Kalmar DRF 400-450 — Safety and interlocks: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the overload warning, stability, emergency equipment, towing and access 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: who may operate it, and when is operation prohibited?
Only specially trained operators with the management's permission, according to the operator's manual (series 1), as set out in the HIT SRL technical cards. The same manual prohibits operation if safety and warning equipment does not work, with defective brakes, steering or lifting equipment, after repairs or modifications without the supervisor's permission, with tyres not approved by the manufacturer, or with the overload protection system not working during load handling, the HIT SRL technical desk notes. The full list of prohibitions for a given machine 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/safety-and-interlocks/#hit-drf-operator-requirements · HIT ref KDRF-104 · fingerprint cc42ee · see HIT ref KDRF-109, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-load-capacity-limits
Kalmar DRF 400-450: what is the wind limit for lifting loads?
Up to 12.2 m/s: the operator's manual (series 1) warns to avoid lifting loads when the wind exceeds that speed, as recorded by the HIT SRL technical desk. The same manual designs the machine for outdoor temperatures of -40 to 40 °C and a relative humidity of 10 to 90 %, and for higher wind speeds it refers to the manufacturer, as HIT SRL's technical desk reads it. On site, the wind limit to respect is the figure in the specific machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-environment-and-wind · HIT ref KDRF-105 · fingerprint 686353 · see HIT ref KDRF-109, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-load-capacity-limits
Kalmar DRF 400-450: how is a load carried?
Low, centred and with the boom fully retracted: the operator's manual (series 1) calls this the transport position, with the load lifted only enough for forward visibility and the cab at the rear, as HIT SRL's technical desk reads it. On grades the same manual keeps the load facing uphill, never lets the machine turn across a grade and forbids anyone to stand under a raised load, as recorded by the HIT SRL technical desk. Rules for a given terminal and machine come from the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-transport-position · HIT ref KDRF-106 · fingerprint f5ea4a · see HIT ref KDRF-107, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-retract-before-lowering
Kalmar DRF 400-450: which boom movement comes first when a load is lowered?
The boom is always retracted before it is lowered, according to the operator's manual (series 1), as set out in the HIT SRL technical cards. The same manual warns that load handling at long boom extension carries a risk of tipping, and the maintenance manual (series 1) repeats the rule for all load handling. The sequence to follow on site is set by the specific machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-retract-before-lowering · HIT ref KDRF-107 · fingerprint 950eec · see HIT ref KDRF-106, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-transport-position
Kalmar DRF 400-450: what should the operator do if the machine tips over?
Stay in the cab, holding on to the steering wheel, and not jump out until the machine has stopped moving, according to the operator's manual (series 1), as logged by the HIT SRL technical desk. The same manual repeats the instruction on a warning plate, and the behaviour to adopt 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/safety-and-interlocks/#hit-drf-roll-over · HIT ref KDRF-108 · fingerprint ce3a4c · see HIT ref KDRF-106, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-transport-position
Kalmar DRF 400-450: what limits its load capacity?
The number of containers in height and the size and centre of gravity of the load, with the limits on the marking plate and load diagram never to be exceeded, according to the operator's manual (series 1), as recorded by the HIT SRL technical desk. The same manual warns that the stability limit may be exceeded if the overload protection system is not working, and asks to lower a side-heavy load and centre it with the sideshift, as HIT SRL's technical desk reads it. The capacity to respect is the one on the plate and in the manual that comes with the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-load-capacity-limits · HIT ref KDRF-109 · fingerprint 1ee080 · see HIT ref KDRF-110, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-llmc-warning-system
Kalmar DRF 400-450: what does the LLMC warning system do?
It warns near the forward stability limit and interrupts boom movement, after which only retraction is possible until the warning stops, according to the maintenance manual (series 1), the HIT SRL technical desk notes. The same manual describes three versions, mechanical, mechanical with analogue sensors and electrical with pressure sensors in the lift cylinders, and states that the LLMC must always be functional, as set out in the HIT SRL technical cards. It does not control sideways stability or stability while driving and ignores sloping ground, according to the same manual, so the limits of a given machine are those of its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-llmc-warning-system · HIT ref KDRF-110 · fingerprint e26106 · see HIT ref KDRF-111, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-steering-axle-overload
Kalmar DRF 400-450: what happens when the steering axle is overloaded?
A warning only, with no function interrupted, according to the maintenance manual (series 1), as recorded at HIT SRL. With the mechanical systems the same manual gives the warning when the boom angle exceeds 35 degrees with less than 1.5 m of extension above 10 km/h, while the electrical system also limits speed, and lowering or extending the boom reduces the load, as logged by the HIT SRL technical desk. The operator's manual (series 1) speaks of reduced lateral stability and asks to move the load forward, lower the attachment and slow down, and the reaction to adopt is the one in the manual of each machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-steering-axle-overload · HIT ref KDRF-111 · fingerprint 28827d · see HIT ref KDRF-110, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-llmc-warning-system
Kalmar DRF 400-450: what do the height limitation and the LC limitation do?
