Kalmar ContChamp DRD S Series Technical Handbook
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Kalmar ContChamp DRD S Series Technical Handbook

Kalmar ContChamp DRD S Series Technical Handbook

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Technical
Handbook
ContChamp
DRD
S
This Handbook deals with the design
and maintenance of Kalmar machines,
type DRD-S for the handling of contai-
ners.
In addition, it gives details of trouble-
shooting and the most common
corrective maintenance.
Operation and other matters that are
primarily of interest to the operator are
included it the Instruction Manual.
Kalmar Industries AB
This handbook applies to
machines from and including
machine number T34107.0784 as
well as T34107.0621 and
T34107.0769, see next page.
We reserve the right to modify
our design and material specifi-
cations without prior notice.
Publ. Nr 920 937 9407 04-10
AdEra Dokument AB, Växjö 2004
00
General
10
Chassis and cab
20
Electrical system
30
Engine
Transmission,
40
drive axle, brakes
50
60
Steering axle
70
Hydraulic system
80
Boom and attachment
90
Periodic supervision

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Summary of Contents for Kalmar ContChamp DRD S Series

  • Page 1 Handbook ContChamp Engine Transmission, drive axle, brakes This Handbook deals with the design and maintenance of Kalmar machines, type DRD-S for the handling of contai- ners. In addition, it gives details of trouble- shooting and the most common corrective maintenance.
  • Page 2 This Handbook applies to machines from and including machine number T34107.0784 as well as T34107.0621 and T34107.0769 These machines are of a new design that entails the following differences from older machines. The chang- es do not apply to machines with combi-attachments or top-lift with pileslope. 1.

  • Page 3: Table Of Contents

    ContChamp DRD-S 9407 04-10 Contents Technical Handbook Grupp 00 Contents Group 00 Safety regulations..............2 General..................6 Design – Overview .............. 6 Component units ..............7 Supplementary books ............9 Replacement system – Spare parts ........9 Tools ................... 9 Tightening torques..............
  • Page 4 The truck may not, without specific permission in your daily work. from Kalmar, be modified or re-built so that its func- tion or performance is altered. The instruction manual must always be kept in the ma- chine.

  • Page 5: Safety Regulations

    Safety regulations ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 00 Continued from previous page must be emptied into the tank, with the help of the special accumulator evacuation valve. Operating regulations Handle batteries and junction boxes with great Before starting, make sure that the cab is locked care.
  • Page 6 Safety regulations ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 00 Safety regulations Only authorized and qualified personnel may Never run hands or fingers along any tubes, work with the safety system. (ECS-system) pipes or hoses whilst investigating for possible leaks as some of these lines (diesel fuel, hydrau- If the overload safety system override function lic, steering, etc.) operate at extremely high has been used, there is a risk of forward tipping.
  • Page 7 Safety regulations ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 00 Safety instructions for working with tyres Tyre changing can be dangerous and should only be Rim inspection carried out by specially trained – Check rim components periodically for fatigue personnel using proper tools and procedures. Fail- cracks.

  • Page 8: General

    Technical Handbook Grupp 00 Design – Overview Kalmar DRD420–450 model S diesel trucks are of sturdy design for particularly heavy duty handling of 20-40' loaded containers. They are built around a chassis which has high strength and tor- sional stiffness and an extremely low centre of gravity.

  • Page 9: Component Units

    General ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 00 The Volvo six-cylinder turbocharged engine, combined with a four-speed gearbox with torque converter, provides smooth power whenever needed. The drive axle with hub reduction, oil-cooled hydraulic brake sys- tem and pendulum-mounted steered axle with double-acting steering cylinder satisfy very strict demands on strength and mo- bility when travelling on irregular surfaces.
  • Page 10 General ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 00 Hydraulic system, that occurs in two versions: 1. With common tank for all hydraulic and brake circuits. – a double variable hydraulic pump, feeds Lift 1, Extension 1, hydraulic servo, steering system –...

  • Page 11: Supplementary Books

    For the contents of these kits, see the Spare parts catalogue. Tools Kalmar offers a wide range of tools for truck maintenance work. For further information, please contact Kalmar's service depart- ment.

  • Page 12: Tightening Torques

    ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 00 Tightening torques (According to Kalmar K Standards 20060.0001) The tightening torques are applicable to steel bolts and nuts tight- ened with a torque wrench under the following conditions: Surface treatment Condition Lubriation...
  • Page 13 General ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 00 To reduce the risk of settlement of the material and the associated reduction in the preloading force if the hardness of the surface supporting the bolt head or nut is lower than 200 HB, a washer should be fitted under the bolt head and nut.

  • Page 14: System Of Units

    General ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 00 Quality 10,9 12,9 Tightening torque, Nm Condition Thread 5/16 7/16 9/16 1050 1058 1320 1560 1 1/8 1350 1200 1525 1900 2250 1 1/4 1860 1655 2100 2630 3110 1 3/8 2500 2225 2825...
  • Page 15 ContChamp DRD-S 9407 04-10 Contents Technical Handbook Grupp 10 Group 10 Chassis and cab Specification ................2 Chassis..................3 Description ................3 Chassis................3 Support jacks..............3 Operator’s cab..............4 Steering column .............. 9 Hydraulics control unit ........... 10 Service ................11 Changing the fresh air filter ...........
  • Page 16 Specifications ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 10 Air conditioner Cab unit Circulated air flow 500-600 m Electric power consumption approx. 350 W Compressor Max. speed 4000 r/min Refrigerant R134a *) Electric power consumption approx. 50 W Oil capacity Zexel PAG SP-20 1.5 dl Condenser Electric power consumption...

  • Page 17: Chassis

    Chassis ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 10 Chassis The chassis consists of: A unit construction frame built up around two box- sections for best possible strength. Mountings for the drive axle, steered axle, telescope-boom, lifting cylinders and transmission. The necessary counterweights to provide a very low centre of gravity.

  • Page 18: Operator's Cab

    Operator’s cab ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 10 Operator’s cab The operator’s cab is a separate structure and rests on the chas- sis on rubber dampers. The operator’s seat, steering wheel and hydraulic control levers can be adjusted for best possible operator comfort.
  • Page 19 Operator’s cab ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 10 KL1406 1. Gear selector 6. Control lever and control panel for hydraulic functions FORWARD/NEUTRAL/REVERSE 1/2/3/4 7. Electrical central unit with fuses and relays 2. Lever DIRECTION INDICATORS/HORN 8. Brake pedals, normal driving brake FRONT WINDSCREEN WASHER/ 9.
  • Page 20 Operator’s cab ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 10 KL581 37 38 39 35 36 40 41 42 43 44 45 47 48 49 50 51 54 55 56 60 59 KL582 KL580 57 58 64 62 63 21.
  • Page 21 Operator’s cab ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 10 Joy-stick functions 1. Tilt 2. a. Locking of tilt b. Locking of levelling 3. Rotation 4. Side shift 5. Vertical lift 6. Boom OUT/IN 7. Levelling 8. Length adjustment 20'–40' 9.
  • Page 22 Operator’s cab ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 10 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: Go out after lift: B KL20 Engagement and disengagement WARNING!

  • Page 23: Steering Column

    Operator’s cab ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 10 Steering column Surrounding the steering column are multi-function levers for gear changing, indicators, windshield wipers, etc., as well as the instrument panel with the ECS terminal. At the very foot of the steering column is the steering valve (Orbitrol), activated by the steering wheel via an angled gear.

  • Page 24: Hydraulics Control Unit

    Operator’s cab ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 10 Hydraulics control unit Control lever and switches used to manoeuvre the hydraulics system are located on an adjustable console with comfortable working position The control lever is a joystick that is electrohydraulically connect- ed to the main valves.

  • Page 25: Service

    Operator’s cab ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 10 Changing the fresh air filter (every 200 hours or when needed) 1. Remove the filter casing retaining bolts and remove the filter element. 2. Wash the filter insert with water and detergent or by using a high pressure washer.

  • Page 26: Windscreen Wipers

    Operator’s cab ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 10 Windscreen wipers The wiper arms are fixed to the wiper motor shafts via conical splines. The shafts are manufactured of hardened steel and the wiper arm mounting of soft, pressed metal. When fitting, the nuts must be tightened so hard that the splines are pressed well into the mounting and function as a carrier.

  • Page 27: Air Conditioning Unit

    Air conditioning unit ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 10 Air conditioning unit The air conditioning unit consists of the parts shown in the illus- tration and its function is to maintain the climate in the operator’s cab as comfortable as possible. The air conditioning unit: heats the air when it is cold dehumidifies the air when it is humid removes impurities from the air...
  • Page 28 Air conditioning unit ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 10 1. Liquid receiver/filter dryer A High-pressure gas 2. Evaporator B High-pressure liquid 3. Fan C Low-pressure liquid 4. Expansion valve D Low-pressure gas 6. Condenser E Warm air in cab 7.
  • Page 29 Air conditioning unit ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 10 Compressor The air conditioning system is driven by the compressor. This performs as a pump, drawing cold, low-pressure gas from the evaporator, compressing it and thereby raising its temperature, and discharging it at high pressure to the condenser.

