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Kalmar ContChamp DRD S Series, Technical Handbook

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ContChamp DRD-S

Technical Handbook

Engine

Description

4

S.

Grupp

30

9407

04-10

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 hub
2. Twin fuel filters of throw-away 

type

3. Lift eyelet
4. Gear driven coolant pump
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 type

21. Oil cooler
22. Vibration damper
23. Automatic belt tensioner

Volvo TWD1231VE engine

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Summary of Contents for ContChamp DRD S Series

Page 1: ...ook deals with the design and maintenance of Kalmar machines type DRD S for the handling of contai ners In addition it gives details of trouble shooting and the most common corrective maintenance Oper...

Page 2: ...hments or top lift with pileslope 1 The electrical system is equipped with a separate KDU for the top lift component number 791 The KDU communicates with ECU 2 via a CAN bus 2 The main valve of the to...

Page 3: ...hnical Handbook 1 S Grupp 00 9407 04 10 Contents Group 00 Safety regulations 2 General 6 Design Overview 6 Component units 7 Supplementary books 9 Replacement system Spare parts 9 Tools 9 Tightening t...

Page 4: ...rgency exit A rear window that can be opened is standard on ma chines with hydraulically moveable cab Optional on other machines Safety regulations aimed at reducing the risk of personal injury and da...

Page 5: ...to remember z The truck s hydraulic system includes high pres sure hydraulic accumulators Always be extremely careful when working with the hydraulic system and avoid being unnecessarily close to the...

Page 6: ...e i e with the boom retracted and lowered as far as possible without obstructing vision see pic ture below z Never run hands or fingers along any tubes pipes or hoses whilst investigating for possible...

Page 7: ...aged and severely rusted components Always select the correct tyre size and construc tion matching the manufacturer s rim or wheel rat ing and size Do not use over size tyres too large for the rims e...

Page 8: ...t all round visibility There are many adjustments that can be made to the operator s driving position The position of the seat back support and firm ness of the driving seat can be adjusted in a numbe...

Page 9: ...olvo TWD1031VE TWD1231VE six cylinder four stroke turbocharged diesel engine with direct injection and thermostatically controlled water cooling The engine is equipped with Injection pump with centrif...

Page 10: ...ulic fluid cooler for the main tank z 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 a...

Page 11: ...s catalogue Instruction Manual for Volvo Industrial engines Replacement system Spare parts Kalmar operates a system of replacement parts repair kits and gasket sets covering most of the vital componen...

Page 12: ...e 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 Surface treatment Condition Lubriation Bolt...

Page 13: ...tightened to the specified torque Quality 8 8 10 9 12 9 Tightening torque Nm Condition Thread M 1 2 3 1 1 4 5 6 8 10 3 2 6 4 11 26 52 2 9 5 7 9 8 24 47 3 6 7 2 12 5 30 59 4 6 9 1 16 38 74 5 5 11 19 4...

Page 14: ...16 5 8 3 4 7 8 1 1 1 8 1 1 4 1 3 8 1 1 2 164 227 396 629 937 1350 1860 2500 3260 145 202 352 560 834 1200 1655 2225 2900 185 256 447 710 1058 1525 2100 2825 3680 231 321 559 889 1320 1900 2630 3530 4...

Page 15: ...2 Chassis 3 Description 3 Chassis 3 Support jacks 3 Operator s cab 4 Steering column 9 Hydraulics control unit 10 Service 11 Changing the fresh air filter 11 Check and lubrication of brake pedal 11 Wi...

Page 16: ...h Electric power consumption approx 350 W z Compressor Max speed 4000 r min Refrigerant R134a Electric power consumption approx 50 W Oil capacity Zexel PAG SP 20 1 5 dl z Condenser Electric power cons...

Page 17: ...transmission z The necessary counterweights to provide a very low centre of gravity Moreover the steered axle is designed to serve as an additional counterweight The hydraulic oil tank and the fuel ta...

Page 18: ...ssible operator 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 recirculatio...

Page 19: ...ONT WIPERS MAIN BEAM 3 Instrument panel 4 Steering wheel panel 5 Starting switch 6 Control lever and control panel for hydraulic functions 7 Electrical central unit with fuses and relays 8 Brake pedal...

Page 20: ...frost cab 37 Switch fan 38 Control heat 39 Control cold 1 40 Spare 41 Spare 42 Warning lamp battery charging 43 Warning lamp low engine oil pressure 44 Warning lamp low gearbox oil pressure 45 Warning...

Page 21: ...ion 9 above 17 Stop at 30 and 35 1 18 Cab movement horizontal vertical1 19 Support jacks DOWN UP 1 20a Red lamp the support jacks have left the upper position 1 20b Green lamp support jacks down 1 1 O...

Page 22: ...ist locks locked green B Alignment orange C Twist locks unlocked red Lit lamps at container lift A B Go out after lift B WARNING Overriding of the safety system is at one s own risk and involves a ris...

Page 23: ...th the ECS terminal At the very foot of the steering column is the steering valve Orbitrol activated by the steering wheel via an angled gear The steering column is equipped with an adjustment knob fo...

Page 24: ...l lever is a joystick that is electrohydraulically connect ed to the main valves 1 Control lever 2 Connection and disconnection of servo cir cuits 3 Control switches for attachment 4 Switch for overri...

Page 25: ...sh the filter insert with water and detergent or by using a high pressure washer Replace the insert if necessary 3 Reinstall the filter insert Check and lubrication of brake pedal Every 1000 e hours 1...

Page 26: ...e arms to and fro Fitting 1 Check to ensure that the splines on the motor shaft are free from the softer material from the wiper arm mounting If this is not the case clean the splines so that they can...

Page 27: ...r when it is cold z dehumidifies the air when it is humid z removes impurities from the air z cools the air when it is warm The equipment is controlled by switches and controls on the in strument pane...

Page 28: ...7 04 10 1 Liquid receiver filter dryer 2 Evaporator 3 Fan 4 Expansion valve 6 Condenser 7 Compressor A High pressure gas B High pressure liquid C Low pressure liquid D Low pressure gas E Warm air in c...

Page 29: ...The function of the liquid receiver with integrated filter dryer is to collect the liquid coolant bind the moisture and to filter and re move impurities The receiver which is located in the condenser...

Page 30: ...ds the compressor should be run for a few minutes every week to lubri cate the rubber hoses couplings seals and shaft seal 1 Start the engine and start the air conditioner At an outdoor temperature be...

Page 31: ...GL 1 5 SV 1 5 RD 1 5 4 4 R R RD 1 5 M M M BR 1 5 BR 1 5 VT 1 5 7 BR 1 5 8 30 85 87 86 GL 1 5 10 LOW IN CAB UNIT CONDENSER UNIT 1 Fan switch 2 Cooler on off 3 Anti freeze thermostat 4 Resistor 5 Fan m...

Page 32: ...Tom sida Empty page Leere Seite Face vide...

Page 33: ...40 54 Module 50 Mechanical Overload Protection 56 Module 51 Vertical lift for Module 50 59 Module 52 Vertical lift Balance for Module 50 60 Module 57 Hydraulic Balance 61 Module 59 Limitation Height...

Page 34: ...ContChamp DRD S Technical Handbook Specifications 2 S Grupp 20 9407 04 10 Alternator rating 1920 W Starting battery voltage 24 V 2 x 12 V capacity 140 Ah earthing negative...

