Instruction Manual DRD ContChamp GB

CONTCHAMP
DRD 400-450
CONTAINER HANDLING
Publ. no 920935.0389 0206
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
Operators 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
Safety regulations
It is important that you read the instruction

manual.
Incorrect handling can lead to personal injury or damage to products and/or property. Therefore, read the instruction book very carefully before operating the truck.
The instruction manual contains important information
about your Kalmar truck, about the operation of the
truck, about safety during operation and about the
trucks daily maintenance. In addition, you will find useful information that will make operations easier for you
in your daily work.
The instruction manual must always be kept in the machine. If the manual should be lost, a replacement must
be immediately obtained. Never use a machine with a
missing instruction manual.
Ask your foreman/group leader if there is anything in
the manual that you do not understand or if you feel that
information is missing in any area.
The symbol
is used on our products in certain
cases and then refers to important information contained in the instruction manual. Make sure that warning and information symbols are always clearly visible
and legible. Replace symbols that have been damaged
or painted over.
In this instruction manual warnings are inserted that apply to your own safety. Warnings point out the risk of accident that can cause personal injury.
Safety regulations aimed at reducing the

risk of personal injury and damage to
loads or other property.
Intended of use
z
The truck may only be used for the purpose for
which it was intended, namely, to lift and transport
goods, the weight of which does not exceed the
maximum permitted load capacity of the truck.
z
The truck may not, without specific permission
from Kalmar, be modified or re-built so that its function or performance is altered.
z
The truck may not be driven on public highways if
it has not been adapted to comply with national
road safety regulations.
Operator requirements
The truck may only be driven by operators who
have been specially trained and who have the
companys authority to do so.
z
Laws and other regulations relating to driving licence, operator ID, log book, etc., must be followed at all times.
z
The operator must be aware of and follow all local
safety regulations.
z
It is always the responsibility of the operator to ensure that the truck has approved fire extinguishing
equipment in accordance with currently applicable
regulations.
z
Operation of the truck is prohibited:

If any of the fitted safety equipment, such as rear
view mirrors, headlights, reversing alarm (optional), does not function correctly.
z
If there is a fault with the brakes, steering or lift
equipment.
z
If it has been repaired, modified or adjusted without the approval of the work supervisor.
z
If the truck is fitted with tyres not approved by
Kalmar.
z
WARNING!
Warns of the risk of serious personal injury, possible death and/or serious damage to product or
property if the regulations are not followed.
For technical warnings, that point out the risk of break

down, the word IMPORTANT is used:
IMPORTANT!
Is used to draw attention to such occurrences
that can cause damage to the product or
property.
Continued on next page
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 machines with hydraulically moveable cab. Optional on
other machines.
KL749
Safety regulations
Continued from previous page
Operating regulations
z
Before starting, make sure that the cab is locked
in the rear-most position by means of the latches,
one on each side. The latches must be secured
with spring pins. (Applies to manually moveable
cabs).
z
Before starting, always check to ensure that nobody is in the way of the truck or its equipment.
z
Make sure that nobody walks or stands underneath raised forks or other equipment, whether
they are loaded or not.
z
The operator must always face the direction of operation and take particular care in areas where
persons or other vehicles are likely to appear in
the vicinity. If visibility is limited by the load, the operator should operate the truck in reverse.
z
It is prohibited to transport passengers on the
truck outside the cab or on the load. Passengers
may be transported inside the cab only on condition that it is equipped with a fixed passenger
seat.
z
It is prohibited to lift people if the truck is not
equipped with an approved lift cage.
z
It is prohibited to exceed the load capacity of the
truck. See capacity plate and loading diagram.
z
It is prohibited to transport loads in the raised position as this entails a risk of the truck tipping. All
transportation shall take place with the load in the
transport position.
z
The operator must adapt the speed of the truck to
the character of the load, conditions of visibility,
the character of the roadway/surface, etc.
z
The operator shall avoid powerful acceleration
and braking when turning. In addition, the operator shall always moderate the speed of the truck
when turning so as to avoid the risk of lateral skidding or tipping.
z
The operator shall take particular care when operating in the vicinity of electrical power lines, viaducts, quay-sides, ramps, gates/doors etc.
z
Safety belts must always be worn, if fitted. In the
event of the truck tipping, always remain in the
cab and grip the steering wheel securely. Never
try to jump out of the cab.
z
The parking brake can also be used as an EMERGENCY 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 parking brake function.
Interrupted operation, parking
z
Always check that the gear lever is in the neutral
position before turning the ignition key to restart or
to reset an emergency stop.
z
Never leave the operators cab without applying
the parking brake (ON position).
z
Always remove the ignition key if the truck is to be
left unattended.
Other important points to remember
z
The trucks hydraulic system includes high pressure hydraulic accumulators. Always be extremely careful when working with the hydraulic system
and avoid being unnecessarily close to the hydraulic equipment, lines and hoses. Before working on the hydraulic system, the accumulators
must be emptied into the tank, with the help of the

special accumulator evacuation valve.
z
Handle batteries and junction boxes with great
care. The batteries must always be protected over
the poles and connections.
z
Always rectify any damage or wear and tear that
can risk personal safety or that can affect the
functions of the truck or its service life.
z
Avoid touching oils and greases. Avoid inhaling
exhaust and oil fumes.
z
Always use steps and handrails when entering or
leaving the machine - Never jump!
To avoid the risk of slipping, tread only on anti-slip
surfaces. If the anti-slip protection has become
worn, loose or in any way less effective, it should
be replaced.
z
Welding painted steel produces poisonous gasses. Paint should therefore be stripped before
welding, good ventilation ensured and/or face
mask with filter used.
z
Mobile phones used in the cab must always have
fixed connections to the machines electrical system, with a fixed antenna outside the machine,
mounted in accordance with the manufacturers
instructions. This will avoid interference with the
machines important electronic functions.
Operating with attachments
z
The operator must always take the effect of the
wind into account when handling containers.
Avoid lifting with a wind strength in excess of 12
m/s (27 mph/40 feet per second).
z
Always drive carefully so as to avoid attachments
colliding with pillars, cables, etc.
z
Carefully study the "Lift methods" section of the
instruction manual.
z
The tensile strength of the top pane can be seriously weakened by exposure to elements that
contain: Aromatic hydrocarbon, ketone, esters or
chlorinated hydrocarbon.
Regularly check the surface condition of the top
pane and clean only with screen wash or other
mild cleaning fluid. After cleaning, rinse thoroughly with warm water. It is prohibited to modify or in
any other way make alterations to the top pane.
Immediately replace damaged top panes that
show signs of cracking or scratching.
CE marking
All trucks and equipment (though not thoses fitted on
the truck or intended as spare parts) supplied from Kalmar are CE marked, which indicates that they comply
with the requirements of the EU Machine Safety Directive. In addition, each truck has a so called, EU Declaration of Conformity which is the legal proof that the
truck complies with the health and safety requirements laid down in the Machine Safety Directive, the
EMC directive (electro-magnetic compatibility) and the
LVD directive (electrical equipment).
Vibration standard
The truck complies with and is below the limits for vibration standard EN 13059.
Introduction
Kalmar ContChamp, version DRD are specialized machines for
container handling.
The machines are part of the Kalmar range of forklift trucks, loghandling trucks and various special machines with lifting capacities 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
For further information, see the section entitled
SUPERVISION.
Introduction
1. Electro-hydraulically activated telescopic boom

2. Top lift frame. Electro-hydraulically
operated, 2040' top lift spreader, with
800 mm sideshifting and +195/
105 rotation.
3. Operators cab, rubber mounted,
moveable longitudinally
4. Drive axle with hub reduction and hydraulic, oil cooled brake system
5. Steered axle with pendulum suspension and double acting steering cylinder.
6. Six cylinder diesel engine with turbo
compressor
7. Gearbox, combined with torque converter
DRD420-60S5
4
KL595C
Signs
The information plates on the machine are shown below. The operator 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 numbers are stated on respective plates. They can also be found in
the Spare Parts catalogue.
101
101
A38193.0100A
101
803 701 103 403
403 109
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
101 423049.0100 Lift point.
Fixing point for lift
equipment when lifting the truck.
102 A26939.0100 Warning!
Read the Instruction
Manual.
112 A32442.0100 Warning!

