Kalmar DRD-S, DRD-GB Handbook

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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

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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

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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

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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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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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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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ContChamp DRD-S

Technical Handbook

Chassis

Description

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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.

ContChamp DRD-S

Technical Handbook

IN CAB UNIT CONDENSER UNIT

Air conditioning unit

Service

9407

04-10

S.Grupp 10

RD 1,5

GL 1,5

SV 1,5

M H

RD 1,5

BR 1,5

GL 1,5

VT 1,5

RD 1,5

30 85

87 86

BR 1,5

HIGH

LOW

1.Fan switch

2.Cooler on/off

3.Anti-freeze thermostat

4.Resistor

5.Fan motor

6.Indicator lamp – cold (in push button)

7.High-/low-pressure monitor

8.Relay

9.Condenser fan

10.Compressor

Tom sida Empty page Leere Seite Face vide

ContChamp DRD-S

Technical Handbook

Group 20 Electrical system

Contents

9407

04-10

S.Grupp 20

Specifications..............................................................2

Electrical system.........................................................3

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

Checking the electrolyte level of the batter ies .... 5

Fuses..................................................................5

Relays.................................................................6

Bulbs...................................................................7

Starting from another battery..............................8

Air operated operator’s seat................................8

ECS-system

Overview..................................................................9

Terminal ................................................................ 10

Menu structure..................................................10

Operating menues ........................ ....................11

Error messages.................................................15

Service menues ...................... ... .......................20

ECU-processor unit................................................22

Transmission data kit....... .................................23

Engine data kit ........................... .......................23

ECU 1

Functions................................................................24

Circuit board...........................................................26

01 Automatic gear changing .............................27

04 Lever steering ..............................................28

07 Monitoring ....................................................31

ECU 2

Functions................................................................33

Circuit board...........................................................34

Installation, boom.................. .... ... ..........................35

Electric servo..........................................................36

Control lever......................................................37

Pressure sensors right and left lift cylinders ..... 41

Lift - regeneration - lower.................................. 42

Boom extension - regeneration.........................45

Rotation.............................................................49

Twist-locks........................................................51

Side-shift...........................................................53

Length adjustment 20-40’ .................................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/

LC-distance for Module 50/60................................62

Module 60 Electronic Overload Protection.............63

ECU 3

Functions............................................................... 66

Circuit board .......................................................... 67

Module 54 Tilt........................................................ 68

Module 56 Cab movement..................................... 69

Module 61 Support jacks ....................................... 71

Diagrams

Gearchanging systems......................... ... .............. 73

Components, A38630.0100 and A38630.0200......77

ECS overview.................................... ... ... .... ... ....... 78

Electrical diagram explanations............................. 79

Cable markings...................................................... 80

Component list

Electrical diagrams ECS top lift – page

A24925.2000 - 1, 2, 3 A24925.2200 - 1 A24927.2000 - 1, 2 A24927.2200 - 1, 2 A24929.2000 - 1, 2

Electrical diagram, truck body....................A08334.1200

Electrical diagram, inner, standard............A08333.1000

El-servo, singel ECU (S)............................A38630.0100

El-servo, double ECU (S) .......................... A38630.0200

Diagram attachment, 4 pages..............A38414.0100,1-4

Feed ........... ........................ A38414.0100, 1/4

Indication............................ A38414.0100, 2/4

Servo.................................. A38414.0100, 3/4

Working lights..................... A38414.0100, 4/4

Cable to twist-locks.............................. ... ... A38636.0100

Cable feed KDU 791..................................A38415.0100

ContChamp DRD-S

Technical Handbook

Specifications

Alternator rating 1920 W

Starting battery voltage 24 V (2 x 12 V)

capacity 140 Ah earthing negative

9407

04-10

S.Grupp 20

ContChamp DRD-S

Technical Handbook

IMPORTANT! Always open the main switch whenever work is to be carried out on the electrical system, if the truck is to remain idle for some time and whenever welding work is to be carried out on the truck.

Electrical system

Description

The system voltage is 24V and the supply is taken from two 12V batteries connected in series and charged by an alternator across electronic rectifying and voltage stabilisation circuits.

. The negative and positive poles are both connected across a

main switch. The negativ e po le 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 the lower section of the cab’s rear wall.

9407

04-10

S.Grupp 20

1. Main switch

2. 24 V battery

3. Running lights

4. Rear lights

5. Rotating warning light

ContChamp DRD-S

Technical Handbook

Electrical system

Description

9407

04-10

S.Grupp 20

1. Sensor, outgoing revs (ECS or reversing block)

2. Sensor, gearbox oil temperature, warning lamp and meter

3. Sensor, gearbox oil pressure, warning 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 temperature, meter

10.Starter motor

11.Sensor, coolant level

12.Alternator

13.Solenoid valve, stop engine

14.Throttle lever, injection pump

15.Sol enoid valve for gear changing

14 15

Engine electrics

ContChamp DRD-S

Technical Handbook

Electrical system

Description

9407

04-10

S.Grupp 20

N.B. The starting batteries accompanying the truck are of the maintenan ce-free type, which implies that it should not be necessary to top-up with electrolyte during the life of the batteries.

However, the level of the electrolyte should preferably be c hecked once or twice a year. Fill as required by adding de-ionized water.

S1-6 7-12 13-18 19-24 25-30 31-36

KL1749

WARNING!

Never use fuses of a higher amperage than stated on the lid decal. Risk of damage or fire.

WARNING!

It is prohibited to connect extra consumers to any fuse.

Checking the electrolyte level of the batteries

The batteries are fitted behind a cov er on the left-hand side of the truck. The electrolyte level should be about 10 mm above the cells. Top up with de-ionized water as necessary.

Relay box in cab – fuses

Fuse Rating No. Circuit protected A

S1 Wiper motor front, direction indicators,

seat buzzer, parking brake sensor............................... 10

S2 Ignition key, preheater, starter motor,

air conditioner, cab lighting ......................................... 15

S3 Container attachment, safety interlock........................ 15

S4 Electric gear-changing ............................................... 5

S5 Warning lamps, instrument illumination, relay,

coolant level .................................................................. 5

S6 Brake lights, reversing lights, reversing alarm ............ 15

S7 Fan (Option: Air condit ioning) S8 Spare (Option:Container lights) S9 Working lights (15 A for 4 lamps)

Hazard beacon ........................................................... 10

S10 Working lights, standard (15 A for 4 lamps) ............... 10

S11 Horn, screenwash motor, wiper rear and roof,

wiper front, intermittent relay....................................... 10

S12 Driving lights (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 light, right-hand..................................................... 5

S19 ECU1

S20 ECU2........................................................................... 10

S21 Voltage converter .......................................................... 5

S22-S24 Extra........................................................................... –

S25-S30 Extra........................................................................... –

S31 Illumination entry steps, engine compartment S32 Compressor, air operated chair

S33 electrically operated parking brake............................. 5

S34 Oil cooler, hydraulic oil S36 Central lubrication

S36 Water separator1) ...................................................... –

)Optional equipment

)........................................................................ 10

....................................... ............ –

).................................. 25

)............................... 15

)

.............................. –

............................................ –

........ –

KL593A

Miscellaneous fuses

A Main switch B Main fuse, boom (1x25 A) D Main fuse for truck electrical system

Fitted on the engine, 2x50 A

ContChamp DRD-S

Technical Handbook

Electrical system

Description

Relays

305 Reversing light 314 Parking brake, disengagement 315 High power (Starting switch) 316 Wiper motor, front 320 Electric stop (ECS 07) 322 Coolant level (ECS 07) 323 Pulse relay, direction indicators 328 Gear shift (ECS 01) 330 Starting block 331 Propulsion forward 332 Propulsion reverse 334 Clutch release (ECS 01) 367 Lever steering (ECS 04) 322-1 Coolant level 322-2 Coolant level (ECS 07) 399 Spare

Miscellaneous

321-1 Intermittent relay wiper front 321-2 Intermittent relay wiper rear 960 Reversing interlock (excluded at ECS 01)

) Optional equipment

)

9407

04-10

S.Grupp 20

KL 1541

ContChamp DRD-S

Technical Handbook

Electrical system

Description

9407

04-10

S.Grupp 20

KL 1542

Bulbs

Rating

Description 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/dipped beam) 75/70 P43t-38 Reversing lights, white 70 PK22s Working lights 70 PK22s Hazard beacon 70 PK22s

ContChamp DRD-S

Technical Handbook

Electrical system

Description

Starting from another battery

 Make sure the auxiliary batteries are connected in series, so

that 24 V will be supplied.

N.B. Do not disconnect the truck-battery cables

9407

04-10

S.Grupp 20

WARNING!

Batteries emit oxyhydrogen which is an explosive gas. A spark, for example from incorrectly connected starting cables, could cause a battery to explode and result in serious injury and damage.

 Connect the jumper cables in the following order:

1. Red cable (+) to auxiliary battery

2. Red cable (+) to truck battery

3. Black cable (–) to auxiliary battery

4. Black cable (–) to a location some distance 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 either battery.

 Disconnect the jumper cables in exactly the reverse order.

1. Motor and compressor Installed in a box on the right hand side of the machine or beneath the cab

2. Pressure monitor

3. Fuse 3, 56.3

Air operated operator’s seat

ContChamp DRD-S

Technical Handbook

ECS

Overview

9407

04-10

S.Grupp 20

Kalmar’s ECS - Electronic Control System - is a modular control and monitoring system to ensure optimum operational security and total economy . It is possible to combine the system’ s diff erent modules in a number of different ways.

All vital points of the trucks different systems are connected to one or several central computer units, ECUs. A terminal display in the operator’s cab shows current values and generates an alarm if the values exceed the programmed tolerances.

DRD Container machines are equipped with ECS as standard. Depending on how respective machines are equipped, one, two or three ECU central units ma y be fitted.

 ECU 1 is used for different additional modules, such as 01 Au -

tomatic Gear Changing, 04 Lever Steering, 06 Mini-steering, 07 Monitoring. See separate descriptions in respective sections.

 ECU 2 is obligatory and is used to control the El-Servo cir-

cuits. See the El-Servo section. ECU 2 also functions as overload protection and for the regeneration system.

 ECU 3 is used for machines with modules according to the

table below.