Page 35: ...switch The negative pole is then connected to the chassis Warning lamps and instruments are clearly arranged on the in strument panel The central electrical unit with fuses and relays is located on t...

Page 36: ...arning lamp and meter 4 Main fuses 2 X 50A 5 Relay preheater 6 Sensor engine oil pressure warning lamp 7 Sensor engine oil pressure meter 8 Sensor coolant temperature warning lamp 9 Sensor coolant tem...

Page 37: ...main fuse rear lights main fuse position lights 15 S13 Main beam right hand 5 S14 Main beam left hand 5 S15 Dipped beam right hand 5 S16 Dipped beam left hand 5 S17 Rear light left hand 5 S18 Rear li...

Page 38: ...322 Coolant level ECS 07 1 323 Pulse relay direction indicators 328 Gear shift ECS 01 1 330 Starting block 331 Propulsion forward 332 Propulsion reverse 334 Clutch release ECS 01 1 367 Lever steering...

Page 39: ...Watts Base Instruments 3 BA7s Indicating lamps 1 2 W2x4 6d Cab lighting 10 S8 5 Rear lights red 5 BA15s Brake lights 21 BA15s Direction indicators 21 BA15s Position lights 5 SV8 5 Driving lights full...

Page 40: ...nce away from the truck battery such as the negative cable connection on the chassis Start the engine Do not disturb the jumper cables while starting as sparks may otherwise be caused Do not lean over...

Page 41: ...onitors the engine and gearbox to ensure reasonable operating conditions monitors the components in the system e g sensors to ensure their correct function provides torque controlled automatic gear ch...

Page 42: ...nal display has 4 lines with space for 20 characters on each line Graphical presentation of operating menus and error messages Menu structure There are three types of menu 1 Operating menus The operat...

Page 43: ...ted loop Access to the sub menus under the service menu requires an ac cess code If ENTER CODE is displayed by mistake return to the operating menu by pressing ENTER N B Additional menus may occur as...

Page 44: ...ll when the indicator is filled to the right 5 Red lamp blinks The steering axle is overloaded It is not possible to switch to other menus until the overload is rectified 6 The system interrupts opera...

Page 45: ...DRD S Technical Handbook ECS Terminal 13 S Grupp 20 9407 04 10 Operating menus with electronic overload protection module 60 60 01 60 01 07 60 07 60 KL1411 2 4 1 1 4 3 1 3 4 5 6 7 8 9 Explanations see...

Page 46: ...y to the right for 0 100 loads When the load indicator reads full the system inter rupts operation due to forward overload The red warning lamp lights continually It is not possible to switch to other...

Page 47: ...and contact service 03 Faulty signal from injection pump motor sensor Engine speed reduction Stop as soon as possible and contact service 04 Gear lever not functioning Engine speed reduction Stop as...

Page 48: ...x oil pressure Check oil level and top up as required 13 High gearbox oil temperature Check oil level and top up as required 14 Fuel level extremely low Fill the tank to avoid air in the system 15 Low...

Page 49: ...n as possible 23 Service interval exceeded Contact service as soon as possible 24 Faulty signal from prop shaft rpm sensor Engine speed reduction Stop as soon as possible and contact service 25 Steeri...

Page 50: ...ty signal from angle sensor Stop as soon as possible and contact service 54 Faulty signal from length sensor Stop as soon as possible and check the sensor wire Contact service if the fault remains 55...

Page 51: ...more sensors remains on for more than 60 sec after unlocking of twist locks Check that the contact pins can move freely up and down Contact service as soon as possible if the fault remains 61 System f...

Page 52: ...tion is unique for each machine The illustrations below and on the following page provide an over view of all available service menus All of them are accessed from the KALMAR INDUSTRIES SERVICE main m...

Page 53: ...r re spective section descriptions The connected loops then appear as shown in the adjacent picture The arrows beside the menus show the switch paths between menus Use RIGHT LEFT arrow keys KL723 C 1...

Page 54: ...emitting diodes Analogue IN signals are not indicated The LEDs are marked LE1 LE42 and are used for fault finding For each ECU there is a table listing the relevant junction box pins the correspondin...

Page 55: ...Factor Comments 0 DRD Cummins M11 118 260 Magnetic pick up 1 VOLVO TD TWD 30 1023 Volvo engines without frequency control 4 Scania DSI 11 158 194 6 VOLVO TWD1231ME 30 1023 Frequency control 7 VOLVO T...

Page 56: ...8 LE22 Seat rotation x 55 Digital IN 9 LE15 Brake pressure x 56 Digital IN 10 LE18 Lever steering ON OFF LE18 lights up when the button for lever steering is in the ON position a check that the cable...

Page 57: ...x x x 60 Pulse sensor 3 LE25 Steering wheel revolutions anti clockwise x 36 Pulse sensor 3 LE26 Steering wheel revolutions clockwise LE25 and 26 will light up alternately with overlap when the steerin...

Page 58: ...with the ECS ter minal Applies to the ECU that is connected to the terminal LE39 shows communication from the terminal and since ECU 1 is slave under ECU 2 LE39 should be extinguished LE40 shows commu...

Page 59: ...tor brakes and the speed of the truck is lower than 3 kph Provides the required engine revolutions based on the posi tion of the accelerator pedal Continually shows the currently engaged gear on the E...

Page 60: ...gnals from ECU 1 The standard steering wheel is equipped with two inductive sen sors that sense any movement of the steering wheel The sen sors are used to disconnect the lever steering function if th...

Page 61: ...be set see Technical Handbook ECS SERVICE Initiation Module 06 Monitoring of steering lever wheel angle sensor If a fault occurs in the lever steering system sensor steering le ver cables an alarm is...

Page 62: ...position The standard steering wheel is equipped with inductive sensors that sense the movement of the steering wheel The sensors dis connect the Mini steering if the operator is faced with an emer ge...

Page 63: ...d the risk of break down are monitored on two levels A red warning lamp lights and an error message appears on the terminal display If the reason for the fault is not rectified the system limits the t...

Page 64: ...vel min 13 Operating time max service interval period shows the time remaining to the next service and generates an alarm when operating time has been exceeded 14 Brake pressure The following sensors...

Page 65: ...50 LE12 Blocking valves lift cylinders 22 Digital OUT PNP NPN 46 Buzzer overload and warning of overloaded steering axle 40 Analogue IN 0 10V Boom length 42 Control lever LIFT LOWER P1 64 Pressure sen...

Page 66: ...tra circuit board B Switches all should be in the ON postion LE39 shows communication from the terminal and should always blink LE40 shows communication to the terminal and should blink on all ECUs If...

Page 67: ...t the switches are in the positions shown in the illustra tions ECU 1 1 2 3 4 ON OFF 1 2 3 4 ON OFF ECU 2 ECU 3 1 2 3 4 ON OFF 1 2 3 4 ON OFF ECU 2 ECU 2 A 1 2 3 4 ON OFF 1 2 3 4 ON OFF A ECU 3 1 2 3...

Page 68: ...t is active See error code on the ECS display X70 Connection block on boom mounting X400 Connection block X401 Connection block X405 Connection block X410 Box with relays for emergency stop For safety...

Page 69: ...2 El servo S A38630 0200 ECU2 ECU 3 For top lift circuits refer to separate diagram When following the circuit descriptions first select an S diagram and an top lift diagram that correspond to the ma...