  • Page 30: Service

    Air conditioning unit ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 10 The liquid refrigerant should be completely evaporated before it is allowed to flow from the evaporator. The refrigerant is still cold WARNING! even when it has completely evaporated. The cold vapour which flows through what remains of the evaporator continues to absorb heat, and then becomes overheated.
  • Page 31 Air conditioning unit ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 10 IN CAB UNIT CONDENSER UNIT GL 1,5 SV 1,5 RD 1,5 BR 1,5 BR 1,5 GL 1,5 VT 1,5 HIGH 1. Fan switch 2. Cooler on/off 3. Anti-freeze thermostat 4.
  • Page 32 Tom sida Empty page Leere Seite Face vide...
  • Page 33 ContChamp DRD-S 9407 04-10 Contents Technical Handbook Grupp 20 Group 20 Electrical system Specifications.............. 2 ECU 3 Electrical system............3 Functions ............... 66 Description ............... 3 Circuit board ............67 Checking the electrolyte level of the batteries ..5 Module 54 Tilt ............68 Fuses ..............

  • Page 34: Specifications

    Specifications ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 20 Alternator rating 1920 W Starting battery voltage 24 V (2 x 12 V) capacity 140 Ah earthing negative...

  • Page 35: Electrical System

    Electrical system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 20 The system voltage is 24V and the supply is taken from two 12V batteries connected in series and charged by an alternator IMPORTANT! across electronic rectifying and voltage stabilisation circuits. Always open the main switch when- ever work is to be carried out on the electrical system, if the truck is to...
  • Page 36 Electrical system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 20 1. Sensor, outgoing revs (ECS or reversing block) 2. Sensor, gearbox oil temperature, warning lamp and meter 3. Sensor, gearbox oil pressure, warning lamp and meter 4. Main fuses 2 X 50A 5.

  • Page 37: Checking The Electrolyte Level Of The Batteries

    Electrical system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 20 Checking the electrolyte level of the batteries N.B. The batteries are fitted behind a cover on the left-hand side of the The starting batteries accompanying truck. The electrolyte level should be about 10 mm above the the truck are of the maintenance-free cells.

  • Page 38: Relays

    Electrical system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 20 Relays Reversing light Parking brake, disengagement High power (Starting switch) Wiper motor, front Electric stop (ECS 07) Coolant level (ECS 07) Pulse relay, direction indicators Gear shift (ECS 01) Starting block Propulsion forward Propulsion reverse...

  • Page 39: Bulbs

    Electrical system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 20 KL 1542 Bulbs Rating Description Watts Base Instruments BA7s Indicating lamps W2x4,6d Cab lighting S8,5 Rear lights, red BA15s Brake lights BA15s Direction indicators BA15s Position lights SV8,5 Driving lights (full/dipped beam) 75/70 P43t-38 Reversing lights, white PK22s...

  • Page 40: Starting From Another Battery

    Electrical system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 20 Starting from another battery Make sure the auxiliary batteries are connected in series, so that 24 V will be supplied. N.B. Do not disconnect the truck-battery cables Connect the jumper cables in the following order: WARNING! 1.

  • Page 41: Overview

    Overview Technical Handbook Grupp 20 Kalmar’s ECS - Electronic Control System - is a modular control and monitoring system to ensure optimum operational security and total economy. It is possible to combine the system’s different modules in a number of different ways.

  • Page 42: Terminal

    DUSTRIES 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.
  • Page 43 ContChamp DRD-S 9407 04-10 Terminal Technical Handbook Grupp 20 Operating menus The menus that are displayed on the terminal depend on the modules with which the truck’s ECS is equipped. The overview below shows the possible combinations. Use either arrow RIGHT/LEFT to switch between menus.
  • Page 44 ContChamp DRD-S 9407 04-10 Terminal Technical Handbook Grupp 20 Operating menus, module 50 Main menu KALMAR INDUSTRIES SERVICE Normal operating condition, module 50 a. 1750rpm Engine speed, r/min Normal operating condition, module 50 + module 01 a. 1750rpm Engine speed, r/min b.
  • Page 45 ContChamp DRD-S 9407 04-10 Terminal Technical Handbook Grupp 20 01.60 07.60 01.07.60 KL1411 Explanations, see next page Operating menus with electronic overload protection, module 60...

  • Page 46: Operating Menues

    Module 60 overload protection function, under normal conditions, functions as a balance and gives a continual reading of the size and position of the load. Main menu KALMAR INDUSTRIES SERVICE Normal operating condition, module 60. a. 1750 rpm Engine speed, r/min c.

  • Page 47: Error Messages

    ContChamp DRD-S 9407 04-10 Terminal Technical Handbook Grupp 20 Error messages In order of priority. If two faults occur at the same time, the termi- nal displays the fault with the highest priority. Error messages al- ways have a higher priority than normal menus. 01 = Automatic gear changing Errors 01-08 are level 2 errors and cannot be reset prior to the 04 = Lever steering...
  • Page 48 ContChamp DRD-S 9407 04-10 Terminal Technical Handbook Grupp 20 09. Faulty signal from engine rev sensor. 01, 07 Engine speed reduction. Stop as soon as possible and contact service. 10. Low engine oil pressure. Check oil level and top up as required. 11.
  • Page 49 ContChamp DRD-S 9407 04-10 Terminal Technical Handbook Grupp 20 19. Faulty signal from engine oil pressure sensor. Operation possible. Contact service 20. Faulty signal from coolant temperature sensor. Operation possible. Contact service. 21. Faulty signal from gearbox oil temperature sensor. Operation possible.
  • Page 50 ContChamp DRD-S 9407 04-10 Terminal Technical Handbook Grupp 20 31. System fault ECU 1. Contact service as soon as possible. 32. System fault ECU 2. Contact service as soon as possible. 50. Battery voltage very low/high. Contact service as soon as possible. 51.
  • Page 51 ContChamp DRD-S 9407 04-10 Terminal Technical Handbook Grupp 20 58. Faulty analog signal from joystick. All boom functions are interrupted. Stop as soon as possible and contact service. 59. Faulty signal from sensor for end position damping Contact service as soon as possible. 60.
  • Page 52 Technical Handbook Grupp 20 Service menus All service sub-menus are accessible from the main KALMAR IN- DUSTRIES SERVICE menu, thereafter, a code must be regis- tered. There are four different codes, codes 1, 2, 3 and 4. Code 1 leads to the SETUP, INITIATION and CALIBRATION Detailed descriptions of SETUP, of the modules in ECU1.
  • Page 53 ContChamp DRD-S 9407 04-10 Terminal Technical Handbook Grupp 20 Code 2 Code 3 Code 4 19 20 CALIBRATION SETUP EL-SERVO MODULE 60 ECU2 KL723-C DIAGNOSIS Detailed information about the different service menu paths can be found under re- spective section descriptions. The connected loops then appear as shown in the adjacent picture.

  • Page 54: Ecu-Processor Unit

    N.B. The only permissible action to be taken with the ECU is the replacement of the EPROM. If this does not rectify the problem, then the complete ECU, including the housing, must be replaced with an exchange unit from Kalmar. EPROM = Erasable Programmable Read Only Memory Kalmar special tools 1, 2 and 3 below, are parts of the ECS kit, art.

  • Page 55: Transmission Data Kit

    ContChamp DRD-S 9407 04-10 ECU - Processor Unit Technical Handbook Grupp 20 Transmission data kit Data kit Truck Gearbox No. of Wheel Wheel Pulses Comments gears dimensio radius per rev DRD 450 36 000 18.00x25 0.73 40 000 DRD 450 18.00x25 0.73 DRD 450-80X...

  • Page 56: Ecu 1 Functions

    ECU 1 ContChamp DRD-S 9407 04-10 Functions Technical Handbook Grupp 20 ECU 1 functions Signal Function Module 01 04/06 Analogue IN 1. 0-10V Steering lever/Mini-steering signal A Analogue IN 2. 0-10V Accelerator pedal 2 Analogue IN 3. 0-10V Wheel return wheel position, steering axle Analogue IN 4.
  • Page 57 ECU 1 ContChamp DRD-S 9407 04-10 Functions Technical Handbook Grupp 20 Signal Function Module 01 04/06 NTC 1 Engine coolant temperature NTYC 2 Gearbox oil temperature NTC 3 Hydraulic fluid temperature Ambient temperature Pulse sensor 1 LE28 Engine revs., functions only on Perkins engines Pulse sensor 2 LE27 Drive shaft revolutions...

  • Page 58: Circuit Board

    ECU 1 ContChamp DRD-S 9407 04-10 Circuit Board Technical Handbook Grupp 20 Should always be lit,indicating a LE39 shows communication from the terminal 5V feed from the voltage and since ECU 1 is “slave” under ECU 2, LE39 transformer should be extinguished. LE29 Not used LE40 shows communication to the terminal LE30 Not used...