Do not jump!
Always remain in the
truck and firmly grip
the steering wheel
when there is a risk
of tipping.
113 A32653.0200 Type, machine
70 Hydraulic system
701 450203.0100 Hydraulic fluid.
708 A30168.0200 Hydraulic pressure.

See Technical
Handbook.
MPa
MPa
MPa
MPa
MPa
MPa
103 A26939.0200 Warning!

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

ON-OFF.
107 A30536.0300 Warning!
No Riders!
Passengers may be
carried in the cab
only if it is equipped
with a fixed
passenger seat.
108 A30770.0100 Warning!
Air conditioning
equipment, read the
Technical Handbook.
Coolant may be
topped up only by
authorized
specialist.
109 A30770.0200 Warning!
Air conditioning
equipment, see 108.
Located on the
inside of left hand
frame beam.
110 A30770.0300 Warning!
Air conditioning
equipment,
see 108.
M = Model
S/N = Serial number
Q = Classified lift capacity of the
truck at lift height in accordance with EN1551, EN1459
standards.
W = Unloaded weight of machine
L = Distance between leading
edge of wheel and the load
centre
H = Classified lift height
20 Electrical system
203 A30537.0100 Main switch.
In position 0 the
batterys plus pole is
isolated.
30 Engine
301 450202.0100 Fuel.
710 A30529.0100 Warning!

High pressure!
Always release
pressure from the
accumulator before
working on the
hydraulic system.
80 Attachments
801 A30533.0100 Warning!
Rotating parts.
803 A32440.0100 Warning!

Do not walk under a
hanging load.
D
450202.0100
302 A30530.0100 Warning!

Rotating fan.
304 A30532.0100 Warning!

Hot surface.
811 A33852.0100 Type, attachment
S/N =Serial number
306 A32439.0100 Engine oil.

1
2
3
1 = Refrigerant, type
2 = Amount, kg
3 = Pressure, bar
111 A32441.0100 Warning!
Do not step here.
40 Transmission, tyres
403 A32049.0100 Tyre pressure,
1,0 MPa
408 A32439.0200 Transmission oil.
OPERATION
Instruments and controls
4 3 2 1
L 0
N
R
R
4
KL1406
1. Gear lever .............................................................. 14

FORWARD/NEUTRAL/REVERSE 1/2/3/4
2. Lever DIRECTION INDICATORS/HORN................ 14
FRONT WINDSCREEN WASHER/
FRONT WIPERS/MAIN BEAM
3. Instrument panel ....................................................... 9
4. Steering wheel panel ................................................ 9
5. Starting switch......................................................... 13
6. Control lever and control panel for ......................... 10
hydraulic functions
10
11
12
13
7. Electrical central unit

with fuses and relays ...............................................49
8. Brake pedals, normal driving brake .........................15
9. Release clutch .........................................................15
10. Accelerator pedal.....................................................15
11. Steering wheel adjustment ......................................15
12. Servo circuit breaker................................................11
13. Parking brake ..........................................................15
OPERATION
21
23
22
KL581
29
25
26
27
30
31
32
33
34
37 38 39
35 36
40 41 42 43 44 45 46
52
53
28
47 48 49 50 51
24
54 55 56 60 59
KL582
66
L 0
4 3 2 1
F
N
R
KL580
R
57 58 64
21. Pressure gauge, gearbox oil pressure

22. Fuel gauge
23. Temperature gauge, engine coolant temperature
24. Switch, working lights
27. Switch, flashing beacon
28. Switch, hazard warning lights
29. Switch, driving lights
30. Spare
31. Spare
32. Spare
33. Spare
34. Switch, compressor air conditioning 1)

35. Control, recirculation/fresh air
36. Control, defrost/cab
37. Switch, fan
38. Control, heat
39. Control, cold 1)
KL675
61
62 63
40. Spare
41. Spare
42. Warning lamp, battery charging
43. Warning lamp, low engine oil pressure
44. Warning lamp, low gearbox oil pressure
45. Warning lamp, low brake pressure
(accumulator pressure)
46. Warning lamp, low engine coolant level
47. Indicating lamp, preheating
48. Warning lamp, high engine coolant temperature
49. Warning lamp, high gearbox oil temperature
50. Spare
51. Warning lamp, parking brake ON
52. Spare
53. Spare
54. Spare (Green lamp TWIST-LOCKS LOCKED)
55. Spare (Orange lamp ALIGNMENT)
56. Spare (Red lamp TWIST-LOCKS UNLOCKED)
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
63. Switch, windscreen wiper, roof
64. Spare
65. Fuses
66. Hour meter
1)
Optional
65
OPERATION

2a
2b
Joy-stick functions
1. Tilt 1)
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)
8. Length adjustment 20'40'
9. Unlocking of twist-locks
10. LIFT/LOWER
1)
Optional
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)
Button 17 for the connection and disconnection of

the 30 and 35 stops
The
position gives crawling speed the whole time during extension and retraction. In order to by-pass the 30 stop press
and thereafter
. The next stop will be 35.
It is practical to connect in
once the 30 position has been
passed.
10
Optional
N.B. When operating a machine

which is equipped with hydraulically moveable cab, the doors should
be closed or the cab in its rear position otherwise all functions will be
broken.
OPERATION
A
Lamp panel on the boom
Container handling
A. Twist-locks locked, green
B. Alignment, orange
C. Twist-locks unlocked, red
Lit lamps at container lift:
A+B
Go out after lift: B
Warning!
Overriding of the safety system is at ones own risk and
involves a risk of forward
tipping.
Engagement and
disengagement
of servo circuits
KL20
KL 1407
Override
(Only in emergency situations)
1. Lower
2. Container coupling
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 operation.
A steady light and a buzzer indicate failure.
42
Battery charging lamp (42)

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.
43
Lubricating oil pressure, engine (43)

The lamp will light briefly on starting, and somewhat longer in wintertime 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 level? See Supervision.
44
Oil pressure, gearbox (44)
45
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 operation. If this happens, stop the truck immediately and report to the
service personnel.
46
Low brake pressure (45)
47
KL598
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 accumulators for leakage in accordance with the section entitled Supervision.
Engine coolant level (46)
48
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)
51
The lamp will light up if the temperature of the gearbox oil exceeds 120C. Stop the truck and make sure that the cause is
identified and remedied.
Spare (50)
N.B. Always start in first gear to
prevent overheating of the gearbox.
12
Parking brake lamp (51)

The lamp will lights while the parking brake is applied.
OPERATION

Trucks equipped with ECS System, module 07, are not fitted
with instruments 21, 22 and 23.
Pressure gauge, gearbox oil pressure (21)

The gauge shows the clutch pressure which should be
16.919.3 bar.
Activated parking brake. Idle speed 400600 r/min. Working temperature 8293C.
21
Fuel gauge (22)
22
The tank is full when the gauge reading is 4/4. The tank is halffull 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)
KL581
The temperature gauge shows the engine coolant temperature,

which should normally be approx. 80C. This temperature will be
reached after the engine has run for about 5 minutes. The temperature may vary between 75 and 97C.
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.
Dont run the engine if the coolant temperature is too high.
Operating hour meter (66)

66
KL1307
The operating hour meter records the number of engine operating 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.
Starting switch (5)

P
0
I
II
III
All functions switched off, the key can be removed

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.
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.
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.
13
OPERATION

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 FORWARD
N NEUTRAL
R REVERSE
TURN, lever 1, 2, 3, 4
4
4 3
21
KL676
The engine cannot be started unless the gear lever is in neutral.

