RS 2003 ADD Training Mat

DRS ContMaster Extra Training Material 2002

H. Koskinen 11/2002

DRS ContMaster 2002

Good visibility front Cabin position. Side view is better. More space for maintenance of power train (engine).

DRS ContMaster 2002

DRS ContMaster 2002

DRS ContMaster 2002

Better visibility reversing. Exhaust pipe is far of the cab and hydraulic.

Boom • 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 proximity sensors = smooth operation • floating wear pads on the basic boom • easy replacement • excellent support

• inverted telescopic cylinder A Partek Company

15

Steering axle • Sandwich - type heavy duty design 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 electronic overload system (rear) • mechanical stops to limit the axle oscillation improving lateral stability • spherical plain bearings on pivot points A Partek Company

13

DRS ContMaster Rear view from the cabin

Clark Transmission filters

DRS ContMaster 2002

The Spreader rotation is std with two hydraulic motor

Container attachment cont. • 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/retraction of T-beams • ISO-type floating twistlocks • landing pin with stronger spring and longer move • reliable safety system • pile slope as option A Partek Company

18

DRS ContMaster 2002 service view Front end view of power train and hydraulic pumps. Brake pump. Pressure check points fittings. Main directional valve and priority valve. Pilot pressure valve. Pressure accumulator of pilot circuit. Pressure sensor(s). Parking brake. Transmission check and service points.

DRS ContMaster hydraulic Engine

View from middle of the chassis front of the cabin

All hydraulic pumps are Transmission driven

Main hydraulic valves Steering priority valve Fast Hoist valve Signal pressure valve Pressure sensor(s)

DRS ContMaster Engine bay cover open Engine Scania DI12

Scania DI12 54A Engine LH-side

PRELIMINARY

Industrial & Marine Engines

Technical data and cooling equipment recommendation DI12 54A, order ref. 10-00 This engine complies to exhaust emission Rating regulations Stage 2 EURO and TIER 2 acc. to 1200 USA. 187 (254) Gross power kW (hp) ICFN IFN 187 (254) Gross torque Nm (kpm) ICFN 1488 (152) IFN 1488 (152)

1500

1800

2100

237 (322) 237 (322) 1509 (154) 1509 (154)

240 (326) 240 (326) 1273 (130) 1273 (130)

243 (330) 1105 (113)

Spec. fuel consumption 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)

106

134

155

189

to exhaust gas

134

171

190

230

to surrounding air

22

22

23

25

Engine speed, r/min

g/kWh (g/hph)

Heat rejection to cooling water

kW

Air consumption

kg/min

15

23

28

31

Exhaust flow

kg/min

16

24

29

32

501

427

399

431

Exhaust temperature

°

C

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

dm3/min

360

360

420

420

Puller

Puller

Puller

Puller

Coolant pump flow Fan type Ø

mm

787

787

787

787

power losses

kW

9

9

21

21

1

1

1

1

1:1.08

1:1.08

1:1.08

1:1.08

m3/s

8.5

8.5

9.8

9.8

mm Wc

35

30

35

30

number of drive belts (poly-V) speed ratio Air flow free air flow pressure reserve

© Scania Industrial & Marine Engines

PRELIMINARY

Industrial & Marine Engines

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

260

350 hp

kW x 1.36 = hp

330

240 IFN

ICFN

310

220 290 200

270 250

180

230 160

210 190

140

TORQUE Nm Nm ---------- = kpm 9,81

1700

Max torque 1589 Nm/1400 r/min

170 kpm

1500

150

1300

130 ICFN

1100

110 IFN

250 SPECIFIC FUEL CONSUMPTION g/kWh g ⁄ kWh ------------------ = g ⁄ hph 1,36

IFN

230 ICFN

160

210 190 1200

1400

1600

1800

© Scania Industrial & Marine Engines

180 g/hph

2000

140 2200 r/min

DRS ContMaster Engine bay cover open

Engine QM 11

Air to Air inlet line cooler before Turbo charger of Cummins QSM11 Engine

DSR ContMaster inlet air line inside frame space QSM11 Cummins Engine inlet line

LH-side inlet air line from filter to air/air cooler

RH-side inlet air line from cooler to the Turbo Charger

DRS ContMaster Electric multi pin sockets 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-2000 Emission 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 Torque RPM 700 900 1,000 1,100 1,200 1,400 1,600 1,800 2,000 2,100

