Hình ảnh DRS 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 (9’6”)
• made to last =welds on the
neutral axle
• rollers for inner boom
• low friction =>less power
needed = fuel economy
• end damping with proximity
sensors = smooth operation
• floating wear pads on the
basic boom
• easy replacement
• excellent support
• inverted telescopic cylinder
A Partek Company 15
Steering axle
• Sandwich - type heavy duty
design made to last
• same for 25 and 33 tires
• basic model without brakes
• disc brakes only as option for
33 tire models
• built-in gauge for electronic
overload system (rear)
• mechanical stops to limit the
axle oscillation improving
lateral stability
• spherical plain bearings on
pivot points
A Partek Company 13
DRS ContMaster
Rear view from the cabin Clark Transmission filters
DRS ContMaster 2002
The Spreader rotation

is std with two
hydraulic motor
Container attachment cont.
• automatic twistlocking std.
• std. positions 20’ and 40’
• proportionally controlled
rotation +200 / -100 degrees
• side shift +/- 800 mm
• +/- 5 degree free tilting
• forward/backward tilt as std.
• Separate extension/retraction
of T-beams
• ISO-type floating twistlocks
• landing pin with stronger
spring and longer move
• reliable safety system
• pile slope as option
A Partek Company 18
DRS ContMaster 2002 service view
Front end view of
power train and
hydraulic pumps.
Brake pump.
Pressure check points
fittings. Main
directional valve
and priority valve.
Pilot pressure valve.
Pressure accumulator
of pilot circuit.
Pressure sensor(s).
Parking brake.
Transmission check
and service points.
DRS ContMaster hydraulic
Engine
View from middle of the
chassis front of the cabin
All hydraulic pumps

are Transmission
driven
Main hydraulic valves

Steering priority valve
Fast Hoist valve
Signal pressure valve
Pressure sensor(s)
DRS ContMaster Engine bay
cover open
Engine Scania DI12

Scania DI12 54A Engine LH-side
Industrial & Marine Engines PRELIMINARY
Technical data and cooling equipment recommendation
DI12 54A, order ref. 10-00
This engine complies to exhaust emission Engine speed, r/min
Rating
regulations Stage 2 EURO and TIER 2
acc. to 1200 1500 1800 2100
USA.
Gross power kW (hp) ICFN 187 (254) 237 (322) 240 (326) -
IFN 187 (254) 237 (322) 240 (326) 243 (330)
Gross torque Nm (kpm) ICFN 1488 (152) 1509 (154) 1273 (130) -
IFN 1488 (152) 1509 (154) 1273 (130) 1105 (113)
Spec. fuel consumption g/kWh (g/hph)
full load 195 (143) 195 (143) 203 (149) 220 (162)
3/4 load 200 (147) 199 (146) 211 (155) 233 (171)
1/2 load 203 (149) 205 (151) 220 (162) 242 (178)
Heat rejection kW
to cooling water 106 134 155 189
to exhaust gas 134 171 190 230
to surrounding air 22 22 23 25
Air consumption kg/min 15 23 28 31
Exhaust flow kg/min 16 24 29 32
Exhaust temperature °
C 501 427 399 431
ICFN, 1800 r/min IFN, 2100 r/min

Air-on temp. Air-on temp.
35 °C 50 °C 35 °C 50 °C
Radiator
front area m2 1.0 1.0 1.0 1.0
weight kg 55 55 55 55
Coolant pump flow dm3/min 360 360 420 420
Fan
type Puller Puller Puller Puller
Ø mm 787 787 787 787
power losses kW 9 9 21 21
number of drive belts (poly-V) 1 1 1 1
speed ratio 1:1.08 1:1.08 1:1.08 1:1.08
Air flow
free air flow m3/s 8.5 8.5 9.8 9.8
pressure reserve mm Wc 35 30 35 30
© Scania Industrial & Marine Engines

Industrial & Marine Engines PRELIMINARY
DI12 54A, order ref. 10-00 (optimized for Clark 36000 transmission)
OUTPUT 260
350 hp
kW
kW x 1.36 = hp 330
240
IFN
ICFN
310
220
290
200 270
250
180
230
160
210
140 190
Max torque
TORQUE 1700 1589 Nm/1400 r/min 170 kpm
Nm
Nm
1500 150
---------- = kpm
9,81
1300 130
1100 ICFN 110

