DRD400-450 920935 - 0393 PDF

CONTCHAMP
DRD 400-450
CONTAINER/TRAILER HANDLING
Publ. no 920935.0393 0206

Contents
Safety regulation........................................................................ 2
Introduction................................................................................ 4
Signs.......................................................................................... 6
Operation................................................................................... 8
Instrument and controls ........................................................ 8
ECS .................................................................................... 16
Module 01, Automatic gear changing............................ 27
Module 04, Lever Steering ............................................ 27
Module 06, Mini Steering............................................... 28
Module 07, Monitoring................................................... 28
Module 56, Cab lift ........................................................ 29
Module 57, Hydraulic balance ....................................... 30
Module 58, Container counter ....................................... 31
Module 59, Limitation Height/LC-distance..................... 32
Module 61, Support jacks.............................................. 33
Module 70, Printer ......................................................... 34
Heating and air conditioning system .................................. 35
Operator’s seat, adjustments ............................................. 37
Engine heater ..................................................................... 38
Running in .......................................................................... 38
Starting the engine ............................................................. 38
Warming up of engine ........................................................ 38
Volvo EDC-engine .............................................................. 39
Functional checks............................................................... 40
Stopping of engine, parking................................................ 40
Power steering ................................................................... 40
Lifting technique ................................................................. 41
Special procedures.................................................................. 43
Supervision.............................................................................. 44
Daily supervision ................................................................ 44
Tyres................................................................................... 45
Fuel system ........................................................................ 46
Cooling system ................................................................... 46
Engine oil............................................................................ 47
Checking the accumulators ................................................ 47
Hydraulic system ................................................................ 48
Gearbox oil ......................................................................... 48
Air cleaner .......................................................................... 49
Windscreen washer ............................................................ 49
Electrical system ................................................................ 50
Lubrication chart ...................................................................... 52
Technical data.......................................................................... 56
Oil and lubricant recommendations ......................................... 57
Detailed technical descriptions with circuit diagrams, periodic su-

pervision, trouble shooting and repairs are dealt with in the Tech-
nical Handbook
We reserve the right to alter design and material without
notice.
ContChamp DRD400-450 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 ap- sure that the truck has approved fire extinguishing
ply to your own safety. Warnings point out the risk of ac- equipment in accordance with currently applicable
cident 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 ContChamp DRD400-450
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
care. The batteries must always be protected over
in the rear-most position by means of the latches,
one on each side. The latches must be secured the poles and connections.
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
functions of the truck or its service life.
z Before starting, always check to ensure that no-
body is in the way of the truck or its equipment. z Avoid touching oils and greases. Avoid inhaling
z Make sure that nobody walks or stands under- exhaust and oil fumes.
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!
To avoid the risk of slipping, tread only on anti-slip
z The operator must always face the direction of op- 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 be replaced.
the vicinity. If visibility is limited by the load, the op-
erator should operate the truck in reverse. z Welding painted steel produces poisonous gas-
z It is prohibited to transport passengers on the ses. Paint should therefore be stripped before
welding, good ventilation ensured and/or face
truck outside the cab or on the load. Passengers mask with filter used.
may be transported inside the cab only on condi-
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.
z It is prohibited to transport loads in the raised po- Operating with attachments
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
z The operator must adapt the speed of the truck to m/s (27 mph/40 feet per second).
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
any other way make alterations to the top pane.
cab and grip the steering wheel securely. Never Immediately replace damaged top panes that
try to 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 CE marking
the 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-
lmar are CE marked, which indicates that they comply
z Always check that the gear lever is in the neutral with the requirements of the EU Machine Safety Direc-
position before turning the ignition key to restart or
to reset an emergency stop. tive. In addition, each truck has a so called, “EU Dec-
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 extreme-
ly 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
Introduction
Kalmar ContChamp, version DRD-C are specialized machines
for handling containers and trailers, i.e. combi or intermodal han-
dling.
The machines are part of the Kalmar range of forklift trucks, log-
handling trucks and various special machines with lifting capaci-
ties between 2 and 90 tonnes.
The picture on the next page shows the most important units of
the truck.
The Instruction Manual applies to all machines in the series un-
less otherwise stated. Since the trucks are delivered with differ-
ent equipment, minor deviations from the Instruction Manual may
occur.
Kalmar
Type designation
DRD450-65C5XS
Diesel engine
Reach Stacker
Generation
Lift capacity
1:st row, decitonnes
Distance between axles,
decimetres
Combination attachment
Max number of containers
at stacking
Extra counterweigt
Optional
Support jacks
Optional
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.
Introduction
1. Electro-hydraulically activated
telescopic boom
2. Combi lift unit. Electro-hydraulically
operated, Adjustable 20–40' top lift for
containers.
Connection legs for trailers.
±800 mm sideshifting and
+195°/–105° rotation.
Levelling ±5°
3. Operator’s cab, rubber mounted,
moveable longitudinally
4. Drive axle with hub reduction and hy-
draulic, oil cooled brake system
5. Steered axle with pendulum suspen-
sion and double acting steering cylin-
der.
6. Six cylinder diesel engine with turbo
compressor
7. Gearbox, combined with torque con-
verter
DRD420-60C5
KL685C
5 6 7
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
A38193.0100A
101 403 109 803 701 103 403 101
103
801
A38193.0100B
403 203 803 113 301 708 110 403
710
A38193.0100C
304 111 302 306

408
104
107
A38193.0100E
A38193.0100D
811 803 101
108 112 102
Signs
10 Chassis, cab 112 A32442.0100 Warning! 70 Hydraulic system

Do not jump! 701 450203.0100 Hydraulic fluid.
101 423049.0100 Lift point.
Always remain in the
Fixing point for lift
truck and firmly grip
equipment when lift-
the steering wheel
ing the truck.
when there is a risk 708 A30168.0200 Hydraulic pressure.
102 A26939.0100 Warning! of tipping. See Technical
Read the Instruction 113 A32653.0200 Type, machine Handbook.
Manual.
MPa MPa MPa MPa MPa MPa
103 A26939.0200 Warning!

Read the Instruction
Manual.
MPa
MPa
104 A26940.0100 Parking brake

ON-OFF.
M = Model 710 A30529.0100 Warning!
S/N = Serial number High pressure!
107 A30536.0300 Warning! Q = Classified lift capacity of the Always release
No Riders! truck at lift height in accord- pressure from the
Passengers may be ance with EN1551, EN1459 accumulator before
carried in the cab standards. working on the
only if it is equipped W = Unloaded weight of machine hydraulic system.
with a fixed L = Distance between leading 80 Attachments
passenger seat. edge of wheel and the load
centre 801 A30533.0100 Warning!
108 A30770.0100 Warning! Rotating parts.
H = Classified lift height
Air conditioning
equipment, read the 20 Electrical system
Technical Handbook. 203 A30537.0100 Main switch.
Coolant may be In position 0 the
topped up only by battery’s plus pole is 803 A32440.0100 Warning!
authorized isolated. Do not walk under a
specialist. hanging load.
30 Engine
109 A30770.0200 Warning!
Air conditioning 301 450202.0100 Fuel.
equipment, see 108.
Located on the D
450202.0100
inside of left hand

frame beam. 302 A30530.0100 Warning! 811 A33852.0100 Type, attachment
Rotating fan.
110 A30770.0300 Warning!

Air conditioning
equipment,
see 108. 304 A30532.0100 Warning!
Hot surface. S/N =Serial number
306 A32439.0100 Engine oil.