lb-ft 800 1,050 1,200 1,235 1,235 1,235 1,083 963 867 825

N-m 1,085 1,424 1,627 1,674 1,674 1,674 1,468 1,306 1,175 1,119

Power Output RPM 700 900 1,000 1,100 1,200 1,400 1,600 1,800 2,000 2,100

hp 107 180 228 259 282 329 330 330 330 330

kW 80 134 170 193 210 245 246 246 246 246

Fuel Consumption RPM 1,400 1,500 1,800 2,000 2,100

lb/hp-hr 0.328 0.32 0.316 0.325 0.33

gm/kW-hr 200 195 192 198 201

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:

Final

TOLERANCE: 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 Maximum allowable air temperature rise over ambient at Intake Manifold (Naturally Aspirated Engines) or Turbo Compressor inlet (Turbo-charged Engines):

140 deg F

60 deg C

30 delta deg F

16.7 delta deg C

3 in-Hg 63 delta deg F 140 deg F

78 mm Hg 35 delta deg C 60 deg C

Charge Air Cooling System: Maximum pressure drop from turbo compressor outlet to intake manifold (IMPD): Maximum Intake Manifold Temperature Differential (Ambient to IMT) (IMTD): Intake Manifold Temperature for Fan-ON:

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): @ 25 deg C (77F) ambient (1P-2L, 2P-2L): Max. coolant temperature from the aftercooler radiator at 25C (77F) ambient: Maximum coolant temperature into aftercooler at Limiting Ambient conditions:

deg F deg F

deg C deg C

deg F

deg C

deg F

deg C

Exhaust System: Maximum exhaust back pressure:

3 in-Hg

76 mm Hg

Lubrication System: Nominal operating oil pressure At minimum low idle: At maximum rated RPM: Minimum engine oil pressure for engine protection devices At maximum rated speed: At minimum low idle:

15 psi 35 psi

103 kPa 241 kPa

28 psi 10 psi

193 kPa 69 kPa

Fuel System: Maximum supply fuel flow: Fuel cooling requirements (with diesel fuel) Maximum heat rejection to return fuel at max. coolant and inlet fuel temperature: At fuel return flow rate of: At fuel return temperature prior to cooler: Maximum return fuel flow: Minimum torque required to hold throttle at full travel ( Mech. System) Engine fuel compatibility (consult Appl. Eng. For appropriate use of low viscosity fuels)

591 lb/hr 260 572 212 572

BTU/min lb/hr deg F lb/hr lb-in DF1, DF2

268 kg/hr 4.57 259 100 259

kW kg/hr deg C kg/hr N-m

Performance Data Engine low idle speed: Maximum low idle speed: Minimum low idle speed: Maximum allowable governor droop: Maximum allowable governor regulation: Maximum no load governed speed: Governor break speed: Maximum torque available at closed throttle low idle speed: Maximum power available from the front of the Crankshaft -Consult Cummins Application Engineer for Information

Cummins Confidential

900 lb-ft

RPM 1,200 RPM 600 RPM % % 2,350 RPM 2,130 RPM 1,220 N-m

FR 2926 Governed Power Engine Speed Output Power Torque Friction Horsepower Intake Manifold Pressure Turbo Comp. Outlet Pressure Turbo Comp. Outlet Temperature Intake Air Flow Charge Air Flow Exhaust Gas Flow Exhaust Gas Temperature Fuel Flow to Pump *Heat Rejection to Coolant Heat Rejection to Aftercooler Coolant (LTA) Heat Rejection to Fuel Heat Rejection to Ambient **Steady State Smoke

