Kalmar ContChamp — Transmission, axle and wheels: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the Clark gearbox, drive axle, tyres and wheels 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 gearbox does the 1990 technical handbook give?
A Clark 14.5 HR 34442 with four forward and four reverse gears, according to the 1990 technical handbook, as set out in the HIT SRL technical cards. The same specification table gives 42 l of API CD or CD+ engine oil, an operating temperature of 82-93 °C with 120 °C as the maximum and a clutch pressure of 17-20 bar, the HIT SRL technical desk notes. The 1995 instruction manual names a Clark 14.5 HR 34415, and the 1996 handbook a Clark 15.5 HR 34432.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-gearbox-in-the-1990-handbook · HIT ref KCC-031 · fingerprint 956b52 · see HIT ref KCC-032, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-gearbox-in-the-1995-instruction-manual
Kalmar ContChamp DC 4160-4560: which gearbox does the 1995 instruction manual give?
A Clark 14.5 HR 34415 powershift gearbox with torque converter, according to the 1995 instruction manual, as HIT SRL's technical desk reads it. The RC instruction manual of the same edition prints the same designation. The 1994 data sheets and the 1996 technical handbook give a Clark 15.5 HR 34432 instead.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-gearbox-in-the-1995-instruction-manual · HIT ref KCC-032 · fingerprint 92987b · see HIT ref KCC-031, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-gearbox-in-the-1990-handbook
Kalmar ContChamp DC 4160-4180 RS: which gearboxes does the 1996 handbook give?
A Clark 15.5 HR 34432 with the TWD 1030 ME engine and a Clark 15.5 HR 36432 with the TWD 1230 ME, according to the RS technical handbook (1996 edition), as recorded by the HIT SRL technical desk. According to the handbook, both have a torque converter and four ratios in each direction, as HIT SRL's technical desk reads it. The 1994 data sheets of the DC4160RS4 and DC4560RC4 give the 15.5 HR 34432 with four forward and four reverse gears.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-gearboxes-in-the-1996-handbook · HIT ref KCC-033 · fingerprint e02d12 · see HIT ref KCC-035, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-transmission-oil-and-clutch-pressure
Kalmar ContChamp DC: how are the gears engaged?
By clutches worked hydraulically through spool valves, which solenoid valves move on the command of the gear selector in the cab, according to the RS technical handbook (1996 edition), the HIT SRL technical desk notes. The handbook offers an automatic gear-changing system as an option. The 1995 instruction manual also describes the electric control of the gearbox through solenoid valves.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-gear-engagement-and-automatic-option · HIT ref KCC-034 · fingerprint 90da80 · see HIT ref KCC-033, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-gearboxes-in-the-1996-handbook
Kalmar ContChamp DC 4160-4180 RS: what clutch pressure and oil data does the 1996 handbook give?
A clutch pressure of 17-20 bar, read with the parking brake applied, the oil at 82-93 °C and the engine idling at 625 r/min, with all clutches within 0.4 bar of each other, according to the RS technical handbook (1996 edition), as recorded at HIT SRL. The same table gives 42 l of oil for the whole system and an operating temperature of 82-93 °C, with 120 °C as the maximum, as logged by the HIT SRL technical desk. The service pages of the same handbook give the idle for the clutch pressure check as 400-600 r/min.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-transmission-oil-and-clutch-pressure · HIT ref KCC-035 · fingerprint 0a65eb · see HIT ref KCC-036, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-clutch-pressure-in-1995
Kalmar ContChamp DC 4160-4560: what clutch pressure does the 1995 instruction manual give?
16.9-19.3 bar on the gearbox pressure gauge, with the parking brake applied, the engine idling at 400-600 r/min and the oil at 82-93 °C, according to the 1995 instruction manual, as HIT SRL's technical desk reads it. The RC instruction manual of the same edition prints 16.6-19.3 bar under the same conditions. The 1996 technical handbook gives 17-20 bar.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-clutch-pressure-in-1995 · HIT ref KCC-036 · fingerprint 4a0998 · see HIT ref KCC-035, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-transmission-oil-and-clutch-pressure
Kalmar ContChamp DC: which oil goes in the transmission?
Engine oil to API CD with the C-3 rating, according to the oil recommendations of the RS technical handbook (1996 edition), as set out in the HIT SRL technical cards. The viscosity is SAE 10 above -23 °C and SAE 30 above 0 °C in that table, and topping up with ATF is forbidden. The 1995 instruction manual writes API-CD engine oil, without the C-3.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-transmission-oil-grade · HIT ref KCC-037 · fingerprint 23680a · see HIT ref KCC-035, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-transmission-oil-and-clutch-pressure
Kalmar ContChamp DC 4160-4180 RS: what stall speed does the 1996 handbook give?