1
2
3
1 = Refrigerant, type
40 Transmission, tyres
2 = Amount, kg
3 = Pressure, bar 403 A32049.0100 Tyre pressure,
1,0 MPa
111 A32441.0100 Warning!
Do not step here.
408 A32439.0200 Transmission oil.
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. Electrical central unit

FORWARD/NEUTRAL/REVERSE 1/2/3/4 with fuses and relays ...............................................50
2. Lever DIRECTION INDICATORS/HORN ................ 14 8. Brake pedals, normal driving brake .........................15
FRONT WINDSCREEN WASHER/ 9. Release clutch .........................................................15
FRONT WIPERS/MAIN BEAM 10. Accelerator pedal.....................................................15
3. Instrument panel ....................................................... 9 11. Steering wheel adjustment ......................................15
4. Steering wheel panel ................................................ 9 12. Servo circuit breaker................................................11
5. Starting switch......................................................... 13 13. Parking brake ..........................................................15
6. Control lever and control panel for ......................... 10
hydraulic functions
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 beacon (accumulator pressure)
28. Switch, hazard warning lights 46. Warning lamp, low engine coolant level
29. Switch, driving lights 47. Indicating 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, compressor air conditioning 1) 52. Spare
35. Control, recirculation/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 UNLOCKED)
39. Control, cold 1) 57. Spare (LOCK/UNLOCK TWIST-LOCKS)
58. Spare (LENGTH ADJUSTMENT 20-40’)
59. Indicating lamp, headlights
60. Indicating lamp, direction indicators
61. ECS terminal
KL675 62. Switch, windscreen wiper, rear
63. Switch, windscreen wiper, roof
64. Spare
65. Fuses
66. Hour meter
1)
Optional
2a Joy-stick functions
1 3 4
1. Tilt 1)
2b 2. a. Locking of tilt 1)
b. Locking of levelling 1)
3. Rotation
4. Side shift
5. Vertical lift 1)
6. Boom OUT/IN
7. Levelling 1)
5 6 8. Length adjustment 20'–40'
9. Unlocking of twist-locks
10. LIFT/LOWER
1)
Optional
7 8 9 10
Switch functions
11. Front legs DOWN/UP
AUT 12. Rear legs DOWN/UP
13. Rotation limiting 1)
14. Activation of remote control.
Cuts out the lever functions.
See separate Manual.
15. AUT = Automatic locking of
twist-locks. The parking brake must
be OFF
MAN = Manual locking of
twist-locks (spring-back)
Unlocking off twist-locks,
see Joy-stick function 9 above
16. Clamping front and rear legs
17. Stop at 30' and 35' 1)
18. Cab movement 1)
Horizontal or vertical, see page 29.
19. Support jacks DOWN/UP.
Parking brake OFF. See page 33.
20a. Red lamp, the support jacks
have left the upper position
20b. Green lamp, support jacks down
1)
Optional
Button 17 for the connection and disconnection of N.B. When operating a machine
which is equipped with hydraulic-
the 30’ and 35’ stops ally moveable cab, the doors should
The position gives crawling speed the whole time during ex- be closed or the cab in its rear posi-
tension and retraction. In order to by-pass the 30’ stop press tion otherwise all functions will be
and thereafter . The next stop will be 35’. broken.
It is practical to connect in once the 30’ position has been
passed.
Lamp panel on the boom
A C D E H K Container handling
A. Twist-locks locked, green
B. Alignment, orange
C. Twist-locks unlocked, red
Lit lamps at container lift:

A+B+K
Go out after lift: B
Trailer handling
All lamps yellow (except K)
D. Front trailer foot supporting
E. Front right trailer foot supporting
F. Rear left trailer foot supporting
G. Rear right trailer foot supporting
H. Front legs clamping
J. Rear legs clamping
K. Front legs up (white)
L. Front legs down
KL437 Lit lamps at trailer lift:

B F G J L C+D+E+F+G+H+J+L
Engagement and
Warning! disengagement
Overriding of the safety sys- of servo circuits
KL 1407
tem is at one’s own risk and
involves a risk of forward Override
tipping. (Only in emergency situations)
1. Lower
2. Container coupling
OPERATION Instrument and controls
Warning lamps
Trucks equipped with ECS System, module 07, are not fitted
with warning lamps 43, 44, 46, 48 and 49.
42 All of these lamps should be extinguished when the truck is in op-

eration.
A steady light and a buzzer indicate failure.
Battery charging lamp (42)

43 If the lamp should light up this indicates that the alternator is not
charging. If this should happen, identify the cause and remedy it.
Never use the truck when the charging lamp lights.
Lubricating oil pressure, engine (43)

44 The lamp will light briefly on starting, and somewhat longer in win-
tertime when the oil is cold and viscous.
If the lamp lights up when the truck is travelling, stop immediately
and make sure that the cause is identified and remedied. Oil lev-
el? See Supervision.
45 Oil pressure, gearbox (44)

The lamp should go out immediately after the engine has started.
Pressure is too low if the lamp lights up while the truck is in oper-
ation. If this happens, stop the truck immediately and report to the
service personnel.
46
Low brake pressure (45)
The lamp will light up if the hydraulic pressure in the accumulator,
i.e. the brake system pressure, should drop 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-
47 KL598 lators for leakage in accordance with the section entitled Super-
vision.
48 Engine coolant level (46)

The lamp will light momentarily on starting. If the lamp lights up
when the truck is travelling, the coolant level is too low. Check the
level and top up as necessary.
49 Engine preheating (47)

The lamp will lights during the preheating period.
Engine coolant temperature (48)

The lamp will light up if the coolant temperature becomes too
high. Make sure that the cause is identified and remedied.
50
Oil temperature, gearbox (49)
The lamp will light up if the temperature of the gearbox oil ex-
51 ceeds 120°C. Stop the truck and make sure that the cause is
identified and remedied.
Spare (50)
N.B. Always start in first gear to Parking brake lamp (51)

prevent overheating of the gearbox. The lamp will lights while the parking brake is applied.
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. Idle speed 400–600 r/min. Working tem-
perature 82–93°C.
22 Fuel gauge (22)

The tank is full when the gauge reading is 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,
KL581
which should normally be approx. 80°C. This temperature will be
reached after the engine has run for about 5 minutes. The tem-
perature may vary between 75 and 97°C.
A higher temperature may be an indication that 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.
66
Operating hour meter (66)
The operating hour meter records the number of engine operat-
ing hours. Use the meter to determine when the truck is due for
periodic service – all service is based on the operating hours of
the truck.
KL1307
Starting switch (5)

P –
0 All functions switched off, the key can be removed
I Operating position. All electrical functions are energized.
The key may be set to this position to switch on the lighting,
for instance, when the engine is not running.
II Glow position. In this position the glow-plug is energized.
The glow mode is indicated by lamp 47. Turn directly to
position III if the engine is warm.
III Starter motor energized.
The truck has an electrical restart guard protecting the starter

motor from meshing while the engine is rotating.
WARNING!
Risk of explosion.
Never use start spray to assist in starting.
Gear lever – Forward/Neutral/Reverse (1)
– 1/2/3/4
The gear-changing mechanism is electrical, and the gearbox is
operated via solenoid valves.
2 3 F F – FORWARD
1 4
N – NEUTRAL
R – REVERSE
21
TURN, lever 1, 2, 3, 4
4 3
The engine cannot be started unless the gear lever is in neutral.