Page 70: ...e output signal in proportion to the lever movement The output signal is amplified in the control unit ECU 2 and thereafter used for controlling the hydraulic servo output from the converter T1 Side s...

Page 71: ...lock 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 The control pressure output delivered...

Page 72: ...ply 5V to S42 and from there on to connector S55 The end positions provide 0V and 10V respectively 4 The SIDE SHIFT LOCKING TILT PILE SLOPE STRAIGHT LIFT AND RELEASE TWIST LOCKS functions are fed with...

Page 73: ...t K Clamping HS Cab movement SB Support jacks U Lamp support jacks up VS By pass connection rotation stop TP By pass connection Max hight Min LC dist N Lamp support jacks down S By pass connection saf...

Page 74: ...are identical See also the el servo diagrams S Module 50 Sensor in the feed line to left lift cylinder Out signal 4 20 mA Module 57 Sensor in the feed line to right lift cylinder Out signal 4 20 mA N...

Page 75: ...he forward position doors closed With remote control contact OK Twist locks either LOCKED or RELEASED Signal from 791 Control DIAGNOS menu 4 8 No front overload no steering axle overload Module 50 LE2...

Page 76: ...N no indication 11 Out signal right return 768 11 2 1 10V to X69 4 to X62 4 to S2 65 ANA IN no indication 12 Out signal left pressure side 768 12 2 4 20 mA to X69 5 to X62 5 to S2 63 ANA IN no indicat...

Page 77: ...7 8 10 Main valve section S7 2 and S7 8 opens for LOWER Conditions No alignment indication from attachment LE14 extin guished Dead man s grip activated LE19 lit No front overload no steering axle over...

Page 78: ...IN S2 66 3 ANA OUT S2 05 LE4 lights depending on voltage 4 X63 4 5 Main valve converter S7 3 opens for servo pressure Simultaneous feed of servo pressure to S7 6 6 Main valve sections S7 3 and S7 6 op...

Page 79: ...ont d p 14 next page Module 60 or module 52 Conditions for regeneration Connects when the pressure in lift circuit 85 Bar Disconnects when the pressure is approx 185 Bar 8 Feed right sensor 24V over X...

Page 80: ...it 15 X61 4 16 Connector X67 4 see illustration 17 Connector X68 4 see illustration 18 Regeneration valve S18 opens and regeneration starts The regeneration starts with a time delay which is set in th...

Page 81: ...ogue signal via S42 4 via cable S33 2 X55 2 3 ANA IN S2 66 4 ANA OUT S2 01 LE5 lit 5 X63 3 6 Main valve converter S7 4 opens for servo pressure Simultaneous feed of servo pressure to S7 5 7 Main valve...

Page 82: ...ad indication on the display Rotation anti clockwise 1 P3 signal 5 1 V out via S42 11 2 X55 3 3 ANA IN S2 67 no indication 4 ANA OUT S2 2 LE6 lit 5 X62 10 6 X69 10 7 Activate solenoid valve top lift S...

Page 83: ...gnal from 7202R to X403 3 to X403 3 2 DIG IN 791 2 40 3 Signal from 7203R to X403 6 to X402 6 4 DIG IN 791 2 26 5 Signal from 7202L to X404 3 to X402 7 6 DIG IN 791 2 13 7 Signal from 7203L to X404 6...

Page 84: ...k cylinder that turn the twist locks to locked position Twist locks manual locking 1 Feed 24V from central electrical unit S1 fuse 3 to connector X32 1 2 X50 1 3 X56 4 4 Main switch S36 on through loo...

Page 85: ...405 3 6 Indicator lamp 563 Twist locks locked lit Signal from 791 via CAN bus to ECU 2 Control DIAGNOS 4 8 Indicator twist locks released 1 Signal from 7204R to X403 4 to X402 4 2 DIG IN 791 2 41 3 Si...

Page 86: ...UT 791 2 31 to 6020 REF OUT 791 2 35 to 6020 11 6020 opens for hydraulic feed to the side shift cylinder Side shift left Side shift right 1 Control lever switch T1 is used for side shift right 2 24 v...

Page 87: ...UT 791 2 4 to 6018 REF UT 791 2 18 to 6018 17 6018 opens for hydraulic feed to the cylinder length adjust ment OUT begins Length adjustment IN 1 Control lever switches T1 T4 are used T1 2 T1 to the l...

Page 88: ...End position damping for IN and OUT length adjustment 1 Feed sensor DIG OUT 791 2 11 to X402 1 Reference voltage sensor REF OUT 791 2 38 to X402 2 2 Signal from 769 to X402 11 3 DIG IN 791 2 12 gives...

Page 89: ...ssure sensor 768 12 in the left lift cylinder feed line Five inductive sensors for monitoring boom angle boom ex tension and end position An inductive sensor on the steering axle suspension to indi ca...

Page 90: ...ases an overload warning is generated and LIFT LOWER and BOOM OUT functions are interrupted while BOOM IN works as usual This means that the machine may become locked in position To rectify such a sit...

Page 91: ...S18 Regeneration valve BOOM OUT S19 Terminal bar S20 Sensor steering axle overload S21 Sensor boom angle S22 Sensor end position boom angle S23a Sensor boom inner position S23b Sensor boom outer posi...

Page 92: ...xample Printer Container counter Automatic gear changing Module 51 consists of see illustration below A potentiometer type length sensor S17 with wire to indicate boom extension length An oil filled p...

Page 93: ...le 52 consists of see illustration below A pressure sensor 768 10 11 12 13 in each of the lift cyl linder lyftcylinderns feed and return line A potentiometer type length sensor S17 with wire to indica...

Page 94: ...the position where the red flags on the left lift cylinder are aligned with each other 5 Lower the boom until the red flags are exactly aligned with each other By first lifting the boom too high and...

Page 95: ...imitation the system functions as nor mal In front of limitation A limitation of Lc distance the system functions as normal In parallel with switch S71 the switch for by passing the safety system loca...

Page 96: ...precision 0 5 tons over 80 of the complete measurement area controls the end position damping of LIFT LOWER and BOOM OUT IN Electronic overload protection see illustration below consists of A pressure...

Page 97: ...type of machine the red warning lamp on the ECS terminal blinks and the buzzer sounds intermittently Regeneration The regeneration function operates on the LIFT and BOOM OUT functions and is a system...

Page 98: ...9407 04 10 S16 Angle sensor S17 Length sensor S18 Regeneration valve 768 10 Pressure sensor feedline right lift cylinder 768 11 Pressure sensor returnline right lift cylinder 768 12 Pressure sensor f...

Page 99: ...UT 4 PNP I O LE8 48 Digital OUT 5 PNP I O LE9 49 Digital OUT 6 PNP I O LE11 50 Digital OUT 7 PNP I O LE12 24 V feed to switch for support jacks 22 Digital OUT 1 PNP NPN 46 Digital OUT 2 PNP NPN 40 Ana...

Page 100: ...s 5V feed to ECU3 from the voltage transformer LE29 Not used LE30 Not used LE39 Should be extinguished LE40 indicates communication to the terminal and should blink If it lights continuously or not at...

