Documente Academic
Documente Profesional
Documente Cultură
Group 00
General
Safety rules 2
Applications 4
Design - Overview 4
Component units 5
Supplementary books 7
Replacement system - Spare parts 7
Tools 7
Tightening torques 8
System of units 10
ContChamp DC-RS «Kalmar
912996·03 00 2
Technical Handbook General Pub!. I Gr.1 P.
Safety rules··
• Before starting, check that nobody is in the way of the.truck and its'
accessories.
• The truck should be driven only by specially trained operators who are authorised to do so by
the work supervisor.
• Warning! Only authorized and qualified personnel may work with the safety system.
• Warning! If the overload safety system override function has been used, there is a risk of
forward tipping. The truck should be operated with extreme care to prevent accidents.
• The truck must not be used if its brakes, steering or lifting equipment is faulty. Neither must it
be used if it has been repaired, modified or adjusted without the approval of the work super-
visor.
• Great care must be exercised at all times when driving the machine. Always remember the
great height and width of the machine so that collision with beams, cables etc. is avoided.
• It is prohibited to start lifting a container if the red warning light TWIST-LOCK UNLOCKED is lit
or if any of the yellow warning lights TWIST-LOCK UNLOCKED or ALIGNMENT are unlift. N.B.
the ALIGNMENT warning light goes out once the lift has begun.
• If the safety system warning lamps are not functioning, the system must be immediately
repaired. To use a truck with faulty warning lamps is a great safety risk.
• Do not drive the truck with load raised high above the ground, since the truck may overturn.
The transport of heavy loads must be carried out with the load as close to the truck as possible,
Le. with the boom retracted as far as possible without obstructing vision.
• Never run hands or fingers along any tubes, pipes or hoses whilst investigating for possible
leaks as some of these lines (diesel fuel, hydraulic, steering, etc.) operate at extremely high
pressures and even the most minute of leaks can cause oil or fluid to penetrate the skin.
• Always apply the parking brake before leaving the cab. Always remove the key if the truck is
left unattended.
• The parking brake may also be used as EMERGENCY BRAKE (see Brake system).
• Under no circumstances may compressed air be used to remove a hydraulic piston from its
cylinder.
• Always attend to damage and wear that may be of significance to the performance and useful
life of the truck or to the safety of the personnel.
• Follow the safety rules whenever carrying out service work on the air conditioner. The
refrigerant is injurious to the skin and eyes. Only authorized service personnel may repair the
system.
• Never carry out any service work on the boom or attachmentt when the engine is running.
«Kalmar
ContChamp DC-RS 9129 96-03 00 ~
Technical Handbook General Pub!. I Gr.1 P.
Tyre changing can be dangerous and should only be carried out by specially trained personnel
using proper tools and procedures. Failure to comply with these procedures may result in faulty
positioning of the tyre and/or rim and cause the assembly to burst with explosive force sufficient
to cause physical injury or death. Never fit or use damaged tyres or rims. Never position body in
front of a damaged rim or tyre.
Deflation and dismantling
- The truck should be properly jacked up before dismantling.
- Always check the tyre/rim assembly for proper component seating prior to removal from the truck.
- Never position body in front of the rim during deflation.
- Always deflate the tyre by removing the valve core prior to removing the complete assembly from the
truck or dismantling any of the component. Before loosening mounting bolts, run a wire through the valve
stem to ensure that it is not blocked. Ice or dirt can prevent the air from escaping.
- Always follow the manufacturer's instruction manual, or other recognized industry instruction manuals.
Rim inspection
- Always select the correct tyre size and construction matching the manufacturer's rim or wheel rating and
size ..
- Do not use over-size tyres, too large for the rims, e.g. 14.5 inch tyres with 14 inch rims or 16.5 inch tyres
with 16 inch rims.
- Never use damaged, worn or corroded rims/wheels or fitting hardware. Always verify that the rim is in a
serviceable conditioning.
- Always clean and repaint lightly rusted rims.
- Never use a rim/wheel component that can not be identified. Check rim parts against multi-piece rim/
wheel matching charts.
Assembly
- Always double check to ensure that the rim assemblies have been correctly assembled and that secu-
ring studs and nuts are tightened to the correct torque setting.
- Always follow assembly and dismantling procedures outlined in the manufacturer's instruction manual, or
other recognized industry instruction manuals. Use proper rubber lubricant.
- Never use a steel hammer to assembling or dismantling rim components - use a lead, brass or plastic
type mallets. The correct tools are available through rim/wheel distributors.
Inflation
- When adding air to a tyre on an industrial truck, use a clip-on chuck and stay out of the danger
area. If the tyre has been run flat then the rim must -be dismantled and all parts inspected for damage.
- Tyres must first be inflated to the correct seating pressure (0.3 bar). During inflation, check that the
tyre is correctly seated on the wheel and that all components are correctly positioned. Double
check that the locking ring has been correctly fitted. If the tyre or the locking ring are not correctly
positioned or any other fault is discovered, discontinue tyre inflation immediately and rectify the fault.
- Tyres fitted to split-rim wheels must not be inflated above the seating pressure prior to the wheels being
fitted onto the truck.
- Tyre inflation should be carried out from a protected position and during inflation it is strictly forbidden
for any person to remain within "dangerous proximity" of the wheel.
- Tyres should be inflated in areas that will withstand, inhibit or disperse the pressure wave caused, for
example, by an exploding tyre. At the same time, the position should be so protected as to eliminate the
possibility of personal injury caused by flying wheel components in the event of such an explosion. If
possible, tyres should be inflated outdoors.
- When fitting the wheels onto the truck, the wheel nuts must be tightened to the recommended torque
settings. Use staggered sequence: Le. top bolt, bottom bolt, etc
- Under-inflated tyres have a serious effect on the stability of the truck and reduces the safe load handling
capacity. Always maintain tyres at the correct inflation pressures. Check inflation pressures daily.
- Inspect tyres regulary - every day if possible. Look for and remove broken glass, torn pieces
of tread, embedded metal chips etc. Inspect for uneven or rapid tread wear.
ContChamp DC-RS .. ({Kalmar
9129 96~03 00 4"
Technical Handbook General
- '''\. 0(
Pub!. I Gr.1 P.
Design - Overview
Kalmar LMV DC 416D-4180 model RS 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 torsional ~tiffness and an extremely low
centre of gravity.
The operator's cab is provided with vibration isolation and
sound insulation and offers excellent all-round visibility. It
satisfies with a comfortable margin the demands for a safety
cab specified by various standards and regulations.
There are.many adjustments that can be made to the operator's
driving position. The position of the seat, back support and
firmness of the driving seat can be adjusted in a number of
ways.
The trucks are equipped with a sliding cab. This puts the
operator in an exeptional position to superwise trailer
attachment and offers excellent accessibility to the transmission
and hydraulic pumps. The engine is easily accessible through a
removable running board.
Component units
• Sound-insulated and safety-tested operator's cab with
excellent all-round visibility. The non-slip, substantial steps
provide convenient access to the cab. All models in the
series can be equipped with a rotatable operator's seat.
As an optional extra, a hydraulically movable cab is
available.
•... \ "
Main components
I ~t-5~
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•~ ~
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00
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-CD
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~ 00
Drive .!::
C..-
axle ::II-
,~
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enD
ca"-
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E<{ in
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Engine
~ (")o!
• Standard 0 Option
Supplementary books
In addition to the Instruction Manual and the Technical Hand-
book, the following books are delivered with every truck.
Tools
Kalmar LMV offers a wide range of tools for truck maintenance
work.
Tightening torques
(According to Kalmar LMV K Standards 20060.0001)
Surface treatment
Condition Lubrication
Bolt Nut
I11
12,9
Quality 1 30
3
61
48
2
I 108
85
2446
39
91
76
162
135
260
I205
388
323
373
294
559
466
520
409
4480
777
2640
3730
888
1763
3005
700
1388
2367
1100
2200
1330
647 27
54
96
230
330
8,8 2660
1560
460
786
M30x2
M36x3
M10x1,25
M24x2
M12x1,25
M16x1,5
M18x1,5 Thread M fin
I
I
Condition
L 10,9
MM20x1,5
8x1 Tightening torque, Nm
1 1 121 1005
237
1424
173
418
671
1990
2620
50
79
3455
39
62
103
250
30
3 1
2720
1120
791
136
390
528
1565
2065
187
95
1
255
42
1672
490
848
59
47
24
81
2 1780
216
178
353
298
73
62
118
524
20
00
35
1317
386
668
198 51 12,5
1050
2500
2080
74
154
1270
45
38
89
19
375
313
732
610
11
16
28
2100
2490
619
4320
12,5
9,8
22,3
28,3
14,1990
839
2940
1480
1260
3870
3280
5100
5,7
11,1
7,2
3,6 5,5
17,6
9,1
2,9
4,6 12320
210
153
370
107
44
70
261760
3060
594
25889
1480
11
220
430
750
52
91
1260
6,4
3,21 ..
' .. ,
General· .......
"..,....
ContChamp
f settlement Ithe
I material
ofCondition DC-RS
110,9
Tightening
and the torque, Nm
C associated
HB,
the
be
ned
is surface
tripped
to
applied
not theCondition
a applicable
washer 8,8
reduction
I should
supporting
specified
by
without
I~ II the static
pause,
if in
be
torque.
flanged the
thefitted
preloading
bolt
friction
to ensure
bolts under
head
before
~.. \ I"or
that the
or
flanged force
the bolt
nut isif
jointhead
torque
nuts the
lower
has
arehardness
and
thannut.
been
wrench
use9. This
of
tighte-
200
will not
When tightenin"g is carried out, the specified torque should be
m
Quality
, .• .t.. ' ... ...... -,"
1 29
31200
42
66
1050
122
661
44
2250
4170
1560
1320
191
379
3110
19
37
126
1900
67
162
559
889
5450
07 629
114
227
396
47
13
26
752
447
710
14 321Tightening
1058
2100
2825
128
256
3680
1525
53
85
2225
834
101
202
352
560
1655
11
23
2900
1852630
4610
79
3530
145
2500
3260
1350
1860
937 torque, Nm
-General
231
ContChamp I273 164~~.-
DC-RS"
. ..... .
UNFCondition •" \ 0{
System of units
The 81 system of units is employed in this handbook:
The conversion factors are as foolows:
Pressure 1.02
10.2
1 bar
10
1
0,98
Kilogram-force Pound-force
14.5
145
14.2
inch,
psi
per
per
square
square
centimetre,
MPa
0.1
0.098 kgf/cm2
Atmosphere, at
megapascal
1
Torque metre
0.102
1
1.36
Kilogram
hp
kgf m Ibf
7.23
0.74
force-
Horsepower hp ft
Pound-force
0.986
1.34
Horsepower
(metric) foot
metre
0.735
9.81
kW
Nm
1 1 Kilowatt
newton-
Power
{{Icalmar
ContChamp DC-RS, 9129 96-03 10 1
Technical Handbook Contents Pub!. I Gr.1 P.
Group 10
Chassis and
cab
Specification 2
Chassis 3
Description 3
Operator's cab 4
Description 4
Steering column 9
Hydraulic control unit 10
Service 11
Changing the fresh air filter 11
Air conditioning 12
Description 12
Compressor 14
Condenser 14
Liquid receiver and filter-dryer 14
Expansion valve I 14
Evaporator 14
Service 15
Checking the air-conditioning lunit 15
General instructions for the
air-conditioning system 16
,
•..•...Kalmar
'~ContChamp,DC-RS:;;,' '.-' , .
I •.
-"'
~ •
... 9129 '96-03 10 '2
Technical Handbook Specifications. Pub!. I Gr,1 p,
Air conditioner
• Cab unit
- Circulated air flow
- Electric power consumption
• Compressor
- Max. speed 4000 r/min
- Refrigerant Freon R12
or R134a
- Electric power consumption 48W
- Oil.capacity (Sunriso 5.GS) 1.6 dl (R12)
Zexel PAG 0:1 1.6 dl (R134a)
• Condenser
- Electric power consumption 160W
Chassi· ..>.. «Kalmar
ContChamp DC-RS 9129 96-03 10 3
Technical Handbook Description PubL I Gr.1 P.
o. \ •
Chassis
The chassis consists of:
• A unit construction frame built uplaround two box- sections
for best possible strength.
• Mountings for the drive axle, ste~red axle, telescope'-boom,
lifting cylinders and transmission.!
• The necessary counterweights tol provide a very low centre
of gravity. Moreover, the steered laxle is designed to serve
as an additional counterweight.
The hydraulic oil tank and the fuel ta1nkare produced as separa-
te units and are bolted to the side of Ithe chassis. The tanks
have a low profile, which contributes to the good visibility.
Support jacks I
Certain machines are equipped with support jacks to increase
the capacity in the third container ro~,
I see group 20.
Inner boom
Outer boom
Operator's cab
,
Rubber suspended
I
Drive axle
With hub reductions
and hydr~ulic,
,
oil-cooled
brake system
Steering axle
With pendulum suspension and
double-acting steering cylinder
Chassi i.~.. «Kalmar
ContChamp .DC-RS :\ 9129 96~03 10'4 .
Technical Handbook .
Description ---';'-:;.'!"
PubL I Gr.1 P.
Operator's cab
The operators·cab is a separate structure and rests on the
chassis on· rubber dampers. The cab is of safety design, and is
an efficient and safe workplace. The operator's seat, steering
wheel and hydraulic control levers can be adjusted for best
possible opera~or comfort. Effective insulation minimises the
vibrations and sound level in the cab.
3. Heating
4. Air filter system . I
«Kalmar
ContChamp DC-RS Operator's cab 9129 '96-03 1"0 5
Technical Handbook Description Pub!. I Gr.1 P.
'''''' "
19 1 2 3 4 5 6
7 8 9 10 '11 12 13 14 15 16 . 17
21 22 23 24 25
DD~¢ ®4;+
~$.~-
26 27 2~ §D
29 ~30
(I)
31
raT
32
¥~
I~
33
I
34
RPM
35
1) Optional equipment
Chassi·.':
«Kalmar
ContChamp DC-RS·· 9129 96-03 10 7
Technical Handbook Description - Pub!. I Gr.1 P.
.,\, ,,'
Joy-stick functions
1. Unlocking of twist-locks
2: Side ~hift
3. Boom'OUT/IN
4. LlFTIlOWER
5. a. Locking of levelling
b. Lodking of tilt
6. Tilt I
7. Rotation
8. Vertical lift ;
9. Levelfing
10. Length adjustment 20'-40'
Switch fJnctions
15. AUT :::iAutomatic locking of
twist-locks. The parking brake
must be OFF.
DODD MAN+Manuellocking of
twist-locks (spring-back).
AUT
I
Stop
I®I 30' 35'
NOTE! The doors should be closed or The -- position gives crawling speed the whole time during
the cab in its rear position otherwise extension and retraction. In order to by-pass the 30' stop
all functions will be broken. press ••• and thereafter ~. The next stop will be 35'. It
Only on trucks with hydraulically is practical to connect in .•••. onc~ the 3D' position has been
powered sliding cab. passed.