KL676 The truck must be stopped completely before changing between
forward and reverse, in order to prevent overloading the gearbox
R and power transmission.
z Run the engine at idle speed, select the direction of travel with
the gear lever and engage first gear, using the rotary con-
trol. 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 be stopped complete- gaged, accelerate, and so on.
ly before changing between forward z Reverse the procedure when changing down. Remember to
and reverse, in order to prevent over- increase engine speed before engaging a lower gear, since
loading the power transmission the truck will otherwise brake heavily.
Direction indicators/Dip switch/Horn (2)

FORWARD/BACKWARDS – Direction indicators
UPWARDS – Headlamp flashing
DOWNWARDS – Full beam
INWARDS, button – Horn
INWARDS, lever – Screen wash
TURN – Screen wiper, front
0 = Off/J = Intermittent
I = Continuous wiping
II = –
0 J
KL677
Brake pedals and release clutch activator (8 and 9)
The brake pedals are hydraulically-actuated and connected to
the hydraulic 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 accumu-
lator pressure falls below a certain level, lamp 45 on the panel will
F come on.
4 3 2 1
L 0
R
The brake pedal (8) is used as the ordinary foot brake.
4
R
3
The brake pedal is combined with a separate release clutch acti-
vator (9). When this pedal is pressed at the same as the brake
pedal, the clutch is activated (gearbox 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 actuates 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 slope and height of the steering wheel and instrument panel
can be adjusted to the desired driving position.
Upper handle upwards: Steering wheel height position
Upper handle downwards: Steering wheel angle
11
Lower handle: Steering column angle
Loosen the handle clockwise and ad-
just as required.
Tighten the handle firmly after
adjustment
KL588
Parking brake (13)

The parking brake is applied by a powerful spring in the hydraulic
cylinder of the parking brake.
13 The brake is actuated hydraulically by means of lever 13.
A warning buzzer will be sound if the operator inadvertently
leaves his seat before applying the parking brake.
Warning lamp 51 will show a steady light when the parking brake
is applied.
If the accumulator pressure should drop below a certain level,
warning lamp 45 will light up. After that, the parking brake is ap-
plied automatically by a heavy spring in the brake cylinder.
If the wheels then need to be rotated – the brake must be me-
KL596
chanically released, see page 43.
The parking brake may also be used as emergency brake.
IMPORTANT!
WARNING! After any emergency braking the brake pads should be
checked and replaced if necessary.
Never leave the operator’s seat without Report to service personnel.
applying the parking brake
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 a
central computer unit, ECU. A terminal display in the operator’s
cab shows current values and generates an alarm if the values
exceed the programmed tolerances.
DRD type machines are equipped with ECS as standard. De-
pending on how respective machines are equipped, one, two or
three ECUs may be fitted.
z ECU 1 is used for different additional modules.
z ECU 2 is mandatory and is used to control the El-Servo cir-
cuits. ECU 2 also controls the overload protection and regen-
eration systems.
z ECU 3 is used for machines with combi-attachments and con-
trols bottom lift functions.
The ECS:
– provides torque controlled automatic gear changing
(Module 01)
– provides electro-hydraulic lever steering with or without
wheel return (Module 04)
DRD400-60S5
– provides electro-hydraulic steering with micro steering
wheel (Module 06)
– monitors the engine and gearbox to ensure reasonable op-
KL621a-c
erating conditions (Module 01)
– monitors the components in the system, e.g., sensors, to
. ensure their correct function (Module 07)
ECU 1 1) ECU 2 ECU 3 1) – interrupts hydraulic functions with forward overload and
01 Automatic El-Servo Bottom lift 1) when overload of the steering axle occurs (module 50/60)
Gear 50 Mechanical 54 Tilt 1) – controls vertical lift and balance (standard el-servo
Changing 1) overload 55 Pile-slope1) – adapts the speed of movement of the BOOM OUT function
04 Lever protection 56 Cab
Steering 1) Regeneration movement in relation to the load and adapts the speed of movement of
06 Mini 51 Vertical lift 1) 1) the LOWER function in relation to boom extension and load
Steering 1) 52 Balance + 61 Support (standard el-servo)
07 vertical lift 1) jacks 1)
MonitoringL 53 Tilt locking 1) If a fault occurs:
1) 57 Hydraulic – a red warning lamp blinks on the terminal
balance 1)
58 Container – an error message appears on the terminal display
Counter 1) – The ECS limits the functions of the truck in different ways
59 Limitation of depending on the seriousness of the fault. Certain functions
height/LC-
distance 1) are monitored on two levels, where level 2 limits the func-
70 PC/Printer 1) tions of the truck. See the error messages on the terminal
60 Electronic display on the following pages.
overload protec-
tion
Regeneration
Vertical lift
53 Tilt locking 1)
58 Container
Counter 1)
59 Limitation of
height/LC-
distance 1)
70 PC/Printer 1)
1)
Optional equipment
OPERATION ECS
Terminal functions
1. Arrow left is used to scroll between the different menus.
8 7
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
4. - is used to decrease a value.
5. + is used to increase a value.
3 2
KL580B 6. ENTER is used to access the service menus and to save new
1 2 3
R 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 extin-
guished when reset by pressing button 3.
R 8. The terminal display has 4 lines with space for 20 characters
1 2 3 on each line. Graphical presentation of operating menus and
error messages.
4 5
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 menus
are part of a connected loop. Use arrow RIGHT/LEFT to move
around the loop. The loop also contains:
1.a Overload indicator
Depends on the selected overload protection, module 50/ 60.
2. Error messages
Displayed automatically and have priority over other menus.
3. Service menus
The operating menu loop always contains the KALMAR IN-
DUSTRIES SERVICE main menu.The service sub-menus un-
der 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 dis-
played, return to the operating menu by pressing ENTER.
1.
1. 1.
1.
KL1409
1.
Enter
2.
1.
1a.
1a.
3.
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
Access to the sub-menus under the service menu requires an ac-
50 Mechanical overload protection
cess code. If ENTER CODE is displayed by mistake, return to the
60 Electronic overload protection
operating menu by pressing ENTER.
N.B. Additional menus may occur as a result of adaptation

to specific customer requirements.
50
6
5
2
1
01.50
6
5
3
1
1 10
07.50
01.07.50
6
5 9
4
7 8
KL1410
Explanations, see next page
Operating menus with mechanical overload protection, module 50
OPERATION ECS
Operating menus, module 50
1. Main menu KALMAR INDUSTRIES SERVICE

1
2. Normal operating condition, module 50

2
a. 1750rpm Engine speed, r/min
a
a
3 b 3. Normal operating condition,
module 50 + module 01
c
a. 1750rpm Engine speed, r/min
b. F3 Current gear
c. 14 km/h Current speed
a
4 b 4. Normal operating condition,
module 50 + module 01 + module 07
c a. 1750rpm Engine speed, r/min
d b. F3 Current gear
d. Fuel level. The tank is full when the indicator is filled to
the right.
5 5.
Red lamp blinks
The steering axle is overloaded.
It is not possible to switch to other menus until the overload
is rectified.
6 6. The system interrupts operation. The red warning lamp lights

continuously.
The machine has forward overload.
is rectified.
a
7 7. a. 75 °C Engine coolant temperature
b. 3.8 bar Engine oil pressure
b
a
8 8. a. 75 °C Gearbox oil temperature
b. 3.8 bar Gearbox oil pressure
b
a
9. a. 24.5 v Battery voltage
9
b b. 75 °C Hydraulic oil temperature
a
10. a. 28756:21.54h Total operating time, tim: min. sek.
10 b. 130h Time to next service, tim
b
OPERATION ECS
60
2 1
4
01.60
3 1
4
07.60
01.07.60 8
9 7
1 6
5
3 4
KL1411
Explanations, see next page
Operating menus with electronic overload protection, module 60
OPERATION ECS
Operating menues, module 60
Modul 60 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 60.

