Instruction DRD100-200 PDF

GB
Publ. No. 920935-0397 01-10
Instruction Manual
ContChamp
DRD100-200
Empty container handling
Contents
Safety regulations ..................................................................... 2
Introduction................................................................................ 4
Signs ......................................................................................... 6
Operation................................................................................... 8
Instruments and controls ...................................................... 8
ECS .................................................................................... 16
Heating and air conditioning system .................................. 29
Operator’s seat, adjustments.............................................. 31
Engine heater ..................................................................... 32
Running in .......................................................................... 32
Starting the engine ............................................................. 32
Warming up of engine ........................................................ 32
Functional checks............................................................... 33
Stopping of engine, parking................................................ 33
Power steering.................................................................... 33
Lifting technique ................................................................. 34
Special procedures.................................................................. 35
Supervision.............................................................................. 36
Daily supervision ................................................................ 36
Tyres ................................................................................... 37
Fuel system ........................................................................ 38
Cooling system ................................................................... 38
Engine oil............................................................................ 39
Checking the accumulators ................................................ 39
Hydraulic system ................................................................ 40
Gearbox oil ......................................................................... 40
Air cleaner .......................................................................... 41
Windscreen washer ............................................................ 41
Electrical system ................................................................ 42
Lubrication chart...................................................................... 44
Technical data.......................................................................... 48
Oil and lubricant recommendations ......................................... 49
Detailed technical descriptions with circuit diagrams, periodic

supervision, trouble shooting and repairs are dealt with in the
Technical Handbook.
We reserve the right to alter design and material without notice.
DRD100-200 1
Safety regulations
It is important that you read the instruction Safety regulations aimed at reducing the
manual. risk of personal injury and damage to
Incorrect handling can lead to personal injury or dam- loads or other property.
age to products and/or property. Therefore, read the in-
struction book very carefully before operating the truck. Intended of use
The instruction manual contains important information z The truck may only be used for the purpose for
about your Kalmar truck, about the operation of the which it was intended, namely, to lift and transport
truck, about safety during operation and about the goods, the weight of which does not exceed the
truck's daily maintenance. In addition, you will find use- maximum permitted load capacity of the truck.
ful information that will make operations easier for you z The truck may not, without specific permission
in your daily work. from Kalmar, be modified or re-built so that its func-
The instruction manual must always be kept in the ma- tion or performance is altered.
chine. If the manual should be lost, a replacement must z The truck may not be driven on public highways if
be immediately obtained. Never use a machine with a it has not been adapted to comply with national
missing instruction manual. road safety regulations.
Ask your foreman/group leader if there is anything in Operator requirements
the manual that you do not understand or if you feel that z The truck may only be driven by operators who
information is missing in any area. have been specially trained and who have the
company's authority to do so.
The symbol is used on our products in certain z Laws and other regulations relating to driving li-
cases and then refers to important information con- cence, operator ID, log book, etc., must be fol-
tained in the instruction manual. Make sure that warn- lowed at all times.
ing and information symbols are always clearly visible z The operator must be aware of and follow all local
and legible. Replace symbols that have been damaged safety regulations.
or painted over. z It is always the responsibility of the operator to en-
In this instruction manual warnings are inserted that sure that the truck has approved fire extinguishing
apply to your own safety. Warnings point out the risk of equipment in accordance with currently applicable
accident that can cause personal injury. regulations.
Operation of the truck is prohibited:
z If any of the fitted safety equipment, such as rear
WARNING! view mirrors, headlights, reversing alarm (option-
al), does not function correctly.
Warns of the risk of serious personal injury, pos- z If there is a fault with the brakes, steering or lift
sible death and/or serious damage to product or equipment.
property if the regulations are not followed.
z If it has been repaired, modified or adjusted with-
out the approval of the work supervisor.
For technical warnings, that point out the risk of break z If the truck is fitted with tyres not approved by
down, the word IMPORTANT is used: Kalmar.
IMPORTANT! Continued on next page

Is used to draw attention to such occurrences
that can cause damage to the product or
property.
For information that facilitates the working process or

handling, N.B. is used:
N.B. Draws attention to useful information that

helps the working process.
Emergency exit
If the doors should not open in an emergency, open the
rear window for emergency exit.
A rear window that can be opened is standard on ma- KL749
chines with hydraulically moveable cab. Optional on

other machines.
2 DRD100-200
Safety regulations
Continued from previous page must be emptied into the tank, with the help of the
special accumulator evacuation valve.
Operating regulations
z Before starting, make sure that the cab is locked z Handle batteries and junction boxes with great
in the rear-most position by means of the latches, care. The batteries must always be protected over
the poles and connections.
one on each side. The latches must be secured
with spring pins. (Applies to manually moveable z Always rectify any damage or wear and tear that
cabs). can risk personal safety or that can affect the func-
z Before starting, always check to ensure that no- tions of the truck or its service life.
body is in the way of the truck or its equipment. z Avoid touching oils and greases. Avoid inhaling
exhaust and oil fumes.
z Make sure that nobody walks or stands under-
neath raised forks or other equipment, whether z Always use steps and handrails when entering or
they are loaded or not. leaving the machine - Never jump!
z The operator must always face the direction of op- To avoid the risk of slipping, tread only on anti-slip
surfaces. If the anti-slip protection has become
eration and take particular care in areas where worn, loose or in any way less effective, it should
persons or other vehicles are likely to appear in
the vicinity. If visibility is limited by the load, the op- be replaced.
erator should operate the truck in reverse. z Welding painted steel produces poisonous gas-
ses. Paint should therefore be stripped before
z It is prohibited to transport passengers on the welding, good ventilation ensured and/or face
truck outside the cab or on the load. Passengers
may be transported inside the cab only on condi- mask with filter used.
tion that it is equipped with a fixed passenger z Mobile phones used in the cab must always have
seat. fixed connections to the machine’s electrical sys-
tem, with a fixed antenna outside the machine,
z It is prohibited to lift people if the truck is not mounted in accordance with the manufacturer’s
equipped with an approved lift cage.
instructions. This will avoid interference with the
z It is prohibited to exceed the load capacity of the machine’s important electronic functions.
truck. See capacity plate and loading diagram.
Operating with attachments
z It is prohibited to transport loads in the raised po-
sition as this entails a risk of the truck tipping. All z The operator must always take the effect of the
transportation shall take place with the load in the wind into account when handling containers.
transport position. Avoid lifting with a wind strength in excess of 12
m/s (27 mph/40 feet per second).
z The operator must adapt the speed of the truck to
the character of the load, conditions of visibility, z Always drive carefully so as to avoid attachments
the character of the roadway/surface, etc. colliding with pillars, cables, etc.
z The operator shall avoid powerful acceleration z Carefully study the "Lift methods" section of the
and braking when turning. In addition, the opera- instruction manual.
tor shall always moderate the speed of the truck z The tensile strength of the top pane can be seri-
when turning so as to avoid the risk of lateral skid- ously weakened by exposure to elements that
ding or tipping. contain: Aromatic hydrocarbon, ketone, esters or
z The operator shall take particular care when oper- chlorinated hydrocarbon.
ating in the vicinity of electrical power lines, via- Regularly check the surface condition of the top
ducts, quay-sides, ramps, gates/doors etc. pane and clean only with screen wash or other
mild cleaning fluid. After cleaning, rinse thorough-
z Safety belts must always be worn, if fitted. In the ly with warm water. It is prohibited to modify or in
event of the truck tipping, always remain in the cab
and grip the steering wheel securely. Never try to any other way make alterations to the top pane.
Immediately replace damaged top panes that
jump out of the cab. show signs of cracking or scratching.
z The parking brake can also be used as an EMER-
GENCY BRAKE. However, having been used for
emergency braking, the brake linings must be
checked and replaced if necessary. If the parking
brake has been mechanically released, it must
always be reset in order for the truck to regain the CE marking
parking brake function. All trucks and equipment (though not thoses fitted on
Interrupted operation, parking the truck or intended as spare parts) supplied from Ka-
z Always check that the gear lever is in the neutral lmar are CE marked, which indicates that they comply
with the requirements of the EU Machine Safety Direc-
position before turning the ignition key to restart or tive. In addition, each truck has a so called, “EU Dec-
to reset an emergency stop.
laration of Conformity” which is the legal proof that the
z Never leave the operator's cab without applying truck complies with the “health and safety” require-
the parking brake (ON position). ments laid down in the Machine Safety Directive, the
z Always remove the ignition key if the truck is to be EMC directive (electro-magnetic compatibility) and the
left unattended. LVD directive (electrical equipment).
Other important points to remember
z The truck's hydraulic system includes high pres- Vibration standard
sure hydraulic accumulators. Always be extremely
careful when working with the hydraulic system The truck complies with and is below the limits for vi-
and avoid being unnecessarily close to the hy- bration standard PREN 13059.
draulic equipment, lines and hoses. Before work-
ing on the hydraulic system, the accumulators
DRD100-200 3
Introduction
Kalmar ContChamp, version DRD100-200 are specialized ma-
chines for empty container handling.
The machines are part of the Kalmar range of forklift trucks and
various special machines with lifting capacities between 2 and 90
tonnes.
The illustration on the following page shows the most important
units of the truck.
The Instruction Manual applies to all container models unless
otherwise stated. Since the trucks are delivered with different
equipment, minor deviations from the Instruction Manual may
occur.
Kalmar
Type designation
DRD100-52S8
Diesel engine
Reach Stacker
Generation
Lift capacity, decitonnes
Distance between axles, decimetres
Max number of containers
at stacking
IMPORTANT!
BEFORE USING THE TRUCK CHECK:
– the engine oil
– the fuel
– the coolant level
– the tyre pressures
For further information, see the section

entitled SUPERVISION.
4 DRD100-200
Introduction
1
2
4
DRD100-52S6
KL939C
7 6 5
1. Electro-hydraulically activated telescopic boom 4. Drive axle with hub reduction and hydraulic, oil cooled
2. Top lift, electro-hydraulically operated brake system
20-40’ top lift spreader, with ±1000 mm side-shift and 5. Gearbox, combined with torque converter
+195°/-105° rotation 6. Six cylinder diesel engine with turbo compressor
3. Operator’s cab, rubber mounted, moveable longitudinally 7. Steered axle with pendulum suspension and double
acting steering cylinder.
DRD100-200 5
SIGNS
The information plates on the machine are shown below. The op-
erator shall be aware of and follow the warnings and instructions
given on them. Plates that have disappeared, been damaged or
become illegible shall be immediately replaced. Spare parts num-
bers are stated on respective plates. They can also be found in
the Spare Parts catalogue.
101
101
803
101 801
403 109 302 109 701 403

