 18,100 mm. From model year 2009 the workshop manual (series 3, revision 2) prints 31* and 16* tonnes in the second and third rows for the same version, against 30* and 15* up to model year 2008. According to the same tables, the asterisks refer to the container positions marked in the drawing above them.

The operator's manual (series 1) states that the machine is CE-marked to the Machinery Directive 98/37/EG, with an EU Declaration of Conformity for each machine to be kept for at least 10 years, as recorded by the HIT SRL technical desk. Machines for the North American market carry the ANSI/ASME B56.1 marking, according to the same manual.

The maintenance manual (series 1) arranges its information in function groups 0 to 12, from the complete machine to common pneumatics, the HIT SRL technical desk notes. According to that manual, the main and two-digit levels of the groups are common to all machines of the manufacturer, while the third and fourth levels are specific to each machine. The manufacturer's documentation uses the same main groups with three different names: 3 power transmission, 6 wheel suspension and 8 control and monitoring system.

Kalmar DRF 400

Reach stacker · Also written as: DRF400, DRF-400, DRF 400 C5, DRF400-60C5

The Kalmar DRF 400 is the DRF 400-450 reachstacker whose designation gives 400 decitonnes in the first row, listed as the DRF400-60C5 in the workshop manual (series 3, revision 1), as recorded at HIT SRL. The maintenance manual (series 1) gives the DRF400 and the DRF450 the same 18.00x25/40 tyres, against 18.00x25/36 on the DRF420, all inflated to 1.0 MPa.

Kalmar DRF 420

Reach stacker · Also written as: DRF420, DRF-420, DRF 420 S5, DRF420-65S6

The Kalmar DRF 420 is the DRF 400-450 reachstacker whose designation gives 420 decitonnes in the first row, listed as DRF420-60S5, -65S5, -65S6 and -70S5 in the capacity tables, as HIT SRL's technical desk reads it. The dimension table of the maintenance manual (series 1) gives the DRF420-60S5 the lowest service weight of the range, 64,500 kg, and all DRF models a width of 4150 mm. Published sources report a DRF420-450L, presented in December 2009 for terminals with medium capacity and average operational requirements, with 45 t in the first row, 30 t in the second and 15 t in the third.

Kalmar DRF 450

Reach stacker · Also written as: DRF450, DRF-450, DRF 450-65S5, DRF450-65S5XS

The Kalmar DRF 450 is the DRF 400-450 reachstacker whose designation gives 450 decitonnes in the first row, listed with -60 to -75 axle distances in the capacity tables, as set out in the HIT SRL technical cards. According to the same tables, the DRF450 versions include the DRF450-65S5, DRF450-65S6, DRF450-65S5X, DRF450-65S6X, DRF450-70S5X and DRF450-70S5XS, and the workshop manual (series 3, revision 1) adds the C versions. The maintenance manual (series 1) gives the DRF450-70S5XS the highest service weight of the range, 79,300 kg. The manufacturer's technical information gives the DRF450-65S5 a lifting speed of 0.42 m/s unloaded and 0.25 m/s at 70 % of rated load, travel speeds of 25 km/h unloaded and 21 km/h at rated load, and a maximum drawbar pull of 370 kN.

Industrial history and parts supply

Published sources date the first Kalmar reachstacker prototype to 1985, with the first commercial units in the following year, as logged by the HIT SRL technical desk. Another published source states that the company was the first to commercialise the machine in 1985, and the manufacturer's technical information says that Kalmar has built reachstackers since the mid-1980s. According to a trade publication of 2011, the DRF was introduced in 2002 and was the company's best-selling reachstacker.

The operator's manual (series 1) names Kalmar Industries AB as the manufacturer, and the workshop manual (series 3, revision 2) names Cargotec as the machine supplier, as recorded by the HIT SRL technical desk. According to published sources, Partek bought Sisu Terminal Systems and the majority of Kalmar Industries in 1997, KONE acquired Partek in 2002, Cargotec was formed in 2005 and Kalmar was demerged from Cargotec on 30 June 2024. The DRT 450 operator's manual (series 2) names Cargotec Industries Co., Ltd in China as the manufacturer of that model.

The workshop manual (series 3, revision 2) lists parts to be replaced only with original spare parts for safety reasons, among them the brake valve, drive axle, steering valves and cylinder, rims, lift boom, lift and extension cylinders, twistlocks, frame, accumulators and control units, the HIT SRL technical desk notes.