IFN
250
180 g/hph
SPECIFIC FUEL IFN
230
CONSUMPTION ICFN 160
g/kWh 210
g ⁄ kWh
------------------ = g ⁄ hph 140
1,36 190
1200 1400 1600 1800 2000 2200 r/min
© Scania Industrial & Marine Engines

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 RH-side inlet air line from cooler
filter to air/air 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 lb-ft N-m
700 800 1,085
900 1,050 1,424
1,000 1,200 1,627
1,100 1,235 1,674
1,200 1,235 1,674
1,400 1,235 1,674
1,600 1,083 1,468
1,800 963 1,306
2,000 867 1,175
2,100 825 1,119
Power Output
RPM hp kW
700 107 80
900 180 134
1,000 228 170
1,100 259 193
1,200 282 210
1,400 329 245
1,600 330 246
1,800 330 246
2,000 330 246
2,100 330 246
Fuel Consumption
RPM lb/hp-hr gm/kW-hr
1,400 0.328 200
1,500 0.32 195
1,800 0.316 192
2,000 0.325 198
2,100 0.33 201
Curves shown above represent gross engine performance capabilities obtained and corrected in accordance with SAE J1995 conditions
of 29.61 in. Hg(100 kPa) barometric pressure [300ft.(91m) altitude] 77F (25 C) inlet air temperature, and 0.30 in Hg (1kPa) water vapor
pressure with No.2 diesel fuel. The engine may be operated up to 12,000 ft (3,657.6 m) altitude before electronic derate is applied.
STATUS FOR CURVES AND DATA: Final CHIEF ENGINEER:

TOLERANCE: Within +/- 5% Richard D Johnston
Cummins Confidential
FR 2926 (Continued) Page: 2
Intake Air System:

Intake Manifold Temperature at 25 deg C (77 F) Ambient 140 deg F 60 deg C
Maximum allowable air temperature rise over ambient at Intake Manifold
(Naturally Aspirated Engines) or Turbo Compressor inlet (Turbo-charged
Engines): 30 delta deg F 16.7 delta deg C
Charge Air Cooling System:

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

Coolant temperature from the Aftercooler Radiator outlet
(for LTA system with 1 Pump - 2 Loop or 2 Pump - 2 Loop):
@ Maximum engine coolant out temperature at Limiting Ambient
Temperature (1P-2L): deg F deg C
@ 25 deg C (77F) ambient (1P-2L, 2P-2L): deg F deg C
Max. coolant temperature from the aftercooler radiator at 25C (77F)
ambient: deg F deg C
Maximum coolant temperature into aftercooler at Limiting Ambient
conditions: 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: 15 psi 103 kPa
At maximum rated RPM: 35 psi 241 kPa
Minimum engine oil pressure for engine protection devices
At maximum rated speed: 28 psi 193 kPa
At minimum low idle: 10 psi 69 kPa
Fuel System:
Maximum supply fuel flow: 591 lb/hr 268 kg/hr
Fuel cooling requirements (with diesel fuel)
Maximum heat rejection to return fuel at max. coolant and inlet fuel temperature: 260BTU/min 4.57 kW
At fuel return flow rate of: 572lb/hr 259 kg/hr
At fuel return temperature prior to cooler: 212deg F 100 deg C
Maximum return fuel flow: 572lb/hr 259 kg/hr
Minimum torque required to hold throttle at full travel ( Mech. System) lb-in N-m
Engine fuel compatibility (consult Appl. Eng. For appropriate use of low viscosity fuels) DF1, DF2
Performance Data
Engine low idle speed: RPM
Maximum low idle speed: 1,200 RPM
Minimum low idle speed: 600 RPM
Maximum allowable governor droop: %
Maximum allowable governor regulation: %
Maximum no load governed speed: 2,350 RPM
Governor break speed: 2,130 RPM
Maximum torque available at closed throttle low idle speed: 900 lb-ft 1,220 N-m
Maximum power available from the front of the Crankshaft --
Consult Cummins Application Engineer for Information
FR 2926 (Continued) Page: 3
Governed Power Peak Power Peak Torque
Engine Speed 2,100 RPM 1,800 RPM 1,400 RPM
Output Power 330 hp 246 kW 330 hp 246 kW 329 hp 245 kW
Torque 825 lb-ft 1,119 N-m 963 lb-ft 1,306 N-m 1,235 lb-ft 1,674 N-m
Friction Horsepower -61 hp -46 kW -45 hp -33 kW -28 hp -21 kW
Intake Manifold Pressure 46 in-Hg 1,165 mm Hg 49 in-Hg 1,241 mm Hg 56 in-Hg 1,418 mm Hg
Turbo Comp. Outlet Pressure 49 in-Hg 1,228 mm Hg 52 in-Hg 1,304 mm Hg 59 in-Hg 1,482 mm Hg
Turbo Comp. Outlet Temperature 333 deg F 167 deg C 337 deg F 169 deg C 365 deg F 185 deg C
Intake Air Flow 875 ft3/min 413 L/s 810 ft3/min 382 L/s 710 ft3/min 335 L/s
Charge Air Flow 62 lb/min 28 kg/min 56 lb/min 26 kg/min 50 lb/min 23 kg/min
Exhaust Gas Flow 1,860 ft3/min 878 L/s 1,780 ft3/min 840 L/s 1,750 ft3/min 826 L/s
Exhaust Gas Temperature 745 deg F 396.1 deg C 780 deg F 416 deg C 905 deg F 485 deg C
Fuel Flow to Pump 427 lb/hr 194 kg/hr 360 lb/hr 163 kg/hr 250 lb/hr 113 kg/hr
*Heat Rejection to Coolant 4,800 BTU/min 84.4 kW 4,450 BTU/min 78.25 kW 4,700 BTU/min 82.65 kW
Heat Rejection to Aftercooler BTU/min kW BTU/min kW BTU/min kW
Coolant (LTA)
Heat Rejection to Fuel 220 BTU/min 3.87 kW 165 BTU/min 2.9 kW 87 BTU/min 1.53 kW
Heat Rejection to Ambient 1,075 BTU/min 18.9 kW 960 BTU/min 16.88 kW 1,025 BTU/min 18.02 kW
**Steady State Smoke 0.5 Bosch 0.5 Bosch 1 Bosch
*Engine with dry manifold.