The truck must be stopped completely before changing between
forward and reverse, in order to prevent overloading the gearbox
and power transmission.
z
z
z
IMPORTANT!
The truck must be stopped completely before changing between forward
and reverse, in order to prevent overloading the power transmission
Run the engine at idle speed, select the direction of travel

with the gear lever and engage first gear, using the rotary
control. Never pull away in a higher gear, since this may lead
to unnecessary overheating.
Release the parking brake, and accelerate carefully.
To change up, turn the gear selector handle to second gear,
release the accelerator pedal and the second gear will be engaged, accelerate, and so on.
Reverse the procedure when changing down. Remember to
increase engine speed before engaging a lower gear, since
the truck will otherwise brake heavily.
Direction indicators/Dip switch/Horn (2)

FORWARD/BACKWARDS
UPWARDS
DOWNWARDS
INWARDS, button
INWARDS, lever
TURN
Direction indicators
Headlamp flashing
Full beam
Horn
Screen wash
Screen wiper, front
0 = Off/J = Intermittent
I = Continuous wiping
II =
0 J
KL677
14
OPERATION

Brake pedals and release clutch activator (8 and 9)
4 3 2 1
F
L 0
N
R
R
4
KL597
10
The brake pedals operate hydraulically, 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 accumulator pressure
falls below a certain level, lamp 45 on the panel will come on.
The brake pedal (8) is used as the ordinary foot brake.
The brake pedal is combined with a separate release clutch activator (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.
Accelerator (10)
The accelerator pedal is mechanical and actuates the fuel injection 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
Lower handle:
Steering column angle
Loosen the handle anti- clockwise
and adjust as required.
Tighten the handle firmly after
adjustment
11
KL588
Parking brake (13)
13
KL596
WARNING!
Never leave the operators seat without
applying the parking brake.
The parking brake is applied by a powerful spring in the hydraulic

cylinder of the parking brake.
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 applied automatically by a heavy spring in the brake cylinder.
If the wheels then need to be rotated the brake must be mechanically released, see page 42.
The parking brake may also be used as emergency brake.
IMPORTANT!
After any emergency braking the brake pads should be
checked and replaced if necessary.
Report to service personnel.
15
OPERATION
ECS
1
2
ECU 3
DRD400-60S5
KL621b-c
.
ECU 1 1)
ECU 2
ECU 3 1)
01 Automatic
Gear
Changing 1)
04 Lever
Steering 1)
06 Mini
Steering 1)
07
MonitoringL
1
)
El-Servo
50 Mechanical
overload
protection
Regeneration
51 Vertical lift 1)
52 Balance +
vertical lift 1)
53 Tilt locking 1)
57 Hydraulic
balance 1)
58 Container
Counter 1)
59 Limitation of
height/LCdistance 1)
70 PC/Printer 1)
60 Electronic
overload protection
Regeneration
Vertical lift
53 Tilt locking 1)
58 Container
Counter 1)
59 Limitation of
height/LCdistance 1)
70 PC/Printer 1)
Bottom lift 1)
54 Tilt 1)
55 Pile-slope1)
56 Cab
movement
1)
16
1)
61 Support
jacks 1)
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 systems different
modules in a number of different ways.
All vital points of the trucks different systems are connected to
one or several central computer units, ECUs. A terminal display
in the operators 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 circuits. ECU 2 also functions as overload protection and for
the regeneration system.
z
ECU 3 controls the separate bottom lift and other specific
modules
The ECS:
provides torque controlled automatic gear changing
(Module 01)
provides electro-hydraulic lever steering with or without
wheel return (Module 04)
provides electro-hydraulic steering with micro steering
wheel (Module 06)
monitors the engine and gearbox to ensure reasonable
operating conditions (Module 01)
monitors the components in the system, e.g., sensors, to
ensure their correct function (Module 07)
interrupts hydraulic functions with forward overload and
when overload of the steering axle occurs (module 50/60)
controls vertical lift and balance (standard el-servo
adapts the speed of movement of the BOOM OUT function in relation to the load and adapts the speed of movement of the LOWER function in relation to boom extension
and load (standard el-servo)
If a fault occurs:
a red warning lamp blinks on the terminal
an error message appears on the terminal display
The ECS limits the functions of the truck in different ways
depending on the seriousness of the fault. Certain functions are monitored on two levels, where level 2 limits the
functions of the truck. See the error messages on the terminal display on the following pages.
Optional equipment
OPERATION
ECS
Terminal functions
8
1.
2.
3.
4.
5.
6.
3 2
F
N
R
KL580B
R
1
7.
8.
R
1
Arrow left is used to scroll between the different menus.

Arrow right is used to scroll between the different menus.
R is used to reset the display after an error message. All errors, with the exception of certain level 2 errors can be reset
by pressing this button. The red warning lamp is then extinguished. The lamp begins to blink again after 3-10 minutes,
depending on the fault, if it has not been rectified.
- is used to decrease a value.
+ is used to increase a value.
ENTER is used to access the service menus and to save
new values when setting up and calibrating the system.
Access to the service menus also requires the use of special
codes, that are separately obtainable from Kalmar.
A red warning light blinks in the event of an error and is extinguished when reset by pressing button 3.
The terminal display has 4 lines with space for 20 characters
on each line. Graphical presentation of operating menus and
error messages
Menu structure
There are three types of menus:
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
SERVICE main menu.The service sub-menus under this
main menu require access to codes that can be found on a
special list from Kalmar. If ENTER is pressed by mistake in
the service menu and the ENTER CODE menu is displayed,
return to the operating menu by pressing ENTER.
For further information, refer to the respective headings.
1.
1.
1.
1.
KL1409
1.
Enter
2.
1.
1a.
1a.
3.
17
OPERATION
ECS
Operating menus
The menus that are displayed on the terminal depend on the
modules with which the trucks ECS is equipped. The overview
below shows the possible combinations. Use either arrow
RIGHT/LEFT to switch between menus. All operating menus are
in a connected loop.
Access to the sub-menus under the service menu requires an access code. If ENTER CODE is displayed by mistake, return to the
operating menu by pressing ENTER.
01 Automatic gear changing

07 Monitoring
50 Mechanical overload protection
60 Electronic overload protection
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
10
07.50
01.07.50
6
5
4
7
KL1410
Explanations, see next page

Operating menus with mechanical overload protection, module 50
18
OPERATION
ECS
Operating menus, module 50
1.
Main menu KALMAR INDUSTRIES SERVICE
2.
Normal operating condition, module 50

a. 1750rpm Engine speed, r/min
3.
Normal operating condition,

module 50 + module 01
b. F3
Current gear
c. 14 km/h
Current speed
4.

module 50 + module 01 + module 07
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.
2
a
a
3
b
c
a
4
b
c
d
5.
Red lamp blinks
The steering axle is overloaded.
It is not possible to switch to other menus until the overload
is rectified.
6.
The system interrupts operation. The red warning lamp lights

continuously.
The machine has forward overload.
is rectified.
7.
a. 75 C
b. 3.8 bar
Engine coolant temperature

Engine oil pressure
8.
a. 75 C
b. 3.8 bar
Gearbox oil temperature

Gearbox oil pressure
9.
a. 24.5 v
b. 75 C
Battery voltage
Hydraulic oil temperature
a
7
b
a
8
b
a
9
a
10
10. a. 28756:21.54h Total operating time, tim: min. sek.

b. 130h
Time to next service, tim
19
OPERATION
ECS
60
2
01.60
3
1
4
07.60
01.07.60
5
3
KL1411
Explanations, see next page
Operating menus with electronic overload protection, module 60

20
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
and position of the load..
1. Main menu KALMAR INDUSTRIES SERVICE
2.
a
c
d
e
f
a
b
c
d
e
f
3.
a
b
c
d
4.
a
b
c
d
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.
d. 25.5 t
Current load in tonnes
e. Indicator showing steering axle load, fills the display to the
left for 95-100% of the permitted load. When the indicator
reads full, the system interrupts operation due to overloading
of the steering axle. The red warning lamp blinks.
is rectified.
f. Load indicator, fills the display to the right for 0-100%
loads. When the load indicator reads full, the system interrupts operation due to forward overload.
The red warning lamp lights continually.
has been rectified.
module 60 + module 01 + module 07
a. 1750 rpm Engine speed r/min
b. F3
Current gear
c. d. e. f.
See menu 2 explanation above.
a. 10.38 t
Current load in tonnes
b. 1.07 m
Boom extension
c. 3.08 m
Lc-distance. Distance between drive axle
centre and load centre.
d. 23.0
Boom angle
5.
a. 1750 rpm
b. F3
c. 14 km/h
d. Fuel level.
Engine speed r/min

