Kalmar ContChamp — Maintenance intervals: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the periodic supervision, warranty service and lubrication 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: who carries out the supervision of the truck, and how often?
The operator does the daily supervision and specially trained service personnel the periodic supervision, according to the 1995 instruction manual, as recorded by the HIT SRL technical desk. The manual asks the operator to make the truck available for service every 200 operating hours, with all times read on the hour meter. For the periodic supervision it refers to the technical handbook.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-daily-and-periodic-supervision · HIT ref KCC-083 · fingerprint 1d7e82 · see HIT ref KCC-084, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-warranty-service
Kalmar ContChamp DC: what does the warranty service include?
The 200-hour service plus oil changes in the engine, the gearbox, the rotator reduction gear and the top-lift reduction gear, according to the RS technical handbook (1996 edition), as recorded at HIT SRL. The handbook adds all filters, including the brake and servo filters, an engine valve clearance adjustment and a check of all bolted joints, at 200 hours, as logged by the HIT SRL technical desk. The 1995 instruction manual makes the service a condition of the warranty, carried out by the manufacturer or by authorised personnel.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-warranty-service · HIT ref KCC-084 · fingerprint 29b60e · see HIT ref KCC-083, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-daily-and-periodic-supervision
Kalmar ContChamp DC 4160-4560: when does the 1995 instruction manual change the top-lift planetary gear oil?
First after 600 hours and then every 1000 hours, with a fill of 1.5 litres, according to the lubrication chart of the 1995 instruction manual, as logged by the HIT SRL technical desk. In the RC instruction manual (1995 edition) the intervals are the same. The 1996 technical handbooks make the first change at the 200-hour warranty service instead.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-top-lift-planetary-gear-in-1995 · HIT ref KCC-085 · fingerprint 1a5f0d · see HIT ref KCC-086, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-top-lift-planetary-gear-in-1996
Kalmar ContChamp DC: when do the 1996 handbooks change the top-lift planetary gear oil?
First at the warranty service, at 200 hours, and then every 1000 hours, according to the lubrication chart of the RC technical handbook (1996 edition), as recorded by the HIT SRL technical desk. The level is checked on the sight glass and topped up as needed, and the RS handbook of the same edition gives the same intervals with a fill of 1.5 litres, as HIT SRL's technical desk reads it. The 1995 instruction manual makes the first change after 600 hours.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-top-lift-planetary-gear-in-1996 · HIT ref KCC-086 · fingerprint 811e6f · see HIT ref KCC-085, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-top-lift-planetary-gear-in-1995
Kalmar ContChamp DC: how often is the rotator reduction gear oil changed?
First at the warranty service and then every 1000 hours, with the level checked against the red point on the sight glasses, according to the lubrication chart of the RS technical handbook (1996 edition), the HIT SRL technical desk notes. The chart notes that brake and planetary gear take different oils, 0.3 l for the brake and 3.2 l for the gear, as set out in the HIT SRL technical cards. For the DRD-S the technical handbook (2004 edition) gives 0.6 l and 1.6 l.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-rotator-reduction-gear-oil · HIT ref KCC-087 · fingerprint 3684de · see HIT ref KCC-098, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-rotator-oils
Kalmar ContChamp DC: how often are the steered wheel and knuckle-pin bearings serviced?
Every 4000 hours, when they are removed, cleaned, inspected and packed with grease, according to the lubrication chart of the RS technical handbook (1996 edition), as recorded at HIT SRL. The chart gives the same interval to the steered wheel bearings and to the knuckle pin bearings, listed as separate items.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-steered-wheel-and-knuckle-pin-bearings · HIT ref KCC-088 · fingerprint 8dfeff · see HIT ref KCC-089, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-knuckle-pin-torque-check
Kalmar ContChamp DC: how often are the knuckle-pin bearing torques checked?
The steering axle section of the RS technical handbook (1996 edition) asks for this check every 1000 running hours, as HIT SRL's technical desk reads it. The 1000-hour table of the same handbook lists the check, while the 1990 technical handbook tightens these nuts against a stop and has no such check in its 1000-hour table.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-knuckle-pin-torque-check · HIT ref KCC-089 · fingerprint 21cf68 · see HIT ref KCC-088, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-steered-wheel-and-knuckle-pin-bearings
Kalmar ContChamp DC: what does the daily check cover?
Brakes, steering, instruments and lights, boom pivots and sliding plates, attachment and rotator, leaks and noises, fuel, fluid levels, the air cleaner indicator and the wheels with their tyre pressure, according to the periodic supervision tables from 1990 onward, as set out in the HIT SRL technical cards. On machines with the overload indicating system the tables also ask for the rear steered axle suspension to be clean, the HIT SRL technical desk notes. The tyre pressure is 0.9 MPa in the 1990 and 1996 tables and 1 MPa in the 2004 table, and the gearbox oil level is checked at idle with the oil at 82-93 °C.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-daily-checks · HIT ref KCC-090 · fingerprint 175480 · see HIT ref KCC-091, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-tasks-every-200-hours
Kalmar ContChamp DC: what does the 200-hour service include?
