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«Kalmar

'ContChamp. DC-RS .. 912996-03 00 1


Technical Handbook Contents Pub!. I Gr.1 P.

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··

• Follow the local safety regulations.

• 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.

• Do not exceed the lifting capacity of the truck.

• 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.

• The brake system is equipped with accumulators charged to a pressure of up to 21 MPa. To


prevent accidents when working on the brake system, never disconnect any component without
previously relieving the accumulator pressure by means of the accumulator discharge valve.

• 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.

Safety instructions for working with tyres

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.

To special order, the trucks are equipped with hydraulically


powered sliding cab.

DC 4160 RS with 20-40' adjustable top lift


«Kalmar
ContChamp DC-RS' 9129 96-03 {)O 5
Technical Handbook General Pub!. I Gr.1 P.

The Volvo six-cylinder turbocharged engine, combined with a


four-speed gearbox with torque converter, provides smooth
power whenever needed.

The drive axle with hub reduction, oil-cooled hydraulic Qrake


system and pendulum-mourited steered axle with double-acting
steering cylinder satisfy very strict demands on strength and
mobility when travelling on irregular surfaces.

The hydraulic system is reliable and has high performance. It


comprises four hydraulic pumps that supply:
- Lift, boom extension, steering, attachment functions and the
hydraulic servo system ...

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.

• Clearly arranged instrument panel, with a circuit board for


fuses and relays.

• Engine - Volvo TWD 1030 ME alt TWD 1230 ME six-cylin-


der, four-stroke, turbocharged diesel engine with direct
injection and thermostatically controlled water cooling.

The engine is equipped with:


- Injection pump with centrifugal governor that compensates
for load variations.
- Alternator.

• Gearbox with torque converter


- Constant-mesh gearbox changes by means of
hydraulically activated clutches which are electrically
operated.
- Torque converter, which is a hydraulic coupling that
amplifies the output torque on an increase in load. Torque
conversion takes place smoothly and steplessly throug-
hout the engine speed range.
- Oil cooler connected to the engine cooling system fO,r
cooling the oil in the gearbox and torque converter.
- Oil pump which supplies oil under pressure to the gearbox
and torque converter.
- Full-flow oil filter for effective cleaning of the gearbox oil.

• Drive axle with two-stage reduction - in the differential and


the hub reductions.
- Hydraulic, oil cooled disk brakes - wet disk brakes - for
the foot brake.
- Disc type parking brake applied by sturdy springs and
released by hydraulic oil pressure.
(Kalmar
.., ContChampDC-RS' 9129 96-03 00 6
Technical Handbook General Pub\. I Gr.1 P.

•... \ "

• Hydraulic system with


- Four ving-type hydraulic pumps connected to take-offs on
the torque converter. The pumps feed:
- LIFT 1, BOOM OUT 1, hydraulic servo
- LIFT 2, BOOM OUT 2
- Steering system, attachment, hydraulic servo
- Brake system
- Main valves for controlling the main hydraulics. The valves
are controlled by an electro-hydraulic servo system from
the cab. An electro-hydraulic servo system is available as
an option.
- High pressure filters for effective cleaning of the hydraulic
fluid before it is returned to the tank.
- Priority valve giving priority to the steering system when
required. Used as a flow divider and supplies also the
attachment.
- Steering valve (Orbitrol) - flow-control valve which supplies
hydraulic fluid to the steering cylinder.

• Steered axle with pendulum mounting and double-acting


steering cylinder.

• Lift cylinders equipped with stop valves, which eliminate any


undesirable sinking of the load.

• Boom of a slender, high-tensile steel construction. The boom


is pivot-mounted and comprises a fixed and a telescope
section manoeuvered by means of a double-acting exten-
sion cylinder.

• Top-lift attachment, adjustable for handling 20 and 40 foot


containers.

• Safety system, which supervises loading and guards both


forward tipping and overloading of the steering axle at the
rear. The system is connected to a panel in the operator's
cab and indicates the loading conditions.
«Kalmar
·ContChampDC-RS ,.' General
912996-03' 00 7
Technical Handbook - Pub\. I Gr.1 P.

Main components

I ~t-5~
0 ,-•
u-x
>1- -~
•... •o{")
c_
..-0Q.
0
c::I
0en00 0•
,-
0 ..-CD
0.> ~~oz ••Gearbox
•~ ~
-~>1-
C> •...
00
a:a..
-CD
..- ::I
~ 00
Drive .!::
C..-
axle ::II-
,~
~o
C\I
C')enD
enD
ca"-
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0-1~LO
•...
caO
oa:
u~en
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,~ caO
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en"-
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CD~o6
7
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E<{ in
•..• ([LO
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.

Spare parts catalogue


Instruction Manual for the Volvo TWD 1030 ME alt
TWD 1230 ME
Workshop Manual for the Volvo
Workshop Manual for the Clark 34000 transmission.

Replacement system - Spare parts


Kalmar LMV operates a system of replacement parts, repair kits
and gasket sets covering most of the vital components of the
truck.
For the contents of these kits, see the Spare parts catalogue.

Tools
Kalmar LMV offers a wide range of tools for truck maintenance
work.

For further information, please contact Kalmar LVM's service


department.
«Kalmar
<;':. ContChamp-DC-RS.:::· 912996-03 '00 8
Technical Handbook General Pub!. I Gr.1 P.

Tightening torques
(According to Kalmar LMV K Standards 20060.0001)

The tightening torques are applicable to steel bolts and nuts


tightened with a torque wrench under the following conditions:

Surface treatment
Condition Lubrication

Bolt Nut

1 untreated untreated oiled

bright galvanised untreated


2 bright galvanised bright galvanised dry or oiled
bright galvanised hot-dip galvanised

3 hot-dip galvanised untreated dry or oiled

The values sp-ecified in Table 1 are applicable to nut-and-bolt


joints, but can also be used for bolts fitted into tapped holes:
However, in the latter case, the preloading force will be some-
what lower, depending on its depth of engagement.

When tightening by machine, the torque specified in Table 1


should be reduced by approx. 5%, due to the increased scatter
and to prevent the bolt from being tightened beyond its yield
point.

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

Top lift frame


Electro-hydraulically operated,
2Q-40 foot top lift frame, with
±800 mm sideshifting
and ±90o: rotation

Outer boom

Operator's cab
,

Rubber suspended
I

Emergency safety cab,


,
fixed or
exit moveable lengthways
on trucks with
hydraulically
powered sliding cab

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.

The standard heating system consists of a fan and heater for


heating the air in the cab by recirculation. Fresh air is drawn in
through a ventilation air filter. Full air conditioning, with cooling,
heating and dehumidification, is available ~o special order.

1. Control lever and switches for


hydraulic functions I

2. Steering column with instrument panel


including warning lamp~ and switches
for the electrical syste~

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

1. Gear selector FORWARD/· 10. Brake pedals, normal driving brake


NEUTRAUREVERSE1/~~4 11. Release clutch
2. Lever DIRECTION INDICATORS/ 12. Accelerator pedal
HORN/WINDSCREEN WASHER 13. Steering wheel adjustment
FORWARD/FRONT WIPERS/MAIN BEAM 14. Parking brake
3. Warnings lamps 15. Stop control
4. Control panel, overload indicating system 16. Servo circuit breaker
5. Switches
17. Control lever and control panel for
6. Starting switch hydraulic functions
7. Fuses
19. Control panel with micro steering wheel
8. Heating (Air conditioning available and gear selectors 1)
as extra equipment)
1) Optional equipment
9. Operator's seat
({Kalmar
CoritChamp ·DC-RS' <, "., .. , , .Chassh-.:. ~... 9129 '96·03 10 6
Technical Handbook Description Pub!. I Gr.\ P.

21 22 23 24 25

DD~¢ ®4;+
~$.~-
26 27 2~ §D
29 ~30

(I)
31
raT
32
¥~
I~
33
I
34
RPM
35

21. Warning lamp, battery charging 36. Switch, working lights


22.- I 37. Switch, working lights 1)
23. Indicating lamp, direction indicators 38. Switch, working lights 1)
24. Warning lamp, parking b~ake ON 39. Switch, flashing beacon
25. Warning lamp, low engine oil pressure 40. Switch, hazard warning lights
26. Warning lamp, high engine coolant 41. Switch, driving lights and instrument
temperature I
illumination
27. Warning lamp, low gearbox oil pressure 42. Switch, fan 0/1/11
28. Warning lamp, high gearbox oil temperature 43. Switch, air conditioning
29. Indicating lamp, headlights
I 44 Switch, windscreen wiper rear
30. Spare
31. Warning lamp, low brake pressure - Switched off .
32. Indicating lamp, engine preheating - Intermittent wiping
33. Warning lamp, low engine coolant level - Continuous wiping
34. Warning lamp, high cooling oil
temperature (wet disc brake system) 45. Switch, windscreen wiper roof
35. Spare I

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).

~D~~I: Unlocking of twist-locks,


see Joystick
I
function 1 above.
17. Stop at 30' and 35'
18. Cab movement

AUT
I
Stop
I®I 30' 35'

Button 17 for the connectio'n and disconnection


of the 3D' and 35' stops I

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.

.~ \ «

Overload safety system Overload indication


Forward overload
Forward overload
Red area: Stop for Lift,
Lower, Boom out. Red lamp: Stop for Lift,
R/TOH Lower, Boom out.
Buzzer sound.
OKtot Boom in. Other lamps go out.
OK for Boom in.

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

Lamp panel on the boom


Container handling
A. Twist-locks locked, yellow
B. Alignment, yellow I
KL440
C. Twist-locks unlocked, red
I

Lit lamps at container lift: I


A+B
Go out after lift: B

Engagement and
disengagement
of servo circuits

Dead mans handle

Warning! I

Overriding of the safety system Override


is at one's own risk and involves (Only in emergency
situations) Ii
a risk of forward tipping. I
1. Lower i/
/'1U.I1,.
2. Container coupling
, -' Chassi,': ({Kalmar
ContChampDC-RS" 9129 96-03 10 9
Technical Handbook Description. _~.. Pub!. I Gr.1 P.
',.. \ "

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.

Hydraulics control unit


. Control lever and switches used to manoeuvre the hydrauiics
system are located on an adjustable console fitted with locking
handle to achieve the most comfortable working position.

L, ----- The control lever is a joystick that is electrohydraulically


connected to the main valves.

\
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.

Changing the fresh air filter I

(every 1000 hours) I

• Remove the filter casing retaining bolts and remove the filter
element.

• Fit a new filter element.


. Air
~ condition,
~. ".-,:,- .. , , {<Kalmar
J . ContChamp DC-RS· " "....' ." , .: .-\.
9129' 96-03 1012
Technical Handbook Description. Pub\. I Gr.1 P.

Air conditioning unit


The air conditioning unit consists of the parts shown in the iIIu-
strationand its function is to maintain the climate in the ope-
rator's cab as comfortable as possible. The air conditioning unit:
• heats the air when it is cold
• dehumidifies the air when' it is humid
• removes· impurities from the air
• cools the air when it is warm
The air conditioning unit is controlled by means of switches on
the instrument panel and controls on the fan casing below the
instrument panel.

Different phases of the refrigerant


A - - - High-pressure,1 gaseous •
B -- High-pressure,lliquid ~
I :::ob' .~
C -- Low-pressure, liquid (from expansion
vessel to evapbrator
I
coil)
D -.-.- Low-pressure, I,gaseous
2

KL1S4

1. Liquid receiver with filter-dryer


2. Evaporator coil
3. Fan
4. Expansion valve
5. Fan
6. Condensor
7. Engine-driven compressor with
electro-magnetic
8. Belt tensioner

Air conditioning unit


(.Kalmar
ContChampDC-RS . Air condition.:' \. 9129 96-03 10 13
Technical Handbook Description Pub!. I Gr.1 P.