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
has been rectified.
e
f 3. Normal operating condition,
module 60 + 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
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
7. a. 75 °C Gearbox oil temperature
b b. 3.8 bar Gearbox oil pressure
8 a
b
8. a. 24.5 v Battery voltage
b. 75 °C Hydraulic oil temperature
a
9
b 9. a. 28756:21.54 h. Total operating time, h: min. sec.

b. 130h Time to next service, h
OPERATION ECS
Error messages
In order of priority. If two faults occur at the same time, the termi-
nal displays the fault with the highest priority. Error messages al-
01 = Automatic gear changing ways have a higher priority than normal menus.
04 = Lever steering Errors 01-08 are level 2 errors and cannot be reset prior to the
06 = Micro Steering fault being rectified.
07 = Monitoring The first two figures show to which module the error message re-
50 = Mechanical overload protection lates.
60 = Electronic overload protection (These figures do not appear on the display)
01, 07 01 01. Battery voltage very low/high

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

01, 07 02 Engine speed reduction.
03 03. Faulty signal from injection pump motor sensor.

01, 07
Engine speed reduction.
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.
OPERATION ECS
01, 07 09 09. Faulty signal from engine rev sensor.

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.
16. High hydraulic oil temperature.

07 16
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.
OPERATION ECS
07 19 19. Faulty signal from engine oil pressure sensor.

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

Operation possible.
Contact service.
21 21. Faulty signal from gearbox oil temperature sensor.

07
Operation possible.
Contact service.
07 22 22. Faulty signal from hydraulic oil temperature sensor.

Operation possible.
Contact service as soon as possible.
23 23. Service interval exceeded.

07
24. Faulty signal from prop shaft rpm sensor

01, 07 24
04 25 25. Steering lever fault.

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

04 26 Switch off the steering system.
06 27 27. Faulty signal from mini steering sensor.

Switch off the steering system.
07 28
28. Warning! Low brake pressure.
OPERATION ECS
- 31 31. System fault ECU 1.

- 32 32. System fault ECU 2.

50 50. Battery voltage very low/high.

07 Contact service as soon as possible .
60 51
51. Communication with ECU 3 broken.
60 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.
53 53. Faulty signal from angle sensor

60 Stop as soon as possible and contact service.
60 54
54. Faulty signal from length sensor.
Stop as soon as possible and check the sensor wire.
Contact service if the fault remains.
50, 60 55 55. Faulty signal from regeneration sensor.

The regeneration is discontinued.
Contact service.
50, 60 56
56. Faulty signal from hydraulic pressure sensors for left lift cyl-
inder. (There is a sensor in both feed and return lines)
50, 60 57 57. Faulty signal from hydraulic pressure sensors for right lift cyl-
inder. (There is a sensor in both feed and return lines)
OPERATION ECS
50 58
58. Faulty analog signal from joystick.
All boom functions are interrupted.
50 59 59. Faulty signal from sensor for end position damping

- 60
60. Faulty signal from twist-locks sensors.
Applies to both locked and unlocked position.
60 61 61. System fault.

Load curve is missing.
60 62
62. Each one of the Module 60 errors will activate error menu 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.
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
speed of the truck exceeds 3 kph
2 3 z Locks the gearbox in the current gear if the signal from the
1 4 F propeller shaft sensor is excessive or if the signal ceases
z Reduces engine revolutions when changing to a higher gear
so that the speed of the truck remains constant
z Disengages the gearbox if the operator brakes and the speed
21
of the truck is lower than 3 kph

4 3
z Provides the required engine revolutions based on the posi-

tion of the accelerator pedal
KL676
z Continually shows the currently engaged gear on the ECS ter-
minal display
R 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 4 to 3, 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 switch lamp 5, 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
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 eve-
ry 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 steer-
ing. The lamp in switch 2 is alight when the Mini steering is ac-
KL1404 tivated
6. Extra function
Module 07, Monitoring

The monitoring module checks that the engine and gearbox op-
erate within reasonable limits and thereby prevents a major
The following signals are monitored: breakdown from occurring. The module also monitors the correct
1. Battery level, min. <14.4 Volts function of the different system components, such as sensors,
2. Engine oil pressure, min. level 1 <1.0 bar etc.
3. Engine oil pressure, min. level 2 <0.5 bar
4. Coolant temperature, max. level 1 >98°C
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 The most serious faults lead to a reduction in engine revolutions.
>130°C
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
OPERATION ECS
Module 56, Cab lift
WARNING!
Before operating the cab lift, check to make sure that no-
body is in the way of the cab when it moves up or down.
18
1. Close the doors

KL 1407
2. Fasten the safety chains across both doors.
3. Fasten the safety belt.
4. Operate the cab lift using switch 18.
N.B. When the cab is lifted from its lower position, the ma-
chine can be driven in 1st or 2nd gears only.
Conversely, the cab lift is operative in 1st or 2nd gears only
A
WARNING!
If work must be carried out under the cab when lifted, the
KL1089 hinged mechanical safety latches on both sides must be
placed in position under the cab.
See A on the adjacent illustration
N.B. If the cab gets stuck in its upper position, it can be low-
ered by means of an emergency lowering valve. This is fitted
under the front cover in front of the main hydraulic valves.
See B on the adjacent illustration
A Hinged safety latch

B Emergency lowering valve
KL1090
OPERATION ECS
Module 57, Hydraulic Balance
The hydraulic balance is included in the ECU 2 el-servo system.
Calibration of the balance must be carried out in accordance with
A the instructions in Technical Handbook ECS SERVICE, ECU 2
SETUP, points 20 and 21.
1. Connect a loaded container to the machine

Extend the boom until the red lamp A lights.
2. Lift the boom approx. 20 cm over the position where the red
flags B on the left lift cylinder are aligned with each other.
3. Lower the boom until the red flags are exactly aligned with
each other.
(By first lifting the boom too high and then lowering it to the
correct position, the regeneration system is prevented from
B building up pressure that can affect the measurement)
4. Press the button for weighing

= the vertical lift button on the control lever
KL1412
5. The result is shown on the ECS terminal display

25 t = The actual weight in tonnes.
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.
OPERATION ECS
Module 59, Limitation Height/LC-distance
In certain cases it may be necessary to limit how high the boom
can be lifted, for example, for operations in areas with overhead
power lines, bridges, traverses, etc., or how close to the cab the
load can be moved.
Limitation Height
When measure A1 is reached: The boom stops and the menu for
height limitation shows the set max height.
The pre-set limitation of height, A1 on the adjacent illustration,
can be by-passed using the switch D on the hydraulic control
panel.
The switch D must be continually pressed in whilst the boom
moves through the area B (700 mm).
In parallel with switch D, the switch E for by-passing the safety
system (located on the side of the hydraulic control panel) can
also be used.
Above height C the system functions as normal.
Limitation Lc-distance
When measure A2 is reached: LIFT - The lifting movement
becomes VERTICAL LIFT
BOOM IN - The boom stops
The pre-set limitation of Lc-distance, A2 on the adjacent illustra-
tion, can be by-passed using the switch D on the hydraulic control
panel.
The switch D must be continually pressed in whilst the load
moves inside limitation A2.
In parallel with switch D, the switch E for by-passing the safety
system (located on the side of the hydraulic control panel) can
also be used.
In front of limitation of Lc-distance A2 the system functions as
normal.
KL1093a
OPERATION ECS
Module 61, Support jacks
The upper and lower positions of the support jacks are controlled
by inductive sensors, which in turn are connected to the overload
protection system.
The support jacks can be lowered at overload.
The support jacks cannot be raised until the overload is neutral-
ized by disengaging the load or retracting the boom.
Support jacks down

z Release the parking brake.
z Press switch 19 – SUPPORT JACKS DOWN.
z When the support jacks have left the upper position, the red
lamp 20a will light and the transmission will be disengaged.
z When the support jacks have reached the lower position,
20a green lamp 20b will light. The overload protection system will
20b change parameter curve. The additional capacity for contain-
er row 3 (+7 tons) can be utilized.
KL 1407
Support jacks up
z Disengage the load or retract the boom to prevent the over-
19 load protection system from interrupting the functions.
z Press switch 19 – SUPPORT JACKS UP.
z When the support jacks have left the lower position, red lamp
20a will light (Green 20b is extinguished).
z When the support jacks have reached the upper position, red
lamp 20a is extinguished. The overload protection system
shifts to the normal parameter curve. Ready for normal oper-
ation.
Support jacks
19. Switch, support jacks UP/DOWN