110 304 110
101 101
101
403 203 803 708 403

111 301
803
711
104
121
107
811
108 112 102
6 DRD100-200
SIGNS
10 Chassis, cab 113 A32653.0200 Type, machine 70 Hydraulic system

101 423049.0100 Lift point. 701 450203.0100 Hydraulic fluid.
Fixing point for lift
equipment when lift-
ing the truck.
708 A30168.0200 Hydraulic pressure.
102 A26939.0100 Warning! See Technical
Read the Instruction Handbook.
Manual.
MPa MPa MPa MPa MPa MPa
104 A26940.0100 Parking brake

ON-OFF. M = Model
S/N = Serial number
Q = Classified lift capacity of the
truck at lift height in accord-
107 A30536.0300 Warning!
No Riders! ance with EN1726-1, MPa
Passengers may be EN1551, EN1459 standards. MPa
carried in the cab W = Unloaded weight of machine

only if it is equipped L = Distance between leading 711 A30529.0100 Warning!
with a fixed edge of wheel and the centre High pressure!
passenger seat. of gravity of the load Always release
H = Classified lift height pressure from the
108 A30770.0100 Warning!
121 A33607.0100 Type, machine accumulator before
Air conditioning
working on the
equipment, read the
hydraulic system.
Technical Handbook.
Coolant may be 80 Attachments
topped up only by 801 A30533.0100 Warning!
authorized Rotating parts.
specialist.
109 A30770.0200 Warning! M= Model
Air conditioning S/N = Serial number
equipment, see 108. H= Classified lift height
L= Distance between leading 803 A32440.0100 Warning!
edge of wheel and the centre Do not walk under a
of gravity of the load hanging load.
20 Electrical system
203 A30537.0100 Main switch.
110 A30770.0300 Warning! In position 0 the
Air conditioning battery’s plus pole is
equipment, isolated.
see 108. 811 A33852.0100 Type, attachment
30 Engine
301 450202.0100 Fuel.
D
450202.0100
302 A30530.0100 Warning! S/N =Serial number

1 Rotating fan.
2
3
1 = Refrigerant, type
2 = Amount, kg
3 = Pressure, bar 304 A30532.0100 Warning!
Hot surface.
111 A32441.0100 Warning!
Do not step here.
40 Transmission, tyres
112 A32442.0100 Warning! 403 A32049.0100 Tyre pressure,
Do not jump! 1,0 MPa
Always remain in the
truck and firmly grip
the steering wheel
when there is a risk
of tipping.
DRD100-200 7
OPERATION Instruments and controls
3 1 4 5 2 6
F
4 3 2 1
L 0
R
R
4 5
KL1406
7 8 9 10 11 12 13
1. Gear lever .............................................................. 14 7. Central electrical unit

FORWARD/NEUTRAL/REVERSE 1/2/3 with fuses and relays ...............................................42
2. Lever DIRECTION INDICATORS/HORN ................ 14 8. Brake pedals, normal driving brake .........................15
FRONT WINDSCREEN WASHER/ 9. Clutch release .........................................................15
FRONT WIPERS/MAIN BEAM 10. Accelerator pedal ....................................................15
3. Instrument panel ....................................................... 8 11. Steering wheel adjustment ......................................15
4. Steering wheel panel ................................................ 8 12. Servo circuit emergency breaker.............................11
5. Ignition switch ......................................................... 13 13. Parking brake ..........................................................15
6. Joy stick control lever and control panel for ........... 10
hydraulic functions
8 DRD100-200
21 22 23
KL581
37 38 39
35 36
34
33 40 41 42 43 44 45 46 52 53
32
31
30
29
28
27
26
25
24 47 48 49 50 51
54 55 56 60 59
KL582
66
F
4 3 2 1
L 0
R
KL580
R
1 2 3
4 5
57 58 64 61 62 63
21. Pressure gauge, gearbox oil pressure 40. Spare

22. Fuel gauge 41. Spare
23. Temperature gauge, engine coolant temperature 42. Warning lamp, battery charging
24. Switch, working lights 43. Warning lamp, low engine oil pressure
25. Switch, working lights 44. Warning lamp, low gearbox oil pressure
26. Switch, working lights 45. Warning lamp, low brake pressure
27. Switch, flashing hazard beacon (accumulator pressure)
28. Switch, hazard warning lights 46. Warning lamp, low engine coolant level
29. Switch, driving lights 47. Indicator lamp, preheating
30. Spare 48. Warning lamp, high engine coolant temperature
31. Spare 49. Warning lamp, high gearbox oil temperature
32. Spare 50. Spare
33. Spare 51. Warning lamp, parking brake ON
34. Switch, air conditioning compressor 52. Spare
35. Control, re-circulation/fresh air 53. Spare
36. Control, defrost/cab 54. Spare (Green lamp TWIST-LOCKS LOCKED)
37. Switch, fan 55. Spare (Orange lamp ALIGNMENT)
38. Control, heat 56. Spare (Red lamp TWIST-LOCKS RELEASED)
39. Control, cold 57. Spare (LOCK/RELEASE TWIST-LOCKS)
58. Spare (LENGTH ADJUSTMENT 20-40')
59. Indicator lamp, headlights
60. Indicator lamp, direction indicators
61. ECS terminal
62. Switch, windscreen wiper, rear
KL675 63. Switch, windscreen wiper, roof
64. Spare
65. Fuses
66. Operating hour meter (no. of hours)
1) Optional
65
DRD100-200 9
1 2a 3 4
2b
Joy-stick functions
1. Tilt 1)
2. a. Damping lock 1)
b. -
3. Rotation
4. Side-shift
5 6 5. Vertical lift
6. Boom OUT/IN
7. -
8. Length adjustment 20'–40'
9. Twist-locks release
10. LIFT/LOWER
1) Optional
7 8 9 10
Switch functions
13. Rotation limiter 1)
15. AUT = Automatic locking oftwist-locks.
The parking brake must be OFF
MAN = Manual locking of
twist-locks (spring-return)
Release off twist-locks,
see Joy-stick function 9 above
17. Stop at 30' and 35' 1)
18. Cab movement 1)
1) Optional
Button 17 for the connection and disconnection of N.B.

When operating a machine which is
the 30' and 35' stops equipped with a hydraulically move-
The position provides crawling speed the whole time during able cab, the doors should be closed
extension and retraction. In order to by-pass the 30' stop press or the cab be in its rear position,
and thereafter . The next stop will be 35'. otherwise all functions will be inter-
rupted.
It is practical to connect in once the 30' position has been
passed.
10 DRD100-200
A C
Lamp panel on the boom
Container handling
A. Twist-locks locked, green
B. Alignment, orange
C. Twist-locks released, red
Lamps lit when container is lifted:

A+B
Extinguished after lift:
B
KL20
Engagement and
WARNING! disengagement
of servo circuits
Overriding the safety sys-
tem is carried out at the op- KL 1407
erator’s own risk and Override
entails a risk of forward tip- (Only in emergency situations)
ping. 1. Lower
2. Container coupling
DRD100-200 11
Warning lamps
Trucks equipped with ECS System, module 07, are not fitted
with warning lamps 43,44 46, 48 and 49.
All warning lamps should be extinguished when the truck is in op-
eration.
42 A constant light and a buzzer indicate failure.
Battery charging lamp (42)

If this lamp lights, this indicates that the alternator is not charging
the battery. If this occurs, identify the cause and remedy it.
43 Never use the truck when the charging lamp lights.
Engine oil pressure (43)

The lamp will light briefly on starting, and somewhat longer in
winter time when the oil is cold and more viscous.
44 If the lamp lights when the truck is travelling, stop immediately
and make sure that the cause is identified and remedied.
Oil level? See Supervision.
Gearbox oil pressure (44)

45 The lamp should extinguish immediately after the engine has
been started.
Pressure is too low if the lamp lights while the truck is in opera-
tion. If this occurs, stop the truck immediately and report to the
service personnel.
46
Low brake pressure (45)
The lamp will light if the hydraulic pressure in the accumulator, i.e.
the brake system pressure, drops below 100 bar. After the lamp
has lit, sufficient capacity is still available for applying the brakes
a number of times.
If the pressure is not built up and maintained, check the accumu-
lators for leakages in accordance with the Supervision section.
47 KL598
Engine coolant level (46)
The lamp will light momentarily on starting. If the lamp lights
48 when the truck is travelling, the coolant level is too low. Check the
level and top up as necessary.
Engine pre-heating (47)

49 The lamp will light during the pre-heating period.
Engine coolant temperature (48)

The lamp will light if the coolant temperature becomes too high.
Make sure that the cause is identified and remedied.
Gearbox oil temperature (49)

50 The lamp will light if the temperature of the gearbox oil exceeds
120°C. Stop the truck and make sure that the cause is identified
and remedied.
51
Spare (50)
Parking brake lamp (51)

The lamp will light when the parking brake is applied.
N.B. Always start in first gear to
prevent overheating of the gearbox.
12 DRD100-200
Trucks equipped with ECS System, module 07, are not fitted
with instruments 21, 22 and 23.
Pressure gauge, gearbox oil pressure (21)

21 The gauge shows the clutch pressure which should be
16.9–19.3 bar.
Activated parking brake. Idling speed 600 rpm. Working temper-
ature 82–93°C.
Fuel gauge (22)

22 The tank is full when the gauge reads 4/4. The tank is half-full
when the pointer is vertical.
Always refuel before the gauge reading has dropped to 0.
Air may otherwise be drawn into the fuel system, which will then
have to be bled.
23
Temperature gauge (23)
The temperature gauge shows the engine coolant temperature,
which should normally be approx. 80°C. This temperature will be
reached after the engine has run for about 5 minutes. The tem-
KL581 perature may vary between 75 and 97°C.
A higher temperature may be an indication that the coolant level
is low. Check and top up as required, see under Supervision.
If the temperature is still too high, the cause must be identified
and remedied.
Don’t run the engine if the coolant temperature is too high.
Operating hour meter (66)

The operating hour meter records the number of engine operat-
66 ing hours. Use the meter to determine when the truck is due for
service – all service is based on the operating hours of the truck.
Starting switch (5)

KL1307
P –
0 All functions switched off, the key can be removed
I Operating position. All electrical functions are activated.
The key may be set to this position to switch on the lighting,
for example, when the engine is not running.
II Pre-heater position. In this position the pre-heater is activat-
ed.
The pre-heater mode is indicated by lamp 47. Turn directly to
position III if the engine is warm.
III Starter motor activated.
The truck has an electrical re-start guard that prevents the starter
motor from meshing while the engine is rotating.
WARNING!
Risk of explosion.
Never use start spray to help start the engine.
DRD100-200 13
Gear lever – Forward/Neutral/Reverse (1)
– 1/2/3
The gear-changing mechanism is electrical, gear-changing being
effected via solenoid valves.
2 3 F F – FORWARD
1 4
N – NEUTRAL
R – REVERSE
21
TURN, lever 1, 2, 3
4 3
The engine cannot be started unless the gear lever is in neutral.