330 825 -61 46 49 333 875 62 1,860 745 427 4,800

hp lb-ft hp in-Hg in-Hg deg F ft3/min lb/min ft3/min deg F lb/hr BTU/min BTU/min

220 BTU/min 1,075 BTU/min

2,100 246 1,119 -46 1,165 1,228 167 413 28 878 396.1 194 84.4

Peak Power

RPM kW N-m kW mm Hg mm Hg deg C L/s kg/min L/s deg C kg/hr kW kW

330 963 -45 49 52 337 810 56 1,780 780 360 4,450

3.87 kW 18.9 kW 0.5 Bosch

hp lb-ft hp in-Hg in-Hg deg F ft3/min lb/min ft3/min deg F lb/hr BTU/min BTU/min

165 BTU/min 960 BTU/min

1,800 246 1,306 -33 1,241 1,304 169 382 26 840 416 163 78.25

(Continued) Page: 3 Peak Torque

RPM kW N-m kW mm Hg mm Hg deg C L/s kg/min L/s deg C kg/hr kW kW

329 1,235 -28 56 59 365 710 50 1,750 905 250 4,700

2.9 kW 16.88 kW 0.5 Bosch

hp lb-ft hp in-Hg in-Hg deg F ft3/min lb/min ft3/min deg F lb/hr BTU/min BTU/min

87 BTU/min 1,025 BTU/min

1,400 245 1,674 -21 1,418 1,482 185 335 23 826 485 113 82.65

RPM kW N-m kW mm Hg mm Hg deg C L/s kg/min L/s deg C kg/hr kW kW

1.53 kW 18.02 kW 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: Motoring friction horsepower at minimum cranking speed: Minimum ambient temperature Breakaway torque at minimum unaided cold start temperature using 15W40 oil: Cranking torque at minimum unaided cold start temperature using 15W40 oil: Aided Cold Start Minimum ambient temperature with Grid Heater only Minimum ambient temperature with Ether only: Minimum ambient temperature with coolant and lube heater only:

6 hp 10 deg F

110 RPM 5 kW -12.2 deg C

170 lb-ft

230 N-m

215 lb-ft

292 N-m

-10 deg F -10 deg F 0 deg F

-23 deg C -23 deg C -18 deg C

Emissions Noise Emission: Top Right Side Left Side Front

101.5 103.8 104.5 105

dBa dBa dBa 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 Weight Specific HC Weight Specific CO Weight Specific Particulate

4.5 0.3 2.61 0.15

gm/hp-hr gm/hp-hr gm/hp-hr gm/hp-hr

6 0.4 3.5 0.2

gm/kW-hr gm/kW-hr gm/kW-hr gm/kW-hr

Water Management Rating Data-(If Applicable) Advertised Power Advertised Speed Intake Air Flow Exhaust Gas Flow Heat Rejection to Coolant [Engine] Heat Rejection to Coolant [Aftercooler(s)]

340 hp 810 ft3/min 1,810 ft3/min 4,600 BTU/min BTU/min

End of Report

Cummins Confidential

254 1,800 382 51,253 80.89

kW RPM L/s L/min kW kW

DRS ContMaster LH-side view

Stairs to the cabin Engine air filter with pre cleaner

DRS ContMaster covers open front of the cabin

Drive 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 uncompromised acceleration & speeds in all operating conditions

A Partek Company

22

DRS ContMaster double rotation motors with single gear boxes

DRS ContMaster Boom stand Spreader rotation limit sensor S100 when boom is lifted up OPTION

Back up light and alarm

Weighing position sensor S79 OPTION Exhaust pipe

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

DRS ContMaster 2002

Access to and from the cabin is safe with steps on both sides of the machine

RH-side service door open

DRS ContMaster Service View

Batteries normal location and locked

Batteries “rolled” out for checking and for service

DRS ContMaster Main contactor, Fuses, Cab transfer unit, First version

DRS ContMaster Service Points RH-side view of service space Main contactor (Battery relay)

Cabin transfer unit

Batteries

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

DRS ContMaster RH-side frame Electric box Module A81 MCC2212 XQS2 (Engine plug) PCB of hydraulic function, amplifier and sockets