{.Kalmar
ContChamp. DC-RS'; Chassi:~.;" 9129 96-03 '10 8'
Technical Handbook Description Publ. I Gr.1 P.
.~ \ «
A~
Steered axle overload
Yellow lamp: WARNING Steered axle overload
Red lamp: Stop for I
Note! At low gear (1, 2) and
Lift, Boom in. low speed the green lamp
OK for Lower, Boom out. C<,..-LMV will be alight despite overload.
I KL103
Display AITON Steered axle load OK
Shows distance drive axel centre-
load. Note! The overload safety system Test button
When vertical lift button is is delivered in different versions. For checking of indicator
depressed, the display shows load. This picture covers all. lamps. KL154
Engagement and
disengagement
of servo circuits
Warning! I
Steering column
Controls for gear-changing, direction indicators, lighting and
horn are mounted on the steering column. The Orbitral steering
valve is fitted at the extreme bottom Iof the steering column
shaft ...
1. Instrument panel
2. Gear selector
3. Multi function lever
4. Steering wheel adjustment
Steering column
.' Ch assl.::
... ','';,-,:.: .: «Kalmar
ContChamp DC-RS': 9129 96-03'10 10
Technical Handbook Description' ."'..•.
:" Pub!. I Gr.1 P.
\
Locking handle
411
I
\
Console
:::==E .
1- - .....e:=:
I
I
I
I
I
I
I
I
I
I
I
.•...•
(<.Kalmar
.ContChamp .DC-RS 'Chassr..:;: i ••• : . ' , I
9129 96-03 10 11
Technical Handbook Service Pub!. I Gr.1 P.
• Remove the filter casing retaining bolts and remove the filter
element.
KL1S4
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KL185
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. .
Condenser
The function of the condenser is to convert the hot high-pressu-
re gas from the compressor into liquid form. The tubes and fins
of the condenser coil absorb heat, which is then removed by the
air delivered by the fan.
After flowing through the dryer in the bottom of the liquid recei-
ver, the refrigerant flows through a riser tube. A sight glass
enables the operator to check that the liquid flows without the
presence of any bubbles, and that the system is filled with a
sufficient amount of refrigerant.
Expansion valve
The expansion valve throttles the flow and passes an optimised
quantity of refrigerant that the evaporator is capable of
evaporating.
Evaporator
The heat necessary for evaporating the refrigerant is extracted
from the cab air which is circulated by a fan through the evapo-
rator coil. The cab air is thus cooled, and is distributed and
retumed to the cab.
'
... \ "
intentionally.
If the unit is used very little during cold and dry winter periods,
Only the prescribed refrigerant may be used
the compressor should be run for a few minutes every week, to
when refilling.
lubricate the rubber hoses, cOupling:s, seals and shaft seal.
I
I
Air condition. ..- : ~ {<Kalmar
ContChamp DC-RS .'. ' . 912996-0310 16
Technical Handbook Service .. Pub!. I Gr.1 P.
".. \ "
I
SVI.
+ 1+
1 1 1 M "'.
I~ 1.5
RD ~.IL
1,\ 4
GL 1,5
I
@I AI
I
I",
I~ c:c
---
~
l~ ~
ffi_, ~_
311~ VT 1,5
1. Fan switch
2. Cooler onfoff
3. Anti-freeze thermostat
4.
5. Resistor
Fan motor
i
I
8. Relay
9. Condenser
10. Compressorfan I
Group 20 I
I
Electrical system I
Specifications 2
Electrical system I 4
Description I 4
Service I 9
Checking the electrolyte level in the batteries 9
Relay box inside the cab - fuses 9
Bulbs 9
Relays ......;. 10
Starting from another battery 10
Cable markings ......;. . 11
Electro-servo system 12
Description ~~ 12
General ......;. 12
Control lever ......;. 13
Dead man's handle 14
Control unit 1 och 2 "'-- 15
Converters 16
Boom LIFT LOWER 17
Boom OUT/IN ......;. 17
Twist-lock, manual and
Length adjustment automatic
20-40' lOCking
__ ......;. 18
19
Sideshift I 19
Rotation; rotation stopper I 20
Hydraulic re-positioning of operator cab 22
Electric interlock I 22
Support jack I 24
Electric servo for machine RS, container (components) __ 26
Electric servo for machine RS, v.erticallift, .
container (components) I 27
Electric servo for machine RS5, container (components) __ 28
Service I 29
Converter 29
Control unit 1 och 2 (IPS 302) _-'-- 29
Cables and wiring I 29
Trimming of the electro-hydraulic servo system
with measuring instrument I 30
Trimming without measuring instrument 32
Testing after trimming I 32
Fault tracing in the electro-hydraul"c servo system 33
Fault symptoms 33
Overload indicating system 36
Description "'-- 36
Frontal overload 36
Overloading the steering axle 36
Sensors "'-- 36
Overload safety system, SNP-system 38
Description 38
Forward overload 39
Overload, steered axle "'-- 39
Service "'-- 41
Coarse adjustment of the outreac length sensor 41
Coarse adjustment of the boom angle sensor 41
Fine adjustment in the control unit· 41
Adjustment of sensors: 43
Manual electric gear-changing system I
Description I 44
Clark 34000/36000 (components) 44
Automatic electric gear-changing system'
Description : 45
Clark 34000/36000 (components 1 48
Automatic engine shut down ' 49
Electro-hydraulic accelerator I 50
Air operated seat 51
Circuit diagrams I
Converter
Ambient I temperature, 24 V version -30°C to +50 °C
Max. control pressure output P = 3.1 MPa (100,.. duly cycle)
out 4.0 MPa (50% duty cycle)
Recom~ended
I
inlet pressure p. = Pout+ 1.0 - 2.0 MPa
I
Weight 0.9 kg
Kalmar
•...•...
ContChamp DC-RS·.,· • __ L ".n
9129 96-03 20 3
Technical Handbook Specifications ;~ , Pub!. I Gr.1 P.
Outputs:
All outputs are short-circuit protected and can
withstand a loa.d of 1A. .:,
However, the total output must not exceed 4A.
Inputs:
8 inputs for gear selection control.
Input for manual gear-changing.
Input for lock-up.
Input for kick-down.
2 inputs for fault indication, one of which can be
used for monitoring the engine spe~d.
Input for tacho pulses from the output shaft.
Heat dissipation 15 W
«Kalmar
ContChanip, DC-RS", ' , Electrical system.:: ,'~. 9129 96-03' 20 4
Pub!. I Gr.1 P.
Technical Handbook Description -, ~~,.:
",.. \. 0(
The system voltage is 24V and the supply is taken from two
12V batteries connected in series and charged by an alternator
across electronic rectifying and voltage stabilisation circuits.
The negative and positive poles are both connected across a
main switch. The negative pole is then connected to the' chas-
sis. Always open the main switch whenever work is to be
carried out on the electrical system, if the truck is to remain idle
for some time and whenever welding work is to be carried out
on the truck.
I
I
I
,
I
I
..
I
i,I,
j' KL454
;;rf~
~J
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0 o~
0 ~0 124vo. ba'.'Y
Main switch
ContChamp. DC-RS'···:, -.. ..~.Electrical~.system :'-':.:.:...
~<Kalmar
9129 96-03 20 5
Technical Handbook Description .....- .. Pub!. I Gr.1 P.
12 1 2 3 4
I
11
/
/---<./'\
I
1. Relay, preheating
2. Sensor, pressure gauge, oil pressure engine
3. Semor, warning lamp low oil pressure engine
4. Sensor, warning lamp low coolant level
5. Sensor, temperature gauge coolant temperature (in engine block)
6. Sensor, warning lamp high coolant temperature (in T-connection)
7. Alternator
8. Starter motor I
9. Sensor, warning lamp low oil pressure and pressure gauge oil pressure gearbox
10. Sensor, warning lamp low oil pressure gearbox
11. Sensor, pressure gauge oil pressure gearbox
12. Main fuse for electrical system, 2 x 50 A Electrical components of the Volvo TWD 1030 ME engine
Kalmar
~j ContChamp.DC-RS:. '... '-;''':;'',_'::Electrical :system::::·:,. 9129 96-03; 20 6
Technical Handbook Description _•.,.•.... Pub!. I Gr.1 P.
3
. 4 5 6
lffl U II
(
I 1----
7 8 9, 10
11
o \. ,.
1 2 3 4
10 9 8 7 KL459
." \ "
1 2 3
+
,1
/11
\\
r,'- .............
r----</
/ '
/
/
/
8 9 10 11
KL494
1. Sensor, warning
,
lamp and
I
temperature gauge, oil temperature gearbox
2. Sensor, warning lamp and temperature gauge, coolant temperature
3. Sensor, warning lamp, low coolant level
4. Stop solenoid I
5. Alternator I
6. Main fuse for the electrical system, 2 x 50 A
7. Sensor, pressure gauge', oil pressure gearbox
8. Sensor, warning lamp and pressure gauge, oil pressure engine
9. Starter motor I
" \ " I
Bulbs
Rating
Description Watts I Base
Instruments 3
Indicating lamps 1,2 I BA7s
W2x4,6d
Cab lighting 10 I S8,5
Rear lights, red 5 : BA 15s
Brake lights 21 BA 15s
Direction indicators 21 , BA 15s
Position lights 5
Driving lights 75nO P43t-38
i SV8,5
(full/dipped beam)
Reversing lights, white 70 PK22s
Working lights 70 PK22s
Hazard beacon 70 , PK22s
Kalmar
•....•.
" ContChamp:DC'!'RS=,,: Electricalsystem~,;',:":' ',"" . 9129 96-03' 20 10
Technical Handbook Service. _.,_ Pub!. I Gr.1 P.
I
Relays
'305 Reversing light
~r~
~ M ~ § sIr .'314 Parking brake, disengagement'
~ H 9 H ~1r.19 Q 9 ~ ~ ~I I 315 High power (Starting switch)
316 Wiper motor, front
320 Electric,stop ')
321-1 Intermittent relay wiper front
321-2 Intermittent relay wiper rear ')
322 Coolant level
323 Pulse relay, direction indicators -
330 Starting block
331 Propulsion forward
332 Propulsion reverse
334 Release clutch at automatic gearbox')
960 Reversing interlock
I
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') Optional equipment
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Main fuse
for electrical
I
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II!D Fitted on the engine
2 x 50 A
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.
110
KL'37
.,' \ '(-
Cable markings
All cables are marked with a numbe~ for identifying the terminal
points as follows: I
P = Pressure
T = Temperature
Cable -L Eestinatior
11 = Coolant level
Goes from ·271 (657) , Ruris to
o = Fuel level
block 27 6571
T erminal1
terminal T J -c: cOn]ponent
in block 27
terminal terminal
block 10 block 26
Goes from]]
Terminal 3 1 L-.::-R-un-s-t-o-' Terminal 1 in block 26
in block 10
Connected to
supply the next function
Jumper
Relay markingi
87
87a
85 -+ll J 86
I 30
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f6 81 87a KL190
Terminal blocks
6, 7, 8, 9, .19,20, 21, 22, 28. To steering wheel panel 17, 18. Engine transmitte~s
10. Roof panel
11. Lamps front left 24. Working
23. To cabin lights
roof I
General
.The electro-servo system consists of the following components:
• Control lever
• Switches
• Control uni~s
• Converters on the main valves
-. " 5
.
" •
I
-.
. 1
•" •" •
~
1. Control lever
2. Switches
3. Control unit IPS
4. 24 V battery
5. Converters at main valves
Kalmar
ContChamp DC-RS'"' Electro-servo system .,. -, J 91~~6-03 20 13
Publ. I Gr.1 P.
Technical Handbook Description
" \ ..
T1 P1 Control lever I
T4 The plus feed from the control unit is! delivererd via sliding
shoes when manoeuvring the machi~e.
T1 Side shift
T2 Unlocking of twist-locks
T3 a) Locking of levelling
b) Locking of tilt
T4 Vertical lift
P1 Lift/Lower
P2 Boom out/in
P3 Rotation
P4 Tilt (Optional)
I
I
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Lever connections
1. Earth 8. Unlocking of twist-locks 16. SidLhifllefV2D-40 inwards
2. Feed front tilt 9. Feed T2 17. Fe~d sideshift/20-40
3. Tilt inwards (option) 10. Switch alt function/verticallift 19. Fe~d lift/lower
4. Tilt outwards (option) 11. Feed T4 20. Lower
5. Feed rotation/I.evelling 12. Locking of levelling 21. Lift I
6. Rotation counter-clockwise/ 13. Locking of front tilt 22. Feed boom extension
levelling, left 14. Feed, locking switch 23. Boom in
7. Rotation clockwise/ 15. Sideshift right/20-40 outwards 24. Boom out
levelling, right
,ContChamp.DC.;RS::'/ , - ..Electro-servo: system:~~;·.:,:: ,', _«Kalmar
-, .. 9129' 96-03 20 14
Technical Handbook Description ... :.,...__ Pub!. I Gr.1 P.
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verters. ~~. ,. I :
Compensation for changes in the resistance of the converter
solenoid coil due to temperature variations and supply voltage
variations is provided automatically Iby means of a current-
sensing feedback loop. :
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«Kalmar
9129 96-03 20 16
Technical Handbook Description Pub!. I Gr.1 P.
'''\. 'If'
Converters
"The converter is an electrically controlled pressure reducing
valve for the remote control of hydraulic functions. The output
signal is a proportional hydraulic servo pressure which is used
to control the spools of the lJ'Iain valves.
Servo pressure 6p
bar
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7_S
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30
25
KL467
20
15
8 I I 9
10
1. Vent screw 5
BOOM LIFT/LOWER
See Electric servo (S), group 20
X
I
BOOM OUT/IN
Se Electric servo (S), group 20
Automatic locking
T2 1. Feed to switch 516 from the parking brake. Condition:
Parking brake OFF. '...
-
2. Feed to relay 55.24 from 516. At full alignment, Le. there is
a signal from the series connected sensors E20.1 and E20.2
on the top lift (Circuit diagram top lift group 80) the relay
55.24 shifts.
4. When lifting, the alignment signal goes out, Le. the signal
from sensors E20.1 and E20.2 on the top lift go out. Relay
55.24 shifts and makes section Z in the main valve close.
Also valve E23 (twist-locks) closes.
T2 Unlocking of twist.loel
Manual locking
1. Plus feed to switch 516 from the main switch 515. This
enables locking even when the parking brake is ON.
Twist-lock unlocking
1. Activate switch UNLOCK TWI5T -LOCK5 on the control
lever.
NOTE: The switch must be kept pressed in during lift.
