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Instruction Drd420 450
Instruction Drd420 450
Instruction Drd420 450
Instruction Manual
ContChamp
DRD420-450
Container handling
Contents
Safety regulations ...................................................................... 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, Micro 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.................................................................. 42
Supervision.............................................................................. 43
Daily supervision ................................................................ 43
Tyres ................................................................................... 44
Fuel system ........................................................................ 45
Cooling system ................................................................... 45
Engine oil............................................................................ 46
Checking the accumulators ................................................ 46
Hydraulic system ................................................................ 47
Gearbox oil ......................................................................... 47
Air cleaner .......................................................................... 48
Windscreen washer ............................................................ 48
Electrical system ................................................................ 49
Technical data.......................................................................... 51
Lubrication chart...................................................................... 52
Oil and lubricant recommendations......................................... 58
Detailed technical descriptions with circuit diagrams, periodic
supervision, trouble shooting and repairs are dealt with in the
Technical Handbook.
We reserve the right to alter design and material without
notice.
ContChamp DRD420-450 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 sure that the truck has approved fire extinguishing
apply to your own safety. Warnings point out the risk of equipment in accordance with currently applicable
accident that can cause personal injury. regulations.
Operation of the truck is prohibited:
z If any of the fitted safety equipment, such as rear
WARNING! view mirrors, headlights, reversing alarm (option-
al), does not function correctly.
Warns of the risk of serious personal injury, pos- z If there is a fault with the brakes, steering or lift
sible death and/or serious damage to product or equipment.
property if the regulations are not followed.
z If it has been repaired, modified or adjusted with-
out the approval of the work supervisor.
For technical warnings, that point out the risk of break z If the truck is fitted with tyres not approved by
down, the word IMPORTANT is used: Kalmar.
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
2 ContChamp DRD420-450
Safety regulations
Continued from previous page must be emptied into the tank, with the help of the
special accumulator evacuation valve.
Operating regulations
z Handle batteries and junction boxes with great
z Before starting, make sure that the cab is locked
in the rear-most position by means of the latches, care. The batteries must always be protected over
the poles and connections.
one on each side. The latches must be secured
with spring pins. (Applies to manually moveable z Always rectify any damage or wear and tear that
cabs). can risk personal safety or that can affect the func-
z Before starting, always check to ensure that no- tions of the truck or its service life.
body is in the way of the truck or its equipment. z Avoid touching oils and greases. Avoid inhaling
exhaust and oil fumes.
z The operator must always face the direction of op-
eration and take particular care in areas where z Always use steps and handrails when entering or
persons or other vehicles are likely to appear in leaving the machine - Never jump!
the vicinity. If visibility is limited by the load, the op- To avoid the risk of slipping, tread only on anti-slip
erator should operate the truck in reverse. surfaces. If the anti-slip protection has become
worn, loose or in any way less effective, it should
z It is prohibited to walk or stand underneath raised
forks or other equipment, whether they are loaded be replaced.
or not. z Welding painted steel produces poisonous gas-
ses. Paint should therefore be stripped before
z It is prohibited to transport passengers on the welding, good ventilation ensured and/or face
truck outside the cab or on the load. Passengers
may be transported inside the cab only on condi- mask with filter used.
tion that it is equipped with a fixed passenger z Mobile phones used in the cab must always have
seat. fixed connections to the machine’s electrical sys-
tem, with a fixed antenna outside the machine,
z It is prohibited to lift people if the truck is not
equipped with an approved lift cage. mounted in accordance with the manufacturer’s
instructions. This will avoid interference with the
z It is prohibited to exceed the load capacity of the machine’s important electronic functions.
truck. See capacity plate and loading diagram.
Operating with attachments
z It is prohibited to transport loads in the raised po-
sition as this entails a risk of the truck tipping. All z The operator must always take the effect of the
transportation shall take place with the load in the wind into account when handling containers.
transport position. Avoid lifting with a wind strength in excess of 12
m/s (27 mph/40 feet per second).
z The operator must adapt the speed of the truck to
the character of the load, conditions of visibility, z Always drive carefully so as to avoid attachments
the character of the roadway/surface, etc. colliding with pillars, cables, etc.
z The operator shall avoid powerful acceleration z Carefully study the "Lift methods" section of the
and braking when turning. In addition, the opera- instruction manual.