ECU 3

DRD400-60S5

KL621b-c

ECU 1 01 Automatic

Gear Changing

04 Lever Steering 06 Mini-steering 07 Monitoring

Optional equipment

ECU 2 ECU 3 El-Servo

50 Mechanical over-

load protection

Regeneration

51 Vertical lift 52 Balance + vertical

lift

53 Locking tilt 57 Hydraulic

balance

58 Container

counter

59 Limitation Height/

LC-distance

70 PC/Printer 60 Electronic over-

load protection

Regeneration V ertical lift

53 Locking tilt 58 Container

counter

59 Limitation Height/

LC-distance

70 PC/Printer

Bottom lift

54 Tilt 55 Pile slope 61 Support jacks

The ECS:

– monitors 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 anging – interrupts hydraulic functions when ove rload of the steer-

ing axle occurs – controls the regeneration func tion for boom e xtension and

lift cylinders – controls vertical lift, balance, pile slope etc.

If a fault occurs:

– a red warning lamp blinks on the terminal – an error message appears on the terminal display – The ECS limits the functions of the truck in different ways

depending on the seriousness of the fault. Certain func-

tions are monitored on two le v e ls, whe re le vel 2 limits the

functions of the truck. See the error messages on the ter-

minal display on the following pages.

ContChamp DRD-S

Technical Handbook

ECS

Terminal

9407

04-10

S.Grupp 20

Terminal functions

KL580B

1. Arr ow left is used to sc ro ll betwee n th e different menus.

2. Arrow right is used to scroll between the different menus.

3. R is used to reset the display after an error message. All errors, with the ex ception of certain lev el 2 errors ca n be reset by pressing this button. The red warning lamp is then extinguished. The lamp begins to b link again af te r 3-1 0 m inutes, depending on the fault, if it has not been rectified.

4. - is used to decrease a value.

5. + is used to increase a value.

6. ENTER is used to access the service menus and to save

new values when setting up and calibrating the system. Access to the service menus also requires the use of spe cial codes, that are separately obtainable from Kalmar.

7. A red warning light blinks in the event of an error and is extinguished when reset by pressing button 3.

8. The terminal displa y has 4 lines with space for 20 chara cters on each line. Graphical presentation of operating menus and error messages.

Menu structure

There are three types of menu:

1. Operating menus

The operating menus are accessible to the operator. The menus that can be selected depend on how the truck is equipped and are determined in SETUP. All operating me nus are part of a connected loop. Use arrow RIGHT/LEFT to move around the loop. The loop also contains:

1.a Overload indicator Depends on the selected overload protection, module 50/

60.

2. Error messages Displayed automatically and have priority over other menus.

3. Serv ice menus The operating menu loop always contains the KALMAR INDUSTRIES SERVICE main menu.The service sub-menus under this main menu require access to codes that can be found on a special list from Kalmar. If ENTER is pressed by mistake in the service menu and the ENTER CODE menu is displayed, return to the operating menu b y pressing ENTER. For further information, refer to the respective headings.

KL1409

1a.

Enter

ContChamp DRD-S

Technical Handbook

01 Automatic gear changing 07 Monitoring 50 Mechanical overload protection system 60 Electronic overload protection system

ECS

Terminal

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Operating menus

The menus that are displayed on the terminal depend on the modules with which the truck’s ECS is equipped. The overview below shows the possible combinations. Use either arrow RIGHT/LEFT to switch between m enus . All operating men us are in a connected loop.

Access to the sub-menus under the service menu requires an access code. If ENTER CODE is displayed by mistak e, return to the operating menu by pressing ENTER.

N.B. Additional menus may occur as a resu lt of adaptation to specific customer requirements.

01.50

07.50

01.07.50

KL1410

Operating menus with mechanical overload protection, module 50

Explanations, see next page

ContChamp DRD-S

Technical Handbook

ECS

Terminal

Operating menus, module 50

1. Main menu KALMAR INDUSTRIES SERVICE

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3ab

4ab

2. Normal operating condition, module 50 a. 1750rpm Engine speed, r/min

3. Normal operating condition,

c d

module 50 + module 01 a. 1750rpm Engine speed, r/min b. F3 Current gear c. 14 km/h Current speed

4. Normal operating condition, module 50 + module 01 + module 07 a. 1750rpm Engine speed, r/min b. F3 Current gear c. 4 km/h Current speed d. Fuel level. The tank is full 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 operation. The red warning lamp lights continuously. The machine has forward overload. It is not possible to switch to other menus until the overload is rectified.

7. a. 75 °C Engine coolant temperature b. 3.8 bar Engine oil pressure

8. a. 75 °C Gearbox oil temperature b. 3.8 bar Gearbox oil pressure

9. a. 24.5 v Battery voltage b. 75 °C Hydraulic oil temperature

10. a. 28756:21.54h Total operating time, tim: min. sek. b. 130h Time to next service, tim

ContChamp DRD-S

Technical Handbook

ECS

Terminal

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01.60

07.60

01.07.60

KL1411

Operating menus with electronic overload protection, module 60

Explanations, see next page

ContChamp DRD-S

Technical Handbook

c d

b c

d e

b c

a b

c d

ECS

Terminal

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Operating menues, module 60

Module 60 overload protectio n function, under normal conditions, functions as a balance and gives a continual reading of the size and position of the load.

1. Main menu KALMAR INDUSTRIES SERVICE

2. Normal operating condition, module 60. a. 1750 rpm Engine speed, r/min c. 3.0 m Distance between the front edge of the

wheels and the centre of gravity of the load. d. 25.5 t Current load in ton nes e. Indicator showing steering axle load, fills the display to the left for 95-100% of the permitted load. When the indicator reads full, the system interrupts operation due to overloading of the steering axle. The red warning lamp blinks. It is not possible to switch to other menus until the overload is rectified. f. Load indicator, fills the display to the right for 0-100% loads. When the load indicator reads full, the system interrupts operation due to forward overload. The red warning lamp lights continually. It is not possible to switch to other menus until the overload has been rectified.

3. Normal operating condition, module 60 + module 01 + module 07 a. 1750 rpm Engine speed r/min b. F3 Current gear c. d. e. f. See menu 2 explanation above.

4. a. 10.38 t Current load in tonnes b. 1.07 m Boom extension c. 3.08 m Lc-distance. Distance between driv e axle

centre and load centre.

d. 23.0 ° Boom angle

5. a. 1750 rpm Engine speed r/min b. F3 Current gear c. 14 km/h Current speed d. Fuel level. The tank is full when the indicator is filled

to the right.

6. a. 75 °C Engine coolant temperature

b a

b. 3.8 bar Engine oil pressure

7. a. 75 °C Gearbox oil temperature b. 3.8 bar Gearbox oil pressure

8. a. 24.5 v Battery voltage b. 75 °C Hydraulic oil temperature

9. a. 28756:21.54 h. Total operating time, h: min. sec. b. 130h Time to next service, h

ContChamp DRD-S

Technical Handbook

01 = Automatic gear changing 04 = Leve r steering 06 = Mini Steering 07 = Monitoring 50 = Mechanical overload protection 60 = Electronic overload protection

ECS

Terminal

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Error messages

In order of priority. If two faults occur at the same time, the terminal displays the f au lt wit h the h igh est p riority. Error messages always ha ve a higher priority than normal menus. Errors 01-08 are level 2 errors and cannot be reset prior to the fault being rectified. The first two figures to the left of the menu pictur es show to which module the error message relates. (These figures do not appear on the display)

01, 07

01. Battery voltage very low/high Stop as soon as possible and contact service.

02. Faulty signal from accelerator sensor. Engine speed reduction. Stop as soon as possible 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 soon as possible and contact service.

05. Engine oil pressure extremely low. Engine speed reduction. Stop as soon as possible and contact service.

06. Coolant temperature ext remely high. Engine speed reduction. Stop as soon as possible and contact service.

07. Gearbox oil pressure extremely low. Engine speed reduction. Stop as soon as possible and contact service.

08. Gearbox oil temperature extremely high. Engine speed reduction. Stop as soon as possible and contact service.

ContChamp DRD-S

Technical Handbook

ECS

Terminal

9407

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01, 07

09. Faulty signal from engine rev sensor. Engine speed reduction. Stop as soon as possible and contact service.

10. Low engine oil pressure. Check oil level and top up as required.

11. High coolant temperature. Check coolant le vel and top up as required.

12. Low gearbox 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 coolant level. Top up the coolant fluid.

16. High hydraulic oil temperature. Operation possible. Contact service.

17. Faulty signal from fuel gauge sensor. Operation possible. Contact service.

18. Faulty signal from gearbox oil pressure sensor. Operation possible. Contact service.

ContChamp DRD-S

Technical Handbook

ECS

Terminal

9407

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19. Faulty signal from engine oil pressure sensor. Operation possible. Contact service

20. Faulty signal fro m coolant temperature sensor. Operation possible. Contact service.

21. Faulty signal from gearbox oil temperature sensor. Operation possible. Contact service.

22. Faulty signal from hydraulic oil temperature sensor. Operation possible. Contact service as soon as possible.

23. Service interval exceeded. Contact service as soon as possible.

01, 07

24. Faulty signal from prop shaft rpm sensor Engine speed reduction. Stop as soon as possible and contact service.

25. Steering lever fault. Switch off the steering system. Contact service as soon as possible.

26. Faulty signal from steering sensor. Switch off the steering system. Contact service as soon as possible.

27. Faulty signal from mini steering sensor. Switch off the steering system. Contact service as soon as possible.

28. Warning! Low brake pressure. Contact service as soon as possible.

ContChamp DRD-S

Technical Handbook

ECS

Terminal

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31. System fault ECU 1. Contact service as soon as possible.

32. System fault ECU 2. Contact service as soon as possible.

50. Battery voltage very low/high. Contact service as soon as possible.

51. Communication with ECU 3 broken. Contact service as soon as possible.

52. Communication with ECU 1 broken. First try switching off and then re-starting the engine! If the fault remains, contact service as soon as possible.

50, 60

53. Faulty 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. Faulty signal from regeneration sensor. The regeneration is discontinued. Contact service.

56. Faulty signal from hydraulic pressure sensors for left lift cylinder. (There is a sensor in both feed and return lines) Stop as soon as possible and contact service.

57. Faulty signal from h ydraulic pressure sensors f or right lift cylinder. (There is a sensor in both feed and return lines) Stop as soon as possible and contact service.

ContChamp DRD-S

Technical Handbook

ECS

Terminal

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58. Faulty analog signal from joystick. All boom functions are interrupted. Stop as soon as possible and contact service.

59. Faulty signal from sensor for end position damping Contact service as soon as possible.

60. Faulty signal from twist-locks sensors. Applies to both locked and unlo cked position. The signal from one or 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 fault. Load curve is missing. Stop as soon as possible and contact service.