Power unit and driveline as installed

The maintenance manual (series 1) lists two engine alternatives for the DRF 400-450, the Volvo TWD1240VE and the Cummins QSM11, both straight six-cylinder four-stroke turbocharged low-emission diesels with unit injectors, as recorded at HIT SRL. According to the same manual, the Volvo has a liquid-to-air intercooler and the Cummins an air-to-air intercooler. The workshop manual (series 3) lists three engine alternatives: the Volvo TWD1240VE, stage II to Directive 97/68/EG, and the Volvo TAD1250VE and Cummins QSM11, both stage III. The manufacturer's technical information names the Volvo TAD1250VE the standard engine and the Cummins QSM11 an option, and gives both as meeting 97/68 and 2004/26 EC stage 3 and US EPA Tier 3. The workshop manual (series 3, revision 2) separates the Cummins QSM11 of model years up to 2008 from that of 2009 onward.

The manuals give the Cummins QSM11 three different power ratings: 288 kW at 2000 rpm in the operator's manual (series 1), 280 kW in the maintenance manual (series 1) and 261 kW in the workshop manual (series 3), the maintenance manual (series 3) and the technical information, as HIT SRL's technical desk reads it. The torque is 1898 Nm at 1100-1400 rpm with 288 and 280 kW, and 1830 Nm at 1100-1400 rpm with 261 kW, according to the same documents. For the Volvo TWD1240VE the maintenance manual (series 1) gives 256 kW net at 2000 rpm and 1751 Nm at 1200 rpm, to ISO 3046, while the workshop manual (series 1) gives 246 kW with the same torque. The workshop manual (series 3, revision 1) gives the Volvo TAD1250VE 247 kW at 1900 rpm and 1760 Nm at 1400 rpm.

The maintenance manual (series 1) prescribes engine oil meeting both VDS-2 and ACEA E3, SAE 15W40 or SAE 5W30 by ambient temperature, with API CG-4 or CH-4 accepted instead of ACEA E3 outside Europe, as set out in the HIT SRL technical cards. The workshop manual (series 3) prescribes VDS-2 and ACEA E5 for the Volvo TWD1240VE, VDS-3 for the Volvo TAD1250VE and API CH-4 or ACEA E5 for the Cummins QSM11. According to the workshop manual (series 3, revision 1), the TAD1250VE may use the oil prescribed for the TWD1240VE if the oil change interval is reduced to 400 hours. The same manual presumes a fuel sulphur content not above 0.5 % for the oil change interval and changes the oil filters together with the oil. The maintenance manual (series 1) gives an engine oil fill of 35 l for the Volvo TWD1240VE and 34 l for the Cummins QSM11, a cooling system of 68 l or 40 l and a 550 l fuel tank for diesel to EN 590, while the workshop manual (series 1) gives 31 l for the Volvo, excluding filter.

The workshop manual (series 3, revision 2) prescribes coolant of distilled water with at least 40 % glycol, or the ready-mixed Volvo Penta Coolant VCS, and states that different coolant types must not be mixed, as logged by the HIT SRL technical desk. On machines with a coolant filter the same manual takes distilled water with at least 40 % ethylene glycol or ES Compleat Premix.

The maintenance manual (series 1) fits a fully automatic Dana TE32000 transmission with torque converter and four gears in each direction, selected by pressure modulation through electrically controlled valves, as recorded by the HIT SRL technical desk. According to the same manual, the hydraulic pumps are driven from power take-offs on the transmission, which takes 60 l of ATF Dexron III at a change out of 80 l in total. According to the maintenance manual (series 1), a warning is given and performance is reduced at a transmission oil temperature of 120 °C, and the transmission is disengaged above 125 °C. In serious faults the transmission control unit uses a limp-home mode, shown as LH, with neutral and then only the first two gears in each direction selected by hand, or a shut-down mode, shown as Sd, with permanent neutral, according to the same manual.

The drive axle is a Meritor PRC7534 or a Kessler D102, with a differential after the input shaft and hub reductions at the wheel hubs, according to the maintenance manual (series 1), the HIT SRL technical desk notes. The same manual fills the differential with 50 l on the Meritor or 65 l on the Kessler and the hub reductions with 2 x 10 l or 2 x 12 l of API GL-5 oil, SAE 80W140 or 75W90 by ambient temperature. The drive axle attaching bolts are check-tightened to 2350 Nm after the axle mounting has been checked for corrosion, and the propeller shaft bolts to 200 Nm, according to the same manual.

The maintenance manual (series 1) fits 18.00x25/36 tyres on the DRF420, 18.00x25/40 on the DRF400/450 and 18.00x33/36 on the DRF450 X versions, all at 1.0 MPa, and refers also to the pressure plate on the machine, as recorded at HIT SRL. The wheel nuts are tightened crosswise to 400 Nm and, on a new machine, check-tightened every 4-5 operating hours up to about 40-50 hours, according to the same manual. According to the same manual, tyres are pressurised containers: the wheels on the other side of the axle are blocked, the tyre is deflated before removal, both tyres on twin wheels, and rims are never repaired by welding.