I1II 1II I

~I

/
Tl

iJ . iJ
~(fffff'((ff('ffffm1ifrfr~\II

/.
~
I-

~
,
•.
~~~
~

~
3
IB I) !<'

I1II IIII

@
~

/ @
I
6 ,(W~1'(ff'11'r( I 11111111

G
KL185

1. Liquid receiver/filter dryer A High-pressure gas


2. Evaporator B High-pressure liquid
3. Fan C Low-pressure liquid
4. Expansion valve D Low-pressure gas
6. Condenser E Warm air in cab
7. Compressor F Cooled air to the cab I
G Outside air for removing ~eat

Function of refrigerant circuit


Itlon.:::, ..'~.,
A"Ir con d""' {(Kalmar
~, ContChamp DC-RS " 9129 96-03 to'14'
Technical Handbook Description', - Pub!. I Gr.1 P.

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. .

The compressor is driven by V-belts directly from the diesel


engine. Switching between operation and idling is controlled by
an electro-magnetic clutch which, in turn, is controlled by a
thermostat whose sensor is located between the fins of the
evaporator coil. The thermostat switches off the compressor at
low temperatures, to prevent icing of the evaporator.

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.

The temperature of the refrigerant in the condenser varies from


about +50°C to +70°C. The pressure varies between 12 and 20
bar, depending on the ambient temperature and the flow of air
through the condenser. When the refrigerant is condensed into
liquid form, it is transferred under pressure to the liquid receiver/
filter dryer.

Liquid receiver with filter-dryer


The function of the liquid receiver with integrated filter dryer is to
collect the liquid coolant, bind the moisture, and to filter and
remove impurities. The receiver, which is located in the conden-
ser housing, also serves as the expansion vessel in the refrige-
ration circuit.

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.

The expansion valve is also the part of the circuit which


separates the high- pressure side from the low-pressure side.
The refrigerant flows to the expansion valve under high
pressure and leaves it under low pressure.

The amount of refrigerant which passes the evaporator varies,


depending on the thermal load. The valve operates from 'fully
open' to 'fully closed' and in-between searches for a pOint to
give optimum evaporation.

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.

In the evaporator, the refrigerant reverts to the gaseous state


and returns to the compressor suction, thereby completing the
cycle.
{{Kalmar
ContChamp DC-RS Air condition:; . , 9129 96-03 10 15
Technical Handbook Service Pub!. I Gr-I P.

'
... \ "

The liquid refrigerant should be completely evaporated before it


is allowed to flow from the evaporator. The refrigerant is still
cold even when it has completely evaporated. The cold vapour
which flows through what remains of the evaporator continues
to absorb heat, and then becomes overheated. This means that
CAUTION
the temperature of the refrigerant h~s risen to above th~ point
• If the refrigerant hose should fail or if where it evaporates without changing the pressure.
otherrefrigerant leakage should occur,
switch off the air conditioner immediately. -In an evaporator which operates at a suction pressure of 2 bar,
the liquid refrigerant will have a temperature of -1.1 °C. When
• Refrigerant is injurious to the skin and the refrigerant is subsequently evaporated through heat absorp-
eyes. tion in the
" -
evaporator, the temperatJre
I
of the
'
gas will rise at the
evaporator outlet to + 1.6°C. This represents a difference of
• Never release refrigerant in an enclosed 2.7°C between the evaporation temperature and the tem-
space. If released into a service pit, for perature at the outlet. This is called overheating.
instance, the gas may cause asphyxia.
All expansion valves should be adjukted at the plant in such a
• It is forbidden by law to discharge way that maximum evaporation with' overheating is performed in
refrigerants into the air the air conditioning system. I

intentionally.

• Never carry out welding on a charged


refrigeration system or in its vicinity.
Checking the air conditioni~g unit
If the unit is in continuous operation! this check should be
o Only authorised service mechanics are
carried out every week from early spring to late autumn and
allowed to drain off and fill
during extended periods of high hurflidity during the winter.
refrigerant in the air conditioning system.
I

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.

1. Start the engine and start the air:conditioner.


I

At an outdoor temperature below aoc, the system cannot


start since the low-pressure relay breaks contact.

2. After 1a minutes of operation, check that no bubbles are


visible in the sight glass of the filter-dryer. (Bubbles should
occur only when the compressor I is started and stopped.)
I

If there are any air bubbles, subsequent filling should be


performed by an authorised serviceI mechanic.

3. Check that the condenser is not bogged. If necessary, clean


the condenser fins with compres1sed
I
air.

4. Change the fresh air filter as ne~essary.

5. Check the V-belt tension and thJI compressor mounting.

6. Check that the magnetic couplinb engages and disengages


satisfactorily. i

7. Check that the condensate drain from the cooling element is


not clogged. Check for leakage. I

I
I
Air condition. ..- : ~ {<Kalmar
ContChamp DC-RS .'. ' . 912996-0310 16
Technical Handbook Service .. Pub!. I Gr.1 P.

".. \ "

IN CAB UNIT CONDENSER UNIT


I

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

301 It" 187


2
GL 1,5 85

---
~
l~ ~
ffi_, ~_

311~ VT 1,5

1. Fan switch
2. Cooler onfoff
3. Anti-freeze thermostat

4.
5. Resistor
Fan motor
i
I

6. Indicator lamp cold (in push button)


7. High-flow-pressure monitor
I

8. Relay
9. Condenser
10. Compressorfan I

Circuit diagram in cab climate unit/condenser unit


,-".
«Kalmar
ContChamp DC-RS Contents
In 9129 96-03 20 1
Pub!. I Gr.1 P.
Technical Handbook

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

Component list for A08334.0300 01 and A08333.0500 02


Electrical system DC 9-90, outer I A08334.0300 01
Electrical system DC 9-90, inner I A08333.0500 02
Electric servo for machine RS, container A21531.0100 02
Electric servo for machine RS, vertical lift, container A21533.0100 02
Electric servo for machine RS5, container A21535.0100 02
Manual electric gear-changing system,
Clark 34000/36000 A08118.0100 05
Automatic electric gear-changing system,
Clark 34000/36000 A08899.0100 06
, Kalmar
.•.~
ContCham'pDC-RS~~·:':
... > • ':-."
., ..
.. .•, 9129 96-03 20 2'
Technical Handbook Specifications Pub!. IGr.1 P.

AlternatorI rating 1540 W

Starting! battery voltage 24 V (2 x 12 V)


capacity 135 Ah
e~rthing negative
I

Control unit IPS


10% max.
Ripple I
Continuous load per channel 10 A max.
External fuse 8A
Overvoltage protection >33 V
Adjustment ranges
Starting current 100 - 400 mA
Difference between starting
and
I
closing current o - 850 mA
Max. current adjusted individually for each
i function
Fuse 3 A
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

Recommended return pressure P, = 0.1 - 0.2 MPa


I

Solenoid coil resistance Rv = 270 Q


I
Inductance L = 0.32 H
I

Maximu~ output flow qout= approx. 10 I/min

Lea kageI. In neutra I"position


I
from S to R q <0.20 I/min
I

Weight 0.9 kg
Kalmar
•...•...
ContChamp DC-RS·.,· • __ L ".n
9129 96-03 20 3
Technical Handbook Specifications ;~ , Pub!. I Gr.1 P.

Automatic electric gear-changing system


Fuse .. 5A

Outputs:
All outputs are short-circuit protected and can
withstand a loa.d of 1A. .:,
However, the total output must not exceed 4A.

9 outputs for gear selection.


Output for engine control.
Output for lock-up.
Output for fault indication.

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.

Warning lamps and instruments are clearly arranged on the


instrument panel, to the left of the driver. The panel is hinged,
and a ciicuit board with relays, fuses and terminal blocks is
located below it.

I
I
I
,
I
I
..
I

i,I,

j' KL454

;;rf~
~J
\
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

1. Sensor, warning lamp, oil jtemperature gearbox


2. Main fuse for the electrical system, 2 x 50 A
3. Relay, preheating I

4. Sensor, temperature gauge, coolant temperature


5. Sensor, warning lamp, high coolant temperature
6. Sensor, warning lamp, low coolant level
7. Starter motor I
8. Earth lead and battery cabel
9. Sensor, warning lamp, low oil pressure engine
10. Sensor, pressure gauge, bil pressure engine
11. Sensor, pressure gauge, bil pressure gearbox
Electrical components of the Volvo TWD 1230 ME engine
(<.Kalmar
.ContChampDC-RS c .Electrical system.- ::... 9129 96-03 20 7
Technical Handbook Description ..,,,,._ Pub!. I Gr.1 P.

o \. ,.

1 2 3 4

10 9 8 7 KL459

1. Sensor, pressure gauge, oil pressure engine


2. Sensor, warning lamp and temperature gauge,
oil temperature gearbox
3. Sensor, temperature gauge, coolant temperature
4. Sensor, warning lamp, low oil pressure engine
5. Sensor, warning lamp, high coolant temperature
6. Sensor, warning lamp, low coolant level
7. Battery cabel.
8. Starter relay
9. Earth cabel
10. Main fuse for the electrical system, 2 x 50 A
Electrical components of the Cummins LTA 10C engine
...~
Kalmar
.;.-
ContChamp'DC;'RS,~.'~~, ..:~.:Electrical system :~';:':::
r p ."".
9129 96-03 20' 8
Technical Handbook Description. ,:~" Pub!. I Gr.1 p,

." \ "

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

10. Battery cabel I

11. Switch, starting interlock


I Electrical components for the Scania DS11 engine
«Kalmar
ContChamp DC-RS,'· "... ..Electrical'system .~:.: 9129 96-03 209
Technical Handbook Service Pub!. I Gr.1 P.
i
I

" \ " I

Checking the electrolyte level of the batteries


The batteries supplied with the truck are The batteries are fitted behind a coJer on the left-hand side of
of sealed-for-life type, i.e. they need not the truck. The electrolyte level should be about 10 mm above
normally be topped up during the life of the cells. Top up with de-ionized water
, as necessary.
the battery.

However, we would advise you to check


the electrolyte level once or twice a year
and, if necessary, top up with deionised Relay box in cab - fuses
water. Fuse Rating
No . '.' Circuit protected A
S1 . Wiper motor front, direction indicators,
-=-seat buzzer, parking brak~ sensor 10
S2 Ignition key, pre heater, st~rter motor,
air conditioner, cab lighting 10
S3 10
S4 Electric 5
Spare gear-changing I

S5 Warning lamps, instrument illumination, relay,


5
coolant level I
S6 Brake lights, reversing lig~ts, reversing alarm 15
S7 .Fan, compressor, air conditioner,
I condenser 15
S8 Spare
51 • 56 57 • 512 513·518 S9 Working lights (15 A for 41lamps) 1)
Hazard beacon I
10
S10 Working lights, standard (15 A for 4 lamps) 10
S11 Horn, screenwash motor, ~iper rear and roof,
wiper front, intermittent rel'ay
S12
Driving lights (main fuse), Irear lights
(main fuse), position lights 15
S13 Main beam, right-hand I
5
S14 Main beam, left-hand 5
S15 Dipped beam, right-hand I 5
S16 Dipped beam, left-hand 5
S17 Rear light, left-hand 5
Kl136 S18 Rear light, right-hand 5
') Optional equipment

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

JIIJ I
°§1B8~§J° I
') Optional equipment
...0··
...
•• @
1iliJ ...
.• 1illJ• Iili}:
•• ••
.
.. 1iliJ

011


••.••••••

I· ••

o~§]~~~"
I!I!I I
Main fuse
for electrical
I
system
II!D Fitted on the engine
2 x 50 A

i
~·.I
.
110

KL'37

Starting from another battery-


• Make sure that the auxiliary batteries are connected in
series, so that 24 V will be supplied.
Note: Do not disconnect the truck- battery cables.
• Connect the jumper cables in the following orders:
CAUTION 1. Red cable (+) to auxiliary battery
2. Red cable (+) to truck battery
3. Black cable (-) to auxiliary battery
Batteries emit oxyhydrogeh which is
4. Black cable (-) to a location some distance away from
a very explosive gas. A sp~rk
the truck battery, such as the negative cable connection on
occurring when auxiliary starting the main switch.
cables are incorrectly conrlected may
be sufficient for a battery to explode • Start the engine
Do not disturb the jumper cables while starting, as sparks
and cause damage. I
may otherwiswe be caused. Do not lean over either battery.
• Disconnect the jumper cables in exactly the reverse order.
~<Kalmar
ContChamp DC-RS ~ -- Elf3ctrical system,.'" j' , 9129 96-03 20 11
Technical Handbook Service ,,;;:""
__
' Pub!. I Gr.1 p,

.,' \ '(-

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

If there i~ a dot in the destination nu1mber it describes a terminal


~
KLH block. i

If the cable has a jumper, e.g. a common cable for supplying


v = ON/OFF several functions, a capital letter is added to the cable number.
G = Variable sensor
Cable --:=i-- r-- Destinatioh
103A (26.1) I

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
..::.. LJ

I
.aJ

1.
~--t\ 130

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

12. Lamps front right


25. To chassis I
13. Wiper motor rear 26. To cabin underneath ~ide, front wiper motor
14. Lamps rear right, reversing alarm 27. Wipers front, air conditioner
15. Lamps rear left 30,31. Container attachment
16. Gearbox valve housing 29, 32, 33, 34, 35, 36, 37, 38, 39, 40. Options
Kalmar
... "'"
t: ' ContChamp DC.;.RS -'~."';. :--··.·Electro-servo.system ,:',.,.,'- 9129 96-0320 12
Technical Handbook Description ~....,,_ Pub!. I Gr.1 P.

General
.The electro-servo system consists of the following components:

• Control lever
• Switches
• Control uni~s
• Converters on the main valves

In addition there are relays; solenoid valves and sensors in the


system. This is made clear in the circuit diagrams for respective
units. '"

-. " 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

The control lever regulates electrical,signals which operate


electrohydraulic converters which in tum feeds hydraulic servo
~ pressure to the main valve sections. I
T2
P2 . I

P4 The lever handle is equipped with po~entiometers P1-P4 and


T3
four finger-tip controlles switches T1 +T4.

T4 The plus feed from the control unit is! delivererd via sliding
shoes when manoeuvring the machi~e.

When manoeuvring, the potentiometbr setting is altered, and


thus the output signal, in proportion to the lever movement. The
output signal is amplified in the cont(ol
I unit and thereafter used
for controlling the hydraulic servo output
I
from the converter.

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

_J
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.

"/ \ 0(

Dead man's handle (Option)


To special order; the control lever can be equipped with so
called dead man's handle; This means that all servo circuits,
and thus all functions, will be interrupted if the operator drops
the grip of the control lever. The active component is a .
capacitive sensor. When the hand grips the lever the magnetic
field of the sensor is influenced and the sensor is activated.

--
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51
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KL449

1. Emergency switch on t~e hydraulic console


2. Control lever I
I

3. Sensor, dead man's handle


4. Bar 55 in the electrical ¢entral unit

Connection of the dead man's handle


Kalmar
.ContChamp-DC-RS.,~.' ., ,Electro~servo.system; I 9129' 96-03' 20 15
Technical Handbook Description .:... Pub!. I Gr.1 p,
j
I
~/ \ "

Control units 1 and 2 I


I

The IPS 302 is'an electronic control unit which incorporates a


voltage stabiliser and is used to supply the control lever.
I

Stabilised 8V d.c. is supplied to the 'potentiometers in the


control lever. An ,8.1t:..190 mA signal is returned to the control
unit from the appropriate -potentiometer,
I depending on the lever
movement. In the control unit, the signal is modulated to a
square-wave form, is amplified to approx. 400mA and is used
• •• •• • as a control signal for the electro-hydraulic converters. Square-
•• wave modulation is required to ens8re accuracy of the con-

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. :

Each function can be regulated by ~eans of two potentiome-


ters, one of which determines the starting point of the curve and
r the other its slope and end point. Crhe settings are adjusted at
the factory.) . I

. I

"MIN" regulates the starting point of the curve


"MAX" regulates the slope and end Ipoint
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Control unit, Voltage Converters


5-8 V 100-400 mA

WHITE GREEN
~. ContChampDC •.RS··
i1 .~ I
. Electro-servo:system.':::.', .~
«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.

The converter consists of a solenoid and a pilot valve. It is


connected to the main valve spool actuator block.

The solenoid exerts a proportional force on the pilot valve. The


end of the unit is provided with a vent screw and a pushbutton
for emergency manual operation. t;

The control pressure output delivered by the pilot valve to the


2 spool actuator of the main valve is practically proportional to the
input current.

The solenoid is supplied with square-wave modulated d.c. to


mini mise the hysteresis effect and ensure maximum accuracy.

The pilot valve is closed in the neutral position.

Servo pressure 6p
bar
i ~
C
40
7_S
35

30

25
KL467

20

15
8 I I 9
10

1. Vent screw 5

2. Push button, manual operation Control current


3. Solenoid I o 100 200 300 400 500 600 700 800 is mA
4. Pilot valve I "
5. Main valve 2I 4I 6I 8I 10
I 12I 14I 16I 18I 20I 22I Voltage ' U , V
6. Spool actuator Equivalent voltage across 27 .0.solenoid coil
7. Control current
8. Inlet servo pressure
9. Return servo pressure

A given control is rsults in aldefinite


servo pressure at the spool actuator

Converter Servo pressure as function of input current


... --Kalmar
ContChamp.DC-RS ,..,~, c:.Electro-servosyste'm',::: .. I, 9129 96-03 20 17
Technical Handbook Pub/. I Gr.1 p,
Description .'._..

BOOM LIFT/LOWER
See Electric servo (S), group 20

The BOOM LIFT/LOWER function is' a proportional function, Le.


the speed is depending on the degr~e of lever movement.
, . I

1. The IPS-unit (S3) feeds a signal to the potentiometer P1


LIFT or LOWER in the control lever.

X
I

2. Depending on the degree of leve~ movement, P1 returns a


signal of 5-8 V back to the IPS-u~it.
P1
' •. ' I

3. The IPS-unit converts the signal and feeds it to the main


valve (S1) of the hydraulic system.

Section 1 for LIFT 1


Section 7 for LIFT 2
Section 2 for LOWER 1
J<s Section 8 for LOWER 2

4. Depending on the degree of leve~ movement, hydraulic


pressure supply to the lift cylinder.

BOOM OUT/IN
Se Electric servo (S), group 20

The BOOM OUT/IN function is a proportional function, i.e. the


speed is depending on the degree 6f lever movement.
I

1. The IPS-unit (S3) feeds a signal to the potentiometer P2


BOOM OUT or BOOM IN in the bontrollever.
P1 Lift/lower
P2 Boom OUT/IN
2. Depending on the degree of levjr movement, P2 feeds a
signal of 5-8 V back to the IPS-unit.

3. The IPS-unit converts the Signallnd feeds it to the main


valve (S1) of the hydraulic system.

Section 3 for BOOM IN 1


Section 4 for BOOM OUT 1
Section 5 for BOOM IN 2
Section 6 for BOOM OUT 2

4. Depending on the degree of lever movement, hydraulic


pressure supply to the extension~cylinder.
..~Kalmar
ContChamp DC-RS '.:" -.- .;,1-_ :.'. Electro-servo.system :;-:;', 9129 96·032018
Technical Handbook Description Pub!. I Gr.1 P.

Twist-lock, manual and automatic locking


• 5ee electric servo (5), group 20 .
Circuit diagram, top lift (E) A04454;0100, group 80
Hydraulic system top lift (H), A05433.0100, group 80

The switch 51 ~ gives automatic twist-lock locking when in its


forward, fixed postion. In order to get the automatic locking
active, the parking brake must be OFF. The backward, spring-
back, position on switch 516 gives manual twist-lock locking.

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.

3. Relay 55.12 also shifts and makes the valve Twist-locks


(E23) on the top lift open. This valve is normally closed. The
result is hydraulic pressure supply from Z in the top lift main
valve to the locking cylinder.

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.

2. 5witch 516 changed over to its backward, spring-back


position. This bridges relay 55.24.

3. Continuous function as described in Automatic locking


above.

Twist-lock unlocking
1. Activate switch UNLOCK TWI5T -LOCK5 on the control
lever.
NOTE: The switch must be kept pressed in during lift.

2. Plus feed to relay 55.25.

3. At alignment, signal from sensors E20.1 and E20.2 on the


top lift to relay 55.25 which shifts. This interrupts the
automatic locking.

4. Plus feed to section Z in the top lift main valve which opens.

5. Hydraulic pressure supply to the twist-lock cylinder which


opens the twist-locks.
«Kalmar
ContChamp DC-RS Electro-servo'system '.. 9129 96-0320 19
Technical Handbook - Pub!. I Gr.1 P.
Description '-Y'
" \ ,
Length adjustment 20-40' I

T1 Se Electric servo (S), group 20 j

Circuit diagram top lift (E) A04454.0~00 group 80


Hydraulic system top lift (H) A05433.0100 group 80
. I

LENGTH ADJUSTMENT is an ON/OFF function, Le. the speed

can not be manually controlled. I

1. Activate control lever switches T1 + T4

T4
2. Relay S5.19 and S5.20 shifts. I .

The following measures refer to Circuit diagram and Hydraulic

system fop lift, group 80. I'


3. The top lift main valve section Z recieves plus feed and
opens for inward or outward moVement depending on the

position of switch T1. 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,

the length adjustment starts. I

5. Solenoid valve E25 (H24) is normally activated by the signal


T1 +T4 Length adjustment from sensor E21. At approx 200 Imm remaining length
adjustment the sensor is deactiv~ted by an opening in the

lower extension bar. I

6. Solenoid valve E25 (H25) shifts whereby the return from the
hydraulic motor is forced through a nozzle thus reducing the

length adjustment speed. I

7. At length reduction from 40' to 20', the movement starts at


low speed and increases as the ppening in the extension bar
has passed the sensor E21.

T1
Sideshift
Se electric servo (S), group 20 I

Circuit diagram top lift (E) A04454.0100 group 80


Hydraulic diagram top lift (H) A05433.0100 group 80

SIDESHIFT is an ON/OFF function.! Le. the speed can not be

manually controlled. I

1. Switch T1 SIDESHiFT in the control lever gets plus feed


over relay S5.18 from the main switch S15.
I

2. T1 is activated for SIDESHIFT RIGHT


I .

3. Plus feed over relay S5.19 to the top 11ft.


I

4. The top lift main valve, section V}'1 gets plus feed and opens
for hydraulic pressure supply to the sideshift cylinders which

gives right sideshifting. i


5. T1 is activated for SIDESHIFT LEFT

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 is? proportional function, Le. the speed is


depending on the degree of lever movement.

1. The IPS-unit S4-E1 feeds a signal to potentiometer P3


ROTATION in the control lever.

