RS 2003 ADD Training Mat

DRS ContMaster Extra Training Material

2002

H. Koskinen 11/2002

DRS ContMaster 2002

Good visibility frontCabin position.Side view is better.More space for maintenanceof power train (engine).

DRS ContMaster 2002

DRS ContMaster 2002

Better visibility reversing.Exhaust pipe is far of the caband hydraulic.

A Partek Company 15

BoomBoom

• For 5 high stacking (9’6”)• made to last =welds on the

neutral axle

• rollers for inner boom• low friction =>less power

needed = fuel economy

• end damping with proximitysensors = smooth operation

• floating wear pads on thebasic boom

• easy replacement

• excellent support

• inverted telescopic cylinder

A Partek Company 13

Steering axleSteering axle

• Sandwich - type heavy dutydesign made to last• same for 25 and 33 tires• basic model without brakes• disc brakes only as option for

33 tire models

• built-in gauge for electronicoverload system (rear)

• mechanical stops to limit theaxle oscillation improvinglateral stability

• spherical plain bearings onpivot points

Rear view from the cabin Clark Transmission filters

DRS ContMaster

DRS ContMaster 2002

The Spreader rotationis std with two hydraulic motor

A Partek Company 18

Container attachment Container attachment contcont..

• automatic twistlocking std.

• std. positions 20’ and 40’• proportionally controlled

rotation +200 / -100 degrees

• side shift +/- 800 mm

• +/- 5 degree free tilting• forward/backward tilt as std.

• Separate extension/retractionof T-beams

• ISO-type floating twistlocks

• landing pin with strongerspring and longer move

• reliable safety system• pile slope as option

Front end view ofpower train and hydraulic pumps.

Brake pump.Pressure check points

fittings. Main directional valve

and priority valve.Pilot pressure valve.

Pressure accumulatorof pilot circuit.

Pressure sensor(s).Parking brake.

Transmission checkand service points.

DRS ContMaster 2002 service view

View from middle of thechassis front of the cabin

All hydraulic pumps are Transmission

driven

Main hydraulic valvesSteering priority valve

Fast Hoist valveSignal pressure valve

Pressure sensor(s)

DRS ContMaster hydraulic

Engine

DRS ContMaster Engine baycover open

Engine Scania DI12

Scania DI12 54A Engine LH-side

Industrial & Marine Engines PRELIMINARY

© Scania Industrial & Marine Engines

Technical data and cooling equipment recommendation

DI12 54A, order ref. 10-00This engine complies to exhaust emission regulations Stage 2 EURO and TIER 2 USA.

Rating acc. to

Engine speed, r/min

1200 1500 1800 2100

Gross power kW (hp) ICFN 187 (254) 237 (322) 240 (326) -IFN 187 (254) 237 (322) 240 (326) 243 (330)

Gross torque Nm (kpm) ICFN 1488 (152) 1509 (154) 1273 (130) -IFN 1488 (152) 1509 (154) 1273 (130) 1105 (113)

Spec. fuel consumption g/kWh (g/hph)

full load 195 (143) 195 (143) 203 (149) 220 (162)

3/4 load 200 (147) 199 (146) 211 (155) 233 (171)

1/2 load 203 (149) 205 (151) 220 (162) 242 (178)

Heat rejection kW

to cooling water 106 134 155 189

to exhaust gas 134 171 190 230

to surrounding air 22 22 23 25

Air consumption kg/min 15 23 28 31

Exhaust flow kg/min 16 24 29 32

Exhaust temperature °C 501 427 399 431

ICFN, 1800 r/min IFN, 2100 r/min

Air-on temp. Air-on temp.

35 °C 50 °C 35 °C 50 °C

Radiator

front area m2 1.0 1.0 1.0 1.0

weight kg 55 55 55 55

Coolant pump flow dm3/min 360 360 420 420

Fan

type Puller Puller Puller Puller

Ø mm 787 787 787 787

power losses kW 9 9 21 21

number of drive belts (poly-V) 1 1 1 1

speed ratio 1:1.08 1:1.08 1:1.08 1:1.08

Air flow

free air flow m3/s 8.5 8.5 9.8 9.8

pressure reserve mm Wc 35 30 35 30

Industrial & Marine Engines PRELIMINARY

© Scania Industrial & Marine Engines

DI12 54A, order ref. 10-00 (optimized for Clark 36000 transmission)

2200

TORQUENm

Nm9,81---------- kpm=

180

200

220

260

240

OUTPUTkW

kW x 1.36 = hp

350 hp

330

310

290

270

250

160

1300

1100

130

1501500

1200 1400 1600 1800 2000

SPECIFIC FUELCONSUMPTIONg/kWh

g kWh⁄1,36

------------------ g hph⁄=

180 g/hph

230

210160

170 kpm

110

230

210

140

1700

250

r/min

190

190 140

IFN

ICFN

IFN

ICFN

Max torque1589 Nm/1400 r/min

IFNICFN

DRS ContMaster Engine bay cover open

Engine QM 11

Air to Air inlet line cooler before Turbocharger of Cummins QSM11 Engine

LH-side inlet air line fromfilter to air/air cooler

RH-side inlet air line from coolerto the Turbo Charger

QSM11 Cummins Engine inlet line

DSR ContMaster inlet air line insideframe space

DRS ContMaster Electric multi pinsockets QSM11 Cummins

Cummins Engine Company, Inc QSM11

Engine Data Sheet & Performance Curve FR 2926

Industrial Market CPL 2828-SC2

Engine Configuration: D353014CX03 Compression ratio: 16.3 Revision:Fuel System: Celect Electronic Rating: 330 hp (246 kW) @ 2,100 RPM 1-Nov-2000Emission Certification: U.S. EPA Tier 2, CARB Tier 2, NRMM (Europe) Tier 2

All data is based on the engine operating with fuel system, water pump, and 15 in H2O (381 mm H2O) inlet air restriction and with 3 in Hg (76 mm Hg) exhaust restriction; not included are alternator, fan, optional equipment and driven components. Coolant flows and heat rejection data based on coolants as 100% water in U.S. GPM.

Rating Type: Intermittent

TorqueRPM lb-ft N-m700 800 1,085900 1,050 1,424

1,000 1,200 1,6271,100 1,235 1,6741,200 1,235 1,6741,400 1,235 1,6741,600 1,083 1,4681,800 963 1,3062,000 867 1,1752,100 825 1,119

Power OutputRPM hp kW700 107 80900 180 134

1,000 228 1701,100 259 1931,200 282 2101,400 329 2451,600 330 2461,800 330 2462,000 330 2462,100 330 246

Fuel ConsumptionRPM lb/hp-hr gm/kW-hr1,400 0.328 2001,500 0.32 1951,800 0.316 1922,000 0.325 1982,100 0.33 201

Curves shown above represent gross engine performance capabilities obtained and corrected in accordance with SAE J1995 conditions of 29.61 in. Hg(100 kPa) barometric pressure [300ft.(91m) altitude] 77F (25 C) inlet air temperature, and 0.30 in Hg (1kPa) water vapor pressure with No.2 diesel fuel. The engine may be operated up to 12,000 ft (3,657.6 m) altitude before electronic derate is applied.