  • Page 59: 01 - Automatic Gear Changing

    ECU 1 ContChamp DRD-S 9407 04-10 01 - Automatic gear changing Technical Handbook Grupp 20 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.

  • Page 60: 04 Lever Steering

    ECU 1 ContChamp DRD-S 9407 04-10 04 - Lever Steering Technical Handbook Grupp 20 04 Lever Steering 4 a b See electric diagrams. The lever steering module is an electrical system for the steering of the truck by means of a linear steering lever. The steered wheel deflection is inversely proportional to the speed of the truck, i.e.,at low speeds, the steered wheel deflection is greater than at higher speeds.
  • Page 61 ECU 1 ContChamp DRD-S 9407 04-10 04 Lever Steering Technical Handbook Grupp 20 Lever steering characteristics Also applies to Module 06, Mini-steering The maximum wheel displacement from maximum lever move- ment is determined by the speed of the truck. Wheel displace- ment decreases when speed increases.
  • Page 62 ECU 1 ContChamp DRD-S 9407 04-10 06 Mini-Steering Technical Handbook Grupp 20 Fitting/Adjustment of wheel angle sensor Applies only to wheel return system Adjust the wheels so that they are parallel to the truck. Remove the cover of the left hand steering knuckle. Lift off the carrier 3.

  • Page 63: 07 - Monitoring

    ECU 1 ContChamp DRD-S 9407 04-10 07 - Monitoring Technical Handbook Grupp 20 Module 07 Monitoring See electrical diagrams. The monitoring module checks that the engine and gearbox op- erate 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.
  • Page 64 ECU 1 ContChamp DRD-S 9407 04-10 07 - Monitoring Technical Handbook Grupp 20 The following signals are monitored: 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 >98°C Coolant temperature, max.

  • Page 65: Ecu 2 Functions

    ECU 2 ContChamp DRD-S 9407 04-10 Functions Technical Handbook Grupp 20 ECU 2 Functions Pin no. Signal Function ECU 2 Digital IN I/O LE14 Working lights, top-lift ” LE17 Control lever, side-shift Right (15) ” LE20 Control lever, side-shift Left (16) “...

  • Page 66: Circuit Board

    ECU 2 ContChamp DRD-S 9407 04-10 Circuit board Technical Handbook Grupp 20 LE1 Should always be lit,indicating a LE39 shows communication from the terminal and 5V feed from the voltage transformer should always blink. LE40 shows communication to the terminal and Extra circuit board should blink on all ECUs.
  • Page 67 ECU 2 ContChamp DRD-S 9407 04-10 Circuit Boards Technical Handbook Grupp 20 Different combinations of ECU Every ECU has four switches. Check that the switches are in the positions shown in the illustra- tions. ECU 2 + A ECU 2 1 2 3 4 1 2 3 4 1 2 3 4...

  • Page 68: Installation, Boom

    ECU 2 ContChamp DRD-S 9407 04-10 Installation boom Technical Handbook Grupp 20 X410 KL1533b KL1534 KL1533a KL1535 Electronic central unit for top-lift, KDU 1. 10 pole connection box KDU 791 2. 42 pole connection box 3. Indicator lamp POWER, green. lit with 24V feed 4.
  • Page 69 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 El-servo The el-servo system includes: Control lever functions for boom movement All attachment functions Overload protection Cab movement Support jacks The references in the following descriptions relate to components in the el-servo diagrams (diagrams marked S), if nothing to the contrary is stated.

  • Page 70: Control Lever

    ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Control lever The control lever regulates electrical signals which operate elec- trohydraulic converters which in turn feeds hydraulic servo pres- sure to the main valve sections. The lever handle is equipped with potentiometers P1–P4 and four finger-tip controlles switches T1–T4.
  • Page 71 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Converter The converter is a electrically controlled pressure reducing valve for the remote control of hydraulic functions. The output signal is a porportional hydraulic servo pressure which is used to control the spools of the main valves.
  • Page 72 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Control lever feed The LIFT/LOWER, BOOM OUT/IN and ROTATION functions are fed with 10 V from ECU2, contact S2 (70 pole junction box on ECU2), pin 45 of connector S55 pin 12. From there via cable S33 to the D sub-contact S42 on the control lever S32.
  • Page 73 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Cable S33 of the el-servo system...

  • Page 74: Pressure Sensors Right And Left Lift Cylinders

    ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Pressure sensors right and left lift cylinders Sensor in the feed line to left lift cylinder. Out signal: 4-20 mA N.B. The pressure sensors are different for different modules. (768-10 and 11 are identical.
  • Page 75 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 LIFT See el-servo diagram (S) Control lever used for LIFT, P1 gives a 5-9V analogue signal via 42.8, via cable S33 to X55.1 ANA IN S2.42. No indication in ECU2 for analogue IN sig- nals.
  • Page 76 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Module 60 (or module 52) Conditions for regeneration: Connects when pressure in lift circuit <85 Bar Disconnects when pressure is approx. 185 Bar Feed right sensor: 24V over X69.1 to 768-10.3 and 768-11.3. Ref.voltage =0V from X69.2.
  • Page 77 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 LOWER See el-servo diagram (S) S7.2 Control lever used to LOWER, P1 gives a 5-1 V analogue signal via D sub-contact S42.8, via cable S33 to X55.1 ANA IN S2.42. No indication in ECU2 for analogue IN sig- nals.
  • Page 78 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 BOOM OUT See el-servo diagram (S) Control lever used to BOOM OUT, P2 gives a 5-9 V analogue signal via S42.4, via cable S33 to X55.2 ANA IN S2.66. ANA OUT S2.05.
  • Page 79 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Regeneration, BOOM OUT See el-servo diagram (S) 24V to X62.8 Connector X69.7, see illustration. Module 50 Conditions for regeneration: Connects when the pressure in lift circuit <85 Bar Disconnects when the pressure is approx. 185 Bar Pressure sensor 768-12.3 for lift cylinder feed IN=24 V, see illustration Pressure sensor 768-12.2 OUT=4-20 mA, corresponds to 0-...
  • Page 80 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Modules 50, 52, 60 14.DIG OUT S2.48. LE9 lit 15.X61.4 16.Connector X67.4, see illustration KL704-D 17.Connector X68.4, see illustration KL705 18. Regeneration valve S18 opens and regeneration starts The regeneration starts with a time-delay which is set in the SET UP EL-SERVO ECU 2, see Technical Handbook ECS SERVICE.
  • Page 81 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 BOOM IN See diagram S. Control lever used for BOOM IN, P2 gives a 5-1 V analogue signal via S42.4, via cable S33) X55.2. ANA IN S2.66. ANA OUT S2.01. LE5 lit X63.3.
  • Page 82 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Rotation clockwise See el-servo diagram (S) Electrical diagram attachments (A38414.0100 Top-lift) P3 signal 5-9 V out via S42.11. X55.3. ANA IN S2.67 (No indication) ANA OUT S2.2 (LE6 lit) X62.10.
  • Page 83 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Feed, sensor DIG OUT from 791.2.11 to X402.1, X403.1 and 404.1. 7202R 7202L Earthing reference REF OUT from 791.2.38 to X402.2, X403.2 and 404.2. X404 T5655870-1 X403 X402 7203L 7203R Indicator, ALIGNMENT Signal from 7202R to X403.3 to X403.3.

  • Page 84: Twist-Locks

    ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Twist-locks, automatic locking Feed +24V from central electrical unit S1 connector X38.7. Condition: Parking brake RELEASED. X51.7. X56.11. Signal in to switch S34, pin 3 Switch S34 in AUT position, signal out from pin 7 X56.1.
  • Page 85 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Indicator, twist-locks locked 7205R 7204L Signal from 7205R to X403.5 to X402.5. DIG IN 791.2.24. Signal from 7205L to X404.5 to X402.9. DIG IN 791.2.23. Points 1-4 satisfied gives DIG OUT 791.2.39 to X405.3 X404 Indicator lamp 563 Twist-locks locked lit.

  • Page 86: Side-Shift

    ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Side-shift left Control lever switch T1 is used for side-shift left. 24 v to S42.14. X55.7. DIG IN S2.10, LE20 lit. Condition: S2.11 - LE23 extinguished, or S2.56 - LE18 lit, and S2.31 - LE13 extinguished.

  • Page 87: Length Adjustment 20-40

    ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 Length adjustment OUT Control lever switches T1 + T4 are used. T1 to the right. Signal out to S42.16. X55.8. DIG IN S2.09, LE17 lit. T4 depressed. Signal out to S42.19. X55.9.
  • Page 88 ECU 2 ContChamp DRD-S 9407 04-10 Elservo Technical Handbook Grupp 20 End-position damping for IN and OUT length adjustment Feed, sensor: DIG OUT 791.2.11 to X402.1 Reference voltage, sensor: REF OUT 791.2.38 to X402.2 Signal from 769 to X402.11 DIG IN 791.2.12 gives lowered speed at both end positions. X402 T5655870-2 769 Sensor, damping...

