DRT 450 Training Material 150423

DRT 450
Technical Training – Course 204 - 007

DRT 450
Course overview
A. Forward
B. Safety
C. Preventative Maintenance
0. Complete machine
1. Engine
2. Transmission
3. Drive axle
4. Brakes
5. Steering
6. Wheel suspension
7. Load handling
8. Control system
9. Frame, body, cab and accessories
10. Common hydraulics
11. Common electrics
D. Error codes
E. Wiring diagrams
03/06/2023 3
DRT 450
Forward:
The Kalmar DRT 450 is a reach stacker for container handling, the machine has a lift capacity of 45 tonnes in
the first row
The DRT has a fixed length wheelbase of 6250 mm.
03/06/2023 4
DRT 450
Documentation:
 All Kalmar machines are supplied with a standard documentation package:
 Operators Manual
 Maintenance Manual
 Spare parts Manual
The operators and maintenance manuals are standard manuals. the spare parts manual is order specific meaning
that you will find the serial number of the machine on the parts manual
Optional manuals that are also available include:

 Workshop Manual
 Engine Manuals
 Transmission Workshop Manuals
 Drive axle workshop Manual
All Kalmar manuals are produced to SAE J2008.
03/06/2023 5
DRT 450
SAE J2008
The standard SAE J2008 means that you can find the same parts of the machine in the same part of the manuals.
The manuals are split into the following sections.
A Forward
B Safety
C Preventative Maintenance (Maintenance Manual only)
1. Engine
2. Transmission
3. Drive Axle
4. Brakes
5. Steering
6. Suspension
7. Load Handling
8. Control Systems
9. Frame, Cab
10. Common Hydraulics
11. Common Electrics
D Error Codes (Workshop Manual only)
E Schematics (Workshop Manual only)
F Technical Data
G Index
03/06/2023 6
DRT 450
SAE J2008
The various sections of the manual are broken down into sub sections which will give further information.
An example is shown below:

1. Engine
1.1.1 Ignition switch
1.1.2 Accelerator pedal
1.2 Fuel system

1.2.1 Fuel tank
As can be seen the sub menu will cover all areas of the machine
03/06/2023 7
DCT 450
Description and group number as in

Maintenance manual
03/06/2023
8
DCF 80 – 100 E
Safety
General:
Throughout Kalmar manuals there will be reference to the machine in the service position. The service
position is for service and maintenance.
The service position is:
Machine parked with the park brake applied
Boom lowered and completely in
Engine off
Main electrical isolator off
03/06/2023 9
DRT 450
Hydraulic system de pressurising

1. Machine in service position
2. Turn on the main power (battery isolator) turn on the ignition
switch to position 1, repeatedly move the joystick to relief
servo pressure
3. Turn off the ignition switch and main power
03/06/2023
10
DRT 450
Brake system de pressurising

De pressurize the brake system by opening accumulator
drain valve located on the accumulator charge valve.
At the end of the service / maintenance work ensure the
drain valve is closed again
03/06/2023 11
DRF 400 - 450
Attachment depressurization
Open the relief valve for the spreader
The illustration shows the valve closed
03/06/2023 12
DRT 450
Preventative maintenance (PM)
The PM intervals on the DRF are 500 hrs except the first service which is to conducted at 50 hrs.
The 50 hr service is important as fluids and filters are replaced after allowing the major components to bed in
Filters and fluids replaced at 50 hrs are:

Engine oil
Engine oil and fuel filters
Transmission filter
Hydraulic fine filter
As well as checking all components for loose fasteners, leaks, and making adjustments to the machine in general
Lubrication of the machine at 50 hrs will be as with 500 hr services
Warranty can become void if service intervals are not followed starting with the 50 hr service
03/06/2023
13
DRT 450
Above is a section taken from the service schedule as can be seen the services are divided between 500,
1000 and 2000 hours
The 500 hour service is performed at 500hrs, 1500hrs, 2500hrs etc
There are also the letters C, R, L

C = Check
R = Replace
L = Lubricate
03/06/2023 14
J 2008 description DRT 450
PM service schedule overview
Operation
Location in manual where further information can be

found in
03/06/2023
15
DRT 450
Reference in manual
Location
Lubrication schedule
Along with the service schedule there is a lubrication guide, again
the guide is broken into 500hr and 1000hr intervals. Kalmar
recommends that lubrication be carried out with the working
conditions of the site in mind, if additional lubrication is required
then complete the 1000hr schedule at all service intervals
03/06/2023
16
DRT 450
0. Complete machine
The DRT range of machines are powered by a 6 cylinder Tier III engine,
options for the engine available are,
a) Cummins QSM 11 / Dana 36000 Tier IIIa
b) Cummins QSM 11 / Dana TE 32000 FF Tier IIIa
All engines are electronically controlled

The transmissions are electronically controlled
Double reduction drive axle Kessler or Axletech
Top lift spreader with Twist locks
Control system is a Kalmar developed system based on a
distributed system (KDCS)
The hydraulic system includes 6 pumps driven of the transmission
c) Four variable pumps for load handling steering
d) A gear pump for brake circuit
e) A gear pump for cooling
Electrical system is based on control units located in strategic
locations of the machine. Control units have redundant voltage
feeds and communicate via CAN bus
03/06/2023 17
DRT 450
1. Engine: Cummins QSM 11
• Cummins QSM 11
• Power 261Kw @ 2000 RPM
• Torque 1830 Nm @ 1100 – 1400 RPM
• Air cooled Intercooler
• Longer service intervals due to high quality oil
• Universal engine oil 15W40, type VDS II, ACEA E3 etc.
03/06/2023
18
DRT 450
03/06/2023 19
DRT 450
03/06/2023 20
DRT 450
03/06/2023 21
DRT 450
1. AC compressor
2. Fuel connection (inlet)
3. D794
4. Sump plug
5. Starter motor
6. Fuel connection (outlet)
7. Water drain point
8. Fuel filter
9. Sensor fuel sensor
10. Fuel pump
11. Oil pressure / temperature sensor
12. Sensor Crankshaft
03/06/2023 22
DRT 450
1. Fill point Engine oil

2. Dipstick
3. Heater connection
4. Connection Air cleaner
5. Turbo
6. Connection Intercooler (In)
7. Connection Intercooler (out)
8. Sensor intake temp
9. Connection exhaust
10. Sensor boost pressure
11. Connection expansion tank
12. Alternator
13. Connection radiator (in)
14. Intercooler Inlet
15. Intercooler
16. Radiator
17. Thermostat
18. Transmission cooler
19. Connection radiator (out)
20. Coolant pump
21. Connector expansion tank
22. Thermostat housing
23. Oil filter
24. Coolant filter
25. Shut off valve coolant filter
03/06/2023 23
DRT 450
2. Transmission
4 5
3
6
7
2 8
10
1
03/06/2023 24
DRT 450
2. Transmission HR 32000
Engine running
06/03/23 25
DRT 450
Drive
06/03/23 26
DRT 450
Inching / De-clutch
06/03/23 27
DRT 450
Actuated valves
Y6067 - 1 Y6069 Y6067 - 3
1st gear On On On
2nd gear Off On On
3rd gear Off Off On
4th gear Off Off Off
06/03/23 28
DRT 450
Actuated valves
Engine Running N
06/03/23 29
DRT 450
Actuated valves
Rev / 1st
06/03/23 30
DRT 450
Actuated valves
Rev / 2nd
06/03/23 31
DRT 450
Actuated valves
Rev / 3rd
06/03/23 32
DRT 450
Actuated valves
Rev / 4th
06/03/23 33
DRT 450
Actuated valves
Fwd / 1st
06/03/23 34
DRT 450
Actuated valves
Rev / 2nd
06/03/23 35
DRT 450
Actuated valves
Rev / 3rd
06/03/23 36
DRT 450
Actuated valves
Rev / 4th
06/03/23 37
DRT 450
Component location
06/03/23 38
DRT 450
2. Transmission
TE 32000
 DANA Spicer Off-Highways TE32
 4 gears forward & reverse
 Electronic controlled by Transmission Control Unit