2. Depending on the degree of lever movement, P3 returns a


signal of 5-8 V to the IPS-unit.

3. The IPS-unit converts the signal and feeds it to the hydraulic


rotation motor (H5) which gives rotation RIGHT or LEFT
depending on lever movement.

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°.

Two inductive sensors (3) are positioned on the upper rotation


yoke outside the gear wheel.

1. The maximum rotation angle is reached when each sensor


reaches the activator 4.

2. The sensor feeds a signal to relay 8.26 or 8.27 (Model RS5


also relay 8.18 or 8.19). The relay shifts and interrupts the
rotation signal between lever and IPS-unit (9 or 10)

3. Switch 7, positioned nearby the lever in the operator's cab


can be used for bridging of the rotation stopper. When the
switch is set to its OFF position the signal from either of the
sensors 3 is interrupted.
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5. Terminal bar on the top lift
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.

Hydraulic re-positioning of operator cab


. As an optional extra; a system for hydraulically repositioning the·
, operator's cab is available. The cab is then mounted on a frame which
glides on two rails drawn by a hydraulic motor driven chain. The system
is controlled by means of a switch mounted on the instrument I?anel.
The hydraulic motor is fed from' the priority valve in the steering
system. When the manoeuvre valve for cab positioning is activated an
LSsignal'is fed to the priority valve which is reset to feed the hydraulic
motor via the manoeuvre valve.

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

T he num b"enng IS continue


. d onI
the wiring diagram, next pictu~e.
I Hydraulic re-positioning of operator cab
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S' 10. Limit switch, closes the circuit 'when the cab is moved
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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

7.1-2 Inductive sensor, support jacks up,


right and left (A203'49.01 00)
7.3-4 Inductive sensor, support
I
jacks down,
right and left (A20349.0100)
I

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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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•.....•.
.ContChamp,DC.;,.RS~':'::':~.:-,~~.:_.
Electro-.servo.system::;: ' 912996-03' 20 26
Technical Handbook Description .. d- Pub!. I Gr.1 P.

Electric servo machine model RS (Container)


. I '

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 __
=-"
'"'' ..

Electric servo machine model RS, vertical lift (Container)

10. Control lever


Components A21533.0100
T1 SIDE SHIFT
1. Main valve T2 Unlocking of TWIST-LOCKS
S (1-2) LIFT-LOWER T3 a) Locking of LEVELLING I
U (3-4) BOOM IN-BOOM OUT b) Locking of TILT
V (5-6) BOOM IN 2-BOOM OUT 2 T4 Vertical LIFT
T (7-8) LIFT 2-LOWER 2 P1 LIFT/LOWER
2. Cut-off valve for lift cylinders P2 BOOM OUT/IN
3. Control unit IPS P3 ROTATION
5. Relays P4 TILT
1. Control of Red lamp and interruption of functions Lever connections
at overload 1. Earth (OV)
2, 3, 4. Interruption of LIFT, LOWER, BOOM OUT at 2. Feed, front TILT
overload (low steering axle load) 3. TILT IN (option)
5. Interruption of LOWER at ALIGNMENT 4. TILT OUT (option)
6. Control of cut-off valves on lifting cylinders 5. Feed, ROTATION/LEVELLI~G
7,8. Control of Green indicating lamp for suitable 6. ROTATION anti-clockwise/L,EVELLlNG, left
transport position. (On lamp panel 17) 7. ROTATION clockwise/LEVELLING, right
9. Control of Green indicating lamp for suitable 8. Unlocking of·TWIST-LOCKS
transport position, 1:st and 2:nd gear 9. Feed T2 :
(On lamp panel 17) 10. Switch, alt. functionNERTICAL LIFT
10. Signal converter (Amplifying of IPS-signal to 11. Feed T4 I

control current for relays) 12. Locking of LEVELLING


11. Safety interlocking LIFT 13. Locking of front TILT
12. Safety interlocking TWIST-LOCKS 14. Feed, switch, locking I

13. Stop at 30' and 35' 15. SIDESHIFT, right/20'-40' qUT


14. - 16. SIDESHIFT, left/20'-40' IN
15. Control relay for overload sensor 17. Feed, SIDESHIFT/20'-40' I
16. Interlocking of relay at overload 19. Feed, LIFT/LOWER
17. Interruption at overload 20. LOWER
(Std 4580. Others optional, jumped) 21. LIFT
18. Feed SIDESHIFT/20'-40' 22. Feed, boom extension
19. SIDESHIFT RIGHT/20'-40' OUT 23. BOOM IN
20. SIDESHIFT LEFT/20'-40' IN 24. BOOM OUT
24. Locking of TWIST-LOCKS 13. Switch, stop at 30'-35' I

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

18. EI. system for hydraulically moveable cab, see separate


diagram :
19. Connection to electrical central unit
20. Terminal bar for diodes, in the telay box below the
, *',li-LU
l*
l*:
,-
.•... 0\
-! ~~U
1..1....
r;=.
0 ,~. , ••t:-t:-•.••ro-)
•,LU,~~t:-Jj'p\'
~~ Po
~I o 0 IPo
.
:= :
0
~
~I t:- operator's seat I
M
= :=
o•••
:!N ..•...
::=; H: ·
U,
0
0
Po t~~ 11..!

........
; 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

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 p eat separate diagram
Kalmar
•...•..
ContChampDC-RS. ", ":. ',-~-':',·.Electro-servo system,~;;:.: 9129 96'03"20 28
Technical Handbook Description',', _. Pub!. I Gr.1 P.

Electric servo machine fT'odel RS5 (Container)


Components A2153S.0100
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 OUT
T3 a) LQcking of LEVELLING
V (5-6) BOOM IN 2-BOOM GUT 2
b) Locking of TILT
T (7-8) LIFT 2-LOWER 2 T4 Vertical LIFT
2. Cut-off valve for lift cylinders
P1 LIFT/LOWER
3. Control unit IPS
P2 BOOM OUT/IN
5. Relays
P3 ROTATION
1. Control of Red lamp and interruption of functions
P4 TILT
at overload '
Lever connections
2, 3, 4. Interruption of LIFT, LOWER, BOOM OUT at
overload (low steering axle load) 1. Earth (OV)
2. Feed, front TILT
5. Interruption of LOWER at ALIGNMENT
3. TILT IN (option)
6. Control of cut-oft valves onllifting cylinders 4. TILT OUT (option)
7,8. Control of Green indicating lamp for suitable
transport position. (On lamp panel 17) 5. Feed, ROTATION/LEVELLING
9. Control of Green indicating'lamp for suitable 6. ROTATION anti-clockwise/LEVELLING, left
transport position, 1:st and 2:nd gear 7. ROTATION clockwise/LEVELLING, right
8. Unlocking of TWIST-LOCKS
(On lamp panel 17) I 9. Feed T2
10. Signal converter (Amplifying of IPS-signal to
control current for relays) I
10. Switch, alt. functionNERTICAL LIFT
11. Feed T4
11. Safety interlocking LIFT I
12. Safety interlocking TWIST-LOCKS 12. Locking of LEVELLING
13. Stop at 30' and 35' 13. Locking of front TILT
14. - 14. Feed, switch, locking
15. Control relay for overload sensor 15. SIDESHIFT, right/20'-40' OUT
16. Interlocking of relay at overload 16. SIDESHIFT, left/20'-40' IN
17. Feed, SIDESHIFT/20'-40'
17. Interruption at overload I
(Std 4580. Others optional, jumped) 19. Feed, LIFT/LOWER
20. LOWER
18. Feed SIDESHIFT/20'-40' I
19. SIDESHIFT RIGHT/20'-40' OUT 21. LIFT
22. Feed, boom extension
20. SIDESHIFT LEFT/20'-40'IIN
21. Control of valve for lower pressure BOOM OUT 23. BOOM IN
and LIFT at a boom angle over 59°. 24. BOOM OUT
22. Blocking of LIFT 2 (S) : 13. Switch, stop at 30'-35'
23. Blocking of BOOM OUT 2:(V) 14. Switch, override of the container coupling safety system'
24. Locking of TWIST-LOCKS 15. Servo circuit cut out switch
25. Unlocking of TWIST-LOCKS 16. Switch, locking and unlocking of TWIST-LOCKS (Manual)
7. Inductive sensor for boom angle 17. Lamp panel, overload indication system (mechanical system)
8. Inductive sensor for boom extension 18. EI. system for hydraulically moveable cab, see separate
9. Inductive sensor for indicatio~ of forward overload, diagram
on steered axle (mechanical system) 19. Connection to electrical central unit
.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.

Control units 1 and 2 (IPS 302)


The control units need no actual mairtenance. To change the
circuit board, proceed as follows:

1. Isolate'the power supply by opening the main switch.


I

2. Rem~ve the two screws retainingl the ~1~stiCcover and


remove the cover. I

3. Remove the four screws retaining the black light-alloy cover


and remove the cover.

4. Remove the screw securing the ~ottom of the circuit board


to the cooling . and mounting rail. ,I
I

5. Withdraw the circuit board by harid, taking care not to


damage the components. The board is a relatively tight fit in
the edge connector. I

6. Fit the new circuit board. Ensure that it is located in the


guides on the sides of the case and that the bottom connec-
tor engages. Press down the bo~rd firmly and refit the
screw.

7. Refit the cover.

Cables and wiring I

Long experience has shown that mqst electrical faults are due
to defective cables. So check the fol,lowing at regular intervals:

1. Check that none of the cables is physically damaged.


2. Check that none of the connectidns has worked loose.

3. Check that there is no risk of shdrt-circuits due to water


leakage into sensitive parts. Chetk in particular the connec-
tions to the converters. I
(<.Kalmar
",. ContChamp >DC-RS.~·.i~~ ~·.'-:..Electro"servo·system~ ..:.~. -' : 9129 96-03 20 30
Technical Handbook Service . Pub!. I Gr.1 P.

Trimming of the electro-hydraulic servo system


using a measuring instrument
Trimming may be necessary for a number of reasons, such as
after replacement of the circuit board, replacement of the
alternator or battery which will alter the supply voltage, replace-
ment of a converter, etc ..
The. most reliable method of trimming is to use a universal
meter with a range of 0 - 1000mA. Connect the universal meter
between the control unit and the converter for the relevant
function. This requires a special cable which allows the univer-
sal meter to be connected in series'. The connection points are
shown in the circuit diagram ..

1. Check the system specifications:


- Supply voltage at least 24 V ,---
- Supply voltage to control lever approx. 8 V
- Hydraulic servo pressure 30-40 bar

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.

When the starting value P1 is adjusted by means of the MIN


potentiometer, the entire pressure curve will be displaced in
parallel. As a result, the final pressure P2 will change as much
as P1 (see the graph below) and the idle travel of the lever will
increase or decrease.
The MAX potentiometer alters only the slope of the pressure
curve, Le. the starting pressure will remain unaltered when the
MAX potentiometer is adjusted, but the slope of the curve and
the final pressure will change (see the Potentiometer function
graph).

3. Start the machine and run the engine up to operating speed.


The engine must be at normal operating temperature before
measurement is started.

4. Connect the universal meter to the appropriate function.

5. Move the lever slowly in the direction corresponding to the


relevant function until the corresponding LED lights up.
Move the lever further in the same direction until the hydrau-
lic function just begins to move. Read the universal meter.

6. Release the lever to the neutral position.

7. Move the lever in the same direction again until the LED
lights up.

8. Turn the MIN potentiometer until the reading of the universal


meter is the same as that in point 5. above. The starting
point of the curve is now preset. The control lever should
have the required idle travel from the neutral position.

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.

"." \ .. -

Electric servo Electric servo


A21531.0100 A21533.0100
A21535.0100

-
~;;'
"f .......~
••
!. s
••••••••
I••••
•,•e'".-•8
Switch............•
~••
ItJ .-..0_"
G~
I>nlTCllff,..".. ~
(j •••••.•@0••••au
8 ••';;'
';(
'-"
00
:.::.-:t. M
-!!!!!!I.!!!P
';'
~ ~......
~';;' e 8 •• •••••••• ..••-•8.-..8
f',.
S imIiiIMIi !. 00
Switch nno iff Nftl
ItJ .. 'if::
.•.h•••..,IS V(j ••••
,••••••
:::
..., ci
0
•• ~~ _II ••••••••••
... u
.@ ......,

,...,. ~~,.....
Half •••. ,..... I> Hili
~ ItJ .-.. IIIIt
I> •••.
~~ 9J

1a 1b 5a 5b

2a 2b 6a 6b

3a 3b 7a 7b

4a 4b 8a 8b

1a
2a
LOWER
ROTATION
1b
2b
LIFT
-!!!!!!I.!!!P~
9J ~~,......
ROTATION CLOCKWISE
1111'
ItJ ••••
.
';''if~ ,...,......~•• ••••••••
,.....1>
Switch
.-8•••~---......0_"..00
• 8•8~,....
.•........
imIiiIMIi ItJIS
,
nnCllff NftI

!. :H~.-::••
';;' .
8'if ••••••••
0 ••\...J @M
••••••

ANTI-CLOCKWISE 3b BOOM IN
3a BOOM OUT 4b Forward tilt 9a 9b
4a Forward tilt OUTWARDS 1) 10a 10b
INWARDS 1)

1>Optional

......

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

9a ROTATION ANTI- 9b ROTATION


CLOCKWISE CLOCKWISE
10a Forward tilt 10b Forward tilt
INWARDS 1> OUTWARDS 1>

1>Optional
Servo pressure
p

....-
....-
--- ••..

.•..
.•..
.•..
....-
....-

-
....-

" - - - - -
-- -
.•...
~
.•... .•..

-- --
-
Control lever
KL469a
Control lever 100%
movement

Potentiometer function IPS


ContChamp:DC-RS' ":'- i_"., Electro:-servosystem:- '''C'.,'
,~ Kalmar
.. , 9129- 96-03 - 20 32'--
Technical Handbook Service Pub!. I Gr.1 P.

1a.Adjust the MAX potentiometer until the universal meter


reading is 400 • 600 mA. - -

11.Test the function and adjust the MAX potentiometer upwards


until the required speed of the function is obtained (the
actual speed depends on .the function). Note that the lowe-
ring brake valve will determine the lowering rate. The MAX
potentiometer must thus not be set so that it limits the
speed.

Trimming without measuring instrument


If no universal meter or cable is available, trimming may still be
carried out as described below, although it will be somewhat
less reliable:

1. Turn all potentiometers concerned to the anti-clockwise limit


of travel.

2. Turn the MAX potentiometers clockwise through about one


turn.

3. Use the MIN potentiometer to set the required starting


pressure for that particular function, Le. so that starting and
stopping will take place smoothly, without jerks and without.
unnecessary idle travel.

4. Set the maximum speed of that particular function by means


of the MAX potentiometer
- clockwise adjustment increases the final speed
- anti-clockwise adjustment reduces the final speed

5.After the system has been adjusted, use only the MAX
potentiometer for individual adjustment of the speeds.

Testing after trimming


1. Start the machine and check that each function starts
smoothly and without excessive idle travel.

2. Check that all functions can be operated simultaneously at


both high and low engine speeds without affecting one
another.

3. If the idle travel of the lever is excessive, increase the


starting pressure by turning the MIN potentiometer
clockwise.
N.S. Turn the potentiometers very carefully. If the idle travel
cannot be eliminated by adjustment, the potentiometer in the
control lever unit is probably defective.

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-tracing in the electro-hydraulic


servo system '
Preparatory work
1. Always check the system specifications
- minimum supply voltage' of 24 V
- hydraulic servo pressure 30 - 40 bar
- supply voltage to the control lever unit approx. 8V

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

.No response to lever movement


1. Check that the supply pressure to the converters is 30 - 40
bar.

2. Disconnect the connector from the converter and'measure


the full output voltage as described under "Description".
- If the voltage is correct, press the emergency operating
button of the converter and check that output voltage is
obtained. If so, the converter is defective and must be
replaced.
- If the voltage is not controlled correctly, the fault is in the
electrical components or the wiring.
3. Check the control lever unit for the relevant function.

4. Check whether the ERROR lanip is alight on any of the


regulator units.
- Shut off the hydraulics
- Set the lever to neutral.

- Remove the plastic cover from the control unit.

- Depress the ERROR RESET button through the hole.


The button is very easy to operate.

- If the ERROR lamp lights up ,again when the button is


released, press the ERROR RESET button again and
keep it depressed.

- Check which output LED is alight. This circuit board is


probably defective and must be replaced.
.~.. ContCha'mp. DC-RS~..".:~' (<.Kalmar
Electr~servo:system:. ~.~.,;
,~:. 9129 96-03 20 34
Technical Handbook Service Pub!. I Gr,l p,

•... \ ..

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.

- Check that the hydraulic servo pressure is 30 - 40 bar.


Check that the pressure does not drop when a load is
applied ..
...• ~
- Check the converter which actuates the movement. Fit a
different converter and check the movement again. If the
function is not correct, the original converter was defective
and must be replaced.

Jerky movements when starting and stopping


1. Remove the plastic cover from the relevant control unit. See
the section entitled Description to determine where the
relevant function is located. Operate the lever to check
which LED is alight. Turn the MIN potentiometer adjacent to
this diode anti-clockwise.

2. If the reduction described in point 1. above provides a large


amount of lever play but the jerkiness persists, the converter
pilot valve may be sticking. Check by replacing the converter
with another unit which performs well in another function.

Excessive "dead" movement of the control lever


1. Adjust the start pressure by means of the MIN potentiometer
- Remove the plastic cover from the regulator unit. Check
which diodes lights up by moving the control lever. Turn
the MIN potentiometer for the relevant diode in a
clockwise direction.
2. If voltage adjustment does not help
- Check the lever unit.

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

- Check the supply voltage to the control unit. If the voltage


oscillates below 23V, the control unit will sometimes be
unable to stabilise these troughs and will transmit them to
the system as disturbances, usually at a low frequency.

2. Individual functions oscillate

- Vent the converter solenoid by' means of the screw on its


rear. Back off the screw to allow the pressure to expel the
air, and keep it open until drops of oil begin to escape
from the hole.

Failure of an individual function


This may be due to short-circuit in the wiring.

Miscellaneous faults
1. The red lamp lights up only when the corresponding
function in the lever has been actuated.

- Check that the electrical connection to the solenoid valve


on the corresponding converter has not worked loose.

- Check that the cable connected to the solenoid valve has


not failed.

2. The red lamp is switched off when the lever is not actuated.

- The lever does not return to neutral.

3. The red lamp does not light up.


(<.Kalmar
ContChampDC.;.RS.; ."'.":':~·~,Overload:indicating.·system;,: .. " ... 9129 '96-03 20 36" .
Technical Handbook Description ..."",_ Pub!. I Gr.1 P.

Overload indicating system


.The overload' indication system oversees the front and rear
loads and warns the operator by means of warning lamps on
the panel in the cab. The system comprises A 11460.0100:
• A sensor on the steering axle suspension for indicating
frontal overload
• Two sensors onthe boom to indicate overload of steering
axle
• Lamp panel in the cab with:
- Red lamp for frontal overload
- Yellow lamp for overload of steering axle
- Green lamp indicating steering axle load ok
- Test button with a blue lamp for checking lamp functions

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.

The signal for a frontal overload is transmitted by a sensor


"located on the steering axle suspension. The rear suspension
includes a pivoted joint that creates a "gap". When the maxi-
mum permitted load is exceeded and only the weight of the
steering axle remains as a counter-weight, this gap is used to
increase the distance between the sensor and the angle iron
that activates the sensor. When the gap is fully extended, the
signal from the sensor is interrupted, the red lamp lights up and
LIFT, LOWER and BOOM OUT functions are interrupted.

The system can result in the machine being "lifted to a stand


still" . To get out of such a situation, it is possible to make a by-
pass connection of the system with the help of a switch on the
hydraulic console. Once the by-pass connection has been
made, the BOOM IN and LOWER functions can be used.

Overloading the steering axle


There are two sensors on the boom, one for boom extension
and one for boom angle. When the boom is extended less than
1 metre and the angle of the boom is greater than 42° the signal
from the sensors is interrupted and the yellow lamp on the
panel lights up, which means that there is a risk that the load on
the steering axle is becoming too great.

The system is so connected that at low speed and in a low


gear, the green lamp lights' up, despite the risk of overload.

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.

The sensor for frontal overload is connected so that an


interruption in the signal from the sensor interrupts the function
of the whole servo system - in other words, it is not possible to
run the machine with a faulty sensor.
«Kalmar
ContChamp DC-RS ." Overloa~ indicating. system : .. 9129' 96-03 20 37
PubL I Gr.1 P.
Technical Handbook Description :.;,<;-~"

',- \ "

."
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.

".. \ -(

The SNP 300 system is available in four different versions:


SNP 301: overload safety system with interruption of functions
SNP 302: As 301 but added with load indicator and vertical lift
function
SNP 303: Only load indicat.or (scales)
SNP 304: Only vertical lift function
AILsystems include, see also electric diagram:
- electronic control unit
- length sensor for boom outreach
- angle sensor for boom angle
- pressure sensor for lift cylinder pressure (Not SNP 304)
The control unit comprises printed circuit board mith micro-
processor, pointer instrument and warning lamps. All
adjustment potentiometers are located on the printed circuit
board. To facilitate calibration, each potentiometer is combined
with a LED-diode showing either red or green light or is
extinguished.
The input signals to the microprocessor are:
- boom length
- boom angle
- lift cylinder pressure
- control lever position
- vertical lift button signal
The microprocessor calculates:
- outreach from drive axle centre to load centre
- permissible load at the actual outreach
- the actual load
The systems SNP 301 and 302 interrupt machine functions both
at forward and backward overload. The utilized forward capacity
is shown on a green/red analogue instrument scale. Backward
overload, e.g. steered axle overload, is indicated first with a
yellow and then with a red warning lamp. When the red lamp
lights up, the functions LIFT and BOOM OUT are interrupted.
The SNP 303 system has a digital display which'shows the
actual load or, alternatively, the outreach. The choice between
load and outreach is controlled with the vertical lift button.
The SNP 304 system comprises a digital display for outreach
monitoring.

Overload safety system


Forward overload