Finger tip steering valve L90LS

Batteries. Rolling out for service

Inside the main frame, II-version,RH-side, first level in Electric box Wire numbers from Fuses are same as Fuse number is. From Fuse F34 wire number is also 34

Fuses F34, F35 15A F36, F37, F38, F39 and F41 10A F40 25A F42 to F49 are Options A81 MCC2212 MODULE Hydraulic, Cab transfer, Accelerate and Indication light of the spreader

XQS2 Only for Cummins QSM11 for Cummins Service Group

Electric box II-version RH-side lower level 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

DRS ContMaster Electric Maintenance Location: Back wall of the Cabin

Maintenance Key S3. When watching values of input/output from the Display

DRS ContMaster Electric on the cabin rear wall (behind driver) Electric center rear wall of the Cabin Fuses: F10; 11; 12 and 33 are 15A F13 to F32 are 10A Multi pole socket (9pins of each) XR12,XSR,XHR spare wires front panel XR2 spare wires RH-s armrest panel XR3 spare wires from engine XP0 force use panel X44 from AC unit X191 Minirat (FS) SX191 Mini Steering Wheel. SX1 RH-s arm rest panel X22, X37 Front inst.. Panel X21,X31,X35,X95,XE4,X115 From the Frame. XKTJ and X32 from the ceiling XPC from the Display

DRS ContMaster Electric Center in the Cabin on the rear wall Relays, diodes, resistors connectors and rails

A84 CONTROL UNIT MCKC. Input orders from cabin instruments (info position of the cab switches) A82 CONTROL UNIT MCC2212. Engine control, Auto gear,Stab 1/2, Mini steer, Idle stop, Vertical lift, Load scale.

Alarm buzzer

Maintenance key

DRS ContMaster Forced Motion Switches RH-side drivers seat on the back wall S186 S187 S188

S186 Engine Throttle selector 1300 RPM. Switch position 1 S187 First (1) position Engine Power ON. Second (2) position Engine Start. S188 Gear selector Forward or Reverse and II-gear only.

Transformer A12

LOCATION RH-SIDE DRIVER ON THE REAR WALL OF THE CABIN

DRS ContMaster RH-side Joystick and hand panel

Over load by-pass Twist Lock auto or manual closed Automatic T-L Length adjusting selector

Twist Lock By-pass

DRS ContMaster Cabin transfer smooth motion both end position

Cabin transfer Dumping sensors: Forward S97A Reverse S97B Location RH-side Cabin under and inside profile

DRS ContMaster Valve control

L = Lift LTO = Lift Telescope Out LTI = Lift Telescope In TO = Telescope Out CC = Twist Lock Close

TI = Telescope In D = Boom Down DTO = Down +TO DTI = Down+TI

A81:D18 = FCV auto/manu RL = Fast Lift RC = T-Lift Rotate Clockwise RC.= T-Lift Rotate Counter Clockwise

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 2K5692460

Tila: APP Nimitys: Hydr. kaavio,peruskone,säätötilavuuspumput

Tulostettu 29.10.2002 09:14:01

_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 oil cooler of main hydraulic DRS ContMaster Hydraulic cooler (option) on return Spreader circuit #18

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

One way valve #25 for by-bass of the cooler 5 bar

DRS ContMaster LH-side view

-Brake hydraulic tank for brake system and cooling. -Cooler for brake oil 50 ºC fan start running. -Main hydraulic oil tank is separate and normal ISOstandard oil. -Lincoln central lube system is complete Lincoln design.

DRS ContMaster lift cylinder mounting Lift cylinder top bearing service free

Lift cylinder lock valve, pressure signal output and bearing not service free

DRS ContMaster view front of the cabin when it is rear -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.

Hydraulic pumps Clark driven Variable pump #16/98 (PM1) 206 l/min 2100RPM Variable pump #16/74 (PM2) 155 l/min 2100 RPM RH-side

CLARK Brake pump #16, 33 l/min gear type,PM22

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

ENGINE LH-side Variable pump #17/98 (PM3) 206 l/min 2100 RPM

Vickers Displacement Pump PVH Swash Plate (Yoke)

Control Piston, LS - signal pressure reducing the swash plate angle

Pistons

Bias piston

Outlet pressure gauge port, M10 O-ring boss. (plugged)

Vickers displacement hydraulic pump PVH STAND-BY SITUATION

Only 30…40 bar open the LSspool and pressure behind the control piston regulate the swash plate to zero flow. Control piston Bias piston

Vickers displacement hydraulic pump.

