Kalmar DRF 400-450 — Brakes and steering: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the brake system, accumulators, parking brake and steering of the Kalmar DRF 400-450 reachstacker, one fact per card, each with its source stated in the text. For the overall picture, see the Kalmar DRF 400-450 technical legacy guide.
Kalmar DRF 400-450: what kind of brakes does it have?
The service brakes are wet discs in oil inside the drive wheel hubs, braking the drive axle alone, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. That manual leaves the steering axle without brakes and fits the parking brake, of disc type, to the input shaft of the drive axle.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-service-and-parking-brakes · HIT ref KDRF-035 · fingerprint bb1b63 · see HIT ref KDRF-036, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-parking-brake-operation
Kalmar DRF 400-450: how does the parking brake work?
It is applied by spring force and released by hydraulic pressure, with electro-hydraulic control, according to the operator's manual (series 1), as recorded at HIT SRL. The same manual applies it automatically when the ignition voltage drops. The workshop manual (series 3, revision 2) adds that it engages if the machine loses its electrical supply or if the brake system loses pressure.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-parking-brake-operation · HIT ref KDRF-036 · fingerprint 1d0014 · see HIT ref KDRF-035, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-service-and-parking-brakes
Kalmar DRF 400-450: is the brake system separate from the working hydraulics?
Yes, the brake system has its own oil tank, pump, filter, accumulator charging valve, accumulators and oil cooler with a temperature-controlled electric fan, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. When the accumulators are charged, the same manual has the charging valve route the oil through the brake units of the drive axle to cool the brakes, as recorded by the HIT SRL technical desk. The operator's manual (series 1) also describes the brake system as separate from the working hydraulics.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-brake-system-layout · HIT ref KDRF-037 · fingerprint 2df22c · see HIT ref KDRF-038, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-brake-oil
Kalmar DRF 400-450: which oil goes into the brake system?
140 l of a UTTO, Universal Tractor Transmission Oil, meeting GM Allison C-4, John Deere J20 C or D or Caterpillar TO-4, viscosity SAE 5W30, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The same manual gives the quantity in its technical data and the oil specification in its lubricant table.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-brake-oil · HIT ref KDRF-038 · fingerprint fe7bca · see HIT ref KDRF-037, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-brake-system-layout
Kalmar DRF 400-450: what brake pump pressure do the manuals give?
Before the switch to cooling, the maintenance manual (series 1) gives 19 ±0.5 MPa, the maintenance manual (series 3) 22 MPa and the workshop manual (series 3) 20.5 ±1.0 MPa, as logged by the HIT SRL technical desk. For the cooling phase at maximum engine speed the same documents give at most 1-1.5 MPa, 0.10-0.15 MPa and 1.0-1.5 MPa, as recorded at HIT SRL. The maintenance manual (series 1) reads the pressure with the brake oil at 50 °C or more on a 0-25 MPa gauge, and the value to use is the one in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-brake-pump-pressure · HIT ref KDRF-039 · fingerprint e8bced · see HIT ref KDRF-040, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-accumulator-charging-pressures
Kalmar DRF 400-450: which pressures does the accumulator charging valve work at?
The accumulator pressure rises slowly to 20.5 ±1.0 MPa and, on repeated braking, the charging valve switches back to charging at 15.5 ±0.5 MPa, according to the workshop manual (series 3, revision 1), as recorded by the HIT SRL technical desk. The maintenance manual (series 3) prints the same two values in its accumulator charging check.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-accumulator-charging-pressures · HIT ref KDRF-040 · fingerprint 552c0a · see HIT ref KDRF-039, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-brake-pump-pressure
Kalmar DRF 400-450: how are the brake accumulators checked?