Brakes and steering

The DRF 400-450 brakes with wet disc service brakes in oil, built into the drive wheel hubs and acting on the drive axle only, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. According to the same manual, the steering axle has no brakes and the parking brake is a disc brake on the input shaft of the drive axle. The operator's manual (series 1) states that the electro-hydraulically controlled parking brake is applied by spring force, automatically when the ignition voltage drops, and released by hydraulic pressure.

The brake system is separate from the working hydraulics, with its own oil tank, pump, filter, accumulator charging valve, accumulators and an oil cooler with a temperature-controlled electric fan, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. Once the accumulators are charged, the charging valve sends the oil through the brake units of the drive axle to cool the brakes, according to the same manual. The brake system takes 140 l of a UTTO oil meeting GM Allison C-4, John Deere J20 C or D or Caterpillar TO-4, viscosity SAE 5W30, according to the same manual.

The manuals give three different brake pump pressures before the accumulator charging valve switches to cooling: 19 ±0.5 MPa in the maintenance manual (series 1), 22 MPa in the maintenance manual (series 3) and 20.5 ±1.0 MPa in the workshop manual (series 3), as logged by the HIT SRL technical desk. During cooling at maximum engine speed the pressure stays at most at 1-1.5 MPa in the maintenance manual (series 1), 0.10-0.15 MPa in the maintenance manual (series 3) and 1.0-1.5 MPa in the workshop manual (series 3). In the accumulator charging check of the workshop manual (series 3, revision 1), the accumulator pressure rises to 20.5 ±1.0 MPa and the charging valve switches back to charging at 15.5 ±0.5 MPa on repeated braking. According to the maintenance manual (series 1), checked pressures must match the pressure plate of the machine, and the manual of the specific machine prevails.

At least eight brake applications must be possible with the engine stopped before the low brake pressure warning light comes on, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. Otherwise an accumulator is probably defective, and the operator's manual (series 1) asks for the same test when the light comes on. The clearance between brake pedal and brake valve is 1-1.5 mm, set with the pedal set screw, according to the maintenance manual (series 1).

The DRF 400-450 steers with the rear axle through a double-acting hydraulic cylinder acting on the wheel pair, with progressive steering, according to the operator's manual (series 1), the HIT SRL technical desk notes. According to the same manual, a quick movement of the steering wheel gives a greater steering angle per turn. A priority valve between the hydraulic pumps and the steering valve gives oil to the steering before any other function, load handling included, according to the maintenance manual (series 1). The optional mini-wheel and joystick steering in the left armrest can only be activated below 3 km/h, and the ratio between control and wheel deflection can be set in 31 steps, according to the workshop manual (series 3, revision 2).

The steering axle cradle is attached to the frame with two bushings and oscillates in the frame, carrying two hinged wheel spindles with single wheels, according to the maintenance manual (series 1), as recorded at HIT SRL. The same manual checks the wheel spindle clearance, maximum 1.5 mm, every 1000 hours and the bearing pre-load of the steering axle wheel hubs every 2000 hours. The bearing nut is tightened to 250 Nm, the hub turned at least two revolutions and the nut turned a further 45 degrees, both steps done twice, before the lock washer and outer lock nut are fitted at not less than 250 Nm, according to the same manual.

Hydraulic system as installed

The hydraulics of the DRF 400-450 are supplied by six pumps in two pump banks on the power take-off of the transmission, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. According to that manual, four variable-displacement axial piston pumps, coupled in pairs, serve the working hydraulics and steering, one fixed gear pump the brake system, and one fixed pump circulates the hydraulic oil through cooler and filter. The manufacturer's technical information gives instead four load-sensing pumps and two vane pumps for brakes and cooling, with 10 micron return filters and a 10 micron pressure filter for the brakes. The workshop manual (series 3, revision 2) gives two pump alternatives for the working hydraulics: Rexroth, with four axial piston pumps, and Sauer-Danfoss, with two.

On a standard machine the stand-by pressures of the four pumps at idle, with the oil at about 50 °C, are 1.8, 2.1, 2.9 and 3.1 MPa for pumps 1 to 4, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The same manual keeps the pressure difference between the pumps and requires the maximum pressure, the same for all pumps, to match the pressure plate. For the Sauer-Danfoss alternative the workshop manual (series 3, revision 2) gives 2.9 MPa for pump 1 and 3.0 MPa for pump 2. The pressure plate on the left side of the frame, in front of the cab steps, carries the settings of each machine, among them the servo accumulator gas pressure, the brake accumulator pressures and the maximum pump pressure, according to the maintenance manual (series 1).

The hydraulic oil tank holds 600 l and the whole system 940 l of oil to DIN 51524 Part 3 HVLP in ISO VG 68 or 46, or HV ISO VG 32, chosen by ambient temperature, according to the maintenance manual (series 1), as logged by the HIT SRL technical desk. The same manual replaces the hydraulic oil fine filter every 500 hours, the hydraulic oil filter and the high-pressure filter every 1000 hours and the hydraulic oil every 2000 hours. Before work on the hydraulics the machine goes into the service position, the boom functions are operated with the key in the operating position to release pressure, and the drain valve on the accumulator charging valve stays open while work is in progress, according to the same manual.