Red area: Stop for Lift,
Lower, Boom out.
RITON
Buzzer sound.
OK for Boom in.
Steered axle overload
Yellow lamp: WARNING
Red lamp: Stop for
Lift, Boom in.
OK for Lower, Boom out.

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 .

1. The SNP-system recieves signals from angle sensor, length


sensor and lift cylinder pressure. Th~ system calculates these
signals in comparison to programmed load curve ..
. I

2. Overload signal from the SNP-system (25) P9-9 to terminal


64-9

3. Plus feed to relay 5.17 which is bridged


I
to relay 5.15. Relay
5.15 makes contact and 5.16 breaks .•

4. The signal from relay 5.16 is pasled o~ ~o relay 5.1 which


makes contact. This will cause follo~ing relays to break: 5.2
controlling LIFT, 5.3 controlling LOWER and 5.4 controlling

BOOM OUT. I

5. Functions LIFT, LOWER and BOOM OUT are interrupted.

6. The SNP-system alerts with red laming lamp and buzzer on


the instrument in the operator's cab~

7. When the overload signal from the SNP-system drops, 5.15


breaks and 5.16 makes contact. ThiS is a reset function which
holds the overload signal until the control lever is brought to
neutral position. (5.16 cannot break' until the lever is brought to
neutral)

Overload, steered axle


See Electric servo and circuit diagram A 11465.0300

1. The SNP-system recieves signals from angle sensor, length


sensor and lift cylinder pressure. The system calculates these
signals in comparison with program'med load curve.

2. Normally there is a fixed signal frbm


I the SNP-system P9-8
bar 64-8. This gives plus feed to relay 5.30 and 5.31. These
relays are normally ON and lead the fixed signal for LIFT and
BOOM IN from the lever to the IPSJunit.
I

3. When the SNP-system has calcJlated the steered axle


overload, the fixed signal disappears and relay 5.30 and 5.31
bffia~ I

4. The signal from the lever to the IPS-unit is interrupted and so


are the functions LIFT and BOOM IN.
~'

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Relays, which can be dismounted on machines with SNP overload system
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
** = To be jumpered

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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~ .. ,~;:,

Coarse adjustment of the outreach length sensor


The length sensor is located at the rJar of the boom ..
I .

1. Retract the boom fully and turn t~e potentIometer 1 counter-


clockwise half a turn.
2

KL210

1. Potentiometer
2. String
Length sensor

Coarse adjustment of the b~om angle sensor


The angle sensor is located on the right hand side of the boom
o o suspension .. I

The potentiometer in the boom angle sensor must be :


approximately correctly set from the Istart. Fine adjustment is
then made in the control unit.

1. Lower the boom to bottom position.


2. Check that the LED-diode 3 is ektinguished. If not, loosen
the two screws 2 and turn the diSc (which carries both
1
potentiometer and circuit board) I until the LED-diode stays
off. Fasten the disc in that position.
I

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

Fine adjustment in the cont~olunit


I

1. Retract and lower the boom fully.


2. Adjust potentiometer 6 until the ~orresponding LED-diode is
extinguished.
3. Adjust potentiometer 2 until the borresponding LED-diode is
extinguished.
4. Lift the boom to max height andl extend to max outreach.
5. Adjust potentiometer 1 until cor~esponding LED-diode is
extinguished.
6. Adjust potentiometer 3 until cor~esponding LED-diode is
extinguished.
7. Repeat measures 1-6.
8. Retract the boom fully and lowe'r to bottom position.
9. Adjust potentiometer 4 until cor~esponding LED-diode is
extinguished.
," . ContChamp-DC-RS,~ ",. ",.-$ ...,.:' «Kalmar
Overload safety .system ;-,,' 9129' 96--0320 42
Technical Handbook Service ""~
. Pub!. I Gr.1 P.

••.• \ 0{

10. This measure is applicable only on systems with display.


If a display is missing, continue on measure 11.
Lift the boom approximately 10 mm and adjust potentio-
meter 4 until the display shows 0-1 alternately.
11. Lift the load just free oft the ground and extend the boom to
the maximum Load center distance according to the data
plate. on the. machine.
12. Turn the potentiometer 5 turns clockwise. Then
carefully adjust counter-clockwise until the instrument
needle is in the beginning of the red field and the warning
buzzer sounds, e.g. the system is interrupting.
13. Retract the boom fully. Then extend again and readjust if
necessary on potentiometer 5.
If the system interrupts too early - carefully adjust clockwise.
If the system interrupts too late - carefully adjust counter-
clockwise.

DD ]

o
[jl
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.

15. Disconnect the load

16. Repeat the fine adjustment


«Kalmar
. ContChamp DC-RS~" ····-:::··:Overload.safety:system .. 9129 96-03 20 43' .
Technical Handbook . Service ...~
...,.
Pub!. I Gr.1 P.

-,.\ 'i

Checking of the pressure sensors in the lift


cylinder supply lines.
1. Disconnect the electrical connector on top of the pressure
sensor at the left lift cylinder. This should activate the
control unit alarm and cause interruption of the boom
functions .. I

2. Reconnect the connector and repeat measure 1 for the right


lift cylinder. .

Checking of the angle sensor 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

Checking of the length sensor


1. Lift off the string from the hook iMthe inner boom and let the
roller pull back the entire string length. This should also
activate the control alarm and cause interruption of the
2
boom functions. I

2. Connect the string to the inner boom. Then turn the


potentiometer counter-clockwis~ against stop and from
thereon half a turn clockwise. '

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.

Manual electric gear-changing system


Clark 34000/36000 A08118.0100 05

The manual electric gear-changing system is electro-hydraulic


and controls the transmission by means of solenoid valves. Oil
under pressurE? is supplied to the solenoid valves from the oil
pump built into the transmission.

An inductive sensor senses' the speed of the propeller shaft and


applies a signal to a speed monitor which prevents gear-
changing at speeds above 3 km/h.

A. Gearbox control valve


B. Employed gear
C. Activated solenoids
D. To seat buzzer switch
F. To starter motor (50)
G. From starter switch
H. From alternator (D+)
J. To parking brake warning lamp
3. Gear selector
5. Speed sensor on gearbox output shaft
(output speed)
6. Valve cover with solenoid valves
7. Electrical central unit
8. Switch at parking brake - ON when brake is released
9. Switch at inching - OFF when inching
10. Relays
3. Wiper motor
4. Starting interlock
5. Stop
6. -
7. Reversing lights
8. Inching
9. Reverse gear
10. Forward gear
11. Reverse interlock

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,....:.,.

Automatic electric gear-changing system


The automatic electric gear-changirig system is based on a
control unit incorporating a microprocessor.

The control unit has connec~ions fo~


- Gear-changing control
- Display (programming unit for programming)
- Solenoid valves on the transmission
- Speed sensor on the torque converter and transmission

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.

~
~ LA
p-t;J
Green POWER LED
::+) ............
•••••••••••••••

The LED is alight when power supply is available to the control


unit and the unit is sufficiently warml to operate. (The electronics
will be automatically switched off when the temperature inside
the case is below O°C.)

Red HEATER LED


The LED is alight when the heater in the case is switched on.
Heating is controlled by an electroni'c thermostat, so that the
temperature will quickly rise to the operating temperature of
20°C.
SHIFTRONIC
RESET button
For resetting of sensor loss and shdrt-circuit protection.
P1 - connection to transmission v~lve housing via the relay
box.
P2 - connection to the gear selector in the cab.
P3 - connection to the display in the cab or to the
programming terminal.
P4 - connection to sensors for engine speed and output speed
from the transmission.

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.

The control unit changes up to the gear selected by the driver


Control unit by means of the gear-selector control.
· ...
«Kalmar I.
'ContChamp.DC-RS. 'Automatic:electric'gear.!'changing system,~. '.-. 9129 96-03 .20 46
Technical Handbook Description'. _-,;., Pub!. I Gr.1 P.

~•• \ t(

Safety functions
'These functions are always active.

Reversing protection: In the neutral position, the control unit


inhibits gear engagement if ~he speed of the output shaft is in
excess of a prQgrammed limit (REV PROT).

Speed sensor: When the speed exceeds a certain minimum


value (SENS CHECK), a check is made to ensure that the
tachometer pulses are received regularly. If the rate should
suddenly-change, this is interpreted as the sensor being inope-
rative. The transmission is shifted to neutral and the fault output
is activated. The display shows SENS. This condition can be
acknowledged by means of the reset button.

Short-circuit protection: If any of the outputs is short-circuited,


all outputs will be de-energised so that improper gear engage-
ment will not be initiated. This condition can be acknowledged
by means of the reset button.

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.

A thermistor on the circuit board senses the temperature inside


the case. If the temperature should drop below approx. 5 DC,
-I
the supply to all logic on the circuit board will be isolated and
the fault output will be activated. Nothing will be shown on the
display, since the display is dependent on the microprocessor.
The green LED will be switched off.

The same thermistor is also used for controlling a 15W heating


element in the case, so that the control unit will quickly become
usable. This heater delivers full output when the temperature is
below 5 DC, and the output then tapers off to zero at 20 DC.

A temperature fuse which blows at 60 DC is provided inside the


case to prevent overheating. This fuse interrupts the power
supply to all logic circuits and the heater element. If the thermal
fuse has blown, it must be replaced.
«Kalmar
ContChamp DC-RS· A.utomati~ t!!e~tric gea.r-changing sy.stem . 9129 96-03 2047
Technical Handbook Description ;:;..w~•.
Pub\. I Gr.1 P.

P1 - Connection to the transmission valve I

housing via the relay box


Pin 3 is output signal GO for gear selection.
Pin 4 is output signal G1 for gear selection.
Pin 5 is output signal
.
G2 for 'gear selkction
I
.
Pin 6 is output signal G3 for gear sel~ction
Pin 7 is output signal G4 for gear selection.

P2 - Connection to the cab


The connector in the control unit is al14-pole AMP 206043-1
plug connector. A socket connector 5uitablefor fitting to the
wiring is AMP 20644-1.
Pin 1 is the +24 V supply to the control unit. This is fused.
Pin 2 is earth.
Pin 3 is input signal UGO from the gJar selector.
Pin 4 is input signal UG1 from the gJar selector.
Pin 5 is input signal UG2 from the gJar selector.
Pin 6 is input signal UG3 from thegJar selector.
Pin 7 is input ~ignal UG4 from the g~ar selector. If stepping
control is used, REVERSE is connected here.

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.

Automatic electric gear-changing system


Clark 34000/36000 A08899.01 00 06
A. Gearbox control valve
B. Employed gear
C. Activated solenoids
D. To seat buzzer switch
E. Relay 9 and 10 are not mounted
Jumper between 86 and 87
F. To starter motor (50)
G. From starter switch
H. From alternator (0+)
J. To parking brake warning lamp
1. Control unit
2. Display
3. Gear selector
4. Speed sensor in torque converter housing
(engine speed)
5. Speed sensor on gearbox output shaft
(output speed)
6. Valve cover with solenoid valves
7. Electrical central unit
8. Switch at parking brake - ON when brake is released
9. Switch at inching - OFF when inching
10. Relays
3. Wiper motor
4. Starting interlock
5. Stop
6. -
7. Reversing lights
8. Inching
9. Reverse gear
10. Forward gear
11. Reverse interlock

Cable colours
Svart = Black
Gra = Grey
ROd = Red
Bla = Blue
Gul = Yellow
Gran = Green
Brun = Brown
Vit = White
Rosa = Pink
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1,'/ ~ 18&~.~ - - - - - - - - - - - - -t - FOR AKTUELL DRIVLINA
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OETTA SYSTEM KOMBINERAS MEO
SE STD. SCHEMA AOBJJ4.0100
o IlstJ~~-;-~-.~-~~-;--;--=~_:-=~-=-==-----,-
---I :;
3I»
..•
-tr_------------, I I , ~, The engine shut down is activated
at high engine coolant temperature
o· -.:'1 -=!·'I=-~=~I---II ~ and low engine or gearbox oil pressure.
CD
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1f Concerning connections av ignition key, see standard circuit

I
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..• (:) 22-' 242- 765 ,654 -L 759 215 202 638 diagram A08334.0100. ~ ~
Q.
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Q) 2. Will be added if engine shut down at low coolant level is required ..
~I~~
3. Electrical central unit.
~
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ContCha'mp' DC-RS ; '.'..'::Electro hydraulic:speedcontroJ.;. ""
~<Kalmar
.. 9129' 96-03 20 50
Technical Handbook Description·, .:~~, Pub!. I Gr.1 P.

.. \ ..

- su.uc.
[E1
I~--
:
[ ~
.!l!.. 5

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I d I I i , ___ .!22

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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

Electro-hydraulic speed control


«Kalmar
ContChamp DC-RS Air' operated seat 9129 96-03 20 51
Pub!. I Gr.1 P.
Technical Handbook Description ".=~
..' \. -(

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

Air operated operator's seat


,.•...•
Appendix -;'",
Technical Handbook Catalogue of Components

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 ".;,>

703 Engine rev meter 850 Horn


704 Air pressure gauge, 853 Buzzer
705 Gear box oil pressure gauge,
706 Temperature gauge, engine coolant 900 Radioltape recorder
707 Fuel gauge 901 Voltage converter
708 Hour meter 902 Loud speaker
709 Capacity gauge, battery 903 Aerial, radio
710 Timer, engine- and cab heater 905 Communication radio
712 Motor oil pressure gauge 906 Aerial, communication radit'
715 Extra instrur.,ent, general 910 Voltage converter 80 V I 24 V
753 Transmitter, engine revolution 940 Logic switch watch
754 Transmitter, air pressure 950 Logic transistor ignition
756 Transmitter, engine coolant temperature 955 Logic overspeed protection (LPG)
757 Transmitter, fuel level 960 Logic unit, reversing interlock/automatic gear
758 Transmitter, gear box revolution changing
759 Transmitter, coolant level 961 Engine- and cab heater
760 Transmmer, reversing interlock I automatic 962 Logic indication of wear, brush electrical motor
gear changing system (on gear box output 965 Reversing alarm
shaft)
761 Transmitter, reversing interlock I automatic
gear changing system (engine speed)
762 Transmitter, brake flushing circuit
763 Transmitter, hydraulic fluid level
764 Transmitter, gearbox servo pressure
765 Transmitter, oil pressure gear box
766 TransmittRr, oi' temperature gear box
767 Transmitter, oil pressure engine
768 Transmitter, hydraulic pressure
770 Transmitter, steering wheel angle
771 Transmitter, angle
773 Transmitter, presence
774 Transmitter, ambient temperature
775 Transmitter, temperature air condition
776 Transmitter, hydraulic temperature
m Transmitter, position
778 Transmitter, drive break
779 Control system, recharging (EC)
780 Control system main motor (EC)
781 Control system pump motor (EC)
782 Logic (interface) two main motors (EC)
783 Logic (interface) throttle
784 Logic (interface) brake control
785 Logic (interface) control system
795 Display
799 Logic, general (option)
800 Start element
802 Electrical heated observation mirror
803 Electrical heated seat

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(<.Kalmar
'ContChamp DC-RS 9129 96-03 30 1
Contents I Gr.1
Technical Handbook Pub!. P.

'.'\. .,'

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.

Manufacturer, type TWD 1030 ME TWD 1230 ME

Coolant volume, I 46 48

Rating, ISO 3046, kW (hp) 180 (245) 275 (374)


at r/min 2200 2100

Torque, ISO 3046, Nm 1057 1745


at r/min 1400 1100

Number of cylinders 6 6

Swept volume, lit res 9.60 12

Valve clearance, cold engine


inlet, mm 0.40 0.40
exhaust, mm 0.70 0.70

Idling speed, r/min 675±25 600±25


(adjust so that the engine
runs smoothly)

Injection pump timing

Thermostat,
starts to open at °C 82 82
fully open at °C 95 95

Lubricating oil filter Full-flow, disposable paper elements


with by-pass valve

Lubricating oil pressure, kPa


running speed 30D-500 35D-500
idling speed 60 min. 150 min.

Lubricating oil grade API-CD


viscosity see figure below

Volume incl filters, I 21 27

30 -20 -10 0 iOn-2O

;+10'C

22 -4 14 32 50 -0' E

*) Engine wear may increase if these oils are used at temperatures


above +15 °C and +30 °C respectively.

**) 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

Volvo TWD 1030 ME engine


ContChamp DC~RS' Engine,': .
,~ Kalmar
9129' 96-03 30 4
Technical Handbook Description . :_. Pub!. I Gr.1 P.

The engine is pressure-lubricated and incorporates an oil pump


which delivers oil to all lubrication· points. A full-flow oil filter
effectively cleans the lubricating oil. The fuel system is
protected against impurities by replaceable filters. The engine
has replaceable wet cylinder liners. The engine has separate,
mutually interchangeable cylinder heads for each cylinder.

,,
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

Volvo TWD 1230 ME engine


{<Kalmar
ContChamp .DC-RS ""' .E·ngme':.-::· . 9129 96-03 -30 5
Pub\. I Gr.1 P.
Technical Handbook Description.' ;-...;";,~;
.~
\. -(

The following description is valid for both 1030ME and


, 1230ME if not otherwise stated.

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

The coolant flows through a longitudinal passage into the


engine block. The opening into the cooling jacket of each
cylinder is individually sized to ensure that each cylinder will be
supplied with the same rate of coolant flow.

The coolant flows in the separate return ·Iines converge into a


common pipe in the thermostat housing. The coolant then flows
to the coolant pump and then into the engine and to the oil
cooler.

When the engine has reached its normal operating temperature,


the thermostat will open the circuit to the radiator.

The piston-type thermostat is capable of passing a high coolant


flow rate at a minimum of pressure drop, thus contributing to
favourable coolant circulation in the engine.

The coolant pump is gear-driven with high capacity.

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.

•.-\. ..

The cooling system is equipped with a sensor which activates


the "Low coolant level" warning lamp on the instrument panel,
see group 20.

The engine lubricating oil is cooled efficiently and reliably in a


separately mounted tubular oil cooler. The gearbox oil is also
cooled by the engine coolant; but in a separate shell-and-tube
cooler.

1. Oil cooler, engine oil


2. Thermostat housing
3. Oil cooler, gearbox oil
4. Thermostat, closed 4
5. Thermostat, open

KL496

Pump och termostat


KKaimar
ContChamp' DC-RS' . Engine: 9129 96-03 "30 7
Pub!. I Gr.1 P.
Technical Handbook Description

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.

Excess fuel which is circulated in the low-pressure system is


also cleaned in the fine filters and is returned through a spill
valve back to the tank.

The fuel system includes the following components:


Fuel tank - a separate unit located on the left-hand side of the
truck. The fuel volume in the tank can be read on a gauge on
r
the instrument panel.

Feed pump - of piston type, supplies fuel at a certain pressure


and flow rate to t~e injection pump.

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

Fuel system, principal


Engine",
. ~'. .."
'" ~",';,~ ..
«Kalmar
ContChamp DC-RS '.' .. , ,. , . 0

9129 96-03 30 8 ..
Technical Handbook Description ,,"; Pub!. I Gr.1 P.

., \ 0(

Fuel filters - two filters connected in parallel and with a com-


o. mon cover. The. filters are of disposable type, with the filter
elements made of spirally wound paper.

Kl499

Fuel filter

Injectors - each with a nozzle holder and a nozzle. When the


fuel pressure has risen to the preset value, the needle will lift
and atomised fuel will be injected into the combustion chamber
1 through accurately calibrated holes in the nozzle sleeve.

4
5

KL196

1. Supply pipe coupling


2. Spill fuel pipe connection
3. Spacers for adjusting the opening
pressure
4. Compression spring
5. Thrust pin
6. Nozzle sleeve
7. Needle

Injector
'Engine,' ':', _ «Kalmar
, ContChamp DC-RS' 9129 96·03 30 9 .
Technical Handbook Description:, 'c,, __
.,:-,.,~1.";_
Pub!. I Gr.1 P.

Injection pump - located on the left-hand side of the engine


and driven by gears. The pump is equipped with an RSV .
govemorwhich has a steep control characteristic at low engine
speeds. As a result, the engines appear more powerful and
have a higher tractive effort at low speeds.

1. Stop screw for maximum speed, sealed


2. Accelerator lever
3. Adjusting screw for idle speed
4. Adjusting screw for idle speed stabilizing

RSV centrifugal governor


{<.Kalmar
ContChampDC-RS"" : , .t;ngil1e:-~" ": 9129 96-03'30 10

'Technical Handbook Description '. , Pub\. I Gr.1 P.

~••. \ t{

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.

The lubricating. oil is cooled in an externally mounted tubular oil


cooler by the engine coolant.

The lubricating system includes the following main components:


Oil pump - of gear type, which draws oil through a coarse
strainer that arrests larger particles. The pump delivers oil
through the lubricating oil filters to the variqus passages of the
lubricating system.

Piston cooling - reduces substantially the piston temperature


which, in turn, contributes to a longer life of the piston rings,
reduces the risk of carbon deposits and lowers the oil consump-
tion.

The pistons are cooled by oil which is sprayed by nozzles into


the underside of each piston and into the cooling passages
when the pistC?nis at the bottom dead centre.

Cooling is controlled by a piston cooling valve which shuts off


the cooling oil supply at low engine speeds. This ensures that
the lubricating oil flow will be a maximum when the engine is
started and when it is running at idling speed. The valve also
Piston cooling restricts the pressure of the piston cooling oil at high engine
speeds, to make more oil available for lubrication.

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

Lubrication system, principle


{{Kalmar
ContChamp DC-RS Engine""- . 9129'96-03 30 11
Pub!. I Gr.1 P.
Technical Handbook Description
.. ' \. .. -

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.