STATUS FOR CURVES AND DATA: FinalTOLERANCE: Within +/- 5%

CHIEF ENGINEER: Richard D Johnston

Cummins Confidential

FR 2926 (Continued) Page: 2

Intake Air System:Intake Manifold Temperature at 25 deg C (77 F) Ambient 140 60deg F deg CMaximum allowable air temperature rise over ambient at Intake Manifold

(Naturally Aspirated Engines) or Turbo Compressor inlet (Turbo-charged Engines): 30 16.7delta deg F delta deg C

Charge Air Cooling System:Maximum pressure drop from turbo compressor outlet to intake manifold (IMPD): 3 78in-Hg mm HgMaximum Intake Manifold Temperature Differential (Ambient to IMT) (IMTD): 63 35delta deg F delta deg CIntake Manifold Temperature for Fan-ON: 140 60deg F deg C

Low Temperature Aftercooling System:Coolant temperature from the Aftercooler Radiator outlet(for LTA system with 1 Pump - 2 Loop or 2 Pump - 2 Loop):

@ Maximum engine coolant out temperature at Limiting Ambient Temperature (1P-2L): deg F deg C

@ 25 deg C (77F) ambient (1P-2L, 2P-2L): deg F deg CMax. coolant temperature from the aftercooler radiator at 25C (77F)

ambient: deg F deg CMaximum coolant temperature into aftercooler at Limiting Ambient

conditions: deg F deg C

Exhaust System:Maximum exhaust back pressure: 3 76in-Hg mm Hg

Lubrication System:Nominal operating oil pressure

At minimum low idle: 15 103psi kPaAt maximum rated RPM: 35 241psi kPa

Minimum engine oil pressure for engine protection devicesAt maximum rated speed: 28 193psi kPaAt minimum low idle: 10 69psi kPa

Fuel System:Maximum supply fuel flow: 591 268lb/hr kg/hrFuel cooling requirements (with diesel fuel)Maximum heat rejection to return fuel at max. coolant and inlet fuel temperature: 260 4.57BTU/min kW

At fuel return flow rate of: 572 259lb/hr kg/hrAt fuel return temperature prior to cooler: 212 100deg F deg C

Maximum return fuel flow: 572 259lb/hr kg/hrMinimum torque required to hold throttle at full travel ( Mech. System) lb-in N-mEngine fuel compatibility (consult Appl. Eng. For appropriate use of low viscosity fuels) DF1, DF2

Performance DataEngine low idle speed: RPMMaximum low idle speed: 1,200 RPMMinimum low idle speed: 600 RPMMaximum allowable governor droop: %Maximum allowable governor regulation: %Maximum no load governed speed: 2,350 RPMGovernor break speed: 2,130 RPMMaximum torque available at closed throttle low idle speed: 900 1,220lb-ft N-mMaximum power available from the front of the Crankshaft --

Consult Cummins Application Engineer for Information


FR 2926 (Continued) Page: 3

Governed Power Peak Power Peak Torque

Engine Speed 2,100 RPM 1,800 RPM 1,400 RPMOutput Power 330 hp 246 kW 330 hp 246 kW 329 hp 245 kWTorque 825 lb-ft 1,119 N-m 963 lb-ft 1,306 N-m 1,235 lb-ft 1,674 N-mFriction Horsepower -61 hp -46 kW -45 hp -33 kW -28 hp -21 kWIntake Manifold Pressure 46 in-Hg 1,165 mm Hg 49 in-Hg 1,241 mm Hg 56 in-Hg 1,418 mm HgTurbo Comp. Outlet Pressure 49 in-Hg 1,228 mm Hg 52 in-Hg 1,304 mm Hg 59 in-Hg 1,482 mm HgTurbo Comp. Outlet Temperature 333 deg F 167 deg C 337 deg F 169 deg C 365 deg F 185 deg CIntake Air Flow 875 ft3/min 413 L/s 810 ft3/min 382 L/s 710 ft3/min 335 L/sCharge Air Flow 62 lb/min 28 kg/min 56 lb/min 26 kg/min 50 lb/min 23 kg/minExhaust Gas Flow 1,860 ft3/min 878 L/s 1,780 ft3/min 840 L/s 1,750 ft3/min 826 L/sExhaust Gas Temperature 745 deg F 396.1 deg C 780 deg F 416 deg C 905 deg F 485 deg CFuel Flow to Pump 427 lb/hr 194 kg/hr 360 lb/hr 163 kg/hr 250 lb/hr 113 kg/hr*Heat Rejection to Coolant 4,800 BTU/min 84.4 kW 4,450 BTU/min 78.25 kW 4,700 BTU/min 82.65 kWHeat Rejection to Aftercooler Coolant (LTA)

BTU/min kW BTU/min kW BTU/min kW

Heat Rejection to Fuel 220 BTU/min 3.87 kW 165 BTU/min 2.9 kW 87 BTU/min 1.53 kWHeat Rejection to Ambient 1,075 BTU/min 18.9 kW 960 BTU/min 16.88 kW 1,025 BTU/min 18.02 kW**Steady State Smoke 0.5 Bosch 0.5 Bosch 1 Bosch

*Engine with dry manifold.

** Note for Nat. Aspirated Engines: When operating Naturally Aspirated engine above SAE J1995 conditions, it should be noted that smoke levels will increase due to combustion inefficiencies associated with a reduction in the air to fuel mixture.

Cranking System (Cold Starting Capability)Unaided Cold Start

Minimum cranking speed: 110 RPMMotoring friction horsepower at minimum cranking speed: 6 5hp kWMinimum ambient temperature 10 -12.2deg F deg CBreakaway torque at minimum unaided cold start temperature using

15W40 oil: 170 230lb-ft N-mCranking torque at minimum unaided cold start temperature using

15W40 oil: 215 292lb-ft N-mAided Cold Start

Minimum ambient temperature with Grid Heater only -10 -23deg F deg CMinimum ambient temperature with Ether only: -10 -23deg F deg CMinimum ambient temperature with coolant and lube heater only: 0 -18deg F deg C

EmissionsNoise Emission:

Top 101.5 dBaRight Side 103.8 dBaLeft Side 104.5 dBaFront 105 dBa

Estimated Free Field Sound Pressure Level at 3.28ft. (1m) and Full-Load Governed Speed(Excludes Noise from Intake, Exhaust, Cooling System and Driven Components)

Gaseous Emissions Limits per ISO 8178, are equal to or less than:Weight Specific Nox 4.5 6gm/hp-hr gm/kW-hrWeight Specific HC 0.3 0.4gm/hp-hr gm/kW-hrWeight Specific CO 2.61 3.5gm/hp-hr gm/kW-hrWeight Specific Particulate 0.15 0.2gm/hp-hr gm/kW-hr