tor shall always moderate the speed of the truck z The tensile strength of the top pane can be seri-
when turning so as to avoid the risk of lateral skid- ously weakened by exposure to elements that
ding or tipping. contain: Aromatic hydrocarbon, ketone, esters or
z The operator shall take particular care when oper- chlorinated hydrocarbon.
ating in the vicinity of electrical power lines, via- Regularly check the surface condition of the top
ducts, quay-sides, ramps, gates/doors etc. pane and clean only with screen wash or other
mild cleaning fluid. After cleaning, rinse thorough-
z Safety belts must always be worn, if fitted. In the ly with warm water. It is prohibited to modify or in
event of the truck tipping, always remain in the cab
and grip the steering wheel securely. Never try to any other way make alterations to the top pane.
Immediately replace damaged top panes that
jump out of the cab. show signs of cracking or scratching.
z The parking brake can also be used as an EMER-
GENCY BRAKE. However, having been used for
emergency braking, the brake linings must be
checked and replaced if necessary. If the parking
brake has been mechanically released, it must
always be reset in order for the truck to regain the CE marking
parking brake function. All trucks and equipment (though not thoses fitted on
Interrupted operation, parking the truck or intended as spare parts) supplied from Ka-
z Always check that the gear lever is in the neutral lmar are CE marked, which indicates that they comply
with the requirements of the EU Machine Safety Direc-
position before turning the ignition key to restart or tive. In addition, each truck has a so called, “EU Dec-
to reset an emergency stop.
laration of Conformity” which is the legal proof that the
z Never leave the operator's cab without applying truck complies with the “health and safety” require-
the parking brake (ON position). ments laid down in the Machine Safety Directive, the
z Always remove the ignition key if the truck is to be EMC directive (electro-magnetic compatibility) and the
left unattended. LVD directive (electrical equipment).
Other important points to remember
z The truck's hydraulic system includes high pres- Vibration standard
sure hydraulic accumulators. Always be extremely
careful when working with the hydraulic system The truck complies with and is below the limits for vi-
and avoid being unnecessarily close to the hy- bration standard EN 13059.
draulic equipment, lines and hoses. Before work-
ing on the hydraulic system, the accumulators
ContChamp DRD420-450 3
Introduction
Kalmar ContChamp, version DRD are specialized machines for
container handling.
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 container models unless
otherwise stated. Since the trucks are delivered with different
equipment, minor deviations from the Instruction Manual may
occur.
Kalmar
Type designation
DRD450-65S5XS
Diesel engine
Reach Stacker
Generation
Lift capacity
1:st row, decitonnes
Distance between axles,
decimetres
Top lift spreader
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
4 ContChamp DRD420-450
Introduction
DRD420-60S5
4
KL595C
5 6 7
ContChamp DRD420-450 5
Signs
The information plates on the machine are shown below. The op-
erator shall be aware of and follow the warnings and instructions
given on them. Plates that have disappeared, been damaged or
become illegible shall be immediately replaced. Spare parts num-
bers are stated on respective plates. They can also be found in
the Spare Parts catalogue.
101 101
A38193.0100A
103
801
A38193.0100B
710
A38193.0100C
107
A38193.0100E
A38193.0100D
6 ContChamp DRD420-450
Signs
centre
108 A30770.0100 Warning! MPa
1 = Refrigerant, type
2 = Amount, kg
3 = Pressure, bar 306 A32439.0100 Engine oil. S/N =Serial number
111 A32441.0100 Warning!
Do not step here.
ContChamp DRD420-450 7
OPERATION Instruments and controls
3 1 4 5 2 6
F
4 3 2 1
L 0
R
R
4 5
KL1406
7 8 9 10 11 12 13
8 ContChamp DRD420-450
OPERATION Instruments and controls
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
62. Switch, windscreen wiper, rear
KL675 63. Switch, windscreen wiper, roof
64. Spare
65. Fuses
66. Hour meter
1) Optional
65
ContChamp DRD420-450 9
OPERATION Instruments and controls
Joy-stick functions
1 2a 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
13. Rotation limiting
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 function1 above
17. Stop at 30' and 35' 1)
18. Cab movement horizontal/vertical1)
See page 29
19. Support jacks 1)
See page 33
20a. Red lamp, the support jacks
have left the upper position 1)
20b. Green lamp, support jacks down 1)
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.