4. Plus feed to section Z in the top lift main valve which opens.
T4
2. Relay S5.19 and S5.20 shifts. I .
4. Solenoid valve E24 (H24) recieves plus feed and opens for
inward or outward movement depending on the position of
switch T1. Hydraulic pressure supply to hydraulic motor H4,
6. Solenoid valve E25 (H25) shifts whereby the return from the
hydraulic motor is forced through a nozzle thus reducing the
T1
Sideshift
Se electric servo (S), group 20 I
manually controlled. I
4. The top lift main valve, section V}'1 gets plus feed and opens
for hydraulic pressure supply to the sideshift cylinders which
T1 Sideshift
6. Plus feed O\fer relay 85.20 to thl the top lift.
I
7. The top lift main valve, section W2 gets plus feed and opens
for hydraulic pressure supply to the sideshift cylinders (H2)
which gives left sideshifting.
«Kalmar
~'". ContChamp~DC~RS'-",... ," ,. -Electro~servo:system:,';-:: 9129 96-03' 20 20
Technical Handbook Description - .-'>C',-
Pub I. I Gr.1 P.
••..\ 'i
Rotation
- See electric servo (S), group 20
. Circuit diagram toplift (E) A04454.0100 group 80
Hydraulic system top lift (H) A05433.0100 group 80
Rotation -stopper
A07688.0300 .
P3 Rotation
In order to prevent damage to the machine when lifting or
lowering a rotation stopper is available to order. The stopper
allows a maximum rotation of ±20°.
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6. Hydraulic valve for rotation motor supply
7. Switch, bridging of rotation stopper
8. Aelays 18, 19, 26, 27
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Alternative on ASS machines
10. IPS-unit 2, installation alternative for ASS-machines
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':ContChamp DC-RS ,-',.....'. ,. .Electro-servo:system:::': . •..--Kalmar
912996-03 20 22
Technical Handbook Description . ':::.. Pub!. I Gr.1 P.
Electrical interlock
In order to avoid accidents, the system is electrically interlocked with
switches 8 and 9 and the limit switch 10, se circuit diagram
A07687.0100. The cab must be in the rear position and have both
doors closed, otherwise the electro hydraulic servo system is
interrupted for all hydraulic functions.
1. Condition: The cab has been moved more than 100 mm forwards
and both or any of the doors are open. 10 and 8 or 9 close.
2. Relay 28 in the elctrical central unit (11 on the diagram) is activated.
This will brake the feed to the main switch 13.
3. The switch for cab movement 12 gets no feed and the cab cannot
be repositioned.
1. Hydraulic motor
2. Chain sprocket
3. Cab frame
4. Cable draw chain
5. Steering valve
6. Priority valve
7. Manoeuvre valve
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S' 10. Limit switch, closes the circuit 'when the cab is moved
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100 mm forwards.
11. Relay 28 in electrical central unit
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13. Main switch, electro-hydraulic servo.
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Kalmar
" ContChamp ,DC~RS,~:;,.~.~
.. '! Electro-servo system ',,-:' 9129'96-03 20 24"
Technical Handbook Description ",,':: Pub!. I Gr.1 p,
Support jacks
Certain machines are equipped with support jacks in order to
increase the capacity in the third container row. The support
jacks are controlled with a switch in the operator's cab. A
hydraulic cylinder affects a linkage system which presses the
support jack down and thereby reduces the load center by
600 mm, which increases the third row capacity.
As the support jacks have left their upper position, a red
warning lamp will light up simultaneously as the transmission is
disengaged. When the support jacks have reached the bottom
position'a green lamp will light up. Furthermore, the overload
safety system changes load curve. Asa result of this, the higher
capacity (+7 tonnes) in container row 3 can be utilized.
The upper and lower support jack positions are controlled by
inductive sensors which are connected to the overload safety
system.
If overload occurs, the support jacks can be lowered. On the
contrary, the support jacks cannot be raised until the overload is
neutralized by disengaging the load or retracting the boom.
7.1-2 7.3-4
1. Hydraulic cylinder
2. Linkage system Kl4n
3. Support jack 3
4. Bolt, fastening torque 2350 Nm
(oiled bolt) I
I Support jack
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n 7 4. Electrical central unit 1. Right support jack raised
~ I 5. Relays 2. Left support jack raised
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34. Control of support jacks at overload
35. Indication support jacks raised
3. Right support jack lowered
4. Left support jack lowered
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INN'" rULL 1 SL.e
co 37. Inverting of + signal to - signal cylinder supply
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•.....•.
.ContChamp,DC.;,.RS~':'::':~.:-,~~.:_.
Electro-.servo.system::;: ' 912996-03' 20 26
Technical Handbook Description .. d- Pub!. I Gr.1 P.
Components A21531.0100
I
10. Control lever
1. Main valve T1 SIDE SHIFT
S (1-2) LIFT-LOWER T2 Unlocking of TWIST-LOCKS
U (3-4) BOOM IN-BOOM OlF T3 a) Ldcking of LEVELLING
V (5-6) BOOM'IN 2-BOOM'OUT 2' b) Locking of TILT
T4 Vertical LIFT
T (7-8) LIFT 2-LOWER 2 I
P1 LIFT/LOWER
2. Cut-off valve for lift cylinders
3. Control unit IPS P2 BOOM OUT/IN
5. Relays P3ROTATION
1. Control of Red lamp and interruption of functions P4TILT
at overload I
Lever connections
2, 3, 4. Interruption of LIFT, LOWER, BOOM OUT at 1. Earth (OV)
overload (low steering axle load) 2. Feed, front TILT
5. Interruption of LOWER at ALIGNMENT 3. TILT IN (option)
6. Control of cut-off valves onllifting cylinders 4. TILT OUT (option)
7,8. Control of Green indicating lamp for suitable 5, Feed, ROTATION/LEVELLING
transport position. (On lamp panel 17) 6. ROTATION anti-clockwise/LEVELLING, left
9. Control of Green indicating' lamp for suitable 7; ROTATION clockwise/LEVELLING, right
transport position, 1:st and 2:~d gear 8. Unlocking of TWIST-LOCKS
(On lamp panel 17) 9. Feed T2
10. Signal converter (Amplifying of IPS-signal to 10. Switch, alt. functionNERTICAL LIFT
control current for relays) I
11. Feed T4
11. Safety interlocking LIFT 12. Locking of LEVELLING
12. Safety interlocking TWIST-LOCKS 13. Locking of front TILT
13. Stop at 30' and 35' I 14. Feed, switch, locking
14. - 15. SIDESHIFT, right/20'-40' OUT
16. SIDESHIFT, left/20'-40' IN
15. Control relay for overload Isensor
16. Interlocking of relay at overload 17. Feed, SIDESHIFT/20'-40'
19. Feed, LIFT/LOWER
17. Interruption at overload I
(Std 4580. Others optional, jumped) 20. LOWER
18. Feed SIDESHIFT/20'-40'1 21. LIFT
19. SIDESHIFT RIGHT/20'-40' OUT 22. Feed, boom extension
20. SIDESHIFT LEFT/20'-40'1 IN 23. BOOM IN
24. Locking of TWIST-LOCK~ 24. BOOM OUT
25. Unlocking of TWIST-LOCKS 13. Switch, stop at 30'-35'
7. Inductive sensor for boom angle 14. Switch, override of the container coupling safety system
8. Inductive sensor for boom extension 15. Servo circuit cut out switch
9. Inductive sensor for indication of forward overload, 16. Switch, locking and unlocking of TWIST-LOCKS (Manual)
on steered axle (mechanical system) 17. Lamp panel, overload indication system
(mechanical system)
I
18. EI. system for hydraulically moveable cab, see separate
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19. Connection to electrical central unit
;- 20. Terminal bar for diodes, in the relay box below the
operator's seat
1. Override of LOWER at overload
2. Impuls LIFT, LOWER for reset function
3. Inhibitor for reverse current ALIGNMENT
4. Signal for parking brake for TWIST-LOCKS
5-6. Opens TWIST-LOCK valve on the attachment
7-8. Opens 20'-40' valve on the attachment
21. Length sensor, signal to overload safety system
22. Angle sensor, signal to overload safety system
23. Printed circuit board for checking of sensors 24
24. Pressure sensors, forward overload, in each lift
cylinder sypply line
25. Control unit for overload safety system (SNP-300)
26. Signal (+) from sensor which cuts out LIFT, LOWER,
BOOM OUT
27. Relays for cut-out at overload (SNP-300), see
y pera eat separate diagram
«Kalmar
ContChamp.DC-RS \. Electro-servo system': :::." 9129 96-03 20 27
Pub!. I Gr.1 P.
Technical Handbook Description __
=-"
'"'' ..
25. Unlocking of TWIST-LOCKS 14. Switch, override of the container coupling safety system
7. Inductive sensor for boom angle 15. Servo circuit cut out switch I
8. Inductive sensor for boom extension 16. Switch, locking and unlocking of TWIST-LOCKS (Manual)
9. Inductive sensor for indication of forward overload, 17. Lamp panel, overload indicati6n system
on steered axle (mechanical system) (mechanical system) I
........
; 1. Override of LOWER at overload
2. Impuls LIFT, LOWER for reset function
3. Inhibitor for reverse current IALIGNMENT
4. Signal for parking brake foriTWIST-LOCKS
IL 5-6. Opens TWIST-LOCK valve I on the attachment
7-8. Opens 20'-40' valve on the attachment
21. Length sensor, signal to overload safety system
22. Angle sensor, signal to overload safety system
23. Printed circuit board for checking of sensors 24
24. Pressure sensors, forward ov~rload, in each lift
cylinder sypply line I
I
20. Terminal bar for diodes, in the relay box below the
operator's seat
1. Override of LOWER at overload
2. Impuls LIFT, LOWER for reset function
3. Inhibitor for reverse current ALIGNMENT
4. Signal for parking brake for TWIST-LOCKS
5-6. Opens TWIST-LOCK valve on the attachment
7-8. Opens 20'-40' valve on the attachment
21. Length sensor, signal to overload safety system
22. Angle sensor, signal to overload safety system
23. Printed circuit board for checking of sensors 24
24. Pressure sensors, forward overload, in each lift
cylinder sypply line
25. Control unit for overload safety system (SNP-300)
26. Signal (+) from sensor which cuts out LIFT, LOWER,
BOOM OUT
27. Relays for cut-out at overload (SNP-300), see separate
diagram
28. Solenoid valve, reduces the BOOM OUT pressure at a boom
angle over 59°.
Relay box below operator's seat 29. Solenoid valve, reduces the LIFT pressure at a boom angle
over 59°
«Kalmar
ContChamp DC-RS" . Electro-servo system.":.:' 9129 96-03 20 29
Technical Handbook Service -- Pub!. I Gr.1 P.
'..\ «.
Converter
The useful life of the converters is ndrmallY the same as that of
other hydraulic components. No mai~tenance
I in the true sense
is required, but check at regular interyals that the mounting
screws have not worked loose.
Long experience has shown that mqst electrical faults are due
to defective cables. So check the fol,lowing at regular intervals:
2. Remove the plastic cover from the control units. Use the
trimming potentiometers on the top of the units. Each con-
verter corresponds to one group (see figure);' Each group
consists of an LED, and MIN and MAX potentiometers. The
LED will light up when the corresponding function is in
operation.
7. Move the lever in the same direction again until the LED
lights up.
9. Move the lever to the limit of its travel in the direction corres-
ponding to the relevant function.
"
«Kalmar
ContChamp DC-RS' ":.,'Electro-servo system:;'; .-; 9129' 96-03 20 31
Technical Handbook Service Pub!. I Gr.1 P.
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3a BOOM OUT 4b Forward tilt 9a 9b
4a Forward tilt OUTWARDS 1) 10a 10b
INWARDS 1)
1>Optional
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5a LOWER 1 5b LIFT 1
6a LOWER 2 6b LIFT 2
7a BOOM OUT 1 7b BOOM IN 1
8a BOOM OUT 2 8b BOOM IN 2
1>Optional
Servo pressure
p
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Control lever
KL469a
Control lever 100%
movement
5.After the system has been adjusted, use only the MAX
potentiometer for individual adjustment of the speeds.
4. If the final speed of any function is too low, turn the MAX
potentiometer clockwise to the required position.
5. If the final speed of any function is too high, turn the MAX
potentiometer anti-clockwise to the required position.
«Kalmar
ContChamp DC-RS;-" 9129 96-03 20 33
Technical Handbook Pub\. I Gr.1 P.
Fault symptoms
- No response to lever movement
Uncontrolled movements
Jerky movements
Excess play in the control lever
Too high a speed
Too Iowa speed
Oscillations
Failure of individual functions
Miscellaneous defects
•... \ ..
Uncontrolled movements
·1.' A function operates unintentionally when another is opetated.
- Check the wiring against the circuit diagram. The relevant
functions have been connected either in series or in
parallel.
2. A function has been started but fails to stop when the lever
is returned.
I.
I
«Kalmar
· ContChamp .DC-RS, = • ::.Electr~servo:system:;: '".. ' 9129 96-03 20 35
Technical Handbook Service Pub!. I Gr.1 P.
Oscillations
1. All functions oscillate
Miscellaneous faults
1. The red lamp lights up only when the corresponding
function in the lever has been actuated.
2. The red lamp is switched off when the lever is not actuated.
Frontal overload
With a frontal overload, when there is a risk that the truck will tip
forwards, a red lamp lights up. At the same time, the functions,
LIFT, LOWER and BOOM OUT are interrupted.
Sensors
The sensors used are of the same type for all functions. In
normal positions they transmit a signal, that is, when the sensor
activator is a maximum of 5 mm in front of the sensor. On the
sensor there are two diodes used to check the functions of the
sensor. A green diode for connected current and a red diode for
transmitted signal.
',- \ "
."
w
~ A 11460.0100 01
1. Inductive sensor, activated at boom extension <1 m 9. Lamp panel in operator's cab
2. Inductive sensor, activated at boom angle >420 a. Red=overi'oad
3. Inductive sensor on the steered axle, brakes at overload b. Orange=the load position is not
4. Activator, activates the sensor 3 suitable folr transport
5. Angle link c. Green=th~ load position is
6. Chassies suitable folrI transport
7. Steered axle d. Lamp test button
8. At a distance of less than >5 mm, the sensor brakes 10. Electro-servo
«Kalmar
·'ContChamp: DC"!RS, ,,~': ',::-' ~~Overload.safety:system
~.",7.'. " 9129 96·03 20 38'
TechnicaJ Handbook Description·' . ,,=-, Publ. I Gr.1 P.
".. \ -(
Display AITON
Shows distance between drive axel
~t
centre and load. Notel The overload safety system
When vertical lift button is is delivered in different versions.
depressed, the display shows load. This picture covers all.
,Overload. safety, system
«Kalmar
"ContChamp .DC..RS: ,.; 9129 96-03 . 20 39
Technical Handbook Description .. -~--"",-
_, Pub!. I Gr.1 p,
'" \ «
Forward overload
See Electric servo I .