(TCU)
 Automatic gear box as standard
KTCG
DRT 450
2. Transmission
4 5
3
6
7
2 8
10
1
03/06/2023 40
DRT 450
2. Transmission
Engine running
DRT 450
2. Transmission
Drive
DRT 450
2. Transmission
De-clutch
DRT 450
2. Transmission
CTA
DRT 450
3. Drive axle
 Axle tech or Kessler
 Fits all models

DRT 450
4. Brakes
 Separate brake system with a fan- radiator - less

heat and cleaner hydraulic system
 More efficient cooling of the oil
 Electrical parking brake
 One separate high pressure filter for the brake

system
 Volume 140 litres
 New breathing filter
 Oil type UTTO API GL-4 SAE 5W30

DRT 450
4. Brakes
2 4
5
10
8 7
9
DRT 450
4. Brakes
03/06/2023 48
DRT 450
4. Brakes
The brake system has one gear pump driven of the

left hand main pumps. The brake pump is used to
charge the accumulators and also to supply cooling
oil to the wet disc brake assemblies.
03/06/2023
49
DRT 450
Pre charge to match
4. Accumulators information on data
plate
Nitrogen
Oil
Accumulator pressure
to match information on
data plate
03/06/2023 50
DRT 450
4. Brakes, Accumulator charge valve
03/06/2023 51
DRT 450
4. Brakes: Accumulator charging
Pressure limiting valve
03/06/2023 52
DRT 450
4. Brake Valve
Brake valve.
1: Main spool, Brakes
2: Main pressure spring
3: Return spring
P = Accumulator
A = Brake Circuit
T = Tank
03/06/2023 53
DRT 450
4. Brake Valve
Rest position
With the brake pedal released the spool is held in place by the
springs. The connection from the accumulator is closed and the
connection between the brake circuit and the tank is open
T
T
T
T
A
T
03/06/2023 54
DRT 450
4. Brake Valve
Position I
P The pedal is pressed and the valve spool opens the connection
between the accumulator connection and the brake circuit.
A Pressure builds up in the brake circuit, the pressure in the brake
circuit is used as back pressure on the underside of the spool
T
The valve spool is forced up until balance is obtained between

pedal force and brake pressure.
T
T
T
T
03/06/2023 55
DRT 450
4. Brake Valve
Position II
In the balance position the spool closes the connection between
the accumulator and the brake circuit, the brake pressure is now
constant. This results in the brake pressure increasing
proportionally to the force on the brake pedal.
T
T
T
T
T
03/06/2023 56
DRT 450
4. Brake Valve
Position III
When the brake is released the connection between the brake
circuit and the tank is open and the pressure drains to tank
T
T
T
T
A
T
03/06/2023 57
DRT 450
4. Brakes Pressure switch
S204: Brake pressure NC
DIAG HYD 4 (6)

PRESSURE SWITCHES
BRAKE PRESSURE 1
0
BRAKE LIGHT PRESS 0
DECLUTCH PRESSURE 0
03/06/2023 58
DRT 450
4. Brakes Pressure switch
S204 NC Pressure switch
CONN 1 CONN 2
Adjusting screw
03/06/2023 59
DRT 450
4. Brake Light switch
S 216 brake light switch
DIAG HYD 4 (6)

PRESSURE SWITCHES
BRAKE PRESSURE 0
BRAKE LIGHT PRESS 10
DECLUTCH PRESSURE 0
03/06/2023 60
DRT 450
4. Brakes Wheel unit Steel discs
From pedal
Piston seals
Piston
Friction discs
03/06/2023 61
DRT 450
4. Park brake, Components
2
4 5
1 6
7
8
03/06/2023 62
DRT 450
4. Park brake,
03/06/2023 63
DRT 450
4. Park brake solenoid
DIAG HYD 5 (6)

P-BRAKE
SWITCH 1/0
0/1
FEEDBACK SWITCH 01
VALVE 0/0
0/1
1/1
1/0
03/06/2023 64
DRT 450
4. Brakes S200 pressure switch
CONN 1 CONN 2
03/06/2023 65
DRT 450
4. Cooling and temperature control
03/06/2023 66
DRT 450
4. Cooling and temperature control
03/06/2023
67
DRT 450
5. Steering components
1
2
3
4
5
03/06/2023 68
DRT 450
5. Steering function
03/06/2023
69
DRT 450
5. Priority valve
P. Pump
R. Tank
PP. Pilot Port
EF. Main valve CF. Steering LS. Load signal

DRT 450
5. Steering, Orbitrol
Pump
Load signal
Right
Left Tank
03/06/2023 71
DRT 450
6. Suspension
 New design - Cut from 150 mm plate. King pin bearings

are plain bearings along with thrust plates.
 Axle is mounted in the chassis with lubrication free

bearings
DRT 450
6. Suspension
Both front and rear axle mounting bearings are made up of two bearing shell haves and a center
spherical bearing
DRT 450
6. Suspension
03/06/2023 74
DRT 450
6. Suspension, Tyres
03/06/2023 75
DRT 450
6. Suspension, Tyre inflation
3 Mt
03/06/2023 76
DRT 450
6. Suspension Rim crack testing
A B
0.5 mm Max
Areas to be cleaned
C D
03/06/2023 77
DRT 450
7. Load handling
DRT 450
7. Load handling
DRT 450
7. Load handling Lift
DRT 450
7. Load handling, diagnostics
Lift / Lower
BOOM menu 1
Lift / lower input
DIAG BOOM 1 (8)
Lift: 2.50 – 4.50 volts
Lower 2.50 – 0.50 volts
PRESENT INPUT SIGNALS
BOOM UP/DOWN 02.56V
BOOM IN/OUT 02.51V
BOOM menu 4 / 5
Output lift
DIAG BOOM 3 (8)
Reference,
Status for control current to main control valve,
OUTPUT BOOM UP
00 = no output signal PWM off,
REFERENCE 11
10 = output signal active, short circuit
REQUIRED VALUE 550 mA
11 = output signal active, circuit OK
FEEDBACK 548 mA
Required value,
Reference value for control current to main control valve
380 – 650 mA (typical, final setting made at factory)
Feedback,
Present control current to main control valve
380 – 650 mA
Note: BOOM menu 4 is identical to menu 5 but is for lower
03/06/2023 81
DRT 450
Lift / Lower block valves
BOOM menu 2
Status voltage supply to blocking solenoid valves lower,
DIAG BOOM 1 (2) 00 = no output signal
BLOCK VALVES 01 = no output signal, circuit Ok or short circuit
UP/DOWN LE11 RI11 10 = output signal active, short circuit
IN/OUT 01 11 = output signal active, circuit OK
RELIEVE PRESS 01
03/06/2023 82
DRT 450
7. Load handling Lift –
Regeneration
DRT 450
Lift regeneration
BOOM menu 3
Status for voltage to regeneration boom up,