KL676 The truck must have stopped completely before changing be-
tween forward and reverse gears, in order to prevent overloading
R the gearbox and transmission.
z Run the engine at idling speed, select the direction of travel

with the gear lever and engage first gear, using the rotary
control. Never pull away in a higher gear, since this may lead
to unnecessary overheating.
z Release the parking brake, and accelerate carefully.
z To change up, turn the gear selector handle to second gear,
IMPORTANT! release the accelerator pedal and the second gear will be en-
The truck must have stopped com- gaged, accelerate, and so on.
pletely before changing between for- z Reverse the procedure when changing down. Remember to
ward and reverse gears, in order to increase engine speed before engaging a lower gear, other-
prevent overloading the transmission wise the truck will brake suddenly.
Direction indicators/Dip switch/Horn (2)

FORWARD/BACKWARDS – Direction indicators
UPWARDS – Headlamp flashing
DOWNWARDS – Main beam
INWARDS, button – Horn
INWARDS, lever – Screen wash
TURN – Screen wiper, front
0 = Off/J = Intermittent
I = Continuous wiping
II = –
0 J
KL677
14 DRD100-200
Brake pedals and clutch release activator (8 and 9)
The brake pedals operate hydraulically, connected to the hydrau-
lic system of the truck via accumulators which ensure that there
will always be sufficient pressure for braking, even in the event of
the engine stopping for a brief period. If the accumulator pressure
falls below a certain level, warning lamp 45 on the instrument
F panel will light.
4 3 2 1
L 0
R
The brake pedal (8) is used as a normal foot brake.
4
R
3 The brake pedal is combined with a separate clutch release acti-
vator (9). When this pedal is pressed at the same as the brake
pedal, the clutch is disengaged at a certain brake pressure. The
clutch feature is used if hydraulic functions are required while a
gear is engaged.
KL597
Accelerator (10)
8 9 10 The accelerator pedal is mechanical and activates the fuel injec-
tion pump by means of a wire.
Options: Some trucks are equipped with hydraulic or electrical
accelerator.
Adjusting the steering wheel (11)

The rake and height of the steering wheel and instrument panel
can be adjusted to the required operating position.
Upper handle upwards: Steering wheel height position
Upper handle downwards: Steering wheel angle
11 Lower handle: Steering column angle
Loosen the handle anti-clockwise
and adjust as required.
Tighten the handle firmly after
adjustment
KL588
Parking brake (13)

The parking brake is applied by powerful springs.
The parking brake is hydraulically operated by means of lever 13.
A warning buzzer will sound if the operator inadvertently leaves
13 his seat before applying the parking brake.
Warning lamp 51 will light continuously when the parking brake is
applied.
If the accumulator pressure should drop below a certain level,
warning lamp 45 will light. After that, the parking brake is applied
automatically by a powerful spring in the brake cylinder. If the
wheels then need to be rotated – see page 35.
The parking brake may also be used as emergency brake.
KL596
WARNING!
Never leave the operator’s seat without

applying the parking brake
DRD100-200 15
OPERATION ECS
Kalmar’s ECS - Electronic Control System - is a modular control
and monitoring system to ensure optimum operational security
and total economy. It is possible to combine the system’s different
modules in a number of different ways.
All vital points of the trucks different systems are connected to
one or two central computer units, ECUs. A terminal display in the
operator’s cab shows current values and generates an alarm if
the values exceed the programmed tolerances.
z ECU 1 is used for different additional modules, such as 01
Automatic Gear Changing, 04 Lever Steering, 06 Micro
steering or 07 Monitoring.
z ECU 5 is mandatory and is used to control the El-Servo cir-
cuits. ECU 5 also contains the overload protection function
and controls the modules according to the table below.
z ECU 9 is used for module 56 Cab movement and other op-
tional modules.
ECU 1 1) ECU 5 ECU 9 1)
01 Automatic Gear El-Servo 56 Cab

Changing 1) 53 Damping lock 1) movement
04 Lever Steering 1) 58 Container
06 Micro-steering 1) Counter 1)
07 Monitoring 1) 70 PC/Printer 1)
80 Overload pro-
tection system 1)
1) Optional equipment
The ECS:
– provides torque controlled automatic gear changing (Mod-
ule 01)
– provides electro-hydraulic lever steering with or without
wheel return (Module 04)
– provides electro-hydraulic steering with micro steering
wheel (Module 06)
– monitors the engine and gearbox to ensure reasonable
DRD100-52S6
operating conditions (Module 01)

– interrupts hydraulic functions with forward overload and
when overload of the steering axle occurs (module 80)
KL942C
– controls vertical lift and balance (standard el-servo
– adapts the speed of movement of the BOOM OUT func-
tion in relation to the load and adapts the speed of move-
ment of the LOWER function in relation to boom extension
and load (standard el-servo)
If a fault occurs:
– a red warning lamp blinks on the terminal
– an error message appears on the terminal display
– The ECS limits the functions of the truck in different ways
depending on the seriousness of the fault. Certain func-
tions are monitored on two levels, where level 2 limits the
functions of the truck. See the error messages on the ter-
minal display on the following pages.
16 DRD100-200
OPERATION ECS
Terminal functions
8 7 1. Arrow left is used to scroll between the different menus.
2. Arrow right is used to scroll between the different menus.
3. R is used to reset the display after an error message. All er-
rors, with the exception of certain level 2 errors can be reset
by pressing this button. The red warning lamp is then extin-
guished. The lamp begins to blink again after 3-10 minutes,
depending on the fault, if it has not been rectified.
F
N
4. - is used to decrease a value.
R
5. + is used to increase a value.
KL580B
R 6. ENTER is used to access the service menus and to save
1 2 3
new values when setting up and calibrating the system.
4 5
Access to the service menus also requires the use of special
codes, that are separately obtainable from Kalmar.
7. A red warning light blinks in the event of an error and is ex-
tinguished when reset by pressing button 3.
R
1 2 3
8. The terminal display has 4 lines with space for 20 characters
on each line. Graphical presentation of operating menus and
4 5 error messages.
6 Menu structure
There are three types of menu:
1. Operating menus
The operating menus are accessible to the operator. The
menus that can be selected depend on how the truck is
equipped and are determined in SETUP. All operating men-
us are part of a connected loop. Use arrow RIGHT/LEFT to
move around the loop. The loop also contains Overload in-
dicator.
2. Error messages
Displayed automatically and have priority over other menus.
3. Service menus
The operating menu loop always contains the KALMAR
INDUSTRIES SERVICE main menu.The service sub-menus
under this main menu require access to codes that can be
found on a special list from Kalmar. If ENTER is pressed by
mistake in the service menu and the ENTER CODE menu is
displayed, return to the operating menu by pressing ENTER.
1.
1. 1.
1.
KL1414
1.
Enter
2.
3.
3.
DRD100-200 17
OPERATION ECS
Operating menus
The menus that are displayed on the terminal depend on the
modules with which the truck’s ECS is equipped. The overview
below shows the possible combinations. Use either arrow
RIGHT/LEFT to switch between menus. All operating menus are
01 Automatic gear changing in a connected loop.
07 Monitoring
80 Overload protection system N.B. Additional menus may occur as a result of adaptation
to specific customer requirements.
80
2 1
4
01.80
3 1
4
07.80
01.07.80 8
9 7
1 6
5
3 4
KL1413
Explanations, see next page
Operating menus with electronic overload protection, module 80
18 DRD100-200
OPERATION ECS
Operating menus, module 80
Modul 80 overload protection function, under normal conditions,
functions as a balance and gives a continual reading of the size
1 and position of the load.
1. Main menu KALMAR INDUSTRIES SERVICE
2. Normal operating condition, module 80.

a. 1750 rpm Engine speed, r/min
c. 3.0 m Distance between the front edge of the
wheels and the centre of gravity of the load.
a d. 25.5 t Current load in tonnes
2 c e. Indicator showing steering axle load, fills the display to the
d left for 95-100% of the permitted load. When the indicator
reads full, the system interrupts operation due to overloading
e of the steering axle. The red warning lamp blinks.
f It is not possible to switch to other menus until the overload
is rectified.
a f. Load indicator, fills the display to the right for 0-100%
3 loads. When the load indicator reads full, the system inter-
b
c rupts operation due to forward overload.
The red warning lamp lights continually.
d
It is not possible to switch to other menus until the overload
has been rectified.
e
f 3. Normal operating condition,
module 80 + module 01 + module 07
a a. 1750 rpm Engine speed r/min
4 b. F3 Current gear
b
c c. d. e. f. See menu 2 explanation above.
d 4. a. 10.38 t Current load in tonnes
b. 1.07 m Boom extension
c. 3.08 m Lc-distance. Distance between drive axle
a centre and load centre.
5 b d. 23.0 ° Boom angle
c
d 5. a. 1750 rpm Engine speed r/min
b. F3 Current gear
c. 14 km/h Current speed
a d. Fuel level. The tank is full when the indicator is filled
6 to the right.
6. a. 75 °C Engine coolant temperature

b b. 3.8 bar Engine oil pressure
a
7. a. 75 °C Gearbox oil temperature
7
b. 3.8 bar Gearbox oil pressure
8 a
8. a. 24.5 v Battery voltage
b b. 75 °C Hydraulic oil temperature
a
9 9. a. 28756:21.54 h. Total operating time, h: min. sec.
b. 130h Time to next service, h
b
DRD100-200 19
OPERATION ECS
Error messages
If two faults occur at the same time, the terminal displays the fault
with the highest priority.
Error messages always have higher priority than normal menus.
Faults 01-08 are level 2 faults and cannot be reset before the fault
is rectified.
The first two figures show to which module the error message re-
lates
(These figures are not shown on the display)
01 = Automatic gear changing
07 = Monitoring
04 = Lever Steering
06 = Micro-steering
80 = Overload protection system
01, 07 01 01. Battery voltage very low/high.