  • Page 89: Module 50 Mechanical Overload Protection

    ECU 2 ContChamp DRD-S 9407 04-10 50 Mechanical Overload Protection Technical Handbook Grupp 20 Module 50 Mechanical Overload Protection The mechanical overload protection function: monitors the forward load and generates an alarm on the ECS terminal. monitors the rear load on the steering axle. controls the regeneration system for LIFT and BOOM OUT.
  • Page 90 ECU 2 ContChamp DRD-S 9407 04-10 50 Mechanical Overload Protection Technical Handbook Grupp 20 Overload indicator Normal operating condition. Steering axle overload Monitored by two inductive sensors, 24 for boom extension and 21 for boom angle. When boom extension is less than 1.5 m, the boom angle is greater than 35°...
  • Page 91 ECU 2 ContChamp DRD-S 9407 04-10 50 Mechanical Overload Protection Technical Handbook Grupp 20 S23a S23b 768-12.Pressure sensor, S21. Sensor, boom angle feed line left lift cylinder S22. Sensor, end position boom angle See also, page 42. S23a.Sensor, boom inner position S23b.Sensor, boom outer position S24.

  • Page 92: Module 51 Vertical Lift For Module 50

    LC-Distance = 3.80 m, Distance between the centre of the drive axle and the centre of When Module 51 is installed, ECU 2 must be initiated. Con- gravity of the load tact Kalmar to obtain the necessary parameters. ECU 2 DRD420-60S5 KL1060-C...

  • Page 93: Module 52 Vertical Lift + Balance For Module 50

    50. axle and the centre of gravity of When Module 52 is installed, ECU 2 must be initiated. Con- the load) tact Kalmar to obtain the necessary parameters. ECU 2 DRD420-60S5 KL586C KL1062-C...

  • Page 94: Module 57 Hydraulic Balance

    ECU 2 ContChamp DRD-S 9407 04-10 57 Hydraulic Balance Technical Handbook Grupp 20 Module 57 Hydraulic Balance The hydraulic balance is included in the ECU 2 el-servo system. The signal to the system comes from the 768-12 pressure sensor in the left lift cylinder feed and from 768-14, right cylinder. Calibration of the balance must be carried out in accordance with the instructions in ECU 2 SETUP, points 20 and 21 Connect a loaded container to the machine...

  • Page 95: Module 59 Limitation Height/Lc-Distance For Module 50/60

    ECU 2 ContChamp DRD-S 9407 04-10 59 Limitation Height/Lc-distance Technical Handbook Grupp 20 Module 59 Limitation Height/LC-distance for module 50/60 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.

  • Page 96: Module 60 Electronic Overload Protection

    ECU 2 ContChamp DRD-S 9407 04-10 60 Electronic Overload Protection Technical Handbook Grupp 20 Module 60, Electronic overload protection The electronic overload protection: monitors the front load and continually shows the results via two different menus on the ECS terminal display, switch be- tween menus using the arrow RIGHT/LEFT keys monitors the rear load on the steering axle controls the regeneration system for LIFT and BOOM OUT...
  • Page 97 ECU 2 ContChamp DRD-S 9407 04-10 60 Electronic Overload Protection Technical Handbook Grupp 20 Overload indicator Under normal circumstances, the overload protection system functions as a balance and gives a continual read-out of the size and position of the load. L-TP 4.22M = The distance between the front edge of the wheels and the centre of gravity of the load.
  • Page 98 ECU 2 ContChamp DRD-S 9407 04-10 60 Electronic Overload Protection Technical Handbook Grupp 20 S16. Angle sensor 768-10. Pressure sensor, feedline right lift cylinder S17. Length sensor 768-11. Pressure sensor, returnline right lift cylinder S18. Regeneration valve 768-12. Pressure sensor, feedline left lift cylinder 768-13.

  • Page 99: Ecu 3 Functions

    ECU 3 ContChamp DRD-S 9407 04-10 Functions Technical Handbook Grupp 20 ECU 3 Functions Signal Size Function Digital IN 1 LE14 Parking brake (Remote control) Digital IN 2 LE17 Digital IN 3 LE20 Digital IN 4 LE23 Digital IN 5 LE13 Digital IN 6 LE16...

  • Page 100: Circuit Board

    ECU 3 ContChamp DRD-S 9407 04-10 Circuit Board Technical Handbook Grupp 20 LE1 Should always be lit, indicates 5V feed to ECU3 LE39 Should be extinguished from the voltage transformer LE40 indicates communication to the terminal and LE29 Not used should blink.

  • Page 101: Module 54 Tilt

    ECU 3 ContChamp DRD-S 9407 04-10 54 Tilt Technical Handbook Grupp 20 Module 54 Tilt 10V feed from S3.45 (ECU3) to connector S55.14 Via cable S33 to S42.3 Reference voltage 10V from ECU 3 S3.44 to connector S55.15 Via cable S33 to S42.1 Signal from D sub-contact S42.2 to S55.4 ANA IN 2 S3.42 Tilt - OUT...

  • Page 102: Module 56 Cab Movement

    ECU 3 ContChamp DRD-S 9407 04-10 56 Cab movement Technical Handbook Grupp 20 Module 56 Cab movement See diagram next page and the el-servo diagram S. Conditions: The doors must be closed, otherwise it is only possi- ble to move the cab 100 mm. Connector S56.7 feeds 24 V to the cab movement system.
  • Page 103 ECU 3 ContChamp DRD-S 9407 04-10 56 Cab movement Technical Handbook Grupp 20 Electrical circuit, cab movement...

  • Page 104: Module 61 Support Jacks

    ECU 3 ContChamp DRD-S 9407 04-10 61 Support jacks Technical Handbook Grupp 20 Module 61 Support jacks Certain machines are equipped with support jacks in order to in- crease the capacity in the third container row. The support jacks are controlled with a switch in the operator’s cab. A hydraulic cyl- inder affects a linkage system which presses the support jack down and thereby reduces the load center by 600 mm, which in- creases the third row capacity.
  • Page 105 ECU 3 ContChamp DRD-S 9407 04-10 61 Support jacks Technical Handbook Grupp 20 Support jacks...

  • Page 106: Diagrams

    Diagrams ContChamp DRD-S 9407 04-10 Gear changing systems Technical Handbook Grupp 20 Manual electrical gear-changing system Clark 36000/40000 Components The components shown in this diagram can also be found inte- grated in the general electrical diagram in this handbook. A. Gearbox control valve B.
  • Page 107 Diagrams ContChamp DRD-S 9407 04-10 Gear changing systems Technical Handbook Grupp 20 Clark 36000/40000 Manual electrical gear-changing system...
  • Page 108 Diagrams ContChamp DRD-S 9407 04-10 Gear changing systems Technical Handbook Grupp 20 Automatic electrical gear-changing system Clark 36000/40000 Components The components shown in this diagram can also be found inte- grated in the general electrical diagram in this handbook. A. Gearbox control valve B.
  • Page 109 Diagrams ContChamp DRD-S 9407 04-10 Gear changing systems Technical Handbook Grupp 20 Clark 36000/40000 Automatic electrical gear-changing...
  • Page 110 Diagrams ContChamp DRD-S 9407 04-10 Component Lists Technical Handbook Grupp 20 El-servo (S) A38630.0100/0200 Components Central electrical unit ECU2 ECU3 ECS terminal PC connection (beside connectors under seat) Main valve 1. LIFT 2. LOWER 3. BOOM OUT 4. BOOM IN 5.
  • Page 111 Diagrams ContChamp DRD-S 9407 04-10 Overview, ECS diagrams Technical Handbook Grupp 20 ECS Diagrams The following pages contain the diagrams for the current circuits in the ECS. Those diagrams that apply to a specific machine, are combined in certain ways, depending on the modules with which the machine is equipped.

  • Page 112: Electrical Diagram Explanations

    Diagrams ContChamp DRD-S 9407 04-10 Diagram explanations Technical Handbook Grupp 20 Electrical diagram explanations H C L Connector, located outside the central electrical unit circuit board. The second figure denotes the pin number. Cable marking. M1 shows that the cable goes between ECU 1 and the Central electrical unit.

  • Page 113: Cable Markings

    Diagrams ContChamp DRD-S 9407 04-10 Diagram explanations Technical Handbook Grupp 20 Cable markings All cables are marked with a number for identifying the terminal points as follows: Cable Destination (657) From P = Pressure Block component T = Temperature η = Coolant level o = Fuel level Connection 1 on block 27...
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  • Page 163 ContChamp DRD-S 9407 04-10 Contents Technical Handbook Grupp 30 Group 30 Engine Specifications ................2 Engine ..................3 Description ................3 General................3 Cooling system..............5 Fuel system ..............7 Lubrication system ............10 Combusting air system..........12 Service ................14 Coolant quality...............