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

Unaided Cold Start
Minimum cranking speed: 110 RPM
Motoring friction horsepower at minimum cranking speed: 6 hp 5 kW
Minimum ambient temperature 10 deg F -12.2 deg C
Breakaway torque at minimum unaided cold start temperature using
15W40 oil: 170 lb-ft 230 N-m
Cranking torque at minimum unaided cold start temperature using
15W40 oil: 215 lb-ft 292 N-m
Aided Cold Start
Minimum ambient temperature with Grid Heater only -10 deg F -23 deg C
Minimum ambient temperature with Ether only: -10 deg F -23 deg C
Minimum ambient temperature with coolant and lube heater only: 0 deg F -18 deg C
Emissions
Noise Emission:
Top 101.5 dBa
Right Side 103.8 dBa
Left Side 104.5 dBa
Front 105 dBa
Estimated Free Field Sound Pressure Level at 3.28ft. (1m) and Full-Load Governed Speed
(Excludes Noise from Intake, Exhaust, Cooling System and Driven Components)
Gaseous Emissions Limits per ISO 8178, are equal to or less than:
Weight Specific Nox 4.5 gm/hp-hr 6 gm/kW-hr
Weight Specific HC 0.3 gm/hp-hr 0.4 gm/kW-hr
Weight Specific CO 2.61 gm/hp-hr 3.5 gm/kW-hr
Weight Specific Particulate 0.15 gm/hp-hr 0.2 gm/kW-hr
Water Management Rating Data-(If Applicable)

Advertised Power 340 hp 254 kW
Advertised Speed 1,800 RPM
Intake Air Flow 810 ft3/min 382 L/s
Exhaust Gas Flow 1,810 ft3/min 51,253 L/min
Heat Rejection to Coolant [Engine] 4,600 BTU/min 80.89 kW
Heat Rejection to Coolant [Aftercooler(s)] BTU/min kW
End of Report
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 un-

compromised 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
Weighing position
Back up sensor S79
light and OPTION
alarm
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 Batteries “rolled” out for checking

locked 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 XQS2 Only for Cummins QSM11
light of the spreader 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 TI = Telescope In A81:D18 = FCV auto/manu

LTO = Lift Telescope Out D = Boom Down RL = Fast Lift
LTI = Lift Telescope In DTO = Down +TO RC = T-Lift Rotate Clockwise
TO = Telescope Out DTI = Down+TI RC.= T-Lift Rotate Counter Clockwise
CC = Twist Lock Close
N:o 3K5692470 Tila: APP Nimitys: Hydr. kaavio, Jarrut
Tulostettu 20.08.2002 08:37:23