20a. Red indicating lamp – the support jacks
have left the upper position
20b. Green indicating lamp – the support
jacks have reached the lower position
OPERATION ECS
Module 70, Printer
The printer Module 70 contains three menus (see illustration),
A = PRINTOUT WEIGHT is the main menu and is accessed via
the normal operating menus.
B = SAVE WEIGHT
C
C = PRINTOUT LATEST XX 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 total
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
KALMAR menus, press the arrow right/left keys.
WEIGHT IS 28,5T
Example of PRINTOUT WEIGHT
KALMAR
1. 10,5T
2. 9,5T
3. 1,0T
4. 5,0T
5, 8,0T
TOTAL WEIGHT 48,0T
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 coolant system
and starts delivering heat after the engine has warmed up.
34 The fan is controlled by switch 37. The air conditioning system
can be switched on and off by means of switch 34.
35
NOTE. The air conditioner is optional equipment.
34. Switch, compressor air conditioner

35. RECIRCULATION switch
Closed – 100% air from outside of cab
36 39 Open – 20% air from outside of cab
KL599 37 36. Control DEFROSTER/CAB
37. Fan control
38 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-
KL1452
trol 39 so that the cooling thermostat will trip at regular inter-
vals for defrosting the cooling element.
z Close recirculation with 35.
A A Note that the cooling is used for dehumidifying the air in the
cab.
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.
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. Switch DEMIST/DEHUMIDIFYING FUNCTION.
33
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, ex-
tending 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.
OPERATION Opeartor’s seat
Operator’s seat adjustments
The operator’s seat is provided with the following adjustment
facilities:
A Distance from the pedals.
Release the seat by means of the lever and move it forward
or towards the rear.
B Height of the seat cushion.
Turn the knob until the desired height is achieved.
The springing will automatically correspond to the opeator’s
weight.
C Backrest rake
Turn the knob.
D Armrest slope
E Tilt – simultaneous sloping 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
spring travel to 25 mm.
3. Locked position – lever pushed in fully. Used when
springing is not required.
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 V 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 – the stoppages and breakdowns will be fewer.
Start
WARNING!
IMPORTANT!
IF THE ENGINE DOES NOT START Never use a starting spray to facilitate starting, since this
may cause an explosion.
Make a new attempt after 15 to 20
seconds.
Do not run the starter motor for more z Set the gear lever to NEUTRAL.
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 approximately 50 seconds.
cause should be determined and Turn the key further to position III – the starting position –
remedied. and release it as soon as the engine has fired.
– Above +5°C
Turn the key directly to position III – the starting position –
Air in the fuel system? – see page 46. 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.
OPERATION EDC engine
Trucks with Volvo EDC engines (Optional extra)
IMPORTANT!
Certain Volvo engines are equipped with EDC, an electronic sys-
Starting the EDC engine tem for the control of the diesel engine’s operation. The system’s
1. Switch on the ignition. central unit receives information relating to a number of parame-
The engine cannot be started before ters, such as, engine revolutions, coolant temperature, fuel tem-
the lamp in the Diagnostic Switch (A) perature, turbo-charge pressure, turbo-charge temperature, etc.,
has extinguished. The EDC system and on the basis of the values received, determines the volume
first checks all engine systems of injected fuel.
2. Turn the ignition key to the start posi- The EDC system also contains a diagnostic system that enables
tion and immediately release the key rapid fault finding, if a fault should occur. A diagnostic switch on
again. the instrument panel shows the current fault, by means of differ-
Depending on the temperature, pre- ent series of blinking of the in-built lamp.
heating of the EDC system then
starts. Pre-heating times varies from 0 Function
s at +25°C to 50 s at - 20°C. A = Diagnostic Switch.
(In emergency situations, the pre- The switch lamp starts to continually blink if the EDC system re-
heater can be by-passed by turning ceives abnormal values from the engine, or if there is a fault in the
the ignition key to the start position EDC system itself. When the switch is pressed for at least one
twice) second, the alarm is reset and it is then possible to read off the
3. Thereafter, turn the ignition key to the diagnostic code.
start position again - and the engine The switch lamp shows the diagnostic code by means of two-
starts, but not directly, only after a stage blinking. First a series, then a pause, then a further series
number of revolutions. This pre-heats of blinks.
the engine combustion chamber If several diagnostic codes are stored in the system, press the
which reduces smoking at start up. switch again and read off the next code, and so on. When the first
N.B. On an EDC engine, the starter mo- code re-appears, all diagnostic codes have been read.
tor must turn longer than with conven- The system stores the codes until they are deleted and it possible
tional engines. to check the codes again at any time.
Stopping the EDC engine
Reading off the diagnostic codes
1. Stop the engine in the normal way, by
1. Press switch A down for at least one second.
turning the ignition key to 0
When the lamp starts to blink, the first fault is shown
For example: 2 blinks - pause - 4 blinks = diagnostic code 2.4
2. Press switch A down again to check if there are further diag-
nostic codes. Continue until the first code re-appears.
KL1257 Deleting diagnostic codes

IMPORTANT! Never delete a diagnostic code before the
fault in question has been rectified
1. Switch off the ignition.
2. Press switch A down and switch on the ignition whilst the
A switch is still held down. Keep the switch pressed down for
at least 3 seconds.
3. All diagnostic codes are now deleted.
Diagnos- Fault Result of fault Action
tic code
1.3 Incorrectly calibrated throttle - Contact service
2.2 Incorrect position of throttle lever Engine stops -”-
2.3 Throttle control rod fault Engine stops -”-
2.4 Engine speed (rpm) sensor fault Engine stops -”-
2.5 Engine speed sensor - incorrect signal Engine stops -”-
2.6 Throttle control sensor fault Reduced engine revs. 1000 rpm -”-
2.7 Throttle control sensor - incorrect signal Engine stops -”-
4.6 Short circuit or breakdown in start relay - -”-
5.1 Short circuit or breakdown in main relay - -”-
8.1 Fault in the EDC central unit - -”-
8.3 Fault in the EDC central unit - -”-
9.9 EDC program fault - -”-
IMPORTANT! If the diagnostic system has resulted in re-

duced engine revs. or engine stop, all diagnostic codes
must be deleted before the engine can be restarted.
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:
z that the engine temperature gauge reading is about 80°C.
WARNING!
z that the reading on the fuel gauge is sufficiently above 0.
If results of the functional checks N.B. The reading should never be allowed to drop to 0.
are in any way doubtful, report z that all warning lamps are extinguished.
immediately to the supervisor. z that the horn, lighting, brake lights and direction indicators op-
erate correctly.
z that all hydraulic functions operate correctly.
z that the indicating lamps for the twist-locks and alignment op-
erate as intended.
z that the contact plates at the twist-locks can be moved freely
up and down. Note that a plate which binds in the top position
will indicate alignment even if the frame is not in contact with
WARNING! the container.
If mirrors or CC TV cameras are used z that the twist-lock interlock performs satisfactorily. Lift an emp-
to aid vision, the speed of the ma- ty container sufficiently for the ALIGNMENT lamp to be extin-
chine must be adapted to the limited guished. It must then be impossible to release the twist-locks.
vision. z that the trailers legs alignment indicators in the trailer shoes
are functioning and that the yellow lamps light up.
z that the trailer legs grip indicator and front legs indicator for
raised and lowered positions function and that the respective
yellow lamps light up.
Stopping the engine, parking

