Kalmar DRD-S, DRD-GB Handbook

General

Technical

Handbook

ContChamp

DRD

This Handbook deals with the design and maintenance of Kalmar machines, type DRD-S for the handling of containers.

In addition, it gives details of troubleshooting and the most common corrective maintenance.

Chassis and cab

Electrical system

Engine

Transmission, drive axle, brakes

Operation and other matters that are primarily of interest to the operator are included it the Instruction Manual.

Kalmar Industries AB

This handbook applies to machines from and including machine number T34107.0784 as well as T34107.0621 and T34107.0769, see next page.

We reserve the right to modify our design and material specifications without prior notice.

Publ. Nr 920 937 9407 04-10 AdEra Dokument AB, Växjö 2004

Steering axle

Hydraulic system

Boom and attachment

Periodic supervision

This Handbook applies to machines from and including machine number T34107.0784 as well as T34107.0621 and T34107.0769

These machines are of a new design that entails the f ollowing dif ferences from ol der machines. The changes do not apply to machines with combi-attachments or top-lift with pileslope.

1. The electrical system is equipped with a separat e KDU for the top-lift, comp onent number 791. The KDU communicates with ECU 2 via a CAN bus.

2. The main valve of the top-lift is fed by a variable hydraulic pump. The main valve is common for all of the top-lift’s functions.

3. The length adjustment of the top-lift is manoeu vred by means of a hydraulic motor and chain.

4. The top-lift rotation brake is manoeuvred completely hydraulically.

ContChamp DRD-S

Technical Handbook

9407

Contents

04-10

S.Grupp 00

Contents Group 00

Safety regulations...................................... .... ........................... 2

General...................................................................................... 6

Design – Overview .............................................................. 6

Component units ........................................... ... ... ............... 7

Supplementary books ......................................................... 9

Replacement system – Spare parts ................................... 9

Tools .............................. .......................... ......................... .. 9

Tightening torques.............................................................. 10

System of units ................................................................. 12

ContChamp DRD-S

Technical Handbook

Safety regulations

9407

04-10

S.Grupp 00

It is important that you read the instruction manual.

Incorrect handling can lead to personal injury or damage to products and/or property . Therefore , read the instruction book very carefully before ope rating the truck. The instruction manual contains important information about your Kalmar truck, about the operation of the truck, about safety during oper ation and about the truck's daily maintenance. In addition, you will find useful information that will make operations easier for y ou in your daily work.

The instruction manual must always be kept in the machine. If the manual should be lost, a replacement m ust be immediately obtained. Never use a machine with a missing instruction manual.

Ask your foreman/group leader if there is anything in the manual that you do not understand or if you f eel that information is missing in any area.

The symbol is used on our products in certain cases and then refers to important information contained in the instruction manual. Make sure that warn ing and information symbols are always clearly visible and legible. Replace symbols tha t have been d amaged or painted over.

In this instruction manual war n in gs ar e inserted that apply to your own safety. Warnings point out the risk of accident that can cause personal injury.

WARNING!

Warns of the risk of seriou s personal injury, possible death and/or serious dama ge to product or property if the regulations are not followed.

For technical warnings, that point out the risk of break down, the word IMPORTANT is used:

Safety regulations aimed at reducing the risk of personal injury and damage to loads or other property.

Intended of use

z The truck may only be used for the purpose for

which it was intended, namely, to lift and transport goods, the weight of which doe s not exceed the maximum permitted load capacity of the truck.

z The truck may not, without specific permission

from Kalmar, be mod ified or re-built so that its function or performance is altered.

z The truck may not be driven on public highways if

it has not been adapted to comply with national road safety regulations.

Operator requirements

z The truck may only be driven by operators who

have been specially trained and who have the company's authority to do so.

z Laws and other regulations relati ng to driving li-

cence, operator ID, log book, etc., must be followed at all times.

z The operator must be aw are of and f oll ow all local

safety regulations.

z It is always the responsibility of the operator to en-

sure that the truck has appro v ed fire e xt inguishing equipment in accordance with currently applicab le regulations.

Operation of the truck is prohibited:

z If any of the fitted safety equipment, such as rear

view mirrors, headlights, reversing alarm (optional), does not function correctly.

z If there is a fault with the brakes, steering or lift

equipment.

z If it has been repaired, modified or adjusted with-

out the approval of the work supervisor.

z If the truck is fitted with tyres not appro ved by

Kalmar.

IMPORTANT! Is used to draw attention to such occurrences that can cause damage to the product or property.

For information that facilitates the working process or handling, N.B. is used:

N.B. Draws attention to useful information tha t helps the working process.

Emergency exit

If the doors should not o pen in an emergency, open the rear window for emergency exit.

A rear window that can be opened is standard on machines with hydraulically moveable cab. Optional on other machines.