Water Management Rating Data-(If Applicable)Advertised Power 340 254hp kWAdvertised Speed 1,800 RPMIntake Air Flow 810 382ft3/min L/sExhaust Gas Flow 1,810 51,253ft3/min L/minHeat Rejection to Coolant [Engine] 4,600 80.89BTU/min kWHeat Rejection to Coolant [Aftercooler(s)] BTU/min kW

End of Report


DRS ContMaster LH-side view

Stairs to the cabinEngine air filter withpre cleaner

DRS ContMaster coversopen front of the cabin

A Partek Company 22

Drive axleDrive axle

Rockwell 7534 series

* proven & well known globally* practically wear-resistant WDB* filtering after forced cooling* 18.00-25 tire with 26.0 ratio* 18.00-33 tire with 30.45 ratio

Different ratios will give the un-compromised acceleration &speeds in all operating conditions

DRS ContMaster double rotationmotors with single gear boxes

Back uplight and alarm

Spreader rotation limit sensor S100when boom is lifted up OPTION

Weighing positionsensor S79

OPTION

Exhaust pipe

DRS ContMaster Boom stand

LH-side hydraulic components-Filter-Cooler-Pressure accumulators-Valves-Test points

DRS ContMaster 2002

Access to and fromthe cabin is safewith steps on both sides of the machine

RH-side service door open

DRS ContMaster Service View

Batteries normal location andlocked

Batteries “rolled” out for checkingand for service

DRS ContMaster Maincontactor, Fuses, Cab

transfer unit, First version

RH-side view of servicespace

Main contactor(Battery relay)

Cabin transfer unit

Batteries

DRS ContMaster Service Points

DRS ContMaster 2002, First version

• PCB - Hydraulic– Relays– Fuses– LED indicator lights– Multi-pin sockets– Diodes– First level

Relay box RH-side inside frame, First version

Door open PCB view

PCB open, module and amplifier shown

Electric boxModule A81 MCC2212XQS2 (Engine plug)PCB of hydraulic function, amplifier and sockets

Finger tip steeringvalve L90LS

Batteries.Rolling out for service

DRS ContMaster RH-side frame

A81 MCC2212 MODULEHydraulic, Cab transfer,Accelerate and Indicationlight of the spreader

XQS2 Only for Cummins QSM11for Cummins Service Group

Fuses F34, F35 15AF36, F37, F38, F39 and F41 10AF40 25A

F42 to F49 are Options

Wire numbers from Fuses are same as Fuse number is. From Fuse F34 wire number isalso 34

Inside the main frame, II-version,RH-side, first level in Electric box

Electric box II-version RH-side lowerlevel inside the frame

• Main fuses 50A• K71 and K72 relays• A85 Amplifier• Diodes• 9-pole sockets• Earth bar• Wire colour:

– Black is supply line– White is control

supply– Blue is earth (ground)– Orange is 12 Volts line

Cabin back wall electric of DRS ContMaster

Location:Back wall

of the Cabin

MaintenanceKey S3. When

watching valuesof input/output

from the Display

DRS ContMaster Electric Maintenance

Electric center rear wall of the Cabin

Fuses:F10; 11; 12 and 33 are 15AF13 to F32 are 10A

Multi pole socket (9pins of each)XR12,XSR,XHR spare wires front panelXR2 spare wires RH-s armrest panelXR3 spare wires from engineXP0 force use panelX44 from AC unit X191 Minirat (FS)SX191 Mini Steering Wheel. SX1 RH-sarm rest panelX22, X37 Front inst.. PanelX21,X31,X35,X95,XE4,X115 From theFrame. XKTJ and X32 from the ceilingXPC from the Display

DRS ContMaster Electric on the cabinrear wall (behind driver)

Relays, diodes, resistorsconnectors and rails

A84 CONTROL UNITMCKC. Input orders

from cabin instruments(info position of the cab

switches)

A82 CONTROL UNITMCC2212. Engine control,Auto gear,Stab 1/2, Mini steer, Idle stop, Vertical lift, Load scale. Alarm buzzer Maintenance

key

DRS ContMaster Electric Center in theCabin on the rear wall

S186 S187 S188

Transformer A12

S186 Engine Throttle selector1300 RPM. Switch position 1

S187 First (1) position EnginePower ON.Second (2) position EngineStart.

S188 Gear selector Forwardor Reverse and II-gear only.

LOCATION RH-SIDE DRIVERON THE REAR WALL OF THE

CABIN

DRS ContMaster Forced Motion SwitchesRH-side drivers seat on the back wall

Over loadby-pass

Twist LockBy-pass

Automatic T-L Length adjusting selector

DRS ContMaster RH-side Joystick andhand panel

Twist Lockauto or manual

closed

Cabin transfer Dumpingsensors:Forward S97AReverse S97BLocation RH-side Cabin under and insideprofile

DRS ContMaster Cabin transfer smoothmotion both end position

L = Lift TI = Telescope In A81:D18 = FCV auto/manuLTO = Lift Telescope Out D = Boom Down RL = Fast LiftLTI = Lift Telescope In DTO = Down +TO RC = T-Lift Rotate ClockwiseTO = Telescope Out DTI = Down+TI RC.= T-Lift Rotate Counter ClockwiseCC = Twist Lock Close

DRS ContMaster Valve control

N:o 3K5692470 Tila: APP Nimitys: Hydr. kaavio, Jarrut

Tulostettu 20.08.2002 08:37:23

_PRELIMINARY N:o 3K5698320 Tila: DR Nimitys: HYDR. KAAVIO ,TARTTUJA

Tulostettu 20.08.2002 08:33:50

N:o

2K

56

92

46

0 T

ila: A

PP

Nim

itys: Hyd

r. kaa

vio,p

eru

skon

e,sä

ätö

tilavu

usp

um

pu

t

Tu

loste

ttu 2

9.1

0.2

00

2 0

9:1

4:0

1

_PRELIMINARY N:o 2K5698240 Tila: DR Nimitys: Hydr. kaavio,peruskone,miniratti

Tulostettu 20.08.2002 08:31:54

_PRELIMINARY N:o 2K5698310 Tila: DR Nimitys: Hydr. kaavio,peruskone,säätötilavuuspumput

Tulostettu 20.08.2002 08:28:37

N:o 3K5688040 C Tila: APP Nimitys: HYDR. KAAVIO ,TARTTUJA

Tulostettu 20.08.2002 08:35:52

LH-side hydraulic components-Filter-Cooler-Pressure accumulators-Valves-Test points

Hydraulic cooler (option)on return Spreader circuit#18

One way valve # 20 forback pressure 5 bar Fill up dumping cylinders

One way valve #25 for by-bass of the cooler

5 bar

Hydraulic oil cooler of main hydraulicDRS ContMaster

-Brake hydraulic tank forbrake system and cooling.-Cooler for brake oil 50 ºCfan start running.-Main hydraulic oil tank isseparate and normal ISO-standard oil.-Lincoln central lube sys-tem is complete Lincolndesign.