Stop as soon as possible and contact service.
01, 07 02 02. Faulty signal from accelerator sensor.

Engine speed reduction.
01, 07 03 03. Faulty signal from injection pump motor sensor.

01, 07 04
04. Gear lever not functioning.
07 05 05. Engine oil pressure extremely low.

07 06
06. Coolant temperature extremely high.
07 07 07. Gearbox oil pressure extremely low.

07 08
08. Gearbox oil temperature extremely high.
20 DRD100-200
OPERATION ECS
09. Faulty signal from engine rev sensor.

01, 07 09 Engine speed reduction.
07 10 10. Low engine oil pressure.

Check oil level and top up as required.
07 11
11. High coolant temperature.
Check coolant level and top up as required.
07 12
12. Low gearbox oil pressure.
07 13 13. High gearbox oil temperature.

07 14
14. Fuel level extremely low.
Fill the tank to avoid air in the system.
07 15
15. Low coolant level.
Top up the coolant fluid.
07 16
16. High hydraulic oil temperature.
Operation possible.
Contact service.
07 17
17. Faulty signal from fuel gauge sensor.
Operation possible.
Contact service.
07 18
18. Faulty signal from gearbox oil pressure sensor.
Operation possible.
Contact service.
DRD100-200 21
OPERATION ECS
19. Faulty signal from engine oil pressure sensor.

07 19 Operation possible.
Contact service
07 20 20. Faulty signal from coolant temperature sensor.

Operation possible.
Contact service.
07 21
21. Faulty signal from gearbox oil temperature sensor.
Operation possible.
Contact service.
07 22
22. Faulty signal from hydraulic oil temperature sensor.
Operation possible.
Contact service.
07 23
23. Service interval exceeded.
Contact service as soon as possible.
01, 07 24
24. Faulty signal from prop shaft rpm sensor
04 25 25. Steering lever fault.

Switch off the steering system.
04 26 26. Faulty signal from steering sensor.

06 27
27. Faulty signal from mini steering sensor.
07 28
28. Warning! Low brake pressure.
22 DRD100-200
OPERATION ECS
- 31 31. System fault ECU 1.

- 32
32. System fault ECU 2.
07 50
50. Battery voltage very low/high.
52 52. Communication with ECU 1 broken.

-
First try switching off and then re-starting the engine!
If the fault remains, contact service as soon as possible.
80 53 53. Faulty signal from angle sensor

80 54
54. Faulty signal from length sensor.
Stop as soon as possible and check the sensor wire.
Contact service if the fault remains.
80 56
56. Faulty signal from hydraulic pressure sensors for left lift cyl-
inder. (There is a sensor in both feed and return lines)
80 57 57. Faulty signal from hydraulic pressure sensors for right lift cyl-
inder. (There is a sensor in both feed and return lines)
80 58
58. Faulty analog signal from joystick.
All boom functions are interrupted.
DRD100-200 23
OPERATION ECS
59 59. Faulty signal from sensor for end position damping

80 Contact service as soon as possible.
60. Faulty signal from twist-locks sensors.

80 60 Applies to both locked and unlocked position.
62. Each one of the Module 80 errors will activate error menu 62.
80 62 When error menu 62 is activated:
Warning lamp on the ECS-terminal lights up
When pressing RESET:

Menu 62 starts blinking, 5 sec ON and 5 sec OFF
The hydraulic functions LIFT/LOWER and BOOM OUT/IN
are operative but at a lower speed.
24 DRD100-200
OPERATION ECS
Module 01, Automatic gear changing
Module 01 - Automatic gear changing, is designed for gearboxes
with torque converters. The system controls up and down chang-
ing of gears, simplifies operation and extends the service life of
the transmission equipment.
The system
z Prevents the gears from being engaged if engine revolutions
exceed 1100 rpm
z Prevents changing between forward and reverse gears if the
2 3 F speed of the truck exceeds 3 kph
1 4 z Locks the gearbox in the current gear if the signal from the
propeller shaft sensor is excessive or if the signal ceases
z Reduces engine revolutions when changing to a higher gear
21
so that the speed of the truck remains constant

z Disengages the gearbox if the operator brakes and the
4 3
speed of the truck is lower than 3 kph

z Provides the required engine revolutions based on the posi-
KL676
tion of the accelerator pedal
R z Continually shows the currently engaged gear on the ECS
terminal display
Function
The point at which the gearbox changes gear is optimized to the
truck’s transmission equipment. The torque in the torque convert-
er initiates the change of gear. The system changes to a lower
gear when the torque is higher than a pre-programmed value -
and vice versa.
The operator can limit gear changes from 3 to 2 or 1 by moving
the gear selector to the corresponding position. If the selector is
in the 2nd gear position, the system changes automatically be-
tween 1st and 2nd gears.
Module 04, Lever steering
4ab 5 The lever steering module is an electrical system for the steering
of the truck by means of a steering lever. The steered wheel de-
flection is inversely proportional to the speed of truck, i.e. at lower
speeds, the steered wheel deflection is greater than at higher
2 speeds. The system is available in two versions:
3
z Standard: Without wheel return, i.e. when the operator re-
leases the lever the steered wheels stay in their set position.
1 z Optional: With wheel return, i.e. when the operator releases
the lever the steered wheels return to a central position.
The ordinary steering wheel is equipped with inductive sensors
that sense the movement of the steering wheel. The sensors dis-
6 connect the lever steering if the operator is faced with an emer-
gency situation. As soon as the standard steering wheel is used,
the lever steering disconnects and the lamp in switch 2, se below,
is extinguished.
1. Steering lever
2. Direction switch F/N/R. The lamp in the switch is alight when
the lever steering is activated
Forwards position = F. Centre position = N
Backwards position = R
3. Signal horn
4. Switches for gear changing, a=UP, b=DOWN
(Excluded if the truck is equipped with module 01 Automatic
gear changing). Press 4a to shift gears 1-2-3-(4) (once for
every gear) and 4b to shift down. The gear changing always
starts with gear 1 on starting and after the direction switch
has passed the N position.
5. Switch for activating lever steering
KL1405 Condition: The truck speed must not exceed 3 kph. If the
speed exceeds 3 kph it not possible to activate the lever
steering. The lamp in switch 2 is alight when the lever steer-
ing is activated
6. Extra function
DRD100-200 25
OPERATION ECS
Module 06, Mini steering
The Mini steering module is an electrohydraulical system for
3 6 comfortable steering of the truck with the arm on the armrest. The
steered wheels follow the position of the Mini steering device. If
the operator releases the Mini steering device, both the steering
device and the steered wheels remain in the set position.
The standard steering wheel is equipped with inductive sensors
2
that sense the movement of the steering wheel. The sensors dis-
b connect the Mini steering if the operator is faced with an emer-
1 4 gency situation and starts using the standard steering wheel.
a
When the Mini steering is disconnected, the lamp in switch 2, see
below, is extinguished.
1. Mini steering device
5 2. Direction switch F/N/R. The lamp in the switch is alight when
the lever steering is activated
Forwards position = F. Centre position = N
Backwards position = R
3. Signal horn
4. Switches for gear changing, a=UP, b=DOWN
(Excluded if the truck is equipped with module 01 Automatic
gear changing) Press 4a to shift gears 1-2-3-(4) (once for
every gear) and 4b to shift down. The gear changing always
starts with gear 1 on starting and after the direction switch
has passed the N position.
5. Switch for activating Mini steering
Condition: The truck speed must not exceed 3 kph. If the
speed exceeds 3 kph it not possible to activate the Mini
steering. The lamp in switch 2 is alight when the Mini steer-
KL1404 ing is activated
6. Extra function
Module 07, Monitoring

The monitoring module checks that the engine and gearbox op-
The following signals are monitored:
erate within resonable limits and thereby prevents a major break-
1. Battery level, min. <14.4 Volts
down from occuring. The module also monitors the correct
2. Engine oil pressure, min. level 1 <1.0 bar
3. Engine oil pressure, min. level 2 <0.5 bar function of the different system components, such as sensors,
4. Coolant temperature, max. level 1 >98°C etc.
5. Coolant temperature, max. level 2 >103°C Values, such as oil pressure and temperature, that are of vital im-
6. Gearbox oil pressure, min. level 1 <12-15 portance when it comes to wear and tear and the risk of break-
bar (dependent on selected transmission down, are monitored in two levels. A read warning lamp lights and
data kit) an error message appears on the terminal display. If the reason
7. Gearbox oil pressure, min. level 2 <10 bar
for the fault is not rectified, the system limits the truck’s functions.
8. Gearbox oil temperature, max. level 1
>130°C The most serious faults lead to a reduction in engine revolutions.
9. Gearbox oil temperature, max. level 2
>134°C
10. Fuel level, min.
11. Hydraulic fluid temperature, max. >100°C
12. Coolant level, min.
13. Operating time, max. service interval peri-
od, shows the time remaining to the next
service and generates an alarm when oper-
ating time has been exceeded.
14. Brake pressure
26 DRD100-200
OPERATION ECS
Module 58, Container counter
Module 58, Container counter contains two separate counters,
C1 and C2. Of these, C1 is most suitable for use for shorter work-
ing periods, for example, with a change of operator, per hour or
similar. C2 is a total counter, suitable to be used, for example, per
week, per assignment or similar.
The conditions necessary for a container lift to be registered are:
z The twist-locks must be locked.
z The container must be lifted, at least to that point where the
ALIGNMENT light is extinguished.
ENTER
z The twist-locks must not be released for at least 10 seconds.
Resetting the counters

RESET C1 Counter C1:
ENTER 1. Press ENTER when the CONTAINER COUNTER main
menu is displayed.
2. Press the right/left arrow keys until the RESET C1 menu is
displayed.
RESET C2
3. Press ENTER, and C1 is reset.
ENTER 4 SEC
Counter C2:
1. Press ENTER when the CONTAINER COUNTER main
menu is displayed.
RETURN TO MENU
2. Press the right/left arrow keys until the RESET C2 menu is
ENTER displayed.
3. Press ENTER for at least 4 seconds and C2 is reset.
ENTER Returning to the main menu

