UDRS01_01GBMaintenance DRS Last

00 General Information/ Scheduled Maintenance 01 Power Unit

Maintenance Manual

UDRS01.01GB DRS 4527-4531

02 Power Transmission 03 Hydraulic System 04 Electric System 05 Cabin 06 Working Devices 07 Frame and Shields 08 Equipment

General Information/Scheduled Maintenance

00

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General Information/Scheduled Maintenace 00.1 General Information .......................................................................... 00.1.1 About the Documentation ....................................................... 00.1.2 Warranty Agreement ............................................................... 00.1.3 To the Maintenance Personnel ...............................................

3 3 3 4

00.2 Instructions for Initiating into Maintenance Work ......................... 5 00.2.1 General Instructions ............................................................... 5 00.2.2 Maintenance and Repair Personnel ....................................... 5 00.3 Regulations for Safe Maintenance Work ........................................ 00.3.1 General Safety View Points .................................................... 00.3.2 Concerning the Maintenance and Repair Personnel .............. 00.3.3 Preparing for Hazardous Situations ........................................

6 6 7 8

00.4 Preparing of the Machine for Maintenance ..................................... 9 00.4.1 Maintenance Enviroment ........................................................ 9 00.5 Maintenance Reports ...................................................................... 10 00.6 Lubrication Oil Recommendations ................................................ 11 00.7 Running-In ....................................................................................... 13 00.7.1 Initial Maintenance ................................................................ 14 00.8 Scheduled Maintenance ................................................................. 15 00.8.1 Scheduled Maintenance for Engine Scania DI12 ................. 15 00.9 Scheduled Maintenance ................................................................. 00.9.1 Scheduled Mainteanance for Engine Cummins QSM11 ...... 00.9.2 Scheduled Maintenance for Gear Box and Power Unit ....... 00.9.3 Scheduled Maintenance for Steering ................................... 00.9.4 Scheduled Maintenance for Hydraulics ............................... 00.9.5 Scheduled Maintenance for Boom ........................................ 00.9.6 Scheduled Maintenance for Spreader .................................. 00.9.7 Scheduled Maintenance for Others ...................................... 00.9.8 Unit Conversation ................................................................. 00.9.9 General Tightening Torques .................................................

Maintenance Manual DRS 4527-4531

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00.1 General Information The maintenance manual contains the actual information required during maintenance work. This information acquaints the maintenance and repair personnel with correct and safe methods of maintenance and repair work. The professional support of our maintenance organization and the maintenance instructions make possible the safe, reliable and efficient operation for the machine during its operation life.

00.1.1 About the Documentation The following documentation is supplied with the machine: • Operator's manual DRS 4527-4531 (in cab with machine) • Maintenance manual DRS 4527-4531 • Spare parts catalogue with machine card All documentation can be ordered from Kalmar Industries. 00.1.1.1 Ordering of documentation Documenation is ordered from Kalmar Industries: Kalmar Industries AB, SE-341 81 Ljungby, Sweden. Always indicate publication number when ordering.

00.1.2 Warranty Agreement Warning! Negligence of scheduled maintenace measures mentioned in this manual will release Kalmar Industries from all warranty liabilities. Warranty information is at the end of this manual.


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00.1.3 To the Maintenance Personnel Carefully familiarize yourself with the planned maintenance program, maintenance points and instructions and follow them during your maintenance work, to secure the high level of the safety in operation and reliability. Use oils, greases and liquids, defined later in this manual. Only original Kalmar parts shall be used. A strict compliance with cleanness especially by maintenance of hydraulic and fuel devices by scheduled maintenance is the best way to be ensure, that the machine operates as planned. Take care according the instructions on your working place for the oils, greases and liquids, changed during the maintenance. Warning! Never pour oils, greases and liquids changed during the maintenance down the drain or in to the earth! Bear the responsibility for the environment! Only trained personnel is allowed to maintain the machine. Do not maintain the machine, if you are not sure about the safety instructions and orders. Ask if needed for guidance of safety maintenance in your working place the personnel responsible for occupational instruction and guidance or get in contact with the service organization of the manufacturer.

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00.2

5

Instructions for Initiating into Maintenance Work

The service and repair personnel must be clear about the machine operation, the working principles, and the designed functions of the machine systems. The service section is meant as an introduction to enable correct and safe service and repair work. Therefore it is important that the instructions in the manual are studied carefully prior to work.

00.2.1 General Instructions To the commissioning of a new machine and the first scheduled services should be paid a special attention. The manufacturer has drawn up a special service schedule particularly for this machine. The manufacturer has contributed significantly to develop a service program to maintain the proper safety level of the machine. Data for correct maintenace measures have been collected as result of an extensive research work. In addition to this, feedback from different operating conditions has been considererd very carefully. By careful following of the maintenance schedule specified by the manufacturer, a rational and economic maintenance of the machine is enabled. The manufacturer has invested in the profitable training maintenances of a high level performance. Qualified and experienced trainers are always available, if problems arise at the client.

00.2.2 Maintenance and Repair Personnel The machine may be serviced and repaired by qualified and trained personnel only. The employer is responsible for selecting of the person suited to the service and repair duties. The employer is responsible for training of the service and repair personnel into the proper workmanship considering the safety at work. The service person refers to a person, who performs the scheduled services and eventual repairs at the machine. The service person must attend to maintain his qualifications, e.g. by periodically repeated training. The employer is responsible for maintaining of the qualifications of the service and repair personnel. The machine must not be serviced or repaired by personnel who has lost skills. If necessary, the employer must retrain the person selected for the service and repair work at the machine.


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00.3

Regulations for Safe Maintenance Work

The person performing the service shall be physically suited for this kind of work. As far as health and power of seeing are concerned, the person shall fulfil the requirements necessary for the work. The employer is responsible for selecting the person suited for the duty as well as for initiating into the correct and safe service work at the machine.

00.3.1 General Safety View Points The service and repair personnel of the Reach Stacker is responsible for that the machine doesn't cause damage to other persons in connection with the service or repair work. 1. Thoroughly acquaint yourself with the machiner's structure and the manuals. Observe the instructions and warnings. 2. Try to determine the hazards, and avoid them. Report any faults that you have noticed to your superior or to the person in charge of repairs. 3. Wear required protective clothing. 4. Always observe sufficient caution and care when climbing into or coming down from the machine. Always move along the paths designated as walkways. Keep the walkways clean. Remove all safety risks, such as snow and ice, and other foreign matter. Wipe away all oil leakages at once to prevent slipping. 5. Keep the machine clean, especially the adjusting and control devices. 6. Do not allow any unauthorized persons to operate the machine entrusted in your use. The operator of the machine is responsible for any damage caused by the machine. 7. Acquaint yourself in advance with the use of emergency exits. 8. Do not stand under a hanging container or load. 9. If problems arise, remember to stay calm. Think first, and then act accordingly.

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00.3.2 Concerning the Maintenance and Repair Personnel 1. Before starting off, make sure that nobody is standing in front or behind the machine. 2. Avoid sudden stops and starts. 3. Always perform the maintenance and repair work according to the instructions given. 4. By observing a danger spot, immediately report to the person responsible for safety. 5. The machine must not be handed over for operation, until the observed faults and damages have been repaired. 6. Observe the signs and instructions indicating free height. You should know the exact total height of your machine before driving into places with rstriced free height. Be especiallycareful with temporary structures, hanging overhead power lines, etc. 7. You may perform the service and repair work only in compliance with your actual qualification. 8. Don't try to guess! Maybe you make a wrong guess, causing a possible danger to yourself and the other personnel. 9. If necessary, consult a person being aware of how to proceed. 10.When servicing pressurised systems, proceed very carefully. Non-discharged energy sources always are hazardous. 11.Follow unconditionally the instructions given. 12.If it is necessary to remove protective guards during the service, place warning signs and take other measures to protect other persons from danger. 13.When changing driving direction, stop the machine completely with the service brake before moving the direction selector lever. 14.Watch out for the edges of driveways where the surface may be yelding and cause the danger of overturning. 15.Remember that the machine is not intended for carrying persons. 16.Always stop the engines whenever you leave the machine even for a short while. Lower any load to the ground.


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17.Always remember to engage the parking brake before leaving the cabin. 18.Make a detailed report on any collisions, including the damage caused. This could prevent accidents from being repeated. 19.Observe the weight of your carrier, and its total weight loaded. Do not drive on surfaces with insufficient load capacity. 20.Follow the periodic maintenance schedule. This ensures that the controls and the whole carrier operate reliably and safely. 21.The engine must always be stopped when service or inspections are being carried out. 22.The use of open flame is absolutely forbidden when checking fuel or battery electrolyte levels. 23.The radiator is pressurized when the coolant is hot open the radiator cap slowly and cautiously. 24.Do not open the main switch when the engines are running. 25.Only a person that is well acquainted with the carrier's control and the cabin equipment is allowed to be in the cabin during service and repairs. 26.Driving is forbidden without fastened seatbelts. 27.Never park the machine on a inclined plane.

00.3.3 Preparing for Hazardous Situations 00.3.3.1 Maintenance Reports Inform your superior or the person responsible for repairs of faults observed at the service. The machine must not be operated until the faults and damages have been repaired. See to it that your service reports are perfectly recorded. Record the objects to be repaired individually, and note the repair measures precisely. In addition to this, try to find out, why the object has been damaged. 00.3.3.2 Tools Use only proper tools at the service and repair work.

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00.3.3.3 Reporting of Dangers Always inform in writing your superior or the person responsible for safety of dangers observed in the service environment or in machines serviced. The reports recorded must be filed carefully. It is essential that the reports are available to be analyzed if necessary.

00.4

Preparing of the Machine for Maintenance

The service and repair work should be performed in the premises intended for this use. State the extent of the service work. Prepare yourself for the service or repair work by reading the service and repair manuals. Prepare yourself for the work by tools and materials needed. See to it that the tools to be used are proper and in good condition. See to it that the warning signs for eventual hazardous situations have been placed in position. Prior to the service work: Check the reparations made in the operation of the machine since the last service. Check the previous service report. Try to find out the expected safety level on the basis of the information collected; which points shall be particularly considered at the next service.

00.4.1 Maintenance Enviroment 1. Provide for placing the service environment to premises, where the machines can be serviced safely and without exposing the regular work to danger. 2. See to it that the environment cannot be contaminated by the machine being serviced. 3. Always keep the service environment clean and trim. 4. See to it that there is no danger in the service environment, which possibly could endanger the personnel. 5. Be aware of the correct action in case of possible accidents. Keep yourself informed about the location of the electrical main switches of the service environment, as well as of the fire extinguishing equipment. 6. Keep yourself informed about the safety regulations regarding the service environment.


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00.5

Maintenance Reports

When performing the service, report the work systematically in accordance with the service schedule drawn up by the manufacturer. Note carefully damages observed and repair measures. The service schedule drawn up by the manufacturer is presented in section 'First service and scheduled service' of this main group. Define and record the safety level of the machine in the service report after every service. If, by your estimation, the machine doesn't correspond to the designed safety level, inform of this your superior responsible for the safety. After every service, file the service reports.

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00.6

11

Lubrication Oil Recommendations

Required oils, greases and fluids Item

Class Filling API/ASTM/ capacity / l SAE

Type

Engine Cummins QSM11 Diesel motor oil All Seasons, but not Artic condi- SAE 15W-40 tions

API CH4 or ACEA E5

Engine Scania DSI 12 <-40 ... +30°C -25 ... +30°C -20 ... +45°C > -15 ... +30°C -10 ... +30°C -5 ... +45°C > 0 ... +45°C >

Diesel motor oil

API CE or 33 CF CCMC-D5 ACEA E3

Hydraulic oil tank Cabin transfer hydraulic -30+25°C -10+35°C -10+35°C -20+30°C 0+30°C +10+50°C

Hydraulic oil

Drive axle PRC7534 Rockwell Differential Planetary gear -40°C...> -26°C...> -12°C...>

SAE 5W-30 SAE 10W-30 SAE 15W-40 SAE 20W-30 SAE 30 SAE 40 SAE 50

36

600 2,8

1)

NESTE MJ 46, BP Tracton 9, TEXACO TDH Esso Torque Fluid 62 ISO-VG 46 ISO 68 ISO-100

60 2X12,5 Hypoid oil SAE 75W/90 EP Hypoid oil SAE 80W/90 EP Hypoid oil SAE 85W/140 EP

GL-5 -"-"-

Gearbox Clark 36000 -25 ... +45°C

Transmission oil SAE 5W30 UTTO transmission oil 4)

Rotation transmission

Hypoid oil SAE 80W/90 EP

GL-5

Lubricating points of chassis and lifting device

EP Multi-purpose grease example ESSO Unirex EP 2

NLGI 2

Lubricating slide planes of boom EP Multi-purpose grease and spreader example ESSO Unirex EP 2 ore ESSO Moly Grease 2

NLGI 2

Central lubrication, optional 2)

EP Multi-purpose grease, Class example ESSO Unirex EP 2 If the temperature is continuously under -10×C, EP Multi-purpose grease example ESSO Unirex EP 0

Fuel tank Cooling system3) Windscreen washer

High-quality diesel fuel Glycol 50% / water 50% Windscreen washer liquid


NLGI 2

5,5

2kg

NLGI 0

500 60 10

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Required oils, greases and fluids Item

Type

Class Filling API/ASTM/ capacity / l SAE

1. In colder weather, a hydraulic oil heater should be used. 2. Refer to the 'Central oiler' section 08 of the manual. 3. Add DCA4 additive to coolant for Cummins engine, 1,2 units / US gallon. Check the amount of additive with the test serie CC-2602. 4. UTTO-transmission lubricant must be qualified by on of the following specifications in order of preferance: Caterpillar TO-4 John Deere J20 C, D Allison C-4 Dexron oils must not be used.

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00.7

13

Running-In

Long life of the machine can be ensured bu avoiding great loads and high engine speeds during the first 300 operating hours. During this time, all finely machined surfaces reach their final smoothness and hardness. The engine should not, however be lugged at low speeds or allowed to idle long. Especially observe during the running-in period that the engine and transmission oil pressures and temperatures are normal. Oil change during running-in should also be done sooner than normally. Also refer to the engine's manual for running-in instructions. During running-in you should also pay special attention to the tightness of screws and nuts, and tighten them as necessary. Running-in of an overhauled engine follows the same principles as above, but the running-in period is somewhat shorter.


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00.7.1 Initial Maintenance Special attention should be paid to taking a new vehicle into operation and to its first maintenaces. Maintenance charges are small compared with cost of repairs caused by neglect. Warning! In addition the proceeding stated in this maintenance volume a new machine must be subjected to all the maintenance and checks mentioned in the book. In addition to the instructions in the maintenance chart, the following service should be carried out during the first 50...150 hours. Maintenance of a new machine during first 150 hours Maintenance itemUDRS01.01GB

Interval/working hours 50

100

150

1.

Replace hydraulic system filters

X

2.

Change engine oil

X

3

Replace engine oil filter

X

4.

Change transmission oil

X

5.

Replace transmission filter

X

6.

Change differential and planetary gear oil

X

7.

Change brake oil

X

Warning! Please consult also the engine instruction manual for running-in directions. Apply these directions after replacements of major components, too. After the initial maintenace do follow scheduled maintenance program, where service intervals are based upon operating hours.

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00.8

15

Scheduled Maintenance

In the scheduled maintenance of the reach stacker the maintenance instructions of this groupshall be followed, though the instructions in the maintenance of the components may differ from them.

00.8.1 Scheduled Maintenance for Engine Scania DI12 Interval in operating hours Maintenance item

Daily

ENGINE, see also engine manual 1. Check the engine oil level

x

2. Check the coolant level

x

3. Clean the air pre-filter and replace the air filter when

x

400 h

1000 h

2500 h

6000 h or at least every two years

At least every fifth years

the clogging indicators show fully red 4. Check cooling fan

x

5. Check the possible oil- and the fuel leakages

x

6. Clean water separator, if needed

x

7. Change engine lubricating oil

x

x

8. Cleaning oil cleaner

x

9. Replace engine oil filter

x

x x

10. Clean the air pre-filter

x

11. Check engine intake system

x

12. Checking electrolyte level in batteries, if needed

x

x

add only battery water 13. Check state of charge and cleanliness in batteries

x

14. Check engine screws and tighten to spec. torque

x

15. Check hoses and replace if necessary

x

16. Replace the air filter and clean the air pre-filter, also

x

x

when the clogging indicators show fully red 17. Replace engine fuel filter

x

18. Clean and replace the fuel pre-filter (optional)

x

19. Check the condition and tightness of the fan belt

x

x x x

20. Clean crankcase breather

x

21. Wash up engine

x

22. Checking/adjusting valve clearances

x

23. Checking/adjusting injectors DI12

x

x

24. Checking/adjusting PDE injector rocker arms DI12 PDE

x

x

25. Cleaning cooling system and changing cooland fluid


x

x

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00.9

Scheduled Maintenance

In the scheduled maintenance of the reach stacker the maintenance instructions of this group shall be followed, though the instructions in the maintenance of the components may differ from them.

00.9.1 Scheduled Mainteanance for Engine Cummins QSM11 Maintenance item

Interval in operating hours Dai-ly

1.Check the engine belt

x

2.Check the engine oil level

x

3.Check coolant level

x

4.Check cooling fan

x

5.Clean water separator

x

6.Check air cleaner service indicator; replace filter if indicator shows red

x

250 h

7.Change engine oil *)

x

8.Replace engine oil filter *)

x

9.Replace engine fuel filter

x

10.Check additive content of coolant (SCA)

x

11.Replace coolant filter

x

12.Check engine intake system

x

13.Check crankcase breather

x

14.Check engine wiring harness

x

500 h

1500 h

15.Adjust valves and atomizer

x

16.Clean crankcase breather

x

17.Steam wash engine

x

18.Check turbocharger nuts and tighten to spec. torque

x

19.Check engine screws and tighten to spec. torque

x

20.Check hoses and replace as necessary

x

21.Check state of charge and cleanliness in batteries

x

22.Service exhaust catalysis CRT**) (optional)

x

6000 h or at least every two years

23.Flush cooling system and Change coolant

x

24.Clean and adjust electronic controlled fuel system ***)

x

25.Check water pump

x

26.Check fan hub

x

27.Check turbocharger

x

28.Check idley pulley mouting

x

29.Check vibration damper

x

*) Change interval 125 operating hours, if engine lubricating oil does not comply with API CF-4 specific. **) See instructions: CRT-service manual, part C appendixes ***) Adjust requires special equipment and must be done a Cummins Authorized Repair Location

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00.9.2 Scheduled Maintenance for Gear Box and Power Unit Maintenance item

Interval in operating hours

Transmission

250 Dai-ly h

1.Check transmission oil level

x

2.Check possible oil leaks

x

3.Replace transmission oil filters

500 h

1000 h

2000 h

At least once a year

x

4.Change transmission oil

x

5.Clean screen filter

x

6.Check transmission oil pressure

x

Drive Axle 1.Check oil level in differential and planetary gear (common oil space)

x

2.Adjust parking brake according to instructions

x

3.Check and tighten screw connections

x

4.Check and tighten wheel nuts

x

5.Check tyre pressure

x

6.Change differential and planetary gear oil

x

7.Check parking brake friction surfaces for wear, replace as necessary (wet disk brakes on drive axle needs no maintenance)

x

6.Change brake oil

x

x

00.9.3 Scheduled Maintenance for Steering Maintenance item


Steering Axle

Dai-ly

250 h

1.Check steering lingake joints

x

2.Check and tighten wheel nuts

x

3.Check tyre pressure

x

4.Check and tighten screw connections

500 h

1000 h

2000 h


x

5.Lubricate wheel bearings

x

00.9.4 Scheduled Maintenance for Hydraulics Maintenance item


HYDRAULICS

Dai-ly

1.Check hydraulic hoses and connections for possible leaks

x

2.Check hydraulic oil level. Sight glass attached to hydraulic tank is used for checking. Oil level should be in the midway of the gauge when spreader is lowered to its standard position and boom telescopic extension is fully retracted.


250 h

500 h

At least 1000 2000 4000 once a h h h year

x

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3.Replace brake hydraulics filter

x

4.Replace hydraulic oil filter

x

5.Replace filter element of hydraulic system breather

x

6.Measure hydraulic system pressure

x

7.Change hydraulic oil and clean tank of possible impurities

x x

x

8.Change brake oil and clean tank of possible impurities

x

x

9.Check the pressure of possible pressure accumulators in system

x

x

10.Change cabin transfer hydraulic oil

1)

1) Every two years

00.9.5 Scheduled Maintenance for Boom Maintenance item


BOOM

Dai ly

1. Lubricate the slide pieces in boom front end 1)

x

2. Lubricate bearings of the boom 1)

x

3. Lubricate sliding surfaces of inner boom

50 h

250 h

500 h

1000 h


x

4. Lubricate boom support rollers

x

5. Check sliding pads

x

1) Daily lubrication, if there is not central lubrication.

00.9.6 Scheduled Maintenance for Spreader Maintenance item


SPREADER

Dai ly

50 h

1. Lubricate bearings of longit. tilting cylinders 2)

x

2. Lubricate bearings of lengthening cylinders 2)

x

3. Lubricate rocker bearings of turning device 2)

x

4. Lubricate bearing of turning device 2)

x

250 h

5. Lubricate slide planes

x

6. Lubricate bearings of bearer

x

7. Lubricate gear rim

1000 h


x

8. Lubricate twistlocks

x

9. Lubricate bearings of twistlock turning cylinder 10. Check rotation transmission oil level

x x

11. Change oil to rotation transmission

x

12. Check sliding pads

x

13. Inspection of twistlocks 3)

x

2) Central lubrication point (optional equipment) 3) First time 5000 operating hours or 2 years whichever occurs first.

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00.9.7 Scheduled Maintenance for Others Maintenance item


OTHERS

Dai-ly

1.Fill lubricant tank of central lubricational system, (optional equipment)

x

2.Check instrument panel, indication lights and signal horn

x

250 h

3.Check operation of central lubricator dispencers and condition of pipes

x

4.Check operation of electric devices

x

5.Check by driving all machine function

500 h

1000 h

x

7.Measure braking system pressures

x

8.Check screw connections and tighten them as necessary to specified torques

x

9.Wash the whole machine throughly clean

x

10.Check the operation of the overload control system and adjust it if necessary

x


x

x

x

6.Check brake system for possible oil leaks

11.Clean fuel tank of possible impurities

2000 h


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00.9.8 Unit Conversation Convert to SI-units Old unit

Coefficient

Si-units

1 kp....... 1 kpm....... 1 kpm/s....... 1 kp/mm2....... 1 mm vp.......

9,80665 (9,81) (10)

.. .. .. .. ..

N Nm = J = Ws W = J/s = Nm/s N/mm2 = MPa Pa

98,1 1 kp/cm2.......

0,980665 (0,98) (1,0)

.. kPa

1 mmHg.......

133,322

.. Pa

1 atm.......

101,325

.. kPa

1 bar.......

100

.. kPa

1 hv.......

0,7355 (0,75)

.. kW

1 hp.......

0,7457

.. kW

1 cal....... 1 kcal/kg.......

4,1868 (4,19) (4,2)

.. J = Nm = Ws .. kJ/kg

1 kWh.......

3,6

.. MJ

1 km/h.......

0,278

.. m/s

1 mpk/h(solmu) ....

0,514

.. m/s

1 m3/h.......

0,000278

.. m3/s

1 l/min.......

0,00167

.. m3/s

1 kcal....... 1 kcal/h.......

1,163 (1,16) (1,2)

.. Wh .. W

Note!Calorie (cal) from Ws 1 kWh = 860 kcal = 3,6 MJ

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Convert to old units Si-units

Coefficient

Old unit

N....... Nm = J = Ws....... W = J/s = Nm/s .... N/mm2 = MPa .... Pa.......

0,101972 (0,102) (0,1)

.. .. .. .. ..

1 Pa.......

0,0010

.. bar

0,0075

.. mm Hg

0,00987

.. atm

0,010

.. bar

0,0102

.. kp/cm2

0,000102

.. kp/mm2

1 bar.......

1,02 (1,0)

.. kp/cm2

1 MJ.......

0,278 (0,3)

.. kWh

1 kJ/kg....... 1 J = Nm =Ws.......

0,239 (0,24) (0,25)

.. kcal/kg .. cal

1 Wh....... 1 W.......

0,859845 (0,86)

.. kcal .. kcal/h

1 kW.......

1,36

.. hv

1,34

.. hp

1 m/s.......

3,6 1,94

.. km/h .. mpk/h (knot)

1 m3/s.......

0,0036 0.060

.. m3/h .. l/min

1 kPa.......

1 kp 1 kpm 1 kpm/s 1 kp/mm¡ 1 mm vp

Note!All the above presented conversion coefficients are approximations of some degree.

Length 1 in = 25,4 mm

1 mm = 0,039 in

1 ft = 0,3048 m = 304,8 mm

1 cm = 10 mm = 0,39 in

1 yd = 0,9144 m = 914,4 mm

1 dm = 10 cm = 3,9 in


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Length 1 naut. mile = 1852 m

1 m = 10 dm = 3,28 ft

1 stat. mile = 1609 m

1 km = 1000 m = 1090 yd

Area 1 sq in = 645,2 mm2

1 mm2 = 0,0015 sq in

1 sq ft = 0,09290 m2

1 cm2= 100 mm2 = 0,15 sq in

1 sq yd = 0,8361 m2

1 dm2 = 100 cm2 = 15 sq in

1 sq mile = 2,590 km2

1 m2 = 100 dm2 = 1,19 sq yd = 10,76 sq ft 1 km2 = 1000000 m2 = 0,38 sq mile

Volume 1 US fl oz = 29570 mm3 1 cu in = 0,01639 dm3 1 cu ft = 0,02832 m3 1 cu yd = 0,7646 m3 1 US qt = 0,9464 dm3 1 US gal = 3,785 dm3

Mass 1 oz = 28,35 g

1 g = 0,0353 oz

1 lb = 0,4536 kg

1 kg = 1000 g = 35,3 oz

1 short ton = 0,9072 t

1 kg = 2,205 lb

1 long ton = 1,016 t

Force 1 ozf = 0,2780 N

1 N = 3,597 ozf

1 lbf = 4,448 N

1 N = 0,2248 lbf

1 kp = 9,807 N

1 N = 0,1020 kp

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Pressure 1 ft H2O = 2,989 kPa

1 bar = 100 kPa = 100000 Pa

1 in Hg = 3,386 kPa

1 kPa = 7,5 mmHg

1 in H2O = 0,2941 kPa

1 kPa = 0,33 ft H2O

1 psi = 1 lbf/sq in = 6,895 kPa

1 kPa = 0,29 in Hg 1 kPa = 4,01 in H2O 1 kPa = 0,15 psi 1 kPa = 0,15 lbf/sq in

Energy 1 Btu = 1055 Nm = 1055 J

1 Nm = 1 J = 1 Ws

1 ft-lbf = 1,356 Nm

1 kJ = 1000 Nm = 0,95 Btu

1 kcal = 4187 Nm

1 Nm = 0,74 ft-lbf

1 Wh = 3600 Nm

1 kJ = 0,24 kcal

1 Ws = 1 Nm

1 kJ = 0,00028 Wh

1 kpm = 9,807 Nm

1 Nm = 0,102 kpm

Power 1 Btu/hr = 0,2931 W

1 W = 3,412 Btu/hr

1 ft-lbf/s = 1,356 W

1 W = 0,7376 ft-lbf/s

1 hp = 0,746 kW = 746 W

1 kW = 1000 W = 1,341 hp

1 hv = 0,736 kW = 736 W

1 kW = 1000 W = 1,359 hv

Temperature °C = 5/9 X (°F-32) °F = 9/5 X °C+32 K = °C + 273,15


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24


00.9.9 General Tightening Torques General tightening torques for screw connections, metric ISO-standard thread Screw size

Tightening torque Nm Strength class, surface treatment, material 5.8 Zne

8.8 oiled

8.8 Zne

10.9 oiled

12.9 oiled

M4

1,77

-

-

-

-

M5

3,53

6,35

5,66

8,94

10,7

M6

6,04

10,9

9,69

15,3

18,3

M8

14,5

26,1

23,2

36,8

44,1

M10

28,6

51,5

45,8

72,4

89,9

M12

49,7

89,4

79,6

125

151

M14

79,0

142

127

200

239

M16

121

218

194

307

368

M18

169

304

271

428

513

M20

236

426

379

598

718

M22

319

573

510

806

967

M24

409

735

655

1030

1240

M27

591

1060

943

1490

1790

M30

807

1450

1290

2040

2450

M33

1090

1950

1740

2750

3290

M36

1410

2520

2243

3550

4260

M39

1800

3240

2880

4560

5460

M42

2250

4020

3580

5660

6790

- 1 Nm = 0,102 kpm - Zne = electrogalvanized If the screw shank is reduced in diameter (thinned) or the thread terminates in a clear end groove, the values listed in the table must not be used. Tightening torques for these cases must be calculated separately.

UDRS01.01GB


Power Unit

01

1

Power Unit 01.1 Power Unit - Scania ........................................................................................ 3 01.2 Power Unit - Cummins .................................................................................. 4 01.2.1 Tightening Connection between Engine and Transmission ................. 5 01.3 Engine - Scania .............................................................................................. 6 01.4 Engine - Cummins .......................................................................................... 8 01.4.1 Maintenance Points for Fuel Tank and Coolant Expansion Tan .......... 9 01.5 Transmission CLARK 15.5 36431 ............................................................... 01.5.1 Checking Transmission Oil Level ...................................................... 01.5.2 Changing Transmission Oil ................................................................ 01.5.3 Transmission CLARK 15.5 36431 ..................................................... 01.5.4 Cross Section of Transmission .......................................................... 01.5.5 Oil Pump ............................................................................................