10 ContChamp DRD420-450
OPERATION Instruments and controls
A C
Lamp panel on the boom
Container handling
A. Twist-locks locked, green
B. Alignment, orange
C. Twist-locks unlocked, red
KL20
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
ContChamp DRD420-450 11
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.
All of these lamps should be extinguished when the truck is in op-
eration.
42
A steady light and a buzzer indicate failure.
49
Engine preheating (47)
The lamp will lights during the preheating period.
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.
12 ContChamp DRD420-450
OPERATION Instrument and controls
Trucks equipped with ECS System, module 07, are not fitted
with instruments 21, 22 and 23.
23
Temperature gauge (23)
The temperature gauge shows the engine coolant temperature,
which should normally be approx. 80°C. This temperature will be
reached after the engine has run for about 5 minutes. The tem-
KL581 perature may vary between 75 and 97°C.
A higher temperature may be an indication that 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.
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.
WARNING!
Risk of explosion.
Never use start spray to assist in starting.
ContChamp DRD420-450 13
OPERATION Instrument and controls
Gear lever – Forward/Neutral/Reverse (1)
– 1/2/3/4
The gear-changing mechanism is electrical, gear-changing being
effected via solenoid valves.
2 3 F F – FORWARD
1 4
N – NEUTRAL
R – REVERSE
21
TURN, lever 1, 2, 3, 4
4 3
KL677
14 ContChamp DRD420-450
OPERATION Instrument and controls
Brake pedals and release clutch activator (8 and 9)
The brake pedals operate hydraulically, connected to the hydrau-
lic system of the truck via accumulators which ensure that there
will always be sufficient pressure for braking, even in the event of
the engine stopping for a brief period. If the accumulator pressure
falls below a certain level, lamp 45 on the panel will come on.
F
The brake pedal (8) is used as the ordinary foot brake.
4 3 2 1
L 0
R
KL597
Accelerator (10)
The accelerator pedal is mechanical and actuates the fuel injec-
8 9 10 tion pump by means of a wire.
Options: Some trucks are equipped with hydraulic or electrical
accelerator.
KL588
WARNING! IMPORTANT!
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.
ContChamp DRD420-450 15
OPERATION ECS
Kalmar 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 way s .
All vital points of the trucks different systems are connected to
one or several central computer units, ECUs. A terminal display
in the operator’s cab shows current values and generates an
alarm if the values exceed the programmed tolerances.
DRD Container machines are equipped with ECS as standard.
Depending on how respective machines are equipped, one, two
or three ECU central units may be fitted.
z ECU 1 is used for different additional modules, such as 01
Automatic Gear Changing, 04 Lever Steering, 06 Micro
Steering, 07 Monitoring.
z ECU 2 is obligatory and is used to control the El-Servo cir-
cuits. ECU 2 also functions as overload protection and for the
1 regeneration system.
2 z ECU 3 controls the separate bottom lift and other specific
modules
ECU 3 The ECS:
– provides torque controlled automatic gear changing
(Module 01)
– provides electro-hydraulic lever steering with or without
wheel return (Module 04)
DRD400-60S5
16 ContChamp DRD420-450
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
1.
1. 1.
1.
KL1409
1.
Enter
2.
1.
1a.
1a.
3.
ContChamp DRD420-450 17
OPERATION ECS
Operating menus
The menus that are displayed on the terminal depend on the
modules with which the truck’s ECS is equipped. The overview
below shows the possible combinations. Use either arrow
RIGHT/LEFT to switch between menus. All operating menus are
01 Automatic gear changing in a connected loop.
07 Monitoring 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.
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
18 ContChamp DRD420-450
OPERATION ECS
Operating menus, module 50
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
c. 4 km/h Current speed
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.
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
ContChamp DRD420-450 19
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
20 ContChamp DRD420-450
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
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
ContChamp DRD420-450 21
OPERATION ECS
Error message s
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 04
04. Gear lever not functioning.
Engine speed reduction.
Stop as soon as possible and contact service.
07 06
06. Coolant temperature extremely high.
Engine speed reduction.
Stop as soon as possible and contact service.
07 08
08. Gearbox oil temperature extremely high.
Engine speed reduction.
Stop as soon as possible and contact service.
22 ContChamp DRD420-450
OPERATION ECS
07 13
13. High gearbox oil temperature.
Check oil level and top up as required.
