DRF 400 450 instruction 5GB

DRF 400-450

Publ. no IDRF01.05GB



1

1

Foreword ........................................................................................... 3
1.1
About the Operator’s manual ...................................................... 3
1.2
About the documentation kit ....................................................... 6
1.3
Inspection and maintenance ....................................................... 7
2 Safety ................................................................................................. 9
2.1
Safety and emergency equipment ............................................. 11
2.2
CE-marking ................................................................................. 13
2.3
ANSI/ASME-marking .................................................................. 14
2.4
Keep in mind .............................................................................. 15
3 Overview.......................................................................................... 23
3.1
Description DRF 400-450 ........................................................... 23
3.2
Plates .......................................................................................... 29

4 Instruments and controls................................................................ 37
4.1
Warning and indicator lights ...................................................... 42
4.2
Instruments ................................................................................ 46
4.3
Ignition ........................................................................................ 47
4.4
Switches ..................................................................................... 48
4.5
Gear selector and
multi-function lever .................................................................... 55
4.6
Control lever ............................................................................... 57
4.7
Pedals ......................................................................................... 60
4.8
Steering wheel ........................................................................... 61
4.9
Operator’s seat .......................................................................... 64
4.10 Heating/Air conditioning ............................................................ 67
4.11 Control and monitoring system ................................................. 70
5 Handling........................................................................................... 81
5.1
Running-in .................................................................................. 83
5.2
Daily inspection .......................................................................... 84
5.3
Handling error codes .................................................................. 85
5.4

Operating .................................................................................. 127
5.5
Load handling ........................................................................... 138
6 Inspection and maintenance ........................................................ 157
6.1
Daily inspection ........................................................................ 158
6.2
Maintenance ............................................................................ 161
6.3
Service ...................................................................................... 186
7 Transport of machine .................................................................... 187
7.1
Towing ...................................................................................... 188
7.2
Lifting and transporting machine ............................................. 190
7.3
Service position ........................................................................ 204
7.4
Long-term storage ................................................................... 205
8 Environment and standards ......................................................... 207
9 Specifications ................................................................................ 209
10 Terminology ................................................................................... 217


2


1 Foreword

3

1 Foreword

mm mm mm mm

1 Foreword
1.1

page
–

About the Operator’s
manual

General
Thank you for choosing Kalmar Industries as your machine supplier.
We hope that we’ll meet your expectations.
This Operator’s manual contains information that you must keep in
mind for safe handling and optimal use of your new machine.

–

Purpose of the Operator’s manual
This Operator’s manual applies to machine DRF 400-450.
The Operator’s manual describes how the machine should be operated and maintained in a correct manner.

–

Storage
The Operator’s manual should always be kept in the machine.

–

About the machine version
The information in this Operator’s manual corresponds to the machine’s design and appearance at the time of delivery from Kalmar Industries. Due to customer adaptations, there may be variations and/
or deviations.
Kalmar Industries reserves the right to modify specifications and
equipment without prior notice. All information and data in the
manual are valid at the time of publication.

–

Copyright
Kalmar Industries AB
Duplication of the content in this manual, in whole or in part, is
strictly prohibited without written permission from
Kalmar Industries AB.
Duplication by any means, such as copying, printing, etc., is strictly
prohibited.

–

Manufacturer
This machine is manufactured by Kalmar Industries AB,
Torggatan 3, SE-340 10 Lidhult, Sweden.

Operator’s Manual DRF 400-450

IDRF01.05GB

4

1 Foreword – 1.1.1 Reading Instructions

1.1.1

Reading Instructions

page
–

Warning information
This Operator’s manual contains warnings that involve your safety.
The warnings provide information on potential dangers that, if not
heeded, could lead to personal injury or product damage.

D AN GE R
Situation that could lead to severe personal injury or
death if regulation is not followed.

W AR N IN G
Situation that could lead to personal injury if regulation is not followed.

CAUTION
Situation that could lead to product damage if regulation is not followed.

–

Important information

Important information is denoted with NOTE and is intended to facilitate the work process, handling or to increase understanding of the
information.

NOTE
Important information not related to safety.

IDRF01.05GB

Operator’s Manual DRF 400-450


1 Foreword – 1.1.1 Reading Instructions

5

Read operator’s manual

–

000262

The symbol to the left is used in certain cases on the machine and
refers to important information in the Operator’s manual.

