Tdce01_04gb Manual Dce 80-100e

Technical Handbook

00

General

10

Chassis and cab

20

Electrical system

30

Engine

40

Transmission,

DCE80-100E drive axle, brakes

This Handbook deals with the design and maintenance of Kalmar empty container trucks, type DCE. In addition, it gives details of troubleshooting and the most common corrective maintenance. Operation and other matters that are primarily of interest to the operator are included in the Instruction Manual.

50

60

Steered axle

70

Hydraulic system

80

Lifting mast, carriage and side lift attachment

90

Periodic supervision

Kalmar Industries AB

We res erve the the rig ht to to modify modify our des ig n and and mate materi ria al specispeci fications fi cations without wi thout prio pr iorr notic e.

TDCE01.04GB

DCE80-100E Technical Handbook

Contents

Grou Group p 00

TDCE01 04GB P. 1

Group 00 Contents Safety regulations ..................................................................... 2 General ..................................................................................... 5 Applications ......................................................... ................ 5 Design ................................................................................. 6 Component units ........................................................... ...... 6 Main components ................................................................ 8 Supplementary books .......................................................... 9 Replacement system – Spare parts .................................... 9 Tools .................................................................................... 9 Tightening torques ............................................................. 10 System of units .................................................................. 12

DCE80-100E

Safety regulations

Technical Handbook

It is important that you read the instruction manual. Incorrect handling can lead to personal injury or damage to products and/or property. Therefore, read th e instruction book very carefully before operating the truck. The instruction manual contains important information about your Kalmar truck, about the operation of the truck, about safety during operation and about the truck's daily maintenance. In addition, you will find useful information that will make operations easier for you in your daily work. The instruction manual must always be kept in the machine. If the manual should be lost, a replacement must be immediately obtained. Never use a machine with a missing instruction manual. Ask your foreman/group leader if there is anything in the manual that you do not understand or if you feel that information is missing in any area. The symbol is used on our products in certain cases and then refers to important information contained in the instruction manual. Make sure that warning and information symbols are always clearly visible and legible. Replace symbols that have been damaged or painted over. In this instruction manual warnings are inserted that apply to your own safety. Warnings point out the risk of accident that can cause personal injury.

WARNING! Warns Warns of the the ris k of s erious pers onal onal injury, pospos s ible ib le death death and/or and/or seri s eri ous damage to to product prod uct or property prop erty if i f the reg ulati ulati ons are not followed. For technical warnings, that point out the risk of break down, the word IMPORTANT is used:

IMPORTANT! Is us ed to to draw att attent ention ion to suc h occurr ences that that can caus e dama damag e to the product or proper ty. For information that facilitates the working process or handling, N.B. is used:

N.B . Dr aws atte attention ntion to to useful infor mation mation that that help helpss the the worki worki ng proces proces s .

Grou Group p 00

TDCE01 04GB P. 2

Safety regulations aimed at reducing the risk of personal injury and damage to loads or other property. Intended of use  The truck may only be used for the purpose for which it was intended, namely, to lift and transport goods, the weight of which does not exceed the maximum permitted load capacity of the truck. 

The truck may not, without specific permission from Kalmar, be modified or re-built so th at its function or performance is altered.



The truck may not be driven on public highways if it has not been adapted to comply with national road safety regulations.

Operator requirements  The truck may only be driven by operators who have been specially trained and who have the company's authority to do so.  Laws and other regulations relating to driving licence, operator ID, log book, etc., must be followed at all times.  The operator must be aware of and follow all local safety regulations.  It is always the responsibility of the oper ator to ensure that the truck has approved fire extinguishing equipment in accordance with currently applicable regulations. Operation of the truck is prohibited:  If any of the fitted safety equipment, such as rear view mirrors, headlights, reversing alarm (optional), does not function correctly.  If there is a fault with the brakes, steering or lift equipment.  If it has been repaired, modified or adjusted without the approval of the work supervisor.  If the truck is fitted with tyres not approved by Kalmar. Continued on next page

DCE80-100E

Safety regulations

Technical Handbook

Continued from previous page Operating regulations  Before starting, always check to ensure that nobody is in the way of the truck or its equipment.  The operator must always face the direct ion of operation and take particular care in areas where persons or other vehicles are likely to appear in the vicinity. If visibility is limited by the load, the operator should operate the truck in reverse.  It is prohibited to walk or stand underneath raised forks or other equipment, whether they are loaded or not.  It is prohibited to transport passengers on the truck outside the cab or on the load. Passengers may be transported inside the cab only on condition that it is equipped with a fixed passenger seat.  It is prohibited to lift people if the truck is not equipped with an approved lift cage.  It is prohibited to exceed the load capacity of the truck. See capacity plate and loading diagram.  It is prohibited to transport loads in the raised position as this entails a risk of the truck tipping. All transportation shall take place with the load in the transport position.  The operator must adapt the speed of the truck to the character of the load, conditions of visibility, the character of the roadway/surface, etc.  The operator shall avoid powerful acceleration and braking when turning. In addition, the operator shall always moderate the speed of the truck when turning so as to avoid the risk of lateral skidding or tipping.  The operator shall take particular care when operating in the vicinity of electrical power lines, viaducts, quay-sides, ramps, gates/doors etc.  Safety belts must always be worn, if fitted. In the event of the truck tipping, always remain in the cab and grip the steering wheel securely. Never try to jump out of the cab.  The parking brake can also be used as an EMERGENCY BRAKE. However , having been used for emergency braking, the brake linings must be checked and replaced if necessary. necessary. If the parking brake has been mechanically released, it must always be reset in reset in order for the truck to regain the parking brake function. Interrupted operation, parking  Always check that the gear lever is in the neutral position before turning the ignition key to restart or to reset an emergency stop.  Never leave the operator's cab without applying the parking brake (ON position).  Always remove the ignition key if the truck is to be left unattended. Other important points to remember  The truck's hydraulic system includes high pressure hydraulic accumulators. Always be extremely careful when working with the hydraulic system and avoid being unnecessarily close to the hydraulic equipment, lines and hoses. Before working on the hydraulic system, the accumulators must be emptied into the tank, with the help of the special accumulator evacuation valve.

Grou Group p 00

TDCE01 04GB P. 3

Handle batteries and junction boxes with great care. The batteries must always be protected over the poles and connections.  Always rectify any damage or wear and tear that can risk personal safety or that can affect the functions of the truck or its service life.  Avoid touching oils and greases. Avoid inhaling exhaust and oil fumes.  Always use steps and handrails when entering or leaving the machine - Never jump! To avoid the risk of slipping, tread only on anti-slip surfaces. If the anti-slip protection has become worn, loose or in any way le ss effective, it should be replaced.  Welding painted steel produces poisonous gasses. Paint should therefore be stripped before welding, good ventilation ensured and/or face mask with filter used.  Mobile phones used in the cab must always have fixed connections to the machine’s electrical system, with a fixed antenna outside the machine, mounted in accordance with the manufacturer’s instructions. This will avoid interference with the machine’s important electronic functions.  The tensile strength of the top pane can be seriously weakened by exposure to elements that contain: Aromatic hydrocarbon, ketone, esters or chlorinated hydrocarbon. Regularly check the surface condition of the top pane and clean only with screen wash or other mild cleaning fluid. After cleaning, rinse thoroughly with warm water. It is prohibited to modify or in any other way make alterations to the top pane. Immediately replace damaged top panes that show signs of cracking or scratching. Operating with attachments  The operator must always take the effect of the wind into account when handling containers. Avoid lifting with a wind strength in excess of 12 m/s (27 mph/40 feet per second).  Always drive carefully so as to avoid attachments colliding with pillars, cables, etc.  Carefully study the "Lift methods" section of the instruction manual. 

CE marking All trucks and equipment (though not thoses fitted on the truck or intended as spare parts) supplied from Kalmar are CE marked, which indicates that they comply with the requirements of the EU Machine Sa fety Directive. In addition, each truck has a so called, “EU Declaration of Conformity” which is the legal proof that the truck complies with the “health and safety” requirements laid down in the Machine Safety Directive, the EMC directive (electro-magnetic compatibility) and the LVD directive (electrical equipment).

Vibration standard The truck is tested according to test method described in EN 13059, see Technical Technical data.

DCE80-100E

Safety regulations

Technical Handbook

Grou Group p 00

Safety regulations









Never run hands or fingers along any tubes, pipes or hoses whilst investigating for possible leaks as some of these lines (diesel fuel, hydraulic, steering, etc.) operate at extremely high pressures and even the most minute of leaks can cause oil or fluid to penetrate the skin. Under no circumstances may compressed air be used to remove a hydraulic piston from its cylinder. Always attend to damage and wear that may be of significance to the performance and useful life of the truck or to the safety of the personnel. Follow the safety rules whenever carrying out service work on the air conditioner. The refriger-ant is injurious to the skin and eyes. Only authorized service personnel may repair the system.

TDCE01 04GB P. 4

DCE80-100E

Safety regulations

Technical Handbook

Group 00

TDCE01 04GB P. 5

Safety instructions for working with tyres 

Tyre changing can be dangerous and should only be carried out by specially trained personnel using proper tools and procedures. Failure to comply with these procedures may result in faulty positioning of the tyre and/or rim and cause the assembly to burst with explosive force sufficient to cause physical injury or death. Never fit or use damaged tyres or rims.



Never attempt to weld on an inflated tyre/rim assembly. Never let anyone assemble or disassemble tyres without proper training. Never run the truck on one tyre of a dua l assembly. The load capacuty of a single tyre is then dangerous-ly exceeded and operation in this manner may damage the rim. Deflation and dismantling – Always block the tyre and wheel on the opposite side of the vehicle before you place the jack in position. Always crib up the blocks to prevent the jack from slipping. – Always check the tyre/rim assembly for proper component seating prior to removal from the truck. – Always deflate the tyre by removing the valve core prior to removing the complete assembly from the truck or dismantling any of the component. Before loosening mounting bolts, run a wire through the valve stem to ensure that it is not blocked. Ice or dirt can prevent all the air from escaping. Deflate and remove valve cores from both tyres of a dual assembly. – Never position body in front of the rim during deflation. – Always follow assembly and dismantling procedures outlined in the manufacturer’s instruction manual, or other reconized industry instruction manuals. Use proper rubber lubricant. – Never use a steel hammer to assembling or dismantling rim components – use a lead, brass or plastic type mallets. The correct tools are available through rim/wheel distributors. – remove bead seat band slowly to prevent accidents. support the band with your thigh and roll it slowly to the ground in order to protect back and toes. – Disassembly tools apply pressure to rim flanges to unseat tyre beads. Keep your fingers clear. Slant disassembly tool about 10 degrees to keep it firmly in place. Always stand to one side when applyin g hydraulic pressure. Should the tool slip off, it may cause fatal injury . Rim inspection – Check rim components periodically for fatigue cracks. Replace all cracked, badly worn, damaged and severely rusted components. – Always select the correct tyre size and construction matching the manufacturer’s rim or wheel rating and size.

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









– Do not use over-size tyres, too large for the rims, e.g. 14.5 inch tyres with 14 inch rims or 16.5 inch tyres with 16 inch rims. – Never use damaged, worn or corroded rims/ wheels or fitting hardware. Always verify that the rim is in a serviceable conditioning. – Always clean and repaint lightly rusted rims. – Never use a rim/wheel component that can not be identified. Check rim parts against multipiece rim/wheel matching charts. Assembly and inflation – It is important that the inflation equipment is equipped with a water separator to remove moist-ure from the air line in order to prevent coorosion. Check the separator periodically to ensure that it is working properly. – Make sure that the lockring is in its right position. – Never mix different manufacurer’s parts since this is potentially dangerous. Always check manufacturer for approval. – Never seat rings with hammering while the tyre is inflated. Do not hammer on an inflated or partially inflated tyre/rim assembly. – Always double check to ensure that the rim assemblies have been correctly assembled and that securing studs and nuts are tightened to the correct torque setting. – Never inflate tyres before all side and lockrings are in place. Check components for proper assembly after pumping to approximately 5 psi (=34 kPa, =0.34 bar) – When adding air to a tyre on an industrial truck, use a clip-on chuck and stay out of the danger area. If the tyres has been run flat then the rim must be dismantled and all parts inspected for damage. – Under-inflated tyres have a serious effect on the stability of the truck and reduces the safe load handling capacity. Always maintain tyres at the correct inflation pressures. Check inflation pressure daily. Do not over-inflate. – Inspect tyres regulary – every day if possible. Look for and remove broken glass, torn pieces of tread, embedded metal chips etc. Inspect for uneven or rapid tread wear, usually caused by mechanical irregularities, such as brakes out of adjustment or excessive toe-in and toe-out. If discovered, correct the irregularity immediately. When installing and tightening trail wheel bolts, observe the following: – Ensure that trail wheel or hub mounting surfaces and trail wheel fastener mounting surfaces are clean and free from paint and grease. – Tighten bolts to specified torque settings. use staggered sequence; i.e. top bolt, bottom bolt etc.

DCE80-100E

General

Technical Handbook

Group 00

TDCE01 04GB P. 6

Applications The Kalmar DCE80-100E is a range of trucks is based on an entirely new approach to the design and production of heavy dieselpowered trucks. The trucks are durable and safe and their accessibility for service and maintenance is unexcelled. The trucks are intended for handling of empty containers in harbours and container terminals with stacking up to 8 containers high

Design – general survey Kalmar DCE80-100E diesel trucks are of sturdy design for heavy duty. They are built around a chassis which has high stren gth and torsional stiffness and an extremely low centr e of gravity. The operator’s cab is provided with vibration isolation and sound insulation and offers excellent all-round visibility. The operator is provided with many facilities for adjusting his seating attitude. The seat, backrest and springing of the operator’s seat can be adjusted in a wide variety of ways. The engine is easily accessible through a casing. The six-cylinder turbocharged engine combined with a threespeed gearbox with torque converter, provides smooth power whenever needed. The drive axle with hub reductions, the oil-cooled hydraulic brake system and the pendulum-mounted steered axle with double-acting steering cylinder satisfy very strict demands on strength and mobility when travelling on irregular surfaces. The hydraulic system is reliable and has high performance charged by two, three or four hydraulic pumps. For further details, see group 70.

General


Group 00

TDCE01 04GB P. 7

1 2

4

1. 2. 3. 4.

3

5

6

Lifting mast, free lift mast with double cylinders Operator’s cab, rubber suspended Engine, six cylinder diesel with turbocompressor Steering axle with pendular suspension and double-acting steering cylinder

7

5. Gearbox, combined with torque converter 6. Drive axle, with hub reduction and oil sooled, hydraulic brake system 7. Carriage with side lift attachment Hydraulically controlled length adjustment and side-shift

General


Group 00

TDCE01 04GB P. 8

Component units 

Sound-insulated operator’s cab with excellent all-round visibility. The non-slip, substantial steps provide convenient access to the cab.



Centrally positioned steering column. Clearly arranged instrument panel. Engine – Volvo TAD720VE (standard) six-cylinder, fourstroke, turbocharged diesel engine with direct injection and thermostatically controlled water cooling. Gearbox with torque converter

 

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– Constant-mesh gearbox in which hydraulically actuated clutches for the different gears. The clutches are electrically operated. – Torque converter, which is a hydraulic coupling that amplifies the output torque on an increase in load. Torque conversion takes place smoothly and steplessly throughout the engine speed range. – Oil cooler connected to the engine cooling system for cooling the oil in the gearbox and torque converter. – Oil pump which supplies oil under pressure to the gearbox and torque converter. – Full-flow oil filter for effective cleaning of the gearbox oil. Drive axle with two-stage reduction - in the differential and the hub reductions. – Oil cooled hydraulic brakes for the foot brake, e.g. Wet disc brakes. – Disc type parking brake applied by a sturdy spring and released by hydraulic oil pressure. Tha parking is electrically activated by a switch in the operator’s cab. Hydraulic system with – Hydraulic pumps connected to take-offs on the torque converter. In the standard version, the system has one pump for lift and one pump for other working hydraulics. Some machines have a separate system for side-lift which is then fed by a separate pump. The optional cab tilt is also fed by a separate pump. – Main valve for controlling the main hydraulics. The valve is controlled hydraulically from the cab. – A high pressure filter after each pump for effective cleaning of the hydraulic fluid before it is fed to the system. – Steering valve (Orbitrol) - flow-control valve which supplies hydraulic fluid to the steering cylinder. – Oil cooler with electrically powered fan. Steered axle with pendulum mounting and double-acting steering cylinder. Sturdy clear-vision mast. – Outer mast with hydraulically controlled forward and backward tilting. – Tilting cylinders with back-pressure valves to prevent the load from tilting the mast forward. – Inner mast with support wheels that carry the axial forces on the mast. Sliding plastic plates to carry sideforces. Yoke with guide rollers for t he hydraulic hoses and guide sprockets for the lifting chains. – Lifting cylinders - two cylinders mounted on the outer mast. Carriage with: – Support wheels to carry axial forces – .Sliding plastic plates to carry side forces

DCE80-100E

General

Technical Handbook

Group 00

TDCE01 04GB P. 9

Supplementary books In addition to the Instruct ion Manual and the Technical Handbook, the following books are delivered with every truck. Spare parts catalogue Instruction Manual for engine Workshop Manual för Engine

Replacement system - Spare parts Kalmar operates a system of replacement parts, repair kits and gasket sets covering most of the vital components of the truck. For the contents of these kits, see the Spare parts catalogue.

Tools Kalmar offers a wide range of tools for truck maintenance work. For further information, please contact Kalmar's service department.

DCE80-100E

General

Technical Handbook

Group 00

TDCE01 04GB P. 10

Tightening torques The tightening torques are applicable to steel bolts and nuts tightened with a torque wrench under the following conditions: Surface treatment Condition

Lubriation Bolt

Nut

1

untreated

untreated

oiled

2

bright galvanised bright galvanised bright galvanised

untreated bright galvanised bright galvanised

dry or oiled

3

hot-dip galvanised bright galvanised

dry or oiled

The values specified in Table 1 are applicable to nut-and-bolt joints, but can also be used for bolts fitted into tapped holes. However, in the latter case, the preloading force will be somewhat lower, depending on its depth of engagement. When tightening by machine, the torque specified in Table 1 should be reduced by approx. 5%, due to the increased scatter and to prevent the bolt from being tightened beyond its yield point.

Quality

8,8

10,9

12,9

Tightening torque, Nm Condition Thread M fin

1

2

3

1

1

M8×1 M10×1,25 M12×1,25 M16×1,5 M18×1,5

27 54 96 230 330

24 48 85 205 294

30 61 108 260 373

39 76 135 323 466

46 91 162 388 559

M20×1,5 M24×2 M30×2 M36×3

460 786 2660 1560

409 700 1388 2367

520 888 1763 3005

647 1100 2200 3730

777 1330 2640 4480

DCE80-100E

General

Technical Handbook

Group 00

TDCE01 04GB P. 11

To reduce the risk of settlement of the material and the associated reduction in the preloading force if the hardness of the surface supporting the bolt head or nut is lower than 200 HB, a washer should be fitted under the bolt head and nut. This is not applicable if flanged bolts or flanged nuts are used. When tightening is carried out, the specified tor que should be applied without pause, to ensure that the torque wrench will not be tripped by the static friction before the joint has been t ightened to the specified torque.

Quality

8,8

10,9

12,9

Tightening torque, Nm Condition Thread M

1

2

3

1

1

4 5 6 8 10

3,2 6,4 11 26 52

2,9 5,7 9,8 24 47

3,6 7,2 12,5 30 59

4,6 9,1 16 38 74

5,5 11 19 45 89

12 16 20 24 30

91 220 430 750 1480

81 198 386 668 1317

103 250 49 848 1672

128 313 620 1050 2080

154 375 732 1270 2500

10,9

12,9

Quality

8,8

Tightening torque, Nm Condition Thread UNC

1

2

3

1

1

1/4 5/16 3/8 7/16 1/2

12,5 25 44 70 107

11,1 22,3 39 62 95

14,1 28,3 50 79 121

17,6 35 62 100 151

20 42 73 118 178

9/16 5/8 3/4 7/8

153 210 370 594

136 187 390 528

173 237 418 671

216 298 524 839

255 353 619 990

1 1 1/8 1 1/4 1 3/8 1 1/2

889 1260 1760 2320 3060

791 1120 1565 2065 2720

1005 1424 1990 2620 3455

1260 1780 2490 3280 4320

1480 2100 2940 3870 5100

DCE80-100E

General

Technical Handbook

Group 00

Quality

8,8

10,9

TDCE01 04GB P. 12

12,9

Tightening torque, Nm Condition Thread UNF

1

2

3

1

1

1/4 5/16 3/8 7/16 1/2

13 26 47 75 114

11 23 42 66 101

14 29 53 85 128

19 37 67 107 162

22 44 79 126 191

9/16 5/8 3/4 7/8

164 227 396 629

145 202 352 560

185 256 447 710

231 321 559 889

273 379 661 1050

1 1 1/8 1 1/4 1 3/8 1 1/2

937 1350 1860 2500 3260

834 1200 1655 2225 2900

1058 1525 2100 2825 3680

1320 1900 2630 3530 4610

1560 2250 3110 4170 5450

System of units The SI system of units is employed in this handbook: The conversion factors are as follows: Pressure megapascal

bar

Kilogram-force per square centimetre, kpf/cm² Atmosphere, at

Pound-force per square inch, psi

1 0,1 0,098

10 1 0,98

10,2 1,02 1

145 14.5 14.2

Torque Newtonmeter Nm

Kilogram force-metre kgf m

Pound-force foot lbf ft

1 9,81

0,102 1

0.74 7.23

Kilowatt kW

Horsepower (metric) hp

Horsepower hp

1 0,735

1,36 1

1.34 0.986

Power


Contents

Group 10

TDCE01 04GB P. 1

Group 10 Chassis and cab Specifications ........................................................ ................... 2 Chassis...................................................................................... 3 Description ........................................................................... 3 Operator’s cab ........................................................... ................ 4 Description ........................................................................... 4 Steering column .............................................................. 7 Service ................................................................................. 8 Changing the fresh air filter ............................................. 8 Check and lubrication of brake pedal .............................. 8 Windscreen wipers ....................................................... ... 9 Air conditioning unit ....................................................... .......... 10 Description ......................................................................... 10 Service ............................................................................... 13 Checking the air conditioning unit ................................. 13

DCE80-100E

Specifications

Technical Handbook

Group 10

TDCE01 04GB P. 2

Air conditioner 

Cab unit Circulated air flow Electric power consumption

500-600 m3/h approx 350 W



Compressor Max. speed Refrigerant Electric power consumption Oil capacity Zexel PAG SP-20

4000 r/min R134a *) approx 50 W 1.5 dl

Condenser Electric power consumption

250 W

Cooling effect Heating effect

6-8,5 kW approx 11 kW



 

*) Refrigerant R12 is no longer in production due to legislation


Chassis Description

Group 10

TDCE01 04GB P. 3

Chassis The chassis consists of:  A unit construction frame built up around two beams with a minimum of welds for best possible strength.  Mountings for the drive axle, steered axle, mast, lifting cylinders and transmission.  The necessary counterweights to provide a very low centre of gravity. Moreover, the steered axle is designed t o serve as an additional counterweight.  The hydraulic oil tank and the fuel tank are produced as separate units and are bolted to the side of the chassis. The tanks have a low profile, which contributes to the good visibility.  Separate mounting for cab, attached with screws to the chassis. Two different heights are available. Steps and platform on the left hand side, optional also right hand side. 2

3

1

4

1. 2. 3. 4. 5. 6.

Mounting for mast Mounting for tilt cylinder Space for counter weights Mounting for steering cylinder Mounting for cab Step with platform on the left hand side of the cab, standard 7. Step with platform on the right hand side of the cab, optional

5

6

7

Chassis


Operator’s cab Description

Group 10

TDCE01 04GB P. 4

Operator’s cab The operator’s cab is a separate structure and rests on the chassis on rubber dampers. The operator’s seat, steering wheel and hydraulic control levers can be adjusted for best possible operator comfort. Effective insulation minimises the vibrations and sound level in the cab. The standard heating system consists of a fan and heater for heating the air in the cab by recirculation. Fresh air is drawn in through a ventilation air filter. Full air conditioning, with cooling, heating and dehumidification, is available to special order.

1

4

2

3

1. 2. 3. 4.

Steering column with instrument panel and switches, ECS-terminal (option) Air filter Heating system Electrical central unit


DCE80-100E Technical Handbook 3

1

Group 10

4

5

2

TDCE01 04GB P. 5

6

 

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











 









a

b

c

d e



7

8

9

10

11

12

13

14

15

KL743

6 1. Gear lever FORWARD/NEUTRAL/REVERSE 1/2/3 2. Lever DIRECTION INDICATORS/HORN FRONT WINDSCREEN WASHER/ FRONT WIPERS/MAIN BEAM 3. Instrument panel 4. Steering wheel panel 5. Starting switch 6. Control lever, hydraulic functions, See Instruction Manual a. Lift b. Tilt c. Sideshift d. Length adjustment 20’-40’ e. Locking/Unlocking twist-locks 7. Electrical central unit with fuses and relays 8. Brake pedals, normal driving brake 9. Release clutch 10. Accelerator pedal 11. Steering wheel adjustment 12. Operator’s seat 13. Parking brake 14. Emergency switch for all hydraulic functions 15. Key switch for by-passing safety system

13 14 15 

Option: J oy-s tick

6









13 14 15



Option: E lservo



21

Group 10

23

22

KL581

29 26

27

30

31

32

33

34

35

38 39 36 37 40 41 42 43 44 45 46

52

53

28

25

47 48 49 50 51

24

54 55 56 6059 KL582

KL1307

F 1

2

N

L

3

0

4

R

KL580 R

66

1

4

57 58 64

21. Pressure gauge, gearbox oil pressure 22. Fuel gauge 23. Temperature gauge, engine coolant temperature 24. Switch, working lights 25. Switch, working lights 26. Switch, working lights 27. Switch, flashing beacon 28. Switch, hazard warning lights 29. Switch, driving lights 30. Spare 31. Spare 32. Switch with lamp ENGINE MAINTENANCE (QSB5.9) 33. Spare 34. Switch, compressor air conditioning 1) 35. Control, recirculation/fresh air 36. Control, defrost/cab 37. Switch, fan 38. Control, heat 39. Control, cold 1)

KL675

2

3

5

61

62 63

40. Switch with lamp DIAGNOSIS (QSB5.9) 41. a. Warning lamp STOP ENGINE (QSB5.9) b. Indicating lamp CHECK ENGINE (QSB5.9) 42. Warning lamp, battery charging 43. Warning lamp, low engine oil pressure 44. Warning lamp, low gearbox oil pressure 45. Warning lamp, low brake pressure (accumulator pressure) 46. Warning lamp, low engine coolant level 47. Indicating lamp, preheating 48. Warning lamp, high engine coolant temperature 49. Warning lamp, high gearbox oil temperature 50. Spare 51. Warning lamp, parking brake ON 52. Spare 53. Spare 54. Green lamp TWIST-LOCKS LOCKED 55. Orange lamp ALIGNMENT 56. Red lamp TWIST-LOCKS UNLOCKED 57. Spare 58. Spare 59. Indicating lamp, headlights 60. Indicating lamp, direction indicators 61. ECS terminal 1) 62. Switch, windscreen wiper, rear 63. Switch, windscreen wiper, roof 64. Spare 65. Fuses 66. Hour meter 1)

Optional

65

TDCE01 04GB P. 6



Group 10

TDCE01 04GB P. 7

Steering column Surrounding the steering column are multi-function levers for gear changing, indicators, windshield wipers, etc., as well as the instrument panel with the ECS terminal. At the very foot of the steering column is the steering valve (Orbitrol), activated by the steering wheel via an angled gear. The steering column is equipped with an adjustment handles for the alterat ion of steering wheel height and rake.

F 1

2

N

L

3

0

4

R

R

1

1

2

4

5

3

2 3 KL580A

4



1. 2. 3. 4.

Gear lever Multi-function lever ECS terminal Steering wheel adjustment handles 5. Orbitrol steering valve

5 

S teering column

Operator’s cab Service


Group 10

TDCE01 04GB P. 8

Changing the fresh air filter (every 200 hours or when needed) 1. Remove the filter casing retaining bolts and remove the filter element. 2. Wash the filter insert with water and detergent or by using a high pressure washer. Replace the insert if necessary. 3. Reinstall the filter insert.

Checking condensate draining 1.

2.



On certain machines with air conditioning system, there are two hoses for draining of condensate from the condensor. The hoses can be found on the underside of th e cab’s front, see illustration. Check that the hoses are hanging so that there can be no water accumulation. A bend can create a water lock which will prevent the drainage.



Group 10

TDCE01 04GB P. 9

Check and lubrication of brake pedal (every 1000 hours) 1. 1 2

3 4

1. 2. 3. 4.

Brake pedal Lubricating nipple Locking screw Shaft

2.

Check and tighten the locking screws 3, so that the brake pedal is securely fitted in the console. Lubricate the brake pedal shaft through the nipples 2.



Group 10

TDCE01 04GB P. 10

Windscreen wipers The wiper arms are fixed to the wiper motor shafts via conical splines. The shafts are manufactured of hardened steel and the wiper arm mounting of soft, pressed metal. When fitting, the nuts must be tightened so hard that the splines are pressed well into the mounting and function as a carrier. Removal 1. Remove the wiper arms by loosening the nuts and thereafter tapping and carefully rocking the arms to and fro.

1

Fitting 1. Check to ensure that the splines on the motor shaft are free from the softer material from the wiper arm mounting. If this is not the case, clean the splines so that they can pressed fully into the wiper arm mounting. 2. Fit the wiper arms onto the motor shafts and tighten the nuts to a torque of 16-20 Nm. Hold the wiper arm to take up the torque pressure so that it is not transferred to the motor, which could result in damage

. 2 3 4

1. 2. 3. 4.

Wiper arm fitting Securing nut, wiper arm Räfflad kona på motoraxel Wiper motor

IMPORTANT! The nuts mus t be tig htened suffi ciently hard, otherwis e the shafts may s tart to s lip ins ide the wiper arm mounting , res ulting in damag e.

Air conditioning unit Description


Group 10

TDCE01 04GB P. 11

Air conditioning unit The air conditioning unit consists of the parts shown in the illustration and its function is to maintain the climate in the ope-rator’s cab as comfortable as possible. The air conditioning unit:  heats the air when it is cold  dehumidifies the air when it is humid  removes impurities from the air  cools the air when it is warm The equipment is steered by switches and controls on the instrument panel.

5 6 1 4

3 8

9 7 2

15

12

16

14

10

1. Heating control 2. Heat exchanger 3. Vapourizer 4. Expansion valve 5. To condenser 6. To compressor 7. Heating valve 8. From engine 9. To engine 10. Fan 11. Fan 12. Fan control 13. Fresh air filter 14. Air disperser 15. Control defrost/cab 16. Defroster outlet

11 13

The heating and ventilating s ys tem



Group 10

F

2 4 C

D

E

E 3

7

A

6

1

G

1. 2. 3. 4. 6. 7.

Liquid receiver/filter dryer Evaporator Fan Expansion valve Condenser Compressor

B

A B C D E F

G

High-pressure gas High-pressure liquid Low-pressure liquid Low-pressure gas Warm air in cab Cooled air to the cab

Outside air for removing heat

TDCE01 04GB P. 12



Group 10

TDCE01 04GB P. 13

Compressor The air conditioning system is driven by the compressor. This performs as a pump, drawing cold, low-pressure gas from the evaporator, compressing it and thereby raising its temperature, and discharging it at high pressure to the condenser.

The compressor is driven by V-belts directly from the diesel engine. Switching between operation and idling is controlled by an electro-magnetic clutch which, in turn, is controlled by a thermostat whose sensor is located between the fins of the evaporator coil. The thermostat switches off the compressor at low temperatures, to prevent icing of the evaporator. Condenser The function of the condenser is to convert th e hot high-pressure gas from the compressor into liquid form. The tubes and fins of the condenser coil absorb heat, which is then removed by the air delivered by the fan. The temperature of the refrigerant in the condenser varies from about +50°C to +70°C. The pressure varies between 12 and 20 bar, depending on the ambient temperature and the flow of air through the condenser. When the refrigerant is condensed into liquid form, it is transferred under pressure to the liquid receiver/ filter dryer. Liquid receiver with filter-dryer The function of the liquid receiver with integrated filter dryer is to collect the liquid coolant, bind the moisture, and to filter and remove impurities. The receiver, which is located in the condenser housing, also serves as the expansion vessel in the refrigeration circuit. After flowing through the dryer in the bottom of the liquid receiver, the refrigerant flows through a riser tube. A sight glass enables the operator to check that the liquid flows without the presence of any bubbles, and that the system is filled with a sufficient amount of refrigerant. Expansion valve The expansion valve throttles the flow and passes an optimised quantity of refrigerant that the evaporator is capable of evaporating. The expansion valve is also the part of the circuit which separates the high- pressure side from the low-pressure side. The refrigerant flows to the expansion valve under high pre ssure and leaves it under low pressure. The amount of refrigerant which passes the evaporator varies, depending on the thermal load. The valve operates from ’fully open’ to ’fully closed’ and in-between searches fo r a point to give optimum evaporation. Evaporator The heat necessary for evaporating the refrigerant is extracted from the cab air which is circulated by a fan through the evapor ator coil. The cab air is thus cooled, and is distributed and returned to the cab.

In the evaporator, the refrigerant reverts to the gaseous state and returns to the compressor suction, thereby completing the cycle.


WARNING! If the refrigerant hose should fail or if other refrigerant leakage should occur, switch off the air conditioner immediately.  Refrigerant is injurious to the skin and eyes.  Never release refrigerant in an enclosed space. If released into a service pit, for instance, the gas may cause asphyxia.  It is forbidden by law to discharge refrigerants into the air intentionally.  Never carry out welding on a charged refrigeration system or in its vicinity.  Only authorised service mechanics are allowed to drain off and fill refrigerant in the air conditioning system. Only the prescribed refrigerant may be used when refilling. 

Air conditioning unit Service

Group 10

TDCE01 04GB P. 14

The liquid refrigerant should be completely evaporated before it is allowed to flow from the evaporator. The refrigerant is s till cold even when it has completely evaporated. The cold vapour which flows through what remains of the evaporator continues to absorb heat, and then becomes overheated. This means that the temperature of the refrigerant has risen to above the point where it evaporates without changing the pressure. In an evaporator which operates at a suction pressure of 2 bar, the liquid refrigerant will have a temperature of –1.1°C. When the refrigerant is subsequently evaporated through heat absorption in the evaporator, the temperature of the gas will rise at the evaporator outlet to +1.6°C. This represents a difference of 2.7°C between the evaporation temperature and the temperature at the outlet. This is called overheating. All expansion valves should be adjusted at the plant in such a way that maximum evaporation with overheating is performed in the air conditioning system.

Checking the air conditioning unit If the unit is in continuous operation, this check should be carried out every week from early spring to late autumn and during extended periods of high humidity during the winter. If the unit is used very little during cold and dry winter periods, the compressor should be run for a few minutes every week, to lubricate the rubber hoses, couplings, seals and shaft seal. 1.

2.

3. 4. 5. 6. 7. 8.

9.

Start the engine and start the air conditioner. At an outdoor temperature below 0°C, the system cannot start since the low-pressure relay breaks contact. After 10 minutes of operation, check that no bubbles are visible in the sight glass of the filter-dryer. (Bubbles should occur only when the compressor is started and stopped.) If there are any air bubbles, subsequent filling should be performed by an authorised service mechanic. Check that the condenser is not clogged. If necessary, clean the condenser fins with compre ssed air. Change the fresh air filter as necessary. Check the V-belt tension and the compressor mounting. Check that the magnetic coupling engages and disengages satisfactorily. Check that the condensate drain from the cooling element is not clogged. Check for leakage. On certain machines with air conditioning system, there are two hoses for draining of condensate from the condensor. The hoses can be found on the underside of th e cab’s front, see illustration. Check that the hoses are hanging so that there can be no water accumulation. A bend can create a water lock which will prevent the drainage.

Air conditioning unit Service


IN CAB CLIMATE UNIT

5 , 1 D R

A

1

L M H C

GL 1,5 SV 1,5 RD 1,5

Group 10

TDCE01 04GB P. 15

CONDENSER UNIT

5 , 1 D R

4

4

R

R

5

8 BR 1,5

M 2

GL 1,5

30

87

85

86

BR 1,5

M

M 5 , 1 R B

6

3

9

VT 1,5

7 HIGH LOW

10

1. Fan switch 2. Cooler on/off 3. Anti-freeze thermostat 4. Resistor 5. Fan motor 6. Indicator lamp – cold (in push button) 7. High-/low-pressure monitor 8. Relay 9. Condenser fan 10. Compressor

C irc uit diag ram in cab climate unit/condens er unit


Empty page Group 10

TDCE01 04GB P. 16


Contents

Group 20

TDCE01 04GB P. 1

Group 20 Electrical system Specifications ....................................................................... ......2 Electrical system ........................................................................3 Description ............................................................................3 Service ..................................................................................5 Checking the electrolyte level of the batteries..................5 Fuses ...............................................................................5 Bulbs .................................................................... ............5 Relays .................................................................. ............6 Sockets in electrical central..............................................7 Electrical diagram explanations .......................................8 List of circuit diagrams...........................................................9 Component list

DCE80-100E

Specifications

Technical Handbook

Group 20

Alternator rating

2240 W

Starting battery, voltage capacity earthing

2 x 12 V 140 Ah negative

TDCE01 04GB P. 2


IMPORTANT! A lways open the main s witch whenever work is to be carri ed out on the electrical s ys tem, if the truck i s to remain idle for s ome time and whenever welding work is to be carri ed out on the truck .