By counting brake applications with the engine stopped: at least eight must be possible before the low brake pressure warning light comes on, according to the maintenance manual (series 1), the HIT SRL technical desk notes. The same manual first idles the engine for about one minute, until the charging valve switches to cooling, then stops it with the key left in the operating position, and an earlier warning points to a probably defective accumulator, as set out in the HIT SRL technical cards. The accumulators of the brake system are pre-charged with nitrogen according to the same manual, and the check to follow is the one in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-brake-accumulator-check · HIT ref KDRF-041 · fingerprint 63fbf2 · see HIT ref KDRF-040, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-accumulator-charging-pressures
Kalmar DRF 400-450: what clearance does the brake pedal need?
Between 1 and 1.5 mm at the brake valve, adjusted with the set screw of the pedal, according to the maintenance manual (series 1), as recorded at HIT SRL. The same manual also greases the pedal hinges, using EP2 universal grease for them.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-brake-pedal-clearance · HIT ref KDRF-042 · fingerprint d599c1 · see HIT ref KDRF-035, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-service-and-parking-brakes
Kalmar DRF 400-450: how does the steering respond?
Progressively: a quick movement of the steering wheel gives a greater steering angle per turn, according to the operator's manual (series 1), as HIT SRL's technical desk reads it. The same manual steers the machine with the rear axle, through a double-acting hydraulic cylinder acting on the wheel pair.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-progressive-steering · HIT ref KDRF-043 · fingerprint 8a1292 · see HIT ref KDRF-044, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-priority-valve
Kalmar DRF 400-450: what gives the steering priority over other functions?
Oil reaches the steering first through a priority valve placed between the hydraulic pumps and the steering valve, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. Load handling and the other functions come after the steering in that manual, whose steering cylinder acts on the wheel spindles through link arms, the HIT SRL technical desk notes. The manufacturer's technical information brochure names the Orbitrol together with the priority valve.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-priority-valve · HIT ref KDRF-044 · fingerprint 4d4a0a · see HIT ref KDRF-043, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-progressive-steering
Kalmar DRF 400-450: when can the mini-wheel steering be used?
Only below 3 km/h, according to the workshop manual (series 3, revision 2), which describes the optional mini-wheel and joystick steering in the left armrest, as logged by the HIT SRL technical desk. In that manual the ratio between control and wheel deflection can be set in 31 steps, from linear to extremely progressive, and both controls switch off when the normal steering wheel is used.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-mini-wheel-steering · HIT ref KDRF-045 · fingerprint a375f9 · see HIT ref KDRF-043, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-progressive-steering
Kalmar DRF 400-450: how is the steering axle mounted?
Through a cradle attached to the frame with two bushings, one at its leading and one at its trailing edge, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. The same manual has the cradle carry two hinged wheel spindles on journalled shafts, with the wheel hubs journalled on the spindles.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-steering-axle-cradle · HIT ref KDRF-046 · fingerprint 788411 · see HIT ref KDRF-047, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-wheel-spindle-clearance
Kalmar DRF 400-450: what wheel spindle clearance is allowed on the steering axle?
At most 1.5 mm, checked every 1000 hours together with the steering axle mounting, according to the maintenance manual (series 1), the HIT SRL technical desk notes. The same manual measures the clearance with a feeler gauge between the thrust bearing and the washer, and checks the bearing pre-load of the steering axle wheel hubs every 2000 hours.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-wheel-spindle-clearance · HIT ref KDRF-047 · fingerprint 87b32d · see HIT ref KDRF-048, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-hub-bearing-pre-load
Kalmar DRF 400-450: how is the bearing nut of a steering axle wheel hub tightened?
To 250 Nm, twice, each time followed by at least two turns of the hub and a further 45 degrees, according to the maintenance manual (series 1), as recorded at HIT SRL. Before that the same manual lubricates the spindle thread and the nut face with SAE 80W/140 oil, as logged by the HIT SRL technical desk. Afterwards it fits the lock washer and the outer lock nut at not less than 250 Nm, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-hub-bearing-pre-load · HIT ref KDRF-048 · fingerprint a0601f · see HIT ref KDRF-047, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/brakes-and-steering/#hit-drf-wheel-spindle-clearance