The optional height limitation stops lifting at a preset height, adjustable to the customer's needs, and the LC limitation keeps the load from being lifted over the cab, according to the operator's manual (series 1), as HIT SRL's technical desk reads it. In the same manual the LC limitation is standard with the vertically adjustable cab and starts a synchronised lift, lowering the boom or extending it, when the load reaches a certain distance from the machine, as recorded by the HIT SRL technical desk. The settings of a given machine are those in the manual issued for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-height-and-lc-limitation · HIT ref KDRF-112 · fingerprint d0f346 · see HIT ref KDRF-110, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-llmc-warning-system
Kalmar DRF 400-450: how are the hydraulics stopped in an emergency?
By pressing the control breaker for hydraulics at once, which cuts all power supply and control signals to the hydraulics, according to the operator's manual (series 1), as set out in the HIT SRL technical cards. The same manual resets it by turning it clockwise, and the workshop manual (series 3) calls it the emergency stop switch and tests it by lifting, pressing it and checking that lifting stops, the HIT SRL technical desk notes. The emergency controls of a given machine are those of the specific machine's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-emergency-stop · HIT ref KDRF-113 · fingerprint e5d366 · see HIT ref KDRF-114, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-battery-disconnector
Kalmar DRF 400-450: can the battery disconnector be used as an emergency stop?
No: the workshop manual (series 3, revision 2) states that the battery disconnect switch must not be used for emergency stopping, as logged by the HIT SRL technical desk. The same manual forbids turning it off with the engine running and stops the engine only with the ignition, and the operator's manual (series 1) gives the same prohibition. Emergency stopping on a given machine follows the machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-battery-disconnector · HIT ref KDRF-114 · fingerprint 04f8b0 · see HIT ref KDRF-113, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-emergency-stop
Kalmar DRF 400-450: where are the emergency exits of the cab?
The right door and, if the doors are blocked by the lift cylinders, the rear window, according to the operator's manual (series 1), as recorded by the HIT SRL technical desk. The same manual opens the rear window by removing the split pin and handle on each side, while the vertically adjustable cab has a hammer to break the window instead, as HIT SRL's technical desk reads it. The exits of a given cab are those shown in the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-emergency-exits · HIT ref KDRF-115 · fingerprint 1f200c · see HIT ref KDRF-113, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-emergency-stop
Kalmar DRF 400-450: how is the boom lowered if the hydraulics stop?
Two people, one on each side, open the solenoid valves of the two lift cylinders by hand at the same time, according to the operator's manual (series 1), the HIT SRL technical desk notes. While servo pressure and battery voltage remain, the same manual lowers the boom with the control lever, and in manual lowering the valves are adjusted continuously so that the servo pressure is not lost, as set out in the HIT SRL technical cards. The manual warns that manual lowering carries a risk of crushing and tipping and is to be avoided or done very carefully, following the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-emergency-boom-lowering · HIT ref KDRF-116 · fingerprint 5b1e1d · see HIT ref KDRF-113, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-emergency-stop
Kalmar DRF 400-450: how may it be towed?
Only over short distances, with the engine running if possible, according to the operator's manual (series 1), as recorded at HIT SRL. Without hydraulic pressure the same manual warns that the machine cannot be steered and the brakes do not work, and it requires a towing vehicle heavier than the machine, a tow bar if the engine cannot run and the propeller shaft disconnected from the transmission, as logged by the HIT SRL technical desk. It applies the parking brake and blocks the wheels before and after towing, forbids starting the engine by towing, and the towing procedure of a given machine is the one in its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-towing · HIT ref KDRF-117 · fingerprint 08e712 · see HIT ref KDRF-118, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-parking-brake-release
Kalmar DRF 400-450: how is the parking brake released without accumulator pressure?
By hand, with the wheels blocked: the split pin is removed and the nut screwed in until the pads release, according to the operator's manual (series 1), as HIT SRL's technical desk reads it. Afterwards the same manual screws the nut back and refits the split pin to restore the parking brake, and it warns that the spring force is high and parts may detach if the brake is opened incorrectly, as recorded by the HIT SRL technical desk. The release procedure is the one in the manual that comes with the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-parking-brake-release · HIT ref KDRF-118 · fingerprint e0a571 · see HIT ref KDRF-117, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-towing
Kalmar DRF 400-450: can the parking brake be used as an emergency brake?