Oil filter - of full-flow type, with a filter element of pleated filter


paper. To protect the engine against insufficient lubricating oil, a
by-pass valve is fitted in the oil filter bracket. The valve will open
if the lubricating oil pressure should rise above a certain pressu-
re due to clogging of the filter. When the valve is open, unfilte-
red oil will flow to the engine. The filters are of disposable type
and should be scrapped after use.
~- .
Crankcase ventilation - prevents pressurising of the crank-
case and collects fuel vapour, steam and other gaseous pro-
ducts of combustion. Crankcase ventilation is provided by a
pipe connected to the crankcase inspection cover on the right-
hand side of the engine, between the starter motor and the oil
filter.

2 3

1. Filter by-pass valve


2. Oil cooler by-pass valve
3. Oil cooler
4. Full flow filter
5. Oil pump
6. Suction strainer
7. Oil sump

Lubrication system
Engine ' ... «Kalmar
.,ConIChamp·DC-RS··:· 9129 96-03 30 12 ,.
Technical Handbook Description '. Pub!. I Gr.1 P.

Combustion air system


Large quantities'of air are necessary for burning the fuel stJpp-
lied to the engine. Free; unrestricted flow of fresh air and
exhaust gases is therefore essential to allow the engine to run
efficiently.

Air cleaner
The intake air is cleaned in a two-stage air cleaner, the first
stage of which collects coarse particles by cyclone action, and
the 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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- ---, I
-- \ I
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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.

¢ The turbocharger is lubricated and coo1ed.by the lubricating oil


from the engine.

Intercooler
In intercooling, the air that has been compressed and heated by
the turbo is cooled in an intercooler.

The intercooler increases the oxygen supply during combustion


so allowing the injected fuel to be burnt more effectively whilst
reducing fuel consumption as well as the level of exhaust
emission.

Intercooling also reduces the thermal stressed on the engine,


increasing durability and reducing oil consumption.
1. Exhaust gases to the engine silencer
2. Exhaust gases from the engine Inlet manifold heater
3. Air to the engine intercooler Before the air is admitted into the combustion chamber, it flows
4. Intake air from the air filter across an electrically heated starting element. This has a high
rating of 3 kW and heats the intake air sufficiently for the enigne
to start at low ambient temperatures. The heater element is
energised when the starting key is turned to the heating posi-
Turbocharger
tion. Suitable preheating time is about 50 seconds.

1.
2.
3'.
4.

Intercooler
{<Kalmar
ContChamp DC-RSi Engine:"·~ .. 9129 96-03 30 14
Technical Handbook Service .' Pub!. I Gr.1 P.

Quality of diesel fuel


Diesel fuel conforming to DIN 5160t, SIS 155432, CEC-ERF-
01 or ASTM-D975-No.2 should be used. The fuel should have
the lowest possible sulphur content.
N.S. When light diesel (e.g. Dipolar) is used, follow the
engine manufi[lcturer's recommendations concerning the
addition of extra lubricant, etc., since the injection pump
may otherwise be damaged. Also note that light diesel
includes a certain percentage of paraffin (kerosene), which
reduces the engine output.

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.

Always add a corrosion inhibitor (Kalmar LMV part No.


923.110.0003) to the coolant, if the above mixture is not used in
the cooling system.

N.B. Never add a corrosion inhibitor if the cooling system


contains glycol, since this would cause foaming which seriously
impairs the cooling capacity.

Lubricating oil quality


See Group 90, Periodic supervision.

Draining the water from the fuel tank


Drain any water from the fuel tank by removing the drain plug.
Immediately refit the drain plug as soon as the flow of fuel is
free from water and other impurities.

Inspection of the air cleaner and changing the


filter element
Check the indicator when the engine is running. If it shows red,
the main filter element must be changed. The collecting efficien-
cy of the filter element will not be improved if the element is
changed too early. But if changing of the filter element is de-
layed, smoke emission from the engine will increase, the engine
may lose power due to insufficient supply of combustion air, and
1 2 engine damage may occur in certain cases.

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.

." Change the filter element as follows:

1. The engine must not be running.


KL204

2. Clean the outside of the air cleaner.

1. Main filter insert 3. Remove and clean the dust receiver.


2. Safety filter element
4. Release and carefully remove the main filter element. Do not
remove the safety filter element.
({Kalmar
ContChamp -DC-RS Engine ~::::'." 9129 96-03 30 15
Technical Handbook Service Pub!. IGr.1 P.

5. Fit a new main filter element. Carefully check that it is not


damaged. Note on the safety filter element when the main
element was replaced.

6. Change the safety filter element:


- after the main filter element has been changed five times
- at least every other year
- if the indicator shows red after the main element has been
changed
- if the engine has been run with the main element damaged

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.

Changing the oil and oil filter

N.B. Before draining the oil, make sure that it is at normal


working temperature.

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.

3. Remove and discard the filter canisters, which are of dispo-


sable type.

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.

5. Lubricate the canister seals with oil.

6. Fit the new filters and tighten them - by hand only.

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.

N.B. To avoid serious damage to the engine, use only


genuine Kalmar LMV filters.

Checking the V-belt tension


1. Check at regular intervals that the V-belts are correctly
tensioned. It should not be possible to depress the V-belt
more than 1 °-12 mm mid-way between the pulleys.

2. The engines are equipped with an automatic belt tensioner


which maintains the belt tension constant.

N.B. If the belt drive consists of two belts, always change


both belts.
{{Kalmar
ContChamp' DC';RS,~ Engine. ;';'. '0 • ,. 9129 96-03'30 16
Technical Handbook Service Pub!. I Gr, I p,

'\
... .•

Checking and adjusting the valve clearances


N.S. Never attempt to check the valve clearances when the
engine is running. The engine must be stationary and cold.

1. Turn the crankshaft in its normal direction of rotation- until the


inlet valve Qf NO.6 cylinder has just opened and the exhaust
valve of the same cylinder has not yet closed fully. Check
the valve clearances on No.1 cylinder and adjust as
necessary .

Valve clearances

Engine TWO 1030 ME TWO 1230 ME

Inlet 0.40 mm 0.40 mm


Exhaust 0.70 mm 0.70 mm

2. Check the other valves in accordance with the table below.

Check the valve clearances


of cylinder No .... 1 5 3 6 2 4

... when the inlet and exhaust


valves of the following cylinders are
just changing over
(are moving simultaneously) 624 1 5 3

Changing the fuel filters


1. Clean the outsides of the filters.

2. Remove the filters and discard them.

3. Clean the filter head.

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,

Preventive maintenance on the turbocharger


The turbocharger may be damaged and, in the worst case, may
break down if the engine is not properly serviced.

1. Check that the engine air inlet system is in good co~dition,


i.e. that the, air cleaner is clean, that none of the hoses are
CAUTION.
worn and that hose connections are not defective, which
Never run the engine with the would allow oil to seep past the seals on the compressor
air inlet or exhaust pipes side and be entrained by the inlet air. The latter may lead to
disconnected from the turbo- high exhaust gas temperatures and overheating of the
charger, since personnel could turbine shaft bearing. If corrective action is then not taken,
the turbocharger may break down.
then sustain injuries.
2. Change the lubricating oil and filter at the specified intervals.
Check at regular intervals that the lubricating oil lines to the
turbocharger are in good condition and do not leak. Also
check regularly that the oil pressure is not too low, since this
could quickly lead to damage to the turbocharger.

3. Ensure that the fuel system is serviced at the specified


intervals. Inadequate fuel supply caused by clogged fuel
filters or incorrect setting of the injection pump reduces the
Note! turbocharger speed which, in turn, results in a lower engine
Adjustments on the injection output.
pump are to be performed by 4. Check that there are no restrictions in the crankcase ventila-
authorized personnel only. tion. If the vent is blocked, pressure may build up and may
force oil into the inlet air system of the turbocharger and
engine.

Maintenance of the exhaust gas cleaner


The exhaust-gas cleaner of a well maintained engine needs
hardly any maintenance. Yet, an iterativ check-up for carboniza-
tion ought to be made, appro twice a year. If necessary dis-
mount and clean the exhaust-gas cleaner as follows:

1. Loosen the tube clamps and remove the cleaner.

2. Dry-brush the cleaner on the intake-side.

3. Clean with pressured air from the exhaust-side.

4. Soak the cleaner in soap-water for, at least, one hour.

5. Clean with pressured air from the exhaust-side.

6. Clean with high-pressured water (0.3 MPa max.) from the


exhaust side.

7. Dry with pressured air.


'e'
••..• -.-.-> .

•~ \ v:

.r;,;.,
«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{-

Torque converter and


gearbox
Model Clark - 15.5 HR 34432 Clark - 15.5 HR 36432
Number of gears 4F - 48
Oil capacity, total system, I 42
Oil grade API-CD, Engine oil, see also Group 90,

Oil operating temperature, °C 82-93


Max. permissible temperature, °C 120
Clutch pressure, bar 17-20
with parking brake applied, All clutch pressures should be equal to within
oil temp. 82-93°C, engine 0.4 bar as indicated on pressure gauge in cab.
idling at 625 r/min

Clutch type Multiple disc, hydraulic. Automatic wear compensation (no adjustment).
All clutches oil cooled and lubricated.

Stall speed, r/min 1782±50 TWD 1030 ME/15.5 HR 34432


1923±50 TWD 1230 ME/15.5 HR 36432

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

Parking brake system Spring-activated disc brake on drive axle input-shaft.

Wheel dimensions, front/rear in DC 4160 RS4, 4160 RS5: 18,00x25/18,00x25

DC 4161 RS4, 4161 RS5,


4171 RS4, 4171 SRS5, 4171 RS5 : 23,5x25/23,5x25

DC 4170 RS4, 4170 RS5: 18,00x25/18,OOx25


DC 4180 RS4: 21 ,OOx35/21,OOx35

Tyre pressure, bar 9

Oil change capacities Each hub 12


Differential 50

Oil grade API GL 5


Viscosity 85W-140 or 80W-140, see also Group 90

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'-

The transmission consists of a torque converter integrated with


the gearbox, and a propeller shaft, driven axle with differential,
hub reductions and brakes.

The torque converter and gearbox run together, using a. com-


mon hydraulic system. The torque converter can be regarded
as a hydraulic coupling and is located between the engine
output shaft and the gearbox input shaft.

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.

The turbin wheel is located opposite the pump impeller and is


Caution. The machine must connected to the torque converter output shaft. The oil enters
not be run at stall speed the turbine wheel at the periphery and is discharged at the
centre.
longer than 30 seconds at a
time. The torque converter The stator is located between the pump impeller and the turbine
will otherwise overheat, wheel, at their inside diameter. The function of the stator is to
causing damage to the seals guide the flow of oil from the inside diameter of the turbine
and thus necessitating wheel back to the inside diameter of the pump impeller in the
expensive overhaul. best possible way.

Torque conversion takes place in the oil circuit of the torque


converter. When the load on the truck increases, Le. when the
torque required increases, the turbine wheel slows down in
relation to the pump impeller, and the oil flowing through the
stator then increases the torque.

The output torque gradually increases as the speed of the


output shaft decreases and is a maximum when the output shaft
and thus also the turbine wheel are stationary, Le. are stalled,
see Techincal data.

Gearbox
The gearbox is of constant-mesh type. Gear-changing is carried
out by clutch plates for the various gears being hydraulically
actuated.

The valve body mounted on the side of the gearbox includes


spool valves which guide the oil flow to the various clutches.
The spools are activated in turn by solenoid valves. These are
activated electrically by the gear selector in the cab. As an
optional extra an automatic gear changing system is available.
See Group 20.

The gearbox has four ratios in each direction and is also


provided with disengagement, which is actuated by the brake
pedal and comes into operation at a certain brake pressure.
,~c 'ContChamp DC~RS "',' ,~.4'''-., ' ,Transmission:. : ~" """'Kalmar
-
-. '912996·03-40'4
Technical Handbook Description' Pub!. I Gr.1 P.

•••• \ 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:

- to transmit the engine output to the gearbox. The torque


converter can multiply the engine torque by up to three times.
but at the expense of the speed rotation.

- to apply the clutches in the gearbox.

- to dissipate the heat from the torque converter.


- to lubricate the gearbox and the torque converter.
",if,

- to transport any solid particles to the filter.

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.

The regulating valve delivers oil at the right pressure to the


gearbox valve body, which actuates the clutch plates for For-
ward/Reverse and 1st/2nd/3rd/4th. The clutches use only a
small proportion of oil delivered by the pump. The remainder is
fed through the torque converter circuit to the oil cooler, and
retums to the gearbox for lubrication.

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.

Oil level check (transmission, incl. converter)


Check the oil level daily with the engine at idling speed and the
oil temperature between 82 and 93°C.

Maintain the oil level at the FULL mark.

Changing the gearbox oil and filter


This should be carried out when the oil is at normal working
temperature (82-93°C). -

1. -Remove the gearbox drain plug and drain the oil.

2. Release the suction strainer, withdraw it and clean the


strainer gauze. N.B.,lf metal particles are found in the
strainer gauze, investigate the reason before topping up
By-pass valve
with new oil.

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.

5. Fit the new filter and tighten it.

6. Fit the drain plugs and tighten them.

7. Fill with oil to the MIN mark on the dipstick.

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.

N.S. In the event of gearbox damage, always replace the oil


cooler - the damage may have been caused by the oil
cooler being faulty.

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.

~\
.•. ..

Checking pressures in the Clark 34000 gearbox


The pressure should always be checked when the oil is atthe
normal working temperature of 82-93°C and the gearbox is in
neutral.
NOTE!
When the check is carried out Converter outlet pressure: '
underidenUcalcondftion~ Above 1.7 bar at an engine speed of 2000 r/min, although the
the pressure must not vary pressure must not exceed 4.9 bar when the engine is running at
top speed.
by more than 0.4 bar between
the various clutches. Clutch pressure:
17 - 20 bar with parking brake set, oil temperature 82-93°C,
engine at idle (400-600 r/min) shift through direction and speed
clutches.

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

Clark 34000 Gearbox


ContChamp DC~RS" _Driveaxle ..:t.,; (<..Kalmar
9129 96-03· 40 8
Technical Handbook Description Pub!. I Gr.1 P.

The Rockwell PRC 5324 drive axle features two-stage reduction


(differential and.hub) ..

Rockwell planetary axles permit the bevel or hypoid gearing of


the carrier and the axle shafts to carry only a nominal torsional
load while at the same time providing the highest practical gear
reduction ratio at the wheels.

The differential assembly employs a heavy duty hypoid drive


pinion and ring gear. The differential and gear assembly is
mounted on tapered roller bearings. The straddle mounted
pinion ha~ two tapered roller bearings in front of the pinion teeth
which take the forward and reverse thrusfanda third bearing
behind the pinion teeth to carry the radial load.

The hub reduction consists of a planetary gear. Each hub


reduction consists of a sun wheel, three planet wheels which
rotate around the sun wheel, and a ring gear surrounding the
planet wheels.

The hub reduction consists of a planetary gear with sun gear,


three planet spur gears and a floating ring gear.

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.

Power is transmitted by the pinion and gear of the differential to


the axle shafts driving the sun gear of the second reduction,
through the revolving planet gears, and then to the planetery
spider which drives the wheel hub.

The axle is equipped with an oil-cooled brake system - the wet


disk brake system.
Drive axle~:·.:.":" ""
~Kalmar
ContChamp DC-RS 9129 96-03 40 9
PubL I Gr.1 P.
Technical Handbook Description "",9;;'
.~ \. >(

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.

A cooling circuit is provided to dissipate the heat produced


,when braking. The cooling circuit uses fluid from the general
hydraulic system, which means that the total volume of hydrau-
lic fluid in the truck participates in the cooling process.

I
01"'..-1
l)

I
(

6 •.
KL516

1. Brake pressure from foot brake 7 8


2. Hydraulic piston
3. Disc arrangement
4. Hub to spindel seal
5. To vehicle hydraulic system
6. Cooling fluid from vehicle hydraulic system
7. Cooling fluid cavity
8. Lubricating fluid cavity
Wet-disc brake
Kalmar
•....•.
ContChamp~ DC-RS ,...,' . Drive axle', :,":_...: . ., 9129 96-0340 12
Technical Handbook Description ... ,__~ Pub!. I Gr.1 P.

Parking brake system


The parking brake, which is of the disc type, is mounted on the
drive axle input shaft. The brake is operated by a heavy-duty
spring in the parking brake cylinder and is released by hydraulic
pressure, counteracting the spring force. The brake cylinder and
the caliper ass~mbly form an integral unit. The hydraulic press-
ure is applied via the parking brake control lever in the opera-
tor's cab.

The parking brake can also be used as an emergency brake.


Emergency braking causes heavy wear to the brake pads.
Therefore.the brake pads have to be changed after two
emergency brake operations.

1 2

1. Cylinder and caliper assembly


2. Piston
3. Spring cap
4. Brake linings
6. Seal, large
7. Back up ring, large
8. Seal, small
9. Backup ring, small
10. Stud
11. Lock nut
12. Washer
13. Locking pin
14. Washer
15. Spring
Parking brake
Drive axle. : '..
~Kalmar
ContChamp DC-RS .. 9129 96-03 40 13
Technical Handbook Service PubL I Gr.1 P.

Changing the drive axle oil


IMPORTANT: To assure that the wheel ends of planetary'axles
with a common wheel endlhousing bowl oil level are initially
lubricated, fill each wheel end directly with oil before vehicle is
put back into operation. DO NOT FILL THE AXLE THRQUGH
~)\.
~1 .1
THE DRIVE U~IT OR HOUSING BOWL ONLY.

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.

3. Repeat the procedure on the other wheel.

4. Remove the drain plug from the bottom of the differential


and drain the oil. Refit and tighten the drain 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.

--- :'. J:J

) - 0..:.j~.
- .--- , :J.)
~ ;-.)~
Drive axle mounting bolts KL519

Tightening torques, see Specifications


Rim clamp nuts
Tightening torques, see Specifications
Drive axle ~'.,~.:
' «Kalmar
ContChamp DC-RS'1 "" 9129 96-03 40 14
Technical Handbook Service ' Pub!. I Gr.1 P.

Parking brake· initial adjustment


..
Note! The spring cap (3) has a clock-wise thread and the
stud (10) has an anti- clockwise thread.
The parking brake can Never try to screw the spring cap (3) in with springs in compres-
also be used as an sion as the threads may be damaged.
EJlERGENCYBRAKE..
1. Ensure that the spring cap (3) is fully engaged in the
housing (1).
NOTE!
After two emergency brake 2. Loos~n the parking brake.
operations the brake pads, 3. Turn.thenut (11) against the washer (12).
has to be changed.
4. Apply the parking brake.

5. Turn the spring cap (3) until the total clearance between the
disc and the lining (2) is 0.5 mm.

6. Loosen the parking brake.

7. Back up the nut (11) and lock it with the pin (13). The brake
is now ready for operation.

1 2

1. Cylinder and caliper


assembly
2. Piston
3. Spring cap
4. Brake linings
6. Seal, large
7. Back up ring, large
8. Seal, small "
9. Backup ring, small
10. Stud
11. Lock nut
12. Washer
13. Locking pin
14. Washer
15. Spring

Compensation of lining wear


1. Apply pressure.
2. Turn the nut (11) against the washer (12).
3. Release the pressure.
4. Turn the spring cap (3), until the total clearance between
the disc and the linings (4) is reduced to 0,5 mm.
5. Apply pressure.
6. Back up the nut (11) and lock it with pin (13). The brake is
now operational again.
{<Kalmar
ContChamp DC-RS· 9129 96-03 60 1
Technical Handbook Contents Pub!. I Gr.1 P.

",' \ "

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)

Nuts for lower knuckle-pin


bearings, Nm 1750
Nuts for upper knuckle-pin
bearings, Nm 1500

Mounting screw, M24 670


Steering cylinder, Nm oiled bolt

1) Steered wheel bearings should be tightened during simultaneous rotation


of the wheels. This makes the bearing rollers set correctly.

Note that a jacked-up wheel gives a certain resistance when rotated.

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 steering axle is supported by a pendulum suspension and


is operated by a double-acting steering cylinder. The
mechanism includes the smallest possible number of moving
parts to mini mise the number of service points and to simplify
maintenance.

The mounting in the chassis comprises entirely maintenance-


free rubber elements. On certain machines, the rear suspen-
sion is fitted with a pivoted joint. This is used to indicate a too
low loading of the steering axle, i.e. the risk of tipping forwards.
When only the weight of the steering axle remains, a "gap" is
created which is indicated by a sensor. See further description
under Group 20, overload indication system.

The knuckle pins and wheel axles are mounted in taper roller
bearings. The hydraulic circuits of the steering system are
described in Group 70.

~1
~~~/
'-coI-(ffiI ~-:,
f