62. Each one of the Module 60 errors will activate error menu 62. When error menu 62 is activated: Warning lamp on the ECS-terminal lights up

When pressing RESET: Menu 62 starts blinking, 5 sec ON and 5 sec OFF The hydraulic functions LIFT/LOWER and BOOM OUT/IN are operative but at a lower speed.

ContChamp DRD-S

Technical Handbook

Detailed descriptions of SETUP, INITIATION and CALIBRATION can be found in the separate ECS SERVICE Handbook Contact Kalmar

ECS

Terminal

9407

04-10

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Service menus

All service sub-menus are accessible from the main KALMAR INDUSTRIES SERVICE menu, thereafter, a code must be registered. There are four different codes, codes 1, 2, 3 and 4.

 Code 1 leads to the SETUP, INITIA TION and CALIBRA TION

of the modules in ECU1.

 Code 2 leads to the INITIATION of the El-servo in ECU 2.  Code 3 leads to the CALIBRATION of module 60 in ECU 2.  Code 4 leads to the DIAGNOSIS menu.

Definition of terms: SETUP is the setting of the basic values of the machine, def ining,

for example, the modules with which the machine is equipped. This determines which operational menus then appear.

INITIATION is the basic setting of the diff er ent modules’ par ameters.

CALIBRATION is the individual adjustment of t he max. and min. values of the different modules’ signals. Calibration is u nique for each machine.

The illustrations below and on the f ollowing page provide an ov erview of all av ailable service menus. All of them are accessed from the KALMAR INDUSTRIES SERVICE main menu.

Code 1

ET N

TPEU

NTER

SERVICE 20

+-/)

(

ITMTO

INTERVAL

SERVICE

XETE

ENTE

EMU

I A C

N U H

II T A

ENTE

T T

OMAC

I I

E E

ENTE

SETUP ECU1

INITIATION

MODULE 01

CALIBRATION

KL722-C

MODULE 04

BRATI

TPOS

ENTE

CALIBRATION

N EV

L4RENG

MOT

NI TO

EDA

ENTE

INITIATION

MODULE 04

MODULE 01

T ST

ENTE

Service menus

under Code 1

ContChamp DRD-S

Technical Handbook

ECS

Terminal

Code 2 Code 3

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KL723-C

SETUP EL-SERVO ECU2

Code 4

DIAGNOSIS

Detailed information about the different service menu paths can be found u nder respective section descriptions.

The connected loops then appear as shown in the adjacent picture.

The arrows beside the menus show the switch paths between men us . Use RIGHT/ LEFT arrow keys.

CALIBRATION

MODULE 60

910

Service menus

under Codes 2, 3 & 4

ContChamp DRD-S

Technical Handbook

When replacing the EPROM, always use Kalmar’s special tools

KL679

KL678

ECS

ECU - Processor Unit

ECU - processor unit

The computer processor unit receives signals from connect ed sensors, processes the signals and transmits them to the system’s different controlling organs, such as valves, motors, etc.

Each ECU contains two identical micro-processors. Each microprocessor has its own EPROM that contains the relevant program-ware and parameters for the machine in question. These EPROMs are marked with the same num ber as the last three numbers of the corresponding micro-processor number. These three numbers are used to ensure that the EPR OM is fitted in t he correct location to match the corresponding micro-processor when an EPROM replacement is carried out.

Example: The micro-processor has number 80C592. The corresponding EPROM is then number 592 and must be fitted adjacent to 80C592.

Each EPROM has notch at one end and t his should be matche d with the corresponding notch in the EPROM socket.

Analogue OUT-signals and digital IN-signals are indicated by red or green LEDs (light emitting diodes). Analogue IN-signals are not indicated. The LEDs are marked LE1-LE42 and are use d for fault finding. For each ECU there is a table listing the relevant junction box pins, the corresponding signal, LEDs and machine functions. See respective sections.

In the ev ent o f a fault, first investigate the IN-signals. If an IN- signal is incorrect, the fault lies with the sensor and/or ca b les . If, on the other hand, the IN-signal is correct, the fault lies in the processor.

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KL680

N.B. The only permissible action to be take n with the ECU is the replacement of the EPROM. If this does not rectify the problem, then the complete ECU, including the housing, must be replaced with an exchange unit from Kalmar.

EPROM = Erasable Programmable Read Only Memory

Kalmar special tools

1, 2 and 3 below, are parts of the ECS kit, art. no. 425817.8068.

1. Extractor. Art.nr 923827.0002

2. Fittin g tool. Art.nr 923827.0001

3. Anti-static mat. The mat should be connected to earth and to one wrist. Art.nr 923830.0001

4. The EPROM pack. This must alwa ys be used f or the t ransportation and storage

of the EPROM. The pins should be pressed into the plastic which neutralizes any static electrical charge. Art.nr923830.0002

KL681

ContChamp DRD-S

Technical Handbook

Data kit

no.

Truck Gearbox No. of

ECS

ECU - Processor Unit

Transmission data kit

Wheel

gears

dimensio

Wheel

radius

Pulses per rev

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Comments

1 DRD 450 36 000 8 DRD 450 18.00x25 0.73 50

9 DRD 450-80X 21.00x35 0.93 50 10 DRD 450-X 18.00x33 0.83 50 16 DRD450-80X 21.00x35 0.93 12 19 DRD 450-X 18.00x33 0.83 12

40 000

4 18.00x25 0.73 12

Engine data kit

Data kit

no.

0 DRD Cummins M11 118 260 Magnetic pick-up 1 VOLVO TD/TWD 30 1023 Volvo-engines without

4 Scania DSI 11 158 194 6 VOLVO TWD1231ME 30 1023 Frequency control 7 VOLVO TWD1030 30 1023 The control motor operates

Truck Engine Model Pulses per

engine rev

Factor Comments

frequency control

inverted 8 Scania DSI 9 22.7 1352 W-connection alternator 65A 9 Scania DSI 11 21.1 1457 W-connection alternator 65A

10 Scania DSI 9 30.3 1014 W-connection alternator 90A 11 Scania DSI 11 28.1 1093 W-connection alternator 90A 13 Scania DI 12 21.1 1457 W-connecti on alternator 65A 14 Scania DI 12 28.1 1093 W-connecti on alternator 90A 15 Cummins 6CT 127 242 Magnetic pick-up 20 Volvo TWD1240VE 38 808 No control motor

ContChamp DRD-S

Technical Handbook

ECU 1

Functions

ECU 1 functions

ECU

Signal LED Function Module

40 Analogue IN 1. 0-10V Steering lever/Mini-steering signal A x 42 Analogue IN 2. 0-10V 64 Analogue IN 3. 0-10V 65 Analogue IN 4. 0-10V 66 Analogue IN 5. 0-10V 67 Analogue IN 6. 0-10V Servo motor throttle return x 52 Analogue IN 7. 0-10V Accelerator pedal 1 x

1 Analogue OUT 1 LE5 Steering valve left x 3 Analogue OUT 2 x 4 Analogue OUT 3

5 Analogue OUT 4 47 Analogue OUT 5 LE38 (+37) Steering valve right x 69 Analogue OUT 6 LE36 (+35) Servo motor throttle control (pulses to servomotor) x

8 Digital IN 1 LE14 Gear position 1 x x x

9 Digital IN 2 LE17 Gear position 2 x x x 10 Digital IN 3 LE20 Gear position 3 x x x 11 Digital IN 4 LE23 Gear position F x x x 31 Digital IN 5 LE13 Gear position R x x x 32 Digital IN 6 LE16 Brakes/Parking brake active x 33 Digital IN 7 LE19 Level monitor engine cooling system x 34 Digital IN 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

57 Digital IN 11 LE21 Manual gear change down x 58 Digital IN 12 LE14 Manual gear change up.(Shift MAN/AUT, option) x x

2 Digital OUT 1 LE6 Valve 1 gear changing x x x 24 Digital OUT 2 LE10 Valve 2 gear changing x x x 25 Digital OUT 3 LE7 Valve 3 gear changing x x x 26 Digital OUT 4 LE8 Valve F gear changing x x x 48 Digital OUT 5 LE9 Valve R gear changing x x x 49 Digital OUT 6 LE11 Alarm 1 x 50 Digital OUT 7 LE12 For electric trucks x 22 Digital OUT 8 LE32 (+31) Control for changing be tween steering wheel/lev er

46 Digital OUT 9 LE34 (+33) Direction of servo motor throttle control. LE34 and

Accelerator pedal 2 Wheel return wheel position, steering axle

button for lever steering is in the ON position - a check that the cable is OK

steering and K lamp contact. LE32 lights red when lever steering is connected. LE31+LE32 shows weak light when normal steering is connected (i.e ., lever steering disconnected)

33 alternate depending on the direction of the motor. When the motor stands still, e .g., when the accelerator pedal is in the upper position, both light up “weakly” without alternating. Depress the accelerator and check that the LEDs light alt ernately

01 04/06 07

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ContChamp DRD-S

Technical Handbook

ECU

Signal LED Function Module

6 NTC 1 Engine coolant temperature x

7 NTYC 2 Gearbox oil temperature x 30 NTC 3 Hydraulic fluid temperature x 53 NTC Ambient temperature x 35 Pulse sensor 1 LE28 Engine revs., functions only on Perkins engines x x 59 Pulse sensor 2 LE27 Drive shaft revolutions 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 steering wheel is turned. Wheel turned anti-clockwise: LE25 lights up first. Wheel turned clockwise: LE26 lights up first. If not: Check the sensor and

activator on the steering column 27 Rheostat 1 Fuel level x 28 Rheostat 2 Engine oil pressure 10 bar x 51 Rheostat 3 Gearbox oil pressure 25 bar x

ECU 1

Functions

01 04/06 07

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Technical Handbook

ECU 1

Circuit Board

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LE1 Should always be lit,indicating a

5V feed from the voltage

transformer LE29 Not used LE30 Not used LE39, LE40 show communication 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 communication to the terminal and should blink on all ECUs. If it lights continuously or is extinguished, the program will not start, i.e., something is wrong, f or example, the EPROM or electrical supply.

ECU 1 circuit board

ContChamp DRD-S

Technical Handbook

ECU 1

01 - Automatic gear changing

Module 01 - Automatic gear ch anging, is designed f or gearbo xes with torque converters. The system controls up and down changing of gears, simplifies operation and extends the service life of the transmission equipment.

See electrical diagrams.