BOOM OUT. I
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5: Relays
30. Cut out of LIFT function
31. Cut out of BOOM IN function
7, 8: Indicating lamps for suitable transport position
9: Control of indicating lamps for suitable transport position at 1:st and 2:nd gear
**17: Cut out at overload
**20: Interrupts BOOM OUT at 6400 outreach
21: Control of valve for reduced BOOM OUT and LIFT pressure
(boom angle over 59°)
**22: Cut out of LYFT 2 (S) See also Electro-servo for machine model RS
**23: Cut out of BOOM OUT 2 (V)
~~II
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«Kalmar
ContChamp:DC-RS-- ''-'";:.:':''-~' Overldad s'afety sYstem'~· ' 9129 96·03 20 41
Pub!. I Gr.1 P.
Technical Handbook Service~ .. ,~;:,
KL210
1. Potentiometer
2. String
Length sensor
00 00 KL209
Note. There is a position when the LED-diode shifts directly
from red to green light without passing the off position.
This is not the correct position. C~ntinue to a position
where the LED-diode stays off. I
1. Potentiometer
2. Securing screw
3. LED-diode Angle sensor
••.• \ 0{
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VERTICAL LIFT
START VOLTAGE
D
KL211
14. Retract the boom and put the load down. The lift it in the
same way again and extend the boom until the overload
safety system interruputs. Check the distance.
-,.\ 'i
1. Loosen the screw retaining the round bar on the back side
of the sensor. Pull out the bar.
I
1. Lift cylinder
2. Pressure sensor 2. Turn the sensor axle below 0°. ~his should activate the
3. Electrical connector control unit alarm and cause interruption of the boom
functions. I
Kl210
1. Potentiometer
2. String
Length sensor
" 'ContChamp' D'C-RS,: ,Manual electric;gear"~changing,system" ": , ....
,,~Kalmar
• 9129 '96-03 20 44
Technical Handbook Description :,..,~_. Pub!. I Gr.1 P.
Cable colours
Svart = Black
Gra = Grey
Rod = Red
Bla = Blue
Gul = Yellow
Gron = Green
Brun = Brown
Vit = White
Rosa = Pink
(<.Kalmar
·ContChamp. DC-RS:,. Automatic. eleCtricgear~changingsystem:j. 9129 96-03 20 45'·
Pub!. I Gr.1 P.
Technical Handbook Description,....:.,.
Control unit
The control unit is simple to program, even while the truck is in
operation. It measures the speed oflrotation with high accuracy
and stability, and it has fully programmable outputs for gear
selection.
~
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p-t;J
Green POWER LED
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•••••••••••••••
Automatic gear-changing
The control unit (Shiftronic) continuously senses the speed of
the output shaft and selects a suitable gear In accordance with
the programmed table. Hysteresis is also programmed into the
table to prevent excessively frequent gear-changing.
~•• \ t(
Safety functions
'These functions are always active.
Other functions
Selectable function (REENTER IF REV): If the transmission has
been shifted from a particular gear to neutral, the gear can be
re-engaged if the speed of rotation is still within the correct
range.
Tachometer
To facilitate programming, built-in opportunities are available for
direct indication of the transmission speed and engine speed (if
AUX1 is used). This function is activated by depressing the
reset button when there is no fault to acknowledge. When the
button is depressed, the display first shows the speed which will
be displayed (TRANS or ENGINE) and, after a brief pause, the
speed will be displayed. To revert to the display showing the
gear which has been selected, depress the reset button again.
If AUX1 is used for engine speed control, the transmission
speed and the engine speed are displayed alternately.
Temperature monitoring
Since the control unit has standard circuits with a temperature
range of 0 - 70 DC, it cannot be operated when the temperature
in the case is below 0 DC.
P3 - Display, programming
The display in the cab is connected here by means of a multi-
pole connector, except during programming, when the
programming equipment is connected instead.
Programming unit
ContChamp DC-RS~"Automatic electric gear-changing system, J91~<g~~48"
Technical Handbook Description',",.~-
.. Pub I. I Gr.1 P.
Cable colours
Svart = Black
Gra = Grey
ROd = Red
Bla = Blue
Gul = Yellow
Gran = Green
Brun = Brown
Vit = White
Rosa = Pink
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3. Electrical central unit.
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~<Kalmar
.. 9129' 96-03 20 50
Technical Handbook Description·, .:~~, Pub!. I Gr.1 P.
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KL214
1. Accelerator pedal
2. Control valve
3. Injection pump
4. Servo cylinder
5. Electrical central unit
T. Return to tank
P. Hydraulic pressure from accelerators
A13173.0100 01
1
MOUNTED IN A BOX
RIGHT -HAND
FUSE 3 56-3
3
1121314
25 ""H'
KL21S
2 PRESSURE GUARD ~
1. Mo~or and compressor
Mounted in a box on the right-hand side of the truck
2. Pressure guard
3. Fuse 3 56-3
A08906.0100 01
Catalogue of C.omponents
Classification
Components are classed in the following groups:
30-99 Battery, fuse holder, etc.
100 Switch.
200 Making/Breaking contacts (sensors, etc).
300 Relays.
400 Light bulbs.
500 Indicating/Warning lamps. ~
600-664 Switching devices (solonoid valves, wiper motor, starter motor).
665-684 Semiconductor components (thyristor, transistors).
685-699 Other control system components (not contactors).
700 Instruments, sensors (analog types of tachometers, etc.)
800-900 Other components.
1000 Cable mats
Component list
30 Battery 130 Switch, highllow gear
32 Printed circuit board, Junction box 131 Switch, gear selector forward
37 Earthing terminal on chassis 132 Switch, gear selector rear
39 Terminal, negative terminal 135 Switch, gear shift
51 Fuse holder, 1-pole 142 Switch, foot
52 Fuse holder, 2-pole 143 Switch, seat heater
56 Fuse holder, 6-pole 144 Battery disconnecting switch
59 Fuse holder, 12-pole 145 Switch, AT-regulator
62 Battery connector, 2-pole 147 Switch, direction indicators
64 Battery connector, 4-pole 149 Switch, horn
72 Outlet 2-pole 150 Switch, main key switch
77 Outlet, 7-pole 152 Switch, intermittent wiper
78 Outlet, extra, 7-pole 156 Switch, cab heating
157 Switch, seat tilt
100 Switch, light 158 Switch, rear fog light
101 Switch, main/dipped beam 160 Switch, combi-forward/reverse
102 Switch, fog light 161 Swi1ch,combi- horn, light main/dipped beam,
103 Switch, distance light washer, wiper (intermittent), direction indicator
104 Switch, mast lights 165 Switch, seat heater
105 Switch, working lights 166 Switch, interlocking of turntable
106 Switch, container light 167 Switch, pneumatic springing
\ 107 Switch, parking brake 168 Switch, interlocking of seat
108 Switch, central lubricator 169 Switch, reversible seat
109 Switch, hazard lights 170 Switch, evaporator (LPG)
110 Switch, rotating hazard beacon 171 Switch, fifth wheel up/down
111 Switch, window regulator 172 Switch, fifth wheel forward/reverse
112 Switch, air conditioner (AC) 175 Switch, cab hoist up
113 Switch, alternative steering 176 Switch, cab hoist down
114 Switch, reading light 180 Switch, 4-WD
115 Switch, instrument illumination 190 Switch, air conditioner
116 Switch, interior lighting 195 Switch, joy-stick X
117 Switch, heating 196 Switch, joy-stick X+Y
118 Switch, heater fan 197 Switch, length/sideways driving
119 Switch, wiper 199 Switch, option
120 Switch, washer
123 Switch, observation mirror 200 Contact, breaking, warning lamp, parking brake
125 Switch, exhaust brake 201 Contact, breaking, warning lamp, brake
126 Switch, diff. block 202 Contact, breaking, warning lamp, oil pressure engine
128 Switch, power take off side 204 Contact, breaking, pressure accumulatortank
129 Switch, power take off rear 205 Contact, breaking, interior lighting
~ .• ' .• ~;.< i., .>. __~'•.•••. J
r! ••
.~ Appendix' . ~
Technical Handbook Catalogue of Components.
206 Contact, breaking, glove 320 Relay, electical stop
207 Contact, making, diff. hiterlock 321 Relay, intermittent wiper
208 Contact, making, warning lamp temperature brake 322 Relay, coolant level
cooling 323 Relay, blinkers
214 Contact, making, over drive 324 Relay, range interlock
215 Contact, making, temperature engine 325 Relay, flashing brake lights (reversing)
216 Contact~making, brake lights-· 326. Relay, flashing hazard lights (reversing)
217 Contact, making, reversing light 327 Relay, gear neutral
218 Contact, making, AT-control 328 Relay, gear shift
219 Contact, making, indicating light air filter 329 Relay, high/low gear
220 Contact, breaking, drive cut off 330 Relay, start interlock
221 Contact, making, temperature gear box 331 Relay, forward driving
222 Contact, making, warning lamp temperature torque 332 Relay, reversing driving
amplifier. 333 Time relay, automatically preheating
223 Contact, brush, horn 334 Relay, free wheeVdrive disconnection
224 Contact, making, injection pump 335 Relay, gear change valve 1-gear (diesel,LPG)
228 Contact, making, cab locking 336 Relay, gear change valve 2-gear (diesel,LPG)
229 Contact, making, seat locking 337 Relay, motor drive direction
230 Contact, breaking, seat 338 Relay, cooling fan drive motor
231 Contact, making, seat rotation, foot switch 339 Relay, cooling fan electrical box
232 Contact, breaking, warning lamp air connection 340 Time relay, start delay
233 Contact, warning, interlocking of turntable 341 Time relay, stop delay
235 Contact, making, side shifting of seat 342 Relay, switching 214WD
239 Contact, breaking, thermic 343 Relay, fog light rear
240 Contact, making, thermic 344 Relay, torque amplifier
241 Contact, breaking, warning lamp air supply to 345 Relay, interlocking of turntable
trailer 346 Relay, releasing of seat interlocking
242 Contact, making, warning lamp, oil pressure gear 347 Relay, multifunction, seat rotation/light signal
box 348 Relay, fan heating
243 Contact, breaking, coolant pressure (air condition) 349 Relay, speed control
244 Contact, making, hydraulics 350 Relay, pump contactor/pump control
250 Contact, breaking, emergency stop 351 Relay, cab hoist up
251 Contact,making,VBFS 352 Relay, cab hoist down
260 Contact, making, hoist step 1 353 Relay, safety loop
261 Contact, making, hoist step 2 354 Relay, signal control system
262 Contact, making, tilting 355 Relay, sensor control
263 Contact, making, fork positioning 356 Shift relay, length/sideways driving
264 Contact, making, sideshift 357 Relay, hazard beacon
265 Contact, making, lifting mast in-out 360 Relay, starting solenoid
299 Contact, making/braking option 365 Relay, electrical screenelevator up
366 Relay, electrical screenelevator down
300 Relay, main/dipPe.dbeam 375 Main contactor, operating control
301 Relay, fog light 376 Contactor, forward operating control
302 Relay, distance light 377 Contactor, reversing operating control
303 Relay, mast light 378 Contactor, "by-pass" operating control
304 Relay, working light. 379 Contactor, pump motor
305 Relay, reversing light 380 Contactor
306 Relay, main beam 381 Contactor, recharging
307 Relay, dipped beam 399 Relay, option
308 Relay, brake light
309 Relay, parking light 400L Light bulb, roading light left hand front
310 Relay, direction indicator left 400R Light bulb, roading light left hand rear
311 Relay, direction indicator right 401L Light bulb, roading light left hand front
312 Relay, element preheater 401 R Light bulb, TOadinglight left hand rear
313 Relay, rotating driver's seat (VBFS) 402 Light bulb, distance light
314 Relay, parking brake 403 Light bulb, mast light
315 Relay, starting key 404 Light bulb, working light
316 Relay, wiper 405 Light bulb, rear light
317 Relay, roading lights wiper 406L Container light left-hand
318 Relay, AT-regulator 406R Container light right-hand
319 Relay, hazard blinkers 408L Light bulb, parking light, left-hand forward
Appendix·
Technical Handbook Catalogue of Components~.
408R Light bulb,
parking light, right-hand forward 569 Indicating lamp, electric heater
410L Light bulb,
brake light, left-hand forward 590 Indicating lamps complete (15 pes)
410R Light bulb,
brake light, right-hand forward 599 Indicating lamp, option
411 L Light bulb,
brake light, left-hand rear
411 R Light bulb,
brake light, right-hand rear 600 Solenoid valve, exhaust brake
412L Light bulb,
rear light, left-hand rear 601 .Solenoid valve, ditt. inter10ck
412R Ught bulb,
rear light right:-handrear 602 Solenoid valve, brake
413L Light bulb,
rear light, left-hand forward (VBFS) 604 Solenoid valve, power take off, side
413R Light bulb,
rear light, right-hand forwward (VBFS) 605' Solenoid valve, power take off, rear
416-1 Light bulb,
side position light, left-hand forward 606 Solenoid valve, 2J4WD
416-2 Light bulb,
side position light, left-hand rear ..
· ·,607 Solenoid valve, high/low gear
417-1 Light bulb,
side position light, right-hand forward .",;,6 08 Pump unit, cab hoist
417-2 Light bulb,
side position light, right-hand rear . 609 Regulating motor, throttle
420 Light bulb,
position light, left-hand 610 Solenoid valve, hydraulics, general
421 Light bulb,
position light, right-hand 611 Solenoid valve, flow restriction
422 Light bulb,
direction indicator left-hand forward 613 Solenoid valve, torque amplifier
423 Light bulb,
direction indicator right-hand forward 614 Solenoid valve, ranging interlock
426 Light bulb,
direction indicator left-hand rear 615 Solenoid valve, wheel turning
427 Light bulb,
direction indicator right-hand rear 617 Solenoid valve, AT-regulator "by-pass"
428 Light bulb,
flashing beacon lamp 620 Solenoid valve, fifth wheel up
429 Light bulb,
cigarett lighter illumination 621 Solenoid valve, fifth wheel down
431 Light bulb,
instrument illumination 622 Solenoid valve, fifth wheel forward
432 Light bulb,
glove pocket light 623 Solenoid valve, fifth wheel rear
433 Light bulb,
step-in lighting 626 Solenoid valve, AT-regulator
434 Light bulb,
interior lighting 630 Solenoid valve, gear box, forward gear
435 Light bulb,
reading lighting 631 Solenoid valve, gear box, rear gear
436 Light bulb,
identification light 632 Solenoid valve, gear box, 1 gear
437 Light bulb,
identification light/roof sign 633 Solenoid valve, gear box, 2 gear
440 Light bulb,
heating control light 634 Solenoid valve, gear box, 3 gear
445 Light bulb,
extra direction indicator left 635 Solenoid valve, clamping pressure
446 Light bulb,
extra direction indicator right 638 Solenoid valve, stop injection pump
451 Light bulb,
fog light rear left 640 Solenoid valve, LPG
452 Light bulb,
fog light rear right 641 Solenoid valve, evaporator (LPG)
464 Light bulb,
electrical box lighting 642 Solenoid valve, parking brake
643 Solenoid valve, seat locking (VBFS)
500 Indicating lamp, direction indicator 644 Solenoid valve, fifth wheel locking
501 Indicating lamp, direction indicator extra 645 Magnetic clutch, compressor AC
503 Warning larnp, oil pressure engine 646 Solenoid valve. seat rotation
504 Indicating lamp, main beam 647 Solenoid valve, seat tilt
505 Warning lamp, loading 648 Solenoid valve, pneumatic springing
506 Warning lamp, loading extra 649 Thermostat, air condition
507 Warning lamp, brake 650-1 Wiper motor forward
508 Warning lamp, parking brake 650-2 Wiper motor rear
509 Warning lamp, coolant level 650-3 Wiper motor roof
510 Indicating lamp, ditt. interlock 650-4 Wiper motor roof (option)
512 Warning lamp, ternperature converter 651 Washer motor
514 Indicating lamp, overdrive clutch 652 Light motor
519 Indicating lamp, dipped lights 653 Light washer motor
524 Indicating lamp, air filter 654 Starter motor
547 Warning lamp, central warning 655 Cooling fan, main motor (EC)
528 Indicating larnp, preheating 656 Cooling fan, electrical box (EC)
549 Warning larnp, oil pressure gear box 657 Heating fan
550 Warning lamp, cab lock 658 Alternator extra
551 Warning lamp, temperature gear box 659 Alternator without loading regulator
552 Warning lamp, brake pressure 660 Alternator with loading regulator
554 Warning lamp, temperature cooling system brakes 661 Screenelevator motor
555 Warning lamp, temperature coolant engine 662 Loading regulator
556 Waming lamp, interlocking of turntable 663 Dosage pump, air condition
560 Waming lamp, temperature, drive motor 664 Circulating pump, air condition
561 Warning lamp, temperature, pump motor 665 Diode
, ...