Read the operator’s manual

Read maintenance manual
001128

–

Read the maintenance manual

Optional equipment
000264

–

Indicates optional equipment

The symbol to the left is used in certain cases on the machine and
refers to important information in the maintenance manual.

There is a wide range of optional equipment for the machine. Each
description of optional equipment in the Operator’s manual is
marked with a symbol and contains an explanatory text. The symbol
is highly visible and is placed next to the text and figure item in
question.
See the machine card for complete specifications of the machine’s
product alternatives and optional equipment.

Operator’s Manual DRF 400-450

IDRF01.05GB


6

1 Foreword – 1.2 About the documentation kit

1.2
page
–

About the documentation
kit

The documentation kit
The following documentation is supplied with the machine:
•

Operator’s manual DRF 400-450 (in cab with machine)

•

Maintenance manual DRF 400-450

•

Spare parts catalogue with machine card

There is supplementary documentation that can be ordered for the
machine. The following is included:
•

Workshop manual DRF 400-450 and supplier documentation
for engine, transmission and drive axle.

All documentation can be ordered from Kalmar Industries.
–

Ordering of documentation
Copies of the Operator’s manual and maintenance manual can be
ordered from Kalmar Industries:
Kalmar Industries AB, SE-341 81 Ljungby, Sweden.
Always indicate publication number when ordering.

IDRF01.05GB

Operator’s Manual DRF 400-450


1 Foreword – 1.3 Inspection and maintenance

1.3
page
–

7

Inspection and maintenance

General
For satisfactory function of the machine to the lowest cost, maintenance must be performed correctly. Intervals for care and lubrication refer to normal environment and operating conditions.
Maintenance work described in this Operator’s manual can be performed by the operator, see chapter 6 Inspection and maintenance.
This section describes the running checks and actions that the operator should perform in connection with work shifts.

–

Maintenance

For other maintenance not included in this Operator’s manual
(service and repairs), contact an authorized brand name workshop.

Operator’s Manual DRF 400-450

IDRF01.05GB


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1 Foreword – 1.3 Inspection and maintenance

Operator’s Manual DRF 400-450


2 Safety

9

2 Safety

2 Safety

mm mm mm mm

General

page

–

Safety rules are intended to reduce the risk of personal injuries as
well as damage to the load or other property.

Important to read the Operator’s
manual

000262

–

Incorrect handling can lead to personal injuries and damages to product and/or property. Therefore, read the Operator’s manual very
thoroughly before starting to use the machine. The Operator’s manual contains important information about your Kalmar machine,
handling the machine, safety during operation, and daily maintenance of the machine. You’ll also find a lot of valuable information that
will make your work easier.
The Operator’s manual should always be kept in the machine. If it’s
lost, replace it immediately with a new Operator’s manual.

NOTE
Never use a machine that doesn’t have an Operator’s manual.
Ask your foreman or supervisor if there’s anything in the text you do
not understand or if you feel information is missing in any area.
–

Intended use
•

The machine may only be used for the purpose for which it is designed and adapted, that is, to lift and transport goods (the
weight of which is not to exceed the machine’s max. allowed

load capacity). If it’s used in another way or in potentially
dangerous environments (for example, explosive environment,
area with dust containing asbestos), special safety regulations
must be followed and the machine must be equipped for such
operation.

•

The machine may not be modified or rebuilt so that its function
or performance is altered, for example, areas that affect lift capacity, visibility conditions from the cab, protective equipment,
brakes, steering or lift equipment, without specific permission
from Kalmar Industries. When modifications/rebuilds authorized
by Kalmar Industries have been performed, the affected machine plates and documentation shall be adapted so that they are
valid for the modification/rebuild.
The machine may only be modified or rebuilt if Kalmar Industries
accepts product responsibility (without any other manufacturer
assuming the product responsibility). Modifications and rebuilds
may only be performed if there is knowledge for implementing
and testing modifications and rebuilds. Modifications and re-

Operator’s Manual DRF 400-450

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10

2 Safety

builds shall be documented (date and actions) and the responsible organization shall be indicated with name and

address. Plates and decals shall be updated according to the
machine’s new version.

–

–

•

The machine may not be operated on public roads unless it has
been adapted according to national road safety regulations.