Electrical system Description

Group 20

The system voltage is 24V and the supply is taken from two 12V batteries connected in series and charged by an alternator across electronic rectifying and voltage stabilisation circuits. . The positive pole is connected across a main switch. The negative pole is connected to the chassis. Warning lamps and instruments are clearly arranged o n the instrument panel. The central electrical unit with fuses and relays is located on the lower section of the cab’s rear wall.

3

2

5

5

5

1

4

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

Driving lights Washer fluid container Electrical central Rear lights Position lights Main switch Battery

TDCE01 04GB P. 3

6 7



1

2

3 4

8

9

Group 20

5

TDCE01 04GB P. 4

6

7

10

1. Sensor, warning lamp low oil pressure and gearbox oil pressure gauge 2. Sensor, warning lamp high oil temperatur and gearbox oil temperature gauge 3. Fuse 4. Relay preheater element 5. Sensor, coolant temp gauge 6. Sensor, high coolant temp warning lamp 7. Sensor, engine oil pressure instrument 8. Starter motor 9. Sensor, low coolant level warning lamp 10. Engine wiring

E lectric al components, Volvo TWD 731VE



1

2

3

Group 20

4

9

8

TDCE01 04GB P. 5

5

7

6

10

1. Sensor, warning lamp low oil pressure and gearbox oil pressure gauge 2. Sensor, warning lamp high oil temperatur and gearbox oil temperature gauge 3. Sensor, coolant temp gauge 4. Solenoid, fuel shut off valve 5. Alternator 6. Sensor, engine oilpressure 7. Relay, preheater element 8. Main fuse 9. Sensor, outgoing engine speed 10. Starter motor

E lectric al components , Volvo TAD 720VE



1

2

3

4

5

Group 20

6

7

TDCE01 04GB P. 6

8

9 10

11

12

1. Sensor, outgoing speed gearbox. 2. sensor, warning lamp low oil pressure and gearbox oil pressure gauge 3. Starter motor relay 4. Main fuse 5. Starter motor 6. Sensor, coolant temperature gauge 7. Sensor, engine oil pressure 8. Generator 9. Sensor, warning lamp high oil temperature and gearbox oil temperature gauge 10. Preheater element 11. Sensor, outgoing engine speed 12. Solenoid valve housing,gearbox

E lectrical components , C ummins QS B 5.9


Electrical system Electrical system

Group 20

TDCE01 04GB P. 7

Electrical system N.B. The starting batteries accompanyi ng the truc k are of the maintenance-free type, which i mplies that it s hould not be neces s ary to top-up with electrolyte duri ng the life of the batteries . However, the level of the electrolyte s hould preferably be check ed once or twice a year. Fill as requir ed by adding de-ionized water.

The electrical system operates at 24 V. The source of power supply are two 12 V batteries which ar e charged by an alternator. The negative pole is connected to the chassis. The positive pole is connected to a main switch A.

IMPORTANT! When worki ng with the electric al s ys tem, when carry ing out welding on the truck or at long time parking , always is olate the batteri es .

Checking the electrolyte level of the batteries

WARNING! The battery electrolyte contains cor ro s iv e sulphuric acid. Immediately remove any electrolyte that comes into contact with the s ki n. Was h with s oap and lots of water. If electrolyte g ets i nto the eyes , i mmediately ri ns e with lots of water and immediately contact a doctor.

The batteries are fitted behind a cover on the left-hand side of the truck. The electrolyte level should be about 10 mm above the cells. Top up with de-ionized water as necessary.

Bulbs Description Instruments Indicating lamps Cab l ighting Rear lights, red Brake lights Direction indicators Position lights Driving lights (full/dipped beam) Reversing lights, white Working lights Hazard beacon

A Main switch

Rating Watts ...................................... B ase 3 ............................................. BA7s 1,2.................................... W2x4,6d 10 ............................................ S8,5 5 ........................................... BA15s 21 ......................................... BA15s 21.........................................BA15s 5 ............................................ SV8,5 75/70 .................................. P43t-38 70.........................................PK22s 70 ......................................... PK22s 70 ......................................... PK22s

Electrical system Electrical system


Group 20

TDCE01 04GB P. 8

Relay box in cab – fuses Fuse No.

S1-6 S7-12 S13-18 S19-24 S25-30

S31-36

WARNING! Never us e fuses of a hig her amperag e than stated on the lid decal. R is k of damag e or fire.

WARNING! It is prohibited to connect more consumers to any fus e.

Rating, A Circuit protected TWD TAD QSB 731 720 5.9 S1 Hazard lights, ignitions key, preheater relay, 15 15 15 start relay S2 Cab lighting, seat buzzer, parking brake sen- 15 15 15 sor, disengagement relay (ECS 01), hydr oil cooler supply S3 Stopp, engine 5 S4 Electric gear-changing 5 5 5 S5 Warning lamps, instrument illumination, 5 5 5 coolant level relay brake pressure relay S6 Horn, screenwash motor, front wiper motor, 10 10 10 intermittent relay front wiper S7 Wiper motors and intermittent relay rear and 10 10 10 roof S8 Heating fan, AC compressor, seat heater, 25 25 25 recirculation motor S9 AC condensor, manual hydraulic oil cooler 15 15 15 S10 Main fuse, driving lights, rear lights, position 15 15 15 lights, direction indicators S11 Brake lights, flashing beacon 10 10 10 S12 Reversing lights, reversing alarm 15 15 15 S13 Working lights on mast 15 15 15 S14 Working lights on cabin roof 15 15 15 S15 Container lights 15 15 15 S16 24/12 V converter (radio, com radio) 15 15 15 S17 Stop, engine 5 5 S18 El-operated parking brake 5 5 5 S19 ECU 1 (Aut gearchanging, lever steering, 15 15 15 monitoring S20 ECU 4 (El-servo system) 15 15 15 S21 Container attachment, safety interlock 10 10 10 S22 Spare S23 Working lights, chassis front 15 15 15 S24 Spare S25 Left hand main beam 5 5 5 S26 Right hand main beam 5 5 5 S27 Left hand dipped beam 5 5 5 S28 Right hand dipped beam 5 5 5 S29 Left hand rear light, right hand position light 5 5 5 S30 Right hand rear light, left hand position light 5 5 5 S31 Waterseparator 15 20 20 S32 Central lubrication 15 15 15 S33 Compressor for air suspended seat 15 15 15 S34 Compressed air horn 15 15 15 S35 Spare S36 Spare NB. The table contains extra equipment

SUPERVISION Electrical system


Group 20

TDCE01 04GB P. 9

Relays 305 314 315 316 320 322-1 322-2 323 328 330 331 332 334 368 399

Reversing light Parking brake, disengagement High power (Starting switch) Wiper motor, front Electric stop (ECS 07) 1) Coolant level Coolant level (ECS 07) 1) Pulse relay, direction indicators Lever steering (ECS 04) 1) Starting interlock Propulsion forward Propulsion reverse Release clutch at automatic gearbox (ECS 01) 1) Low brake pressure (ECS 07) 1) Spare

Miscellaneous



321-1 321-2 960 1)

Intermittent relay wiper front Intermittent relay wiper rear 1) Reversing interlock

Optional equipment

Main fuse for electrical system Fitted on the engine 2 x 50 A



Starting from another battery 



WARNING! B atteries emit oxyhydrog en which is an explosive g as . A s park, for example from incor rectly connected s tarting cables , could caus e a battery to explode and res ult in s erious injury and damage.





Make sure the auxiliary batteries are connected in series, so that 24 V will be supplied. Note: Do not disconnect the truck-battery cables Connect the jumper cables in the following order: 1. Red cable (+) to auxiliary battery 2. Red cable (+) to truck battery 3. Black cable (–) to auxiliary battery 4. Black cable (–) to a location some distance away from the truck battery, such as the negative cable con nection on the chassis. Start the engine Do not disturb the jumper cables while starting, as sparks may otherwise be caused. Do not lean over either battery. Disconnect the jumper cables in e xactly the reverse order.

SUPERVISION Electrical system


Group 20

TDCE01 04GB P. 10

Sockets in electrical central Socket No. XK1-XK5 X6-X7 X8 X9-X10





Destination

Internally electrical central Right instrument panel, indicating lamps Instruments Left instrument panel, switches for driving and working lights X11-X12 Left instrument panel, other switches X13 Gear lever X14-X15 Multi function lever X16 Starting key X17 Switch, windscreen wipers X18 Indicating lamps, attachment X19 ECS-terminal 1) X20 Driving lights, left front X21 Driving lights, right front X22 Driving lights, left rear X23 Driving lights, right rear X24-X25 Connector, roof X26 Connector, chassi X27 Windscreen wiper, rear X28 Heating fan, windscreen wiper front X29 Horn, compressor for air operated seat X30 Sensors under cab X31-X34 Engine, gearbox X35 Control motor, accelerator (ECS) 1) X36-X37 ECU 1 1) X38 Accelerator pedal (ECS) 1) X39 ECU 1 1) X40-X41 ECU 1 1) X42-X44 Armrest, steering valve (ECS m04/06) 1) X45 Chassis front X46 Chassis attachment X47 Central lubrication 1) X48-X52 ECU 4 (ECS elservo m08) 1) X53-X55 Option X80 Electrical central, main connector X81 Chassis front X82 Carriage Ground sockets 37-1, -2 Electrical central 37-5 Chassi 37-6 Engine 37-7 Cab 37-8 Cab, roof 37-10 Attachment 1) Optional equipment

No. of pins 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 19 7

SUPERVISION Diagram explanations


Group 20

TDCE01 04GB P. 11

Electrical diagram explanations A

H CL

A.

B. C. D. E.

H

R

N O M

F. G. H.

J

KL1085

K D

C

J

H

L

J. K. L. M. N. O.

A M

R

C

KL1084

P. Q.

P

R.

Connector, located outside the central electrical unit circuit board. X = Connector 33 = Pin number /4 = Pin number 4 in connector number 33 Cable marking. M1 = the cable goes between ECU 1 and the Central electrical unit. Component marking, for more detailed explanation, see the components list in the Technical Handbook, Group 20. + feed after the ignition key. Function, see tables under headings ECU 1 Functions and ECU 5 Functions respectively. Pin on the 70 pole coupling on the ECU. Type of signal. Cable marking, A = the cable is located inside the central electrical unit. Reference, the cable continues on diagram A08333.1000 Ignition key dependent feed, battery + 24V Chassis connection The cable continues on the same diagram, but on another page P3 = page 3 Cable marking, the cable is loacted outside the central electrical unit. Cable colours BK = Black BN = Brown RD = Red OG = Orange YE = Yellow GN = Green BU = Blue VT = Violet GY = Grey WH = White PK = Pink Connection marking on the actual component. Cable M131B continues on diagram A24927, page 1 P1 = page 1 1) = Only with Lever steering Connector on the circuit board in the central electrical unit X = Connector K = Circuit board 5 = Connector number

A

B

E

C

F

G

D

KL1083

Q

KL1081

KL1082


SUPERVISION Diagram explanations

Group 20

TDCE01 04GB P. 12

List of circuit diagrams Every truck is electrically described by a selection of circuit diagrams from the following list Diagram A35082.0200 A35083.0100 A35083.0300 A35084.0300 A35084.0200 A35085.0300 A35086.0100 A35087.0100 A35088.0100 A35089.0100 A35089.0200 A35090.0100 A35091.0100 A35092.1100 A35093.0200 A35093.0300 A35093.0400

Circuit Current, Volvo 730/731 VE Gearchanging ECS 01, aut gearchanging 1) Sensors, instruments ECS 07, monitoring 1) Accelerator 1-Ped. ECS 01/ECS 07 1) ECU 1 1) Lever/Mini steering ECS 04/06 1) Wipers AC Termostatically controlled AC 1) Driving lights Working lights Cabin Central lubrication, hydraulic fluid cooler 1) Blinking brakelights when reversing 1) Autom. engine stop, alarm function (valve) All faults after the same set time 1) A35093-0900 Autom. engine stop, low oil pressure after 6 sec. other faults after 25 sec. A35094.0100 Side lift attachment -Truck (Twistlocks) A35094.0200, Side lift attachment-Truck (Hooks) A35094.1200 A35094.0400, Side lift attachment-Truck (ECS 08) A35094.1400 A35094.0500- Side lift attachment-Truck (option) A35094.0700 A35095.0200 ECU 4 at ECS 08 1) A35096.0200 ECS 08, linear levers 1) A35097.0100 Side lift attachment (Twistlocks) A35097.0200 Side lift attachment (Hooks) A35098.0100 CAN-Bus (Trucks with more than one ECU) 1) A42796.0100 Hydraulic oil cooler 1) Optional equipment

4 0

0 0 2 0 . 3 9 0 5 3 A

Komponentfört eckning / List of Components NUMBER CATEG

SVENSKA

ENGLISH

30 32 37 39 51 52 56 58 59 62 64 72 77 78 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 135 136 137 138 139

Batteri Kretskort elcentral Terminal stomanslutning Terminal minusanslutning Säkringshållare 1-polig Säkringshållare 2-polig Säkringshållare 6-polig Säkringshållare 8-polig Säkringshållare 12-polig Batterihandske 2-polig Batterihandske 4-polig Stickuttag 2-polig Stickuttag 7-polig Stickuttag extra 7-polig Strömställare ljus Strömställare omk hel/halvljus Strömställare dimljus Strömställare fjärrljus Strömställare lastljus Strömställare arbetsljus Strömställare containerljus Strömställare park broms Strömställare centr smörjning Strömställare varningsljus Strömställare rot varningsljus Strömställare fönsterhiss Strömställare kylanläggning (AC) Strömställare styrning alt Strömställare läsbelysning Strömställare instr belysning Strömställare innerbelysning Strömställare värme Strömställare fläktm värme Strömställare vindrutetorkare Strömställare spolare Strömställare blackout Strömställare nöd hydraulpump Strömställare backspegel Strömställare kallstart Strömställare avgasbroms Strömställare diff spärr/broms Strömställare värmesystem diesel Strömställare kraftuttag sida Strömställare kraftuttag bak Strömställare hög/lågväxel Strömställare färdväljare fram Strömställare färdväljare bak Strömställare växelväljare Strömställare framhjuls styrning Strömställare 4-hjuls styrning Strömställare crab styrning Strömställare defroster

Battery Printed circuit board, Junction box Earthing terminal on chassis Terminal, negative terminal Fuse holder, 1-pole Fuse holder, 2-pole Fuse holder, 6-pole Fuse holder, 8-pole Fuse holder, 12-pole Battery connector, 2-pole Battery connector, 4-pole Outlet, 2-pole Outlet, 7-pole Outlet, extra, 7-pole Switch, light Switch, main/dipped beam Switch, fog light Switch, distance light Switch, mast lights Switch, working lights Switch, container light Switch, parking brake Switch, central lubricator Switch, hazard lights Switch, rotating hazard beacon Switch, window regulator Switch, air conditioner (AC) Switch, alternative steering Switch, reading light Switch, instrument illumination Switch, interior lighting Switch, heating Switch, heater fan Switch, wiper Switch, washer Switch, blackout Switch, emergency hydraulic pump Switch, observation mirror Switch, cold start Switch, exhaust brake Switch, diff. Block Switch, heating system diesel Switch, power take off side Switch, power take off rear Switch, high/low gear Switch, gear selector forward Switch, gear selector rear Switch, gear shift Switch, forward wheel steering Switch, 4-wheel steering Switch, crab steering Switch, defroster

2006-05-11

G A X X F F F F F F F X X X S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S

Page 1 of 18

NUMBER CATEG

SVENSKA

141 142 143 144 145 147 149 150 152 156 157 158 159 160 161

S S S Q S S S S S S S S S S S

Strömställare Stegbelysning Strömställare fot Strömställare sitsvärme Batterifrånskiljare Strömställare AT-regulator Strömställare körvisare Strömställare signalhorn Strömställare startlås/ellas Strömställare intervalltorkare Strömställare kupevärmare Strömställare stoltilt Strömställare dimbakljus Strömställare extra fram/back väljare Strömställare komb fram/back Strömställare komb signal, ljus hel/halv spol,torkare m intervall körvisare

162

S

163 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 190 191 192 195 196 197 198 199 200

S S S S S S S S S S S S S S S S S S S S S S S S S S

201

S

Switch, Steplight Switch, foot Switch, seat heater Battery disconnecting switch Switch, AT-regulator Switch, direction indicators Switch, horn Switch, main key switch Switch, intermittent wiper Switch, cab heating Switch, seat tilt Switch, rear fog light Switch, extra direction selector Switch, combi-forward/reverse Switch, combi-horn, light main/dipped beam, washer, wiper (intermittent), direction indicator Strömställare komb signal ljus hel/halv, Switch, combi horn, light main/dipped spol, torkare m 2 int, fram/bacK beam, washer, wiper w 2int., forward/revers Strömställare start på 2-an Switch, start 2nd gear Strömställare stolvärme Switch, seat heater Strömställare låsning vändskiva Switch, interlocking of turntable Strömställare luftfjädring Switch, pneumatic springing Strömställare låsn stol Switch, interlocking of seat Strömställare stolsvändning Switch, reversible seat Strömställare förångare (LPG) Switch, evaporator (LPG) Strömställare v-skiva upp/ner Switch, fifth wheel up/down Strömställare v-skiva fr/back Switch, fifth wheel forward/reverse Strömställare v-skiva skevning Switch, fifth wheel, levelling Strömställare,utskjut Switch, projecting Strömställare hyttlyft upp Switch, cab hoist up Strömställare hyttlyft ner Switch, cab hoist down Strömställare hyttskjutning Switch, cab movement Strömställare nollställning Switch, reset Strömställare Aut/man växling Switch Aut/man gearshifting Strömställare fyrhjulsdrift Switch, 4-WD Strömställare klimatanläggning Switch, air conditioner Strömställare recirkulation Switch, re-circulation Strömställare vattenavskiljare Strömställare joy-stick X Switch, joy-stick X Strömställare joy-stick X+Y Switch, joy-stick X+Y Strömställare längs/tvärskörning Switch, length/sideways driwing Strömställare flytläge skevning Switch, equalizing fifth wheel Strömställare option Switch, option Brytkontakt lampa park broms Contact, breaking,warning lamp,parking brake Brytkontakt lampa färdbroms Contact, breaking, warning lamp, brake

202

S

Brytkontakt lampa oljetryck motor

204

S

Brytkontakt tryck ackumulator

205

S

Brytkontakt innerbelysning

2006-05-11

ENGLISH

Page 2 of 18

Contact, breaking, warning lamp, oil pressure engine Contact, breaking, pressure accumulatortank Contact, breaking, interior lighting

NUMBER CATEG

SVENSKA

ENGLISH

206 207 208

S S S

214 215 216 217 218 219

S S S S S S

Brytkontakt handskfack belysning Slutkontakt diff spärr Slutkontakt lampa temperatur spolkrets bromsar Slutkontakt överväxel Slutkontakt temp motor Slutkontakt bromsljus Slutkontakt backljus Slutkontakt AT-regulator Slutkontakt lampa luftfilter

Contact, breaking, glove Contact, making, diff. interlock Contact, making, warning lamp temperature brake Contact, making, over drive Contact, making, temperature engine Contact, making, brake lights Contact, making, reversing light Contact, making, AT-control Contact, making, indicating light air filter

220 221

S S

Brytkontakt drivning Slutkontakt temp växellåda

Contact, breaking, drive cut off Contact, making, temperature gear box

222

S

223 224 225 228 229 230 231

S S S S S S S

Slutkontakt lampa temp moment förstärkare Släpkontakt signal Slutkontakt insprutningspump Brytkontakt säkerhetsbälte Slutkontakt hyttlåsning Slutkontakt stolslåsning Brytkontakt stol Slutkontakt fotkontroll stolvändning

232

S

Brytkontakt lampa luftanslutning släp

233

S

Slutkontakt lampa låsning vändskiva

235 236 239 240 241

S S S S S

Slutkontakt sidoskjutning stol Slutkontakt vattennivå Brytkontakt termisk Slutkontakt termisk Brytkontakt lampa luftmatning släp

242

S

Slutkontakt lampa oljetryck v-låda

243

S

Brytkontakt tryck kylmedia AC

244 245

S S

Slutkontakt hydraulik aktiverad Slutkontakt hydraultryck styrning

246 250 251 260 261 262 263 264 265 266 267 268 269

S S S S S S S S S S S S S

Slutkontakt tryck kylmedia Manöverbrytare Slutkontakt vändbar förarstol Slutkontakt lyft steg 1 Slutkontakt lyft steg 2 Slutkontakt tilt Slutkontakt gaffelspridning Slutkontakt sidoföring Slutkontakt stativ in/ut Brytkontakt hyttdörr Slutkontakt bromstryck Slutkontakt kompressor Slutkontakt sax inne

Contact, making, warning lamp temperature torque amplifier. Contact, brush, horn Contact, making, injection pump Contact, breaking, seat belt Contact, making, cab locking Contact, making, seat locking Contact, breaking, seat Contact, making, seat rotation, foot switch Contact, breaking, warning lamp air connection Contact, warning, interlocking of turntable Contact, making, side shifting of seat Contact, water level Contact, breaking, thermic Contact, making, thermic Contact, breaking, warning lamp air supply to trailer Contact, making, warning lamp, oil pressure gear box Contact, breaking, coolant pressure (air condition) Contact, making, hydraulics Contact, making, hydraulic pressure control Contact, pressure refrigerant Operating Switch Contact, making, VBFS Contact, making, hoist step 1 Contact, making, hoist step 2 Contact, making, tilting Contact, making, fork positioning Contact, making, sideshift Contact, making, lifting mast in-out Contact, breaking cab door Contact, making, brake pressure Contact, making, Compressor Contact, making extender in

2006-05-11

Page 3 of 18

NUMBER CATEG

SVENSKA

ENGLISH

270 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325

S S K K K K K K K K K K K K K K K K K K K K K K K K K K

Slutkontakt överlastskydd Slut/brytkontakt option Relä hel/halvljus Relä dimljus Relä fjärrljus Relä lastljus Relä arbetsljus Relä backljus Relä helljus Relä halvljus Relä bromsljus Relä parkeringsbroms Relä körvisare vä Relä körvisare hö Relä startelement Relä vändbar förarstol Relä parkeringsbroms Relä tändningslås Relä torkare Relä strålkastartorkare Relä AT-regulator Relä varningsblinkers Relä elektrisk stopp Relä intervalltorkare Relä kylvätskenivå Relä blinkers Relä rangespärr Relä blinkande bromsljus (back)

Contact, making, overload protection Contact, making/braking option Relay, main/dipped beam Relay, fog light Relay, distance light Relay, mast light Relay, working light Relay, reversing light Relay, main beam Relay, dipped beam Relay, brake light Relay, parking light Relay, direction indicator left Relay, direction indicator right Relay,element preheater Relay, rotating driver´s seat (VBFS) Relay, parking brake Relay, ignition key Relay, wiper Relay, roading lights wiper Relay, AT-regulator Relay, hazard blinkers Relay, electical stop Relay, intermittent wiper Relay, coolant level Relay, blinkers Relay, range interlock Relay, flashing brake lights (reversing)

326 327 328 329 330 331 332 333 334 335

K K K K K K K K K K

Relä blinkande bromsljus (runt) Relä växel neutral Relä växelskifte Relä växel hög/låg Relä startspärr Relä drivning fram Relä drivning bak Tidrelä förvärmning Relä frikoppling/drivbrytning Relä växelventil 1:a (diesel, gas)

336

K

Relä växelventil 2:a (diesel, gas)

337 338 339 340 341 342 343 344 345 346 347

K K K K K K K K K K K

Relä drivriktning motor Relä kylfläkt drivmotor Relä kylfläkt elskåp Tidrelä fördröjt tillslag Tidrelä fördröjt frånslag Relä drivning 2/4 hjul Relä dimbakljus Relä momentförstärkare Relä låsning vändskiva Relä frikoppling stollåsning Relä stolvändning/ljussignal

Relay, flashing hazard brake lights Relay, gear neutral Relay, gear shift Relay, high/low gear Relay, start interlock Relay, forward driving Relay, reversing driving Time relay, automatically preheating Relay, free wheel/drive disconnection Relay, gear change valve 1-gear (diesel,LPG) Relay, gear change valve 2-gear (diesel,LPG) Relay, motor drive direction Relay, cooling fan drive motor Relay, cooling fan electrical box Time relay, start delay Time relay, stop delay Relay, switching 2/4 WD Relay, fog light rear Relay, torque amplifier Relay, interlocking of turntable Relay, releasing of seat interlocking Relay, multifunction, seat rotation/light signal

2006-05-11

Page 4 of 18

NUMBER CATEG

SVENSKA

ENGLISH

348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366

K K K K K K K K K K K K K K K K K K K

Relä fläktmotor värmare Relä fartreglage Relä pumpkontaktor/pumpkontroll Relä hyttlyft upp Relä hyttlyft ner Relä säkerhetsslinga Relä styrsystem Relä sensorstyrning Skiftrelä längskörning/tvärskörning Relä roterande varningsljus Relä komressor luft Relä Hydrauloljekylare Relä startsolenoid Relä kompressor AC Relä vattenventil AC Relä kondensor AC Relä stolsbrytare Relä fönsterhiss upp Relä fönsterhiss ner

Relay, fan heating Relay, speed control Relay, pump contactor/pump control Relay, cab hoist up Relay, cab hoist down Relay, safety loop Relay, signal control system Relay, sensor control Shift relay, length/sideways driving Relay, hazard beacon Relay, compressor air Relay hydraulic oil cooler Relay, starting solenoid Relay, compressor air conditione Relay, water valve air conditioner Relay, condenser air conditione Relay seat switch Relay, electrical screen elevator up Relay, electrical screen elevator down

367 368 369 370

K K K K

Relä styrning Relä lågt bromstryck Relä centralsmörjning Relä centralsmörjning, aggregat

Relay, steerin Relay, low brake pressure Relay, central lubrication Relay, central lubrication, attatchment

371 372

K K

373 375 376 377 378

K K K K K

379 380 381 382 383 384 385 386 387 388 389 399 400 400

K K K K K K K K K K K K E E

Relä lyfthöjd Relay, liftheight Relä blinkande varn.ljus, höjdbegränsn. Relay, flashing beacon, lifting height limiter Relä bakljus Relay light Huvudkontaktor reglersystem Main contactor, operating control Kontaktor fram reglersystem Contactor, forward operating control Kontaktor bak reglersystem Contactor, reversing operating control Kontaktor by-pass Contactor, ¿by-pass¿ operating control/ reglersystem/Fältförsvagning Field weakening Kontaktor pumpmotor Contactor, pump motor Kontaktor Contactor Kontaktor återladdning Contactor, recharging Relä, förbikoppling säkerhetssystem Relay, by-pass safety system Relä, Stolsvärme Relay, heated seat Relä vattenseparator Relay, waterseparator Relä bränslepump insprutning Relay, fuel injection pump Relä, hög motortemperatur. Relay, high motor temperature Relä alternativ gaspedal Relay alternative throttle pedal Relä, Extra färdriktningsväljare Relay, Extra direction selector Relä, Pausvärme Relay, Paus heat Relä option Relay, option G-lampa vä fram Light bulb, roading light left hand front G-lampa hö fram Light bulb, roading light right hand rear

401 401

E E

G-lampa vä bak G-lampa hö bak

Light bulb, roading light left hand front Light bulb, roading light right hand rear

402 403

E E

G-lampa fjärrljus G-lampa lastljus

Light bulb, distance light Light bulb, mast light

2006-05-11

Page 5 of 18

NUMBER CATEG

SVENSKA

ENGLISH

404 405 406 406 408

E E E E E

G-lampa arbetsljus G-lampa backljus G-lampa cont belysning vänster G-lampa cont belysning höger G-lampa park ljus vä fram

408

E

G-lampa park ljus hö fram

410

H

G-lampa broms ljus vä fram

Light bulb, working light Light bulb, rear light Container light left-hand Container light right-hand Light bulb, parking light, left-hand forward Light bulb, parking light, right-hand forward Light bulb, brake light, left-hand forward

410

H

G-lampa broms ljus hö fram

411 411 412 412 413

H H H H H

G-lampa broms ljus vä bak G-lampa broms ljus hö bak G-lampa bak ljus vä bak G-lampa bak ljus hö bak G-lampa bak ljus vä fram (VBFS)

413

H

G-lampa bak ljus hö fram (VBFS)

416

H

G-lampa sidomarkering vä fram

416

H

G-lampa sidomarkering vä bak

417

H

G-lampa sidomarkering hö fram

417

H

G-lampa sidomarkering hö bak

420 421 422

H H H

G-lampa positionsljus vänster G-lampa positionsljus höger G-lampa körvisare vä fram

423

H

G-lampa körvisare hö fram

426

H

G-lampa körvisare vä bak

427

H

G-lampa körvisare hö bak

428 429 431 432 433 434 435 436 437 438 439 440 445

H E E E E E E E E E E E H

G-lampa roterande varningsljus G-lampa cigarettändare belysning G-lampa instrument belysning G-lampa handsfack belysning G-lampa instegs belysning G-lampa innerbelysning G-lampa låsbelysning G-lampa identifikationsljus G-lampa identifikationsljus/takskylt G-lampa motorrumsbelysning Nummerskyltsbelysning G-lampa värmereglage belysning G-lampa körvisare vä (extra)

Light bulb, brake light, right-hand forward Light bulb, brake light, left-hand rear Light bulb, brake light, right-hand rear Light bulb, rear light, left-hand rear Light bulb, rear light right-hand rear Light bulb, rear light, left-hand forward (VBFS) Light bulb, rear light,right-hand forward (VBFS) Light bulb, side position light, left-hand forward Light bulb, side position light, left-hand rear Light bulb, side position light, right -hand forward Light bulb, side position light, right-hand rear Light bulb, position light, left-hand Light bulb, position light, right-hand Light bulb, direction indicator left-hand forward Light bulb, direction indicator right-hand forwrd Light bulb, direction indicator left-hand rear Light bulb, direction indicator right-hand rear Light bulb, flashing beacon lamp Light bulb, cigarett lighter illumination Light bulb, instrument illumination Light bulb, glove pocket light Light bulb, step-in lighting Light bulb, interior lighting Light bulb, reading lighting Light bulb, identification light Light bulb, identification light/roof sign Light bulb, engine compartment light Light license plate Light bulb, heating control light Light bulb, extra direction indicator left

446

H

G-lampa körvisare hö (extra)

Light bulb, extra direction indicator right

2006-05-11

Page 6 of 18

NUMBER CATEG

SVENSKA

ENGLISH

451 452 453

H H H

G-lampa dimbakljus vänster G-lampa dimbakljus höger G-lampa bromsljus/körvisare vänster

453

H

G-lampa bromsljus/körvisare höger

454

H

G-lampa bromsljus blackout vänster

Light bulb, fog light rear left Light bulb, fog light rear right Light bulb, brake light/dir. indicator lefthand Light bulb, brake light/dir. indicator righthand Light bulb, brake light blackout left-hand

454

H

G-lampa bromsljus blackout höger

456

E

G-lampa backljus blackout IR vänster

456

E

G-lampa backljus blackout IR höger

457

H

G-lampa positionsljus blackout vänster

457

H

G-lampa positionsljus blackout höger

458

E

G-lampa fram blackout vänster

458

E

G-lampa fram blackout höger

459

E

G-lampa fram blackout IR vänster

459

E

G-lampa fram blackout IR höger

460

E

460

E

461

E

461

E

462

E

462

E

463

H

G-lampa arb.belysning hytt blackout IR vä G-lampa arb.belysning hytt blackout IR hö G-lampa arb.bel. bom 20' blackout IR vä G-lampa arb.bel. bom 20' blackout IR hö G-lampa arb.bel. bom 40' blackout IR vä G-lampa arb.bel. bom 40' blackout IR hö G-lampa bak ljus vänster bak, blackout

463

H

G-lampa bak ljus höger bak, blackout

464 464

E E

G-lampa cont belysning IR vänster G-lampa cont belysning IR höger

Light bulb, brake light blackout righthand Light bulb, rear light blackout IR lefthand Light bulb, rear light blackout IR righthand Light bulb, position light blackout lefthand Light bulb, position light blackout righthand Light bulb, roading light blackout lefthand Light bulb, roading light blackout righthand Light bulb, roading light blackout IR lefthand Light bulb, roading light blackout IR right hand Light bulb, working light cab blackout IR left Light bulb, working light cab blackout IR right Light bulb, working light boom20' b.out IR left Light bulb, working light boom20' b.out IR right Light bulb, working light boom40' b.out IR left Light bulb, working light boom40' b.out IR right Light bulb, rear light left-hand rear, blackout Light bulb, rear light right-hand rear, blackout Light bulb,Container light IR left-hand Light bulb,Container light IR right-hand

465 466 467 468 500 501

H H H H H

G-lampa röd saxagregat ute G-lampa orange vertikalhålning på G-lampa grön klämtryck OK G-Lampa Röd Maxlast Kont lampa körvisare Kont lampa körvisare (extra)

Light-bulb, red extender exended Light bulb, orange vertical hold on Light bulb, green clamp pressure OK Light bulb,Red Overload Indicating lamp, direction indicator Indicating lamp, direction indicator extra

503 504

H H

Varn lampa oljetryck motor Kont lampa helljus

Warning lamp, oil pressure engine Indicating lamp, main beam

2006-05-11

Page 7 of 18

NUMBER CATEG

SVENSKA

ENGLISH

505 506 507 508 509 510 512 514 519 524 525 528 530

H H H H H H H H H H H H H

Varn lampa laddning Varn lampa laddning (extra) Varn lampa färdbroms Varn lampa parkerings broms Varn lampa nivå kylvatten Kont lampa diff spärr Varn lampa temp momentförst Kont lampa överväxel Kont lampa halvljus Kont lampa luftfilter Kont lampa UNIKAT Kont lampa förvärmning Kont lampa framhjuls styrning

Warning lamp, loading Warning lamp, loading extra Warning lamp, brake Warning lamp, parking brake Warning lamp, coolant level Indicating lamp, diff. interlock Warning lamp, temperature converter Indicating lamp, overdrive clutch Indicating lamp, dipped lights Indicating lamp, air filter Indicating lamp, UNIKAT Indicating lamp, preheating Indicating lamp, forward wheel steering

531 532 533

H H H

Kont lampa 4-hjuls styrning Kont lampa crab styrning Kont lampa hyd.pump

Indicating lamp, 4-wheel steering Indicating lamp, crab steering Indicating lamp, emergency hyd. pump

547 549 550 551 552 554

H H H H H H

Varn lampa centralvarning Varn lampa oljetryck v-låda Varn lampa hyttlåsning Varn lampa temp v-låda Varn lampa bromstryck Varn lampa temp spolkrets bromsar

555

H

Varn lampa temp kylvatten mot

556

H

Varn lampa låsning vändskiva

Warning lamp, central warning Warning lamp, oil pressure gear box Warning lamp, cab lock Warning lamp, temperature gear box Warning lamp, brake pressure Warning lamp, temp. cooling system brakes Warning lamp, temperature coolant engine Warning lamp, interlocking of turntable

560

H

Varn lampa temp drivmotor el

Warning lamp, temperature, drive motor

561

H

Varn lampa temp pumpmotor el

562 563 564 565 569 569 570

H H H H H H H

571 572 573 574 575

H H H H H

Varn lampa öppen twistlock Varn lampa låst twistlock Varn lampa anliggning Varn lampa temp motor el Kont lampa elvärme Kont lampa elvärme Varn lampa överkoppling säkerhetssystem Kont lampa bränslenivå Varningslampa lyfthöjd Kontroll lampa motor information Kontroll lampa stödben nere Kontroll lampa stödben ur arb.läge

Warning lamp, temperature, pump motor Warning lamp, unlocked twist lock Warning lamp, locked twist lock Warning lamp, alignement Warning lamp ,temperature motor Indicating lamp, electric heater Indicating lamp, electric heater Warning lamp, by-pass safety system

576 577 578

H H H

Kontroll lampa anliggning främre ben Kontroll lampa anliggning bakre ben Kontroll lampa klämläge främre ben

Indicating lamp, fuel level Warning lamp lifting height Indicator lamp engine information Indicator lamp support jacks down Indicator lamp support jacks out of working pos Indicator lamp, alignment front legs Indicator lamp, alignment rear legs Indicator lamp, clamp position front legs

579

H

Kontroll lampa klämläge bakre ben

Indicator lamp, clamp position rear legs

2006-05-11

Page 8 of 18

NUMBER CATEG

SVENSKA

ENGLISH

580

H

Kontroll lampa främre ben uppe

Indicator lamp, front legs upper position

581

H

Kontroll lampa främre ben nere

Indicator lamp, front legs lower position

582 583 584 599 600 601 602 603 604 605 606 607 608 609 610 611 612 613 614 615 616 617

H H H H Y Y Y Y Y Y Y Y M M Y Y M Y Y Y Y Y

Varningslampa överlast Kontroll lampa anliggning ett ben Kontroll lampa anliggning alla ben Kont lampa option M-ventil avgasbroms M-ventil diff spärr M-ventil broms M-ventil värme M-ventil kraftuttag sida M-ventil kraftuttag bak M-ventil 2/4 hjulsdrift M-ventil hög/låg växel Pumpaggregat hyttlyft Ställmotor gaspådrag M-ventil hydraulsystem allm M-ventil flödesbegränsning Ställmotor recirkulation M-ventil momentförstärkare M-ventil rangespärr M-ventil hjulvridning M-ventil kallstart M-ventil AT-regulator by-pass

Warning lamp overload Indicator lamp, alignment one leg Indicator lamp, alignment all legs Indicating lamp, option Solenoid valve, exhaust brake Solenoid valve, diff. interlock Solenoid valve, brake Solenoid valve, heater Solenoid valve, power take off, side Solenoid valve, power take off, rear Solenoid valve, 2/4WD Solenoid valve, high/low gear Pump unit, cab hoist Regulating motor, throttle Solenoid valve, hydraulics, general Solenoid valve, flow restriction Regulating motor, re-circulation Solenoid valve, torque amplifier Solenoid valve, ranging interlock Solenoid valve, wheel turning Solenoid valve, cold start aid Solenoid valve, AT-regulator ¿by-pass¿

