Table of Contents
Advertisement
Quick Links
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
Advertisement
Chapters
Table of Contents
Related Manuals for Kalmar ContChamp DRD450
Summarization of Contents
00 General
Safety Regulations
Covers essential safety rules and regulations for operating the machine and handling loads.
General Design Overview
Provides an overview of the machine's design and general features.
Component Units
Describes the key component units that make up the machine.
Related Documentation and Parts
Lists supplementary books, spare parts system, and tools.
Tightening Torques
Provides specific torque values for bolts and nuts used in assembly.
System of Units
Details the SI units used in the handbook and conversion factors.
10 Chassis and cab
Specification
Technical specifications for the chassis and cab components.
Chassis
Describes the chassis construction, frame, mountings, and counterweights.
Operator’s cab
Details the operator's cab features, insulation, adjustments, and HVAC system.
Steering column
Explains the steering column layout, controls, and adjustment features.
Hydraulics control unit
Describes the control lever and switches for operating the hydraulics system.
Operator's Cab Service
Provides procedures for maintenance tasks related to the operator's cab.
Air conditioning unit
Details the air conditioning unit's function, components, and service procedures.
20 Electrical system
Specifications
Technical specifications related to the electrical system, including alternator and battery details.
Electrical System Overview
Details the truck's electrical system, voltage, and component layout.
Battery Maintenance
Procedure for checking and topping up battery electrolyte levels.
Fuses, Relays, and Bulbs
Lists and describes the purpose and rating of fuses, relays, and bulbs.
Starting from another battery
Instructions for jump-starting the truck using an external battery.
Air operated operator’s seat
Describes the motor and compressor for the air-operated operator's seat.
ECS-system Overview
Overview of the Electronic Control System (ECS), its modules, and fault indicators.
ECU System Details
Details functions, circuit boards, and I/O signals for ECUs 1, 2, and 3.
30 Engine
Specifications
Technical specifications for Volvo TWD1031VE and TWD1231VE engines.
Engine Description
Provides a general overview and labeling of engine components.
Cooling system
Explains the engine's liquid-cooled system, components, and coolant flow.
Fuel system
Details the fuel system's circuits, components like fuel tank, pump, and injectors.
Lubrication system
Describes the engine's pressure lubrication system, oil cooler, and piston cooling.
Combusting air system
Explains the air cleaner, turbocharger, intercooler, and inlet manifold heater.
Engine Maintenance Procedures
Covers maintenance procedures for coolant, air cleaner, oil, filters, valves, and turbocharger.
40 Transmission, drive axle, brakes
Specification
Technical specifications for the torque converter, gearbox, and drive axle.
Transmission Overview
Provides an overview of the transmission system, including torque converter and gearbox.
Drive axle
Describes the drive axle's two-stage reduction, differential, hub, and brake systems.
WDB-system
Explains the Wet Disc Brake (WDB) system's advantages and construction.
Parking brake system
Explains the parking brake system, its operation, and emergency use.
Parking brake Service
Covers parking brake adjustment procedures and compensation for lining wear.
60 Steered axle
Specifications
Details tightening torques for wheel nuts, bearing nuts, and steering cylinder.
Description
Explains the steered axle's design, pendulum suspension, and hydraulic circuits.
Steered Axle Service Procedures
Covers service procedures for steering cylinder and knuckle pin bearings replacement.
Inspection of Dismountable Rims
Procedure for inspecting dismountable rims for wear and damage.
Safety Test When Changing Tyres
Describes magnetic and penetrance tests for detecting cracks in wheels.
70 Hydraulic system
Specifications
Details hydraulic system settings, pressures, and accumulator specifications.
Main Hydraulics Overview
Overview of hydraulic system, servo, working hydraulics, and servo circuits.
Lift System
Explains the lift cylinder function, blocking valves, and regeneration system.
Boom Extension and Retraction
Details the boom extension/retraction cylinder, damping, and regeneration.
Hydraulic Fluid and Filters
Provides information on hydraulic fluid properties, handling, and filter maintenance.
Steering System
Overview of the steering system, its components, and principles of operation.
Priority Valve
Explains the priority valve's function in regulating hydraulic flow to the steering system.
Brake System
Describes the wet disc brake system, its circuits, and main components.
Accumulators
Details the hydraulic system's accumulators, their function, and safety precautions.
Parking Brake System
Explains the parking brake system, its operation, and emergency use.
Brake System Service
Covers service procedures for the brake system, including accumulator checks and bleeding.
Hydraulic Pumps
Describes the variable axial piston pumps and vane pumps used in the system.
Main Valve
Describes the main valve, its sections, functions, and load sensing principles.
Hydraulic Cylinders
Covers service procedures for hydraulic cylinders, including seal replacement and piston repair.
80 Telescope-boom with rotator, attachment
Specification
References current data sheet for specifications.
Telescope Boom Description
Details the telescope boom's construction from high-resistance steel and its components.
Rotator
Describes the rotator's components, including yoke, bearing, brake, and over-centre valve.
Damping/Forward tilt
Explains the damping system using hydraulic cylinders and the optional forward tilt.
Boom and Attachment Service
Covers service procedures for boom lubrication, fixtures, and sliding plates.
Top Lift System
Details the top-lift's function, construction, control, and hydraulic installation.
Twist-locks
Describes the twist-lock system, its sensors, alignment, and locking mechanism.
Top Lift Indicating Lamps and Controls
Explains indicating lamps, alignment, safety interlocking, and control systems.
Sliding Plate Adjustment and Lubrication
Instructions for adjusting play and lubricating the sliding plates.
Twist-lock Lifting Pin Control
Procedure for controlling and checking the twist-lock lifting pins.
Inductive Sensors
Details the inductive sensors used for alignment control and their adjustment.
Chain Adjustment
Instructions for adjusting chain tension and lubrication.
Damping Cylinder Service
Procedures for bleeding and setting the resistance of damping cylinders.
Control Valve Pressure Settings
Procedure for setting pressures on the manoeuvre sections of the control valve.
90 Periodic supervision
General Survey
Outlines the importance of regular periodic supervision for truck longevity and safety.
General Survey Chart
Provides a chart detailing maintenance intervals for various truck components.
Daily Supervision
Lists checks to be performed daily, including brakes, steering, and fluid levels.
Periodic Maintenance Schedules
Details maintenance tasks for 200, 600, and 1000 hour intervals.
Oil and Lubricant Recommendations
Provides recommendations for engine oil, gearbox oil, hydraulic fluid, and greases.
Need help?
Do you have a question about the ContChamp DRD450 and is the answer not in the manual?
Questions and answers