•

It is always the machine owner’s responsibility to ensure that
the machine has approved fire-fighting equipment according to
governing regulations.

•

The machine is designed for use in outdoor temperatures -40 °C
to 40 °C, relative humidity 10 to 90% and max. wind speed
12.2 m/s. In case of higher wind speeds, contact Kalmar
Industries.

Operator requirements
•

The machine may only be operated by specially trained operators who have the management’s permission to operate the
machine.

•

Laws and regulations regarding driver’s licenses, operator ID,
etc. must always be followed.

•

The operator must be aware of and follow all local safety regulations.

Prohibited operation of machine
Machine operation is prohibited:

IDRF01.05GB

•

If safety and warning equipment such as rear-view mirrors,
headlights, etc., do not function correctly.

•

In case of defective brakes, steering or lifting equipment.

•

If the machine has been repaired, modified or adjusted without
the supervisor’s/work management’s permission.

•

If the machine is fitted with tyres not approved by Kalmar
Industries.

•

The overload protection system (OP) is non-functional during
load handling.

Operator’s Manual DRF 400-450


2 Safety – 2.1 Safety and emergency equipment

2.1
page
–

11

Safety and emergency
equipment

General
A good working environment has safety and warning equipment to
make the operator’s work easier and safer.
The machine may be equipped with the following equipment:
1.

Back-up alarm

2.

Rotating beacon

3.

Horn

4.

Electrically powered loud air horn

5.

Fire extinguisher
A fire extinguisher may also be located externally.
If the machine is provided with a fire extinguisher, it should be
of the type ABE according to EN 3 pt. 1, 2, 4 and 5. With such a
fire extinguisher, it is possible to put out fires in both solid organic materials and fluids. Adapted fire extinguishing equipment
can be ordered from Kalmar Industries.

6.

Seatbelt
For hydraulic vertically adjustable cab, there’s always a seatbelt
and safety chains by the doors.

7.

Buzzer in cab to indicate alarm, overload or forgotten action, for
example, leaving cab without applying the parking brake.

8.

TV-camera with monitor
Used to give improved rearward visibility during operation of the
machine. Monitor is located inside the cab on the left side.

9.

External rear-view mirrors
Used to give improved visibility when operating and load handling. One rear-view mirror on each side.

10. Control breaker for hydraulics
Cuts off all power supply and control signals to hydraulics.

Operator’s Manual DRF 400-450

IDRF01.05GB


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2 Safety – 2.1 Safety and emergency equipment

2
7
1, 8

10

5

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3

9

Operator’s Manual DRF 400-450

003637

4


2 Safety – 2.2 CE-marking

2.2

13

CE-marking

CE-marking

page

–

(Declaration of Conformity, only applies to machines sold
within the EU/EEA).

0

Machine plates for CE-marking, machine and
attachment

003584

This machine is CE-marked. This means that, when delivered, it fulfills the applicable "Essential Health and Safety requirements", stated in EU’s Machine directive, 98/37/EG as well as other applicable
EU directives for the machine type.
As proof that the requirements have been fulfilled, an EU Declaration
of Conformity is supplied, issued by Kalmar Industries for each and
every machine. This EU Declaration of Conformity also covers attachments and options made by Kalmar Industries. The documentation is valuable and should be kept in a safe location and saved for
at least 10 years. The documentation should always accompany the
machine when it is sold.
Any person performing modifications or changes affecting the
machine’s safety is also responsible for the same. Safety must be
ensured in each separate case if the machine is used for other purposes or with other attachments than described in these instructions. The machine owner is responsible for ensuring that the
machine is used as described in the Operator’s Manual. Areas of use
may in certain cases require new CE-marking as well as issuance of
a new EU Declaration of Conformity.
For further information, see standards in section 8 Environment and
standards.

Operator’s Manual DRF 400-450

IDRF01.05GB


14

2 Safety – 2.3 ANSI/ASME-marking

2.3

ANSI/ASME-marking

ANSI/ASME-marking

page
–

Only applies to machines for the North American market).
Kalmar Industries AB

This machine is ANSI/ASME-marked. This means that, when delivered, it fulfills the basic safety requirements according to
ANSI/ASME B56.1.