Continued on next page

KL749

ContChamp DRD-S

Technical Handbook

Safety regulations

9407

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S.Grupp 00

Continued from previous page

Operating regulations

z Before starting, make sure that the cab is locked

in the rear-most position by me ans of the latches, one on each side. The latches must be secured with spring pins. (Applies to manually moveable cabs).

z Before starting, always check to ensure that no-

body is in the way of the truck or its equipment.

z The operator must alw ays f ace the direction of op -

eration and take particular care in areas wher e persons or other vehicles are likely to appear in the vicinity . If visibility is limited by the load, the operator should operate the truck in reverse.

z It is prohibited to walk or stand underneath raised

forks or other equipment, whether the y are loaded or not.

z It is prohibited to transport passengers on the

truck outside the cab or on the load. Passengers may be transported inside the cab only on condition that it is equipped with a fixed passenger seat.

z It is prohibited to lift people if the truck is not

equipped with an approved lift cage.

z It is prohibited to exceed the load capacity of the

truck. See capacity plate and loading diagram.

z It is prohibited to transport loads in the raised po-

sition as this entails a risk of the truck tipping. All transportation shall take place with the load in the transport position.

z The operator must adapt the speed of the truck to

the character of the load, conditions of visibility, the character of the roadway/surface, etc.

z The operator shall avoid powerful acceleration

and braking when turning. In addition, the operator shall always moderate the speed of the truck when turning so as to avoid the risk of lateral skidding or tipping.

z The operator shall take pa rticular care when oper-

ating in the vicinity of electrical power lines, viaducts, quay-sides, ramps, gates/doors etc.

z Safety belts must always be worn, if fitted. In the

event of the truck tipping, always remain in the cab and grip the steering wheel securely. Never try to jump out of the cab.

z The parking brake can also be used as an EMER-

GENCY BRAKE. However, having been used f or emergency braking, the brake linings must be checked and repl aced if necessary. If the parking brake has been mechanically released, it must always be rese t in order for the truck to regain the parking brake function.

Interrupted operation, parking

z Always check that the gear lever is in the neutral

position before turning the ignition k ey to restart or to reset an emergency stop.

z Never leave the operator's cab without applying

the parking brake (ON position).

z Always remov e the ignition key if the truck is to be

left unattended.

Other important points 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 hydraulic equipment, lines and hoses. Before working on the hydraulic system, t he accumulators

must be emptied into the tank, with the help o f the special accumulator evacuation valve.

z Handle batteries and junction boxes with great

care. The batteries must alwa ys be protected over the poles and connections.

z Always rectify any damage or wear and tear that

can risk personal safety or that can af fect the functions of the truck or its service life.

z Avoid touching oils and greases. Avoid inhaling

exhaust and oil fumes.

z Always use step s and handrails when en tering or

leaving the machine - Never jump! T o avoid t he risk of slipping, tread only on anti-slip surfaces. If the anti-slip protection has become worn, loose or in any way less effective, it should be replaced.

z Welding painted steel produces poisonous gas-

ses. Paint should therefore be stripped before welding, good ventilation ensured and/or face mask with filter used.

z Mobile phones used in the cab must alw a ys ha v e

fixed connections to the machine’s elec trical system, with a fixed antenna outside the machine, mounted in accordance with the manufacturer’s instructions. This will avoid interference with the machine’s important electronic functions.

Operating with attachments

z The operator must always take the effect of the

wind into account when handling containers. Avoid lifting with a wind strength in excess of 12 m/s (27 mph/40 feet per second).

z Always drive carefully so as to avoid attachments

colliding with pillars, cables, etc.

z Carefully study the "Lift methods" section of the

instruction manual.

z The tensile strength of the top pane can be seri-

ously weakened by exposure to elements that contain: Aromatic hy droca rbo n, ketone, esters or chlorinated hydrocarbon. Regularly check the surface condition of the top pane and clean only with screen wash or other mild cleaning fluid. After cleaning, rinse tho roughly with warm water. It is prohibited to modify or in any other way make altera tions to the top pane. Immediately replace damaged top panes t hat show signs of cracking or scratching.

CE marking

All trucks and equipment (though not thoses fitted on the truck or intended as spare parts) supplied from Kalmar are CE marked, which indicates that th ey co mply with the requirements of the EU Machine Saf ety Directive. In addition, each truck has a so called, “EU Declaration of Conformity” which is the legal pr oof that the truck complies with the “health and safety” requirements laid down in the Machine Safety Directive, the EMC directive (electro-magnetic compatibility) and the LVD directive (electrical equipment).

Vibration standard

The truck complies with and is below the limits for vibration standard EN 13059.