11 11 11 12 13 14

01.6 Instructions for Checking Transmission Operation ................................. 01.6.1 Electric Inspections ............................................................................ 01.6.2 Hydraulic Inspections ......................................................................... 01.6.3 Pressure Measuring ........................................................................... 01.6.4 Selector Valve .................................................................................... 01.6.5 Measuring Points ............................................................................... 01.6.6 Troubleshooting ................................................................................. 01.6.7 Tightening Torques of Transmission Bolts and Screws .....................

15 15 15 15 16 17 18 19

01.7 Stall Use: Testing of Engine and Transmission ........................................ 20 01.7.1 Testing ............................................................................................... 20


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2

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Power Unit


Power Unit

3

01.1 Power Unit - Scania 4

5

11

1

6

9

7

3

2

10

Y3 Y2 Y1 Y4 Y5

8 Figure 1. Power Unit 1

Engine

2

Transmission and the torque converter

3

Transmission pump

4

Engine oil dipstick

5

Engine oil filling

6

Oil cleaner

7

Oil filter

8

Fuel filter

9

Transmission oil filling

10

Transmission oil dipstick

11

Transmission oil filters

Weight of power unit 1930 kg (4250 lb)


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4

Power Unit

01.2

Power Unit - Cummins 2

1

Figure 2. Power Unit 1. Engine 2. Transmission and the torque converter Weight of power unit 1930 kg (4250 lb)

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Power Unit

5

01.2.1 Tightening Connection between Engine and Transmission

A

C

B

45 Nm (33 lbf.ft)

1 71...77 Nm (52,5...57 lbf.ft) CUMMINS L10, M11: 185 Nm (136,5 lbf.ft) SCANIA DS11: 190 Nm (140,5 lbf.ft)

Figure 3. A = Engine

B = Transmission

If the tension discs connecting transmission and engine; point 1; shall be changed, check by mounting that the new discs are suitable. They must be closed against the surfaces of engine and transmission. If not, remove with grindstone the sharp edge of the disc opening. Engine flywheel housings face of joint (C) SAE J617 No. 3.


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Power Unit

01.3

Engine - Scania

Scania DI12 turbocharged and recooled direct injection engine, low emissions. Principal dimensions and data Power

243 kW (330 hv) / 2100 rpm

Max. torque

1458 Nm / 1300 rpm

Number of cylinders

6

Cylinder numbering from the front end

1-2-3-4-5-6

Engine displacement

11.7 dm3

Cylinder bore

127 mm

Stroke

154 mm

Aspiration

turbocharged

Cooling

by liquid

Direction of rotation of the crankshaft clockwise viewed from engine front end Dry weight

UDRS01.01GB


995kg

Power Unit

7

9

17

1, 2

14

8

19 11

15 13 12 10

3

7 4 5 6

16

18

Figure 4. Engine 1

Type plate

2

Engine serial number, stanped in engine block

3

Oil cooler

4

Dipstick

5

Oil cleaner

6

Oil filter

7

Draining, engine oil

8

Cooland pump

9

Charger air cooler

10

Turbocharger

11

Hydraulic pump

12

Control unit A96

13

Starter motor

14

Fuel filter

15

Automatic belt tensioner

16

Draining, coolant

17

Oil filling

18

Fuel hand pump

19

Compressor

For complete details and instructions on the engine, see the Operator’s Manual.


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Power Unit

01.4

Engine - Cummins

Cummins QSM11 turbocharged and recooled low emission diesel engine, which fullfills emission and regulations step III.

Figure 5. Cummins QSM11 Engine Principal dimensions and data Power

246 kW (330 hv) / 2100 rpm

Max.torque

1458 Nm / 1300 rpm

Number of cylinders

6

Cylinder numbering from the front end

1-2-3-4-5-6

Engine displacement

10.8 dm3

Cylinder bore

125 mm

Stroke

147 mm

Aspiration

turbocharged

Cooling

by liquid

Direction of rotation of the crankshaft clockwise viewed from engine front end Dry weight

940 kg

For complete details and instructions on the engine, see the Operator’s Manual.

UDRS01.01GB


Power Unit

9

01.4.1 Maintenance Points for Fuel Tank and Coolant Expansion Tan

1

A

3

2

5

4 Figure 6. Maintenance Points for Fuel Tank and Coolant Expansion Tank A

Checking hose

B

Filling cap of coolant system

1

Coolant expansion tank

2

Fuel tank

3

Filling of fuel system

4

Draining plug

5

Sensor of fuel level


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10

Power Unit

01.4.1.1 Air Cleaner

5

3

4 2

1

Figure 7. Air Cleaner 1

Main filter element

2

Safety element

3

Prefilter

4

Air cleaner maintenance indicator

5

Indicator reset The air filter element must be replaced immediately when the indicator (4) shows red. After replacing the filter element, reset the indicator using the button (5). Clean the pre-filter (3) frequently enough, daily in dusty conditions.

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Power Unit

11

01.5 Transmission CLARK 15.5 36431 The Clark transmission incorporates two main components: the torque converter and gearbox. The assembly is mounted as one unit to the flywheel housing of the engine.

01.5.1 Checking Transmission Oil Level Oil level is checked daily with the engine running at idle speed and the oil temperature at normal level 82 to 93°C (180 to 200 °F). If the oil temperature is below 82°C (180 °F), it must be warmed up. Run the engine at 20 to 30 r/s (1200-1800 r/ min) with the highest speed range selected (lever in extreme position away from driver) while applying brakes (STALL). The oil level must be on the highest level plug. Warning! Do not use the converter transmission in stall-use continuously more than 30 seconds that the torque converter does not become too warm. Keep between the stall-uses a pause of about 1 minute.

01.5.2 Changing Transmission Oil Drain out the used oil when its temperature is 65 to 95°C (150 to 203 °F). The drain plug is under the transmission. Remove the oil sump screen, clean it thoroughly, and reinstall. Remove the oil filter, remove the cartridge, clean the housing, install a new cartridge and reinstall the filter. Fill the gearbox with clean oil up to the lower mark level. Check the oil level with the dipstick located to the right of the cabin (beside oil filling cap). Run the engine at idling speed to fill the torque converter and the pipelines with oil. Add oil up to the upper plug while the engine is running. Final inspection of oil level is done when the oil is at normal operating temperature 82-93°C (180-200 °F). For oil quality, filling capacity, see Lubrication Oil Recommendations and changing interval, see Scheduled maintenance.


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Power Unit

01.5.3 Transmission CLARK 15.5 36431 630 rpm Min. 40 l/min (10 USgal/min) 2300 rpm Max. 140 l/min (37 USgal/min)

Converter inlet

Breather

Main pressure measuring point

Oil fill Converter out

Oil dipstick

Oil cooler

From oil cooler Lube pressure Fwd. clutch

Control valve 4th clutch pressure port

Oil filters (2 pcs) From filter

This line: 117 l/min (31 USgal/min) Measuring point for converter output pressure Measuring point for converter output temperature

1st speed clutch pressure port

3rd speed clutch pressure port Oil sump intake screen Oil drain plug

Figure 8. Transmission CLARK 15.5 36431

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13

01.5.4 Cross Section of Transmission

1 st 2 nd 3 rd 4 th

Figure 9. Cross Section of Transmission


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14

Power Unit

01.5.5 Oil Pump

Torque converter safety valve Main pressure measuring point

Pressure regulating valve

Figure 10. Oil Pump

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Power Unit

01.6

15

Instructions for Checking Transmission Operation

01.6.1 Electric Inspections Check the functioning of conductors, sensors, connectors and solenoid valves in the electric system of the transmission control.

01.6.2 Hydraulic Inspections Check the transmission oil level before checking the oil pressures and volume flows of the transmission and torque converter.

01.6.3 Pressure Measuring When checking pressures keep the engine speed at 33 r/ s (2000 RPM), and make sure that the speed range selector is in the neutral position. Clutch Pressures: Normally 17 to 19 bar (240-280 PSI) Allowed deviation in all clutch pressures in the same conditions is 0,34 bar (4 PSI). Torque Converter Outlet Pressure: Min 1,7 bar (25 PSI) / 2000 RPM Max 4,9 bar (70 PSI) / unloaded at max . speed Converter Outlet Lines Flow: 90 l/min (24 USgal/min) For measuring points, see the illustration in this chapter.


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Power Unit

01.6.4 Selector Valve

12/24 Volt

Figure 11. Selector Valve

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Power Unit

17

01.6.5 Measuring Points

Figure 12. Measuring Points Pressure measurement

Measuring point

Clutch pressure, forwards

FC

Clutch pressure, 2nd

2C

Clutch pressure, reverse

RC

Pilot pressure, forwards

FP

Pilot pressure, reverse

RP

Pilot pressure, 3rd gear

3P

Pilot pressure, 2nd gear

2P

Pilot pressure, 1st gear

1P

Clutch pressure, 1st gear

See section 01.5.3 Transmission CLARK 15.5 36431

Clutch pressure, 3rd gear


Clutch pressure, 4th gear



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Power Unit

01.6.6 Troubleshooting Fault

Cause

Remedy

Low clutch pressure

• Low oil level • Clutch pressure regulating valve spool stuck open • Faulty feed pump • Broken or worn clutch axle or piston sealing rings • Clutch piston bleed • valve stuck open

• Fill to proper level • Clean valve spool and housing • Replace pump • Replace sealing rings • Clean bleed valves thoroughly

Low output of converter feed pump

• Low oil level • Intake screen dirty • Air leak in pump feed hose, connections, or broken hose • Damaged oil pump

• Add oil • Clean intake screen • Tighten all connections and replace hose as necessary • Replace pump

Overheating

• Worn oil seeling rings

• Inspect and repair converter • Replace pump • Add oil • Check and tighten oil sleeve connections

• Worn oil pump • Low oil level • Air leak in pump intake sleeve

UDRS01.01GB

Noisy converter

• Worn coupling gears • Replace • Worn oil pump • Replace • Worn or damaged bear- • Complete overhaul to ings determine damaged bearing

Lack of power

• Low Stall speed of engine • Cf. "overheating"


• Adjust engine correctly See "Overheating" for repair instructions

Power Unit

19

01.6.7 Tightening Torques of Transmission Bolts and Screws Grade 5 Thread size

Nm (kpm) (lbf.ft) Fined thread

Coarse thread

3/8"

35-39 (3,6-4,0) (26-29)

31-34 (3,2-3,5) (23-25)

7/16"

56-61 (5,7-6,2) (41-45)

50-56 (5,1-5,7) (37-41)

1/2"

87-95 (8,9-9,7) (64-70)

77-85 (7,9-8,7) (57-63)

9/16"

123-136 (12,6-13,9) (91100)

111-122 (11,3-12,4) (82-90)

Grade 8 Thread size

Nm (kpm) (lbf.ft) Fined thread

Coarse thread

50-55 (5,1-5,7) (37-41)

45-49 (4,6-5,0) (34-36)

7/16"

79-87 (8,1-8,9) (58-64)

71-77 (7,2-7,9) (52-57)

1/2"

122-134 (12,4-13,7) (90-99) 109-120 (11,1-12,2) (80-88)

9/16"

174-191 (17,7-19,4) (128141)

3/8"


156-172 (15,9-17,6) (115127)

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20

Power Unit

01.7

Stall Use: Testing of Engine and Transmission

With help of STALL use the engine and transmission condition will be tested. Check the STALL running speed of this machine in the user's manual chapter Technical Information. Compare this value with running speed value in STALL use. If the STALL- running speed is lower than the given engine STALL-running speed, the engine function has to be adjusted and / or repaired. If the measured STALL-running speed is higher than the given engine STALL-running speed, the transmission function has to be adjusted and/or repaired.

01.7.1 Testing Select the driving direction forwards and engage the highest gear. Keep the brake pedal engaged and rev the engine speed up to the highest running speed. Compare the highest running speed with the given STALL- speed of the machine. Warning! Do not use the converter transmission in stall-use continuously more than 30 seconds so that the torque converter does not become too warm. Keep between the stall-uses a pause of about 1 minute.

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Power Transmission

1

02 Power Transmission 02.1 Power Train Components - Scania .................................................. 3 02.1.1 Main Components of the Power Train .................................... 3 02.2 Power Train Components - Cummins ............................................. 4 02.2.1 Main Components of the Power Train .................................... 4 02.3 Drive Shaft ......................................................................................... 5 02.3.1 Change Differential Gear Unit Oil ........................................... 5 02.3.2 Change Planetary Gear Units Oil ........................................... 5 02.3.3 Construction of the Wheel Hub ............................................... 7 02.3.4 Torque Chart: Wheel Hub and Brake Housing ....................... 8 02.3.5 Brake Housing Cover .............................................................. 9 02.3.6 Friction Discs for Brake ......................................................... 10 02.3.7 Housing Pressure Measuring for Coolant Fluid .................... 10 02.3.8 Tightening of the Wheel Hub ................................................ 11 02.3.9 Instruction for Pinion Shaft Bearings .................................... 12 02.3.10 Rolling Resistance of Differential Bearings ......................... 15 02.4 Steering Axle ................................................................................... 02.4.1 Installation of Steering Axles ................................................ 02.4.2 Tightening and Lubrication of Wheel Bearings ..................... 02.4.3 Turning Resistance Control of the Steering Pivot Bearings ..

17 19 20 22

02.5 Wheels .............................................................................................. 02.5.1 Tyre Pressure ....................................................................... 02.5.2 Torque of Wheel Nuts ........................................................... 02.5.3 Checking of the Rims ............................................................

23 23 24 25


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Power Transmission


Power Transmission

3

02.1 Power Train Components - Scania 02.1.1 Main Components of the Power Train 1

5

2 3

4

Figure 1. Main Components of the Power Train 1. Engine 2. Transmission and the torque converter 3. Prop shaft and the spring-loaded disc brake as a parking brake 4. Drive axle with differential, drive shafts and planetary gears in the both axle ends 5. Transmission pump


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4

Power Transmission

02.2

Power Train Components Cummins

02.2.1 Main Components of the Power Train

1

5

2 3

4

Figure 2. Main Components of the Power Train 1. Engine 2. Transmission and the torque converter 3. Prop shaft and the sring-loaded disc brake as a parking brake 4. Drive axle with differential, drive shaft and planetary gears in the both axle ends 5. Transmission pump

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Power Transmission

02.3

5

Drive Shaft

The casing of the drive shaft assembly mounted rigidly to the machine frame is of sturdy steel casting construction. On the ends of the drive shaft are planetary gear unit and the hubs. On the hubs are mounted wet disc brakes, free of maintenance. In a new and/or renovated machine the oil for the differential or planetary gear unit must be changed first time after 150 operating hours and after it regularly at 1000 operating hour intervals, yet at least twice a year.

02.3.1 Change Differential Gear Unit Oil It is better to drain direct after driving because the warm oil runs faster out of the differential. Open the drainage plug on the bottom of the differential case to drain the oil out (see figure). Filling is done through the filler plug and in such a way that the oil starts to flow back from the filler opening (see figure). Oil quality and volumes are defined in the maintenance group 00 "Recommended lubricants and fluids".

02.3.2 Change Planetary Gear Units Oil The oil change interval of the planetary gear units and the oil grade to be used are the same as in the differential gear assembly. Before the drain plug of the planetary gear unit is opened, the wheel must be turned so that the drain/filling plug will be in the bottom position. Before oil filling turn the wheel so that the drain/filling plug is in upper position. Fill oil until it starts to flow out of the opened oil level opening (see figure).


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6

Power Transmission

2250 Nm

A

3

B 1

2

A

Differential gear unit

1

Oil level and fill plug

2

Drain plug

B

Planetary gear unit

3

Drain/fill plug

4

Oil level plug

4

Adhere to cleaness when changing the oil. Remember to check the tightness of threaded plugs after filling.

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Power Transmission

7

02.3.3 Construction of the Wheel Hub Wheel (rim)

Wheel nut and stud

Planetary wheel hub

Ring gear

Piston return spring hub

O- ring

Roll pin Ring gear hub

Piston return spring Brake housing Return spring quide Plug

Brake housing cover Connector Plug Piston

Planetary gear

Lockwire Hub bearing

Capscrew

Hub seals

Cover Bearing Sleeve Hub nut Adjusting disc Sun gear

Seal wear

Locking ring

Sealing of the hub

Hub bearing lock disc and screw

O- ring Plug

Screw

O- ring Piston seals Stationary disc Seals Friction disc Housing to stationary disc spacer

Cover screw

Figure 3. Construction of the Wheel Hub


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8

Power Transmission

02.3.4 Torque Chart: Wheel Hub and Brake Housing

2

3

1

6

4

5 7

Figure 4. Wheel Hub and Brake Housing

UDRS01.01GB

No:

Description

Size

1

Cover-to-planetary spider capscrew

2

Torque Lbf.ft

Nm

7/16" - 14 1/2" - 13

60-75 85-115

82-102 116-156

Piston return spring plug

-

61-75

81-102

3

Cover and spindle-to-axle housing capscrew - internal mount

5/8" - 11 3/4" - 10 7/8" - 9 7/8" - 14 1" - 12 1-1/4" - 12

180-230 310-400 500-650 500-650 725-950 1700-2200

244-312 450-542 678-881 678-881 938-1288 2305-2983

4

Cover and spindle-to-axle housing capscrew - external mount

M16 x 2.00 M20 x 2.50

199-258 369-479

270-350 500-650

5

Planetary spider-to-wheel hub capscrew

3/8" - 16 1/2" - 13 3/4" - 10

35-50 85-115 310-400

48-68 116-156 450-542

6

Bearing adjusting nut lock plate screw

3/8" - 16 7/16" - 14

35-50 60-75

48-68 81-102

7

Cover-to-brake housing capscrew

9/16" - 12 M16 x 2.00 M20 x 2.50

125-165 199-258 369-479

169-224 270-350 500-650


Power Transmission

9

02.3.5 Brake Housing Cover

1

2

3 4

5

9 11

6

12

10

7

9

8

Figure 5. Braking House Cover No:

Description

1

Torque Lbf.ft

Nm

Hydraulic bleeder

15-20

20-27

2

Plug

10 min.

14 min.

3

Housing cover plug

20 min.

27 min.

4

Coolant fill/level plug - Sump cooling only

35 min.

47 min.

5

Plug

10 min.

14 min.

6

Hydraulic fluid inlet fitting - Tapered seat

25-31

34-47

7

Hydraulic fluid inlet fitting - O-ring

25-35

34-47

8

Magnetic drain plugsg - Cooling system

20 min.

27 min.

9

Coolant input port plugs

60-75

81-102

10

Hydraulic fluid inlet

25-35

34-47

11

Plug

10 min.

14 min.

12

Coolant output port plugs

60-75

81-102

Note! Removing air from the brake housing takes about ten times more time than by usual brakes. This is due to the big capacity of the housing.


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Power Transmission

02.3.6 Friction Discs for Brake 1

2

Figure 6. 1 = Stationary disc 2 = Friction disc Checking the wear of the brake friction discs: Friction disc diameter

Minimum thickness

13"

3,81 mm

17"

4,31 mm

22"

5,08 mm

02.3.7 Housing Pressure Measuring for Coolant Fluid

Figure 7. Pressure Level in the Coolant Output is 1 "0.5 Bar

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Power Transmission

11

02.3.8 Tightening of the Wheel Hub

1

2

Figure 8. 1 = Adjusting nut

2 = Locking plate

Adjust the wheel hub bearings as follows: 1. Tighten the axle nut to 1355-1630 Nm (1000-1200 lbf.ft) pretorque, so that the bearings are without clearance in the wheel hub. 2. Turn the hub 5-10 turnings in both directions. 3. Open the axle nut half turn and turn the hub 3-5 turnings in both directions. 4. Tighten the axle nut to 745-815 Nm (550-600 lbf.ft) torque with new bearings and 500-550 Nm (370-407 lbf.ft) with used bearings. 5. Turn the hub 5-6 turnings and check the torque value. Tighten if needed. 6. Lock the axle nut with the locking plate. 7. If you cannot tighten the locking plate so tighten the axle nut, until the mounting of the locking plate is possible.


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12

Power Transmission

02.3.9 Instruction for Pinion Shaft Bearings

A

B

Figure 9. A = Spacers

B = Stamped number

Disassemble the bearings of the pinion shaft. Measure the thickness of the spacers located between the faces, and check the pinion shaft end for the number stamped to it. If the number is an integer, the value is defined as thousandths of an inch, and if the number is a decimal, the value is defined as hundredths of a millimetre. Example: +3 or -3 =.003" and +.03 or -.03 =.03 mm. Calculate the nominal spacer thickness according to the following examples. Take the value of the number stamped on the pinion shaft and add it to the old spacer thickness. The sum is the thickness of the new spacer when installing the bearings of a new pinion shaft. Calcuting examples of the thickness of spacer between pinion shaft bearings Example 1:

UDRS01.01GB

Thickness of old space

0,76 mm (0.030")

Number stamped on old pinion shaft -2

-0,05 mm (0.002")

Nominal spacer thickness

0,71 mm (0.028")

Number stamped on new pinion shaft +5

+0,13 mm (0.005")

Thickness of new spacer

0,84 mm (0.033")


Power Transmission

13

Example 2 Thickness of old space

0,76 mm (0.030")

Number stamped on old pinion shaft 2

-0,05 mm (0.002")

Nominal spacer thickness

0,81 mm (0.032")

Number stamped on new pinion shaft +5

+0,13 mm (0.005")

Thickness of new spacer

0,94 mm (0.037")

02.3.9.1 Rolling Resistance of Pinton Shaft Bearings

A

Figure 10. F = Force

A = Sleeve

The rolling resistance is 0.56-5.08 Nm (0.41-3.75 lbf.ft) with new bearings. The rolling resistance with used bearings is 1,13-3,39 Nm (0.83-2.50 lbf.ft).


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14

Power Transmission

02.3.9.2 Torque Value of the Nut on Drive Pinion

1

Figure 11. 1 = Flange bar Torque values:

UDRS01.01GB

Thread size

Torque value

7/8" - 20

271 - 373 Nm

1" - 20

407 - 542 Nm

1 1/4" - 12

949- 1220 Nm

1 1/4" - 18

949 - 1220 Nm

1 1/2" - 12

1085 - 1491 Nm

1 1/2" - 18

1085 - 1491 Nm

1 3/4" - 12

1220 - 1627 Nm

2" - 12

1627 - 2034 Nm


Power Transmission

15

02.3.10 Rolling Resistance of Differential Bearings

1

Figure 12. 1 = Adjusting Ring Use the adjusting ring to set the rolling resistance of the differential bearings to 1.7-3.9 Nm (1.3-3.0 lbf.ft). Adjust the backlash between the pinion and the crown wheel to 0.20-0.46 mm (0.008"-0.018") with a used wheel pair, and to 0.30 mm (0.012") with a new wheel pair.


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16

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Power Transmission


Power Transmission

17

02.4 Steering Axle The steering axle is one swing axle pivoted longitudinally on the machine frame with two pivot-axles (1). The overload control gauge (2) is mounted to the Pivot-axle to measure the shear force acting on the axle, (optional). Turning of the wheels is performed by one steering cylinder (3) with one piston rod passing through. Strong stub axles (4) are mounted with sliding bearings (5) to the axles. Disk brakes (11) for steering axle, (optional).


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18

Power Transmission

C C 1.2 3

B

B A

A

5 6.7 4

1 8

9

10

6 5

A-A

B-B Figure 13. Steering Axle

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Pivot-axle

2

Overload control gauge (optional)

3

Cylinder

4

Axle spindle

5

Sliding bearing

6

Sliding ring

7

Bearing

8

Axle

9

Cone bearing

10

Retainer screw


C-C

Power Transmission

19

02.4.1 Installation of Steering Axles Install the pivot axles and bearing housings into place. Secure axle retainer screw (1) with a screw locking. Set the axles into place. Tighten the fixing screws (2) of the bearing housings to a tightness of 380 Nm (280 lbf.ft). Make sure that the axles are in place and that they are free from backlash tighten up fixing screw (3). Finally, open the fixing screw (3) 1/4 turns and lock with a nut (4).

A

2

A

380 Nm 280 ft- lbf

1

4 3 A -- A

Figure 14. Installation of Steering Axles


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Power Transmission

02.4.2 Tightening and Lubrication of Wheel Bearings Tightening and lubrication of the wheel hub have to be performed according to the maintenance table intervals.

B

D A E

B C

Figure 15. Wheel Hub of the Steering Axle A

Adjusting nut

B

Locking plate

C

Protecting cover

D

Grease nipple

E

Locking nut

Measure the continuous rolling resistance, nominal value is 30-50 Nm ( 22 - 37 lbs / ft ). If the measured rolling resistance differs from the nominal value, remove the protecting cover of the wheel hub and change the tightness of the bearing adjusting nut, until the continuous bearing rolling resistance corresponds with the above-mentioned value. Check by mounting the locking plate between adjustment and locking nuts, that the shoulder in the axle keyway prevents the rotation of the locking plate on the axle. Lubricate both sides of the locking plate with grease. Tighten the locking nut of the bearings to 1000 Nm ( 740 lbs / ft )

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Warning! After tightening check that the continuous rolling resistance of wheel hub is not more than 50 Nm ( 37 lbs / ft ). Turn the edge of the locking plate over the edge of adjusting nut and locking nut and remount the bearing protecting cover. Lubricate the wheel bearing pumping through the grease nipple (D) new recommended grease. 02.4.2.1 Lubrication Points of the Steering Axle In machine without an optional central lubrication the lubrication points have to be lubricated manually according to the lubrication table intervals in this manual. Pump through the grease nipples shown in the figure below enough grease to the lubrication points.

1

2 3

4

5

6 Figure 16. Lubrication Points of the Steering Axle


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Power Transmission

02.4.3 Turning Resistance Control of the Steering Pivot Bearings The turning resistance of the pivot bearings is defined by axial torque of the pivot axle cone bearings. This torque may reduse during the operating hours of the machine, and at worst cause damages in stub axle. Check the pivot bearings turning resistance approximately every 2000 operating hours and adjust if needed the pivot axial torque.

150- 170 Nm A

A 150- 170 Nm

194 Nm

The axial torque of the pivot axle pivot is correct, when the starting turning resistance of the pivot bearings (A) is 150-170 Nm by turning the wheel hub by the rim (B). The pivot axle pivot must be released from the lever (C) between cylinder and stub axle when measuring the turning resistance. Adjustment of the Turning Resistance The turning resistance will be adjusted by axial tightening of the stub axle pivot: install a shim/ shims (D) into the bearing house of the stub axle pivot, mount the covering of the bearing house and tighten the fixing nuts to 194 Nm. The starting turning resistance of the stub axle must be 150-170 Nm measured like before. If the resistance is lower than this value adjust the turning resistance again.

D

Figure 17.Turning Resistance of the Stubaxle Pivot

C

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Power Transmission

02.5

23

Wheels

The wheels on the drive- and steering axle are identical and interchangeable. The drive axle is fitted with double wheels. Warning! It is absolutely necessary that always before tyre work pressure is removed or reduced to 1 bar (15PSI).

02.5.1 Tyre Pressure Driving with underinflated tyres, with lower pressure than defined in this group, may cause the tyre cords to break, and the tyre may slip on the rim, causing valve failure. Over-inflation subjects the tyres to harmful effects of impacts. Tyre size

Tyre pressure

18.00-25PR40

10 bar

18.00-33PR36

10 bar

Figure 18. Tyre Pressure Mark


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Power Transmission

02.5.2 Torque of Wheel Nuts Before taking the machine into the service, check the tightness of all wheel nuts with the wheels lifted up. Check the driving wheels during running-in after 2, 4 and 8 operating hours. If You change one wheel, check the tightness of the nuts according to the running-in regulations.

305Nm

400Nm

Figure 19. Checking interval for tyre pressure and torque of the nuts is 250 operating hours.

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02.5.3 Checking of the Rims

Figure 20. Checking of the Rims During the long operation time the rims can catch fine cracks and breaks. They can be caused by following reasons: • Some tyres has been empty or the tyre pressure has been too low while machine has been loaded. • The tyre pressure differs from the base value. • Genuine spare tyres has not been used after the first installation. The material and strength of non genuine spare tyres may not meet the requirements of heavy machines. • Deformation of the rim caused by external hits. Measures to be taken We recommend annual checks for cracks for example using magnetic particle test (SFS 3286 or DIN 54131). This can take place during tyre work, one rim after another. The rims which has been checked can easily be recognized, if You mark them with colour, which is changed every year. Warning! It is absolutely necessary that always before tyre work pressure is removed or reduced to 1 bar (15PSI).


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Power Transmission

Check Procedure 1. Deflate the tyre, see figure The wheel 2. Dismount the wheel from the machine 3. Dismount the tyre from the rim. 4. Disassemble the loose parts from the rim, see figure Rim of the wheel. (loose parts are No. 1 + 3 + 6 + 9). 5. Clean the areas shown ---- down to bare metal (rim part No. 4 + 8), see figure Rim of the wheel and figure Gutterband and Backband. 6. The cleaned areas of the rim must be magnetic particle tested. 7. If cracks or crack indications appear, grind smoothly maximum 0,5mm in depth. Then carry through a crack detection test, using the penetrant method (use solvent based penetrant). 8. If no cracks appear after point 6: Approve the wheel. 9. If no cracks appear after point 7: Approve the wheel. 10.If cracks appear after point 7: Reject the wheel. 11.Approved wheel have to be protected against rust (painted) . 12.Reassemble the tyre and the loose parts, see figure Rim of the wheel. Make sure that all loose rim parts are in the correct place. 13.Reinflate the tyre & remount the wheel 14.Records: When the wheel has been checked, mark the wheel and record the result. Warning! Because of the material and manufacturing method of a rim, it is not advisable to repair a rim by welding. To avoid uneven load, check the tyre pressure regularly.