07 18
18. Faulty signal from gearbox oil pressure sensor.
Operation possible.
Contact service.
ContChamp DRD420-450 23
OPERATION ECS
07 22
22. Faulty signal from hydraulic oil temperature sensor.
Operation possible.
Contact service as soon as possible.
07 28
28. Warning! Low brake pressure.
Contact service as soon as possible.
24 ContChamp DRD420-450
OPERATION ECS
60 51
51. Communication with ECU 3 broken.
Contact service as soon as possible.
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 56
56. Faulty signal from hydraulic pressure sensors for left lift cyl-
inder. (There is a sensor in both feed and return lines)
Stop as soon as possible and contact service.
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)
Stop as soon as possible and contact service.
ContChamp DRD420-450 25
OPERATION ECS
50 58
58. Faulty analog signal from joystick.
All boom functions are interrupted.
Stop as soon as possible and contact service.
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
26 ContChamp DRD420-450
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 kpm
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
21
ContChamp DRD420-450 27
OPERATION ECS
Module 06, Mini steering
The Mini steering module is an electrohydraulical system for
3 6 comfortable steering of the truck with the arm on the armrest. The
steered wheels follow the position of the Mini steering device. If
the operator releases the Mini steering device, both the steering
device and the steered wheels remain in the set position.
The standard steering wheel is equipped with inductive sensors
2
that sense the movement of the steering wheel. The sensors dis-
b connect the Mini steering if the operator is faced with an emer-
1 4 gency situation and starts using the standard steering wheel.
a
When the Mini steering is disconnected, the lamp in switch 2, see
below, is extinguished.
1. Mini steering device
5 2. Direction switch F/N/R. The lamp in the switch is alight when
the lever steering is activated
Forwards position = F. Centre position = N
Backwards position = R
3. Signal horn
4. Switches for gear changing, a=UP, b=DOWN
(Excluded if the truck is equipped with module 01 Automatic
gear changing) Press 4a to shift gears 1-2-3-(4) (once for
every gear) and 4b to shift down. The gear changing always
starts with gear 1 on starting and after the direction switch
has passed the N position.
5. Switch for activating Mini steering
Condition: The truck speed must not exceed 3 kph. If the
speed exceeds 3 kph it not possible to activate the Mini
steering. The lamp in switch 2 is alight when the Mini steer-
KL1404 ing is activated
6. Extra function
28 ContChamp DRD420-450
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
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
KL1090
ContChamp DRD420-450 29
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.
KL1412
30 ContChamp DRD420-450
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.
ContChamp DRD420-450 31
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 pan-
el.
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
32 ContChamp DRD420-450
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 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
ContChamp DRD420-450 33
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
WEIGHT IS 28,5T
KALMAR
1. 10,5T
2. 9,5T
3. 1,0T
4. 5,0T
5, 8,0T
34 ContChamp DRD420-450
OPERATION Heating and air conditioning system
Heating and air conditioning system
The standard version of the truck is equipped with heater and de-
froster only.
The heating system is connected to the engine cooling system
and starts delivering heat after the engine has warmed up.
34 The fan is controlled by switch 37. The air conditioning system
35 can be switched on and off by means of switch 34.
NOTE. The air conditioner is optional equipment.
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.
KL1452
z When the windows have been demisted, set the cooling con-
trol 39 so that the cooling thermostat will trip at regular inter-
vals for defrosting the cooling element.
A z Close recirculation with 35.
A
Note that the cooling is used for dehumidifying the air in the
cab.
ContChamp DRD420-450 35
OPERATION Heating and air conditioning system
Thermostatically controlled Air Conditioning unit
As an optional extra, a thermostatically controlled system for air
conditioning, cooling, demisting/dehumidifying and heating, is
available.
The system is equipped with a sensor that senses both inner and
outer temperatures and automatically regulates the temperature
to the pre-set level, either by heating or by cooling.
33 33. Switch DEMIST/DEHUMIDIFYING FUNCTION.
34. Switch COOLING FUNCTION OFF.
34 35. Switch RE-CIRCULATION.
Switch forwards - air from outside.
35 Switch backwards - air from inside.
36. Control DEMIST/CAB.
37. Control FAN. Infinitely variable setting of fan speed.
38. Control TEMPERATURE. Infinitely variable setting of cab
temperature from 16-26°C.