ContChamp DRD-S

Technical Handbook

Safety regulations

9407

04-10

S.Grupp 00

z Only authorized and qualified personnel may

work with the safety system. (ECS-system)

z If the overload safety system override functio n

has been used, there is a risk of forw ard tipping. The truck should be operated with e xtreme car e to prevent accidents.

z Great care must be exercised at all times when

driving the machine. Always re member the great height and width of the machine so that collision with beams, cables etc. is avoided

z It is prohibited to start lifting a container if the

warning light TWIST -LOCK UNLOCKED (red) is lit or if any of the warning lights TWIST-LOCK LOCKED (green) or ALIGNMENT (orange) are extinguished. N.B. the ALIGNMENT warning light goes out once the lift has begun.

z If the safety system warning lamps are not func-

tioning, the system must be immediately repaired. To use a truck with faulty w arning lamps is a great safety risk.

z Do not drive the truck with load raised high

above the gr ound, since the truck ma y ov erturn. The transport of heavy loads must be carried out with the load as close to the truck as possible, i.e. with the boom retracted and lowered as far as possible without obstructing vision, see picture below.

z Never run hands or fingers along any tu bes,

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.

z Under no circumstances may compressed air be

used to remove a hydraulic piston from its cylinder.

z Always attend to damage and w ear that ma y be

of significance to the perf ormance and useful life of the truck or to the safety of the personnel.

z 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.

z The truck’s h ydraulic syst em includes high pres-

sure hydraulic accumulators. Bef ore working on the hydraulic system, the accumulators must be emptied into the tank, with the help of the special accumulator evacuation valve. Also valve B for emergency pressure to servo system must be opened.

z Never carry out any service work on the boom or

attachment when the engine is running.

Transport position

KL591

KL1103

A. Quick evacuation valve, accumulators B. Valve for emergency pressure to servo system

ContChamp DRD-S

Technical Handbook

Safety regulations

Safety instructions for working with tyres

9407

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S.Grupp 00

z 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.

z Ne v er attempt to weld on an inflated tyr e/rim assem-

bly.

z Never let anyone assemble or disassemble tyres

without proper training.

z Never run the truck on one tyre of a dual assembly.

The load capacity of a single tyre is then dangerously exceeded and oper ation in this manner may damage the rim.

z Deflation and dismantling

– Always block the tyre and wheel on the opposite

side of the vehicle bef ore yo u place the jac k in position. Always crib up the blocks to prevent the jack from slipping.

– Always check the tyre/rim assembly for proper

component seating prior to removal from the truck.

– Always deflate the t yre by removing the v alve core

prior to removing the complete assembly from the truck or dismantling any of th e component. Before loosening mounting bolts, run a wire through the valve stem to en sure that it is not blocked. Ice or dirt can prevent all the air from escaping. Deflate and remove valve cores from both tyres of a dua l assembly.

– Never position body in front of the rim during de-

flation.

– Always follow assembly and dismantling proce-

dures outlined in the manufacturer’s instruction manual, or other reconized indu stry instruction manuals. Use proper rubber lubricant.

– Never use a steel hammer to assembling or dis-

mantling rim components – use a lead, brass or plastic type mallets. The correct tools are available through rim/wheel distributors.

– remove bead seat band slowly to prevent acci-

dents. support the band with your thigh and ro ll it slowly to the ground in order to protect back and toes.

– Disassembly tools apply pressure to rim flanges

to unseat tyre beads. Keep your fingers clear. Slant disassembly tool about 10 degrees to keep it firmly in place. Always stand to one side when applying hydraulic pressure. Should the tool slip off, it may cause fatal injury.

z Rim inspection

– Check rim components periodically for fatigue

cracks. Replace all cracked, badly worn, damaged and sev erely rusted components.

– Always select the correct tyre size and construc-

tion matching the manuf actur er’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 ca n not be

identified. Check rim parts against multi-

piece rim/wheel matching charts.

z Assembly and inflation

– It is important that the inflation equipment is

equipped with a water separator to remove mois-

ture from the air line in order to pr ev ent co rrosion.

Check the separator periodically to ensure that it

is working properly. – Make sure that the lockring is in its right position. – Never mi x different manuf acturer’ s parts since this

is potentially dangerous. Always check manufac-

turer for approval. – Never seat rings with hammering while the tyre is

inflated. Do not hammer on an inflated or partially

inflated tyre/rim assembly. – Always double check to ensure that the rim as-

semblies have been correctly assembled and that

securing studs and nuts are tightened to the cor-

rect torque setting. – Never inflate tyres before all side and lockrings

are in place. Check components for proper as-

sembly after pumping to appro xim ately 5 psi (=34

kPa, =0.34 bar) – When adding air to a tyre on an industrial truck,

use a clip-on chuck and stay out of the dange r ar-

ea. If the tyres has been run flat then the rim must

be dismantled and all parts inspected f or damage . – 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 pres-

sure daily. Do not over-inflate. – Inspect tyres regulary – every day if possible.