Page 101: ...2 1 5 Signal from D sub contact S42 2 to S55 4 6 ANA IN 2 S3 42 Tilt OUT 7 Control lever P4 is moved downwards 8 If ANA IN 2 is 5 10V supplies ANA OUT S3 1 LE5 lit 9 S59 1 10 Via S29 13 to top lift E5...

Page 102: ...3 47 LE38 lit 15 S63 13 16 24 V feed to hydraulic valve 6 that opens for hydraulic feed to the cab movement cylinder Cab movement forwards or backwards 17 The cab moving button 2 backwards as above 18...

Page 103: ...switch 3 Limit switch makes when cab is moved 100 mm forwards 4 Limit switch makes when right door is open 5 Limit switch makes when left door is open 6 H37 Control valve feed to hydraulic motor H38 7...

Page 104: ...d When the support jacks have reached the bottom position a green lamp will light up Furthermore the overload safety sys tem changes load curve As a result of this the higher capacity 7 tonnes in cont...

Page 105: ...t jacks RAISE LOWER 4 Electrical central unit 5 Relays 43 Control of support jacks at overload 44 Indication support jacks raised 45 Indication suppot jacks lowered 6 Inductive sensors activated 100 m...

Page 106: ...arter motor 50 G From starter switch H From alternator D J To parking brake warning light K For gearbox M Included in engine wiring 1 Gear lever 3 Sensor for outgoing gearbox revolutions 4 Valve housi...

Page 107: ...ContChamp DRD S Technical Handbook Diagrams Gear changing systems 75 S Grupp 20 9407 04 10 1 4 3 M K F G H J 6 7 D 8 A B C KL 1564 Clark 36000 40000 Manual electrical gear changing system...

Page 108: ...h H From alternator D J To parking brake warning light K For gearbox L ECU connections M Included in engine wiring 1 Gear lever 2 Revolution sensor on the torque converter engine revs 3 Sensor for gea...

Page 109: ...ContChamp DRD S Technical Handbook Diagrams Gear changing systems 77 S Grupp 20 9407 04 10 Clark 36000 40000 Automatic electrical gear changing A B C D E F G H J K L M 1 2 3 4 4 5 6 7 8 KL1565...

Page 110: ...s beside ECU 2 under seat 10 Relays 1 Overload and red warning lamp 2 3 Warning overload steered axle 14 Regeneration valves lift 15 Blocking valves right and left lift cylinders With emergency loweri...

Page 111: ...dule 01 Automatic gear changing Module 04 Lever steering Module 06 Mini steering Module 07 Monitoring Module combination Variations Electrical diagram 01 4 gears A24925 2000 04 06 Modules 04 06 in com...

Page 112: ...unctions and ECU 4 Functions respectively H Cable marking A shows that the cable is located inside the central electrical unit J Reference the cable continues on diagram A08333 1000 K Ignition key dep...

Page 113: ...block 27 If there is a dot in the destination number it describes a terminal block If the cable has a connector strap e g a common cable for supp lying several functions a capital letter is added to t...

Page 114: ...Tom sida Empty page Leere Seite Face vide...

Page 115: ...witch fog light Schalter Nebelscheinwerfer Interrupteur feux de brouillard 103 S Str mst llare fj rrljus Switch distance light Schalter Fernscheinwerfer Interrupteur feux longue porte e 104 S Str mst...

Page 116: ...are kraftuttag bak Switch power take off rear Schalter Nebenantrieb hinten Interrupteur prise de puissance arri re 130 S Str mst llare h g l gv xel Switch high low gear Schalter Rangegetriebe Hoch Nie...

Page 117: ...ard revers Schalter Kombi Signal Beleuchtung Fern Abblendlicht Waschanlage 2 Intervallwischer vor r ckw rts Interupteur avertisseur feux de route et de croisement essuie glace balayage intermittent 16...

Page 118: ...llare option Switch option Schalter Option Interrupteur option 200 S Brytkontakt lampa park broms Contact breaking warning lamp parking brake Unterbrecherkontakt Warnlampe Feststellb remse Contact ouv...

Page 119: ...locking Schlie kontakt Kabinenverriegelung Contact fermeture verrouillage de la cabine 229 S Slutkontakt stolsl sning Contact making seat locking Schlie kontakt Sitzsperre Contact fermeture verrouill...

Page 120: ...lverstellung Contact fermeture cartement des bras de fourche 264 S Slutkontakt sidof ring Contact making sideshift Schlie kontakt Seitenverschiebung Contact fermeture d placement lat ral 265 S Slutkon...

Page 121: ...Relay intermittent wiper Relais Intervallwischer Relais balayage intermittent 322 K Rel kylv tskeniv Relay coolant level Relais K hlfl igkeitsstand Relais niveau radiateur 323 K Rel blinkers Relay bli...

Page 122: ...ge 347 K Rel stolv ndning ljussignal Relay multifunction seat rotation light signal Relais Multifunktion Sitzdrehen Lichtsignal Relais multifonction si ge appel de phare 348 K Rel fl ktmotor v rmare...

Page 123: ...beacon lifting height limiter Relais blinkende Rundumleuchte H hebegrenzung Relais lampe clignotante limiteur de hauteur 373 K Rel bakljus Relay light Relais beleuchtung Relais feux 375 K Huvudkontak...

Page 124: ...nd Containerbeleuchtung links Eclairage conteneur gauche 406 E G lampa cont belysning h ger Container light right hand Containerbeleuchtung rechts Eclairage conteneur droite 408 E G lampa park ljus v...

Page 125: ...rd Gl hlampe Fahrtrichtungsanzeiger rechts vorn Ampoule clignotant avant droite 426 H G lampa k rvisare v bak Light bulb direction indicator left hand rear Gl hlampe Fahrtrichtungsanzeiger links hinte...

Page 126: ...fall links Ampoule feux stop clingnotant gauche blackout 454 H G lampa bromsljus blackout h ger Light bulb brake light blackout right hand Gl hlampe Bremslicht Ausfall rechts Ampoule feux stop clingno...

Page 127: ...droit sur la poutre pour les 40 blackout infra rouge 463 H G lampa bak ljus v nster bak blackout Light bulb rear light left hand rear blackout Gl hlampe Rueckfahrtleuchte links hinten Ausfall Ampoule...

Page 128: ...lenkung T moin roue avant directrice 531 H Kont lampa 4 hjuls styrning Indicating lamp 4 wheel steering Kontrollampe Vierradlenkung T moin 4 roues drectrices 532 H Kont lampa crab styrning Indicating...

Page 129: ...e information Kontrolllampe Motor Information Lampe de contr l information moteur 574 H Kontroll lampa st dben nere Indicator lamp support jacks down Kontrollampe Stuetzbein unten Lampe de contr l beq...

Page 130: ...n ral 611 Y M ventil fl desbegr nsning Solenoid valve flow restriction Magnetventil Flie begrenzung Electrovanne limiteur de d bit 612 M St llmotor recirkulation Regulating motor re circulation Stell...

Page 131: ...injection 639 Y M ventil l sning orbitrol ls Solenoid valve locking LS orbitrol Magnetventil Sperren LS Orbitrol Electrovanne verrouillage de LS Orbitrol 640 Y M ventil gasol Solenoid valve LPG Magne...

Page 132: ...e Pompe de dosage climatisation 664 M Cirk pump klimatanl ggning Circulating pump air condition Umw lzpumpe Klimaanlage Pompe de circulation climatisation 665 V Diod Diode Diode Diode 666 M Fl ktmotor...