DRS ContMaster LH-side view

Lift cylinder top bearing service free

Lift cylinder lock valve, pressuresignal output and bearing not

service free

DRS ContMaster lift cylindermounting

-Hydraulic pumps -Piston type variable for main and steering hydraulic. -Intra vane fixed for spreader functions. -Gear type for brake hydraulic--All pumps are Clark transmission driven -Main directional valve is front of pumps.-All are covered light metal service covers.

DRS ContMaster view front of the cabin when it is rear

Brake pump#16, 33 l/mingear type,PM22

Intra vane pump#67 (PM4), 142 l/min 2100 RPM(oil to the Spreader)

Variable pump#17/98 (PM3) 206l/min 2100 RPM

Variable pump #16/98 (PM1) 206 l/min 2100RPM

Variable pump #16/74 (PM2)155 l/min2100 RPM

ENGINE

RH-side

LH-side

Hydraulic pumps Clark driven

CLARK

Vickers Displacement Pump PVH

Swash Plate (Yoke) Control Piston, LS - signal pressure reducing the swash plate angle

Pistons

Bias piston

Outlet pressure gauge port, M10O-ring boss. (plugged)

Vickers displacementhydraulic pump PVH

STAND-BY SITUATION

Only 30…40 bar open the LS-spool and pressure behindthe control piston regulate the swash plate to zero flow.

Control piston

Bias piston

Vickers displacement hydraulic pump.

Load signal pressure toadjust swash plate angleas in demand.Pump outlet pressureand LS - pressure are balancing Load SensingSpool and oil volume isordered level.

Vickers displacementhydraulic pump PVH

LS - signal pressure is higher level than max pressure limiting spool. Pump outlet oil pressure to adjust swashplate angle to zero as indemand.

Ls - spool

Pressurelimitingspool

Max Pressure Situation

PM 2 Stand-byandMax pressure

Stand-by adjusting screwvalue 30 bar

Max pressure adjusting screwvalue 175 ± 5 bar

PM 1Stand-by 30barand max pressure 210 ± 5bar

Steeringpump16/74

Hoist andTelescopepump16/98

RH - side hydraulic pumps

First spool

Second spool

Pump connection both side

Directional control valve M400LS. Proportional,load-sensing directional valve

Flow rate (recommended) Pump connection 900 l/min. Return from service port1000 l/min. Max. flow rate to service port 450 l/min (double port each function)Weight 95 kg (210 lb)

Leakage from service port to tankFrom A- or B-port: max. 20 cm³/minat 100 bar, oil 50 °C and viscosity30 mm²/s (cSt).

Main directional valve M400LS

ContMaster don’t use Counterpressurevalve and spring

View from the Cabin and components are like diagram shows

Left side Rightside

Pilot pressure reducing

Main directional valve(Lift cylinders and Telescoping cylinders)

Priority valve of steering

Lift/Low

Boom

Fast hoist Y87 fromSpreadercircuit

35±2bar

To steeringvalve

Components front end middle of frameand diagram is done like mounted

Fast hoist Y87, ifpressure <<90barand joystick used

Pressure reducingvalve #31, 35±2bar

(Pilot pressure)

Check valve#28.2

PM4125±5bar

PM8 35±2bar

Pilot linepressureaccumulatorgas press.10 bar

Main directional valve of DRS ContMaster

Forward

Main directional valve of ContMasterfrom Top View

Shuttle valve#33. LS-signal eitherfrom steering valve or main directionalvalve

PM10 Mainpressure 210±5 /30

bar

PM8 Pilot pressure35±2 bar

PM5 Steering pressure

Pressure Check point close M400 mainvalve of ContMaster

Y51 Boom out (PSL)

Y52 Boom in (PSS)

Y58 Boom Lifting (PL)

Y57 Boom Lowering (PS)

Orifice Ø 0,8 mmB1 leak of rod side

Main valve Proportional solenoid valvesDRS ContMaster

Own weight 95 kg (210 lb)

Priority valve #27 Check valve #28.1

Y87 FastHoist fromSpreader

Check valve#28.2

Pressureaccumulator,Pilot line, #35

Main directional valve #30(Lift- and Boom cylinder)

Hydraulic components front end of DRSContMaster



(Pilot pressure)

Check valve#28.2

PM4125±5bar

PM8 35±2bar



PM10 Mainpressure 210 ±5 bar

Pressure Sensor B6from Right LiftingCylinder Pressure.Purpose: Fast Hoist and

Reducing loweringspeed

FWD

DRS ContMaster Pressure sensor location

PM4 125±5 bar

Check valve 28.2

Fast Hoist valve #26(Y87).

Oil from the Spreaderpump

Fast hoist circuit of DRS ContMaster

Oil to Liftcylinders(A2 M400)

A and BPilot restrictors

NOTE! If you remove remote control valve, check thoserestrictors when you assembly!

Pilot restrictor for smooth control, sizes available from 0,45…..1,6 mm diameter

Proportional solenoid valve for L90LS,K220 and M400 directional valves

Pilot restrictor off from remote-controlled spool actuator

Restrictor mounted. Available differentdiameter, marked dots. Note check thatrestrictor is with the spool!

Pilot restrictors sizes and marking

NOTE: numbers aren’t Kalmar numbers

Priority valve #27 Check valve #28.1

Y87 FastHoist fromSpreader

Check valve#28.2

Pressureaccumulator,Pilot line, #35

Main directional valve #30(Lift- and Boom cylinder)

Hydraulic components front end of DRSContMaster



(Pilot pressure)

Check valve#28.2

PM4125±5bar

PM8 35±2bar



PM10 Mainpressure 210 ±5 bar

Pressure Sensor B6from Right LiftingCylinder Pressure.Purpose: Fast Hoist and

Reducing loweringspeed

FWD

DRS ContMaster Pressure sensor location

PM4 125±5 bar

Check valve 28.2

Fast Hoist valve #26(Y87).

Oil from the Spreaderpump

Fast hoist circuit of DRS ContMaster

Oil to Liftcylinders(A2 M400)

DRS Steering hydraulic diagrams

Right turn Neutral oil to EF Left turn

Steering hydraulic diagram Left Turnsituation

Pump #74 155 l/minLS-signal from steeringvalve or main directionalvalve

Priority valve.Always steering isfirst. When no steeringoil flow from EF gate tomain valve.

Steering valve nowL output position.Double shock valves245 bar with anti-cavitation valves.

LS-signal pressureOrifice Ø 0,8…1,2mm

EF CF

POver pressurevalve 200 bar

PP-signalØ 0,8mm

SteeringMain hydraulic

Priority valve of steering hydraulicDRS ContMaster

Dynamic type Ø1.2mm

Eaton Steering Hydraulic withVariable pump

EATON Steering valveNeutral

Eaton Steering valveLeft Turn

Eaton Steering valveRight Turn

Eaton Steering valve Neutral and Right/Left turn

Oil from the pump

Pressure compensator

Damping of pressurecompensator

Setting pressure, feed reduction valve

Port relief and/or anti- cavitation function

Pilot pressure supply

Finger Tip Steering Valve L90LS DRS 2002Neutral Position

H.Koskinen

A B

Finger Tip Steering Valve of DRS 2002 Over pressure from cylinder

+

Finger Tip Steering Valve L90LS DRS ContMaster

+

Valve of Finger Tip Steering DRS 2002

Port A Port B

A and BPilot restrictors

NOTE! If you remove remote control valve, check thoserestrictors when you assembly!