z Apply the parking brake.
z Retract the boom and lower it to its lowest position.
z Set the gear lever in NEUTRAL.
z Allow the engine to run for 1/2–1 minute while at idling speed
before stopping it. This will allow the engine to cool down and
the turbo bearings to be lubricated.
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 main switch to OFF when the engine is run-
ning – the voltage regulator may be damaged.
Power steering
The truck has pure power assisted steering, and there is thus no
mechanical connection between the steering column and the
IMPORTANT! steered wheels. Movements of the steering wheel is transmitted
Remember to carry out the hydraulically to the steered wheels.
daily supervision. Never let the truck run downhill when the engine is not running,
See page 44.
since no hydraulic pressure will then be available and the
steering of the truck will be very restricted.
OPERATION Lifting technique
Lifting technique, container
In all lifting operations, remember not to exceed the maximum
WARNING! lifting capacity.
All four corners of the top lift must be See the picture below.
in contact with the container when Always drive carefully. Remember that the truck is wide and tall,
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. Put the gear selec-
Heavy loads must not be driven in tor in neutral or disengage the gearbox with brake and clutch
highly hoisted positions because this pedals.
is detrimental to lateral stability and
may also cause forward tipping. 3. Adjust by rotating, side shifting and rising or lowering the
boom. Then lower the top lift onto the container.
4. Align the twist-locks with the container locking holes.
Transport position 5. Check that the orange ALIGNMENT lamp is alight, which in-
dicates that all four twist-locks are aligned in the locking
holes of the container.
6. Lock the twist-locks by means of the TWIST-LOCKS button.
If switch 15 (page 10) is in the AUT position, the twist-locks
will lock automatically.
7. Check that the green TWIST-LOCKS LOCKED lamp is
alight.
8. Ready for lifting. When the container is lifted, the
ALIGNMENT lamp should be extinguished.
9. Always start in 1:st gear for all transport operations.
WARNING!
KL1103
Great care must always be taken when rotating a container
in order to avoid any collision with boom or chassis.
WARNING!
The cab MUST ALWAYS be in the rear- WARNING!

most position during ALL transport
operations to avoid risk of injury or If the indicating lamps for the overload indication system
damage. are inoperative, the system must immediately be re-
paired. Safety may be affected if the truck is used when
the lamps are defective.
Never start lifting a load if the TWIST-LOCKS UNLOCKED
(red) lamp is ON or if any of the TWIST-LOCKS LOCKED
See rating plate (green) or ALIGNMENT (orange) lamps is extinguished.
for machine The ALIGNMENT lamp is extinguished on lifting.
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
earthed when you come into contact with the ground.
OPERATION Lifting technique
Lifting technique, trailer
1. Before connecting up the trailer – check that lamp K is lit. If
not, press button 11 – FRONT LEGS DOWN/UP until lamp K
lights up, i.e. the front legs are fully raised.
2. Lower the rear legs by pressing button 12 . The rear legs
lower in sequence – left and then right – and are angled for-
ward into connecting position.
3. Drive up to the trailer and set the attachment parallell to the
trailer
4. Move the attachment forward until the rear legs lie against the
trailer and lamp J lights up.
N.B. Do not touch button 16 – TRAILER LEG GRIP when
in this position.
5. Lower the front legs by pressing button 11. When both of the
front legs have been fully lowered lamp L lights up.
NOTE. When lowering/raising the legs, the front and rear legs
grip is always in the off position to avoid damage to the trailer.
6. Grip the front and rear legs by pressing button 16 – TRAILER
LEG GRIP until lamp H and J lights up.
7. Lift – lamps D, E, F and G should then light up, indicating that
all trailer shoes are gripping and that the trailer is ready for
transport.
The system will disengage the gearbox as soon as any of the
lamps D, E, F, G, H, J lights up. The gearbox will be engaged
again when all lamps are alight. (Applies to automatic gearbox
only)
N.B. Should all lamps D, E, F, G not be alight within
3-4 seconds, the system will interrupt the functions
LIFT/LOWER and BOOM OUT/IN.
If this should happen:
– Turn the override key switch X to override the interruption.
– Lower the trailer fully and release the leg grip.
– Check that lamps D; E; F; G, H, J go out.
– Repeat from point 6.
8. Lower the trailer – until the lamps D, E, F and G go out.
KL 1407 9. Release front and rear legs by pressing button 16 – TRAILER
LEG GRIP .
X Y 10.Raise the front legs by pressing button 11 . Lamp L goes out
Override Safety system as soon as the first leg moves upwards. When the second leg
key switch override switch is fully raised lamp K will light up.
11. Time for the next trailer lift.
WARNING! Place the rear legs in the connecting position by pressing but-
ton 12 (the legs angled towards the trailer – without touching
If the safety systems have been over- button 16 – TRAILER LEG GRIP). Thereafter, repeat the op-
ridden (switch Y) and the boom is fur- eration from point 3.
ther lowered there is a risk of forward
tipping. Observe the utmost care. X. Override key switch, if lift and extension functions are
Overriding the safety system is at interrupted caused by failing alignment signals.
one’s own risk.
Y. Override switch, overload protection and safety
Do not touch the leg grip before the systems
trailer legs have been completely low-
ered! Otherwise the legs can fold and
Measures to be taken during the winter
damage the trailer when the unit is During the winter it is possible that the alignment sensors in the
lowered. trailer shoes freeze solid and continuously indicate alignment. It
is then impossible to release the leg grip. Take the following
When alignment lamps D, E, F and G measures:
light up, the leg grip and leg lowering 1. Lower the trailer so that it is definitely free.
front and rear are disconnected. This
is to ensure that it is not possible for 2. Make an override of the alignment safety system by pressing
the trailer to slide out if the buttons for button on the side of the control console.
leg grip and the lowering of the legs 3. Release the leg grip by pressing button 16 – TRAILER LEG
should be inadvertently pressed. It is GRIP .
possible, in emergency situations, to
make an override of this function by 4. Remove the ice or other obstacle so that the sensors can
pressing the switch Y. move free again.
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 and
chine rolling. The greatest possible
care must be exercised during towing the parking brake is automatically applied. If, thereafter, it is
operations to prevent personal injury. 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! and brake capacity.
The truck cannot be started by
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 damage Mechanical release of Parking Brake
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
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
B 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.
Fire protection
KL1102
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.
SUPERVISION Daily supervision
IMPORTANT! Supervision
The following must be carried out in Supervision is differentiated as follows:
addition to daily and periodic supervi-
sion:
z DAILY SUPERVISION – carried out by the operator
Service during the running-in period
z PERIODIC SUPERVISION – carried out by specially trained
z Tighten the wheel nuts and propshaft service personnel.
bolts after 8, 16 and 24 hours of oper-
ation. Tightening torque in accord-
ance with the Technical Handbook. Proper supervision contributes to making the truck safe to work
Tighten the wheel nuts in a zig-zag with.
sequence. Tighten the nuts in the
same way every time after changing a Periodic supervision is described in the Technical Handbook. The
wheel. operator must make sure that the truck is available for service
Guarantee service after 50 hours. every 200 hours of operation.
The guarantee service is performed by All times refer to the hours of operation, i.e., the time recorded by
Kalmar, or by personnel authorized by the hour meter on the panel.
Kalmar, and is part of the Kalmar delivery
commitments.
N.B. Only genuine Kalmar spare parts may be used. Spare
The guarantee service is also a condition tyres and replacement tyres must be of a make
for continued validity of the guarantee. approved by Kalmar.
Or when Refill as More details