  • Page 164: Specifications

    Specifications ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 30 Manufacturer, type Volvo, TWD1031VE Volvo TWD1231VE Coolant volume, litres Rating ISO 3046 kW (hp) 235 (320) 275 (374) at r/min 2100 2100 Torque ISO 3046, Nm 1500 1745 at r/min 1100 1100 Number of cylinders Swept volume, litres...

  • Page 165: Engine

    Engine ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 30 General The engine TWD1031VE or TWD1231VE is a 6-cylinder, inline, 4-stroke diesel engine with overhead valves. The engine is turbo- charged, i.e. combustion air is supplied under pressure. As a re- sult, the quantity of fuel injected can be increased, which increases the engine output.
  • Page 166 Engine ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 30 The engine is pressure-lubricated and incorporates an oil pump which delivers oil to all lubrication points. A full-flow oil filter effectively cleans the lubricating oil. The fuel system is protected against impurities by replaceable filters.

  • Page 167: Cooling System

    Engine ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 30 The following description is valid for both TWD1031VE and TWD1231VE if not otherwise stated. Cooling system The engine is liquid-cooled and equipped with a closed cooling system consisting of the following main components: Coolant pump Radiator Thermostat...
  • Page 168 Engine ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 30 The cooling system is equipped with a sensor which activates the ”Low coolant level” warning lamp on the instrument panel, see group 20. The engine lubricating oil is cooled efficiently and reliably in a separately mounted tubular oil cooler.

  • Page 169: Fuel System

    Engine ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 30 Fuel system The fuel circulates in two circuits - the high-pressure circuit and the low-pressure circuit. When the engine is started, the feed pump draws fuel from the tank and delivers it at relatively low pressure through fine filters up to the injection pump.
  • Page 170 Engine ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 30 Fuel filters - two filters connected in parallel and with a common cover. The filters are of disposable type, with the filter elements made of spirally wound paper. Fuel filter Injectors - each with a nozzle holder and a nozzle.
  • Page 171 Engine ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 30 Injection pump - located on the left-hand side of the engine and driven by gears. The pump is equipped with an RSV governor which has a steep control characteristic at low engine speeds. As a result, the engines appear more powerful and have a higher tractive effort at low speeds.

  • Page 172: Lubrication System

    Engine ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 30 Lubrication system The engine is pressure-lubricated, and the oil is supplied by a pump in the oil sump. All lubricating oil flows through a double full- flow filters. The lubricating oil is cooled in an externally mounted tubular oil cooler by the engine coolant.
  • Page 173 Engine ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 30 Reducing valve - located just before the filter. The valve will open if the lubricating oil pressure is too high and will return excess oil back to the sump. Oil filter - of full-flow type, with a filter element of pleated filter pa- per.

  • Page 174: Combusting Air System

    Engine ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 30 Combustion air system Large quantities of air are necessary for burning the fuel supplied to the engine. Free, unrestricted flow of fresh air and exhaust gas- es is therefore essential to allow the engine to run efficiently. Air cleaner The intake air is cleaned in a two-stage air cleaner, the first stage of which collects coarse particles by cyclone action, and the par-...
  • Page 175 Engine ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 30 Turbocharger The turbocharger supplies more air to the combustion chambers than the engine would be capable of drawing naturally. This ena- bles the engine to burn more fuel which, in turn, increases the en- gine output.

  • Page 176: Service

    60% of water and 40% of ethylene glycol. The coolant should be changed and the cooling system should be flushed once a year. Always add a corrosion inhibitor (Kalmar part No. 923.110.0003) to the coolant, if the above mixture is not used in the cooling sys- tem.

  • Page 177: Changing The Oil And Oil Filter

    9. Stop the engine and check the oil level after a few minutes. Top up as necessary to the MAX level on the dipstick. N.B. To avoid serious damage to the engine, use only genuine Kalmar filters. Checking the V-belt tension 1. Check at regular intervals that the V-belts are correctly tensioned.

  • Page 178: Checking And Adjusting The Valve Clearances

    Engine ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 30 Checking and adjusting the valve clearances N.B. Never attempt to check the valve clearances when the engine is running. The engine must be stationary and cold. 1. Turn the crankshaft in its normal direction of rotation until the inlet valve of No.

  • Page 179: Preventive Maintenance On Turbo-Charger

    Engine ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 30 Preventive maintenance on the turbocharger The turbocharger may be damaged and, in the worst case, may break down if the engine is not properly serviced. WARNING! 1. Check that the engine air inlet system is in good condition, i.e. that the air cleaner is clean, that none of the hoses are worn Never run the engine with the air inlet and that hose connections are not defective, which would al-...
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  • Page 181 ContChamp DRD-S 9407 04-10 Contents Technical Handbook Grupp 40 Group 40 Transmission, drive axle, brakes Specification ................2 Transmission ................3 Description ................3 Torque converter ............. 3 Gearbox................3 Oil circuit................5 Service ................. 6 Oil level check ..............6 Changing gearbox oil and filter........
  • Page 182 Specifications ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 40 Torque converter and gearbox Model Clark - 15.5 HR 36432 Number of gears 4F - 4R Oil capacity, total system, litres Oil grade See group 90 Oil operating temperature, °C 82-93 Max permissible temperature, °C Clutch pressure, bar 17-20...

  • Page 183: Transmission

    Transmission ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 40 The transmission consists of a torque converter integrated with the gearbox, and a propeller shaft, driven axle with differential, hub reductions and brakes. The torque converter and gearbox run together, using a common hydraulic system.
  • Page 184 Transmission ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 40 FORWARD 1ST = 2ND = 3RD = 4TH = 1. Pump impeller 2. Turbine wheel 3. Stator 4. Charging pump 5. Suction tube 6. From engine 7. Clutch plates Gearbox Clark 36000...

  • Page 185: Oil Circuit

    Transmission ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 40 Oil circuit The function of the oil is: – to transmit the engine output to the gearbox. The torque converter can multiply the engine torque by up to three times, but at the expense of the speed rotation. –...

  • Page 186: Service

    Transmission ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 40 Oil level check (transmission, incl. converter) Check the oil level daily with the engine at idling speed and the oil temperature between 82 and 93°C. Maintain the oil level at the FULL mark. Changing the gearbox oil and filter This should be carried out when the oil is at normal working tem- perature (82–93°C).

  • Page 187: Checking Pressures In The Clark 36000 Gearbox

    Transmission ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 40 Checking pressures in the Clark 36000 gearbox The pressure should always be checked when the oil is at the normal working temperature of 82–93°C and the gearbox is in neutral. IMPORTANT! Converter outlet pressure: When the check is carried out under...

  • Page 188: Drive Axle

    Drive axle ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 40 The drive axle features two-stage reduction (differential and hub). Rockwell planetary axles permit the bevel or hypoid gearing of the carrier and the axle shafts to carry only a nominal torsional load while at the same time providing the highest practical gear reduction ratio at the wheels.
  • Page 189 Drive axle ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 40 1. Planet holder 2. Insert axle with sun wheel 3. Planet wheel 4. Axle end 5. Ring wheel 6. Ring wheel hub 7. Wheel hub...
  • Page 190 Drive axle ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 40 1. Crown wheel 2. Radial roller bearing 3. Pinion 4. Tapered roller bearings for axial thrust 5. Parking brake assembly 6. Brake cylinder 7. Brake disc Differential assembly...

  • Page 191: Wdb-System

    Drive axle ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 40 WDB-system The wet disc brake system is maintenance free, being immune to wear. Neither are the brakes prone to the fading which normally occurs under tough operating conditions. Furthermore, adjust- ment of the brakes is not required.

  • Page 192: Parking Brake System

    Drive axle ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 40 Parking brake system The parking brake, which is of the disc type, is mounted on the drive axle input shaft. The brake is operated by a heavy-duty spring in the parking brake cylinder and is released by hydraulic pressure, counteracting the spring force.

  • Page 193: Service

    Drive axle ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 40 Changing the drive axle oil IMPORTANT! To assure that the wheel ends of planetary axles with a common wheel end/housing bowl oil level are initially lubricated, fill each wheel end directly with oil before ve- hicle is put back into operation.

  • Page 194: Parking Brake - Initial Adjustment

    Drive axle ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 40 Parking brake - initial adjustment Note! The spring cap (3) has a clock-wise thread and the stud (10) has an anti- clockwise thread. The parking brake can also be used as Never try to screw the spring cap (3) in with springs in compres- an EMERGENCY BRAKE.
  • Page 195 ContChamp DRD-S 9407 04-10 Contents Technical Handbook Grupp 60 Group 60 Steered axle Specifications ................2 Steered axle ................3 Description ................3 Service ................. 4 Replacement of steering cylinder ........4 Replacement of knuckle pin bearings ......4 Replacement of steering wheel bearings ......6 Miscellanous..............