The system

 Prevents t he gears from being engaged if eng ine rev olutions

exceed 1100 rpm

 Preven ts changing between f orw ard and re verse gea rs if the

speed of the truck exceeds 3 kpm

 Locks the present gear if the signal from the prop shaft rev-

olution sensor is incorret or absent

 Reduces engine rev olutions when chan ging to a higher gear

so that the speed of the truck remains constant

 Disengages the gearbox if the operator 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 ECS

terminal display

Function

The point at which the gearbox chan ges gear is optimiz ed to the truck’s t ransmission equipment. T he torque in the torque conv erter initiates the change of gear. The system changes to a lower gear when the torque is higher than a pre-programmed value and vice versa.

The operator can limit gear chan ges from 4 to 3, 2 or 1 b y moving the gear selector to the corresponding position. If the selector is in the 2nd gear position, the system changes automatically between 1st and 2nd gears.

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11 2

1. Injection pump motor

2. Electronic accelerator pedal

3. Sensor, gearbox disengagement

4. Sensor, engine revolutions

5. Sensor, propeller shaft revolutions

Fitting and adjustment, see group 40

01 Automatic gear changing, included units

ContChamp DRD-S

Technical Handbook

ECU 1

04 - Lever Steering

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KL1405

4 a b 5

04 Lever Steering

See electric diagrams. The lever steering module is an electrical system for the steering

of the truck by means of a linear stee ring lever . The steered wheel deflection is inv ersely proportional to the speed of the truck, i.e., at low speeds, the steered wheel deflection is greater than at higher speeds. The system is available with or without wheel return. With the wheel return system, when the operat or releases th e lever the steered wheels return to a central position.

The steering valve is electronically controlled with one magnet for right and one for left. This feeds the flow of hydraulic fluid to and from the steering cylinder. Th e magnets receive analogue signals from ECU 1.

The standard steering wheel is equipped with two inductive sensors that sense any movement of the steering wheel. The sensors are used to disconnect the lever steering function if the operator is faced with an emer gency situation. As soon as the standard steering wheel is used, the lever steering disconnects. This satisfies the relevant safety requirements for a wheel-return system.

The sensor that returns the wheels to a central position is located under a hood adjacent to the steering axle’s left hand king pin.

The lever steering module includes a steering lever console .

1. Steering lever

2. Rocker switch F-N-R

3. Signal horn

4. Switch for gear changing a. Up b. Down (excluded if the truck is equipped with Module 01)

5. Switch for activating lever steering

6. Extra function

7. Sensor, steering wheel speed

8. Control valve, steering

9. Steered wheel sensor

46-49 = Electrical connections

24031

04 Lever steering, included units

ContChamp DRD-S

Technical Handbook

100%

65%

40%

0 5 10 15 Km/hr.

Wheel displacement at full lever movement.

Values as per INITIATION 04, menus 3-7

BP1

BP2

BP3

ECU 1

04 Lever Steering

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Lever steering characteristics

Also applies to Module 06, Mini-ste ering

The maximum wheel displacement from maximum lever movement is determined by the speed of the truck. Wheel displacement decreases when speed increases. The reduction in displacement follows a curve with three break points, see diagram.

This curve determines the steering sensitivity of the truck. The standard factory setting is as sho wn in the diagram, i.e., full wheel displacement at 5 kph, 65% displacement at 10 kph and 40% displacement at 15 kph. All of these levels corresponding to full movement of the steering lever.

It is possible to alter the break points and the displacement , see INITIATION MODULE 04. One reason for altering lever steering characteristics can be that a new op erator would like less wheel displacement at a certain speed - the truck feels “smoother” to steer. A mor e experienced operator, on the other hand, may like a quicker steering response, which allows a faster pace of operation.

WARNING!

If wheel displacement is set too high at higher speeds, there is a risk of the truck tipping. An y alteration of le ver steering characteristics must be made with great care.

Alteration of the Steering lever output signal

It is possible to alter the output signal from the Steering Lever to follow two different curves - linear or logarithmic

The logarithmic curve provides less sensitive steering.

In the ECS SERVICE Technical Handbook, under Initiation Module 04, a description can be foun d a s to how to choose between the two curves.

Alteration of the Mini-steering device output signal

The number of turns that corresponds to normal steering wheel movement can be set, see Technical Handbook ECS SERVICE, Initiation Module 06.

1. Output signal

2. Stop voltage

3. Start voltage

4. Middle position

5. Free-play zone

6. Lever mo vement

7. Linear output signal

8. Logarithmic output signal

LE25 LE26

Anti-clockwise turning: LE25 lights first Clockwise turning: LE26 lights first

Monitoring of steering lever & wheel angle sensor

If a fault occurs in the lever steering system - sensor, steering lever , cab les - an alarm is generated b y the ECS . L e v er steering is frozen, i.e., the wheels remain at the current steering angle and the operator must the refore use the steering wheel. Aft er such a fault, re-calibra tion must be carried out in accor dance with the instructions in the Calibration section.

Checking the sensors and activator on the steering column

Two sensors on the steering column monitor steering wheel movement. The senors are activated by an activator with four cams on the steering column. See the illustration of included units. When a certain movement of the steering wheel occurs, lever steering is disconnected.

The sensors and activator must be regularly checked during service. If a fault occurs with the sensors , there is a danger that the truck will go straight forward.

1. Open ECU 1 so that the LEDs are visible.

2. Locate LE25 and LE26, see ECU 1 Circuit board.

3. T urn the steering wheel and at the same time , check LE25 and LE26. They should light alternately, with a certain overlap, as per the curve.

ContChamp DRD-S

Technical Handbook

12 3 45

1. Cover

2. Potentiometer

3. Carrier

4. Locking screw

5. Axle 48 = Electrical connections

ECU 1

06 Mini-Steering

Fitting/Adjustment of wheel angle sensor

Applies only to wheel return system

1. Adjust the wheels so that they are parallel to the truck.

2. Remove the cover of the left hand steering knuckle.

3. Lift off the carrier 3.

4. Loosen the locking screw 4, remove the connections to the

potentiometer and lift it out.

5. Co nn ect a multimeter between the centre pin of the potenti-

ometer and one of the outer pins .

6. Tu rn the potentiometer until the instrument sho ws 2,5 ko hm.

Re-connect the potentiometer.

7. Slide the potentiometer back into the axle 5. Fit the carrier

and tighten the locking screw 4. Fit the cover and seal with sealing compound.

Calibrate as per T echnical Handbook ECS-SER VICE, Calibration Module 04.

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N.B. Module 06 Mini-steering has a great deal in common with Module 04 Lever steer ing. See section 04 Lever steering.

Module 06 Mini-Steering

The Mini steering module is an electrohydraulical system for comfortable steering of the truc k with the arm on the armrest. The steered wheels follow the position of the Mini steering device. If the operator releases the Mini steering de vice, both the steering device and the steered wheels remain in the set position.

The standard steering wheel is equipped with inductive sensors that sense the moveme nt of the steering wheel. The sensors disconnect the Mini steering if the operator is faced with an emergency situation and starts using the standard steering wheel. When the Mini steering is disconnected, the lamp in switch 2, see below, is extinguished.

1. Mini steering device

2. Direction switch F/N/R. The lamp in the switch is alight when

the lever steering is activated Forwards position = F. Centre position = N Backwards position = R

3. Signal horn

4. Switches for gear changing, a=UP, b=DOWN

(Excluded if the truck is equipped with module 01 Automatic gear changing) Press 4a to shift gears 1-2-3- (4) (once for every gear) and 4b to shift do wn. The gear changing alw a ys starts with gear 1 on starting and after the direction switch has passed the N position.

5. Switch for activating Mini steering

Condition: The truck speed must not exceed 3 kph. If the speed exceeds 3 kph it not possible to activate the Mini steering. The lamp in switch 2 is alight when the Mini steering is activated

6. Extra function

KL1404

ContChamp DRD-S

Technical Handbook

ECU 1

07 - Monitoring

9407

04-10

S.Grupp 20

Module 07 Monitoring

See electrical diagrams. The monitoring module checks that the engine and gearbox op-

erate within reasonable limits and thereby prevents a major breakdown from occurring. The module also monitors the co rrect function of the different system components, such as sensors, etc.

V alues, su ch as oil pressure and tempe rature , that are of vital importance when it comes to wear and tear and the risk of breakdown, are monitored on two le vels . A red warning lamp lights and an error message appears on the terminal display. If the reason for the f ault is not rectified, the system limits the truck’ s functions . The most serious faults lead to a reduction in engine re v olutions .

DRD420-60S5

KL586C

1. Sensor, drive shaft revolutions

2. Sensor, engine rev olutions

3. Control motor

4. Sensor , brake pressure

5. Sensor, gearbox oil pressure and oil temperature

6. Sensor, gearbox oil temperature

7. Sensor, engine oil pressure

8. Sensor, coolant level

9. Sensor, coolant temperature

10.Sensor, hydraulic fluid temperature

11.Sensor, fuel level

07 Monitoring, included units

ContChamp DRD-S

Technical Handbook

ECU 1

07 - Monitoring

9407

04-10

S.Grupp 20

The following signals are monitored:

1. Battery level, min. <14.4 Volts

2. Engine oil pressure, min. level 1 <1.0 bar

3. Engine oil pressure, min. level 2 <0.5 bar

4. Co ola n t tem p erature, max. level 1 >98°C

5. Coolant temperature, max. level 2 >103°C

6. Gearbox oil pressure, min. level 1 <12-15 bar (dependent on selected transmission data kit)

7. Gearbox oil pressure, min. level 2 <10 bar

8. Gearbox oil temperature, max. level 1 >130°C

9. Gearbox oil temperature, max. level 2 >134°C

10. Fuel level, min.

11. Hydraulic fluid temperature, max. >100°C

12. Coolant level, min.

13. Operating time, max. service interval period, shows the time remaining to the next service and generates an ala rm when operating time has been exceeded.

14. Brake pressure

The following sensors are checked:

1. Engine revolutions

2. Gear lever

3. Accelerator pedal

4. Fuel injection pump motor

5. Fuel gauge

6. Gearbox oil pressure

7. En gin e oil pr es su re

8. Engine oil temperature

9. Gearbox oil temperature

10. Hydraulic fluid temperature

With non-permissible levels of any of the signals, an alarm is activated - a red warning lamp lights and the terminal display shows in clear text which signal is incorrect. If any signal begins to approach level 2, engine revolutions are reduced, following a defined curve, to a lower rate of rpm.

The different le vels are pre-prog rammed into the ECU and cannot be altered.