618 620 621 622 623 624 625 626 627 628 630 631 632 633 634 635 636 637 638 639 640 641 642 643 644 645 646

Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y

M-ventil vatten klimatanläggning M-ventil vändskiva upp M-ventil vändskiva ner M-ventil vändskiva fram M-ventil vändskiva bak M-ventil skevning hö M-ventil skevning vä M-ventil AT-regulator M-ventil vakuum M-ventil bränsleblandning M-ventil v-låda fram M-ventil v-låda back M-ventil v-låda spole 1 M-ventil v-låda spole 2 M-ventil v-låda spole 3 M-ventil klämtryck M-ventil styrning M-ventil flytläge skevning M-ventil stopp insprut pump M-ventil låsning orbitrol ls M-ventil gasol M-ventil förångare (LPG) M-ventil park broms M-ventil låsning stol (VBFS) M-ventil låsning vändskiva Magnetkoppling komp AC M-ventil stolsvändning

Solenoid valve, water air conditioner Solenoid valve, fifth wheel up Solenoid valve, fifth wheel down Solenoid valve, fifth wheel forward Solenoid valve, fifth wheel rear Solenoid valve, levelling right hand Solenoid valve, levelling left hand Solenoid valve, AT-regulator Solenoid valve vacuum Solenoid valve fuelmixture Solenoid valve, gear box, forward gear Solenoid valve, gear box, rear gear Solenoid valve, gear box, 1 gear Solenoid valve, gear box, 2 gear Solenoid valve, gear box, 3 gear Solenoid valve, clamping pressure Solenoid valve, steering Solenoid valve, equalizing fifth wheel Solenoid valve, stop injection pump Solenoid valve, locking LS orbitrol Solenoid valve, LPG Solenoid valve, evaporator (LPG) Solenoid valve, parking brake Solenoid valve, seat locking (VBFS) Solenoid valve, fifth wheel locking Magnetic clutch, compressor AC Solenoid valve, seat rotation

2006-05-11

Page 9 of 18

NUMBER CATEG

SVENSKA

ENGLISH

647 648 649 650 650 650 650 651 652 653 654 655 656 657 658 659 660 661 662 663 664 665 666 667 668 669 670 671 672 673 674 675 676 685 690 693 694 695 696 697 698 699 700 701 702 703 704 705 706 707 708 709 710 711

M-ventil stolstilt M-ventil luftfjädring Termostat klimatannläggning Torkarmotor fram Torkarmotor fram Torkarmotor fram Torkarmotor fram Vindrutespolarmotor Strålkastarmotor Strålkastarspolarmotor Startmotor Kylfläkt drivmotor (EC) Kylfläkt elskåp (EC) Fläktmotor värme Generator (extra) Generator utan laddregulator Generator med laddregulator Fönsterhissmotor Laddregulator Doseringspump klimatanläggning Cirk pump klimatanläggning Diod Fläktmotor cirkulation Cirkulationspump värmesystem Kylfläkt hydraulolja Värmare kupe/ motor diesel Kompressor Doseringspump diesel Spjäll motor, ECC Vatten ventil motor, ECC Kylfläkt bromsolja Motor, Stolsvändning Solenoid Broms stolsvändning Reglerenhet termostat AC Fartreglage (EC) Pump centralsmörjning Styrmotor Drivmotor (EC) Pumpaggregate nödstyrning Elbroms Pumpmotor (EC) M-ventil option Hastighetsmätare Mätare oljetemp v-låda Klocka Varvtalsmätare Tryckluftsmätare Mätare oljetryck v-låda Termometer temp kylvätska motor Bränslemätare Timräknare Kapacitetsmätare batteri Tidur motor/kupevärmare Räknare, impuls

Solenoid valve, seat tilt Solenoid valve, pneumatic springing Thermostat, air condition

2006-05-11

Y Y B M M M M M M M M M M M G G G M G M M V M M M E M M M Y M M Y A B M M M M B M Y P P P P P P P P P P P P

Page 10 of 18

Washer motor Light motor Light washer motor Starter motor Cooling fan, main motor (EC) Cooling fan, electrical box (EC) Heating fan Alternator extra Alternator without loading regulator Alternator with loading regulator Screenelevator motor Loading regulator Dosage pump, air condition Circulating pump, air condition Diode Circulation fan Circulation pump heating system Cooling fan, hydraulic oil Heater compartment/engine diesel Compressor Dosage pump diesel Draught valve motor, ECC Water valve motor, ECC Cooling fan, brake fluid Motor, Seat rotation Solenoid brake , seat rotation Control unit, termostat AC Speed control (EC) Pump, central lubrication Steering motor Drive motor (EC) Pump, emergency steering Electric brake Pump motor (EC) Solenoid valve, option Speedometer Gear box oil temperature gauge Clock Engine rev meter Air pressure gauge Gear box oil pressure gauge Temperature gauge, engine coolant Fuel gauge Hour meter Capacity gauge, battery Timer, engine- and cab heater Counter, impulse

NUMBER CATEG

SVENSKA

ENGLISH

712 714 715 720

P P P S

Mätare oljetryck motor Mätare, temp. Hydraulolja Extra instrument allm Givare vändbar förarstol

740 741 742 743 751 752

D U D D B B

FleetManager kontrollenhet FleetManager batterifilter FleetManager kortläsare FleetManager accelerations givare Givare varvtal turbin Givare varvtal inre växellåda

Motor oil pressure gauge Hydraulic fluidtemperature, guage Extra instrument, general Transmitter, revolving driver´s seat (VBFS) FleetManager control unit FleetManager battery filter FleetManager card device FleetManager acceleration sensor Transmitter, speed turbin Transmitter, speed internal gear chain

753 754 755

B B B

Varvtalsgivare motor Givare lufttryck Givare hydraulfilter indikering

Transmitter, engine revolution Transmitter, air pressure Transmitter, hydraulics filter indication

756

B

Temperatur kylvätska motor

Transmitter, engine coolant temperature

757 758 759 760

B B B B

Bränslenivågivare Varvtalsgivare v-låda Nivåindikator kylvätska Givare rev-spärr/aut-vxl trans

761

B

Givare rev-spärr/aut-vxl motor

762 763 764 765 766 767 768 769 770 771 772 773 774 775 776 777 778 779 780 781 782

B B B B B B B B B B B B B B B B B A A A A

Givare temp,spolkrets bromsar Givare nivå hydraulolja Givare servotryck växellåda Givare oljetryck v-låda Givare oljetemp. v-låda Givare oljetryck motor Givare oljetryck hydraulik Givare ändläge Givare rattutslag Givare vinkel Givare temp bromsolja Givare närvaro Givare utomhustemp Givare temp klimatanläggning Givare temp hydraulolja Givare läge Givare drivbrytning Reglersystem återladdning (EC) Reglersystem åkmotor (EC) Reglersystem pumpmotor (EC) Logik interface 2 drivmotorer

Transmitter, fuel level Transmitter, gear box revolution Transmitter, coolant level Transmitter, reversing interlock / automatic gear change system (on gearbox output shaft) Transmitter, reversing interlock / automatic gear changing system (engine speed) Transmitter, brake flushing circuit Transmitter, hydraulic fluid level Transmitter, gear box servo pressure Transmitter, oil pressure gear box Transmitter, oil temperature gear box Transmitter, oil pressure engine Transmitter, hydraulic pressure Transmitter, end position Transmitter, steering wheel angle Transmitter, angle Transmitter, temperature brake fluid Transmitter, presence Transmitter, ambient temperature Transmitter, temperature air condition Transmitter, hydraulic temperature Transmitter, position Transmitter, drive break Control system, recharging (EC) Control system main motor (EC) Control system pump motor (EC) Logic (interface) two main motors (EC)

783 784 785 786 789

A A A A B

Logik interface gaspådrag Logik interface bromsregl Logik interface styrsystem Servoförstärkare styrsystem Givare allmän

Logic (interface) throttle Logic (interface) brake control Logic (interface) control system Servo amplifier steering system Transmitter, common

2006-05-11

Page 11 of 18

NUMBER CATEG

SVENSKA

ENGLISH

790 791 792

D D D

Elektronisk kontrollenhet ECU, hytt Elektronisk kontrollenhet aggregat Elektronisk kontrollenhet styrning

Electronic Control Unit ECU, cab Electronic Control Unit, attachment Electronic Control Unit, steering system

793 794 795 796

D D P D

Elektronisk kontrollenhet växellåda Elektronisk kontrollenhet motor Display Elektronisk kontrollenhet, lasthantering

Electronic Control Unit, gearbox Electronic Control Unit, engine Display Electronic Control Unit, Loadhandling

797 798

D D

Elektronisk kontrollenhet, ram Electronic Control Unit, frame Elektronisk kontrollenhet, stolvändning Electronic Control Unit, seat rotation

799 800 802 803 804 805 806 807 808 810 815 820 821 822 823 824 825

A S E E E E A R E A S R C Z U U R

Logik allm (option) Startelement Eluppvärmd backspegel Eluppvärmd stol Cigarettändare Elvärme hytt Aggregat klimatanläggning Potentiometer Eluppvärmd lufttorkare Kondensor AC, fläkt Manöverspak Motstånd KONDENSATOR Signalfilter Signalomvandlare höger Signalomvandlare vänster Reglage spakstyrning

Logic, general (option) Start element Electrical heated observation mirror Electrical heated seat Cigarett lighter Electrical heating cab Aggregate, air conditioner Potentiometer Electrical heater air dryer Condensor AC, fan Control lever Resistor CAPACITOR Signal filter Signal amplifier, right Signal amplifier, left Controls, (steering with control levers).

826 827 828 830 835 840 850 853 888 900 901 902 903 905 906 907 908 909 910 911 940 941 950 955

Y A R L E S H H E A U B W A W A A A U A A U A A

Ventil spakstyrning Växellåda Shuntmotstånd Tändspole Tändstift Strömfördelare Signalhorn Summer Lufttork, kompressor Radio/bandspelare Spänningsomvandlare Högtalare Antenn radio Kommunikationsradio Antenn kommunikationsradio Monitor Kamera Skrivare Spänningsomvandlare 80V/24V Dataterminal Logik batterivakt Laddningsutjämnare Logik transistortändning Logik övervarvningsskydd (LPG)

Valve, (steering with control levers). Gearbox Shunt-resitor Ignition coil Ignition plug Distributor Horn Buzzer Air Dryer, Compressor Radio/tape recorder Voltage converter Loud speaker Aerial, radio Communication radio Aerial, communication radio Monitor Camera Printer Voltage converter 80 V / 24 V Dataterminal Logic switch , battery watch Even charger Logic transistor ignition Logic overspeed protection (LPG)

2006-05-11

Page 12 of 18

NUMBER CATEG

SVENSKA

ENGLISH

960

A

Logik rev-spärr/aut-vxl

961 962

A E

Motor/kupevärmare Logik slitageind kol elmotor

965 1001 1002 1003 1004 1005

H S S S S S

1006 1007 1008 1009 1010 1011 1012 1013 1014

S S S S S S S S S

1015

S

Backvarnare Strömställare, TW Strömställare, lossa TW Strömställare, låsa TW Strömställare, stopp vid 30'-35' Strömställare, förbikoppling av säkerhetssystem Strömställare, fällning främre ben Strömställare, fällning bakre ben Strömställare, klämma/lossa ben Strömställare, Motor information Srömställare, tilt av hytt Strömställare IR ljus Strömställare utskjut 20¿-40¿ Strömställare stödben Strömställare förbikoppling rotationstopp Strömställare förbikoppling höjdbeg/tpbeg

Logic unit, reversing interlock/automatic gear changing Engine- and cab heater Logic indication of wear, brush electrical motor Reversing alarm Switch, TW Switch, unlocking of TW Switch, locking of TW Switch, stop at 30 -35¿ Switch, overriding of the safety system

1016 1017

S

Strömställare diagnostik öka/minska

Switch, diagnostics increase/decrease

1018 1019 1020

S S S

1021 1022 1023 1024 1025 1026

S S S S S S

Switch, diagnostics on/off Switch, paus heat Switch automatic release/clamp funktion Switch extender Switch, vertical position Switch, lock upper arm Switch, Short Arm on/off Switch, paper funktions on/off Switch, switch papper/bale clamp

1027 1028 1029 1030

S S S S

1031 1032 1033 1034 1035 1036 1037 1038 1039 1040 1041

S S S S S S S S S S S

Strömställare diagnostik on/off Strömställare rastvärme Strömställare automatisk släpp/kläm funktion Strömställare sax Strömställare vertikalhållning Strömställare låsning övre arm Strömställare Korta Armen av/på Strömställare pappersfunktioner av/på Strömställare omkoppling pappers/klämmagregat Strömställare lyfthöjdsförval Strömställare lyfthöjdsförval öka Strömställare lyfthöjdsförval minska Strömställare läraringång givare ultraljud Strömställare, Over Height Upp/Ned Brytare backljus Flytta korta armen Strömställare förbikoppling startspärr Strömställare Val av klämtryck Strömställare Korta Armen av/på Strömställare låsning skevning Strömställare Övre armpar/Sidoföring Strömställare Inching Switch stopp motor Strömställare motorrumsbelysning

2006-05-11

Page 13 of 18

Switch, front legs down Switch, rear legs down Switch, clamping/-releasing legs Switch, Engine information Switch, tilt of cab Switch IR light Switch, Extension 20¿-40¿ Switch, Support jacks Switch, over ride rotation stop Switch, over ride height limit/tp-limit

Switch, lift height selection Switch, lift height selection increase Switch, lift height selection decrease Switch, teaching ultrasonic sensor Switch, Over Height Up/Down Switch reverse light. Move short arm Switch Override Start interlock Switch, Clamp pressure selection Switch , Short Arm on/off Switch, lock levelling Switch Upper arms/Sideshift Switch, Inching Switch, Stop engine Switch, light engine compartment

NUMBER CATEG

SVENSKA

ENGLISH

1042 1043 1044 1045 2000

S S S S D

Switch, Seat height level Switch, Seat for/aft adjustment Switch, Tankselector Switch, Rev. Alarm on/off Electronic control unit, propotional valve

3001 3002 3003 3004 3005 3006 3007 3008 3009 3010 3011

K K K K K K K K K K K

Strömställare höjdjustering stol Strömställare längdjustering stol Strömställare Tankväljare Strömställare Avstängning backalarm Elektronisk kontrollenhet, proportionalventil Relä rotation Relä tilt Relä sidoföring Relä längdinställning Relä twist lock Relä spridning Relä lyft/sänk Relä hydraulfunktion extra Relä manöverbrytare hydr Relä bromsljus vxl std/blackout Relä backljus vxl std/blackout

3012

K

Relä arb.bel hytt vxl std/blackout

3013

K

Relä arb.bel. bom 20' vxl std/blackout

3014

K

Relä arb.bel. bom 40' vxl std/blackout

3015

K

Relä vxl bromsljus/blinkers vä

3015

K

Relä vxl bromsljus/blinkers hö

3016 3017 3018 3305

K K K K

Relä signalhorn Relä containerbelysning Relä containerbelysning IR Relä VBFS, backljus

3306

K

Relä VBFS, helljus

3307

K

Relä VBFS, halvljus

3308

K

Relä VBFS, bromsljus

3310

K

Relä VBFS, körvisare vä

3311

K

Relä VBFS, körvisare hö

3330 3331

K K

Relä, säkerhetsbälte Relä VBFS, drivning fram

3332

K

Relä VBFS, drivning bak

3349

K

Relä VBFS, fartreglage

3404

K

Relä VBFS, mastljus

Relay, rotating driver´s seat, direction indicator left Relay, rotating driver´s seat, direction indicator right Relay, seat belt Relay, rotating driver´s seat, forward driving Relay, rotating driver´s seat, reversing driving Relay, rotating driver´s seat, speed control Relay, rotating driver´s seat, mast light

3412 3768

K K

Relä bak ljus Relä oljetryck hydraulik

Relay, rotating driver´s seat, rear light Relay, hydraulic pressure

2006-05-11

Relay, rotation Relay, tilt Relay, side shifting Relay, length adjustment Relay, twist lock Relay, spreading Relay, lifting/lowering Relay, extra hydraulic function Relay, operating switch Relay, brake light shift std/blackout Relay, reversing light shift std/blackout Relay, working light cab, shift std/blackout Relay,working light boom20' shift std/b.out Relay,working light boom40' shift std/b.out Relay, shift brake light/direction indicator left Relay, shift brake light/direction indicator right relay, horn Relay, Container light Relay, Container light IR Relay, rotating driver´s seat, reversing light Relay, rotating driver´s seat, main beam Relay, rotating driver´s seat, dipped beam Relay, rotating driver´s seat, brake light

Page 14 of 18

NUMBER CATEG

SVENSKA

ENGLISH

3769 3770 3771 3772 3773 3774 3775 5000 5001

K K K K K

Relä, blockering av hyttilt Relä anliggning Relä Krok Relä laddsignal (D+) Relä 12V för minne radio Relä kylfläkt olja

Relay, blocking of cab tilt Relay, alignment Relay, Hook Relay, charge signal (D+) Relay 12V for radio memory Relay, cooling fan oil

H H

Kont lampa tryck lyfttång Varn lampa, Over Height ben uppe

Indicating lamp, pressure lift tong Warn. Lamp, Over Height leg upper pos

6001 6002 6003

Y Y Y

6004 6005 6006 6007 6008 6009

Y Y Y Y Y Y

M-ventil blockering höger M-ventil blockering vänster M-ventil inkoppling av hydraulik till topplyft M-ventil sänk M-ventil lyft M-ventil bom ut M-ventil bom in M-ventil vridning medsols M-ventil vridning motsols

6010 6011 6012 6013 6014 6015

Y Y Y Y Y Y

M-ventil tilt ut M-ventil tilt in M-ventil tilt M-ventil fällning främre ben M-ventil fällning bakre ben M-ventil klämma/lossa ben

Solenoid valve, blocking right Solenoid valve, blocking left Solenoid valve, activation of toplift hydraulics Solenoid valve, lower Solenoid valve, lift Solenoid valve, boom out Solenoid valve, boom in Solenoid valve, rotation clockwise Solenoid valve, rotation counterclockwise Solenoid valve, tilt out Solenoid valve, tilt in Solenoid valve, tilt Solenoid valve, lowering front legs Solenoid valve, lowering rear legs Solenoid valve, clamping/releasing legs

6016

Y

M-ventil Hyttskjutning fram

Solenoid valve, cab movement forward

6017

Y

M-ventil Hyttskjutning bak

Solenoid valve, cab movement reverse

6018 6019 6020 6021 6022

Y Y Y Y Y

M-ventil spridning ut M-ventil spridning in M-ventil sidoföring vänster M-ventil sidoföring höger M-ventil extra hydraulfunktion ut

6023

Y

6024 6025 6026

Y Y Y

6027

Y

6028

Y

6029

Y

6030

Y

6031

Y

2006-05-11

Solenoid valve, spreading out Solenoid valve, spreading in Solenoid valve, side shift left Solenoid valve, side shift right Solenoid valve, extra hydraulic function out M-ventil extra hydraulfunktion in Solenoid valve, extra hydraulic function in M-ventil stativ ut Solenoid valve, mast out M-ventil stativ in Solenoid valve, mast in M-ventil höger framhjul styrning vänster Solenoid valve, right front wheel, steering left M-ventil höger framhjul styrning höger Solenoid valve, right front wheel, steering right M-ventil vänster framhjul styrning Solenoid valve, left front wheel, steering vänster left M-ventil vänster framhjul styrning höger Solenoid valve, left front wheel, steering right M-ventil höger bakhjul styrning vänster Solenoid valve, right rear wheel, steering left M-ventil höger bakhjul styrning höger Solenoid valve, right rear wheel, steering right Page 15 of 18

NUMBER CATEG

SVENSKA

6032

Y

6033

Y

6034 6035 6036 6037 6038 6039 6040 6041 6042 6043

Y Y Y Y Y Y Y Y Y Y

M-ventil vänster bakhjul styrning vänster Solenoid valve, left rear wheel, steering left M-ventil vänster bakhjul styrning höger Solenoid valve, left rear wheel, steering right M-ventil skevning Solenoid valve, levelling M-ventil skevning höger Solenoid valve, levelling right M-ventil skevning vänster Solenoid valve, levelling left M-ventil kylfläkt Solenoid valve, Cooling fan M-ventil frikoppling koppling Solenoid valve, lockup clutch M-ventil öppna twistlock Solenoid valve, unlocked twist lock M-ventil låsa twistlock Solenoid valve, locked twist lock M-ventil nöd, twistlock Solenoid valve, emergency, twistlock M-ventil mellan bom Solenoid valve, middle boom Magnetventil, fällning torn (RTCH) Solenoid valve, boom lowering (RTCH)

6044 6045 6046 6047 6048 6049 6050 6051 6052 6053 6054 6055 6056 6057 6058 6059 6060 6061 6062

Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y

M-ventil blockering twistlock M-ventil blockering lyft M-ventil utskjut M-ventil, hyttilt upp M-ventil, hyttilt ner M-ventil, kylkrets broms M-ventil blockering utskjut M-ventil, regenerering höger M-ventil, regenerering vänster M-ventil, körläge M-ventil, klämma ihop M-ventil, klämma isär M-ventil, främre knä ut M-ventil, främre knä in M-ventil, bakre knä ut M-ventil, bakre knä in M-ventil, främre ben upp M-ventil, bakre ben upp M-ventil, urkoppling hydraulpump

6063 6064 6065 6066 6067

Y Y Y Y Y

6068 6069

Y Y

6070 6071 6072 6073 6074

Y Y Y Y Y

6075

Y

6076 6077

Y Y

2006-05-11

ENGLISH

Solenoid valve, blocking twistlock Solenoid valve, blocking lift Solenoid valve, projecting Solenoid valve, cab tilt up Solenoid valve, cab tilt down Solenoid valve, cooling cicuit brake Solenoid valve, blocking projecting Solenoid valve, regeneration right Solenoid valve, regeneration left Solenoid valve, driving position Solenoid valve, clambing in Solenoid valve, clambing out Solenoid valve, front knee out Solenoid valve, front knee in Solenoid valve, rear knee out Solenoid valve, rear knee in Solenoid valve, front legs up Solenoid valve, rear legs up Solenoid valve interruption hydraulic pump M-ventil, stödben upp Solenoid valve, brace up M-ventil, stödben ner Solenoid valve, brace down M-ventil, frikoppling vridbroms Solenoid valve, lockup rotation brake M-ventil, v-låda, drivning Solenoid valve, gearbox, drive M-ventil, v-låda, oljetryck till 1:a/3:e Solenoid valve, gearbox,oilpressure to växeln 1st/3rd gear M-ventil sax/rotation Solenoid valve externder/rotation M-ventil, v-låda, oljetryck till 2:a/4:e Solenoid valve, gearbox,oilpressure to växeln 2nd/4th gear M-ventil Over Height upp Solenoid valve, Over Height up M-ventil Over Height ner Solenoid valve, Over Height down M-ventil klämtryck Solenoid valve clamp pressure Propertional ventil, Opti speed Proportional valve, Opti speed M-ventil, v-låda, växelväljare för 2:a/4:e Solenoid valve, gearbox, gearswitch for växeln 2nd/4th gear M-ventil, v-låda, växelväljare för 1:a/3:e Solenoid valve, gearbox, gearswitch for växeln 1st/3rd gear M-ventil blockering sänk Solenoid valve, blocking lower M-ventil Inching Solenoid valve, Inching Page 16 of 18

NUMBER CATEG

SVENSKA

ENGLISH

6078 6079 6080 7200 7201 7202 7202 7203 7203 7204 7204 7205 7205 7206 7207 7208 7209 7210

Y Y Y S S S S S S S S S S S S S S S

M-ventil,Avstängning Övre klämarm M-Ventil, Sidoföring/Övre armar M-ventil, aktivering hyttkörning Givare, axeltryck höger Givare, axeltryck vänster Givare, anliggning vänster fram Givare, anliggning höger fram Givare, anliggning vänster bak Givare, anliggning höger bak Givare, öppen vänster twistlock Givare, öppen höger twistlock Givare, låst vänster twistlock Givare, låst höger twistlock Givare, gaffel aggregat Givare, 2WD/4WD Givare, hytt i körläge Givare, oljefilter indikering Givare, hytt i transportläge

Solenoid valve, upper arm off Solenoid valve, Sideshift/Upper arms Solenoid valve, activate sliding cab Sensor, axle pressure right Sensor, axle pressure left Sensor, alignment left front Sensor, alignment right front Sensor, alignment left rear Sensor, alignment right rear Sensor, unlocked twistlock left Sensor, unlocked twistlock right Sensor, locked twistlock left Sensor, locked twistlock right Sensor, fork attachment Sensor, 2WD/4WD Sensor, Cab in drive position Sensor, Oil filter indication Sensor, Cab in transportation position

7211 7212 7213 7214 7215 7216 7217 7218 7219 7220 7221 7222 7223 7224 7225 7226 7227 7228 7229 7230 7231

S S S S S S S S S S S S S B B B B B B B B

Givare, lyfthöjd Givare, körläge Givare, Anliggning främre ben Givare, Anliggning bakre ben Givare, kläm främre ben Givare, kläm bakre ben Givare, främnre knä Givare, bakre knä Givare, främre ben Givare, bakre ben Givare, styraxel Givare, stödben uppe Givare, stödben nere Givare, mätläge våg Givare, rotationsstopp Givare, tryck lyftcylinder Givare, tryck klämma Givare lyfthöjd analog Givare tiltvinkel analog Givare ultraljud last position Givare, Over Height, Ben uppe

Sensor, lifting height Sensor, driving position Sensor, Alignment front legs Sensor, Alignment rear legs Sensor, Clamp front legs Sensor, Clamp rear legs Sensor, front knee Sensor, rear knee Sensor, front legs Sensor, rear legs Sensor, steering axle Sensor, brace up Sensor, brace down Sensor, measurepoint scale Sensor, rotation stop Sensor, pressure lift cylinder Sensor, pressure clamp Sensor lift height analogue Sensor tilt angle analogue Sensor, ultrasonic load position Sensor, Over Height, Leg upper position

7232 7233 7234 8071 8072 8073 8074 8075 8076 8077 8078 8079 8080

B B B R R R R R R R R R R

Givare,IR Last position Givare lambda sond Givare vatten i bränsle Potentiometer lyft/sänk Potentiometer tilt Potentiometer sidoföring Potentiometer spridning Potentiometer extra Potentiometer mast in/ut Potentiometer höger framhjul Potentiometer vänster framhjul Potentiometer höger bakhjul Potentiometer vänster bakhjul

Givare,IR Load position Sensor lambda sond Transmitter water in fuel Potentiometer lift/lower Potentiometer tilt Potentiometer side shifting Potentiometer spreading Potentiometer extra Potentiometer reach in/out Potentiometer right front wheel Potentiometer left front wheel Potentiometer right rear wheel Potentiometer left rear wheel

2006-05-11

Page 17 of 18

NUMBER CATEG

SVENSKA

ENGLISH

8081 8082 8083 8084 8085 8086 8087 8088 8089 8090 8091 9000 9001 9002 9003 9888 93774

R R R R R R R R R V

Potentiometer tiltvinkel Potentiometer fläkthastighet, ECC Potentiometer temperatur, ECC Potentiometer spjäll, ECC Potentiometer rotation Potentiometer sax Potentiometer klämma Potentiometer skevning Potentiometer kroklåsning Laser, pappersaggretgat

Potentiometer tilt angle Potentiometer fan speed, ECC Potentiometer temperature, ECC Potentiometer draught valve, ECC Potentiometer rotation Potentiometer extender Potentiometer clamp Potentiometer levelling Potentiometer flaps Lase, Pulp an Paper

M D

Motor höj/sänkbar stolspelare Åkerströms fjärrkontroll

Motor rise/lower seat column Åkerströms Remote Control

H A K

Varningssignal aut. rörelse test Relä hållkrets

Warning alarm aut. movement

2006-05-11

Page 18 of 18

Relay, Holdcircuit

DCE80-100 Technical Handbook

Contents

Group 30

TDCE01 04GB P. 1

Group 30 Volvo TWD731VE

Specifications..............................................................2 Engine TWD731VE.....................................................3 Description ............................................................. 3 Overview...........................................................3 Cooling system .................................................5 Fuel system.......................................................7 Lubrication system..........................................10 Combustion air system ...................................12 Service ................................................................. 14 Coolant quality ................................................ 14 Lubrication oil quality ......................................14 Draining the water from the fuel tank............. .14 Inspection of air cleaner and changing insert .14 Changing the oil and oil filter ..........................15 Checking V-belt tension..................................15 Checking and adjusting the valve clearances.16 Changing the fuel filter....................................16 Preventive maintenance on turbo-charger......17

Volvo TAD720VE

Specifications............................................................19 Engine TWD1031VE/TWD1231VE ...........................20 Description ........................................................... 20 Overview.........................................................20 Cooling system ...............................................22 Fuel system.....................................................24 Lubrication system..........................................26 Combustion air system ...................................28 Service ................................................................. 30 Coolant quality ................................................ 30 Lubrication oil quality ......................................30 Draining the water from the fuel tank............. .30 Inspection of air cleaner and changing insert .30 Changing the oil and oil filter ..........................31 Checking V-belt tension..................................31 Checking and adjusting the valve clearances.32 Changing the fuel filter....................................33 Preventive maintenance on turbo-charger......34

Cummins QSB5.9 See also Cummins Operation and Maintenance Manual Specifications........................................................... 36 Engine QSB 5.9 ....................................................... 37 Description.......................................................... 37 Overview........................................................ 37 Cooling system .............................................. 39 Fuel system ................................................... 40 Lubrication system......................................... 41 Combustion air system .................................. 42 Service ................................................................ 44 Coolant quality............................................... 44 Lubrication oil quality ..................................... 44 Draining the water from the fuel tank............. 44 Inspection of air cleaner and changing insert 44 Changing the oil and oil filter ........................ 45 Checking V-belt tension................................. 45 Checking and adjusting the valve clearances 46 Changing the fuel filter................................... 47 Preventive maintenance on turbo-charger .... 48

DCE80-100 Technical Handbook

Contents

Group 30

TDCE01 04GB P. 2

DCE80-100E

Specifications

Technical Handbook

Group 30

Manufacturer, type

Volvo TWD731VE

Coolant volume, l

41

Rating ISO 3046 kW (Hk) at r/min

167 (227) 2200

Torque ISO 3046, Nm at r/minl

893 1300-1450

Number of cylinders

6

Swept volume, l

6.73

Valve clearance, engine cold inlet, mm exhaust, mm

0.40 0.55

Idle speed, r/min (adjust so that the engine runs smoothly)

650±25

Injection pump, timing

10°±0.5° BTDC

Thermostat, starts to open at °C fully open at °C

75 88

Lubricating oil filter Lubricating oil pressure, kPa running speed idling speed

TDCE01 04GB P. 2

Full flow, disposable paper element with by-pass valve 300–500 min 150

Lubricating oil grade viscosity

See Group 90

Volume, l

19


Engine TWD731VE Description

Group 30

TDCE01 04GB P. 3

Overview The TWD731VE engine is a 6-cylinder, inline, 4-stroke, low emission diesel engine with overhead valves. The engine is turbocharged, i.e. combustion air is supplied under pressure. As a result, the quantity of fuel injected can be increased, which increases the engine output. The turbocharger is driven by the exhaust gases and uses energy that would otherwise be lost. In order to further increase the engine efficiency, the engine is equipped with a water to air intercooler. The engine is pressure-lubricated by an oil pump which delivers oil to all lubrication points. A full-flow oil filter effectively cleans the lubricating oil. The fuel system is protected against impur ities by replaceable filters. The engine has replaceable wet cylinder liners and two cylinder heads, each covering three cylinders. The low emission engine has a new design of combustion chamber, injection equipment and charge air cooler (intercooler) which satisfy future emission requirements from both the USA (California) and Europe. The new engines represent a considerable improvement, not only in terms of exhaust gas emissions, but also in terms of power and torque curves. In addition, all Volvo engines comply with the R24 exhaust smoke requirements.



Grou Group p 30

TDCE01 04GB P. 4

TWD731VE 1. Fan hub 2. Gear Gear driv driven en cool coolant ant pump pump 3. Lift Lift eyel eyelet et 4. Twin fuel fuel filters filters of throw-a throw-away way type 5. Turbo urbo-c -cha harg rger er 6. Air cool cooled ed exhau exhaust st mani manifol fold d 7. Lift Lift eyel eyelet et 8. Cool Coolan antt pipe pipe,, inle inlett 9. Pump Pump cou coupl plin ing g guard guard 10. Smoke Smoke limiter 11. Oil cooler cooler 12. Fuel shut-off shut-off valve 13. Injection Injection pump 14. Relay for inlet manifold heater 15. Cable iron 16. 16. 17. Coolant Coolant pipe, outlet 18. Flywheel housing housing SAE 2 (Adaptor for SAE3) 19. Starter Starter motor motor 20. Crankcase ventilation 21. Full-flow filter of spin-on type 22. By-pass filter of spin-on type 23. Vibration damper 24. Automatic belt tensioner 25. Intercoole Intercoolerr

1

2

3

8

25

4

9

10 14

18

6

5

11

12

15

7

13 17

 

19 20

21

22

23

24

E ng ine Volvo Volvo TWD731VE



Grou Group p 30

TDCE01 04GB P. 5

Cooling system The engine is liquid-cooled and equipped with a closed cooling system consisting of the following main components:  Coolant pump  Radiator  Expansion tank  Thermostat Radiator fan  Coolant passages  Engine oil cooler  Gearbox oil cooler The coolant flows through a longitudinal passage into the engine block. The opening into the cooling jacket of each cylinder is individually sized to ensure that each cylinder will be supplied with the same rate of coolant flow. The coolant flows in the separate return lines converge into a common pipe in the thermostat housing. The coolant then flows to the coolant pump and then into the engine and t o the oil cooler. When the engine has reached its normal operating temperature, the thermostat will open the circuit to the radiator. The piston-type thermostat is capable of passing a high coolant flow rate at a minimum of pressure drop, thus contributing to favourable coolant circulation in the engine. The coolant pump is fitted on the transmission cover and is driven by a gear wheel from the transmission wheel. The intercooler is connected to the cooling system by a pipe f rom the coolant pump. The outlet from the intercooler is connected to the oil cooler. 

1. 2. 3. 4. 5. 6.

Fill Fille er cap cap Pipe thermos thermostat tat housing housing-- upper expa expansion nsion tank tank Pist Piston on ther thermo most stat at Distri Distribut bution ion chann channel el Cyli Cylind nder er hea head d Oil coole ooler r

7. Cyli Cylind nder er linin lining g 8. Cool Coolan antt pum pump p 9. Pipe to the the suction suction side side of of the pump 10. Radiator Radiator 11. Intercooler Intercooler



Grou Group p 30

TDCE01 04GB P. 6

The cooling system is equipped with a sensor which activates the ”Low coolant level” warning lamp on the instrument panel. The engine lubricating oil is cooled efficiently and reliably in a plate oil cooler that requires no external pipes on the engine. The gearbox oil is also cooled by the engine coolant, but in a separate shell-and-tube cooler.

Thermostat function during heating-up period

Thermostat function, full coolant circulation



Grou Group p 30

TDCE01 04GB P. 7

Fuel system The fuel circulates in two circuits - the high-pressure circuit and the low-pressure circuit. When the engine is started, the feed pump draws fuel from the tank and delivers it at relatively low pressure through fine filters up to the injection pump. This then delivers fuel at high pressure to the injectors which supp ly the fuel in atomised form to the engine combustion chambers. Excess fuel which is circulated in the low-pressure system is also cleaned in the fine filters and is returned through a spill valve back to the tank. The fuel system includes the following components: Fuel tank tank - a separate unit located on the left-hand side of the truck. The fuel volume in the tank can be read on a gauge on the instrument panel. Feed pump pump - of piston type, supplies fuel at a certain pressure and flow rate to the injection pump. Spill valve valve - which restricts the fuel feed pressure and provides continuous venting of the fuel system. Excess fuel flows through the injection pump before returning to the tank, thus cooling the fuel in the fuel chamber of the pump, which contributes to more uniform distribution of the fuel to the various cylinders. . See diagram below

Normal operation

8

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

Coar Coarse se fil filte ter r Fuel Fuel shu shutt off off valv valve e Feed Feeder er pump pump Fine ine filt filter er Fuel uel tank ank Chec Check k valv valve e IInj IInjec ecti tion on pump pump Over Overfl flow ow valv valve e

Shut down

8

Fuel s ys tem, tem, sc hema hematic



Grou Group p 30

TDCE01 04GB P. 8

Fuel shut off valve At normal operation, the solenoid in the shut off valve is activated and fuel is fed to the injection pump. When the starting key is turned to 0, the solenoid valve is deactivated and the flow is reversed. Thereby the feeder pump drains the fuel from the injection pump resulting in engine shut down. The check valve prevents return fuel from flowing into the injection pump.

Shut down

T. F. P. I.

Normal operation

Inlet Inlet from from fuel fuel tank tank Outlet Outlet to to fuel fuel pump pump Inlet Inlet from from fuel fuel filter filter Outle Outlett to inje inject ctio ion n pump pump

Fuel Fu el s hut off valve



Grou Group p 30

TDCE01 04GB P. 9

Fuel filters filters - two filters connected in parallel and with a common cover. The filters are of disposable type, with the filter elements made of spirally wound paper.

Fuel fi lter lter

Injectors Injectors - each with a nozzle holder and a nozzle. When the fuel pressure has risen to the preset value, the needle will lift and atomised fuel will be injected into the combustion chamber through accurately calibrated holes in the nozzle sleeve.

