Training MTRL CM 2002 Nueva PDF

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 (96)
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
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
mm
787
787
787
787
power losses
kW
21
21
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
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
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,sttilavuuspumput
Tulostettu 29.10.2002 09:14:01
Tila: DR Nimitys: Hydr. kaavio,peruskone,miniratti
Tulostettu 20.08.2002 08:31:54
Tila: DR Nimitys: Hydr. kaavio,peruskone,sttilavuuspumput
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 C
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 3040 bar open the LSspool and pressure behind

the control piston regulate
the swash plate to zero flow.
Control piston
Bias piston
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
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 cm/min
at 100 bar, oil 50 C and viscosity
30 mm/s (cSt).
Main directional valve M400LS
ContMaster
dont use
Counterpressure
valve and spring
Components front end middle of frame

and diagram is done like mounted
352bar
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 352bar
Pressure reducing
valve #31, 352bar
(Pilot pressure)
Pilot line
pressure
accumulator
gas press.
10 bar
Fast hoist Y87, if

pressure <90bar
and joystick used
Check
valve
#28.2
PM4
1255bar
Main directional valve of ContMaster

from Top View
Forward
Pressure Check point close M400 main

valve of ContMaster
PM5 Steering pressure
PM10 Main
pressure
2105 /30
bar
PM8 Pilot pressure
352 bar
Shuttle valve
#33. LS-signal either
from steering valve
or main directional
valve
Main valve Proportional solenoid valves

DRS ContMaster
Orifice 0,8 mm
B1 leak of rod side
Y51 Boom out (PSL)
Y52 Boom in (PSS)

Y58 Boom Lifting (PL)
Y57 Boom Lowering (PS)
Own weight 95 kg (210 lb)
Hydraulic components front end of DRS

ContMaster
Main directional valve #30
(Lift- and Boom cylinder)
Pressure
accumulator,
Pilot line, #35
Check valve
#28.2
Y87 Fast
Hoist from
Spreader
Check valve #28.1
Priority valve #27

PM8 352bar
Pressure reducing
valve #31, 352bar
(Pilot pressure)
Pilot line
pressure
accumulator
gas press.
10 bar
Fast hoist Y87, if

pressure <90bar
and joystick used
PM10 Main
pressure
210 5 bar
Check
valve
#28.2
PM4
1255bar
DRS ContMaster Pressure sensor location
FWD
Pressure Sensor B6
from Right Lifting
Cylinder Pressure.
Purpose: Fast Hoist and
Reducing lowering
speed
Fast hoist circuit of DRS

ContMaster
Fast Hoist valve #26
(Y87).
Check valve 28.2
Oil to Lift
cylinders
(A2 M400)
PM4
1255 bar
Oil from the Spreader

pump
Pilot restrictor for smooth control, sizes

available from 0,45..1,6 mm diameter
NOTE! If you remove remote

control valve, check those
restrictors when you assembly!
A and B
Pilot
restrictors
Proportional solenoid valve for L90LS,

K220 and M400 directional valves
Pilot restrictor off from remotecontrolled spool actuator
Restrictor mounted. Available different

diameter, marked dots. Note check that
restrictor is with the spool!
Pilot restrictors sizes and marking

NOTE: numbers arent Kalmar numbers
Hydraulic components front end of DRS

ContMaster
Main directional valve #30
(Lift- and Boom cylinder)
Pressure
accumulator,
Pilot line, #35
Check valve
#28.2
Y87 Fast
Hoist from
Spreader
Check valve #28.1
Priority valve #27

PM8 352bar
Pressure reducing
valve #31, 352bar
(Pilot pressure)
Pilot line
pressure
accumulator
gas press.
10 bar
Fast hoist Y87, if

pressure <90bar
and joystick used
PM10 Main
pressure
210 5 bar
Check
valve
#28.2
PM4
1255bar
DRS ContMaster Pressure sensor location
FWD
Pressure Sensor B6
from Right Lifting
Cylinder Pressure.
Purpose: Fast Hoist and
Reducing lowering
speed
Fast hoist circuit of DRS