ContChamp DRD-S

Technical Handbook

ECU 2

Functions

9407

04-10

S.Grupp 20

ECU 2 Functions

Pin no. ECU 2 S2

8 Digital IN I/O LE14 Working lights, top-lift

9 10 11 “ LE23 C ontrol lever, vertical lift 31 “ LE13 C ontrol lever, twist-locks release (8-9) 32 “ LE16 Twist-loc k s locking/Auto 33 “ LE19 Control lever, doors OK 34 “ LE22 Warning for overloading of steering axle 55 “ LE15 Sensor, activating stop at 30-35’ 56 “ LE18 Sensor, activating locking, tilt 57 “ LE21 Overload, mechanical system 58 “ LE24 By-pass connection of safety system 2 Digital OUT PNP I/O LE6 Activating top-lift/loading of hydraulic pump 24 “ LE10 Indication of alignment, on steering wheel panel 25 “ LE7 Indication of twist-locks released, on steering wheel panel 26 “ LE8 Indication of twist-locks locked, on steering wheel pane l 48 “ LE9 Regeneration BOOM OUT 49 “ LE11 Regeneration LIFT 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 sensor, right lift cylinder, piston side (mod 60) 65 “ Pressure sensor, right lift cylinder, piston rod side (mod 60) 66 “ Control lever, BOOM OUT/IN P2 67 “ Control lever, ROTATION P3 52 “ Boom angle Min=2V, Max=8V 43 Analogue IN 4-20 mA Pressure sensor, right lift cylinder, piston side (mod 57) +

63 “ Pressure sensor, left lift cylinder, piston side (mod 50, 60) 27 Digital IN 0-196 OHM End position BOOM OUT (mechanical system) 28 “ End position BOOM ANGLE (mechanical system) 51 “ Separate bottom lift (disconn. of tw-loc ks and 20-40’ funct.) 6 Analogue IN 70-120°C 7 “ -20-120°C 30 By-pass of rotation stop 53 “ 70-120°C 1 Analogue OUT pwm PNP1 LE5 Boom IN 3 I1 Boom LIFT 4 I2 Boom LOWER 5 “ PNP4 LE4 Boom OUT 17 18 35 Pulse transmitter 1 59 Pulse transmitter 2 36 Digital IN Rotation stop, counter-clockwise 60 Digital IN Rotation stop, clockwise 23 Battery plus 24V 13 Battery plus 24V 37, 70, 12 Battery minus

Signal LED Function

” ”

LE17 Control lever, side-shift Right (15) LE20 Control lever, side-shift Left (16)

Pressure sensor, left lift cylinder, piston rod side (mod 52, 60)

ContChamp DRD-S

Technical Handbook

ECU 2

Circuit board

9407

04-10

S.Grupp 20

LE1 Should always be lit,indicating a

5V feed from the voltage transformer

A Extra 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 it lights continuously or is extinguished, the program will not start, i.e., something is wrong, for example, the EPROM or electrical supply.

ECU 2 circuit board

ContChamp DRD-S

Technical Handbook

ECU 2

Circuit Boards

9407

04-10

S.Grupp 20

Different combinations of ECU

Every ECU has four switches. Check that the switches are in the positions sho wn in the illustra -

tions.

OFF

234

OFF

ECU 1

234

ECU 2

OFF

ECU 2 + A

234

OFF

234

OFF

A = Extra circuit board

OFF

234

ECU 3

OFF

234

ECU 2

OFF

234

ECU 1

KL1795

ECU 2 is always superior Other ECU’s are “slaves”

234

OFF

ContChamp DRD-S

Technical Handbook

X410

ECU 2

Installation boom

9407

04-10

S.Grupp 20

KL1533b

KL1533a

KDU 791

KL1536

N.B. The permitted load on KDU 791 is limited. Therefore, connection of extra equipment to the KDU is not allowed.

KL1534

KL1535

791 Electronic central unit for top-lift, KDU

1. 10 pol e connection box

3 4

5 6

2. 42 pol e connection box

3. Indicator lamp POWER, green. lit with 24V feed

4. Indica to r la mp SYSTEM, green lit when the program registers a system voltage of 20-29 V

5. Indicator lamp MODE, y ellow Blinks once a second if the communication with ECU 2 via CAN bus is correct

6. Indicator lamp STATUS, red lit when any fault 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 reasons, there are two rela ys connected in parallel. The relays are controlled from the emer-

gency switch, see 36 on the servo diagram (S) 562 Indicator lamp, red, TWIST-LOCKS RELEASED 563 Indicator lamp, green, TWIST-LOCKS LOCKED 564 Indicator lamp, orange, ALIGNMENT

Electrical installation ECS, boom

ContChamp DRD-S

Technical Handbook

ECU 2

Elservo

9407

04-10

S.Grupp 20

El-servo

The el-servo system includes:

 Control lever functions for boom movement  All attachment functions  Overload protection  Cab movement  Support jacks

The references in the f ollowing descriptions relate to components in the el-servo diagrams (diagrams marked S), if nothing to the contrary is stated.

El-servo (S) A38630.0100 (ECU 2) El-servo (S) A38630.0200 (ECU2 + ECU 3)

For top-lift circuits, refer to separate diagram.

When following the circuit de scriptions , f irst select an S diagram and an top-lift diagram that corr espond to the machine in question.

Example: S7 shows component no. 7 on the el-servo diagram, i.e., the main valve in the hydraulic system.

S50-S65 show the connectors for ECU 2 under operator’s seat. ANA IN = Analogue IN signal ANA OUT = Analogue OUT signal DIG IN = Digital IN signal DIG OUT = Digital OUT signal LE1-LE43 = LEDs, with green or red light. These can be located

on the overview illustration of the ECU 2 circuit board.

ContChamp DRD-S

Technical Handbook

ECU 2

Elservo

9407

04-10

S.Grupp 20

Control lever

The control lever regulates electrical signals which operate electrohydraulic converters which in turn feeds hydraulic servo pressure to the main valve sections.

The lever han dle is equipped with potentiometers P1–P4 and fo ur finger-tip controlles switches T1–T4.

The plus feed from the contr ol unit is deliv ererd via sliding shoes when manoeuvring the machine.

When manoeuvring, the potentiometer setting is altered, and thus the 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 con verter.

T1 Side shift

1=Left, 2=Right T2 Unlocking of twist-locks T3 1=Locking of tilt

2=Locking of levelling T4 Vertical lift P1 Lift/Lower P2 Boom out/in P3 Rotation P4 Tilt (Optional)

1. TILT (analogue)

4. Boom OUT/IN (analogue)

8. LIFT/LOWER (analogue)

9. 0-ref. LIFT, EXTENSION, ROTATION

10.10 V feed LIFT, EXTENSION, ROTATION

11.ROTATION CLOCKWISE/ANTI-CLOCKWISE (analogue)

14.SIDE-SHIFT LEFT/40-20 inwards

15.Feed 24V

16.SIDE-SHIFT RIGHT/20-40 outwards

17.Locking of pile-slope

18.Locking of forward tilt

19.Vertical lift

20.Twist-locks release

ContChamp DRD-S

Technical Handbook

ECU 2

Elservo

9407

04-10

S.Grupp 20

Converter

The converter is a electrically controlled pressure reducing v alv e for the remote control of h ydr aulic functi ons . The out put signal is a porportional hydraulic servo pressure which is used to control the spools of the main valves.

The converter consists of a solenoid and a pilot valve. It is connected to the main valve spool actuator block.

The solenoid exerts a proportional force on the pilot valve. The end of the unit is provided wit h a vent screw and a pushbutton f or emergency manual operation.

The control pressure output delivered by the pilot v alve to the spool actuator of the main valve is practically proportional to the input current.

The pilot valve is closed in the neutral position.

1. Vent screw

2. Push button, manual operation

3. Solenoid

4. Pilot valve

5. Main valve

6. Spool actuator

7. Control current

8. Inlet servo pressure

9. Return servo pressure A given control current i

servo pressure at the spool actuator

results in a definite

Converter

ContChamp DRD-S

Technical Handbook

ECU 2

Elservo

9407

04-10

S.Grupp 20

Control lever feed

1. The LIFT/LOWER, BOOM OUT/IN and RO T ATION functions are fed with 10 V from ECU2, contact S2 (70 pole junction box on ECU2), pin 45 of connector S55 pin 12. From there via cable S33 to the D sub-contact S42 on the control lever S32.

2. Earth refe rence to the 10V is f ed from S2 pin 44 to connector S55 pin 13. From there via cable S33 to S42 on the control lever S32.

3. When the lever is in the neutral position P1, P2, P3 and P4 supply 5V to S42 and from there, on to connecto r S55. The end positions provide 0V and 10V respectively.

4. The SIDE-SHIFT, LOCKING TIL T/PILE SLOPE, STRAIGHT LIFT AND RELEASE TWIST-LOCKS functions are fed with 24V from fuse 3 of the central electrical unit S1. Via the central electrical unit’s connector 32 pin 3 to the el-servo connector S55 pin 11. Via cab le S33 t o S42 pin 11. From there, feed to switches T1, T2, T3 andT4.

12345678910111213

14 15 16 17 18 19 20 21 22 23 24 25

1. Control lever

2. D sub-contact for control lever(S42)

3. Cable (S33)

4. Connectors for ECU2 under operator’s seat

5. Earth connections

6. CAN bus for communication between ECUs 1-2-3

7. Relays S2. 70 pole contact for ECU2 (S2)

ContChamp DRD-S

Technical Handbook

Cable S33 of the el-servo system

ECU 2

Elservo

KL 1547

9407

04-10

S.Grupp 20

30 = Stop at 30-35’

TW = Twist-locks

S42 = D-sub contact at control lever

S42

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 safety system

FB = Front legs, bottom lift

BB = Rear legs, bottom lift

K = Clamping

HS = Cab movement

SB = Support jacks

ContChamp DRD-S

Technical Handbook

ECU 2

Elservo

9407

04-10

S.Grupp 20

Sensor in the feed line to left lift cylinder. Out signal: 4-20 mA

Pressure sensors right and left lift cylinders

N.B. The pressure sensors are different for different modules.

(768-10 and 11 are identical. 768-12, 13 and 14 are identical) See also the el-servo diagrams (S).