  • Page 196: Specifications

    Specifications ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 60 Tightening torques Wheel nuts, Nm 400 (41 kpm) Steered wheel bearing nuts, Nm Nuts for lower knuckle-pin bearings, Nm 1750 Nuts for upper knuckle-pin bearings, Nm 1500 Mounting screw, M24 Steering cylinder, Nm oiled bolt 1) Steered wheel bearings should be tightened during simulta- neous rotation of the wheels.

  • Page 197: Steered Axle

    Steered axle ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 60 The steered axle is supported by a pendulum suspension and is operated by a double-acting steering cylinder. The mechanism includes the smallest possible number of moving parts to minimise the number of service points and to simplify maintenance.

  • Page 198: Service

    Steered axle ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 60 Replacement of steering cylinder 1. Disconnect the hydraulic connections from the steering cylin- der, and protect the open ends of the cylinder and hoses by means of caps or plugs. 2.
  • Page 199 Steered axle ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 60 1. Upper bearing 10. Spacer 19. Inner bearing 2. Steering cradle 11. Lower bearing 20. Hub 3. Bearing nut 12. Split pin 21. Outer bearing 4. Cover 13. Cover 22.

  • Page 200: Replacement Of Steering Wheel Bearings

    Steered axle ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 60 Assembly 1. Pack the outer races of the bearings with grease and press them into the steering cradle. Note that these are taper bearings. Fit the inner races so that the larger inside diameter faces outwards.
  • Page 201 Steered axle ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 60 5. Remove the tab washer, locknut and bearing nut. The plain washer is loose. 6. Remove the hub off the wheel axle by means of the hand truck. The inner race of the outer bearing will accompany the hub.

  • Page 202: Inspection Of Dismountable Rims

    Steered axle ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 60 Inspection of dismountable rims Due to special operating conditions for dismountable rims, theres is a risk of excessive wear of the lock ring groove in the rim bead, the lock ring itself and the 45° face on the beadseat or loose flange.
  • Page 203 Information on the minimum diameter of your rim bead can be recieved from Kalmar. High stress areas, how to identify rim damage 1. High stress areas are marked with B on the illustration 2.

  • Page 204: Safety Test When Changing Tyres

    Steered axle ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 60 Safety test when changing tyres The test is intended for detecting cracks in wheels. Cracks can lead to safety risks if they are not detected and remedied. Potential cracks that cause air leakage are not detected in the test described here.
  • Page 205 ContChamp DRD-S 9407 04-10 Contents Technical Handbook Grupp 70 Group 70 Hydraulic system Specifications ................2 Main hydraulics ................3 Description ................3 Overview ................3 Electro-hydraulic servo system, principles .......3 Working hydraulics, feed..........4 Servo circuits..............10 Lift ..................11 Boom extension .............13 Service ................15 Hydraulic fluid..............15 Hydraulic oil filter............15 Breather filter..............15 Hydraulic fluid filter for the servo hydraulics....16...

  • Page 206: Specifications

    Specifications ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 70 See the hydraulic plate where all present settings are specified. 1. Warning! High pressure accumulators. Always empty the accumulators before working on the system. Use the accumulator evacuating valve. Carefully study the Instruction Manual and the Technical Handbook. 2.

  • Page 207: Main Hydraulics

    Main hydraulics ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Overview The numbers in the text preceded by an H, for example, H13, re- fer to the hydraulic system diagram. The numbering in the differ- ent illustrations is common with the hydraulic system diagram. The hydraulic system consists of the following sub-systems: Working hydraulics that include: –...

  • Page 208: Working Hydraulics, Feed

    Main hydraulics ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Working hydraulics, feed, standard system The trucks working hydraulics are fed from five different pumps. Pumps H2 and H3 are double variable axial piston pumps that feed the main valves for lift and boom extension as well as the steering system's priority valve.
  • Page 209 Main hydraulics ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 System with separate tank for brake system Certain machines are equipped with a separate hydraulic tank for the brake system. The brake system is fed, as with the standard system, by means of the fixed pump 5 and is cooled by means of the hydraulic fluid cooler 41.
  • Page 210 Main hydraulics ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 The double variable pumps H2 and H3 are controlled by load sig- nals (LS). The flow requirement in each function determines the degree of pump output. The outer pump H3b receives LS-signal from the priority valve H10.
  • Page 211 Main hydraulics ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 System with separate tank for brake system The fixed hydraulic pump 44 provides the circulation in the cooling circuit of the working hydraulics. Tank 43 is completely separate from the other hydraulics and contains hydraulic fluid for the brake system’s brake and cooling circuits.
  • Page 212 Main hydraulics ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Numbering corresponds with the KL1566 hydraulic system diagram (H) Pumps, feed A. Feed to attachment working hydraulics, 1. Hydraulic tank standard 2. Double variable hydraulic pump, LIFT, EXTENSION, SERVO 3.
  • Page 213 Main hydraulics ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Numbering corresponds with the hy- KL1568 draulic system diagram (H) Pumps, feed A. Feed to attachment working hydraulics, 1. Hydraulic tank separate tank for 2. Double variable hydraulic pump, LIFT, brake system EXTENSION, SERVO 3.

  • Page 214: Servo Circuits

    Main hydraulics ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Numbering corresponds with the hydraulic system diagram (H) 1. Hydraulic tank 10a. Pressure regulator valve SERVO, 30-35 bar 11. Filter, servo circuit 13. Main valve 14. Converter, EXTENSION 15. Converter, LIFT 16.

  • Page 215: Lift

    Main hydraulics ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Lift Both lift cylinders are, on the piston side, provided with valve 768-11,13 blocks (H17) which contain blocking valves. When the lift cylinder is in the bottom position and the lift lever is not touched, the blocking piston is held in the closed position by spring pressure as well as by blocking pressure through the solenoid valve.
  • Page 216 Main hydraulics ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 D Draining to tank C+ Feed to lift cylinder C- Return from lift cylinder T Tank return VA Feed from pumps H17.Valve block, lift cylinders a. Blocking valve b. Solenoid valve, control of blocking valve c.

  • Page 217: Boom Extension

    Main hydraulics ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Boom extension and retraction The extension cylinder is fed with hydraulic pressure from a sec- tion of each of the main valves. In this way advantage can be taken of the flow from all four hydraulic pumps. In each of the feed lines there is a lowering (retraction) brake valve with pressure compensated choking, which prevents the boom from being retracted too quickly due to the load.
  • Page 218 Main hydraulics ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 The numbers correspond to the hydraulic diagram (H) H19.Valve block, extension cylinder a. Lowering brake valve with pressure compensated choking C– b. Solenoid valve, control of regeneration valve c. Regeneration valve d.

  • Page 219: Service

    90, Oil and luricant recommendations 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. IMPORTANT! Systems with separate tank for the brake system: The hydraulic fluid for the brake system must never contain any additives.
  • Page 220 Main hydraulics ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 70 Hydraulic oil filter for the servo hydraulics The high-pressure filter filters the circulating servo oil to protect the components downstream of the filter and prevent malopera- tion. A by-pass valve opens at 3.5 bar if the filter should become clogged.

  • Page 221: Steering System

    Steering system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Steering system The steering system is fed from hydraulic pump 2. A priority valve ensures that the steering valve always has suffi- cient fluid. The residual flow goes to the working hydraulics. From the ORB2 connection on the priority valve there is always a certain signal pressure in communication with the steering valve's pressure connection.

  • Page 222: Steering Valve

    Steering system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Steering valve The steering valve is of the closed-centre, non-reaction type with a load signal connection to the priority valve. The load signal en- sures load-dependent control of the flow from the priority valve to the steering valve.
  • Page 223 Steering system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 1. Dust seal 15. O-ring 2. Housing - spool - sleeve 16. Distributor plate 3. Ball 17. Gear set 4. Threaded bush 18. O-ring 5. O-ring 19. End cover 6.

  • Page 224: Priority Valve

    Steering system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Priority valve The priority valve apportions the flow of fluid from the pump H2 so that a sufficient flow always goes to the steering valve. The priority valve is built into a valve block that also contains the pressure regulator valve for the servo system.
  • Page 225 Steering system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 H10.Priority valve a. Pressure regulator valve SERVO, 30-35 bar b. Valve, feed for working hydraulics c. Priority valve, feed for steering system d. Overflow valve, setting of steering pressure e.

  • Page 226: Brake System

    Brake system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 WDB brake system This system is known as the wet disc brake system, in which each hub is equipped with a multiple-disc assembly.The disc assembly comprises stationary discs arranged alternately with a number of rotating discs.

  • Page 227: Brake System

    Brake system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Cooling circuit When the accumulators are charged, oil is fed to the cooling oil cavities in the drive axle. A by-pass valve between the supply and return lines ensures that the cooling oil pressure will not exceed 1,5 bar, in order to protect the drive axle.