Look for and remove brok en gla ss, torn pieces of

tread, embedded metal chips etc. Inspect f or une-

ven or rapid tread wear, usually caused by me-

chanical irregularities, such as brakes out of

adjustment or excessive toe-in and toe-out. If dis-

covered, correc t the irregularity immediately.

z When installing and tight ening trail wheel bolts, ob-

serve the following: – Ensure that trail wheel or hub mounting surfaces

and trail wheel fastener mounting surfaces are

clean and free from paint and grease. – Tighten bolts to specified torque settings . use

staggered sequence; i.e. top bolt , bott om bolt e tc.

ContChamp DRD-S

Technical Handbook

General

9407

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Design – Overview

Kalmar DRD420–450 model S diesel trucks are of sturdy design for particularly heavy duty handling of 20-40' loaded con tainers. They are built around a chassis which has high strength and torsional stiffness and an extremely low centre of gravity.

The operator’ s cab is prov ided with vibr ation isolat ion and so und insulation and offers excellent 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 firmness of the driving seat can be adjusted in a number of ways.

The trucks are equipped with a sliding cab . This puts the opera tor in an exceptional position to superwise th e top lift attachment and offers excellent accessibility to the transmission and hydraulic pumps. The engine is easily accessib le through a remo vab le running board.

To special order, the trucks are equipped with hydraulically powered sliding cab.

DRD420-60S5

KL586C

DRD420-65S5 with 20-40’ adjustable top lift

ContChamp DRD-S

Technical Handbook

General

9407

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The Volvo six-cylinder turbocharged engine, combined with a four-speed gearbox with torque converter, prov ides smooth power whenever needed.

The drive axle with hub reduction, oil-cooled h y draulic br ak e system and pendulum-mounted 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.

Component units

z Sound-insulated operator’ s cab with excellent all-round visibil-

ity. The non-slip, substantial steps provide convenient access to the cab. As an optional extra, a hydraulically movable cab is available.

z ECS-system which controls the electric servo circuits and also

overload protection system. (With elect ronic balance, module 60 or 52, the loading conditions are indicated on a displa y on the ECS-terminal in the operator’s cab.)

z Engine - Volvo TWD1031VE/TWD1231VE six-cylinder, four-

stroke, turbocharged di esel engine with direct injection and thermostatically controlled water cooling.

The engine is equipped with: – Injection pump with centrifugal gov ernor that compensates

for load variations.

– Smoke limiter f or reduced free acceleration and full load

smoke.

–Alternator.

z Gearbox with torque converter

– Constant-mesh gearbox changes b y means of hydraulically

activated clutches which are electrically operated.

– Torque converter, which is a hydraulic coupling that ampli-

fies the output torque on an increase in load. Torque conversion takes place smoothly and steplessly throughout th e engine speed range.

– Oil cooler connected to the engine cooling system for cool-

ing the oil in the gearbox and torque converter.

– Oil pump which supplies oil under pressure to the gearbo x

and torque converter.

– Full-flow oil filter for effective cleaning of the gearbox oil.

z Drive axle with two-stage reduction - in the diffe rential and the

hub reductions. – Hydraulic, oil cooled disk brak es – wet disk brak es – for the

foot brake.

– Disc type parking brake applied by sturdy springs and re-

leased by hydraulic oil pressure.

ContChamp DRD-S

Technical Handbook

General

z Hydraulic system, that occurs in two versions:

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1. With common tank for all hydraulic and brake circuits. – a double variab le hydr aulic pump , feeds L ift 1, Extension 1,

hydraulic servo, steering system

– a double variab le hydr aulic pump , feeds L ift 2, Extension 2,

attachment functions – a fixed, wing type pum p f or the feeding of the brake system – hydraulic fluid cooler for the brake system cooling circuit

2. With a separate tank f or th e working hydraulics and a separ ate tank for the brake circuit.

– a double variab le hydr aulic pump , feeds L ift 1, Extension 1,

hydraulic servo, steering system

– a double variab le hydr aulic pump , feeds L ift 2, Extension 2,

attachment functions – a fixed, wing type pum p f or the feeding of the brake system – a hydraulic fluid cooler for the brake system cooling circuit – a fixed, wing type pump for the circulation of the main tank’ s

hydraulic fluid through a hydraulic fluid cooler – hydraulic 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 available as an option.

z High pressure filters for effe ctive cleaning of the h ydraulic fluid

before it is returned to the tank.

z Priority valve giving priority to the steering system when re-

quired.

z Steering valve (Orbitrol) - flow-control valve which supplies h y-

draulic fluid to the steering cylinder.

z A hydraulic oil cooler with electrically powered fan

z Steered axle with pendulum mounting and double-acting

steering cylinder.

z Lift cylinders equipped with blocking valves, which eliminate

any undesirable sinking of the load. A regeneration system gives high lifting speed at no load conditions.

z Boom of a slender, high -tensile ste el construction. Th e boom

is pivot-mounted and comprises a fixed and a telescope section manoeuvred by means of a double-acting extension cylinder. The extension system is equipped with regeneration system for quick boom-out speed at no-load conditions.