" AppendiX"', '..
Technical Handbook Catalogue. of Components
670 Compressor 804 Cigarett lighter
685 Control unit, termostat AC ,. 805 'Electrical heating cab
690 Speed control (EC) 806 Aggregate, air conditioner
693 Pump, central lubrication 807 Potentiometer
695 Drive motor (EC) 808 Electrical heater air dryer
697 Electric brake 810 Condensor AC '
698 Pump motor (EC) 820 Resistor
699 Solenoid valve, option 825 Controls, (steering with control levers).
826 Valve, (steering with control levers).
700 Speedometer 830 Ignition coil
701 Gear box oil temperature gauge 835 Ignition plug
702 Clock 840 Distributor ".;,>
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34415
34432
A08899.0100 06
'.'\. .,'
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
Quality of diesel fuel 14
Coolant quality 14
Lubrication oil quality 14
Draining the water from the fuel tank 14
Inspection of air cleaner and changing
the filter element 14
Changing oil and oil filter 15
Checking V-belt tension 15
Changing and adjusting the valve clearances 16
Changing the fuel filters 16
Preventive maintenance on turbo-charger 17
Maintenance of exhaust-gas cleaner 17
{{Kalmar
~: . ContChamp DC-RS< .,,- ., .. 9129 96-03' 30 2
Technical Handbook Specifications' >,
..
•
..;."
Pub!. I Gr.1 P.
Coolant volume, I 46 48
Number of cylinders 6 6
Thermostat,
starts to open at °C 82 82
fully open at °C 95 95
;+10'C
22 -4 14 32 50 -0' E
**) Synthetic or semi-synthetic oil. N.S. Use only SAE 5W/30 oil.
{{Kalmar
ContChamJ)' DC-RS Engine' ..:; . 9129 96-03 30 3
Pub!. I Gr.1 P.
Technical Handbook Description' ._",
General
The engine TWD1 030ME or TWD1230ME is a 6-cylinder, -inline,
4-stroke diesel engine with overhead valves. The engine is
turbocharged, i.e. combustion air is supplied under pressure. As
a result, the quantity of fuel injected can be increased, which
increases the ~ngine output. The turbocharger is driven by the
exhaust gases and uses energy that would otherwise be lost.
1. Fan hub
2. Twin fuel filters of throw-away type
3. Lift eyelet 8 9 10 11 12
4. Gear driven coolant pump 13 14 15 16
5. Air cooled exhaust manifold
6. Turbo-charger
7. Lift eyelet
8. Coolant pipe, inlet
9. Pump coupling guard
10. Smoke limiter
11. Injection pump
12. Fuel pipes for tank connection
13. Relay for inlet manifold heater
14. Intercooler
15. Cable iron
16. Coolant pipe, outlet
17. Flywheel housing, SAE 1
18. Starter motor
19. Crankcase ventilation
20. Full-flow oil filters of spin-on typ
21. Oil cooler
22. Vibration damper
23. Automatic belt tensioner
17 18 19 20 21 22 23
,,
1. \Fan ,15,19
18 11
hub2120
91216
14 10 \ 22 23 8
I 13
10.
14.
15.
21.
5.
18.
19.
23.
6.
7.
8.
11.
13.
16.
9.
12.
17.
22. Turbo-charger
3.
20. Air
Smoke
Intercooler
Cable
Oil cooled
Starter
Coolant
Pump
Relay
Coolant cooler
Crankcase
Automatic
Injection
Fuel
Flywheel
Lift
Full-flow
Vibration limiter
iron
pipes exhaust
motor
coupling
eyeletforpipe,belt
pipe,
pump
inlet
housing,
oilfor
damperinlet manifold
ventilation
tensioner
outlet
tank
guard
manifold
filters SAE
ofconnection
heater
1
spin-on typ
Cooli.ng system
The engine is liquid-cooled and equipped with a closed cooling
system consisting of the following main components: .
• Thermostat
Radiator
Gearbox
Coolant fan
oilcooler
pump cooler
passages
Engine oil
•
2 3 4
1. Cooler
2. Coolant pump
3. Thermostat housing
4. Oil cooler
C{:Kalmar
ContChamp DC-RS:'. Engine-;;; 9129 96-03 '30"6
Technical Handbook Description . Pub\. I Gr.1 P.
•.-\. ..
KL496
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. This then
delivers fuel at ,high pressure' to the injectors which supply the
fuel in atomised form to the engine combustion chambers.
Spill valve - which restricts the fuel feed pressure and provides
continuous venting of the fuel system. Excess fuel flows through
the injection pump before returning to the tank, thus cooling the
fuel in the fuel chamber of the pump, which contributes to more
uniform distribution of the fuel to the various cylinders.
KL498
5
1. Fuel filter 4 6 7
6.
7.
3.
4. Fuel
Feedtank
Suction
5. Injection
Injector strainer
pump pump
9129 96-03 30 8 ..
Technical Handbook Description ,,"; Pub!. I Gr.1 P.
., \ 0(
Kl499
Fuel filter
4
5
KL196
Injector
'Engine,' ':', _ «Kalmar
, ContChamp DC-RS' 9129 96·03 30 9 .
Technical Handbook Description:, 'c,, __
.,:-,.,~1.";_
Pub!. I Gr.1 P.
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Lubrication system
'; The engine:is pressure-lubricated, and the oil is supplied I:>ya
'pump in the oil sump. Alllubricating9i1 flows through a double
full-flow filters.
1. Oil filter
2. By-pass valve
3. By-pass valve for oil cooler
4. Reducing valve
5. Oil cooler
6. Oil pump
7. Piston cooling valve
8. Oil under pressure to the
lubrication system
9. Oil under pressure for piston
cooling
Reducing valve - located just before the filter. The valve will
.open if the lubricating oil pressure is too high and will retur.n
excess oil back to the sump.
2 3
Lubrication system
Engine ' ... «Kalmar
.,ConIChamp·DC-RS··:· 9129 96-03 30 12 ,.
Technical Handbook Description '. Pub!. I Gr.1 P.
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 particles are disposed of through a particle ejector. The
second stage consists of a filter element - the main filter ele-
ment. Apressure indicator shows red sigDa! jf the pressure drop
in the filter exceeds approximately 500 mm water column. At
this point the filter insert should be replaced. A safety filter
element is located on the inside of the main element. The safety
element prevents the ingress of impurities into the engine while
the main element is being changed and if the main element
should sustain damage while the engine is running, e.g. due to
incorrect installation.
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1 2 3
1. Particle ejector
2. Air filter
3. Pressure drop indicator
Air cleaner
{<Kalmar
'ContChamp-DC-RS Engine.: :', 9129 96-03 30 13
Pub!. I Gr.1 P.
Technical Handbook Description .
.. ' \ ..
Turbocharger
The turbocharger supplies more air to the combustion cham-
bers than the engine would be capable of drawing naturally.
This enables the engine to burn more fuel which, in turn, increa-
ses the engine output.
1 The turbocharger consists ot' a turbine wheel and a centrifugal
compressor impeller, each with a separate casing but mounted
on a common shaft.
The exhaust gases provide the energy necessary for driving the
4 turbine wheel which, in turn, drives the compressor.
Intercooler
In intercooling, the air that has been compressed and heated by
the turbo is cooled in an intercooler.
1.
2.
3'.
4.
Intercooler
{<Kalmar
ContChamp DC-RSi Engine:"·~ .. 9129 96-03 30 14
Technical Handbook Service .' Pub!. I Gr.1 P.
Coolant, quality P.
Throughout the year, the coolant should consist of a mixture of
60% of water and 40% of ethylene glycol. The coolant should
be changed and the cooling system should be flushed once a
year.
The air pipe from the air cleaner to the engine" should be check-
ed for tightness from time to time. Minor leakage, such as that
caused by loose hose clips, and damaged or porous hoses may
cause dust to be drawn into the engine, which will give rise to
il~
costly engine wear.
The safety filter element must not be clean~d and reused. The
engine must not be run without the main "filter element. If the
main element must be cleaned and refitted in emergency cases,
don't use compressed air to clean it, since the filter element
may be damaged. Before refitting it, carefully check that the
main filter element is undamaged.
1. Remove the drain plug from the underside of the sump and
drain the oil.
2. Clean the area round the filters and place a tray under the
filters to collect any spillage.
4. Pour clean oil into the centre of the new filters, wait until the
oil has seeped through the filter paper and top up until the
filters are full.
7. Fill the engine with oil (see Group 90, Lubrication chart).
8. Run the engine and check that no oil leaks at the filters.
9. Stop the engine and check the oil level after a few minutes.
Top up as necessary to the MAX level on the dipstick.
'\
... .•
Valve clearances
4. Check that the new filters are perfectly clean and that the
seals are in good condition.
5. Fit the new filter canisters and tighten them by hand until the
seal is in contact with the seating surface. Then tighten them
a further half a turn.
I(LS06
{<Kalmar
ContChamp DC-RS Engine." 9129 96-03 3017
Technical Handbook Service Pub\. I Gr.1 p,
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«Kalmar
ContChamp- DC-RS 9129 96-03 40 1
Technical Handbook Contents Pub!. I Gr.1 P.
~,'\. .-'
Grupp 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 6
Checking pressures in the Clark 34000 gearbox _ 7
Drive axle 8
Description 8
WDB-system 11
Parking brake system 12
Service 13
Changing the drive-axle oil 13
Parking brake - initial adjustment 14
Compensation of lining wear 14
«Kalmar
ContChanip DC~RS~.' C' .- ". -;
.- --.'
9129 96-03 40 2
Technical Handbook Specifications Pub!. I Gr.1 P.
~.' \ o{-
Clutch type Multiple disc, hydraulic. Automatic wear compensation (no adjustment).
All clutches oil cooled and lubricated.
Oil filtration Full-flow oil filter with safety by-pass; also strainer screen in sump at
bottom of transmission case.
Drive axel
Model Rockwell PRC 5324 W4H
Brakesystem Wet disc brakes
Tightening torque
Drive axle mounting bolts, Nm 2350 (240 kpm)
Rim clamp nuts, Nm 402 (41 kpm)
Universal drive axle joint, Nm
- against gear box 99 (10 kpm) oiled screw
- against drive axle 115 (12 kpm) oiled screw
Kalmar
.1 '''"
ContChamp .DC-RS. Transmission:~: .' . 9129 96-03 40 3
Pub!. I Gr.1 P.
Technical Handbook Description .•'"""
~_." 1'-
Torque converter
The most important components of the torque converter are the
pump impeller, turbine wheel and stator. Engine power is
transmitted mechanically to the pump impeller. The impeller
starts an oil flow in the torque converter, and is comparable to a
centrifugal pump which draws oil into the centre and discharges
it at the periphery.
Gearbox
The gearbox is of constant-mesh type. Gear-changing is carried
out by clutch plates for the various gears being hydraulically
actuated.
•••• \ 0(-
6 ::
FORWARD
1:an
2:an---- ---
3:an- - -
4:an- ----
1. Pump impeller
2. Turbin wheel
3. Stator
4. Charging pump
5. Suction tube
6. From engine
7. Clutch plates
Gearbox Clark 34000
Transmission: «Kalmar
ContChamp. DC-RS 9129 96-03 4Q 5
Technical Handbook Description Pub!. I Gr.1 P.
Oil circuit
The function of the oil is:
When the engine is running, the oil pump draws oil through a
suction strainer from the gearbox sump and then delivers it
through a fine filter to a pressure regulating valve.
3
4
1. Converter 12
2. Oil cooler
3. Converter safety valve
4. Lube manifold
5. Automatic clutch release valve
6. Suction from transmission sump
7. Filter
8. Clutch pressure regulating valve
9. For
10. Direction selector valve
11. Rev
12. Speed selector valve
13. Pump
Valve housing of the Clark 34000 gearbox
Kalmar
ContChamp DC-RS" Transmission .,;;",._- - 1912996-03 40 6
Technical Handbook Service - ' ..";";'';'-' Pub!. I Gr.1 P.
3. Fit a new gasket to the suction strainer and fit the strainer.
4. Unscrew the filter bowl, remove the filter and fit a new filter
element.
8. Start the engine and run it at 500-600 r/min until the oil has
reached working temperature, and the hoses, cooler and
torque converter have been filled with oil.
9. Keep the engine running at idling speed, check the oil level
and top up to the MAX mark on the dipstick.
2
1. Suction strainer
Oil filter 2. Drain plug Oil filter
ContChamp DC-RS" Transmission .-;' ,,..Kalmar
9129 96-03 40 7
Technical Handbook Service , -r- Publ. I Gr.1 P.
~\
.•. ..
KlS13
1. Converter "out"
6 2. Clutch pressure port
3. 4th clutch pressure port
4. Fwd clutch
5. Rev clutch
6. Low (1st) speed clutch pressure port
o 7. 3rd speed clutch pressure port
The spur teeth of the sun gear (which floats) mesh with the
teeth of the planet spur gears. The planet spur gears rotate on
planet pins which are mounted in a spider. The planet spur
teeth, in turn, mesh with the teeth of the floating ring gear.
4
(
KL5"
1. Planet holder
7 2. Inser axle with sun wheel
3. Planet wheel
4. Axle end
5. Ring wheel
6. Ring wheel hub
7. Wheel hub
-< •..•
Kalmar
~ ..•...
ContChamp·DC-RS·.'· .Drive axle. :"i. .::. '. 9129 96-'Q3 40' 10'"
Technical Handbook Description- '~_'~ Pub!. I Gr.1 P.
