Kalmar DRF 400-450 — Maintenance intervals: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the service intervals, checks and lubrication 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 often is it serviced?
A service is due every 500 operating hours in the maintenance manual (series 1), as recorded at HIT SRL. That manual splits the cycle into the 500-hour service at 500, 1500 and 2500 hours and so on, the 1000-hour service at odd thousands such as 1000, 3000 and 5000 hours, and the 2000-hour service at even thousands such as 2000, 4000 and 6000 hours, as logged by the HIT SRL technical desk. The operator's manual (series 1) repeats that the service interval is every 500 operating hours.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-service-intervals · HIT ref KDRF-082 · fingerprint 6fdb23 · see HIT ref KDRF-083, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-fifty-hour-check
Kalmar DRF 400-450: what does the 50-hour check of a new machine include?
Changes of the engine oil and filter, of the transmission oil filter and of the hydraulic oil fine filter, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The same manual adds check-tightening of the propeller shaft mounting, wheel nuts and hose connections, adjustment of the spreader chain tension and a check for active error codes, the HIT SRL technical desk notes. Its full list also covers fluid levels, leaks, brakes, batteries and the locking of the mechanical sliding cab, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-fifty-hour-check · HIT ref KDRF-083 · fingerprint fe17d7 · see HIT ref KDRF-082, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-service-intervals
Kalmar DRF 400-450: how often are the lower glide surfaces of the inner boom lubricated on a new machine?
Every 250 hours up to 1000 operating hours and then according to the lubrication chart, in the 50-hour check of the maintenance manual (series 3), as recorded by the HIT SRL technical desk. The maintenance manual (series 1) does not have this entry in its own 50-hour check, and both schedules stay here as printed.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-inner-boom-glide-surfaces · HIT ref KDRF-084 · fingerprint 42f888 · see HIT ref KDRF-083, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-fifty-hour-check
Kalmar DRF 400-450: how often are the engine oil and filter changed?
Engine oil and filter go at every 500-hour service of the maintenance manual (series 1), the HIT SRL technical desk notes. The workshop manual (series 3, revision 1) bases the oil change interval on a fuel sulphur content not above 0.5 % and always changes the oil filters together with the oil. The operator's manual (series 1) adds a first oil and filter change after 50 operating hours.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-engine-oil-change · HIT ref KDRF-085 · fingerprint 423722 · see HIT ref KDRF-086, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-running-in
Kalmar DRF 400-450: how long is the run-in period?
10 operating hours, during which the engine is not run at full load, according to the operator's manual (series 1), as recorded at HIT SRL. The same manual changes the engine oil and filter for the first time after 50 operating hours and then every 500 hours.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-running-in · HIT ref KDRF-086 · fingerprint b74b35 · see HIT ref KDRF-085, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-engine-oil-change
Kalmar DRF 400-450: how often are the fuel filters changed?
At every 500-hour service, fuel filter and pre-filter together, with the condensation water drained from the pre-filter at the same time, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. Every 50 hours the maintenance manual (series 3) has the pre-filter drained, and it brings both filter changes forward when an error code appears, as recorded by the HIT SRL technical desk. Both manuals are quoted here as printed.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-fuel-filters · HIT ref KDRF-087 · fingerprint de62ee · see HIT ref KDRF-085, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-engine-oil-change
Kalmar DRF 400-450: how often is the coolant filter replaced?
Every 1000 hours with the Volvo engine and every 500 hours with the Cummins engine, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The maintenance manual (series 3) gives the same two intervals in its own schedule.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-coolant-filter · HIT ref KDRF-088 · fingerprint 76aa8b · see HIT ref KDRF-089, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-coolant-change
Kalmar DRF 400-450: when is the coolant changed?
After 5000 hours or every other year, according to the maintenance manual (series 1), as logged by the HIT SRL technical desk. The same manual checks the coolant level and its freezing point at every service, and the maintenance manual (series 3) prints the same change interval.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-coolant-change · HIT ref KDRF-089 · fingerprint 56ed7f · see HIT ref KDRF-088, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-coolant-filter
Kalmar DRF 400-450: when are the engine air filter cartridges changed?
The main cartridge at indication, after a check of its indicator at every service, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. The same manual changes the safety cartridge every other time the main cartridge is changed. The maintenance manual (series 3) gives the same rule.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-air-filter · HIT ref KDRF-090 · fingerprint 2a4476 · see HIT ref KDRF-082, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-service-intervals
Kalmar DRF 400-450: when is the valve clearance checked?
At the 2000-hour service, on the Volvo engine only, according to the maintenance manual (series 1), the HIT SRL technical desk notes. The same manual leaves the work to a service shop authorised by Volvo Penta, and the maintenance manual (series 3) gives the same rule.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-valve-clearance · HIT ref KDRF-091 · fingerprint 57dc2c · see HIT ref KDRF-082, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-service-intervals
Kalmar DRF 400-450: how often are the transmission oil and filter changed?
The transmission oil and its filter are changed every 1000 hours under the maintenance manual (series 1), as recorded at HIT SRL. The same manual also recommends calibrating the transmission every 1000 hours, and the operator's manual (series 1) changes the transmission filter for the first time at the 50-hour check and the oil after 1000 hours.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-transmission-oil-change · HIT ref KDRF-092 · fingerprint 3972d4 · see HIT ref KDRF-093, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-drive-axle-oil-change
Kalmar DRF 400-450: how often is the drive axle oil changed?