ContMaster
Fast Hoist valve #26
(Y87).
Check valve 28.2
Oil to Lift
cylinders
(A2 M400)
PM4
1255 bar
Oil from the Spreader

pump
DRS Steering hydraulic diagrams
Right turn
Neutral oil to EF
Left turn
Steering hydraulic diagram Left Turn

situation
Steering valve now

L output position.
Double shock valves
245 bar with anticavitation valves.
Priority valve.
Always steering is
first. When no steering
oil flow from EF gate to
main valve.
Pump #74 155 l/min
LS-signal from steering
valve or main directional
valve
Priority valve of steering hydraulic

DRS ContMaster
Dynamic type 1.2mm
Over pressure
valve 200 bar
EF
LS-signal pressure
Orifice 0,81,2mm
PP-signal
0,8mm
Main hydraulic
CF
Steering
Eaton Steering Hydraulic with

Variable pump
EATON Steering valve

Neutral
Eaton Steering valve

Left Turn
Eaton Steering valve

Right Turn
Eaton Steering valve Neutral

and Right/Left turn
Finger Tip Steering Valve L90LS DRS 2002

Neutral Position
Port relief and/or anticavitation function
Setting pressure,
feed reduction valve
Damping of pressure
compensator
Pilot pressure
supply
Oil from the pump
Pressure compensator
H.Koskinen
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
Pilot restrictor for smooth control, sizes

available from 0,45..1,6 mm diameter
NOTE! If you remove remote

control valve, check those
restrictors when you assembly!
A and B
Pilot
restrictors
Pressure reducing valve #31

for pilot line to main valve
Signal pressure
adjustment
352 bar
Pilot oil to M400
Leakage line
Oil from pumps

#22.1 and 22.3
Pressure reducing valve cut view

and symbol
Pressure reducing valve
DRS ContMaster Lift boom front
A83
MCC2212
Module
X4, F36
DRS ContMaster El box LH-side

front of the boom
A83 MCC2212 MODULE
X4 Junction bar, 120 resistor
Safety
Driving prevented if
low brake system pressure (<
90 bar)
high rpm => no gear
connection (rush start)
high speed => no direction
change accepted
parking brake engaged
De-clutch on the LH side

brake pedal
two circuit system for brakes
A Partek Company
39
Change the flow by turning two valves so that

there is only one output
A Partek Company
Solution
A Partek Company
Cabin transfer hydraulic unit
PM1 120 bar
Oil filling
and breather
Oil volume 2,8 L
Cabin transfer hydraulic unit (2)

E-motor & Hydraulic
pump unit
Y96a and Y96b
210 bar both end

ratio 10:1 (return
flow need 20 bar to
get back)
PS1 100 bar max.
pump pressure
PM1
Cab transfer unit pressure adjust
Pressure relief valve

of max. operating
pressure PS1
1205 bar. When you
adjust pressure, take
off sockets from
directional valve.
Cab transfer double chock valve
Note! Arrow points

downwards and this side facing
towards motor.
Cabin transfer hydraulic unit
PM1 120 bar
Oil filling
and breather
Oil volume 2,8 L
Steering axle, wheel, preload and

side tilt limiter
Max turning is 70. Start
to move use as less as
possible turn!
Mechanic limiter side

way tilt oft he main
frame
Preload of the King
pin bearings START
TO MOVE 150 to
170Nm
Stub Axle Hub Bearing Nuts and Locking

Ring & Preload Instruction
First nut against the bearing
Locking plate
NOTE! Dont use locking
plate twice!
Preload of bearings:
30 - 50 Nm continues rolling
resistance (means about
1000 Nm tightening torque to
FIRST nut but always rolling
resistance is final check)
Locking plate and Second nut
Thread M20 Pointing UP
New steering axle design

Mechanical side tilting
limiter of the frame
New profile of the axle

frame. Strength is
maximize right.
Cylinder rod is covered

with mud cover.
Wet brake cooling oil pressure check

point and orifice 5 mm before
Cooling pressure in
min. 0,5 bar
max. 1,5 bar
Oil cooler of brake cooling return line

from the wheel hub
Lincoln central lube pump and
electric control center
Wet brake cooling oil cooler

before brake oil tank
Brake oil tank with level glas
and temperature gauge
By-bas spring loaded oneway valve 5 bar opening

pressure
Parking brake caliber

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

Pressure Adjustment
min 110 bar
Signal Pressure
Relief to the Tank
System Pressure
A Partek
Company
Brake Pedal Valve