Yes, but the pads must then be checked as soon as possible and changed if needed, according to the operator's manual (series 1), as set out in the HIT SRL technical cards. The same manual forbids leaving the operator's seat without applying the parking brake and sounds a signal if the operator gets up without it, the HIT SRL technical desk notes. After emergency braking the checks to make are those in the manual issued for the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-parking-brake-as-emergency-brake · HIT ref KDRF-119 · fingerprint 3db581 · see HIT ref KDRF-118, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-parking-brake-release
Kalmar DRF 400-450: how is the machine lifted?
With two slings in the front lifting eyes on the frame and two in the rear lifting eyes at the boom mounting, according to the operator's manual (series 1), as logged by the HIT SRL technical desk. The same manual arranges the lifting device so that the lifting point passes through the centre of gravity of the machine and stresses the strict requirements on lifting equipment, as recorded at HIT SRL. The lifting points of a given machine are those in its own operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-lifting-the-machine · HIT ref KDRF-120 · fingerprint afad87 · see HIT ref KDRF-117, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-towing
Kalmar DRF 400-450: what rules apply to access and passengers?
Steps and handles are used facing the machine, without ever jumping down, according to the operator's manual (series 1), as recorded by the HIT SRL technical desk. The same manual keeps the cab doors closed during operation and allows passengers only in the cab, on a permanently installed passenger seat. Access rules for a given machine are those of the specific machine's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-access-and-passengers · HIT ref KDRF-121 · fingerprint 1f2a59 · see HIT ref KDRF-122, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-sliding-cab
Kalmar DRF 400-450: where must the sliding cab be when operating?
In its rearmost position, according to the operator's manual (series 1), the HIT SRL technical desk notes. The same manual locks the manual version there with the lock pins secured, while the hydraulic version may be placed anywhere during stationary load handling, its locking being automatic, and the maintenance manual (series 1) never moves the machine with the cab unlocked, as set out in the HIT SRL technical cards. The cab positions allowed on a given machine are those in the manual of the individual machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-sliding-cab · HIT ref KDRF-122 · fingerprint e87c91 · see HIT ref KDRF-123, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-vertically-adjustable-cab
Kalmar DRF 400-450: what limits apply with the vertically adjustable cab raised?
Speed is limited to second gear and 10 km/h, according to the operator's manual (series 1), as recorded at HIT SRL. Before anyone enters under a raised cab the same manual secures it with the lock lugs, and a cab stuck in the raised position is lowered with an emergency lowering valve at the front of the engine compartment, as logged by the HIT SRL technical desk. The doors stay closed with their safety chains and the seat belt is worn, according to the same manual, whose limits apply only together with the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-vertically-adjustable-cab · HIT ref KDRF-123 · fingerprint d515b9 · see HIT ref KDRF-122, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-sliding-cab
Kalmar DRF 400-450: what should the operator do if the machine touches an overhead power line?
Sit down in the seat, call for help and remain in the cab until help arrives, according to the operator's manual (series 1), as HIT SRL's technical desk reads it. The same manual asks for extreme care in all work near overhead high voltage lines, keeping in mind the reach of boom and attachment, and the 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/safety-and-interlocks/#hit-drf-overhead-power-lines · HIT ref KDRF-124 · fingerprint d32970 · see HIT ref KDRF-106, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-transport-position
Kalmar DRF 400-450: which fire extinguisher does it need?
A type ABE extinguisher to EN 3 parts 1, 2, 4 and 5, if one is fitted, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The operator's manual (series 1) leaves approved fire-fighting equipment to the owner, and the workshop manual (series 3, revision 2) places the extinguisher at the entrance on the left frame beam, the HIT SRL technical desk notes. The equipment required on a given machine is set by the machine's own manual and by local regulations.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-fire-extinguisher · HIT ref KDRF-125 · fingerprint ad9c22 · see HIT ref KDRF-115, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-emergency-exits
Kalmar DRF 400-450: which parts does the workshop manual want replaced only with original spare parts?
Parts that it lists for safety reasons, among them the brake valve, drive axle, steering valves and cylinder, steering axle and rims, according to the workshop manual (series 3, revision 2), as logged by the HIT SRL technical desk. According to the same manual, the list also includes the lift boom and boom nose extension, the lift and extension cylinders with their valve blocks, the rotation motor unit, tilt cylinder, twistlocks and lifting shoes, emergency switch, frame, accumulators and all control units, as recorded at HIT SRL. Which parts a given machine needs in original form is stated in the machine's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-original-spare-parts · HIT ref KDRF-126 · fingerprint 0af78b · see HIT ref KDRF-104, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/safety-and-interlocks/#hit-drf-operator-requirements