Kalmar ContChamp — Electrical, servo and overload systems: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the electro-hydraulic servo, overload systems and gear-changing unit 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 fault tracing in the electro-hydraulic servo system start?
With three checks: a supply voltage of at least 24 V, a servo pressure of 30-40 bar and about 8 V at the control lever unit, according to the RS technical handbook (1996 edition), the HIT SRL technical desk notes. The handbook's list of symptoms continues with jerky or uncontrolled movements, too much play in the lever, speeds too high or too low, oscillations and single functions that fail, as set out in the HIT SRL technical cards. With no response to the lever, the handbook measures the converter output voltage and uses the emergency operating button of the converter to tell a converter fault from an electrical one.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-servo-fault-tracing · HIT ref KCC-075 · fingerprint 203264 · see HIT ref KCC-079, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-overload-sensor-checks
Kalmar ContChamp DC: how does the overload indicating system react to forward overload?
A red lamp in the cab and a stop of the LIFT, LOWER and BOOM OUT functions, according to the RS technical handbook (1996 edition), as recorded by the HIT SRL technical desk. The handbook takes the warning from a sensor on the suspension of the steering axle: when only the axle's own weight remains as counterweight, a pivoted joint opens a gap and the sensor signal stops, as HIT SRL's technical desk reads it. Losing that sensor signal halts the entire servo system, so the machine cannot work with the sensor faulty, according to the handbook, and the overload functions to rely on are those in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-forward-overload-warning · HIT ref KCC-076 · fingerprint 73cf75 · see HIT ref KCC-077, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-steered-axle-overload-warning
Kalmar ContChamp DC: how does it warn of steered axle overload?
With a yellow lamp, lit by two boom sensors when the boom is extended less than 1 m and raised above 42°, according to the RS technical handbook (1996 edition), as recorded at HIT SRL. At low speed in a low gear the green lamp stays lit despite the risk, the handbook states, and the 1995 instruction manual gives the same exception for gears 1 and 2, as logged by the HIT SRL technical desk. How the warning behaves on a given truck is set out in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-steered-axle-overload-warning · HIT ref KCC-077 · fingerprint 407538 · see HIT ref KCC-076, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-forward-overload-warning
Kalmar ContChamp DC: what is the SNP 300 overload safety system?
A control unit fed by length, angle and lift cylinder pressure sensors, which works out the outreach, the load allowed at that outreach and the load being lifted, according to the RS technical handbook (1996 edition), as HIT SRL's technical desk reads it. Of the four versions in the handbook, the SNP 304 only offers vertical lift and the SNP 303 only a load indicator, while the SNP 301 interrupts functions and the SNP 302 adds the load indicator and vertical lift to that, as recorded by the HIT SRL technical desk. At steered axle overload the panel and the relay description stop LIFT and BOOM IN, while the descriptive text of the same handbook says LIFT and BOOM OUT, and the functions to rely on are those in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-snp-300-overload-safety-system · HIT ref KCC-078 · fingerprint 25b9e9 · see HIT ref KCC-079, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-overload-sensor-checks
Kalmar ContChamp DC: how are the sensors of the overload safety system checked?
Each test must trigger the alarm of the control unit and interrupt the boom functions, according to the RS technical handbook (1996 edition), as set out in the HIT SRL technical cards. The handbook disconnects in turn the connector of the pressure sensor on each lift cylinder, turns the angle sensor below 0° and lets the length sensor string run back, the HIT SRL technical desk notes. After the string test the handbook turns the potentiometer fully anticlockwise against its stop and then half a turn clockwise.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-overload-sensor-checks · HIT ref KCC-079 · fingerprint 6de163 · see HIT ref KCC-078, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-snp-300-overload-safety-system
Kalmar ContChamp DC: what protections does the automatic gear-changing unit have?
An irregular speed sensor signal makes it select neutral and display SENS, according to the RS technical handbook (1996 edition), as logged by the HIT SRL technical desk. According to the handbook, a short circuit on any output de-energises all outputs, and both conditions are acknowledged with the reset button, as recorded at HIT SRL. Below about 5 °C the unit isolates its logic and a 15 W heater warms the case towards 20 °C, while a 60 °C thermal fuse inside must be replaced once it has blown, according to the same handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-automatic-gear-changing-unit · HIT ref KCC-080 · fingerprint 283efc · see HIT ref KCC-075, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-servo-fault-tracing
Kalmar DC4160RS4: what alternator and batteries does the 1994 data sheet give?
An AC alternator of 1540 W and two 12 V starting batteries of 135 Ah, according to the engine section of the technical data table of the 1994 data sheet, as recorded by the HIT SRL technical desk. The same table gives a fuel consumption of 14-16 l/h in normal driving, and the DC4560RC4 data sheet repeats all three values.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-alternator-and-batteries · HIT ref KCC-081 · fingerprint 476439 · see HIT ref KCC-082, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-jump-starting
Kalmar ContChamp DC: how is the truck started from auxiliary batteries?
Through auxiliary batteries joined in series to give 24 V, according to the 1995 instruction manual, the HIT SRL technical desk notes. The manual connects the red cable before the black one, from auxiliary to truck battery, and earths the black cable on the chassis well away from the truck battery, removing everything in reverse order, as set out in the HIT SRL technical cards. The same manual warns that batteries give off explosive oxyhydrogen gas and tells the operator not to lean over them or touch the cables during starting, and the starting method to follow is the one in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-jump-starting · HIT ref KCC-082 · fingerprint 9aaeaf · see HIT ref KCC-081, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/electrical-and-control/#hit-contchamp-alternator-and-batteries