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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

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,sttilavuuspumput

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,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

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 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

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

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

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

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

DRS Liftcylinder Lock valve


DRS Nostosylinterin Lukkoventtiili
3/3

DRS Liftcylinder Lock valve


DRS Nostosylinterin Lukkoventtiili
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
Free circulation valve
#32 (Y56 and PS4)

Spreader hydraulic Free Circulation Valve


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 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

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

SISTEMA DE LUBRIFICAO

SISTEMA DE LUBRIFICAO

SISTEMA DE LUBRIFICAO

SISTEMA DE LUBRIFICAO

SISTEMA DE LUBRIFICAO

SISTEMA DE LUBRIFICAO

SISTEMA DE LUBRIFICAO

SISTEMA DE LUBRIFICAO

SISTEMA DE LUBRIFICAO

SISTEMA DE LUBRIFICAO

SISTEMA DE LUBRIFICAO

SISTEMA DE LUBRIFICAO

SISTEMA DE LUBRIFICAO

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

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

Operating Instructions
Grease Lubrication System for Patria Vammas
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

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

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

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 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

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

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

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

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, 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

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

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

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

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

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

SERVICE IS ALWAYS #1

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