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

Supply Supply pipe pipe coupl coupling ing Spill fuel fuel pipe pipe conn connect ection ion Spacers pacers for adjust adjusting ing the opening opening press pressure ure Comp Compre ress ssio ion n spri spring ng Thrus hrustt pin pin Nozz Nozzle le sle sleev eve e Needle

Injector



Group 30

TDCE01 04GB P. 10

Lubricating system The engine is pressure-lubricated, and the oil is supplied by a pump in the oil sump. All lubricating oil flows through a full-flow filter. One part of the oil flows through a by-pass filter for separation of extremely small particles. The lubricating oil is cooled in a plate oil cooler by the engine coolant. The lubricating system includes the following main components: Oil pump - of gear type, which draws oil through a coarse strainer that arrests larger particles. The pump delivers oil through the lubricating oil filters to the various passages of the lubricating system. Piston cooling – reduces substantially the piston temperature which, in turn, contributes to a longer life of the piston rings, reduces the risk of carbon deposits and lowers the oil consumption. The pistons are cooled by oil which is sprayed by nozzles into the underside of each piston and into the cooling passages when the piston is at the bottom dead centre. Cooling is controlled by a piston cooling valve which shuts off the cooling oil supply at low engine speeds. This ensures that the lubricating oil flow will be a maximum when the engine is started and when it is running at idling speed. The valve also restr icts the pressure of the piston cooling oil at high engine sp eeds, to make more oil available for lubrication.

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

Oil pump Reducing valve By-pass valve Oil under pressure to the lubrication system Piston cooling valve Oil under pressure for piston cooling Oil cooler By-pass filter Oil filter

Lubricating s ys tem



Group 30

TDCE01 04GB P. 11

Reducing valve – located just before the filter. The valve will open if the lubricating oil pressure is too high and will return excess oil back to the sump. Oil filter – of full-flow type, with a filter element of pleated filter paper. To protect the engine against insufficient lubricating oil, a by-pass valve is fitted in the oil filter bracket. The valve will open if the lubricating oil pressure should rise above a certain pressure due to clogging of the filter. When the valve is open, unfiltered oil will flow to the engine. The filter is of disposable type and should be scrapped after use. By-pass filter – approx. 5% of the oil passes through the by-pass filter with very low speed. The low speed allows very small particles to be separated. The filter insert is of the disposable type. Crankcase ventilation – prevents pressurising of the crankcase and collects fuel vapour, steam and other gaseous products of combustion. Crankcase ventilation is provided by a pipe connected to the crankcase inspection cover on the right-hand side of the engine, between the starter motor and the oil filter.

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

Piston cooling valve By-pass valve (safety valve) Reducer valve Oil cooler Full-flow filter By-pass filter Oil pump Suction strainer Oil sump

Lubrication s ys tem



Group 30

TDCE01 04GB P. 12

Combustion system Large quantities of air are necessary for burning the fuel su pplied to the engine. Free, unrestricted flow of fresh air and exhaust gases is therefore essential to allow the engine to run efficiently.

Air cleaner The intake air is cleaned in a two-stage air cleaner, the first stage of which collects coarse particles by cyclone action, and the particles are then collected in a dust receiver. The second stage consists of a filter element - the main filter element. A safety filter element is located on the inside of the main element. The safety element prevents the ingress of impurities into the engine while the main element is being changed and if the main element should sustain damage while the engine is running, e.g. due to incorrect installation.

1. To engine 2. Air restriction indicator 3. Dust exit

A ir c leaner



Group 30

TDCE01 04GB P. 13

Turbocharger The turbocharger supplies more air to the combustion chambers than the engine would be capable of dr awing naturally. This enables the engine to burn more fuel which, in turn, increases the engine output. The turbocharger consists of a turbine wheel and a centrifugal compressor impeller, each with a separate casing but mounted on a common shaft. The exhaust gases provide the energy necessary for driving the turbine wheel which, in turn, drives the compressor. The turbocharger is lubricated and cooled by the lubricating oil from the engine.

Intercooler

1. 2. 3. 4.

Exhaust gases to silencer Air to the engine intercooler Exhaust gases from the engine Intake air

In intercooling, the air that has been compressed and heated by the turbo is cooled in an intercooler. The intercooler increases the oxygen supply for combustion so allowing the injected fuel to be burnt more effectively whilst reducing guel consumption as well as the level of exhaust emission. Intercooling also reduces the thermal stressed on the engine, increasing durability and reducing oil consumption

Turbo charg er

Inlet manifold heater Before the air is admitted into the combustion chamber, it flows across an electrically heated starting element. This has a high rating of 3 kW and heats the intake air sufficiently for the engine to start at low ambient temperatures. The heater element is energised when the starting key is turned. Suitable preheating time is about 50 seconds.

1. Air from turbocompressor 2. Engine cooling system 3. Air to combustion chamber

1. Heater element

Engine TWD731VE Service


Group 30

TDCE01 04GB P. 14

Coolant quality Throughout the year, the coolant should consist of a mixture of 60% of water and 40% of ethylene glycol. The coolant should be changed and the cooling system should be flushed once a year. Always add a corrosion inhibitor (Kalmar part No. 923.110.0003) to the coolant, if the above mixture is not used in the cooling system.

N.B . Never add a corros ion inhibi tor if the cooling s ys tem contains g lycol, s ince this would cause foaming whi ch s eriously i mpairs the cooling capacity.

Lubricating oil quality See Group 90, Periodic supervision.

Draining the water from the fuel tank Drain any water from the fuel tank by removing the drain plug. Immediately refit the drain plug as soon as the flow of fuel is free from water and other impurities.

Inspection of the air cleaner and changing the filter element

1

2



Check the indicator when the engine is runningor stopped. If it shows red, the main filter element must be changed. The collecting efficiency of the filter element will not be improved if the element is changed too early. But if changing of the filter element is delayed, smoke emission from the engine will increase, the engine may lose power due to insufficient supply of combustion air, and engine damage may occur in certain cases. The air pipe from the air cleaner to the engine should be checked for tightness from time to time. Minor leakage, such as that caused by loose hose clips, and damaged or porous hoses may cause dust to be drawn into the engine, which will give rise to costly engine wear. Change the filter element as follows: 1. The engine must not be running. 2. Clean the outside of the air cleaner. 3. Remove the cover. 4.

1. Main filter element 2. Safety filter element

Release and carefully remove the main filter element. Do not remove the safety filter element. Fit a new main filter element. Carefully check that it is not damaged. Note on the safety filter element when the main element was replaced. 5. Reset the filter indicator. 6. Change the safety filter element: – after the main filter element has been changed five times – at least every other year – if the indicator shows red after the main element has been changed – if the engine has been run with the main element damaged The safety filter element must not be cleaned and reused. The engine must not be run without the main filter element. If the main element must be cleaned and refitted in emergency cases, don’t use compressed air to clean it, since the filter element may be damaged. Before refitting it, carefully check that the main filter element is undamaged.



Group 30

TDCE01 04GB P. 15

Changing the oil and oil filter N.B . B efore draining the oil, make s ure that it is at normal worki ng temperature. 1.

Remove the drain plug from the underside of the sump and drain the oil.

2.

Clean the area round the filters and place a tray under the filters to collect any spillage. Remove and discard the filter canisters, which are of disposable type. Pour clean oil into the centre of the new filters, wait until the oil has seeped through the filter paper and top up until the filters are full. Lubricate the canister seals with oil. Fit the new filters and tighten them - by hand only.

3. 4.

5. 6. 7. 8. 9.

Fill the engine with oil (see Group 90, Lubrication chart). Run the engine and check that no oil leaks at thefilters. Stop the engine and check the oil level after a few minutes. Top up as necessary to the MAX level on the dipstick.

N.B . To avoid s erious damag e to the eng ine, us e only g enuine K almar filters .

Checking the V-belt tension 1.

Check at regular intervals that the V-belts are correctly tensioned. It should not be possible t o depress the V-belt more than 10 - 12 mm mid-way between the pulleys.

2.

The engines are equipped with an automatic belt tensioner which maintains the belt tension constant.

N.B . If the belt driv e consi s ts of two belts , always change both belts .



Group 30

TDCE01 04GB P. 16

Checking and adjusting the valve clearances N.B . Never attempt to check the valve clearances when the engi ne is running . The engi ne mus t be s tationary but may be cold or hot. 1.

Turn the crankshaft in its normal direction of rotation until the inlet valve of No. 6 cylinder has just opened and the exh aust valve of the same cylinder has n ot yet closed fully. Check the valve clearances on No. 1 cylinder and adjust as necessary.

Valve clearance Engine

TD730VE/TWD731VE

Inlet Exhaust

0.40 mm 0.55 mm

2.

Check the oter valves in accordance with the table below.

Check the valve clearance of cylinders No...

1

5

3

6

2

4

...when the inlet and exhaust valves of the following cylinders are just changing over

6

2

4

1

5

3

(are moving simultaneously)

Changing the fuel filters 1. 2. 3.

Clean the outsides of the filters. Remove the filters and discard them. Clean the filter head.

4.

Check that the new filters are perfectly clean and that the seals are in good condition. Fit the new filter canisters and tighten them by hand until the seal is in contact with the seating surface. Then tighten them a further half a turn.

5.



Group 30

TDCE01 04GB P. 17

Preventive maintenance on the turbocharger

WARNING! Never r un the eng ine with the air inlet or exhaust pipes dis connected from the turbocharg er, s ince pers onnel could then s ubstain injuries .

The turbocharger may be damaged and, in the worst case, may break down if the engine is not properly serviced. 1. Check that the engine air inlet system is in good condition, i.e. that the air cleaner is clean, that none of the hoses are worn and that hose connections are not defective, which would allow oil to seep past the seals on the compressor side and be entrained by the inlet air. The latter may lead to high exhaust gas temperatures and overheating of the turbine shaft bear-ing. If corrective action is then not taken, the turbocharger may break down. 2. Change the lubricating oil and filter at the specified intervals. Check at regular intervals that the lubricating oil lines to the turbocharger are in good condition and do not leak. Also check regularly that the o il pressure is not too low, since this could quickly lead to damage to the turbocharger. 3.

IMPORTANT! A djus tments on the injection pump are to be performed by authori zed pers onnel only.

4.

Ensure that the fuel system is serviced at the specified intervals. Inadequate fuel supply caused by clogged fuel filters or incorrect setting of the injection pump reduces the turbocharger speed which, in turn, results in a lower engine output. Check that there are no restrictions in the crankcase ventilation. If the vent is blocked, pressure may build up and may force oil into the inlet air system of the turbocharger and engine.


Group 30

Volvo TAD720VE

TDCE01 04GB P. 18

DCE80-100E

Specifications

Technical Handbook

Group 30

Manufacturer, type

Volvo TAD720VE

Coolant volume, l

40


174 (237) 2300


854 1400

Number of cylinders

6

Swept volume, l

7,15

Valve clearance, engine cold inlet, mm exhaust, mm Idle speed, r/min (adjust so that the engine runs smoothly) Thermostat, starts to open at °C fully open at °C Lubricating oil filter Lubricating oil pressure, kPa running speed idling speed

TDCE01 04GB P. 19

0,35 0,55 700±50

87 102 Full flow, disposable paper element with by-pass valve 350 min 80


Se Grupp 90

Volume, l

20


Engine TAD720VE Description

Group 30

TDCE01 04GB P. 20

Overview The TAD720VE engine is a 6-cylinder, inline, 4-stroke, low emission diesel engine with overhead valves. The engine is turbocharged, i.e. combustion air is supplied under pressure. As a result, the quantity of fuel injected can be increased, which increases the engine output. The turbocharger is driven by the exhaust gases and uses energy that would otherwise be lost. In order to further increase the engine efficiency, the engine is equipped with a air-to air intercooler. The engine is pressure-lubricated by an oil pump which delivers oil to all lubrication points. A full-flow oil filter effectively cleans the lubricating oil. An integrated, side mounted oil cooler is cooling the entire oil flow. The fuel system is protected against impurities by replaceable filters. To maintain a controlled working temperature in cylinders and combustion chambers, the engine is provided with piston cooling. The low emission engine has a new design of combustion chamber, injection equipment and charge air cooler (intercooler) which satisfy future emission requirements from both the USA (California) and Europe. The new engines represent a considerable improvement, not only in terms of exhaust gas emissions, but also in terms of power and torque curves. In addition, all Volvo engines comply with the R24 exhaust smoke requirements.



1

2

3

4

Group 30

TDCE01 04GB P. 21

5

6

1. Coolant connection, outlet 2. Turbo-compressor 3. Manifold 4. Lifting eylet 5. Crankcase ventilation 6. Starter motor 7. Injection pump 8. Oil cooler 9. Generator 10. Oil dip stick 11. Full flow filter, of “spin-on” typ 12. Fuel filter of disposable type 13. Fuel pump

7



8

10

11

9

12 13

E ng ine Volvo TA D720VE



Group 30

TDCE01 04GB P. 22

Cooling system 1. Charge air cooler air-to-air 2. Radiator, air-coolant 3. Oil cooler gearbox, air-oil

The engine is liquid-cooled and equipped with a closed cooling system consisting of the following main components:  Coolant pump  Radiator with integrated intercooler and gearbox oil cooler  Expansion tank  Thermostat   

Radiator fan Coolant passages Engine oil cooler

The coolant flows through a longitudinal passage into the engine block. The opening into the cooling jacket of each cylinder is individually sized to ensure that each cylinder will be supplied with the same rate of coolant flow.

1 2 3

The coolant flows in the separate return lines converge into a common pipe in the thermostat housing. The coolant then flows to the coolant pump and then into the engine and t o the oil cooler. When the engine has reached its normal operating temperature, the thermostat will open the circuit to the radiator. The piston-type thermostat is capable of passing a high coolant flow rate at a minimum of pressure drop, thus contributing to favourable coolant circulation in the engine. .

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

Coolant connection, inlet Thermostat housing Coolant pump Oil cooler Cylinder cooling Cylinder head cooling Coolant connection, outlet



Group 30

TDCE01 04GB P. 23

The cooling system is equipped with a sensor which activates the ”Low coolant level” warning lamp on the instrument panel. The engine lubricating oil is cooled efficiently and reliably in a plate oil cooler. The gearbox oil is also cooled by the engine coolant, but in a separate shell-and-tube cooler.

1

1. Plate oil cooler



Group 30

TDCE01 04GB P. 24

Fuel system The fuel circulates in two circuits - the high-pressure circuit and the low-pressure circuit. When the engine is started, the feed pump draws fuel from the tank and delivers it at relatively low pressure through fine filters up to the inject ion pumps. These then deliver fuel at high pressure to the injectors which supply the fuel in atomised form to the engine combustion chambers. Excess fuel which is circulated in the low-pressure system is also cleaned in the fine filters and is returned through a spill valve back to the tank. The fuel system includes the following components: Fuel tank - a separate unit located on the left-hand side of the truck. The fuel volume in the tank can be read on a gauge on the instrument panel. Feed pump - of piston type, supplies fuel at a certain pressure and flow rate to the injection pumps. Spill valve - which restricts the fuel feed pressure and provides continuous venting of the fuel system. The excessive fuel is flowing through the injection pumps before it is fed through th e return line to the fuel cooler and thereafter to the fuel tank. Fuel cooler The fuel cooler is positioned on top of the charge air cooler. Its purpose is to lower the return fuel temperature and thereby also the temperature in the fuel tank. A lower fuel temperature gives higher combustion efficiency.

1. Fuel tank 2. Fuel hose to fuel pump 3. Feed pump 4. Fuel hose to fuel filter 5. Fuel filter 6. Fuel hose to fuel channel 7. Injection pumps, 6 pcs 8. Fuel line to injectors 9. Injector 10. Leak oil line 11. Over flow valve, return fuel 12. Return to fuel tank 13. Fuel line 14. Pre filter with water separator 15. Manual feed pump 16. Fuel cooler, air/fuel

B räns les ys tem, principschema



Group 30

TDCE01 04GB P. 25

Fuel pre filter - with washable filter insert and draining valve for condensate . 1 2 1. Filter holder 2. Sealing between filter holder and filter insert 3. Filter insert, washable 4. Draining valve for codensate 5. Filter container 6. Sealing ring

6 3

5

4

Bränsleförfilter

Injection pumps and injectors The injection pumps are of the single type, e.g. one for each cylinder and feed high pressure fuel to the injectors. These have an opening pressure of 27.5 MPa. When adjustment of the injectors is needed this has to be made separately with shims for every single pump.

2 1

1. Injection pump 2. Injector

Ins prutning s pump och i nsprutare



Group 30

TDCE01 04GB P. 26

Lubricating system The engine is pressure-lubricated, and the oil is supplied by a pump in the oil sump. All lubricating oil flows through a full-flow filter. One part of the oil flows through a by-pass filter for separation of extremely small particles. The lubricating oil is cooled in a plate oil cooler by the engine coolant. The lubricating system includes the following main components: Oil pump - of rotor type, draws oil through a strainer which separates coarse particles. The oil is fed from the pressure side of the pump through the oil filter and is then distributed to the different ducts of the lubricating system Piston cooling – reduces substantially the piston temperature which, in turn, contributes to a longer life of the piston rings, reduces the risk of carbon deposits and lowers the oil consumption. The pistons are cooled by oil which is sprayed by nozzles into the underside of each piston and into the cooling passages when the piston is at the bottom dead centre.

1. Oil pressure switch 2. Lifter with pulse lubrication 3. Push rod, oil duct for lubrication of rocker arm assembly 4. Rocker arm 5. Return oil duct to oil sump 6. Piston cooling, 2-hole nozzle for each cylinder 7. Oil filter, full flow with by-pass valve which opens at 250±50 kPa 8. Ruduction valvee, opening pressure 400±40 kPa 9. Safety valve oil cooler, opening pressure 1± 0,1 MPa 10. Oil pump of rotor type, driven from the crankshaft 11. Oil cooler

Lubricating s ys tem



Group 30

TDCE01 04GB P. 27

Reducing valve – located just before the filter. The valve will open if the lubricating oil pressure is too high and will return excess oil back to the sump. Oil filter – of full-flow type, with a filter element of pleated filter paper. To protect the engine against insufficient lubricating oil, a by-pass valve is fitted in the oil filter bracket. The valve will open if the lubricating oil pressure should rise above a certain pressure due to clogging of the filter. When the valve is open, unfiltered oil will flow to the engine. The filter is of disposable type and should be scrapped after use. By-pass filter – approx. 5% of the oil passes through the by-pass filter with very low speed. The low speed allows very small particles to be separated. The filter insert is of the disposable type. Crankcase ventilation - prevents over-pressure in the crankcase and separates fuel mist, water mist and other gaseous combustion products. The crankcase ventilation is controlled by a pressure regulator which discharges excessive pressure from the crankcase through a pipe connceted to the turbo-compressor suction line. .

4 1

5 3

2

6

7 8

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

Adapter Fuel filter Oil pump Suction line Suction strainer Oil sump Pressure regulator, crankcase vantilation 8. Connecting pipe

Lubricating system



Group 30

TDCE01 04GB P. 28

Air system Large quantities of air are necessary for burning the fuel su pplied to the engine. Free, unrestricted flow of fresh air and exhaust gases is therefore essential to allow the engine to run efficiently.


6

5

4

1 2 3

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

Air filter Filter indikator To engine Dust exit Prefilter (optional) Charge air cooler To turbo compressor To charge air cooler

7

8

A ir s ys tem



Group 30

TDCE01 04GB P. 29

Turbocharger The turbocharger supplies more air to the combustion chambers than the engine would be capable of dr awing naturally. This enables the engine to burn more fuel which, in turn, increases the engine output. The turbocharger consists of a turbine wheel and a centrifugal compressor impeller, each with a separate casing but mounted on a common shaft. The exhaust gases provide the energy necessary for driving the turbine wheel which, in turn, drives the compressor. The turbocharger is lubricated and cooled by the lubricating oil from the engine.

3 1

Intercooler

4

2

1. 2. 3. 4.

Exhaust gases to silencer Air to the engine intercooler Exhaust gases from the engine Intake air

In intercooling, the air that has been compressed and heated by the turbo is cooled in an intercooler. The intercooler increases the oxygen supply for combustion so allowing the injected fuel to be burnt more effectively whilst reducing guel consumption as well as the level of exhaust emission. Intercooling also reduces the thermal stressed on the engine, increasing durability and reducing oil consumption The intercooler is of the air-to-air type and integrated with the radiator and the gearbox oil cooler.

Inlet manifold heater Turbocharger

Before the air is admitted into the combustion chamber, it flows across an electrically heated starting element. This has a high rating of 3 kW and heats the intake air sufficiently for the engine to start at low ambient temperatures. The starter heater is automatically controlled through separate electronic circuits. 1. 2. 3. 4.

Intercooler air-to-air Radiator, air-coolant Oil cooler gearbox, air-oil Inlet manifold heater

4

1

2



3

Radiator

Engine TAD720VE Service


Group 30

TDCE01 04GB P. 30






1

2



Check the indicator when the engine is running orstopped. If it shows red, the main filter element must be changed. The collecting efficiency of the filter element will not be improved if the element is changed too early. But if changing of the filter element is delayed, smoke emission from the engine will increase, the engine may lose power due to insufficient supply of combustion air, and engine damage may occur in certain cases. The air pipe from the air cleaner to the engine should be checked for tightness from time to time. Minor leakage, such as that caused by loose hose clips, and damaged or porous hoses may cause dust to be drawn into the engine, which will give rise to costly engine wear. Change the filter element as follows: 1. The engine must not be running. 2. Clean the outside of the air cleaner. 3. Remove the cover. 4.





Group 30

TDCE01 04GB P. 31

Changing the oil and oil filter N.B . B efore draining the oil, make s ure that it is at normal worki ng temperature.

1. 2. 3.

Remove the drain plug from the underside of the sump and drain the oil. Fit the plug with a new gasket. Clean the area round the filters and place a tray under the filters to collect any spillage. Remove and discard the filter canisters, which are of disposable type.

4.

Pour clean oil into the centre of the new filters, wait until the oil has seeped through the filter paper and top up until the filters are full.

5. 6. 7. 8. 9.

Lubricate the canister seals with oil. Fit the new filters and tighten them - by hand only. Fill the engine with oil (see Group 90, Lubrication chart). Run the engine and check that no oil leaks at thefilters. Stop the engine and check the oil level after a few minutes. Top up as necessary to the MAX level on the dipstick.

N.B . To avoid s erious damag e to the eng ine, us e only g enuine K almar filters .

Checking the V-belt tension 1.

Check at regular intervals that the V-belts are correctly tensioned. It should not be possible t o depress the V-belt more than 10 - 12 mm mid-way between the pulleys.

Coolant-fuel pump 1. Loosen the screws 1 and 2 2. Push the fuel pump in the direction of the arrow 3 (A or B) until the correct belt tension is achieved. 3. Tighten the screws 1 and 2

Alternator 1. Loosen the screws 1 and 2. 2. Move the alternator until the right belt tension is achieved. 3. Tighten the screws 1 and 2

N.B . If the belt driv e consi s ts of two belts , always change both belts .



Group 30

TDCE01 04GB P. 32

Checking and adjusting the valve clearances N.B . Never attempt to check the valve clearances when the engi ne is running . The eng ine must be stationary and cold. 1. Remove valve cover and crankcase ventilation

Crankshaft position 1 2. Rotate the crankshaft until the valves of cylinder 1 overlap. See picture for valve adjustment

N.B . Overlaping of valves means Crankshaft position 1

Crankshaft position 2

The exhaust valve is just closing and the inlet valve is just opening. Neither of the push-rods can be turned around in this position. Cylinder 1 is closest to the flywheel. 3. Adjust the valve clearances according to the black markings in the adjoining picture. Inlet valve: 0,30 mm Exhaust valve: 0,50 mm 4. Tighten the lock nut with 20±2 Nm. Re-check the clearance with a feeler guge. 5. Make a chalk mark on every adjusted valve. Crankshaft position 2 6. Rotate the crank shaft another turn (360°) 7. Adjust the valve clearances according to the black markings in the adjoining picture.

8. Fit a new gasket for the valve cover.

9. Fit the valve cover and tighten the cover screws with 9+/-1 Nm.



Group 30

TDCE01 04GB P. 33

Changing the fuel filter 1. 2. 3. 4. 5.

Clean the outsides of the filter. Remove the filter and discard it. Clean the filter head. Check that the new filter is perfectly clean and that the seal is in good condition. Fit the new filter canister and tighten them by hand until the seal is in contact with the seating surface. Then tighten it a further half a turn.



Fuel pre-filter, checking and filter replacement

1

2

1. 2.

Place a container underneath the filter Drain condensate from the filter by opening the draining valve 4, se picture.

3. 4.

Unscrew the filter container from the filter head. Rinse the filter in diesel or replace it if necessary. For new filter, moisten the new O-ring with fuel. Fit the filter in the container and fit the O-ring. Fasten the container to the filter head and tighten it by hand until the O-ring is in contact with the seating surface. Then tighten it a further half a turn. Remove the collection container. The contained fuel should be handled as environmentally dangerous waste.

5. 6.

5 3

7.

4 1. Filter head 2. Sealing between filter head and filter container 3. Filter insert, washable 4. Draining valve for condensate 5. Filter container



Group 30

TDCE01 04GB P. 34


WARNING! Never run the eng ine with the air inlet or exhaust pipes di s connected from the turbocharg er, s ince pers onnel could then subs tain injuri es.


4.




Engine Cummins QSB 5.9 Description

Group 30

TDCE01 04GB P. 35

Cummins QSB 5.9 The following information concerns mainly the specific Kalmar installation. For general engine information such as system descriptions, diagnosis and error codes, refer to the separate Cummins documents.

DCE80-100E

Specifications

Technical Handbook

Group 30

Manufacturer, type

Cummins QSB 5.9

Coolant volume, l

33


160 (215) 2200


938 1300-1500

Number of cylinders

6

Swept volume, l

5.9

Valve clearance, engine cold inlet, mm exhaust, mm Idle speed, r/min (adjust so that the engine runs smoothly) Thermostat, starts to open at °C fully open at °C Lubricating oil filter Lubricating oil pressure, kPa running speed idling speed

TDCE01 04GB P. 36

0,25 0,51 700±50

84 91 Full flow, disposable paper element with by-pass valve 310 min 103


Se Grupp 90

Volume, l

16



Group 30

TDCE01 04GB P. 37

Overview The Cummins QSB 5.9 engine is a 6-cylinder, inline, 4-stroke, low emission diesel engine with overhead valves. It has an Electronic Controlled Fuel system. The engine is turbocharged, i.e. combustion air is supplied under pressure. As a result, the quantity of fuel injected can be increased, which increases the engine output. The turbocharger is driven by the exhaust gases and uses energy that would otherwise be lost. In order to further increase the engine efficiency, the engine is equipped with a water-to air intercooler. The engine is pressure-lubricated by an oil pump which delivers oil to all lubrication points. A full-flow oil filter effectively cleans the lubricating oil. An integrated, oil cooler is cooling the entire oil flow. The fuel system is protected against impurities by replaceable filters. To maintain a controlled working temperature in cylinders and combustion chambers, the engine is provided with piston cooling. The low emission engine satisfies future emission requirements from both the USA (California) and Europe. The new engines represent a considerable improvement, not only in terms of exhaust gas emissions, but also in terms of power and torque curves. In addition, all engines comply with the R24 exhaust smoke requirements.

IMPOR TA NT! For details in the different s ys tems, s ee C ummins Operation and Maintenance Manual



15

7

12

14

10

Group 30

TDCE01 04GB P. 38

13

5 6

3

2

11

4

9

1

16



1. Coolant outlet to charge air cooler 2. 3. 4. 5. 6. 7. 8. 9.

Turbo-compressor Air cooled manifold Lift eyelet Crankcase ventilation Starter motor Injection pump Oil cooler Alternator

10. Oil dip stick 11. Full flow filter, of “spin-on” typ 12. Fuel pre-filter with condensate separator 13. Fule lift pump 14. Electroninc control unit 15. Inlet manifold heater 16. Coolant inlet to engine

E ngine Cummins QS B 5.9



Group 30

TDCE01 04GB P. 39

Cooling system The engine is liquid-cooled and equipped with a closed cooling system consisting of the following main components:  Coolant pump  Radiator with integrated intercooler and gearbox oil cooler  Expansion tank  Thermostat   

Radiator fan Coolant passages Engine oil cooler

N.B . F or further information, s ee Cummins Operation and Maintenance Manual.

A. To engine B. To engine C. To radiator





Group 30

TDCE01 04GB P. 40

Fuel system The fuel circulates in two circuits - the high-pressure circuit and the low-pressure circuit. When the engine is started, the feed pump draws fuel from the tank and delivers it at relatively low pressure through fine filters up to the injection pump. This then delivers fuel at high pressure to the injection pump which supplies the fuel in atomised form to the engine combustion chambers. Excess fuel which is circulated in the low-pressure system is also cleaned in the fine filters and is returned through a spill valve back to the tank. The fuel system includes the following components: Fuel tank - a separate unit located on the left-hand side of the forklift. The fuel volume in the tank can be read on a gauge on the instrument panel. Feed pump - supplies fuel at a certain pressure and flow rate to the injection pumps. Spill valve - which restricts the fuel feed pressure and provides continuous venting of the fuel system. The excessive fuel is flowing through the injection pump before it is fed through the return line to the fuel tank. Fuel pre-filter - with drain valve for condensate Injection pump and injectors



Group 30

TDCE01 04GB P. 41

Lubricating system The engine is pressure-lubricated, and the oil is supplied by a gear pump. All lubricating oil flows through a full-flow filter. The lubricating oil is cooled in a plate oil cooler by the engine coolant. The lubricating system includes the following main components: Oil pump - of rotor type, draws oil from the sump. The oil is fed from the pressure side of the pump through the oil filter and is then distributed to the different ducts of the lubricating system Piston cooling – reduces substantially the piston temperature which, in turn, contributes to a longer life of the piston rings, reduces the risk of carbon deposits and lowers the oil consumption. The pistons are cooled by oil which is sprayed by nozzles into the underside of each piston and into the cooling passages when the piston is at the bottom dead centre. Reducing valve – located just before the filter. The valve will open if the lubricating oil pressure is too high and will return excess oil back to the sump. Oil filter – of full-flow type, with a filter element of pleated filter paper. To protect the engine against insufficient lubricating oil, a by-pass valve is fitted in the oil filter bracket. The valve will open if the lubricating oil pressure should rise above a certain pressure due to clogging of the filter. When the valve is open, unfiltered oil will flow to the engine. The filter is of disposable type and should be scrapped after use. Crankcase ventilation - prevents over-pressure in the crankcase and separates fuel mist, water mist and other gaseous combustion products.



Group 30

TDCE01 04GB P. 42

Air system Large quantities of air are necessary for burning the fuel su pplied to the engine. Free, unrestricted flow of fresh air and exhaust gases is therefore essential to allow the engine to run efficiently.


6

5

1 2 3

4

7

8



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

Air filter Air restriction indicator To engine Dust exit Prefilter (optional) Charge air coooler To turbo-compressor To Charge air coooler

A ir s ys tem



Group 30

TDCE01 04GB P. 43

Turbocharger 2 5 4

3

1

The turbocharger supplies more air to the combustion chambers than the engine would be capable of dr awing naturally. This enables the engine to burn more fuel which, in turn, increases the engine output. The turbocharger consists of a turbine wheel and a centrifugal compressor impeller, each with a separate casing but mounted on a common shaft. The exhaust gases provide the energy necessary for driving the turbine wheel which, in turn, drives the compressor. The turbocharger is lubricated and cooled by the lubricating oil from the engine.

Intercooler 3 1. 2. 3. 4. 5.

Exhaust gases to the silencer Compressed air to the intercooler Exhaust gases from the engine Air from the filter Intake air from the intercooler

In intercooling, the air that has been compressed and heated by the turbo is cooled in an intercooler. The intercooler increases the oxygen supply for combustion so allowing the injected fuel to be burnt more effectively whilst reducing fuel consumption as well as the level of exhaust emission. Intercooling also reduces the thermal stressed on the engine, increasing durability and reducing oil consumption The intercooler is of the water-to-air type and integrated with the radiator and the gearbox oil cooler.

Inlet manifold heater Turbocharger

Before the air is admitted into the combustion chamber, it flows across an electrically heated starting element. This heats the intake air sufficiently for the engine to start at low ambient temperatures. The starter heater is automatically controlled through an electronic control module.

Engine Cummins QSB 5.9 Service


Group 30

TDCE01 04GB P. 44






1

2



Check the indicator when the engine is running or stopped. If it shows red, the main filter element must be changed. The collecting efficiency of the filter element will not be improved if the element is changed too early. But if changing of the filter element is delayed, smoke emission from the engine will increase, the engine may lose power due to insufficient supply of combustion air, and engine damage may occur in certain cases. The air pipe from the air cleaner to the engine should be checked for tightness from time to time. Minor leakage, such as that caused by loose hose clips, and damaged or porous hoses may cause dust to be drawn into the engine, which will give rise to costly engine wear. Change the filter element as follows: 1. The engine must not be running. 2. Clean the outside of the air cleaner. 3. Remove the cover. 4.





Group 30

TDCE01 04GB P. 45

Changing the oil and oil filter N.B . B efore draining the oil, make s ure that it is at normal worki ng temperature.

1. 2. 3.

Remove the drain plug from the underside of the sump and drain the oil. Fit the plug with a new gasket. Clean the area round the filter and place a tray under the filters to collect any spillage. Remove and discard the filter canister, which are of disposable type.

4.

Pour clean oil into the centre of the new filter, wait until the oil has seeped through the filter paper and top up until the filter are full.

5. 6. 7. 8. 9.

Lubricate the canister seal with oil. Fit the new filter and tighten it - by hand only. Fill the engine with oil (see Group 90, Lubrication chart). Run the engine and check that no oil leaks at the filter. Stop the engine and check the oil level after a few minutes. Top up as necessary to the MAX level on the dipstick.

N.B . To avoid s erious damag e to the eng ine, us e only g enuine K almar filter.

Checking the drive belt tension 1.

Check at regular intervals that the V-belts are correctly tensioned.

N.B . S ee C ummins Operation and Maintenance Manual



Group 30

TDCE01 04GB P. 46

Checking and adjusting the valve clearances N.B . Never attempt to check the valve clearances when the engi ne is running . The eng ine must be stationary and the temperature below 60° C . 1. Remove valve cover.

Crankshaft position 1 2. Using the barring tool, rotate the crankshaft to algin the top dead center marks on the gear cover and fuel pump gear With the engine in this position, valve clearanc can be checked on following valves: 1I, 1E, 2I, 3E, 4I and 5E. 3. Adjust the valve clearances according to the nominal specifications. Inlet valve: 0,25 mm Exhaust valve: 0,50 mm 4. Tighten the lock nut with 24 Nm. Re-check the clearance with a feeler guge. 5. Make a chalk mark on every adjusted valve.

Crankshaft position 2 6. Rotate the crank shaft another turn (360°)

7. Adjust the valve clearances according for valves 2E, 3I, 4E, 5I, 6I and 6E.

8. Inspect the valve cover gasket for cracks or other damage. Fit the gasket, replace with a new gasket if needed..

9. Fit the valve cover and tighten the cover screws with 12 Nm.



Group 30

TDCE01 04GB P. 47

Changing the fuel filter 1. 2. 3.

Clean the outsides of the filter. Place a container underneath the filter. Drain any water and fuel from the filter container. Push draining valve upwards, see picture.

4.

Remove the water-in fuel sensor from the engine harness.

5.

Remove the filter.

6.

Drain the filter and remove the water-in fuel sensor from the fitler. See picture. Discard the old filter. Clean the filter head. Check that the new filter is perfectly clean and that the seals are in good condition. Install the water-in fuel sensor into the new filter.

7. 8. 9.

10. Lubricate the O-ring seal with clean lubricating oil. 11. Fit the new filter canister and tighten it by hand until the seal is in contact with the seating surface. Then tighten it a further half a turn. 12. Reconnect the water-in fuel sensor to the engine harness. 13. Remove the collection container. The contained fuel should be handled as environmentally dangerous waste.



Group 30

TDCE01 04GB P. 48


WARNING! Never r un the eng ine with the air inlet or exhaust pipes dis connected from the turbocharg er, s ince pers onnel could then s ubstain injuries .



4.



Contents

Group 40

TDCE01 04GB P. 1

Group 40 Transmission, drive axle, brakes Specification .............................................................. ................ 2 Transmission .......................................................... ................... 3 Description ........................................................................... 3 Torque converter ............................................................. 3 Gearbox........................................................................... 4 Oil circuit.......................................................................... 5 Service ................................................................................. 6 Oil level check ........................................................... ...... 6 Changing gearbox oil and filter........................................ 6 Checking pressures in the Clark gearbox ....................... 7 Drive axle................................................................................... 7 Description ........................................................................... 7 The differential................................................................. 7 Hub reduction .................................................................. 9 Service brake .................................................................. 9 Parking brake system.................................................... 10 Releasing the parking brake by mechanical means...... 10 Service ............................................................................... 11 Changing the drive-axle oil............................................ 11 Installation of disc brake................................................ 12 Installing the brake on the axle...................................... 14 Installing of hub reduction ............................................. 16 Dismantling the planet gear........................................... 18 Inspection of dismountable rims .................. see group 60 Safety test when changes tyres ................... see group 60

DCE80-100E

Specifications

Technical Handbook

Group 40

TDCE01 04GB P. 2

Torque converter and gearbox Model

Clark - 13.7 HR 32000

Number of gears

3F – 3R

Oil capacity, total system, l

32

Oil grade

See group 90

Oil operating temperature, °C

82–93

Max. permissible temperature, °C

120

Clutch pressure, bar with parking brake applied, oil temp. 82–93°C, engine idling at 625 r/min

17–20 All clutch pressures should be equal to within 0.4 bar as indicated on pressure gauge in cab.

