Kalmar DRF 400-450 — Hydraulics: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the hydraulic pumps, pressures, oil and filters 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: how many hydraulic pumps does it have?
Six, in two pump banks on the power take-off of the transmission, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. Its working hydraulics and steering draw on four variable-displacement axial piston pumps coupled two by two, while one fixed gear pump serves the brakes and another fixed pump moves the hydraulic oil through cooler and filter, according to the same manual, the HIT SRL technical desk notes. Two vane pumps for brakes and cooling, next to four load-sensing pumps, appear instead in the manufacturer's technical information brochure, and both descriptions stay here as printed.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-hydraulic-pumps · HIT ref KDRF-049 · fingerprint d484f6 · see HIT ref KDRF-050, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-pump-alternatives
Kalmar DRF 400-450: which hydraulic pump alternatives does the workshop manual give?
Two alternatives for the working hydraulics: Rexroth, with four axial piston pumps, and Sauer-Danfoss, with two, according to the workshop manual (series 3, revision 2), as recorded by the HIT SRL technical desk. The same manual gives each alternative its own set of stand-by pressures for the pumps.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-pump-alternatives · HIT ref KDRF-050 · fingerprint e7846d · see HIT ref KDRF-049, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-hydraulic-pumps
Kalmar DRF 400-450: what are the stand-by pressures of the hydraulic pumps?
1.8, 2.1, 2.9 and 3.1 MPa for pumps 1 to 4 of a standard machine, at idle with the oil at about 50 °C, according to the maintenance manual (series 1), the HIT SRL technical desk notes. The same manual requires the pressure difference between the pumps always to be kept, as set out in the HIT SRL technical cards. The maximum pressure, the same for all pumps and read by forcing the extension to its end stop at about 1100 rpm, must match the pressure plate, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-stand-by-pressures · HIT ref KDRF-051 · fingerprint 76c560 · see HIT ref KDRF-052, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-sauer-danfoss-pressures
Kalmar DRF 400-450: what stand-by pressures apply to the Sauer-Danfoss pumps?
2.9 MPa for pump 1 and 3.0 MPa for pump 2, according to the workshop manual (series 3, revision 2), as recorded at HIT SRL. In the same manual the maximum pressure is the same for both pumps and has to match the pressure plate of the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-sauer-danfoss-pressures · HIT ref KDRF-052 · fingerprint 89c7c7 · see HIT ref KDRF-051, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-stand-by-pressures
Kalmar DRF 400-450: where are the pressure settings of a machine given?
On a pressure plate on the left side of the frame, in front of the cab steps, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. According to the same manual, the plate carries the settings of each machine: servo accumulator gas pressure, control pressure, brake accumulator oil and gas pressures, feed pressures of the attachment and lift leg control valves, maximum brake pressure, lift and extension servo pressure and maximum pump pressure, as recorded by the HIT SRL technical desk. Pressures checked on the machine must match that plate, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-pressure-plate · HIT ref KDRF-053 · fingerprint 44c4d6 · see HIT ref KDRF-051, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-stand-by-pressures
Kalmar DRF 400-450: which hydraulic oil does it take, and how much?
Oil to DIN 51524 Part 3 HVLP in ISO VG 68 or ISO VG 46, or HV ISO VG 32, chosen by ambient temperature, with 600 l in the tank and 940 l in the whole system, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The same manual uses this oil also for the brake of the attachment hydraulic motor.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-hydraulic-oil · HIT ref KDRF-054 · fingerprint 131e4e · see HIT ref KDRF-055, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-hydraulic-filters
Kalmar DRF 400-450: how often are the hydraulic filters changed?
The fine filter every 500 hours and the hydraulic oil filter and the high-pressure filter every 1000 hours, with an oil change every 2000 hours, according to the maintenance manual (series 1), as logged by the HIT SRL technical desk. The same manual checks the tank breather filter at the 500-hour service, changes it at indication and replaces it at the 1000-hour and 2000-hour services, as recorded at HIT SRL. It also replaces the servo filter of the load handling hydraulics at every 500-hour service, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-hydraulic-filters · HIT ref KDRF-055 · fingerprint 1f4514 · see HIT ref KDRF-054, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-hydraulic-oil
Kalmar DRF 400-450: how are the hydraulic and brake systems depressurised before work?
From the service position, by operating the boom functions with the key in the operating position, opening the top lift relief valve and opening the drain valve on the accumulator charging valve, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. The service position of the same manual means parking brake applied, boom fully retracted and lowered to horizontal, engine off and main power off at the battery disconnector, as HIT SRL's technical desk reads it. The drain valve stays open while work is in progress, and the procedure 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/hydraulics/#hit-drf-depressurising · HIT ref KDRF-056 · fingerprint b750d6 · see HIT ref KDRF-053, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/hydraulics/#hit-drf-pressure-plate