Pilot restrictor for smooth control, sizes available from 0,45…..1,6 mm diameter

Oil from pumps#22.1 and 22.3

Pilot oil to M400

Signal pressureadjustment

35±2 bar

Leakage line

Pressure reducing valve #31for pilot line to main valve

Pressure reducing valve cut view and symbol

Pressure reducing valve

DRS ContMaster Lift boom front

A83MCC2212ModuleX4, F36

A83 MCC2212 MODULE

X4 Junction bar, 120 ΩΩ resistor

DRS ContMaster El box LH-sidefront of the boom

A Partek Company 39

SafetySafety

• Driving prevented if• low brake system pressure (<

90 bar)• high rpm => no gear

connection (rush start)

• high speed => no directionchange accepted

• parking brake engaged

• De-clutch on the LH sidebrake pedal

• two circuit system for brakes

A Partek Company

• Change the flow by turning two valves so thatthere is only one output

A Partek Company

• Solution

Cabin transfer hydraulic unit

PM1 120± bar

Oil fillingand breather

Oil volume 2,8 L

Cabin transfer hydraulic unit (2)

E-motor & Hydraulicpump unit

Y96a and Y96b

210 bar both endratio 10:1 (returnflow need 20 bar toget back)

PS1 100 bar max.pump pressure

PM1

Cab transfer unit pressure adjust

Pressure relief valveof max. operating pressure PS1 120±5 bar. When you adjust pressure, takeoff sockets from directional valve.

Cab transfer double chock valve

Note! Arrow pointsdownwards and this side facing towards motor.

Cabin transfer hydraulic unit

PM1 120± bar

Oil fillingand breather

Oil volume 2,8 L

Steering axle, wheel, preload andside tilt limiter

Max turning is 70°. Startto move use as less aspossible turn!

Mechanic limiter sideway tilt oft he main frame

Preload of the Kingpin bearings STARTTO MOVE 150 to170Nm

Stub Axle Hub Bearing Nuts and LockingRing & Preload Instruction

First nut against the bearing Locking plate

Locking plate and Second nut

NOTE! Don’t use locking plate twice!Preload of bearings:30 - 50 Nm continues rollingresistance (means about1000 Nm tightening torque toFIRST nut but always rollingresistance is final check)

Thread M20 Po in t ing UP

Mechanical side tiltinglimiter of the frame

New profile of the axleframe. Strength is maximize right.

Cylinder rod is coveredwith mud cover.

New steering axle design

Wet brake cooling oil pressure checkpoint and orifice 5 mm before

Cooling pressure inmin. 0,5 barmax. 1,5 bar

Lincoln central lube pump andelectric control center

Wet brake cooling oil coolerbefore brake oil tank

By-bas spring loaded one-way valve 5 bar opening

pressure

Brake oil tank with level glasand temperature gauge

Oil cooler of brake cooling return line from the wheel hub

Parking brake caliber

Instruction:Pressure to cylinder; Screw nut 5 in; Releasepressure; screw on 1 until brake pads touch brake plate 3; Unscrew nro1 1½ turn; Pressure to cylinder; Unscrew nut 5; Check that brake is open also on brake recharge pressure level.

A PartekCompany

Brake System Relief Valve

Signal Pressure

Relief to the Tank

System Pressure

Pressure Adjustmentmin 110 bar

A PartekCompany

Brake Pedal Valve

P

P

T

T

No Function

A PartekCompany

Brake Pedal Valve

P

P

T

T

Full Braking

Charging-, Parking-, Pressure ReliefValves and Pressure Filter.

Filter #5

Pressure relief valvePS22 160±5 bar/128bar

Pressure check point PM26 160±5 bar(Parking brake open)

Parking brake valveY12 #3

Charging valve

Load lowering/lock valve(s) DRS ContMaster

Lift cylinder RH side

Breather line from rod side

Lock lowering valve

Line to the directionalvalve (P and T)

Solenoid valve Y68(67)

Connection to pressureswitch S79 (fast hoist andreduced lowering)

DRS Liftcylinder Lock valveDRS Nostosylinterin Lukkoventtiili 1/3

Lowering valve / Laskuventtiili DRS ContMaster

Solenoidiventtiili laskun lukkoventtiilin avaukseen, normaalisti kiinni.

Solenoid poppet valve 2/2 way, normally closed, high pressure.

24 V DC 19 W, 0.79 Amps, 30, 30 ΩΩ

Max internal oil leak at 210 bar 3000 PSI

At 38 cSt 180 SSU 0.33 ml/min (5 drops/ min)

40 Nm

44400o

DRS Lift cylinder Lock valve DRS Nostosylinterin lukkoventtiili 1/1

Varo- ja imusuojaosuus Nostosylinterien lukkoventtiileistäLift cylinder lock valve pressure relief and vacuum preventer

LOAD LOWERING VALVE

The ratio between control pressure (opening X) and load pressure (opening B) is 1:20.

Pressure valves

Figure 1. Pre-controlled pressure limiting valve equipped with a magnet controlled pressurerelease, type DBW.

Figure 2. Control-blow baffling plate, Figure 3. Control-blow baffling plate,direction valve closed. direction valve open.

koskihe

Free circulation valve #32 Y56 PS4 125 bar

Free circulation valve #32, Y56 andpressure relief valve

PS4125±bar

PM4 One way valve #20 5bar

Y56

Free circulation valve of the Spreader function, standard 125 bar

LH-side open

Free circulation valveand instruments

One way valve #20 (5bar)

S72 Temperature switchfor controlling cooler fanstart point is >50 ºC

PM 4 Spreader pressurecheck max 125±5 bar

Free circulation valve#32 (Y56 and PS4)

DRS ContMaster Spreader Hydraulic

Free circulation valve

Y56

Pressurerelief valve

PS4

Free flowspool

Spreader hydraulic Free Circulation Valve

125±5 bar

One way valve#20 5 bar

spring load

DANFOSS HYDRAULIC MOTOR

Inner oil leakage to tank is 4 l/min when operating pressure is 210 bar.

Tightening torque of the valve housing bolts for OMT 120 Nm (1050±± 90 lbf in)

OMV 200 Nm (1750±± 90 lbf in)

Tighten the cover bolts at torque 10 Nm (90 lbf in)

See also timing marks.

Reduction gearbox of the Spreader rotating

Spreader rotating gear box oil

SPREADER ROTATE GEARMOUNTING PLACE

Rotating - Tilting - Damping/Locking valves end ofthe Boom

Rotating, Tilting and Locking/Damping

Adjusting valves # 30, adjust main pressure relief valve #85 (Y56) over 175 bar and after setting back to 125 bar.

