Kalmar DRF 400-450 — Transmission, axle and wheels: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the transmission, drive axle, propeller shaft, tyres and wheels 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 is the driveline laid out?
From a six-cylinder four-stroke direct-injection diesel through a torque converter, a hydromechanical constant-mesh transmission with four forward and four reverse gears and a propeller shaft to a rigid drive axle with hub reduction on the front wheels, according to the maintenance manual (series 1), as recorded at HIT SRL. The same manual steers the rear wheels with a double-acting cylinder, the steering axle being oscillation-mounted in the frame, as logged by the HIT SRL technical desk. It fits twin wheels on the drive axle and single wheels on the steering axle, all fixed to the hubs with clamps, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-driveline-layout · HIT ref KDRF-024 · fingerprint 759e98 · see HIT ref KDRF-025, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-dana-te32000-transmission
Kalmar DRF 400-450: which transmission does it use?
A fully automatic Dana TE32000 with torque converter and four gears in each direction, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. In that manual the gears are selected by pressure modulation through electrically controlled valves, and power take-offs on the transmission drive the hydraulic pumps.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-dana-te32000-transmission · HIT ref KDRF-025 · fingerprint d12ba0 · see HIT ref KDRF-026, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-transmission-oil
Kalmar DRF 400-450: how much oil does the transmission take?
60 l at an oil change, out of 80 l in the whole Dana TE32000 transmission, of ATF Dexron III, according to the technical data of the maintenance manual (series 1), the HIT SRL technical desk notes. The same manual warns against overfilling the transmission.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-transmission-oil · HIT ref KDRF-026 · fingerprint bbba93 · see HIT ref KDRF-025, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-dana-te32000-transmission
Kalmar DRF 400-450: how does the transmission protect itself?
With a warning and reduced performance at a transmission oil temperature of 120 °C and disengagement above 125 °C, according to the maintenance manual (series 1), as recorded at HIT SRL. When a serious fault occurs, the same manual has the transmission control unit fall back on limp-home mode (LH on the display: neutral, then the first two gears in each direction, chosen by hand) or on shut-down mode (Sd: neutral held permanently, no oil pressure to select gears), as logged by the HIT SRL technical desk. The workshop manual (series 3, revision 2) repeats both modes, and the procedure for a machine in one of them is the one in its own maintenance manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-transmission-protection-modes · HIT ref KDRF-027 · fingerprint 5e3633 · see HIT ref KDRF-025, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-dana-te32000-transmission
Kalmar DRF 400-450: which drive axle does it have?
A Meritor PRC7534 or a Kessler D102, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. In both cases the axle has a differential after the input shaft and hub reductions at the wheel hubs, according to the same manual, while the operator's manual (series 1) prints the Meritor type as PRC7534W4H.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-drive-axle · HIT ref KDRF-028 · fingerprint 82759c · see HIT ref KDRF-029, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-drive-axle-oil
Kalmar DRF 400-450: how much oil does the drive axle take?
50 l in the differential of the Meritor PRC7534 or 65 l in that of the Kessler D102, plus 2 x 10 l or 2 x 12 l in the hub reductions, according to the maintenance manual (series 1), as set out in the HIT SRL technical cards. The same manual specifies API GL-5 oil, SAE 80W140 or SAE 75W90 according to the ambient temperature.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-drive-axle-oil · HIT ref KDRF-029 · fingerprint 577178 · see HIT ref KDRF-028, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-drive-axle
Kalmar DRF 400-450: what torque do the drive axle bolts take?
To 2350 Nm, according to the maintenance manual (series 1), when the drive axle attaching bolts are check-tightened, as logged by the HIT SRL technical desk. Before that check-tightening the same manual asks for the mounting of the axle to the frame to be inspected for corrosion on its structural elements.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-drive-axle-bolts · HIT ref KDRF-030 · fingerprint d3dace · see HIT ref KDRF-028, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-drive-axle
Kalmar DRF 400-450: how is the propeller shaft maintained?
Its bolts at drive axle and transmission are check-tightened to 200 Nm after 50 hours, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. After 500 hours the same manual cleans the universal joints and checks their clearance. After 1000 hours it greases the universal joints with EP2 universal grease and check-tightens the bolts to 200 Nm again, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-propeller-shaft · HIT ref KDRF-031 · fingerprint 3cf593 · see HIT ref KDRF-024, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-driveline-layout
Kalmar DRF 400-450: which tyres and pressure does it use?
The same 1.0 MPa for every version, on 18.00x25/36 tyres for the DRF420, 18.00x25/40 for the DRF400 and DRF450 and 18.00x33/36 for the DRF450 X versions, according to the maintenance manual (series 1), the HIT SRL technical desk notes. For the tyre pressure the same manual refers also to the pressure plate on the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-tyres · HIT ref KDRF-032 · fingerprint dcd2ac · see HIT ref KDRF-033, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-wheel-nuts
Kalmar DRF 400-450: how are the wheel nuts tightened?
Crosswise to 400 Nm, according to the maintenance manual (series 1), as recorded at HIT SRL. On a new machine the same manual check-tightens them every 4-5 operating hours during the first working week, up to about 40-50 hours, until they stay tight. The operator's manual (series 1) asks for the same check about 4-5 operating hours after a wheel has been replaced.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-wheel-nuts · HIT ref KDRF-033 · fingerprint 4204fc · see HIT ref KDRF-032, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-tyres
Kalmar DRF 400-450: what safety rules apply to the tyres?
Tyres are treated as pressurised containers, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. Before removal the same manual blocks the wheels on the other side of the axle and deflates the tyre, both tyres on twin wheels, and with a damaged tyre or rim a hole is drilled in the tread instead of using the valve, as recorded by the HIT SRL technical desk. The manual forbids standing in front of the tyre during inflation or deflation, repairing rims by welding and operating with a flat tyre, and the instructions to follow are those in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-tyre-safety · HIT ref KDRF-034 · fingerprint f3db39 · see HIT ref KDRF-032, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/transmission-and-driveline/#hit-drf-tyres