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

containers.

ContChamp DRD-S

Technical Handbook

General

9407

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S.Grupp 00

Supplementary books

In addition to the Instruction Manual and the Technical Handbook, the following books are delivered with every truck.

Spare parts 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 components of the truck.

For the contents of these kits, see the Spare parts catalogue.

Tools

Kalmar offers a wide range of tools for truck maintenance work. For further information, please contact Kalmar's service depart-

ment.

ContChamp DRD-S

Technical Handbook

General

9407

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Tightening torques

(According to Kalmar K Standards 20060.0001) The tightening torques are applicab le to steel bolts and n uts tight-

ened with a torque wrench under the following conditions:

Surface treatment

Condition Lubriation

Bolt Nut

1 untreated untreated oiled

bright galvanised

3 hot-dip galvanised bright galvanised dry or oiled

The values specified in Table 1 are applicable to nut-and-bolt joints, but can also be used f or bolts fitted into tapped holes . However , in the latter case, the preloading f orce will be somewhat 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.

Quality 8,8 10,9 12,9

Thread M fin

M8×1 M10×1,25 M12×1,25 M16×1,5 M18×1,5

bright galvanised bright galvanised

Tightening torque, Nm

12311

27 54

96 230 330

24 48

85 205 294

untreated bright galvanised bright galvanised

Condition

61 108 260 373

135 323 466

dry or oiled

39 76

91 162 388 559

M20×1,5 M24×2 M30×2 M36×3

460

786 2660 1560

409

700 1388 2367

520

888 1763 3005

647 1100 2200 3730

777 1330 2640 4480

ContChamp DRD-S

Technical Handbook

General

To reduce the risk of settlement of the material and the associated reduction in the preloading f orce if the hardness of t he surface supporting the bolt head or nut is lower than 200 HB, a washer should be fitted under the bolt head and nut. This is not applicable if flanged bolts or flanged nuts are used.

When tightening is carried out, the specified torque shou ld be applied without pause, to ensure that the torque wrench will not be tripped by the static friction before the joint has been tightened to the specified torque.

Quality 8,8 10,9 12,9

Tightening torque, Nm

Condition

Thread M

12311

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S.Grupp 00

4 5 6 8

10 12

16 20 24 30

Quality 8,8 10,9 12,9

Thread UNC

1/4 5/16 3/8 7/16 1/2

3,2 6,4

11 26 52

91 220 430 750

1480

12311

12,5

70 107

2,9 5,7 9,8

24 47

81 198 386 668

1317

Tightening torque, Nm

11,1 22,3

3,6 7,2

12,5

30 59

103 250

848

1672

Condition

14,1 28,3

50 79

121

4,6 9,1

16 38 74

128 313

620 1050 2080

17,6

62 100 151

5,5

11 19 45 89

154 375

732 1270 2500

20 42

73 118 178

9/16 5/8 3/4 7/8

1 1 1/8 1 1/4 1 3/8 1 1/2

153 210 370 594

889 1260 1760 2320 3060

136 187 390 528

791 1120 1565 2065 2720

173 237 418 671

1005 1424 1990 2620 3455

216 298 524 839

1260 1780 2490 3280 4320

255 353 619 990

1480 2100 2940 3870 5100

ContChamp DRD-S

Technical Handbook

General

Quality 8,8 10,9 12,9

Tightening torque, Nm

Condition

Thread UNF

12311

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S.Grupp 00

1/4 5/16 3/8 7/16 1/2

9/16 5/8 3/4 7/8

1 1 1/8 1 1/4 1 3/8 1 1/2

13 26 47 75

114 164

227 396 629

937 1350 1860 2500 3260

11 23 42 66

101 145

202 352 560

834 1200 1655 2225 2900

14 29 53 85

128 185

256 447 710

1058 1525 2100 2825 3680

19 37

67 107 162

231 321 559 889

1320 1900 2630 3530 4610

System of units

The SI system of units is employed in this handbook: The conversion factors are as follows:

