Kalmar DRF 400-450 — Troubleshooting and error codes: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the error code levels, code tables and fault finding 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 does troubleshooting start?
With the battery supply: the battery disconnector in position 1, a battery voltage of 22-30 V and intact fuses, according to the maintenance manual (series 1), as recorded at HIT SRL. The same manual then checks all fluid levels and reads the error codes with their lists, as logged by the HIT SRL technical desk. Without an error code it works through the function description, whose flags mark pressure check points with C and diagnostic menus with D, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-troubleshooting-order · HIT ref KDRF-127 · fingerprint 5297fe · see HIT ref KDRF-128, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-error-code-levels
Kalmar DRF 400-450: what do the STOP, WARNING and INFORMATION levels mean?
STOP is a serious malfunction that may affect operator safety or cause a breakdown, and work stops with service called at once, according to the workshop manual (series 3, revision 2), as recorded by the HIT SRL technical desk. WARNING is a fault to be fixed soon, with service contacted after the shift, and INFORMATION a minor fault such as a broken bulb, stored in the error code list, according to the same manual, as HIT SRL's technical desk reads it. The maintenance manual (series 1) gives the same three levels with their warning lights.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-error-code-levels · HIT ref KDRF-128 · fingerprint b40b2c · see HIT ref KDRF-129, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-error-code-repetition
Kalmar DRF 400-450: how often are active error codes repeated on the display?
STOP codes every third minute and WARNING codes every fifth minute while still active, according to the maintenance manual (series 1), as logged by the HIT SRL technical desk. In the same manual both appear automatically on the display, are acknowledged with the Reset key and are stored in the error code list.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-error-code-repetition · HIT ref KDRF-129 · fingerprint 44b40a · see HIT ref KDRF-128, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-error-code-levels
Kalmar DRF 400-450: how are the error codes read?
Through the service menu, holding Enter for at least two seconds, according to the maintenance manual (series 1), as recorded by the HIT SRL technical desk. The same manual forbids starting the engine with WARNING or STOP codes until the cause has been identified or repaired, as HIT SRL's technical desk reads it. It states that codes leave the list once the cause is remedied and asks always to use the code menus so that no code is missed, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-reading-error-codes · HIT ref KDRF-130 · fingerprint c38c8f · see HIT ref KDRF-131, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-error-code-formats
Kalmar DRF 400-450: how are machine, engine and transmission codes written?
Machine codes have three characters, engine codes three characters plus two after a slash to SAE J1939 SPN/FMI, and transmission codes two plus two after a slash, according to the workshop manual (series 3, revision 2), the HIT SRL technical desk notes. The same manual gives display fields for the type of error, such as temperature, solenoid valve signal, hydraulic pressure, sensor, control, bulb or open circuit, and for the affected function, as set out in the HIT SRL technical cards. It reads Volvo engines also with SAE J1587 codes, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-error-code-formats · HIT ref KDRF-131 · fingerprint f03f56 · see HIT ref KDRF-130, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-reading-error-codes
Kalmar DRF 400-450: which Volvo engine codes shut the engine off?
Low engine oil pressure, code 100/1, shuts the engine off, while high coolant temperature, 110/0, and low coolant level, 111/1, reduce power step by step and shut it off after 30 seconds, according to the maintenance manual (series 1), as recorded at HIT SRL. For these codes the same manual checks oil level, filters and valves, coolant level, a clean radiator, air in the circuit, the expansion tank cap and the sensors, as logged by the HIT SRL technical desk. The manufacturer's technical information brochure describes the same protection.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-volvo-engine-protection-codes · HIT ref KDRF-132 · fingerprint 24bf77 · see HIT ref KDRF-133, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-water-in-fuel-codes
Kalmar DRF 400-450: what does a water-in-fuel code call for?
Draining the water trap, cleaning the metal filter in the fuel feed connection on the engine and checking the fuel filter and pre-filter, for code 97/1, according to the maintenance manual (series 1), as HIT SRL's technical desk reads it. For code 97/3 the same manual adds a clogged fuel line among the causes, and neither code limits the operation of the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-water-in-fuel-codes · HIT ref KDRF-133 · fingerprint ca2240 · see HIT ref KDRF-132, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-volvo-engine-protection-codes
Kalmar DRF 400-450: what does code 144 mean?
High brake oil temperature, with reduced braking performance, according to the machine code table of the maintenance manual (series 1), as set out in the HIT SRL technical cards. The same manual checks that the cooling fan works, that the cooler is not clogged and the wiring through the diagnostic menu, and gives code 145 for an implausible value of the brake oil temperature sensor, with the same checks.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-brake-oil-temperature-code · HIT ref KDRF-134 · fingerprint 9a3c12 · see HIT ref KDRF-135, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-overload-protection-code
Kalmar DRF 400-450: what does code 150 mean?
A malfunction in the overload protection, which then does not work, while all lift functions run at reduced speed, according to the maintenance manual (series 1), as logged by the HIT SRL technical desk. The same manual looks for error codes on the overload system sensors and checks components and wiring through the OP diagnostic menus, as recorded at HIT SRL. According to the same manual, a signal error of a lift cylinder pressure sensor, such as code 134, also activates code 150, and the fault finding 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/troubleshooting/#hit-drf-overload-protection-code · HIT ref KDRF-135 · fingerprint 35bbae · see HIT ref KDRF-134, https://www.hitsrl.it/technical-resources/guides/kalmar-drf-400-450/troubleshooting/#hit-drf-brake-oil-temperature-code