Sensor in the feed line to right lift cylinder. Out signal: 4-20 mA

N.B. Module 57, apart from sensor 768-14, also includes sensor 768-12 from Module 50

Module 50

Module 57

Sensor in the feedline and returnline to right and left lift cylinder. Out signal right sensor: 1-10 V Out signal left sensor: 4-20 mA

Module 60 (52)

ContChamp DRD-S

Technical Handbook

KL700

S7.1

X69

ECU 2

Elservo

9407

04-10

S.Grupp 20

LIFT

See el-servo diagram (S)

1. Control lev er used f or LIFT, P1 gives a 5-9V analogue signal via 42.8, via cable S33 to X55.1

2. ANA IN S2.42. No indication in ECU2 for analogue IN signals.

3. ANA OUT S2.03. 24V, varies with lever position.

4. X63.1

5. Main valve converter S7.1 opens for servo pressure. Simultaneous feed of servo pressure to S7.8

6. Main valve sections S7.1 and S7.8 opens for LIFT

Conditions:

1. DIG IN S2.7 . LE19 lit, wh ich m eans :

 Cab in rear position  If the cab is in the 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 o verload. (Module 50:

LE21 shall be lit. Module 60: No overload indication on the display)

KL701-D

Regeneration, LIFT

See el-servo diagram (S)

1. 24V to X62.8

2. Connector X69.8, see illustration

Module 50

Conditions for regeneration: Connects when pressure in lift circuit <85 Bar Disconnects when pressure is approx. 185 Bar

3. Pressure sensor 768-12.3 in lift cylinder feed IN 24 V, see illustration

4. Pressure sensor 768-12.2 OUT, 4-20 mA, corresponds to 0250 bar pressure in lift circuit

5. X69.5

6. X62.5

7. ANA IN S2.63 (no indication) (cont’d p.14 next page)

KL1418c

ContChamp DRD-S

Technical Handbook

KL1418b

ECU 2

Elservo

9407

04-10

S.Grupp 20

Module 60 (or module 52)

Conditions for regeneration: Connects when pressure in lift circuit <85 Bar Disconnects when pressure is approx. 185 Bar

8. Feed right sensor: 24V over X69.1 to 768-10.3 and 768- 11.3. Ref.voltage =0V from X69.2.

9. Feed left sensor: 24V over X69.1 to 768-12.3 and 768-13.3

10. Out signal right pressure side 768-10.2: 1-10V to S19.3 to X62.3, to S2.64 ANA IN (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 indication)

13. Out signal left return 768-13.2: 4-20 mA to X69.6 to X62.6, to S2.43 ANA IN (no indication)

KL1418a

Modules 50,52,60

14. DIG OUT S2.49. LE11 lit (Lever movement >50%)

15. X62.8

16. X69.8

17. Regeneration valves S14, right and left, open an d re gener ation starts. The regeneration starts with a time-delay which is set in the SET UP EL-SERVO ECU 2, see Technical Handbook ECS SERVICE.

18. Earth signal back via X69.2

19. S62.2 to earth

KL702-C

S14

ContChamp DRD-S

Technical Handbook

KL700

S7.2

ECU 2

Elservo

9407

04-10

S.Grupp 20

LOWER

See el-servo diagram (S)

1. Control lever used to LOWER, P1 gives a 5-1 V analogue signal via D sub-contact S42.8, via cable S33 to X55.1

2. ANA IN S2.42. No indication in ECU2 for analogue IN signals.

3. DIG OUT S2.50. (Opens the lift cylinders’ blocking valves S15). LE12 lit.

4. 24 V to X62.7.

5. X69.7

6. 24 V to the blocking valv es S15, right and left, that open.

7. ANA OUT S2.04 to X63.2

8. Varies 24V between X63.2 and X63.5.

9. Main valve converter S7.2 opens for servo pressure at the same time servo pressure is fed to S7.8.

10. Main valve section S7.2 and S7.8 opens for LOWER

KL701-D

X69

Conditions:

 No alignment indication from attachment, LE14 extin-

guished.

 Dead man’s grip activated, LE19 lit.  No front overload, no steering axle overload (Module 50:

LE21 extinguished. Module 60: No overload indication on the display).

Emergency lowering

In the eve nt of an electrical f a ult that leads t o the b loc king v alv es on the lift cylinders being unable to be opened, i.e., the boom cannot be lowered, there is an emergency lowering function.

On the solenoid S15 for the blocking valves (right and left lift cylinders) there is a knob, A in the illustration. Pull this straight out and turn it one quarter turn and the boom will slowly lower.

KL702-C

S15 A

NOTE: The emergency lowering applies to unloaded machine only.

ContChamp DRD-S

Technical Handbook

KL700

S7.3

ECU 2

Elservo

9407

04-10

S.Grupp 20

BOOM OUT

See el-servo diagram (S)

1. Control lever used to BOOM OUT, P2 gives a 5-9 V analog ue signal via S42.4, via cable S33 to X55.2

2. ANA 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 opens for BOOM OUT.

Conditions:

1. DIG IN S2.33, LE19 lit.

 Safety system not by-passed (S37)  No front overload. (Module 50: LE21 lit. Module 6 0: no o ver-

load indication on the display).

Regeneration, see next page.

ContChamp DRD-S

Technical Handbook

ECU 2

Elservo

9407

04-10

S.Grupp 20

KL1418c

X69

Regeneration, BOOM OUT

See el-servo diagram (S)

1. 24V to X62.8

2. Connector X69.7, see illustration.

Module 50

Conditions for regeneration: Connects when the pressure in lift circuit <85 Bar Disconnects when the pressure is approx. 185 Bar

3. Pressure sensor 768-12.3 for lift cylinder feed IN=24 V, see illustration

4. Pressure sensor 768-12.2 OUT=4-20 mA, corresponds to 0250 bar pressure in the lift circuit.

5. X69.5.

6. X62.5.

7. ANA IN S2.63 (No indication) (cont’d p.14 next page)

KL1418b

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 X69.1 to 768-10.3 and 768-11.3.

Ref.voltage =0V from S19.2.

9. Feed left sensor: 24V over X69.1 to 768-12.3 and 768-13.3

10.Out signal right pressure side 768-10.2: 1-10V to X69.3

to X62.3, to S2.64 ANA IN (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 indication)

13.Out signal left return 768-13.2: 4-20 mA to X69.6

to X62.6, to S2.43 ANA IN (no indication)

KL1418a

ContChamp DRD-S

Technical Handbook

KL704-D

X67

ECU 2

Elservo

Modules 50, 52, 60

14.DIG OUT S2.48. LE9 lit

15.X61.4

16.Connector X67.4, see illustration

9407

04-10

S.Grupp 20

X68

17.Connector X68.4, see illustration

KL705

18. Regeneration valve S18 opens and regeneration starts The regeneration starts with a time-delay which is set in the SET UP EL-SERVO ECU 2, see Technical Handbook ECS SERVICE.

19.Earth signal to X68.

S18

KL703

ContChamp DRD-S

Technical Handbook

ECU 2

Elservo

9407

04-10

S.Grupp 20

BOOM IN

See diagram S.

1. Control lever used for BOOM IN, P2 giv es a 5-1 V anal 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 sections S7.4 and S7.5 opens for BOOM IN.

KL700

S7.4

Conditions:

 DIG IN S2.33, LE19 lit.  Module 60: No steered axle overload indication on the dis-

play.

ContChamp DRD-S

Technical Handbook

KL701-D

X69

ECU 2

Elservo

9407

04-10

S.Grupp 20

Rotation clock wise

See el-servo diagram (S)

Electrical diagram attachments (A38414.0100 Top-lift)

1. P3 signal 5-9 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 S73 (loadin g of hydraulic pump).

8. Signal from ECU 2 via CAN bus to KDU Attachment 791.

9. DIG OUT 791.2.2 to 6008 REF OUT 791.2.16 to 6008

KL727-D

6008

6009

Conditions:

 LE19 lit.  No front overload. (Module 50: LE21 extinguished. Module

60: No overload 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 S73 (loading of hydraulic pump).

8. Signal from ECU 2 via CAN bus to KDU Attachment 791.

9. DIG OUT 791.2.3 to 6009 REF OUT 791.2.17 to 6009.

Conditions:

 LE19 lit.  No front overload. (Module 50: LE21 extinguished. Module

60: No overload indication on the display).

N.B. In attachment function descriptions, the term CAN bus occurs. The CAN bus in question effects communication,

in the form of a digital pulse stream, between the ECU 2 and 791 computers. These signals cannot be measured without advanced specialised equipment.

ContChamp DRD-S

Technical Handbook

7202L

X404

7202R

ECU 2

Elservo

9407

04-10

S.Grupp 20

Feed, sensor

1. DIG OUT from 791.2.11 to X402.1, X403.1 and 404.1.

2. Earthing reference REF OUT from 791.2.38 to X402.2, X403.2 and 404.2.

7203L

X402

T5655870-1

X403

7203R

KL1535

Indicator, ALIGNMENT

1. Signal 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 to X402.10.

8. DIG IN 791.2.27.

9. Points 1-8 satisfied, gives DIG OUT 791.2.29 to X405.2.

10. Indicator lamp ALIGNMENT lit. Signal from 791 via CAN bus to ECU 2. Control: DIAGNOS 4(8).

ContChamp DRD-S

Technical Handbook

KL701-D

6039

X69

6040

ECU 2

Elservo

9407

04-10

S.Grupp 20

Twist-locks, automatic locking

1. Feed +24V from central electrical unit S1 connector X38.7. Condition: Parking brake RELEASED.

2. X51.7.

3. X56.11.

4. Signal in to switch S34, pin 3

5. Switch S34 in AUT position, signal out from pin 7

6. X56.1.

7. DIG IN S2.32, LE16 lit. Condition: Signal for alignment from 791. Control: DIA GNOS menu 4(8). Or signal from switch S37 for by-pass of safety system (DIG IN S2.58, LE24 lit).

8. DIG OUT S2.2, LE6 lit.

9. X62.10

10. X69.10.

11. Activate solenoid valve, top-lift (loading of hydraulic pump).

12. Signal from ECU 2 via CAN bus to 791.

13. DIG OUT from 791.2.37 to 6039791.2.32 to 6040. REF OUT from 791.2.36 to 6040.

14. Hydraulic feed to twist-lock cylinder that turn the twist-locks to locked position.

KL727-D

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 loop 567 via S35.

5. Switch S34 in MAN position, signal out from pin 2 as for point 6 above.

Twist-locks, release

1. Control lever switch T2 used.

2. 24 V to S42.20.

3. X55.10.

4. DIG IN S2.31, LE13 lit. Condition: Signal for alignment from 791. Control: DIA GNOS menu 4(8). Or by-pass of safety system with S37 (DIG IN S2.58, LE24 lit) and no side-shift, i.e., no signal in to S2.09 (LE17 extinguished) or S2.10 (LE20 extinguished).