1. Press the right/left arrow keys until RETURN TO MAIN
MENU is displayed.
2. Press ENTER to return to the CONTAINER COUNTER main
menu.
3. Use the right/left arrow keys to move on through the operat-
ing menus.
DRD100-200 27
OPERATION ECS
Module 70, Printer
The printer Module 70 contains three menus (see illustration).
A = PRINTOUT WEIGHT, that is main menu and it appears to-
gether with the normal operating menus.
C
B = SAVE WEIGHT
C = PRINTOUT XX LATEST WEIGHTS
Save current weight
1. Press - to access the SAVE WEIGHT menu.
(-) 2. Press ENTER to save the current weight, the rectangle in
(+) front of the word ENTER will then be filled in, to confirm that
the command has been executed.
3. Press + to return to the main PRINTOUT WEIGHT menu.
A
Printout of current weight
1. Press ENTER, the rectangle in front of the word ENTER will
then be filled in, to confirm that the command has been exe-
cuted.
(-) Printout of latest weights
(+) 1. Press + to access the PRINTOUT LATEST XX WEIGHTS
menu.
2. Use the +/- keys to register the required number of latest
B weights to be printed out. The system also calculates the to-
tal weight.
3. Press ENTER, the rectangle in front of the word ENTER will
then be filled in, to confirm that the command has been exe-
cuted.
4. Press - to return to the main PRINTOUT WEIGHT menu.
Return to operating menus
To return to the operating menus from any of the three printout
menus, press the arrow right/left keys.
KALMAR INDUSTRIES
WEIGHT IS 28,5T
Example of PRINTOUT WEIGHT
KALMAR INDUSTRIES
1. 10,5T
2. 9,5T Example of PRINTOUT 5 LATEST WEIGHTS
3. 1,0T
4. 5,0T with a summary of the total weight.
5, 8,0T
TOTAL WEIGHT 48,0T
28 DRD100-200
OPERATION Heating and air conditioning system
Heating and air conditioning system
The standard version of the truck is equipped with heater and de-
froster only.
The heating system is connected to the engine cooling system
and starts supplying heat once the engine has warmed up.
34 The fan is controlled by switch 37. The air conditioning system
35 can be switched on and off by means of switch 34.
NOTE. The air conditioning system is an optional extra.
34.Switch, air conditioner compressor (optional)

35.RECIRCULATION switch
Closed – 100% air from outside the cab
36 39 Open – 20% air from outside the cab
KL599 37 (the lamp in the switch lights)
36.Control DEFROSTER/CAB
38 37.Fan control
38.HEAT control
39.COOLING control (optional)
Setting the heating mode

z Close the recirculation control 35. Open if the weather is very
cold.
z Switch off the air conditioner, switch 34.
z Set the heater control 38 and the fan 37 as required.
During the autumn and early winter when high air humidity
causes misting of the windows
z Switch on the air conditioner, switch 34.
z Open the recirculation control 35.
z Set the COOLING control 39 to MAX:
z Increase the temperature as required with 38.
z Set the fan to maximum speed with 37.
z When the windows have been demisted, set the cooling con-
trol 39 so that the cooling thermostat will trip at regular inter-
vals in order to defrost the cooling element.
z Close recirculation with 35.
KL1452
Note that the cooling is used for dehumidifing the air in the
cab.
A A
Setting the cooling mode

z Close the recirculation control with 35. Open during hot
weather and high humidity.
z Set the heater control 38 to COOL.
z Switch on the air conditioner, switch 34.
z Adjust the cooling control 39 as required.
z Open and direct the panel nozzles A towards the roof.
DRD100-200 29
OPERATION Heating and air conditioning system
Thermostatically controlled Air Conditioning unit
As an optional extra, a thermostatically controlled system for air
conditioning, cooling, demisting/dehumidifying and heating, is
available.
The system is equipped with a sensor that senses both inner and
outer temperatures and automatically regulates the temperature
to the pre-set level, either by heating or by cooling.
33 33. Switch DEMIST/DEHUMIDIFYING FUNCTION.
34. Switch COOLING FUNCTION OFF.
34 35. Switch RE-CIRCULATION.
Switch forwards - air from outside.
35 Switch backwards - air from inside.
36. Control DEMIST/CAB.
37. Control FAN. Infinitely variable setting of fan speed.
38. Control TEMPERATURE. Infinitely variable setting of cab
temperature from 16-26°C.
36 39 Control fully clockwise: Full heating effect = heating valve
KL599A continuously open.
37 Control fully anti-clockwise: Full cooling effect = cooling func-
tion running continuously.
38 N.B. When the controls are in respective full positions, pre-
cise temperature regulation cannot be achieved.
39. Cover. The climate equipment’s demist thermostat is located
under this cover. The thermostat must always be set in the
max. clockwise position.
Normal operation
N.B. Run the compressor from time 1. Set controls 37 FAN and 38 TEMPERATURE to the required
to time, even during the winter, in fan speed and temperature.
order to lubricate and ensure The fan must be running for cooling to function. (If the fan is
correct function. switched off, the compressor and condenser stop.)
2. The system then operates automatically, as follows:
N.B. The cooling is not operative at – When heat is required:
temperatures below 0°C. The system operates in 10 second cycles. The water valve
opens for heating at intervals from 0 seconds, extending
to 4 seconds. Thereafter, the valve is open for continual
heating.
– When cooling is required:
The system operates in 2 minute cycles. The compressor
operates at intervals from 30 seconds, extending to con-
tinual operation. The condenser operates continuously as
long as cooling is required.
Demisting/Dehumidifying the air in the cab
1. This function is used when the windscreen/windows mist up.
2. Start demisting by pressing switch 33.
The fan then runs at full speed for 3 minutes, the compressor
and condenser run continuously. The switch lamp lights.
N.B. The cooling system is used for dehumidifying air.
3. After 3 min. the fan speed returns automatically to the previ-
ously set level. Control 37 can be used to select a lower fan
speed at any time.
4. Press switch 33 again to switch off the demisting function.
The switch lamp extinguishes.
Operating without automatic cooling
1. Press switch 34 to the OFF position.
The compressor and condenser then stop. The switch lamp
lights. the cooling function is thereby de-selected in all posi-
tions and does not start even when control 38 TEMPERA-
TURE is set to the MIN. position.
2. Set control 38 to the required temperature.
30 DRD100-200
OPERATION Operator’s seat
Operator seat adjustments
The operator’s seat can be adjusted in the following ways:
A Distance from the pedals
Release the seat by means of lever A and move it forwards
or backwards.
B Height of the seat cushion

Turn the knob until the desired height is achieved.
The cushioning will automatically adjust itself to the opera-
tor’s weight.
C Back rest rake

Turn the knob.
D Arm rest angle
E Tilt – simultaneous tilting of seat and backrest.
F Adjustment of cushioning in three steps.

1. Normal position – lever pulled out. Used in normal
operation.
2. Restricted – lever pushed in to the intermediate position.
Used in operation on rough surfaces and restricts the
cushion travel to 25 mm.
3. Locked position – lever pushed in fully. Used when
cushioning is not required.
DRD100-200 31
OPERATION Engine heater, running-in, start, warming-up
Engine heater
The truck can be equipped with an engine heater to facilitate
starting at temperatures below 0°C.
The engine heater consists of a heater cartridge fitted into the en-
gine block and is designed to heat the engine coolant.
The engine heater must be connected to a 220 Volt A.C. earthed
outlet.
Running-in
A new engine should always be treated with care during a certain
running-in period. During this period, the surfaces of the bores,
gears and bearings will become hard and polished, and this will
ensure a long useful life of the engine.
Avoid running the engine at full load during the first 50 hours. The
load can then be gradually increased.
Try to extend the running-in period to 200 hours. This will pay in
the long run – stoppages and breakdowns will be fewer.
Start
WARNING!
IMPORTANT!
Never use a starting spray to facilitate starting, since this
IF THE ENGINE DOES NOT START may cause an explosion.
Make a new attempt after 15 to 20
seconds.
Do not run the starter motor for more z Place the gear lever in the NEUTRAL position.
than 10 seconds at each z Turn the starter key directly to position II. Then:
attempt. – Below +5°C
Hold the key in position II, the pre-heater position, for
If the engine still refuses to start, the
cause should be determined and approximately 50 seconds.
remedied. Turn the key further to position III – the starting position –
and release it as soon as the engine has fired.
Air in the fuel system? – see page 38. – Above +5°C
Turn the key directly to position III – the starting position –
and release it as soon as the engine has fired.
Warming-up
Never race a cold engine. Run the engine at 1400–1500 r/min un-
til it starts to warm up. It is essential that the engine oil be warm
and that it is circulating correctly before the turbocharger starts
running at high speeds. Nor should the engine be run at critically
low speeds. Start using the truck only when the engine has
reached normal working temperature, i.e. when the temperature
gauge on the instrument panel reads about 80°C.
32 DRD100-200
OPERATION Functional checks, stopping of engine, steering
Functional checks
When starting the truck and from time to time when using it, make
a habit of checking:
WARNING! z that the engine temperature gauge reading is about 80°C.
If results of the functional checks
z that the reading on the fuel gauge is sufficiently above 0.
are in any way doubtful, report N.B. The reading should never be allowed to drop to 0.
immediately to the supervisor. z that all warning lamps are extinguished.
z that the horn, lighting, brake lights and direction indicators
operate correctly.
z that all hydraulic functions operate correctly.
z that the indicating lamps for the twist-locks and alignment
operate as intended.
z that the twist-lock contact plates can be moved freely up and
down. Note that a plate which binds in the top position will in-
WARNING!
dicate alignment even if the frame is not in contact with the
container.
If mirrors or CC TV cameras are used
to aid vision, the speed of the ma- z that twist-lock locking performs satisfactorily. Lift an empty
chine must be adapted to the limited container sufficiently for the ALIGNMENT lamp to be extin-
vision. guished. It must then be impossible to release the twist-
locks.
Stopping the engine, parking