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Figure 21. Rim of the Wheel 1,9

Flange

2

Lockring driver

3

Locking

4

Gutterband

5

Wheel Driver

6

Beadseatband

7

Centerband

8

Backband

Figure 22. Gutterband and Backband


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Hydraulic System

1

03 Hydraulic System 03.1 Operating Principle of Hydraulic System ....................................... 2 03.1.1 Letter and Number Signals in the Hydraulic Diagrams ........... 2 03.1.2 Pumps ..................................................................................... 2 03.1.3 Boom Movement Hydraulic ..................................................... 4 03.1.4 Steering Hydraulics ................................................................. 5 03.1.5 Top-lift Hydraulic ..................................................................... 6 03.1.6 Pre-control Pressure ............................................................... 7 03.1.7 Filtering of Hydraulic Oil .......................................................... 7 03.1.8 Cooling of Hydraulic Oil .......................................................... 7 03.1.9 Clean Hydraulics ..................................................................... 8 03.1.10 Measures to Prevent Pollution of the Hydraulic System ..... 10 03.1.11 Fault Finding for Leakage ................................................... 12 03.1.12 Dismantling Hydraulic Cylinders ......................................... 13 03.2 Hydraulic Brake System ................................................................. 03.2.1 General ................................................................................. 03.2.2 Brake Hydraulics ................................................................... 03.2.3 Adjusting and Measuring Points for Brake System ............... 03.2.4 Adjusting of Brake Pressure ................................................. 03.2.5 Adjusting the Brake Pedal .................................................... 03.2.6 Adjusting the Parking Brake .................................................

15 15 15 17 18 20 21

03.3 Maintenance of Diaphragm Accumulators ................................... 03.3.1 Structure of a Diaphragm Accumulator and Filling Device ... 03.3.2 Checking of the Pressure Accumulators ............................... 03.3.3 Filling Pressure Accumulators with Nitrogen Gas .................

22 22 23 25

03.4 Steering Hydraulic System ............................................................. 03.4.1 Steering System ................................................................... 03.4.2 Steering Device .................................................................... 03.4.3 Oil Flow in Load Sensing Steering System ........................... 03.4.4 Fault Diagnosis .....................................................................

27 27 28 29 30

03.5 Hydraulic Components for Basic Machine ................................... 31 03.5.1 Hydraulic Oil Tank Maintenance Points ................................ 32 03.5.2 Pumps ................................................................................... 34 03.6 Hydraulic Components for the Cabin Transfer ............................ 03.6.1 Pressure Adjusting for the Load Control Valve ..................... 03.6.2 Pressure Relief Valve (Rv) Adjusting .................................... 03.6.3 Oil Changing to the Cabin Transfer Hydraulic ......................

36 37 37 39

03.7 Hydraulic Components for the Spreader ...................................... 40 03.7.1 Adjusting the Spreader Lengthening .................................... 41


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Hydraulic System

03.1

Operating Principle of Hydraulic System

This chapter describes the operating principle of the hydraulic system in RS2002 Reach Stacker . Item numbers in the text refer to the hydraulic diagrams. In operating principle the numbers of components are marked with parenthesis, for example valve (30). Electronic solenoid valves, which control actuators or functions, are shown in the diagrams with the letter Y, for example Y57. The diagrams are attached to section C of the manual.

03.1.1 Letter and Number Signals in the Hydraulic Diagrams 03.1.1.1 Pumps In a diagram, the maximum volume flow produced by a pump is marked above the picture symbol of the pump, e.g. 206 l/min. 03.1.1.2 Pipes and Hoses Pipes and hoses related to valves and/or actuators are marked, for example, with letters P and T. P1 is a pressure line, T1 is a return line, TP is a drain line, and LS is an LS signal line. Letters A, B, show connection items for valves and actuators, to which pipes or hoses are connected. 03.1.1.3 Valves Pressure adjustment valves are marked in the diagrams with letters PM and a number. Adjustment values of pressure adjustment valves with a PS marking are described in table form in that diagram, where said valve is defined. For example, from PS 4 valve you adjust the pressure to a numerical value, which is shown in the table as a nominal pressure value of PM 4 measurement point. Adjustment values of pressure adjustment valves with a fixed pressure setpoint are shown in the diagram as a numerical value next to the picture symbol of the adjustment valve.

03.1.2 Pumps Pumps for work movements and steering are adjustabledisplacement pumps ( 16.1, 16.2, 17.1), connected with transmission power converter. Running speed is same as by diesel engine.

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Pump for top lift movements and extra speed by boom lifting (17.2) is a vane pump. Brake pump (17.3) is a gear pump. Inner pumps (17.1 and 16.1) are used for boom lift and telescope movements. Middlemost (17.2) pump is used for top lift movements and extra speed by boom lifting with light load. Outer (16.2) pump is used for steering, boom and telescope movements. Brake pump (17.3) acts as a charging pump for pressure batteries and as a pump for wet brake cooling. Pressure reduction valve PS22 (4) in pressure-battery charging valve is connected to the brake pump pressure connection, and the pressure reduction valve acts as the pump's relief valve.

16.1

17.1

16.2 17.2 17.3 Figure 1. Pumps 16.1

Lift and boom in/out

16.2

Steering, lift and boom in/out

17.1


17.2

Spreader and fast lifting

17.3

Brakes


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Hydraulic System

03.1.3 Boom Movement Hydraulic 03.1.3.1 General Boom lifting and telescope are controlled by proportional valves controlling the load sensing main valve units. The pump pressure is determined by drive pressure (load). Movement speed in lifting and on telescope are adjusted after start-up phase by changing the pump's output angle and by altering the diesel engine's running speed. Simultaneous movement on boom lifting and telescope e.g. vertical lifting movement can be performed by operating two functions of the boom control manual controller simultaneously (cross movement lever of boom control). 03.1.3.2 Boom Lifting / Lowering Boom lifting is performed by means of the single acting cylinders, because piston arm sides of hoist cylinders (2.1 and 2.2) are connected to the tank line. Boom lifting is controlled with proportional valve Y58. Pumps output is controlled simultaneously for both hoist cylinders. The lifting speed will be adjusted in the beginning stepless by valve control, by changing pumps' output angles. During lifting, oil from arm side of hoist cylinders (2.1 and 2.2) is drained directly through the tank line to the tank. In lifting lock valves (6.1 and 6.2) do not affect lifting, instead they let the oil flow unhindered to lifting cylinders (2.1 and 2.2). Extra speed by boom lifting is acted, when the pressure of the lifting cylinders is under 90 bar (19.2) B6. Then toplift-pumps' output is controlled by solenoid valve Y87 (26) direct to hoist cylinder, while free circulation valve Y56 (32) is closed. Boom lowering is controlled with proportional valve Y57 , which let the oil from hoist cylinders (2.1 and 2.2) through main valve (30) to the tank, and at the same time adjust lowering speed steplessly. Boom hoist cylinders are equipped with lock valves (6.1 and 6.2 ), which are opened with a hydraulic control command. Boom is lowered because of load and boom weight, so pump output is not needed for the lowering movement. Lowering speed is slowed by limit electric adjusting value. When the boom is lowered, there is formed underpressure at arm sides of hoist cylinders (2.1 and 2.2), which sucks oil directly from the tankline to the cylinder arm side. Pressure at piston side of the lifting cylinder is measured by pressure transmitter (19.2) B6, and on the basis of pressure data it sends, electronic control reduces flow of return oil from lifting cylinders (2.1 and (2.2) on heavy loads through valve (30) to the tank. It tries, as much as possible, to electronically adjust lowering speed to be equal on all loads.

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03.1.3.3 Boom Extend / Retract Boom extend is controlled by proportional valves Y51, which are used to guide the volume flow produced by the pumps to the piston side of the boom's telescope cylinder (3) through valve (30) A1-port. Oil is drained from the arm side through B1-gate of valve to tank. Lifting speed is adjusted steplessly with valve controls, by changing the pumps' output angles. Boom retract is controlled with proportional valve Y52, which is used to guide oil's volume flow to the piston rodder side of the boom's telescope cylinder (3) through valve (30) B1-port. At the same time telescope's lock valve (7) is opened, and oil is drained from the piston side to the tank through the main valve (30) through valve (30) B1-port to tank. Adjustment of movement speed is done steplessly with the joystick.

03.1.4 Steering Hydraulics When machine steering is used, the volume flow produced by the pump (16.2) goes to the priority valves (27). In the priority valve the volume flow is divided into two, primarily for use of the steering device (23) and mini steering control valve (36) and secondarily for use of lifting and telescoping valve (30). Steering speed is determined by turning speed of the steering wheel, by higher speed the priority valve (27) directs stronger flow to the steering cylinders (1). System is load-sensitive. The load (steering cylinder's pressure) transmits an LS signal to the pump's adjuster, which adjusts pump output as necessary. The LS signal is also transmitted to a priority valve (27), which guides oil flow to be used by steering. Steering speed and pressure are determined by adjusting pump output according to the LS signal received by the steering device. When turning speed is increased, the priority valve guides a bigger volume flow through the steering device to the steering cylinders ( 1 ). Steering circuit is equipped with relief valves which protect it from outside shocks. The relief valves are located in a relief valve block in connection with the steering device (23). Maximum pressure going to steering device (23) mini steering control valve (36) is limited with LS-signal's pressure reduction valve adjustment of the priority valve (27).


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Hydraulic System

03.1.5 Top-lift Hydraulic 03.1.5.1 General Top-lift movements are performed by solenoid valves, some of them are mounted on the top of the boom and some on the top-lift. Pressure to the boom upper end is directed through one extra pressure line from the top-lift pump (17.2) by closing the free circulation from valve Y56 (32), which is switched on always, when one of the top-lift movements is in function. Return oil into the tank is flowing through one extra tank line. In this line is mounted one 5 bar non-return valve to prevent the draining of the lenghtening cylinders and to keep the back edge of the top-lift allways lower than the front edge. 03.1.5.2 Longitudinal Tilting In normal function the longitudinal tilting of top-lift is in so called reducing position (Y63 switched on), the top-lift is positioned because of the earth gravity in horizontal position and the movements for-/backwards are reduced with throttles (12.3 and 12.4). With a reversible locking switch the current can be switched off in solenoid Y63, the toplift is locked in respect to the boom. It is used specially by turning the top-lift/container in longitudinal position, where free movements can be harmful. In this situation the top-lift will be tilted by means of one special longitudinal tilting switches, which are controlling solenoidvalve Y65a/b. The tilting speed can be adjusted by throttle valves (12.1 and 12.2). Shock valves 175 bar (21.1 and 21.2) are mounted in the cylinders. 03.1.5.3 Rotation Motor Regulating valve Y59 (9) is a proportional valve, which makes the stepless adjustment of the rotation speed possible. Rotation circuit is equipped with a 200 bar shock valve (8), which limits the rotation moment to given maximum value and specifies on the other hand the maximum retarding by stopping to prevent the overloading of the rotation devices. Rotation engine is one slow hydraulic engine, which is mounted in the gear reducer. Between engine and transmission is one plate-compressor brake. The brake will be opened automatically by throttle check valve (13.1) and closed, when the rotation movement is stopped.

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03.1.5.4 Use of the Twistlocks Control by solenoid valve Y71a/b and closed / open-position of the twistlocks is secured by non-return valves (32.1 and 32.2). 03.1.5.5 Side Shift Control by solenoid valve Y62a/b. Motion speed is adjusted by fixed throttles (38.1 and 38.2) and the circuit is equipped with shock valves (8.1). 03.1.5.6 Adjustment of Gripping Length Control by solenoid valves (Y73a/b and Y74a/b). By lenghtening the gripping length the return line will be opened by non-return valves (33.1 and 33.2). 03.1.5.7 Pile Slope, Optional Control by solenoid valves (Y73a/b and Y74a/b). By lenghtening the gripping length the return line will be opened by non-return valves (33.1 and 33.2).

03.1.6 Pre-control Pressure Pre-control pressure is taken from pressure line of pumps and pressure is reduced with a pressure reduction valve (31). This pressure is used as the pre-control pressure of the direction valve (30) and mini steering control valve (36).

03.1.7 Filtering of Hydraulic Oil Filtering is performed by full flow return filters (15). Absolute filtering value is 10 µm. Filters are equipped with 1 bar electrical pressure-difference sensor and signal light in the cabin and with one 1,5 bar by-pass valve. The sensor is in function only in temperatures over 20°C to prevent the malfunction signals because of the viscosity changes in low temperatures. The main pump can be optionally equipped with a pressure filter (53) with 10 µm filtering value and a visual indicator.

03.1.8 Cooling of Hydraulic Oil Oil cooler (18) is equipped with electrical fan controlled by thermostat ( 50°C). The cooler is ptotected against pressure shocks with shock valve of 5 bar.


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Hydraulic System

03.1.9 Clean Hydraulics Hydraulic systems are extremely sensitive to impurities a hydraulic system is just as sensitive as a diesel engine's fuel system, with its pumps, filters and lines. It is therefore extremely important that hydraulic systems are kept clean and free from impurities. A clean system means that there are no impurities in the system, whether it be in the hydraulic fluid, component parts of the system or hydraulic lines and hoses. By impurity, we refer to everything and anything that is not intended to be in the system: • solid particles such as dust, grit, threads of cotton waste, flakes of rubber from hoses or seals, etc. • liquids • gasses 03.1.9.1 Possible Sources of Impurity • Existing impurities - Casting sand, welding cinder, dust, water, etc., from components, hydraulic lines and hoses. • Generated impurities - Scaling. When particles that come between two moving surfaces attach themselves to one of the surfaces and thereafter act as a cutting surface to the opposite surface where it cuts or grinds off material. The newly formed particles then harden and cause even more wear and tear as they circulate in the system. - Erosion - Cutting or "cold welding" - Cavitation, insufficient flow to pump - Corrosion that generates particles - Fatigue/wear and tear that generates particles • Accidentally added impurities - During repair operations

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- As a result of topping up with impure hydraulic fluid • Penetrative impurities - Penetration via breather air to the hydraulic tank - Penetration via the piston rod's lubricating film - Penetration through poorly sealed inspection hatches - Condensation - Penetration via rod seals 03.1.9.2 Solid Particles It is possible to see a particle of 40 µ in size with the naked eye, but not one of 10 µ.. (1 µ = 1/1000 mm). By comparison, a strand of human hair is approx. 70µ thick. The smallest particles are less than 25 µ in size and are not visible to the naked eye. It is not, therefore, possible to judge, with the naked eye, whether or not hydraulic fluid is sufficiently clean! A particle count using special machinery or magnification equipment must be made to establish the degree of impurity. Solid impurities in hydraulic systems cause many different types of problem. Large quantities of impurity dramatically reduce the operative life span of the system. Hydraulic components break down as a result of internal wear. Particle accumulation can cause the check valves and servo valves to jam, which may lead to movement problems. Some movement might not work, or movement could be slow or in the wrong direction. 03.1.9.3 Gasses The most common gas that occurs as an impurity in a hydraulic system is air. Unlike fluids, gasses can be compressed. If air is allowed to enter a hydraulic system, this compression will be experienced as a "sponginess" of operation, making hydraulic movements difficult to control. Air in the hydraulic fluid can also cause corrosion damage, particularly when localized, sudden reductions in pressure, known as cavitation, occur. 03.1.9.4 Liquids The most common liquid impurity that occurs in a hydraulic system is water, for example, through condensation.


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Hydraulic System

This can cause rust to form, resulting in flakes or particles of rust entering the system. This most commonly occurs in the tank and those parts that are above the level of the hydraulic fluid. Such parts can be inside single action cylinders where the complete length of the hydraulic piston stroke, is seldom or never used. One simple preventive measure for such parts is to regularly run all hydraulic functions to their end positions so that the whole of the cylinders are lubricated.

03.1.10 Measures to Prevent Pollution of the Hydraulic System 03.1.10.1 When Changing Attachments Many machines have attachments that can be changed, which also means that hydraulic lines and hoses must be loosened and switched over. This entails a major risk of impurities penetrating into the system. • Always clean the connection point extremely thoroughly before disconnecting • If possible, use quick release connectors fitted with a non-return valve. This will then reduce the risk of impurities entering the system and fluid being spilt • Clean the connectors extremely thoroughly before making the connection. Make sure that no impurities are forced into the connectors themselves. 03.1.10.2 When the System is Operating All protruding hydraulic components, such as hydraulic piston rods, are at considerable risk from both mechanical damage and impurities. Due to the fact that the level of hydraulic fluid in the tank varies, the tank will "breath" through the breather filter and if the level becomes too low, the hydraulic pump will fill the system with air. • Be extremely careful with hydraulic piston rods so as to avoid physical damage to them • Regularly empty condensation water from the hydraulic tank • Make sure that the fluid level in the hydraulic tank is always right level • Make sure that all filters in the system function correctly. Regularly replace filter elements, in accordance with the machine's lubrication chart

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• Regularly check the wiper and rod seals and replace them as required 03.1.10.3 Storage and Topping up of Hydraulic Fluid • Be particularly careful when topping up hydraulic fluid - carelessness is one of the major causes of impurities entering the system • Store drums, cans and funnels in as clean conditions as possible, for example, under a tarpaulin and not directly on the floor. • Handle drums, cans and funnels with care and clean them as necessary • Store drums of hydraulic fluid horizontally so that bungs and taps are below the fluid level, which will reduce the risk of impurities and humid air entering the drum. • Always top-up hydraulic fluid through a clean strainer, preferably through a filter, using a top-up pump. • Never use the very last of the fluid in the drum. This could contain water and other impurities, depending on the number of times that the drum has been opened. • Hydraulic oil provided by oil companies in closed containers is not clean enough to be used in the hydraulic system as is. The oil must be cleaned/filtered before it can be added to the machine's hydraulic oil tank. 03.1.10.4 Repairs and Service As soon as a hydraulic system is opened, there is always a great risk of impurities entering the system • Thoroughly clean the around the area of the system on which work is to be carried out • Isolate the area where work is to be carried out with the help of, for example, clean protective plastic sheeting • Do not open sensitive components out in the field, replace the complete component instead • Immediately insert protective plugs in all open connections


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Hydraulic System

• Make sure that exchange components are thoroughly clean • Carry out the repair as soon as possible • After dismounting, clean all parts • If a serious breakdown has occurred, for example, if a pump or hydraulic motor has seized, metal particles may have been spread and polluted the entire system. In such cases, it is extremely important to carefully filter or replace the hydraulic fluid. Under all such circumstances, the system's filters must always be replaced • Never fit components where the protective plugs have fallen out - impurities may have entered the system. Warning! If there is the slightest doubt about the purity of the hydraulic fluid - send a fluid sample to the manufacturer of the fluid.

03.1.11 Fault Finding for Leakage • All fault finding should take place with the minimum hydraulic pressure required to actually discover the leakage. High pressure will tighten all seals and make it more difficult to discover any leakage. • Check extremely carefully where the leakage comes from before taking any action. It may be possible to stop the leakage without the necessity of costly dismantling. • Check for external leakage - welds on cylinder ends - welds on coupling connections - Leakage between the cylinder pipe and the cylinder head, could be due to a faulty O ring or damage to the O ring's sealing surface. Both problems can be corrected with the cylinder in place. - Leakage between the cylinder head and the piston rod, could be due to a damaged piston rod or damaged/worn piston rod seal. • Check for internal leakage

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- Leakage between the hydraulic piston seal and the cylinder pipe, due to worn piston seal. Put the cylinder under pressure and check to see if the piston sinks back. Warning! Do not check for leaks with your hand, as even a small leak could be strong enough to penetrate the hand. Use a face mask that covers your entire face, as well as protective clothing and footwear that provide protection against high-pressure liquid sprays. Always wear these when working near pressurised hydraulic hoses, pipes, or components.

03.1.12 Dismantling Hydraulic Cylinders Before dismantling, always check that the piston rod is free from any remains of paint. Also check to ensure that there are no burrs or impact damage by the connections or couplings. Make sure that the chamfer up to the chrome surface of the piston rod is free from burrs and any remains of paint. • Loosen the cylinder from its mounting and loosen the hydraulic connections • Immediately plug the cylinder connections and hoses/ lines. • When the cylinder is opened - observe the highest possible level of cleanliness! Study the Technical Handbook to see how respective cylinders are designed and constructed. 03.1.12.1 Check Surfaces • Check the surfaces of seals. Always think about how the seals function and the type of sealing surfaces that they have. See the following descriptions: - O ring grooves internal and external - piston rod seals in the cylinder head - sealing groove on the piston - cylinder pipe surface - piston rod surface. The piston rod has a chromium plated surface of 20-50 µ in thickness. Very minor damage to this plated surface will not necessarily directly result in leakage


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Hydraulic System

- All sliding surfaces (dynamic surfaces). These are always the most difficult to ensure a tight seal, for example, cylinder pipe and piston rod. Warning! When fitting the cylinder head: Fit the head absolutely straight, preferably by hand. Do not, under any circumstances, hit it with a mallet or hammer. If the cylinder head is fitted askew the lip of the piston rod seal can be damaged and any sealing function will be lost. This applies to all types of piston rod seals.

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Hydraulic System

03.2

15

Hydraulic Brake System

03.2.1 General The hydraulic brake system consist of hydraulic pump, charge valve of brake pressure accumulators, brake pressure accumulators, pedal valve and wet disc brake of drive axle. The parking brake is spring-loaded dry disc brake unit on the cardan shaft, which can be switched on by the operating switch in the cabin. The system is completely hydraulic and controlled by charge valve, pressure accumulators and brake pedal valve. The hydraulic pump fills through the charge valve the pressure accumulators. When they are filled, the charge valve leads the pressure of the pump to the hydraulic system. The pressure accumulators are selected, so that they make it possible to brake several times, before pressure in the accumulators falls below the specified pressure limit and the charge valve switches the pump to fill the system. The brake pedal valve controls the hydraulic brake cylinders in the axle. By adjusting the movement of the brake pedal the hydraulic pressure to the brake cylinders can be adjusted.

03.2.2 Brake Hydraulics Brake hydraulics gets volume flow from the brake pump (9). The pump gives volume flow to both charging of pressure accumulators of brakes and to cooling of the brakes. From the pump the oil goes first through a pressure filter (5) to charge valve of the accumulators, from where it goes to brake cooling and is distributed evenly to each brake. From the brakes the cooling oil returns back to the tank. A thermo bypass valve (18) prevents generation of excessive cooling pressure inside the brakes, when the oil is cold. If pressure in the pressure accumulators has fallen below about 128bar, accumulators' charge valve charges the pressure accumulators (8), and when pressure of accumulators is 160bar, the valve switch the pump (9) to free circulation. Integrated to the charge valve of accumulators in the brakes is handbrake valve Y12, which releases handbrake cylinder (2) when it is energized. Then pressure of the hydraulic oil can squeeze in the spring of handbrake cylinder (2) and release the handbrake. When Y12 is de-


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Hydraulic System

energized, the spring force pushes hydraulic oil from the cylinder to the tank, and at the same time spring force causes braking force on the handbrake. Brake pedal valve (11) gets pressurized hydraulic oil from pressure accumulators (8) Pressure accumulators are so-called diaphragm-type accumulators, with volume of 2,8 litres. Pre-filling pressure is nitrogen gas (service manual instruction). Installed into the parking brake circuit is one accumulator (8.1), and installed into the driving brake circuit are three corresponding accumulators (8.2,8.3,8.4), which are separated from each other with counter valves. Pressure switch S13 in charge valve (4) is switched on, if pressure in the accumulator circuit is low (115 bar). Pressure switch (7) S23 for brake lights is switched on, if pressure is below 2,5bar.

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Hydraulic System

17

03.2.3 Adjusting and Measuring Points for Brake System PM27

PS22

8.4 PM26

8.3 PM21

PM24

8.2

PM22

8.1 S13

PM23

Drive axle 5

Y12

17 18

Figure 2. Adjusting and Measuring Points for Brake System 5

Pressure filter

8.1-8.4

Pressure accumulators

17

Oil cooler

18

Brake tank

PM21

Pressure measuring for charging pressure

PM22

Pressure measuring for accumulator pressure, handbrake

PM23

Pressure measuring for accumulator pressure, footbrake

PM24

Pressure measuring for brake pressure

PM26

Pressure measuring for handbrake

PM27

Pressure measuring for cooling pressure

PS22

Pressure adjusting for charging pressure

S13

Pressure switch for low brake pressure

Y12

Parking brake valve

Numbering corresponds to the brake hydraulics flowchart.


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Hydraulic System

03.2.4 Adjusting of Brake Pressure

PM26 PM26 PM26 PM21 PM22

S13

PM23

Figure 3. Adjusting of Brake Pressure 1. Adjust the pressure adjusting valve PS22 in charging valve of pressure accumulators full open. 2. Start the engine. 3. Connect the pressure gauges measuring 0-250 bar to the measuring points PM21 and PM22. 4. Adjust the pressure adjusting valve PS22 to160 bar, which is the end point of charging and lock the adjusting screw. 5. Check the indication of pressure gauge connected to measuring point PM21 when the engine is running at idle. The charging valve of pressure accumulators is functioning as planned, if the gauge shows 5-10 bar pressure, when the pressure accumulators are full charged. When the charging valve is charging the pressure accumulators, the pressure gauges connected measuring points PM21 and PM22 show the charging pressure of that moment. When the adjusted 160 bar pressure is reached, the pressure gauge connect-

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Hydraulic System

19

ed measuring point PM22 shows 160 bar and the pressure gauge connected measuring point PM21 shows 5-10 bar. 6. Follow the changes in pressure accumulators charged hydraulic pressure on the pressure gauge connected in pressure measuring point PM22, when the engine is running at idle. The charging valve is functioning as planned, if the gauge shows 123-132 bar, when the charging valve starts to charge again the pressure accumulators. The starting pressure of charging can not be adjusted. If the starting pressure is under 123 bar, please inform the manufacturer of the machine for pressure cartridge calibration.


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Hydraulic System

03.2.5 Adjusting the Brake Pedal

S52 1

3

2,S23 Figure 4. Brake Pedal

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1

Brake pedal

2

Brake pedal valve

3

Adjusting screw

S23

Braking light switch, 2.0bar

S52

Declutch


Hydraulic System

21

03.2.6 Adjusting the Parking Brake

1 1

4

2

5

3

2 1

4

2

5

3

Figure 5. Parking Brake 1

Adjust screw

2

Release screw of the parking brake

3

Brake disc

4

Brake pad

5

Locknut

Start to adjust switching the parking brake out of function (pressure in cylinder) by pressing the operating switch. Make sure, that the pressure accumulators are charged. Adjust the nut 5 (picture 1) close and switch the parking brake on by pressing the operating switch (pressure out of cylinder). Adjust with hook plug spanner the adjusting screw 1 and close until the brake pads (4) touch the brake disc (3). After that open the adjusting screw 1 adjusting 1,5 revolutions. Switch the parking brake out of function (pressure in cylinder) by pressing the operating switch and then open the nut 5 (picture 2) ending the adjusting work.


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Hydraulic System

03.3

Maintenance of Diaphragm Accumulators

03.3.1 Structure of a Diaphragm Accumulator and Filling Device M28X1.5 SW6

17

1

5 2

8 1/2

12

3

11

W24.32x1/13

14 15

13

4

6

SW36

16

9 M28X1.5

Figure 6. Diaphragm Accumulator and Filling Device

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1

Diaphragm accumulator

2

Sealing ring

3

Diaphragm

4

Shut-off valve

5

Shut-off screw

6

Bleed valve

8

Intermediate piece

9

O-ring

11

Non-return valve

12

Connection to nitrogen bottle

13

High-pressure hose

14

Pressure gauge

15

Shut-off screw

16

Diaphragm accumulator

17

Filling device for diaphragm accumulator


Hydraulic System

23

03.3.2 Checking of the Pressure Accumulators

8.1

8.2

8.3

8.4

Figure 7. Pressure Accumulators During adjustment and maintenance works of the brake system you must pay special attention to the operating condition of the pressure accumulators. If the common pressure accumulators of the whole system are damaged, the charging valve is operating frequently and the braking effect is declining rapidly when the engine is stopped. To ensure planned operation of the braking system, the pressure accumulators should be checked at least twice a year. The accumulator used in the brake system is a precharged diaphragm accumulator with a non-replaceable diaphragm. The precharging pressure of the brake system pressure accumulators is 100 bar. An exact measuring of the precharging pressure and possible increasing is described in group KH03-0106. Check the precharging pressure from the "oil side" as follows: 1. Install a pressure gauge with pressuer area 0-250 bar to the pressure measuring point PM22. 2. Start the engine and run at idle speed for a while to increase the pressure reading to 150 bar. Stop the engine. 3. Engage the parking brake. If the pressure gauge shows a reading at the measuring point PM22 still after several engagings of the parking brake, the accumulator diaphgrams are OK. 4. Checking of the pressure accumulators of the circuits after non-return valves:


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Hydraulic System

Install a pressure gauge to the pressure measuring point PM24. Depress the brake pedal several times while observing the pressure gauge reading. The pressure drops when the brakes are applied until the pressure drops very quickly close to zero. The pressure reading before this sudden dropping is the precharging pressure of the accumulator to be checked.

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03.3.3 Filling Pressure Accumulators with Nitrogen Gas Diaphragm accumulators are precharged with nitrogen gas to the required precharging pressure before installation. The precharging pressure for each accumulator is specified in the hydraulic flowcharts in the operation and maintenance manuals of the machine. The precharging pressures specified by the manufactured must absolutely be observed. 03.3.3.1 Filling By measuring the hydraulic accumulator make sure that there is no hydraulic pressure in the system. The oil must flow free out of the hydraulic accumulator. If there is no free outflow, the filling pressure may be too low. To empty the pressure in the hydraulic system, pump the brake pedal many times. A filling device is used for precharging pressure accumulators and checking the precharging pressure. First, remove the cap and the sealing lacquer on the shut-off screw. Clean the sealing surface in the end of the accumulator, and the external thread, and loosen the shut-off screw just a little with an allen key. Connect the filling device to the pressure accumulator and the hose to a nitrogen gas bottle. Make sure that the O-ring is properly positioned between the filling device and the accumulator sealing surface. Using a square key, open the pressure accumulator shut-off screw with the aid of the intermediate piece in the filling device. Open just enough to get the precharge pressure reading in the pressure gauge. If the precharging pressure is too high, you can lower it to the specified value by opening the bleed valve of the filling device. Note that the bleed valve must be closed to check the correct reading. 03.3.3.2 Note ! As the precharging pressure changes with the temperature, recheck the accumulator precharging pressure approximately 2 minutes after filling. Correct possible deviations from the specified value. Tighten the pressure accumulator shut-off screw to 25 Nm, and close the nitrogen gas bottle valve. Open the bleed valve of the filling device to let out the gas in the filling device.