I, __ -,
II II
~r-----J

; ..•......•....•...•...••.
_ 9

1. Pivoted joint 8 KL520


2. Rubber element
3. Steering cradle
4. Upper bearing
5. Knuckle pin
6. Lower bearing
7. Steering cylinder
8. Wheel axle
9. Link lever
Steering axle
ContChampDC-RS"': , {<Kalmar
Steering.axle ,'_.. 9129 96-03 60 4
Technical Handbook Service -- .~:'.i.'.-
Pub!. I Gr.1 P.

Replacement of steering cylinder


-1. Disconnect the hydraulic connections from the steering
cylinder; and protect the open ends of the cylinder and
hoses by means of caps or plugs.

2. Release 8:nd remove the piston rod pivot spindles.

3. Remove the bolts retaining the cylinder on the steering


cradle.

4. Remove the cylinder.

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.

7. Connect the hydraulic hoses.

Replacement of knuckle pin bearings


Dismantling
1. Jack up the steered wheel end of the truck and block it up
in a safe manner.

2. Remove the retaining ring from the steered wheel and


remove the wheel.
1. Steering cylinder
Note. A trolley with a rest for holding the wheel
2. Locking washer
securely will be needed for handling purposes.
3. Spindle
4. Mounting bolt, lock with LOCTITE
3. Secure a sling around the hub neck and lift until the hub is
5. Steering cradle
held in position.
Note. Use a trolley, pallet truck or the like provided
with a rest.

4. Remove the protective cover from the upper bearing of the


knuckle pin.

5. Release the tabs of the tab washer. Remove the upper


bearing nut and remove the tab washer and plain washer.

6. Remove the protective cover from the lower bearing,


remove the split pin from the bearing nut and remove the
nut. The inner race of the bearing is loose and can be
removed.

7. Remove the knuckle pin by tapping it upwards. The inner


race of the upper bearing will accompany the pin.

8. Use a trolley to lift out the wheel axle.

9. Remove the wipers from the steering cradle.

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

1. Upper bearing 10. Spacer 19. Inner bearing


2. Steering cradle 11. Lower bearing 20. Hub
3. Bearing nut 12. Split pin 21. Outer bearing
4. Cover 13. Cover 22. Washer
5. Bearing nut 14. Gaiter 23. Bearing nut
6. Tab washer, to be greased 15. Steering cylinder 24. Tab washer, to be greased
7. Plain washer 16. Wheel axle 25. Lock nut
8. Knuckle pin 17. Spacer 26. Cover
9. Wiper 18. Sealing ring 27. Wheel nut
{(Kalmar
ContChamp DC-RS' .\ Steering.axle'.-::. , '. ,j 9129 96'03'60' 6
Technical Handbook Service Pub!. I Gr.1 p,
".' \ ,,-

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.

A round plate should be made for each bearing size for


pressing in the races. A heavy hammer can then be used
to hammer the plate for driving in the race. Don't hammer
the bearings directly since they may rot enter straight and
may become jammed in the housing.,

2. Fit new wipers to the steering cradle, using a suitable ring


to tap them in. Tapping the wipers in with a hammer will
damage them.

3. Lift the wheel axle into position by means of a hand trolley


or hoist.

4. Make sure that the contact surface of the whell axle is


clean and in proper contact with the knuckle pin.
Insert the' knuckle pin, fit the spacer and lower bearing
inner race (packed with grease), and fit the bearing nut.

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.

8. Coat the covers with sealing compound, pack them with


grease and top up with grease through the grease nipple
when the cover is in position and the sealin~ compound
has dried.

9. Check the tightening torques every 1000 running hours.

Replacement of steered wheel bearings


Dismantling
1. Jack up the steered wheel end of the truck and block it up
in a safe manner.

2. Remove the retaining ring from the steered wheel and


remove the wheel.
Note. A trolley with a rest for holding the wheel
securely will be needed for handling purposes.

3. Remove the hub cover.

4. Secure a lifting sling to the hub, preferably using one of the


hub bolts. Fit a nut to secure the bolt. Use a hand trolley,
pallet truck orthe like for lifting the hub.
{<Kalmar
ContChamp DC-RS . Steering axle,. -.. 9129 96-03 60 7
Technical Handbook Service Pub!. I Gr.1 P.

5. Remove the tab washer, locknut and bearing nut. The


plain washer is loose.

6. Remove the hub off the wheel axle by means of the hand
truck. The inner race of the outer bearing will accompany
the hub ..

7. Withdraw the inner race of the inner bearing from the


wheel axle.

8. Remove the seal, but leave the spacer in position.

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.

A round plate should be made for each bearing size for


pressing in the races. A heavy hammer can then be used
to hammer the plate for driving in the race. Don't hammer
the bearings directly since they may not enter straight and
may become jammed in the housing.

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.

3. Clean the spacer and pack it with grease.

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.

8. Pack the outer bearing with grease, pack the bearing


cover with grease and fit it into position. Top up with
grease through the grease nipple.

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,

See the hydraulic system data plate


where all present pressure settings are specified.
..--Kalmar
ContCham'p DC-RS Main hydraulics ..-- 9129 96-03 '70 3
Technical Handbook Description- <,i.~ Pub!. I Gr.1 P.

General
The hydraulic system consists of the following sub-systems.
• Main hydraulics comprising

- Servo system supplying the electro-hydraulic syste.m.


- Telescoping of the boom
- Lifting/lowering of the boom
- Rotation of attachment
- Length adjustment of the top-lift frame
- Sideshifting
- Locking/unlocking twist-locks

• Foot-brake system - WDS hydraulically operated, oil-cooled


multi-disc brake system with circuit

• Parking brake system consisting of a disc brake on the drive


axle input shaft. Applied by spring force and released
hydraulically.

• Steering system

Principle of the electro-hydraulic servo system


The main hydraulics are controlled by means of an electro-
hydraulic servo system, the basic arrangement of which is
shown diagrammatically on the next page.

Each function of the hydraulic system is controlled by a total of


three individual sub-systems - electric servos, hydraulic servos
and main hydraulics.

The control unit in the electrical system is supplied at the


battery voltage of 24V. The control unit delivers a pulsed d.c.
output to the coordinate lever's potentiometer for each function.
The signal is modulated by the amount of movement of the
lever and is retumed to the control unit for amplification.

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 servo pressure, in turn, actuates the operating spool of the


main valve and thereby controls the main flow.

Main valve 2 has no converters but retains the servo pressure


from the converters for main valve 1. (If the truck is equipped
with a vertical lift then main valve 2 is also equipped with
converters).

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 '
~"'.I~I~I,," IIr-
IIPS2.

---------, ·-01-

I
t------
I
10 I a b 12 I a I b I I 23 a b I c d


6

7 8

- 22-
KL524

The numbers correspond to


the hydraulic diagram
1. Hydrulic pump 11. Converters 24. Accumulator charging valve
2. Hydraulic pump /121 Main valve 2 25. Accumulator
3. Hydraulic pump a. BOOM OUT 1/BOOM IN 1 26. Parking brake system
4. Hydraulic pump b. LIFT 2ILOWER 2 27. Driving brake system
5. High pressure filter 22. Hydraulic tank 28. Cooling circuit, driving
6. Pressure reduction valve, 23. Main valve on top lift brake system
servo system a. Rotation ±90° 29. Control unit IPS 1
7. Priority valve b. Sideshift ±800 mm 30. Control unit IPS 2
8. Steering system c. Feed, top lift 31. Coordinate lever
10. Main valve 1 d. Tilt 32. Switches
a. LIFT 1/LOWER 1
b. BOOM OUT 2IBOOM IN 2

Hydraulic system
({Kalmar
'ContChamp- DC-RS:' Main hydraulics: ' ... 9129 96-03 70 5
Technical Handbook Description' --.~_ Pub!. I Gr.1 P.
'.'\. "

Main hydraulics, feed


The truck's main hydraulics are fed by four different pumps.

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

Pump 4 feeds the steering system and the attachment via a


priority valve together with a pressure regulator valve for the
hydraulic 'servo. The priority valve ensures that the requirements
of the steering system are always satisfiediirst and feeds the
remaining flow to the different functions of the attachment.

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.

The hydraulic system is controlled from the cab by means of a


coordinate lever a collection of switches.
..
KKalmar
. 'ConiChamp·DC-RS. '<'<" Main hydraulics:~ . 9129' 96-03 706
Technical Handbook Description _..,.
,~__ Pub!. I Gr.1 P.

<:) ,

4~ I:::J " ,I

, I
I
"

12
~
I ~
,

ee
: I

22
Kl525

The numbers correspond to


the hydraulic diagram

1. Hydraulic pump, LIFT/LOWER 1, BOOM OUT/IN 2


2. Hydraulic pump, brake system
3. Hydraulic pump, LIFT/LOWER 2, BOOM OUT/IN 1
4. Hydraulic pump, STEERING SYSTEM, SERVO, TOP LIFT
5. High pressure filter
7. Priority valve, steering system
10. Main valve for LIFT/LOWER 1, BOOM OUT/IN 2
12. Main valve for LIFT/LOWER 2, BOOM OUT/IN 1
22. Hydraulic fluid tank

Main hydraulics, feed


{<.Kalmar
.ContChamp DC-RS ,. Main. hydraulics .;",.. • I 9129 96-03 '70 7
Technical Handbook Description "._ Pub!. I Gr.1 P.

•... \ "

11

The numbers correspond to


the hydraulic diagram

6. Pressure reduction valve with accumulator for servo pressure


6a. High pressure filter
10. Main valve 1
11 . Converters
12. Main valve 2

The illustration shows a servo system for a machine with overload


indication system. One set of converters feed both main valves.

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:

1 - Body, equipped with a spring- and pressure-loaded plston


y - Shuttle valve
';:-,

- 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
/

The numbers correspond to


the hydraulic diagram
10. Main valve 1
12. Main valve 2
15. Extension cylinder
16. Over-center valve

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.

If the truck has an oil-cooled wet disc brake system, any


hydraul~ oil used for topping-up should c~>ntain 6% of Lubrizol
additive which is necessary for good performance of the brake
system.

The additive is not consumed during normal operation and


must only be added at oil change and refill. Lubrizol may be
ordered from Kalmar LMV Service department.
CAUTION! Hydraulic fluid with Lubrizol additive is
chemically aggressive. Avoid extended contact with the
skin.

Hydraulic oil filter


The high pressure filter for the hydraulic oil must be changed at
the intervals specified in the lubrication chart. In addition, the
filter must always be changed whenever work has been carried
out on the hydraulic system.

1. Clean the outside of the filter and the area around it.

2. Place a vessel under the filter to collect any spillage.

3. Remove the filter bowl. Use an open-ended or ring spanner.

4. Remove the filter cartridge.

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.

7. Remove the filter cartridge from its package and fit in


immediately.

8. Carefully clean the filter bowl and fill it half-full with hydrau-
lic oil.

9. Fit the bowl and tighten it.

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.

".. \. ,,'

High-pressure filter for the servo hydraulics


The high-pressure filter mounted adjacent to the main valve and
at the attachment main valve filters the circulating servo oil to
protect the components downstream of the filter and prevent
maloperation.

A by-pass valve opens at 3.5 bar if the filter should become


~.... clogged.

The filter contain a cartridge which should be changed every


1000 ho~ts of operation.
1. Unscrew the bottom section of the housing and withdraw the
cartridge downwards.

2. Fit a new cartridge, check the a-ring and refit the bottom
section of the housing.

Hydraulic-fluid filter for the brake cooling circuit


Change the filter every 1000 hours of operation.
(Option: Two filters. Change both filters every 1000 hours of
operation.)
KKalmar
ConlChamp .DC-RS .~:: .i:.. : . f. . Steering:system:; ..'...:. 9129 96-03 70'12
Pub!. I Gr.1 P.
Technical Handbook Description-- .~"

Steering system
The steering system is supplied from hydraulic pump 4, which
. also supplies the main hydraulics for the attachment.

A priority valve ensures that,the steering valve will always be


supplied with a.sufficient amount of fluid. Any remaining fluid is
routed to the main hydraulics.

A certain signal pressure at connection CF in the priority valve


is always in communication with pressure connection P of the
steering valve. As soon as the steering wheel is operated, a
load signal LS will immediately be applied, to the priority valve
which changes over and supplies a sufficient quantity of fluid to
the steering valve.