  • Page 228: Brake System, Feed

    Brake system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 KL1571 The numbers correspond to the hydraulic diagram (H) 1. Hydraulic tank Alternative 43 for system with separate tank 5. Hydraulic pump, BRAKE SYSTEM 21. Accumulator charging valve 22. Accumulators 23.
  • Page 229 Brake system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 The numbers correspond to the hydraulic diagram (H) 1. Hydraulic tank Alternative 43 for system with separate tank 26. Filter, cooling circuit 29. Service brake valve Brake system, brake and cooling circuits...
  • Page 230 The accumulator is fitted at the top with a connection for testing the pressure of the nitrogen, and for refilling nitrogen with the aid of special filling equipment. Contact KALMAR spare parts. Part. No. 923120–0542. The pressurized fluid from the accumulator is utilized to power the driving brake and parking brake systems.

  • Page 231: Accumulator Charging Valve

    Brake system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Accumulator charging valve The function of the accumulator charging valve is to divert the pump flow to the accumulator whenever the latter needs charg- ing. This ensures that the brake system is given priority and is first to receive oil.

  • Page 232: Hydraulic Brake Pedal

    Brake system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Hydraulic brake pedal The hydraulic brake pedal consists of a direct-acting pressure-re- ducing valve of three-way type designed for continuously variable mechanical operation. The pressure-reducing valve consists of the components shown in the figure. When stop 4 is depressed by the pedal, the main spring acts on the control piston which moves and closes outlet T to the tank.

  • Page 233: Parking Brake

    Brake system ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Parking brake The parking brake consists of a disc brake with a brake cylinder on the drive axle input shaft. The brake is applied by a heavy spring in the brake cylinder. The parking brake can also be used as an EMERGENCY BRAKE.

  • Page 234: Service

    Brake system ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 70 Accumulators, checking the pre-charging pressure (At least once every year) Always check that the engine shut-off controls function correctly. 1. Empty the accumulators into the tank by opening the accumu- WARNING! lator evacuating valve (23) –...

  • Page 235: Hydraulic Oil Cooler

    Brake system ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 70 Hydraulic oil cooler An oil cooler with electrically powered fan is used for dissipation of heat, produced mainly by frequent braking. Machines with a common tank for working hydraulics and braking system have a common hydraulic fluid cooler for both systems.
  • Page 236 Brake system ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 70 Machines with a separate tank for braking system have one hy- draulic fluid cooler for the braking system and one for the working hydraulics, see illustration below and hydraulics diagram.. KL 1573 Numbering in common with the hydraulics diagram 21.

  • Page 237: Adjusting The Wdb Brake System

    Brake system ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 70 Adjusting the WDB brake system The engine and hydraulic system should be at normal operating temperature before adjustments are carried out. Always check that the engine stopping device is working. The various pressures for the machine are given on a separate plate attached to the machine.

  • Page 238: Cab Movement

    Cab movement ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Cab movement Cab movement is a hydraulic system that uses the flow from hy- draulic pump 2. The start and stop of the cab's movement are dampened, which is controlled by the ECS system. For further in- formation see description in group 20.

  • Page 239: Hydraulic Pumps

    Hydraulic pumps ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Variable axial piston pump The two double variable pumps H2 and H3 that feed the lift, boom extension and top lift are variable axial piston pumps with five pis- tons placed in a cylinder rotor.

  • Page 240: Vane Pump

    Hydraulic pumps ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Vane pump The pumps for ATTACHMENT (H4) and BRAKE SYSTEM (H5) are of the vane type and driven from take-offs on the variable pumps (H2 and H3). These pumps consist of a pump casing and a pump unit, and are of simple design.

  • Page 241: Service

    Hydraulic pumps ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 70 Setting the variable pumps These settings may be carried out only by authorized personnel Settings must be carried out with the hydraulic system at normal working temperature. Venting the pumps 1.
  • Page 242 Hydraulic pumps ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 70 Setting of steering pressure 21.Connect the manometer to the test outlet (9) on the priority valve H10. Turn the steering wheel to max wheel deflection and rev up the engine to 1200 rpm. Check that the pressure reading corresponds to the hydraulic plate.

  • Page 243: Main Valve

    Main valve ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 70 Main valve The main valve is a load-sensing, pressure-compensated direc- tional control valve of modular type. In the hydraulic system there are two units, each one comprising: Inlet section Control section Combined control and outlet section The inlet section is provided with:’...

  • Page 244: Service

    Main valve ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 70 Main valve The main valves are of precision type and must be handled with great care to safeguard their good performance. The following rules apply to service work: 1. Never use the spool ends or housings for clamping or gripping when lifting a valve block.

  • Page 245: Hydraulic Cylinders

    Hydraulic cylinders ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 70 Repairs to leaking hydraulic cylinders – replacing the seal IMPORTANT! Never use compressed air for re- moving the piston from the cylinder. See also separate Supplement You could sustain serious injuries. Hydraulic cylinders, Publ.

  • Page 246: Lifting Cylinder

    Hydraulic cylinders ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 70 Lifting cylinder 1. The lifting cylinder is provided with bearings at both ends. The piston rod lug is threaded into the piston rod and locked with locknut. 2. The cylinder head and the cylinder tube are provided with mounting flanges joint together with hexagon-headed screws.

  • Page 247: Telescoping Cylinder, Main Boom

    Hydraulic cylinders ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 70 Telescoping cylinder, main boom 1. The extension cylinder's piston rod end is lug shaped with a flange that is fixed to the piston rod with hexagonal bolt. 2. The cylinder head is fitted with a flange that is attached to the cylinder tube with hexagonal bolts.

  • Page 248: Damping Cylinders, Attachment

    Hydraulic cylinders ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 70 Damping cylinder, attachment 1. The mounting lug is welded to the piston rod which, in turn, is threaded into the piston and locked with a locking screw. 2. The cylinder head is threaded into the cylinder tube. 1.
  • Page 249 Diagrams ContChamp DRD-S 9407 04-10 Component list Technical Handbook Grupp 70 Hydraulic diagram, components Diagram (H), A23056.0400/0500 35. Sensor, indicator lamp parking brake ON and seat 1. Hydraulic tank buzzer 2. Double variable hydraulic pump, LIFT, EXTEN- 36. Parking brake cylinder SION, STEERING SYSTEM, SERVO 37.
  • Page 250 Diagrams ContChamp DRD-S 9407 04-10 Component list Technical Handbook Grupp 70...
  • Page 251 4YFPRS   +& 7YTTPIQIRX ,]HVEYPMG ']PMRHIVW 8IGLRMGEP ,ERHFSSO %PP 8VYGOW...
  • Page 253 All trucks 9279 02-09 Contents Technical Handbook Publ. Gr. P. Contents Clean hydraulics ................ 3 Measures to prevent pollution of the hydraulic system....4 Fault finding for leakage ............6 The function and removal of seals..........7 Piston rod seals ..............7 Support ring and O ring ............

  • Page 255: Clean Hydraulics

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Clean hydraulics Hydraulic systems are extremely sensitive to impurities - a hy- draulic system is just as sensitive as a diesel engine’s fuel sys- tem, with its pumps, filters and lines. It is therefore extremely important that hydraulic systems are kept clean and free from impurities.

  • Page 256: Measures To Prevent Pollution Of The Hydraulic System

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Gasses The most common gas that occurs as an impurity in a hydraulic system is air. Unlike fluids, gasses can be compressed. If air is allowed to enter a hydraulic system, this compression will be ex- perienced as a “sponginess”...
  • Page 257 Never fit components where the protective plugs have fallen out - impurities may have entered the system IMPORTANT! If there is the slightest doubt about the purity of the hy- draulic fluid - send a fluid sample to the manufacturer of the fluid, or to Kalmar Service...

  • Page 258: Fault Finding For Leakage

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Fault finding for leakage 1. All fault finding should take place with the minimum hydraulic pressure required to actually discover the leakage. High pres- sure will tighten all seals and make it more difficult to discover any leakage.

  • Page 259: The Function And Removal Of Seals

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. The function and removal of seals Piston rod seals The piston rod seal is the seal that sits in a groove in the hydraulic cylinder head forming a seal against the piston rod. This seal is very exposed as it performs both dynamic and static sealing func- tions, i.e., it is seals against the moving surface of the piston rod whilst the sealing surface against the cylinder head is static.
  • Page 260 Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Piston rod seal type TICLA is of compact design with integrated support ring. It has an inner sealing lip against the piston rod and an outer sealing lip which seals with press fit against the cylinder head.

  • Page 261: Support Ring And O Ring

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. The compressible piston rod seal consists of a solid rubber profile and gives a greater sealing area than V seals. Use a screwdriver to remove the seal, see illustration. Lever out and twist up the seal.

  • Page 262: Wiper

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Wiper The task of the wiper is to scrape the piston rod clean and prevent øD+10 any impurities being drawn into the cylinder pipe. The wiper must be fitted with a special tool. This tool must have a greater outer diameter than the wiper, so that the pressure against the wiper ceases just as the wiper is pressed into posi- tion.

  • Page 263: Single Action V Type Piston Seals With Support Ring

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Single action V type piston seals with support ring On single action V seals it is always the long side that seals against the static and the short side that seals against the moving surface.