Load signal pressure to adjust swash plate angle as in demand. Pump outlet pressure and LS - pressure are balancing Load Sensing Spool and oil volume is ordered level.

Max Pressure Situation

Ls - spool Pressure limiting spool

Vickers displacement hydraulic pump PVH LS - signal pressure is higher level than max pressure limiting spool. Pump outlet oil pressure to adjust swash plate angle to zero as in demand.

RH - side hydraulic pumps Stand-by adjusting screw value 30 bar

PM 2 Stand-by and Max pressure

Steering pump 16/74

Max pressure adjusting screw value 175 ± 5 bar

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

Hoist and Telescope pump 16/98

Directional control valve M400LS. Proportional,load-sensing directional valve Flow rate (recommended) Pump connection 900 l/min. Return from service port 1000 l/min. Max. flow rate to service port 450 l/min (double port each function) Weight 95 kg (210 lb)

First spool Pump connection both side Second spool Leakage from service port to tank From A- or B-port: max. 20 cm³/min at 100 bar, oil 50 °C and viscosity 30 mm²/s (cSt).

Main directional valve M400LS

ContMaster don’t use Counterpressure valve and spring

Components front end middle of frame and diagram is done like mounted 35±2bar

Priority valve of steering Pilot pressure reducing

Right side

Left side Boom

Lift/Low

Fast hoist Y87 from Spreader circuit

Main directional valve (Lift cylinders and Telescoping cylinders)

To steering valve

View from the Cabin and components are like diagram shows

Main directional valve of DRS ContMaster PM8 35±2bar Pressure reducing valve #31, 35±2bar (Pilot pressure) Pilot line pressure accumulator gas press. 10 bar

Fast hoist Y87, if pressure 50 ºC PM 4 Spreader pressure check max 125±5 bar Free circulation valve #32 (Y56 and PS4)

Spreader hydraulic Free Circulation Valve Free circulation valve One way valve #20 5 bar spring load 125±5 bar

Free flow spool Pressure relief valve PS4 Y56

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 GEAR MOUNTING PLACE

Rotating - Tilting - Damping/Locking valves end of the Boom

Rotating, Tilting and Locking/Damping Location Front end of the Boom Damping or Locking valve Y63

Tilting valve Y65 a/b

Rotating Y59a/b

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

Boom valves adjustment PM9

One way restrictor valves both side (dumping)

175± bar both side

One way restrictor valves both side (dumping)

COUNTERBALANCE VALVE 0 to 120 L/min Nominal Series 2 Cartridge T-2A Cavity Installation Torque 60 to 65 Nm Turn screw clockwise to reduce setting and release load. Complete adjustment range in 3 turns.

Rotate, Tilt and Locking valves end of the the boom

SPREADER SIDE SHIFT ADJUSTMENT Relief valves setting (150 bar) -adjust main relief valve #85 to 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 Y62

SPREADER LENGTH, SHORT, TWIST LOCK VALVES TOP OF THE SPREADER RH SIDE Lengthening Shortening Valves

Adjusting screws (100 bar)

Twist Locks valve

Twistlock Counterpressure valves T-beam of the spreader Counterbalance valve setting 100 bar Open locking nut anti clockwise Turn screw fully open clockwise. Adjust 1¾ turns anti clockwise. Lock the adjusting screw with lock nut.

Top-Lift length sensors

30’ position sensor

Note at least one have to be activated until twistlock start operating

20’ and 40’ position sensor

Landing pin sensors (4 Pcs)

Landing pin every corner. All 4 are connected series and all of them must be activated until twistlock open or close operation is possible.

Twist lock Sensors end of T-bems Twist lock cylinder Sensor of Twist lock close (one each end of the Spreader

Sensor of Twist lock open (one each end of the Spreader).