1. Crown wheel
2. Radial roller bearing
3. Pinion
4. Tapered roller bearings for axial thrust
5. Parking brake assembly
5. Brake cylinder
7. Brake disc
Differential assembly
Kalmar
''''
ContChamp. DC-RS:: ' Drive.axle ~''';' " " 9129 96-03' 40 11
Technical Handbook Pub!. I Gr,l P.
Description- .~ __
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,
adjustment of the brakes is not required.
The brakes consist of a series of stationary and rotary discs
arranged altemately. The stationary discs are anchored (spli-
ned) to the brake housing. The friction discs fit between the
stationary discs and revolve with the wheel hub. Hydraulic
pressure supplied by the accumulator when the brake pedal is
operated' moves a large hydraulic piston outwards which in turn
pushes the discs together to slow the rotation of the re-volving
friction discs. This slows the motion of each wheel hub and
stops the vehicle.
The system is fully enclosed, thereby effectively excluding all
dirt and contamination.
I
01"'..-1
l)
I
(
6 •.
KL516
1 2
1. Drive the truck forward until the oil drain plug on one of the
wheel hub reductions is at its lowest point of travel.
Drain Refill 2. Remove the oil plug and drain the oil. Refit the plug.
5. Fill each reduction with fresh oil. The level indicator shall be
horisontal as shown on figure. Remove the filler plug and
top up with oil. Refit and tighten the filler plug Volume: See
Specifications.
6. Remove the level plug from the differential and fill the
Drive axle oil differential with oil. Refit and tighten the level plug. Volume:
See specifications.
) - 0..:.j~.
- .--- , :J.)
~ ;-.)~
Drive axle mounting bolts KL519
5. Turn the spring cap (3) until the total clearance between the
disc and the lining (2) is 0.5 mm.
7. Back up the nut (11) and lock it with the pin (13). The brake
is now ready for operation.
1 2
",' \ "
Group 60
Steered axle
Specifications 2
Steering axle 3
Description 3
Service 4
Replacement of steering cylinder 4
Replacement of knuckle pin bearings 4
.Replacement of steering wheel bearings 6
Miscellanous 7
.. ~.
,.-
.KKalmar
. ContChamp: DC-RS,~'::,' 9129 96-03 60 2
Pub!. I Gr.1 P.
Technical Handbook Specifications _;:
•... \ .{-
Tightening torques
Wheel nuts, Nm 400 (41 kpm)
Steered wheel bearing nuts, Nm 5001)
After tightening of steered wheel bearings, the truck should be run for
some 100 meters. After that1he bearing nut should be tightened again to
500 Nm. Then the bearing nut must not be loosened.
{<Kalmar
ContChamp DC-RS y Steering axle':' .',:. 9129 96-03 60 3
Technical Handbook Description ..._ Pub!. I Gr.1 P.
•... \ ...
The knuckle pins and wheel axles are mounted in taper roller
bearings. The hydraulic circuits of the steering system are
described in Group 70.
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_ 9
5. Fit the new cylinder and coat the mounting bolts with
LOCTITE.
6. Connect the piston rod ends to the link levers. Secure the
pivot spindles by means of the locking washers.
10. Remove the outer bearing races from the steering cradle
by means of an internal puller.
Note. If a suitable puller is not available, lugs for a
pulling tool may be welded to the inner race. The race
will then shrink and will be easier to remove.
KKalmar
ContChamp DC-RS' . Steering ·axle.'.-· 9129 96-03 60 5
Technical Handbook Service Pub!. I Gr.1 P.
•• \ 0(
~4
&----56
••••.
~
~
7
KL522
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 raGes so
that the larger inside diameter faces outwards.
5. Fit the upper bearing inner race (packed with grease), the
plain washer and the tab washer in position. Grease the tab
washer to ensure that it will not be damaged by the bearing
nut.
6. Tighten the lower bearing nut, see Data, and secure it with
a split pin.
7. Tighten the upper bearing nut, see Data. Release the lifting
device as the nut is tightened to ensure that the lifting
device does not prevent tightening.
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 ..
Assembly
1. Pack the outer races of the bearings with grease and
press them into the hub.
Note that these are taper bearings. Fit the inner races so
that the larger inside diameter faces outwards.
2. Press a new seal into the hub. Use a suitable round plate
for this purpose. Tapping the seal itself with a hammer will
damage it.
4. Tap the inner race of the inner bearing onto the wheel
axle, using a suitable tube. Pack the inner race with grease.
5. Lift the hub onto the axle, fit the inner race of the outer
bearing position and pack it with grease.
6. Fit the plain washer and bearing nut with the flat surface
facing inwards. Tighten the bearing nut, see Data.
7. Fit the tab washer and locknut. Grease the tab washer to
prevent damage by the nut. Tighten the locknut and lock
both the bearing nut and the locknut with the tabs.
Miscellaneous
The steered wheel alignment is not adjustable. If the link levers
have been deformed so that the wheel alignment has been
disturbed, the link levers must be replaced.
2 3 KL523
NOTE. The orientation of the link levers must be correct,
since they will otherwise be damaged by the wheels when
1. Steering cylinder the steering movements are large. The correct orientation
2. Wheel axle of the levers is shown in the figure.
3. Link lever
' .
.~,
•.1.
.. \
... :
.., ..~ Kalmar
ContChamp DC-RS 9129 96-03 .70 1
Technical Handbook Contents Pub!. I Gr.1 P.
Group 70
Hydraulic system
Specifications 2
Main hydraulics ,. 3
Description 3
Principle of the electro-hydraulic servo system __ 3
Main hydraulics, feed 5
Servo circuits 7
Lift 8
Telescoping of boom 9
Over-centre valve 9
. Service 10
Hydraulic fluid 10
Hydraulic oil filter 10
Breather filter 10
High pressure filter for the servo hydraulics 11
Steering system 12
Description 12
Steering valve 13
Priority valve 15
Hydraulic pumps 16
Description 16
Main valve 17
Description 17
Service 18
Main valve, adjusting the supply pressure 18
Brake system 19
Description 19
Brake system 19
Cooling circuit 20
Main components of the brake system 20
Hydraulic accumulators 23
Accumulator charging valve 24
Hydraulic brake pedal 25
Parking brake 26
Parking brake valve 26
Service 27
Adjusting the WDB brake system 27
Hydraulic cylinders 29
Service 29
Repairs to leaking hydraulic cylinders 29
Lifting cylinder 30
Telescoping cylinder, main boom 31
Damping cylinders, attachment 32
Side-shifting cylinders 33
Locking cylinders, twist-locks 34
Steering cylinder 35
Hydraulic system, vertical lift (components) 36
Hydraulic system, (components) 37
Diagrams
Hydraulic system, vertical lift ~ A 10205.0100
Hydraulic system A 10205.0200
{<Kalmar
ContChamp"DC ...RS'·'r':,'~,: . ..•. .... .. -- " ..
9129 96-03 70 2
Technical Handbook Specifications .~.; Pub!. I Gr.1 p,
General
The hydraulic system consists of the following sub-systems.
• Main hydraulics comprising
• Steering system
The amplified signal is then fed to the converters - one for each
lift and lower and a further two for boom out and in. The
converters are electrically controlled pressure reduction valves
which converts the electrical signal to a proportional hydraulic
servo pressure.
The pressure regulating valve for the servo circuit receives its
pressures from pump 1 or 4 and delivers 30-35 bar servo
pressure to the converters. An accumulator on the valve
ensures that servo pressure is available even if the engine
should temporarily stop.
~Kalmar
·ContChamp;CC-RS. ;. Mainhydraulics.:' ...' 9129 96·03'70 4
Technical Handbook Description:. :;: Pub!. I Gr.1 P.
.. \. ..
29 1
I
IPS 1~.lAI~.j,,"
I 32 '
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IIPS2.
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I
10 I a b 12 I a I b I I 23 a b I c d
I·
6
7 8
- 22-
KL524
Hydraulic system
({Kalmar
'ContChamp- DC-RS:' Main hydraulics: ' ... 9129 96-03 70 5
Technical Handbook Description' --.~_ Pub!. I Gr.1 P.
'.'\. "
Pump 1 feeds one main valve for lift and boom extension
together with a pressure regulator valve for the hydrauli~ servo.
Pump 2 feeds the brake system, see separate description.
Pump 3 feeds the other main valve for lift and boom extension
Both main valves are connected in parallel, both for the servo
and the main flow, which makes maximum use of the pump's
capacity for lift and boom extension.
The pumps draw hydraulic fluid from the hydraulic tank which is
located on the right hand side of the truck. The pressurized fluid
travels from the pumps to high pressure filters for cleaning
before circulating in the system.
<:) ,
4~ I:::J " ,I
, I
I
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12
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ee
: I
22
Kl525
•... \ "
11
Servo circuit
· '
«Kalmar
"ContCha'mp DC-RS.:'.':'.. :.;~ .J>. ' - Main.hydraulics,:..:-.L-: .. 9129 '96-03 70 8
Technical Handbook Description, ':.....
,.' Pub!. I Gr.1 P.
Lift
, The double-acting cylinders are, at the piston end equipped with
flange-mounted 2-way blocking valves, consisting of:
- Magnet valve
- Cover
When the lift cylinder is in the lowest position and the lift lever
not activated, the piston is held in the closed position by means
of spring pressure and by the pressure through the solenoid
valve. When lifting, hydraulic fluid is fed to inlet A, the solenoid
valve opens and dispreses the pressure to the tank. The
pressure on the piston is thereby relieved, which opens and
releases hydraulic fluid through outlet B to the lift cylinder. The
opening pressure is 2.5 bar.
The valve holds the load by means of the fluid pressure from
the lift cylinder to outlet B. The pressure flows via the check
1. Tank connection valve, through the solenoid valve as cut-off pressure and
2. Solenoid valve presses the piston to the closed position.
3. Check valves
The valves prevent communication between the lift cylinders,
4. Cut-off piston which in turn prevents twisting of the boom with uneven loads_
A. Feed from pump
B. Outlet to cylinder The lift cylinders are connected in parallel and fed from both
main valves with the combined capacity of the two hydraulic
Electrically controlled blocking valve pumps.
«Kalmar
ContChamp DC-RS', ' ::'oMainhydraulics::.;·,~·:', 9129 96-03' 70'9
Technical Handbook Description ',~'" Pub!. I Gr.1 P.
Telescoping of boom
The extension cylinder is fed with hydraulic pressure from'one
section of each main valve. The flow from two hydraulic pumps
is thereby utilized.
Main valve
An over-centre,valve is located in each of the feed lines. These
prevent the boom retracting too quickly due to the weight of the
load. They also act as a safeguard against hose fractures.
Over-centre valve
The over-centre valve contains a counter-pressure valve that
opens with the pilot pressure from the piston rod side of the
extension cylinder. A shuttle valve allows a free flow of hydrau-
Cylinder lic fluid to the extension cylinder with the BOOM OUT. For
BOOM IN the pressure on the piston rod side must increase to
at least 1.3 times the pressure created by the loaded piston.
Then the over-centre valve is opened by the pilot pressure and
Over-centre valve
the hydraulic fluid on the piston side can pass on the tank.
I
/
Telescoping of boom
{{Kalmar
ContChamp.DC-RS.'",~'- ;, .. i,." Main.hydraulics.;:.:·, .: 912996'03' 70'10
Technical Handbook Servica··, Pub\. IGr.1 P.
Hydraulic fluid
'. The hydraulic·fluid tank is located on the right-hand side of the
truck.
Check the fluid level on the fluid sight-glass, with all hydraulic
pistons in the bottom positions.
/
Top up the hydraulic fluid as necessary. See the Specification
for the oil grades.
1. Clean the outside of the filter and the area around it.
5. Replace the a-ring between the filter head and the bowl
and the a-rings on the adapter. The a-rings are packed
together with the filter cartridge.
6. Lubricate the a-ring for the filter head with hydraulic oil.
8. Carefully clean the filter bowl and fill it half-full with hydrau-
lic oil.
10. Start the engine to purge the system of air, and check that
the filter does not leak.
Breather filter
Change the breather filters every 1000 hours. In dusty
conditions, replacement may be necessary more frequently.
A clogged breather filter will cause pump cavitation and
drastically reduce the hydraulic pumps life time.
{{Kalmar
ContChamp DC-RS· _Main hydraulics',",~: 9129 96-03 70 11
Technical Handbook Service Pub!. I Gr.1 P.
".. \. ,,'
2. Fit a new cartridge, check the a-ring and refit the bottom
section of the housing.
Steering system
The steering system is supplied from hydraulic pump 4, which
. also supplies the main hydraulics for the attachment.
Steering valve
The steering valve is of the closed-center, non-reaction type
8a
with a load signal connection to the priority valve. The load
signal ensures load-dependent control of the flow from the
8b
11 I
priority valve to the steering valve. The closed-center feature
means that th~ valve shuts off the flow between the pump and
the tank when the valve is in the neutral position. This is neces-
sary to enable a load signal to be connected to the steering
valve.
W-.----. _.J
KL257
pump should cease, the steering valve will automatically per-
form as a manual pump, Le. some degree of emergency control
will still be available.
8. Steering valve
8a. Valve block
8b. Double shock valve with
suction valve
8c. Check valve
Shock valve
A valve block with built-in double shock and suction valves is
connected to the steering valve. The shock valves, opening at
200 bar, prevent pressure surges caused by blows against the
steered wheels from being propagated to the steering valve.
The suction valves open to prevent vacuum on the opposite
side of the piston, which could lead to cavitation.
6
7
26
23
KL259
22
25
Steering valve
«Kalmar
·ContChamp DC-RS:' Steering.system,,· ~.. 9129 96-03·70 15
Technical Handbook Description __
""._ Pub!. I Gr.1 P.
Priority valve
The priority valve distributes the oil flow from the pump so-that
the steering valve will always be supplied with an adequate
flow.
A certain pressure is always supplied from connection GF to the
steering valve ..When the steering wheel is operated, a load
signal LS will be fed back to the priority valve to reset the valve
spool. When the steering wheel valve is not operated, the entire
pump flow is diverted to the main hydraulics.
The valve spool is stabilised by an internal connection PP to the
supply line of the steering valve.
5 6
1. Tank connection
CF EF 'LS
I 2. Supply from pump
3. Plugged connection PP connected
f:--
Iv
pp,A-
>i(-l internally (see diagram below)
4. Load signal connection from
steering valve
5. Supply to main hydraulics
6. Supply to steering valve (priority flow)
L_ J
p T KL260
Priority valve
«Kalmar
ContChamp~DC-RS ' Hydraulic:pumps" '~; 9129 96-03' 70 16"
Technical Handbook Pub!. I Gr.1 P.
Description --";-'-
Hydraulic pumps
1. Replaceable cartridge assembly, icludes cam The hydraulic system is served by two vane-type pumps driven
ring, rotor, vanes, pins and sideplates by the take-off on the torque converter.