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Hydraulic System

Remove the filling device, and check the shut-off valve for tightness using, for example, soap liquid. Repair possible leaks at once as it may cause damage to the pressure accumulator diaphragm. Seal the shut-off screw with sealing lacquer and install the shut-off screw cap. The pressure accumulator is now ready to be installed. Warning! Oxygen or air should never be used for precharging. Danger of explosion!

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Hydraulic System

03.4

27

Steering Hydraulic System

03.4.1 Steering System Steering system has the following characteristics: 1. A defined amount of hydraulic oil passes from steering device to the steering cylinder, whereby the wheels turn according to the turning of the steering wheel. 2. The required steering power remains low in all circumtances. 3. The system incorporates no mechanical connections between the steering wheel and the road wheels. 4. Load sensing. In steering system with load sensing both load sensing and working hydraulics pressure can be produced with a common pump. Load sensing device have an extra connection for load sensing (LS) so that the load sensing signals can be transferred from the steering device to the priority valve. The LS connection is open directly into the tank when steering is in the middle position. The structure of the steering system is described on the following page. The operation of the system is as follows: When the steering wheel is turned, the inner rotary sleeve (5) turns and shuts off free circulation of oil. It directs the incoming oil to the other side of the metering pump, depending on the turning direction of the steering wheel. As the metering pump has a constant flow volume, the rotator (1) makes it possible to have a precise amount of oil flow to the steering cylinder. The rotator is mechanically connected to the outer rotary sleeve (6), whereby the turning of the rotator also moves the rotary sleeve. The rotary sleeve shuts off the oil flow to the metering pump, when the rotator has turned the same amount as the steering wheel. Thus, the amount of oil corresponding to the turning of the steering wheel can be accurately determined. Steering responds already to a relative small turning of the steering wheel, corresponding to a 2° to end from turning rotary sleeve. When this turning is 6° as an average, the valve is completely open. The turning of the rotary sleeves is mechanically restricted in both directions to an average of 8° from the middle position. The oil returning from the steering cylinders is directed through the tank channel back into the tank.


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Hydraulic System

03.4.2 Steering Device

Figure 8. Steering Device

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1

Rotor

2

Centering springs

3

Body

4

Ball-valve

5

Inner control spool

6

Outer control spool

7

Drive-shaft

8

Stator

LS

Load-sensing-line


Hydraulic System

29

03.4.3 Oil Flow in Load Sensing Steering System

Figure 9. Load Sensing Steering System A

Middle position - Oil flow situation

B

Steering right - Oil flow

1

Oil to priority valve

2

Oil to steering divice

3

Oil in load sensing line

4

Oil in steering cylinder

5

Oil not flowing


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Hydraulic System

6

Oil to working hydraulics

7

Oil to tank connection

8

Oil in intake pipe line

9

Load sensing LS-line connected to tank

03.4.4 Fault Diagnosis Possible disturbances in steering system operation, and instructions for their removal. 1. Slow steering a) Overpressure valve or steering device ball partly open because of dirt and causing constant bypass flow of oil. b) Clamped pressure hose resticking oil flow. 2. Lack of steering power a) Insufficient amount of oil in tank, due to leaking. b) As in 1a above. 3. Jerky or sticky steering a) Clamped hose causing overpressure in return side. 4. Motoric operation (self-steering) a) Dirt in oil causing steering device rotary sleeves to stick. Clean the system troughly and fill with new clean oil.

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Hydraulic System

03.5

31

Hydraulic Components for Basic Machine

18

1

32 36 PM2

16

PM1

29

27 PM5

30 37

31, PM8

26, PM4

PM3

17

15

Figure 10. Hydraulic Components for Basic Machine 1

Hydraulic oil tank

15

Return filter

16

Pumps

17

Pumps

18

Oil cooler

27

Priority valve

26

Directional control valve

29

Pressure accumulator

30

Directional control valve M400LS

31

Pressure reducing valve

32

Pressure release- free circulation valve

36

Directional control valve, miniratti (optional)

37

Pressure filtres (optional)

PM

Pressure measuring


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Hydraulic System

03.5.1 Hydraulic Oil Tank Maintenance Points

4 2 3

10

1

5

6

8

11

7

9

Figure 11. Hydraulic Oil Tank Maintenance Points

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1

Hydraulic oil return filter

2

Magnet rod. Clean when change filter

3

Hydraulic oil filling cap. Do not open plug when the engine is running

4

Hydraulic oil tank breather

5

Sight glass/ oil temperature

6

Hydraulic oil tank draining plug

7

Brake hydraulic oil tank draining plug

8

Brake hydraulic oil filling cap

9

Filter indicator, hydraulic system (S239A)

10

Hydraulic oil cooler

11

Brake hydraulic oil cooler

12

Filter indicator, brake system (S239B)


Hydraulic System

33

Warning! Do not open the plug when the engine is running! Hydraulic oil level is correct when it is between the min. and max. lines. Retract the telescope and lower the boom before checking hydraulic oil level.


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Hydraulic System

03.5.2 Pumps

16.1

17.1

PM1 16.2 17.2 17.3 PM2

Figure 12. Pumps

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16.1


16.2

Steering, lift and boom in/out

17.1


17.2

Spreader and fast lifting

17.3

Brakes

PM1

Pressure measurement

PM2


PM3



PM3

Hydraulic System

35

03.5.2.1 Adjusting Pressure of Adjustable Displacement Pump 1. Connect a pressure gauge to pressure measurement point (PM) of pump to be adjusted. 2. Open safety valve A. 3. Twist stand-by controller B closed. 4. Start the engine. 5. Twist safety valve A to requested adjustment value. Open stand-by controller B, until yo reach the correct adjustment value, 30 bar.

B A

Figure 13. Adjustable Displacement Pump


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Hydraulic System

03.6

S97A,S97B

Hydraulic Components for the Cabin Transfer

1

S97b

N

3 Y96a

N

Y96b

2 Pm1 5

A B

Rv

S296

S297

4

Figure 14. Hydraulic Components of the Cabin Transfer

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Pm1

Pressure measuring

Rv

Relief valve

S97a

Cabin transfer forwards

S97b

Cabin transfer backwards

S296

Cabin transfer forwards

S297

Cabin transfer backwards

S97A,S97B

Inductive limit switchs for cabin transfer

1

Cabin transfer cylinder

2

Locking valve

3


4

Pump and tank

5

Filling, V=2.8L


Hydraulic System

37

03.6.1 Pressure Adjusting for the Load Control Valve 1. Open locking anticlockwise. 2. Turn the adjusting screw (5) fully closed anticlocwise. 3. Adjust 3 turns clockwise. 4. Lock the adjusting screw (5). Working pressure for cabin movements: Forward Pm1 ≈ 90bar Rearward Pm1 ≈ 40bar

03.6.2 Pressure Relief Valve (Rv) Adjusting 1. Connect the pressure gauge (min.150bar) to the measuring point Pm1. 2. Take off the sockets (6) from the directional valve. 3. Adjust pressure to 120bar. 4. Take off the pressure gauge and put the sockets on.


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Hydraulic System

60

6

60

96a

96b

Pm1 120

Rv 5

Rv

Figure 15. Hydraulic Schema of the Cabin Transfer

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Pm1

Pressure measuring

Rv

Relief valve

1

Cabin transfer hydraulic cylinder

2

Locking valve

3


4

Pump unit

5

Adjusting screw

6

Socket


Hydraulic System

39

03.6.3 Oil Changing to the Cabin Transfer Hydraulic 1. Move the cabin to the rear position (the cylinder full stroke in). 2. Open the pipe (A) from the pressure side of the pump and drain the tank by using the pump carefully. Warning! Do not use the pump without oil in any circumstances! 3. Plug the pipe (A) from the pressure side of the pump and fill the tank (2,8l) through filling cap (5). 4. Move the cabin forwards and backwards 1-2 times and check oil quantity.


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Hydraulic System

03.7

Hydraulic Components for the Spreader

Figure 16. Hydraulic Components for the Spreader

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1.1 1.2

Cylinders for sideshifting

2.1 2.2

Cylinders for spreader lengthening/shortening

3.1 3.2

Cylinders for twistlocks

4.1

Valve for sideshifting

4.2 4.3 4.4

Valve block for twistlocks and spreader lengthening/ shortening

32.1 32.2

Counterbalance valves of twistlocks


Hydraulic System

41

03.7.1 Adjusting the Spreader Lengthening 4.2

4.3

4.4

1 Figure 17. Valves of Spreader Lengthening / Shortening and Twistlocks 1

Adjust screw

33.1

Locking valve, left

33.2

Locking valve, right

4.2

Spreader lengthening/shortening, left

4.3

Spreader lengthening/shortening, right

4.4

Twistlocks

PM41

Pressure measuring

PM33

Pressure measuring

Counterbalance Valves Setting (100bar) : - Open locking anticlockwise. - Turn screw fully open anticlockwise. (1) - Adjust 3 turns clockwise. (1) - Lock the adjust screw. Locking valve (33.1, 33.2) opening pressure after adjusting is 100bar. Pilot ratio is 3:1


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Hydraulic System


Electric Systems

1

04 Electric Systems 04.1 Electrical System General ................................................................ 2 04.1.1 Safety ...................................................................................... 2 04.2 Maintenance of Electric System ...................................................... 04.2.1 Batteries .................................................................................. 04.2.2 Alternator ................................................................................ 04.2.3 Welding Machine .................................................................... 04.2.4 Locating Electric Faults ........................................................... 04.2.5 Electric Diagram's Reading Order ..........................................

3 3 4 5 6 7

04.3 Reach Stacker's CAN-based Control System ................................ 8 04.3.1 System Structure .................................................................... 8 04.3.2 Multi-function Display A80 .................................................... 11 04.3.3 Alarms ................................................................................... 16 04.3.4 Tests ..................................................................................... 18 04.3.5 Control Module A81 .............................................................. 20 04.3.6 Control Module A82 .............................................................. 23 04.3.7 Control Module A83 .............................................................. 26 04.3.8 Control Module A84 .............................................................. 29 04.3.9 Engine Control ...................................................................... 31 04.3.10 Control of Boom and Spreader ........................................... 35 04.3.11 Monitoring of Stability ......................................................... 46 04.3.12 Load Weighing .................................................................... 46 04.3.13 Calibrations ......................................................................... 48 04.3.14 Functions of By-pass and Emergency Switches ................. 55 04.3.15 Bus Errors ........................................................................... 56 04.3.16 Replacement of a Module ................................................... 58 04.4 Electric Equipment for the Power Unit Scania DI12 EDC/PDE ... 59 04.5 Electric Equipment for the Power Unit .......................................... 60 04.6 Electrical Equipment in the Frame ................................................ 61


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Electric Systems

04.1

Electrical System General

The nominal voltage of the electric system is 24 VDC. The electric system follows the 1-conductor principle, where the frame acts as the other conductor. To make detecting of possible malfunctions and troubleshooting easier, all leads are numbered according to the markings specified in the electric diagrams.

04.1.1 Safety The insulation material of the conductors is oil resistant. Wiring may not, however, be in contact with oils or other solvent fluids. Close to the engine and other hot surfaces, make sure that the cable insulations are not damaged of the heat. Replace cables with damaged insulations immediately. Warning! Blowing of a fuse always indicates a fault in the electric system. Repalr the fault prior to fitting a new fuse. Warning! The new fuse must absolutely have the same specification as the previous one! The size and locations of fuses are specified in the wiring diagram. Warning! The control and alarm system of the machine protects it and gives warnings to the driver and the environment. Don't make any alterations in the electric system without manufacturer's permission. The alterations in the electric system may deteriorate the safety of the machine and will release the manufacturer from all warranty liabilities.

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Electric Systems

04.2

3

Maintenance of Electric System

04.2.1 Batteries

G1

Figure 1. Batteries The 24V electric system of the stacker is provided with two 12V lead-acid batteries connected in series. Regular maintenance of the batteries lengthens their life. 04.2.1.1 Checking and Service Instructions for Batteries: • Check that the batteries are properly fastened in their mountings. • Keep the outside of the batteries clean. • Clean away possible dirt and oxidation from the battery terminal connections. • When connecting the cable lugs to the battery terminals, observe that the positive cable is always connected to the positive terminal. Incorrect connecting damages the battery and the electric equipment. Connect the negative (frame) cable to the negative battery terminal after connecting the positive cable. • When connecting the cable lugs, take care not damage the battery terminals or the lugs, which are made of soft material. After connecting, smear the cable with protective grease • Check the electrolyte level in the battery cells at 250 h intervals. The level should be approx. 1 cm above the plates. Check also that the vent holes in the battery caps are clear. • Use a hydrometer to check the state of charge of the battery, if the electric system of the machine has malfunctions. The specific gravity of the electrolyte in a ful-


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Electric Systems

ly charged battery is approx. 1.280 and approx. 1.150 in a partially charged battery. If the specific gravity of the electrolyte is approx. 1.150 it will freeze at approx. -10°C. Warning! Do not leave a partially charged battery where it may freeze.

04.2.2 Alternator

Figure 2. Alternator An alternator has been chosen to supply the electrical energy due to its long life and small need for service. The bearing houses are sealed and they should be repacked with grease only at major overhauls. Due to the construction of the alternator the following precautions must be kept in mind, since severe damage might be otherwise caused to the electrical equipment.

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Electric Systems

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04.2.2.1 Warnings • When connecting the battery to the circuit, always make sure that the battery and the alternator are grounded by terminals of same polarity. • Never short circuit or ground the terminals of the alternator or the regulator. • Never run the alternator at "no load" and therefore make sure all connections are clean and tight. • When the battery is in the circuit and you have to connect a charger to the circuit, make sure that terminals of similar polarity are connected. • Do not switch off the main electrical switch with engine running. • When repairing the vehicle by electric welding, all alternator and regulator terminals must be disconnected. Warning! Repairs and adjustments of the alternator and the regulator should only be carried out by professional personnel.

04.2.3 Welding Machine Before starting to weld: • Disconnect the negative battery cable from frame. • Disconnect the alternator cables at their terminals on the alternator. • Disconnect the electronic control modul of engine. • Connect the ground cable of the welding machine as close to the welding point as possible. This is prevent the welding current from flowing through and damaging the bearing surfaces of parts and components.


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Electric Systems

04.2.4 Locating Electric Faults Check the fuse if an electric function of the machine is not working. If the fuse is not blown, check the circuit of the function with the aid of the wiring diagram. If the fuse is blown, turn all electric switches open, and replace the blown fuse with a new one of the same amperage. Switch the electric functions on one by one to determine which of the functions causes the fuse to blow. When the fault has been located, switch off the machine's electric circuit with the main switch or the ignition key while carrying out the repairs. If the fault is in the starter motor or alternator circuits, disconnect the negative cable between the battery and the frame while carrying out the repairs. Warning! When the machine is used, the frame cables of the cabin, the engine, and the frame structures must be connected. Insufficient ground connections cause fire hazards !

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Electric Systems

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04.2.5 Electric Diagram's Reading Order 11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

A

B

C

D

E

F

G

H

J

K

L

M

N

P

R

Nimi Title T˜ T˜ ASIAKIRJAA EI SAA ILMAN SUOSTUMUSTAMME KOPIOIDA, ESITT˜ ˜ TAI LUOVUTTAA KOLMANNELLE HENKIL LLE EIK˜ K˜ YTT˜ ˜ MUIHIN KUIN MEID˜ N SALLIMIIMME TARKOITUKSIIN

IT IS FORBIDDEN TO COPY THIS DOCUMENT OR REPRODUCE IT OR SURREND ER IT TO A THIRD PARTY. IT MUST NOT BE USED FOR ANY OTHER PURPOSES THAN THOSE APPROVED BY US.

El. schema

Piirustus n:o Drawing n:o

T5656860

Muutos Rev.

Lehti Sheet

16

Muutosehdotuksista on heti ilmoitettava piirustuskonttoriin.

Figure 3. Electric Diagram’s Reading Order 1

Page number of electric diagram

2

Drawing number of electic diagram

3

X-coordinate on the margin

4

Because there are no wire numbers on card, L3 is a line edentification with a direct relation to the corresponding line identifications on the next page.

5

Device identification

6

Connector number and pole number

7

Wire number

8

Pole number on the device

9

Y-coordinate on the margin

10

Wire continues on page 3 of the el. diagram, coordinate position 27B.

11

Grounding on the frame


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Electric Systems

04.3

Reach Stacker's CAN-based Control System

04.3.1 System Structure The system consists of control modules located in various parts of the machine. They are located in accordance with actuators or sensors, A81 in the frame's electric box, A82 and A84 in the cabin's electric box, A83 in the boom end and display module A80 in the left dashboard. The modules are connected to each other with a CAN bus, through which communication between the modules takes place. (CAN=Controller Area Network) A display module is used as the user interface. Each module has its own application program. *

A96 (ECU)

* *

*

K19 K33 K17

35 1

7 9 113 15 VASTUKSET

35 1

7 9 11 3 15

46 2

18 0 12 14 16

46 2

18 0 12 14 16

+5V REF OUT SY T T SUMMERI

KIN

9 40 8 41 7 42 4 43 50 8 7 51 53 6 54 4 5 52 55 3 56 1 2 57

F1 F13 F1 4 F1 5

F1F1 8 F2 9 0 F2 F21

2 1 7 3 5 4 6 1 3 2 4 5 6 7

9 6 5 4 2 3 1 9 8 7 6 5 4 3 2 1

48 0 44 21 443 45 44 67 44 89 50 55 12 53 5 4 55 56 57

17 18 2 16 3 15 4 14 13 5 12 7 6 9 10 11 8 8 1 9 2 7 43 6 5 6 4 5 3 7 2 1 9 8

182 1 4 15 16 37 13 6 5 14 119 7 20 87 1 9 5 16 5 4 2 3 4 7 8 3 1 2 9

F2F2 6 F2 7 8 F3 F29 F3 0 F3 1 2F33 XR1 XSR

X44

XPO

SX1

X191

XR2

XR3

XHR

X115

XKTS X22

X32

X37

XPC

A80 A84

A82

A81

A83

Figure 4. Location of modules and wiring of CAN-bus Modules control functions of the machine as follows: A81 Hydraulics module • Boom lifting/lowering • Lock valves of lowering • Retardation of lowering • Quick movement of lifting • Βoom movements out/in • Spreader rotation

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9

• Αdditional limits of spreader rotation • Spreader indicator lights • Cabin transfer • Electric gas • Coolant level A82 Cabin module • Monitoring of engine • Monitoring of stability • Automatic changer (option) • Mini-steering wheel (option) • Load display (option) • Pressure weighing, (option) • Vertical lifting/lowering (option) • Idling stop (option) A83 Spreader module • Spreader rotation • Limits of rotation • Spreader extension/shortening • Tilting forward/backward • Locking of tilting • Sideshift • Automatic gripping of spreader • Movements of shafts manually • Container contact • End dampening of boom movements • Spreader indicator lights • Active tilting (option) A84 Input module Cabin's switch data has been collected to the input module. (Module does not contain a program). A80 Display module • Driver's displays, gauges • Alarms • Error messages


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Electric Systems

• Settings of functions - Automatic gripping on/off - Automatic changer on/off • Μaintenance displays • Calibrations - Stability - Gas pedal - Load weighing Maintenance personnel can see the statuses of module outputs and inputs on the maintenance displays, so separate measurements are not needed. From the calibration displays you perform, depending on the options, calibration of gas pedal, stability and load weighing. 04.3.1.1 General When you switch on the power to the machine, the display will show the type of the machine (e.g. DRS4531-S5) for 1 second. After this the display will show the basic display and you can start the machine. Displays vary according to the options installed.

Stability 1

40 % N

1

Stability 2

N

1.1 m

40 % 3.5 t

2

Figure 5. 1 = Basic display 2 = Basic display with options

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11

04.3.2 Multi-function Display A80 Module-controlled functions of the machine are displayed on a multi-function display. In normal operation the display shows a basic display, which is one of the ones below depending on the options installed in the machine. In addition to the driver's displays, there are also maintenance and calibration displays, which are protected with key switch S3 (located in the cabin's electric box). The display also shows alarms reporting errors in the engine, bus and sensors. See item Alarms. Number and contents of displays depend on the options installed in the machine. You can select a language version for the display from 13 alternatives. If you select English USA, the units of measurement will change to those used in the USA.

1 2

40 % 3.5 t

1.1 m

1F

3

4

5

6

7

Figure 6. Multi-function Display 1

1st line of display

2

2nd line of display

3

Change display to maintenance displays (only for professional maintenance personnel)

4

Scrolling of displays

5

Return to driver's displays, to basic display

6

Container counter reset: press * key for two seconds (optional)

7

Automatic gripping on/off / Automatic gearshift on/off (optional)

04.3.2.1 Driver's Displays There are 7-9 driver's displays, (depending on options) which can be scrolled with the arrow keys.


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Electric Systems

Driver's display 1, Basic display line 1

Stability %

line 2

Gear and driving direction

Spreader’s reach (option) *

Load (option)

1 2 3 4 F = Forward N = Neutral 1 2 3 4 R = Reversed

m (ft)

t (l.t.)

*) Horizontal distance from the centre of the drive axle to the centre of the spreader. Driver's display 2 line 1

Speed

km/h (mph)

line 2

Slip ratio

%

engine/transmission

Driver's display 3 line 1

Engine

rpm

rotation speed of engine

line 2

Gears

rpm

rotation speed of transmission

°C (F)

engine water temperature

bar

engine oil pressure

h

operating hours / effective operating hours


Engine Water

line 2


Engine oil

line 2


Operating hours

line 2

h


Containers

Containers counter (optional)

line 2

Container counter reset: press * key for two seconds.

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13


Autom. gripping

line 2

on/off

automatic gripping on / automatic gripping off

on/off selecting with OK key Driver's display 9 line 1

Autom. changer

(option)

line 2

on/off

automatic gearshift on/off

on/off selecting with OK key 04.3.2.2 Maintenance Displays Maintenance displays are only intended for professional maintenance personnel, so they can correct error situations and make the necessary calibrations in connection with repairs. Move to maintenance displays by turning key switch S3 to the ON position and then pressing the M key once. Select module to check with arrow keys: Module A81, A82, A83 or A84. Use OK key to move to displays of the selected module, and browse displays with arrow keys. Module displays show: DI=digital inputs (1 or 0), A =analog inputs (0,00…5,00V), DO =digital outputs (1 or 0) and PR =proportional outputs (%). In order to locate the error, values are compared to module-specific reference values. (see Control module A80 A84). Maintenance Display Module A81 line 1

Module A81

line 2

Can bus

module 1 1/0

bus in operation / bus oout of order

Maintenance Display Module A81 Sub-display 1 line 1 line 2

DI 1234567890 0000000000


digital input 1-12 status of said input 1 or 0

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Electric Systems

Maintenance Display Module A81 Sub-display 2 Analog input and its voltage value 0.0 ...5.00 V. line 1

A1 0.00

A2 0.00

line 2

A3 0.00

A4 0.00

Maintenance Display Module A81 Sub-display 3 Analog input and its voltage value 0.0 ...5.00 V. line 1

A5 0.00

A6 0.00

line 2

A7 0.00

A8 0.00

Maintenance Display Module A81 Sub-display 4 line 1

DO 123456789012

line 2

000000000000

digital output 1-12 status of said output 1 or 0

Maintenance Display Module A81 Sub-display 5 Value of propo outputs %. line 1

PR1 0

PR2 0

line 2

PR3 0

PR4 0


PR5 0

PR6 0

line 2

PR7 0

PR8 0


PR9 0

PR10 0

Corresponding displays for modules A82 and A83. Maintenance Display Module A84

UDRS01.01GB

line 1

Module A84

line 2

Can bus


xxxx 1/0

bus in operation / bus out of order

Electric Systems

15


DI 123456789012

digital input 1-12

line 2

A 000000000000

status of said input 1 or 0


DI 345678

digital input A 13-18

line 2

A 000000



DI 123456789012

digital input B 1-12

line 2

B 000000000000



DI 345678

digital input B 13-18

line 2

B 000000



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Electric Systems

04.3.3 Alarms Alarms are divided into alarms and critical alarms. The division is explained in the tables below. 04.3.3.1 Critical Alarm When a critical fault appears, the display shows an alarm text and the buzzer sounds twice for 1 second (1s_1s_1s). When the driver has noticed the message, he can return to the basic display with the OK button. The alarm text will disappear from the display after a specified time. If the reason for the error disappears, the message will also disappear from the display. If there are several alarms on the display at the same time, the most critical will be topmost [P]. You can scroll them with the arrow key. If alarms have been acknowledged from the display with the OK button and there is a new alarm, the already acknowledged alarms will also appear on the display if the errors have not been removed. P

Alarm

Reason

Consequence

1

LOAD PARAMETERS

Parameters have not been loaded

Movements controlled by modules are forbidden

2

ERROR CAN ENGINE

Breakdown in Can communication or Emergency-button is pressed

Lifting/lowering and boom out movements are forbidden, only permitted if you press stability by-pass button S85

3

ERROR ENGINE

Wrong engine type selected with parameter

Engine will start and stop but gas pedal will not work. Display shows zero.

4

ERROR ENGINE 00000

QSM Engine error

Fault code on display has to be checked and done according that.

5

ENGINE WATER TOO HOT Temperature over set alarm limit

6

ENGINE WATER TOO HOT Temperature has been over set limit Engine stalls, will not start value for a specified amount of time

7

ENGINE OIL PRESSURE LOW

Oil pressure below set alarm limit

8

ENGINE OIL PRESSURE LOW

Oil pressure has been below set Engine shut-off value for a specified amount of time

9

ERROR CAN A82

Breakdown in Can communication


10

ERROR CAN A83



11

ERROR CAN A84



12

ERROR R60

Sensor value is not within acceptable limits. Calibration < 100mV

Boom movements permitted only by pressing stability by-pass button S85.

UDRS01.01GB


Limit maximum power

Limit maximum power

Electric Systems

17

P

Alarm

Reason

Consequence

13

ERROR R61

Sensor value is not within acceptable limits. Calibration value < 100mV


14

ERROR B6

Sensor value is not within acceptable limits 0.1-4.9V.


15

ERROR B8

Sensor value is not within acceptable limits 0.1-4.9V.


16

ERROR CAN A81



17

ERROR A312

Sensor value is not within acceptable limits 0.1-4.9V (during calibration 0.75-1.25V)

Gas demand is 0% , engine is idling

18

LOW BRAKE BRESSURE

Low brake pressure when starting or driving

Driving direction cannot be selected

19

ERROR ENGINE TEMPERA- Engine error code on display TURE

Limit maximum power

20

ERROR OIL PRESSURE

Engine error code on display

Limit maximum power

21

ERROR ENGINE RPM

Engine error code on display

Limit maximum power

04.3.3.2 Non-critical Alarms When an error appears, the display shows an alarm text and the buzzer sounds once for 1 second. When the driver has noticed the message, he can return to the basic display with the OK button. The alarm text will disappear from the display after a specified time. If the reason for the error disappears, the message will also disappear from the display. If there are several alarms on the display at the same time, the most critical will be topmost. You can scroll them with the arrow key. Alarm

Reason

Consequence

DIRECTION SELECTED, WILL NOT START

You try to start with the direction selected

Engine will not start until you select direction into neutral

F/R SELECTED

Direction forward and rearward are Engine will not start until you select selected at the same time direction into neutral

IDLING, ENGINE WILL STALL

Pedal and lever have not been used for the specified idling alarm time

Engine shut-off in 2 min

IDLING, ENGINE WILL STALL

Pedal and lever have not been used for the specified idling stopping time

Engine shut-off

STEERING AXLE OVERLOAD

Rear-axle is overloaded

Lifting and boom in movements are forbidden, only permitted if you press stability by-pass button S85.

ENGINE UNDER-TEMPERATURE Temperature has been below the set limit value for a specified amount of time


Check thermostat

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Electric Systems

Alarm

Reason

Consequence

SHUT-OFF DELAY

Option to stop after-running has been selected and the engine is shut off with the key

Engine will only shut off after a time specified by the parameter

EMERGENCY STOP PRESSED

S112 emergency stop switch has been pressed

Engine shuts off, will not start until switch has been released

HANDBRAKE

Handbrake was pressed when starting

Driving direction cannot be selected

ENGINE WATER LOW

LEVEL TOO

Engine water level too low

04.3.4 Tests 04.3.4.1 Tested During Operation When the machine is operated, you should make sure that counter-movements are not controlled simultaneously. Input voltage B6 and B8 of lifting cylinder's pressure transmitters (right and left) must be greater than 0,1V and smaller than 4,9V. Otherwise the display will show alarm: ERROR B6 or ERROR B8, and boom movements are only allowed by pressing stability by-pass button S85. Steering axle loading is tested during operation, and if it is overloaded the display will show alarm: STEERING AXLE OVERLOAD. Gas pedal voltage is monitored during use. The display will show alarm ERROR A312 and request for gas will be 0% (idling), if voltage is 0,1V or smaller, or if voltage is 4,9V or greater, or if voltage is 25% smaller than calibrated minimum, or if voltage is 25% greater than calibrated maximum. If voltage is between the 25% alarm mimit and the calibration value, control will be according to minimum or maximum. There will not be a gas pedal alarm from a 25% deviation, if the gas has not been calibrated. When the emergency stop switch has been pressed, after the half-second delay the display will show message EMERGENCY STOP SWITCH PRESSED. If the machine was shut off from the emergency stop switch, it will not start until you have lifted the "mushroom switch". When A82_DI5 =0 (shut-off from key), there will be no alarm. If handbrake is pressed and you try to move, the display will show message HANDBRAKE and direction solenoids will not go on until you disengage the handbrake. Also, if you get a handbrake alarm during driving, direction solenoids go into neutral. When you start moving, brake pressure is checked, and if it is too low (A84_DI13B=1), the display will show message LOW BRAKE PRESSURE and direction solenoids will not go on. Also, if you get a brake pressure alarm during driving, direction solenoids will go into neutral.