DIAG BOOM 3 (8)
00 = no output signal PWM off
BOOM HIGH SPEED
01 = no output signal circuit OK or short circuit
UP LE 01 RI 01
OUT 01
OP menu
Signal from sensor hydraulic lift cylinder pressure
DIAG OP 3 (5)
LE: signal from B768 – L
PRESENT INPUT SIGNAL
RI: signal from B768 - R
LIFT CYL LE RI
C- 0.50V 0.50V
Signal value: 0.50 – 4.50 V
C+ 1.00V 1.02V
Hydraulic oil pressure: 0.50 V = 0 Mpa
4.50 V = 25 MPa
C-
C+
03/06/2023 84
DRT 450
7. Load handling Lift –
Damping
DRT 450
7. Load handling lift cylinder valve block
1
9
5
8
6
7
DRT 450
7. Load handling extension
DRT 450
Boom
BOOM menu 1
Boom in / out input
DIAG BOOM 1 (8)
Boom out: 2.50 – 4.50 volts
Boom in: 2.50 – 0.50 volts
PRESENT INPUT SIGNALS
BOOM UP/DOWN 02.56V
BOOM IN/OUT 02.51V
BOOM menu 6 / 7
Output Boom In
DIAG BOOM 6 (8)
Reference,
Status for control current to main control valve,
OUTPUT BOOM IN
00 = no output signal PWM off,
REFERENCE 11
REQUIRED VALUE 550 mA
FEEDBACK 548 mA
Required value,
Reference value for control current to main control valve
380 – 650 mA (typical, final setting made at factory)
Feedback,
Present control current to main control valve
380 – 650 mA
Note: BOOM menu 7 is identical to menu 6 but is for out
03/06/2023 88
DRT 450
Boom block valve
BOOM menu 2
Status voltage supply to blocking solenoid valves lower,
DIAG BOOM 1 (2) 00 = no output signal
BLOCK VALVES 01 = no output signal, circuit Ok or short circuit
UP/DOWN LE11 RI11 10 = output signal active, short circuit
IN/OUT 01 11 = output signal active, circuit OK
RELIEVE PRESS 01
03/06/2023 89
DRT 450
DRT 450
DRT 450
Boom regeneration
BOOM menu 3
Status for voltage to regeneration boom out,

DIAG BOOM 3 (8)
00 = no output signal PWM off
BOOM HIGH SPEED
01 = no output signal circuit OK or short circuit
UP LE 01 RI 01
OUT 01
OP menu
Signal from sensor hydraulic lift cylinder pressure
DIAG OP 3 (5)
LE: signal from B768 – L
RI: signal from B768 - R
LIFT CYL LE RI
C- 0.50V 0.50V
Signal value: 0.50 – 4.50 V
C+ 1.00V 1.02V
Hydraulic oil pressure: 0.50 V = 0 Mpa
4.50 V = 25 MPa
C-
C+
03/06/2023 92
DRT 450
DRT 450
Length sensor
BOOM menu 2
Status voltage from angle and length sensors
DIAG OP 4 (5)
BOOM ANGLE 3.56V
BOOM EXTENSION 2.97V
03/06/2023 94
DRT 450
7. Load handling, main valve
1. Rod side extension cylinder

2. Y6006 servo valve boom out
3. Y6005 servo valve lift
4. Rod side R/H lift cylinder
5. Piston side R/H lift cylinder
6. Y6004 servo valve lower
7. Y6007 servo valve boom in
8. Pumps
9. Piston side extension cylinder
06/03/23 95
DRT 450
Boom cylinder block valve
1
7
2
6
3
5 4
1. Connection rod side (C-)

2. Drain (D)
3. Servo valve (Y6046)
4. Control valve connection (VB)
5. Control valve connection (VA)
6. Control valve connection (VA)
7. Servo valve blocking (Y6050)
DRT 450
7. Load handling, Boom sliders
1. Side mounted slide plates

2. Lower slide plates
Boom slider adjustment Front

1. Lower the boom to its lowest position, inner boom out 500 mm
2. Remove the cover plates for the side mounted slide plates, remove the spacers and slide plate
3. Inspect the slide plate for wear or damage
4. Refit in the reverse order
5. Check the clearance between the boom and the slide plate, clearance should be 1 mm. Adjust with spacers if needed
6. Remove the bolts, slide plate housings and slide plates from the upper boom
7. Lift the inner boom and pack up with wooden blocks. Crush hazard.
8. Remove the bolts, slide plate housings and slide plates for the lower boom slide plates.
9. Remove and transfer the nuts from the old slide plates to the new slide plates
10. Install the new lower slide plates to the lower boom,
11. Remove the wooden blocks and allow the inner boom to rest on the slide plates.
12. Transfer the nuts from the old upper slide plates to the new upper slide plates
13. Install the new upper slide plates to the upper boom
14. Check the clearance between the boom and the stop on the leading edge / top edge of the boom, clearance can be a
maximum of 2 mm
15. adjust the clearance with spacers if required.
DRT 450
7. Load handling, Boom sliders
1. Upper slide plates

2. Side slide plates
3. Lower slide plates
Boom slider adjustment Rear

1. Start the engine and full retract the inner boom
2. Remove the cover plates for the side mounted slide plates, remove the spacers and slide plate
3. Inspect the slide plate for wear or damage
4. Refit in the reverse order
5. Check the clearance between the boom and the slide plate, clearance should be 1 mm. Adjust with spacers if needed
6. Remove the bolts, slide plate housings and slide plates from the upper boom
7. Lift the inner boom and pack up with wooden blocks. Crush hazard.
8. Remove the bolts, slide plate housings and slide plates for the lower boom slide plates.
9. Remove and transfer the nuts from the old slide plates to the new slide plates
10. Install the new lower slide plates to the lower boom,
11. Remove the wooden blocks and allow the inner boom to rest on the slide plates.
12. Transfer the nuts from the old upper slide plates to the new upper slide plates
13. Install the new upper slide plates to the upper boom
14. Check the clearance between the boom and the stop on the leading edge / top edge of the boom, clearance can be a
maximum of 2 mm
15. adjust the clearance with spacers if required.
DRT 450
7. Load handling, Boom sliders Lubrication
Lubricate the boom with Gletimol slide paste in the areas shown above
DRT 450
7. Load handling, side shift
DRT 450
2
8
16
9
10
11
12
15
14 13
DRT 450
DRT 450
DRT 450
7. Load handling, valve blocks
Top lift, pump unload
Y6003
Y6062 Spreader hydraulics
Pump unload
DRT 450
7. Load handling, valve blocks
Top lift, main valve pressures
Function Pressure
Sideshift 16.0 MPa
Spreading 12.0 MPa
Rotate 15.0 MPa
Tilt + 15.0 MPa
Leveling + 15.0 Mpa
Twistlocks Same as feed pressure
Overheight legs + 10.0 MPa
Lift legs, knee out/in + 10.0 MPa
Lift legs, leg down/up + 13.0 MPa
Lift legs, clamp + 13.0 MPa
DRT 450
7. Load handling, spreading
DRT 450
7. Load handling, spreading. 30’ stop
DRT 450
7. Load handling
Spreading, position sensors
30 ’ – 35’ indicator
40’ indicator
30’ damping sensor