SE-341 81 Ljungby Sweden

M
S/N
Q

kg

W

kg
L4 mm
H4

mm

H

mm

L5 mm

Any person performing modifications or changes affecting the
machine’s safety is also responsible for the same.

L6 mm

Safety must be ensured in each separate case if the machine is used
for other purposes or with other attachments than described in these instructions. The machine owner is responsible for ensuring that
the machine is used as described in the Operator’s Manual.

kg

H

kg
H

mm

H

mm

H

mm

kg

"In compliance
with ANSI/ASME B56.1 Part III"

kg
A32653.7200

003585

kg
L

For further information, see standards in section 8 Environment and
standards.

Machine plates for ANSI/ASME-marking, machine
and attachment

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Operator’s Manual DRF 400-450


2 Safety – 2.4 Keep in mind

2.4
page
–

15

Keep in mind

Interrupted operation and/or parking

NOTE
Never leave the operator’s seat without first applying the
parking brake (ON position).

NOTE
Always remove the start key if the machine is to be left
unattended.

Operator’s Manual DRF 400-450

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–

2 Safety – 2.4 Keep in mind

During work shifts

D AN GE R
The attachment is a tool that handles heavy loads.
Fatal danger and risk of property damage!
Never walk under hanging loads.

D AN GE R
The machine’s work area is large and visibility from
the operator’s cab is restricted.
Fatal danger and risk of property damage!
Keep in mind:
• Always check that no persons are in the way of
the machine or its equipment.
• The operator must always face in the travel direction and should operate with special care
where persons or vehicles may appear.
• The operator shall adjust travel speed according
to the nature of the load, visibility conditions,
road conditions, etc.
• The operator should pay extra attention and operate with special care near electrical power
lines, viaducts, docksides, ramps, gates/doors,
etc.
• Always operate carefully so that the attachment
does not collide with posts, power lines, etc.
• Use available visibility equipment such as rearview mirrors and TV-camera

when
reversing.

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Operator’s Manual DRF 400-450


2 Safety – 2.4 Keep in mind

17

W AR N IN G
Transport of loads is associated with great risks.
Risk of roll-over and tipping over! Risk of load damage to property!
Respect the machine’s lift capacity and operate
with great care during load handling:
• The machine shall only be operated on even surfaces, intended for the machine’s total weight
and ground pressure.
• All loads should be carried in the transport position. Always operate carefully, keep in mind the
width and height, so that the boom or attachment does not collide with posts, power lines,
etc.
• Do not transport the load in high position since
this may cause the machine to roll or tip over.
• Always operate with the load facing uphill on an
uphill or downhill grade, never operate or turn
across a grade.
• Operate the machine in reverse if the transported load obscures visibility to the front.
• No personnel may enter/stand under a raised
load.

• The operator should avoid powerful acceleration
and braking.
• The operator should always adjust the speed
when turning to prevent skidding and risk of
roll-over or tipping over.
In case the machine rolls over or tips, always
stay in the cab. Do NOT try to jump out of the cab
until the machine has stopped moving.

Operator’s Manual DRF 400-450

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2 Safety – 2.4 Keep in mind

W AR N IN G
The machine’s load capacity is limited.
Risk of roll-over and tipping over!
It is prohibited to exceed the machine’s load capacity. See marking plate and load diagram. The machine’s stability limit may be exceeded if the
overload protection system is not working.

W AR N IN G
The strength of the roof window may be significantly reduced in case of exposure to substances containing: aromatic hydrocarbons, ketones, esters
and chlorinated hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at
regular intervals. Clean only with windshield washer fluid or a mild cleaning agent. Rinse thoroughly

with plenty of lukewarm water. Replace a damaged
roof window immediately if it’s cracked or
scratched!

W AR N IN G
Lifting loads in very windy conditions is associated
with great difficulties.
Risk of roll-over and tipping over!
Avoid lifting loads when wind speeds exceed 12.2
metres per second.

W AR N IN G
The machine emits exhausts during operation.
Health hazards in poorly ventilated facilities!
If possible, avoid operating the machine indoors in
poorly ventilated facilities. Use exhaust venting
equipment!

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Operator’s Manual DRF 400-450


2 Safety – 2.4 Keep in mind

19

W AR N IN G
Work position on the machine is located up high.
Risk of falling and body injury!

Always use the steps and handles when you climb
up or down from the machine. Always face the machine. Do not jump!