5. DIG OUT S2.2, LE6 lit.

6. X62.10

7. X69.10.

8. Activate solenoid valve, top-lift (loading of hydraulic pump).

9. Signal from ECU 2 via CAN bus to 791.

10. DIG OUT from 791.2.23 to 6039. REF OUT from 791.2.37 to 6039.

11. Hydraulic feed to twist-lock cylinder that turns the twist-locks to the open position.

ContChamp DRD-S

Technical Handbook

ECU 2

Elservo

9407

04-10

S.Grupp 20

7204L

7205L

X404

X402

T5655870-1

X403

7205R

7204R

KL1535

Indicator, twist-locks locked

1. Signal from 7205R to X403.5 to X402.5.

2. DIG IN 791.2.24.

3. Signal from 7205L to X404.5 to X402.9.

4. DIG IN 791.2.23.

5. Points 1-4 satisfied gives DIG OUT 791.2.39 to X405.3

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. Signal from 7204L to X404.4 to X402.8.

4. DIG IN 791.2.22.

5. Points 1-4 satisfied gives DIG OUT 791.2.25 to X405.1

6. Indicator lamp 562 Twist-locks released lit. Signal from 791 via CAN bus to ECU 2. Control: DIAGNOS 4(8).

ContChamp DRD-S

Technical Handbook

KL701-D

6021

6020

X69

ECU 2

Elservo

9407

04-10

S.Grupp 20

Side-shift left

1. Control lever switch T1 is used for side-shift left.

2. 24 v to S42.14.

3. X55.7.

4. DIG IN S2.10, LE20 lit. Condition: S2.11 - LE23 extinguished, or S2.56 - LE18 lit, and S2.31 - LE13 extinguished.

5. DIG OUT S2.2, LE6 lit.

6. X62.10.

7. X69.10.

8. Activate solenoid valve top-lift (loading of hydraulic pump).

9. Signal out from ECU 2 via CAN bus to 791.

10. DIG OUT 791.2.31 to 6020 REF OUT 791.2.35 to 6020

11. 6020 opens for h ydraulic f eed to the side-shift cylinder . Sideshift left.

Side-shift right

1. Control lever switch T1 is used for side-shift right.

2. 24 v to S42.16.

3. X55.8.

4. DIG IN S2.09, LE17 lit. Condition: S2.11 - LE23 extinguished, or S2.56 - LE18 lit, and S2.31 - LE13 extinguished.

5. DIG OUT S2.2, LE6 lit.

6. X62.10.

7. X69.10.

8. Activate solenoid valve, top-lift (loading of hydraulic pump).

9. Signal out from ECU 2 via CAN bus to 791.

10. DIG OUT 791.2.30 to 6021 REF OUT 791.2.34 to 6021

11. 6021 opens for h ydraulic f eed to the side-shift cylinder . Sideshift right.

KL727-D

ContChamp DRD-S

Technical Handbook

KL701-D

6018

6019

X69

ECU 2

Elservo

9407

04-10

S.Grupp 20

Length adjustment OUT

1. Control lever switches T1 + T4 are used.

2. T1 to th e right.

3. Signal out to S42.16.

4. X55.8.

5. DIG IN S2.09, LE17 lit.

6. T 4 de pr e sse d.

7. Signal out to S42.19.

8. X55.9.

9. DIG IN S2.11, LE23 lit.

10. DIG OUT S2.2. LE6 lit.

11. X62.10

12. X69.10

13. Activate solenoid valve, top-lift (loading of hydraulic pump).

14. Signal out from ECU 2 via CAN bus to 791.

15. Conditions: Signal twist-locks released. Control: DIAGNOS 4(8). Or signal for by pass connection of safety system with S37 (DIG IN S2.58, LE 24 lit)

16. DIG UT 791.2.4 to 6018 REF UT 791.2.18 to 6018

17. 6018 opens for hydraulic feed to the cylinder, length adjustment OUT begins.

KL727-D

Length adjustment IN

1. Control lever switches T1 + T4 are used.

2. T1 to th e lef t.

3. Signal out to S42.14.

4. X55.7.

5. DIG IN S2.10, LE20 lit.

6. T 4 de pr e sse d.

7. Signal out to S42.19.

8. X55.9.

9. DIG IN S2.11, LE23 lit.

10. DIG OUT S2.2. LE6 lit.

11. X62.10

12. X69.10

13. Activate solenoid valve, top-lift (loading of hydraulic pump).

14. Signal out from ECU 2 via CAN bus to 791.

15. Conditions: Signal twist-locks released. Control: DIAGNOS 4(8). Or signal for by pass connection of safety system with S37 (DIG IN S2.58, LE 24 lit)

16. DIG OUT 791.2.5 to 6019 REF OUT 791.2.19 to 6019

17. 6019 opens for hydraulic feed to the cylinder, length adjustment IN begins.

ContChamp DRD-S

Technical Handbook

769

X402

T5655870-2

ECU 2

Elservo

9407

04-10

S.Grupp 20

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. Sig na l from 76 9 to X402 .1 1

3. DIG IN 791.2.12 gives lowered speed at both end positions.

769 Sensor, damping

ContChamp DRD-S

KL1418c

Technical Handbook

ECU 2

50 Mechanical Overload Protection

Module 50 Mechanical Overload Protection

The mechanical overload protection function:

 monitors the forward load and generates an alarm on the

ECS terminal.

 monitors the rear load on the steering axle.  controls the regeneration system for LIFT and BOOM OUT.  controls the end position damping for LIFT, LOWER and

BOOM OUT.

The mechanical overload protection system consists of (see illustration below)

 A pressure sensor, 768-12, in the left lift cylinder fe ed line.  Five inductive sensors for monitoring boom angle, boom ex-

tension and end position.

 An inductive sensor on the steering axle suspension to indi-

cate forward overload.

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S23a

S72

KL1051

S22

DRD420-60S5

S23b

S24

S21

ECU 2

768-12. Pressure sensor, feed line left lift cylinder (page 42)

See servo diagram (S) S2. ECU2 S4. ECS te rminal

S20

See page 59 S20. Sensor, steering axle overload S21. Sensor, boom angle S22. Sensor, end position boom angle S23a. Sensor, boom inner position S23b. Sensor, boom outer position

KL1058-C

S24. Sensor, BOOM OUT S72. Relay box, relays for determina-

tion inner or outer boom position

Module 50 Mechanical Overload Protection

ContChamp DRD-S

Technical Handbook

ECU 2

50 Mechanical Overload Protection

Overload indicator

1. Normal operating condition.

2. Steering axle overload Monitored by two inductive sensors, 24 for boom extension and 21 for boom angle. When boom extension is less than

1.5 m, the boom angle is greater than 35 ° and 3rd or 4th gear is engaged both sensors interrupt and gen erate an alarm f or overload of the steering axle. A re d lamp blinks and the b uzzer sounds intermittently.

3. With forward overload, i.e., when approximately 33% of the safety margin remains (remaining counter-weight), the red warning light on the ECS terminal lights up, a buzzer sounds and the ECS terminal display shows “ov erload”. At the same time, the system interrupts the LIFT, LOWER and BOOM OUT functions. Of these, it is possible to make a by-pass connection of the LOWER fun ction, using the by-pass s witch on the side of the hydraulic console in the cab .

WARNING!

At any bypassing of th e safety asystem, ext reme care must be taken when operating the machine.

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S.Grupp 20

1. Chassis

2. Angle-iron activator, activates sensor Play > 5 mm sensor breaks

3. Hinged linkage

4. Steering axle

S20. Inductive sensor for overload

S20

The signal for forward overload is supplied by the sensor on the steering axle suspension. The rear steering axle suspension includes a flexibly mounted hinged linkage with pre-determined amount of “play”. When the permitted load is exceeded and the steering axle is the only remaining counter-weight, this play increases the distance between the sensor and the angle-iron that activates the sensor. When this play is at its maximum, the sensor’s signal ceases, an overload warning is generated an d LIFT, LOWER and BOOM OUT fun ctions ar e interrupted while BOO M IN works as usual.

This means that the machine ma y become loc k ed in position. To rectify such a situation it is possible to mak e a by-pass connection with the help of the by-pass switch located on the side of the hydraulic console in the cab . Once the by-pass connection is made , the BOOM IN and LOWER functions can be used.

Regeneration

Regeneration operates on the LIFT and BOOM OUT functions and is a system that leads return fluid from the piston sides of the lift and extension cylinders directly ba ck to the cylinder f eed. The system is activated at hydraulic pressures lower than 8.5 MPa and considerably increases the piston speed by increasing the flow of hydraulic fluid. More rapid boom mo vement can thereby be achieved on an unloaded machine. The greatest load which will still allow the regeneration system to be activated is, for example, an empty container in the first row. With a greater load, LIFT and BOOM OUT function as normal.

The regeneration starts with a time delay which is set in the SETUP EL-SERVO menus, see Technical Handbook ECS SERVICE

End position damping

End position damping reduces the speed of LIFT/LOWER and BOOM OUT/IN functions in order to reduce jolting at stop positions.

Sensors 22 for boom angle and 23a+b for boom extension are activated before the end positions. The system feeds out less current to the main valves which provide a reduced hydraulic flow and thereby, a reduction in speed.

ContChamp DRD-S

Technical Handbook

ECU 2

50 Mechanical Overload Protection

9407

04-10

S.Grupp 20

S20

S21

S72

S22

S23a

S23b

S18

S24

768-12.Pressure sensor, feed line left lift cylinder See also, page 42.

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 position S24. Sensor, BOOM OUT S72. Relay box, relays for determination

inner or outer boom position

Module 50 Mechanical Overload Protection

ContChamp DRD-S

Technical Handbook

LC-Distance = 3.80 m, Distance between the

centre of the drive axle and the centre of gravity of the load

ECU 2

51 Vertical Lift

9407

04-10

S.Grupp 20

Module 51, vertical lift for Module 50

Module 51 Vertical lift:

 steers LIFT/LOWER and BOOM OUT/IN and coor dinates

both of these functions so that the load moves completely vertically both up or down.

 numerically displays WEIGHT, BOOM EXTENSION,

LC-DISTANCE and BOOM ANGLE.

 displays the Module 50 o verload men us, as sho wn in the ad-

jacent illustration. The menus vary if additional modules are selected, for e 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 potentiometer angle sensor S16 that indicates

the lift angle of the boom.

 S16 and S17 replace S21, S22, S23a+b , S24 and S72 from

module 50.

 When Module 51 is installed, ECU 2 must be initiated. Con-

tact Kalmar to obtain the necessary parameters.