20’ indicator
20’ - 40’ damping sensor,

30; stop
06.03.2023 108
DRT 450
7. Load handling
Rotate
DRT 450
7. Load handling
Rotate stop
DRT 450
7. Load handling
Rotate
1
7
4
3
DRT 450
7. Load handling
Tilt
DRT 450
7. Load handling
Tilt lock
DRT 450
7. Load handling
Tilt control
DRT 450
7. Load handling
Adjusting damping
Damping adjustment screws

DRT 450
7. Load handling
Twist locks, open
DRT 450
7. Load handling
Twist locks / landed
DRT 450
7. Load handling
Twistlocks, landed function
DRT 450
7. Load handling
Twistlocks locked
DRt 450
7. Load handling
Twist lock sensors
Operating link
Cylinder
Twist lock open sensor Twist lock closed sensor
Sensor flag
06.03.2023 120
DRT 450
7. Load handling
Twist locks
Operating link
Alignment sensor
Guide block
Twist lock
Landed pin
06.03.2023 121
DRT 450
7. Load handling
Alignment sensors
06.03.2023 122
DRT 450
7. Load handling
Weighing
DRF 400 - 450
7. Load handling
Container counter
DRT 450
7. Load handling
Synchronous lift
DRT 450
8. Control system
KDCS:
The DRT range of machines are controlled by the Kalmar Distributed Control System (KDCS) the system
comprises a number of control units linked by Can bus. The various control units receive inputs and
outputs for the components connected to them. Each module or node controls different parts of the
machine, these components will be explained in detail in section 11 common electrics.
The KDCS also monitors the machine for errors, enables calibrations, as well as changes to the basic set
up of the machine.
The main interface for the KDCS is the drivers display and key pad, both located on the steering column,
to access the various menus of the KDCS a 5 digit pass code is needed.
There are 4 different codes for the DCF, these are:
Diagnostics: 54145
Calibration: 13143
Initiation: 25213
Service interval reset: 52331.
There is also a connection port located inside the EL central panel, this port provides a connection for
Kalmar Soft Tool (KST), the KST provides further fault finding tools as well as downloading, uploading
and controlled parameter changes.
03/06/2023 126
DRT 450
8. Control system, Drivers Screen
03/06/2023 127
DRT 450
a. Engine rpm
a d b. Speed in kph / mph
b e c. Time
d. Present gear
e. Fuel level
c
Setting the clock
1. Go to the set mode by holding the enter key for 3

seconds
2. Using the 1 and 2 keys scroll between, hours minutes
a etc
3. Change the value with the + / - keys
4. Press enter to store the change
5. To exit press the R key
03/06/2023 128
DRT 450
a. Coolant temperature
a b. Oil pressure
a. Transmission oil temperature

a b. Hydraulic oil temperature
Battery voltage
03/06/2023 129
DRT 450
The display shows alignment against the container, when

alignment is correct both circles will be filled in and the
display shown disappears
This display is shown when the sensors for the twistlocks

cannot detect if the twist locks are open or closed.
03/06/2023 130
DRT 450
a c a. Set temperature
b. Fan speed
d c. Vent setting
d. De-mist
b e. Recirculation
e
03/06/2023 131
DRT 450
error messages
307
353
1
!
STOP
03/06/2023 132
DRT 450
error messages
03/06/2023 133
DRT 450
error messages
03/06/2023 134
DRT 450
8. Control system, Overload system
Electronic
DRT 450
8. Control system, service interval
SERVICE INTERVAL
NEXT SERVICE 500h
SERVICE INTERVAL
STORED 500h
PRESENT 500h
03/06/2023 136
DRT 450
8. Control system, diagnostics
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
The machine has a built in function for troubleshooting call diagnostic test. The diagnostic test
consists of several menus shown on the display. The menus are grouped for faster access, the main
menu is shown above which shows the sub menus that can be accessed.
Further information of these groups can be found on the following slides

DRT 450
1 2 3 4
7 DIAG CAB 4 (X)

FRONT WIPER
SWITCH (1-3) 2
6 OUTPUT 11 5
FEEDBACK 0
1. DIAG = Diagnostic menus

2. Menu group
3. Menu number
4. Total number of menus in the loop, the number of
menus depends on the machine configuration
5. Signal value
6. Variable
7. Menu heading
DRT 450
DIAG: Indicates that diagnostic test are selected

CAB: Indicates which menu is selected
2: Number of current menu
(X): Total number of menus in the selected group
Variable: the signal that is measured, Different signals are
DIAG CAB 4 (X)
designated in different ways
FRONT WIPER
SWITCH: a digital input signal: e.g. a switch
SWITCH (1-3) 2
OUTPUT: a digital output signal e.g. feed to a motor
OUTPUT 11
INPUT: an analogue input signal e.g. from a sensor
FEEDBACK 0
REFERENCE: status for an analogue output signal
REQUIRED: output signal for a control current
FEEDBACK: either feedback signal from a motor or measured
current on the negative side for an analogue output signal.
Signal value: measurement value or status for a variable. On the
same row there are different that are interpreted in different ways
SWITCH: 1 or 0, 1 means closed circuit
OUTPUT: two numbers, the first number is 1 if the output signal is
active, the second number is the status for the circuit: 1=OK, 0=open
or short circuit
INPUT: a value corresponding to the signal
REFERENCE: two numbers, the first number is 1 if the output signal
is active, the second number is the status for the circuit: 1=OK,
0=open or short circuit
REQUIRED: value corresponding to the signal
FEEDBACK: value corresponding to the return signal
Menu heading: description of the function
DRT 450
DIAGNOSIS
DIAG CAN/POWER 4 (X)
CAN/POWER LIGHTS CAB PRESENT REDCAN STATUS
CLIMATE HYD ENGINE COMMUNICATION MODE 3
TRANSM BOOM ATTACH
NUMBER OF UNITS 4
OP EXTRA RMI
SEGMENT ERROR 0
DIAGNOSIS
DIAG LIGHTS 2(X)
CAN/POWER LIGHTS CAB PRESENT OUTPUT SIGNAL
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI SIDE LIGHTS 11
REAR LIGHTS 11
DIAGNOSIS
DIAG CAB 4 (X)
CLIMATE HYD ENGINE
SWITCH (1-3) 2
TRANSM BOOM ATTACH
OUTPUT 11
OP EXTRA RMI
FEEDBACK 1
DRT 450
DIAGNOSIS DIAG CLIMATE 6 (X)

CLIMATE HYD ENGINE FAN SPEED 255
TRANSM BOOM ATTACH
RECIRCULATION 11
OP EXTRA RMI
COMPRESSOR 00
DIAGNOSIS
DIAG HYD 5 (X)
PARK BRAKE
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH SWITCH 01
OP EXTRA RMI FEEDBACK SWITCH 11
VALVE 11
DIAGNOSIS
DIAG ENGINE 1 (X)
CAN/POWER LIGHTS CAB PRESENT INPUT SIGNAL
CLIMATE HYD ENGINE
ACCELERATOR 0.55V
TRANSM BOOM ATTACH
OP EXTRA RMI REQUIRED SPD PROC 25
REQUIRED SPD RPM 1100
DRT 450
DIAGNOSIS DIAG TRANSM 2 (X)