36 39 Control fully clockwise: Full heating effect = heating valve
KL599A continuously open.
37 Control fully anti-clockwise: Full cooling effect = cooling func-
tion running continuously.
38 N.B. When the controls are in respective full positions, pre-
cise temperature regulation cannot be achieved.
39. Cover. The climate equipment’s demist thermostat is located
under this cover. The thermostat must always be set in the
max. clockwise position.
Normal operation
N.B. Run the compressor from time 1. Set controls 37 FAN and 38 TEMPERATURE to the required
to time, even during the winter, in fan speed and temperature.
order to lubricate and ensure The fan must be running for cooling to function. (If the fan is
correct function. switched off, the compressor and condenser stop.)
2. The system then operates automatically, as follows:
N.B. The cooling is not operative at – When heat is required:
temperatures below 0°C. The system operates in 10 second cycles. The water valve
opens for heating at intervals from 0 seconds, extending
to 4 seconds. Thereafter, the valve is open for continual
heating.
– When cooling is required:
The system operates in 2 minute cycles. The compressor
operates at intervals from 30 seconds, extending to con-
tinual operation. The condenser operates continuously as
long as cooling is required.
Demisting/Dehumidifying the air in the cab
1. This function is used when the windscreen/windows mist up.
2. Start demisting by pressing switch 33.
The fan then runs at full speed for 3 minutes, the compressor
and condenser run continuously. The switch lamp lights.
N.B. The cooling system is used for dehumidifying air.
3. After 3 min. the fan speed returns automatically to the previ-
ously set level. Control 37 can be used to select a lower fan
speed at any time.
4. Press switch 33 again to switch off the demisting function.
The switch lamp extinguishes.
Operating without automatic cooling
1. Press switch 34 to the OFF position.
The compressor and condenser then stop. The switch lamp
lights. the cooling function is thereby de-selected in all posi-
tions and does not start even when control 38 TEMPERA-
TURE is set to the MIN. position.
2. Set control 38 to the required temperature.
36 ContChamp DRD420-450
OPERATION Operator’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.
C Backrest rake
Turn the knob.
D Armrest slope
ContChamp DRD420-450 37
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
cause should be determined and approximately 50 seconds.
remedied. Turn the key further to position III – the starting position –
and release it as soon as the engine has fired.
Air in the fuel system? – see page 45. Above +5°C
Turn the key directly to position III – the starting position –
and release it as soon as the engine has fired.
Warming-up
Never race a cold engine. Run the engine at 1400–1500 r/min un-
til it starts to warm up. It is essential that the engine oil be warm
and that it is circulating correctly before the turbocharger starts
running at high speeds. Nor should the engine be run at critically
low speeds. Start using the truck only when the engine has
reached normal working temperature, i.e. when the temperature
gauge on the instrument panel reads about 80°C.
38 ContChamp DRD420-450
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 c odes
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.
ContChamp DRD420-450 39
OPERATION Functional checks, stopping of engine, steering
Functional checks
When starting the truck and from time to time when using it, make
a habit of checking:
WARNING! z that the engine temperature gauge reading is about 80°C.
z that the reading on the fuel gauge is sufficiently above 0.
N.B. The reading should never be allowed to drop to 0.
If results of the functional checks
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
operate correctly.
z that all hydraulic functions operate correctly.
z that the indicating lamps for the twist-locks and alignment
operate as intended.
z that the contact pins at the twist-locks can be moved freely
up and down. Note that a pin which binds in the top position
WARNING!
will indicate alignment even if the frame is not in contact with
the container.
If mirrors or CC TV cameras are used
to aid vision, the speed of the ma- z that the twist-lock interlock performs satisfactorily. Lift an
chine must be adapted to the limited empty container sufficiently for the ALIGNMENT lamp to be
vision. extinguished. It must then be impossible to release the twist-
locks.
IMPORTANT!
Never turn the the main switch to OFF when the engine
is running – the voltage regulator may be damaged.
Power steering
The truck has hydraulic power steering with no mechanical con-
nection between the steering column and the steered wheels.
Movements of the steering wheel is transmitted hydraulically to
IMPORTANT!
Remember to carry out the the steered wheels.
daily supervision. Never let the truck run downhill when the engine is not running,
See page 43. since no hydraulic pressure will then be available and the
steering of the truck will be very restricted.
40 ContChamp DRD420-450
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!