Current gear
Current speed
The tank is full when the indicator is filled
to the right.
6.
a. 75 C
b. 3.8 bar
Engine coolant temperature

Engine oil pressure
7.
a. 75 C
b. 3.8 bar
Gearbox oil temperature

Gearbox oil pressure
8.
a. 24.5 v
b. 75 C
Battery voltage
Hydraulic oil temperature
9.
a. 28756:21.54 h. Total operating time, h: min. sec.

b. 130h
Time to next service, h
a
6
b
a
7
b
a
b
a
9
b
21
OPERATION
ECS
Error messages
01 = Automatic gear changing

04 = Lever steering
06 = Micro Steering
07 = Monitoring
50 = Mechanical overload protection
60 = Electronic overload protection
01, 07
22
01
01, 07
02
01, 07
03
01, 07
04
07
05
07
06
07
07
07
08
In order of priority. If two faults occur at the same time, the terminal displays the fault with the highest priority. Error messages always have a higher priority than normal menus.
Errors 01-08 are level 2 errors and cannot be reset prior to the
fault being rectified.
The first two figures show to which module the error message relates.
(These figures do not appear on the display)
01. Battery voltage very low/high.

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

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

04. Gear lever not functioning.

05. Engine oil pressure extremely low.

06. Coolant temperature extremely high.

07. Gearbox oil pressure extremely low.

08. Gearbox oil temperature extremely high.

OPERATION
01, 07 09
ECS
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
07
14
14. Fuel level extremely low.

Fill the tank to avoid air in the system.
07
15
15. Low coolant level.

Top up the coolant fluid.
07
16
07
17
07
18
13. High gearbox oil temperature.

16. High hydraulic oil temperature.

Operation possible.
Contact service.
17. Faulty signal from fuel gauge sensor.

Operation possible.
Contact service.
18. Faulty signal from gearbox oil pressure sensor.

Operation possible.
Contact service.
23
OPERATION
24
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.
07
21
21. Faulty signal from gearbox oil temperature sensor.

Operation possible.
Contact service.
07
22
07
23
01, 07
24
04
25
04
26
06
27
07
28
22. Faulty signal from hydraulic oil temperature sensor.

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

24. Faulty signal from prop shaft rpm sensor

25. Steering lever fault.

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

27. Faulty signal from mini steering sensor.

28. Warning! Low brake pressure.

OPERATION
ECS
31
31. System fault ECU 1.

32
32. System fault ECU 2.

07
50
50. Battery voltage very low/high.

Contact service as soon as possible .
60
51
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.
60
53
53. Faulty signal from angle sensor

60
54
50, 60
55
50, 60
56
50, 60
57
51. Communication with ECU 3 broken.

54. Faulty signal from length sensor.

Stop as soon as possible and check the sensor wire.
Contact service if the fault remains.
55. Faulty signal from regeneration sensor.

The regeneration is discontinued.
Contact service.
56. Faulty signal from hydraulic pressure sensors for left lift cylinder. (There is a sensor in both feed and return lines)
57. Faulty signal from hydraulic pressure sensors for right lift cylinder. (There is a sensor in both feed and return lines)
25
OPERATION
50
58
50
59
60
60
61
60
62
ECS
58. Faulty analog signal from joystick.

All boom functions are interrupted.
59. Faulty signal from sensor for end position damping

60. Faulty signal from twist-locks sensors.

Applies to both locked and unlocked position.
61. System fault.

Load curve is missing.
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.
26
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 changing of gears, simplifies operation and extends the service life of
the transmission equipment.
2 3
4
4 3
21
KL676
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
z
Locks the gearbox in the current gear if the signal from the
propeller shaft sensor is excessive or if the signal ceases
z
Reduces engine revolutions when changing to a higher gear
so that the speed of the truck remains constant
z
Disengages the gearbox if the operator brakes and the
speed of the truck is lower than 3 kph
z
Provides the required engine revolutions based on the position of the accelerator pedal
z
Continually shows the currently engaged gear on the ECS
terminal display
Function
The point at which the gearbox changes gear is optimized to the
trucks transmission equipment. The torque in the torque converter 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 between 1st and 2nd gears.
Module 04, Lever steering

4ab
KL1405
The lever steering module is an electrical system for the steering

of the truck by means of a steering lever. The steered wheel deflection is inversely proportional to the speed of truck, i.e. at lower
speeds, the steered wheel deflection is greater than at higher
speeds. The system is available in two versions:
z
Standard: Without wheel return, i.e. when the operator releases the lever the steered wheels stay in their set position.
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 disconnect the lever steering if the operator is faced with an emergency situation. As soon as the standard steering wheel is used,
the lever steering disconnects and the lamp in switch 2, se below,
is extinguished.
1. Steering lever
2. Direction switch F/N/R. The lamp in the switch is alight when
the lever steering is activated
Forwards position = F. Centre position = N
Backwards position = R
3. Signal horn
4. Switches for gear changing, a=UP, b=DOWN
(Excluded if the truck is equipped with module 01 Automatic
gear changing). Press 4a to shift gears 1-2-3-(4) (once for
every gear) and 4b to shift down. The gear changing always
starts with gear 1 on starting and after the direction switch
has passed the N position.
5. Switch for activating lever steering
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 steering is activated
6. Extra function
27
OPERATION
ECS
Module 06, Mini steering
3 6
2
b
4
a
KL1404
The Mini steering module is an electrohydraulical system for

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
that sense the movement of the steering wheel. The sensors disconnect the Mini steering if the operator is faced with an emergency situation and starts using the standard steering wheel.
When the Mini steering is disconnected, the lamp in switch 2, see
below, is extinguished.
1. Mini steering device
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 steering is activated
6. Extra function
Module 07, Monitoring

The following signals are monitored:
1.
2.
3.
4.
5.
6.
Battery level, min. <14.4 Volts

Engine oil pressure, min. level 1 <1.0 bar
Engine oil pressure, min. level 2 <0.5 bar
Coolant temperature, max. level 1 >98C
Coolant temperature, max. level 2 >103C
Gearbox oil pressure, min. level 1 <12-15
bar (dependent on selected transmission
data kit)
7. Gearbox oil pressure, min. level 2 <10 bar
8. Gearbox oil temperature, max. level 1
>130C
9. Gearbox oil temperature, max. level 2
>134C
10. Fuel level, min.
11. Hydraulic fluid temperature, max. >100C
12. Coolant level, min.
13. Operating time, max. service interval period, shows the time remaining to the next
service and generates an alarm when operating time has been exceeded.
14. Brake pressure
28
The monitoring module checks that the engine and gearbox operate within reasonable limits and thereby prevents a major
breakdown from occurring. The module also monitors the correct
function of the different system components, such as sensors,
etc.
Values, such as oil pressure and temperature, that are of vital importance when it comes to wear and tear and the risk of breakdown, are monitored in two levels. A read warning lamp lights and
an error message appears on the terminal display. If the reason
for the fault is not rectified, the system limits the trucks functions.
The most serious faults lead to a reduction in engine revolutions.
OPERATION
ECS
Module 56, Cab lift
WARNING!
Before operating the cab lift, check to make sure that nobody is in the way of the cab when it moves up or down.
18
1.
2.
3.
4.
KL 1407
Close the doors

Fasten the safety chains across both doors.
Fasten the safety belt.
Operate the cab lift using switch 18.
N.B. When the cab is lifted from its lower position, the machine 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
hinged mechanical safety latches on both sides must be
placed in position under the cab.
See A on the adjacent illustration
KL1089
N.B. If the cab gets stuck in its upper position, it can be lowered 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
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
the instructions in Technical Handbook ECS SERVICE, ECU 2
SETUP, points 20 and 21.
1.
2.
3.
Connect a loaded container to the machine