Boom, attachment and cab

The maintenance manual (series 1) divides load handling into lift and lower, extension, sideshift, spreading, rotation, tilt, levelling, securing the load with twistlocks and lift legs, and auxiliary functions such as the support jacks, as recorded by the HIT SRL technical desk. According to the same manual, two lift cylinders raise the boom and an extension cylinder pushes the inner boom in and out of the outer boom. Position sensors reduce the speed near the end positions, and oil from the rod side is fed back to the piston side to increase speed, functions that the same manual calls damping and regeneration.

The operator's manual (series 1) lists five attachment alternatives: top lift with sideshift of ±800 mm, top lift with hydraulic levelling, bottom lift for containers and trailers, a tool carrier for different lifting tools and an over-height top lift attachment, the HIT SRL technical desk notes. According to the manufacturer's technical information, the standard top lift attachment takes 20-40 ft containers at 45 tonnes, with a sideshift of ±800 mm, mechanical levelling of ±5 degrees, rotation of +195/-105 degrees and floating ISO twistlocks. The maintenance manual (series 1) changes the oil of the rotation motor unit and of the spreader motor unit every 1000 hours, with 1.6 l of API GL-5 oil in the planetary gear of the attachment hydraulic motor and 0.6 l of hydraulic oil in its brake.

The container is secured by four twistlocks turned through linkages by two hydraulic cylinders, one in each spreader beam, according to the maintenance manual (series 1), as recorded at HIT SRL. According to the same manual, position sensors report open or locked status, and four alignment sensors, one at each twistlock, must all show contact before the twistlocks can be operated. The operator's manual (series 1) requires the top lift attachment to be aligned at all four corners both when locking and when releasing, and with the bottom lift attachment the load can be lifted for only 4 seconds without correct alignment. The maintenance manual (series 1) checks the twistlocks for cracks every other year or every 5000 operating hours and replaces them every 10,000 hours or at the first crack or external damage, refitting them with a new nut and washers.

The dimension table of the maintenance manual (series 1) gives turning radii of 8100-9000 mm with 20 ft containers and 9400-9450 mm with 40 ft containers, as HIT SRL's technical desk reads it.

The operator's manual (series 1) fits the Spirit Delta cab, a closed cab with a structural frame built to withstand falling loads to the applicable standards and a roof window of high-strength material, as set out in the HIT SRL technical cards. According to the same manual, the cab moves fore and aft manually or, as an option, hydraulically, or is vertically adjustable as an option. The frame of high-strength steel carries engine, transmission, drive axle and steering axle, with the fuel, hydraulic oil and brake oil tanks on its sides, cab mounts at four points and the counterweights at the rear, according to the maintenance manual (series 1).

Electrical and control system

The electrical system works at 24 V from two 12 V batteries in series charged by an alternator, with the minus terminal on the chassis and the plus terminal on the battery disconnector, according to the operator's manual (series 1), as logged by the HIT SRL technical desk. The maintenance manual (series 1) gives two 12 V 140 Ah batteries, a battery voltage of 23-25 V with the engine off and 27-29 V at maximum engine speed, and an electrolyte level 10 mm above the cells. The alternator is rated 2240 W with the Volvo engines, according to the maintenance manual (series 1) and the workshop manual (series 3), while for the Cummins engine the maintenance manual (series 1) gives 2800 W and the operator's manual (series 1) and the workshop manual (series 3, revision 1) give 2400 W.

The control units of the DRF 400-450 are linked by a redundant CAN bus that can handle the loss of one segment, each unit having two communication connections, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. According to the same manual, the engine and transmission control units communicate on a separate drivetrain CAN bus. Machine codes 1 to 8 are communication errors with single control units, each listing the functions lost, and the faulty segment is found with diagnostic menu CAN/POWER 2, according to the workshop manual (series 3, revision 2).

A built-in diagnostic test shows, in display menus grouped from CAN/POWER to OP and EXTRA, how each control unit reads its input signals and what output signals it sends, according to the maintenance manual (series 1), the HIT SRL technical desk notes. The manufacturer's technical information gives more than 400 error codes and 140 diagnostic menus. For cable harness faults the same maintenance manual turns off the main power at the battery disconnector, unplugs the connector and measures resistance, and checks for short circuit to frame with the lead disconnected at both ends, where the multimeter must show infinite resistance.

Safety systems

The LLMC (Longitudinal Load Moment Control) warning system must always be functional, according to the maintenance manual (series 1), as recorded at HIT SRL. Near the forward stability limit a buzzer sounds, a warning figure appears and boom movement is interrupted, after which the boom can only be retracted until the warning stops, according to the same manual. The same manual states that the LLMC does not control sideways stability or stability while driving and does not take sloping ground into account. The maintenance manual (series 1) checks the overload system at every 500-hour service by lifting a load about 1 m and running out the boom until the system activates.