Location Front end of the Boom

RotatingY59a/b

Tilting valveY65 a/b

Damping or Locking valve Y63

Boom valves adjustment

PM9

175± bar bothside

One wayrestrictor valvesboth side(dumping)

One way restrictorvalves bothside(dumping)

COUNTERBALANCE VALVE

0 to 120 L/min NominalSeries 2 Cartridge T-2A Cavity

Installation Torque 60 to 65 NmTurn screw clockwise

to reduce settingand release load.

Complete adjustmentrange in 3 turns.

Rotate, Tilt and Locking valves endof the the boom

Relief valves setting (150 bar)-adjust main relief valve #85to 160 bar (is of FCV) -remove cap, open lock nut-adjust relief valves #8 (A, B) 150 bar (PM4) side shift end left and right

-adjust main relief valve (#85) back to 125±5bar-lock the adjusting screws-mount cabs

SPREADER SIDE SHIFT ADJUSTMENT

Y62

SPREADER LENGTH, SHORT, TWIST LOCKVALVES TOP OF THE SPREADER RH SIDE

Adjusting screws(100 bar)

LengtheningShorteningValves

Twist Locks valve

Twistlock Counterpressure valves

Counterbalance valve setting 100 bar

Open locking nut anti clockwiseTurn screw fully open clockwise.Adjust 1¾ turns anti clockwise.Lock the adjusting screw with lock nut.

T-beam of the spreader

Top-Lift length sensors

30’ position sensor

20’ and 40’ position sensor

Note at least one have to be activated until twistlock startoperating

Landing pin sensors (4 Pcs)

Landing pin everycorner. All 4 are connected series andall of them must be activated until twistlockopen or close operation ispossible.

Twist lock Sensors end of T-bems

Sensor of Twist lock close (one each end of the Spreader

Sensor of Twistlock open (oneeach end of theSpreader).

Twist lock cylinder

Spreader rotation limit sensors

Spreader rotationlimit sensor (one each side +200 -100degrees)

CONTROL MODULE, GENERAL INFO

Multipoleconnectors

When youweld - unplugconnectorswhen power isturn off. When plug inpower must beoff.

All terminalsare marked andshort descriptionbeside eachplug ( input,output, GND,Power, CANLow - High -Shield and Ref Out

Module get spare parts number after programming

24 V out pin no 36

24 V outpin no 42

Operation:

LED 1 Supply +24V out (pin no 36)LED 2 Supply +24V out (pin no 42)LED 3 Active when power on (main switch is closed)LED 4 Active when pin of processor PE0/DSACK0 is grounded

MCC2212 Module LED-indicator lights

Module MCC2212

Module is usedwhen current

control is necessary

Maintenancedisplayselector

Scrolling ofdisplays

Return first“page” andSetting of

automatic gear

Drivers Displays and Maintenance Displays

Drive speed(km/h)

Slip relation (%)

Module A81Can comm. : 0

CalibrateStability 1


CalibrationAre you sure?

OK OK

SERVICE DISPLAYSDRIVER’SDISPLAY

ALARMS CRITICALALARMS

2

3

4

5

6

7

8

10

11

12

13

14

15

16

PR9 00% PR10 00%17

18

39

40

41

29

43

46

1

Calibrateaccel.

CalibratePressure weighing

CalibrateStability 2

Send param.+ kalibrations

BASIC DISPLAYstability (%)

geardirection

reachload

Kalmar tai machine type Load parameters

M

3x during 2s M

45

PR5 00% PR6 00%PR7 00% PR8 00%

PR1 00% PR2 00%PR3 00% PR4 00%

DO 123456789012 000000000000

A5 0.00 A6 0.00A7 0.00 A8 0.00

A1 0.00 A2 0.00A3 0.00 A4 0.00

DI 123456789012 000000000000

19

20

21

22

23

24

PR9 00% PR10 00%25

PR5 00% PR6 00%PR7 00% PR8 00%

PR1 00% PR2 00%PR3 00% PR4 00%

DO 123456789012 000000000000

A5 0.00 A6 0.00A7 0.00 A8 0.00

A1 0.00 A2 0.00A3 0.00 A4 0.00

DI 123456789012 000000000000

OK 40.140.2

OK 41.1

41.2

OK 42.1

42.2

OK 43.1

43.2

43.3

43.4

DIRECTIONCHOSEN

DOES NOT START

Engine (rpm)Gear (rpm)

Engine water(°C)

Engine oil (bar)

Operating hours

Containercounter

Autom. gripping

Autom. changer

OK

OK

9

40.3

41.3

43.5

OK 45.1

42.3

OK

55 ENGINE WATERTOO HOT

47F/R SELECTED

48 IDLING ENGINESHUTS OFF

49 STEERING AXLEOVERLOAD

50 ENGINETEMPERATURE

LOW

51SHUT OFF DELAY

52 EMERGENCYSTOP PRESSED

53HAND BRAKE

54 ENGINE WATERLEVEL TOO LOW

Language

OK 44.1

44.244.344.4

44.5

44.6

44.7

44.844.9

44.1044.11

44.12

44.1344.14

OK

A

OK

56 ENGINE OILPRESSURE LOW

57 ERROR R60

58 ERROR R61

59 ERROR B6

60 ERROR B8

61 ERROR CAN A81

62 ERROR CAN A82

63 ERROR CAN A83

64 ERROR CAN A84

65 ERROR CANENGINE

66 ERROR ENGINETEMPERATURE

67 ERROR OILPRESSURE

68 ERROR ENGINERPM

69 ERROR ENGINE

70 ERROR ENGINE_____________

71 ERROR A312

72 LOW BRAKEPRESSURE

0.1 0.2



OK

26

27

29

30

31

32

PR9 00% PR10 00%33

34

PR5 00% PR6 00%PR7 00% PR8 00%

PR1 00% PR2 00%PR3 00% PR4 00%

DO 123456789012 000000000000

A5 0.00 A6 0.00A7 0.00 A8 0.00

A1 0.00 A2 0.00A3 0.00 A4 0.00

DI 123456789012 000000000000

35

36

37

38 DI 345678B 000000

DI 123456789012B 000000000000

DI 345678A 000000

DI 123456789012A 000000000000

42

44

OK

28

Displays. Following picture there are all the displays. The text can be 13 languages

22.11.02

56(62)

Version management

There is only one (the latest) version of each module program in use. The list of parameters is inpractice always different according to the options asked by the client.

15. List of parameters

The list of parameters is an Excel-file. In the file there are three pages: parameters, data and print-page. From the parameters-page the parameters will be changed and sent. Up in G1-cell there is aSend-button, by pressing of which the parameters can be loaded. The result of sending to A80,A81, A82 and A83 can be seed beside, OK=sending was successful and Error=sending was notsuccessful. The sending time of the parameters comes always visible to Time-field. After loading ofparameters it shall be made reset, that the changes will become valid. If the sent parameters arenot between the defined limits, it comes a message Sending not successful and wrong parameterand the number of it. Of the boom movements there is a graph. The x-axle of the graph there is thehandle position in percents and the y-axle is the control value of propo in current mA. The graphsare changing when the parameters are changed.

From the data-page it can be checked the allowed min and max values for the parameters.