DAILY SUPERVISION Check
refuelling required on page
Brakes Operation
Steering Operation Check that the rear steered axle

suspension is free from dirt and that
the sensor is free from grease
(Mechanical overload safety system)
All instruments: Operation

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

Pivot points, slide plates
Lift unit and rotator Operation

Twist-locks At suspected damage,
check the twist-locks
immediately
All hydraulic 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 reading • 46
should never drop to 0
Engine oil Level • 47
Coolant • Level • 46
Hydraulic oil • Level • 48
Gearbox oil • Level • 48
Windscreen washer • Fluid level • 49
Wheels • Tyre pressure 1,0 MPa
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 me-
of a make approved by Kalmar. chanical 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
SUPERVISION Fuel system, cooling system
Fuel system
Always refuel with ordinary diesel oil.
Never use any additives for 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 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
clean.
KL590
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 Back off 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 screws is completely free from air. Continue pump-
ing 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. Back off the
fuel pipe at any two injectors and run the starter motor until airfree
fuel sprays out. Tighten the coupling immediately. Make a fresh
starting attempt.
Cooling system
The coolant is topped up via the header on top of the radiator,
which is located under the cab.
WARNING!
Do not open the cap when the engine is hot, since steam
or hot water 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 up.
Insufficient coolant may impair the coolant circulation which may
cause the coolant to boil and give rise to engine damage.
SUPERVISION Engine oil, accumulators
Engine oil
The dipstick for the engine oil (B) is 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.
Clean the dipstick before checking the oil level.
It is advisable to top up with oil when the engine is warm and the
oil flows easily. Top up – wait a while – check on the dipstick.
B 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 should light 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, holding
it down in the depressed position for a brief while on every oc-
casion.
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 re-
peat the test a couple of times.
6. If the brakes cannot be applied six times before lamp 45 lights
up, the accumulators are faulty. If so, ensure that the fault re-
ceives attention as soon as possible and that the accumula-
tors are charged with nitrogen.
KL591 WARNING!
Charging should be made with approved equipment by

authorized personnel.
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
working 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. Open also valve B!
SUPERVISION Hydraulic system, gearbox oil
Hydraulic system
The hydraulic tank is on the right-hand side of the truck.
A Refill
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% of Lubrizol additive to
ensure satisfactory performance of the oil-cooled brake system.
The additive is not consumed during normal operation and must
only be added at oil change and refill. Lubrizol may be ordered
from Kalmar Service department.
WARNING!
Hydraulic fluid with Lubrizol additive is chemically

aggressive. Avoid extended contact with the skin.
Gearbox oil
The oil filler cap and dipstick for the gearbox oil are beneath the
service cover in front of the cab.
A Filler pipe
B Dipstick
Check the level with the engine idling.
KL950B
SUPERVISION Air cleaner, windscreen washer
Air cleaner
The dust container is emptied automatically.
The filter element in the air cleaner 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 cleaner and the
engine.
Check the indicator regularly and get in touch with the service
personnel as soon as the indicator has turned red.
N.B. Inadequately filtered intake air may quickly cause
serious damage to the engine.
Time to change
the filter!
Windscreen washer
The windscreen washer container is beneath the service cover in
front of the cab.
Check that there is sufficient washer fluid in the bottle. Refill if
necessary. Use anti-freeze fluid during the winter, e.g. methylat-
ed spirits or special washer fluid.
KL592
SUPERVISION Electrical system
IMPORTANT!
Electrical system
The starting batteries accompanying 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 implies that it should not negative pole is connected to the chassis.
be necessary to top-up with electro- The positive pole is connected to a main switch A.
lyte during the life of the batteries. When working with the electrical system, when carrying out
welding on the truck or at long time parking, always isolate the
However, the level of the electrolyte batteries.
should preferably be checked once or
twice a year. Fill as required by add-
ing 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.
WARNING! If electrolyte gets into the eyes, immediately rinse with
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
B S1 Wiper motor front, direction indicators,
seat buzzer, parking brake sensor ........................... 10
S2 Ignition key, pre-heater, starter motor,
cab lighting (Option: air conditioner 25 A) ................ 15
S3 Container attachment, 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
Fan (Option: Air conditioning) 1) ............................... 25
A KL593A S7
S8
S9
Spare (Option: Container lights) 1) ........................... 15
Working lights (15 A for 4 lamps) 1)
Hazard beacon ........................................................ 10
S10 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
2 4 6 8 10 12 14 16 19 (main fuse), positional lights 15
S13 Main beam, right-hand ............................................... 5
1 3 7 9 11 13 15 S14 Main beam, left-hand ................................................. 5
S15 Dipped beam, right-hand............................................ 5
S16 Dipped beam, left-hand .............................................. 5
S17 Rear light, left-hand .................................................... 5
C S18
S19
S20
Rear light, right-hand.................................................. 5
ECU11) ..................................................................... 10
ECU2........................................................................ 10
KL728A
S21 Voltage converter ....................................................... 5
S22-24 Spare.......................................................................... –
1)
Optional equipment
Miscellaneous fuses
A Main switch
B Main fuse, boom (1x25 A)
D C
D
Attachment fuse, in the attachment electrical central box
Main fuse for truck electrical system
Fitted on the engine, 2x50 A
LUBRICATION CHART
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 lamps 1,2 W2x4,6d
Cab lighting 10 S8,5
Rear lights, red 5 BA15s
Brake lights 21 BA15s
Direction indicators 21 BA15s
Position lights 5 SV8,5
Driving lights (full/dipped beam) 75/70 P43t-38
Reversing lights, white 70 PK22s
Working lights 70 PK22s
Hazard beacon 70 PK22s
Starting from another battery