WARNING!
ContChamp DRD420-450 41
SPECIAL PROCEDURES
Towing
If possible, the engine should be running during towing in order
WARNING!
to retain braking and steering functions. When the engine is not
running, there is no hydraulic pressure for the steering of the
If it is not possible to run the engine
running during towing, a tow bar must truck which is then extremely limited. Furthermore, the gearbox
be used. will be insufficiently lubricated.
z Towing may only take place over very short distances.
Before preparations for towing begin z If a tow bar is used, it shall be connected to the connection/
and after towing has been completed, towing hitch at the rear of the machine.
the parking brake must be applied and z The brakes function as long as there is pressure in the accu-
the wheels chocked to prevent the ma- mulator, thereafter the operating brakes cease to function
chine rolling. The greatest possible
and the parking brake is automatically applied. If, thereafter,
care must be exercised during towing
operations to prevent personal injury. it is necessary to move or tow the truck, the parking brake
must be released mechanically (see instructions below).
z The vehicle or machine use to for towing must be at least as
heavy as the machine to be towed and have sufficient engine
IMPORTANT! and brake capacity.
The truck cannot be started by z For towing over longer distances or at speeds higher than 10
being towed.
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!
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-
B tinue tightening until the brake pads are released from the
brake disc.
3. Once the fault has been rectified, reset the parking brake
function by returning the nut (B) to the same position as in
point 1.
WARNING!
KL1102
Fire protection
If the machine is equipped with fire extinguishers these should be
of the ABE type, in accordance with EN 3 parts 1, 2, 4 and 5. With
such a fire extinguisher it is possible to extinguish a fire in both
fixed organic materials and liquids. Furthermore, the medium
used to extinguish fire does not conduct electricity.
Suitable fire extinguishers can be ordered from Kalmar.
WARNING!
42 ContChamp DRD420-450
SUPERVISION Daily supervision
Supervision
IMPORTANT! Supervision is differentiated as follows:
The following must be carried out in
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- Proper supervision contributes to making the truck safe to work
ance with the Technical Handbook. with.
Tighten the wheel nuts in a zig-zag
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
Kalmar, or by personnel authorized by All times refer to the hours of operation, i.e., the time recorded by
Kalmar, and is part of the Kalmar delivery the hour meter on the panel.
commitments.
The guarantee service is also a condition N.B. Only genuine Kalmar spare parts may be used. Spare tyres
for continued validity of the guarantee. and replacement tyres must be of a make
approved by Kalmar.
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 sys-
tem)
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 Check all functions.
Run every function to its end position in order to lubricate the
cylinders and prevent corrosion
Engine, gearbox, drive axle, Noises?
hydraulic hoses Oil leakage?
Fuel Amount
The gauge reading • 45
should never drop to 0
Coolant • Level • 45
Engine oil • Level • 46
Gearbox oil • Level • 47
Hydraulic oil • Level • 47
Windscreen washer • Fluid level • 48
Wheels • Tyre pressure 1,0 MPa
ContChamp DRD420-450 43
SUPERVISION Tyres
Tyres
Checks
1. Check the tyres regularly, if possible, daily.
2. Remove objects that could penetrate the tyres, such as bro-
WARNING! ken glass, pieces of wood, metal shvings, etc.
Spare and replacement tyres shall be 3. Check for uneven and rapid wear. This is caused by mechan-
of a make approved by Kalmar. ical faults such as unevenly acting brakes. Make sure that
such faults are immediately rectified.
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!
KL1470RS
Tyre inflation
44 ContChamp DRD420-450
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
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.
ContChamp DRD420-450 45
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
KL591 WARNING!
WARNING!
46 ContChamp DRD420-450
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!
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
ContChamp DRD420-450 47
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.
IMPORTANT!
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.
KL592
48 ContChamp DRD420-450
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. The positive pole is
be necessary to top-up with electro- connected to a main switch A. When working with the electrical
lyte during the life of the batteries. system, when carrying out welding on the truck or at long time
However, the level of the electrolyte parking, always isolate the 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!