On the print-page the parameters have been compressed in A4-size area, where it can be seenthe parameter numbers (co-ordinates) used in definition. From the print-page it is not allowed tochange the parameters because they have been linked to it from parameters-page. The print-pageis presented in the figure below.

These parameters should be changed only:- Machine type- Language versions- Options- Engine selection: Scania=1, Cummins=2If it is needed to change other parameters Excell needs password, which is restricted. Protection isunprotected in this way: Tools->Protection->Unprotect sheet and password. After that protectionshould be set: Tools->Protection->Protect sheet and password.

22.11.02

57(62)

22.11.02

59(62)

In IO-program to the point of Display Parameters it will come date and time of the latest loading ofparameters (on the display). The value of Module A81, Module A82 and Module A83 -field is theversion number of the module program and in the same time it tells if the modules are in the bus,otherwise ERROR-text. F2 tell the frequency of the transmission in hertzes, F1 is spare for lateruse.

In IO-program the propo-outputs can be seen in percents and milliamperes (accuracy 4mA). Digitalinputs and outputs are 1 or 0. Analog inputs are percents and volts (accuracy 20mV).

Load tells the container weight in accuracy of tenth of ton and as difference with the display result itwill be updated all the time. Reach tells the reach in accuracy of deci-meters. The stability point tellsstability at the moment in question in accuracy of one percent without average calculation; thereading is not limited to 100% as it is on the display. The angle is shown in accuracy of onedegree.

CONTROL MODULE CONNECTORS, EXAMPLE

Wires are screw mountedto multipole connectors

One example: X6 X6.5 DO7 165 Y96A Cabin Forward

X6 = Multipole plug #65 = Pin number of X6DO7 = Digital out-

put 0 or 24 V165 = wire numberY96A Cabin Forward

to the cylinder rod end

Wire nro 165 shows:1 means last module nro (A81) = 16 means multipole connector nro (6) 5 means pin number of connector

Front end of the boom RH-side are damping

sensors

S80 Dumping sensor in

S81 Dumping sensorout, no function ifload is >15000 kg

Boom in damping A83_DI11 Boom out damping DI12

Telescoping end positions dampingsensors

Boom front sliders adjustment

Front sliders are laterally adjustable (2 screw both side).

When you adjust, check that thereis enough space through fullstroke Boom OUT and IN.

Side clearance max. is total 5 mm (2,5 + 2,5).

Remember side sliders have to adjust with shims which are inthe cabin pocket.

FRONT END SLIDERS OF THE BOOM

New Minimum level wearing surface

8 × 45º

Support of slider

Bottom shape

Boom Reach Cylinder Mounting

Cylindercan floatinside mounting bracket

Sleeves are1 mm longerthan cylinderflange

Sliders of theSpreader

Frame. Aroundof outer end.

Sliders of theT-beam. Around inner end of T-

beam.

SLIDERS OF THE SPREADER

T-beam

SpreaderFrame

Spreader Carriage Side sliders 8 PCs

Side shiftcylinder

Support beam 2 PCs and side shift sliders 4 PCs

Spreader Carriage- and Support Beamwith Side Shift Sliders

SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO

Operating InstructionsGrease Lubrication System for Patria VammasPSB5500H

Operating instructions PSB5500H/ 06.09.01/ml Subject to change without notice 1LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗

QUICKLUBMOBILE CHASSIS LUBRICATION SYSTEM



SAFETY INSTRUCTIONS

Appropriate Use• Use of the 203 pump and progressive divider valves only for dispensing lubricants in

centralized lubrication systems. The system is designed for intermittent operation.

General Safety Instructions• The progressive centralized lubrication system connected to the QUICKLUB pump

Model 203 must always be secured with a safety valve.• Incorrect use may result in bearing damage caused by poor or over-lubrication.• Unauthorized modifications or changes to an installed system are not admissible. Any

modification must be subject to prior consultation with the manufacturer of thelubrication system.

• Use only original LINCOLN spare parts (Parts Catalog) approved by LINCOLN

Regulations for Prevention of Accidents• Adhere to the regulations for prevention of accidents, which are effective in the country

where the system is to be used.

Operation, Repair and Maintenance• Repair should only be performed by:

- Authorized and- Instructed personnel who are familiar with the centralized lubrication systems.

This is a brief Owner Manual only. More detailed safety and operation instructions aredescribed in the following Owner Manuals that are available:

Manual Name Manual numberQuicklub Pump model 203 2.1A-30001-C99Quicklub, Progressive Metering Devices for Oil and Grease 2.2A-10001-C99Printed Circuit Board for Pump 203 2.6A-20002-C00Quicklub Parts Catalogue 2.0A-20001-E00

For technical service contact Lincoln customer service at:

LINCOLNOne Lincoln WaySt. Louis, MO 63120-1478Phone 314-679-4200Fax 314-679-4359www.lincolnindustrial.com



Lubrication frequency and volume adjustment

Pause time setting switch(lubrication interval)

Operating time setting switch (amount per lubrication event)

SecondaryDivider Valve

Main (master) Divider Valve

P203Pump

Feed line to Lubrication Point(Ø8.6x2.3 or Ø6x2)

Main SupplyLine Ø8.6x2.3

Reservoir

Key components and tubing

Test button



Pause time setting(Lubrication interval)

Factory setting: 4 h (4)

Operating time setting(Amount per lubrication event

Factory setting: 4 h (4)

Factory setting: 8 min (4)



Reservoir filling

• Always fill through the filling nipple. The best practice is to use standard refinery drumsor pails. Impurities in grease can greate operational problem.

• NLGI 2 greases are applicable up to –20 ºC (-4 ºF)• Use NLGI 1 in extreme temperatures• Do not mix two greases - Consult your grease supplier first

Emergency lubrication

The pump can be by-passed by feeding grease manually through the manual greasefitting attached on the pressure relive valve. Alternatively by attaching a manual fitting on adivider valve will make manual greasing possible.

Pressure relief valve with a by-pass fitting

Filling nipple



PRACTICAL SYSTEM INFORMATION AND TROUBLESHOOTING TIPS

System check

• Initiate an extra lubrication cycle• The stirring paddle will start to rotate and pump will start to operate• If necessary open one feed line and verify grease flow. NOTE! Depending on the

operation sequence it may take a few minutes until the dividers will feed.

Indicator lights

Once the power is connected to thepump the left side LED is lit.

When the pump operates the right sideLED is lit.



PUMP ELEMENT AND PRESSURE RELIEF VALVE OPERATION

Pump element operation

Suction phase Pumping phase

Pump does not feed

The main reason is impurities in the pump element check valve seat. Remove the pumpelement and clean it. In case the element is damaged replace it.

System blockage

In case the system is blocked the pressure relief valve will start to bleed at 5000 psi (350bar). Since the system piping will hold the pressure after the pump has stopped theblockage can be detected by carefully loosing the supply line fittings between the mainvalve and secondary valves (A, B, C). If necessary use manual grease gun to apply morepressure through the by-pass fitting.• The secondary valve feed line fitting that will bleed grease is blocked.• It is fastest to detect the blockage in a secondary valve loop by attaching a manual

fitting in the valve inlet. The blockage can be found with grease gun by openinglubrication feed lines.

