Kalmar ContChamp — Engine and power: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the engines, engine oils, coolant, fuel and air cleaner 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 4160-4560: which engine does the 1990 technical handbook describe?
A Volvo TD 100 G, according to the 1990 technical handbook, as logged by the HIT SRL technical desk. That handbook calls it a turbocharged six-cylinder four-stroke diesel with water cooling and an injection pump with a centrifugal governor. The 1994 data sheets and the 1995 instruction manual give the Volvo TWD 1030 ME instead, and the 1996 handbook the TWD 1030 ME or the TWD 1230 ME.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-in-the-1990-handbook · HIT ref KCC-018 · fingerprint 206775 · see HIT ref KCC-019, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-in-the-1995-instruction-manual
Kalmar ContChamp DC 4160-4560 RS: which engine does the 1995 instruction manual give?
A Volvo TWD 1030 ME six-cylinder four-stroke diesel for both the DC 4160 RS and the DC 4560 RS, according to the 1995 instruction manual, as recorded by the HIT SRL technical desk. The RC instruction manual of the same edition gives the same engine in its DC 4560 RC column, and the 1994 data sheets of the DC4160RS4 and DC4560RC4 agree.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-in-the-1995-instruction-manual · HIT ref KCC-019 · fingerprint aff07b · see HIT ref KCC-021, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-twd-1030-me-rating-in-1995
Kalmar ContChamp DC 4160-4180 RS: which engines does the 1996 handbook describe?
The Volvo TWD 1030 ME or the TWD 1230 ME, according to the RS technical handbook (1996 edition), the HIT SRL technical desk notes. The handbook describes both as six-cylinder in-line four-stroke diesels with turbocharger, direct injection, overhead valves and thermostatically controlled water cooling. The RC technical handbook of the same edition names the same two engines.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engines-in-the-1996-handbook · HIT ref KCC-020 · fingerprint 0b5dcb · see HIT ref KCC-022, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-ratings-in-1996
Kalmar ContChamp DC 4160-4560: what output does the 1995 instruction manual give for the TWD 1030 ME?
212 kW (288 hp) at 2200 r/min, net to ISO 3046, according to the 1995 instruction manual, as recorded at HIT SRL. The same manual gives a maximum torque of 1260 Nm at 1200 r/min and a compression ratio of 18.0:1. The 1994 data sheets give the same figures and add a fuel consumption of 14-16 l/h in normal driving.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-twd-1030-me-rating-in-1995 · HIT ref KCC-021 · fingerprint 96c86b · see HIT ref KCC-022, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-ratings-in-1996
Kalmar ContChamp DC 4160-4180 RS: what ratings does the 1996 handbook give for its engines?
180 kW (245 hp) at 2200 r/min and 1057 Nm at 1400 r/min for the TWD 1030 ME, and 275 kW (374 hp) at 2100 r/min and 1745 Nm at 1100 r/min for the TWD 1230 ME, both to ISO 3046, according to the RS technical handbook (1996 edition), as HIT SRL's technical desk reads it. The same table gives swept volumes of 9.60 l and 12 l, idling speeds of 675±25 and 600±25 r/min and cold valve clearances of 0.40 mm inlet and 0.70 mm exhaust, as recorded by the HIT SRL technical desk. The 1990 handbook prints the same 180 kW and 1057 Nm for the TD 100 G, against 212 kW in the 1995 instruction manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-ratings-in-1996 · HIT ref KCC-022 · fingerprint 2b11d3 · see HIT ref KCC-021, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-twd-1030-me-rating-in-1995
Kalmar ContChamp DC: which engine oil does the 1996 handbook prescribe?
Engine oil to API CD for turbocharged engines, with the viscosity chosen from a chart according to the ambient temperature, according to the RS technical handbook (1996 edition), as set out in the HIT SRL technical cards. The 1990 technical handbook gives API CD and CD+ for its engine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-oil-grade · HIT ref KCC-023 · fingerprint e1ffe0 · see HIT ref KCC-024, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-oil-change-interval
Kalmar ContChamp DC: how often is the engine oil changed?