  • Page 264: Double Action Piston Seals

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Double action piston seals Double action seals function with pressure from both directions, e.g., in a steering cylinder. The whole of the surface within the cylinder pipe is the sealing surface, it is therefore extremely important that this surface is not damaged in any way.

  • Page 265: Lubrication

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Lubrication 1. Within the actual hydraulic system - never anything other than the normal hydraulic fluid used in the hydraulic system. 2. On the cylinder head thread - use copper paste (e.g., Moly- cote CU 7439).

  • Page 266: Dismantling The Steering Cylinder

    Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Dismantling the steering cylinder On the steering cylinder, it can be very difficult to remove the pis- ton from the cylinder as the O ring in the cylinder head sticks in the locking ring groove of the cylinder pipe.
  • Page 268 [[[OEPQEVMRHGSQ % 4EVXIO 'SQTER] /EPQEV -RHYWXVMIW 7ZIVMKI %& 7)  0NYRKF] 7[IHIR XIP     JE\    ...
  • Page 269 ContChamp DRD-S 9407 04-10 Contents Technical Handbook Grupp 80 Group 80 Telescope-boom with rotator, attachment Specification ................2 Boom with rotator ..............3 Description ................3 Telescope boom.............. 3 Rotator................4 Damping/Forward tilt ............5 Service ................. 6 Checking lubrication ............6 Checking boom fixtures, extension boom and fixed boom ........
  • Page 270 Specifications ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 80 See current data sheet...

  • Page 271: Boom With Rotator

    Boom with rotator ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 80 Telescope boom The telescope-boom of the ContChamp is made of highly resist- ant steel of a very sturdy design. The number of welds has been kept to a minimum to ensure the highest possible strength. The boom comprises the following: –...

  • Page 272: Rotator

    Boom with rotator ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 80 Rotator The rotator consists of an upper and lower yoke, connected to each other by a gear wheel and a powerful roller bearing, which facilitates the rotation of the lower yoke in relation to the upper yoke.

  • Page 273: Damping/Forward Tilt

    Boom with rotator ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 80 Damping/Forward tilt The suspension of the rotating yoke is equipped with two hydraul- ic cylinders (49) the function of which is to dampen uncontrolled swinging. The cylinders are filled with fluid that, when the yoke moves, must pass a throttle-check valve (51), which determines the degree of damping.

  • Page 274: Service

    Boom with rotator ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 80 Checking lubrication Check regularly that hoses and connections are undamaged. Also check that the lubricant actually reaches the point of lubrica- tion. Checking boom fixtures, extension boom and fixed boom 1.
  • Page 275 1. Slding plate 2. Lubricator mm, the sliding plates should be fitted with more shims. 3. Shims Please, contact Kalmar service department for further informa- tion. KL1424d Wearing of sliding plates on one side 1. If the sliding plates are worn on one side, the boom will be ex- posed to torsional stress.

  • Page 276: Top Lift

    Top-lift ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 80 Top-lift For a detailed function description, see group 20, El-servo. The top-lift is adjustable for 20-40' containers and is constructed of welded steel profiles that run within each other on sliding plates made of Robalon.
  • Page 277 Top-lift ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 80 KL 1558 47. Main valve 52. Hydraulic motor 55. Hydraulic cylinder, SIDE-SHIFT 58. Hydrauic lcylinder, TWIST-LOCKS Top lift, hydraulic installation...

  • Page 278: Twist-Locks

    Top-lift ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 80 Twist locks A spring loaded contact pin and an inductive sensor at each twist lock are used to control and check the alignment. An electrical locking system prevents twisting of the twist locks before they 7202/ have fully entered the container locking holes.
  • Page 279 Top-lift ContChamp DRD-S 9407 04-10 Description Technical Handbook Grupp 80 1. Main switch 2. Main fuse 3. Coupling, at rear of boom 4. See electrical installation ECS boom, see group 20, page 36 24 V feed of top-lift...

  • Page 280: Service

    Top-lift ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 80 Indicating lamps The top lift has a set of three indicating lamps for container han- dling: A. Green left: TWIST-LOCKS LOCKED B. Orange middle: ALIGNMENT (The lamp will be extinguished at lifted container) C.

  • Page 281: Adjustment And Lubrication Of Sliding Plates

    Shims of various thickness can be ordered from Kalmar, see Spare Parts Catalogue. N.B. The shims must be fitted equilateral in order to maintain the attachment aligned and levelled, otherwise there is a risk of malfunction.

  • Page 282: Control Of Twist-Lock Lifting Pins

    Top-lift ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 80 Control of twist-lock lifting pins N.B. This control should be first carried out after 5000 hours of service, or after 2 years - which ever occurs first. Thereafter, the lifting pins should be checked every year. Removing the lifting pins 1.

  • Page 283: Chain Adjustment

    Top-lift ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 80 Chain, adjustment 15/16 17/18 The chain tension is controlled by two sets of plate springs and adjusting nuts. The chain play should be max 10-15 mm at retracted attach- ment, when pressing with the thumb. Adjust if needed with adjusting nuts.

  • Page 284: Setting The Resistance Of The Damping Cylinders

    Top-lift ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 80 Setting the resistance of the damping cylinders 1. Run the boom up and down again. Check to see how the top- lift moves. In the lower position it shall, relatively easily, set it- self in the horizontal after having hung somewhat angled in- wards.
  • Page 285 Top-lift ContChamp DRD-S 9407 04-10 Service Technical Handbook Grupp 80 Control valve, setting the pressures 1. The main pressure limitation valve (5) shall be set at the over- all system pressure as shown on the hydraulic plate. 2. The pressure of the manoeuvre sections shall be set sepa- rately for each section.
  • Page 286 Top-lift ContChamp DRD-S 9407 04-10 Diagrams Technical Handbook Grupp 80 Hydraulic diagram, top-lift Components 3. Dubbel variabel hydraulic pump b. Top lift supply 42.Solenoid valve, activation of pump 3b for top lift supply 47. Top lift main valve a. Control section TILT b.
  • Page 287 ContChamp DRD-S 9407 04-10 Contents Technical Handbook Grupp 90 Group 90 Periodic supervision General survey ................3 General survey chart ............4 Daily supervision ..............8 Every 200 hours ..............9 Every 600 hours ..............10 Every 1000 hours ............... 11 Oil and lubricant recommendations ........
  • Page 288 Empty page ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 90...

  • Page 289: General Survey

    Periodic supervision ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 90 General survey To extend the service life of the truck and to prevent the risk of faults causing injury to personnel or damage to equipment, the truck must be subjected to regular periodic supervision. If the truck is used under conditions in which road traffic regula- tions are applicable, the special maintenance instructions issued by the authorities must be followed.
  • Page 290 Periodic supervision ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 90 DRD420-60S5 6, 7 KL586C Refill Brake Planetary gear Sight glass...
  • Page 291 Periodic supervision ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 90 LUBRICATION CHART Item Description Interval No. of Remarks operating hours lub. points 1000 Boom mounting Slide plates, boom Manually pump grease while the boom is moved slowly outwards and inwards to its end positions Rotator mounting Tilt cylinders...
  • Page 292 Periodic supervision ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 90 KL 1553a KL 1553 KL 1555a KL1555...
  • Page 293 Periodic supervision ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 90 LUBRICATION CHART, Top lift Item Interval No. of No. Description operating hours lub. Remarks points 1000 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 top- lift fully side-shifted in both directions...

  • Page 294: Daily Supervision

    Periodic supervision ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 90 DAILY SUPERVISION DAILY SUPERVISION Or when Check Refill if required refueling Brakes Function Steering Function Rear steered axle suspension Check that the rear suspension is clean. Check that the sensor is free from grease (On machines with mechanical overload protection system) All instruments.
  • Page 295 Periodic supervision ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 90 Every 200:e hours Item Unit Action Remarks Truck Wash Note! Do not use highpressure on bearings or bearing housings Radiator Clean the fins of the radiator with Note! Do not usehigh-pressure. water and detergent Engine Check the oil and coolant con-...

  • Page 296: Every 600 Hours

    Periodic supervision ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 90 Every 600 hours Item Unit Action Remark Air cleaner Change the filter element if the See Group 30 indicator shows red. Turbo charger Check for leakage. See Group 30 Exhaust system Check for leakage.

  • Page 297: Every 1000 Hours

    Periodic supervision ContChamp DRD-S 9407 04-10 Technical Handbook Grupp 90 Every 1000 hours Item Unit Action Remarks Fresh-air filter Change filter element See Group 10 Engine Check valve clearances, cooling See Volvo Workshop Manual system, starter motor, alternator and Group 30 and fuses Fuel tank Drain...
  • Page 298 Use EP universal grease to NLGI Grade 2 with 3–5% molyb- denum disulphide additive for all lubrication points, including wheel bearings. Grease for Plastic plates Use grease recommended by Kalmar. Ordered from Kalmar’s Spares department. 0,65 kg cartridge for grease gun Art. no 923110.0360...

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