Every 1000 hours, in the differential and in the hub reductions, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. The same manual inspects the drive axle mounting at the same interval and describes the oil change procedure in its driveline group.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-drive-axle-oil-change · HIT ref KDRF-093 · fingerprint 0394ae · see HIT ref KDRF-092, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-transmission-oil-change
Kalmar DRF 400-450: what brake maintenance does the 500-hour service include?
The brake oil filter is replaced and the brake accumulators and parking brake pads are checked, the pads being changed when needed, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The same manual changes the brake system oil and the breather filter of the brake oil tank every 2000 hours, the HIT SRL technical desk notes. It cleans the brake oil cooler when needed, without a high-pressure washer, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-brake-filters-and-oil · HIT ref KDRF-094 · fingerprint 6086de · see HIT ref KDRF-082, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-service-intervals
Kalmar DRF 400-450: how often are tyres, wheel nuts and rims checked?
Tyres are checked for damage, wear and pressure at every service and the wheel nuts are check-tightened every 1000 hours, according to the maintenance manual (series 1), as logged by the HIT SRL technical desk. The maintenance manual (series 3) adds a rim check to its 1000-hour and 2000-hour services, to be done at a tyre change or once a year.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-tyre-and-rim-checks · HIT ref KDRF-095 · fingerprint aecc24 · see HIT ref KDRF-082, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-service-intervals
Kalmar DRF 400-450: how often is the overload system checked?
The overload system is checked at each 500-hour service listed in the maintenance manual (series 1), as recorded by the HIT SRL technical desk. The same manual lifts a load about 1 m and runs out the boom to check that the system activates, and on a given machine the overload test follows the manual issued for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-overload-system-check · HIT ref KDRF-096 · fingerprint 9c4aa3 · see HIT ref KDRF-097, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-weight-indicator
Kalmar DRF 400-450: how is the optional weight indicator checked?
Without load it may deviate by at most 0.5 tonnes, a check placed in the 1000-hour column of the service table of the maintenance manual (series 1), the HIT SRL technical desk notes. With a known weight the same manual accepts ±0.5 t, and the maintenance manual (series 3) has the same entry.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-weight-indicator · HIT ref KDRF-097 · fingerprint 00a57a · see HIT ref KDRF-096, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-overload-system-check
Kalmar DRF 400-450: how often is the cab fresh air filter replaced?
Depending on the outside environment and at the latest every 500 operating hours, according to the maintenance manual (series 1), as recorded at HIT SRL. The maintenance manual (series 3) gives the same interval in its frame, body, cab and accessories group.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-cab-fresh-air-filter · HIT ref KDRF-098 · fingerprint d3a84a · see HIT ref KDRF-082, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-service-intervals
Kalmar DRF 400-450: what is lubricated at the 500-hour service?
Only the steering axle wheel hubs and spindles, the link arms and the brake pedal, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. To relieve the bearings the same manual raises each steering wheel with a 40-tonne jack, without lifting the wheel clear of the ground, and greases the upper and lower spindle bearings separately.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-steering-axle-lubrication · HIT ref KDRF-099 · fingerprint fb9e70 · see HIT ref KDRF-100, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-grease-and-glide-paste
Kalmar DRF 400-450: which grease does it use?
An EP universal grease to NLGI grade 2 with 3-5 % molybdenum sulphide for all lubrication points except the glide plates, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The same manual treats the glide plates with Gleitmo 805 lubrication paste or a paste of the same grade.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-grease-and-glide-paste · HIT ref KDRF-100 · fingerprint ebc009 · see HIT ref KDRF-099, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-steering-axle-lubrication
Kalmar DRF 400-450: is the sliding cab locking part of the maintenance schedule?
In the maintenance manual (series 3) it is, with 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) leaves it out of the schedule and states that the lock catches of the sliding cab must be intact and checked regularly, as recorded at HIT SRL. How often to inspect the lock catches on a given machine is set by the machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-sliding-cab-lock-check · HIT ref KDRF-101 · fingerprint 7620ce · see HIT ref KDRF-082, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-service-intervals
Kalmar DRF 400-450: what does the daily inspection cover?
A walk-round check for leaks, loose wheel studs, rim and tyre damage and tyre pressure, then fluid levels, the air filter indicator and the fuel pre-filter, according to the operator's manual (series 1), as recorded by the HIT SRL technical desk. The same manual then starts the machine to test instruments and lights and drives it slowly to test brakes with at least three test brakings, steering, all gears and the attachment indicators, as HIT SRL's technical desk reads it. It asks for this inspection before each work shift, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-daily-inspection · HIT ref KDRF-102 · fingerprint 0b82f9 · see HIT ref KDRF-103, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-twistlock-daily-test
Kalmar DRF 400-450: how are the twistlocks tested every day?
By lifting an empty container until the alignment light goes out, after which the twistlocks must not be possible to release, according to the operator's manual (series 1), the HIT SRL technical desk notes. In the same daily inspection the twistlock contact pins must move freely, and the manual notes that a pin binding in the upper position can show alignment with the frame not against the container, as set out in the HIT SRL technical cards. Each day the twistlock test is done as the manual that comes with the machine describes it.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-twistlock-daily-test · HIT ref KDRF-103 · fingerprint c66fbe · see HIT ref KDRF-102, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/maintenance-intervals/#hit-drf-daily-inspection