Page 133: ...it tsmesser Indicateur de capacit batterie 710 P Tidur motor kupev rmare Timer engine and cab heater Schaltuhr motor und Kabinenheizung Minuterie chauffage moteur et habitacle 711 P R knare impuls Cou...

Page 134: ...uit Geber Temperatur Sp lkreis Bremsen Capteur temp circuit refroidiss freins 763 B Givare niv hydraulolja Transmitter hydraulic fluid level Geber Hydraulik lf llstand Capteur niveau huile hydraulique...

Page 135: ...kare styrsystem Servo amplifier steering system Servoverst rker Steuerungssystem Amplificateur pour le servo commande du systeme de direction 789 B Givare allm n Transmitter common Geber allgemein Cap...

Page 136: ...l 823 U Signalomvandlare h ger Signal amplifier right Signalverst rker rechts Amplificateur de signaux droit 824 U Signalomvandlare v nster Signal amplifier left Signalverst rker links Amplificateur d...

Page 137: ...alter L sen der TW Interrupteur deverroulliage TW 1003 S Str mst llare l sa TW Switch locking of TW Schalter Verriegelung der TW Interrupteur verroulliage TW 1004 S Str mst llare stopp vid 30 35 Switc...

Page 138: ...arm 1024 S Str mst llare Korta Armen av p Switch Short Arm on off 1025 S Str mst llare pappersfunktioner av p Switch paper funktions on off 1026 S Str mst llare omkoppling pappers kl mmagregat Switch...

Page 139: ...vxl std blackout Relay working light cab shift std blackout Relais Arbeitsbeleuchtung schaltung std Ausfall Relais normal blackout pour l clai ge de la cabine 3013 K Rel arb bel bom 20 vxl std blackou...

Page 140: ...s seat speed control Relais drehbarer Fahrersitz Geschwindigkeitsregelung Relais si ge pivotant commande de vitesse 3404 K Rel VBFS mastljus Relay rotating driver s seat mast light Relais drehbarer Fa...

Page 141: ...kl mma lossa ben Solenoid valve clamping releasing legs Magnetventil Klemmen L sen der Beine Electrovanne serrage deserrage b quilles 6016 Y M ventil Hyttskjutning fram Solenoid valve cab movement fo...

Page 142: ...lenoid valve left rear wheel steering right Magnetventil Hinterrad links Lenkung rechts Electrovanne roue arri re gauche direction droite 6034 Y M ventil skevning Solenoid valve levelling Magnetventil...

Page 143: ...mmern Electrovanne serrage 6055 Y M ventil kl mma is r Solenoid valve clambing out Magnetventil aufklammern Electrovanne d serrage 6056 Y M ventil fr mre kn ut Solenoid valve front knee out Magnetvent...

Page 144: ...Inching Solenoid valve Inching Magnetventil Inching Electrovanne Inching 6078 Y M ventil Avst ngning vre kl marm Solenoid valve upper arm off Magnetventil Electrovanne 7200 S Givare axeltryck h ger Se...

Page 145: ...osition Capteur position de conduite 7213 S Givare Anliggning fr mre ben Sensor Alignment front legs Geber Anliegen vordere Beine Capteur alignement jambes avants 7214 S Givare Anliggning bakre ben Se...

Page 146: ...v nster framhjul Potentiometer left front wheel Potentiometer vorderrad links Potentiometre roue avant gauche 8079 R Potentiometer h ger bakhjul Potentiometer right rear wheel Potentiometer hinterrad...

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Page 163: ...ng air system 12 Service 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 the oil and oil...

Page 164: ...s 9 60 12 Valve clearance cold engine inlet mm exhaust mm 0 40 0 70 0 40 0 70 Idling speed r min Adjust so that the engine runs smoothly 675 25 600 25 Injection pump timing 10 0 5 BTDC 12 0 5 BTDC The...

Page 165: ...ould otherwise be lost 1 Fan hub 2 Twin fuel filters of throw away type 3 Lift eyelet 4 Gear driven coolant pump 5 Air cooled exhaust manifold 6 Turbo charger 7 Lift eyelet 8 Coolant pipe inlet 9 Pump...

Page 166: ...eads for each cylinder 1 Fan hub 2 Twin fuel filters of throw away type 3 Lift eyelet 4 Gear driven coolant pump 5 Air cooled exhaust manifold 6 Turbo charger 7 Lift eyelet 8 Coolant pipe inlet 9 Pump...

Page 167: ...jacket of each cylinder is indi vidually sized to ensure that each cylinder will be supplied with the same rate of coolant flow The coolant flows in the separate return lines converge into a common pi...

Page 168: ...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...

Page 169: ...turned 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...

Page 170: ...nd paper Injectors each with a nozzle holder and a nozzle When the fuel pressure has risen to the preset value the needle will lift and at omised fuel will be injected into the combustion chamber thro...

Page 171: ...The pump is equipped with an RSV governor which has a steep control characteristic at low engine speeds As a result the engines appear more powerful and have a higher tractive effort at low speeds 1 S...

Page 172: ...to a longer life of the piston rings re duces the risk of carbon deposits and lowers the oil consumption The pistons are cooled by oil which is sprayed by nozzles into the underside of each piston and...

Page 173: ...g oil pressure should rise above a certain pressure due to clogging of the filter When the valve is open unfiltered oil will flow to the engine The filters are of disposable type and should be scrappe...

Page 174: ...ticles are disposed of through a particle ejector The second stage consists of a filter element the main filter element A pres sure indicator shows red signal if the pressure drop in the filter ex cee...

Page 175: ...oler increases the oxygen supply during combustion so allowing the injected fuel to be burnt more effectively whilst re ducing fuel consumption as well as the level of exhaust emission Intercooling al...

Page 176: ...ngine may lose pow er due to insufficient supply of combustion air and engine dam age may occur in certain cases The air pipe from the air cleaner to the engine should be checked for tightness from ti...

Page 177: ...ull 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 a...

Page 178: ...clearances 2 Check the other valves in accordance with the table below Changing the fuel filters 1 Clean the outsides of the filters 2 Remove the filters and discard them 3 Clean the filter head 4 Ch...

Page 179: ...ified inter vals Inadequate fuel supply caused by clogged fuel filters or incorrect setting of the injection pump reduces the turbocharg er speed which in turn results in a lower engine output 4 Check...

Page 180: ...Tom sida Empty page Leere Seite Face vide...

Page 181: ...circuit 5 Service 6 Oil level check 6 Changing gearbox oil and filter 6 Checking pressures in the Clark 36000 gearbox 7 Drive axle 8 Description 8 WDB system 11 Parking brake system 12 Service 13 Cha...

Page 182: ...All clutches oil cooled and lubricated Stall speed r min 1782 50 TWD1031VE 15 5 HR 36432 1923 50 TWD1231VE 15 5 HR 36432 Oil filtration Full flow oil filter with safety by pass also strainer screen i...

Page 183: ...to the inside diameter of the pump impeller in the best pos sible way Torque conversion takes place in the oil circuit of the torque con verter When the load on the truck increases i e when the torque...

Page 184: ...Technical Handbook Transmission Description 4 S Grupp 40 9407 04 10 FORWARD 1ST 2ND 3RD 4TH 1 Pump impeller 2 Turbine wheel 3 Stator 4 Charging pump 5 Suction tube 6 From engine 7 Clutch plates Gearb...