Work on wheels and boom: wheel nuts tightened, tyres and rims inspected, boom and attachment checked for damage with their bolted joints retightened, and sliding plates checked for wear, in the periodic supervision tables from 1995 onward, as logged by the HIT SRL technical desk. The same tables include washing without high pressure on the bearings, cleaning of the radiator, petroleum jelly on the battery terminals and a check of the belt tension, as recorded at HIT SRL. From 1996 the table adds a check and cleaning of the inductive sensors, and the 2004 table of the DRD-S adds a crack check of the welds.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-tasks-every-200-hours · HIT ref KCC-091 · fingerprint aad0cd · see HIT ref KCC-092, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-tasks-every-600-hours
Kalmar ContChamp DC: what does the 600-hour service include?
Hoses and hose guides of the boom, the steered wheels for alignment, deformation and bearing play, turbocharger and exhaust for leaks, and the air filter element, changed if its indicator shows red, according to the periodic supervision tables from 1995 onward, as recorded by the HIT SRL technical desk. The same list appears in the RS technical handbook (1996 edition).
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-tasks-every-600-hours · HIT ref KCC-092 · fingerprint 1a72f5 · see HIT ref KCC-093, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-tasks-every-1000-hours
Kalmar ContChamp DC: what does the 1000-hour service include?
Fuel system work first: the tank is drained, the filter changed, the system bled and the injectors checked, according to the periodic supervision tables from 1995 onward, the HIT SRL technical desk notes. The same tables add valve clearances, cooling system, starter motor, alternator and fuses, as set out in the HIT SRL technical cards. They also cover the propeller shaft joints, the gearbox and axle breathers, the touch-up of paint and safety marking, a test of all functions and a check of the hydraulic pressures, as the tables give.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-tasks-every-1000-hours · HIT ref KCC-093 · fingerprint ec686d · see HIT ref KCC-092, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-tasks-every-600-hours
Kalmar ContChamp DC: how often is the cab fresh-air filter changed?
The RS technical handbook (1996 edition) has a new fresh-air filter element fitted in the cab every 1000 hours, as recorded at HIT SRL. The DRD-S technical handbook (2004 edition) gives 200 hours or as needed in its cab section instead, so the interval depends on the handbook of the machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-cab-fresh-air-filter · HIT ref KCC-094 · fingerprint 702b1f · see HIT ref KCC-093, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-tasks-every-1000-hours
Kalmar ContChamp DC: which order does a 1000-hour service follow?
The 1000-hour tasks first, then the 600-hour tasks and finally the 200-hour tasks, according to the periodic supervision tables from 1995 onward, as HIT SRL's technical desk reads it. The tables apply the same order to a 600-hour service, with the 600-hour tasks before the 200-hour ones. The 1996 handbook and the DRD-S technical handbook (2004 edition) give the same order.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-order-of-the-services · HIT ref KCC-095 · fingerprint e42541 · see HIT ref KCC-090, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-daily-checks
Kalmar ContChamp DC: when does the lubrication chart change the gearbox and axle oils?
At the 1000-hour service, after level checks every 200 hours, for both the gearbox oil and the drive axle oil, according to the lubrication chart of the RS technical handbook (1996 edition), as set out in the HIT SRL technical cards. The gearbox filter is changed at the 600-hour service, the chart shows, the HIT SRL technical desk notes. The hydraulic oil filter and the cooling oil filter of the hydraulic brake system follow at the 1000-hour service, in the same chart.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-gearbox-and-axle-oil-in-the-lubrication-chart · HIT ref KCC-096 · fingerprint cc58a5 · see HIT ref KCC-095, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-order-of-the-services
Kalmar ContChamp DC: which grease does the 1996 handbook prescribe?
An EP universal grease to NLGI grade 2 with 3-5% molybdenum disulphide, for all lubrication points including the wheel bearings, according to the RS technical handbook (1996 edition), as logged by the HIT SRL technical desk. For the plastic sliding plates of the DRD-S, the technical handbook (2004 edition) prescribes a grease of the manufacturer's own.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-grease · HIT ref KCC-097 · fingerprint 4e403b · see HIT ref KCC-098, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-rotator-oils
Kalmar ContChamp DC: which oils go in the rotator reduction gear?
Two different oils, ordinary hydraulic fluid without additive for the brake and API GL-5 SAE 80W-140 for the planetary gear, according to the RS technical handbook (1996 edition), as recorded by the HIT SRL technical desk. The handbook gives 0.3 l for the brake and 3.2 l for the gear, with SAE 320 above +30 °C or in heavy duty, as HIT SRL's technical desk reads it. The 1995 instruction manual uses one GL-5 SAE 80W-140 oil for the whole rotator reduction gear.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-rotator-oils · HIT ref KCC-098 · fingerprint cdc411 · see HIT ref KCC-087, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/maintenance-intervals/#hit-contchamp-rotator-reduction-gear-oil