W AR N IN G
Cab doors must always be closed when operating.
Risk of personal injury and crushing in case of rollover and tipping!
Always close the operator door(s) during the work
shift.

W AR N IN G
Passengers are only allowed in the cab if there is a
specific passenger seat. It is prohibited to carry passengers on the machine outside the cab or on the
load.
Risk of personal injury!
Passengers in the cab must use the permanently installed passenger seat.

Operator’s Manual DRF 400-450

IDRF01.05GB


20

2 Safety – 2.4 Keep in mind

W AR N IN G
The cab has the sliding cab feature, manual or
hydraulic (
). The cab shall ALWAYS be in its rearmost position when operating.
Warning - risk of crushing!

For manual sliding cab, always make sure that the
cab is locked in its rearmost position before operating, and that the locks are secured with the lock
pins.
For hydraulic longitudinal displacement, the cab
may be positioned as desired (locking is automatic)
during stationary load handling.

W AR N IN G
The machine’s hydraulic system includes accumulators with high pressure.
Risk of personal injury!
Always be very careful when working with the hydraulic system, and avoid standing close to hydraulic components or hoses. Before working on the
hydraulic system, the accumulators must be
drained (see Maintenance manual).

W AR N IN G
Handle batteries and connectors with great care
during charging and boosting (auxiliary start).
Risk of short-circuiting and generation of hydrogen
gas!
Batteries should always be provided with protective
caps over the terminals and connections. Connect
the positive (plus) terminals first. Then connect the
negative (minus) terminals to prevent sparks that
may ignite the hydrogen gas.

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Operator’s Manual DRF 400-450

2 Safety – 2.4 Keep in mind

21

W AR N IN G
The machine uses oils and lubricants.
Health hazard in case of long-term skin contact!
Avoid skin contact with oils and lubricants. Wear
protective gloves.

CAUTION
Cracks or scratches result in reduced strength of
the roof window.
Low strength!
Replace a damaged roof window immediately.

CAUTION
The parking brake can be used as an EMERGENCY
BRAKE.
Brake pads wear out and lose their braking performance! Unwanted movement of parked machine!
Following emergency braking with the parking
brake, check the brake pads as soon as possible,
change if needed! Braking action of the parking
brake may be lost as the brake pads may have been
worn down.
If the parking brake has been released mechanically, it must always be reset to restore the machine’s
parking brake functions.

NOTE
Mobile phone and communication radio may be used in the

cab. The equipment should not be used while operating or
handling loads, as your concentration on operating is reduced.
Kalmar Industries will not assume any responsibility for optional
equipment not installed by Kalmar Industries. Further, no responsibility will be assumed for installations performed by others who are not approved by Kalmar Industries.

Operator’s Manual DRF 400-450

IDRF01.05GB


22

IDRF01.05GB

2 Safety – 2.4 Keep in mind

Operator’s Manual DRF 400-450


3 Overview

23

3 Overview

mm mm mm mm

3 Overview
3.1

page
–

Description DRF 400-450

General
Machine DRF 400-450 is a reachstacker for handling containers and
trailer goods (for bottom lift attachment). It has a lift capacity of 40
to 45 tonnes and a lift height of up to 6 containers ("8 foot 6"-containers).
This section provides a short presentation of the machine’s parts,
see General page 24.

3.1.1
page
–

Identification of the machine

Type designation of reachstacker
Each Kalmar machine has a type designation. Type designation
DRF 450-65S5XS (example) indicates the following:

–

•

D – Diesel engine

•

R – Reachstacker

•

F – Generation

•

450 – Lift capacity, 1st row, decitonne

•

65 – Axle distance, decimetre

•

S – Spreading, adjustable top lift

•

5 – Max. no. of containers when stacking

•

X – Extra counterweight

•

S – Support jacks

Machine card
When ordering and after putting the machine into operation, it’s possible to modify and adapt Kalmar Industries’ machines in different
ways with product alternatives and optional equipment. This makes
it possible to satisfy a very broad range of customers.
A machine card is delivered together with the spare parts catalogue.
The machine card contains a complete specification of the machine’s product alternatives and optional equipment.
The machine card shall be updated when the machine is modified
and Kalmar Industries shall be informed.

Operator’s Manual DRF 400-450

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