Clutch type

Multiple disc, hydraulic. Automatic wear compensation (no adjustment). All clutches oil cooled and lubricated.

Stall speed, r/min

1990±50

Oil filtration

Full-flow oil filter with safety bypass; also strainer screen in sump at bottom of transmission case.

Drive axle Model

Kessler D81

Brake system

Wet disc brakes

Parking brake system

Spring-activated disc brake on drive axle input-shaft.

Wheel dimensions, in / Tyre pressure, MPa

DCE70: 12.00x24 - 1.0 DCE90: 14.00x24 - 1.0

Oil capacity, liter

B=4000 B=4500

Oil grade

3.5 each hub, 51 differential 2,0 each hub. 63 differential See Group 90

Tightening torque Drive axle mounting bolts (oiled), Nm (kpm Rim clamp nuts, Nm (kpm) Universal drive axle joint, Nm (kpm)

M24: 650 (66 (M30: 1275 (130) M22: 650 (66) UNF 3/8'': 59 (6.0)


Transmission Description

Group 40

TDCE01 04GB P. 3

The transmission consists of a torque converter integrated with the gearbox, and a propeller shaft, driven axle with differential, hub reductions and brakes. The torque converter and gearbox run together, using a common hydraulic system. The torque converter can be regarded as a hydraulic coupling and is located between the engine output shaft and the gearbox input shaft.

Torque converter IMPORTANT! The machine mus t not be run at s tall s peed long er than 30 s econds at a time. The torque converter will otherwis e overheat, causi ng damag e to the s eals and thus neces s itating ex pensi ve overhaul.

The most important components of the torque converter are the pump impeller, turbine wheel and stator. Engine power is transmitted mechanically to the pump impeller. The impeller starts an oil flow in the torque converter, and is comparable to a centrifugal pump which draws oil into the centre and discharges it at the periphery. The turbin wheel is located opposite the pump impeller and is connected to the torque converter output shaft. The oil enters the turbine wheel at the periphery and is discharged at the centre. The stator is located between the pump impeller and the turbine wheel, at their inside diameter. The function of the stator is to guide the flow of oil from the inside diameter of the turbine wheel back to the inside diameter of the pump impeller in the best possible way. Torque conversion takes place in the oil circuit of the torque converter. When the load on the truck increases, i.e . when the torque required increases, the turbine wheel slows down in relation to the pump impeller, and the oil flowing through the stator then increases the torque. The output torque gradually increases as the speed o f the output shaft decreases and is a maximum when the output shaft and thus also the turbine wheel are stationary, i.e. are stalled, see Technical data.

Gearbox The gearbox is of constant-mesh type. Gear-changing is carried out by clutch plates for the various gears being hydraulically actuated. The valve body mounted on the side of the gearbox includes spool valves which guide the oil flow to the various clutches. The spools are activated in turn by solenoid valves. These are activated electrically by the gear selector in the cab. As an optional extra an automatic gear changing system is available. See Group 20. The gearbox has three ratios in each dire ction and is also provided with disengagement, which is actuated by the brake pedal and comes into operation at a certain brake pressure.



TDCE01 04GB P. 4

Group 40

1 5

2 3

6

4

7

KEY 1ST 2ND 3RD 1. 2. 3. 4. 5. 6. 7.

Turbine wheel Pump impeller Stator Torque converter Oil filter Oil pump Clutch disc

G earbox C lark 28000/32000



Group 40

TDCE01 04GB P. 5

The valve body mounted on the side of the gearbox includes spool valves which guide the oil flow to the various clutches. The spools, in turn, are electrically activated from the selector lever in the cab. A mechanical gear-changing system is available as an option. The gearbox has three ratios in each dire ction and is also provided with disengagement, which is actuated by a separate inching pedal at the left brake pedal and comes into operation at a certain brake pressure. The electrical gear-changing system is either manual or automatical, see Group 20.

1 N F

Clark 32000 Gear Activated solenoids

3 2 R

The g earbox valve housing , C lark 32000

F3

F

F2

F, 2

F1

F, 1, 2

N3

-

N2

2

N1

1, 2

R3

R

R2

R, 2

R1

R, 1, 2



Group 40

TDCE01 04GB P. 6

Oil circuit The function of the oil is: – to transmit the engine output to the gearbox. The t orque converter can multiply the engine torque by up to three times, but at the expense of the speed rotation. – to apply the clutches in the gearbox. – to dissipate the heat from the torque converter. – to lubricate the gearbox and the torque converter. – to transport any solid particles to the filter. When the engine is running, the oil pump draws oil through a suction strainer from the gearbox sump and then delivers it through a fine filter to a pressure regulating valve. The regulating valve delivers oil at the right pressure to the gearbox valve body, which actuates the clutch plates for Forward/Reverse and 1st/2nd/3rd/4th. The clutches use only a small proportion of oil delivered by the pump. The remainder is fed through the torque converter circuit to the oil cooler, and returns to the gearbox for lubrication.

1. Converter 2. Oil cooler 3. Converter safety valve 4. Lube manifold 5. 6. Suction from transmission sump 7. Filter 8. Clutch pressure regulating valve 9. Solenoid valve, Forw 10. Solenoid valve, Rev 11. Clutches 12. 13. Pump

Oil circui t

Transmission Service


Group 40

TDCE01 04GB P. 7

Oil level check (transmission, incl. converter) Check the oil level daily with the engine at idling speed and the oil temperature between 82 and 93°C. Maintain the oil level at the FULL mark.

C lark 32000

Changing the gearbox oil and filter This should be carried out when the oil is at normal working temperature (82–93°C). 1. 2.

3. 4.

Oil filter

5. 6. 7. 8.

9.

Remove the gearbox drain plug and drain the oil. Release the suction strainer, withdraw it and clean the strainer gauze. N.B. If metal particles are found in the strainer gauze, investigate the reason before topping up with new oil. Fit a new gasket to the suction strainer and fit the strainer. Unscrew the filter bowl, remove the filter and fit a new filter element. Fit the new filter and tighten it. Fit the drain plugs and tighten them. Fill with oil to the MIN mark on the dipstick. Start the engine and run it at 500–600 r/min until the oil has reached working temperature, and the hoses, cooler and torque converter have been filled with oil. Keep the engine running at idling speed, check the oil level and top up to the MAX mark on the dipstick.

C lark 32000

IMPORTANT! In the event of g earbox damage, always replace the oil cooler – the damag e may have been caus ed by the oil cooler being faulty. 2

1 1. Suction strainer 2. Drain plug

S ucti on s trainer and drain plug

Transmission Service


Group 40

TDCE01 04GB P. 8

Checking pressures

IMPORTANT! When the check is carri ed out under identic al conditions , the pres s ure mus t not vary by more than 0.4 bar between the various clutches.

Converter outlet pressure: (”Converter out”) 1. The pressure should always be checked when the oil is at the normal working temperature of 80–95°C, the gearbox is in neutral and the engine is running at 2000 r/min. 2. The pressure should be above 1.7 bar, although the pressure must not exceed 4.9 bar when the engine is running at top speed.

Clutch pressure, all gears: 1. Indicated on the pressure gauge in the cab. 2. Parking brake set, oil temperature 80–95°C and engine at low idle. 3. Shift through all gears and F/R. The pressure should be 1720 bar.

N.B. In case of i ncorrect clutch press ure, firs t check the g earbox pres s ure s ens or, s ee pictur e. If more details concerning indivi dual tes t outlets are required, contact K ALMAR INDUSTR IES S E R VICE

C lark 32000 1

2

3

1. Oil cooler 2. Clutch pressure sensor 3. Measurement point “converter outlet”


Drive axle Kessler Description

Group 40

TDCE01 04GB P. 9

Downshifting in the drive axle is in two stages: in the differential, and in the hub reduction. This gives a minimum of stresses in the power transmission system since the final torque is achieved first at the driven wheels..

The differential The differential is a simple, hypoid type of taper gear drive, which means that the centre line of the pinion is offset in relation to the centre line of the crown wheel. The pinion is firmly journalled in two robust bearings.

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

Parking brake Hub reduction Wet disc brakes Differential Differential gear Crown wheel Differential spider Pinion Bearing



Group 40

TDCE01 04GB P. 10

Hub reduction The hub reduction consists of a cylindrical pla netary gear in each hub. The planetray gear comprises a sun gear, 4 planet gears, and a ring gear that surrounds the planet gears. When the drive axle, and thereby the sun gear, rotates, the rotational movement is transmitted to the planet gears. Because the ring gear is fixed firmly in the planetary gear carrier/hub, the planet gears move towards the ring gear. The hub follows this m ovement and the rotation is transmitted to the wheels. The gear ratio is determined by the number of teeth in the various gears.

1

2

3 4

5

1. 2. 3. 4. 5.

Planet gear Ring gear carrier Ring gear Sun gear Wheel hub/Planetary gear carrier



Group 40

TDCE01 04GB P. 11

Service brake The service brake consists of oil-cooled discs that are alternately fixed to and rotating with the hub. Hydrualic pressure is applied to activate a piston in each hub, the discs are then pressed together, and the wheels are braked. The resulting heat caused by friction is led away by the cooling oil circulating in the system. Oil from the truck’s hydraulic system is used as cooling oil, and this gives a high cooling capacity.

2 1

1. Brake piston 2. Brake discs



Group 40

TDCE01 04GB P. 12

Parking brake 5

13 11 7

The parking brake is a disc brake that acts on the drive axle’s input shaft and is applied by means of a powerful spring in a spring brake cylinder. The brake is released by a hydraulic pressure of at least 10 MPA from the parking brake valve in the driver’s cab. When the hydraulic pressure is too low, the parking brake is applied automatically. To be able to move the truck in that situation, the parking brake must be released by mechanical means, see below. When the parking brake is applied, the parking brake valve e vacuates hydraulic pressure from the brake cylinder. The cup spring then expands and its force is transmitted through the piston (6) to the adjusting screw (7) and then on to the thrust shaft (8), which in turn transmits the braking force to the brake linings. The position of the adjusting screw (7) determines the location of the spring’s working range in relation to the brake linings.

Adjustment 1

4

3

8 10

6

9

12

2

1. 2. 3. 4.

5. 6.

Apply a pressure to the brake cylinder by putting the parking brake valve in the ‘OFF’ position. Unscrew the lid 12. Loosen the lock nut 11 and screw in the adjusting screw 7 clockwise until the brake pads are close up to the brake disc. Unscrew the adjusting screw 7 counter-clockwise until the space between the pads and the disc is approx. 1 mm. Note that the spring in the brake cylinder has a very small working space. Fix the adusting screw with a hexagonal socket head wrench and lock the lock-nut 11. Fasten the lid 12 by hand.

Releasing the parking brake by mechanical means If the acumulator pressure drops below a certain level, the parking brake is applied automatically.

WARNING! Chock the wheels on s loping g round. 1. Housing 2. Bolt 3. Brake lining 4. Brake lining 5. Plate spring package 6. Piston 7. Adjusting screw 8. Thrust shaft 9. Ring 10. Space for hydraulic oil on releasing the parking brake 11. Lock-nut 12. Lid 13. Lock ring

If the truck needs to be moved: 1. Unscrew the lid 12. 2. Loosen the lock-nut 11 and unscrew the adjusting screw 7 counter-clockwise until the brake pads have loosened from the brake disc. 3. Fasten the lid 12 by hand.

WARNING! If the parking brake has been mechanically dis eng aged it must always be res et in order to res tore the park ing brak e function.

WARNING! The park ing brake contains a powerful, plate s pri ng pack ag e under heavy tens ion. If the cylinder i s dis mantled in an unproper way, parts may become loos e and fly out thus c ausi ng s erious damag e. DANGER TO LIFE! A lways chec k that the s pri ng pack ag e tens ion i s released before dis mantling the brake cylinder, s ee Dis mantling of the brake cy linder.

Dismantling of the parking brake cylinder Normally, there is no need of dismantling the parking brake cylinder. However, if for some reason it needs dismantling, follow the instructions below: 1. Unscrew the lid 12. 2. Loosen the lock-nut 11 and unscrew the adjusting screw 7 counter-clockwise until the brake pads have loosened from the brake disc. 3. Remove the lock ring 13, thereafter the integral parts can be removed.

Drive axle Kessler Service


Group 40

TDCE01 04GB P. 13

Changing the drive axle oil IMPORTANT! To as s ure that the wheel ends of planetary axles with a common wheel end/hous ing bowl oil level are ini tially lubric ated, fill each wheel end directly wi th oil before vehicle is put back i nto operation. DO NOT F ILL THE A XLE THROUGH THE DR IVE UNIT OR DIFFE RE NTIAL HOUSING ONLY.

1

1. 2. 3. 4. 3 2

5. 6.

4

7. 8.

9.

3 2

1. 2. 3. 4.

Differential Drain Fill up/level Hub

Drive axle oil

Drive the truck forward until the oil drain plug on one of the wheel hub reductions is at its lowest point of travel. Remove the oil plug and drain the oil and refit the plug. Repeat the procedure on the other wheel. Remove the drain plug from the underside of the differential and drain the oil. Refit and tighten the drain plug. Drive the truck forward so that the mark at the filling hole hub is horisontal. Fill the hub reduction with oil and refit the plug. Volume: See specifications. Repeat for next wheel. Remove the level plug from the differential and fill the differential with oil. Refit an tighten the leel plug. Volume: See specifications. Check oil level an refill as necessary.



Group 40

TDCE01 04GB P. 14

Installation of disc brake 1.

Insert the brake discs (4) and (5) alternately in the brake housing (2). 2. Measure the clearance A. 3. Fit the piston (3) in the brake spider (1). 4. Measure the clearance B. The difference between clearance A and B should be 2.5–3 mm.

5.

Slide ring

6.

7.

Installation taper NOTE the direction of installation The thin edge of the slide ring shall face the pressure area.

Fit the piston (3) so that the part with the largest diameter is facing downwards. Then place the seals in the groove using special installation tapers, one large and one small, free from any scratches, and not lubricated. Fit the O-ring in the lower groove using an installation taper, and push it over the large slide ring with the thinner edge facing upwards. Fit the O-ring in the upper groove using the other installation taper, and push it over the small slide ring with the thinner edge facing downwards.


Drive axle Kessler Service 8.

9.

10. 11. 12. 13. 14.

1. Brake 2. Brake housing 3. Piston 4. Inner disc 5. Outer disc 6. O-ring 7. Screw 8. Plug 9. Seal 10. Seal 11. Connection piece 12. Breather 13. Sealing ring 14. Sealing ring 15. Spring 16. Screw 17. Seal 18. Plug 19. O-ring 20. Face seal 21. Washer 23. Screw 25. Tube

Group 40

TDCE01 04GB P. 15

Check to marke sure the brake carrier (1) is free from scratches. Lubricate all internal surfaces, fit the brake piston (3), and align it to the tapped holes. Insert the springs (15) an washers (21) in the piston. Screw the piston firmly into the brake carrier (1) using the screws (16) coated and sealed with LOCTITE 262. Fit the O-rings (6) and (19). Screw in the breather (12) with seal (10) and connection (11). Screw in the sealing plugs (8) and (18) with seals (9) and (17). Move the brake carrier (1) up against the brake housing (2) and screw on securely using screws (7). Bleed the brake circuit and then check to make sure the circuit is fully sealed. When loading with a pressure of 12 MPa for 15 minutes, a pressure drop of 2% (down to 11.76 MPa) is permitted.



Group 40

TDCE01 04GB P. 16

Installing the brake on the axle 1. 2

1

2. 3.

4

3

5 4. 5. 1. 2. 3. 4. 5.

O-ring Slide ring Blocking edge Seat Tool

6. 7.

Check the sealing surfaces for the O-ring and apply a coat of LOCTITE 270 to the contact surfaces on the b rake spider. Push the brake onto the axle and screw on securely. Fit the slide ring seal (20) into the brake housing (2) using an installation tool. – Lubricate the sealing ring seat – Place the slide ring seal onto the tool; the tool presses only on the O-ring; – Push the O-ring over the blocking edge unti it snaps into position; – Lubricate the slide ring. Screw the sheel studs (35) into the wheel hub (24). Press the taper roller bearing’s cones (23) and (25) into the wheel hub (24). N.B. Do not hit it! Fit the slide ring seal (22) in the wheel hub (24). See also item 3. Fit the wheel hub.


Drive axle Kessler Service 8. 9.

Group 40

TDCE01 04GB P. 17

Align and centre the discs (4) using the tool. Apply pressure to the discs with the help of the brake’s hydraulic system. Fit the wheel hub onto the axle’s splines. Release the brake pressure.

10. Insert the taper roller bearing (8) against the stop in the ring gear carrier (7). Fit the ring gear (6) onto the ring gear carrier and secure with screws. 11. Fit the ring gear carrier and ring gear onto the axle’s splines. Turn the ring gear carrier so that the oil flow hole faces downwards. Then push the carrier and ring gear into the hub. 12. Screw the bearing nuts on and tighten them so that the hub can be turned by hand only with some difficulty. Then unscrew the bearing nut 1/8 of a turn and secure the nut. Check the resistance to roll – in the case of new bearings it should be about 11–17 Nm.



Group 40

TDCE01 04GB P. 18

Installation of hub reduction 1.

Press the spacer wahser (1) onto the spindle and seal with LOCTITE 270.

2.

Push the sun gear (2) onto the spindle and secure with the lock ring (3). Push the input shaft into the hub so that the spacer washer, sun gear, and lock ring are closely flush with each other.



Outer cardboard sleeve

Group 40

TDCE01 04GB P. 19

3.

Push the needle bearing into the planet gear (4). The outer cardboard sleeve in which the bearings are packed will then slide off.

4.

Fit the planet gears (4) onto the planetary gear carrier (5) – with needle bearing, inner cardboard sleeve, and spacer washer – as follows: – Apply a sealant to the hole in the planetary gear carrier for the planet gear shafts (6). (Fit an O-ring where applicable). – Press the planet gear shaft (6) in from the inside, and make sure the security holes in the shaft and planetary gear carrier are opposite each other. When the planet gear shafts are pressed in, the inner cardboard sleeves in the bearings will be pressed outwards.

Inner cardboard sleeve

N.B . T he s hafts are slig htly tapered and cannot, therefore, be pres s ed outwards in the other dir ection as the planetary g ear carrier would then be damaged. Sealant

Cardboard sleeve

5. 6.

Secure the planet gears with the safety pin (7). Install the planetary gear carrier onto the hub.

7.

Screw the adjusting screw (8) in against the stop on the insert shaft and then unscrew the adjusting screw 45–90°. This corresponds to an axial clearance of between 0.2 and 0.4 mm for the insert shaft. Secure the adjusting screw with the lock nut. Hold the adjusting screw firmly to prevent it from turning with the lock nut.

8.



Group 40

TDCE01 04GB P. 20

Dismantling the planet gear 1. 2.

Tap the safety pin out from the inside. Press the planet gear shafts out from the outside and inwards in the planetary gear carrier.

N.B . T he s haft are s lig thly tapered and cannot, therefore, be pres s ed outwards in the other dir ection as the planetary g ear carrier would then be damaged. 3.

Remove the planet gear, spacer washers, bearings.


Contents

Group 60

TDCE01 04GB P. 1

Group 60 Steering axle Specifications ............................................................................ 2 Steering axle.............................................................................. 3 Description ........................................................................... 3 Service ................................................................................. 4 Replacement of steering cylinder .................................... 4 Replacement of steered wheel bearings ......................... 4 Replacement of knuckle pin bearings ............................. 6 Inspection of dismountable rims...................................... 8 Safety test when changing tyres ................................... 10

DCE80-100E

Specifications

Technical Handbook

Group 60

TDCE01 04GB P. 2

Tightening torques

Nm (kpm)

Wheel nuts

650 (66)

Steered wheel bearing nuts

500 (51)1)

Nuts for upper knuckle-pin bearings

500 (51)

Nuts for lower knuckle-pin bearings

500 (51)

Steering cylinder, mounting screw M20

385 (39), oiled screw

1)

Steered wheel bearings should be tightened d uring simultaneous rotation of the wheels. This makes the bearing rollers set correctly. Note that a jacked-up wheel gives a certain resistance when rotated. After tightening of steered wheel bearings, the truck should be run for some 100 meters. After that the bearing nut should be tightened again to 500 Nm. Then the bearing nut must not be loosened.

Steering axle Description


Group 60

TDCE01 04GB P. 3

The steered axle is supported by a pendulum suspension and is operated by a double-acting steering cylinder. The mechanism includes the smallest possible number of moving parts to minimise the number of service points and to simplify maintenance. The mounting in the chassis comprises entirely maintenance-free rubber elements. The knuckle pins and wheel axles are mounted in taper roller bearings. The hydraulic circuits of the steering system are described in Group 70.

1

2

3 4

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

Rubber element Steering cylinder Upper bearing Link lever Lower bearing Knuckle pin Steering cradle

S teered axle

Steering axle Service


Group 60

TDCE01 04GB P. 4

Replacement of steering cylinder 1

2

1.

Disconnect the hydraulic connections from the steering cylinder, and protect the open ends of the cylinder and hoses by means of caps or plugs.

2. 3.

Release and remove the piston rod pivot spindles. Remove the bolts retaining the cylinder on the steering cradle. Remove the cylinder. Fit the new cylinder and coat the mounting bolts with LOCTITE. Tighten according to specification.

3

4. 5. 6. 7.

Connect the piston rod ends to the link levers. Secure the pivot spindles by means of the locking washers. Connect the hydraulic hoses.

Replacement of steered wheel bearings Dismantling 1. Jack up the steered wheel end of the truck and block it up in a safe manner. 2. Unscrew the wheel bolts from the steered wheel and remove the wheel.

N.B . A trolley with a res t for holding the wheel s ecurely will be needed for handling purposes .

4 1. 2. 3. 4.

Steering cylinder Spindle Locking screw Mounting screw, lock with LOCTITE

3. 4.

5. 6.

7. 8. 9.

Remove the hub cover. Secure a lifting sling to the hub, preferably using one of the hub bolts. Fit a nut to secure the bolt. Use a hand trolley, pallet truck or the like for lifting the hub. Remove the locknut, tab washer and bearing nut. The plain washer is loose. Remove the hub off the wheel axle by means of the hand truck. The inner race of the outer bearing will accompany the hub. Withdraw the inner race of the inner bearing from the wheel axle. Remove the seal. Remove the outer races from the hub.

Assembly 1. Pack the outer races of the bearings with grease and press them into the hub. Note that these are taper bearings. Fit the inner ra ces so that the larger inside diameter faces outwards. A round plate should be made for each bearing size for pressing in the races. A heavy hammer can then be used t o hammer the plate for driving in the race. Don’t hammer the bearings directly since they may not enter straight and may become jammed in the housing. 2.

Press a new seal into the hub. Use a suitable round plate for this purpose. Tapping the seal itself with a hammer will damage it.

3.

Clean the spacer and pack it with grease.



Group 60

TDCE01 04GB P. 5

1. Rubber element 2. Steering cylinder 3. Spindle 4. Locking screw 5. Lubricating nipple 6. Upper bearing 7. Wiper 8. Knuckle pin 9. Protective ring 10. Sealing ring 11. Lower bearing 12. Locking ring 13. Shims 14. Bearing holder 15. Steering cradle 16. Lubricating nipple 17. Spindle 18. Link lever 19. Sealing ring 20. Inner bearing 21. Wheel screw 22. Hub 23. Outer bearing 24. Washer 25. Bearing nut 26. Locking washer 27. Locknut 28. Protective cover 29. Wheel nut

R eplacement of s teered wheel bearing s and knuc kle pin beari ng s


Steering axle Service 4. 5.

Group 60

TDCE01 04GB P. 6

Tap the inner race of the inner bearing onto the wheel axle, using a suitable tube. Pack the inner race with grease. Lift the hub onto the axle, fit the inner race of the outer bearing position and pack it with grease.

6.

Fit the plain washer and bearing nut with the flat surface facing inwards. Tighten the bearing to 500 Nm during simultaneous rotation of the wheel to make the bearing rollers set correctly. After tightening of the steered wheel bearings, the truck should be run for some 100 meters. After that the bearing nuts should be retightened to 500 Nm. Thereafter, the bearing nut must not be loosened. 7. Fit the tab washer and locknut. Grease the tab washer to prevent damage by the nut. Tighten the locknut and lock both the bearing nut and the locknut with the tabs. 8. Pack the outer bearing with grease, pack the bearing cover with grease and fit it into position . Top up with grease through the grease nipple.

Replacement of knuckle pin bearings Dismantling To replace the knuckle pin bearings, the wheel bearings must also be removed. 1. To replace the knuckle pin bearings, the wheel bearings must also be removed. 2. Remove the wheel nuts from the steered wheel and remove the wheel.

N.B . A trolley with a res t for holding the wheel s ecurely will be needed for handling purposes . 3.

4. 5. 6. 7.

Remove the protective cover and release the lock washer. Remove the locknut and bearing nut, and remove the inner part of the outer baring. Remove the hub. Remove the inner part of the inner bearing.

Remove the steering link. Remove the protective cover and the sealing from the lower bearing. 8. Unscrew the three screws above the knuckel pin’s upper bearing, on top of the steering cradle. Depress the knuckle pin be screwing three screws (length 17 mm) into the holes. 9. Lift out the wheel axle. 10. Remove the inner race of the upper and lower bearing.



Group 60

TDCE01 04GB P. 7

Assembly 1. Tap the outer race of the upper bearing into the steering cradle from below, using a piece of tube. 2. Fit the screw back into the drift holes. Seal with sealing compound. 3.

Attach the following parts to the knuckle pin: upper bearing’s inner race and sealing, lower bearings nut, tab washer, spacer and inner race. 4. Mount the knuckle pin. 5. Tap the outer race of the lower bearing into the steering cradle. 6. Tighten the cover and sealing upon the lower bearing. 7. Check that the knuckle pin rotates smoothly with a maximum play of 0.25 mm. if not, adjust with the bearing nut and lock with the tab washer. Make sure that the se aling ring align tightly. 8. Lubricate the bearings by means of the lubricators. 9. Mount the link lever. 10. Mount the steering wheel bearing. See Replacement of steering wheel bearing, Assembly.

1

Miscellaneous The steered wheel alignment is not adjustable. If the link levers have been deformed so that the wheel alignment has been disturbed, the link levers must be replaced. NOTE. The orientation of the link levers must be correct, since they will otherwise be damaged by the wheels when the steering movements are large. The correct orientation of the levers is shown in the figure.

2

1. Link lever 2. Knuckle pin



Group 60

TDCE01 04GB P. 8

Inspection of dismountable rims Due to special operating conditions for dismountable rims, theres is a risk of excessive wear of the lock ring groove in the rim bead, the lock ring itself and the 45° face on the beadseat or loose flange. In extreme circumstances this can lead to breakage of the rim bead which in turn has potentially dangerous consequences. To minimize the risk of an accident the inspection should be carried out on all EM-wheels (EM=Earth Moving) a nd dismountable rims.

7 2 3

1

6

5

4

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

Lock ring Beadseat 45° surface on the beadseat or loose flange Lock ring groove Rim bead O-ring Support ring

Di fferent parts of the dis mountable rim



Group 60

TDCE01 04GB P. 9

Inspection procedure 1. 2. 3.

4.

A

5. 6. 7.

Dismantle the rim according to the standard procedures, see also Safety instructions when working with tyres, group 00. Carefully clean the outside of the rim beadrim bead by using a wire brush. The wear of the lock ring on the rim bead outside diameter can produce a mark A. The mark is located between the ends of the lock ring, see picture. Measure the depth of the wear at this point using av straight edge and feeler gauge. If the wear exceeds 0,5 mm, the wheel, the lock ring, and the beadseat or loose flange must be discarded and replaced with new. If a wear mark is not possible to find, measure the circumference of the rim bead using a measuring tape. Calculate the diameter D = Circumference/3.14 If the diameter is below the minimum specified, the wheel, the lock ring and the beadseat or loose flange must be discarded. Information on the minimum diameter of your rim bead can be recieved from Kalmar LMV.

D D

High stress areas, how to identify rim damage 1. 2. 3.

B B

B

High stress areas are marked with B on the illustration Typical faults are: circumferential cracks, fretting, corrosion pitting, distortion, wear. Inspect above areas at each tyre change



Group 60

TDCE01 04GB P. 10

Safety test when changing tyres The test is intended for detecting cracks in wheels. Cracks can lead to safety risks if they are not detected and remedied. Potential cracks that cause air leakage are not detected in the test described here. The test is carried out in two steps 1. Magnetic examination, which quickly indicates the crack. 2. The actual crack is then tested with penetrance. Magnetic examination 1. Dismantle the loose componentes of the wheel 2. Clean area A on the the wheel totally for paint residue by using shot blasting.

A

3.

Carry out magnetic examination by using e.g.: Equipment: Yoke Tiede Technique: a. Electricity AC b. Contrast paint Test medium: a. Wet b. colour (E-G- Tiede ferrolux)

4.

If no cracks are indicated in the magnetic examination, the test is completed and the wheel approved. In case cracks are indicated, carry out the penetrance test.

Penetrance test 1. Clean area B with cleaning fluid, part.no. 923626.0668. 2. Spray penetrance on the cleaned area and let the sprayed area dry for approximately 10 minutes Penetrance: Part no. 923626.0669 3. Clean off the penetrance by using cleaning fluid (Part.no. 923626.0668). All excessive penetrance should be removed. 4. Wipe off the cleaning fluid with a cloth, the remaining penetrance must evaporate.

B

5. 6. 7. 8. 9.

C

C = Linear split or crack D = Dot shaped crack

D

Spray developer on the area B. Developer: Part.no 923626.0670 Let the sprayed area dry for 1-2 hours. Inspect the lock ring groove visually. If the marked area B shows no linear or dot shaped cracks the wheel is approved. If the marked area B shows linear or dot shaped cracks, the wheel must be rejected.

C = Linear split or crack D = Dot shaped crack


Contents

Group 70

TDCE01 04GB P. 1

Group 70 Hydraulic system Specifications ........................................................ ................... 2 Main hydraulics.......................................................................... 3 Description ........................................................................... 3 General survey ............................................................... 3 Standad hydraulic system ............................................... 3 Supply ........................................................................ 4 Hydraulic servo .......................................................... 5 Electric servo ............................................................. 6 Hydraulic system with separate side-lift hydraulics ......... 7 Supply ........................................................................ 9 Electric servo ........................................................... 10 Lifting ............................................................................ 11 Lowering brake valve .................................................... 12 Tilting............................................................................. 13 Attachment supply........................................................ . 14 Service ............................................................................... 15 Checking the hydraulic hoses ...................................... 15 Breather filter................................................................. 15 Changing the hydraulic fluid .......................................... 10 Mounting of fittings on hydraulic hoses ........................ 15 Checking the pressures and settings, standard system 16 Checking of pressure and setting, system with separate side-lift hydraulics........................................... 17 Steering system 19 Description ......................................................................... 19 Steering valve ............................................................... 20 Brake system........................................................................... 22 Description ......................................................................... 22 Brake system WDB-system........................................... 22 Oil cooler ............................................................. .......... 24 Service ............................................................................... 25 Checking the brake system ........................................... 25 Parking brake .......................................................................... 26 Description ......................................................................... 26 Hydraulic pumps...................................................................... 27 Description ......................................................................... 27 Service ............................................................................... 30 Accumulator............................................ ................................. 32 Description ......................................................................... 32 High pressure filter .................................................................. 33 Description, service ........................................................... . 33 Main valve ............................................................................... 34 Description ......................................................................... 34 Service ............................................................................... 37 Hydraulic cylinders .................................................................. 38 Service ............................................................................... 38 Hydraulic circuit diagram, components............................... .... 44 Hydraulic circuit diagram, hydraulic servo A06195.0500......... 45 Hydraulic circuit diagram, electric servo A06195.0600............ 47 Hydraulic circuit diagram, electric servo A44866.0100............ 49


Group 70

TDCE01 04GB P. 2

For different pressure settings, see the hydraulic plate on each truck

5

6

7

1 2

3

4

1. Test outlet and pressure setting separate lift section (14 and 12 on hydraulic diagram) 2. Test outlet and pressure setting working hydraulics (9 and 13 on hydraulic diagram) 3. Test outlet and pressure setting steering system (15 and 2 on hydraulic diagram) 4. Test outlet servo pressure, not adjustable ((8 on hydraulic diagram) 5. Test outlet, brake pressure (52 on hydraulic diagram) 6. Test outlet accumulator charging (10 on hydraulic diagram) 7. Pre charging pressure, accumulators


Main hydraulics Description

Group 70

TDCE01 04GB P. 3

General survey

. There are two different hydraulic systems  Standard with hydraulic servo Diagram A06195.0600 or with el-servo Hydraulic diagram A06195.0500  System with separate side-lift hydraulics Diagram 44866.0100

Standard hydraulic system, Diagram A06195.0600 The hydraulic system consists of the following sub-systems.  Main hydraulics with the following functions: – Lifting – Tilting – Sideshift – Length adjustment – Twist-locks  Steering system  Driving brake system for wet brakes with: – Brake circuit – Cooling circuit  Parking brake system The hydraulic system is configured around two single hydraulic pumps which are driven by take-offs on the torque converter. All of the essential valve functions are concentrated to a valve block that is directly connected to the main valve. One of the pumps powers the lifting function. Some of the return fluid is by-passed to the cooling circuit of the driving brake system to dissipate heat and is then le ad to the reservoir.

1. Hydraulic pump, working hydraulics, steering system, accumulator charge 2. Hydraulic pump, LIFT 3. High pressure filter 4. Main valve with valve block a.Accumulator charging valve With charged accumulator feed to brake cooling circuit or tank return b .Feed to servo system c. Priority valve, steering system d. Feed to steering system e. Main pressure limiting valve f. Control section TWIST-LOCKS g. Control section LENGTH ADJUSTMENT h. Control section SIDESHIFT j. Control section TILT k. Main pressure limiting valve m. Control section LIFT 5. Steering system 6. Cooling circuit for service brake system 7. Brake circuit service brake system 8. Parking brake system 9. Accumulator 10. Accumulator discharge valve 11. Safety valve, accumulator 12. Servo controlled control levers 13. Solenoid valve, safety system, twistlocks 14. Solenoid valve, safety system, lift 15. Hydraulic tank 16. Breather filter, hydraulic tank 17. Hydraulic oil cooler

Hydr aulic s ys tem, standard



Group 70

TDCE01 04GB P. 4

The other hydraulic pump delivers fluid to the other functions of the main system and to the accumulator which in turn serves the parking brake, driving brake and servo system of the control levers (optional). All surplus fluid is supplied to the lifting function. When the accumulator is fully charged and the lifting function is deflected to maximum, the capacity of both pumps is utilized for maximum lifting speed. The fluid is cleaned through a high pressure filter upstream after each pump.

20a

20b

23

50 23

31

The numbers correspond to the hydraulic diagram 20a. 20b. 23. 31. 50.

Hydraulic pump Hydraulic pump High pressure filter Hydraulic tank Breather filter

Hydraulic system, supply



Group 70

TDCE01 04GB P. 5

Standard hydralic system, hydraulic servo In its standard version, the hydraulic system is equipped with a hydraulic servo-operated main valve. A pressure reducing valve in the valve block delivers 35 bar servo pressure for the controllever valves. The servo fluid is then supplied to the main valve for setting the valve spools, at a rate that is proportional to the lever movement. Safety interlock, container handling To prevent accidents when lifting containers, the servo circuit for lift is supplied with a solenoid valve. This is activated from the inductive sensors for twist-locks locked or unlocked on the attachment. Should the twist-locks not be fully locked or unlocked, lifting is prevented. In the same way the servo circuit for twist-locks is supplied with two solenoid valves, one for locking and one for unlocking twistlocks. The solenoid valves are fed with signals from the inductive sensors for alignment on the attachment. If full alignment is not achieved, the locking and unlocking of twist-locks is prevented.

43

16 45 46 44

The numbers correspond to the hydraulic diagram 16. Control valve LIFT 43. Control levers 44. Control valve TWIST-LOCKS 45. Solenoid valve, brakes the servo circuit for TWIST-LOCKS 46. Solenoid valve, bryter the servo circuit for LIFT

S tandard hydraulic s ys tem, hydraulic s ervo



Group 70

TDCE01 04GB P. 6

Standard hydraulic system, el-servo Standard hydraulic system can be equipped with a electronically servo-operated main valve. The ECS-system’s out-signals for the lever functions are fed to converters. The converters are electrically controlled pressure reduction valves that convert the electrical signal to a proportional hydraulic pressure - servo pressure. The servo fluid is then supplied to the main valve for setting the valve spools, at a rate that is proportional to the lever movement. The security locking is integrated in the ECS-system, se separate publications.

E C S -s ys tem, s ee s eparate publications

6





 









51 



51. Electro-hydraulic converters 1. TWIST-LOCKS 2. LENGTH ADJUSTMENT 3. SIDESHIFT 4. TILT 5. LIFT 6. Feed 35 bar servo pressure

S tandard hydraulic s ys tem, E lectro-hydr aulic s ervo



Group 70

TDCE01 04GB P. 7

Hydraulic system with separate side-lift hydraulics Hydraulic diabram A44866.0100 The hydraulic system consists of the following sub-systems:  Working hydraulics, machine, that include: Servo hydraulics that supply pressure to the electro-hydraulic servo system

– TILT – LIFT 

Attachment hydraulics (see group 80) – SIDESHIFT – TWIST-LOCKS – LENGTH ADJUSTMENT 20-40’ – LEVELLING



Service brake system, WDB system – Brake circuit, hydraulically controlled, oil-cooled plate brakes – Cooling circuit



Parking brake system, disk brake on the drive axle's ingoing shaft. Applied by spring pressure, released hydraulically.