The pressure in the steering system is determined by a relief


valve in the priority valve.

The numbers correspond to


the hydraulic diagram
7. Priority valve
7a. Test outlet, steering pressure
7b. Feed from pump
8. Steering valve
8a. Valve block
9. Steering cylinder
22. Hydraulic tank Steering system
{<Kalmar
ContChampDC-RS" ,Steering system:'. 9129 96-03 70 13
Technical Handbook Description ..;0 •••• Pub!. I Gr.1 P.

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.

The steering valve consists of a gear pump and a distribution


valve. When the steering valve is turned.Jluid is supplied from
I
the steering pump across the gear pump to the distribution
II
T'OSPB I
valve, which ensures that the flow will be supplied to the port
corresponding to the direction in which the steering valve has
,.. :. - I .
ILS . ._1 been turned. The gear pump ensures that the flow supplied to
8c the cylinder will be proportional to the angle through which the
I steering wheel has been turned. If the flow from the steering

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

Steering valve and valve block

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.

Adjusting screw for double shock valve


under the plug, should be completely
tightened up.
Valve block OVPK
{{Kalmar
ContChamp DC~RS.~>;L •• Steering.system ~_: .':'. 9129 96-03 70 14
Technical Handbook Description· ... ",.-,,..., .•...
Pub\. I Gr.1 P.

Item 12 - assembly configuration

6
7

26

23

KL259

22

25

1. Oil seal Tightening torque: 30 ±5 Nm


15. O-ring
2. Housing - spool - sleeve 16. Distributor plate
3. Ball 17. Gear set
4. Threaded bush 18. O-ring
5. O-ring 19. End cover
6. Guide ring 20. Washer
7. Front bearing race 21. Pin
10. Ring 22. Bolt
11. Dowel 23. Locking wire
12. Neutral position springs. 1 set 24. Nameplate
13. Shaft 25. Self-tapping screw
14. Spacer 26. Spacer

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

tem there are two units, each one comprising:


A Inlet section
B Control section
---~------~
I,
r.~ 1
C Combined control and outlet section

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.

The control section is equipped with a check valve in the


2 supply passage to prevent inadvertent lowering of the load
when several functions are operated simultaneously. The
control section incorporates a valve for transmitting the load
-
I-
signal to the regulator (shunt valve) in the inlet section of the
main valve.

The load signal valve employs the load pressure to control a


1. No-load relief vlave spool which, in turn, is supplied with oil from the supply passage
2. Regulator (shunt valve) for controlling the shunt valve. The design permits the
3. Main pressure limiting valve circulation of a small constant flow in the load signal circuit,
4. Spool for lift thereby ensuring a supply of warm oil for fast and accurate
5. Load signal valve' control.
6. Reducing valve
The outlet section has a tank connection and connections for
Main valve
the load-sensing and no-load relief signals.

The valve spools are spring-centered and mechanically control-


led. In the hydraulic system with electro-hydraulic servo, the
spools are controlled by hydraulic servo pressure using electro-
hydraulic converters.
~Kalmar
ContChamp DC-RS(· ".d',!., Main .valve::~:: ... 9129 96~03 70 18"
Technical Handbook Service Pub!. I Gr.1 P.

Main valve
The main valves are of precision type and must be handled
with great care to safeguard their good performance. The
following rules apply to service work:

1. Never use .the spool ends or housings for clamping or


3 gripping when lifting a valve block.

2. Never subject spool ends or housings to blows or shocks.


Rough treatment may deform the spool, which will lead to
.immediate seizure.

3. Protect the valves from moisture and dirt. Take particular


care to prevent dirt from entering the connection ports.
Protect the ports and other joint faces to prevent scoring
and bruising: Keep unconnected ports plugged with plastic
plugs or the like.

4. When fitting pipes and hose couplings, observe meticulous


cleanliness. Make sure that no swarf, flakes of paint or other
impurities enter the valve. To avoid unnecessary stresses in
the valve, do not overtighten the couplings.

Main valve - adjusting the supply pressure


The supply pressure to the main valve is determined by the
main pressure limiting valve.
This is located in the inlet section (see figure). When adjusting:
- Release the locknut and turn the adjusting screw the projec-
ting pin with a drilled hole.
- Check the pressure by connecting a pressure gauge to the
measurement tapping on the relevant inlet section.

1. Adjustment, main' pressure limiting


valve
2. Locknut
3. Return
4. Supply
5. Measurement tapping
«Kalmar
ContChamp. DC-RS Brake. system ~.',:'.. '9129 96-03 70 19
Technical Handbook Description, '"...~ ...
Pub!. I Gr.1 P

WDS brake system


This system is known as the wet disc brake system, in which
each hub is equipped with a multiple~disc assembly.The disc
assembly comprises stationary discs arranged alternately with c
number of rotating discs. The disc assembly is compressed by
hydraulic pres1:!ureto provide effective braking action, The
assembly is submerged in a hydraulic oil bath to dissipate the
heat generated by braking. A separate cooling circuit is provi-
ded to cool the hydraulic oil.

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.

The wet disc brake system comprises three separate hydraulic


circuits, Le. the foot-brake circuit, the cooling circuit and the
parking brake circuit.

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.

The charging valve ensures that a minimum pressure will


always be maintained in the accumulators. During the charging
process, the charging valve serves as a priority valve, so that a
certain residual flow will be supplied to the cooling circuit. If the
engine runs at no load, the residual flow may be so small that
the flow in the cooling circuit engine will temporarily stop. When
the accumulator has been charged to full pressure, the chargin~
valve transfers the entire pump flow to the cooling circuit.
{<Kalmar
·ContChamp DC~RS· ' Brake.system:,~..,.<,.. :~:_: .. 9129 96-03 70 20
Technical Handbook Description·, . ;~.;>' Pub!. I Gr.1 P.

'" '\ 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.

Main components of the brake system


The figures refer to the diagram for the WDB brake system.
A 10206.0100

1. Accumulator charging valve serving as a priority valve


which gives first priority to the brake system. The remaining
flow is delivered to the cooling circuit.

2. Hydraulic pump, which generates the brake pressure and is


driven by ~ power take-off on the engine.

4. Accumulator discharge valve, used for emptying the .,


accumulator to tank.

5. Accumulators which are charged by the accumulator


charging valve, are pre-charged with nitrogen and ensure
that pressure will be available in the brake circuit even if the
engine should temporarily stop.

7. Driving brake cylinder in the hubs, compresses the brake


discs when braking.

8. Disc assemblies in the wheel hubs.

10. Parking brake cylinder. Actuated by a heavy spring when


the brake is applied, i.e. when the oil has been discharged
through the parking brake valve. The brake is released by
hydraulic oil from the parking brake valve.

11. Brake pedal. Supplies oil at a reduced pressure from the


accumulator to the drive axle disc brake assembly.

15. Parking brake valve which supplies fluid at a reduced


pressure from the accumulator to the parking brake cylinder
when the parking brake is released. Sensor 16 switches on
the parking brake warning lamp when the parking brake is
applied, and initiates a signal to a buzzer in the cab to
indicate that the operator has left the seat without applying
the parking brake.
~"
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- 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 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

3 10. Parking brake cylinder


»... 11. Foot brake valve I\)
0w
~=
<0
o~ 12. Sensor, inching -"
c:<0 0> -.j
b:-c~ ~ ~~
o0) 13. Sensor, brake lights
g>

(:) 14. Sensor, low brake pressure


..•
oo 15. Parking brake valve
o~ 16. Sensor, parking brake warning lamp and seat buzzer
ContCham'p DC.;.RS.··.
~Kalmar
Brake.system::><' :, - .:; 9129 96-03 7022'"
Technical Handbook Description Pub\. I Gr.1 P.

-/ .>,
1 5
r
I
\

I
5
II

II
' •••
t', ...•I ••••I
~.~ ~ •• J

L:'

The numbers correspond to


the brake system hydraulic diagram
1. Accumulator charging valve
2. Hydraulic pump 2, see A1 0205.01 00
3. Pressure limiting valve
4. Accumulator discharge valve
5. Accumulator
6. Cooling circuit filter
11. Foot brake valve
17. Test outlet, brake pressure
(accumulator pressure)
Brake system
KKalmar
ContChamp DC-RS Brake system,~.. 9129 96-03 70·23
Technical Handbook Description'" "c>,;;,- Pub!. I Gr.1 P.

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.

Warning! The hydraulic system contains accumulators


with high pressure. Always open the accumulator
discharge valve prior to any service work on the
hydraulic system.
Accumulator discharge 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.

Accumulator charging valve


The function of the' accumulator charging valve is to divert the
pump flow to the accumulator whenever the latter needs char-
ging. This ensures that the brake system is given priority and is
first to receive oil.
During charging, the pump delivers oil through a check valve to
the accumulator. A restriction limits the flow to a maximum of
approx. 17 Vmin. At the same time, pilot oil pressure is supplied
across the pilot valve to the main valve, where it is added to the
spring force and keeps the main valve closed.
When the accumulator has beencharged.the oil pressure from
the accumulator overcomes the spring forpe in the pilot valve
which changes over and relieves the pilot pressure to the tank.
The main valve changes over and opens the connection to the
cooling circuit motor.
The difference between the pressures at which charging is
started and stopped is determined by the difference in area
between the pressure and tank connections of the valve, and
amounts to about 18% of the pressure at which charging is
stopped, i.e. 'about 27 bar at a pressure of 150 bar and about
30 bar at 165 bar.

/
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 ;:;;':',

Hydraulic brake pedal


The hydraulic brake pedal consists of a direct-acting pressure-
reducing valve of three-way type des,igned for continuously
variable mechanical operation. The pressure-reducing valve
consists of the components shown in the figure.

When stop 4 is depressed by the pedal, the main spring acts on


the control piston which moves and closes outlet T to the tank.
The circuit between pressure connection P and brake line B is
then opened. As the pressure in the brake line increases, a pilot
pressure will act on the control piston through the pilot orifice,
counteracting the main spring load. As a r~ult. the brake
pressure will increase in proportion to the force exerted on the
pedal. If the pedal force is maintained constant, the brake line
B pressure will also be constant.
[--:=t~==""""'_ When the pedal is released, the spring returns the control piston
so that it closes the connection between P and B, simultaneou-
~\
~ sly opening a connection between Band T to relieve the brake
pressure to the tank.

1. Housing
2. Control piston
3. Main pressure spring
4. Pedal stop
5. Return spring
6. Pilot pressure orifice

T 3
P 4
2

1. Neutral position adjustment


2. Brake line
3. Return to tank
4. From accumulator

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.

The parking br.ake can also be used as an EMERGENCY


BRAKE. During emergency braking, the brake linings are
subjected to very heavy wear. The linings should therefore be
changed after two emergency braking operations.

The parking brake is released by hydraulic pressure being


supplied .to the cylinder to counteract the .spring force. All supply
is controlled by a manual valve which is open when the parking
brake is released.

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.

,. I Parking brake valve


The parking brake valve is a direct-acting, three-way pressure- ..'
reducing valve. The pressure output is continuously variable,
although for practical use in the parking brake system, the
valve can be regarded as an ON/OFF valve.

To prevent inadvertent application of the parking brake, the


lever is provided with a latch which must be raised before the
lever can be moved.
{<Kalmar
ContChamp DC~RS. Brake system:':.: ,". 9129 96-03 70 27
Technical Handbook Service Pub!. I Gr.1 P.

Adjusting the WDB brake system


The engine and hydraulic system should be at normal operating
temperature before adjustments are carried out.
The various pressures for the machine are given on the instruc-
tion plate in the hydraulic compartment.
Caution!
The brake system includes accumula- 1. Check the pre-charging pressure of the accumulators.
tors charged at a pressure· of up to - Connect a pressure gauge (0-250 bar) to the measure-
21.0 MPa. Take extreme care whenever ment tapping in the accumulator charging valve.
carrying out any work on the brake - Slowly release the pressure from the accumulators by
system. Before disconnecting any opening very carefully the accumulator discharge valve.
component from the system, always - At a pressure which is a minimum of about 5 bar below the
discharge the accumulators by means specified pre-charging pressure (gas pressure), the
of the accumulator discharge valve pressure should drop instantaneously to O. If it does not,
located below the accumulators. the accumulators require charging, for which special
equipment must be available. Get in touch with authorised
service personnel.

2. Start the engine and keep it running up to and including item


7 below.

3. Check the accumulator charging pressure.


- Connect a pressure gauge (0-250 bar) to the measure-
ment tapping on the accumulator charging valve.
- Use the pressure release valve to discharge the
accumulator. Close the valve, allow the accumulators to be
charged and read the charging pressure. Adjust the accu-
1 2 mulator charging valve as necessary.
- If the adjustment must be repeated, discharge the accumu-
lators again, let them recharge, read the new charging
pressure, and so on.

4. Bleed the cooling circuit.


- A plug/bleed nipple is provided on the inside of each drive
axle hub. Open the nipple and keep it open until the oil
flowing out is completely free from air bubbles. Retighten
the plug/nipple while the engine is still running. N.B. Carry
this out at both hubs.

5. Check the pressure in the cooling circuit.


Connect a pressure gauge (0-25 bar) to the measurement
tapping on the distribution block at the drive axle.
- Check that the pressure is a maximum of 1.5 bar. The
pressure should normally be approx. 0.5 bar. If the pressu-
re is constantly 1.5 bar, the by-pass valve has presumably
opened. This, in turn, indicates a fault on the drive axle.
6 5 Get in touch with authorised service personnel.
6. Bleed the brake circuit.
1. Brake circuit bleed nipple A bleed nipple is provided on the inside of each drive axle
2. Cooling circuit bleed pump hub. Use a piece of hose to discharge the oil into a suitable
3. Cooling circuit supply container.
4. Cooling circuit return - Open the bleed nipple, depress the brake pedal and let the
5. Sensor for high cooling fluid temp oil flow out of the nipple until it is completely free from air
(>115°C) bubbles. Shut off the nipple while the brake pedal is still
6. Drain plugs depressed.
7. Brake circuit supply and return - Bleed in the same way for the other axle hub.

Inside of drive axle hub


{<.Kalmar
'ContCham'p .DC-RS·,,: Brake.system::'.; ::'; "9129 -96'-~3' 70 '28
Technical Handbook Service' ~, Pub!. I Gr.1 P.

7. Check the outlet pressure at the brake pedal.


- Connect a pressure gauge (0-250 bar) to the measure-
ment tapping on the distribution block below the cab.
- Depress the pedal as far as it will go and read the
pressure. The reading should be in accordance wi~h the
hydraulic system plate: Leave the pressure gauge in
position. -

8. Stop the engine and check that there is no leakage at the


brake pedal.
- Depress the pedal and read the pressure on the pressure
gauge. The pressure should be the same as in item 7
above and must not drop for 15 seconds.
- Release the pedal, and the pressure should then drop to O.
If not, the brake valve is leaking and may cause the brake
to remain applied while the truck is being used, and thus
overheat.

9. Use the accumulator discharge valve to release the pressu-


re from the accumulator.

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'

Repairs to leaking hydraulic cylinders - replacing


the seal .1

CAUTION!
Never use compressed air for
removing the piston from the
cylinder. You could sustain
serious injuries.

General instructions applicable to all cylinders

1. Remove the relevant hydraulic cylinder. Fit immediately


protective caps or plugs to the hydraulic cylinder and hose
connections.

2. Take the cylinder to the workshop, drain any oil remaining in


it and carefully wash the outside of the cylinder.

3. Dismantle and assemble the cylinder in accordance with the


instructions for that particular cylinder type.

4. Removing the seals.


3 - Whenever repair work is carried out on hydraulic cylinders,
2 all seals, scraper rings, etc. must be replaced.
- Take extreme care when removing the seal in the cylinder
head, to avoid scratching the bottom of the groove, since
1. Screwdriver
oil leakage will otherwise occur in the future. Use a screw-
2. Lip seal
driver or the like to remove the seal from the piston side.
3. Scraper ring Use the screwdriver as shown in the figure.
- Clean all components very thoroughly.

5. Fitting of lip seals


- Fit the seal in the cylinder head with the lip facing inwards
towards the piston. Oil the seal and press it in by hand.
N.B. Don't use any tools, since the seal may otherwise be
scratched. Even a minute scratch may cause the seal to
leak.

6. Fitting the piston seal


- All piston seals are of the same design and consist of five
components, i.e. a centre sealing ring, two backing rings
and two guide rings.
- Dismantle the piston seal and start by fitting the sealing
ring onto the piston, and then fit the backing rings and the
guide rings. All of this must be done by hand.

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.

Telescoping cylinder, main boom


1. The mounting lug is welded to the piston rod and provided
with a bearing. The piston is attached to the piston rod by
means of a threaded gable.

2. The cylinder head is joint 10 the cylinder tube by means of


mounting flanges.

, •••••• ,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.

Damping cylinders, attachment


.. 1. The damping cylinders are provided with bearings at both
ends. The mounting lug is welded to the piston rod which, in
turn, is threaded into the piston and locked with a locking
screw.

2. The cylinder head is threaded into the cylinder tube .

•••
••••
•••

••••••••
•••
•••••••
15 ""

1. Damping (tilt) cylinder


2. Retaining ring
3. Guide bearing
4. Lubricant niple
5. Cylinder tube
6. Screw
17 7. Piston
8. Sealing kit
9. Sealing
10. O-ring
11 . O-ring
12. Support ring
13. Piston rod sealing
14. Wiper
15. Spacer
16. Cylinder head
17. Piston rod
16

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.

2. The cylinder head is threaded into the cylinder tube.

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.

Locking cylinders, twist-locks


1.. The cylinder end mounting lug is provided with a bushing.
The cylinder head is threaded into the cylinder tube.

2. The piston rod end is threaded onto the piston rod.

~
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

I 13. Cylinder tube


II 14. Cylinder head
15. Spacer ring
II
I

Locking cylinder, twist-locks


«Kalmar
ContChamp DC-RS Hydraulic cylinders, . 9129 96-03 70 35
Technical Handbook Service Pub!. I Gr.1 P.

".. \ ..:

Steering cylinder
1. The steering cylinder has a double-acting piston, with the
piston seal in the centre.

2. On each side is a cylinder head with sealings. The cylinder


ends are cqvered by washers, secured with screws to the
cylinder tube-

.'

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,

Hydraulic system, vertical lift


. Components A 10205;0100

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

Telescope-boom al1d rotator,


attachments

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.

The boom comprises the following:


Fixed boom
Extension boom
Extension cylinder.