Extend the boom until the red lamp A lights.
Lift the boom approx. 20 cm over the position where the red
flags B on the left lift cylinder are aligned with each other.
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
building up pressure that can affect the measurement)
4.
Press the button for weighing

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

25 t = The actual weight in tonnes.
KL1412
30
OPERATION
ECS
Module 58, Container counter
ENTER
RESET C1
ENTER
RESET C2
Module 58, Container counter contains two separate counters,

C1 and C2. Of these, C1 is most suitable for use for shorter working 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.
z
The twist-locks must not be released for at least 10 seconds.
Resetting the counters
Counter C1:
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.
3. Press ENTER, and C1 is reset.
ENTER 4 SEC
RETURN TO MENU
ENTER
ENTER
Counter C2:
1. Press ENTER when the CONTAINER COUNTER main
menu is displayed.
2. Press the right/left arrow keys until the RESET C2 menu is
displayed.
3. Press ENTER for at least 4 seconds and C2 is reset.
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 operating menus.
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
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 illustration, 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
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 neutralized by disengaging the load or retracting the boom.
20a
20b
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,
green lamp 20b will light. The overload protection system will
change parameter curve. The additional capacity for container row 3 (+7 tons) can be utilized.
KL 1407
19
Support jacks up
Disengage the load or retract the boom to prevent the overload 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 operation.
z
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
33
OPERATION
ECS
Module 70, Printer
(-)
(+)
(-)
(+)
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.
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 executed.
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
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 executed.
4. Press - to return to the main PRINTOUT WEIGHT menu.
Return to operating menus
To return to the operating menus from any of the three printout
menus, press the arrow right/left keys.
KALMAR
WEIGHT IS
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 = PRINTOUT LATEST XX WEIGHTS
28,5T
Example of PRINTOUT WEIGHT
KALMAR
34
1.
2.
3.
4.
5,
10,5T
9,5T
1,0T
5,0T
8,0T
TOTAL WEIGHT
48,0T
OPERATION
Heating and air conditioning system

The standard version of the truck is equipped with heater and defroster only.
The heating system is connected to the engine cooling system
and starts delivering heat after the engine has warmed up.
The fan is controlled by switch 37. The air conditioning system
can be switched on and off by means of switch 34.
NOTE. The air conditioner is optional equipment.
34
35
36
39
37
KL599
38
34. Switch, compressor air conditioner (Optional)

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

z
z
z
KL1452
Close the recirculation control 35. Open if the weather is very

cold.
Switch off the air conditioner, switch 34.
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 control 39 so that the cooling thermostat will trip at regular intervals for defrosting the cooling element.
z
Close recirculation with 35.
Note that the cooling is used for dehumidifying the air in the
cab.
Setting the cooling mode

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.
z
35
OPERATION

Thermostatically controlled Air Conditioning unit
33
34
35
KL599A
39
36
37
38
N.B. Run the compressor from time

to time, even during the winter, in
order to lubricate and ensure
correct function.
N.B. The cooling is not operative at
temperatures below 0C.
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.
34. Switch COOLING FUNCTION OFF.
35. Switch RE-CIRCULATION.
Switch forwards - air from outside.
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 16-26C.
Control fully clockwise: Full heating effect = heating valve
continuously open.
Control fully anti-clockwise: Full cooling effect = cooling function running continuously.
N.B. When the controls are in respective full positions, precise temperature regulation cannot be achieved.
39. Cover. The climate equipments demist thermostat is located
under this cover. The thermostat must always be set in the
max. clockwise position.
Normal operation
1. Set controls 37 FAN and 38 TEMPERATURE to the required
fan speed and temperature.
The fan must be running for cooling to function. (If the fan is
switched off, the compressor and condenser stop.)
2. The system then operates automatically, as follows:
When heat is required:
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 continual 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 previously 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 positions and does not start even when control 38 TEMPERATURE is set to the MIN. position.
2. Set control 38 to the required temperature.
36
OPERATION
Operators seat
Operators seat adjustments
The operators 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.
Height of the seat cushion.

Turn the knob until the desired height is achieved.
The springing will automatically correspond to the operators
weight.
Backrest rake
Turn the knob.
Armrest slope
Tilt simultaneous sloping of seat and backrest.
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.
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 0C.
The engine heater consists of a heater cartridge fitted into the engine 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
than 10 seconds at each
attempt.
If the engine still refuses to start, the
cause should be determined and
remedied.
Air in the fuel system? see page 45.
z
z
Set the gear lever to NEUTRAL.

Turn the starter key directly to position II. Then:
Below +5C
Hold the key in position II, the pre-heater position, for
approximately 50 seconds.
Turn the key further to position III the starting position
and release it as soon as the engine has fired.
Above +5C
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 14001500 r/min until 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 80C.
38
OPERATION
EDC engine
IMPORTANT!
Starting the EDC engine
1. Switch on the ignition.
The engine cannot be started before
the lamp in the Diagnostic Switch (A)
has extinguished. The EDC system
first checks all engine systems
2. Turn the ignition key to the start position and immediately release the key
again.
Depending on the temperature, preheating of the EDC system then
starts. Pre-heating times varies from 0
s at +25C to 50 s at - 20C.
(In emergency situations, the preheater can be by-passed by turning
the ignition key to the start position
twice)
3. Thereafter, turn the ignition key to the
start position again - and the engine
starts, but not directly, only after a
number of revolutions. This pre-heats
the engine combustion chamber
which reduces smoking at start up.
N.B. On an EDC engine, the starter motor must turn longer than with conventional engines.
Stopping the EDC engine
1. Stop the engine in the normal way, by
turning the ignition key to 0
KL1257
Trucks with Volvo EDC engines (Optional extra)

Certain Volvo engines are equipped with EDC, an electronic system for the control of the diesel engines operation. The systems
central unit receives information relating to a number of parameters, such as, engine revolutions, coolant temperature, fuel temperature, turbo-charge pressure, turbo-charge temperature, etc.,
and on the basis of the values received, determines the volume
of injected fuel.
The EDC system also contains a diagnostic system that enables
rapid fault finding, if a fault should occur. A diagnostic switch on
the instrument panel shows the current fault, by means of different series of blinking of the in-built lamp.
Function
A = Diagnostic Switch.
The switch lamp starts to continually blink if the EDC system receives abnormal values from the engine, or if there is a fault in the
EDC system itself. When the switch is pressed for at least one
second, the alarm is reset and it is then possible to read off the
diagnostic code.
The switch lamp shows the diagnostic code by means of twostage blinking. First a series, then a pause, then a further series
of blinks.
If several diagnostic codes are stored in the system, press the
switch again and read off the next code, and so on. When the first
code re-appears, all diagnostic codes have been read.
The system stores the codes until they are deleted and it possible
to check the codes again at any time.
Reading off the diagnostic codes
1. Press switch A down for at least one second.
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 diagnostic codes. Continue until the first code re-appears.
Deleting diagnostic codes
IMPORTANT! Never delete a diagnostic code before the
fault in question has been rectified
1.
2.
A
3.
Diagnostic code
1.3
2.2
2.3
2.4
2.5
2.6
2.7
4.6
5.1
8.1
8.3
9.9
Switch off the ignition.