Steering system

Electro-hydraulic servo system, principles The working hydraulics are controlled via an electro-hydraulic servo system, the principle components of which are illustrated on the next page. All hydraulic system functions are controlled via three independent sub-systems: – El-servo – hydraulic-servo – working hydraulics The el-servo system is controlled by the ECU5 centra l computer unit as part of the truck's ECS system. Descriptions of the servo circuits can be found in separate pub lications. From ECU5, digital or analogue signals are fed to the control lever. The signals are affected by the degree of movement of the control lever, after which they are fed back t o and processed in ECU5. The out-signals for LIFT/LOWE R and TILT INWARDS/OUTWARDS from ECU5 are fed to converters. The converters are electrically controlled pressure reduction valves that convert the electrical signal to a proportional hydraulic pressure - servo pressure. The side-lift is controlled in the same way. The servo pressure affects the control slide in the main valve for the function in question and from there, the main flow.

E C S -s ys tem, s ee s eparate publications





Group 70

TDCE01 04GB P. 8

















 



























 

  









 

 





  

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

Variable axial piston pump Relief valve Fixed ving pump Fixed ving pump Fixed ving pump High pressure filter Cab tilting Connector, side-lift hydraulics Main valve a. Accumulator charging valve b. Pressure reducing valve servo system c. Pressure reducing valve and priority valve, steering system d. Differential valve, gives max 11 bar pressure difference between steering valve LS-signal and the pump pressure e. Main pressure limiting valve TILT f. Control section, TILT g. Main pressure limiting valve LIFT h. Control section LIFT 10. Steering system

12. Accumulator 13. Accumulator evatuating valve 14. Safety valve, accumulator 15. Service brake system 20. Cooling circuit, service brake system 21. Parking brake system 24. Oil cooler 25. Converter el-servo/hydraulic servo 30. Hydraulic oil tank 31. Breather filter 32. Nozzle-check valve cooling circuit 33. Main valve, attachment a. Control section SIDESHIFT b. Control section TWIST-LOCKS c. Control section 20-40’ d. Control section LEVELLING e. Pressure reducing valve servo

Hydr aulic s ys tem with separate si de-lift hydraulics



Group 70

TDCE01 04GB P. 9

Working hydraulics, supply The hydraulic system is supplied from four different pumps. Pump 18+19 is a double combination pump where one section is a variable axial piston pump and the other section is a fixed ving pump. The variable pump 18 feeds the side-lift and is equipped with relief valve 18a which allows the pump to start without counter pressure.The ving pump 19 feeds the machine’s working hydraulics over the valve block 54. The valve block is equipped with accumulator charging valve, pressure reducing valve for servo system, pressure limitiation and priority valve for the steering circuit. The priority valve ensures pressure to the steering system, thereafter servo pressure and that the rest flow is fed to tilt and lift. Pump 20a + 20b is a double pump of the ving type, where pump 20a feeds lift and pump 20b feeds the cab tilt. (Cab tilt is extra equipment) The oil is cleaned by high pressure filters, one after each pump.

20a 20b 18

53 23

12

13

19 16 23

18a

17 51 23

31

54

Numreringen gemensam med Hydraulschema A44866.0100 12. 13. 16. 17. 18. 18a. 19.

Huvudtryckbegränsningsventil LYFT Huvudtryckbegränsningsventil TILT Manöverventil LYFT Manöverventil TILT Variabel axialkolvpump, matning aggregat Tryckavalstningsventil Vingpump, matning ackumulatorladdning och TILT

20a. Vingpump, matning LYFT (Kugghjulspump vid system utan hyttilt) 20b. Vingpump, matning hyttilt (Extra utrustning) 23. Högtrycksfilter 31. Hydraultank 51. Andningsfilter 53. Växlingsventil, hyttilt 54. Plint, matning aggregat, se vidare grupp 80

Hydr aulic s ys tem with s eparate s ide-lift hydraulic s , feed machine hydr aulics



Grou Group p 70

TDCE01 04GB P. 10

Hydraulic system with separate side-lift hydraulics, el-servo This hydraulic system is equipped with a electronically servooperated main valve. The ECS-system’s out-signals for the lever functions are fed to converters. The converters are electrically controlled pressure reduction valves that convert the electrical signal to a proportional hydraulic pressure - servo pressure. The servo fluid is then supplied to the main valve for setting the valve spools, at a rate that is proportional to the lever movement

E C S -s ys tem, tem, s ee s eparat eparate e publications publications S ee als als o Gro G roup up 80 Sid S ide-lift e-lift

3

51

2 1

51. Elektrohydrauliska omvandlare 1. Matning 35 bar servo 2. Elektro-hydraulisk omvandlare TILT 3. Elektro-hydraulisk omvandlare LYFT LYFT

E l-s l-s ervo machine, machine, s eparat eparate e s ide-lift ide-lift hydraulics



Grou Group p 70

TDCE01 04GB P. 11

Lifting The lifting cylinders are supplied from a separate section in the main valve. The lifting speed is determined by the position of the lift control lever. The flow of fluid from the hydraulic pumps can be changed by altering the engine speed, which thus provides an additional means of controlling the lifting speed. During lowering, the fork carriage and the effect of the load force the fluid from the lifting cylinder s into the reservoir. A lowering brake valve in the supply line to each lifting cylinder determines the lowering speed and also limits the flow of fluid in the event of hose failure. The lowering brake valves are of pressure-compensated type and therefore permit only a certain predetermined flow, thus ensuring a constant lowering speed, regardless of the actual load. Some of the return fluid is by-passed to the valve block and from there to the cooling circuit of the driving brake. The lifting cylinders are filled with fluid on the piston side to prevent corrosion. This fluid is not pressurized and is fed back to the reservoir in step with movement of the piston. Any leakage is also drained to the reservoir through these lines.

A 16

12



27 26

27

26

31

The numbers correspond to the hydraulic diagram A = System with separate side-lift side-lift hydraulics 12. Main pressure limiting valve LIFT 16. Main valve, control section LIFT 26. Lift cylinder 27. 27. Lowe Loweri ring ng brak brake e val valve ve

Li fting fting function function



Grou Group p 70

TDCE01 04GB P. 12

Lowering brake valve The lowering brake valves are screwed into t he connecting pipes at the bottom of the cylinders. They are preset and no adjustment facilities are provided. The valve contains a spring-loaded control plunger and a movable orifice plate, both of which interact to provide a constant flow through the valve regardless of the prevailing load. During lifting, the orifice plate and the control plunger are in a p osition which allows unrestricted flow of fluid. During lowering, the orifice plate moves to the throttling position. The inter nal pressure drop in the valve and the pre-load force of the control plunger spring counteract one another and set the control plunger in an equilibrium position, ie. in relation to the corresponding size of the throttle gap. Large load – small gap, small load – large gap.

1

. 2

3

4 1. 2. 3. 4.

Cont Contro roll plun plunge ger r Thro Thrott ttlin ling g slot slot Orifice Orifice plate plate in the thrott throttling ling position position Orifice Orifice plat plate e in the open open posit position ion

Lowering brake valve valve



Grou Group p 70

TDCE01 04GB P. 13

Tilting The two tilting cylinders enable the mast to be tilted 3° forward and 3° to the rear. (Optional 2°/3° or 3°/6°) In each of the return lines is a valve which provides counter-pressure to avoid inadvertent forward tilt, which would otherwise occur in unrestricted flow in the forward tilt mode.

A



29

28

17

28

1. Contro Controll sect section ion,, TIL TILT T 2. Tiltin ilting g cyli cylind nder er 3. Counte Counterr pres pressur sure e valv valve e

29

The numbers correspond to the hydraulic diagram A = System with separat side-lift hydraulics hydraulics 17. Control valve, TILT 28. Tilt Tilt cylinder 29. Counter Counter pressure valve

Tilting function



Grou Group p 70

TDCE01 04GB P. 14

Attachment supply One section in the main valve for each of the functions sideshift, length adjustment 20’-40’ and twist-locks feeds the attachment cylinders.

Only S tanda tandard rd hydraulic s ys tem. tem. S ee als als o Gro G roup up 80 Si S i de-lift attachment attachment

18 19

44

The numbers correspond to the hydraulic diagram

48

47

30

18. Control valve SIDESHIFT 19. Control valve LENGTH LENGTH ADJUSTMENT 30. Supply cylinder SIDESHIFT 44. Control valve TWIST-LOCKS 47. Supply cylinders LENGTH LENGTH ADJUSTMENT 48. Supply cylinders TWIST-LOCKS TWIST-LOCKS

A ttachment ttachment s upply

Main hydraulics Service


Grou Group p 70

TDCE01 04GB P. 15

WARNING! The hydraulic hydraulic sy s tem tem includes a hig h-press ure accumuaccumulator. lator. Open the acc umulator umulator evacuating valve 42to release lease press ure before before worki ng on the the hydraul hydraulic ic s ys tem. tem.

Take great care during all work on the hydraulic system. Avoid being close to pressurized hydraulic components and hoses. Observe strict cleanliness, since the presence of foreign matter can easily result in a valve seizing or in other operational disturbances.

42

Checking the hydraulic hoses Check hydraulic hoses and connections for leakage, cracking and wear. Replace hoses if there is the slightest indication of weakness. Tighten the connections as required. Breather filter The hydraulic reservoir is fitted with a breather filter which prevents airborne impurities from entering the reservoir. Change the filter as specified in the lubrication chart. The filter is of the spinon type. To change the filter, remove the old filter element, discard it and screw on a new element.

42. Accumulator evacuating valve

Changing the hydraulic fluid Change the hydraulic fluid in accordance with the lubrication chart. 1. Remove Remove the the bottom bottom plug of the the hydrau hydraulic lic rese reservoi rvoirr and drain drain off the fluid. 2. Refit Refit the plug plug and and fill the the reserv reservoir oir with with fresh fresh hydra hydrauli ulic c fluid. fluid. The capacity is given in the Technical Specification.

1

2

Mounting of fittings on hydraulic hoses. 1. Measure Measure the length length of the the hose to be be repla replaced ced.. 2. Thread Thread the the sleeve sleeve ANTICLO ANTICLOCKWI CKWISE SE onto onto the the end end of the the hose until the hose bottoms in the sleeve. The sleeve has an internal thread which will thus be pressed into the hose. 3. Grease Grease the the adapt adapter er thre thread ad and and screw screw in the the adapte adapterr CLOCKWISE until it bottoms on the sleeve. The hose will thus be clamped between the threads of the sleeve and adapter.

4. Carefully Carefully flush flush the the hose with white white spirit, spirit, or equivalent, equivalent, and blow compressed air through it, so that the hose is abso lutely clean. 3 1. 2. 3. 4.

IMPORTANT! The above procedure may may be us ed only on 1" and smaller smaller diamet diameter er hos es. In addition, it may may only be us ed on hoses s hown in i n the s pare parts c atalog atalog ue, with wi th the the sleeve s leeve and and adapter adapter s eparated eparated from the hos e.

Hose Sleeve Adapter Meas Measur ure e the the hose hose length like this:

4

Hos es s hown in the spare parts parts catal catalog og ue as as complet complete e units with the end connections connections fitted fitted must be ordered as as complete complete units in acc ordance with the catalog catalog ue.



Group 70

TDCE01 04GB P. 16

Checking the pressures and settings

42

1. 2.

3. 4. 5. 6.

7. 8.

Open the accumulator evacuating valve 42 and start the engine. Stop the engine to check that the stopping device is working. When making the following tests, use a manometer with a hose of suficcient length so as the reading can be made fr om inside the operator’s cab. Start the engine and let it run at approximately 1200 r/min. Close the accumulator evacuating valve 42. Servo pressure on test point 8. The pressure should be 35±5 bar and it cannot be adjusted. Steering pressure on test point 15. Allow the engine to run in the mid-speed range and turn the steering wheel to full lock in one direction. Pressure setting, see hydraulic plate. Correct with adjusting screw 2 as required. Accumulator charging pressure on test point 10. Pressure setting, see hydraulic plate. Correct with adjusting screw 1. Main hydraulic pressure on test point 9, and lifting section pressure on test point 14. The pressure of each output shall be equal. The pressure is set individually for each truck and is stated in the delivery specification and the hydraulic plate. The pressure should be set equally on adjusting screws 12 and 13 so that the truck can only just lift its rated load at the appropriate load centre. The adjusting screw must be sealed after making any adjustment.

The numbers corrspond to the hydraulic diagram 1. Adjusting screw, accumulator charging pressure 2. Adjusting screw, steering system pressure 7. Test point, brake system cooling circuit, max. 1 bar 8. Test point, servo pressure, not adjustable 9. Test point, main hydraulics Shall be same pressure as 14 10. Test point, accumulator charging 12. Adjusting screw, main pressure limiting valve Set the same as 13 13. Adjusting screw, main pressure limiting valve Set the same as 12 14. Test point, separate lifting section Shall be same pressure as 9 15. Test point, LS-signal from steering valve

Test and adjus ting points for valve block and main valve



Group 70

TDCE01 04GB P. 17

Checking of pressures and settings, system with separate side-lift hydraulics

A

1. When making the following tests, use a manometer with a hose of suficcient length so as the reading can be made from inside the operator’s cab. 2. Unscrew the connection at A on the variable pump and fill the pump with hydraulic oil. Reconnect A.

42

3.

Open the accumulator evacuating valve 42 and start the engine. 4. Stop the engine to check that the stopping device is working. Pressure, accumulator charging 5. Connect the manometer to test outlet 10. 6. Start the engine and let it run at 1200 r/min. 7. Close the accumulator charging valve 42. 8. The pressure in 10 should increase from the accumulator pre.charging pressure up to the charging pressure according to the hydraulic plate. Adjust if necessary on adjustment screw 1.

12

Pressure Steering system 9. Stop the engine and slightly lift up the machine to relieve the steering wheels.

13

2 15

14 

10.Connect th manometer to test outlet 15. 11.Start the engine and let it run at 1200 r/min 12.Check the steering pressure in test outlet 15. Turn the steering wheel in one direction. Let the steering spindle go to stop and read the pressure. The pressure readin g should be according to the hydraulic plate. Adjust if necessary on adjustment screw 2. Pressure servo system 13.Connect the manometer to test outlet 8. The pressure reading should be 35±5 bar. Tis pressure cannot be adjust ed.

9 10 8

1

(Numreringen gemensam med Hydraulschema A44866.0100) 1 2. 8 9 10 12 13 14

Justerskruv, ackumulatorladdningstryck Justerskruv, tryck i styrsystem Mätuttag servotryck 35±5 bar, ej justerbart Mätuttag, TILT Skall ha samma tryck som 14 Mätuttag, ackumulatorladdning Justerskruv, huvudtryckbegränsningsventil LYFT. Ställs lika med 13 Justerskruv, huvudtryckbegränsningsventil TILT. Ställs lika med 12 Mätuttag, LYFT Skall ha samma tryck som 9

Pressure working hydraulics, TILT and LIFT 14.Connect the manometer to test outlet 9. Operate the tilt function until stop and read the manometer. The pressure reading should be according to the hydraulic plate. The pressure reading should also be equal to the pressure in outlet 14, see next item. Justera vid behov på justerskruv 13. 15.Connect the manometer to test outlet 14. The pressure is set individually for each truck and is stated in the delivery specification and the hydraulic plate. The pressure should be set so that the truck can only just lift its rated load at the appropriate load centre. The pressure should be equal to the pressure in outlet 9. Adjust if necessary on adjustment screw 12. 16.The adjusting screw must be sealed after making any adjustment.

..to be continued next page.

Mät- och jus tering s punk ter, ventilblock och huvudventil



Group 70

TDCE01 04GB P. 18

Pressure side-lift 17.Connect the manometer to test outlet B on the sid-lift sidlyftens main valve.

B

C

20.Connect the manometer to test outlet D Check the pressure for the different functions of the side-lift by allowing the function to run to its end position and then read the manometer. The pressures shluld be. – LEVELLING 180 bar – SIDESHIFT 130 bar – TWIST-LOCKS 180 bar – LENGTH ADJUSTMENT 20-40’ 130bar

D

F

18.Increase the pump pressure by adjusting screw C. At 210 bar the main pressure limiting valve should open and the pressure should not increase further. The overflowing in the main pressure limiting valve could be heard in the main valve. 19.Reduce the pressure to 180 bar as read on the manometer. The adjusting screw must be sealed after making any adjustment.

E

21.Connect the manometer to test outlet E on the cab tilt control valve. 22.Run the cab tilt to its end position and read the manometer. The pressure should be 70±5 bar. Adjust if necessary on adjusting screw F The adjusting screw must be sealed after making any adjustment.


Steering system Description

Group 70

TDCE01 04GB P. 19

Steering system The steering system comprises the steering valve and the steering cylinder. The system is supplied with fluid from the valve block adjoining the main valve. An adjustable pressure limiting valve provides the control pressure. An LS signal from the steering valve actuates the priority valve in the valve block to always ensure sufficient supply to the steering system.

A 

25

24

37 31

The numbers corrspond to the hydraulic diagram A = System with separat side-lift hydraulics 24. Steering valve 25. Steering cylinder 31. Tank 37. Throttle-check valve

S teering s ys tem



Group 70

TDCE01 04GB P. 20

Orbitrol steering valve The steering valve is of the closed centre, non-reaction type with load sensing signal connection to the valve block. The load signal gives load-dependent control of the fluid pressure from the va lve block to the steering valve. The type closed centre implies tha t it closes for flow of fluid between the pump and reservoir in the neutral mode. This is necessary to enable signal pressure to be connected to the steering valve. The steering valve consists of a gear pump and a distribution valve. When the steering wheel is turned, fluid is supplied from the valve block via the gear pump to the distribution valve which ensures that the flow of fluid will be supplied to the port corresponding to the direction in which the steering wheel has been turned. Due to the gear pump, the flow of fluid supplied to the steering cylinder is proportional to the angle through which the steering wheel has been turned. A valve block with built-in double shock and suction valves is connected to the steering valve. The shock valves opening at 280 bar, prevent pressure surges caused by blows against the steered wheels from being propagated to the steerin g valve. The suction valves open to prevent vacuum on the opposite side of the piston, which could lead to cavitation. 1. Steering valve 2. Valve block 3. Double shock valve with suction valve 4. Check valve

S teering valve with valve block



Group 70

TDCE01 04GB P. 21

Item 12 – assembly pattern

Tightening torquet: 30±5 Nm 1. Dust cover 2. Body – spool – sleeve 3. Ball 4. Threaded bush 5. O-ring 6. Guide ring 7. Front bearing race 8. Needle bearing holder 9. Rear bearing race 10. Ring 11. Pin 12. Neutral position springs, 1 set 13. Shaft 14. Spacer 15. O-ring 16. Distributor plate

17. Gear set 18. O-ring 19. End plate 20. Washer 21. Pin 22. Screw with drilled head 23. Locking wire 24. Nameplate 25. Self-tapping screw 26. Spacer 27. Spacer

S teering valve


Brake system Description

Group 70

TDCE01 04GB P. 22

Brakesystem – WDB-system The foot brake system is known as the wet disc brake system, in which each hub is equipped with a multiple-disc assembly. The disc assembly comprises stationary discs arranged alternately with a number of rotating discs. The disc assembly is compressed by hydraulic pressure to provided effective braking action. The assembly is submerged in a hydraulic fluid bath to dissipate the heat generated by braking. A separate cooling circuit is provided to cool the hydraulic fluid. The advantages of the wet disc brake system include the fact that no adjustment is needed, and that no fading o r wear occur. Moreover, the enclosed oil bath keeps the system completely free from water and impurities. The brake system comprises three separate hydraulic circuits, i.e. the foot-brake circuit, the cooling circuit and the parking brake circuit. All circuits are supplied with hydraulic fluid under pressure from the same hydraulic pump. The brake circuits are supplied from four hydraulic accumulators and the cooling circuit from the valve block. Excess fluid from the main hydraulic system is passed on to the cooling circuit.

32

40

39

38

21

34 52

41

42

22

35

31

21. Accumulator 22. Pressure limiting valve 31. Tank 32. Service brake valve 33. Service brake cylinder 34. Parking barke valve 35. Parking brake cylinder 36a. Brake cooling curcuit supply 36b. Brake cooling curcuit, return

38. Pressure switch, disengagement 39. Pressure switch brake lights 40. Pressure switch low brake pressure 41. Pressure switch warning lamp parking brake and seat buzzer. 42. Accumulator evacuating valve 52. Test outlet brake pressure

B rake s ys tem, accumulator s upply



Group 70

TDCE01 04GB P. 23

49

33 A

36a 36b

31

31. Tank 33. Service brake cylinder 36a. Brake cooling curcuit supply 36b. Brake cooling curcuit, return 49. Oil cooler A. From brake pedal

B rake s ys tem, cooling ci rcuit supply



Group 70

TDCE01 04GB P. 24

Oil cooler A cooler with electrically powered fan is used for evacuation of heat which is generated in the hydraulic system, mainly when braking frequently.

49

The numbers correspond to the hydraulic diagram 49. Oil cooler

Brake system Service


Group 70

TDCE01 04GB P. 25

Checking the brake system The figures in the following text refer to the Hydraulic circuit diagram. See also Checking the pressures and settings, group 70 page 10 The checks are to be made with the hydraulic system at the working temperature. 1. Start the engine. 2. Bleed the brake lines – press the brake pedal – open carefully the bleed nipple located on the inside of one of the hubs until oil free of any air starts to flow from the bleed nipple. tighten the nipple – repeat the procedure for the other hub.

1

3.

1. Bleed nippel

4.

52

5.

6. 7. 8.

9.

10. 11.

12.

42

Connect a manometer to the test outlet (10) on the main valve. Allow the engine to run to full charging pressure as stated on the hydraulic plate. See also section Checking of pressures and settings Gru pp 70 page 16 - 17. Stop the engine and depress the brake pedal fully. The pressure reading in test outlet 52 should be according to the hydraulic plate. Release the brake pedal and check that the pressure falls to 0. Check to make sure that there is enough charge in the accumulator to cover at least eight brakings. Check the clutch activating pressure – Parking brake OFF – Gear selector in F or R – Depress the clutch pedal and listen for a clicking sound in the electrical central unit in the cab. At the clicking sound, e.g. the clutch being activated, the pressure reading in outlet 52 should be 30±2 bar. Check the activating pressure for warning lamp LOW BRAKE PRESSURE – Connect the manometer to test outlet 10 on the main valve. – Charge up the accumulator fully. – Stop the engine, leave ignition key ON and depress the brake pedal repeadetly. – The warning lamp LOW BRAKE PRESSURE shoul light up at 110-115 bar. Check the accumulator’s pre-charging pressure as follows – it should be according to the hydraulic plate. Open, carefully. the accumulator evacuating valve (42) , keeping a check on the manometer in the test outlet (10). At the specified pre-charging pressure, the pressure should drop sharply to 0. If the pressure is lower, the pre-charging pressure should be raised to the correct level using special filling equipment for nitrogen gas accumulators.

WARNING! The charg ing equipment may be handled only by s pecially trained personnel. 42 Accumulator evacuating valve

Parking brake system Description


Group 70

TDCE01 04GB P. 26

Parking brake

1



2

The parking brake consists of a disc brake with a brake cylinder on the drive axle input shaft. The brake is applied by a heavy spring in the brake cylinder. The parking brake can also be used as an EMERGENCY BRAKE. During emergency braking, the brake linings are sub jected to very heavy wear. The linings should therefore be checked after any emergency braking operations and changed if necessary. The parking brake is released by hydraulic pressure being supplied to the cylinder to counteract the spring force. The brake is controlled electrically by means of a switch adjacent to the hydraulic levers. The switch is connected to a solenoid valve which controls the brake cylinder hydraulic supply and return. When the parking brake is applied, the flow of fluid to the brake cylinder is interrupted and the fluid in the cylinder is discharged to the tank. The brake is then applied by the spring in the cylinder.

Bleeding and checking the parking brake 1. Release the parking brake 2. Check that the yoke can move freely on its suspension axles. If not, this mus be remedied. 3. Carefully open the bleed niple 4, see illustration, tighten the nipple when oil free from any air comes out. 4. Check the plat between between brake pads and brake disc. the play should be between 1-1.5 mm Adjust if necessary, see group 40.

Des cri ption and adjus tment of park ing brake cylinder , s ee g roup 40 3



4

1. 2. 3. 4.

Switch parking brake Parking brake valve Brake cylinder Bleed nipple

Parking brake

Hydraulpumpar Description


Group 70

TDCE01 04GB P. 27

Hydraulpumpar

1. Replaceable cartridge assembly, includes cam ring, rotor, vanes, pins and sideplates 2. Front and rear sideplates 3. Ball bearing 4. Front sideplate, is fixed axially by discharge pressure to reduce internal leakage 5. – 6. – 7. Vane, is urged outward at suction ramp by pin force and centrifugal force 8. Cam ring 9. Suction ramp where unloaded ramp moves out 10. Pressure ramp with working vanes which press likquid towards the discharge port 11. Working vane on inor arc seals discharge pressure from the suction port 12. Discharge ramp where unloaded vane moves in 13. Pin cavity is at a steady pressure slightly higher than at discharge port 14. Lub side holes, lubricate the sideplate surfaces 15. Pressure pins, force the vanes outward 16. Vanes

Pump 18 +19 is a kombination pump where the inner section is a variable piston pump 18 of constant pressure type and the outer section is a fixed vane pump19. Pump 20 a+b is a double fixed vane pump. Variable axialkolvpump, see illustration next page Pumps 18 that feeds the side-lift attachment is a variable axial piston pump with five pistons placed in a cylinder rotor. The stroke length of the pistons is determined by the position of an angled pressure plate. The pistons are secured in slip-shoes that rotate against the pressure plate. The stroke volume area and the area within the pistons are filled with hydraulic fluid during the suction phase. During the pressure phase, the hydraulic fluid is fed into the pressure lines via a valve plate. A hole in the head of each of the pistons allows hydraulic fluid to be forced out and gives a balanced counter pressure from the pressure plate as well as a film of fluid th at lubricates the surfaces and inhibits wear. Fixed vanepump, see illustrations below and next page These pumps consist of a pump casing and a pump unit, and are of simple design. A rotor in the pump unit comprises a number of vanes fitted in radial slots. The rotor is driven by a shaft and rotates in a cam ring. The rotor vanes follow the profile of the cam ring, and each vane performs two cycles – each comprising one suction stroke and one delivery stroke – per revolution. The fluid flows radially through the pump unit. The vanes are forced outwards towards th e cam ring by centrifugal force and by thrust pins which are subjected to the same pressure as the pump delivery pressure. This ensure s that the vanes will alwqys be in contact with the cam profile. An fluid film prevents the vanes from coming into metallic contact with the cam profile. In the same way, an fluid film prevents metallic contact with the side plates. Since the vanes, ports and pressures are balanced diametrically, the net load on the rotor is a pure torque caused by the pumping action. Sturdy shaft bearings carry the forces caused by the pump drive. 2

4

3 1

16 8 10

7 9

15

13

14

14 12 11

Fas t ving pump, dubbel

Hydraulpumpar Description


Group 70

TDCE01 04GB P. 28

22

23 21

20

19

18 3

4

1 17 15

16

8

2 7

10 13 9

14

14 12 11

Fixed vane pump 1. Replaceable cartridge assembly, includes cam ring, rotor, vanes, pins and sideplates 2. Front and rear sideplates 3. Ball bearing 4. Front sideplate, is fixed axially by discharge pressure to reduce internal leakage 5. – 6. – 7. Vane, is urged outward at suction ramp by pin force and centrifugal force 8. Cam ring 9. Suction ramp where unloaded ramp moves out 10. Pressure ramp with working vanes which press likquid towards the discharge port 11. Working vane on inor arc seals discharge pressure from the suction port

12. Discharge ramp where unloaded vane moves in 13. Pin cavity is at a steady pressure slightly higher than at discharge port 14. Lub side holes, lubricate the sideplate surfaces 15. Pressure pins, force the vanes outward 16. Vanes

Variable axial piston pump 17. Cylinderrotor 18. Ställskiva 19. Pumpkolv 20. Regulator 21. Justerskruv, stand-by tryck, 18 bar 22. Avlastningsventil 23. Justerskruv, pumptryck

C ombination pump, variable pis ton pump and fixed vane pump

Hydraulic pumps Description

DCE80-100E Technical Handbook 6 1

5

2

Group 70

TDCE01 04GB P. 29

Hydraulic pump of gear type Machines that are not equipped with cab tilt supplied with hydraulic pumps of the gear type. The hydraulic pump is directly driven by the engine via splines. The pump spindles are mounted in plain bearings which are lubricated by the hydraulic fluid flowing through the pump. Pressure plates on each side of the pump gearwheels seal between the suction and pressure side.

3

1. 2. 3. 4. 5. 6.

4

Pump body Outlet Driving gear Gap between teeth Inlet Driven gear

1. 2. 3. 4. 5.

Splines Driving gear Pump body Pressure plate Driven gear

Hydraulic pump


Hydraulpump Service

Group 70

TDCE01 04GB P. 30

Hydraulic pumps of gear type General instructions are given below for service operations that should be carried out on the pumps and how much wear is acceptable on the various components before a particular component must be replaced. 1.

2. 3. 4.

5. 6.

7. 8.

If different sections of the pump must be prised apart, take great care not to damage any of the mach ined surfaces. The use of excessive force may damage the parts. It is essential that all parts are blown clean and wiped with a lint-free linen cloth before being assembled. If the parts are difficult to fit during assembly, tap with a soft mallet - never use a steel hammer. The gears are carefully matched, and they must therefore be kept together as a unit during dismantling. Treat them with extreme care, so that the shafts and the teeth are not damaged. Avoid touching the shaft ends. Never hammer a plain bearing or roller bearing into place. Use a press or other suitable tool. Before assembly, fill all ports with hydraulic fluid, so that the pump is thoroughly lubricated from the start. All pumps must turn in the intended direction of rotation, since the pressure will otherwise damage the seals. Hot fluid must not be allowed into a cold pump, since it may otherwise seize. After starting, run the pump without load and with the engine running at idling speed for at least two minutes. During this running-in period, check that the pump does not run hot.


Hydraulpump Service

Group 70

TDCE01 04GB P. 31

Permissible wear of the pump components

9. Pump body The pump pressure presses the pum p gears towards the walls of the body on the low-pressure sid e, and since the shafts and bearings wear, the pump gears will rub against the body. If the pump body has worn more than 0.13 mm, it must be changed. Check by placing a straight edge inside t he pump body, and use feeler gauges to measure the wear. 10. Driven gear The driven gear must be replaced if any kind of scoring or wear is found on the shaft ends or teeth. 11. Driving gear Fit a new driving gear if wear can be felt on the sealing surfaces. 12. Pressure plates The pressure plates seal at the sides of the pump section. Wear of the pressure plates will cause internal leakage. The maximum permissible wear is 0.05 mm. Fit new pressure plates if the existing ones are scored, worn or pitted. Check the centres of the pressure plates where the teeth mesh. Wear here indicates that there are impurities in the fluid. Pitting indicates cavitation or the formation of gas. Discolouration of the pressure plates indicates overheating. 13. Dowels If a dowel or its hole has been damaged, the dowel and possibly the section containing the dowel must be changed. If more than reasonable force is needed for pressing in a dowel, this may be due to inadequately deburred or fouled parts, deformation of the dowel or poor fit of the dowel hole. 14. Plain bearings and roller bearings If new gears are fitted, the bearings must also be changed. Plain bearings must be a hard press fit. Roller bearings must be a light press fit, and it is acceptable if they can be pressed in by hand. If a bearing can drop out of its seat, the hole is too large. 15. Seals Replace all rubber and plastic seals, including all O-rings, seals at the pressure plates, shaft seals and gaskets.


Accumulator Description

Group 70

TDCE01 04GB P. 32

Accumulator

42

The hydraulic system is connected to membrane type accu-mulators which are pre-charged with nitrogen at a pressure of 100 bar. The membrane is forced upward causing the pressure of the nitrogen to increase as the accumulator becomes charged with hydraulic fluid. When the hydraulic system requires power from the accumulator, the membrane presses fluid back into the system. The accumulator is fitted at the top with a connection for testing the pressure of the nitrogen, and for refilling nitrogen with the aid of special filling equipment. The pressurized fluid from the accumulator is utilized to power the driving brake and parking brake systems, and to supply the pressure reducing valve of the servo hydraulics. An evacuating valve is fitted between the accumulator and reservoir. This valve shall be used to relieve the accumulator of pressure before carrying out any work on the hydraulic system.

WARNING! 42. Accumulator evacuating valve

1. 2. 3. 4. 5.

The hydraulic s ys tem includes hig h-press ure accumulators . Open the accumulator evacuating valve to releas e pres s ure before work ing on the hydr aulic s ys tem.

Connection Seal Membrane Safety plate Steel bottle

A cc umulator


High pressure filter Description, service

Group 70

TDCE01 04GB P. 33

High pressure filter Two high pressure filters located immediately after the pumps are used to clean the fluid. The filter head is equipped with a by-pass valve which opens at 5 bar. The opening area is initially small but gradually increases with the pressure drop across the filter, ie, as the amount of impurities trapped by the filter cartridge increases. The filter element is a fibreglass cartridge with an absolute mesh of 25 µ. High pressure filter The high pressure filter for the hydraulic fluid must be changed at the intervals specified in the lubrication chart. In addition, the filter must always be changed whenever work has been carried out on the hydraulic system.

1

2 1. 2. 3. 4. 5. 3

1. Filter head 2. Filter bowl 3. Arrow, flow direction

Clean the outside of the filter and the area around it. Place a vessel under the filter to collect any spillage. Remove the filter bowl. Use an open-ended or ring spanner. Remove the filter cartridge. Replace the O-ring between the filter head and the bowl and the O-rings on the adapter. The O-rings are packed together with the filter cartridge. 6. Lubricate the O-ring for the filter head with hydraulic fluid. 7. Carefully clean the filter bowl and fill it half-full with hydraulic fluid. 8. Remove the filter cartridge from its package and fit it immediately. 9. Fit the bowl and tighten it to a torque of 140 Nm. 10. Start the engine to purge the system of air, and check that the filter does not leak.

IMPORTANT! The hig h press ure filter cartri dg e mus t always be changed when a pump has been exc hang ed. The filter must always be fitted with its top arr ow pointing in the flow direction.

Main valve Description


Group 70

TDCE01 04GB P. 34

Valve block Several hydraulic functions are concentrated to a valve block which is connected directly to the main valve. . Valve block, main functions: (Numbering is the same as in the Hydraulic Circuit Diagrams)

1. 2. 3.

Accumulator charging valve Pressure limiting valve, steering system Differential valve, providing max. 11 bar difference between the steering valve LS-signal and the pump pressure 4. Priority valve for the steering circuit Provides 11 bar initial pressure in the main valve Actuated by the steering valve LS-signal and ensures that the steering circuit has sufficient supply 5. Pressure reducing valve for servo to control levers. 6. Relief valve, cooling circuit. Provides max. 1 bar, opens to the reservoir at higher pressure in the cooling circuit. .



A



1

2

1. Main valve 2. Valve block



Group 70

TDCE01 04GB P. 35

Main valve

1. Inlet section with main pressure limiting valve 2. Control section 3. Control/outlet section 4. Inlet/control/outlet section, LIFT 5. Valve block

The main valve, in its standard version, is actuated via a hydraulic servo. The valve consists of the following main components:  Inlet section  Control sections, corresponding to the number of functions ofthe truck  Combined control and outlet section The main valve has a separate inlet and outlet section, and also a separate main pressure limiting valve for the lifting section. The entire flow from one of the hydraulic pumps goes to this section. If the lifting function is not actuated, the flow from this pump goes instead to the cooling circuit of the driving brake or to the reservoir. In addition, any flow from the other pump that is not utilized in the remaining main hydraulic functions is also supplied. When the lifting function is not actuated, the return flow from this pump goes to the cooling circuit of the driving brake.

Main valve

1. Inlet section 1a. Main pressure limiting valve 2. Control section 2a. Control spool 3. Control/outlet section

Main valve



Group 70

TDCE01 04GB P. 36

Control valve for servo control of the main valve The control valves are integrated into a block, and the number of valves corresponds to the number of functions of the truck. Each valve or section is equipped with two pressure reducing valves. The valve spools are hardened and precision-ground to minimize any internal leakage. The control forces are low, and the valve travel is proportional to the lever travel, which ensures smooth control of the main hydraulics.

1

2

1. Adjusting screw for lever travel 2. Pressure reducing valve

Control valve

1. Servo pressure 35 bar 2. Reservoir 3. Lifing

1 2 3

S ervo control of the lifting s ection


Main valve Service

Group 70

TDCE01 04GB P. 37

Main valve The main valve is precision made and must be treated with great care so that its performance will not be impaired. The following rules apply whenever service work is carried out. 1. Protect the valve against moisture and dirt. Take particular care to avoid dirt entering the connection ports. Also protect the ports from damage by scratching or bruising. Keep unconnected ports plugged with plastic plugs or the like. 2. Protect the ends of the spools and covers against blows. The valve spool may be bent if handled carelessly, and it will then immediately jam on being used.


Hydraulic cylinders Service

Group 70

TDCE01 04GB P. 38

Repairs to leaking hydraulic cylinders – replacing the seal IMPORTANT! Never us e compress ed air for removing the pis ton from the cylinder. Y ou could sus tain serious i njuries.

Se also separate information Supplement Technical Handbook, Hydraulic cylinders

Publ. No. 920937-9279

1. Screw driver 2. Lip seal 3. Scraper ring

General instruction applicable to all cylinders If necessary, see Group 80 for instructions on t he dismantling of the fork carraige and mast. 1. Remove the relevant hydraulic cylinder. Fit immediately protective caps or plugs to the hydraulic cylinder and hose connections. 2. Take the cylinder to the workshop, drain any oil remaining in it and carefully wash the outside of the cylinder. 3. Dismantle and assemble the cylinder in accordance with the instructions for that particular cylinder type. 4. Removing the seals: – Whenever repair work is carried out on hydraulic cylinders, all seals, scraper rings, etc. must be replaced. – Take extreme care when removing the seal in the cylinder head, to avoid scratching the bottom of the groove, since oil leakage will otherwise occur in the futur e. Use a screwdriver as shown in the figure. – Clean all components very throughly. 5.