Pressure

megapascal bar Kilogram-force per

square centimetre, kpf/cm² Atmosphere, at

Pound-force

per square

inch,

psi

22 44

79 126 191

273 379 661

1050

1560 2250 3110 4170 5450

1 0,1 0,098

Torque

Newtonmeter Nm

1 9,81

Power

Kilowatt kW

1 0,735

10 1 0,98

10,2 1,02 1

Kilogram force-metre kgf m

0,102 1

Horsepower (metric)hpHorsepower

1,36 1

145

14.5

14.2

Pound-force foot lbf ft

0.74

7.23

1.34

0.986

ContChamp DRD-S

Technical Handbook

9407

Contents

04-10

S.Grupp 10

Group 10 Chassis and cab

Specification .............................................................................. 2

Chassis...................................................................................... 3

Description ........................................................................... 3

Chassis............................................................................ 3

Support jacks................................................................... 3

Operator’s cab................................................................. 4

Steering column .............................................................. 9

Hydraulics control unit................................................... 10

Service ............................................................................... 11

Changing the fresh air filter ........................................... 11

Check and lubrication of brake pedal............................ 11

Windscreen wipers........................................................ 12

Air conditioning unit ................................................................. 13

Description ......................................................................... 13

Service ............................................................................... 16

Checking the air conditioning unit ................................. 16

ContChamp DRD-S

Technical Handbook

Specifications

Air conditioner

z Cab unit

Circulated air flow 500-600 m 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 consumption 250 W

z Cooling effect 6-8,5 kW z Heating effect approx. 11 kW

*) Refrigerant R12 is no longer in production due to legislation

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S.Grupp 10

ContChamp DRD-S

Technical Handbook

Chassis

Description

9407

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S.Grupp 10

Chassis

The chassis consists of:

z A unit construction frame built up around t wo box- sections for

best possible strength.

z Mountings for the drive axle, steered axle, telescope-boom,

lifting cylinders and transmission.

z The necessary counterweights to provide a very low centre of

gravity. Moreover , the ste ered axle is designed to serve as an additional counterweight.

The hydraulic oil tank and t he fuel tank are produced as separat e units and are bolted to the side of the chassis. The tanks have a low profile, which contributes to the good visibility.

Support jacks

Certain machines are equipped with support jacks to increase the capacity in the third container row, see group 20.

KL1436

ContChamp DRD-S

Technical Handbook

Operator’s cab

Description

9407

04-10

S.Grupp 10

Operator’s cab

The operator’ s cab is a separ ate structure and rests on the chassis on rubber dampers. The operator’s seat, steering wheel and hydraulic control le vers can be adjusted for best possible 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 recirculation. Fresh air is drawn in through a ventilation air filter. Full air conditioning, with cooling, heating and dehumidification, is available to special order.

1. Steering column with control levers and switches, ECS-terminal

2. Heating system

3. Air filter

4. Electrical central unit

ContChamp DRD-S

Technical Handbook

31 4 5 2 6

Operator’s cab

Description

9407

04-10

S.Grupp 10

789 10111213

1. Gear selector FORWARD/NEUTRAL/REVERSE 1/2/3/4

2. Lever DIRECTION INDICATORS/HORN FRONT WINDSCREEN WASHER/ FRONT WIPERS/MAIN BEAM

3. Instrument panel

4. Steering wheel panel

5. Starting switch

KL1406

6. Control lever and control panel for hydraulic functions

7. Electrical central unit with fuses and relays

8. Brake pedals, normal driving brake

9. Release clutch

10.Accelerator pedal

11.Steering wheel adjustment

12.Servo circuit breaker

13.Parking brake

ContChamp DRD-S

Technical Handbook

Operator’s cab

Description

9407

04-10

S.Grupp 10

55 56 60 59

KL581

40 41 42 43 44 45 52 53

47 48 49 50 51

KL580

KL582

57 58 64 61 62 63

21. Pressure gauge, gearbox oil pressure

22. Fuel gauge

23. Temperature gauge, engine coolant temperature

24. Switch, working lights

25. Switch, working lights

26. Switch, working lights

27. Switch, flashing beacon

28. Switch, hazard warning lights

29. Switch, driving lights

30. Spare

31. Spare

32. Spare

33. Spare

34. Switch, compressor air conditioning

35. Control, recirculation/fresh air

36. Control, defrost/cab

37. Switch, fan

38. Control, heat

39. Control, cold

KL675

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 lamp, low brake pressure (accumulator pressure)