Overload on the steering axle triggers only a warning and interrupts no function, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. With the mechanical systems the warning comes when the boom angle exceeds 35 degrees with less than 1.5 m of extension above 10 km/h, with the electrical system speed is also limited, and lowering or extending the boom reduces the load, according to the same manual. The operator's manual (series 1) links the warning to reduced lateral stability and asks to move the load forward, lower the attachment and reduce speed.

Loads are carried in the transport position, with the boom fully retracted, the load low but with forward visibility and centred sideways, and the cab in the rear position, according to the operator's manual (series 1), as set out in the HIT SRL technical cards. On grades the load faces uphill, the machine never turns across a grade and no one may stand under a raised load, according to the same manual. The same manual warns that load handling at long boom extension carries a risk of tipping and requires the boom always to be retracted before it is lowered. The load capacity on the marking plate and load diagram must not be exceeded, and the operator's manual (series 1) warns that the stability limit may be exceeded if the overload protection system is not working.

The operator's manual (series 1) designs the DRF 400-450 for outdoor temperatures of -40 to 40 °C, relative humidity of 10 to 90 % and wind speeds up to 12.2 m/s, as logged by the HIT SRL technical desk. Operation is prohibited if safety and warning equipment, brakes, steering or lifting equipment do not work, after repairs or modifications without the supervisor's permission, with tyres not approved by the manufacturer or with the overload protection system not working, according to the same manual.

In an emergency the control breaker for the hydraulics is pressed at once, cutting all power supply and control signals to the hydraulics, and it is reset by turning it clockwise, according to the operator's manual (series 1), as recorded by the HIT SRL technical desk. The workshop manual (series 3, revision 2) states that the battery disconnect switch must not be used for emergency stopping and must never be turned off with the engine running, the engine being stopped only with the ignition. The right door is the emergency exit and, if the doors are blocked by the lift cylinders, the rear window opens by removing the split pin and handle on each side, while the vertically adjustable cab has a hammer to break the window, according to the operator's manual (series 1). If the hydraulic functions stop, two people, one on each side, open the solenoid valves of the two lift cylinders by hand at the same time, and the same manual warns that manual lowering carries a risk of crushing and tipping and is to be avoided or done very carefully. A fire extinguisher, if fitted, should be of type ABE to EN 3 parts 1, 2, 4 and 5, according to the maintenance manual (series 1).

Without hydraulic pressure the DRF 400-450 cannot be steered and the brakes do not work, according to the operator's manual (series 1), the HIT SRL technical desk notes. The same manual allows towing only over short distances, with the engine running if possible, a towing vehicle heavier than the machine, a tow bar if the engine cannot run, the propeller shaft disconnected from the transmission, and the parking brake applied and the wheels blocked before and after. Without accumulator pressure the spring-applied parking brake is released by hand, with the wheels blocked, by removing the split pin and screwing in the nut until the pads release, and it is restored afterwards, according to the same manual. If the machine rolls over or tips, the operator stays in the cab holding the steering wheel and does not jump out until the machine has stopped, and on contact with an overhead high-voltage line sits down, calls for help and remains in the cab, according to the same manual.

The procedures to follow on a specific machine are those of its own operator's and maintenance manuals, which prevail over this guide, as recorded at HIT SRL.

Recurring failure points — field reports

Published reports of recurring failures on the DRF 400-450 are scarce, and the published sources consulted for this guide report none, as HIT SRL's technical desk reads it. The checks below are those that the manufacturer's manuals give for the most frequent warnings.

What the documentation says to check

• Low engine oil pressure (code 100/1) shuts the Volvo TWD1240VE off, while high coolant temperature (110/0) and low coolant level (111/1) reduce power step by step and stop the engine after 30 seconds, according to the maintenance manual (series 1).
• For a water-in-fuel code (97/1) the same manual drains the water trap, cleans the metal filter in the fuel feed connection on the engine and checks the fuel filter and pre-filter.
• Code 144, high brake oil temperature, comes with reduced braking performance, and the same manual checks the cooling fan, the cooler and the wiring.
• Code 150 means that the overload protection is not working and all lift functions run at reduced speed, and the same manual looks for error codes on the overload system sensors.
• If the low brake pressure light comes on, the brake accumulator test of the maintenance manual (series 1) applies: at least eight applications with the engine stopped.
• An engine that does not start after attempts of at most 10 seconds, 15-20 seconds apart, has a malfunction to be found by service, and start spray is not to be used, according to the operator's manual (series 1).