Fitting of lip seals: – Fit the seal in the cylinder head with the lip facing inwards towards the piston. Oil the seal and press it in by hand. N.B. Don’t use any tools, since the seal may otherwise be scratched. Even a minute scratch may cause the seal to leak.

6.

Fitting the piston seal: – All piston seals are of the same design and consist of five components, i.e. a centre sealing ring, two backing rings and two guide rings. – Dismantle the piston seal and start by fitting the sealing ring onto the piston, and then fit the backing rings and the guide rings. All of this must be done by hand.

1. 2. 3. 4.

Sealing ring Backing rings Guide rings Piston head



Group 70

TDCE01 04GB P. 39

Lubrication of single acting cylinders 1. 3 2

4

1

KL1006

1. 2. 3. 4.

Normal operating stroke Breather filter Filter connector Area with corrosion risk

2. 3. 4.

This type of cylinders have no oil supply on the piston side. If the cylinders are operated in a limited stroke (1), there is a risk of corrosion damage to the upper part of the cylinder inner surface (4). Loosen the breather filter (2). Inject 300-500 ml of oil into the filter connector (3). Operate the cylinder in its full tavel a number of times until no more oil is pressed out from the connector (3).



Group 70

TDCE01 04GB P. 40

Lifting cylinder 1.

The cylinder head is fitted ito the cylinder tube with 12 screws and nuts

2.

Note that the lowering brake valve is integrated in the cylinder tube

1. Pin 2. Lowering brake valve 3. Piston rod guide 4. Cylinder tube 5. Piston rod tube 6. Spacer 7. Nut 8. Washer 9. O-ring 10. Screw 11. Cylinder head 12. Piston rod guide 13. Seal 14. Wiper 15. Air venting valve

Li ft cylinder



Group 70

TDCE01 04GB P. 41

Steering cylinder 1.

The steering cylinder has a double-acting piston, with the piston seal in the centre. 2. ,On each side of the cylinder tube there is a cyllinder head which is fixed to the cylinder tube by means of a locking ring. At disassembly, the O-ring could be jammed in the locking ring groove thus making it very difficult to pull the piston out of the cylinder tube. For instructions on disassembly, see Supplement Technical Handbook, Hydraulic cylinders, publ No. 920937-9279.

1. Steering cylinder 2. Cylinder tube 3. Piston rod 4. Seal kit 5. Piston seal 6. Seal

7. Wiper 8. O-ring 9. Back-up ring 10. Cylinder head 11. Locking ring 12. Washer

S teering cy linder



Group 70

TDCE01 04GB P. 42

Tilt cylinder 1.

2.

The tilt cylinder is fitted with a clevis mounts. The piston rod clevis is threaded onto the piston rod and is secured by locknuts and locking plate. The cylinder head is threaded and attached to the cylinder tube with flange screws.

S ee als o g roup 80 for C ontrol of tilt cylinders

1. Guide 2. Piston seal 6. Cylinder tube 7. Piston rod 8. O-ring 9. Back-up ring 10. Guide

11. Piston rod seal 12. Cylinder head 13. Skruv 14. Wiper 15. Screw 16. Washer 17. Clevis mount

Tilt cylinder


Empty page Group 70

TDCE01 04GB P. 43


Hydraulic diagram Components

Group 70

TDCE01 04GB P. 44

Hydraulic circuit diagram Components A06195.0500/0600 1. Accumulator charging valve 2. Pressure limiting valve, steering system 3. Differential valve, gives max. 11 bar difference between LS-signal of the steering valve and the pump pressure 4. Priority valve for steering circuit. Gives 11 bar basic pressure in the main valve. Actuated by LS-signal of the steering valve and ensures sufficient supply to the steering system. 5. Pressure reducing valve for servo to the control levers 6. Safety valve in cooling circuit, permits max. 1 bar, opens to the reservoir in event of higher pressure in the cooling system. 7. Test point, brake system cooling circuit, max. 1,5 bar 8. Test point, servo pressure, non-adjustable 9. Test point, main hydraulics (Shall be same pressure as 14) 10. Test point, accumulator charging 11. Test point, steering system 12. Main pressure limiting valve Set the same as 13 13. Main pressure limiting valve Set the same as 12 14. Test point, separate lifting section Shall be same pressure as 9 15. Test point, LS-signal from steering valve 16. Control valve, LIFT 17. Control valve, TILT 18. Control valve, SIDESHIFTING 19. Control valve, LENGTH ADJUSTMENT 20’-40’ 20. Hydraulic pump 21. Hydraulic accumulator, pre-charging pressure 22. Pressure limiting valve 23. High pressure filter 24. Orbitrol steering valve 25. Steering cylinder 26. Lifting cylinder 27. Lowering brake valve 28. Tilting cylinders 29. Counter pressure valve 30. Sideshifting cylinder 31. Hydraulic reservoir 32. Foot brake valve 33. Brake cylinders, foot brake 34. Parking brake valve 35. Parking brake cylinder 36. Oil cooled brake discs 37. Throttle-check valve for tank return counter pressure 38. Pressure switch, inching 39. Pressure switch, brake lights 40. Pressure switch, low brake pressure 41. Pressure switch, indicating lamp parking brake and seal buzzer 42. Accumulator evacuating valve 43. Control levers 44. Control valve TWIST-LOCKS 45. Solenoid valves, interlocking system TWIST-LOCKS 46. Solenoid valve, interlocking system LIFT 47. Hydraulic cylinder, LENGTH ADJUSTMENT 20’-40’ 48. Hydraulic cylinder, TWIST-LOCKS 49. Hydraulicil cooler, brake system cooling circuit 50. Breather filter 51. Electro-hydraulic converters 52. Test point, brake pressure



Group 70

TDCE01 04GB P. 45

6 2

7 2

6 2

6 1

8 2

2 1

9 2

4 1

9 2

8 2

7 1

0 3

8 1

1 5

7 4

9 1 7 4 4 4

0 5

8 4

1 3

3 1 8 4 7

b 0 2

6 3 2

2

8

2 4

a 0 2

4 5 3

1 2

9 2 2

0 1

1

5 1

0 4

2 3

9 4 2 5

8 3

9 3

6 3 4 3

3 3 5 3

1 4

4 2

5 2 3 3

6 3

7 3

Hydraullic s ys tem, electric s ervo A06195.0500



Group 70

TDCE01 04GB P. 46

Hydraulic circuit diagram Components A06195.0500/0600 1. Accumulator charging valve 2. Pressure limiting valve, steering system 3. Differential valve, gives max. 11 bar difference between LS-signal of the steering valve and the pump pressure 4. Priority valve for steering circuit. Gives 11 bar basic pressure in the main valve. Actuated by LS-signal of the steering valve and ensures sufficient supply to the steering system. 5. Pressure reducing valve for servo to the control levers 6. Safety valve in cooling circuit, permits max. 1 bar, opens to the reservoir in event of higher pressure in the cooling system. 7. Test point, brake system cooling circuit, max. 1,5 bar 8. Test point, servo pressure, non-adjustable 9. Test point, main hydraulics (Shall be same pressure as 14) 10. Test point, accumulator charging 11. Test point, steering system 12. Main pressure limiting valve Set the same as 13 13. Main pressure limiting valve Set the same as 12 14. Test point, separate lifting section Shall be same pressure as 9 15. Test point, LS-signal from steering valve 16. Control valve, LIFT 17. Control valve, TILT 18. Control valve, SIDESHIFTING 19. Control valve, LENGTH ADJUSTMENT 20’-40’ 20. Hydraulic pump 21. Hydraulic accumulator, pre-charging pressure 22. Pressure limiting valve 23. High pressure filter 24. Orbitrol steering valve 25. Steering cylinder 26. Lifting cylinder 27. Lowering brake valve 28. Tilting cylinders 29. Counter pressure valve 30. Sideshifting cylinder 31. Hydraulic reservoir 32. Foot brake valve 33. Brake cylinders, foot brake 34. Parking brake valve 35. Parking brake cylinder 36. Oil cooled brake discs 37. Throttle-check valve for tank return counter pressure 38. Pressure switch, inching 39. Pressure switch, brake lights 40. Pressure switch, low brake pressure 41. Pressure switch, indicating lamp parking brake and seal buzzer 42. Accumulator evacuating valve 43. Control levers 44. Control valve TWIST-LOCKS 45. Solenoid valves, interlocking system TWIST-LOCKS 46. Solenoid valve, interlocking system LIFT 47. Hydraulic cylinder, LENGTH ADJUSTMENT 20’-40’ 48. Hydraulic cylinder, TWIST-LOCKS 49. Hydraulicil cooler, brake system cooling circuit 50. Breather filter 51. Electro-hydraulic converters 52. Test point, brake pressure



Group 70

TDCE01 04GB P. 47

6 2

7 2 6 4 6 2

6 1

8 2

2 1

9 2

4 1

9 2

8 2

7 1

0 3

8 1

7 4

9 1 7 4 4 4

0 5

8 4

5 4

1 3

3 1

3 4

8 4 7

b 0 2

6 3 2

2

8 2 4

a 0 2

4 5 3

1 2

9 2 2

0 1

1

5 1

0 4

2 3

9 3

8 3 6 3

3 3

9 4 4 3

5 3

1 4

4 2

5 2

3 3 7 3 6 3

Hydraulsy s tem, hydrauls ervo A06195.0600



Group 70

TDCE01 04GB P. 48

Hydraulic circuit diagram Components A44866.0100 1. Accumulator charging valve 2. Pressure limiting valve, steering system 3. Differential valve, gives max. 11 bar difference between LS-signal of the steering valve and the pump pressure 4. Priority valve for steering circuit. Gives 11 bar basic pressure in the main valve. Actuated by LS-signal of the steering valve and ensures sufficient supply to the steering system. 5. Pressure reducing valve for servo to the control levers 6. Safety valve in cooling circuit, permits max. 1 bar, opens to the reservoir in event of higher pressure in the cooling system. 7. Test point, brake system cooling circuit, max. 1,5 bar 8. Test point, servo pressure, non-adjustable 9. Test point, main hydraulics (Shall be same pressure as 14) 10. Test point, accumulator charging 11. Test point, steering system 12. Main pressure limiting valve Set the same as 13 13. Main pressure limiting valve Set the same as 12 14. Test point, separate lifting section Shall be same pressure as 9 15. Test point, LS-signal from steering valve 16. Control valve, LIFT 17. Control valve, TILT 18. Variabel hydraulpump, matning aggregat 19. Hydraulic pump, feed accumulator charging, TILT 20a.Hydraulic pump, feed LIFT 20b.Hydraulic pump, feed CAB-TILT (Optional eqquipment 21. Hydraulic accumulator, pre-charging pressure 22. Pressure limiting valve 23. High pressure filter 24. Orbitrol steering valve 25. Steering cylinder 26. Lifting cylinder 27. Lowering brake valve 28. Tilting cylinders 29. Counter pressure valve 30. Sideshifting cylinder 31. Hydraulic reservoir 32. Foot brake valve 33. Brake cylinders, foot brake 34. Parking brake valve 35. Parking brake cylinder 36. Oil cooled brake discs 37. Throttle-check valve for tank return counter pressure 38. Pressure switch, inching 39. Pressure switch, brake lights 40. Pressure switch, low brake pressure 41. Pressure switch, indicating lamp parking brake and seal buzzer 42. Accumulator evacuating valve 43. Control levers 44. Control valve TWIST-LOCKS 45. Solenoid valves, interlocking system TWIST-LOCKS 46. Solenoid valve, interlocking system LIFT 47. Hydraulic cylinder, LENGTH ADJUSTMENT 20’-40’ 48. Hydraulic cylinder, TWIST-LOCKS 49. Hydraulicil cooler, brake system cooling circuit 50. Breather filter 51. Electro-hydraulic converters 52. Test point, brake pressure 53. Control valve, CAB-TILT (Optional equipment) 54. Connector for side-lift attachment



Group 70

TDCE01 04GB P. 49

6 2

7 2

6 1

6 2

2 1

8 2

9 2

4 1

9 2

8 2

7 1

1 5

7

6 2

8 2 4

1 2

b 0 2

3 5

3 1

3 2

a 0 2

3 2

9 1

3 2

4 5 3

a 8 1

8 1

9

2 2

0 1

1

9 4

8 3

6 3

4 5

0 4

2 3

9 3

2 5

4 3

3 3 6 3

1 4

4 2

5 2 3 3 6 3

7 3

Hydr aulic s ys tem, hydraulic s ervo A44866.0100


Empty page Grou Group p 70

TDCE01 04GB P. 50

   

      

All trucks

Technical Handbook

Contents

9279 02-09 1 Publ. Gr. P.

Contents Clean hydraulics ........................................................................ 3 Measures to prevent pollution of the hydraulic system.............. 4 Fault finding for leakage ............................................................ 6 The function and removal of seals............................................. 7 Piston rod seals.................................................................... 7 Support ring and O ring ........................................................ 9 Wiper .................................................................................. 10 Single action V type piston seals with support ring ............ 11 Double action piston seals ................................................. 12 Repairing the piston rod surface.............................................. 12 Lubrication ............................................................................... 13 Dismantling the steering cylinder............................................. 14

All trucks Technical Handbook

Hydraulic Cylinders Service

9279 02-09 70 3 Publ. Gr. S.

Clean hydraulics Hydraulic systems are extremely sensitive to impurities - a hydraulic system is just as sensitive as a d iesel 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, 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 Possible sources of impurity Existing impurities – Casting sand, welding cinder, cinde r, 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” welding” – Cavitation, insufficient flow to pump – Corrosion that generates particles – Fatigue/wear and tear that generates particles Accidentally added impurities – During repair operations – As a result of topping up with impure hydraulic fluid Penetrative Penetrative impurities – Penetration via breather air to the hydraulic tank – Penetration via the piston rod’ rod’s lubri lubrica catin ting g film film – Penetration through poorly sealed inspection hatches – Condensation – Penetration via rod seals 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 hu man hair is approx.70µ thick. The smallest particles are less than 25 µ in size and are not visible to the naked eye. If the number of small particles is sufficiently large, they merely discolour the hydraulic fluid - by which time there are far too many impurities in the system. It is not, therefore, possible to judge, with the t he 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. impurity. Solid impurities in hydraulic systems cause c ause many different types of problem. Large quantities of impurity dramatically reduce the operative lifespan of the system. Hydraulic components break down as a result of internal wear. Particles cause directional and servo valves to seize, which, in turn, leads to the burning out of the magnetic spools.



9279 02-09 70 4 Publ. Gr. S.

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. Liquids The most common liquid impurity that occurs in a hydraulic system is water, for example, through condensation. 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.

Measures to prevent pollution of the hydraulic system 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. 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 as high as possible Make sure that all filters in the system function correctly. Regularly replace filter elements, in accordance with the machine’s lubrication chart Regularly check the wiper and rod seals and replace them as required



9279 02-09 70 5 Publ. Gr. S.

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 tapaulin 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. 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 Make sure that exchange components are thoroughly clean Carry out the repair as soon as possible After dismantling, 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

IMPORTANT! If there is the slightest doubt about the purity of the hydraulic fluid - send a fluid sample to the manufacturer of the fluid, or to Kalmar Service



9279 02-09 70 6 Publ. Gr. S.

Fault finding for leakage 1. 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. 2. 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. 3. 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 4. Check for internal leakage – 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

1 2 3 4

5

6

7

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. 1. Loosen the cylinder from its mounting and loosen the hydraulic connections 2. Immediately plug the cylinder connections and hoses/lines. 3. 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.

11

7

11

8

10

9

1. Piston rod 2. Wiper 3. Cylinder head 4. Piston rod seal 5. O ring with support ring 6. Cylinder pipe 7. Sleeve connection 8. Welded cylinder end 9. Piston 10. Piston seal, double action 11. Example of a weld

Lift cylinder

Check surfaces 1. 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 – all sliding surfaces (dynamic surfaces). These are always the most difficult to ensure a tight seal, for example, cylinder pipe and piston rod.

IMPORTANT! 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.


1

3

4 6

1. 2. 3. 4. 5. 6.

9279 02-09 70 7 Publ. Gr. S.

The function and removal of seals

2

5

KL1008


Hydraulic pressure Sealing lip pressed out against piston rod Sealing lip pressed in against cylinder head Sealing surface, piston rod Sealing surface, cylinder head Screwdriver

Piston rod seals The piston rod seal is the seal that sits in a groove in the hydraulic cylinder head forming a seal against the piston rod. This seal is very exposed as it performs both dynamic and static sealing functions, i.e., it is seals against the moving surface of the piston rod whilst the sealing surface against the cylinder head is static. There are different types of piston rod seals: Single V seals Pre-tensioned V seals with support ring Compressible seals The single V seal has a V shaped section with two lips which seal in each respective direction. The hydraulic pressure works itself into the V shape and presses the sealing lips outwards against the sealing surface of the piston rod and in the cylinder. Even the smallest amount of damage to the sealing lips can cause a major leakage. Check the sealing lips by carefully feeling around the seal with a finger nail. Use a screwdriver to remove a V seal, see illustration. Lever out and twist up the seal. It is extremely important that the screwdriver only comes into contact with the inside of the V shape so that it cannot touch and thereby damage any sealing surface. A score from a screwdriver on the sealing surface will have a disastrous effect and cause major leakage.

2 1

7

4

6

KL1009

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

3

7

5

Hydraulic pressure Sealing lip pressed out against piston rod Sealing lip pressed in against cylinder head Sealing surface, piston rod Sealing surface, cylinder head Screwdriver O ring

The pre-tensioned V seal has, in addition, an O ring within the space formed by the V shape. The O ring provides a greater sealing effect at low hydraulic pressure as the O ring, even when not under hydraulic pressure, presses the sealing lips out against the sealing surfaces. It is equally sensitive to damage as t he V seal. Check the seal in the same way. Use a screwdriver to remove the seal, see illustration. Lever out and twist up the seal. It is extremely important that the screwdriver only comes into contact with the inside of the V shape so that it cannot touch and thereby damage any sealing surface. A score from a screwdriver on the sealing surface will have a disastrous effect and cause major leakage.



Piston rod seal type TICLA is of compact design with integrated support ring. It has an inner sealing lip against the piston rod and an outer sealing lip which seals with press fit against the cylinder head. An intermediate bead between the sealing lips provides axial fixation The bead has recesses to admit hydraulic pressure on both outer and inner sealing lips. Even the smallest amount of damage to the sealing lips can cause a major leakage. Check the sealing lips by carefully feeling around the seal with a finger nail. Use a screwdriver to remove the seal, see illustration. Lever out and twist up the seal. It is extremely important that the screwdriver is inserted between the inner sealing lip and the intermediate bead so that it cannot touch and thereby damage any sealing surface. A score from a screwdriver on the sealing surface will have a disastrous effect and cause major leakage.

2 1 4

3 8 5

9279 02-09 70 8 Publ. Gr. S.

7



6 1. Hydraulic pressure 2. Inner sealing lip, pressed against the piston rod 3. Outer sealing lip, pressed against the cylinder head 4. Beam for axial fixation 5. Sealing surface, piston rod 6. Sealing surface, cylinder head 7. Support ring 8. Screwdriver



9279 02-09 70 9 Publ. Gr. S.

The compressible piston rod seal consists of a solid rubber profile and gives a greater sealing area than V seals. Use a screwdriver to remove the seal, see illustration. Lever out and twist up the seal. With this type of seal where the sealing area covers such a large part of the sealing groove, it is vitally important that the screwdriver is not allowed to make any mark.

2 1 3

3

4 6

5

5

KL1010

1. 2. 3. 4. 5. 6.

Hydraulic pressure Sealing lip pressed out against piston rod Sealing lip pressed in against cylinder head Sealing surface, piston rod Sealing surface, cylinder head Screwdriver

Support ring and O ring The support ring and O ring combination is used to seal between two static surfaces, such as, for example, between the cylinder pipe and the cylinder head, even in those cases where the cylinder head is threaded onto the cylinder pipe. The task of the support ring is to brace the O ring so that it does not change shape. The O ring is pressed against the suppor t ring and the sealing surface by the hydraulic pressure in the cylinder. When the cylinder head is to be fitted into the pipe: Be extremely careful so as not to damage the O ring. 3 2

4

KL1011 1 1. 2. 3. 4.

Hydraulic pressure O ring Support ring Sealing area, cylinder head



9279 02-09 70 10 Publ. Gr. S.

Wiper The task of the wiper is to scrape the piston rod clean and prevent any impurities being drawn into the cylinder pipe. The wiper must be fitted with a special tool. This tool must have a greater outer diameter than the wiper, so that the pressure against the wiper ceases just as the wiper is pressed into position. If the wiper should be pressed further in, the metal cap will be deformed (se lower illustration) which would thereby reducing the efficiency of the wiper. To prevent the wiper “bottoming” bottoming” in its slot in the cylinder head, the slot in the cylinder head is somewhat deeper than the width of the wiper.

øD+10

1

2

4

3

øD

5

6 KL1007

1. 2. 3. 4.

Corr Correc ectt fitti fitting ng tool tool Wiper Wiper,, corre correctl ctly y fitte fitted d Cyli Cylind nder er head head Play Play between between the the wiper wiper and and the bottom of the cylinder head slot 5. Incorr Incorrect ect fittin fitting g tool tool 6. Def Deformed ormed wipe wiperr

The wiper can be removed without the necessity of dismantling the cylinder. A screwdriver can be used to remove the wiper. This must always be employed employed against the outer edge ed ge of the wiper, see illustration. Carefully tap the screwdriver s crewdriver down between the wiper and the cylinder head he ad and thereafter, lever the wiper out. Polish off any marks on the cylinder head.

1

2 IMPORTANT! No tools should be introduced from the inside. This can score the cylinder pipe, which in turn, can damage the piston rod. Scoring can also damage the piston rod seals when the piston is fitted.

3 KL1012

1. Scre Screwd wdri riv ver 2. Wiper 3. Cyli Cylind nder er hea head d



Single action V type piston seals with support ring

2

On single action V seals it is always the long side that seals against the static and the short shor t side that seals against the moving surface. Use a screwdriver to remove the seal, see illustration. Lever out and twist up the seal. It is extremely important that the th e screwdriver only comes into contact with the inside of the V shape so that it cannot touch and thereby damage any sealing surface. A score from a screwdriver on the sealing surface will have a disastrous effect and cause major leakage.

1

3 4

6

KL1013

1. 2. 3. 4. 5. 6.

9279 02-09 70 11 Publ. Gr. S.

5

Hydr Hydrau auli lic c pressu pressure re Seal presse pressed d outward outwards s against against cylinder cylinder pipe Seal pressed pressed inwards inwards agains againstt piston piston Sealin Sea ling g surface surface,, cylinder cylinder pipe pipe Sealin Sea ling g surf surface ace,, pisto piston n Scre Screwd wdri riv ver

The seal must always be fitted coupled together with the support ring. Always fit by hand, no tools should be used as the surface of the piston can be easily damaged. To make fitting easier, the seal can be warmed in hot water to soften it. Lubricate with hydraulic fluid.

KL1014



9279 02-09 70 12 Publ. Gr. S.

Double action piston seals 5

3

4

4

1

3

6

2 KL1015

1. Moving Moving sealing sealing surface surface against against cylinder cylinder pipe 2. Static Static sealing sealing surface surface agains againstt piston piston 3. Guide uide ring ring 4. Supp Suppor ortt ring ring 5. Head Head of pis pisto ton n 6. Cyli Cylind nder er pipe pipe

1

2

Double action seals function with pressure from both directions, e.g., in a steering cylinder. The whole of the surface within the cylinder pipe is the sealing surface, it is therefore extremely important that this surface is not damaged in any way. Be very careful when fitting the piston in the cylinder pipe to avoid any damage to the seal from the threading in the cylinder pipe. Dismantling 1. Remove Remove guide rings and and support support rings. rings. 2. Move Move the sealing sealing body over over to one side of the sealing sealing groove. groove. 3. Press up up the materials materials so that there there is a gap between between the the seal and the piston. 4. Without Without damaging damaging the surface surface of of the piston, piston, cut the seal seal off with a knife. 5. Carefully Carefully check check the seal to to discover discover any any damage damage that can have caused leakage. This can be b e achieved most easily by bending over the seal section by section and checking the sealing surface with a finger nail. Fitting 1. All double double action action piston seals seals are construct constructed ed in the same same way, way, a middle sealing body, body, thereafter suppor t rings and finally, ly, guide rings, r ings, see illustration. 2. First fit fit the sealing body body, thereafter thereafter the support rings and finalfinally the guide rings - everything must be done by hand, without the use of tools, in order orde r to prevent damage.

3

Repairing the piston rod surface

4

1

KL1016

1. 2. 3. 4.

Pist Piston on rod rod Chro Chrome me surf surfac ace e Dama Damage ged d sur surfface Finely Finely polishe polished d hamm hammer er

The smallest damage to a piston rod can be enough to cause leakage. The chromium plating has a thickness of 20-50 µ and can be worked on to repair smaller s maller damage. This can be a viable alternative to costly dismantling. 1. Locate the dam damage age with with finger finger tips and and finge fingerr nails. nails. 2. Use a small, small, finely polished polished,, panel beating beating hammer hammer and work in the material from the area surrounding the damage, work from the outside in towards the damage. 3. Instead Instead of a sharp mark, there there will will now be a more more even even irregularity in the chrome surface. 4. Polish with with emery cloth, in stages, stages, use grades grades from from 240 - 600. Wrap the emery cloth around a file to support the cloth well. N.B. Sufficient chrome must always be visible at the point of damage. 5. It is important, important, before before both dismant dismantling ling and fitting, fitting, tto o repair small dents and other physical damage so that they do not damage the cylinder head. 6. For larger larger damag damage e to a piston piston rod: rod: – fill the damaged area with a weld – completely remove all welding cinder – file down the weld to the same level as the chrome surface – polish to an even finish with emery cloth



9279 02-09 70 13 Publ. Gr. S.

Lubrication

1

2 3 4

1. Within Within the actual hydraul hydraulic ic system - never never anything anything other than the normal hydraulic fluid used in the hydraulic system. 2. On the cylinder cylinder head head thread - use use copper paste paste (e.g., (e.g., Molycote CU 7439). Make sure that the paste does not enter the system. 3. In areas where where there there is a risk of condensat condensation ion building building up grease with a thin layer of copper paste in the sealing groove of the cylinder head, in order to prevent condensation. Condensation causes rust formation that can corrode the sealing groove and cause leakage. Apply the copper paste with a finger. 4. If any copper copper paste paste comes outside outside the the sealing sealing groove groove - wipe clean with lint free paper. Never use cotton waste

5

KL1017 1. 2. 3. 4.

Wiper Areas Areas at risk risk for for conde condensa nsatio tion n Pist Piston on rod rod sea seall Rust Rust formati formation on on sealin sealing g surfacsurfaces causes leakage 5. Cyli Cylind nder er hea head d

3

Lubricating single action cylinders 2

4

1

1. This type type of cylinder cylinder does not have have any hydraulic hydraulic fluid fluid supply supply on the piston rod side. If a cylinder normally operates over only a limited part of the piston stroke, there is a risk for corrosion in the upper part of the cylinder. 2. Unscre Unscrew w the breathe breatherr filter filter.. 3. Spray Spray 300-500 ml of hydrau hydraulic lic fluid into into the filter connectio connection. n. 4. Run the cylinder cylinder to the limits limits of the piston piston stroke stroke a number number of times until no more hydraulic fluid is forced out of the breather filter connection point.

Daily lubrication, all cylinders Run all cylinders to the piston stroke limit so that the whole of the cylinder is lubricated. KL1006

1. 2. 3. 4.

Norma Normall work workin ing g area area Brea Breath ther er filte filterr Filter Filter connec connectio tion n poin pointt Area Area at risk from corros corrosion ion



9279 02-09 70 14 Publ. Gr. S.

Dismantling the steering cylinder On the steering cylinder, it can be very difficult to remove the piston from the cylinder as the O ring in the cylinder head sticks in the locking ring groove of the cylinder pipe. It is best, therefore, to first remove the O ring before attempting to draw d raw out the piston rod from the cylinder. 1. Unscrew Unscrew the end piece piece at the cylinder cylinder head. 2. Unscrew Unscrew the connection connection nipple nipple for the hydraul hydraulic ic hose. 3. Push in the the piston piston rod with with piston head head until the O ring is is visivisible through the nipple hole.

A 4. Use a strong, strong, bent steel steel wire wire to hook onto the O ring, illustra illustra-tion A.

B

C

5. Draw up the O ring a little little and get get a grip on the O ring ring with a pair of thin nosed pliers, illustration B. 6. Continue Continue and draw draw out out the O ring ring through through the hole. hole. 7. Maintain Maintain a grip on the the O ring and cut through through it with a knife. knife.

8. Rotate Rotate the piston rod rod and simultaneo simultaneously usly draw draw out the O ring through the hole, illustration C.

9. Remove Remove the lockin locking g ring from the the cylinder cylinder pipe. pipe. 10.Carefully draw out the piston rod from the cylinder pipe.

KL1018

                     


Contents

Group 80

TDCE01 04GB P. 1

Group 80 Lifting mast carriage and side lift attachment Specifications ............................................................................ 2 Lift mast and carriage ............................................................. ... 3 Description ........................................................................... 3 Service ................................................................................. 7 Inspection of lifting chains ............................................... 7 Inspection of the lifting mast............................................ 7 Dismantling the carriage.................................................. 8 Dismantling the lift mast .................................................. 8 Adjusting the support wheels ......................................... 9 Replacing the support wheels ......................................... 9 Lubrication of sliding surfaces and plates ..................... 10 Checking sliding plates.................................................. 10 Inserting shims for sliding plates ................................... 11 Bleeding lift cylinders..................................................... 11 Stretching of hoses........................................................ 11 Tilt cylinder mounting .................................................... 11 Checking tilt cylinders.................................................... 11 Side lift attachment ................................................................. . 13 Description ......................................................................... 13 Service ............................................................................... 15 Sidelift with twist-locks................................................... 15 Sidelift with hook-coupling............................................. 16 Inductive sensors .......................................................... 17 Control of twist-locks .................................................... 18 Control of lifting hooks.................................................. 18 Control and adjustment of alignment aginst container, hook attachment............................................................ 19 Changing main beam sliding plates, older design......... 20 Changing main beam sliding plates, new design .......... 22 Sidelift with hooks, C-type ................................................... .... 24 Description ......................................................................... 24 Service ............................................................................... 26 Indicating lamps on slidelift ........................................... 26 Alignment control.......................................... ................. 26 Sensor for interrupting of lowering ................................ 27 Inductive sensors .......................................................... 27 Control of lifting hooks................................................... 28 Control and adjustment of alignment aginst container .. 28 Changing the main neam sliding plates ........................ 29 Block diagram................................................................ 31 Hydraulic system A46141.0100..................................... 32 Wiring diagram .....................................A45760.0100, page 1-10


Specifications Group 80

Lifting chains Max. permissible wear (see instructions)

TDCE01 04GB P. 2

3%

WARNING! R is k for injuries by squeezing ! A t any work wi th the mast or carriag e, the carri ag e mus t be secur ed ag ains t unitentional lowering by means of s uitable wooden poles or s imi lar.


Mast and carriage

Description

Group 80

TDCE01 04GB P. 3

Lift mast The mast on a Kalmar truck is of very sturdy design. The number of welds has been kept down to a minimum, to ensure the highest possible strength. The stresses on the mast components are low. The mast sections are made of high-strength steel and have slender dimensions, to restrict the field of vision as little as possible. All support wheels for longitudinal forces are fitted with high quality roller bearings. The traditional side support rollers are replaced by plastic sliding plates, there are 4 plates between inner and outer mast. Between carriage and inner mast there are 4 plates and 8 plates between carriage and sidelift attachment.

KL1125a

Mast and carriage


Description

Group 80

TDCE01 04GB P. 4

Carriage Two different integrated carriages are available - a fixed carriage for attachments with twist-locks and a carriage with hydraulic levelling ±4° for attachments with hooks. Both carriages have support wheels to bear longitudinal stresses and sliding plates for lateral stresses.

KL1400

C arriag e with hydraulic levelling

KL1401

C arriag e without levelling

Mast and carriage


Description

TDCE01 04GB P. 5

Group 80

9

32

1 4 5

6

7 8 6

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

Control valve, LENGTH ADJUSTMENT Control valve, TWIST-LOCKS Control valve, SIDESHIFT RETURN from sidelift FEED to sidelift Hydraulic cylinder, TWIST-LOCKS/LOCKING PLATES Hydraulic cylinder, SIDESHIFT Hydraulic cylinder, LENGTH ADJUSTMENT Hoses over mast

Hos es in carri age, S eparate s ide-lift hydraulics C arriag e without levelling

Mast and carriage


Description

Group 80

TDCE01 04GB P. 6

9 4 5

6 10

11

32

1

11

7 6

8

1. Control valve, LENGTH ADJUSTMENT 2. Control valve, TWIST-LOCKS/LOCKING PLATES 3. Control valve, SIDESHIFT 4. RETURN from sidelift 5. FEED to sidelift 6. Hydraulic cylinder, TWIST-LOCKS/LOCKING PLATES 7. Hydraulic cylinder, SIDESHIFT 8. Hydraulic cylinder, LENGTH ADJUSTMENT 9. Hoses over mast 10. Control valve, LEVELLING 11. Hydraulic cylinder, LEVELLING

Hos es i n carriag e, si delift with hooks

Mast and carriage


Service

Group 80

TDCE01 04GB P. 7

Inspection of lifting chains IMPORTANT! If a lifting chain does not pas s this ins pection, replace the whole chain. Li fting chains mus t not be joined or re-riveted.

To increase safety, the lifting chains should be inspected regularly in accordance with the points below. This should be carried out during each 1000 h service. For inspection, the whole length of each chain should be thoroughly clean. Carry out the inspection without any load on the forks. 1.

2. 3. 4. 5. Dimension P Inch mm

Dimension across 25 links of new chain, mm

Max permissible dimension across 25 links at 3% extension, mm

3/4 1 1 1/4 1 1/2 2 2 1/2

476.25 635 793.75 952,5 1270 1587,5

490 654 817 981 1308 1635

19,05 25,4 31,75 38,1 50,8 63,5

6.

The chain extension should not exceed 3%. Measure the extension across the 25 links that run across the guide sprocket most frequently during lifting. The extension will be greatest here. Compare the value obtained with that in the table. If the 3% limit is exceeded, the chain or chains must be replaced. Check that no pins are loose in the outer washers. Check that there are no visible cracks in any of the links. Check that there is no mechanical damage. Check that the chain is not corroded. Check that the chain bends easily around the guide sprocket and does not jam when bent. Drive the truck onto a flat surface and set the mast to the vertical position (0° tilt). Lower the forks to the bottom position. Check that there is a space of 10-20 mm between the forks and the ground. If not, adjust the lifting chains equally.

After inspection, spray the chains with chain spray.

Inspection of the lifting mast 1. 2. 3. WARNING! Never carry out s ervice work on a lifting mas t when the engine is running .

4. 5.

Inspect the lifting mast for damage or wear on the outer or inner masts. Investigate whether any wear of the lifting mast has been caused by the support wheels or by worn down sliding plates. Run the carriage up and down the mast and listen for any unusual sounds from the ball bearings. Check that the hose guide pulley runs freely and that it does not damage the hoses. Run the carriage up and down and check that the hoses do not tend to climb over one another. If they do, find out whether the hoses are twisted, by disconnecting the appropriate hose connections.


Mast and carriage

Service

Group 80

TDCE01 04GB P. 8

Dismantling the carriage 1.

IMPORTANT! Never us e rag s , cotton was te or wooden plug s .

2. 3. 4.

Us e only protective caps and plug s of plastic or metal.

5. 6. 7.

Disconnect all the hoses that connect the cylinders on the carriage with the hydraulic system. Put immediately protective caps on all hoses and connectors. Raise the carriage a little. Fit blocks under the lower beam of the carriage. Lower the carriage so that it rests with the bottom beam on the blocks. Remove the pins from the chain mountings and secure the chains with a rope, so that they will not run off the guide sprockets. Lift the inner mast by a sufficient amount so that the carriage is clear of the inner mast. Reverse the truck from the carriage.

Dismantling the lifting mast 1. 2. 3. 4. 5.

Remove the carriage as described above Disconnect the hydraulic hoses from the lift cylinders. Cap or plug all connections. Set the tilt control lever to the neutral position and secure a sturdy lifting chain to the yoke or lifting lugs on the mast. Disconnect the piston rods from the outer mast. Lift the outer mast so that the mast suspension is unloaded, unscrew the screws for the masts suspension shafts and knock out the shafts.

WARNING! R isk of injury by crushing

6. 7.

Lower the mast forward and lay it down. Fit blocks under the lifting cylinders, remove the piston rods from the inner mast and withdraw the inner mast.

Mast and carriage


Service

Group 80

TDCE01 04GB P. 9

Adjusting the support wheels in the carriage and inner mast 1. 2. 3.

2

1

4. 5.

Remove the carriage. Use a drift to tap out the tubular dowel from the inside. Screw in the clamping screw so that the wheel is firmly locked. Back off the screw until the wheel can be rotated but is somewhat stiff. Turn the clamping screw to line it up with the nearest hole for the tubular dowel. Tap in the tubular dowel to lock the clamping screw.

Replacing the support wheels in the carriage and inner mast 7 6 3

1. 2. 3. 4.

5

4

5.