z Make sure the auxiliary batteries are connected in series, so
that 24 V will be supplied.
N.B. Note: Do not disconnect the truck-battery cables
z Connect the jumper cables in the following order:
WARNING! 1. Red cable (+) to auxiliary battery
2. Red cable (+) to truck battery
Batteries emit oxyhydrogen which is 3. Black cable (–) to auxiliary battery
an explosive gas. A spark, for 4. Black cable (–) to a location some distance away from
example from incorrectly connected the truck battery, such as the negative cable connection on
starting cables, could cause a battery the chassis.
to explode and result in serious injury
and damage. z Start the engine
Do not disturb the jumper cables while starting, as sparks
may otherwise be caused. Do not lean over either battery.
z Disconnect the jumper cables in exactly the reverse order.
LUBRICATION CHART
3 4 5
2
1 24
DRD400-60C5
6, 7
KL686C
Refill
Brake
Planetary
gear
Sight
glass
LUBRICATION CHART
Item Description Interval No. of Remarks
No. operating hours lub.
points
200 600 1000
1 Boom mounting L 2
2 Slide plates, boom L Manually pump grease while the boom is
moved slowly outwards and inwards to its
end positions
3 Rotator mounting L 2
4 Tilt cylinders L 4
5 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
6 Rotator bearing L 4 2 nipples on each side
7 Pinion and ring gear L 3 Brush on with grease
8 Link levers L 4
9 Steered wheel bearing 2 Remove, clean, inspect and pack with
grease every 4000 h
10 Knuckle pin bearings 4 Remove, clean, inspect and pack with
grease every 4000 h
11 Engine oil x x) Change the oil every 200 h1)
12 Engine oil filter x 2 x) Change the filter every 400 h
13 Gearbox oil C x 1 x) Change the oil. Check the level at idling
speed
14 Gearbox oil filter x 2 x) Change the filters
15 Hydraulic oil filter x 2 x) Change the filters
16 Cooling oil filter, hydraulic brake system x 1 x) Change the filters
17 Filter, servo system x 1 x) Change the filters
18 Hydraulic oil filter, top lift frame x 1 x) Change the filters
19 Propeller shaft L 3
20 Drive axle C x 3 Change the oil
21 Breather filters, hydraulic tank x 2 x) Change filters every 2000 h
22 Hydraulic oil C x x) Change oil 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 is greatly dependent on the fuel and lubricant
quality as well as the operating conditions.
If intervals longer than 200 hours are desired, the condition of
the oil must be checked by the company making the oil,
by means of regular lubricant tests.
2)
Note! DIfferent oils in brake and planetary gear. (Volume
brake: 0.6 l. Volume gear: 1.6 l)
For volumes, see Technical Data.
For lubricating oil grades, see
Oil and lubricant recommendations
L = Lubricate
C = Check
IMPORTANT!
If the truck is standing 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.
LUBRICATION CHART, COMBI-LIFT UNIT
A3139001B
7 6 6 7 7
8
LUBRICATION CHART, COMBI-LIFT UNIT
Item Description Interval No. of Remarks
No. operating hours lub.
200 600 1000 points
1 Sliding surfaces, length adjustment L Brush onto all sliding surfaces with the
attachment in the fully extended position
2 Sliding surfaces, sideshifting L Brush onto all sliding surfaces with the
attachment sideshifting to the limit in each
direction
3 Cylinders, levelling L 8
4 Cylinders, sideshift L 4
5 Cylinders, length adjustment L 4
6 Locking cylinder, twist-locks L 6 Check that the sensors are clean from
grease and that the sensor faces are
undamaged.
7 Lift pinion twist connection L 4 Lubricate with grease
8 Lift pinion L 4 Disassemble the twist-locks every 2000 h.
Check for wear. If needed, change compo-
nents accordingly. Clean and pack with
grease. Same procedure should be used at
suspected damage to the twist-locks. Check
that the sensors are free from grease and
that the sensor faces are undamaged.
9 Contact pins L 4 Lubricate with grease. Check that the
sensors are clean from grease and that the
sensor faces are undamaged.
11 Cylinder, lowering/raising L 8
12 Leg bearing L 4
13 Lift shoe mounting L 4
14 Grip cylinder L 8
15 Leg bearing L 4
16 Lift shoe L 4 Lubricate all moving part with oil to prevent
the build up of rust.
Do not use grease.
Check that the sensors are clean from
grease.
L=Lubricate
C=Check
TECHNICAL DATA
Truck model, type designation DRD
400-60C5 – 450-60C5 – 450-60C5X – 450-80C4X

400-70C6 450-70C5 450-70C5XS
Engine
Make – type designation Volvo – TWD1031VE Volvo – TWD1231VE
Fuel – type of engine Diesel – 4-stroke Diesel – 4-stroke
Power ISO 3046 1) – at speed kW -r/m 235 – 2100 275 – 2100
Torque ISO 3046 – at speed Nm-r/m 1500 – 1100 1753 – 1100
No of cylinders – compression 6-18,0:1 6-18,0:1
Alternator, type – power AC – 1920 W AC – 1920 W
Starting battery, voltage – capacity V-Ah 2x12 – 140 2x12 – 140
Transmission
Gearbox, make – type designation Clark – 15,5 HR 36432 Clark – 15,7 HR 40432
Clutch, type Torque converter Torque converter
Gearbox Powershift Powershift
No. of gears, forward – reverse 4–4 4–4
Drive axle, type Double reduction, Double reduction,
planet gear hub planet gear hub
Wheels
Wheels, front and rear 2) Pneumatic
Wheel dimension, 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 dB(A) max 72
with noise reduction kit dB(A) 68
Liquid capacities TWD1031VE/Clark 36000 TWD1231VE/Clark 40000

Cooling system L 65 75
Gearbox L 57 55
Engine L 32 38
Fuel L 510 510

Hydraulic system,tank volume L 600 700
total volume L 880 1000
Drive axle (incl. hub reduction) L 74 222
Truck dimensions and weights vary according to amount of extra

equipment on the truck.
These changes are explained in the product specification and
data sheet.
1)
ISO 3046=Net power.
2)
Spare wheels should be of a brand approved by Kalmar.
Engine oil
Grade: API – CD oil for turbocharged 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 additive,
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.
Viscosity: Class HV, ISO VG46 at normal working temperatures.
Class HM, ISO VG 68 at tropical conditions
Class HV, ISO VG 32 at extremely cold conditions
Additive: 6% LUBRIZOL LZ 9990A
Grease
Use EP universal grease to NLGI Grade 2 with 3–5% molybde-
num disulphide additive for all lubrication points, including wheel
bearings.
IMPORTANT!
Any deviations from these recommen-
dations must be supported by written
approval from Kalmar Service.
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 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
WITH THE APPROVED C-3 SPECIFICATION.
IMPORTANT!
Any deviations from these recommen-
dations must be supported by written
approval from Kalmar Service.
Kalmar Industries Sverige
Torggatan 3 SE-340 10 Lidhult, Sweden
Tel: +46 372 260 10. Fax: +46 372 259 77.
www.kalmarind.com

DRD400-450 920935 - 0393 PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

DRD400-450 920935 - 0393 PDF

Hochgeladen von

Copyright:

Verfügbare Formate

CONTCHAMP

Publ. no 920935.0393 0206

Detailed technical descriptions with circuit diagrams, periodic su-

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 entitled

101 403 109 803 701 103 403 101

403 203 803 113 301 708 110 403

304 111 302 306

811 803 101

108 112 102

10 Chassis, cab 112 A32442.0100 Warning! 70 Hydraulic system

103 A26939.0200 Warning!

104 A26940.0100 Parking brake

inside of left hand

110 A30770.0300 Warning!

306 A32439.0100 Engine oil.

408 A32439.0200 Transmission oil.

1. Gear lever .............................................................. 14 7. Electrical central unit

21. Pressure gauge, gearbox oil pressure 40. Spare

Lamp panel on the boom

Lit lamps at container lift:

KL437 Lit lamps at trailer lift:

42 All of these lamps should be extinguished when the truck is in op-

Battery charging lamp (42)

Lubricating oil pressure, engine (43)

45 Oil pressure, gearbox (44)

48 Engine coolant level (46)

49 Engine preheating (47)

Engine coolant temperature (48)

N.B. Always start in first gear to Parking brake lamp (51)

Pressure gauge, gearbox oil pressure (21)

22 Fuel gauge (22)

Temperature gauge (23)

Starting switch (5)

The truck has an electrical restart guard protecting the starter

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

Direction indicators/Dip switch/Horn (2)

Adjusting the steering wheel (11)

Parking brake (13)

N.B. Additional menus may occur as a result of adaptation

Explanations, see next page

Operating menus with mechanical overload protection, module 50

1. Main menu KALMAR INDUSTRIES SERVICE

2. Normal operating condition, module 50

6 6. The system interrupts operation. The red warning lamp lights

Explanations, see next page

Operating menus with electronic overload protection, module 60

2. Normal operating condition, module 60.

6. a. 75 °C Engine coolant temperature

b 9. a. 28756:21.54 h. Total operating time, h: min. sec.

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

02. Faulty signal from accelerator sensor.

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.

01, 07 09 09. Faulty signal from engine rev sensor.

07 10 10. Low engine oil pressure.

07 11 11. High coolant temperature.

07 12 12. Low gearbox oil pressure.

07 14 14. Fuel level extremely low.