_PRELIMINARY N:o 3K5698320 Tila: DR Nimitys: HYDR. KAAVIO ,TARTTUJA
Tulostettu 20.08.2002 08:33:50

N:o 2K5692460 Tila: APP Nimitys: Hydr. kaavio,peruskone,säätötilavuuspumput
Tulostettu 29.10.2002 09:14:01
_PRELIMINARY N:o 2K5698240 Tila: DR Nimitys: Hydr. kaavio,peruskone,miniratti
Tulostettu 20.08.2002 08:31:54

_PRELIMINARY N:o 2K5698310 Tila: DR Nimitys: Hydr. kaavio,peruskone,säätötilavuuspumput
Tulostettu 20.08.2002 08:28:37

N:o 3K5688040 C Tila: APP Nimitys: HYDR. KAAVIO ,TARTTUJA
Tulostettu 20.08.2002 08:35:52

LH-side hydraulic components
-Filter
-Cooler
-Pressure accumulators
-Valves
-Test points
Hydraulic oil cooler of main hydraulic
DRS ContMaster
Hydraulic cooler (option)
on return Spreader circuit
#18
One way valve # 20 for

back pressure 5 bar
Fill up dumping cylinders
One way valve #25 for

by-bass of the cooler
5 bar
DRS ContMaster LH-side view
-Brake hydraulic tank for

brake system and cooling.
-Cooler for brake oil 50 ºC
fan start running.
-Main hydraulic oil tank is
separate and normal ISO-
standard oil.
-Lincoln central lube sys-
tem is complete Lincoln
design.
DRS ContMaster lift cylinder
mounting
Lift cylinder lock valve, pressure
signal output and bearing not
Lift cylinder top bearing service free 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
ENGINE
Brake pump
#16, 33 l/min
gear type,PM22 LH-side
Variable pump
#17/98 (PM3) 206
Intra vane pump l/min 2100 RPM
#67 (PM4), 142 l/min 2100 RPM
(oil to the Spreader)
Vickers Displacement Pump PVH
Swash Plate (Yoke)
Control Piston, LS - signal
pressure reducing the swash plate angle
Pistons
Bias piston
Outlet pressure gauge port, M10

O-ring boss. (plugged)
Vickers displacement
hydraulic pump PVH
STAND-BY SITUATION
Only 30…40 bar open the LS-

spool 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 Vickers displacement

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
Max pressure adjusting screw
Stand-by adjusting screw
value 175 ± 5 bar
value 30 bar
PM 1
Stand-by 30bar
and max
PM 2
pressure
Stand-by
210 ± 5bar
and
Max pressure
Steering Hoist and

pump Telescope
16/74 pump
16/98
Directional control valve M400LS.
Proportional,load-sensing directional valve
Flow rate (recommended) Pump connection 900 l/min. Return from service port
1000 l/min. Max. flow rate to service port 450 l/min (double port each function)
Weight 95 kg (210 lb)
First spool
Pump connection both side
Second spool
Leakage from service port to tank

From A- or B-port: max. 20 cm³/min
at 100 bar, oil 50 °C and viscosity
30 mm²/s (cSt).
Main directional valve M400LS
ContMaster
don’t use
Counterpressure
valve and spring
Components front end middle of frame
and diagram is done like mounted
35±2bar Priority valve of steering
Pilot pressure reducing
Right
Left side
Boom side
Lift/Low
Main directional valve To steering

Fast hoist
(Lift cylinders and valve
Y87 from
Spreader Telescoping cylinders)
circuit
View from the Cabin and components are like diagram shows
Main directional valve of DRS ContMaster
PM8 35±2bar
Pressure reducing
valve #31, 35±2bar
(Pilot pressure)
Pilot line
pressure
accumulator
gas press. Fast hoist Y87, if
10 bar pressure <90bar
and joystick used
Check
valve PM4
#28.2 125±5bar
Main directional valve of ContMaster
from Top View
Forward
Pressure Check point close M400 main
valve of ContMaster
PM5 Steering pressure
PM10 Main
pressure
210±5 /30
bar Shuttle valve
#33. LS-signal either
from steering valve
PM8 Pilot pressure or main directional
35±2 bar valve
Main valve Proportional solenoid valves
DRS ContMaster
Orifice Ø 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,
Check valve Pilot line, #35
#28.2
Y87 Fast
Hoist from
Spreader
Check valve #28.1 Priority valve #27