Press switch A down and switch on the ignition whilst the
switch is still held down. Keep the switch pressed down for
at least 3 seconds.
All diagnostic codes are now deleted.
Fault
Result of fault
Action
Incorrectly calibrated throttle

Incorrect position of throttle lever
Throttle control rod fault
Engine speed (rpm) sensor fault
Engine speed sensor - incorrect signal
Throttle control sensor fault
Throttle control sensor - incorrect signal
Short circuit or breakdown in start relay
Short circuit or breakdown in main relay
Fault in the EDC central unit
Fault in the EDC central unit
EDC program fault
Engine stops
Engine stops
Engine stops
Engine stops
Reduced engine revs. 1000 rpm
Engine stops
-
Contact service
------------
IMPORTANT! If the diagnostic system has resulted in reduced engine revs. or engine stop, all diagnostic codes
must be deleted before the engine can be restarted.
39
OPERATION
Functional checks, stopping of engine, steering

Functional checks
WARNING!
If results of the functional checks
are in any way doubtful, report
immediately to the supervisor.
WARNING!
If mirrors or CC TV cameras are used
to aid vision, the speed of the machine must be adapted to the limited
vision.
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 80C.
z
that the reading on the fuel gauge is sufficiently above 0.
N.B. The reading should never be allowed to drop to 0.
z
that all warning lamps are extinguished.
z
that the horn, lighting, brake lights and direction indicators
operate correctly.
z
that all hydraulic functions operate correctly.
z
that the indicating lamps for the twist-locks and alignment
operate as intended.
z
that the contact pins at the twist-locks can be moved freely
up and down. Note that a pin which binds in the top position
will indicate alignment even if the frame is not in contact with
the container.
z
that the twist-lock interlock performs satisfactorily. Lift an
empty container sufficiently for the ALIGNMENT lamp to be
extinguished. It must then be impossible to release the twistlocks.
Stopping the engine, parking

z
z
z
z
z
z
Apply the parking brake.

Set the gear lever in NEUTRAL.
Retract the boom and lower it to its lowest position.
Allow the engine to run for 1/21 minute at idling speed before stopping it. This will allow the engine to cool down and
the turbo bearings to be lubricated.
Stop the engine by turning the key to position 0.
If the truck will not be used for a longer period, turn the main
switch to the OFF position.
IMPORTANT!
Never turn the the main switch to OFF when the engine
is running the voltage regulator may be damaged.
Power steering
IMPORTANT!
Remember to carry out the
daily supervision.
See page 43.
40
The truck has hydraulic power steering with no mechanical connection between the steering column and the steered wheels.
Movements of the steering wheel is transmitted hydraulically to
the steered wheels.
Never let the truck run downhill when the engine is not running,
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
lifting capacity.
See the picture below.
Always drive carefully. Remember that the truck is wide and tall,
so make sure that the boom or top lift frame will not collide with
posts, overhead cables, etc.
1. Adjust length setting to suit the length of the container.
2. Drive up to the container from any angle. Put the gear selector in neutral or disengage the gearbox with brake and clutch
pedals.
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.
5. Check that the orange ALIGNMENT lamp is alight, which indicates 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!
All four corners of the top lift must be
in contact with the container when
locking or releasing the twistlocks.
In addition, during release, the
container must rest with all corners
firmly on the surface supporting it.
Heavy loads must not be driven in
highly hoisted positions because this
is detrimental to lateral stability and
may also cause forward tipping.
Transport position
WARNING!
KL1103
Great care must always be taken when rotating a container

in order to avoid any collision with boom or chassis.
WARNING!
WARNING!
The cab MUST ALWAYS be in the rearmost position during ALL transport
operations to avoid risk of injury or
damage.
If the indicating lamps for the overload indication system

are inoperative, the system must immediately be repaired. 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
(green) or ALIGNMENT (orange) lamps is extinguished.
The ALIGNMENT lamp is extinguished on lifting.
See rating plate

for machine
concerned!
Operations close to high tension power lines

Extreme care must be taken when working in close proximity to
overhead, high tension power lines, particularly in respect of the
reach of the boom and attachment.
WARNING!
If the machine comes into contact with overhead high
tension power lines - remain seated in the cab and call for
help!
It is extremely dangerous to leave the cab as you will be
earthed when you come into contact with the ground.
41
SPECIAL PROCEDURES
Towing
WARNING!
If it is not possible to run the engine
running during towing, a tow bar must
be used.
Before preparations for towing begin
and after towing has been completed,
the parking brake must be applied and
the wheels chocked to prevent the machine rolling. The greatest possible
care must be exercised during towing
operations to prevent personal injury.
IMPORTANT!
The truck cannot be started by
being towed.
Any attempt to start the engine by
towing, will inevitably cause damage
to the tranmission.
If possible, the engine should be running during towing in order

to retain braking and steering functions. When the engine is not
running, there is no hydraulic pressure for the steering of the
truck which is then extremely limited. Furthermore, the gearbox
will be insufficiently lubricated.
z
Towing may only take place over very short distances.
z
If a tow bar is used, it shall be connected to the connection/
towing hitch at the rear of the machine.
z
The brakes function as long as there is pressure in the accumulator, thereafter the operating brakes cease to function
and the parking brake is automatically applied. If, thereafter,
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
and brake capacity.
z
For towing over longer distances or at speeds higher than 10
km/h, the propeller shaft must be disconnected.
Mechanical release of Parking Brake
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. Continue tightening until the brake pads are released from the
brake disc.
3. Once the fault has been rectified, reset the parking brake
function by returning the nut (B) to the same position as in
point 1.
WARNING!
If the parking brake has been mechanically released, it
must always be reset in order for the truck to retain its
parking brake function.
KL1102
Fire protection
If the machine is equipped with fire extinguishers these should be
of the ABE type, in accordance with EN 3 parts 1, 2, 4 and 5. With
such a fire extinguisher it is possible to extinguish a fire in both
fixed organic materials and liquids. Furthermore, the medium
used to extinguish fire does not conduct electricity.
Suitable fire extinguishers can be ordered from Kalmar.
WARNING!
If the machine is used in highly inflammable environments, e.g., in explosive environments, it is a strict requirement that the machine be designed, constructed
and equipped in accordance with EN 1755.
42
SUPERVISION
Daily supervision
IMPORTANT!
The following must be carried out in
addition to daily and periodic supervision:
Service during the running-in period
z
Tighten the wheel nuts and propshaft
bolts after 8, 16 and 24 hours of operation. Tightening torque in accordance with the Technical Handbook.
Tighten the wheel nuts in a zig-zag
sequence. Tighten the nuts in the
same way every time after changing a
wheel.
Guarantee service after 50 hours.
The guarantee service is performed by
Kalmar, or by personnel authorized by
Kalmar, and is part of the Kalmar delivery
commitments.
The guarantee service is also a condition
for continued validity of the guarantee.
DAILY SUPERVISION
Or when
refuelling
Supervision
Supervision is differentiated as follows:
z
z
DAILY SUPERVISION carried out by the operator

PERIODIC SUPERVISION carried out by specially trained
service personnel.
Proper supervision contributes to making the truck safe to work

with.
Periodic supervision is described in the Technical Handbook. The
operator must make sure that the truck is available for service
every 200 hours of operation.
All times refer to the hours of operation, i.e., the time recorded by
the hour meter on the panel.
N.B. Only genuine Kalmar spare parts may be used. Spare tyres
and replacement tyres must be of a make
approved by Kalmar.
Check
Refill as
required
More details
on page
Brakes
Operation
Steering
Operation
All instruments:
Direction indicators, horn,
brake lights, headlights
Operation
Lifting boom:
Pivot points, slide plates
Damage?
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,

hydraulic hoses
Noises?
Oil leakage?
Fuel
Amount
The gauge reading
should never drop to 0
45
Check that the rear steered axle