Maintenance interval summary

The maintenance manual (series 1) services the DRF 400-450 every 500 operating hours, with the 500-hour service at 500, 1500 and 2500 hours, the 1000-hour service at odd thousands and the 2000-hour service at even thousands, as set out in the HIT SRL technical cards. On a new machine the same manual adds a 50-hour check that includes the engine oil and filter, the transmission oil filter and the hydraulic oil fine filter, check-tightening of the propeller shaft, wheel nuts and hose connections, and adjustment of the spreader chain. The operator's manual (series 1) recommends a run-in of 10 operating hours without full engine load and a daily inspection before each work shift, with at least three test brakings.

The maintenance manual (series 3) adds to its schedule the lubrication of the lower glide surfaces of the inner boom every 250 hours up to 1000 operating hours, a rim check at a tyre change or once a year, and a check of the sliding cab locking in the 1000-hour and 2000-hour services, as logged by the HIT SRL technical desk. The maintenance manual (series 1) has none of these three entries in its table and states instead that the lock catches of the sliding cab must be intact and checked regularly, outside the preventive maintenance schedule. The maintenance manual (series 3) also drains the water from the fuel pre-filter every 50 hours and changes the fuel filters earlier if an error code is shown.

Key specification table

The table below gives the main data of the DRF 400-450 with the manual that prints each value, and keeps every value where the manuals differ, as recorded by the HIT SRL technical desk.

Related models

According to the manufacturer's documentation, the DRF 100 uses the same main function groups 0 to 12 as the DRF 400-450, with complete-machine sections for Sisu, Volvo TAD760VE, Volvo TAD762VE and Cummins QSB6.7 engines paired with the TE17311 or FTE17311 transmission, the HIT SRL technical desk notes. The DRT 450 and the DRG 420-450, with lift capacities of 45 tonnes in their manual and data sheet, follow in their own sections.

Kalmar DRT 450

Reach stacker · Also written as: DRT450, DRT-450

The Kalmar DRT 450 is a container reachstacker lifting 45 tonnes and stacking five 9 ft 6 in containers high, according to its operator's manual (series 2), as recorded at HIT SRL. The same manual reads the designation DRT450 as D diesel engine, R reachstacker, T generation and 450 lift capacity in the first row in decitonnes. According to the same manual, the DRT 450 has a Yuchai YC6M360-30 or Cummins QSM11 engine, a Dana HR36000 automatic transmission with four forward and four reverse gears, a Meritor PRC7534 drive axle, a manually sliding cab and linear steering. The DRT 450 engines give 243 kW at 2000 rpm and 1550 Nm at 1100 rpm (Yuchai) or 224 kW at 2000 rpm and 1575 Nm at 1400 rpm (Cummins QSM11), according to the same manual. Published sources describe the DRT450 as designed for customers in the Asia-Pacific area and launched in 2011.

The DRT 450 operator's manual (series 2) gives 18.00x25 PR40 E4 tyres at 1.0 MPa, a 600 l hydraulic tank in a 940 l system, a 140 l brake system and, for the Dana HR36000 transmission, oils to Allison C-4, John Deere J20 C/D, Caterpillar TO-4 or MIL-PRF-2104G, never engine oil or GL-5 oil, as HIT SRL's technical desk reads it. According to the same manual, the DRT 450 is designed for outdoor temperatures of -20 to 40 °C and wind speeds up to 12.2 m/s, and is not operated with unauthorised persons or vehicles in the work area. At the slightest sign of fire the same manual has the operator stop the machine, leave the cab, switch off the system voltage with the battery disconnector, alert the rescue services and try to extinguish the fire, or otherwise leave the risk area.

Kalmar DRG 420-450

Reach stacker · Also written as: DRG420-450S, DRG 420-450, DRG450-70S5XS, Kalmar Gloria

The Kalmar DRG 420-450 is a reachstacker range whose DRG450-70S5XS is rated 45,000 kg at load centre L4 and 41,000 kg at L5, according to its data sheet (2017), as set out in the HIT SRL technical cards. According to the same data sheet, the DRG450-70S5XS has a Volvo TAD-1171-VE EU 4 engine, a ZF 5WG-261 powershift transmission with five forward and three reverse gears, a Kessler D-102 drive axle with hub reduction and electronic overload protection. The same data sheet gives 265 kW at 1450-2000 rpm and 1785 Nm at 1000-1450 rpm, a 4200 W alternator, a 550 l fuel tank, a 35 l AdBlue tank, 23.0 MPa maximum hydraulic pressure and a service weight of 80,300 kg. Published sources describe the Gloria as the fifth-generation DRG reachstacker, launched at the TOC Europe 2013 after the F generation, with 42 to 45 t in the first row and wheelbases from 6 to 7 m.

Comparisons

The comparisons below set side by side only differences that the manuals and the data sheet document, as logged by the HIT SRL technical desk.