PM8 35±2bar
Pressure reducing
valve #31, 35±2bar
(Pilot pressure)
Pilot line
pressure
accumulator
and joystick used
Check
PM10 Main valve PM4
pressure #28.2 125±5bar
210 ±5 bar
DRS ContMaster Pressure sensor location
Pressure Sensor B6
from Right Lifting
Cylinder Pressure.
Purpose: Fast Hoist and
FWD 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
125±5 bar
Oil from the Spreader

pump
Pilot restrictor for smooth control, sizes
available from 0,45…..1,6 mm diameter
A and B
Pilot
NOTE! If you remove remote
restrictors
control valve, check those
restrictors when you assembly!
Proportional solenoid valve for L90LS,
K220 and M400 directional valves
Restrictor mounted. Available different

Pilot restrictor off from remote- diameter, marked dots. Note check that
controlled spool actuator restrictor is with the spool!
Pilot restrictors sizes and marking
NOTE: numbers aren’t Kalmar numbers

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

PM8 35±2bar
Pressure reducing
valve #31, 35±2bar
(Pilot pressure)
Pilot line
pressure
accumulator
and joystick used
Check
PM10 Main valve PM4
pressure #28.2 125±5bar
210 ±5 bar
DRS ContMaster Pressure sensor location
Pressure Sensor B6
from Right Lifting
Cylinder Pressure.
Purpose: Fast Hoist and
FWD 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
125±5 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 anti-
cavitation 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 Ø1.2mm
PP-signal
Over pressure
P Ø 0,8mm
valve 200 bar
EF CF
LS-signal pressure
Orifice Ø 0,8…1,2mm Main hydraulic 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 anti-
cavitation function
Setting pressure,
feed reduction valve
Pilot pressure
supply
Damping of pressure Oil from the pump
compensator
Pressure compensator
H.Koskinen
Finger Tip Steering Valve of DRS 2002
Over pressure from cylinder
A B
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
A and B
Pilot
NOTE! If you remove remote
restrictors
control valve, check those
restrictors when you assembly!
Pressure reducing valve #31
for pilot line to main valve
Signal pressure
adjustment
35±2 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 Ω 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
120±5 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! Don’t 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 one-

way 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 1½ 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
A Partek
Company
Brake Pedal Valve
Full Braking
A Partek
Company
Charging-, Parking-, Pressure Relief
Valves and Pressure Filter.
Pressure relief valve
PS22 160±5 bar/128bar
Pressure check
point PM26 160±5 bar Filter #5
(Parking brake open)
Charging valve
Parking brake valve

Y12 #3
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 Ω

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 1/1
Varo- ja imusuojaosuus Nostosylinterien lukkoventtiileistä

Lift cylinder lock valve pressure relief and vacuum preventer
LOAD LOWERING VALVE
The ratio between control pressure (opening X) and load pressure (opening B) is 1:20.
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, Figure 3. Control-blow baffling plate,

direction valve closed. direction valve open.
Free circulation valve of the Spreader
function, standard 125 bar
PM4 One way valve #20 5bar
LH-side open
PS4
125±bar
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 ºC
PM 4 Spreader pressure
check max 125±5 bar

#32 (Y56 and PS4)
Spreader hydraulic Free Circulation Valve
One way valve

#20 5 bar
spring load
125±5 bar
Free flow
spool
Pressure
relief valve
PS4
Y56
DANFOSS HYDRAULIC MOTOR
Inner oil leakage to tank is 4 l/min when operating pressure is 210 bar.
± 90 lbf in)
Tightening torque of the valve housing bolts for OMT 120 Nm (1050±
± 90 lbf in)
OMV 200 Nm (1750±
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 Adjusting valves # 30, adjust main
pressure relief valve #85 (Y56) over
Damping or Locking Tilting valve 175 bar and after setting back
valve Y63 Y65 a/b to 125 bar.
Rotating
Y59a/b
Boom valves adjustment
PM9
One way
restrictor 175± bar both
valves both side
side
(dumping)
One way
restrictor valves
both side
(dumping)
COUNTERBALANCE VALVE
0 to 120 L/min Nominal