2. Front and rear sideplates
These pumps consist of a pump casing and a pump unit, and
3. Ball bearing
4. Front sideplate, is clamped axially by discharge are of simple design. A rotor in the pump unit comprises a
pressure to reduce internal leakage number of vanes fitted in radial slots. The rotor is driven by a
5. Double shaft seal shaft and' rotates in a cam ring. The rotor vanes follow the
6. Drain hole profile of the cam ring, and each vane performs two cycles -
7. Vane, is urged outward at suction ramp by pin each comprising one suction stroke and one delivery stroke -
force and centrifugal force per revolution. The fluid flows radially through the pump unit.
8. Cam ring
9. Suction ramp where unloaded ramp moves out The van~s are forced outwards towards the cam ring by centri-
10. Working vane on major arc pushes fluid to fugal force and by thrust pins which are subjected to the same
discharge port pressure as the pump delivery pressure. This ensures that the
11. Working vane on inor arc seals discharge vanes will alwqys be in contact with the cam profile. An fluid
pressure from the suction port film prevents the vanes from coming into metallic contact with
12. Discharge ramp where unloaded vane moves in the cam profile. In the same way, an fluid film prevents metallic
13. Pin cavity is at a steady pressure slightly higher
contact with the side plates.
than at discharge port
14. Lub side holes, lubricate the sideplatesurfaces Since the vanes, ports and pressures are balanced
15. Pressure pins, force the vanes outward diametrically, the net load on the rotor is a pure torque caused
16. Vanes
by the pumping action. Sturdy shaft bearings carry the forces
caused by the pump drive.
INLET
•
3 3
1
1
5
6
1516
13
14
~
11
SECTION A-A
Hydraulic pump
ContChamp. DC-RS /-. Main .valve;:l:-;:. ,--Kalmar
, I 9129 96-03 70' 17
Technical Handbook Description Pub!. I Gr. I P.
'." \ ..:
Main valve
The main valve:is a load-sensing, pressure-compensated'
:J
en . directional control valve of modular type. In the hydraulic sys-
x ...J
1,__ -a:I::f} __ .J 1
"5 - - - _1-1
~., II The inlet section is provided with a flow regulator (shunt valve),
IriIID-'--, _ main pressure limiting valve, a no-load relief valve and a redu-
I cing valve for the no-load relief signal line.·
-! -
.0
The main pressure limiting valve is pilot-controlled and opens
B the connection to the tank by moving the spool when the preset
pressure is reached.
The no-load relief valve returns the oil flow to the tank and
minimises the pressure losses when all the spools are in the
o
neutral position. The pressure drop between the tank inlet P
and the tank connection T is only approx. 4 bar. The operation
of the valve is such that, as soon as a function is actuated, the
flow to the no-load relief signal line will be interrupted. The no-
load relief valve then closes, and the regulator (shunt) at the
AI same time takes over and builds up a pump pressure of approx.
I 13 bar higher than the highest load pressure.
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:
The advantages of the wet disc brake system include the fact
that no adjustment is needed, and that no fading or wear occur.
Moreover, the enclosed oil bath keeps the system completely
free from water and impurities.
All circuits are supplied with hydraulic fluid under pressure from
the hydraulic pump. The brake circuits are supplied from
hydraulic accumulators and the cooling circuit is supplied
directly from the pump over the accumulator charging valve.
'" '\ y
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 retum lines ensures that the cooling oil pressure will not
exceed 1,5 bar, in order to protect the drive axle,
The supply fluid, and optionally also the retum fluid, is thorough-
ly filtered. Since the suction and return lines of the cooling
system are both connected to the tank, the total hydraulic oil
volume of the truck will be involved in cooling, which contributes
to the excellent cooling capacity of the system.
"~~:
~R ' N·L~--~tii
~~~ I __ ~
3i
I 4
u-,-
I
:
,
I
0"
CD
OJ
D)
J en
(') ~
I ~. (It
I .-
"'0'<
I
I
I o •.•
(It
:::!'.
::J CD
- 3,
I
1. Accumulator charging valve
i
! 2. Hydraulic pump 2, see A10205.0100
i 3. Pressure limiting valve
I 4. Accumulator discharge valve ,~
OJ 5. Accumulator
.., I ,
I»
~ ~~ I 6. Cooling circuit filter
CD
7. Brake cylinder
(II
'< IIi 12
, I
8. Brake discs
(II
..• 9. By-pass for drive axle protection
i
CD
-/ .>,
1 5
r
I
\
I
5
II
II
' •••
t', ...•I ••••I
~.~ ~ •• J
L:'
0., \ "
Hydraulic accumulators
. The brake system is equipped with two accumulators which
ensure that hydraulic fluid under pressure will always be availa-
ble for the brake system.
The accumulators are of piston type and are precharged with
nitrogen to a pressure of 95 bar for the WDS system.
An accumulator consists of a cylinder made of pressure-vessel
steel, an aluminium piston which is free to move along the
entire cylinder length, and two end covers - for the gas supply at
the top and for connection to the hydraulic system at the bot-
tom. The latter is of safety type and is impossible to remove
unless the gas pressure has been compJetely relieved.
The hydraulic connection is connected to the brake system and
to the tank. The tank connection can be opened by means of
the accumulator discharge valve, the key for which is suspen-
f ded adjacent to the valve.
1
2
3. Membrane
1. Connection
4 2.
5. Seal
4. Steel bottle
3 5 Safety plate
Accumulator
«Kalmar
ContChamp DC-RS ,., ." Brake system~::,~" 9129 96"03 '70 24
Technical Handbook Description Pub!. I Gr.1 P.
/
5
KL269
10
1. To brake system
2. Accumulator
3. Charging pressure adjusting screw
4. Pilot valve
5. Main valve
6. Check valve
7. Supply to cooling circuit
8. Tank connection
9. Accumulator connection
10. Pump connection
Accumulator charging valve
{<Kalmar
ContChamp.DC-RS Brake system ;"':: 9129 96-03 70 25
Pub!. I Gr.1 P.
Technical Handbook Description ;:;;':',
1. Housing
2. Control piston
3. Main pressure spring
4. Pedal stop
5. Return spring
6. Pilot pressure orifice
T 3
P 4
2
Brake pedal
«Kalmar
..ContChamp .DC-RS t:.· .," '" .Brake system;:~" 9129 96-03 70 26
Technical Handbook Description· .' \~;;;b\ Pub!. I Gr.1 P.
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.
When the parking brake is applied, the flow of oil to the brake
cylinder is interrupted and the oil in the cylinder is discharged to
the tank. The brake is then applied by the cylinder.
If the accumulator pressure should drop below 18 MPa, a
warning lamp will light up on the instrument panel.
10. Start the engine and run it until full pressure is achieved.
11. Stop the engine and check that the brakes can be applied '.
at least 8 times before the pressure drops t0130 bar. The
warning lamp for low brake pressure should also light up at
this pressure.
«Kalmar
ContChamp DC-RS," Hydraulic: cylinders:-,:,:" ; 9129 96-03 70 29
Technical Handbook Service Pub!. I Gr.1 P.
.~\. l'
CAUTION!
Never use compressed air for
removing the piston from the
cylinder. You could sustain
serious injuries.
1. Sealing ring .
2. Backing rings
3. Guide rings
4. Piston head
«K~lImar
,~,ContChamp-DC-RS~ ' " ,., , ,Hydraulic~cylinders.' ~. 9129 96-03 70 30' '
Technical Handbook Service Pub!. I Gr.1 P.
Lifting cylinder
-1: The Hfting cytinder is provided with bearings 'at both ends.'
The piston rod lug is threaded into the piston rod.
2. The cylinder head and the cylinder tube are provided with
mounting fl~nges joint together with hexagon-headed
screws.
1. Cylinder
2. Guide bearing
3. Retaining ring
4. Cylinder tube
5. Sealing kit
6. Guide ring
7. Piston seal
8. Guide ring
9. O-ring
10. Support ring
11. Piston rod seal
12. Wiper
13. Spacer ring
14. Piston rod
15. Cylinder head
16. Screw
17. Nut
18. Piston-rod bracket
Lifting cylinder
r<Kalmar
ContChamp DC-RS 9129 96-03 7031
Technical Handbook Pub!. I Gr.1 P.
, •••••• ,J~21 I CD 24
•..
25
3 ___
~~
I"~
I -- 17
14
13~ 1~ 1. Cylinder
~"" 2. Sealing kit
3. a-ring
4. a-ring
4a. Guide
5. Guide
6. a-ring
7. Piston sealing
8. a-ring
9. Piston rod seal
10. Guide
11. Wiper
12. Cylinder tube
13. Gable
14. Piston
15. Spacer
16. Support ring
17. Cylinder head
18. Guide bearing
19. Retaining ring
20. Piston rod
21. Screw
22. Stop screw
12
CD---- 16
23.
24.
25.
Screw
Bracket
Screw
8--<!)
,,,
22
,,,
15
,,,, KL489
,,
Telescoping cylinder
KKalmar
0"., :_ - ContChampDC-RS ':- h Hydraulic"cylinders~:;;:.. 9129 96-03 70 32
Technical Handbook Service Pub!. I Gr.1 P.
•••
••••
•••
••••••••
•••
•••••••
15 ""
Damping cylinder
KKalmar
ContChamp DC-RS Hydraulic cylinders ;.:. 9129 96-03 70 33
Technical Handbook Service h-+
Pub!. I Gr.1 P.
Side-shifting cylinders
. 1. The mounting lugs at both cylinder end and piston rod end
are provided with bearings. The piston rod mounting lug is
welded to the piston rod which, in turn, threaded to the
piston and locked with a .Iocking screw.
1. Cylinder
2. Cylinder tube
3. Retaining ring
4. Guide bearing
5. Lubricant nipple
6. Piston
7. Screw
8. Sealing kit
9. Piston sealing
10. O-ring
11. O-ring
12. Support ring
13. Piston rod sealing
14. Wiper
15. Spacer
16. Cylinder head
17. Piston rod
Side-shifting cylinder
ContCh'amp'DC-RS ',.,
«Kalmar
.Hydraulic cylinders, ';.. 912996-03 70 34
Technical Handbook Service' , . Pub!. I Gr.1 P.
~
2
1. Cylinder
2. Retaining ring
3. Bushing
7 4. Screw
5. Sealing kit
6. Piston sealing
7. O-ring
8. O-ring
11 ~ 9. Piston rod sealing
II 10.
11.
Wiper
Piston.
II 12. Piston rod
".. \ ..:
Steering cylinder
1. The steering cylinder has a double-acting piston, with the
piston seal in the centre.
.'
12
1. Steering cylinder
2. Piston rod
3. Cylinder tube
4. Tredor ring
5. Adaptor
6. Sealing kit
7. Piston seal
8. O-ring
9. Support ring
10. Piston rod seal
11. Wiper
12. Spacer ring
13. Cylinder head
14. Retaining ring
15. Washer
16. Screw
Steering cylinder
,,;.,.)' :..... ~
(Kalmar
.. ContChamp DC-RS" , .'", .. , "-' .. " ",:" '. 9129 96-03' 70 '36
Technical Handbook Diagram Pub!. I Gr.1 p,
1. Hydraulic pump
2. Hydraulic pump
3. Hydraulic pump
4, Hydraulic-pump
5. High pressure filter
6. Pressure reduction valve, servo system
7. Priority valve
8. Steering valve
9. Steering cylinder
10. Main valve 1
11. Converters
a. LIFT 1
b. LOWER 1
c. BOOM OUT 2
d. BOOM IN 2
e. BOOM OUT 1
f. BOOM IN 1
g. LIFT 2
h. LOWER 2
12. Main valve 2
13. lift cylinder
14. Blocking valve
15. Extension cylinder
16. Over-center valve
17. Solenoid valve, only RSS, limiting of LIFT pressure
18. Overflow valve, only RSS, limiting of LIFT pressure
19. Solenoid valve, only RSS, limiting of BOOM OUT pressure
20. Overflow valve, only RSS, limiting of BOOM OUT pressure
21. Shock valve
22. Hydraulic fluid tank
23. Pressure line to top lift
{<Kalmar
ContChamp DC-RS 9129 96-03 70 37
Technical Handbook Diagram Pub!. I Gr.1 P.
Hydraulic system
Components A 10205.0200
1. Hydraulic pump
2. Hydraulic pump
3. Hydraulic pump
4. Hydraulic pump
5. High pressure filter
6. Pressure reduction valve, servo system
7. Priority valve
8. Steering valve
9. Steering cylinder,
10. Main valve 1
11. Converters
a. LIFT 1 + LIFT 2
b. LOWER 1 + LOWER 2
c. BOOM OUT 2 + BOOM OUT 1
d. BOOM IN 2 + BOOM IN 1
12. Main valve 2
13. Lift cylinder
14. Blocking valve
15. Extension cylinder
16. Over-center valve
21. Shock valve
22. Hydraulic fluid tank
23. Pressure line to top lift
ContChamp -DC-RS
,--Kalmar
9129 96-03 -80 1
Technical Handbook Contents Publ. I Gr.1 P.
.,-\ \
Group 80
Specification 2
Boom with rotator 3
Description 3
Telescope-boom 3
Rotator 4
Service _~ 5
Checking lubrication 5
Checking boom fixtures, extension boom and
fixed boom 5
Checking sliding plates 5
Replacing sliding plates 7
Checking the gear clearance 7
Attachment 20
,.- .... 12400
15550
±800.
4575
17800
4575
12050
±800
17800
12400
4575
4160RS5
4171RS5
'4575
14799
14500
12200
16500
162504170
+185°/-95°
+185°/-95°
13200
15550
±800
14700
13300
5100 4180
+185°/-95°
16000
14700 mm +185°/-95°
12050
14500
ContChamp DC-RS: . Specifications , .~__
-,-,
'/ \. 't
Boom with rotator .. «Kalmar
ContChamp:DC-RS': . 9129-96·03 80 3
Technical Handbook Description- ,',-"",; Pub!. I Gr.1 p_
Telescope-boom
The telescope-boom of the ContChamp is made of highly'
resistant steel of a very sturdy design. The number of welds has
been kept to a minimum to ensure the highest possible
strength.
1. Fixed boom
2. Extension boom
3. Tilt cylinder
4. Rotator
Telescope boom
. -'.. ;Boom with rotator.:, ::. {(.Kalmar
Con'iCt1amp DC-RS' . 912996-03' 80 '4
Technical Handbook Description Pub!. I Gr.1 P.
Rotator
The rotator comprises an upper and a lower yoke connected to
each other by a gear wheel and and a powerful roller bearing,
which facilitate the rotation of the lower yoke in relation to the
upper yoke. The yoke is rotated by means of a hydraulic motor
provided with a. planetary gear and a multiple brake. The brake
is tightened by springs and discharged when the pressure,
needed for rotation, is built up.
1. Hydraulic motor
2, Planet gear
3. Gear ring
4. Gear
Rotator
«Kalmar
ContChamp DC-RS Boom with rotator, ',:', , 912996-03 80 5
Technical Handbook Service - Pub!. I Gr.1 p,
Checking lubrication
Check regularly that hoses and connections are undama§ed.