CAN/POWER LIGHTS CAB SWITCHES
CLIMATE HYD ENGINE FORWARD 0
TRANSM BOOM ATTACH
REVERSE 1
OP EXTRA RMI
SHIFT MODE 4
DIAGNOSIS
DIAG BOOM 1 (8)
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH BOOM UP/DOWN 2.54V
OP EXTRA RMI BOOM IN/OUT 2.59V
DIAGNOSIS
DIAG ATTACH 6 (X)
CLIMATE HYD ENGINE
IND. LOCKED TW 00
TRANSM ELSERV ATTACH
OP EXTRA RMI IND. UNLOCKED TW 11
IND. ALIGNMENT 00
DRT 450
DIAGNOSIS DIAG OP 3 (5)

CAN/POWER LIGHTS CAB PRESENT INPUT SIGNAL
CLIMATE HYD ENGINE
LIFT CYL LE RI
TRANSM ELSERV ATTACH
C- 0.98V 0.99V
OP EXTRA RMI
C+ 1.90V 1.78V
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAGNOSIS
DIAG SLID-CAB 1 (4)
COMBI SLIDING – CAB SWITCHES
SUPPORT – JACKS
FORWARD 0
EL-STEERING
REVERSE 0
OPENED DOORS 1
06.03.2023
DRT 450
8. Control system, initiation
1 2
INIT BOOM 1 (X)

START CURRENT
LIFT
4 STORED VALUE 350mA 3
PRESENT VALUE 350mA
1. Menu group
2. Number of menus
3. Signal value
4. Current variable
DRT 450
PRESENT: displays the stored value when the

menu is opened. Adjust the value with the plus and
minus keys. Set the value with the enter key. To
navigate to the next menu use the arrow keys. Go
INIT BOOM 1 (X)
back with the R key
START CURRENT
STORED: shows the value for the current variable
LIFT
START CURENT (3): specifies the start current to
STORED VALUE 350mA
the solenoid valve for the selected function, this is
PRESENT VALUE 350mA
the current that is triggered when the lever leaves
the zero position
END CURRENT (1): shows the maximum current to
the solenoid for the selected function. In practice it
controls how fast a function will operate.
I (mA) PROC (2) Damping: specifies ho much the control
current is reduced during damping
1
2
3
t (sec)
DRT 450
INITIATION
INIT BOOM 1 (X)
BOOM ATTACHMENT START CURRENT
SLIDING-CAB STEERING LIFT
DRIVE-TRAIN
STORED VALUE 350mA
PRESENT VALUE 350mA
INITIATION
INIT ATTACH 1 (17)
SLIDING-CAB STEERING
ROTATION CW
DRIVE-TRAIN
STORED VALUE 350mA
PRESENT VALUE 350mA
INITIATION INIT SLID CAB 1 (X)

SLIDING-CAB STEERING FORWARD
DRIVE-TRAIN STORED VALUE 350mA
PRESENT VALUE 350mA
DRT 450
8. Control system, Initiation
INITIATION
INIT STEERING 9 (10)
SLIDING-CAB STEERING STEERING LEFT
DRIVE-TRAIN STORED VALUE 370mA
PRESENT VALUE 400mA
INITIATION
INIT DRIVE-TRN 1 (6)
BOOM ATTACHMENT START IN 2:ND
SLIDING-CAB STEERING
0=NO 1=YES
DRIVE-TRAIN
STORED VALUE 1
PRESENT VALUE 1
06.03.2023
DRT 450
8. Control system, calibration
1 2
5 CALIBR STEERING 1 (X)

STEERING LEVER CENTER
POSITION
4 STORED VALUE 2.50V 3
PRESENT VALUE 2.50V
1. Menu group
2. Number of menus
3. Signal value
4. STORED indicates the stored value
PRESENT indicates the current value of the
signal to be calibrated
5. Heading of menu
DRT 450
SCALE: this menu handles calibration of the

CALIBRATION
sensors connected to the weight indication
SCALE STEERING STEERING: this menu handles the
DRIVE-TRAIN RETURN calibration for lever steering (option)
DRIVETRAIN: this handles calibrations for
the engine and transmission. The loop
contains two different calibrations which are
not connected to each other.
DRT 450
CALIBRATION
CALIBR SCALE 1 (2)
SCALE STEERING MINIMUM BOOM ANGLE
DRIVE-TRAIN RETURN
CALIBR VALUE 0.56V
PRESENT VALUE 0.98V
CALIBRATION
CALIBR STEERING 1 (3)
SCALE STEERING STEERING LEVER CENTER
DRIVE-TRAIN RETURN POSITION
STORED VALUE 2.50V
PRESENT VALUE 2.50V
CALIBRATION
CALIBR DRIVE-TRN 1 (2)
SCALE STEERING ACCELERATOR
DRIVE-TRAIN RETURN RELEASE THE PEDAL
STORED VALUE 0.56v
PRESENT VALUE 0.56V
DRT 450
CALIBRATION
CALIBR DRIVE-TRN 4 (X)
SCALE STEERING GEARBOX WARM UP
DRIVE-TRAIN RETURN MODE 0
ACTUAL TEMP 58
TARGET TEMP 61
To calibrate the transmission the temperature of the oil must be over 60 degrees C, if the oil is below this
temperature carry out the gearbox warm up procedure.
1. Park the machine on level ground, engage neutral and apply the park brake. Run the engine at idle
2. Go to the calibration menu menus and select DRIVE-TRAIN, menu 4
3. Check that the oil temperature is at least 61˚C, if the oil is below the target temperature then carry out
the warm up.
a) Apply the park brake so the machine is stationary
b) Select forward and apply full throttle for 20 seconds
c) Engage neutral, apply full throttle for 10 seconds and then let the engine run at idle
d) Repeat steps b and c until the oil is hot
When the temperature is correct the MODE changes from 0 to 1
DRT 450
CALIBRATION
CALIBR DRIVE-TRN 3 (X)
SCALE STEERING START AUTO CALIBR
DRIVE-TRAIN RETURN PHASE 1 SUB-PH 1
CLUTCH F STATUS 3
ACTION 0 1500rpm
PHASE ACTION (action by technician)

0 = Pre filling of clutch 0 = No action
1 = Calibration of clutch 1 = Increase throttle application
4 = Calibration complete 2 = Reduce throttle application
5 = Calibration incorrect 3 = Select neutral
4 = Select forward
CLUTCH 5 = Stop machine (machine moving, press the brake pedal
F = Forward clutch 6 = Heat transmission
R = Reverse clutch 7 = No action (engine is controlled by the D793)
1 = 1st clutch 8 = Keep accelerator pedal in current position
2 = 2nd clutch 9 = Check error codes
3 = 3rd clutch SUB-PH; Internal value for sub phase 1 or 0
4 = 4th clutch
STATUS
0 = Calibration not in progress
3 = Calibration in progress
DRT 450
Drivers screen
Roof / rear wiper
Front wiper / horn switch S162 switches
Accelerator pedal
Light switches B690
Joystick
ECC switches
Transmission mode
switches
Brake pedal
De – clutch switch S220-1
03/06/2023 153
DRT450
AC description
06.03.2023 154
03/06/2023
DRT 450
9. Climate control, function description
06.03.2023
DRT 450
ECC Diagnostics
Checking the required, present temperature sensors and water valve

DIAG CLIMATE 1 (8)
REQUIRED TEMP: 160 (16.0˚C) = maximum cooling, 280 (28.0˚C)
REQUIRED TEMP 160
PRESENT TEMP: shows the temperature inside the cab
PRESENT TEMP 210 WATER VALVE FEEDB: should show 0 (closed) when the requested
WATER VALVE FEEDB 00
temperature is 160 and 100 (open) when the requested temperature is
280.
Checking the sensors connected to the ECC