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04.3.4.2 Testing of Stability Sensors Values of boom's angle and length sensors and of lifting cylinder's pressure transmitters (right+left) must be within the acceptable range after calibration during operation. Otherwise the display will show alarm: ERROR R60 or ERROR R61. Then boom movements are only permitted by pressing the by-pass button S85. 04.3.4.3 CAN Testing If communication in the Can bus breaks down (monitored constantly) lifting/lowering, telescope out movements will be forbidden and the display will show message: ERROR CAN Axx or ERROR CAN ENGINE. After the bus has returned to normal, the alarm will disappear and the movements are permitted. Bus error overrides short-circuit error. S85 permits movements during the error, but then stability monitoring will not operate reliably. 04.3.4.4 Engine Alarms If you try to start the engine while direction forward or rearward is selected, the display will show alarm DIRECTION SELECTED, WILL NOT START, and the engine will start only after you select the direction into neutral. If direction forward and rearward are selected at the same time (mini wheel in use), the display will show alarm F/R SELECTED. If the engine has been idling for a certain time and the option has been selected, the display will show alarm IDLING, ENGINE WILL STALL. The temperature of the engine's coolant is monitored, and in an error situation the display will show alarm ENGINE WATER TOO HOT or ENGINE UNDERTEMPERATURE. If the oil pressure is low while the engine is running, the display will show alarm ENGINE OIL PRESSURE LOW. If engine water level is too low (A81_DI1=1), the display will show alarm ENGINE WATER LEVEL TOO LOW, alarm does not affect operation of the machine in any way . If option to stop after-running has been selected and the engine is shut off with the key, the display will show alarm: SHUT-OFF DELAY and engine will only shut off after a time. If there is a sensor error the display will show alarm: ERROR ENGINE TEMPERATURE, ERROR OIL PRESSURE or ERROR ENGINE RPM. If you have selected the wrong engine type (Scania/Cummins) with a parameter, the display will show alarm ERROR ENGINE. Cummins engines show an error code, which is displayed as ERROR ENGINE and error code.


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Electric Systems

04.3.5 Control Module A81

1 2 3 4 5 6 7 8

39 38 37 36 35 34 59 58 26 25 24 23 22 21 20 19

1 2 3 4 5 6 7 8

DI3 DI4 GND +24VOut DI5 DI6 DI12 137 DI11 DO12 151 DO11 152 GND DO10 DO9 155 DO8 GND PRO8

A81 controls following functions: boom hoisting and lowering, lowering locking valves, quick function of hoisting, boom out, boom in, spreader rotation and limits of spreader rotation, spreader automatic gripping, spreader signal lights, stability by-pass, el. gas, coolant level, pressure weighing (optional).

X3

S100 114 S79 113

A312 R58 R58 R53 R54 R52 R51

129 128 127 126 125 124 123 122 121

9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1

40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

X5

X6 X1 5 6

S99 S100 117

DI1 DI2 +24VOut GND DI7 DI8 DI9 DI10 AI8 AI7 AI6 AI5 AI4 AI3 AGND AI2 AI1 RefOut

CONTROL UNIT A81 X2

X7

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

PRO7 GND PRO6 PRO5 DO7 DO6 GND DO5 DO4 PRO4 GND PRO3 DO3 PRO2 DO2 GND PRO1 DO1

165 166

Y96A Y96B M97

171

Y57

173 174 175 176

Y52 Y87 Y58 Y67, Y68

178 179

Y51 Y56

6 5 4 3 2 1

60 61 62 63 64 65

X8

RxD TxD GND PRO9 PRO10 GND

GND GND GND VCC VCC WH CAN High CAN Low BN CAN Shield

7 6 5 4 3 2 1

27 28 29 30 31 32 33

X4

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

Figure 7. Control Module A81 Note! When checking the reference values, the engine must not be running. Connector Code

Function

Rating

Wire no.

Note

X1.1

AI8

X1.2

DI10

Jacks down

X1.3

DI9

Scaling position angle

0V off, +24V on

113

S79

X1.4

DI8

Rotation extra limits in use

0V off, +24V on

114

S100

X1.5

DI7

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Electric Systems

Connector Code X1.6

21

Function

Rating

Wire no.

Note

+24V out

+24V

117

S79/ 100

GND

X1.7 X1.8

DI2

X1.9

DI1

Coolant level

0V off, +24V on

X2.1

Refout

Ref. out, Hand lever feed

+5VDC

121

X2.2

AI1

Boom lifting

0V...5V

122

R51

X2.3

AI2

Boom lowering

0V...5V

123

R52

X2.4

AGND

X2.5

AI3

Boom in

0V...5V

125

R54

X2.6

AI4

Boom out

0V...5V

126

R53

X2.7

AI5

Rotation counter-clockwise

0V...5V

127

R58

X2.8

AI6

Rotation clockwise

0V...5V

128

R58

X2.9

AI7

El. gas accelerator pedal

0V...5V

129

A312

X3.1

DI3

X3.2

DI4

X3.3

GND

X3.4

+24

X3.5

DI5

X3.6

DI6

X3.7

DI12

0V off, +24V on

137

S85

X3.8

DI11

X4.1

CAN

CAN shield

X4.2

CAN

CAN Low

BN

X4.3

CAN

CAN High

WH

X4.4

VCC

X4.5

VCC

Feed voltage +24V

F38

X4.6

GND

Earthing rail

X4.7

GND

X5.1

DO12

Twistlocks open information

+24V 10W max

151

H180

X5.2

DO11

Twistlocks closed information

+24V 10W max

152

H191

X5.3

GND

X5.4

DO10

X5.5

DO9

Container contact information

+24V 10W max

155

H195

X5.6

DO8

X5.7

GND

X5.8

PRO8

X6.1

PRO7

X6.2

GND

X6.3

PRO6

X6.4

PRO5

X6.5

DO7

Cabin forward

+24V

165

Y96A

124

+24V out

Stability By-pass


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Electric Systems

Connector Code

Function

Rating

Wire no.

Note

X6.6

DO6

Cabin rearward

+24V

166

Y96B

X6.7

GND

X6.8

DO5

Cabin transfer pump

168

M97

Boom lowering

171

Y57

173

Y52

174

Y87

X6.9

DO4

X7.1

PRO4

X7.2

GND

X7.3

PRO3

Boom in

X7.4

DO3

Lifting quick function

X7.5

PRO2

Boom lifting

175

Y58

X7.6

DO2

Locks of lowering

176

Y67, Y68

X7.7

GND

X7.8

PRO1

Boom out

178

Y51

X7.9

DO1

Free circulation valve

179

Y56

X8.1

GND

X8.2

PRO10

X8.3

PRO9

X8.4

GND

X8.5

TxD

X8.6

RxD

UDRS01.01GB

+24V


Electric Systems

23

04.3.6 Control Module A82

9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1

40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

X5

X6 X1 CONTROL UNIT A82 X2

X7

18 17 16 15

1 2 3 4

14 13 12 11

5 6 7 8 9 1 2 3 4 5

10 9 8 7 6 5 4 3 2 1

Y27 B Y27 A

268

H13B

271

K2

273 274 275 276

Y4 Y5 Y3 Y2

278 279

S6 Y1

GND PRO9 PRO10

61 62 63 64 65 4 3 2 1

RxD TxD

60

6 5

CAN Shield

31 32 33

4 3 2 1

GND GND GND FI6 VCC FI6 VCC WH CAN High BN CAN Low

7 6 5

263 264 265

X8

27 28 29 30

X4

6 7 8 9

PRO7 GND PRO6 PRO5 DO7 DO6 GND DO5 DO4 PRO4 GND PRO3 DO3 PRO2 DO2 GND PRO1 DO1

GND

A32 A32 S56 S56 A312 R61 R60 B6 B8

219 DI1 218 DI2 +24VOut BN GND 215 DI7 214 DI8 213 DI9 212 DI10 211 AI8 229 AI7 228 AI6 227 AI5 226 AI4 225 AI3 224 AGND AI2 AI1 221 RefOut

PRO8

DO9 DO8 GND

X3 S2 B1

6 7 8

5 6 7 8 1 2 3 4 5 35 34 59 58 26 25 24

23 22 21 20 19

1 2 3 4 39 38 37 36

DI3 DI4 GND

+24VOut DI5 DI6 DI12 DI11 DO12 DO11 GND DO10

234 235 236 237 238

231 232

A82 controls following functions: engine control, stability, automatic gearshift system (optional), mini steering wheel (optional), display of the load (optio), vertical lifting and lowering (optional), idling shut-off (option).

Figure 8. Control Module A82 Note! When checking the reference values, the engine must not be running. Connector

Code

Function

X1.1

AI8

Electric gas accelerator pedal

X1.2

DI10

Direction Reverse

212

S56

X1.3

DI9

Direction Forward

213

S56

X1.4

DI8

Mini steering wheel

214

A32

X1.5

DI7

Mini steering wheel

215

A32

X1.6

GND

X1.7

Rating

Wire no.

Note

211

A312

BN +24V out

+24V


UDRS01.01GB

24

Electric Systems

Connector

Code

Function

X1.8

DI2

X1.9

Wire no.

Note

Transmission operating speed

218

B1

DI1

Start

219

S2

X2.1

Refout

Ref. out

X2.2

AI1

X2.3

AI2

X2.4

AGND

X2.5

AI3

Stability sensor lift

0V...5V

225

A85

X2.6

AI4

Pressure of cylinder, left

0V...5V

226

B8

X2.7

AI5

Pressure of cylinder, right

0V...5V

227

B6

X2.8

AI6

Sensor of boom angle

0V...5V

228

R60

X2.9

AI7

Sensor of boom length

0V...5V

229

R61

X3.1

DI3

2 speed

231

S56

X3.2

DI4

3 speed

232

S56

X3.3

GND

X3.4

+24

+24V out

+24V

234

X3.5

DI5

Engine stop, option

0V off, +24V on

235

X3.6

DI6

1 speed

0V off, +24V on

236

S56

X3.7

DI12

Declutch

0V off, +24V on

237

S52

X3.8

DI11

Service Switch

0V off, +24V on

238

S3

X4.1

CAN

CAN shield

X4.2

CAN

CAN Low

BN

X4.3

CAN

CAN High

WH

X4.4

VCC

X4.5

VCC

Feed voltage +24V

F16

X4.6

GND

Earthing rail

X4.7

GND

X5.1

DO12

X5.2

DO11

X5.3

GND

X5.4

DO10

Machine speed < 10 km/h

X5.5

DO9

Neutral speed

X5.6

DO8

X5.7

GND

X5.8

PRO8

X6.1

PRO7

X6.2

GND

X6.3

PRO6

Mini steering wheel

263

Y27B

X6.4

PRO5

Mini steering wheel

264

Y27A

X6.5

DO7

Shut-off delay

265

X6.6

DO6

X6.7

GND

X6.8

DO5

Buzzer

268

UDRS01.01GB

Rating

+5VDC

221

224

S2

F16


H13B

Electric Systems

Connector

Code

X6.9

DO4

X7.1

PRO4

X7.2

GND

Function

25

Rating

Start relay

Wire no.

Note

271

K2

X7.3

PRO3

Direction Reverse

273

Y4

X7.4

DO3

3 speed

274

Y5

X7.5

PRO2

Direction Forward

275

Y3

X7.6

DO2

2 speed

276

Y2

X7.7

GND

X7.8

PRO1

Engine Start/Stop

278

S6

X7.9

DO1

1 speed

279

Y1

X8.1

GND

X8.2

PRO10

X8.3

PRO9

X8.4

GND

X8.5

TxD

X8.6

RxD


UDRS01.01GB

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Electric Systems

04.3.7 Control Module A83 A83 controls following functions of spreader and boom : spreader rotation, limits of spreader rotation, spreader lengthening/shortening, tilting forward/rearward, locking of tilting, sideshift, twistlocks functions, container contact, damping of telescope.

Figure 9. Control Module A83 Note! When checking the reference values, the engine must not be running. Connector

Code

Function

Rating

Wire no.

Note

X1.1

AI8

X1.2 X1.3

DI10

Stop, rotation counter-clockwise

0V off, +24V on

312

S99

DI9

Stop, rotation clockwise

0V off, +24V on

313

S98

X1.4

DI8

Twistlocks open

0V off, +24V on

314

S121 S122

X1.5

DI7

Twistlocks closed

0V off, +24V on

315

S123 S124

UDRS01.01GB


Electric Systems

Connector

Code

X1.6

GND

X1.7

27

Function

Rating

Wire no.

+24V out

+24V

317

Note

X1.8

DI2

Landing pin right

0V off, +24V on

318

S127 S128

X1.9

DI1

Landing pin, left

0V off, +24V on

319

S125 S126

X2.1

Refout

Ref. out

+5VDC

X2.2

AI1

Limit, rotation counter-clockwise

0V...5V

322

S99B (option)

X2.3

AI2

Limit, rotation clockwise limit

0V...5V

323

S98B (option)

X2.4

AGND

X2.5

AI3

X2.6

AI4

X2.7

AI5

X2.8

AI6

X2.9

AI7

X3.1

DI3

20" - 40", right

0V off, +24V on

331

S136

X3.2

DI4

30" , right

0V off, +24V on

332

S236

X3.3

GND

X3.4

+24

+24V out

+24V

334

X3.5

DI5

20" - 40", left

0V off, +24V on

335

S135

X3.6

DI6

30", left

0V off, +24V on

336

S235

X3.7

DI12

Boom out, damping

0V off, +24V on

337

S81

X3.8

DI11

Boom in, damping

0V off, +24V on

338

S80

X4.1

CAN

CAN shield

X4.2

CAN

CAN Low

BN

X4.3

CAN

CAN High

WH

X4.4

VCC

X4.5

VCC

Supply voltage +24V

F36

X4.6

GND

X4.7

GND

X5.1

DO12

Pile slope locking

351

Y66

X5.2

DO11

Pile slope to right

352

Y64A

X5.3

GND

X5.4

DO10

Twistlocks open light

354

H304

X5.5

DO9

Twistlocks closed light

355

H303

X5.6

DO8

Landing pin

356

H305

X5.7

GND

X5.8

PRO8

Pile slope to left

358

Y64B

X6.1

PRO7

Longit. tilting locking

361

Y63

X6.2

GND

X6.3

PRO6

Rotation counter-clockwise

363

Y59A


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28

Electric Systems

Connector

Code

Function

X6.4

PRO5

X6.5

Wire no.

Note

Rotation clockwise

364

Y59B

DO7

Sideshift left

365

Y62A

X6.6

DO6

Sideshift right

366

Y62B

X6.7

GND

X6.8

DO5

Longit. tilting forward

368

Y65A

X6.9

DO4

Longit. tilting rearward

369

Y65B

X7.1

PRO4

X7.2

GND

X7.3

PRO3

Twistlocks open

373

Y71A

X7.4

DO3

Twistlocks closed

374

Y71B

X7.5

PRO2

20”-40”, right

375

Y73A

X7.6

DO2

40”-20”, right

376

Y73B

X7.7

GND

X7.8

PRO1

20”-40”, left

378

Y74A

X7.9

DO1

40”-20”, left

379

Y74B

X8.1

GND

X8.2

PRO10

X8.3

PRO9

X8.4

GND

X8.5

TxD

X8.6

RxD

UDRS01.01GB

Rating


Electric Systems

29

04.3.8 Control Module A84 Module A84 is an input module from different switches in cabin. INPUT B

INPUT A

X2

X7

MCKC-MODULE A84 X6

X1

S7 S990, S980 S60 S97A S97B S97A-B S7

F16

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

24V out DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 DI9 DI10 DI11 DI12 DI13 DI14 DI15

421 422 423 424 425 426 427 428 411 412 413 414 415 416 417 418

S89 S90 S99 S86 S95 S180 S92 S192 S237 S194 S189 S193 S193 S191 S191

WH Pink BN WH

6 5 4 3 2 1

X4

+VCC -GND CANLO CANHI CANLO CANHI

X5 7 6 5 4 3 2 1

8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

457 456 455 454 453 453 452

S23 S13 S199 S115

24V out DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 DI9 DI10 DI11 DI12 DI13 DI14 DI15

DI16 DI17 DI18 DI18 DI17 DI16 24Vout

S112 S58 S97 S97 S192 S251 S251 S71 S72 S68

478 477 476 475 474 473 472 471 468 467 466 465 464 463 462 461

Figure 10. Control Module A84 Connector Code

Function

Rating

Wire no. Note

X1.1

DI8

Twistlocks closed, manual

0 V off, +24 V on

411

S192

X1.2

DI9

Spreader 30' position

0 V off, +24 V on

412

S237

X1.3

DI10

Hoist prevent by-pass

0 V off, +24 V on

413

S194

X1.4

DI11

Spreader autom. lenghtening

0 V off, +24 V on

414

S189

X1.5

DI12

Spreader lengthening, right T-balk

0 V off, +24 V on

415

S193

X1.6

DI13

Spreader shortening, right T-balk

0 V off, +24 V on

416

S193

X1.7

DI14

Spreader shortening, left T-balk

0 V off, +24 V on

417

S191

X1.8

DI15

Spreader shortening, right T-balk

0 V off, +24 V on

418

S191

X2.1

Refout

Ref. output

+24 VDC , max 2 A

421

X2.2

DI1

Side shift, right

0 V off, +24 V on

422

S89

X2.3

DI2

Side shift, left

0 V off, +24 V on

423

S90

X2.4

DI3

Hand lever change button/vertical lift

0 V off, +24 V on

424

S99

X2.5

DI4

Spreader lenghtening/ tilting forward

0 V off, +24 V on

425

S86

X2.6

DI5

Spreader shortening/ tilting rearward

0 V off, +24 V on

426

S95

X2.7

DI6

Twistlocks open

0 V off, +24 V on

427

S180

X2.8

DI7

Spreader tilt locking

0 V off, +24 V on

428

S92

X4.1

CAN

CAN High

WH

X4.2

CAN

CAN Low

BN

X4.3

CAN

CAN High

Pink

X4.4

CAN

CAN Low

WH


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Electric Systems

Connector Code

Function

X4.5

GND

GND Earthing rail

X4.6

+VCC

Feed voltage

X5.1

Refout

Ref. output

+24 VDC , max 2 A

451

S97A-B S7

X5.2

DI16

Cabin rearward, limit

0 V off, +24 V on

452

S97B

X5.3

DI17

Cabin forward, limit

0 V off, +24 V on

453

S97A

X5.4

DI18

Pile slope locking

0 V off, +24 V on

454

S60 (option)

X5.5

DI18

Door switch

0 V off, +24 V on

455

S990, S980

X5.6

DI17

Seat switch

0 V off, +24 V on

456

S7

X5.7

DI16

Rotation speed range

0 V off, +24 V on

457

(option)

X6.1

DI15

Rotation limit by-pass

0 V off, +24 V on

461

S115

X6.2

DI14

Container contact by-pass

0 V off, +24 V on

462

S199

X6.3

DI13

Brake pressure, 115 Bar

0 V off, +24 V on

463

S13

X6.4

DI12

Brake information, 2,5 Bar

0 V off, +24 V on

464

S23

X6.5

DI11

Buzzer on

0 V off, +24 V on

465

X6.6

DI10

Speed locking

0 V off, +24 V on

466

S68 (option)

X6.7

DI9

Starting gear

0 V off, +24 V on

467

S72 (option)

X6.8

DI8

Automatic gear shift on/off 0V off, +24V on 468 S71

0 V off, +24 V on

468

S71 (option)

X7.1

DI7

Jacks up

0 V off, +24 V on

471

S251 (optio)

X7.2

DI6

Jacks down

0 V off, +24 V on

472

S251 (option)

X7.3

DI5

Automatic gripping, on

0 V off, +24 V on

473

S192 (option)

X7.4

DI4

Cabin transfer, rearward

0 V off, +24 V on

474

S97

X7.5

DI3

Cabin transfer, forward

0 V off, +24 V on

475

S97

X7.6

DI2

Parking brake

0 V off, +24 V on

476

S58

X7.7

DI1

Emergency stop switch

0 V off, +24 V on

477

S112

X7.8

Refout

Ref. output

+24 VDC , max 2 A

478

UDRS01.01GB

Rating

Wire no. Note

F16


Electric Systems

31

04.3.9 Engine Control The engine is controlled by an ECU (Engine Control Unit). The ECU is connected to the CAN bus, and control module A82 carries out communication with it. Control module A82 reads the position of the gas pedal and transmits it to the ECU. A82 also performs starting and stopping of the engine. ECU transmits several messages, which contain information about engine status. Control module A82 receives and interprets these messages. 04.3.9.1 Starting the Engine Switch on power to the engine A82:DI1 Æ 1 and set A82:PRO1 (control 100%) Upon starting there are safety checks made to make sure that the engine will start safely. - Direction forward A82 DI9 or rearward A82 DI10 must not be selected. If direction is selected, the display will show alarm: DIRECTION SELECTED, WILL NOT START. - Temperature of the engine coolant must be within the acceptable range, otherwise the display will show error message: ENGINE WATER TOO HOT. - If ECU falls out of the bus, starting is forbidden. When the above conditions are met, activate A82:PRO4 to set the starter motor on. If one of the above conditions is not met during start, A82:PRO1 ja PRO4 will be reset. Starter motor will be on as long as the engine rpm value is below a limit value. While starting boom movements and spreader rotation are forbidden. When the rpm limit is reached, starter motor A82:PRO4 will be deactivated (control 0%), operating hour counter will be activated and oil pressure will be monitored. If the engine stalls, re-start will not begin until rpm is 0. 04.3.9.2 Stopping the Engine Normal stopping by turning the key:- A82:DI5 Æ 0, operating hour counter is deactivated and A82:PRO1 deactivated. - If you have selected idling option, the display will show message SHUT-OFF DELAY and the engine will be shut off after delay once the key has been turned. If you stop the engine in any other way than the usual turning of the key, the display will show an alarm before


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Electric Systems

the engine stops. The engine is stopped, if one of the following is true: A82:DI5 Æ 0 - Idling option, engine is shut off after delay from turning of key and the display immediately shows message: SHUT-OFF DELAY. If operation has been selected, it will be activated for the specified time, when rpm is over 400rpm and A82_DI5=1 and A82_PRO1=100% and A82_DO7=0. Operation: DO7 goes on, when DI5=0 and for specified time PRO1 is 100%. During operation gas is forbidden. Shut-off: PRO1=0% for 3 seconds, and after that DO7=0 and PRO1=100%. Operation is reset immediately, if DI5=1. Re-start is not possible (A82_PRO4) during operation. - Engine idling stop: gas pedal and lever have not been used, the engine has been idling for a certain time, and the handbrake is on. After a warning delay the display will show: IDLING, ENGINE WILL STALL. The engine will stall after the shut-off delay. Idling stop is an option. If the option has not been selected, there will be no alarm and the engine will not be shut off. - If temperature of the engine coolant has been over the set limit value for a specified amount of time, the display will show alarm: ENGINE WATER TOO HOT and the engine will be shut off. (If temperature has been over set alarm limit, maximum power will be limited and display will show alarm: ENGINE WATER TOO HOT) - If oil pressure has been under the set value for a specified amount of time, the display will show alarm: ENGINE OIL PRESSURE LOW and the engine will be shut off. (If oil pressure is below alarm limit, maximum power will be limited and the display will show alarm: ENGINE OIL PRESSURE LOW) - Engine's temperature/pressure stopping is an option. If the option has not been selected, the engine will not stall but maximum power will be limited. When one of the above conditions is met, A82_PRO1 is deactivated for 3 seconds, then the engine will be shut off but you can get engine data after that. At the same time the operating hour counter is deactivated 04.3.9.3 Normal Operation of the Engine Normal operation of the engine mainly consists of analysis of position of the gas pedal, transmission of engine control messages to A86 and reception of status messages from A86. Information regarding errors is also brought

UDRS01.01GB


Electric Systems

33

to the display. Engine rpm value can also be limited according to the status of the engine. Maximum rpm value is limited according to the following conditions. If the cause for limitation disappears, gas limitation will only disappear after the gas value falls below 10%. - RSV: If the gas pedal has been pressed and direction has been selected forward and rpm is above runaway limit Ægas request at 0%. Changing of direction situation and speed below direction change limit km/h Ægas request at 0% and rpm below runaway limit. - Changing gears Ægas request at 0% until slide ratio is reached. - After declutch Æ gas request at 0%, max speed 15km/h. - Engine coolant has overheated (shut-off limit _C) Æ alarm to display and shut-off of engine. If the coolant has overheated above alarm limit, maximum power is limited and display will show alarm: ENGINE WATER TOO HOT. Time coercion will prevent wandering of the engine rpm. - If engine oil pressure is below alarm limit, maximum power will be limited and the display will show alarm: ENGINE OIL PRESSURE LOW. - If A86 has detected an error in the engine's temperature or oil pressure or engine's rpm sensor, maximum power is limited and the display will show alarm: ERROR ENGINE TEMPERATURE, ERROR ENGINE OIL PRESSURE or ERROR ENGINE RPM. The driver's display shows as values 0 _C, 0 bar or 0 rpm, but the program uses normal values, so the engine operates otherwise normally. If the display shows any of the above alarms, you must take in the machine for maintenance immediately. When the rpm value is higher than 900 or the lever is in motion, effective operating hour counter is activated. Correspondingly, the effective operating hour counter is deactivated, when rpm is lower than 900 or the lever is not in motion. If engine's under-temperature option has been selected, engine water's temperature is monitored while the machine is running. If temperature has been below the set value for a specified amount of time, the display will show


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Electric Systems

alarm: ENGINE UNDERTEMPERATURE. The alarm does not affect operation of the machine. If engine's water level is low (A81_DI1=1) the display will show alarm: ENGINE WATER LEVEL TOO LOW. The alarm does not affect operation of the machine. If data transfer to the engine (to A86) breaks down, the display will show alarm: ERROR CAN MOOTTORI. The program monitors that the engine sends an rpm value at regular intervals. If the bus is broken, the engine control unit (A86) will guide the engine into idling.

UDRS01.01GB


Electric Systems

35

04.3.10 Control of Boom and Spreader 04.3.10.1 Valve Control in Various Functions

Function

Y58 PRO2

L

X

LE

X

LR

X

Y57 PRO4

Y51 PRO1

Y52 PRO3

Y56 DO1

Y67, Y68 DO2

Y59a PRO6

Y59b PRO5

Y71b DO3

X X X

E

X

R LO

X

LOE

X

LOR

X

X X

X X

X X

A81 QL

Y87 DO3

X

X

RCC

X

RC

X

X X X

Function code: L

Lifting

E

Extension

R

Retraction

LO

Lowering

QL

Quick lift

RC

Rotation clockwise

RCC

Rotation counter clockwise

A81

Free rotation

E.g. function LE = Lifting + Extension 04.3.10.2 Boom Movements Boom movements are controlled by the joystick. Lifting, lowering, telescope out and in movements have pwm per-


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Electric Systems

centage control Rotations specify power mA. Lowering and lifting movements are also affected by the pressure of the lifting cylinder. Boom out and in movements are also affected by a damping function.

twist locks open=1 or twist locks closed=1 or (S194=1 and S189 = 1)

yes kyll

Rear stability disconnect

yes kyll

Stability disconnect

yes kyll

S85 = 1 S85 = 1 ei no no ei kyll yes yes kyll


kyll yes

Container contact

Conteiner contact

yes ei

yes kyll

S85 = 1 ei no yes

Parameter time past

no ei

rotating clockwise limit=0

no

hoisting=1 and owering=0

yes

LIFTING

lowering=1 and hoisting=0

yes

LOWERING

yes tel out=1 and tel in=0

yes

EXTENSION

rotating counter- clockwise limit=0

yes

rotating clockwise=1 and rotating counter- clockwise =0

rotating counter- clockwise =1 and rotating clockwise =0

yes

yes

ROTATING CLOCKWISE

tel in=1 and tel out=0

yes

ROTATING RETRACTION COUNTERCLOCKWISE

Figure 11. Conditions of Boom Movements when using Stability Guard1

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Electric Systems

37

twist locks open=1 or twist locks closed=1 or (S194=1 and S189 = 1)

yes


yes kyllä


yes kyllä

Stability disconnect

Yes

S85 = 1 S85 = 1

S85 = 1 no ei

No no ei

yes

Yes yes kyllä

Reached angle <50 degree

yes kyllä

Container contact

Container contact

ei no

kyllä yes

Gabarity > -1,0 m

Gabarity > - 1.0m

Parameter time passed

yes ei

yes kyllä no

lifting =1 and lowering=0

yes

LIFTING

lowering=1 and hoisting=0

yes

LOWERING

rotating counter- clockwise limit=0

rotating clockwise limit=0

yes tel out=1 and tel in=0

yes

EXTENSION

yes

rotating clockwise=1 and rotating counter- clockwise =0

rotating counter- clockwise =1 and rotating clockwise =0

yes

yes

ROTATING CLOCKWISE

yes

tel in=1 and tel out=0

yes

ROTATING RETRACTION COUNTERCLOCKWISE

Figure 12. Conditions of Boom Movements when using Stability Guard2 The boom movements are defined with four handle (%) and control /(mA) value, parameters I9-L28. To the lift and drop movement it affects also the pressure of lifting cylinder. To the telescope out and in movements it affects also the decelerations. 04.3.10.3 Spreader Movements Extension and Shortening In order for you to extend or shorten, container contact is not allowed and the twistlocks must be open. You can select with switches to extend/shorten with one button bot left and right side, or extend/shorten left side with one button and right side with another button. If automatic function or 30' stop buttons have not been selected, valve control occurs without limit switches. Auto-


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Electric Systems

matic function has limit switches on right and left side, and 30' stop has also limit switches on right and left side. A83_DI1=0 AND A83_DI2=0 AND A84_DI14B=0

A83_DI7 =0 OR A84_DI10A =1

A84_DI4A =1

A84_DI15A =1 /S191

/S86/

A84_DI12A =1

/S193/

A84_DI14A =1

/S191/

A84_DI13A =1

/S193/

=1

/S95/

A84_DI9A

TRUE

A84_DI11A

A84_DI5A =1

=1 /S237/

/S189/

FALSE TRUE

FALSE A83_DI3=0

A83_DI4=0 /S236/ AND A83_DI3=0

A83_DI5=0

A83_DI6=0 /S235/ AND A83_DI5=0

/S136/

/S135/

A83_PRO1 =100%

SPREADER LENGTHENING LEFT

A83_PRO2 =100%

SPREADER LENGTHENING RIGHT

A83_DO1=1

SPREADER SHORTENING LEFT

A83_DO2=1

A81_DO1=1

SPREADER SHORTENING RIGHT

FREE CIRCULATION VALVE

Figure 13. Extension and Shortening of Spreader

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Electric Systems

39

Rotations Rotation is allowed, if stability is not on cut-off, if there is no container contact, if the twistlocks are open, closed or if their by-pass is pressed. There are limit switches for both directions (clockwise, counterclockwise). You can also take into use the "additional limits" option with a parameter. If the option has been selected and if the boom's position data is correct, additional limits will be used. There is a by-pass switch for the additional limits.