suspension is free from dirt and that
the sensor is free from grease
(Mechanical overload safety system)
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
43
SUPERVISION
Tyres
Tyres
WARNING!
Spare and replacement tyres shall be
of a make approved by Kalmar.
Checks
1. Check the tyres regularly, if possible, daily.
2. Remove objects that could penetrate the tyres, such as broken glass, pieces of wood, metal shvings, etc.
3. Check for uneven and rapid wear. This is caused by mechanical 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 nipple on the tyre.
3. Move away to the side and remain there throughout the entire inflation process.
4. Inflate the tyre to the recommended pressure, see Technical
Data.
With a change of tyres or wheel type, another tyre pressure
may apply, contact KALMAR.
KL1469
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
44
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 days work has been completed, to avoid moisture condensing 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
pumping and tighten screw A.
z
Tighten the pump handle.
z
Run the starter motor in 2030 second bursts, with a pause
of a couple of seconds between each run. The engine will
start after 23 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 therefore be used only if the ambient temperature is constantly above
0C.
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.
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.
A Oil filler cap
B Oil dipstick
B
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 occasion.
4. It should be possible to apply the brakes at least six times
before lamp 45 lights up.
5. Start the engine, allow the accumulators to be charged and
repeat the test a couple of times.
6. If the brakes cannot be applied six times before lamp 45
lights up, the accumulators are faulty. If so, ensure that the
fault receives attention as soon as possible and that the accumulators 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 pressure of up to 210 bar. Take great care therefore when
working on the system and al-ways release pressure from
the accumulators before removing any component from
the system. Discharge the pressure by opening the quickevacuation valve A. Open also valve B!
46
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.
B
A
KL950B
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 personnel as a routine measure. If the truck is used under dusty conditions, 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
SUPERVISION
Electrical system
IMPORTANT!
The starting batteries accompanying
the truck are of the maintenance-free
type, which implies that it should not
be necessary to top-up with electrolyte during the life of the batteries.
However, the level of the electrolyte
should preferably be checked once or
twice a year. Fill as required by adding de-ionized water.
Electrical system
The electrical system operates at 24 V. The source of power supply are two 12 V batteries which are charged by an alternator. The
negative pole is connected to the chassis. The positive pole is
connected to a main switch A. When working with the electrical
system, when carrying out welding on the truck or at long time
parking, always isolate the batteries.
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
cells. Top up with de-ionized water as necessary.
Batteries contain substances dangerous to health and the environment. Discarded batteries must therefore be dealt with in accordance with current local/national regulations.
S1-6 7-12 13-18 19-24
WARNING!
The battery electrolyte contains corrosive sulphuric acid. Immediately remove any electrolyte that comes into
contact with the skin. Wash with soap and lots of water.
If electrolyte gets into the eyes, immediately rinse with
lots of water and immediately contact a doctor.
WARNING!
Never use fuses of a higher amperage
than stated on the lid decal.
Risk of damage or fire.
Relay box in cab fuses

Fuse
No.
S1
S2
S3
S4
S5
KL593A
S6
S7
S8
S9
S10
S11
S12
2
1
8 10 12 14 16
9 11 13 15
C
KL728A
19
S13
S14
S15
S16
S17
S18
S19
S20
S21
S22-24
1)
Circuit protected
Rating
A
Wiper motor front, direction indicators,

seat buzzer, parking brake sensor ........................... 10
Ignition key, pre-heater, starter motor,
cab lighting (Air conditioner 25 A 1)) ........................ 15
Container attachment, safety interlock ..................... 15
Electric gear-changing .............................................. 5
Warning lamps, instrument illumination, relay,
coolant level .............................................................. 5
Brake lights, reversing lights, reversing alarm ......... 15
Fan (Air conditioning 1)) ........................................... 25
Spare (Container lights 1)) ....................................... 15
Working lights (15 A for 4 lamps) 1)
Hazard beacon ........................................................ 10
Working lights, standard (15 A for 4 lamps) ............ 10
Horn, screenwash motor, wiper rear and roof,
wiper front, intermittent relay .................................... 10
Driving lights (main fuse), rear lights
(main fuse), position lights
15
Main beam, right-hand ............................................... 5
Main beam, left-hand ................................................. 5
Dipped beam, right-hand............................................ 5
Dipped beam, left-hand .............................................. 5
Rear light, left-hand .................................................... 5
Rear light, right-hand.................................................. 5
ECU1 1) .................................................................... 10
ECU2 ....................................................................... 10
Voltage converter ....................................................... 5
Spare..........................................................................
Optional equipment
Miscellaneous fuses
D
A
B
C
D
Main switch
Main fuse, boom (1x25 A)
Top lift fuse (2x10 A) in the attachment electrical central box
Main fuse for truck electrical system
Fitted on the engine, 2x50 A
49
SUPERVISION
Electrical system
Relays
305
314
315
316
320
322-1
322-2
323
328
330
331
332
334
367
399
Reversing light
Parking brake, disengagement
High power (Starting switch)
Wiper motor, front
Electric stop (ECS 07) 1)
Coolant level
Coolant level (ECS 07) 1)
Pulse relay, direction indicators
Gear shift (ECS 01) 1)
Starting block
Propulsion forward
Propulsion reverse
Clutch release (ECS 01) 1)
Lever steering (ECS 04) 1)
Spare
Miscellaneous
321-1
321-2
960
1)
Intermittent relay wiper front

Intermittent relay wiper rear 1)
Reversing interlock
Optional equipment
Bulbs
Description
Rating
Watts ............................. Base
Instruments
Indicating lamps
Cab lighting
Rear lights, red
Brake lights
Direction indicators
Position lights
Driving lights (full/dipped beam)
Reversing lights, white
Working lights
Hazard beacon
3 .................................... BA7s
1,2 ........................... W2x4,6d
10 ................................... S8,5
5 ..................................BA15s
21 ................................BA15s
21 ................................BA15s
5 ...................................SV8,5
75/70 .........................P43t-38
70 ................................PK22s
70 ................................PK22s
70 ................................PK22s
Starting from another battery

z
WARNING!
Batteries emit oxyhydrogen which is
an explosive gas. A spark, for
example from incorrectly connected
starting cables, could cause a battery
to explode and result in serious injury
and damage.
50
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
2. Red cable (+) to truck battery
3. Black cable () to auxiliary battery
4. Black cable () to a location some distance away from
the truck battery, such as the negative cable connection on
the chassis.
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.
TECHNICAL DATA
Truck model, type designation DRD
420-60S5
420-70S6
Engine
Make type designation
Fuel type of engine
Power ISO 3046 1) at speed
Torque ISO 3046 at speed
No of cylinders compression
Alternator, type power
Starting battery, voltage capacity
kW -r/m
Nm-r/m
V-Ah
Transmission
Gearbox, make type designation
Clutch, type
Gearbox
No. of gears, forward reverse
Drive axle, type
Wheels
Wheels, front and rear 2)
Wheel dimension, front and rear
Pressure, front rear
MPa
L
L
L
Fuel
Hydraulic system,tank volume
total volume
Brake system
tank volume 3)
Drive axle (incl. hub reduction)
L
L
L
L
L
450-80S4X
Volvo TWD1031VE
Diesel 4-stroke
235 2100
1500 1100
6-18,0:1
AC 1920 W
2x12 140
Volvo TWD1231VE
Diesel 4-stroke
275 2100
1753 1100
6-18,0:1
AC 1920 W
2x12 140
Clark 15,5 HR 36432

Torque converter
Powershift
44
Double reduction,
planet gear hub
Clark 15,7 HR 40432

Torque converter
Powershift
44
Double reduction,
planet gear hub
Hydraulic servo
Hydraulic drive wheels
Spring brake drive wheels
dB(A)
dB(A)
Liquid capacities
Cooling system
Gearbox oil
Engine oil
450-60S5X
450-70S5XS
Pneumatic
See data sheet
1,0
Steering- and brake system

Steering system
Driving brake system, type affected wheels
Parking brake system, type affected wheels
Equivalent noise level in cab
In accordance with machine directive.
Limit 70 dB(A)
with standard engine
with noise reduction kit
450-60S5
450-70S5
max 72
68
TWD1031VE/Clark 36000
65
57
32
510
600
880
100
74
TWD1231VE/Clark 40000
75
55
38
510
700
1000
100
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.