Series 2 Cartridge T-2A Cavity
Installation Torque 60 to 65 Nm
Turn screw clockwise
to reduce setting
and release load.
Complete adjustment
range in 3 turns.
Rotate, Tilt and Locking valves end
of the the boom
SPREADER SIDE SHIFT ADJUSTMENT
Relief valves setting (150 bar)

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

(#85) back to 125±5bar
-lock the adjusting screws
-mount cabs
Y62
SPREADER LENGTH, SHORT, TWIST LOCK
VALVES TOP OF THE SPREADER RH SIDE
Lengthening Twist Locks

Shortening valve
Valves
Adjusting screws
(100 bar)
Twistlock Counterpressure valves
T-beam of the spreader
Counterbalance valve setting
100 bar
Open locking nut anti clockwise

Turn screw fully open clockwise.
Adjust 1¾ turns anti clockwise.
Lock the adjusting screw
with lock nut.
Top-Lift length sensors
30’ position sensor
Note at least one have to be

activated until twistlock start
operating
20’ and 40’ position sensor

Landing pin sensors (4 Pcs)
Landing pin every

corner. All 4 are
connected series and
all of them must be
activated until twistlock
open or close operation is
possible.
Twist lock Sensors end of T-bems
Twist lock cylinder
Sensor of Twist
lock close (one each
end of the Spreader
Sensor of Twist
lock open (one
each end of the
Spreader).
Spreader rotation limit sensors
Spreader rotation
limit sensor (one
each side +200 -100
degrees)
CONTROL MODULE, GENERAL INFO
Module get spare parts number after programming
Multipole
connectors
All terminals
are marked and
When you short description
weld - unplug beside each
connectors plug ( input,
when power is output, GND,
turn off. Power, CAN
When plug in Low - High -
power must be Shield and
off. 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
Return first
Maintenance
display Scrolling of “page” and
displays Setting of
selector
automatic gear
Displays. Following picture there are all
the displays. The text can be 13 languages
0.1 Kalmar tai machine type 0.2 Load parameters
OK
BASIC DISPLAY OK
1
stability (%)
gear
direction
reach
load DIRECTION
2 Drive speed 46 55 ENGINE WATER
(km/h) CHOSEN TOO HOT
Slip relation (%) A 3x during 2s M DOES NOT START
56 ENGINE OIL
PRESSURE LOW
M 39 Calibration 47
3 F/R SELECTED 57 ERROR R60
Engine (rpm) Are you sure?
Gear (rpm)
58 ERROR R61
10 Module A81 18 Module A82 26 Module A83 34 Module A84 OK 48 IDLING ENGINE
Can comm. : 0 Can comm. : 0 Can comm. : 0 Can comm. : 0 SHUTS OFF 59 ERROR B6
4 Engine water 40 Calibrate
(°C) Stability 1 49 60 ERROR B8
OK OK OK STEERING AXLE
OK
OVERLOAD
OK 40.1 61 ERROR CAN A81
40.2
5 11 DI 123456789012 19 DI 123456789012 27 DI 123456789012 35 DI 123456789012 40.3 ENGINE 62 ERROR CAN A82
Engine oil (bar) 000000000000 000000000000 000000000000 A 000000000000 41 Calibrate 50
TEMPERATURE
accel. LOW 63 ERROR CAN A83
12 A1 0.00 A2 0.00 20 A1 0.00 A2 0.00 28 A1 0.00 A2 0.00 36 DI 345678
OK 41.1
A3 0.00 A4 0.00 A3 0.00 A4 0.00 A3 0.00 A4 0.00 A 000000
41.2 51 64 ERROR CAN A84
6 41.3 SHUT OFF DELAY
Operating hours DI 123456789012 29 42 Calibrate
13 A5 0.00 A6 0.00 21 A5 0.00 A6 0.00 29 A5 0.00 A6 0.00 37 65 ERROR CAN
A7 0.00 A8 0.00 A7 0.00 A8 0.00 A7 0.00 A8 0.00 B 000000000000 Pressure weighing ENGINE
52 EMERGENCY ERROR ENGINE
OK 42.1 66
14 DO 123456789012 22 DO 123456789012 30 DO 123456789012 38 DI 345678 STOP PRESSED TEMPERATURE
42.2
7 Container 000000000000 000000000000 000000000000 B 000000 42.3 ERROR OIL
43 Calibrate 67
counter PRESSURE
Stability 2 53
15 PR1 00% PR2 00% 23 PR1 00% PR2 00% 31 PR1 00% PR2 00% HAND BRAKE 68 ERROR ENGINE
PR3 00% PR4 00% PR3 00% PR4 00% PR3 00% PR4 00% OK 43.1 RPM
43.2
8 69 ERROR ENGINE
PR5 00% PR6 00% PR5 00% PR6 00% PR5 00% PR6 00% 44 43.3
Autom. gripping 16 24 32 Language 43.4 54 ENGINE WATER
PR7 00% PR8 00% PR7 00% PR8 00% PR7 00% PR8 00% 70 ERROR ENGINE
43.5
OK LEVEL TOO LOW _____________
OK 44.1 44.8
17 PR9 00% PR10 00% 25 PR9 00% PR10 00% 33 PR9 00% PR10 00% 44.2 44.9 71 ERROR A312
44.3 44.10
9 44.4 44.11 LOW BRAKE
45 72
Autom. changer Send param. 44.5 44.12 PRESSURE
44.6 44.13
OK + kalibrations
44.7 44.14
OK 45.1
DRIVER’S SERVICE DISPLAYS ALARMS CRITICAL