Page 185: ...ner 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 gear box valve body which actuates th...

Page 186: ...the reason before topping up 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 el ement 5 Fit the new filte...

Page 187: ...essure must not exceed 4 9 bar when the engine is running at top speed Clutch pressure 17 20 bar with parking brake set oil temperature 82 93 C en gine at idle 400 600 r min shift through direction an...

Page 188: ...the pinion teeth to carry the radial load The hub reduction consists of a planetary gear Each hub reduc tion consists of a sun wheel three planet wheels which rotate around the sun wheel and a ring ge...

Page 189: ...hamp DRD S Technical Handbook Drive axle Description 9 S Grupp 40 9407 04 10 1 Planet holder 2 Insert axle with sun wheel 3 Planet wheel 4 Axle end 5 Ring wheel 6 Ring wheel hub 7 Wheel hub 7 2 3 4 5...

Page 190: ...ok Drive axle Description 10 S Grupp 40 9407 04 10 1 Crown wheel 2 Radial roller bearing 3 Pinion 4 Tapered roller bearings for axial thrust 5 Parking brake assembly 6 Brake cylinder 7 Brake disc Diff...

Page 191: ...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 wh...

Page 192: ...and the calliper assembly form an integral unit The hydraulic pres sure is applied via the parking brake control lever in the operator s cab The parking brake can also be used as an emergency brake E...

Page 193: ...e Remove the filler plug and top up with oil Refit and tighten the filler plug Volume See Spec ifications 6 Remove the level plug from the differential and fill the differen tial with oil Refit and ti...

Page 194: ...parking brake 7 Back up the nut 11 and lock it with the pin 13 The brake is now ready for operation Compensation of lining wear 1 Apply pressure 2 Turn the nut 11 against the washer 12 3 Release the...

Page 195: ...p 60 Steered axle Specifications 2 Steered axle 3 Description 3 Service 4 Replacement of steering cylinder 4 Replacement of knuckle pin bearings 4 Replacement of steering wheel bearings 6 Miscellanous...

Page 196: ...ting screw M24 670 Steering cylinder Nm oiled bolt 1 Steered wheel bearings should be tightened during simulta neous rotation of the wheels This makes the bearing rollers set correctly Note that a jac...

Page 197: ...ertain machines the rear suspension is fitted with a pivoted joint This is used to indicate a too low load ing of the steered axle i e the risk of tipping forwards When only the weight of the steered...

Page 198: ...eded for handling purposes 3 Secure a sling around the hub neck and lift until the hub is held in position Use a trolley pallet truck or the like provided with a rest 4 Remove the protective cover fro...

Page 199: ...over 5 Bearing nut 6 Tab washer to be greased 7 Plain washer 8 Knuckle pin 9 Wiper 10 Spacer 11 Lower bearing 12 Split pin 13 Cover 14 Gaiter 15 Steering cylinder 16 Wheel axle 17 Spacer 18 Sealing ri...

Page 200: ...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 nu...

Page 201: ...f with a hammer will dam age it 3 Clean the spacer and pack it with grease 4 Tap the inner race of the inner bearing onto the wheel axle us ing a suitable tube Pack the inner race with grease 5 Lift t...

Page 202: ...the 45 face on the beadseat or loose flange In extreme circumstances this can lead to breakage of the rim bead which in turn has potentially dangerous consequences To minimize the risk of an accident...

Page 203: ...e If the wear exceeds 0 5 mm the wheel the lock ring and the beadseat or loose flange must be discarded and replaced with new 5 If a wear mark is not possible to find measure the circumfer ence of the...

Page 204: ...lux 4 If no cracks are indicated in the magnetic examination the test is completed and the wheel approved In case cracks are indi cated carry out the penetrance test Penetrance test 1 Clean area B wit...

Page 205: ...ponents of the brake system 23 Brake system feed 24 Hydraulic accumulators 26 Accumulator charging valve 27 Hydraulic brake pedal 28 Parking brake 29 Parking brake valve 29 Service 30 Accumulators che...

Page 206: ...accumulator evacuating valve Carefully study the Instruction Manual and the Technical Handbook 2 Charging pressure accumulators Setting on the accumulator charging valve 3 Hydraulic servo pressure Not...

Page 207: ...which are illustrated on the next page All hydraulic system functions are controlled via three independ ent sub systems El servo hydraulic servo working hydraulics The el servo system is controlled by...

Page 208: ...ic tank that is located on the right hand side of the truck The pressurized fluid travels from the pumps to the high pressure filter for cleaning prior to circulat ing in the system The hydraulic syst...

Page 209: ...G SYSTEM SERVO 3 Double variable hydraulic pump LIFT EXTENSION ATTACHMENTS 5 Fixed hydraulic pump BRAKE SYS TEM 6 Non return valve 7 High pressure filter 8 Steering system 10 Priority valve STEERING r...

Page 210: ...rking brake is OFF e g when the truck is transporting During lifting when the gear box is in neutral or when the gearbox is disengaged the solenoid valve H40 is activated and the pump H3b works normal...

Page 211: ...g circuits IMPORTANT The hydraulic fluid in the separate tank for the brake sys tem must never contain any additives KL 1563 The numbers correspond to the hydraulic diagram H 1 Hydraulic tank 2 Double...

Page 212: ...le variable hydraulic pump LIFT EXTENSION ATTACHMENTS 5 Fixed hydraulic pump BRAKE SYSTEM 6 Non return valve 7 High pressure filter 10 Priority valve 13 Main valve 16 Main valve Pumps feed working hyd...

Page 213: ...pump LIFT EXTENSION ATTACHMENTS 5 Fixed hydraulic pump BRAKE SYSTEM 6 Non return valve 7 High pressure filter 10 Priority valve 13 Main valve 16 Main valve Pumps feed working hydraulics separate tank...

Page 214: ...esponds with the hydraulic system diagram H 1 Hydraulic tank 10a Pressure regulator valve SERVO 30 35 bar 11 Filter servo circuit 13 Main valve 14 Converter EXTENSION 15 Converter LIFT 16 Main valve 2...

Page 215: ...parallel and are fed from both main valves with the combined capacity from the hydraulic sys tems four variable pumps Regeneration For unloaded lift i e low pressure in the lift circuit the regener at...

Page 216: ...a b c d e D Draining to tank C Feed to lift cylinder C Return from lift cylinder T Tank return VA Feed from pumps H17 Valve block lift cylinders a Blocking valve b Solenoid valve control of blocking v...

Page 217: ...racted too quickly due to the load This also functions as hose protection Regeneration For unloaded lift i e low pressure in the lift circuit the regener ation valve H19c opens The return flow from th...

Page 218: ...sion cylinder a Lowering brake valve with pressure compensated choking b Solenoid valve control of regeneration valve c Regeneration valve d Restriction e Non return valve VA Feed from pumps D Drainin...

Page 219: ...d the area around it 2 Place a vessel under the filter to collect any spillage 3 Empty the filter bowl by unscrewing the drain plug 4 Unscrew the filter bowl 5 Slide off the filter cartridge 6 Replace...

Page 220: ...alve opens at 3 5 bar if the filter should become clogged The filter contain a cartridge which should be changed every 1000 hours of operation 1 Unscrew the bottom section of the housing and withdraw...