Spreader rotation limit sensors

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

CONTROL MODULE, GENERAL INFO Module get spare parts number after programming Multipole connectors

When you weld - unplug connectors when power is turn off. When plug in power must be off.

All terminals are marked and short description beside each plug ( input, output, GND, Power, CAN Low - High Shield and Ref Out

MCC2212 Module LED-indicator lights 24 V out pin no 36

24 V out pin 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 out pin 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

Module MCC2212

Module is used when current control is necessary

Drivers Displays and Maintenance Displays

Maintenance display selector

Scrolling of displays

Return first “page” and Setting of automatic gear

Displays. Following picture there are all the displays. The text can be 13 languages 0.1

0.2

Kalmar tai machine type

Load parameters OK

1

2

Drive speed (km/h) Slip relation (%)

OK

BASIC DISPLAY stability (%) gear direction reach load

46

A

3x during 2s

M

M 3

10 4

39

Engine (rpm) Gear (rpm) Module A81 Can comm. : 0

18

Module A82 Can comm. : 0

26

Module A83 Can comm. : 0

34

OK

OK

OK

48

OK

Module A84 Can comm. : 0

40

Engine water (°C)

OK

Calibrate Stability 1

49

OK

5

11

DI 123456789012 000000000000

19

DI 123456789012 000000000000

27

12

A1 0.00 A2 0.00 A3 0.00 A4 0.00

20

A1 0.00 A2 0.00 A3 0.00 A4 0.00

13

A5 0.00 A6 0.00 A7 0.00 A8 0.00

14

DO 123456789012 000000000000

Engine oil (bar)

DI 123456789012 000000000000

35

28

A1 0.00 A2 0.00 A3 0.00 A4 0.00

36

DI 345678 A 000000

21

A5 0.00 A6 0.00 A7 0.00 A8 0.00

29

A5 0.00 A6 0.00 A7 0.00 A8 0.00

37

DI 123456789012 29 B 000000000000

22

DO 123456789012 000000000000

30

DO 123456789012 000000000000

38

DI 345678 B 000000

6 Operating hours

7

Container counter

15

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

23

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

24

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

31

16

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

32

OK

41

42

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

Calibrate Stability 2

Language OK

17

PR9 00% PR10 00%

25

PR9 00% PR10 00%

33

9

PR9 00% PR10 00%

45

Autom. changer

OK

Send param. + kalibrations OK

DRIVER’S DISPLAY

SERVICE DISPLAYS

41.1 41.2 41.3

51

52

42.1 42.2 42.3

ENGINE WATER TOO HOT

56

ENGINE OIL PRESSURE LOW

F/R SELECTED

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 CAN ENGINE ERROR ENGINE TEMPERATURE

IDLING ENGINE SHUTS OFF

STEERING AXLE OVERLOAD

ENGINE TEMPERATURE LOW

SHUT OFF DELAY

43.1 43.2 43.3 43.4 43.5 44.1 44.2 44.3 44.4 44.5 44.6 44.7

EMERGENCY STOP PRESSED

66 67

53

OK

44

50

55

Calibrate Pressure weighing OK

43

40.1 40.2 40.3

Calibrate accel. OK

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

8 Autom. gripping

DI 123456789012 A 000000000000

47

Calibration Are you sure?