DIAG CLIMATE 2 (8) TEMP COIL: temperature in the air ducts in the cab
TEMP COIL 160 TEMP COOLANT: engine temperature (sent via CAN from D794)
TEMP COOLANT 829 TEMP AMBIENT: outside temperature
TEMP AMBIENT 194 TEMP DE-ICE: AC circuit temperature, De-Ice sensor controls the
TEMP DE-ICE 20 switching on/off of the compressor
Checks the refrigerant circuit

DIAG CLIMATE 3 (8)
PRESSURE SWITCH 0 = no gas, 1 = gas in system
PRESSURE SWITCH 1
OPT DOOR SWITCH 0
03/06/2023 156
DRT 450
ECC Diagnostics
Checks Water valve and Air distributor

DIAG CLIMATE 4 (8) WATER VALVE: should work between 1.0 – 1.24V, this can be
checked by increasing the temperature with the temperature switch
WATER VALVE 1.98V
DRAUGHT VALVE: should work between 1.0 – 4.0V. Check the
DRAUGHT VALVE 3.19V operation by changing the vents with the vent switch
The menu is used to check the signals from the rocker switches for
DIAG CLIMATE 5 (8) temperature, air distribution and fan speed to the D790-1
PRESENT INPUT SIGNAL REQUIRED TEMP: value between 2.4 and 5.0 volt
REQUIRED TEMP 0.01V REQ DRAUGHT: value between 2.4 and 5.0 volt
REQ DRAUGHT 0.01V REQ FAN SPEED: value between 2.4 and 5.0 volt
REQ FAN SPEED 0.01V
Checking the fan speed, Recirculation and compressor PWM and

voltage feeds
DIAG CLIMATE 6 (8) FAN SPEED: PWM output, 0-255 255 = maximum speed
PRESENT INPUT SIGNAL RECIRCULATION: voltage feed to fresh air and recirculation damper.
FAN SPEED 213 01 = No output signal, 10 = output signal active short or open circuit
RECIRKULATION 11 11 = output signal active, circuit OK.
COMPRESSOR 11 COMPRESSOR: voltage feed to compressor, signal readings as
above
03/06/2023 157
DRT 450
ECC Diagnostics
Voltage feed to water valve

DIAG CLIMATE 7(8) Clockwise.
OUTPUT WATER VALVE
The valve is connected to an H bridge, the signal can only be
CLOCKWISE 11 11
diagnosed when the water valve position changes
ANTI-CLOCKWISE 00 11 01 = No output signal, 10 = output signal active short or open circuit
11 = output signal active, circuit OK.
ANTI-CLOCKWISE
As above for Clockwise
Voltage feed to draught valve

DIAG CLIMATE 7(8)
Clockwise.
OUTPUT DRAUGHT VALVE
The valve is connected to an H bridge, the signal can only be
CLOCKWISE 11 11
diagnosed when the water valve position changes
ANTI-CLOCKWISE 00 11
01 = No output signal, 10 = output signal active short or open circuit
11 = output signal active, circuit OK.
ANTI-CLOCKWISE
As above for Clockwise
03/06/2023 158
DRT 450
9. Lights
06.03.2023
DRT 450
Lights
Voltage supply and out put for lights (attachment)

DIAG LIGHTS 13(15) Switch
WORKING LIGHT ATTACH
0 = off
SWITCH 1
1 = on
OUTPUT LE 11 RI 11 Output LE (left) RI (right)
00 = no output, open circuit
01 = no output signal, circuit OK or short circuit. Short circuit can only
be detected when output is active
10 = output active, short circuit
11 = output active, circuit OK
03/06/2023 160
DRT 450
Cab
Signal from multifunction lever for the washer switch

DIAG CAB 1(4) Switch
WASHER
0 = off
SWITCH 1
1 = on
OUTPUT FRONT 11 Output
OUTPUT REAR ROOF 11 01 = no output signal,
10 = output signal active, short – circuit or open circuit
Signal from multifunction lever for the front wiper switch

DIAG CAB 1(4) Switch
FRONT WIPER
0 = off
SWITCH (1-3) 3
1 = intermittent long
OUTPUT 11 2 = intermittent short
FEEDBACK 11 3 = continuous operation
Output
01 = no output signal,
10 = output signal active, short – circuit or open circuit
03/06/2023 161
DRT 450
Cab
DRT 450
Option: Sliding cab / support jacks
Front
Main valve
DRT450
Charging valve for accumulators
Brake pressure
Front
Unfiltered/ Drain
Relief valve
attachment
Filtered return line

DRT 450
Front
Oil filter servo Servo valve
Solenoid valve
park brake Restriction valve
Priority valve steering
Accumulator Servo
DRT 450
Transmission pumps
Solenoid valve switches off

left pumps during boom in
Front
Shuttle valve for oil to the

spreader
Activates hydraulic pressure to the spreader

DRT 450
Pump brake system Pump cooling hydraulics
Front
Pump spreader, lifting,

boom out Pump steering, lifting, boom
in/out
2 Regulators
2 Regulators
Pump steering, lifting, boom

Pump lifting, boom out in/out
DRT 450
DRT 450
KDU
KCU D791-1
D790-1
KID
D795
KIT
D790-2
KDU
D797-F
KDU
D797-O
KDU
D797-R
EDC TCU
D794 D793
A Partek Company
DRT 450
Redundant voltage
1 2 3 4
D1 D2 D3 D4
D8 D7 D9
D11
D795 D790-1 D797-R D797-F D797-O D793

11 5 6 8 7 9
10 12 13 14
D790-2 D791-1 D791-2 D791-3 D791-4 D794
D10 D12 D13 D14

DRT 450
Ignition voltage (15)
D4
1 2
D1 D2 3 6
D3
4 5
D8 D9 D10 D11 D12
D795 D790-1 D797-R D797-F D797-O D793

8 9 10 11 12
D790-2 D791-1 D791-2 D791-3 D791-4 D794

DRT 450
Ignition voltage (15E)
3 4 6
D4
D5
D2
D7 D8
D795 D790-1 D797-R D797-F D797-O D793

1 2 5 7 8
D790-2 D791-1 D791-2 D791-3 D791-4 D794

D12 D11 D10 D9
DRT 450
Cab distribution box
CAN terminating
resistors Diagnostic connector
KDCS
Fuse boxes
D790-1
Diagnostic connector
Drive train
DRT 450
Frame distribution box
Diagnostic
Fuses 15 E port Volvo
Diagnostic
Fuses 15 port Dana Main Fuses D 793
Fuses 30
K 315-1 K 3002 K 3007

K 3009-2 K 3009-1 K 315-2
DRT 450
D790-1
- Display
- Joystick panel
- Left front panel
KDU
- Steering wheel panel
- Accelerator, de-clutch
- Wipers
- Climate system
KIT - Working lights, cab
KCU KID
KDU KDU
EDC TCU
A Partek Company
DRT 450
D791-1
KDU
- Landing pin sensors

- TW-lock sensors
- Hydraulic valves
KIT - Indicator lamps
- Working lights, attch
KCU KID
KDU KDU
EDC TCU
A Partek Company
DRT 450
D797-F
KDU
KIT
KID - Front lights