46. Warning lamp, low engine coolant level

47. Indicating lamp, preheating

48. Warning lamp, high engine coolant temperature

49. Warning lamp, high gearbox oil temperature

50. Spare

51. Warning lamp, parking brake ON

52. Spare

53. Spare

54. Spare (Green lamp TWIST-LOCKS LOCKED)

55. Spare (Orange lamp ALIGNMENT)

56. Spare (Red lamp TWIST-LOCKS UNLOCKED)

57. Spare (LOCK/UNLOCK TWIST-LOCKS)

58. Spare (LENGTH ADJUSTMENT 20-40')

59. Indicating lamp, headlights

60. Indicating lamp, direction indicators

61. ECS terminal

62. Switch, windscreen wiper, rear

63. Switch, windscreen wiper, roof

64. Spare

65. Fuses

66. Hour meter

Optional

ContChamp DRD-S

Technical Handbook

Operator’s cab

Description

9407

04-10

S.Grupp 10

Joy-stick functions

1. Tilt

2. a. Locking of til t b. Locking of levelling

3. Rotation

4. Side shift

5. Vertical lift

6. Boom OUT/IN

7. Levelling

8. Length adjustment 20'–40'

9. Unlocking of twist-locks

10.LIFT/LOWER

Optional

Switch functions

13. Rotation limiting

15. AUT = Automatic locking of

twist-locks. The parking brake must be OFF MAN = Manual locking of twist-locks (spring-back) Unlocking off twist-locks, see Joy-stick function 9 above

17. Stop at 30' and 35'

18. Cab movemen t ho rizontal/vertical

19. Support jacks DOWN/UP 1)

20a. Red lamp, the support jacks have

left the upper position

20b. Green lamp, support jacks down

Optional

Button 17 for the connection and disconnection of the 30' and 35' stops

The position gives crawling speed the whole time during extension and retraction. In order to by-pass the 30' stop press and thereafter . The next stop will be 35'.

It is practical to connect in once the 30' position has been passed.

N.B. When operating a machine which is equipped with hydraulically moveable cab, the doors should be closed or the ca b in it s rea r posi tion otherwise all functions will be broken.

ContChamp DRD-S

Technical Handbook

Operator’s cab

Description

9407

04-10

S.Grupp 10

Lamp panel on the boom Container handling

A. Twist-locks locked, green B. Alignment, orange C. Twist-locks unlocked, red

Lit lamps at container lift: A+B Go out after lift: B

KL20

WARNING!

Overriding of the safety system is at one's own risk and involves a risk of forward tipping.

Engagement and disengagement of servo circuits

Override

(Only in emergency situations)

1. Lower

2. Container coupling

KL 1407

ContChamp DRD-S

Technical Handbook

Operator’s cab

Description

9407

04-10

S.Grupp 10

Steering column

Surrounding the steering column are multi-function levers for gear changing, indicators, windshie ld wipers , et c., as w ell as the instrument panel with the ECS terminal. At the very foot of the steering column is the steering valve (Orbitrol), activated by the steering wheel via an angled gear. The steering column is equipped with an adjustment knob for the alteration of steering wheel height and rake.

KL580A

1. Gear lever

2. Multi-function lever

3. ECS terminal

4. Steering wheel adjustment knob

5. Angled gear

6. Orbitrol steering valve

KL588

Column steering

ContChamp DRD-S

Technical Handbook

KL 1407

Operator’s cab

Description

9407

04-10

S.Grupp 10

Hydraulics control unit

Control lever and switches used to manoeuvre the hydraulics system are located on an adjustable console with comfortable working position

The control lever is a jo ystick that is electroh ydr aulically connected to the main valves.

1. Control lever

2. Connection and disconnection of servo circuits

3. Control switches for attachment

4. Switch for overriding of safety system (for use in emergency situations only). Affects both overload protection and container connection.

WARNING!

Overriding of the safety sy stem is carried out at y our own risk as such overriding i nvolves a ri sk of f or war d tippin g.

ContChamp DRD-S

Technical Handbook

Operator’s cab

Service

04-10

S.Grupp 10

Changing the fresh air filter

(every 200 hours or when needed)

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

2. Wash the filter insert with water and detergent or by using a high pressure washer. Replace the insert if necessary.

3. Reinstall the filter insert.

9407

Check and lubrication of brake pedal

(Every 1000:e hours)

1. Check and tighten the loc king screws 3, so that the br ake ped-

3 4

al is securely fitted in the console.

2. Lubricate the brake pedal shaft through the nipples 2.

1. Brake pedal

2. Lubricating nipple

3. Locking screw

4. Shaft

ContChamp DRD-S

Technical Handbook

Operator’s cab

Service

9407

04-10

S.Grupp 10

Windscreen wipers

The wiper arms are fixed to the wiper motor shafts via conical splines. The shafts are manufactured of hardened steel and the wiper arm mounting of soft, pressed metal. When fit ting, the nu ts must be tightened so hard that the splines are pressed well into the mounting and function as a carrier.

Removal

1. Remove the wiper arms by loosening the nuts and thereafter tapping and carefully rocking the 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 pressed fully into the wiper arm mounting.

2. Fit the wiper arms onto the motor shafts and tighten the nuts to a torque of 16-20 Nm. Hold the wiper arm to take up the torque pressure so that it is not transferred to the motor, which could result in damage

IMPORTANT!

