Kalmar DRF 400-450 — Electrical and control: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the 24 V system, batteries, alternators, CAN bus and diagnostics 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 voltage does the electrical system use?
24 V, from two 12 V batteries in series charged by an alternator, according to the operator's manual (series 1), as recorded at HIT SRL. In the same manual the minus terminal is connected to the chassis and the plus terminal to the battery disconnector.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-electrical-system · HIT ref KDRF-074 · fingerprint 2ee70f · see HIT ref KDRF-075, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-battery-voltage
Kalmar DRF 400-450: what battery voltage should the operating menu show?
23-25 V with the engine off and 27-29 V at maximum engine speed, 2000 rpm, according to the maintenance manual (series 1), the HIT SRL technical desk notes. The same manual keeps the electrolyte 10 mm above the cells and tops it up with distilled water only, while the operator's manual (series 1) gives deionised water and the same level.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-battery-voltage · HIT ref KDRF-075 · fingerprint 5b8735 · see HIT ref KDRF-074, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-electrical-system
Kalmar DRF 400-450: how powerful is the alternator?
2240 W with the Volvo engines, while for the Cummins engine the maintenance manual (series 1) gives 2800 W, as logged by the HIT SRL technical desk. The operator's manual (series 1) and the workshop manual (series 3, revision 1) give 2400 W for the Cummins instead, the latter at 24 V and 100 A against 28 V and 80 A for the Volvo engines, as recorded at HIT SRL. Neither Cummins rating is preferred here: each is given as printed in its manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-alternator-ratings · HIT ref KDRF-076 · fingerprint 6ee3ba · see HIT ref KDRF-074, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-electrical-system
Kalmar DRF 400-450: how are its control units connected?
By a redundant CAN bus in which each unit has two communication connections and the bus can handle the loss of one segment, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. The engine and transmission control units communicate on a separate drivetrain CAN bus, according to the same manual, as HIT SRL's technical desk reads it. The manufacturer's technical information brochure calls the nodes KCU, KDU, TCU and EDC.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-redundant-can-bus · HIT ref KDRF-077 · fingerprint 67a0a0 · see HIT ref KDRF-078, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-communication-error-codes
Kalmar DRF 400-450: what do machine codes 1 to 8 mean?
Communication errors with single control units, each code listing the functions lost, according to the workshop manual (series 3, revision 2), the HIT SRL technical desk notes. For the rear frame unit, for instance, the same manual lists rear lighting, hydraulic oil cooling, the overload system and extension, and it finds the faulty CAN segment with diagnostic menu CAN/POWER 2.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-communication-error-codes · HIT ref KDRF-078 · fingerprint 2f1603 · see HIT ref KDRF-077, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-redundant-can-bus
Kalmar DRF 400-450: what does the built-in diagnostic test show?
How each control unit reads its input signals and what output signals it sends, measured by the internal voltmeters and ammeters of the units, according to the maintenance manual (series 1), as recorded at HIT SRL. The menus of the same manual are grouped into CAN/POWER, LIGHTS, CAB, CLIMATE, HYD, ENGINE, TRANSM, BOOM, ATTACH, OP and EXTRA, as logged by the HIT SRL technical desk. Over 400 error codes and 140 diagnostic menus are counted in the manufacturer's technical information brochure.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-diagnostic-test · HIT ref KDRF-079 · fingerprint 378901 · see HIT ref KDRF-077, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-redundant-can-bus
Kalmar DRF 400-450: how is a cable harness fault traced?
With the main power off at the battery disconnector and the connector unplugged, by measuring the resistance between the connections of the component to find open or short circuits, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. For a short circuit to frame the same manual disconnects the lead at both ends, and the multimeter must then show infinite resistance, as recorded by the HIT SRL technical desk. For hoses it asks to depressurise, follow the hose from one component to the next and look for chafing, crushing and leaks, replacing the O-ring of ORFS fittings whenever one is opened, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-cable-harness-check · HIT ref KDRF-080 · fingerprint 73d636 · see HIT ref KDRF-079, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-diagnostic-test
Kalmar DRF 400-450: how is the machine started with booster batteries?
With booster batteries connected in series for 24 V, the positive terminals first and the negative terminals last, according to the operator's manual (series 1), as set out in the HIT SRL technical cards. The same manual warns of corrosive sulphuric acid and of hydrogen gas that sparks may ignite, and asks for protective caps on the terminals, the HIT SRL technical desk notes. It also forbids disconnecting the ordinary cables of the machine, and the starting procedure to follow is the one in the specific machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-battery-boosting · HIT ref KDRF-081 · fingerprint a98a3f · see HIT ref KDRF-074, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/electrical-and-control/#hit-drf-electrical-system