KCU - Pressure switches
- Hydraulic valves
- Brake oil cooler
KDU KDU - Lift cylinders
- Valves & sensors
EDC TCU
A Partek Company
DRT 450
D797-R
- Rear lights
- Boom sensors
- OP sensors, steering axle
- Hydraulic oil cooler KDU
- Drive-train
- Fuel sensor
- D+
- AC compressor
KIT - Working lights, boom
KCU KID
KDU KDU
EDC TCU
A Partek Company
DRT 450
D793, D794
KDU
KIT
KCU KID
KDU KDU
EDC TCU - Injectors control

- Fuel consumption
- Optimised gear shifting
speed, torque, rpm
- Monitoring
- ‘Limp home’ function
A Partek Company
DRT 450
Control unit description D790-1 KCU
1 2 3 4
The D 790-1 is located on the rear wall of the cab, it is the interface between the drive train CAN and the
KDCS, receives inputs from the switches etc in the cab, controls the redundant power supply and handles
communication via the CAN to the other control units. The D790-1 is programmed with a unique program,
while the unit is used on other Kalmar models the program loaded is written for the DCF 100.
06.03.2023
DRT 450
Control unit description D790-2 KIT
The D790-2 KIT is located on the steering column, it has two parts, one is the information panel and
the second is the key pad. The D790-2 handles the inputs from the direction lever, indicator switch,
transmission keys. The D790-2 has a program loaded but this program cannot be altered
06.03.2023
DRT 450
11. Common Electrics,
Control unit description D 797 - 1
D797 - 1:
The D797 – 1 is located in the front left
hand side of the chassis. The D797-1
processes input data from sensors and
sends control signals to relays and
solenoids. The D797-1 has a program
loaded, again the program is unique for the
DCF 100.
There are 4 LED indicators on the module:

Green: 24 v supply
Green: On: redundant voltage left and
right, 15 voltage Flashing: one of the
following is missing: redundant voltage left /
right or 15 voltage
Yellow: Single flash: communicating with
POWER D795 or D790-1
Double flash: communicating with both
D795 and D790-1
POWER
Red: Active error
MODE
STATUS
03/06/2023 182
DRT 450
Control unit description D 791 - 1
D791 - 1:
The D791 – 1 is located in the carriage for
the attachment, the D791-1 receives inputs
from the various sensors and provides
outputs to the attachment valve.
The D791-1 has a program which is unique

for the DCF 100
There are 4 LED indicators on the module:

Green: 24 v supply
Green: On: redundant voltage left and
right, 15 voltage Flashing: one of the
following is missing: redundant voltage left /
right or 15 voltage
Yellow: Single flash: communicating with
POWER D795 or D790-1
Double flash: communicating with both
D795 and D790-1
POWER
Red: Active error
MODE
STATUS
03/06/2023 183
DRT 450
Control unit description D 795 KID
The D795 KID is the main interface for both the operator and the service technician, basic machine
information for the operator is shown on the screen such as engine, transmission information, as well as error
codes for the service technician the screen is used to access the various menus and sub menus. For security
the service menus are password protected. The D795 is programmed with a unique program for the DCF 100.
DRT 450
11. Common electrics.
Located in section 11 of the workshop manual a list of all of the multi pin connectors for the machine, the list will
give the connector number as well as the individual pins within the connector, an example is shown below.
X209 Front edge of frame Power supply, cab control unit (D790-1)
CAN bus, frame control unit (D797-1)
CAN bus, frame control unit (D797-2)
CAB bus, attachment control unit (D791)
03/06/2023 185
DRT 450
11. Common electrics. Signal types
Analogue Inputs / outputs
Signal type Explanation Example
Rheostat Resistance input 0-200 Ω (accuracy 3%) Fuel level sensor
Temperature Rheostat input with non-liner work area, the resistive value Hydraulic oil temperature sensor, climate
equivalent to -40 to 150˚ C control system temperature sensor
There are two different resistance curves, one for the D790-1
and one for the frame and attachment control units
Voltage An analogue signal 0-5 volts the working range is 0.5 – 4.5 V Accelerator pedal
Current feedback Modulated signal between 0 V and system voltage i.e. 24 V Hydraulics, e.g. lift
voltage out, PWM the working range is 0-2 A
Voltage out, PNP Modulated signal between 0 V and system voltage i.e. 24 V Interior lighting
PWM requires negative for reference
Voltage out, reverse Modulated signal between 0 V and system voltage i.e. 24 V Cab Fan
polarity requires 24 V for reference
DRT 450
11. Common electrics. Signal types
Digital Inputs / outputs
Signal type Explanation Example
Digital input with pull Signal in: V < 5 V generates logic zero (0) Input signal from a fuse with search
down and search Signal in: V > 16 V generates logic one (1) lighting
lighting If there is no signal in: the input is to ground
Digital input with pull Signal in: V < 5 V generates logic zero (0) Inductive sensors, pressure sensors
down Signal in: V > 12 V generates logic one (1)
If there is no signal in: the input is to ground
Bandwidth 300 Hz: i.e. designed for slow sensors
High side driver Logic (1) generates voltage out: V > = 22.5 V Side lights, solenoid valves
1.5 A Max load: 1.5 A
Open load: 0.15 A
Max instantaneous current load: 8 A
High side driver Logic (1) generates voltage out: V > = 22.5 V Work lights, wiper motors
5A Max load: 5 A
Open load: 0.9A
High side driver Logic (1) generates voltage out: V > = 22.5 V Cooling fan
10 A Max load: 10 A
Open load: 1.9 A
H bridge Logic (1) generates voltage out: V > = 22.5 V or grounded Climate control
output, U = 0 V
Max load: 0.5 A
Open load: 0.15 A
DRT 450
11. Common electrics. CAN bus
120 Ω
120 Ω
ECU ECU
CAN +
U (V)
CAN -
T (S)
DRT 450
B C D E F G
A: Length of message F: Checksum for error detection

B: Start bit G: Acknowledge bit
C: Identity field / priority
D: Control field (length of data segment)
E: Data segment
DRT 450
One message
One message
1/1000 Sec
DRT 450
Three bits ‘1’
2-2.5V
One bit ‘0’

DRT 450
3.5 V
U (V)
0.5 V
1.5 V
T (S)
Potential levels CAN + and CAN -

DRT 450
Redundant CAN bus
D791-4 D791-3 D791-2 D791-1

CAN R CAN L CAN R CAN L CAN R CAN L CAN R CAN L
D790-1 D790-2 D795

CAN R CAN L CAN R CAN L
CAN L CAN R CAN L CAN R CAN L CAN R
D797-R D797-0 D797-F

DRT 450
Redundant CAN bus
S5 D791-4 S4 D791-3
D791-1 S2 D791-2 S3
S1 D790-1 S9 D795 S8
D790-2
D797-R S6 D797-O S7 D797-F

DRT 450
Drive train CAN bus
D790-1 D793 D794
Drive train CAN bus
Redundant CAN bus

DRT 450
D. Error codes
All error codes come up on the drivers screen, error codes for the engine and transmission are taken directly
from the respective control units, the machine error codes are Kalmar specific.
The engine and transmission error codes are based on SAE J1939. a brief out line of the error codes is below.
Volvo:
Volvo can use a number of identification fields but the two that are used when connected to the Kalmar CAN
are:
PID – Parameter Identification Description,
The PID consists of a number that designates a parameter (value) to which the fault code relates (for example
oil pressure)
FMI – Failure Mode Identifier
FMI indicates the type of fault
An example of the FMI is listed below.
FMI Description SAE text

0 Too high value Valid data but higher than normal operating range
1 Too low value Valid data but lower than normal operating range
A complete list can be found in the workshop manual
An example of a Volvo error code is: 94/1 = 94: fuel system / 1 = too low value
03/06/2023 196
DRT 450
D. Error codes
Dana
Dana also use the J1939 error code numbering , the main difference is that Dana use SPN.
SPN - -Suspect parameter number.