B

A

C

Feed lines



WEEKLY WALK-AROUND INSPECTION

The Lincoln Industrial Quicklub automated lube system components are designed,engineered, manufactured, and assembled to the highest of quality standards. This lubesystem requires little or no maintenance, however, to ensure maximum reliability and torealize maximum service life of all components, it’s highly recommended that a weeklywalk-around inspection be performed.

The weekly walk-around inspection should include the following:

• Observe lubricant level in reservoir. Fill reservoir if it is low

• Inspect high pressure relief at pump element, noting any lubricant build-up. If build-up is observed, correct this problem by determining cause of blockage

• Inspect all valve and lube point connections to verify that no leaks are occurringInspect supply/feedlines to insure that no punctures or breaks have occurred sincelast inspection.

• Inspect lube points to insure that all lube points have a "fresh greaseappearance".

• Check pump operation by depressing push-button located in base of pump for 2seconds to initiate a manual lube event. This will verify that pump is working (Ignitionswitch must be on).

• Report or repair any problems found in this walk-around inspection immediately

NOTE: Operator to confirm operation of electric pump while machine is in service

PROGRESSIVE GREASE LUBRICATIONSYSTEM FOR KALMAR

§ Why NLGI 2 greasing system?§ Better sealing

§ Wide temperature range

§ Harder grease stays better inbearings and bushings

§ Lower usage - cleaner machineand environment

Manual lubrication enhancement§ single nipple system§ automated system§ automated system with data logger

Basic solution: Single nipple systemOption A: Pump with timer

Option B: Pump with timer and system monitoring

Single point system principle

• Economical initial system

• Cuts lube service time by 80-90 %

• Improves workers‘ safety

• Easy to automate - just add a pump

SSV divider valve

§ 0,2 cm³ per outlet§ Sizes from SSV6 to SSV22

§ metal-to-metal construction (noseals)§ mechanical or electrical

monitoring capability (option)

Outlet Crossporting

Outlets are combined to increase theamount of lubricant for that outlet:

0.2, 0.4, 0.6 ccm, etc

Lubricant from a plugged outlet is

redirected to the next outlet on thesame side of the block

Do not plug outlets 1 & 2

Pump with controller Divider valves System tubing

KEY COMPONENTS

PUMP P203

Pump element:

4 sizes: K5, K6, K7and adjustable

Circuit board

Power supply versions: 12, 24, 110 and 230v

Pump elements: 1, 2, or 3

Output: 0.6….4ccm / element

Output pressure: Max 350 bar

Op. Temperature: +80°C … -40°C

Pumpable grease: up to NLGI 2 (-25°C)

Protection class: IP54 IP 6K 9K

Reservoir: 2, 4 or 8 l

EN - approval

1 Eccentric pump shaft

2 Piston

2 Return spring

3 Check valve

Suction phase Pumping phase

Pump element

K5 element: 0.122 cu in/min (2.0 ccm/min)

K6 element: 0.171 cu in/min (2.8 ccm/min)

Pump element

1. Pressure relief valve

2. Nipple

3. Pumpelement

12

3

Printed circuit board

Circuit board with ajustablepause and operating time

Circuit board part no 236-13891-1

Pause time setting Operating time setting(lubrication interval) (amount per lube event)

Factory setting: 4 hours Factory setting: 8 minutes

Test button

Range setting:

P=pause timehours (minutes)

I =operating timeminutes (seconds)

Setting: 1 2 3 4 5 6 7 8 9 A B C D E F

Pause time [h]: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Setting: 1 2 3 4 5 6 7 8 9 A B C D E F

Operating time [min]: 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

Power connected Pump operates

Indicator lights

Circuit board part no 236-13891-1

Wiring diagram

Reservoir fill and system check

•Always use a filling nipple (never fillfrom top the 4 and 8 liter vesions)

•P203-pump allows the use of NLGI 2grease up to -25°C

• If grease quality is changed checkgrease compatability with yoursupplier

•Loose the plug and press the testbutton for 2 seconds

• The wiper/blender inside the pumpturns and pump feeds grease

•Verify the operation by looseningone feed line (Note: Wait until pumphas competed the cycle)

System check

Ksuun on ’Ki1011’[H]:\\Yhteis\Doktuot\RSD_kop.doc

ContMaster AssemblyThis instruction is applicable in cases when a Contmaster must be finally assembled on

site after transportation.

Necessary space and devicesIn the assembly there is needed a crane with min. lift capacity of 15 tons.

Necessary amount of lift belts to lift boom, spreader and hoist cylinders and manual wire

hoisters with binding belts to tie hoist cylinders. Additionally there are needed stout stands

and wooden bars to temporarily support boom and spreader, see pictures.

Assembly phases:

1 Fixation of hoist cylinders to the boom

- Set the boom to a sloping position, see pic.1.

- Fix the hoist cylinders to the boom with assistance of the crane. Tie a lift belt to a

cylinder under the hydraulic pipe and making sure the fixation will not slip.

- Lubricate the bearings.

- Tie cylinders to shown position with binding belts & wire hoisters (1) either to the

lugs in the boom front end (A) or around the boom (B), see pic. 1.

1

A

B

1,5

m

14000 kg

700 kg

Pic. 1 Fixation of hoist cylinders to the boom

Be extremely careful during assembly of heavy components


2

- Fix the hoisting belts thus the booms stays in a desired sloping when lifted. Lift with

two hooks (A) or with one (B), see pic. 2.

- Move the cabin to its rear position.

- Lift the boom over the machine. Fix first the rear fastening and then the cylinders.

Note! The both bearing lines of the rear fastening must be in line at the same time

otherwise you cannot slot in the pins. Manual wire hoister connected to binding belt

makes adjusting much easier.

LB + 1,5 m LB

LA

+1

m

LA

14000 kg

A AB

Pic. 2 Assembly of boom + cylinders

- Lubricate all bearings

- Connect the cables and hydraulic lines of boom and cylinders

Be extremely careful in joining the hydraulic couplings to avoid anyimpurities to intrude into the hydraulic system


3 Spreader assembly

- Lift the spreader at least 1,2 m over the ground see pic. 3. (it can be lifted even over

a container)

- Move the reach stacker to meet the spreader and lower the boom to its attachment

points. Note! When the boom is operated before the electrics of spreader aren’t yet

connected, you must use by-pass of hoist prevention (switch S194) and by-pass of

stability control (switch S85)

- Fix the spreader onto the boom

- Lubricate the bearings

- Connect the electric and hydraulic lines of spreader

Min

1,2

m

7600 kg

Pic. 3 Spreader assembly

4 Test drive- Test drive movements of boom and spreader. Make sure there are no leakages in

hydraulic joints.

- Test drive with a container.

Attachment: LIFTING BOOM ASSEMBLY KG6027

SERVICE IS ALWAYS #1

RS 2003 ADD Training Mat

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Transcript of RS 2003 ADD Training Mat