Download - 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
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
Cummins Confidential
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
Cummins Confidential
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
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_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
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
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
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
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 Liftcylinder Lock valveDRS Nostosylinterin Lukkoventtiili 3/3
DRS Liftcylinder Lock valveDRS Nostosylinterin Lukkoventtiili 5/3
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.
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
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
Module A82Can comm. : 0
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
Module A83Can comm. : 0
Module A84Can comm. : 0
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
SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO
SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO
SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO
SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO
SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO
SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO
SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO
SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO
SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO
SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO
SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO
SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO
SISTEMA DE LUBRIFICAÇÃOSISTEMA DE LUBRIFICAÇÃO
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
Operating InstructionsGrease Lubrication System for Patria VammasPSB5500H
Operating instructions PSB5500H/ 06.09.01/ml Subject to change without notice 2LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗
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
Operating InstructionsGrease Lubrication System for Patria VammasPSB5500H
Operating instructions PSB5500H/ 06.09.01/ml Subject to change without notice 3LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗
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
Operating InstructionsGrease Lubrication System for Patria VammasPSB5500H
Operating instructions PSB5500H/ 06.09.01/ml Subject to change without notice 4LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗
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)
Operating InstructionsGrease Lubrication System for Patria VammasPSB5500H
Operating instructions PSB5500H/ 06.09.01/ml Subject to change without notice 5LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗
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
Operating InstructionsGrease Lubrication System for Patria VammasPSB5500H
Operating instructions PSB5500H/ 06.09.01/ml Subject to change without notice 6LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗
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.
Operating InstructionsGrease Lubrication System for Patria VammasPSB5500H
Operating instructions PSB5500H/ 06.09.01/ml Subject to change without notice 7LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗
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
Operating InstructionsGrease Lubrication System for Patria VammasPSB5500H
Operating instructions PSB5500H/ 06.09.01/ml Subject to change without notice 8LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗
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
Ksuun on ’Ki1011’[H]:\\Yhteis\Doktuot\RSD_kop.doc
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
Ksuun on ’Ki1011’[H]:\\Yhteis\Doktuot\RSD_kop.doc
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