S8
S9
Spare (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
2 4 6 8 10 12 14 16 19 S12 Driving lights (main fuse), rear lights
(main fuse), position lights 15
1 3 7 9 11 13 15 S13 Main beam, right-hand ............................................... 5
S14 Main beam, left-hand ................................................. 5
S15 Dipped beam, right-hand............................................ 5
S16 Dipped beam, left-hand .............................................. 5
C S17
S18
S19
Rear light, left-hand .................................................... 5
Rear light, right-hand.................................................. 5
ECU1 1) .................................................................... 10
KL728A
ContChamp DRD420-450 49
SUPERVISION Electrical system
Relays
305 Reversing light
314 Parking brake, disengagement
315 High power (Starting switch)
316 Wiper motor, front
320 Electric stop (ECS 07) 1)
322-1 Coolant level
322-2 Coolant level (ECS 07) 1)
323 Pulse relay, direction indicators
328 Gear shift (ECS 01) 1)
330 Starting block
331 Propulsion forward
332 Propulsion reverse
334 Clutch release (ECS 01) 1)
367 Lever steering (ECS 04) 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
A
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:
1. Red cable (+) to auxiliary battery
WARNING! 2. Red cable (+) to truck battery
3. Black cable (–) to auxiliary battery
4. Black cable (–) to a location some distance away from
Batteries emit oxyhydrogen which is
an explosive gas. A spark, for the truck battery, such as the negative cable connection on
example from incorrectly connected the chassis.
starting cables, could cause a battery z Start the engine
to explode and result in serious injury Do not disturb the jumper cables while starting, as
and damage. sparks may otherwise be caused. Do not lean over either
battery.
z Disconnect the jumper cables in exactly the reverse order.
50 ContChamp DRD420-450
TECHNICAL DATA
Truck model, type designation DRD
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
1)
ISO 3046=Net power.
2)
Spare wheels should be of a brand approved by Kalmar.
3)
Only machines with separate tank for brake system
ContChamp DRD420-450 51
LUBRICATION CHART
3 4 5
2
1 24
DRD420-60S5
6, 7
KL586C
25
Refill
Brake
Planetary
gear
Sight
glass
52 ContChamp DRD420-450
LUBRICATION CHART
Item Description Interval No. of Remarks
No. operating hours lub.
200 600 1000 points
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, working hydraulics x 2 x) Change the filters
16 Hydraulic oil filter, brake system cooling x 1 x) Change the filters
circuit
17 Hydraulic oil filter, servo system x 1 x) Change the filters
18 Hydraulic oil filter, top lift 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
25 Hydralic oil, brake system C x 1 x) Change the oil. N.B. Only machines
with separate tank for brake system
1)
The interval is greatly dependent on the fuel and lubricant qual-
ity 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 recommenda-
tions
L=Lubricate
C=Check
ContChamp DRD420-450 53
LUBRICATION CHART TOP-LIFT, cylinder operated extension
1 2 3 3 1
4 4
4 4 5
A3139001B
7 6 6 7
54 ContChamp DRD420-450
LUBRICATION CHART TOP-LIFT, cylinder operated extension
Item Description Interval No. of Remark
No. operating hours lub.
200 600 1000 points
1 Sliding surfaces, length adjustment L Brush onto all sliding surfaces with the at-
tachment in the fully extended position
2 Sliding surfaces, sideshifting L Brush onto all sliding surfaces with the at-
tachment sideshifting to the limit in each di-
rection
3 Cylinders, pile slope L 8 Only top lift with pile slope
4 Cylinders, sideshift L 4
5 Cylinders, length adjustment L 4
6 Cylinder, twist-locks L 4 Check that the sensors are free from grease
and that the sensor faces are undamaged.
7 Lift pinion twist connection L x 4 Disassemble the twist-locks every 2000 h.
Check for wear. If needed, change compo-
8 Lift pinion L x 4
nents accordingly. Clean and pack with
grease. Same procedure should be used at
suspected damage to the twist-locks.
9 Contact pins C 4 Lubricate with grease
Check that the sensors are free from grease
and that the sensor faces are undamaged.
L=Lubricate
C=Check
ContChamp DRD420-450 55
LUBRICATION CHART TOP-LIFT, chain operated extension
1 2 1
KL 1553a
a
b 4 4
3
KL 1553
4 4 5
KL 1555a
7 6 6 7
KL1555
56 ContChamp DRD420-450
LUBRICATION CHART TOP-LIFT, chain operated extension
L = Lubricate
C = Check
ContChamp DRD420-450 57
Oil and lubricant recommendations
ISO-L HV68
58 ContChamp DRD420-450
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