DRF 400-450 and DRT 450: steering and climate range

The DRF 400-450 steers progressively, with a greater steering angle per turn for a quick movement of the wheel, while the DRT 450 has linear steering, and the DRF is designed for -40 to 40 °C against -20 to 40 °C for the DRT 450, according to their operator's manuals, as recorded by the HIT SRL technical desk.

DRF 400-450 and DRT 450: transmission and engines

According to their operator's manuals, the DRF 400-450 has a Dana TE32000 transmission with Volvo or Cummins engines, while the DRT 450 has a Dana HR36000 with a Yuchai YC6M360-30 or Cummins QSM11, and its Cummins gives 224 kW against 288 kW in the DRF operator's manual, the HIT SRL technical desk notes.

Volvo and Cummins engine versions: maintenance

The maintenance manual (series 1) replaces the coolant filter every 1000 hours on the Volvo engine and every 500 hours on the Cummins, checks the valve clearance at 2000 hours on the Volvo only, and gives an alternator of 2240 W with the Volvo against 2800 W with the Cummins, as recorded at HIT SRL.

Maintenance manual series 1 and series 3

Against the maintenance manual (series 1), the schedule of the maintenance manual (series 3) adds the inner boom glide surfaces every 250 hours up to 1000 hours, the fuel pre-filter drained every 50 hours, a yearly rim check and the sliding cab locking at 1000 and 2000 hours, and gives 22 MPa instead of 19 MPa for the brake pump, as HIT SRL's technical desk reads it.

DRF450-65S5 up to model year 2008 and from model year 2009

For the DRF450-65S5 with 8 ft 6 in containers, the workshop manual (series 3, revision 2) gives 30* and 15* tonnes in the second and third rows up to model year 2008 and 31* and 16* tonnes from model year 2009, with the service weight rising from 66,800 kg to 69,000 kg, as set out in the HIT SRL technical cards.

Kalmar DRF 400-450 terminology

The terms below are those of the DRF 400-450 manuals, each defined in plain words with the manual that uses it, as logged by the HIT SRL technical desk.

LLMC (Longitudinal Load Moment Control)

The warning system that watches the forward stability of the machine: near the limit it sounds a buzzer, shows a warning figure and stops boom movement except retraction, according to the maintenance manual (series 1).

Overload protection (OP)

The operator's manual (series 1) name for the load handling protection whose failure prohibits operation during load handling and, according to the same manual, may let the machine exceed its stability limit.

Steering axle overload warning

A warning, without stopping any function, that the load on the steering axle is too high; lowering or extending the boom reduces the load, according to the maintenance manual (series 1).

Transport position

The position for carrying a load: boom fully retracted, load low but with forward visibility and centred sideways, and cab in the rear position, according to the operator's manual (series 1).

Service position

The state of the machine before work on it: parking brake applied, boom fully retracted and lowered to horizontal, engine off and main power off at the battery disconnector, according to the maintenance manual (series 1).

Top lift attachment

The attachment that secures containers with four twistlocks, aligned at all four corners when locking and releasing, offered with sideshift and with hydraulic levelling, according to the operator's manual (series 1).

Bottom lift attachment

The attachment with four legs for containers and trailers; the legs must be aligned and in clamping position before lifting, and without correct alignment the load lifts for only 4 seconds, according to the operator's manual (series 1).

Twistlock

One of the four locks of the top lift attachment, turned by hydraulic cylinders through linkages, with position sensors that report open or locked, according to the maintenance manual (series 1).

Alignment sensor

A sensor at each twistlock; all four must show contact before the twistlocks can be operated, and a contact pin binding in the upper position can give a false alignment, according to the manuals (series 1).

Sideshift

The sideways movement of the attachment, ±800 mm on the top lift attachments, also used to centre a side-heavy load on the machine's centre line, according to the operator's manual (series 1).

Spreading

In the type designation key, the S that stands for spreading, an adjustable top lift; the maintenance manual (series 1) lists spreading among the load handling functions.

Support jacks

In the type designation key, the final S of versions such as the DRF450-70S5XS; the maintenance manual (series 1) lists the support jacks among the auxiliary load handling functions.

Damping

The speed reduction near the end positions of the boom, controlled by position sensors, according to the maintenance manual (series 1), which pairs it with regeneration.

Regeneration

The feeding of oil from the rod side back to the piston side of the boom cylinders to increase speed, according to the maintenance manual (series 1).

Accumulator charging valve

The valve that charges the brake accumulators and, once they are charged, switches the pump flow to cooling the brakes, according to the maintenance manual (series 1).

Pressure plate

The plate on the left side of the frame, in front of the cab steps, stamped with the pressure settings of each machine, which checked pressures must match, according to the maintenance manual (series 1).

Stand-by pressure

The pressure of each hydraulic pump at idle, checked with the oil at about 50 °C; the four pumps of a standard machine run at different values, according to the maintenance manual (series 1).

Priority valve

A valve that serves the steering first: placed between the pumps and the steering valve, it supplies the steering before load handling and the other functions, according to the maintenance manual (series 1).