DISPLAY 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 print-
page. 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 out-
put 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 S80 Dumping S81 Dumping sensor
RH-side are damping sensor in out, no function if
sensors load is >15000 kg
Boom in damping A83_DI11 Boom out damping DI12

Boom front sliders adjustment
Front sliders are laterally

adjustable (2 screw both side).
When you adjust, check that there

is enough space through full
stroke Boom OUT and IN.
Side clearance max. is total

5 mm (2,5 + 2,5).
Remember side sliders have to

adjust with shims which are in
the cabin pocket.
FRONT END SLIDERS OF THE BOOM
Support of slider
8 w 45º
Bottom shape
New
Minimum level wearing surface
Boom Reach Cylinder Mounting
Cylinder
can
float
inside Sleeves are
mounting 1 mm longer
bracket than cylinder
flange
SLIDERS OF THE SPREADER
Sliders of the
T-beam. Around T-beam
inner end of 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 sliders 8 PCs Support beam 2 PCs and
side shift sliders 4 PCs
Side shift
cylinder
SISTEMA DE LUBRIFICAÇÃO
Operating Instructions
Grease Lubrication System for Patria Vammas
PSB5500H
QUICKLUB
MOBILE CHASSIS LUBRICATION SYSTEM
Operating instructions PSB5500H/ 06.09.01/ml Subject to change without notice 1

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 Manual number

Quicklub Pump model 203 2.1A-30001-C99
Quicklub, Progressive Metering Devices for Oil and Grease 2.2A-10001-C99
Printed Circuit Board for Pump 203 2.6A-20002-C00
Quicklub Parts Catalogue 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 Ø8.6x2.3
Secondary
Divider Valve
P203
Pump
Feed line to Lubrication Point

(Ø8.6x2.3 or Ø6x2)
Lubrication frequency and volume adjustment
Pause time setting switch

Reservoir (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 ºC (-4 ºF)
• Use NLGI 1 in extreme temperatures
• Do not mix two greases - Consult your grease supplier first
Emergency lubrication
The pump can be by-passed by feeding grease manually through the manual grease
fitting attached on the pressure relive valve. Alternatively by attaching a manual fitting on a
divider valve will make manual greasing possible.
Pressure relief valve with a by-pass fitting
Filling nipple

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, it’s highly recommended that a weekly
walk-around inspection be performed.
The weekly walk-around inspection should include the following:
• Observe lubricant level in reservoir. Fill reservoir if it is low
• Inspect high pressure relief at pump element, noting any lubricant build-up. If build-
up is observed, correct this problem by determining cause of blockage
• Inspect all valve and lube point connections to verify that no leaks are 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 cm³ per outlet

§ Sizes from SSV6 to SSV22
§ metal-to-metal construction (no
seals)
§ mechanical or electrical
monitoring capability (option)
Outlet Crossporting
Outlets are combined to increase the

amount of lubricant for that outlet:
0.2, 0.4, 0.6 ccm, etc
Lubricant from a plugged outlet is

redirected to the next outlet on the
same side of the block
Do not plug outlets 1 & 2

KEY COMPONENTS
Ÿ Pump with controller

Ÿ Divider valves
Ÿ System tubing
PUMP P203
Power supply versions: 12, 24, 110 and 230v