The extension boom runs inside the fixed boom on greased


sliding plates made of Robalon. The extension boom is provi-
ded with a mounting attachment for the rotator.

The fixed boom's attachments are provided with bearings.


Cables and hydraulic hoses run on a trailer chain on the outside
of the boom.

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.

The rotator is pivot mounted to the extension-boom.

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.

Checking sliding plates


The sliding plates (Robalon) are positioned inside the fixed
boom and outside the extension boom. Also the top-lift frame is
Note! Do not use any other
equipped with sliding plates.
lubricant. The sliding surfaces
and Robalon plates could be Every 200 hours, the boom has to be fully extended for treat-
damaged. ment with a special lubricant, which can be ordered from
Kalmar LMV Part. No. 923110.0360. The lubricant is applied
with a glazing knife. Spread a thin layer of the lubricant on the
extension boom.

-+-
SNITT B-B

1. Sliding plates

Position of sliding plates, telescope-boom


Boom with 'rotator ,; "," «Kalmar
CoritChamp DC-RS' 912996-03 80" 6
Technical Handbook Service Pub!. IGr.1 P.

Check the following:

1. Wearing of sliding plates

- The thickness of the sliding plates should be atJeast 15


mm. The sliding surfaces of the extension boom are
protecfed by a special coating. If the sliding plates are

> 15 I wom, so that the bolts damage the sliding surface, the
boom has to be dismounted for service.

Please, contact Kalmar LMVservice dep(l.rtment for further


information.

Kl286

2. Wearing of sliding plates on one side

- 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.

- The maximum difference in thickness allowed is 2 mm.


If this value is exceeded, the plates have to be dis-
mounted and plained or replaced.

1 f <2
J==~=-==-=--==--==t
Kl287

3. Clearance between upper and lower sliding plates

- Measure the gap between sliding surfaces of the fixed


'4mm boom and the rear sliding plates of the extension boom.
Also measure the gap between the sliding surfaces of
the extension boom and the front sliding plates.

- The gap must not exceed 4 mm.

- If the gap exceeds 4 mm, dismount the sliding plates


and adjust by means of spacers.
. Boom with rotator {<Kalmar
ContChamp DC-RS 9129 96-03 80 7
Technical Handbook Service Pub!. I Gr.1 P.

4. Allowance between side-sliding plates

- The additional gap in front and rear must not exceed


4mm.

- If the gap exceeds the value, adjust by means of


spacers.

Kl4S:

Replacing sliding plates


1. Place the top-lift frame on a container.

2. Loosen the screws and remove the sliding plate.

3. When replacing sliding plates in the rear, extend the boom


until the plates are exposed.

Checking the gear clearance


An adjustment ought to be made every 10.000 hours.

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.

< 0.3 mm - Place the top-lift frame on a container.

- Loosen the bolts, which join the yoke and the gear ring.

- The bolt holes allow a certain tolerance. Rap the lower


part of the yoke.

- Tighten the bolts. Recheck the gear clearance.

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.

''''\. «

Top lift frame


, The top lift frame is adjustable for 20-40' containers and is
constructed of welded steel profiles that run within each other
on sliding plates made of Robalon. The attachment is controlled
electro-hydraulically by means of the control lever in the
operator's cab .and has a main valve with three sections for
LENGTH ADJUSTMENTfTWIST-LOCKS, SIDESHIFTING AND
ROTATION. See separate hydraulic diagram.

Length adjustment is achieved by means of a chain driven by a


hydraulic motor. Extension rods are connected to the chain. For
30 and 35' containers there is a stop which can be
disconnected. The stop is activated by a sensor.

A sensor at one end of the extension rod activates a solenoid


valve approximately 300 mm from each end position. The
solenoid valve connects in a restrictor that reduces the exten-
sion speed so that the shock of the stop is reduced.

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.

The twist-locks are connected in pairs to the locking cylinders


which, in turn, are activated by a switch on the instrument panel
in the cab. When the locking cylinders have twisted the twist-
locks 900 in the container locking holes, the TWIST -LOCKS
LOCKED lamp lights up. This indicates that both sides of the
frame are locked onto the container and the container is thereby
ready to be lifted.

The different functions of the top lift frame are describes in


detail in section Electro-servo, description group 20.
Attachments,:.,' " «Kalmar
ContChamp-DC-RS ., 9129 96-03 80 21
Pub!. I Gr.1 p,
Technical Handbook Description ,~'*.\.:

.l
.~

4 21 6

f
I

KL138

i II

20.1
20.2

20.4 20.3 3
KL485

Hydraulic cylinder, sideshift The numbers correspond to hydraulic


Hydraulic cylinder, twist-locks diagram A05433.0100 and electrical
Hydraulic motor, length adjustment 20-40' circuit diagram A04454.0100
Extension bars
Twist-lock
8. Spring-loaded contact plate
20.1 Inductive sensor, alignment right
20.2 Inductive sensor, alignment right
?0.3 Inductive sensor, twist-locks locked
20.4 Inductive sensor, twist-locks unlocked
21. Inductive sensor, speed reduction before stop
22. Inductive sensor, stop at 30 and 35'
Top-lift frame
ContChamp~'DC;"RS-', ," Attachments,'.,: .. ., -«Kalmar
9129 96-03 eo '22
Technical Handbook Description - Pub!. I Gr.1 P.

".-\ "

r - - - - - - - •. (
I - "\..6.)
I 5

3
~3

29

Z2

KL486

The numbers correspond to


electrical circuit diagram A04454.0100

1 Hydraulic pump 29. Main valve


2. Hydraulic cylinder, side shift X1. Rotation anti-clockwise
3. Hydraulic cylinder. twist-locks X2. Rotation clockwise
4. Hydraulic motor. Length adjustment 20-40' W1. Sideshift right
5. Hydraulic motor, rotation W2. Sideshift left
23. Solenoid valve, locking/unlocking twist-locks Z1-Z2. Length adjustment and twist-locks
24. Solenoid valve, length adjustment 20-40'
25. Solenoid valve, engagement of restrictor for
low speed 300 mm before stop A05433.0100 01

Hydraulic diagram, top lift frame


ContCham'p· DC-RS,
Technical Handbook
Attachment -
Description
.~ Kalmar
912996-0380
Pub\. I Gr.1
23
P.

.. \ .-

KL487

A06521.0300 02

24 V supply to the top lift


, .. ~ •..~
Kalmar
ContChamp DC-RS Attachment ::, >- '
9129 96-03' 80 '24
Technical Handbook Service Pub!. I Gr.1 p,

",,\ .
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

WARNINGI Whenever the indicating lamps do not work


properly, the attachment should be taken out of service for
repair. The use of an attachment with faulty indication
lamps could be hazardous!· 'j'

30A 30B 30C

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.

Safety interlocking system


After locking of the twist-locks the lifting starts. A built in play
Indicating lamps between twist-locks and container corner boxes allows the
attachment to be lifted enough for the inductive sensors to be
deactivated, Le. the distance between sensor and contact pin
increases to more than 8 mm.

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

Checking of ALIGNMENT indicating lamps and


electrical interlocking system
1. Check that the contact plates in the corner boxes are freely
moveable up and down. A plate which binds in the upper
position may indicate correct alignment although the
attachment is not in contact with all four container corners.

7. Twist-lock 2. Check that the indicating lamp ALIGNMENT lights up when


8. Spring-loaded contact plate the attachment is fitted to the container and that the lamps
20.1. Inductive sensor, alignment right are extinguished when the container is lifted.
20.2. Inductive sensor, alignment left
3. When lifting an empty container just enough to make the
lamp ALIGNMENT go out, check that it is impossible to
The numbers correspond to the unlock the twist-locks.
electrical diagram, top-lift frame
Attachment.·,'.'," «Kalmar
ContChamp DC-RS . 912996-03 80 25
Technical Handbook Service' Pub!. I Gr.1 P.

Light diodes for sensor monitoring


For fault tracing purposes all inductive sensors for twist-locks
a and alignment are connected over light diodes in terminal
boxes, one at each side.
b
c The functions are identical on both sides:
d - left side sensors in left side box and right side sensors in right
e side box.
Functions for each diode:
o a. Plus and minus feed to the terminal box
lO b. Signal from sensor TWIST-LOCKS LOCKED
c. Signal from sensor TWIST-LOCKS UNLOCKED
d. Sigrialfrom sensor ALIGNMENT, rear<'~
e. Signal from sensor ALIGNMENT, front
The output signals from the light diodes are used for activating
the control relays in the relay box, see electrical diagram

27

27. Terminal box


(see electrical diagram, top-lift)

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

Sensor adjustment and check


1. The gap between sensor and magnetic activator should be
set to 4-5 mm. At a distance of more than 8 mm, the sensor
is deactivated.
2. When connected to the 24 V system, the yellow LED-diode
should be alight.
1. Yellow LED-diode 3. Check that the sensor is clean and free from grease.
2. Green LED-diode (Grease may activate the sensor).
3. Magnetic activator

Inductive sensor
ContChanip DC-RS Attachment ,- .."'"Kalmar
912996-03 '80 26
Technical Handbook Service Pub!. I Gr,1 p,

Setting of the main pressure limiting valve


1. Connect a pressure gauge to the test outlet on the main
valve.

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.

3. Adjust as necessary on the main valve adjusting screw.


First unscrew a hexagonal protective cap. Adjust with a 6
mm hexagonal wrench.
,
4., Repeat the pressure check and readjust if necessary.

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.

Electrical circuit, top-lift


Components A04454.01 00

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.

If the truck is used under conditions in which road traffic regula-


tions are applicable, the special maintenance instructions
issued by the authorities must be followed.

Special procedures are required on trucks used under difficult


conditions, such as in difficult terrain or for the transport of hot
goods. These. procedures are not dealt ~ith,here.

The intervals at which service measures are carried out can be


determined on the basis of the operating hour meter readings.

When carrying out a 1OOO-hourservice, it is advisable to work


in the following order:

1. Every 1000 hours


2. Every 600 hours
3. Every 200hours

The same procedure also applies to work carried out in a 600-


hour service.
---------
Anm• •200•list1000
•Guarantee
Work
with 600
hours. service••
in accordance
Comprises:below after ••
200 chart
General survey
00
600 ...
1600
1400
1200
800hours
400
me, Operating
2000

Maintenance intervals, hours


200

WARRANTY SERVICE at 200 working hours

1. 200 hours service according to Technical Handbook, group 90


2. Perform and fill in control chart in the Warranty certificate
3. Changing of oil in engine, gearbox, rotator reduction gear and
reduction gear on the top lift.
". 4: Changing filter in engine, gearbox and hydraulic system,
(all filters incl. WDB, servo filter etc)
5. Valve clearance adjustment (engine)
6.' Check all bolt joints (see also SI94-003)
··ContChamp DC-RS·, ..::< -- . {<Kalmar
-,9129-96·03 90 4
Technical Handbook Periodic supervisi~~: -.y"'- Pub!. I Gr.1 P.

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
I glass
17 18 19 15 13 i614

KL146 I .,.
~. _"'":~".~ .• ".~ .. " ',' '. - ~,." ..• c, .••• 0" , .0' ".-._ •• -, -f'~,:~:;~"-:;l;~_'~~~
r,.".:;:::c ••~~.:o:"C~·:'::i::-::o~~~
,.' .....,.•..•...
't-", '"- -,'

"t'··-,
".,
~~, "'~.'. .-
-!.~.
«Kalmar
ContChamp·DC.;RS . ,~-.- -.-
9129 96"-03 90 5
Technical Handbook Periodic supervision
: ;;~.-";' ..•
Pub!. I Gr.1 P.

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)

For volumes, see Technical data.

For lubricating oil grades, see Oil and lubricant recommendations

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.

LUBRICATION·CHART, CONTAINER UNIT

1 4 4 2 '3 5 1

A
4

6 KL138

7 7
8 8
9 9

11 7 10 11

.,,~

'\~
. :::. '", ' ..... ' -."'-
(Kalmar
ContChamp DC-RS" 9129 96-03 90 6
Pub!. I Gr.1 P.
Technical Handbook Periodic supervision
.-\. .-

LUBRICATION·CHART, CONTAINER UNIT

1 4 4 2 '3 5 1

A
4
f
I

-1
"'- ..

~ I. . ~ 11 ·;1

I8
t.'

9
6 10 KL138

7
8
9

A-A':': ,
11 10 7

,."", ":".~r'",· ,,~ .•.•.•.


'
'.''''--'' ,. .. '..,
,.
(<..Kalmar
>:"i~' ContChamp:CC-RS; ., 9129 96-03' ,90 '7
Technical Handbook Periodic supervisi~rt PubL I Gr.1 P.

LUBRICATION CHART, CONTAINER UNIT


Locking
LiftLift C
xx1pinion
Remarks
Twist600
1000
pinion
Contact lock
-
axle
cylinder
twist
plateslidingNo lub.
' connection 46
oflevel,
notsurface1 top up all Intervals
L with
as xLonto (operating
surfaceshours)
ItemSliding
Description
Chain,
Sideshifting
Chain
Planetary
Check
Brush points
surfaces,
sprocket,
leng1h
with
sight
gear
cylinderleng1h
adjustment
oil,
glass
length adjustment
sideshifting
grease
adjustment Brush
Lubricate sliding
grease with the
each
x)
(volume:
frame direction
First
necessary.
xx) oilthe
change
1.5
sideshifting
in
Thereafter litres)
fully at the
to warranty
extended
oil change limit
every inservice
position
1000 h

•• c.

L=Lubricate
C=Check
{<Kalmar
'MrContChamp,DC-RS" ",.. " ." .... "
9129 96·03 '90 8 '
Technical Handbook Periodic supervisi~~_" Pub!. I Gr.1 p,

Daily supervision
..
' ,
Check requirec;1
. .Or
'"
.~-,
,"
"".~
"
•....
Refill
when if Check
Damagethat the
Operation rear
Operation suspension is' clean
,

L Y SUPERVISION I
pension
d with
stem) and sliding plates

, .,t, •.,." •

Engine, gearbox, drive axle ---


Noises?
Oil leakage?
Hydraulic hoses
Fuel Amount
The fuel meter •
Must never show 0
Engine oil Level
••
Air cleaner
Coolant •• Indicator
Level
••
Hydraulic fluid
• Level

----~
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
, -

.. ',

.. . ,

......
'".- ..-
".,
.•.. ,.
.
. \' ..;,

.~
." ..• ,
;7r:)tt~
'. ;;-."
- .. , .. -,
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

17 For optional equipment, please refer


to special instructions issued~

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".
~.- , - •• ;~_~ .",. '" " ••• , J~_ •• '•.•• ~.
9129 96'03 90 10
Technical Handbook Periodic supervisiC?i1
~ -"':~ .•.
Pub\. I Gr.1 P.
~

Every 600 hours

Item Unit Action Remark

1 Air cleaner .,Change the filter element .


iftQeindicator
..~-,... shows red. ' See Group 30

2 Turbo charger '.'Chec!<for


'"i:"~;:' • leakage. See Group 30

3 Exhaust system , Ch~!llk;for leakage.

4 Steered wheels ,Check the wheel alignment, See, Group 60


, and,~check for deformation
pr bearing play.

5 Telescope boom Check that the hose


and attachment guide pulleys run freely
.and: that the hoses are in
good condition.

6 Lubrication points, oil


and filter changes in
accordance with the
Lubrication chart.

7 200 hours service

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.

Every 600 hours

Item Unit Remark


.•.. ,.'
1 Air cleaner Change th~' fiUer element .
if the iridicator shows red. See Group 30

2 Turbo charger Check fQ-r·I~~kage. See Group 30

3 Exhaust system Check fof'lea..~age.


. ,
4 Steered wheels ChecktA~ wheel alignment, See Group 60
and checK,:for deformation
or bearing'play.

5 Telescope boom Check that the hose


and attachment guide pulleys run freely
and thatthe .hoses are in
good condition.

6 Lubrication points, oil


and filter changes in
accordance with the
Lubrication chart.

7 200 hours service

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.
"'I.'

;,.,,,,.';

.P,

:i~

". ,_,r

\~ -i'f

.~. :if"

.;.. ;

':'t' .•.•.) ..• .'~


'of •

':o_;~

,.>' l,';,,-,,
~;\j':~f;;~:
~
.."'", . KKaimar
." .ContChamp.DC-RS ::.., .: "'--
9129 96-03 90 11
Technical Handbook Periodic supe.ryision
.~!::.,..". Pub!. I Gr.1 P.

Every 1000 hours

Item Unit Action Remarks

1 Fresh-air filter Change filter element See Group 10

2 Engine Check valve clearances, See Volvo


cooling system, starter motor, Workshop Manual
alternator and fuses and Group 30

Wheels
V-belts
Fuel
Batteries
tank shaft
filter
Propeller
Injectors 3
7 Drain€;,
468
9 Change the filter. Bleed the
5 fuel system.

Check See Volvo


Workshop Manual
Check and change as
necessary.

Check.

Check for damage

Check the bolted joints and See Group 40


check the universal joints
for play
~
Gearbox
Brakes
Steered
Painting
(Air axle
and
and
conditioner) 10 Clean the breather
13
drive axle
safety marking
11
14· All functions
15
12 Check knuckle pin bearings See Group 60
tightening torque

Check See Group 70

Touch up

Test-drive and check

Check the refrigerant


level

16 Lubrication points, oil


and filter changes in
accordance with the
Lubrication chart.

17 Hydraulic pressure Check and adjust if


necessary .

18 600 and 200 hours service


..
N.B. Always attend to any damage"wear or faults that are important to the performance of
the truck and its service life or tnesafety of the personnel.
,

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Hydraulic system, vertical lift
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OVERCENTRUMVENTIL

14
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1--
Hydraulsystem
Hydraulic system
DIRECTION OF TRAVEL
KORRIKTNING

VANSTER ~
LEFT I ---..HOGER
RIGHT

;
-
s

rs
~S
20

s """

_______ -----11 1_-------


1•.--- ------
II J
1 I
II
II 29 I XI VRIDNING MU
II X2 VRIDNING MOTU
II 1

I
WI SIDOFORING HO

II I
W2
ZI
SIDOFORING VA
OVRIG HYDR UT
II I
Z2 OVRIG HYOR IN
: I I YI TILT IN (GALlER VID BOTTENLYFT)
\I Y2 TILT UT (GALLER VIO BOTTENLYFT)

'f II
-I~ II
I II
I II
I II
I II
_,_ - __ I II
II
II
26 - - - ;-,
1'---
"
II
" 30

A LAST TWISTLOCK

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