No Function
T
P
T
P
A Partek
Company
Brake Pedal Valve

Full Braking
T
P
T
P
A Partek
Company
Charging-, Parking-, Pressure Relief

Valves and Pressure Filter.
Pressure relief valve
PS22 1605 bar/128bar
Pressure check
point PM26 1605 bar
(Parking brake open)
Charging valve
Parking brake valve

Y12 #3
Filter #5
Load lowering/lock valve(s) DRS ContMaster
Lift cylinder RH side
Breather line from rod side

Lock lowering valve
Line to the directional
valve (P and T)
Solenoid valve Y68(67)
Connection to pressure
switch S79 (fast hoist and
reduced lowering)
DRS Liftcylinder Lock valve

DRS 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

Max internal oil leak at 210 bar 3000 PSI
At 38 cSt 180 SSU 0.33 ml/min (5 drops/ min)
40 Nm
44400o

3/3

5/3
DRS Lift cylinder Lock valve

DRS Nostosylinterin lukkoventtiili
Varo- ja imusuojaosuus Nostosylinterien lukkoventtiileist

Lift cylinder lock valve pressure relief and vacuum preventer
1/1
LOAD LOWERING VALVE
The ratio between control pressure (opening X) and load pressure (opening B) is 1:20.
Free circulation valve #32 Y56 PS4 125 bar

Pressure valves
Figure 1. Pre-controlled pressure limiting valve equipped with a magnet controlled pressure
release, type DBW.
Figure 2. Control-blow baffling plate,

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

direction valve open.
Free circulation valve of the Spreader

function, standard 125 bar
LH-side open
PM4
One way valve #20 5bar
PS4
125bar
Y56
Free circulation
valve #32, Y56 and
pressure relief valve
DRS ContMaster Spreader Hydraulic

Free circulation valve
and instruments
One way valve #20 (5bar)
S72 Temperature switch

for controlling cooler fan
start point is >50 C
PM 4 Spreader pressure
check max 1255 bar
#32 (Y56 and PS4)
Spreader hydraulic Free Circulation Valve

One way valve
#20 5 bar
spring load
1255 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 1255bar
-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 1 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 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 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
Drive speed
(km/h)
Slip relation (%)
OK
BASIC DISPLAY
stability (%)
gear
direction
reach
load
46
3x during 2s
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
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
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
PR9 00% PR10 00%
45
Autom. changer
OK
Send param.
+ kalibrations
OK
DRIVERS
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 45
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 LUBRIFICAO
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
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
PSB5500H
Key components and tubing

Main (master) Divider Valve
Main Supply
Line 8.6x2.3
Secondary
Divider Valve
P203
Pump
Feed line to Lubrication Point

(8.6x2.3 or 6x2)
Lubrication frequency and volume adjustment
Reservoir
Pause time setting switch

(lubrication interval)
Operating time setting switch

(amount per lubrication event)
Test button
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)
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 C (-4 F)
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
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.
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
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, its 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
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 cm 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
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:
+80C -40C
Pumpable grease:
up to NLGI 2 (-25C)
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
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
Pause time [h]: 1
10
11
12
13
14
15
Setting:
Operating time [min]:
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 -25C
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
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.
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
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 arent 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
SERVICE IS ALWAYS #1

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Container attachment cont.

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Air to Air inlet line cooler before Turbo

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LH-side inlet air line from

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DRS ContMaster Electric multi pin

Cummins Engine Company, Inc

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Engine Configuration: D353014CX03

STATUS FOR CURVES AND DATA:

TOLERANCE: Within +/- 5%

Intake Air System:

16.7 delta deg C

Charge Air Cooling System:

Low Temperature Aftercooling System:

*Engine with dry manifold.

Cranking System (Cold Starting Capability)

Water Management Rating Data-(If Applicable)

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Stairs to the cabin

DRS ContMaster covers

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LH-side hydraulic components

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Access to and from

RH-side service door open

DRS ContMaster Service View

Batteries normal location and

Batteries rolled out for checking

DRS ContMaster Main

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Cabin transfer unit