DIRECTION CHOSEN DOES NOT START

54

HAND BRAKE

ENGINE WATER LEVEL TOO LOW

44.8 44.9 44.10 44.11 44.12 44.13 44.14

68

ERROR OIL PRESSURE ERROR ENGINE RPM

69

ERROR ENGINE

70

ERROR ENGINE _____________

71

ERROR A312

72

LOW BRAKE PRESSURE

45.1

ALARMS

CRITICAL ALARMS

22.11.02

Version management There is only one (the latest) version of each module program in use. The list of parameters is in practice 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 printpage. From the parameters-page the parameters will be changed and sent. Up in G1-cell there is a Send-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 not successful. The sending time of the parameters comes always visible to Time-field. After loading of parameters it shall be made reset, that the changes will become valid. If the sent parameters are not between the defined limits, it comes a message Sending not successful and wrong parameter and the number of it. Of the boom movements there is a graph. The x-axle of the graph there is the handle position in percents and the y-axle is the control value of propo in current mA. The graphs are 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 seen the parameter numbers (co-ordinates) used in definition. From the print-page it is not allowed to change the parameters because they have been linked to it from parameters-page. The print-page is presented in the figure below. These parameters should be changed only: Machine type Language versions Options Engine selection: Scania=1, Cummins=2 If it is needed to change other parameters Excell needs password, which is restricted. Protection is unprotected in this way: Tools->Protection->Unprotect sheet and password. After that protection should be set: Tools->Protection->Protect sheet and password.

56(62)

22.11.02

57(62)

22.11.02

In IO-program to the point of Display Parameters it will come date and time of the latest loading of parameters (on the display). The value of Module A81, Module A82 and Module A83 -field is the version 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 later use. In IO-program the propo-outputs can be seen in percents and milliamperes (accuracy 4mA). Digital inputs 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 it will be updated all the time. Reach tells the reach in accuracy of deci-meters. The stability point tells stability at the moment in question in accuracy of one percent without average calculation; the reading is not limited to 100% as it is on the display. The angle is shown in accuracy of one degree. 59(62)

CONTROL MODULE CONNECTORS, EXAMPLE One example: X6 X6.5 DO7 165 Y96A Cabin Forward X6 = Multipole plug #6 5 = Pin number of X6 DO7 = Digital output 0 or 24 V 165 = wire number Y96A Cabin Forward to the cylinder rod end Wire nro 165 shows: 1 means last module nro (A81) = 1 Wires are screw mounted 6 means multipole connector nro (6) to multipole connectors 5 means pin number of connector

Telescoping end positions damping sensors Front end of the boom RH-side are damping sensors

S80 Dumping sensor in

Boom in damping A83_DI11

S81 Dumping sensor out, no function if load is >15000 kg

Boom out damping DI12

Boom front sliders adjustment Front sliders are laterally adjustable (2 screw both side). When you adjust, check that there is enough space through full stroke 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 in the cabin pocket.

FRONT END SLIDERS OF THE BOOM Support of slider

8 w 45º Bottom shape New Minimum level wearing surface

Boom Reach Cylinder Mounting

Cylinder can float inside mounting bracket

Sleeves are 1 mm longer than cylinder flange

SLIDERS OF THE SPREADER Sliders of the T-beam. Around inner end of Tbeam.

T-beam

Spreader Frame Sliders of the Spreader Frame. Around of outer end.

Spreader Carriage- and Support Beam with Side Shift Sliders Spreader Carriage

Side shift cylinder

Side sliders 8 PCs

Support beam 2 PCs and side shift sliders 4 PCs

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

SISTEMA DE LUBRIFICAÇÃO

Operating Instructions Grease Lubrication System for Patria Vammas PSB5500H

QUICKLUB MOBILE CHASSIS LUBRICATION SYSTEM

Operating instructions PSB5500H/ 06.09.01/ml

Subject to change without notice

LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗

1

Operating Instructions Grease Lubrication System for Patria Vammas PSB5500H

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 the lubrication 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 are described in the following Owner Manuals that are available: Manual Name Quicklub Pump model 203 Quicklub, Progressive Metering Devices for Oil and Grease Printed Circuit Board for Pump 203 Quicklub Parts Catalogue

Manual number 2.1A-30001-C99 2.2A-10001-C99 2.6A-20002-C00 2.0A-20001-E00

For technical service contact Lincoln customer service at: LINCOLN One Lincoln Way St. Louis, MO 63120-1478 Phone 314-679-4200 Fax 314-679-4359 www.lincolnindustrial.com

Operating instructions PSB5500H/ 06.09.01/ml

Subject to change without notice

LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗

2

Operating Instructions Grease Lubrication System for Patria Vammas PSB5500H

Key components and tubing Main (master) Divider Valve Main Supply Line Ø8.6x2.3

Secondary Divider Valve

P203 Pump

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

Lubrication frequency and volume adjustment

Reservoir

Pause time setting switch (lubrication interval)