Also check that the lubricant actually reaches the point of
Warning! lubrication.
No service work on boom
and attachment is allowed Checking b.oom fixtures, extension boom and
when the engine is running~ fixed boom
1. Check all parts for damage or wear. Check the sliding
surfaces and sliding plates especially.
-+-
SNITT B-B
1. Sliding plates
> 15 I wom, so that the bolts damage the sliding surface, the
boom has to be dismounted for service.
Kl286
- If the sliding plates are worn on one side, the boom will
be exposed to torsional stress. Therefore it is important
to check the plates regularly.
1 f <2
J==~=-==-=--==--==t
Kl287
Kl4S:
1. Measure the gear clearance between the gear ring and the
gear wheel on the output shaft of the hydraulic motor. Max.
allowance: 0,3 mm.
- Loosen the bolts, which join the yoke and the gear ring.
Kl484
'.. \ "
«Kalmar
ContChamp DC-RS··· 9129 96-03 80
Pub!. I Gr.1 P.
Technical Handbook
Attachment
16.1152
Top lift 20'-40'
Attachment 20
Description 20
Top lift frame 20
Twist-locks 20
Top lift frame 21
Hydrauiic diagram, top lift frame, A05433.0100 01 _ 22
24 V supply to the top lift, A06521.0300 02 23
Service 24
Indicating lamps 24
Anlignment control 24
Safety interlocking system 24
Checking of ALIGNMENT indicating lamps
and electrical interlocking system 24
Light diodes for sensor monitoring 25
Inductive sensors 25
Sensor adjustment and check 25
Setting of the main pressure limiting valve 26
Components, A04454.0100 03 27
Electrical circuit, top lift
n. A04454.0100 03
Kalmar
~ ..•..
·ContChamp. DC-RS' " Attachments:'; , 912996-03 '80' 20
Technical Handbook Description Pub\. I Gr.1 P.
''''\. «
The top lift frame is pivot mounted in a cradle with sliding plates.
It is possible to sideshift the top-lift frame ±800 mm by means of
two hydraulic cylinders. The pivot mounting compensates for
uneven surfaces of up to ±4°.
Twist-locks
A spring loaded contact plate and a 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
have fully entered the container locking holes. The system also
makes it impossible to release the twist-locks during a lift. When
all four contact plates are depressed, the ALIGNMENT lamp
lights up. Only then is it permissible to lock the twist-lock.
.l
.~
4 21 6
f
I
KL138
i II
20.1
20.2
20.4 20.3 3
KL485
".-\ "
r - - - - - - - •. (
I - "\..6.)
I 5
3
~3
29
Z2
KL486
.. \ .-
KL487
A06521.0300 02
",,\ .
Indicating lamps
The top lift frames has a set of three indicating lamps for contai-
ner handling:
30A. Yellow left: TWIST-LOCKS LOCKED
30B. Yellow middle: ALIGNMENT
(The lamp will be extinguished at lifted container)
3OC. Red right: TWIST-LOCKS UNLOCKED
Alignment control
A spring-loaded contact plate and an inductive sensor at each
twist-lock is used for alignment control. The attachment is fully
The numbers correspond to the ,aligned onto the container when all pins have been depressed
electrical diagram, top-lift frame and the distance between each pin and sensor have decreased
to 4-5 mm. Then the indicating lamp ALIGNMENT lights up and
the twist-locks are ready for locking.
This will brake the minus feed to the twist-lock solenoid valve,
thus making it impossible to operate the twist-locks when lifting.
20.1 This electrical interlocking can, in emergency situations, be '
20.2 bridged by an override switch in the operator's cab. The override
switch will feed "false" alignment minus signal to the twist-lock
solenoid valve thus making it possible to operate the twist-locks.
A red warning lamp lights up in the operator's cab when the
electrical interlocking is bridged.
KLASS
27
Inductive sensors
The inductive sensors control the various functions of the
1 2 container attachments.
The sensors are of the type NPN - negative/positive/negative,
the last N indicating that the sensor produces a negative signal
when activated. The sensor is activated when a magnetic object
gets closer than approx 8 mm from the top of the sensor.
The sensor has two light diodes, one Green and one Yellow (or
Red), which can be used for checking of the sensor function.
Yellow - indicates 24 V plus and minus feed to the sensor
Green - minus signal from the sensor.
4-5 mm
Inductive sensor
ContChanip DC-RS Attachment ,- .."'"Kalmar
912996-03 '80 26
Technical Handbook Service Pub!. I Gr,1 p,
1 2. Start the engine, give full throttle and let the length .
adjustment go fully inwards. Check the pressure reading in
comparison'with the hydraulic system plate.
KL299
1. Test outlet
2. Adjusting screw, main pressure
limiting valve
Attachments .. «Kalmar
ContChamp DC-RS 912996-03 80 27
Technical Handbook Diagrams _.;:;z;c
Pub!. I Gr.1 P.
20. Sensors
1. Alignment right, front+rear
2. Alignment left, front+rear
3. Twist-locks locked, front, left+right
4. Twist-locks locked, rear, left+right
21. Sensor, engagement of low speed 300 mm before stop
22. Sensor, engagement stop at 30' and 35'
23. Solenoid valve, twist-locks
24. ·Solenoid valve, length adjustment 20-40'
25. Solenoid valve, engagement of nozzle for low speed
300 mm before stop
26. Working lights
27 . Terminal block, each side
28. Relays
1. Alignment right
2. Alignment left
3. Twist-locks locked
4. Twist-locks unlocked
5. Low speed 300 mm before stop
29. Main valve
X. Rotation 1. Clockwise
2. Anti-clockwise
W. Side shift 1. Right
2. Left
Z. Other hydraulic 1. Out
2. In
Y. Tilt 1. In
2. Out
30. Lamp panel on boom
A. Twist-locks locked
B. Alignment
C. Twist-lock unlocked
i:
{<Kalmar
· ContChampDC-RS ' 9129 96-03 90 1
Technical Handbook Contents PubL I Gr.1 P.
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 12
,;. . r<Kalmar
ContChamp'DC-RS ,:." ~'
• ,. "19129' 96-03 90 2
Technical Handbook Pub!. I Gr.1 P.
'.'\. ..
-,1[;'
{<Kalmar
ContChamp DC-RS 9129 96-03 90 2
Technical Handbook Pub!. I Gr.1 P.
'.'\' ..
.'\:
({Kalmar
ContChamp DC-RS 9129 96-'Q3 90' 3
Pub!. I Gr.1 P.
Technical Handbook Periodic supervisi9.!l-
'.'\ "
General survey
To extend the service life of the truck andto prevent the risk of
faults causing injury to personnel or damage to equipment, the
truck must be subjected to regular periodic supervision.
LUBRICATION -CHART
1 2 4 56
CONTO-tAMP
20,21
17 18 19 11 10 8,9 7 12
Refill
Brake
Planetary
gear
KL148
Sight
. 17 18 19 glass
15 13 16 14
KL146
«Kalmar
·ContChamp·DC-RS 9129 96-03 90 4
Technical Handbook Periodic supervisiQn Pub!. I Gr.1 P.
LUBRICATION 'CHART
1 2 3 4 56
CONTOiAMP
20,21
17 18 19 11 10 8,9 7 12
Refill
Brake
Planetary
gear
KL148
Sight
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17 18 19 15 13 i614
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9129 96"-03 90 5
Technical Handbook Periodic supervision
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LUBRICATION CHART
Drive
Ufting
DamperC
Gearbox
Link 600
Knuc~e
3
2Doints
4
xx1mounting
Remove,
Engine
Hydraulic
Breather
Steered
Cooling
Engine
Item Boom x)
Change
Slide
Propeller
Top
Pinion
Rotator
Door
2
Rotator axle
levers
1000 oil
filter
mountinQ
Change
Brush
CheckChange
oil
oil
oil
wheel
plates,
and
nipples
and
and
reduction
cylinder clean,
filters,
oil
filter 2
1bearing
xRemarks
x) No
Change
Description
shaftfilter,
cylinders
pin filter
the
bottom
boom
bearings
on panel
the ring
with
onleveLevery
bearings of
lub.
inspect
hydraulic
hydraulic
filter
filter
oilTop
oil.
each
gear
grease
hinaes
gear 46243 tank
the
2000
every
Check
side
up hoil
and
brake
to 400
the x)
theevery
pack Change
xL
Con by
2000
(operating
h
level
Brush
red with
system
at
point hthe
hours)
hand, Intervals
xoil every
with 200
x boom
the h ') grease
in24the every
Lift4000
on the h doors
sight
off the glasses
and 2)panels
fully
grease
idling
x)
xx) extended
First every
speed
Thereafter
oil changeposition
4000 ath warranty
oil change everyservice1000 h
1) The interval is greatly dependent on the fuel and lubricant quality as well as the operating conditions.
If intervals longer than 200 hours are desired, the condition of the oil must be checked by the company making the oil,
by means of regular lubricant tests.
2) Note! Different oils in brake and planetary gear. (Volume brake: 0.3 I. Volume gear: 3.2 I)
L=Lubricate
C=Check
NOTE!
If the truck is s~anding unused outdoors, with After they have been washed with degreasing
the piston rods protruding, all piston rods agent, all pistons should be moved backwards
must be greased to prevent co"osion. and forwards several times to obtain a new
protective oil film.
«Kalmar
:.~~'ContChampDC~RS'. ,:..' - , ~ " • < -" •
.. 9129 96-03 90 6'
Technical Handbook Periodic supervisi~J) Pub!. I Gr.1 P.
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A
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7 7
8 8
9 9
11 7 10 11
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Technical Handbook Periodic supervision
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L=Lubricate
C=Check
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9129 96·03 '90 8 '
Technical Handbook Periodic supervisi~~_" Pub!. I Gr.1 p,
Daily supervision
..
' ,
Check requirec;1
. .Or
'"
.~-,
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"".~
"
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Refill
when if Check
Damagethat the
Operation rear
Operation suspension is' clean
,
L Y SUPERVISION I
pension
d with
stem) and sliding plates
, .,t, •.,." •
----~
Gearbox oil
Wipers
Wheels
.'• Level
. Fluid level
Damages?
< ••
Tyre pressure 0,9 MPa
«Kalmar
ContChamp DC-RS' 9129 96-03 90 8 .
Technical Handbook Periodic supervision ..: PubL I Gr.1 P.
'.\0 •.
Daily supervision
uments.
Brakes DAIL Y
• '.
• •
Operation
Tyre
Level
.u
. Check
Level
Fluid
, Damages?
SUPERVISION
pressure
..
level
refueling
0,9
require9 . ••
'.. •
MPa
Or- when
Refill if Indicator
Amount
Check
Noises?
Level that the
Operation
. suspension
Damage
Oil leakage? rear
is clean
Must never
detem)
axle
with
ension show ."0 The
and
Boom,fuelpivot
sliding
Blinkers, meter
plates
suspension
brake lights, horn
, -
.. ',
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.
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Remarks
).;. ContChamp.DC-RS',
Radiator
Gear
Air
V~belts
Brakes
Steered
Drive
Truck
Inductive
(Air
(Exhaust box
cleaner
axle
Lubrication
Telescope
Battery
Engine andand
conditioner)
Steering gas
axle Clean
Wash
Check
drivenandCheck
sensors
points,
cables,
boom oilCheck
the
top Action
replace
Inspect
up
Tighten the
the
bolted
Check for
the
as
the
for ",
fins
Note!
oil
belt
terminals
joints. of
and
indicator.
cabies
oil
tyres
play, Ifthe
Specifications
See
setting
petroleum leakage.
and
necessary.
the
boltperformance
See
catalyst
damage.
jelly.
leakage
60
wheel
joints and
high-pressure.
GroupDo
tension
Check
damage
Group rims
!Specifications
~..'p
_\_:.4~;~ --,
not
coolant use
Replace
70.
apply
terminals.
and30.
80
40
30
10
. necessary,
nuts high-
sliding-
for resp
Retighten
Periodic supervisiQ!1
accordance
lubricant.
Lubrication
and
Test
bearingfilter
ifplates
required.
pressurebrake with
chart.
changes tne
performance.
forhousings
wear.
on in or
Apply
bearings special ~-" \. t{
5
6 Item Unit
N.B. Always attend to any damage, wear or faults that are important to the performance of
the truck and its service life or the safety of the personnel.
({Kalmar
;J~~'Cont,~hamp~DC-RS".
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Technical Handbook Periodic supervisiC?i1
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N:B. Always attend to any damage, wear or faults that are important to the performance of
the truck and its service life or the safety of the persormel.
/
«Kalmar:.': .
.' ContChamp DC,;,RS' 9129 96·03 90 ;10
Technical Handbook Pub!. 1G'r.I· P.
N.B.Always.'attend to any damage, wear orfau!ts that are important to the performance of
the truck and its service life. or the safety of the personnel.
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Wheels
V-belts
Fuel
Batteries
tank shaft
filter
Propeller
Injectors 3
7 Drain€;,
468
9 Change the filter. Bleed the
5 fuel system.
Check.
Touch up
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Hydraulsystem
Hydraulic system
DIRECTION OF TRAVEL
KORRIKTNING
•
VANSTER ~
LEFT I ---..HOGER
RIGHT
;
-
s
rs
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20
s """
I
WI SIDOFORING HO
II I
W2
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SIDOFORING VA
OVRIG HYDR UT
II I
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: I I YI TILT IN (GALlER VID BOTTENLYFT)
\I Y2 TILT UT (GALLER VIO BOTTENLYFT)
'f II
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I II
I II
I II
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B ANLIGGNING
C Ol'f'[N tWl51LOCK
A04454.0100 03
Numreringen ar gemensam med hydraulschema A05433.01 00
The numbers correspond to the hydraulic diagram A05433.01 00 Eischema, topplyft
Circuit diagram, top lift
DIRECTION OF TRAVEL
KORRIKTNING
•
VANSTER ~
LEFT I ---..HOGER
RIGHT
~
-
s
rs
~S
20
s
-----------
-----------
-----------
-----------
I~-------------
1-,... -=- -=- :: .. : .. : .. :. -=- -=- ::. ::. ::. J~ •
II
II
II .,
I I 29 I XI VRIDNING MU
II I
X2 VRIDNING MOTU
II I
WI SIDOFORING HO
II I
W2
ZI
SIDOFORING V~
eVRIG HYOR UT
II I
Z2 eVRIG HYOR IN
II I YI TILT IN (G~LlER VIO BOTTENLYFT)
\I Y2 TILT UT (G~LLER VIO BOTTENLYFT)
II II
-I~ II
I II
I II
I II
I II
-.- - --' II
I'
II
26 ,'---
- - - ;-, "II
II 30
A LAST TWISTLOCK
B ANLIGGNING
C OI'PEN tW151LOCK
A04454.0100 03
Numreringen ar gemensam med hydraulschema A05433.01 00
The numbers correspond to the hydraulic diagram A05433.01 00 Eischema, topplyft
Circuit diagram, top lift