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Electric Systems

A81_AI5 > 0

A81_AI6 > 0

TRUE

TRUE

STABILITY < 100% OR A81_DI12=1


TRUE

TRUE

A83_DI1=0 AND A83_DI2=0 AND A84 DI14B=0

A83_DI1=0 AND A83_DI2=0 AND A84 DI14B=0

TRUE

TRUE

A83_DI7=1 OR A83_DI8=1 OR A84_DI10A

A83_DI7=1 OR A83_DI8=1 OR A84 DI10A

TRUE

TRUE

A83_DI10=0

A83 DI9=0

TRUE

OPTIONAL parameter extra limits =1 AND A81 DI8=0

TRUE

TRUE

FALSE

A83_PRO6=X%

ROTATION CLOCKWISE

A83_AI1>4V AND A84 DI15B=0

FALSE

A81_DO1=1


OPTIONAL parameter extra limits =1 AND A81 DI8=0

FALSE

A83_PRO5=X%

ROTATION COUNTERCLOCKWISE

Figure 14. Rotation of Spreader

UDRS01.01GB


TRUE

A83_AI2>4V AND A84 DI15B=0

FALSE

Electric Systems

41

Tilting Tilting is allowed, if there is no container contact. In addition to the direction (left, right, forward, backward) button, you must use the S99 button. Cross-tilting is an option, which you can select into use with parameter F28. Locking switches control the locking valves.


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Electric Systems

A83_DI1=0 AND A83_DI2=0 AND A84_DI14B=0

TRUE

OPTIONAL parameter pileslope=1

TRUE

A84_DI1A=1 /S89/

A84_DI2A=1 /S90/

TRUE

TRUE A84_DI3A =1 /S99/

TRUE

/S99/

TRUE

A83_PRO8

A83_DO11 =1

=100%

PILE SLOPE TO LEFT

PILE SLOPE TO RIGHT

TRUE

A84_DI3A =1 /S99/

A84_DI3A =1

TRUE

A84_DI5A=1 /S95/

A84_DI4A=1 /S86/

A84_DI3A =1

/S99/

TRUE

A81_DO1=1


TRUE

A83_DO4

A83_DO5 =1

=1

SPREADER LONGIT.

SPREADER LONGIT.

TILTING FORWARD

TILTING BACKWARD

A84_DI18A=1

/S60/

TRUE A84_DI7A=1

/S92/

A83_DI7=0

TRUE TRUE A83_PRO7 =100%

A83_DO12=1

SPREADER LONGIT.

PILE SLOPE LOCKING

TILTING LOCKING

Figure 15. Tilting of the Spreader

UDRS01.01GB


Electric Systems

43

Sideshift Sideshift is allowed, if there is no container contact and if stability is not on cut-off Right and left sideshift are selected with their own buttons.


UDRS01.01GB

44

Electric Systems

A83_DI1=0 AND A83_DI2=0 AND A84_DI14B=0

TRUE


TRUE

A84_DI2A=1 /S90/

A84_DI1A=1 /S89/

TRUE

TRUE

A84_DI3A

A84_DI3A =0 /S99/

=0

/S99/

FALSE

FALSE

A81_DO1=1

A83_DO6=1

SIDE SIFT TO LEFT


Figure 16. Sideshift of the Spreader

UDRS01.01GB


A83_DO7=1

SIDE SIFT TO RIGHT

Electric Systems

45

Twistlocks Manually The twistlocks open and closed movement require container contact. Both movements have a limit switch, which is used to control the indicator lights.

A84_DI6A=1

A84_DI8A=1

/S180/

/S192/

TRUE

TRUE

A83_DI7=0

A83_DI8=0

/S123,S124/

/S121,S122/

TRUE

TRUE

A83_DI8=1

/S121,S122/

TWIST LOCKS OPEN

/S123,S124/

TRUE

TRUE

A83_PRO3 =100%

A83_DO10=1

A83_DI7=1

A83_DI2=1)

A83_DI2=1)

TRUE

(A83_DI1=1

A84_DI14B=1 OR (A83_DI1=1 AND

A84_DI14B=1 OR (A83_DI1=1 AND

A81_DO1=1


TRUE

A83_DO9=1

A83_DO3=1

TWIST LOCKS CLOSE

AND A83_DI2=1) OR A84_DI14B=1

TRUE

A83_DO8=1

CONTAINER CONTACT

Figure 17. Twistlocks Open and Closed Manually


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46

Electric Systems

04.3.11 Monitoring of Stability Status of stability is displayed continuously on the driver's basic display graphically and in percentages % When stability has been over 90% for more than 1 second, boom movement out or spreader rotation is active, the buzzer alarms periodically (except stability guard2: If reach is < 3,5 m, there will be no alarm but movements are forbidden). When stability exceeds 100%, lifting, lowering, boom movement out and spreader rotation are prevented, the buzzer alarms constantly. Stability by-pass switch S85 permits movements. If there is a sensor error (B6, B8, R60, R61), the buzzer rings twice and the display will show an alarm. Then boom movements are prevented (stability by-pass switch S85 permits movements). Monitoring of stability can be carried out in two ways: • Stability guard 1 = rear axle sensor and amplifier, standard. Rear axle's overload protector is available as an option. • Stability guard 2 = length and angle sensor and two lifting cylinder pressure transmitters, option.

04.3.12 Load Weighing 04.3.12.1 Stability Guard 1 Operation of the weighing system is based on change in pressure of the lifting cylinder, which is measured by pressure transmitter B6. Pressure transmitter's data is converted into weight of the container on the display. Weighing is done in boom position determined by sensors S79. Conditions of weighing display are: boom in A83:DI11 = 1 and angle data S79 A81:DI9 = 1 and machine does not move A82:DI2<100Hz and boom movements are not made. When the above conditions are met, item "load weighing" on basic display will always show stars, which means that weighing is done, if the machine does not move and boom movements are not made. First weighing result comes in 3 seconds, when pressure level has stabilized. After that the weighing result is shown on the display as long as you are in that status, the display is updated at 1 sec. Intervals. When you leave the weighing status, the display does not show any weighing result. A weighing result shown on the display is always in the range of 0-46 tons. Weighing should always be done after a lifting movement. Weighing is an option, when you are using stability guard 1.

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47

04.3.12.2 Stability Guard 2 Load's value is calculated from lifting cylinder's pressure transmitters B6 A82:AI5 and B8 A82:AI4 as an average value. Measurement result is the average value of two sensors. The measurement result is shown on the display for load weighing only, when the machine's speed is 0-2 km/h and there is no lifting or lowering movement (3 second delay after lifting and lowering). A weighing result shown on the display is always in the range of 0-46 tons. If the machine is in motion, the weighing value on the display is not updated (result does not change). Weighing is standard, when you are using stability guard 2.


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Electric Systems

04.3.13 Calibrations Calibration settings must be checked and calibrated at 1000 h intervals and every time you have handled sensors (A312, B6, B8, R60, R61), which affect the calibrations. Calibration settings are made on the display. Move to calibration displays by turning S3 key switch to ON position (located in the cabin's electric box) and then pressing M button 3 times during 2 seconds. The display will show message: CALIBRATION ARE YOU SURE? Move to calibration settings by pressing the OK key. (Use the -> key to stop calibration and return to basic display.)

CALIBRATION ARE YOU SURE

Figure 18. Calibration Display Calibration displays vary according to options installed in the machine as follows: • Calibrate Stability 1 (if there are no options, Stability 2) • Calibrate gas • Calibrate pressure weighing, option (if there are Stability 1) • Calibrate Stability 2, option Calibrations should be performed, while the machine is on an even surface. For load you need a container, whose weight you know precisely (over 20 t). During calibration the stability guard is not in operation, but the buzzer will alarm at 90%. Boom retardation is not in use during calibration.

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49

Warning! You must make calibrations carefully according to the instructions, otherwise operation of the machine and safety are compromised! 04.3.13.1 Calibrate Stability 1 Display shows text: CALIBRATE STABILITY 1. 1. Press OK Display shows text: BOOM DOWN AND IN n.n. 2. Drive boom fully in and down without a load. 3. Wait for 10 seconds and press OK Program reads a value, which corresponds to stability 0%. Next display appears automatically. Display shows text: REAR WHEELS UP n.n 4. Grab the load and drive the boom slowly out with the load low (about 10 cm from the ground), so that the rear wheels just about rise into the air. 5. Wait for 10 seconds and press OK Program accepts a value, which is at least 2V smaller than the previous value, which had no load. Program caclulates the stability linearly with the help of the points and determines an alarm limit (90%) and max. allowed limit (100%). When the acceptable calibration values have been stored, the next display appears automatically. Display shows text: CALIBRATION OK for 2 seconds, and after that it returns to the basic display. 6. Finish calibration by resetting the system by switching off and on again power of the machine. Warning! Note. Do not switch off power of the machine until display shows the basic display. Otherwise the calibration values are not saved correctly. 04.3.13.2 Calibrate Stability 2 The boom decelerations are not valid when the ”calibrate stability2” is accepted with OK in the calibration menu, so the situation is the same as the by-pass switch pressed to bottom.


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50

Electric Systems

When calibrated the boom is asked to drive completely in, then the minimum value of the length sensor will be received. When driven the boom out, it will be have the maximum value of the length sensor. BOOM IN • The boom is telescoped completely in. • 0,1 < length sensor voltage < 0,3 • Boom in is accepted with the OK button • 0,2V is a recommended value; also 0,1 and 0,3 are acceptable. BOOM OUT • The boom is telescoped completely out. • 4,7 < length sensor voltage < 4,9 • Boom out is accepted with the OK button. • 4,8V is a recommended value, also 4,7 and 4,9 are acceptable When the boom is down it will have the minimum value for the angle sensor and when up the maximum value. BOOM DOWN • The boom is dropped completely down. • 0,4 < angle sensor voltage < 0,8 • Boom down is accepted with the OK button. About 0,5V is a recommended value 0,4 is minimum and 0,8 maximum which are also accepted. BOOM UP • The boom is lifted completely up. • 2,9 < angle sensor voltage < 3,5 • Boom up is accepted with the OK button. About 3,5V is an accepted value. 2,9 is minimum and 3,5 maximum values which are also accepted. When the calibration is made and the calibration values are saved, “OK” will appear on the display.

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Electric Systems

51

04.3.13.3 Calibrate Gas You should calibrate the sensor of the gas pedal every time you replace the pedal. The program contains default values, which allow the gas pedal to function before parameters are loaded. However, you must calibrate the gas as soon as possible. Calibrate the gas pedal as follows: power is on but engine is not running. 1. Move to calibration displays. Press the OK key, and if the display then shows text: CALIBRATE STABILITY 1, move to calibration by pressing the "arrow down" key. Display shows text: CALIBRATE GAS. 2. Press OK Display shows text: PRESS GAS ALL THE WAY DOWN. 3. Press gas all the way down and at the same time press the OK key, and the program will read the voltage value. Next display appears automatically. Display shows text: RELEASE GAS. 4. Release the gas pedal and press the OK key, and the program will read the voltage value. The program accepts the calibration when the previous, with the pedal all the way down, is at least 1V higher. When the acceptable calibration values have been stored, the next display will appear automatically. Display shows text: CALIBRATION OK for 2 seconds, and after that it returns to the basic display. 5. Finish calibration by resetting the system by switching off and on again power of the machine. Warning! Note. Do not switch off power of the machine until display shows the basic display.Otherwise the calibration values are not saved correctly.


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Electric Systems

04.3.13.4 Calibrate Pressure Weighing (option) Pressure weighing shows weight of the load based on voltage values of one pressure transmitter in one position of the boom as determined by sensors S79. Conditions of the weighing display are: boom in A83:DI11 = 1 and angle data S79 A81:DI9 = 1 and machine does not move A82:DI2<100Hz and boom movements are not made. Note. We recommend that you make the calibration after a lifting movement. 1. Move to calibration displays. After you have pressed OK button, if the display shows text: CALIBRATE STABILITY 1, you can access weighing calibration by pressing "arrow down" key 2 times. Display shows text: CALIBRATE PRESSURE WEIGHING 2. Press OK Lift boom without a load to weighing spot, and the display will show signs **.* t Display shows text: BOOM WITHOUT LOAD **.* t 3. Press OK Pressing of OK key is allowed, after you have been at the calibration item for at least 3 seconds. Program read the voltage, which corresponds to 0,0 t. Following display changes automatically. Display shows text: BOOM WITH LOAD **.* t 4. Lift load container (whose weight you know) to weighing spot, and the display will show sign **.* t . Enter from the display weight in tons with accuracy of one decimal (nn,n). 5. Press OK Pressing of OK is allowed, after you have been at the calibration item for at least 3 seconds. Program reads the voltage, which corresponds to the entered weight and checks that the previous value without a load is smaller than with the load. When acceptable calibration values have been saved, the following display changes automatically. Display shows text: CALIBRATION OK for 2 seconds, and then returns to the basic display.

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6. Finish calibration by resetting the system by switching off and on again power of the machine. Warning! Note. Do not switch off power of the machine until display shows the basic display.Otherwise the calibration values are not saved correctly. 04.3.13.5 Pressure Weighing Fixed Scale When the calibration point is correct, A83_DI11 = 1 and A81_DI9 = 1, stars will appear on the calibration display indicating that the calibration can be made. It is recommended that the fcalibration will be made after the lifting movement. The boom is lifted without load to the calibration point and the OK button is pressed on the display. Pressing of the OK button is allowed when A83_DI11 and A81_DI9 have been 1 at least for three seconds. When pressing the OK button the program reads the corresponding voltage (X), which corresponds to 0 ton. The container, the weight of which is known in tons, is lifted to the calibration point. The weight is written with one decimal from the display and is exited with the OK button. Pressing of the OK button is allowed when the A83_DI11 and A81_DI9 have been at 1 for at least three seconds. When pressing the OK button, the program reads the corresponding voltage (/) which corresponds to the written load.


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Electric Systems

The program checks that the calibration value “boom without load” is less than the value “boom with load” and that the calibration values will be saved. The calibration has been made correctly if an OK message appears on the display. The program makes scaling linear with two calibration points. The scaling top level, max is counted according to the formula described in the following figure.

Figure 19. Calibration Points, Scaling

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Electric Systems

55

04.3.14 Functions of By-pass and Emergency Switches S189 A84_DI11A. Locking switch, which in its bottom position stops toplift's automatic extension/shortening movement. S194 A81 DI10A. By-passes shafts open/closed data of toplift's sensors. If S194 is pressed down, boom's lowering and lifting functions are possible, even if shafts open/closed data is missing. Switch does not by-pass stability. S85 A81 DI12. Stability guard's by-pass switch by-passes stability guard, when the shafts are open or closed or when you have pressed S189+S194. Switch permits lifting and lowering of the boom and telescoping out, also permits rotations. Stability does not affect telescoping in of the boom. Telescoping in of the boom is allowed, when stability is 100%. S199 A84_DI14B. Container contact by-pass switch. Permits open movement of shafts, even if container contact is missing. You can only use the switch when the container is on a stable surface (on the ground). S112 A84_DI1B. Emergency stop switch shuts off the engine, and you cannot start the engine until you have released the switch S186* A82_AI8 gas control. Controls the gas directly without conditions 1,6V. S187* A82_PRO4 start of engine and A82_PRO1 engine running/stop. Press the button during starting, engine will remain running, you can also shut off the engine from the switch. Controls directly without conditions. S188* A82_PRO3, A82_PRO2 directions and A82_DO2, A82_DO3 2-gear. You can use the switch to select direction forward or backward and 2-gear. Controls directly without conditions.


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Electric Systems

*) Use of the by-pass button by-passes all protectors of the control system. Use is only permitted for transfer driving to the repair shop.

04.3.15 Bus Errors The display monitors that it receives messages from each module (A81, A82,A83,A84 and A86 (ECU engine) at specified intervals. If reception of message stops (>1s), the display will show an alarm. A81 module also checks that it receives messages from A82 module. If it does not, critical movements will be forbidden. A bus alarm occurs when a bus is broken or a module has fallen out of the entire system. First you should check whether a modules LED lights are burning, and if they are, then you should check the bus for errors. 1. Bus connection broken between A80 and A84 • Machine operates normally without the display. 2. Bus connection broken between A84 and A82 • Display will show alarms ERROR CAN A81, ERROR CAN A82, ERROR CAN A83, ERROR CAN ENGINE • Stability on display 0%, boom movements are forbidden, by--pass switch S85 permits movements, spreader movements do not function (switches on A84 module). • Display shows engine data (rpm, _C, bar) as zeroes, engine will not start from the key but will start from by-pass switch S187. Directions do not function normally, but will function with by--pass switch S188. Gas functions. 3. Bus connection broken between A84 and A81 • Display will show alarms ERROR CAN A81, ERROR CAN A83, ERROR CAN ENGINE • Stability on display 0%, boom movements are forbidden, by--pass switch S85 permits movements, spreader movements do not function (switches on A84 module). • Display shows engine data (rpm, _C, bar) as zeroes, engine will not start from the key but will start from the by--pass switch S187. Directions do not function normally, but will function with the by--pass switch S188. Gas functions, A81 controls it.

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4. Bus connection broken between A81 and engine A86 (ECU) • Display will show alarms ERROR CAN A83, ERROR CAN ENGINE • Stability on display 0%, boom movements are forbidden, by--pass switch S85 permits movements, spreader movements do not function (switches on A84 module). • Display shows engine data (rpm,_C, bar) as zeroes, engine will not start from the key but will start from the by--pass switch S187. Directions do not function normally, but will function with the by--pass switch S188. Gas does not function. 5. Bus connection broken between engine A86 (ECU) and A83 • Display will show alarms ERROR CAN A83 • Stability on display 0%, boom movements are forbidden, by--pass switch S85 permits movements, spreader movements do not function (switches on A84 module). • Display shows engine data normally, engine will start from the key. Directions do not function normally, but will function with the by--pass switch S188. Gas functions. 6. Control unit falls out of the system • A81, alarm ERROR CAN A81. Boom movements do not function even with the by--pass switch. Spreader movements do not function, because free rotation is on A84 module. Stability is 100%, engine functions and starts and gears function. • A82, alarm ERROR CAN A82. You can engage gears and direction with the by--pass button S188. You can start and shut off the engine with S187 button. Gas functions with the by-pass button S186. By-pass switch S85 permits boom movements. • A83, alarm ERROR CAN A83. Spreader movements do not function, boom movements will function with S194 by--pass. • A84, alarm ERROR CAN A84 and EMERGENCY-STOP PRESSED. Boom movements function,


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Electric Systems

spreader movements do not function. Engine will start with the by--pass switch S187, gears and directions function with the by-pass switch S188. Gas functions. 04.3.16 Replacement of a Module If you replace a control module of the machine, you must load the machine-specific software to it. Loading is done at the factory in connection with the spare part delivery. When you order a new module, you must specify the device code of said module (A80, A81, A82 or A83) and the machine's serial number. You must always perform the calibrations after you have replaced a module. See item Calibration.

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Electric Systems

04.4

1

59

Electric Equipment for the Power Unit Scania DI12 EDC/PDE A

A

2

R6- S11 R9 R7- S12

S12- R7 K201 S6

G1

K2 M1

Y3 Y2 Y1 Y4 Y5

B1

B1

S10 R4 S12- R7 R9

1

R6

S11

2

R7

S12

3

R9

B1

4

R4/S10

3 4

S11- R6

Figure 20. Electric Equipment for the Power Unit 1

Engine oil pressure sensor

2

Boost temperature / pressure sensor

3

Coolant temperature sensor

4

Engine RPM sensor

B1

Transmission output sensor

G1

Alternator

K2

Start solenoid

K201

Air conditioner magnet switch (optional)

M1

Start motor

R9

Hydr.oil temperature

R4/ S10

Engine coolant temperature sensor / switch

S6

Electronic control module ECM

R6/ S11

Transmission temperature sensor / switch

R7/ S12

Transmission pressure sensor / switch

Y1 -Y5

Solenoids of gear shift


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Electric Systems

04.5

Electric Equipment for the Power Unit

S10- R4

S12- R7

G1

S11- R6

B1

S11

B2

S12

B1 B2

A86 ECM

K2 S9

S12 R7

R6

R5

Y4 Y5 Y2 Y1 Y3

M1

Figure 21. Electric Equipment for the Power Unit

UDRS01.01GB

A86

Electronic control module ECM

B1

Transmission output sensor

B2

Engine RPM sensor

G1

Alternator

M1

Starting motor

K2

Starting solenoid

R6

Transmission temperature

S11

Transmission temperature switch

S12

Transmission pressure switch

Y1 -Y5

Solenoids of gear shift


Electric Systems

04.6

E39

Electrical Equipment in the Frame

V1- V7

F1

3

1 7

5

9 1 1315

1 3 5 7 9 111315

F2

X3 X1

2 4 6 8 10 14 12 16 4

2 8

6

10

F3

X2

3 2 1 6 5 4 9 8 7

3 2 1 6 5 4 9 8 7

3 2 1 6 5 4 9 8 7

XR3

X85 X78

3 2 1 6 5 4 9 8 7

X95

X35

3 2 1 6 5 4 9 8 7

3 2 1 6 5 4 9 8 7

X7

3 2 1 6 5 4 9 8 7

3 2 1 6 5 4 9 8 7

3 2 1 6 5 4 9 8 7

3 2 1 6 5 4 9 8 7

F42 F43 F44 F45 F46 F47 F48 F49

F34 F35 F36 F37 F38 F39 F40 F41

DI12

XEC

X37

3 2 1 6 5 4 9 8 7

X31

X38 3 2 1 6 5 4 9 8 7

3 2 1 6 5 4 9 8 7

X5 X6

A81

X4

X21

(X39)

F4

3 2 1 6 5 4 9 8 7

61

QSM11

S297 S296

Figure 22. Electrical Equipment in Frame


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62

Electric Systems

A81

Control module

A85

Amplifier (stability)

E39

Service light

K71

Relay, brakes cooler

K72

Relay, hydraulics cooler

S296

Switch, cabin transfering

S297

Switch, cabin transfering

V

Diodes

QSM11

Cummins datalink

DI12

Scania datalink

Fuses F1

Main fuse, cabin (50A)

F2

Main fuse, cabin (50A)

F3

Main fuse, frame/hydraulics (50A)

F4

Main fuse before main switch (50A)

F34

Hydraulics cooler (15A)

F35

Brakes Cooler (15A)

F36

Control module A83 (10A)

F37

Hydraulics (10A)

F38

Control module A81 (10A)

F39

Engine (10A)

F40

Cabin before main switch (25A)

F41

Cabin transfer, engine (10A)

F42- F49

Options

F43

Scania power (90A)

Connectors

UDRS01.01GB

X37

Cabin - boom

X35

Cabin - frame

(X39)

Main switch, Cabin boom in

X85

Cabin - frame

X95

Cabin - frame

XR3

Main switch - cabin

X38

CAN-connector, boom - engine

X21

Cabin - engine

X31

Cabin - engine

X78

Cabin - engine

XEC

Cabin - engine


Cabin

1

05 Cabin 05.1 Electric Equipment for Cabin ........................................................... 2 05.1.1 Electric Box for Cabin ............................................................. 2 05.1.2 Connectors for Cabin .............................................................. 5 05.2 Electric Control System of Engine Speed - Scania ........................ 6 05.2.1 General ................................................................................... 6 05.3 Electric Control System of Engine Speed - Cummins ................... 7 05.3.1 General ................................................................................... 7 05.4 Intake Air Filter and Windscreen Washer Filling ............................ 8


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2

Cabin

05.1

Electric Equipment for Cabin

05.1.1 Electric Box for Cabin

S186 S187 S188

A13

*

* A12

Option

Seat heater R6 R8

K19 K13

1 3

5

1

3

5

17 1

17 1

9

9

2

4

6

12 8

10

2

4

6

12 8

10

K17

H13

F10 F11 F12 F13 F14 F15 F16 F17

S3

F18 F19 F20 F21 F22 F23 F24 F25

F26 F27 F28 F29 F30 F31 F32 F33

1 2 3 4 5 6

A84

9

40

18

1

8

41 42

17

2

16

6 5

43

15 14

3 4

4

45 46

13

6

12

47

11

7 8

10

9

9

1

8

2 3

7

3 2 1

1 2 3 4 5 6 7

44

9

48 49

8

50

7 6

51

A82

7 6

5

52 53

4

54

4

3 2

55

3 2 1

1

56 57

5

X44

XPO

XR1

XSR

XS1

X191

XR2

XR3

XHR

X115

X82

X32

X36

X21

X31

X95

XGE5

5

4 5 6 7 8 9

X35

Figure 1. Electric Box for Cabin

UDRS01.01GB


Cabin

3

A12

Voltage reducer (optional)

A13

Voltage reducer (optional)

A82

Control module

A84

Control module

H13

Alarm buzzer

R6

Resistor 200ohm

R8

Resistor 200ohm

S3

Maintenance switch

S186

Gas pedal by-pass

S187

Engine start

S188

Gear holding

Relays K13

Sound signal

K17

Flashing relay

K19

Reversing light and alarm

Fuses F10

Fan Heater (15A)

F11

Condenser fan (15A)

F12

Seat heater / compressor seat (15A) (optional)

F13

Alarm lights gauges (10A)

F14

Reserved (10A)

F15

Reserved (10A)

F16

Control modules A80, A82 and A84 feed (10A)

F17

Parking brake (10A)

F18

Driving and parking lights (10A)

F19

Flashing beacon (10A)

F20

Reversing lights alarm (10A)

F21

Turn signal lights (10A)

F22

Working lights, boom (10A)

F23

Working lights, boom (10A)

F24

Working lights, front on the roof (10A)

F25

Working lights, rear on the roof (10A)

F26

Working lights, spreader (10A)

F27

Front window wiper and washer (10A)

F28

Rear window wiper and washer (10A)

F29

Roof window wiper and washer (10A)

F30

By-pass

F31

Reserved (10A)

F32

Cabin transferring (10A)

F33

Engine stopping delay, (10A) (optional)

switches (10A)


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4

Cabin

Connectors

UDRS01.01GB

XR1

Spare wirings from hand lever panel

XSR XR2 XHR

Spare wirings from front panels

XR3

Spare wirings from supply cable chassi

XP0

Forced drive control panel

X44

From air conditioner

X191

From mini steering wheel

XS1 XGE5

From hand lever panel

X22, X37

From front panels

X21, X31, X35, X95, X82, X115

From frame

X32 X36

From roof

XPC

From display


Cabin

5

05.1.2 Connectors for Cabin * E35 +12V 6A MAX X32B X36B

E30 +24V 6A MAX F37

* E32

M7 A312 X190

XGE XR1

* E34

S97A S97B

* E33 M5

S980 XR2 X308 X309 X310

* +24V / 12V 6A MAX

XSR

S7

X1 X2 X3

S990 F37

H13

S52

S23 M911 M3 M212 M222 RM212 RM222

+24V 6A MAX

A80

X350 X355 X351 X356 X352 X319 XS2

X304 X305 X306 X307 XSR

M4 M6 M8

K33 K34 * K35 *

*OPTION

X32 X36 XS1 GE5 XR1 X191 X44

XP0 XSR XR2 XHR XR3

X115 X82 X21 X31 X35 X95

Figure 2. Connectors for Cabin


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6

Cabin

05.2

Electric Control System of Engine Speed - Scania

05.2.1 General The movement of the acceleration pedal in the electric control system of engine speed is transferred as an electric signal message to the engine.

1

A312 A82 A96

2

Figure 3. Devices of the Electric Control System of Engine Speed 1

Acceleration pedal

2

Engine Scania DSI12

A82

Control unit

A312

Potentiometer

A96

Engine control unit

Message of the function position of the acceleration pedal (1) is transmitted through the potentiometer (A311) and control unit (A82) to an engine control unit (A96), which controls the function of the engine injectors .

UDRS01.01GB


Cabin

05.3

7

Electric Control System of Engine Speed - Cummins

05.3.1 General The movement of the acceleration pedal in the electric control system of engine speed is transferred as an electric signal message to the engine. 1

A312

2 A86

Figure 4. Devices of the Electric Control System of Engine Speed 1

Acceleration pedal

2

Engine Cummins QSM11

A86

Engine control unit

A312

Potentiometer

Message of the function position of the acceleration pedal (1) is transmitted through the potentiometer (A312) to the engine control unit (A86), which controls the function of the engine injectors.