z Apply the parking brake.
z Retract the boom and lower it to its lowest position.
z Place the lever in the NEUTRAL position.
z Allow the engine to run for 1/2–1 minute while at idling speed
before stopping it.
z Stop the engine by turning the key to position 0.
z If the truck will not be used for a longer period, turn the main
switch to the OFF position.
IMPORTANT!
Never turn the the main switch to OFF when the engine is
running – this could damage the voltage regulator.
Power steering
The truck has hydraulic power steering with no mechanical con-
nection between the steering column and the steered wheels.
Movements of the steering wheel are transmitted hydraulically to
IMPORTANT!
Remember to carry out the steered wheels.
daily supervision. Never allow the truck to run downhill when the engine is not run-
See page 36. ning, since no hydraulic pressure will then be available and the
steering of the truck will be very restricted.
DRD100-200 33
OPERATION Lifting technique
Lifting, lifting technique
In all lifting operations, remember not to exceed the maximum lift-
WARNING! ing capacity.
All four corners of the top lift must be See the illustration below.
in contact with the container when Always drive carefully. Remember that the truck is wide and high,
locking or releasing the twistlocks. so make sure that the boom or top lift frame will not collide with
In addition, during release, the posts, overhead cables, etc.
container must rest with all corners
firmly on the surface supporting it. 1. Adjust length setting to suit the length of the container.
2. Drive up to the container from any angle. Adjust by rotating,
Heavy loads must not be driven in side-shifting and raising or lowering the boom. Then lower
highly hoisted positions because this the top lift onto the container.
is detrimental to lateral stability and
may also cause forward tipping. 3. Align the twist-locks with the container locking holes.
4. Check that the orange ALIGNMENT lamp is lit, which indi-
cates that all four twist-locks are engaged in the locking
holes of the container.
Transport position
5. Lock the twist-locks by means of the TWIST-LOCK button.
If switch 15 (page 10) is in the AUT position, the twist-locks
will lock automatically.
6. Check that the green TWIST-LOCKS LOCKED lamp is lit.
7. Ready for lifting. When the container is lifted, the
ALIGNMENT lamp should be extinguished.
WARNING!
Always take great care when rotating a container. Beware

of collisions with boom or chassis.
KL1103
WARNING!
WARNING! If the indicating lamps for the overload indication system

are inoperative, the system must immediately be re-
The cab MUST ALWAYS be in the rear- paired. Safety may be affected if the truck is used when
most position during ALL transport the lamps are defective.
operations to avoid risk of injury or Never start lifting a load if the TWIST-LOCKS UNLOCKED
damage. (red) lamp is ON or if any of the TWIST-LOCKS LOCKED
(green) or ALIGNMENT (orange) lamps is extinguished.
The ALIGNMENT lamp is extinguished on lifting.
See rating plate

for machine
concerned!
Operations close to high tension power lines
Extreme care must be taken when working in close proximity to
overhead, high tension power lines, particularly in respect of the
reach of the boom and attachment.
WARNING!
If the machine comes into contact with overhead high

tension power lines - remain seated in the cab and call for
help!
It is extremely dangerous to leave the cab as you will be
DRD100-52S6
earthed when you come into contact with the ground.
34 DRD100-200
SPECIAL PROCEDURES
Towing
If possible, the engine should be running during towing in order
WARNING!
to retain braking and steering functions. When the engine is not
running, there is no hydraulic pressure for the steering of the
If it is not possible to run the engine
running during towing, a tow bar must truck which is then extremely limited. Furthermore, the gearbox
be used. will be insufficiently lubricated.
z Towing may only take place over very short distances.
Before preparations for towing begin z If a tow bar is used, it shall be connected to the connection/
and after towing has been completed, towing hitch at the rear of the machine.
the parking brake must be applied and z The brakes function as long as there is pressure in the accu-
the wheels chocked to prevent the ma- mulator, thereafter the operating brakes cease to function
chine rolling. The greatest possible
and the parking brake is automatically applied. If, thereafter,
care must be exercised during towing
operations to prevent personal injury. it is necessary to move or tow the truck, the parking brake
must be released mechanically (see instructions below).
z The vehicle or machine use to for towing must be at least as
heavy as the machine to be towed and have sufficient engine
IMPORTANT!
The truck cannot be started by and brake capacity.
being towed. z For towing over longer distances or at speeds higher than 10
km/h, the propeller shaft must be disconnected.
Any attempt to start the engine by
towing, will inevitably cause Mechanical release of Parking Brake
damage to the tranmission.
WARNING!
Block the wheels before releasing the parking brake.
The parking brake is a disc brake on the in-going axle of the drive
axle. The parking brake is automatically spring-applied if the
pressure in the hydraulic accumulator should sink below a certain
level. If the truck needs to be moved:
1. Note the position of the nut (B) on its bolt and remove the
B split pin securing the nut.
2. Tighten the nut (B), this compresses the brake spring. Con-
tinue tightening until the brake pads are released from the
brake disc.
3. Once the fault has been rectified, reset the parking brake
function by returning the nut (B) to the same position as in
point 1.
WARNING!
If the parking brake has been mechanically released, it

must always be reset in order for the truck to retain its
parking brake function.
KL1102
Fire protection
If the machine is equipped with fire extinguishers these should be
of the ABE type, in accordance with EN 3 parts 1, 2, 4 and 5. With
such a fire extinguisher it is possible to extinguish a fire in both
fixed organic materials and liquids. Furthermore, the medium
used to extinguish fire does not conduct electricity.
Suitable fire extinguishers can be ordered from Kalmar.
WARNING!
If the machine is used in highly inflammable environ-

ments, e.g., in explosive environments, it is a strict re-
quirement that the machine be designed, constructed
and equipped in accordance with EN 1755.
DRD100-200 35
SUPERVISION Daily supervision
Supervision
The following must be carried out in addi- Supervision is differentiated as follows:
tion to daily and periodic supervision:
Service during the running-in period
z DAILY SUPERVISION – carried out by the operator
z PERIODIC SUPERVISION – carried out by specially trained
z Tighten the wheel nuts after 8, 16 and service personnel.
24 hours of operation. Tightening
torque in accordance with the Techni-
cal Handbook. Tighten the nuts in a Correct supervision contributes to making the truck safe to work
zig-zag sequence. Tighten the nuts in with.
the same way every time after chang- Periodic supervision is described in the Technical Handbook. The
ing a wheel. operator must make sure that the truck is available for service
every 200 hours of operation.
Guarantee service after 50 hours. All times refer to the hours of operation, i.e., the time recorded by
The guarantee service is performed by the operating hour meter on the instrument panel.
Kalmar, or by personnel authorized by Ka-
lmar, and is part of the
Kalmar delivery commitment.
WARNING!
The guarantee service is also a condition
for continued validity of the guarantee. Only genuine Kalmar spare parts may be used. Spare tyres
and replacement tyres must be of a make
approved by Kalmar.
DAILY SUPERVISION Or when Check Refill as required More details

refuelling on page
Brakes Operation
Steering Operation
All instruments: Operation

Direction indicators, horn,
brake lights, headlights
Lifting boom: Damage?

Pivot points, slide plates
Lift unit and rotator Operation
Twist-locks When damage is suspected, check the twist-locks

immediately
All hydraulic functions Check all functions

Run every function to its end position in order to lubricate the
cylinders and prevent corrosion
Engine, gearbox, drive axle, Noises?

hydraulic hoses Oil leakage?
Fuel Amount
The gauge read- • 38
ing should never
drop to 0
Engine oil Level • 39
Coolant • Level • 38
Hydraulic oil • Level • 40
Gearbox oil • Level • 40

Windscreen washer • Fluid level • 41
Wheels • Tyre pressure 1,0 MPa
36 DRD100-200
SUPERVISION Tyres
Tyres
Checks
1. Check the tyres regularly, if possible, daily.
2. Remove objects that could penetrate the tyres, such as bro-
WARNING! ken glass, pieces of wood, metal shvings, etc.
Spare and replacement tyres shall be 3. Check for uneven and rapid wear. This is caused by mechan-
of a make approved by Kalmar. ical faults such as unevenly acting brakes. Make sure that
such faults are immediately rectified.
Compressor for tyre inflation

1. An air filter with water separator should be fitted in the line
from the compressor that is used for tyre inflation.
The water separator minimizes the risk of the wheels rusting.
2. Drain the water separator regularly.
Tyre inflation
1. Before inflating, make sure that the wheel locking ring is in
the correct position, see illustration.
N.B. If the tyre has been completely deflated, the wheel
must be dismantled and checked for damage.
2. Connect the compressor hose, with a grip-nozzle to the nip-
ple on the tyre.
3. Move away to the side and remain there throughout the en-
tire inflation process.
4. Inflate the tyre to the recommended pressure, see Technical
Data.
With a change of tyres or wheel type, another tyre pressure
KL1469 may apply, contact KALMAR.
Locking ring
WARNING!
Never stand in front of a tyre being inflated.

Do not exceed the recommended tyre pressure, see
Technical Data.
With a change of tyre or wheel type, another tyre pressure

may apply, contact KALMAR.
Always follow the instructions for tyre inflation to avoid
serious accidents.
When changing tyres, see “Safety instructions for
working with tyres” in Technical Handbook.
KL1470RS
Tyre inflation
DRD100-200 37
SUPERVISION Fuel system, cooling system
Fuel system
Always refuel with ordinary diesel oil.
Never use any additives to the diesel oil.
In the winter, it is advisable to refuel the truck immediately after
the day’s work has been completed, to avoid moisture condens-
ing on the inside of the fuel tank.
Never add water-absorbing agent, such as alcohol, to the fuel.
Tank capacity, see Technical Data.
The filling pipe is on the left-hand side of the truck.
Before refuelling, make sure that the area around the filler cap is
KL949A
clean.
Bleeding the fuel system