Page 221: ...pressure in communication with the steering valve s pressure connection As soon as the steering wheel is moved this via the steering cylinder circuit will give a load signal LS back to the priority va...

Page 222: ...valve which ensures that the flow will be supplied to the port corre sponding to the direction in which the steering valve has been turned The gear pump ensures that the flow supplied to the cyl inder...

Page 223: ...sleeve 3 Ball 4 Threaded bush 5 O ring 6 Guide ring 7 Bearing 10 Ring 11 Dowel 12 Neutral position springs 1 set 13 Shaft 14 Spacer 15 O ring 16 Distributor plate 17 Gear set 18 O ring 19 End cover 20...

Page 224: ...ve When the steering wheel is turned this flow is shut off and pressure builds up The pressure acti vates pump H2 and resets priority valve H10c for feeding of the steering valve H8 P When the steerin...

Page 225: ...Non return valve i Shuttle valve BR ACC Connection reserve servo pressure from accumulator P1 Feed working hydraulics ORB 1 Feed steering valve with lever steering ORB 2 Feed steering valve with norm...

Page 226: ...er and impurities The wet disc brake system comprises three separate hydraulic circuits i e the foot brake circuit the cooling circuit and the park ing brake circuit All circuits are supplied with hyd...

Page 227: ...lator to the tank before any work is carried out on the hy draulic system Valve 25 must be opened when draining the system 24 Safety valve 210 bar 25 Valve for reserve servo pressure Used in emergency...

Page 228: ...respond to the hydraulic diagram H 1 Hydraulic tank Alternative 43 for system with separate tank 5 Hydraulic pump BRAKE SYSTEM 21 Accumulator charging valve 22 Accumulators 23 Accumulator evacuation v...

Page 229: ...Description 25 S Grupp 70 9407 04 10 The numbers correspond to the hydraulic diagram H 1 Hydraulic tank Alternative 43 for system with separate tank 26 Filter cooling circuit 29 Service brake valve B...

Page 230: ...120 0542 The pressurized fluid from the accumulator is utilized to power the driving brake and parking brake systems A special valve 25 can be used to provide reserve servo pres sure to the working hy...

Page 231: ...is added to the spring force and keeps the main valve closed When the accumulator has been charged the oil pressure from the accumulator overcomes the spring force in the pilot valve which changes ove...

Page 232: ...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 result the brake pres sure will increase...

Page 233: ...rking brake is applied the flow of oil to the brake cyl inder is interrupted and the oil in the cylinder is discharged to the tank The brake is then applied by the spring If the accumulator pressure s...

Page 234: ...ely fall to 0 If the accumulator lacks pre charging pressure the pressure shown on the pressure gauge will fall immediately the engine is switched off In both cases this indicates internal leakage and...

Page 235: ...sed for dissipation of heat produced mainly by frequent braking Machines with a common tank for working hydraulics and braking system have a common hydraulic fluid cooler for both systems The numbers...

Page 236: ...king system and one for the working hydraulics see illustration below and hydraulics diagram OUT IN A KL 1573 45 44 Numbering in common with the hydraulics diagram 21 Accumulator charge valve 26 Filte...

Page 237: ...container Open the bleed nipple depress the brake pedal and let the oil flow out of the nipple until it is completely free from air bubbles Shut off the nipple while the brake pedal is still de presse...

Page 238: ...e control valve 37 that feeds a hydraulic motor 38 The rotation of the motor is transmitted to the cab via a chain Tilt attachment optional extra Trucks equipped with forward tilt are fitted with an a...

Page 239: ...suction phase During the pressure phase the hydraulic fluid is fed into the pressure lines via a valve plate A hole in the head of each of the pistons allows hydraulic fluid to be forced out and give...

Page 240: ...the cam profile An fluid film pre vents the vanes from coming into metallic contact with the cam profile In the same way an fluid film prevents metallic contact with the side plates Since the vanes po...

Page 241: ...r to test outlet 6 se illustration 12 Let an assistant increase engine revs to approx 1100 rpm and extend the boom max out until the function is overflowing and keep overflowing during next item 13 Sc...

Page 242: ...u lator charging valve H21 25 Close the accumulator evacuating valve 26 Check that the accumulator charging starts at 15 MPa and stops at the pressure stated on the hydraulic plate 27 Adjust if needed...

Page 243: ...line to prevent inadvertent lower ing of the load when several functions are operated simultane ously 7 Control section EXTENSION with double acting electrohy draulically controlled spool for one doub...

Page 244: ...rotect 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 unconnecte...

Page 245: ...e cylinder head to avoid scratching the bottom of the groove since oil leakage will otherwise occur in the future Use a screwdriv er as shown in the figure Clean all components very thoroughly 5 Fitti...

Page 246: ...nut 2 The cylinder head and the cylinder tube are provided with mounting flanges joint together with hexagon headed screws 1 Lifting cylinder 2 Cylinder pipe 3 Bearing 4 Retaining ring 5 Piston rod 6...

Page 247: ...piston rod with hexagonal bolt 2 The cylinder head is fitted with a flange that is attached to the cylinder tube with hexagonal bolts 1 Cylinder 2 Cylinder pipe 3 Piston rod pipe 4 Seal kit 5 Guide 6...

Page 248: ...to the piston and locked with a locking screw 2 The cylinder head is threaded into the cylinder tube 1 Shock absorbing cyl inder 2 Cylinder pipe 3 Piston rod 4 Piston 5 Seal kit 6 Piston seal 7 O ring...

Page 249: ...ylinders a Blocking valve b Solenoid valve control of blocking valve c Shock valve 280 bar d Solenoid valve control of regeneration e Regeneration valve 18 Lift cylinder left and right 19 Valve block...

Page 250: ...ContChamp DRD S Technical Handbook Diagrams Component list 46 S Grupp 70 9407 04 10...

Page 251: ...4YFP RS 7YTTPIQIRX HVEYPMG PMRHIVW 8IGLRMGEP ERHFSSO PP 8VYGOW...

Page 252: ......

Page 253: ...n of the hydraulic system 4 Fault finding for leakage 6 The function and removal of seals 7 Piston rod seals 7 Support ring and O ring 9 Wiper 10 Single action V type piston seals with support ring 11...

Page 254: ......

Page 255: ...ding Cavitation insufficient flow to pump Corrosion that generates particles Fatigue wear and tear that generates particles z Accidentally added impurities During repair operations As a result of topp...

Page 256: ...achines have attachments that can be changed which also means that hydraulic lines and hoses must be loosened and switched over This entails a major risk of impurities penetrating into the system z Al...

Page 257: ...ened there is always a great risk of impurities entering the system z Thoroughly clean the around the area of the system on which work is to be carried out z Isolate the area where work is to be carri...

Page 258: ...piston rod is free from burrs and any remains of paint 1 Loosen the cylinder from its mounting and loosen the hydrau lic connections 2 Immediately plug the cylinder connections and hoses lines 3 When...

Page 259: ...s into contact with the inside of the V shape so that it cannot touch and thereby damage any sealing surface A score from a screwdriver on the sealing surface will have a disastrous effect and cause m...

Page 260: ...eakage Check the sealing lips by carefully feeling around the seal with a finger nail Use a screwdriver to remove the seal see illustration Lever out and twist up the seal It is extremely important th...