Progressive steering

Steering in which a quick movement of the steering wheel gives a greater steering angle per turn, as on the DRF 400-450, while the DRT 450 has linear steering, according to their operator's manuals.

Limp-home mode

A transmission mode for serious faults, shown as LH: neutral first, then only the first two gears in each direction, selected by hand, according to the maintenance manual (series 1).

Shut-down mode

A transmission mode for serious faults, shown as Sd, with permanent neutral and no oil pressure for gear selection, according to the maintenance manual (series 1).

Error code levels

The three levels of the error codes: Stop for a serious malfunction that stops work, Warning for a fault to fix soon and Information for a minor fault, according to the workshop manual (series 3, revision 2).

Function groups

The numbering 0 to 12 that arranges the maintenance manual (series 1), from the complete machine to common pneumatics, with main and two-digit levels common to the manufacturer's machines.

Control breaker

Called emergency stop switch in the workshop manual (series 3, revision 2), the control breaker of the operator's manual (series 1) stops power and control signals to the hydraulics and resets clockwise.

How to: checks from the maintenance manual

The four checks below follow the manufacturer's maintenance manual step by step, and the manual of the specific machine prevails, as recorded by the HIT SRL technical desk.

How to depressurise the hydraulic and brake systems of the DRF 400-450

Work on the hydraulics and brakes starts from the service position and a depressurised system, according to the manufacturer's maintenance manual (series 1), the HIT SRL technical desk notes.

1. Apply the parking brake, retract the boom fully, lower it to horizontal and stop the engine, according to the manufacturer's maintenance manual.
2. With the engine stopped and the start key in the operating position, operate the boom functions to release the hydraulic pressure, according to the manufacturer's maintenance manual.
3. Turn the main power off at the battery disconnector, according to the manufacturer's maintenance manual.
4. Open the relief valve of the top lift attachment, according to the manufacturer's maintenance manual.
5. Open the drain valve on the accumulator charging valve and keep it open while work is in progress, according to the manufacturer's maintenance manual.

How to check the brake accumulators of the DRF 400-450

The brake accumulator check counts brake applications with the engine stopped, according to the manufacturer's maintenance manual (series 1), as recorded at HIT SRL.

1. Run the engine at idle for about one minute, until the accumulator charging valve switches to cooling, according to the manufacturer's maintenance manual.
2. Stop the engine and leave the start key in the operating position, according to the manufacturer's maintenance manual.
3. Apply and release the brake repeatedly and count the applications until the low brake pressure warning light comes on, according to the manufacturer's maintenance manual.
4. If fewer than eight applications are possible, an accumulator is probably defective and is to be checked further, according to the manufacturer's maintenance manual.

How to check the overload system of the DRF 400-450

The overload system check belongs to every 500-hour service, according to the manufacturer's maintenance manual (series 1), as HIT SRL's technical desk reads it.

1. Lift a load about 1 m, according to the manufacturer's maintenance manual.
2. Run out the boom and check that the overload system activates, according to the manufacturer's maintenance manual.
3. Repeat the check at every 500-hour service, according to the manufacturer's maintenance manual.

How to set the bearing pre-load of the steering axle wheel hubs

The bearing pre-load of the steering axle wheel hubs is checked every 2000 hours, according to the manufacturer's maintenance manual (series 1), as set out in the HIT SRL technical cards.

1. Lubricate the spindle thread and the nut face with SAE 80W/140 oil, according to the manufacturer's maintenance manual.
2. Tighten the bearing nut to 250 Nm, according to the manufacturer's maintenance manual.
3. Turn the hub at least two revolutions and tighten the nut a further 45 degrees, according to the manufacturer's maintenance manual.
4. Repeat the tightening to 250 Nm and the further 45 degrees once more, according to the manufacturer's maintenance manual.
5. Fit the lock washer and the outer lock nut at not less than 250 Nm, according to the manufacturer's maintenance manual.

Spare parts

HIT SRL supplies genuine, OEM and aftermarket spare parts for Kalmar port equipment, including the DRF 400-450 reachstackers and the related DRT 450 and DRG 420-450, as an independent distributor that is not an official representative, affiliate or agent of the manufacturer. For availability, see the Kalmar spare parts page or send the machine model and serial number through the contact page.

Technical cards by system

HIT SRL technical cards, one fact per card, each with its source, HIT ref and fingerprint stated in the text:

• Identification and history (12 cards)
• Engine and power (11 cards)
• Transmission, axle and wheels (11 cards)
• Brakes and steering (14 cards)
• Hydraulics (8 cards)
• Boom, attachment and cab (17 cards)
• Electrical and control (8 cards)
• Maintenance intervals (22 cards)
• Safety and interlocks (23 cards)
• Troubleshooting and error codes (9 cards)
• Related models and comparisons (18 cards)