The nuts must be tightened sufficiently hard, otherwise the shafts may start to slip in side the wiper arm mounti ng, resulting in damage.

1. Wiper arm fitting

2. Securing nut, wiper arm

3. Grooved cone on motor shaft

4. Wiper motor

ContChamp DRD-S

Technical Handbook

Air conditioning unit

Description

Air conditioning unit

The air conditioning unit consists of the parts shown in the illustration and its function is to maintain the climate in the operator’s cab as comfortable as possible. The air conditioning unit:

z heats the air 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 instrument panel.

9407

04-10

S.Grupp 10

1.Heating control

2.Heat exchanger

3.Vapourizer

4.Expansion v alve

5.To condenser

6.To compressor

7.Heating valve

8.From engine

9.To engine

10.Fan

11.Fan

12.Fan control

13.Fresh air filter

14.Air disperser

15.Control defrost/cab

16.Defroster outle t

15 16

The heating and ventilating system

ContChamp DRD-S

Technical Handbook

Air conditioning unit

Description

9407

04-10

S.Grupp 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 cab F Cooled air to the cab G Outside air for removing heat

ContChamp DRD-S

Technical Handbook

Air conditioning unit

Description

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-pressure gas from the compressor into liquid form. The tubes and fins of the condenser coil absorb heat, which is then remov ed b y 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.

9407

04-10

S.Grupp 10

Liquid receiver with filter-dryer

The function of the liquid receiv er 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 condenser housing, also serves as the expansion v essel in t he refrigeration circuit.

After flowing through the dryer in the bottom of the liquid receiver , 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 ev aporating.

The expansion v alve is also the part of the circuit which separ ates the high- pressure side from the low-pressure side. The refrigerant flows to the e xpansion valve under hig h pressure and lea v es 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 se arches f or a point to g ive optimum evaporation.

Evaporator

The heat necessary for evaporating the refrigerant is extracted from the cab air which is circulat ed b y a fan through the evaporator coil. The cab air is thus cooled, and is distributed and returned to the cab.

In the ev aporator , the refrigerant re verts to the gaseous state an d returns to the compressor suction, thereby completing the cycle.

ContChamp DRD-S

Technical Handbook

WARNING!

z If the refrigerant hose should fail or if

other refrigerant leakage should occur , switch off the air conditioner immediately.

z Refrigerant is injurious to the skin and

eyes.

z Never release refrigerant in an en-

closed space. If released into a service pit, for instance, the gas ma y cause asphyxia.

z It is forbidden by law to discharge re-

frigerants into the airintentionally.

z Never carry out welding on a charged

refrigeration system or in its vicinity.

z Only authorised service mechanics are

allowed to drain off and fill refrigerant in the air conditioning system.

Only the prescribed refrigerant may be used when refilling.

Air conditioning unit

Service

The liquid refrigerant should be completely evaporated before it is allowed to flow from the ev aporator. The refrigerant is still cold even when it has completely evapora ted. The cold v ap our which flows through what remains of the e vaporator contin ues to absorb heat, and then becomes overheated. This means that the temperature of the refrigerant has risen to abo ve th e point where it evaporates without changing the pressure.

In an evaporator which operates at a suction pressure of 2 bar, the liquid refrigerant will have a temperature of –1.1°C . When the refrigerant is subsequently e vaporated through heat absorption in the evaporator, the temperature of the gas will rise at the evaporator outlet to +1.6°C. This represents a difference of 2.7°C between the evaporation temper ature and the temperature at the outlet. This is called overheating.

All expansion valv es should be adjusted at the plant in such a wa y that maximum evaporation with overheating is performed in the air conditioning system.

Checking the air conditioning unit

If the unit is in continuous operation, this chec k should be carried out every week from early spring to late autumn and during extended periods of high humidity during the winter.

9407

04-10

S.Grupp 10

If the unit is used very little during cold and dry winter periods, th e compressor should be run for a f e w min utes every week, to lubricate the rubber hoses, couplings, seals and shaft seal.

1. Start the engine and start the air conditioner. At an outdoor temperature belo w 0°C, the system cannot start since the low-pressure relay breaks contact.

2. After 10 minutes of operation, check that no bubb les are visible in the sight glass of the filter-dryer. (Bubbles should occur only when the compressor is started and stopped.) If there are any air bubbles, subsequent filling should be performed by an authorised service mechanic.

3. Check that the condenser is not clogged. If necessary, clean the condenser fins and the fans with compressed air.

4. Change the fresh air filter as necessary.

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

6. Check that the magnetic coupling engages and disengages satisfactorily.

7. Check that the condensate drain from the cooling element is not clogged. Check for leakage.

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