Every 200 hours, according to the lubrication chart of the RS technical handbook (1996 edition), as logged by the HIT SRL technical desk. A note to the chart makes the interval depend heavily on the quality of fuel and lubricant and on the operating conditions. Longer intervals are allowed only if the company that supplies the oil checks its condition with regular lubricant tests, the same chart states.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-oil-change-interval · HIT ref KCC-024 · fingerprint b2482a · see HIT ref KCC-025, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-oil-filter-change
Kalmar ContChamp DC: how often are the engine oil filters changed?
Each 400 operating hours, as the RS technical handbook (1996 edition) prints in its lubrication chart, as recorded by the HIT SRL technical desk. The chart lists the engine oil filter as an item of its own, separate from the engine oil. For the DRD-S, the technical handbook (2004 edition) lists two engine oil filters to change.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-oil-filter-change · HIT ref KCC-025 · fingerprint fad0aa · see HIT ref KCC-024, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-oil-change-interval
Kalmar ContChamp DC: what coolant does the 1996 handbook prescribe, and how often is it changed?
A year-round mixture of 60% water and 40% ethylene glycol, changed once a year with the cooling system flushed, according to the RS technical handbook (1996 edition), the HIT SRL technical desk notes. The handbook adds a corrosion inhibitor only when that mixture is not used and never an inhibitor together with glycol, which it says causes foaming that seriously impairs the cooling capacity, as set out in the HIT SRL technical cards. The 1995 instruction manual asks for at least 40% glycol and states that the inhibitor is not an antifreeze.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-coolant-mixture · HIT ref KCC-026 · fingerprint 17aaea · see HIT ref KCC-027, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-diesel-fuel-quality
Kalmar ContChamp DC: what diesel fuel does the 1996 handbook call for?
Diesel fuel to DIN 51601 or ASTM D975 No. 2, with the lowest possible sulphur content, according to the RS technical handbook (1996 edition), as recorded at HIT SRL. For light diesel the handbook refers to the engine maker's recommendations on extra lubricant for the injection pump. The 1995 instruction manual forbids additives and water-absorbing substances such as alcohol.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-diesel-fuel-quality · HIT ref KCC-027 · fingerprint 85b329 · see HIT ref KCC-026, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-coolant-mixture
Kalmar ContChamp DC: when is the air cleaner safety element replaced?
At least every other year, or earlier after five main element changes, according to the RS technical handbook (1996 edition), as HIT SRL's technical desk reads it. The same handbook also calls for a new safety element when the indicator still shows red after a main element change or when the engine has run with a damaged main element, as recorded by the HIT SRL technical desk. It forbids cleaning and reusing the safety element, according to the handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-air-cleaner-safety-element · HIT ref KCC-028 · fingerprint 772b2e · see HIT ref KCC-023, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-oil-grade
Kalmar ContChamp DC: how is a new truck run in?
No full engine load during the first 50 hours, according to the 1995 instruction manual, as set out in the HIT SRL technical cards. The same manual suggests stretching the running-in period to 200 hours. The wheel nuts get their own running-in routine in that manual: retightening after 8, 16 and 24 hours of operation in a zig-zag order, repeated after any wheel change.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-running-in · HIT ref KCC-029 · fingerprint 6adc8e · see HIT ref KCC-024, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-oil-change-interval
Kalmar ContChamp DC 4160-4560: what fluid capacities does the 1995 instruction manual give?
400 l of fuel, 46 l of coolant, 700 l for the hydraulic system, 67 l for the drive axle with its hub reductions, 42 l for the gearbox and 21 l for the engine, according to the 1995 instruction manual, as logged by the HIT SRL technical desk. The RC instruction manual of the same edition prints identical values, as recorded at HIT SRL. The 1994 data sheets give 600 l for the hydraulic system instead, as does the 1990 technical handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-fluid-capacities-in-1995 · HIT ref KCC-030 · fingerprint 501816 · see HIT ref KCC-019, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/engine-and-power/#hit-contchamp-engine-in-the-1995-instruction-manual