Page 261: ...faces such as for example between the cylinder pipe and the cylinder head even in those cases where the cylin der head is threaded onto the cylinder pipe The task of the support ring is to brace the O...

Page 262: ...s somewhat deeper than the width of the wiper The wiper can be removed without the necessity of dismantling the cylinder A screwdriver can be used to remove the wiper This must always be employed agai...

Page 263: ...f the V shape so that it cannot touch and thereby damage any sealing surface A score from a screwdriver on the sealing surface will have a disastrous effect and cause major leakage The seal must alway...

Page 264: ...ust be done by hand without the use of tools in order to prevent damage Repairing the piston rod surface The smallest damage to a piston rod can be enough to cause leakage The chromium plating has a t...

Page 265: ...er Never use cotton waste Lubricating single action cylinders 1 This type of cylinder does not have any hydraulic fluid supply on the piston rod side If a cylinder normally operates over only a limite...

Page 266: ...nscrew the connection nipple for the hydraulic hose 3 Push in the piston rod with piston head until the O ring is visi ble through the nipple hole 4 Use a strong bent steel wire to hook onto the O rin...

Page 267: ......

Page 268: ...4EVXIO SQTER EPQEV RHYWXVMIW 7ZIVMKI 7 0NYRKF 7 IHIR XIP JE OEPQEVMRH GSQ...

Page 269: ...10 24 V feed 11 Service 12 Indicating lamps 12 Alignment control 12 Safety interlocking system 12 Checking of ALIGNMENT indicating lamps and electrical interlocking system 12 Adjustment and lubricati...

Page 270: ...ContChamp DRD S Technical Handbook Specifications 2 S Grupp 80 9407 04 10 See current data sheet...

Page 271: ...h The boom comprises the following Fixed boom Extension boom Extension cylinder The extension boom runs inside the fixed boom on greased slid ing plates made of Robalon The extension boom is provided...

Page 272: ...ible to rotate the attachment through 195 105 with the help of hydraulic motors steered by the control lever The ro tation brake prevents undesired rotation When the hydraulic mo tors for rotation are...

Page 273: ...a passive system As an optional extra a system is available with forced steering of damping cylinders known as Forward Tilt The cylinders are then fed from main valve section 47a see hydraulic diagra...

Page 274: ...the rear of the outer surface of the ex tension boom The sliding plates are so positioned that they ab sorb both vertical and lateral forces The fixed boom has six sliding plates at the front end Eac...

Page 275: ...lates are thicker than 15 mm and the play be tween sliding plate and sliding surface is bigger than approx 2 mm the sliding plates should be fitted with more shims Please contact Kalmar service depart...

Page 276: ...s controlled electro hydrau lically from the operator s cab and has a main valve with three sections for EXTENSION TWIST LOCKS SIDE SHIFT AND RO TATION See separate hydraulic diagram Extension is achi...

Page 277: ...hnical Handbook Top lift Description 9 S Grupp 80 9407 04 10 KL 1558 Top lift hydraulic installation 52 58 47 52 55 58 47 Main valve 52 Hydraulic motor 55 Hydraulic cylinder SIDE SHIFT 58 Hydrauic lcy...

Page 278: ...5 activates the green TWIST LOCKS LOCKED lamp which indicates that both sides of the top lift are locked onto the container which is thereby ready to be lifted When lifting the ALIGNMENT lamp is extin...

Page 279: ...D S Technical Handbook Top lift Description 11 S Grupp 80 9407 04 10 1 Main switch 2 Main fuse 3 Coupling at rear of boom 4 See electrical installation ECS boom see group 20 page 36 24 V feed of top l...

Page 280: ...e override switch will feed false alignment minus signal to the twist lock so lenoid valve thus making it possible to operate the twist locks A red warning lamp lights up in the operator s cab when th...

Page 281: ...hims under the sliding plates Sliding plates are fitted in the ends of each moveable member and also each end of the fixed main beam see figure Shims of various thickness can be ordered from Kalmar se...

Page 282: ...of the type PNP positive negative positive the last P indicating that the sensor produces a positive signal when activated The sensor is activated when a magnetic object gets closer than approx 8 mm...

Page 283: ...he fixed beam bottom surface see section Adjustment and lubrication of sliding plates Bleeding the damping cylinders 1 Set the boom in its lowest position 2 Allow the engine to idle 3 Carefully loosen...

Page 284: ...izontal after having hung somewhat angled in wards 2 As required adjust the choking of the throttle valve Two different types occur With one adjustment screw for systems with damping only With two adj...

Page 285: ...LOCKS section 4 System pressure as shown on sign 3 To check the pressure connect a T connector to either the output of the manoeuvre section or to the incoming line of re spective cylinders Connect a...

Page 286: ...KS f Converter g Pressure reducing valve individual setting of control sec tion supply pressure h Main pressure limitation valve j Shock valve k Reduction valve for servo pressure 30 bar l Refill valv...

Page 287: ...echnical Handbook 1 S Grupp 90 9407 04 10 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 lub...

Page 288: ...ContChamp DRD S Technical Handbook Empty page 2 S Grupp 90 9407 04 10...

Page 289: ...sis of the operating hour meter readings When carrying out a 1000 hour service it is advisable to work in the following order 1 Every 1000 hours 2 Every 600 hours 3 Every 200 hours The same procedure...

Page 290: ...ContChamp DRD S Technical Handbook Periodic supervision 4 S Grupp 90 9407 04 10 Sight glass Brake Planetary gear Refill KL586C DRD420 60S5 1 2 6 7 3 4 5 24 25...

Page 291: ...wheel bearing 2 Remove clean inspect and pack with grease every 4000 h 10 Knuckle pin bearings 4 Remove clean inspect and pack with grease every 4000 h 11 Engine oil x x Change the oil every 200 h1 12...

Page 292: ...ContChamp DRD S Technical Handbook Periodic supervision 6 S Grupp 90 9407 04 10 KL 1555a 6 6 7 7 KL 1553a 1 2 1 KL 1553 4 4 5 4 4 KL1555 7 8 9 3 a b c...

Page 293: ...up b Sight glass c Magnetic plugg oil drainage C x 1 Level check fill to the red spot on the sight glass Oil volume 2 4 litres x First oil change guarantee service x Then oil change every 1000 hours...

Page 294: ...suspension is clean Check that the sensor is free from grease All instruments Blinkers brake lights horn Head lights reflectors Function Boom pivot suspension and sliding plates Damage Attachment and...

Page 295: ...mountings See Group 80 9 Steering axle Check for play damage 10 Steered and driven wheels Tighten the wheel nuts Inspect tyres and rims for possible dam age See Group 40 resp 60 Specifica tions 11 Dri...

Page 296: ...akage 4 Steered wheels Check the wheel alignment and check for deformation or bearing play See Group 60 5 Telescope boom and attachment Check that the hose guide runs freely and that the hoses are in...

Page 297: ...ck the bolted joints and check the universal joints for play See Group 40 10 Gearbox and drive axle Clean the breather 11 Steered axle Check knuckle pin bearings tightening torque See Group 60 12 Brak...

Page 298: ...nes with separate tank for brake system Transmission oil UTTO Oil in rotator reduction gear and top lift Brake Quality Ordinary hydraulic fluid without additve Planetary gear Quality API GL 5 Viscosit...

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