Kalmar ContChamp — Brakes and steering: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the wet disc brakes, accumulators, parking brake and steering of the Kalmar ContChamp reach stacker, one fact per card, each with its source stated in the text. For the overall picture, see the Kalmar ContChamp technical legacy guide.
Kalmar ContChamp DC: how does the wet disc brake system work?
With a multi-disc pack in each hub that runs in an oil bath, according to the RS technical handbook (1996 edition), as recorded at HIT SRL. The handbook gives the system three hydraulic circuits, for the foot brake, for cooling and for the parking brake, as logged by the HIT SRL technical desk. Accumulators feed the brake circuits, while the pump feeds the cooling circuit directly through the accumulator charging valve, as the handbook describes. The 1990 technical handbook lists the system in two forms, with and without external cooling.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-wet-disc-brake-system · HIT ref KCC-045 · fingerprint acc6cc · see HIT ref KCC-046, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-brake-cooling-circuit-pressure
Kalmar ContChamp DC: what pressure should the brake cooling circuit show?
Normally about 0.5 bar and never above 1.5 bar at the gauge on the drive axle distribution block, according to the RS technical handbook (1996 edition), as recorded by the HIT SRL technical desk. If the gauge stays at 1.5 bar, the handbook takes it as a sign that the pressure-limiting valve has opened and that the drive axle has a fault, as HIT SRL's technical desk reads it. The circuit is bled through the nipples on the inside of the hubs, according to the same handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-brake-cooling-circuit-pressure · HIT ref KCC-046 · fingerprint 439887 · see HIT ref KCC-045, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-wet-disc-brake-system
Kalmar ContChamp DC: what are the brake accumulators like?
Two piston-type accumulators pre-charged with nitrogen to 95 bar, according to the RS technical handbook (1996 edition), as HIT SRL's technical desk reads it. In them an aluminium piston moves freely along the cylinder, the handbook states, while the figure printed with the text shows a membrane. The 1990 technical handbook gives the same 95 bar pre-charge.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-brake-accumulators · HIT ref KCC-047 · fingerprint 36eedd · see HIT ref KCC-045, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-wet-disc-brake-system
Kalmar ContChamp DC: can the parking brake be used as an emergency brake?
Yes, and its pads are then changed after two emergency brake operations, according to the 1995 instruction manual, as set out in the HIT SRL technical cards. The 1990 and 1996 technical handbooks give the same rule. Which rule applies after an emergency stop is stated in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-parking-brake-as-emergency-brake · HIT ref KCC-048 · fingerprint 742675 · see HIT ref KCC-047, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-brake-accumulators
Kalmar ContChamp DC: what kind of steering does it have?
Steering that is power-assisted only, without any mechanical link from the steering column to the steered wheels, according to the 1995 instruction manual, as logged by the HIT SRL technical desk. That manual has the movements of the steering wheel transmitted hydraulically to the wheels. Of the steering valves, the RS technical handbook (1996 edition) names an Orbitrol unit and a priority valve.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-power-steering · HIT ref KCC-049 · fingerprint 34b34a · see HIT ref KCC-050, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-steering-axle-design
Kalmar ContChamp DC: how is the steering axle built?
As a pendulum-suspended axle worked by one double-acting steering cylinder, according to the RS technical handbook (1996 edition), as recorded by the HIT SRL technical desk. The handbook mounts knuckle pins and wheel axles on taper roller bearings and fixes the axle to the chassis through maintenance-free rubber elements.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-steering-axle-design · HIT ref KCC-050 · fingerprint d2e57d · see HIT ref KCC-051, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-steering-axle-torques-in-1996
Kalmar ContChamp DC: how are the steering axle bearings tightened?
To 500 Nm for the steered wheel bearing nuts, tightened while the wheels turn and again after about 100 metres of driving, according to the RS technical handbook (1996 edition), the HIT SRL technical desk notes. The handbook then forbids slackening the bearing nut, as set out in the HIT SRL technical cards. For the knuckle pins the handbook sets 1750 Nm on the lower bearing nuts and 1500 Nm on the upper ones, and the M24 steering cylinder screw, oiled, takes 670 Nm.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-steering-axle-torques-in-1996 · HIT ref KCC-051 · fingerprint 3353c7 · see HIT ref KCC-052, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-steering-axle-in-the-1990-handbook
Kalmar ContChamp DC 4160-4560: how does the 1990 technical handbook tighten the steering axle?
Against a stop, without torque values, for the steered wheel bearing nuts and for both knuckle-pin bearing nuts, according to the 1990 technical handbook, as recorded at HIT SRL. The bearing nuts of the steered wheels are slackened by 1/8 turn after tightening, as that handbook gives. Only the wheel nuts have a torque in that table, 402 Nm (41 kpm).
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-steering-axle-in-the-1990-handbook · HIT ref KCC-052 · fingerprint 772241 · see HIT ref KCC-051, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-steering-axle-torques-in-1996
Kalmar ContChamp DC: can the truck coast downhill with the engine stopped?
No: the 1995 instruction manual forbids letting the truck run downhill with the engine stopped, as HIT SRL's technical desk reads it. Without the engine there is no hydraulic pressure and the steering becomes very limited, the same manual warns. The procedure for moving a truck that cannot run is the one in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-downhill-with-the-engine-stopped · HIT ref KCC-053 · fingerprint 31a480 · see HIT ref KCC-049, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/brakes-and-steering/#hit-contchamp-power-steering