Air will be drawn into the fuel system if the truck is used when the
fuel tank is completely empty. It will be necessary to bleed the
system after refuelling. This is carried out as follows:
z Open the bleed screw A on the fuel filter, half a turn.
z Release the pump handle B by turning it anti-clockwise.
z Pump by means of the hand pump B until the fuel flowing
past the bleed screw is completely free from air. Continue
pumping and tighten screw A.
z Tighten the pump handle.
z Run the starter motor in 20–30 second bursts, with a pause
of a couple of seconds between each run. The engine will
start after 2–3 minutes.
A Bleed screw
B Hand pump
No further bleeding is normally necessary. If the engine fails to
start after having been bled as described above or if it stops after
a few seconds, the fuel system must be bled again. Loosen the
fuel pipe at any two injectors and run the starter motor until air-
free fuel sprays out. Tighten the coupling immediately. Make a
fresh starting attempt.
Cooling system
The coolant is topped up via the cooling system expansion tank
on top of the radiator which is located under the cab.
WARNING!
Open the cap very carefully when the engine is hot,

since steam or hot coolant may spray out.
Fill with water containing at least 40% glycol. If glycol is not used,
a corrosion inhibitor must always be added to the coolant. But the
corrosion inhibitor is not an anti-freeze agent, and should there-
fore be used only if the ambient temperature is constantly above
0°C.
If the coolant level should drop below the minimum level, warning
lamp 46 on the instrument panel will light.
IMPORTANT!
Insufficient coolant may impair the circulation of the cool-
ant which in turn, may cause the coolant to boil and give
rise to engine damage.
38 DRD100-200
SUPERVISION Engine oil, accumulators
Engine oil
The dipstick for the engine oil (B) is located beneath the service
cover in front of the cab. The dipstick has two markings, MIN and
MAX, and the oil level should be between these two marks.
Clean the dipstick before checking the oil level.
It is advisable to top up with oil when the engine is warm and the
B oil flows easily. Top up – wait a while – check the dipstick.
A Oil filler cap
B Oil dipstick
A
KL950A
Checking the brake system accumulators

The accumulators are charged with nitrogen. If lamp 45 for low
brake pressure lights up, check for leakage as follows.
1. Start the engine and let it run until the accumulators are
charged.
2. Stop the engine and then turn the starting key to position I.
3. Depress the brake pedal repeatedly with long strokes, hold-
ing it down in the depressed position for a brief while on eve-
ry occation.
4. It should be possible to apply the brakes at least six times be-
fore lamp 45 lights up.
5. Start the engine, allow the accumulators to be charged and
repeat the test a couple of times.
6. If the brakes cannot be applied six times before lamp 45
A lights up, the accumulators are faulty. If so, ensure that the
fault recieves attention as soon as possible and that the ac-
cumulators are charged with nitrogen.
WARNING!
Charging should be made with approved equipment by

authorized personnel.
KL951A
B A Quick evacuation valve, accumulators.

B Valve for emergency pressure to servo system.
WARNING!
RISK OF SERIOUS INJURY.

The brake pressure accumulators have an internal pres-
sure of up to 210 bar. Take great care therefore when work-
ing on the system and always release pressure from the
accumulators before removing any component from the
system.
Discharge the pressure by opening the quick-evacuation
valve A. Also open valve B!
DRD100-200 39
SUPERVISION Hydraulic system, gearbox oil
Hydraulic system
The hydraulic tank is on the right-hand side of the truck.
A Refill
A B Sight glass
The fluid level should be in the middle of the sight glass when all
hydraulic cylinders are in bottom position.
The hydraulic fluid must always contain 6% Lubrizol additive to
ensure satisfactory performance of the oil-cooled brake system.
A The additive is not consumed during normal operation and must
only be added at oil change and refill. Lubrizol may be ordered
B from Kalmar Service department.
B
WARNING!
Hydraulic fluid with Lubrizol additive is chemically

KL952A aggressive. Avoid extended contact with the skin.
Gearbox oil
The gearbox oil filler cap and dipstick are located beneath the
service cover in front of the cab.
A Filler cap
B Dipstick
Check the gearbox oil level with the engine idling.
KL950B
40 DRD100-200
SUPERVISION Air filter, windscreen washer
Air filter
The dust container is emptied automatically.
The filter element in the air filter is replaced by the service per-
sonnel as a routine measure. If the truck is used under dusty con-
ditions, the filter may become clogged after a relatively short
period of time.
An indicator, which turns red when the filter has become clogged,
is located in the air intake system between the air filter and the
engine.
Check the indicator regularly and get in touch with the service
personnel as soon as the indicator has turned red
KL949B
IMPORTANT!
Inadequately filtered intake air may quickly cause
serious damage to the engine.
Time to replace
filter
Windscreen washer
The windscreen washer container is located beneath the service
cover in front of the cab.
Check that there is sufficient washer fluid in the bottle. Refill if
necessary. Use washer fluid with a frost inhibiter in the winter.
KL950C
DRD100-200 41
SUPERVISION Electrical system
IMPORTANT!
Electrical system
The starting batteries supplied with The electrical system operates at 24 V. The source of power sup-
the truck are of the maintenance-free ply are two 12 V batteries which are charged by an alternator. The
type, which means that it should not negative pole is connected to the chassis. The positive pole is
be necessary to top-up with electro- connected to the main switch A. When working with the electrical
lyte during the life of the batteries. system, when carrying out welding on the truck or when the truck
Even so, the electrolyte level should is parked for a longer period of time, always isolate the batteries.
preferably be checked once or twice a
year. Fill as required by adding
de-ionized water. Checking the electrolyte level of the batteries
The batteries are fitted behind a cover on the left-hand side of the
truck. The electrolyte level should be about 10 mm above the
S1-6 7-12 13-18 19-24 cells. Top up with de-ionized water as necessary.
Batteries contain substances dangerous to health and the envi-
ronment. Discarded batteries must therefore be dealt with in ac-
cordance with current local/national regulations.
WARNING!
The battery electrolyte contains corrosive sulphuric ac-

B
id. Immediately remove any electrolyte that comes into
contact with the skin. Wash with soap and lots of water.
If electrolyte gets into the eyes, immediately rinse with
WARNING! lots of water and immediately contact a doctor.
Never use fuses of a higher amperage
than stated on the lid decal.
Risk of damage or fire. Relay box in cab – fuses
Fuse Rating
No. Circuit protected A
S1 Wiper motor front, direction indicators,
seat buzzer, parking brake sensor ........................... 10
B S2 Ignition key, pre-heater, starter motor,
cab lighting (Option: air conditioner 25 A) ................ 15
S3 Top lift, safety lock .................................................... 15
S4 Electric gear-changing ............................................ 5
S5 Warning lamps, instrument lighting, relay
coolant level .............................................................. 5
S6 Brake lights, reversing lights, reversing alarm ......... 15
S7 Fan (Option: Air conditioning) 1) ............................... 25
S8 Spare (Option: Container lights) 1) ........................... 15
S9 Working lights (15 A for 4 lamps) 1)
A KL593A
S10
Hazard beacon ........................................................ 10
Working lights, standard (15 A for 4 lamps) ............ 10
S11 Horn, screenwash motor, wiper rear and roof,
wiper front, intermittent relay .................................... 10
S12 Driving lights (main fuse), rear lights
(main fuse), positional lights 15
S13 Main beam, right-hand ............................................... 5
2 4 6 8 10 12 14 16 19 S14 Main beam, left-hand ................................................. 5
S15 Dipped beam, right-hand............................................ 5
1 3 7 9 11 13 15 S16 Dipped beam, left-hand .............................................. 5
S17 Rear light, left-hand .................................................... 5
S18 Rear light, right-hand.................................................. 5
S19 ECU11) ..................................................................... 10
C S20
S21
S22-24
ECU5........................................................................ 10
Voltage converter ....................................................... 5
Spare.......................................................................... –
KL728A 1)
Optional equipment
Miscellaneous fuses
A Main switch
B Main fuse, boom (1x25 A)
C Top lift fuses (2x10 A)
in the top lift central electrical unit
D D Main fuses for truck electrical system
Fitted on the engine, 2x50 A
42 DRD100-200
SUPERVISION Electrical system
Relays
305 Reversing light
314 Parking brake, disengagement
315 High power (Starting switch)
316 Wiper motor, front
320 Electric stop (ECS 07) 1)
322-1 Coolant level
322-2 Coolant level (ECS 07) 1)
323 Pulse relay, direction indicators
328 Lever steering (ECS 04)1)
330 Starting block
331 Propulsion forward
332 Propulsion reverse
334 Clutch release (ECS 01) 1)
367 Low brake pressure (ECS 07) 1)
399 Spare
Miscellaneous
321-1 Intermittent relay wiper front
321-2 Intermittent relay wiper rear 1)
960 Reversing interlock
1) Optional equipment
Bulbs
Rating
Description Watts Base
Instruments 3 .....................................BA7s
Indicating/warning lamps 1,2 ............................ W2x4,6d
Cab lighting 10 .................................... S8,5
Rear lights 5 ...................................BA15s
Brake lights 21 .................................BA15s
Direction indicators 21 .................................BA15s
Positional lights 5 ....................................SV8,5
Driving lights (full/dipped beam) 55/50 ............................... P45t
Reversing lights 70 .................................PK22s
Working lights 70 .................................PK22s
Hazard beacon 70 .................................PK22s
A
Starting from an auxiliary battery
z Make sure the auxiliary batteries are connected in series, to
ensure a 24 V supply.
N.B. Note: Do not disconnect the truck-battery cables
z Connect the jump leads in the following order:
1. Red cable (+) to auxiliary battery
2. Red cable (+) to truck battery
3. Black cable (–) to auxiliary battery
WARNING! 4. Black cable (–) to a location some distance away from
the truck battery, such as the negative cable connection on
Batteries emit oxyhydrogen gas which the chassis.
is explosive. A spark, for example, z Start the engine
from incorrectly connected jump Do not disturb the jump leads while starting, as sparks
leads, could cause a battery to explode may otherwise be caused. Do not lean over either bat-
and result in serious injury and dam- tery.
age.
z Disconnect the jump leads in exactly the reverse order.
DRD100-200 43
LUBRICATION CHART
1 24 3 4 5 6
DRD100-52S6
KL940C
Refill
Brake
Planetary
gear
Sight
glass
44 DRD100-200
LUBRICATION CHART
Item Description Interval No. of Remarks
No. operating hours lub.
200 600 1000 points
1 Boom mounting L 2
3 Slide plates, boom L Grease by hand with the boom in its end
positions. Triplex boom: When lubricating
inner boom, the intermediate boom
should be in the inner position. When
lubricating intermediate boom, the inner
boom should be in the inner position.
4 Rotator mounting L 2
5 Tilt cylinders L 4
6 Rotator reduction gear x C xx 4 Check the level. Top up the red point on
(Brake and planetary gear) the sight glasses 2)
x) First oil change at warranty service
xx) Thereafter oil change every 1000 h
7 Rotator bearing L 4 2 nipples on each side
8 Pinion and ring gear L 3 Brush on grease
9 Link levers L 4
10 Steered wheel bearing 2 Remove, clean, inspect and pack with
grease every 4000 h
11 Knuckle pin bearings 4 Remove, clean, inspect and pack with
grease every 4000 h
12 Engine oil x x) Change the oil every 200 h1)
13 Engine oil filter x 2 x) Change the filter every 400 h
14 Gearbox oil C x 1 x) Change the oil. Check the level at idling
speed
15 Gearbox oil filter x 2 x) Change the filters
16 Servo system filter x 2 x) Change the filters
17 Cooling oil filter, hydraulic brake system x 1 x) Change the filters
18 Hydraulic oil filter x 1 x) Change the filters
19 Propeller shaft L 3
20 Drive axle C x 3 Change the oil
21 Breather filter, hydraulic tank x 1 x) Change filters every 2000 h
22 Hydraulic fluid C x x) Hydraulic fluid change every 2000 h
23 Door and panel hinges Lift off the doors and panels
24 Brake pedals CL 2 Check and retighten the pedal axle lock-
ing screws. Lubricate axle nipples
1) The interval greatly depends on the fuel and lubricant quality as
well as the operating conditions.
If intervals longer than 200 hours are desired, regular lubricant
tests must be carried out by the manufacturer of the oil to check
the condition of the oil.
2
) Note! Different oils in brake and planetary gear.
(Volume brake: 0.2 l. Volume gear: 2.2 l)
For volumes, see Technical Data.
For lubricating oil grades, see Oil and lubricant recommenda-
tions
L=Lubricate
C=Check
IMPORTANT!
If the truck stands unused outdoors, with the After they have been washed with degreasing
hydraulic piston rods exposed, all piston rods agent, all pistons should be moved backwards
must be greased to prevent corrosion. and forwards several times to obtain a new pro-
tective film of oil.
DRD100-200 45
LUBRICATION CHART, CONTAINER ATTACHMENT
1 2 2 1
3 3
46 DRD100-200
LUBRICATION CHART, CONTAINER ATTACHMENT
Item Description Interval No. of Remark
No. operating hours lub.
200 600 1000 points
1 Sliding surfaces, length adjustmeng L Brush onto all sliding surfaces with the top
lift in the fully extended position
2 Sliding surfaces, sideshifting L Brush onto all sliding surfaces with the top
lift side-shifting to the limit in each direction
3 Cylinders, sideshifting L 2
4 Cylinders, length adjustment L 4
5 Locking cylinder C 4 Check that the sensors are free from grease
6 Lift pinion twist connection C x 4 Lubricate with grease
check that the sensors are free from grease
7 Twist lock axle C x 4 Dismantle the twist-locks every 2000 h.
Check for wear. If necessary, change com-
ponents accordingly. Clean and pack with
grease. Same procedure should be used if
damage to the twist-locks is suspected.
Check that the sensors are free from grease
8 Contact pin C 4 Lubricate with grease
Check that the sensors are free from grease
L=Lubricate
C=Check
DRD100-200 47
TECHNICAL DATA
Engine
Make – type designation Volvo – TWD 731 VE
Fuel – type of engine Diesel – 4-stroke
Power ISO 3046 1) – at speed kW -r/m 167 – 2200
Torque ISO 3046 – at speed Nm-r/m 893 –1300
No of cylinders – compression 6-17.7:1
Alternator, type – power AC – 1920 W
Starting battery, voltage – capacity V-Ah 2x12 – 140
Transmission
Gearbox, make – type designation Clark – 13.7 HR 32335-2
Clutch, type Torque converter
Gearbox Powershift
No. of gears, forward – reverse 3–3
Drive axle, type Double reduction,
planet gear hub
Wheels/Tyres
Front and rear 2) Pneumatic, tubeless
Dimensions, front and rear See Data sheet
Pressure, front – rear MPa 1,0
Steering- and brake system