1782±50 r/min for the TWD 1030 ME with the 15.5 HR 34432 gearbox and 1923±50 r/min for the TWD 1230 ME with the 15.5 HR 36432, according to the RS technical handbook (1996 edition), as logged by the HIT SRL technical desk. The handbook forbids running at stall speed for more than 30 seconds at a time, warning that the torque converter would overheat and damage its seals, as recorded at HIT SRL. The DRD-S technical handbook (2004 edition) gives the same stall speeds for its TWD1031VE and TWD1231VE with the 15.5 HR 36432.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-stall-speed · HIT ref KCC-038 · fingerprint 73fad1 · see HIT ref KCC-035, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-transmission-oil-and-clutch-pressure
Kalmar ContChamp DC 4160-4560: which drive axle does it have?
A Rockwell PRC 5324 W4H with hub reductions, according to the 1995 instruction manual, as recorded by the HIT SRL technical desk. The 1994 data sheets call it a wide-track axle with hub reduction, and the RS technical handbook (1996 edition) gives the same model in its specifications.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-drive-axle-type · HIT ref KCC-039 · fingerprint 668367 · see HIT ref KCC-040, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-drive-axle-reductions-and-brakes
Kalmar ContChamp DC: how is the drive axle built?
With two reduction stages, one in the differential and one in the planetary hub reductions, according to the RS technical handbook (1996 edition), the HIT SRL technical desk notes. The same handbook gives the axle oil-cooled wet disc brakes for the service brake and a disc parking brake applied by springs and released by hydraulic pressure.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-drive-axle-reductions-and-brakes · HIT ref KCC-040 · fingerprint 44e2ad · see HIT ref KCC-039, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-drive-axle-type
Kalmar ContChamp DC: how much oil does the drive axle take?
12 l in each hub and 50 l in the differential at an oil change, according to the RS technical handbook (1996 edition), as recorded at HIT SRL. The handbook specifies API GL-5 oil of viscosity 85W-140 or 80W-140, as logged by the HIT SRL technical desk. Added up, these are 74 l, while the 1995 instruction manual and the 1994 data sheets give 67 l for the axle including the hub reductions.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-drive-axle-oil-quantities · HIT ref KCC-041 · fingerprint 26da32 · see HIT ref KCC-042, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-drive-axle-oil-grade-in-1995
Kalmar ContChamp DC 4160-4560: which axle oil does the 1995 instruction manual specify?
API GL-5 SAE 80W-140, according to the oil recommendations of the 1995 instruction manual, as HIT SRL's technical desk reads it. The same manual uses that oil also for the rotator reduction gear and for the reduction gear of the top-lift hydraulic motor. The 1996 technical handbook keeps GL-5 oil for the planetary gear of the rotator and gives its brake plain hydraulic fluid without additive.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-drive-axle-oil-grade-in-1995 · HIT ref KCC-042 · fingerprint 77a50f · see HIT ref KCC-041, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-drive-axle-oil-quantities
Kalmar ContChamp DC 4160-4560: which tyres does the 1990 technical handbook give?
Two sizes: 18.00x25 on the DC 4160, and 23.5x25 with 18.00x25 on the DC 4560, inflated to 9 bar, according to the 1990 technical handbook, as set out in the HIT SRL technical cards. The 1994 data sheets of the DC4160RS4 and DC4560RC4 give the same sizes at 0.9 MPa, the HIT SRL technical desk notes. The RS technical handbook (1996 edition) fits 21.00x35 tyres to the DC 4180, 23.5x25 to the DC 4161 and DC 4171 and 18.00x25 to the DC 4160 and DC 4170, front and rear alike.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-tyres-in-the-1990-handbook · HIT ref KCC-043 · fingerprint b8a606 · see HIT ref KCC-044, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-wheel-and-axle-torques
Kalmar ContChamp DC: what tightening torques does the 1996 handbook give for wheels and drive axle?
400 Nm (41 kpm) for the steered wheel nuts, 402 Nm (41 kpm) for the rim clamp nuts listed with the drive axle and 2350 Nm (240 kpm) for the drive axle mounting bolts, according to the RS technical handbook (1996 edition), as logged by the HIT SRL technical desk. The same handbook tightens the universal joints of the propeller shaft to 99 Nm on the gearbox side and 115 Nm on the axle side, with oiled screws, as recorded at HIT SRL. The 1990 technical handbook gives 402 Nm also for the wheel nuts of the steering axle.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-wheel-and-axle-torques · HIT ref KCC-044 · fingerprint 5c8b33 · see HIT ref KCC-043, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/transmission-and-driveline/#hit-contchamp-tyres-in-the-1990-handbook