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8

Cabin

05.4

Intake Air Filter and Windscreen Washer Filling

Take care, that the visibility in the working area is not limited. Check the function of windscreen wipers (1) and the level of the washing fluid in the reservoir. Fill up, if necessary (3). Pay attention to the machine operating temperature, by defining the mixture ratio of washing fluid.

1

1

2

3

Figure 5. Air Filter and Windscreen Washer Filling

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1

Windscreen wipers

2

Intake air filter

3

Filling cap for windscreen washer liquid


Working Devices

1

06 Working Devices 06.1 Maintenance of the Boom ................................................................ 06.1.1 Maintenance Points of the Boom ............................................ 06.1.2 Slide Guides and Telescope Cylinder ..................................... 06.1.3 Adjustment of Play in the Boom .............................................. 06.1.4 Checking the Slide Parts ........................................................ 06.1.5 Replacing Slide Parts in Front End of the Boom .................... 06.1.6 Replacing Slide Parts in Rear End of the Boom: .................... 06.1.7 Mounting the Telescope Cylinder ........................................... 06.1.8 Electrical Equipment of Boom ................................................. 06.1.9 Lift Cylinder .............................................................................

2 2 3 4 4 5 6 7 8 9

06.2 Maintenance for Lifting Device ...................................................... 06.2.1 Turning Device and Side Sift Carriage ................................. 06.2.2 Container Handling Device (Toplift) ...................................... 06.2.3 Rotation Transmission Maintenance Points ......................... 06.2.4 Electrical Equipment for Spreader ........................................

10 10 11 13 14

06.3 Inspection Intervals for the Twistlocks of the Spreader ............. 06.3.1 Disassembly and Assembly .................................................. 06.3.2 Inspection of the Twistlocks .................................................. 06.3.3 Information for Guidance ......................................................

16 16 17 17


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2

Working Devices

06.1

Maintenance of the Boom

06.1.1 Maintenance Points of the Boom

7

7

A 2

A

5

6 3

2

2

KP06- 0117

Figure 1. Maintenance Points of the Boom

UDRS01.01GB

Item

Obs.

2

Slide pieces for boom front end

Daily lubrication, if there is not central lubrication

3

Boom bearings

Daily lubrication, if there is not central lubrication

5

Upper sliding surfaces of inner boom

Spread coating

6

Boom support rollers

Lubrication

7

Shims for bearings

Centralize the boom with shims


Working Devices

3

06.1.2 Slide Guides and Telescope Cylinder 1 7 8

2

9 10

3

11

A-- A

D

4

13

12

C

4

Min. 19- 21

A B

B 5

A 10 11 9

X

8 7 10 11 9

6

X

B- B Figure 2. Slide Guides and Mounting the Cylinder


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Working Devices

1

Slide part

2

Slide part

3

Slide part

4

Slide part

5

Slide part

6

Slide part

7

Screw

8

Mounting plate

9

Shim

10

Slide plate

11

Screw

12

Guide

13

Adjustment screw

06.1.3 Adjustment of Play in the Boom You should always adjust the play in the boom's outer and inner pipe when replacing slide parts, and at other times in accordance with the scheduled maintenance program. Adjust the play between the slide parts ( 1, 2, 3, 5 and 6) and the boom with shims (9), and the play of slide parts (4) with regard to the boom with adjustment screws (13). Total play in the lateral direction can be in range 2 - 4 mm. When adjusting the play, you should try to use the same number of shims on opposite sides of the boom, so that the gap between the outer and inner boom is sufficient on both sides.

06.1.4 Checking the Slide Parts Measure the thickness of slide plate (10) in the slide part. Replace side and upper slide plates (10) if measured thickness is 14 — 16 mm, and lower slide parts (4) if measured thickness is 19 — 21 mm. When chamfer C in the lower slide part (4) has worn off, replace the slide part. Warning! When slide parts wear to minimum thickness, lubrication grooves D are so low that lubrication is not sufficient. This may damage inner pipe of the boom and the telescope cylinder.

UDRS01.01GB


Working Devices

5

06.1.5 Replacing Slide Parts in Front End of the Boom In container handling machines, lower spreader on top of container; in forest machines, lower grapple to the ground. Move the boom carefully, so that the play between inner and outer pipe is loosened on that side of the slide part you want to replace. Remove central lubrication pipes from all slide parts you want to replace (option). Replacing Lower (4) and Upper Slide Parts (1): 1. Remove upper slide parts by opening the mounting screws (7) of the mounting plate (8) and by pulling out the mounting plate and its slide parts. You must remove the upper slide parts, so that the lower slide parts can come out. 2. Lower the boom, so that the play between inner and outer pipe moves to the bottom side of the boom. 3. Open the guide's (12) adjustment screws (13) and pull out the guide and its slide parts. 4. Replace the new slide part and re-install the guide

The guide's bottom surface is designed, so that it can adapt to movements of the boom. When installing, make sure that the guide can roll freely. 5. Adjust later play of lower slide parts to 2 — 4 mm with adjustment screws (13). 6. If necessary, replace new slide plates (10) to upper slide parts (1) and mount them and their mounting plates back into place. 7. Measure lateral play with a feeler gauge and adjust it to 2 — 4 mm by adding or removing shims (9) between mounting plate (8) and slide plate (10). Replacing Side Slide Pats (2 and 3): 1. Check that there is play between the slide part you want to replace and the boom, so that the slide part can come out. 2. Open mounting screws (7) of the mounting plate (8) and pull the slide part out. 3. Replace the new slide plate (10) and mount it and its mounting plate back into place.


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Working Devices

4. After you have replaced slide parts on one side, replace them on the other side. 5. Measure lateral play with a feeler gauge and adjust it to 2 — 4 mm by adding or removing shims (9) between mounting plate (8) and slide plate (10).

06.1.6 Replacing Slide Parts in Rear End of the Boom: Replacing Side Slide Parts (5): 1. Push out the inner boom by 0,5...1 m. 2. Check that there is play between the slide part you want to replace and the boom, so that the slide part can come out. If necessary, move the boom carefully. 3. Open mounting screws (7) of the mounting plate (8) and pull the slide part out. 4. Replace the new slide plate (10) and mount it and its mounting plate back into place. 5. After you have replaced slide parts on one side, replace them on the other side. 6. Measure lateral play with a feeler gauge and adjust it to 2 — 4 mm by adding or removing shims (9) between mounting plate (8) and slide plate (10). Replacing Bottom Slide Parts (6): 1. Pull the inner boom fully in. Check that the mounting screws (11) of the slide parts are at the holes on the bottom surface of the boom, so that you can open the screws.

2. Check that there is play between the slide part you want to replace and the boom, so that the slide part can come out. If necessary, move the boom carefully.

UDRS01.01GB


Working Devices

7

3. Open mounting screws (11) of the slide part (6) and pull the slide part and its shim out. 4. Mount the new slide part back into place. 5. Measure lateral play with a feeler gauge and adjust it to 2 — 4 mm by adding or removing shims (9) between boom and slide plate (10). When all Slide Parts have been Replaced: Push the boom fully out carefully, and at the same time check that the play is not smaller than the adjusted 2 — 4 mm at any point. If necessary, re-adjust the play. Re-

install central lubrication pipes (option) and test to make sure all lubrication items receive enough grease. 06.1.7 Mounting the Telescope Cylinder Warning! Make sure that the cylinder can move in the flange holes. Item X.


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Working Devices

06.1.8 Electrical Equipment of Boom X200 Pg21

7 6 5 4 3 2 1

27 28 29 30 31 X4 32 33

6 5 4 3

60 61 X8 62 63 64 65

Pg21

Pg21

Pg21

Y63 Y65a

Y59b

2

1

X2

X1

A83 X7

X6

39 38 37 36 X3 35 24 59 7 58 8 26 25 X5 24

1 2 3

23 22 21 20

4 5 6 7

19

1 2 3 54 6

H21

X60 BOOM/ CAN E27 E29

8

Pg21

X57 R60

120

R61 S79

Y65b Y59a

E27 E29

S81 S80

E28

E26

E26 E28 X200

H304 H305 H303

X30 RED

YELLOW GREEN

Figure 3. Electrical Equipment of Boom

UDRS01.01GB

E26 E29

Working light

H21

Flashing light

H303

Signal light green, twistlocks closed, 10W

H304

Signal light red, twistlocks open, 10W

H305

Signal light yellow, container in connection, 10W

R60

Boom's angle sensor (optional)

R61

Boom's length sensor (optional)

S79

Sensor, pressure weighing (optional)

S80

Sensor, damping of telescope in

S81

Sensor, damping of telescope out

X57

Connector, boom end

X60

Connector, basic boom end / CAN

X83

Connector, spreader

Y59

Solenoid valve, spreader rotating

Y63

Solenoid valve, spreader tilting locking

Y65

Solenoid valve, spreader longitudinal tilting


Working Devices

9

06.1.9 Lift Cylinder Pm6

1

2

*

*

Figure 4. Lift Cylinder 1

Lock valve

2

Guide bearing

Pm6


*

Gasket set

06.1.9.1 Cylinder Mounting Absolute cleanliness is necessary when assembling the cylinder. Wash the used parts carefully before starting the assembly, close with plastic plugs the open connection points and open the gasket packages just when starting the assembly. Make sure before starting to work, that greases and oils used in assembly are suitable for hydraulic mounting. Mount the guide rings so that the connection points of the rings are not on the same central line. Lubricate with vaseline the gasket set and guide ring surface before mounting the piston into the cylinder liner. Pull the piston carefully into the cleaned cylinder liner. Make sure that the central lines of the piston rod and the piston line are so accurately parallel as possible. Oil the piston rod with hydraulic oil when the piston is pulled into the pipe. Use for lifting crane or forklift truck, then the gross weight of the cylinder is about 800 kg.


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Working Devices

06.2

Maintenance for Lifting Device

06.2.1 Turning Device and Side Sift Carriage

1 3

2 1

3

3 4

3 7

3

1

8 3

1

330 - 350 Nm

6

5

Figure 5. Turning Device and Side Sift Carriage Maintenance item 1

Lubricate bearings of cylinders1)

2

Lubricate shafts of turning device 1)

3

Lubricate slide surfaces for side sift car- Spread coating riage

4

Lubricate bearings

5

Lubricate bearings of gear rim 1)

4 grease points

6

Gear rim

Spread coating

7

Gear oil filling / level dipstick

8

Gear oil drain plug

1)

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Note

Central lubrication point (optional equipment)


Working Devices

11

06.2.2 Container Handling Device (Toplift) The container handling device, toplift is welded steel construction with telescopes on both ends. The length of the device is hydraulic adjustable for the container sizes according ISO and Seeland standards, with length of 20' and 40'. Optional device for handling of containers of 30' is available. 2 5

4

3

5

A

1

A 3

8

9

7

6

6

9 10

5

3

3

1

11 7

7

6

A- A

Figure 6. Container Handling Device (Toplift)


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12

Working Devices

Container Handling Device Maintenance item

Note

1

Toplift frame

2

Side sift carriage

3

T-beam

4

Length cylinder

Both T-beams

5

Lubricate bearings of the length cylinde

T-beams have to be in 40' position

6

Sliding pads in frame

Both ends

7

Sliding pads in T-beam

Both T-beams

8

Lubricate slide planes

Spread coating, especially under sides of the beams

9

Lubricate twistlock turning cylinder

10

Twistlocks

11

Lubricate twistlocks

Moveable parts greassed thoroughly at assembling

06.2.2.1 Check Sliding Pads Check the sliding pads during lubrication maintenance. Adjust the total spacing 1...2 mm with spacing plates. Change outworn sliding pads.

UDRS01.01GB


Working Devices

13

06.2.3 Rotation Transmission Maintenance Points

2

1

3 4

6 5

80 Nm

7

Figure 7. Rotation Transmission Maintenance Points 1

Transmission brake oil filling/draining. Fill to sight glass (2) level (0.6l). Draining: Turn elbow down.

2

Transmission brake oil sight glass

3

Transmission brake breather

4

Transmission oil filling. Fill to sight glass (5) level (2.2l).

5

Transmission oil sight glass

6

Transmission breather

7

Transmission oil drain plug


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14

Working Devices

06.2.4 Electrical Equipment for Spreader The valves of hydraulics

S125

S99B S99

Y73A Y74A Y71B

Y62B Y62A

Y66--1

Y73B Y74B Y71A

Y64B Y64A

Y66--2

S127 S98B S98 S236 S136

S121 S123 S235 S135

X62

E37

E36

S128

S126 X83

Figure 8. Electrical Equipment for Spreader

UDRS01.01GB

S124 S122


Working Devices

15

S98

Sensor, rotation clockwise stop

S98B

Sensor, 20° limit rotation clockwise (optional)

S99

Sensor, rotation counter-clockwise stop

S99B

Sensor, 20° limit rotation counter-clockwise (optional)

S121

Sensor, twistlocks open, left

S122

Sensor, twistlocks open, right

S123

Sensor, twistlocks closed, left

S124

Sensor, twistlocks closed, right

S125

Container contact, front left

S126

Container contact, rear left

S127

Container contact, front right

S128

Container contact, rear right

S135

Sensor, spreader 20’ - 40’ left limit

S136

Sensor, spreader 20’ - 40’ right limit

S235

Sensor, 30’ function left limit

S236

Sensor, 30’ function right limit

X83

Connection

X62

Connection box

E36 E37

Spreader working lights

Y62A

Side shift, left

Y62B

Side shift, right

Y64A

Pile-slope to right (option)

Y64B

Pile-slope to left (option)

Y66-1

Pile-slope locking, left (option)

Y66-2

Pile-slope locking, right (option)

Y71A

Twistlocks open

Y71B

Twistlocks closed

Y73A

Lengthening right

Y73B

Shortening right

Y74A

Lengthening left

Y74B

Shortening left


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16

Working Devices

06.3

Inspection Intervals for the Twistlocks of the Spreader Warning!

The twistlocks must be checked: First time 5000 operating hours or 2 years whichever occurs first. Then after the twistlocks must be checked once a year.

1

300 Nm

2

4 5

3

6

Figure 9. Twistlock Housing

06.3.1 Disassembly and Assembly 1. Disjoin the mounting nut (1) and locking washers (2). 2. Draw the twistlock out (3) from the under side. 3. Check condition of the pivoted level (4) and bearing housing (5). 4. Check condition and functioning of the contact pin (6) and spring. 5. Check condition of the twistlock according to the instructions. 6. While assembling set the key and locking washers and tighten the mounting nut 300 Nm. 7. Check that the parts are functioning correct in accordance with the others.

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Working Devices

17

06.3.2 Inspection of the Twistlocks Liquid penetrant examination or magnetic particle examination shall be used. The area of testing is shown in figure 10. Crack check shall take place every second year or every 5000 operating hours.

1

Figure 10. 1 = The area of the testing Note 1: If any cracks are found the twistlocks must be replaced immediately! Note 2: Twistlocks must be replaced if they are visibly distorted.

Max. 4 mm

M

in

.7

0

m

m

Note 3: Twistlocks must be replaced latest at 10.000 h.

Figure 11. Wear Limits, Lift Pin

06.3.3 Information for Guidance 06.3.3.1 Liquid Penetrant Examination Detailed instructions for liquid penetrant examination is available in, the following publications: • ASME Boiler and Pressure Vessel Code • Section V, Nondestructive Examination • Article 6, Liquid Penetrant Examination


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18

Working Devices

• Article 24, Standard methods for liquid penetrant inspection, SE-165 (=ASTM E 165) • SIS 11 45 01 • Draft International Standard ISO/DIS 2694:1973

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Working Devices

19

06.3.3.2 Magnetic Particle Examination References • Draft International Standard ISO/DIS 2694 • SIS 11 44 01 Magnetpulverprovning • DIN 54 121 Magnetpulver-PrÜfung • ASME Boiler and Pressure Vessel Code, • Section V; Nondestructive Examination: • Article 7, Magnetic Particle Examination • Article 25, Magnetic Particle Standards • SE-109 (=ASTM E 109-63) and • SE-138 (=ASTM E 138-63) and


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20

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Working Devices


Equipment

1

08 Equipment 08.1 Air Conditioner .................................................................................. 08.1.1 Function of the Air Conditioning Device .................................. 08.1.2 Operating Instructions for the Air Conditioner ......................... 08.1.3 Maintenance ........................................................................... 08.2 Automatic Central Lubrication ....................................................... 08.2.1 General ................................................................................. 08.2.2 Indicator Lights and Switch in the Instrument Panels ........... 08.2.3 Central Lubrication Diagram K5698190 ................................ 08.2.4 Central Lubrication Diagram, Toplift .....................................


2 2 3 4

12 12 12 14 16

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2

Equipment

08.1

Air Conditioner

08.1.1 Function of the Air Conditioning Device The circulation of the cold fluid in the air conditioning system R-134A installed in the machine, starts from the compressor;1; which press the hot and gaseous cold fluid to the cooler;2, mounted on the back side of the machine. The air flow through the cooler transfers the heat from the cold fluid to the open air, and the cold fluid will condence. From the cooler the condenced cold fluid is flowing into the filter; 3;, which separates from the cold fluid humidity and impurity. From the filter the cold fluid flows into the expansion valve; 4; which controls the volume of the cold substance flowing into the evaporator; 5. After the expansion valve the cold fluid pressure in the system is lowering. In the evaporator the cold fluid will vaporize again, because of lowering pressure. The vaporizing liquid is binding heat of the air, which flows through the evaporator cell, and the temperature of the cabin will be lower. The compressor sucks the hot gas from the evaporator and press it trough the cooler to one new working circulation

5

4

2 L

H

3

1 Figure 1. Diagram of the Air Conditioner

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Equipment

1

Compressor

2

Cooler

3

Filter and control glass

4

Expansion valve

5

Evaporator

L

Low pressure

H

High pressure

3

08.1.2 Operating Instructions for the Air Conditioner 08.1.2.1 Warm weather, normal humidity: Close the recirculation vent and the heating regulator, turn the cooling system on, and adjust the thermostat as required. 08.1.2.2 Very warm weather, high humidity: Open the recirculation vent, close the heating regulator, turn the cooling system on, and adjust the thermostat as required. In autumn and early winter when humidity is high and windows become misty: Turn the cooling system on, open a window slightly to allow air circulation in the cabin. Adjust the heating regulator for desired cabin temperature. 08.1.2.3 Cold winter weather: Close the recirculation vent, do not turn cooling system on. adjust the heating regulator for desired temperature.


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Equipment

08.1.3 Maintenance The system should be checked once a week, carrying out the following inspections. • Sight glass. Bubbles should only appear when the compressor is started and stopped. • Check that the connection between the compressor pressure plate and the pulley is not slipping, and that it is clean. • Check that the wire between the thermostat and the electomagnetic clutch is in good condition. • Check the drive belt tightness and the compressor mounting. • Clean or replace the fresh air and recirculation filters. • Check the removal of condensate water from the bottom of the air-conditioner. • Check all hose connections. 08.1.3.1 Sight Glass Checking Procedure a) Start the engine and run it at 1500 rpm b) Turn the air-conditioner on. c) Set the fan and the thermostat to maximum.

Figure 2. Fluid Container and Sight Glass Mounted to Top/side

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Equipment

5

1

Sight glass

2

Fluid container

3

Pressure switch

Sight glass Description

Conclusions and remarks

Continuous stream of bubbles or foam-like flow (add refrigerant).

Very little refrigerant Small temperature difference between intake and pressure side. Pressure in output side exceptionally low. Stop compressor at once, and have a specialized mechanic check the system.

A few bubbles every few seconds (add refrigerant).

Insufficient amount of refrigerant High-pressure side warm, low-pressure side cool. Check the system for leaks, and repair possible leaks without delay. Add refrigerant into the system.

Clear fluid, few bubbles pass when speed of rotation is changed.

Correct amount of refrigerant Normal pressure values in highpressure and low-pressure sides. Pressure side hot, intake side cold.

No bubbles (remove refrigerant from system).

Too much refrigerant Pressure side very hot. Abnormally high pressure values in intake and pressure sides. Remove refrigerant from the system, from the pressure side.

08.1.3.2 Cold and Dry Periods with Minimal use of Air Conditioner Start the air-conditioner and allow the compressor to operate a few minutes every week to keep the connections, seals, etc. lubricated. If a low-pressure switch is connected to the system, it must be bypassed if the ambient temperature is below -1°C. Otherwise the compressor cannot be started.


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Equipment

08.1.3.3 Safety Regulations When working on air-conditioning systems you should remember the following precautions: Always wear goggles, because pressurized refrigerant may leak out unexpectedly. Hands and other parts of the skin should also be protected against freezing. If you get refrigerant on your skin, the affected area should be flushed with cold water and treated like frostbite. If refrigerant gets into your eyes, they should be flushed with tap water, preferably approx. 15 minutes. If pain or sight problems occur, seek medical help without delay. Refrigerants may never be handled near open fire or live coals. Toxic gases are formed, if refrigerant and fire get in touch with each other.

Figure 3. Always wear safety classes and protective gloves

Figure 4. Do not release refigerant into the air. Use the recovery unit!

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Equipment

7

Figure 5. Keep caps closed! If an R-134a air conditioner system is mistakenly charged with R12, serious problems such as compressor seizure can result.

Figure 6. Don't mix refrigerants! 08.1.3.4 Changing the Components of the Air Conditioning System Warning! According to a resolution on refrigerants it has been forbidden since July 1, 1989, to release refrigerants into the atmosphere. Therefore, recovery equipment should always be used. With such equipment, the gas can be cleaned and then reused for filling up the system. This procedure should be followed with all refrigerants as they are harmful if released into the atmosphere.


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8

Equipment

When a component is replaced, some of the compressor oil is removed with it from the system. Top up the system according to the following table. Part

Oil amount / cm3

Evaporator

60

Condenser

40

Tank

20

Hose (3-8)

10-20

Warning! Liquid R134-a requires green O-rings. Never use black O-rings with R134-a.

Figure 7. Green O-ring Compressor Oil New compressors are delivered with 1.8 dl of oil in them, an amount that is sufficient for systems with 1.25 kg of refrigerant. For systems up to 1.6 kg of refrigerant, the amount of oil to be added can be calculated as follows: Amount of refrigerant in kg x 1.3 + 0.4 Example: 1.5 kg x 1.3 + 0.4 = 2.35 -> add 0.55 dl (2.351.8=0.55)dl Warning! Use only synthetic PAG-oil such as ZXL 100 PG or equivalent in the air conditioning devices. When the compressor is replaced, measure the amount of oil in the old compressor. Also drain the new compressor and then fill it through the intake connection, using the same amount of oil as was drained from the old one.

UDRS01.01GB


Equipment

9

Figure 8. Don’t mix oil compressors 08.1.3.5 Troubleshooting No Cooling Check: • uses, electric connections, compressor's earthing, compressor's electromagnetic clutch, flow controller, and pressure controller • drive belt • compressor • expansion valve • temperature regulator valve • refrigerant hoses Poor Cooling Power Check: • fan • drive belt tightness • that no air gets past evaporator • that the evaporator and condenser are not clogged • that the fresh air filter is not dirty and clogged • that the capillary tube of the expansion valve is properly fastened to the evaporator outlet pipe • that the thermostat is not switching off too early


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Equipment

Uneven Cooling Check: • that all electric connections at the control switches, magnetic clutch, and pressure controller are properly fastened • that the expansion valve is not clogged • that the system is correctly filled • that the thermostat is not faulty Abnormal Noise Check: • that the compressor drive belt is correctly tightened • that the compressor mounting screws are properly tightened • that the amount of refrigerant in the system is correct Abnormal noises of the system often result from incorrect mounting of components. If, for example, the compressor is noisy at a certain speed and the noise disappears when the speed is raised or lowered, it is likely that the fault is not in the compressor. All machines have their specific resonance frequency where vibrations occur. The speed of rotation at which noise is heard may vary between different machines. Often these vibrations can be eliminated by increasing or decreasing the tightness of the drive belt, or by replacing it with a belt of different length. Too much tightness causes faster wear of the compressor bearings, the drive belt, and the pulleys. Therefore, the drive belt should not be adjusted too tight. The compressor need not be replaced if the drive belt 'jumps' and causes unusual noise. In such cases, it is advisable to try adjusting the belt tightness or change a belt of different length. Also a compressor pressure hose of different length may reduce noise.

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Equipment

11

Figure 9. Abnormal Noise The pressure differences between the intake and output sides also affect the noise level. A compressor with a low intake pressure causes more noise than one with a high intake pressure. Similarly, a compressor with a high output pressure causes more noise as it strains the bearings, etc. You should also check that the system is correctly filled with refrigerant, and that the expansion valve works properly. Make also sure that the air flow through the evaporator is sufficient. Also check that the condenser is clean and the air flow sufficient, and that the system is not too full with refrigerant. As the compressor has many moving parts, all noise cannot be removed. For instance, the compressor's pistons generate noise and vibrations of relatively high frequency.


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Equipment

08.2

Automatic Central Lubrication

08.2.1 General This machine is equipped with a central lubrication system, which lubricates the most important lubrication points on a regular basis. See Central Lubrication Diagram.

Figure 10. Automatic Central Lubrication Machine See detailed operating instructions in the attached P203 Operating instructions.

08.2.2 Indicator Lights and Switch in the Instrument Panels

H200 S200

H202

Figure 11. Instrument Panel

UDRS01.01GB

H200

Lubrication system indicator light, green (light is ON when lube pump is working)

H202

Warning light, red

S200

Central lubrication switch / Extra lube interval / Reset after warning


Equipment

13

08.2.2.1 Filling the Tank Progressive system is designed to feed so-called base greases until classification NLGI 2. You must take into account pumping ability of the grease in very low temperatures. When you change the grease quality or brand, remember that different types of grease may react to each other.

Figure 12. Filling the Tank Fill the tank through a filling nipple, which is equipped with a filter, with a pneumatically or manually operated pump.


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Equipment

08.2.3 Central Lubrication Diagram K5698190

0.16ccm/min

0.08ccm/min

2 6 8 10 12

3

4

2 4 6

1 5 7 9 11

5

0.08ccm/min 0.17ccm/min

1 3

3

5

0.08ccm/min 0.17ccm/min 0.13ccm/min 0.25ccm/min

2 4 6

7

8

2 4

6

1 3 5

4

1 3 5

6

0.17ccm/min 2 4

0.33ccm/min

1 3

6

5

2 4 6 8

7

3 7

0.5ccm/min

1 5

1.0ccm/min

2

distributor

lubricant quantity g/h

4.0ccm/min 0.33ccm/min 2 4 6

8

1 3 5

bypass 4.0ccm/min 2.0ccm/min

1

Figure 13. Central Lubrication Diagram

UDRS01.01GB


cycle/ pause

Equipment

1

Luprication pump

2

Distributor

3

Distributor, steering axle, right

3:1

King pin, upper cap

3:2

Cylinder eye

3:3

Pivot axle, rear end

3:4

Cylinder lever

3:6

King pin, lower end

4

Distributor, steering axle, left

4:1

Cylinder eye

4:2

King pin, upper cap

4:3

Cylinder lever

4:4

Pivot axle, front end

4:5

King pin, lower end

5

Distributor, boom end

5:1,2

Joint pin for turning device

5:5.6

Turning device

5:7.8

Turning device

5:9,10

Longitudinal cylinder, upper end

5:11,12

Longitudinal cylinder, lower end

6

Distributor, boom

6:1,2

Side slide pads

6:3,4

Side slide pads

6:5,6

Lower slide pads

7

Distributor, boom

7:1,2

Hoist cylinder, lower end

7:3,4

Boom end

8

Distributor, jacks (optional)

8:1,2

Lower bearing

8:3,4

Cylinder, lower end

8:5,6

Cylinder, upper end


15

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16

Equipment

08.2.4 Central Lubrication Diagram, Toplift

2 1

3

6

4

7 Figure 14. Central Lubrication Diagram

UDRS01.01GB


3S1221450

Equipment

17

1

Main distributor, toplift

2

Side distributor, shafts

2:1,2

Shaft cylinder

2:3,4

Rotating lever

2:5,6

Bearing housing

2:7,8

Steering piece

3

Side distributor, shafts

3:1,2

Shaft cylinderi

3:3,4

Rotating lever

3:5,6

Bearing housing

3:7,8

Steering piece

4

Side distributor, toplift

4:1,3

Rotating bearing

4:2

Upper head of pitching cylinder

4:4

Upper head of pitching cylinder

4:5,7

Rotating bearing

4:6

Bottom head of pitching cylinder

4:8

Bottom head of pitching cylinder

4:9

Suspension pin, left

4:10

Suspension pin, right

6

Side distributor,

6:1,3

Side shift cylinder

6:5,7

Length adjustment cylinder

7

Side distributor,

7:1,2

Support bearing for side shift wagon

7:3,5

Side shift cylinder

7:4,6

Support bearing for side shift wagon


UDRS01.01GB

APPENDIXES

1.

Warranty information

2.

Environmental issues

3.

Hydraulic diagram

4.

Electrical diagram

5.

Lifting boom assembly: KG6027/1--5

6.

Engine manual

7.