Steering system Hydraulic servo
Driving brake system, type – affected wheels Hydraulic – drive wheels
Parking brake system, type – affected wheels Spring brake – drive wheels
Equivalent noise level in cab
In accordance with machine directive. Limit 70 dB(A)
with standard engine max 71 dB(A)
with noise reduction kit 69 dB(A)
Liquid capacities
Fuel L 400
Cooling system L 31
Hydraulic system L 400
Drive axle oil(incl. hub reduction) L 25
Gearbox oil L 21
Engine oil, incl filters L 29
Truck dimensions and weights vary according to the amount of

extra equipment with which the truck is fitted.
Such variations are explained in the product specification and
data sheet.
1)
ISO 3046=Net power.
2) Spare wheels should be of a make approved by Kalmar.
48 DRD100-200
Oil and lubricant recommendations
Engine oil
Grade: API – CD oil for turbo-charged engines,
from a reputable oil company.
Viscosity: See the chart below
*) If these oils are used at temperatures above +15°C or

+30°C, engine wear may increase.
**) Synthetic or semi-synthetic oil. N.B. Only SAE 5W/30 may be
used.
Drive axle oil

Grade: API GL-5
Viscosity:SAE 80W-140
Oil in rotator reduction gear

Brake
Quality: Ordinary hydraulic fluid without additve, see below
Planetary gear
Quality: API GL-5
Viscosity:SAE 80W-140
Above +30°C or heavy duty: SAE 320
Hydraulic fluid
Grade: Hydraulic fluid for mobile applications from a reputable
oil company.
The oil should correspond to ISO 6743-4
Viscosity:Class HV ISO VG 46 at normal working temperatures
Class HM ISO VG 68 at tropical climate
Class HV ISO VG 32 at extremely cold conditions
Additive: 6% LUBRIZOL LZ 9990A
Grease
IMPORTANT!
Any deviations from these recommen- Use EP universal grease to NLGI Grade 2 with 3–5% molybde-
dations must be supported by written num disulphide additive for all lubrication points, including wheel
approval from Kalmar Service. bearings .
DRD100-200 49
Oil and lubricant recommendations
Gearbox oil
IMPORTANT!
On delivery from Kalmar, the gearbox is filled with API-CD
SAE 10W/30 motor oil.
The gearbox must not be re-filled with ATF oil.
If another recommended oil is chosen, ensure that the

gearbox is completely drained of old oil before re-filling
with the new oil.
Relevant ambient temperatures

Temperature range Recommended oil
1 (a) C-2 SAE Grade 30
(b) C-3 SAE Grade 30
(c) Motor oil, SAE Grade 30 API-CD/SE
or CD/SF
(d) MIL-L-2104C-SAE Grade 30
(e) MIL-L-2104D-SAE Grade 30
2 (a) MIL-L-2104C-SAE Grade 10
(b) MIL-L-2104D-SAE Grade 10
(c) C-2 SAE Grade 10
(d) C-3 SAE Grade 10
(e) Motor oil, SAE Grade 10 API-CD/SE
or CD/SF
(f) Quintolubric 822-220 (Quintolubric
822-220 (Phosphate-free ester
fire-resistant liquid fluid
3 (a) *Dexron
(b) *Dexron II D – See note below!
4 (a) MIL-L-46167
(b) MIL-L-46167 A
5 (a) Conoco Polor Start DN-600 Fluid
IMPORTANT!
Recommended lubricants for Temperature ranges 2 and 3
may be used in lower ambient temperatures when the
sump is pre-heated.
Lubricants for Temperature range 4 should only be used

in the stated temperature range.
IMPORTANT!
Dexron II D is not compatible with the graphite friction
materials used in the clutch plates UNLESS IT COMPLIES
IMPORTANT! WITH THE APPROVED C-3 SPECIFICATION.
Any deviations from these recommen-
dations must be supported by written
approval from Kalmar Service.
50 DRD100-200

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GB

Publ. No. 920935-0397 01-10

Detailed technical descriptions with circuit diagrams, periodic

IMPORTANT! Continued on next page

For information that facilitates the working process or

N.B. Draws attention to useful information that

chines with hydraulically moveable cab. Optional on

For further information, see the section

403 109 302 109 701 403

403 203 803 708 403

108 112 102

10 Chassis, cab 113 A32653.0200 Type, machine 70 Hydraulic system

104 A26940.0100 Parking brake

Passengers may be EN1551, EN1459 standards. MPa

carried in the cab W = Unloaded weight of machine

302 A30530.0100 Warning! S/N =Serial number

1. Gear lever .............................................................. 14 7. Central electrical unit

21. Pressure gauge, gearbox oil pressure 40. Spare

Button 17 for the connection and disconnection of N.B.

Lamps lit when container is lifted:

Battery charging lamp (42)

Engine oil pressure (43)

Gearbox oil pressure (44)

Engine pre-heating (47)

Engine coolant temperature (48)

Gearbox oil temperature (49)

Parking brake lamp (51)

Pressure gauge, gearbox oil pressure (21)

Fuel gauge (22)

Operating hour meter (66)

Starting switch (5)

The engine cannot be started unless the gear lever is in neutral.

z Run the engine at idling speed, select the direction of travel

Direction indicators/Dip switch/Horn (2)

Adjusting the steering wheel (11)

Parking brake (13)

Never leave the operator’s seat without

ECU 1 1) ECU 5 ECU 9 1)

01 Automatic Gear El-Servo 56 Cab

operating conditions (Module 01)

Explanations, see next page

Operating menus with electronic overload protection, module 80

2. Normal operating condition, module 80.

6. a. 75 °C Engine coolant temperature

01, 07 01 01. Battery voltage very low/high.

01, 07 02 02. Faulty signal from accelerator sensor.

01, 07 03 03. Faulty signal from injection pump motor sensor.

07 05 05. Engine oil pressure extremely low.

07 07 07. Gearbox oil pressure extremely low.

09. Faulty signal from engine rev sensor.

07 10 10. Low engine oil pressure.

07 13 13. High gearbox oil temperature.

19. Faulty signal from engine oil pressure sensor.

07 20 20. Faulty signal from coolant temperature sensor.

04 25 25. Steering lever fault.

04 26 26. Faulty signal from steering sensor.

- 31 31. System fault ECU 1.

52 52. Communication with ECU 1 broken.

80 53 53. Faulty signal from angle sensor

59 59. Faulty signal from sensor for end position damping

60. Faulty signal from twist-locks sensors.

When pressing RESET:

so that the speed of the truck remains constant