S17

S16

DRD420-60S5

KL1060-C

ECU 2

Ses servo diagram (S) S2. ECU 2 S4. ECS terminal

See group 20 page 66 S16 Angle sensor S17 Length sensor

ContChamp DRD-S

KL1418b

Technical Handbook

L-TP = 3.0 m, distance between the

front edge of the wheels and the centre of gravity of the load

LC-DISTANCE = 3.80 m, distance

between the centre of the drive axle and the centre of gra vity of the load)

ECU 2

52 Vertical Lift + Balance

Module 52, Vertical Lift + Balance for Module 50

Module 52 Vertical lift + Balance

 steers LIFT/LOWER and BOOM OUT/IN and coor dinates

both of these functions so that the load moves completely vertically both up or down.

 numerically displays WEIGHT, BOOM EXTENSION,

LC-DISTANCE and BOOM ANGLE.

 numerically displays L-TP and current load in tons.

Note that graphic load indicator only appears on module 60.

 displays the Module 50 o verload men us, as sho wn in the ad-

jacent illustration. Overload is indicated by sensor S20 i the steered axle suspension. The menus vary if additional modules are selected, for example, Printer, Container counter, Automatic gear changing.

Module 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 indicate

boom extension length.

 An oil-filled potentiometer angle sensor S16 that indicates

the lift angle of the boom.

 S16 and S17 replace S21, S22, S23a+b , S24 and S72 from

module 50.

 When Module 52 is installed, ECU 2 must be initiated. Con-

tact Kalmar to obtain the necessary parameters.

9407

04-10

S.Grupp 20

S17

DRD420-60S5

KL1062-C

768-10, 11, 12, 13 Pressure sensor, left and right lift cylinder, feedline and return line. See page 42 Pressure sensor.

See servo diagram (S) S2. ECU 2 S4. ECS terminal

See page 66 S16. Angle sensor S17. Length sensor

S16

ECU 2

KL586C

KL1418a

ContChamp DRD-S

Technical Handbook

KL1418c

KL1418d

ECU 2

57 Hydraulic Balance

Module 57 Hydraulic Balance

The hydraulic bala nce is include d in the ECU 2 el- servo system. The signal to the system comes from the 768-12 pressure sensor in the left lift cylinder feed and from 768-14, right cylinder.

1. Calibration of the balance must be carried out in accordance with the instructions in ECU 2 SETUP, points 20 and 21

2. Connect a loaded container to the machine

3. Extend the boom until the red lamp lights.

4. Lift the boom approx. 20 cm ov er the position whe re 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 then lowering it to the correct position, the regeneration system is prevented from building up pressure that can affect the measurement)

9407

04-10

S.Grupp 20

KL1412

6. Press the button for weighing = the vertical lift button on the control lever

7. The result is shown on the ECS terminal display

1. Inductive sensor for activation of red lamp

KL1419

2. Red lamp for weighing position

3. Feed from the attachment lamp panel

768-12 Pressure sensor in the feed line

to left lift cylinder.

768-14 Pressure sensor in the feed line

to right lift cylinder.

ContChamp DRD-S

Technical Handbook

ECU 2

59 Limitation Height/Lc-distance

Module 59 Limitation Height/LC-distance for module 50/60

In certain cases it may be necessary to limit how high the boom can be lifted, for example, for operations in areas with overhead power lines, bridges, traverses, etc, or how close to the cab the load can be moved.

The pre-set limitation of height or Lc-distance, A on the adjac ent illustration, can be by-passed using the switch on the hydraulic control panel (S71)

The switch must be continually pressed in whilst the boom (height limitation) moves through the area B (700 mm) or the load (limitation of Lc-distance) moves inside limitation A.

Above height C (height limitation), the system functions as normal. 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 (located on the side of the hydraulic control panel) can also be used.

Module 59 consists of, see illustration below

 Switch S71 for by-passing th e limitation system (height or

Lc-distance)

 A potentiometer type length sensor S17 with wire to indicate

boom extension length.

 An oil-filled potentiometer angle sensor S16 that indicates

the lift angle of the boom.

 S16 and S17 replace S21, S22, S23a+b , S24 and S72 from

module 50.

 When Module 59 is installed, the limitation A must be set,

see Technical Handbook ECS SERVICE, CALIBRATION MODULE 60.

9407

04-10

S.Grupp 20

S17

S16

ECU 2

DRD420-60S5

S71

See servo diagram (S) S2.ECU 2 S4.ECS-terminal

KL1093-C

See page 66 S16 Angle sensor S17 Length sensor

S71 Switch, height limitation

system by-pass

ContChamp DRD-S

Technical Handbook

ECU 2

60 Electronic Overload Protection

Module 60, Electronic overload protection

The electronic overload protection:

 monitors the front load and continually sho ws the r esults via

two different menus on the ECS terminal display, switch between menus using the arrow RIGHT/LEFT keys

 monitors the rear load on the steering axle  controls the regeneration system for LIFT and BOOM OUT  includes vertical lift, as standard  includes completely electronic balance, as standard,

measurement precision

measurement area

 controls the end position damping of LIFT/LOWER and

BOOM OUT/IN

Electronic overload protection (see illustration below) consists of:

 A pressure sensor 768-10, 11, 12, 13 in each lift cylinder

feed and return lines

 A potentiometer type length sensor S17 with wire to indicate

the length of extension.

 An oil-filled potentiometer type angle sensor S16 to indicate

the lift angle of the boom.

9407

04-10

S.Grupp 20

±0.5 tons over 80% of t he complete

S17

1. ECU 1 See servo diagram (S)

2. ECU 2

3. ECU 3

4. ECS terminal

S16

DRD420-60S5

ECU 3

See group 20 page 66 S16.Angle sensor S17.Length sensor

See page 42 Pressure sensor 768-10, 11, 12, 13 Pressure sensor, left and right lift cylinder, feed line and return line

KL1036-C

KL1418b

KL1418a

ContChamp DRD-S

Technical Handbook

Load

ECU 2

60 Electronic Overload Protection

Overload indicator

Under normal circumstances, the overload protection system functions as a balance and giv es a cont inual read -out of the siz e and position of the load.

L-TP 4.22M = The distance between the front edge of the wheels and the centre of gra vity of the load.

23.5 T = Actual load in tons. X = Load indicator, fills the display to the right for 0-100% loads.

When the load indicator reads full, the system interrupts operation due to forw ard overload. There remains a safety margin of approx. 33% (remaining counter-weight). The red warning lamp lights continuously, the warning buzzer sounds continuou sly and the LIFT, LOWER and BOOM OUT functions are interrupted. Of these, it is possible to mak e a b y-pass connection to the LO WER function using the switch on the side of the hydraulic console in the cab.

9407

04-10

S.Grupp 20

Area with 33% safety remaining

Load curve

centre of drive axle - centre of load

Distance

Load X, along the whole of the load curve corresponds to maximum reading (100%) on the load indicator X (on the ECS terminal display).

Steering axle overload Y = Indicator for steering axle load, fills the display to the left for

95-100% of permitted load. When the indicator reads full, i.e., with a load of 33 or 43 tons, depending on the t ype 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 that directs the return flow of hy draulic fluid from the piston sides of the lift and extension cylinders, directly back to the cylinder feed. The system is activated at hydraulic pressures lower t han 8.5 MPa and considerably increases the piston speed by increasing the flow of hydraulic fluid. This means that much more rapid movement is possible with the machine not under load. The greatest loa d that permits the regeneration system to be activated is, for example, an empty container on the first row. With a greater load, the LIFT and BOOM OUT functions operate normally.

The regeneration starts with a time delay which is set in the SETUP EL-SERVO menus, see Technical Handbook ECS SERVICE

End position damping

End position damping reduces the speed of the LIFT/LOWER and BOOM OUT/IN functions to reduce jolting at stop positions. The system supplies less current to the main valves which then provide a reduced flow of h ydra ulic fluid/pressure and thereb y reduce the speed of the above functions.

When calibrating Module 60 define and set the distance from the stop positions where end position damping is to be activated.

ContChamp DRD-S

Technical Handbook

ECU 2

60 Electronic Overload Protection

9407

04-10

S.Grupp 20

S16

S18

S17

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, feedline left lift cylinder 768-13. Pressure sensor, return left lift cylinder

ContChamp DRD-S

Technical Handbook

ECU

8 Digital IN 1 I/O LE14 Parking brake (Remote control)

9 Digital IN 2 I/O LE17 10 Digital IN 3 I/O LE20 11 Digital IN 4 I/O LE23 31 Digital IN 5 I/O LE13 32 Digital IN 6 I/O LE16 Cab movement, FORWARD 33 Digital IN 7 I/O LE19 Cab movement, BACK 34 Digital IN 8 I/O LE22 Cab movement, front and back end po sitions 55 Digital IN 9 I/O LE15 56 Digital IN 10 I/O LE18 57 Digital IN 11 I/O LE21 Remote control 58 Digital IN 12 I/O LE24 Support jacks , change load curve

2 Digital OUT 1 PNP I/O LE6 24 Digital OUT 2 PNP I/O LE10 25 Digital OUT 3 PNP I/O LE7 26 Digital OUT 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 Analogue IN 1 0-10V 42 Analogue IN 2 0-10V Lever TILT P4 64 Analogue IN 3 0-10V 65 Analogue IN 4 0-10V 66 Analogue IN 5 0-10V 67 Analogue IN 6 0-10V 52 Analogue IN 7 0-10V 43 Analogue IN 1 0-23mA 63 Analogue IN 3 0-23mA 27 Analogue IN 1 0-196ohm 28 Analogue IN 2 0-196ohm 51 Analogue IN 3 0-196ohm

6 Analogue IN 1 70..120°C

7 Analogue IN 2 -20..120°C 30 Analogue IN 3 -20..120°C 53 Analogue IN 4 70..120°C

1 Analogue UT PWM PNP 1 LE5 TILT OUT

3 Analogue UT PWM PNP 2 LE3 TILT IN

4 Analogue UT PWM PNP 3 LE2

5 Analogue UT PWM PNP 4 LE4 47 Analogue UT PWM PNP/NPN 1 LE38 Cab movement, FORWARD 69 Analogue UT PWM PNP/NPN 2 LE36 Cab movement, BACK 35 Pulse sensor 1 59 Pulse sensor 2 60 Counter 36

Signal Size LED Function

ECU 3

Functions

ECU 3 Functions

9407

04-10

S.Grupp 20

ContChamp DRD-S

Technical Handbook

ECU 3

Circuit Board

9407

04-10

S.Grupp 20

LE1 Should always be lit, indicates 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 all, the program will not start, i.e., something is wrong, for example, the EPROM or power supply

ECU 3 Circuit Board

Kalmar DRD-S, DRD-GB Handbook

Specifications and Main Features

Frequently Asked Questions

User Manual