SPN high lights the suspected parameter related to the error
FMI – Failure Mode Identifier

FMI indicates the type of fault
An example of a Dana error code is 20:60
Kalmar error codes
The error codes for the machine are based on 2 or 3 digit codes, all codes are related to a specific component
within the machine,
An example of a Kalmar error code: 155: Incorrect 5 V reference voltage to pressure sensor, Voltage under 4.9
V or over 5.1 V
All error codes are listed in both the operators manual and workshop manual
03/06/2023 197
DRT 450
E. Schematics
A circuit diagram is divided into circuit names (drawing numbers) and consists of a number of numbered sheets
On the circuit diagrams you will see the following information:
X = a connection terminal followed by a number
As a rule the connectors are numbered in such a way that the connector number will advise you of its location within the
machine
X000 - X199: in the cab
X200 – X299: on the frame
X300 – X399: on the boom
X400 - : on the attachment
X37; all ground points start with X37, e.g. X37 – 201 is a grounding point in the frame
Designation: 353 – 2
353 is a component description there is a component list included with the circuit diagram, - 2 indicates that it is the
second component of this type in the specific diagram
Sensors etc are drawn in the rest position on the circuit e.g. no voltage in the circuit
Cable colours
White = ground or negative
Grey = all other cables
Fuse box, for example F58 equals a fuse box with 8 fuses
An arrow symbol indicates that the circuit continues on an other sheet
Ground or negative connections X37A is a ground connection within the electrical distribution box .
Along with the component list there is a cross reference list which names each of the drawings
03/06/2023 198
DRT 450
Circuit diagram
To assist with reading the DCF circuit diagrams here are some observations and rules for navigating through the
diagrams
Diagram numbers:
The main circuit diagram has one number that covers all of the sheets in the diagram (A49226.0100), each sheet
has a number that is linked to a cross reference guide at the start of the circuit diagram, the layout of the sheet
number looks like 1.0_1 etc.
Diagram type:
The diagrams are know as ladder schematics, generally the left hand side of the sheet is positive and the right
negative
DRT 450
Circuit diagram
Diagram grid:
The diagrams have grid rules across the top and down the left and right hand sides for locating wires that
continue on another sheet.
Connectors:
Connectors are indicated by X, connectors can be AMP 9 way connectors or Deutsch connectors.
After the X will be the connector number followed by either a m (male) or a f (female) This designates if the pin
in the connector is male or female
DRT 450
Circuit diagram
If a wire is continuing on to or coming from another sheet you will see an arrow drawn on the
wire which will give information as to the sheet the wire has come from going to.
It will also include information such as if the wire has come from a fuse etc.
Every component on the circuit diagram has a designation, a complete list is included with the
diagram.
DCF 330 - 12
DRT 450
F. Technical data
Data
DCF 280-330 DCF 330 DCF 370-500

Cummins Volvo Volvo Cummins Volvo Volvo TAD
1. Engine QSB6.7 TAD760VE TAD950VE QSM 11 TAD 792VE 1250VE
Power acc. to ISO 3046 (net power) 194 kW at 181 kW at 210 kW at 261 kW at 252 kW at 247 kW at
2200 rpm 2300 rpm 1800 rpm 2000 rpm 1900 rpm 1900 rpm
186 kW at
2000 rpm
Torque ISO 3046 990 Nm at 1100 Nm at 1275 Nm 1830 Nm 1735Nm at 1760Nm at

1500 rpm 1500 rpm at 1000- at 1100- 1300 rpm 1400 rpm
1500 rpm 1400 rpm
Alternator, output 1680 W 1920 W 2400 W 1920 W

Start battery, voltage - capacity 2 x 12 V – 140 Ah
DRF 400 - 450
F. Technical data
Volumes
DCF 280-330 DCF 330 DCF 370-500
1. Engine Cummins Volvo Volvo Cummins Volvo Volvo TAD

QSB6.7 TAD760VE TAD950VE QSM 11 TAD 792VE 1250VE
Engine oil incl, filter 20 litres 23 litres 35 litres 34 litres 35 litres 35 litres
Fuel tank 400 litres
Fuel quality Diesel according to EN 590
Cooling system 40 litres 27 litres 52 litres 40 litres 52 litres 40 litres

DRF 400 - 450
Capacity and DCF280-12 DCF330-12 DCF330-12 DCF370- DCF420- DCF450- DCF500-

dimensions LB LB LB 12 12 12 12
Lifting Capacity
Capacity (kg) 28000 33000 33000 37000 42000 45000 50000
Centre of gravity 1200
distance (L4 mm)
Dimensions, truck
Truck length without
6675 6925 7345 7845 7950 8550
forks (L mm)
Truck width (W mm) 3410 4150

DRT 450 Training Material 150423

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DRT 450 Training Material 150423

Uploaded by

Copyright:

Available Formats

DRT 450

Technical Training – Course 204 - 007

The DRT has a fixed length wheelbase of 6250 mm.

Optional manuals that are also available include:

All Kalmar manuals are produced to SAE J2008.

An example is shown below:

1.2 Fuel system

Description and group number as in

The service position is:

Machine parked with the park brake applied

Boom lowered and completely in

Main electrical isolator off

Hydraulic system de pressurising

Brake system de pressurising

Open the relief valve for the spreader

The illustration shows the valve closed

Preventative maintenance (PM)

Filters and fluids replaced at 50 hrs are:

Lubrication of the machine at 50 hrs will be as with 500 hr services

There are also the letters C, R, L

Location in manual where further information can be

All engines are electronically controlled

1. Fill point Engine oil

Y6067 - 1 Y6069 Y6067 - 3

2nd gear Off On On

3rd gear Off Off On

4th gear Off Off Off

 DANA Spicer Off-Highways TE32

 4 gears forward & reverse

 Electronic controlled by Transmission Control Unit

 Automatic gear box as standard

 Axle tech or Kessler

 Fits all models

 Separate brake system with a fan- radiator - less

 More efficient cooling of the oil

 Electrical parking brake

 One separate high pressure filter for the brake

 Volume 140 litres

 New breathing filter

 Oil type UTTO API GL-4 SAE 5W30

The brake system has one gear pump driven of the

4. Brakes, Accumulator charge valve

Pressure limiting valve

The valve spool is forced up until balance is obtained between

S204: Brake pressure NC

DIAG HYD 4 (6)

S204 NC Pressure switch

S 216 brake light switch

DIAG HYD 4 (6)

DIAG HYD 5 (6)

PP. Pilot Port

EF. Main valve CF. Steering LS. Load signal

 New design - Cut from 150 mm plate. King pin bearings

 Axle is mounted in the chassis with lubrication free

Status for voltage to regeneration boom up,

Status for voltage to regeneration boom out,

1. Rod side extension cylinder

1. Connection rod side (C-)

1. Side mounted slide plates

Boom slider adjustment Front

1. Upper slide plates

Boom slider adjustment Rear

30’ damping sensor

20’ - 40’ damping sensor,