Kalmar ContChamp — Troubleshooting and warning lamps: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the warning lamps, brake and gearbox checks and servo faults 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: what do the warning lamps mean in operation?
All warning lamps should be out while the truck works, and a steady light means a fault, according to the 1995 instruction manual, as recorded by the HIT SRL technical desk. A lit battery charging lamp means the truck must not be used, and an engine oil or gearbox oil pressure lamp coming on while driving means stopping at once, in that manual, as HIT SRL's technical desk reads it. The engine oil pressure lamp lights briefly at start-up, and longer in winter with cold oil, the same manual states.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-warning-lamps · HIT ref KCC-111 · fingerprint c5fc35 · see HIT ref KCC-112, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-gearbox-and-brake-cooling-temperature-lamps
Kalmar ContChamp DC: which temperatures light the gearbox and brake cooling lamps?
115 °C in the cooling oil of the wet disc brakes and 120 °C in the gearbox oil, according to the 1995 instruction manual, as recorded at HIT SRL. When the brake cooling lamp lights, that manual allows no further operation until the cooling circuit is repaired, as logged by the HIT SRL technical desk. The RS technical handbook (1996 edition) shows the same 115 °C sensor on the drive axle hub, and the instruction manual puts the normal engine temperature at about 80 °C, between 75 and 97 °C.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-gearbox-and-brake-cooling-temperature-lamps · HIT ref KCC-112 · fingerprint 51439d · see HIT ref KCC-111, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-warning-lamps
Kalmar ContChamp DC 4160-4560: how does the 1995 instruction manual test the brake accumulators?
With the accumulators charged, the engine stopped and the key in the operating position, the brake pedal is pumped: at least six applications must be possible before the low brake pressure lamp lights, according to the 1995 instruction manual, the HIT SRL technical desk notes. The manual puts that lamp at 175 bar and calls the accumulators faulty if the test fails, to be recharged with nitrogen by authorised personnel, as set out in the HIT SRL technical cards. Whether six applications are enough on a given truck is stated in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-low-brake-pressure-lamp-in-1995 · HIT ref KCC-113 · fingerprint e066ae · see HIT ref KCC-114, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-accumulator-test-in-1996
Kalmar ContChamp DC: what accumulator reserve does the 1996 handbook require?
At least 8 brake applications with the engine stopped before the pressure falls to 130 bar, according to the brake adjustment procedure of the RS technical handbook (1996 edition), as recorded at HIT SRL. The low brake pressure lamp should light at that same pressure, the procedure states, while the parking brake description of the handbook puts the lamp at 18 MPa, as logged by the HIT SRL technical desk. For a particular truck, the pressure and the number of applications to check are those given in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-accumulator-test-in-1996 · HIT ref KCC-114 · fingerprint 5fdef3 · see HIT ref KCC-113, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-low-brake-pressure-lamp-in-1995
Kalmar ContChamp DC: how is the brake valve checked for leaks?
Fifteen seconds of steady pressure with the pedal held down and the engine off, then a fall to zero when the pedal is released, according to the RS technical handbook (1996 edition), as HIT SRL's technical desk reads it. Otherwise the handbook takes the brake valve to be leaking, with the risk that the brakes stay applied in use and overheat, as recorded by the HIT SRL technical desk. A gauge of 0-250 bar on the distribution block under the cab gives the pedal pressure, which must match the plate of the hydraulic system, as the handbook gives.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-brake-valve-leak-check · HIT ref KCC-115 · fingerprint 587088 · see HIT ref KCC-114, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-accumulator-test-in-1996
Kalmar ContChamp DC: how are the gearbox pressures checked?
Above 1.7 bar at 2000 r/min and no more than 4.9 bar at top engine speed at the converter outlet, with the gearbox in neutral and the oil at 82-93 °C, according to the RS technical handbook (1996 edition), as set out in the HIT SRL technical cards. The clutch pressures must not differ by more than 0.4 bar from one another, the handbook adds, the HIT SRL technical desk notes. For the DRD-S the technical handbook (2004 edition) gives the same check for the Clark 36000 gearbox.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-converter-and-clutch-pressure-checks · HIT ref KCC-116 · fingerprint 470c3f · see HIT ref KCC-117, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-metal-particles-in-the-gearbox
Kalmar ContChamp DC: what if metal particles are found in the gearbox?
The cause must be investigated before the gearbox is refilled with oil, according to the RS technical handbook (1996 edition), as logged by the HIT SRL technical desk. After any gearbox damage the handbook has the oil cooler replaced, warning that the damage may have come from a faulty cooler, as recorded at HIT SRL. The oil and filter are changed with the oil hot, at 82-93 °C, filling to the MIN mark, running the engine at 500-600 r/min until hoses, cooler and converter are full and topping up to MAX at idle, as the handbook gives.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-metal-particles-in-the-gearbox · HIT ref KCC-117 · fingerprint c08e9e · see HIT ref KCC-116, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-converter-and-clutch-pressure-checks
Kalmar ContChamp DC: what does the handbook check when servo functions oscillate?
The supply voltage to the control unit, for dips below 23 V, when all servo functions oscillate, according to the RS technical handbook (1996 edition), as recorded by the HIT SRL technical desk. The handbook states that the control unit then passes the dips on to the system as disturbances, usually at a low frequency, as HIT SRL's technical desk reads it. When a single function oscillates, the converter solenoid is bled through the screw on its rear until drops of oil come out, and a missing single function may come from a short circuit in the wiring, as the handbook gives.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-servo-oscillations · HIT ref KCC-118 · fingerprint d250de · see HIT ref KCC-116, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/troubleshooting/#hit-contchamp-converter-and-clutch-pressure-checks