Operating time setting switch (amount per lubrication event)

Test button

Operating instructions PSB5500H/ 06.09.01/ml

Subject to change without notice

LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗

3

Operating Instructions Grease Lubrication System for Patria Vammas PSB5500H

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 instructions PSB5500H/ 06.09.01/ml

Subject to change without notice

LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗

4

Operating Instructions Grease Lubrication System for Patria Vammas PSB5500H

Reservoir filling • • • •

Always fill through the filling nipple. The best practice is to use standard refinery drums or 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 grease fitting attached on the pressure relive valve. Alternatively by attaching a manual fitting on a divider valve will make manual greasing possible. Pressure relief valve with a by-pass fitting

Filling nipple

Operating instructions PSB5500H/ 06.09.01/ml

Subject to change without notice

LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗

5

Operating Instructions Grease Lubrication System for Patria Vammas PSB5500H

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 the pump the left side LED is lit.

When the pump operates the right side LED is lit.

Operating instructions PSB5500H/ 06.09.01/ml

Subject to change without notice

LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗

6

Operating Instructions Grease Lubrication System for Patria Vammas PSB5500H

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 pump element 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 (350 bar). Since the system piping will hold the pressure after the pump has stopped the blockage can be detected by carefully loosing the supply line fittings between the main valve and secondary valves (A, B, C). If necessary use manual grease gun to apply more pressure 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 opening lubrication feed lines. A

B C

Feed lines

Operating instructions PSB5500H/ 06.09.01/ml

Subject to change without notice

LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗

7

Operating Instructions Grease Lubrication System for Patria Vammas PSB5500H

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 lube system requires little or no maintenance, however, to ensure maximum reliability and to realize maximum service life of all components, it’s highly recommended that a weekly walk-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 buildup is observed, correct this problem by determining cause of blockage

•

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

• •

Inspect lube points to insure that all lube points have a "fresh grease appearance". Check pump operation by depressing push-button located in base of pump for 2 seconds to initiate a manual lube event. This will verify that pump is working (Ignition switch 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

Operating instructions PSB5500H/ 06.09.01/ml

Subject to change without notice

LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗

8

PROGRESSIVE GREASE LUBRICATION SYSTEM FOR KALMAR

§ Why NLGI 2 greasing system? § Better sealing § Wide temperature range § Harder grease stays better in bearings and bushings § Lower usage - cleaner machine and environment

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

Basic solution: Single nipple system Option 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 (no seals) mechanical or electrical monitoring capability (option)

Outlet Crossporting Outlets are combined to increase the amount 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 the same side of the block

Do not plug outlets 1 & 2

KEY COMPONENTS

Ÿ Ÿ Ÿ

Pump with controller Divider valves System tubing

PUMP P203 Power supply versions: 12, 24, 110 and 230v

Circuit board

Pump element:

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

4 sizes: K5, K6, K7 and adjustable

Pump element

Suction phase

Pumping phase

1 Eccentric pump shaft

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

2 Piston 2 Return spring

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

3 Check valve

Pump element

1 2

3

1. Pressure relief valve 2. Nipple 3. Pumpelement

Printed circuit board Circuit board with ajustable pause 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

Range setting: P=pause time hours (minutes) I =operating time minutes (seconds)

Setting:

Test button

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

Indicator lights

Power connected

Pump operates

Circuit board part no 236-13891-1

Wiring diagram

Reservoir fill and system check

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

•Loose the plug and press the test button for 2 seconds

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

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

• If grease quality is changed check grease compatability with your supplier

•Verify the operation by loosening one feed line (Note: Wait until pump has competed the cycle)

System check

ContMaster Assembly This instruction is applicable in cases when a Contmaster must be finally assembled on site after transportation. Necessary space and devices In 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.

-

14000 kg

A 700 kg 1

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

1,5 m

B

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.

A

A

B LB

LA+1 m

LA

LB + 1,5 m

14000 kg

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 any impurities 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

-

-

M in 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

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

SERVICE IS ALWAYS #1