Transmission manual

MANAGEMENT OF PRODUCT ENVIRONMENTAL ISSUES

2

Contents 1.1 KALMAR ENVIRONMENTAL POLICY ........................................................................................................ 3 1.2 PRODUCT-SPECIFIC ENVIRONMENTAL CONSIDERATIONS ................................................................ 3 1.2.1 Effects of exhaust gases on health and the environment............................................................................. 3 1.2.2 Use of materials.......................................................................................................................................... 4 1.2.3 Energy consumption ................................................................................................................................... 4 1.2.4 Emissions into water and soil ..................................................................................................................... 4 1.2.5 Environmental problems............................................................................................................................. 4 1.2.6 Occupational health and safety .................................................................................................................. 4 1.2.7 Use of products........................................................................................................................................... 4 1.2.8 Complete overhaul or disposal................................................................................................................... 5 1.2.9 Preventive actions....................................................................................................................................... 5 1.3 RECOGNISING ENVIRONMENTAL ISSUES ............................................................................................... 5 1.3.1 Enhancing your environmental awareness................................................................................................. 5 1.3.2 Laws and regulations.................................................................................................................................. 5 1.4 RECYCLING ..................................................................................................................................................... 6 1.4.1 General ....................................................................................................................................................... 6 1.4.2 Sorting ........................................................................................................................................................ 6 1.5 REMEMBER THESE ........................................................................................................................................ 6

3

1.1 KALMAR ENVIRONMENTAL POLICY ENVIRONMENTAL POLICY The management of environmental issues at Kalmar Industries Oy Ab’s Tampere factory is based on Kalmar Industries AB's operational policy, to which this environmental policy is a supplement. Our operations are based on making continual improvements to prevent pollution of the environment, and on developing environmentally friendly products and services. The operations of the factory are developed in accordance with the principles of sustainable development. Each year, the factory management looks at the main environmental concerns, determines its environmental objectives and develops an environmental management programme to meet the objectives. The management will keep track of the environmental objectives and corrective actions by conducting internal audits as part of the operations system. Reacting to possible environmental abnormalities and taking the necessary corrective actions is the responsibility of the entire staff. Kalmar Industries Oy Ab’s Tampere factory adheres to the current legislation and regulations in its operations. Our operations comply with the international environmental system standard ISO 14001 and the principles of sustainable development set by the International Chamber of Commerce.

1.2 PRODUCT-SPECIFIC ENVIRONMENTAL CONSIDERATIONS 1.2.1 Effects of exhaust gases on health and the environment Diesel engine emissions are the cause of both health and environmental problems. The most serious environmental problem is soil acidification, which is manifested in problems in tree growth and plant formation as well as eutrophication. Of the diesel engine emissions, nitrous oxide (Nox) will form nitric acid when coming into contact with water, and sulphur dioxide will form sulphuric acid. Both of these are strong acids that have an effect on plant formation by decreasing the ability of roots to absorb water and minerals. Particles are primarily the result of poor combustion of the fuel-air mixture in the diesel engine. They consist of small carbon particles (<10 µm) on which toxic hydrocarbons have concentrated. These come from the fuel and lubricating oil. The particles are released into the air along with the exhaust gases and the mutagenic and carcinogenic hydrocarbons may then enter human lungs. Emissions

Maximum allowable exhaust emissions [g/kWh] EU level 1 (1999)

EPA level 1 (1996)

EPA level 2 (1.1.2001) Power range: 225–450 kW

NOx

9.2

9.2

--

CO

5.0

11.5

3.5

HC

1.3

1.3

--

NMHC + NOx PM

6.4 0.54

0.54

0.2

4

Hazardous emissions are mainly the result of incorrect adjustment of the motor and lack of maintenance. For this reason, it is essential that adjustments and maintenance are as described in the instruction manuals.

1.2.2 Use of materials Reasonable and appropriate use of materials can yield surprisingly high savings in costs and also decrease environmental load. Preventive maintenance has a decisive influence on decreasing machine downtime. User and maintenance manuals are intended to teach how to use the machine correctly and safely. Always use spare parts recommended by the manufacturer, and perform maintenance and repairs in accordance with the instructions. Follow all fluid changing intervals. Use environmentally friendly materials when possible. Also try and use recycled materials. In this way, you will achieve the best possible results both for the environment and safety.

1.2.3 Energy consumption When using a machine, energy consumption is most influenced by the condition of the machine and the machine operator’s skills. The manufacturer has installed and set the adjustable values of your machine to the optimal level for both consumption and emissions. Regular maintenance and immediate repair work when necessary are a prerequisite for optimal machine operation. Pay special attention to starting the machine from cold and the instructions given for this.

1.2.4 Emissions into water and soil The main consideration for the environment is to prevent oil and other toxic liquids from entering ground water and surface water courses. Even small oil spills can cause significant damage to water courses. Pay attention to any possible spills on your machine. Make sure the hoses are in good condition to prevent unpleasant surprises. When there is a spillage, absorb the spilled oil in sawdust, for example, and remove the contaminated sawdust according to your site instructions. In case of an accident, immediately contact your supervisor or the person responsible for environmental issues.

1.2.5 Environmental problems By environmental problems, we mean faults detected in machine operation that will or might be harmful to the environment. The most common of these are oil and other liquid spills, toxic waste, leaks and fires. If seals on cabs are damaged or worn, this can also lead to an environmental problem, in case it causes the operator to be exposed to noise levels which are too high. If there are possible environmental problems, immediately contact your supervisor or the person responsible for environmental issues.

1.2.6 Occupational health and safety Pay attention to your working environment. Perform the necessary maintenance and repair work to prevent sickness or accidents caused by vibration, noise or other factors. Recognise the needs for safety training, and get to know the safety bulletins of the hazardous substances you have to work with.

1.2.7 Use of products Get to know the user and maintenance manuals of your machine well. Find out. For example, which detergents to use for cleaning the machine. Follow the maintenance and adjustment schedules carefully. Use the designated oils and other liquids. Check that the oil levels are correct. In general, when using the machine, make sure that it works properly and is in the appropriate condition for the job.

5

1.2.8 Complete overhaul or disposal As the lifetime of the machine draws to a close, there are two options for dealing with the machine: complete overhaul or disposal. If complete overhaul is selected, use the manufacturer's expertise to determine the amount of repairs needed. This also ensures that any new environmental and safety requirements will be taken into account. In the case of complete overhaul, the product needs to be equipped to meet the new requirements. This is the responsibility of the person conducting the repair work. Environmental load can be reduced by sorting materials and components. Please note that the machine mostly consists of various iron structures, which are mainly recyclable. As to the disposal of toxic waste, you must find out the appropriate methods of disposing of the liquids, materials and components. The safety bulletins of the various liquids and materials contain instructions for disposal. You can also consult the suppliers of components and the product manufacturer for disposal and sorting.

1.2.9 Preventive actions Continuous monitoring of the machine operation along with preventive maintenance and repairs ensures the safe and uninterrupted use of the product. Follow the maintenance instructions diligently so as not to jeopardise the machine and its user. By blocking up leaks and checking the joints and pipe installations, you can ensure that no unwanted liquids are released from the machine.

1.3 RECOGNISING ENVIRONMENTAL ISSUES It is the responsibility of the employer to train the employees so that they can recognise environmental and safety issues in their tasks. It is necessary to make sure that the training has been successful and sufficient information has been provided.

1.3.1 Enhancing your environmental awareness Aim to define your own environmental awareness. Ask your supervisor for more training if required. After the training, make sure that you can adapt the information received to your everyday tasks. Product manuals also contain environmental information about the product. Ensure that you have sufficient general knowledge about the matters that have to do with your tasks. You can improve your product knowledge by studying user manuals and spare parts lists provided by the manufacturer. The manufacturer will also provide the necessary user training when needed. Find out about the environmental and safety instructions for using, servicing and repairing the machine. What is most important is to know how to act in exceptional cases. Try to decrease emissions and the amount of waste produced as best you can. Do not take any risks, work with care. Try to do the right things in the right way.

1.3.2 Laws and regulations There are several laws and regulations that have to do with using the machine. It is the employer’s responsibility to make sure the requirements are met in the work. Environmental issues have become increasingly important. It is important to be aware of the current requirements, but it is equally important to follow up on the changes in the requirements. The requirements tend to become tighter all the time.

6

1.4 RECYCLING 1.4.1 General The primary goal of environmental protection is to decrease the amount of waste produced. If waste is produced, you must try to utilise it as a material or source of energy. Appropriate and safe processing must be arranged for all kinds of waste. The sorting of the waste created in our operations is influenced by the legislation, environmental factors and general tidiness, among other things. The amount of waste driven to the landfill can be decreased by sorting the waste in the appropriate, labelled receptacles. The most effective way of protecting the environment is to save material and energy and use environmentally friendly methods and products.

Become familiar with the waste disposal and recycling instructions of your unit.

1.4.2 Sorting Metal waste can be collected, sorted and delivered to the industry for use as a raw material and alloying element. Recycling saves approximately half of the energy that would be consumed if the same amount of metal were obtained from a mine. When recovering oil, light oil waste is separated from black oil into a separate receptacle. Used oil of good quality can be recycled. Take special care when handling oils, as even the smallest amount of oil can cause extensive damage to the environment and ground water courses. Collect all oil filters and other oily waste, such as rags, hydraulic hoses, absorbents (sawdust etc.) in the appropriate, labelled receptacles. Toxic waste means waste that can be hazardous to health or the environment because of some chemical or other property. When collecting and handling toxic waste, these health and environmental risks need to be taken into account. Toxic waste typically includes batteries and accumulators, paints, solvents, other special liquids, fuel waste, coolant waste, aerosols and used fluorescent tubes. Sort all toxic waste and make sure it is treated appropriately.

1.5 REMEMBER THESE Being tidy and systematic is the most important consideration. Remember to: -

Act according to instructions

-

Check that all liquids are filled correctly

-

Check for leaks

-

Make sure that everything is functioning correctly

-

Return the tools used for maintenance and repair work to their right place

-

Store unused components appropriately

-

Recognise environmental problems

-

Sort the waste that is produced

-

Clear up the environment after finishing work

-

Keep the working areas, emergency exits and electric cabinets clear and unobstructed

-

Report all abnormal events

-

Contact your supervisor or the person responsible for environmental issues if necessary.

Keeping your own working environment tidy and in good order is your personal responsibility. Tidiness and orderliness influence how the workplace functions, decrease the number of accidents at work, and contribute to the positive image of the company and its employees.

Hydraulic schemas T561200T91

A48503.0100 Hydr. schema base machine K5687770 Hydr.schema, Cabin transfer A50094.0100 Hydr. schema brakes K5691600 Hydr. instruction, Twistlock K5692320 Hydr. instruction, Side shift K5692370 Hydr. instruction, Tilt

1

K5698240

Hydr. schema for basic machine 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 36

Steering Lift Boom telescope Spreader turning Tilt Lift cylinder safety valve Boom telescopecylinder safety valve Turning pressure shockvalve Turning directional control valve Directional control valve for active tilt Lockvalve for tilt Speed restrictor for tilt Shuttle valve Brake for turning Return filter Pump for steering, lifting and telescoping Pump for lifting, telescoping and spreader Oilcooler Pressure switch Check valve Relief valve for tilt Check valve Steering unit Indicator for return filter Check valve 2/2 solenoid valve, normaly closed Priority valve Check valve Pressure accumulator Directional control valve Pressure reducing valve Pressure relief and free flow valve for spreader Shuttle valve Check valve Directional control valve

N:o 4K5687770 B Tila: APP Nimitys: HYDR.SCHEMA

Tulostettu 16.01.2001 13:20:31

K5687770

Hydraulic schema Cabin transfer 1

Cabin transfer hydraulic cylinder

2

Lock valve for cabin motion

3


4

Pump unit

K5692470

Hydraulic Diagram Brakes 1 2 3 4 5 7 8 9 10 11 14 15 16 17 18 19

Brakes for driving axle Parking brake Parking brake control valve Accumulators charging valve Pressure filter Pressure switch for brake lights Pressure accumulator Hydraulic pump Pressure switch for low brake pressure Brake valve for drive axle brakes Check valve Restrictor Indicator for filter Oil cooler Termo bypass Check valve

N:o 4K5691600

Tila: APP Nimitys: Säätöohje Karojen lukitus

Tulostettu 24.01.2001 09:08:23

_PRELIMINARY N:o 4K5692320

Tila: DR Nimitys: Hydr.säätöohje sivusiirto

Tulostettu 24.01.2001 09:06:56

N:o 4K5692370

Tila: APP Nimitys: Hydr.säätöohje pitkittäiskallistus

Tulostettu 21.02.2001 13:18:56

Instructions manual Appendixes Electrical diagram K52433.50A Cummins Art no. K52431.00 K52431.10 K52431.20 K52431.30 K52431.40 K52431.50 K52431.60 K52431.70 K52431.80 K52431.90 K52431.91 K52432.00 K52432.10 A49448.0100 K52432.20 K52432.30 K52432.40 K52432.50 K52432.60 K52432.70 K52432.80 K52432.90 K52433.00 K52433.40 K52433.10 K52433.20 K52433.30 K52410.70 K52410.80

Sheet Edition A Module A81 A Module A82 A Module A83 A Module A84 10 A Battery circuit 11 A Fuse diagram Cummins QSM11 12 A Engine start/stop Cummins QSM11 13 A Alarm lamp indicator 14 A Gauges 15 A Lights 15 A Flasher red lights (optional) 16 A Working lights 17 A Intermittent windscreen wipers and washer 17 Windows wipers and washer 18 A Transmission control, Mini steering wheel 19 A Oil cooling 20 Transmission operating chart 21 A Air-conditioner 22 A Cabin transferring 23 A Proport control joystick 24 A Spreader movement 25 A Stability control 26 A Lubrication system 27 A Control handle 28 A By-pass switches 29 A Twist locks 30 A Can-bus Cummins Download loader Download programs

Model 36000 Powershift Transmission 3-4-6 Speed Short Drop

Owner Manual

Technical Description 2.6A-20002-C00

Printed Circuit Board for Pump 203 236-13891-1 Models V10 - V13* 236-13891-2 Models V20 - V23*

Subject to change without notice

with Adjustable Pause and Operating Times Applications for Commercial Vehicles or Industrial Applications

*See page 4 Applications 10051327a

LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259

Owner Manual


Survey Pump

Voltage [V]

12/24 203

Control unit

Setting ranges

Part no.

integrated V10-V13*,** V20-V23*,**

P1: 4 to 60 minutes P2: 1 hour to 15 hours A 1: 8 seconds to 120 seconds A 2: 2 to 30 minutes

236-13891-1 236-13891-2

integrated M00-M23***

P : 4 to 60 minutes P : 1 to 15 hours Ü : 5 or 30 minutes

Applications

236-13870-1

without control unit or with external control unit* 12/24

integrated V10-V13*,** ADR

203 12/24 203 12/24 203

24 VDC 203

203

24 VDC, 115 VAC, 230 VAC


A - Operating time ranges

236-13891-1

integrated H*

B : 6 hours, fixed A: 2 to 30 minutes

236-13857-1

integrated H * ADR

B : 6 hours, fixed A : 2 to 30 minutes

236-13857-1

external PSG 01

P : 0.5, 1, 2...to 12 hrs A : 2, 4, 8, 16, 32 min

236-13834-1 664-36875-1

external PSG 02

P : 1 min to 160 hrs A : 1 min to 160 min

236-13860-2

B - Time of availability

P - Pause time range

Ü - Monitoring time

* 1A1 - Version - Pump without connection for the illuminated pushbutton **2A1 - Version - Pump with connection for the illuminated pushbutton ***2A4 - Version - Pump with microprocessor control Note: The applications of the progressive systems are various. There is therefore a corresponding control unit available for each individual application.

Page 2 from 16


Owner Manual


Table of Contents Page Survey ............................................................................. Printed circuit board V10-V13 and V20-V23 ............. Applications ..................................................................... Mode of operation ........................................................... Pause time ................................................................ Operating time .......................................................... Time storage when the power supply is switched off ............................................................. Time setting ......................................................................

2 4 4 4 6 6 6 7

Page Repair .............................................................................. 9 Operational test/To trigger an additional lubrication ..... 9 Troubleshooting .......................................................... 10 Technical data ............................................................... 11 Connection diagram - Industrial applications .............. 12 Connection diagram - Appplications for commercial vehicles ...................................................... 13 Connection diagram - Appplications for commercial vehicles ...................................................... 14 Combinations of the jumper positions .................... 15

Further information can be found in the following manuals:


Technical Description Pump Model 203 Technical Description Progressive Metering Devices for Grease and Oil, model SSV Technical Description for Electronic Control Units of the 203 pump Printed Circuit Board 236-13857-1 - Model H Printed Circuit Board 236-13870-1 - Models M 00 - M 15 Printed Circuit Board 236-13870-1 - Models M 16 - M 23 Timer 236-13860-2 Model PSG 02 Installation Instructions Parts Catalog

Page 3 from 16


Owner Manual


Printed Circuit Board V10-V13 and V20-V23 Applications The printed circuit boards can be used for the following applications 1.) Lubrication cycles only as a function of the machine working hours. When the machine contact (external contact) is switched on the centralized lubrication system is ready for operation. Caution: On the PCB 236-13891-1 (V10-V13)* do not connect the red core of the connecting cable to connection 1, Fig. 1, 14, 16 (terminal 30) since terminal 30 is connected internally with terminal 15. 1191c95

Fig. 1 - Machine contact, printed circuit board 236-13891-1 (V10-V13)

Note: The PCBs 236-13891-1 and 236-13891-2 differ only as regards their connection of the terminals. In the case of PCB 236-13891-2 the terminals 30 and 15 are not connected.

1191d95

Fig. 2 - Machine contact, printed circuit board 236-13891-2 (V20-V23)

2.) Lubrication cycles only as a function of the running hours of the commercial vehicle. When the driving switch (terminal 15) is switched on, the centralized lubrication system is ready for operation Note: In the case of PCB 236-13891-2 also connect the battery voltage (terminal 30).

1060a95


Fig. 3 - Driving switch

This designation shows the version of the PCB installed in the pump. It forms part of the pump designation on the nameplate on each pump. In the case of P 203-...-.K.-.A. ...-V10 the PCB 236-13891-1 is installed, see connection diagrams 1, 14 and 16. In the case of P 203 - ... - .K. - .A.. ..-V20 the PCB 236-13891-2 see connection diagram 2, 17.

*

Page 4 from 16


Owner Manual


Mode of Operation The printed circuit board is integrated in the pump housing.

00002616

Fig. 4 - Printed circuit board installed in the housing

The printed circuit board automatically controls the sequence of the pause and operating times of the model 203 central lubrication pump as a function of the vehicle or machine working hours tB (Fig. 5). The sequence of the pause and operating times is activated when the machine contact or driving switch is switched on.

20002443b

Fig. 5 - Printed circuit board 236-13891-1


A lubrication cycle consists of one pause time and one operating time. Once the pause time has elapsed, the operating time starts to run. This lubrication cycle is repeated permanently after the machine or vehicle has been put into operation. Refer to Fig. 5. During the operating time the pump element dispenses the lubricant to the lubrication points via progressive metering devices.

1059a95

Fig.6 - Time sequence diagram

tB - Working hours tP - Various pause times

T - Lubrication cycle T1 -Stored pause times T2 -Operating times

Page 5 from 16


Owner Manual


The pause time

The operating time

- determines the frequency of the lubrication cycles within a working cycle; - is started and stopped via the machine contact or driving switch; - is adjustable. When the machine contact or the driving switch is switched off, the pause times which have already elapsed are stored and added up (refer to T1, Fig. 6) until the time which has been set on the blue rotary switch (Fig.8) is reached. The pause time setting may be different for each application. It must be adjusted in accordance with the respective lubrication cycles. Also see To set the pause time.

- depends on the systems lubricant requirement ; - is adjustable; - is finished when the machine contact or the driving switch is switched off. The longer the operating time, the greater the lubricant requirement and vice-versa. When the machine contact or the driving switch is switched off, the operating times which have already elapsed are stored and added up until the time which has been set on the red rotary switch (Fig. 10) is reached. After this, the lubrication cycle starts again. The operating time setting may be different for each application. It must be adjusted in accordance with the respective lubricant requirement. Also see To set the operating time.

Time storage


When switching off the ignition voltage and/or the operating voltage the times already expired are saved for an unlimited duration. When the power supply is switched on again the printed circuit board continues to operate from the point where it had been interrupted.

Page 6 from 16


Owner Manual


Time Setting * To set the pause or operating time, remove the cover on the pump housing. Note: To reset a jumper (Fig. 9), remove the printed circuit board. Important: After having set the pause time or operating time, screw the cover on the pump housing again

00002617

Fig. 7 - The cover to access the printed circuit board has been removed

To set the pause time The pause time can be set to 15 different settings by means of the blue rotary switch.

Time ranges: Minutes or hours 20002451b

Fig. 8 - Rotary switch - Pause time

Switch position

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

Minutes

4

8

12

16

20

24

28

32

36

40

44

48

52

56

60

Hours

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Note: When the switch is on 0 a fault is shown at the righthand LED 3, see page 9. At the same time the factory-set pause time is accepted.


Factory setting Rotary switch on : ........................................................... 6 hours or ................................................................................ 24 minutes The time ranges can be modified by replugging the jumper (Fig. 9) on the printed circuit board.

20002452a

Fig. 9 - Preselection of the time range

Factory setting of the jumper: see chart page 15. The combination number can be learnt from the pump type designation code mentioned on the nameplate of each pump. Page 7 from 16


Owner Manual


To set the operating time The operating time can be set to 15 different setting by means of the red rotary switch. Time ranges: Seconds or minutes

20002453b

Fig. 10 - Rotary switch - Operating time

Switch position

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

Seconds

8

16

24

32

40

48

56

64

72

80

88

96

104

112

120

Minutes

2

4

6

8

10

12

14

16

18

20

22

24

26

28

30

Note: When the switch is on 0 a fault is shown at the righthand LED 3 Fig. 12. At the same time the factory-set operating time is accepted. Factory setting Rotary switch on : ...................................................... 6 minutes or ............................................................................... 24 seconds The time ranges can be modified by replugging the jumper (Fig. 11) on the printed circuit board. Factory setting of the jumper: see chart page 15. The combination numbers can be learnt from the pump type designation code mentioned on the nameplate of each pump.

20002437

Fig. 11 - Preselection of the time range


Fault indication Rotary switch set at 0 When one of the rotary switches 2, 3 Fig. 12 is on the 0 setting a fault is shown at the right-hand LED 3. The fault is indicated by 4 flashes of the LED. The pump motor also runs according the flash frequency. If the warning is ignored the controller automatically adopts the factory-set values for the operating or pause time

Pushbutton 5 Fig. 12 continuously actuated (short circuit) If a short circuit occurs at the pushbutton or is present at the external illuminated pushbutton Fig.13 or at the connecting parts a fault is shown at the red LED 3, fig. 12. The fault is indicated by 3 flashes of the LED when the voltage supply is switched on. The motor of the pump also runs according to the flash frequency.

Page 8 from 16


Owner Manual


Repair The defective printed circuit boards should be suitably packed and returned to the factory.

Operational Test / To Trigger an Additional Lubrication Cycle

If the printed circuit board must be replaced, a model V 10 (V20) will always be delivered. See chart page 15. Before installing another printed circuit board, take care that the setting of the jumper or that of the operating/pause time is the same as on the old printed circuit board.

To check the pump operation it is possible to perform an operational test. Pumps model 203 installed on machines * Switch on the machine contact. Pumps model 203 installed on commercial vehicles * Switch on the driving switch

Fig. 12 - LED on the printed circuit board

For all pumps To check whether power is applied to the printed circuit board, observe whether the LED 1 Fig. 12 is lit. * Press pushbutton 5 on the printed circuit board (> 2 seconds) until the right-hand LED 3 lights up.

1 - LED, left-hand 2 - Rotary switch, pause time 3 - LED, right-hand

A shorter pause time elapses, followed by a normal lubrication cycle.

20002457b

4 - Rotary switch, operating time 5 - Pushbutton for additional lubrication

Additional lubrication cycles can be triggered at any time.


Note: In the case of model 203 pump, version 2A1, with external illuminated pushbutton, it is also possible to trigger an additional lubrication cycle via this pushbutton.

20002458

Fig. 13 - To trigger an additional lubrication cycle, only pumps with illuminated pushbutton

Page 9 from 16


Owner Manual


Troubleshooting Note: The pump operation can be checked from the outside by observing whether the stirring paddle is rotating (e.g. by triggering an additional lubrication), whether the LED on the printed

circuit board are lit or whehter the signal lamp of the illuminated pushbutton (if any) is lit.

Fault: the pump motor does not run Cause:

Remedy:

Voltage supply interrupted

Check the voltage supply to the pump. If necessary, eliminate the fault.

Voltage supply to the printed-circuit interrupted

Check the line leading from the pump plug to the printed circuit board. If the voltage is applied, the left-hand LED is lit.

Voltage supply interrupted betweeen the printed circuit board and the motor

Triggering an additional lubrication cycle If the voltage is applied, the right-hand LED is lit.

Printed-circuit board defective

Replace the printed circuit board.

Fault: Right-hand LED 3 Fig. 12 flashes

Cause:

Remedy:

One of the two rotary switches 2, 4 Fig. 12 is on 0. Signal: 4 flashes

Set rotary switch to a number or a letter.

Short circuit at pushbutton 5 Fig. 12 or, if present, at the illuminated push button or at their connecting parts Signal: 3 flashes

Check whether the short circuit is at he PCB or, if present, at the illuminated pushbutton. If necessary, exchange the PCB or the illuminated pushbutton.


.

Page 10 from 16


Owner Manual


Technical Data Rated voltage ............................................................ 12/24V DC Operating voltage 12V/ 24V .......................................................... 9V to 30V Residual rippple in relation with the operating voltage ................... ± 5% acc. to DIN 41755 Motor output ............................ Transistor 7A/short-circuit proof Reverse voltage protection: The operating voltage inputs are protected against polarity reversal Temperature range .................................. -25°C to 70°C Lamp current in the case of pump 2A1 ....................... max. 2 A Class of protection Printed circuit board installed in housing .................... IP 6K 9K

Time setting Pause time, depending on the jumper position: ............................................... 4; 8; 12; 24 to 60 minutes ......................................................... 1, 2, 3...to 15 hours Operating time, depending on the jumper position ............................................ 8; 16; 24;....to 120 seconds ................................................... 2, 4, 6,....to 30 minutes Factory setting Pause time .......................................................... 6 hours or .................................................................... 24 minutes Operating time ................................................ 6 minutes or .................................................................. 24 seconds

In order to protect the printed circuit board against condensation it has been covered with a protective varnish.


All the printed circuit boards comply with the EMC (Electromagnetic compatibility) guidelines for road vehicles acc. to DIN 40839 T1, 3 and 4 and the EMC guideline 89 / 336 / EWG Emitted interference acc. to ................. EN 55011 / 03.91 and ........................................................ EN 50081-1 / 01.92 Noise immunity acc. to ............................. EN 50082-2 / 03.95 The type 203 pumps with PCB V10 - V13 (V20 - V23) comply with the Automotive EMC Directive 95/54/EEC and with the EC approval mark e1 021016 shown on the nameplate

Page 11 from 16


Owner Manual


Connection Diagram - Industrial Applications, Printed Circuit Board 236-13891-1 (V10-V13)

1192c95

Fig. 14 - Connection diagram Quicklub 203 with adjustable pause time Connection via Hirschmann type-in connectors DIN 43650-A

ABCD-

Printed circuit board Pump housing Cable connector 1 Line socket 1 (black) for connection cable, 3-wire

1A1 - Pump without illuminated pushbutton 2A1 - Pump with cable connection for illuminated pushbutton* F - Machine contact * on request

GH-

Cable connector 2* Line socket 2 (grey) for connection cable, 3-wire* IPushbutton for additional lubrication J - Signal lamp in the case of low-level control

Attention! If a pump model 103 CS...E2 is replaced by a pump model P203-...-...-2A1.10, the lamp connection of the illuminated pushbutton must be changed from minus to plus.


- Low-level control* 31 - Earth

N-

Level control*

15 - Driving switch

Z-

Additional lubrication*

M

1009c93

- Motor

- Signal lamp*

Fig. 15 - Terminals of the printed circuit board

* equipment available on request

Page 12 from 16


Owner Manual


Connection Diagram - Applications for Commercial Vehicles Printed Circuit Board 236-13891-1 (V10-V13)

1155d95

Fig. 16 - Connection diagram Quicklub 203 with adjustable pause time Connection via square type plug DIN 43650-A

ABCD-

Printed circuit board Pump housing Cable connector 1 Line socket 1 (black) with connection cable, 3-wire 1A1 - Pump without illuminated pushbutton

2A1 - Pump with cable connection for illuminated pushbutton** F - Driving switch G - Fuse 10 A H - Cable, black ICable, brown

KLMOP-

Cable connector 2** Line socket 2 (grey) with connection cable, 3-wire** Illuminated pushbutton** Signal lamp in the case of low-level control Battery cutoff*

*does not belong to the scope of delivery **equipment available on request


Caution: Do not connect the red core (not shown: cf. J Fig. 17) of the 3-core connecting cable to the wire box 1 (D, Fig. 16) since the PCB is connected internally between 30 and 15.


Page 13 from 16


Owner Manual


Connection Diagram - Applications for Commercial Vehicles Printed Circuit Board 236-13891-2 (USA)

1155e95

Fig. 17 - Connection diagram Quicklub 203 with adjustable pause time Connection via square type plug DIN 43650-A

ABCD-

Printed circuit board Pump housing Cable connector 1 Line socket 1 (black) with connection cable, 3-wire 1A1 - Pump without illuminated pushbutton

2A1 -Pump with cable connection for illuminated pushbutton** F - Driving switch G - Fuse 10 A H - Cable, black ICable, brown J - Cable, red

KLMOP-

Cable connector 2** Line socket 2 (grey) with connection cable, 3-wire** Illuminated pushbutton** Signal lamp in the case of low-level control Battery cutoff*

*does not belong to the scope of delivery **equipment available on request



30 - Battery voltage 31 - Earth

N-

Level control*

15 - Driving switch

Z-

Additional lubrication*

M

1009b93

- Low-level control*

- Motor

- Signal lamp*

* equipment available on request

Fig. 18 - Terminals of the printed circuit board 236-13891-2

Page 14 from 16


Owner Manual


Combinations of the jumper positions - Survey Possibilities of preselection

Pause time ranges P 4 - 60 min 1 - 15 h

Operating time ranges I 8 - 120 s 2 - 30 min

Jumper positions See Fig. 8, 10


Combination no.

V 10, V 20 Standard

X

V 11, V 21

X

V 12, V 22

X

V 13, V 23

X

X

X

X

X

Page 15 from 16


Owner Manual

Technical Description


2.6A-20002-C00

Page 16 from 16


UDRS01_01GBMaintenance DRS Last

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