Spare wheels should be of a brand approved by Kalmar.
3)
Only machines with separate tank for brake system
2)
51
LUBRICATION CHART
3
2
1
4 5
24
DRD420-60S5
6, 7
KL586C
25
Refill
Brake
Planetary
gear
Sight
glass
52
LUBRICATION CHART
Item Description
No.
Interval
operating hours
200
600
1000
No. of Remarks
lub.
points
1
2
Boom mounting
Slide plates, boom
L
L
3
4
5
Rotator mounting
Tilt cylinders
Rotator reduction gear
(Brake and planetary gear)
L
L
x
2
4
4
6
7
8
9
Rotator bearing
Pinion and ring gear
Link levers
Steered wheel bearing
L
L
L
10
Knuckle pin bearings
11
12
13
Engine oil
Engine oil filter
Gearbox oil
14
15
16
17
18
19
20
21
22
23
24
Gearbox oil filter

Hydraulic oil filter, working hydraulics
Hydraulic oil filter, brake system cooling
circuit
Hydraulic oil filter, servo system
Hydraulic oil filter, top lift
Propeller shaft
Drive axle
Breather filters, hydraulic tank
Hydraulic oil
Door and panel hinges
Brake pedals
25
Hydralic oil, brake system
Manually pump grease while the boom is

moved slowly outwards and inwards to its
end positions
xx
4
3
4
2
4
x
x
C
2
1
x
x
2
2
1
x
x
L
C
x
x
x
1
1
3
3
2
CL
Check the level. Top up the red point on

the sight glasses 2)
x) First oil change at warranty service
xx) Thereafter oil change every 1000 h
2 nipples on each side
Brush on with grease
Remove, clean, inspect and pack with
grease every 4000 h
Remove, clean, inspect and pack with
grease every 4000 h
x) Change the oil every 200 h1)
x) Change the filter every 400 h
x) Change the oil. Check the level at idling
speed
x) Change the filters
Change the oil
x) Change filters every 2000 h
x) Change oil every 2000 h
Lift off the doors and panels
Check and retighten the pedal axle locking screws. Lubricate axle nipples
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 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
hydraulic piston rods exposed, all piston rods
must be greased to prevent corrosion.
After they have been washed with degreasing

agent, all pistons should be moved backwards
and forwards several times to obtain a new protective oil film.
53
LUBRICATION CHART TOP-LIFT, cylinder operated extension

1
A3139001B
54
LUBRICATION CHART TOP-LIFT, cylinder operated extension

Item Description
No.
Interval
operating hours
200
600
1000
No. of Remark
lub.
points
Sliding surfaces, length adjustment
Brush onto all sliding surfaces with the attachment in the fully extended position
Sliding surfaces, sideshifting
Brush onto all sliding surfaces with the attachment sideshifting to the limit in each direction
Cylinders, pile slope
Cylinders, sideshift
Cylinders, length adjustment
Cylinder, twist-locks
Check that the sensors are free from grease

and that the sensor faces are undamaged.
Lift pinion twist connection
Lift pinion
Disassemble the twist-locks every 2000 h.

Check for wear. If needed, change components accordingly. Clean and pack with
grease. Same procedure should be used at
suspected damage to the twist-locks.
Contact pins
Only top lift with pile slope
Lubricate with grease

Check that the sensors are free from grease
and that the sensor faces are undamaged.
L=Lubricate
C=Check
55
LUBRICATION CHART TOP-LIFT, chain operated extension

1
KL 1553a
a
b
KL 1553
KL 1555a
KL1555
56
LUBRICATION CHART TOP-LIFT, chain operated extension

Item
No. Description
Interval
operating hours
200
600
1000
No. of
lub. Remarks
points
Sliding surfaces, length adjustment
Brush onto all sliding surfaces with the in

the fully extended position
Sliding surfaces, side-shift
Brush onto all sliding surfaces with the toplift fully side-shifted in both directions
Planetary gear
a. Venting/Topping up
b. Sight glass
c. Magnetic plugg, oil drainage
Cylinders, side-shift
Chains
Locking cylinders, twist-locks
Check that the sensors are free from

grease and that the sensor faces are
undamaged
Lifting pin twist connection
Lifting pin
Dismantle the twist-locks every 2000

h.
Check for wear. If necessary, change
components accordingly. Clean and
pack with grease. Same procedure
should be used if damage to the twistlocks is suspected. See group 80.
Contact pin
Level check, fill to the red spot on the

sight glass. Oil volume 2.4 litres.
x) First oil change - guarantee service
x) Then, oil change every 1000 hours
Lubricate with grease

Check that the sensors are free from
grease and that the sensor faces are
undamaged
L = Lubricate
C = Check
57
Oil and lubricant recommendations

Oil quality
Engine
Cummins
Scania
Volvo
Engine oil
ACEA: E2
API: CF4
Gearbox
Clark 32000
Transmission oil
ATF DEXRON II **
Clark 36000
Clark 40000
MIL-L-2410 C/D ***

C-2, C-3
Drive axle
Hypoid oil
Kessler
Meritor (Rockwell)
API GL5
MIL-L-2105B
Rekommended viscosity at different outer temperatures

+40
C -30
-20
-10
+10
+20
+30
+50
F -22
-4
+14
+32
+50
+68
+86 +104 +122
5W 30
10W 30
15W 40
DEXRON II
SAE 10
SAE 75W 140
SAE 80W 90
SAE 90
SAE 85W 140
Hydraulic system
Hydraulic fluid *
ISO 6743/4
ISO-L HV32
ISO-L HV46
ISO-L HV68
Brake system
only machines with
separate tank for
brake system
Hydraulic fluid ****

DONAX
Additive: 6% LUBRIZOL LZ9990A

Do not apply to all drive axles,
see machine card and signs.
** DEXRON is a registered Trade Mark
*** DEXRON-oils must not be used
for Clark 36000/40000
**** Without additives
Oil in rotator reduction gear and top-lift

Brake
Quality:
Planetary gear
Quality:
Viscosity:
Ordinary hydraulic fluid without additve,

API GL-5
SAE 80W-140
Above +30C or heavy duty: SAE 320
Grease
IMPORTANT!
Any deviations from the above table must
be supported by written approval from
Kalmar Service.
Use EP universal grease to NLGI Grade 2 with 35% molybdenum disulphide additive for all lubrication points, including
wheel bearings.
Grease for Plastic plates

Use grease recommended by Kalmar. Ordered from Kalmars
Spares department.
0,65 kg cartridge for grease gun
Art. no 923110.0360
5 kg can
Art. no 923595.0003
Coolant for air conditioning unit

ZXL100 Seltec PAG oil
58
Kalmar Industries Sverige

Torggatan 3 SE-340 10 Lidhult, Sweden
Tel: +46 372 260 10. Fax: +46 372 259 77.
www.kalmarind.com

Instruction Manual DRD ContChamp GB

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Instruction Manual DRD ContChamp GB

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CONTCHAMP

Publ. no 920935.0389 0206

It is important that you read the instruction

Safety regulations aimed at reducing the

Operation of the truck is prohibited:

For technical warnings, that point out the risk of break

Continued on next page

For information that facilitates the working process or

must be emptied into the tank, with the help of the

1. Electro-hydraulically activated telescopic boom

803 701 103 403

203 803 113 301

304 111 302

112 A32442.0100 Warning!

708 A30168.0200 Hydraulic pressure.

103 A26939.0200 Warning!

104 A26940.0100 Parking brake

710 A30529.0100 Warning!

803 A32440.0100 Warning!

302 A30530.0100 Warning!

304 A30532.0100 Warning!

811 A33852.0100 Type, attachment

S/N =Serial number

306 A32439.0100 Engine oil.

408 A32439.0200 Transmission oil.

Instruments and controls

1. Gear lever .............................................................. 14

7. Electrical central unit

Instruments and controls

21. Pressure gauge, gearbox oil pressure

34. Switch, compressor air conditioning 1)

39. Control, cold 1)

Instruments and controls

Button 17 for the connection and disconnection of

N.B. When operating a machine

Instruments and controls

Instrument and controls

Battery charging lamp (42)

Lubricating oil pressure, engine (43)

Oil pressure, gearbox (44)

The lamp will light up if the hydraulic pressure in the accumulator,

Engine coolant level (46)

The lamp will light momentarily on starting. If the lamp lights up

Engine preheating (47)

Engine coolant temperature (48)

Parking brake lamp (51)

Instrument and controls

Pressure gauge, gearbox oil pressure (21)

Fuel gauge (22)

Temperature gauge (23)

The temperature gauge shows the engine coolant temperature,

Operating hour meter (66)

Starting switch (5)

All functions switched off, the key can be removed

The truck has an electrical restart guard protecting the starter

Instrument and controls

The gear-changing mechanism is electrical, gear-changing being

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

Run the engine at idle speed, select the direction of travel

Direction indicators/Dip switch/Horn (2)

Instrument and controls

Adjusting the steering wheel (11)

Parking brake (13)