Pump elements: 1, 2, or 3
Output: 0.6….4ccm / element
Output pressure: Max 350 bar
Op. Temperature: +80°C … -40°C
Pumpable grease: up to NLGI 2 (-25°C)
Protection class: IP54 IP 6K 9K
Reservoir: 2, 4 or 8 l
Circuit board Pump element: EN - approval
4 sizes: K5, K6, K7
and adjustable
Pump element
Suction phase Pumping phase
1 Eccentric pump shaft

2 Piston
K5 element: 0.122 cu in/min (2.0 ccm/min)
2 Return spring
K6 element: 0.171 cu in/min (2.8 ccm/min) 3 Check valve
Pump element
1
3
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)
Test button
Setting: 1 2 3 4 5 6 7 8 9 A B C D E F
Pause time [h]: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Setting: 1 2 3 4 5 6 7 8 9 A B C D E F
Operating time [min]: 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
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 •Loose the plug and press the test
from top the 4 and 8 liter vesions) button for 2 seconds
•P203-pump allows the use of NLGI 2 • The wiper/blender inside the pump
grease up to -25°C turns and pump feeds grease
• If grease quality is changed check •Verify the operation by loosening
grease compatability with your one feed line (Note: Wait until pump
supplier 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
1,5 m
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
2
- Fix the hoisting belts thus the booms stays in a desired sloping when lifted. Lift with
two hooks (A) or with one (B), see pic. 2.
- Move the cabin to its rear position.
- Lift the boom over the machine. Fix first the rear fastening and then the cylinders.
Note! The both bearing lines of the rear fastening must be in line at the same time
otherwise you cannot slot in the pins. Manual wire hoister connected to binding belt
makes adjusting much easier.
A B A
LB + 1,5 m LB
LA
LA+1 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
3 Spreader assembly
- Lift the spreader at least 1,2 m over the ground see pic. 3. (it can be lifted even over
a container)
- Move the reach stacker to meet the spreader and lower the boom to its attachment
points. Note! When the boom is operated before the electrics of spreader aren’t yet
connected, you must use by-pass of hoist prevention (switch S194) and by-pass of
stability control (switch S85)
- Fix the spreader onto the boom
- Lubricate the bearings
- Connect the electric and hydraulic lines of spreader
7600 kg
M in 1,2 m
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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DRS ContMaster Extra

Good visibility front

The Spreader rotation

All hydraulic pumps

Main hydraulic valves

Engine Scania DI12

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

© Scania Industrial & Marine Engines

1100 ICFN 110

© Scania Industrial & Marine Engines

QSM11 Cummins Engine inlet line

Rating Type: Intermittent

STATUS FOR CURVES AND DATA: Final CHIEF ENGINEER:

Intake Air System:

Charge Air Cooling System:

Low Temperature Aftercooling System:

*Engine with dry manifold.

Cranking System (Cold Starting Capability)

Water Management Rating Data-(If Applicable)

Stairs to the cabin

* proven & well known globally

Different ratios will give the un-

Access to and from

Batteries normal location and Batteries “rolled” out for checking

RH-side view of service

Cabin transfer unit

Finger tip steering

Wire numbers from Fuses are

Fuses F34, F35 15A

F42 to F49 are Options

• Main fuses 50A

Multi pole socket (9pins of each)

Relays, diodes, resistors

A84 CONTROL UNIT

A82 CONTROL UNIT

S186 S187 S188 S186 Engine Throttle selector

S187 First (1) position Engine

S188 Gear selector Forward

Automatic T-L Length

Cabin transfer Dumping

L = Lift TI = Telescope In A81:D18 = FCV auto/manu

Tulostettu 20.08.2002 08:37:23

Tulostettu 20.08.2002 08:33:50

Tulostettu 20.08.2002 08:31:54

Tulostettu 20.08.2002 08:28:37

Tulostettu 20.08.2002 08:35:52

One way valve # 20 for

One way valve #25 for

-Brake hydraulic tank for

Outlet pressure gauge port, M10

Only 30…40 bar open the LS-

Load signal pressure to

Pressure Vickers displacement

Steering Hoist and

Pump connection both side

Leakage from service port to tank

Main directional valve To steering

Y51 Boom out (PSL)

Y52 Boom in (PSS)

Y58 Boom Lifting (PL)

Y57 Boom Lowering (PS)

Own weight 95 kg (210 lb)

Check valve #28.1 Priority valve #27