7 2 6 5 1 3 4



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

Circlip Inner bearing Tubular dowel Clamping screw Sealing washer Outer bearing Support wheel

Dismantle the carriage/inner mast. Remove the circlip securing the support wheel. Remove the support wheel using an extractor. Remove the ball bearings and press in new bearings. Check that the bearings are a close fit in the wheel. Press on the wheel and fit the circlip.


Lifting mast and fork carriage

Service

Group 80

TDCE01 04GB P. 10

Lubrication of sliding surfaces and plates There are 4 plates between inner and outer mast, 4 plates between carriage and inner mast and 8 plates between carriage and sidelift attachment. IMPORTANT! The lubricant should be of a brand approved by K almar, or another of the s ame s pecific ation. The us e of any other lubric ant can lead to exc es s iv e wear and also inv alidate the K almar g uarantee. Lubr ic ants can be ordered from K almar’s s pare parts department. S ee g roup 90.

Maintenance of the sliding plates is extremely important otherwise the sliding surfaces on the mast and carriage could become damaged, resulting in the need for expensive repairs. Lubrication of sliding plates

1. 2.

To be able to lubricate the whole length of the mast, a hydraulic lift or other lift equipment is best used. Lubricate all sliding surfaces with the lubricant. Use a brush and spread the lubricant evenly. Raise the mast to its maximum lifting height.

Check sliding plates

1. 2.

Thoroughly clean the sliding plate and around its holder. The plate should be 3 mm proud of the holder to avoid the risk of the holder or the sliding plate fixing nuts damaging the opposite sliding surface. Check clearance and adjust as necessary with shims according to the following description.

2

3, 4, 7

1

2

Min 3 mm

3 4 5 4 6

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

Shim Sliding plate holder (x 4) Sliding plate, against inner mast (x4) Sliding plate, top edge attachment (x4) Shim with fixing slot Counter hole for 4 and 5 Sliding plate, bottom edge attachment (x 4) 8. Shim 9. Fixing block for attachment, tightening torque for fixing bolts 649 Nm.

KL1126

7 8

9 C arriag e s liding plates



Service

Group 80

TDCE01 04GB P. 11

Inserting shims for sliding plates - general 1. 2. 3.

Check the play in the mast and between the carriage and the mast. When a noticeable gap occurs, equivalent to a play of at least 2 mm, reduce the play with shims. When inserting the last shim, the sliding plates should have at least 5 mm wearing surface remaining, if this is not the case, they should be replaced.

Inserting shims for the upper sliding plate in the attachment mounting See the “Carriage sliding plates” illustration. 1. Shim 5 has a fixing slot, making attachment removal unnecessary when inserting additional shims. 2. Remove holding plate 6. 3. Loosen the sliding plate fixing screws so that the sliding plate loosens from the carriage. 4. Slide in the required shim to adjust/remove the gap between attachment and carriage. 5. Replace the holding plate and secure the sliding plate in place.

Bleeding the lift cylinders WARNING! R isk for injury! Dur ing the bleeding of the cylinders the inner mast and carriag e will lower. E ns ure that nobody is in the way!

1. 2. 3. 4. 5.

Use a hydraulic lift or similar. When the mast is fitted, raise the inner mast approx. 0.3 m. Connect a tube to each of the bleed nipples at the top of each cylinder to collect any spill fluid, in a suitable container. Open the bleed nipples on each of the lift cylinders, until all air has been evacuated. Re-tighten the bleed nipples.

Stretching of hoses 1. 2. KL1127

After a certain amount of use, the hoses will become stretched and will therefore need to be tightened. Stretch the hoses by loosening the hose holder from the carriage and move them down to a suitable new hole profile on the carriage. See the “High-Lift Mast” illustration.

Tilt cylinder mounting, tightening torque 1

2 1. Tilt cylinder 2. Mounting bolts 3. Piston rod head

1

2

3

1.

After any adjustment of the tilt angle, the piston rod head’s mounting bolt should be tightened to a torque of 136 Nm. See adjacent illustration.

Checking tilt cylinders The tilt cylinders should be checked every 500 hours considering på cracks and also tightening torque as stated above. 4. Check to make sure that no cracks occur at welds and fillets. Pay special attention to the items in the illustration below.

3 Risk of crack formation 1. Thread exit 2. Weld 3. Weld



Service

Group 80

1

TDCE01 04GB P. 12

2 3 4

5

KL1125

4 3 2

1. 2. 3. 4. 5.

Bleed nipples at the top of the lift cylinders Shim Sliding plate holder Sliding plate (x 4) Hose holder, mounted on carriage

Hig h-Lift Mas t

Sidelift attachment


Description

Group 80

TDCE01 04GB P. 13

Sidelift attachment

A

B1

C

B2

A. Twist-locks locked (green) B1.Alignment container (orange) B2.Alignment hooks (orange) Only hook attachment C. Twist-locks unlocked (red)

Lamp panel

The sidelift attachment has been designed for easy, safe and rapid handling, low weight and ease of maintenance. The attachment is integrated with the carriage. Two different models of the attachment are available; with twistlocks or with hooks for container connection. The hook connections are used, for example, for the simultaneous lifting of two containers. Both of the attachments’ corner pieces are telescopic and suspended from the main beam by means of springs, which enables 195 mm levelling to both sides for the connection to leaning containers. A hydraulic cylinder between the attachment and the carriage allows ±600 mm side-shift. A hydraulic/mechanical system ensures that the container are locked onto the attachment prior to lifting. Hook attachments are equipped with side locking plates which lock the container onto the attachment prior to lifting. An electrical safety system prevents the locking and release of the twist-locks if the attachment is not correctly positioned against the container. The system also prevents lifting if the twistlocks are not either completely locked or released. A lamp panel displays alignment, locked and released container respectively. See also Group 70, Hydraulic diagram 1

7

2 3 

8

4

9 10

5

11

6

1. 2. 3. 4. 5. 6.

Hydraulic cylinder, twist-locks Twist-lock Contact pin, alignment Spring for mechanical levelling Hydraulic cylinder, sideshift Hydraulic cylinder, length adjustment 20'-40' 7. Mechanical indicator, twist-locks 8. Sensor, twist-locks unlocked 9. Activator 10. Sensor, alignment 11. Sensor, twist-locks locked

S idelift with twis t-lock s

Sidelift attachment


Description

Group 80

TDCE01 04GB P. 14





7

8

2

11

1

3

9

10

4

1. Hook for container coupling 2. Spring for mechanical levelling 3. Hydraulic cylinder, side locking plate 4. Side locking plate 5. Hydraulic cylinder, sideshift 6. Hydraulic cylinder, length adjustment 20'-40 7. Sensor, alignment against container 8. Sensor, alignment on hooks 9. Sensor, lockings plates locked 10. Sensor, locking plates released 11. Spring loaded contact pin, alignment against container

5

6

4

S idelift with hook-coupling

Sidelift attachment


Service

Group 80

TDCE01 04GB P. 15

Sidelift with twist-locks Indicating lamps on side-lift

A

B

Lamp A (Green): Lamp B (orange):

C

Lamp C (Red):

Twist-locks locked Alignment, extinguished when the container is lifted Twist-locks unlocked

Indic ating lamps on si delift

WARNING! Whenever the indicating lamps do not work properly, the attachment sh ould be taken out of s ervi ce for repair. The us e of an attachment with faulty indi cation lamps could be hazardous!

Alignment control

8 9 3

A spring-loaded contact pin and an inductive sensor at each twist-lock is used for alignment control. The attachment is fully aligned onto the container when all pins have been depressed and the distance between each pin and sensor have decreased to 4–5 mm. Then the indicating lamp ALIGNMENT B lights up and the twist-locks are ready for locking.

10 11

3. Contact pin, alignment 8. Sensor, twist-lock unlocked 9. Activator 10. Sensor alignment 11. Sensor, twist-locks locked

Safety interlocking system

After locking of the twist-locks the lifting starts. A built in play between twist-locks and container corner boxes allows the attachment to be lifted enough for the inductive sensors to be deactivated, i.e. the distance between sensor and contact pin increases to more than 8 mm. This will brake the minus feed to the twist-lock solenoid valve, thus making it impossible to operate the twist-locks when lifting. This electrical interlocking can, in emergency situations, be bridged by an override switch in the operator’s cab. The override switch will feed “false” alignment minus signal to the twist-lock solenoid valve thus making it possible to operate the twist-locks. A red warning lamp lights up in the operator’s cab when the electrical interlocking is bridged. Checking of ALIGNMENT indicating lamp B and electrical interlocking system

1. Check that the contact pins in the corner boxes are freely moveable up and down. A pin which binds in the upper position may indicate correct alignment although the attachment is not in contact with all four container corners. Lubricate the contact pins when needed. 2. Check that the indicating lamp ALIGNMENT B lights up when the attachment is fitted to the container and that the lamp is extinguished when the container is lifted. 3. When lifting an empty container just enough to make the lamp ALIGNMENT go out, check that it is impossible to unlock the twist-locks. 4. The sensor for alignment should be adjusted to give a signal when the contact pin is depressed. See Inductive sensors, page 17.

Sidelift attachment


Service

Group 80

TDCE01 04GB P. 16

Sidelift with hook coupling Indicating lamps on sidelift

B1

A

C

B2 Indic ating lamps on si delift

Lamp A (Green): Locking plates locked Lamp B1 (orange): Alignment against container, extinguished when the container is lifted Lamp B2 (orange): Alignment on hooks, the light is on after lift Lamp C (Red): Locking plates unlocked Optional: Both B1 and B2 must be lit before the locking plates can be unlocked. N.B . B 1 and B 2 indicate two different alig nment s ig nals fr om the s idelift. Thi s is to facilitate fault tracing if lamp B in the cab sh ould not lig ht up when coupling a container.

WARNING! Whenever the indicating lamps do not work properly, the attachment sh ould be taken out of s ervi ce for repair. The us e of an attachment with faulty indi cation lamps could be hazardous! 

Alignment control

7

8

12

A spring-loaded contact pin and an inductive sensor at each side is used for alignment control against the container. The sidelift is fully in contact with the container when both pins have been depressed and the distance between each pin and sensor is less that 8 mm. On the hook-coupling sidelift there is an additional alignment lamp B1 and B2. B2 lights up when the hooks have been pressed down enough for activation of sensor 8. When both B1 and B2 light up the locking plates are ready for locking.

11

Checking of ALIGNMENT indicating lamps B1 and B2 Option: Electrical interlocking system



9

10

12

4

4. Side locking plate 7. Sensor, alignment against container 8. Sensor, alignment on hooks 9. Sensor, locking plate locked 10. Sensor, locking plate released 11. Spring-loaded contakt pin, alignment against container 12. Activator for sensor 9

1. Check that the contact pins in the corner boxes are freely moveable in and out. A pin which binds in the inner position may indicate correct alignment although the attachment is not in contact with the container. Lubricate the contact pins when needed. 2. Check that the indicating lamp ALIGNMENT B1 lights up when the sidelift is fitted to the container. 3. Check that the indicating lamp ALIGNMENT B2 lights up when the hooks are engaged in the container. 4. Check that the lamp B1 is extinguished when the container is lifted. 5. Option: Lift an empty container just enough to make the lamp B1 go out. Check that it is impossible to unlock the locking plates. 6. The sensor 7, se picture, for alignment should be adjusted to give a signal when the contact pin is depressed. See Inductive sensors, page 17.

Sidelift attachment


Service

Group 80

TDCE01 04GB P. 17

Inductive sensors The inductive sensors control the various functions of the container attachments. The sensors are of the type PNP – positive/negative/positive, the last P indicating that the sensor produces a positive signal when activated. The sensor is activated when a magnetic object gets closer than approx 8 mm from the top of the sensor. The sensor has a light diode which can be used for checking of the sensor function.

Sensor adjustment and check 1. The gap between sensor and magnetic activator should be set to 4–5 mm. At a distance of more than 8 mm, the sensor is deactivated. 2. When the sensor is activated, the yellow diode should be alight. 3. Check that the sensor is clean and free from grease and that it is undamaged. (Grease may activate the sensor).

1. Yellow LED, sensor activated 2. – 3. Magnetic activator

Inductive s ensor

Sidelift attachment


Service

Group 80

TDCE01 04GB P. 18

Control of twist-locks 3

N.B . Thi s control s hould be firs t carried out after 5000 hours of servic e, or after 2 years - which ever occurs firs t. Thereafter, the twis t-locks s hould be checked every year. Removing the twist-locks

1. 2. 3.

2 4 1

4.

Unscrew the grease nipple 1. Remove the twist-lock 2. Unscrew nut 3, at the same time, support the underside of the twist-lock. Remove the twist-lock 5 downwards, the washer 4 comes with it.

5.



Twist-lock control

1. 5

Check to ensure that there are no fractures or splits in any part of the twist-lock. Use a method for undestructive testing. Contact an authorised representative.

IMPORTANT! If any s plit or fracture is dis covered then the twis t-lock mus t be i mmediately replaced. If the twis t-lock has any other v is ible damag e, then it mus t be i mmediately replaced.



1. 2. 3. 4. 5.

Grease nipple Locking pin Fixing nut for lifting pin Washer Twist-lock

A ll twis t-lock s s hall be replaced after 20,000 hours of s ervic e, even if they appear undamag ed.

2. 3. 4.

Place the washer 4 on the twist-lock and refit the lifting pin. Refit the locking pin 2, and the grease nipple 1. Tighten the nut to a torque of 300 Nm.

Control of lifting hooks N.B . Thi s control s hould be firs t carried out after 5000 hours of servic e, or after 2 years - which ever occurs firs t. Thereafter, the hooks s hould be checked every year.

1

2

Removing the hooks

1. 2.

Unscrew the locknut and remove the fixing screw 1. Remove the lifting hook 2.

Lifting hook control

1.

Check to ensure that there are no fractures or splits in any part of the lifting hook. Use a method for undestructive testing. Contact an authorised representative

IMPORTANT! If any split or fracture is dis covered then the lifting hook mus t be i mmediately replaced. If the lifting hook has any other vis ible damage, then it mus t be i mmediately replaced. 1. Fixing screw 2. Lifting hook

A ll lifti ng hook s s hall be replaced after 20,000 hour s of s ervic e, even if they appear undamag ed.

2.

Refit the lifting hook and fixing screw 2. Secure the fixing screw with a new locknut.

Sidelift attachment


Service

Group 80

TDCE01 04GB P. 19

Control and adjustment of alignment against container, hook attachment





A

B1 B2

C

1. Check the sensor for alignment and adjust if necessary. 2. The measure A over the contact pin in its outer position should be 35 mm. 3. When the measure A is reduced to 28 mm, the lamp B2 for alignment against the container should light up 4. Adjustment: Depress the contact pin until the measure A = 28 mm and fix in a suitable way. Then release the sensor from its bracket and move it along the oval hole. Tighten the sensor in exact the position it has reached when the lamp B2 lights up.


Sidelift attachment

Service

Group 80

TDCE01 04GB P. 20

Changing the main beam sliding plates Older main beam design

2 4

1. 2. 3.

3

Release the piston rod from the extension beam. Unscrew nuts and bolts from the cable chain. Release the hoses from the locking cylinder. Plug the hoses with end plugs. Remove the hose clips. Use a suitable lifting device and pull the extension beam out of the main beam.

4. 5.

1

WARNING! B e extremely careful when the extension beam g ets clear from the main beam

5 

6.

Unscrew nuts and bolts holding the sliding plates See N.B. concerning special tool below.

6

N.B . In order to reach the inner s liding plates s crews i s recommendable to us e a tool as illus trated on the pic ture below. The tools , one for s ide plates and one for bottom and top plates can be ordered from K almar Indus tries .



1. Shims 2. Sliding plate 3. Tool for removing/fitting of sliding plates

1 2 3

Sidelift attachment


Service

Group 80

TDCE01 04GB P. 21

7.

Remove sliding plates and shims from the main beam.

8.

Measure the extension beam’s width X and height Y at the sliding plate positions, see picture, measuring position A and B.

9.

Refit the sliding plates and put a sufficient number of shims under the sliding plates in order to achieve a 5 mm play between sliding plates and main beam both sideways and vertically. This corresponds to the measures X + 5 mm and Y + 5 mm inside between the sliding plates.

7

8

     

    



10. Push the extension beam into the main beam and refit 1-23-4.

Sidelift attachment


Service

Group 80

Changing the main beam sliding plates

TDCE01 04GB P. 22

.

New main beam design from 2005

1. Using the LENGTH ADJUSTMENT function, extend the inner beam approx 1000 mm. No cables or hoses have to be disconnected..



1000 mm

2. Unscrew screws and nuts holding the sliding plates.

2



3. Remove the sliding plates and shims from the main beam. Lift the inner beam slightly to relieve the load from the sliding plates. R ight side 

Left s ide 

Sidelift attachment


Service

Group 80

TDCE01 04GB P. 23

4. Reinstall the sliding plates. Fit sufficient number of shims under the sliding plates to achieve 1-3 mm clearance between sliding plates and main beam both horisontally and vertically. This corresponds to the inside measures between the sliding plates X + (1-3) mm and Y + (1-3) mm.

5. Using the LENGTH ADJUSTMENT function, retract the inner beam to its inner position.



Höger sida



Vänster s ida


Sidelift, hooks, type C

Description

Group 80

TDCE01 04GB P. 24

Sidelift with hooks, type C The sidelift attachment has been designed for easy, safe and rapid handling, good visibility, low weight and ease of maintenance. The attachment is integrated with the carriage. The attachment has hooks for container connection allowing for the simultaneous lifting of two containers. A hydraulic cylinder between the attachment and the carriage allows ±600 mm side-shift. A system with hydraulically controlled side locking plates ensures that the container is locked onto the sidelift prior to lifting. When lifting two containers, both are locked by the side locking plates.. A lamp panel displays alignment, locked and released container respectively. For lever functions, see instruction Manual.

1

2

3

5

4

6

KL1790

1. Side locking plate with hydraulic cylinder 2. Lifting hook 3. Hydraulic cylinder, sideshift 4. Hydraulic cylinder. length adjustment 5. Carriage 6. Lamp panel



Description

Group 80

TDCE01 04GB P. 25

Carriage

The carriage is of either of two different designs, both allowing levelling for hooking up leaning containers. In the standard design the sidelift main beam is moveable over sliding plates in the carriage. A vertical play admits ±3° levelling. The optional design has hydraulical levelling by means of one hydraulic cylinder on each side..

4

2 1

2

2

4 2

2

1. Carriage wheels 2. Sliding plates 3. Hydraulic cylinder, levelling 4. Bolts, tightening torque 370Nm (dry bolts)

2

3

C arriag e with mechanical levelling

2

2 1

2

2

2

2

Carriag e with hydraulic levelling



Service

Group 80

TDCE01 04GB P. 26

Indicating lamps on side-lift

2

1 3

4

5

6

7

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

8

Red lamp Red lamp Orange lamp Orange lamp Orange lamp Orange lamp Green lamp Green lamp

Indicating lamps on the s idelift

Left locking plate released Right locking plate released Alignment Left, upper container Alignment Right, upper container Alignment Left, lower container Alignment Right, lower container Left locking plate locked Right locking plate locked

WARNING! Whenever the indicating lamps do not work properly, the attachment sh ould be taken out of s ervi ce for repair. The us e of an attachment with faulty indi cation lamps could be hazardous!

5 6 4 KL1792

3

2

1 3

7

2

8

Alignment control A spring-loaded contact pin and an inductive sensor at each twist-lock is used for control of alignment against one or two containers . The sidelift is fully aligned onto the container when the contact pins on both sides have been depressed and the distance between each pin and sensor is less than to 8 mm. When lifting one container: When lamps 5 and 6 light up, the side locking plates can be locked. When lifting two containers: When lamps 3, 4, 5 and 6 light up, the side locking plates can be locked. N.B . It is poss ible to lock the s ide locking plates without indication of alig nment. Therefore, never lock before lamps 5 and 6 (one container) or 3, 4, 5 and 6 (two containers ) lig ht up. In the locked position for one or two containers, the red lamps 1 and 2 go out and at the same time the green lamps 6 and 7 light up. During lift operation the lamps 3, 4, 7, 8 should always be alight while 5 and 6 should be extinguished.. Checking of indicating lamps

1.

KL1791

1. Lifting hook 2. Spring loaded contact pin , alignment against lower container 3. Spring loaded contact pin , alignment against upper container 4. Side locking plate 5. Sensor, locking plate locked/released 6. Activator for sensor 7. Sensor, alignment against lower container 8. Sensor, alignment against lower container

2. 3. 4. 5.

Check that the contact pins are freely moveable in and out. A pin which binds in the inner position may indicate correct alignment although the sidelift is not in contact with the container. Lubricate the contact pins when needed. Check that the indicating lamps 1 and 2 Red are alight when the locking plates are released. Check that the indicating lamps 3, 4, 5 and 6 Orange light up at the alignment of two containers, alternatively 5 and 6 at the alignment of one container.. Check that the lamps 7 and 8 Green light up when locking the locking plates and that 1 and 2 Red go out. The sensors 7 and 8, se illustration, for alignment should be adjusted to give a signal when the contact pins are depressed. See Control and adjustment of alignment against container, page 28.



Service

Group 80

TDCE01 04GB P. 27

Sensor for interrupting of lowering Between the carriage and the flexibly suspended main beam is a sensor wich gives a signal when the sidelift has reached its bottom position. This interrupts the lowering thus preventing the lifting chains from excessive slacking which could possibly damage the equipment.

Inductive sensors The inductive sensors control the various functions of the container attachments. The sensors are of the type PNP – positive/negative/positive, the last P indicating that the sensor produces a positive signal when activated. The sensor is activated when a magnetic object gets closer than approx 8 mm from the top of the sensor. The sensor has a yellow light diode, which can be used for checking of the sensor function.

Sensor adjustment and check 1. The gap between sensor and magnetic activator should be set to 4–5 mm. At a distance of more than 8 mm, the sensor is deactivated. 2. When the sensor is activated, the yellow diode should be alight. 3. Check that the sensor is clean and free from grease and that it is undamaged. (Grease may activate the sensor).

1. Yellow LED, sensor activated 2. – 3. Magnetic activator

Inductive s ensor



Service

Group 80

TDCE01 04GB P. 28

Control of lifting hooks N.B . Thi s control s hould be firs t carried out after 5000 hours of servic e, or after 2 years - which ever occurs firs t. Thereafter, the hooks s hould be checked every year. Removing the hooks

1. 2.

Unscrew the locknut and remove the fixing screw 1. Remove the lifting hook 2.

Lifting hook control

1.



Check to ensure that there are no fractures or splits in any part of the lifting hook. Use a method for undestructive testing. Contact an authorised representative

IMPORTANT!

1

2

If any split or fracture is dis covered then the lifting hook mus t be i mmediately replaced. If the lifting hook has any other vis ible damage, then it mus t be i mmediately replaced.

1. Fixing screw 2. Lifting hook

A ll lifti ng hook s s hall be replaced after 20,000 hour s of s ervic e, even if they appear undamag ed.

2.

Refit the lifting hook and fixing screw 2. Secure the fixing screw with a new locknut.

Control and adjustment of alignment against container 1.



2. 3. 4.



5. 

6. 7.

2

1 3 5 7

4 6 8

Check the sensors for alignment and adjust if necessary. Check left and right sensor in the same way. Mesarue A over the contact pin for upper container should be 39 mm, contact pin released. When the pin is depressed until measure A=22 mm, the lamp 3/4 for alignment against upper container should light up. Adjustment: Depress the contact pin until measure A=22 mm and fix the pin in a suitable way. Then release the sensor from its bracket and move it along the oval hole until the lamp 3/4 lights up. Fasten the sensor in exactly its position when the lamp 3/4 lights up. The measure B over the contact pin for lower container should be 30 mm, contact pin released. When the pin is depressed until measure B=18 mm, the lamp 5/6 for alignment against lower container should light up. Adjustment: Depress the contact pin until measure A=18 mm and fix the pin in a suitable way. Then release the sensor from its bracket and move it along the oval hole until the lamp 5/6 lights up. Fasten the sensor in exactly its position when the lamp 5/6 lights up.

Lampor på sidlyft

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

Red lamp Red lamp Orange lamp Orange lamp Orange lamp Orange lamp Green lamp Green lamp

Left locking plate released Right locking plate released Alignment left, upper container Alignment right, upper container Alignment left, lower container Alignment right, lower container Left locking plate locked Right locking plate locked



Service

Group 80

TDCE01 04GB P. 29

Changing the main beam sliding plates 1. Using the LENGTH ADJUSTMENT function extend the inner beam 1000 mm.

1000 mm



2. Unscrew screws and nuts that hold the sliding plates.

.

2





Service

Group 80

TDCE01 04GB P. 30

3. Remove sliding plates ans shims from the main beam.. Lift the inner beam slightly to relive the load from the sliding plates.



Höger sida



Vänster s ida

4. Reinstall the sliding plates. Fit sufficient number of shims under the sliding plates to achieve 1-3 mm clearance between sliding plates and main beam both horisontally and vertically. This corresponds to the inside measures between the sliding plates X + (1-3) mm and Y + (1-3) mm. 5. Skjut in utskjutningsdelen i huvudbalken med hjälp av funktionen LÄNGDINSTÄLLNING.





1

Service

2

3

TDCE01 04GB P. 31

Group 80

6

7

8

1 3

2 4

D

6

5 4

7

5

D

8

C

C

9 Opt.

XB777

10

11

12 25x1,5mm²

1. Sensor alignment, left side 2. Work light, left side 3. Work light right side 4. Sensor, stop at 30’ (optional) 5. Relys and valves, stop at 30’ (optional) 6. Sensor alignment, right side 7. Indikeringslampor left side, see separate description 8. Indikerinslampor right side, see separae description 9. Main valve sidelift 10. Sensor, interruption of lowering at bottom position (mechanical levelling) 11. Electrical central unit 12. From chassis See also circuit diagram A45760.0100

B lock diag ram



Service

  

9 1

  

Group 80

1 1

2 1

  

  

     

0 1



0 1

7



8

2



3

6



8

2

9

9 3 8 1

8

5

2



3 4



2

8

t i u t c s r i u c j s t d t k f c a g o i l i n h l o h l p p t i s t l r m e i s g e o u v d f i w n e l e r p s t l e e , r , r , , t r r l i e e e e f r u d d d d e s n n i n n s i s l i l l i l r e y y y r a p e c c y c c v o t l c i c i c i c c i l l l l l n a v u u u u a f a t n s e r a r a r a r t a r r e d d d n d n i l t e t o e i l y y y e y n C I R F H H H m H . . . . . . . . 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 c i s l a e u t r i a v p e r t t d a a c o y t i l r i h a p n / p l o a e a v r d s n r e n h s a e t e i t c n v w i l i k r t c a e r c o v v o e h n l f l a e s i o v e v y r d e t g l p e a e t v i n a v p r i n l i v e b a a c y u s v o v i c u t e e n v m n t d f r o e o o n e a r u i C s C t A R s s . . . . 0 1 8 9 1 1





          

TDCE01 04GB P. 32

7 1 1  

 

t e n t e n e i m t v h l s i a t u j v w s d t k k r f c a g i o c t n h l o h o a l t i s t l h s e s g e s n d i n v d e e i w e l e t l e p l v s l , , , , l m r a e e e e o r o v e v l v l v l v c l t u a a a a n c k c d v v v v o e l l l l c r e e r o o o o h t u r t r t r t r c t c s s l d e e n n n n e r a i r r e o o o o P g F C C C D C . . . . . . . 1 2 3 4 5 6 7

3 1 4 1 6 1

5 1

Hydraulic system A46141.0100

A

B

C

D

E

F

0 1

6 0

e u t s e 1 I s e / h a S v / å d g a t l U B

8

8

0 0 1 0 . 0 0 9 / 6 0 8 7 E 5 C 4 D A

3 3 C B

8 8 7 7 7 7

.

A B E E E E

.

0 0

.

1 1

4 4 3 3 3 3

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R 5 0 2 7 B -

D E K C O L T H G I R P A L F

N B

U B

R 4 0 2 7 B -

D E K C O L N U T H G I R P A L F

N B

R 1 3 0 2 7 B -

U B

W O L T H G I R T N E M N G I L A

N B

P U T H G I R

.

.

R 2 3 0 2 7 B -

U B

T N E M N G I L A

N B

K B

K B

7

U B 4

5

6

K B

m R 5 0 2 A C B 7 B X -

m R 4 0 2 A C B 7 B X -

m R 1 3 0 2 A C B 7 B X -

m R 2 3 0 2 A C B 7 B X -

f R B A C 5 0 2 7 B X -

f R B A C 4 0 2 7 B X -

f R 1 B A C 3 0 2 7 B X -

f R 2 B A C 3 0 2 7 B X -

f R 6 0 4 1 X -

2

3

4

5

6

m R 6 1 3 0 2 4 X -

4

5

6

1 2 3

4

. t . t g A g k a k o o o r H K t i s u 6 t c g e i r n i r n m e C ä K m n

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1

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4

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t c u d o r P / t k u d o r P

s V R R p i 4 s w _ _ U o 2 s d d _ L + a - e e R h k k R c c t_ C _ o t l o n n n L e e m U m n n g i g l i l A A

1 2 3

K B

6

.

/ / / / / /

s V i 4 s 2 s + a h C

7

.

H 1 6 W

a N

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5 6

2 P S X -

5

5

3 P S X -

2

6 : p r G . H

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4

s s a l C / s s a l K

4

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T

1 P S X n g n i w s r e p a r D p A D / r / / t d s k a n d t i o o R K G

3

3

H

H

W

1

H

5 W

H

1 4 W

1

H

3 W

f L 5 0 2 7 B A C B X -

f L 4 0 2 7 B A C B X -

f L 1 3 0 2 7 B A C B X -

m L 5 B A C 0 2 7 B X -

m L 4 B A C 0 2 7 B X -

m L 1 B A C 3 0 2 7 B X -

5 2 m 2 u e 0 t t a a 5 0 D D

1 6 W

f L 2 3 0 2 7 B A C B X -

m L 2 B A C 3 0 2 7 B X -

1 2 3

m L 6 1 0 4 X -

2

3

f L 1 6 2 3 0 4 X -

4

5

6

4

5

6

4

5

6

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S J C

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n h Ä C

2

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E D .

.

0 0

0 2 7 B -

K B

U B

D E K C O L T F E L P A L F

1 1

N B

L 4

0 2 7 B -

K B

U B

N B

L 1 3 0 2 7 B -

D E K C O L N U T F E L P A L F

K B

U B

N B

L 2 3 0 2 7 B -

W O L T F E L T N E M N G I L A

U B

P U T F E L T N E M N G I L A

1 2 3

4

5

6

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s a W / r a V = V

8 8 7 7 7 7

d e t e l e D / r å g t U = . U T e 1 d g 1 e n 4 d d a h X A c & / k 1 g l n 0 l i n i g 1 T r i s 4 = d e X T n Ä D

A B F F F F . . . . . . 4 4 3 3 3 3 / / / / / /

/ / 1

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. a f t . e u q R R S

A

B

C

D

. d e t u c e s - o r p e b l l i w n o i t n e v a r t n o C . e s o p r u p d e z i r o h t u a n u y n a r o f d e s u e b r o n y t r a p d r i h t a o t d e t r a p m i e b t o n t s u m f o e r e h t s t n e t n o c e h t d n a n o i s s i m r e p n e t t i r w

E

F

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G N I W A R D ³ E R

A

B

C

D

E

F

0 1

6 0

e u t s e s 2 I e / h a S v / å d g a t l U B

8

8

0 0 1 0 . 0 0 9 / 6 0 8 7 E 5 C 4 D A . o N g n i w a r D / . r n . n t i R


7 1

R 2 6 5 H 2

D E K C O L N U T H G I R P A L F

D R

) w o l l e y (

) w o l l e y (

) d e r ( 1

R 1 4 6 5 H 2

D R

P U T H G I R T N E M N G I L A

1

R 2 4 6 5 H 2

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2

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7

D R


6

6 P S X -

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e B

D R

D R

) d e r ( 2

L 2 6 5 H 1

5

D E K C O L N U T F E L P A L F

D R

) w o l 2 l e y ( L 1 P 4 U 6 T 5 F H E L 1 T N E M N G I L A

D R

) w o l l e y ( 2

L 2 4 6 5 H 1

W O L T F E L T N E M N G I L A

2

L 3 6 5 H 1

) n e e r g ( D E K C O L T F E L P A L F

5

6 : p r G . H

Y G

4

m 1 1 0 4 X f 1 1 0 4 X -

D R

K B

U B

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E Y

H W

N B

T V . o n 0 t 0 c e 1 j o 0 . r P 1 / . 6 r n 7 d 5 u v 4 u A H

2

3

4

5

6

7

8

9

2

3

4

5

6

7

8

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P S X . 6 r o 7 n N 2 g e 0 n g 5 i r n 0 d a

n h Ä C A 1 5 4

2

2 m 1 5 4 X -

s a W / r a V = V

2 0 1 A


X X X X . 1 9 0 5 3 A

1

. r o 1 N N


A

B

C

D


E

F



A

B

C

D

E

F

0 1

6 0

e u t s e 0 I s e h 1 / a S v / å d g a t l U B

8

L 7 7 7 B -

P O T S 5 3 0 3

N B

2

2

R 8 1 0 6 Y -

U B

1

2

K B

P O T S 5 3 0 3

R 7 7 7 B -

P O T S 5 3 0 3

N B

8

2

2

U B

L 8 1 0 6 Y -

2

K B

1

1

P O T S 5 3 0 3

1 3

2

1

3



1 2 7

0 0 1 0 . 0 0 9 / 6 0 8 7 E 5 C 4 D A

2

3 X -

X X X X . 4 9 0 5 3 A

7

2

2 5 8

a 7 8

5 8

A 7 7 8 8

R 6 0 0 3 K 6 8

0 3

6 8

0 3

f 8 1 3 X -

6

1

A 3 8 1

R 3 8 X Y -

5 8

A 7 7 8 8

L 6 0 0 3 K -

1

6 8

0 3

6 8

0 3

2

3

4

m R 7 7 A B 7 B X -

5

f R 7 B A 7 7 B X -

B C 3 3 8 8 1 1

7

P O T S 5 3 0 3

1


6

4

4

5

5

5 6

1

L 3 8 X Y -

G

U B

C 4 8 1

a 7 8

6

m 8 1 3 X -

B 4 8 1

P O T S 5 3 0 3

5 8

2

3

4

5 6

a N

e B

G

G O

U B

f R 6 0 0 3 K A B C X -

m L 7 7 A B 7 B X -

C

f L 7 B A 7 7

C

E Y

N B

C

m R 6 B C A 0 0 3 K X -

C

E Y

N B

G O

f L 6 0 0 3 K A B C X -

5

B X -

m L 6 B 0 C A 0 3 K X -

6 1 1

1 1 0 1

4 0 0 1 S -

0 1

0 1

1 1 : p r G . H

9 9 P

O T S 5

0 0 1 3

5 0 1

4 m 4 8 1 X -

C 8 8 1

m R 1 6 1 0 4 X -

m R 0 6 1 0 4 X -

m L 0 6 1 0 4 X -

m L 1 6 1 0 4 X -

f R 1 6 1 0 4 X -

f R 0 6 1 0 4 X -

f L 6 0 0 1 4 X -

f L 1 6 1 0 4 X -


H W

1 1

0 1

H W

1

0 1

1 1

5 2 2 0 5 0

1 . n B g i K S

A 4 4 8 8 1 1 A A

E M L

T

B 8 8 1

s i s s

a h C

X X X X . 4 9 0 5 3 A

4

e 2 t a 1 D / 1 0 m u 4 t a 0 D

f 8 1 4 X -

3


7 1

3 4

4

A

2 . 8

m 8 8 1 X -

V 4 2 +

2 8 X -

X -

1 /

f 8 1 8 X -

1 4 2 8 A

s i s s

7

a h C

A

1 4

4

A

.

. 2

1

1

/

/

8 X -

2 8 2 8 A

2 4 2 8 X -

V 4 2 +

1 n g n i w s r e p a r D p A D / r / / t d s k a n d t i o o R K G

A . 1

3

/

4 4 2 8 A

5 2 m 2 u e 0 t t a a 5 0 D D

3 4 2 8 A

. n g i S

S J C

8 8 1 A . 6 r o 7 n N 2 g e 0 n g 5 i r n 0 d a

b 3

p p a n k p o t s 0 3

4 6 5 F -

2

a 3

5 8

1 C . 4

A 5 8 6 0 0 3 A

2 R 6 0 0 3 K -

/

5 1 +

5 1 +

n h Ä C

B 5 8 - 6 0 0 3 A

s i s s

a h C

5 8

6 8

6 8

8

a P 7 O 8 T S 5 A 3 7 7 8 8 0 3 L A N G I S 0 3 T R E V 0 N I 3

5 8

2 L 6 0 0 3 K -

5 8

6 8

6 8

a P 7 O 8 T S 5 A 3 7 7 8 8 0 3 L A N G I S 0 3 T R E V 0 N I 3

2

B

s a W / r a V = V

. A 0 3 6 0 0 3 A

4 /

p o t s 0 3


B 0 3 - 6 0 0 3 A

8 C

1

. 4

. r o 1 N N

/


A

B

C

D


E

F




Contents

Group 90

TDCE01 04GB P. 1

Group 90 Periodic supervision

Periodic supervision .................................................................. 3 General survey .................................................................. ... 3 General survey chart ......................................................... ... 3 Lubricating chart................................................................... 4 Daily supervision ...................................................... .......... 10 Every 500 hours ................................................................. 11 Every 1000 hours ................................................. .............. 12 Oil and lubricant recommendations .................................... 13


Empty page Group 90

TDCE01 04GB P. 2



Group 90

TDCE01 04GB P. 3

General survey To extend the service life of the truck and to prevent the risk of faults causing injury to personnel or damage to equipment, the truck must be subjected to regular periodic supervision. If the truck is used under conditions in which road traffic regulations are applicable, the special maintenance instructions issued by the authorities must be followed. The intervals at which service measures are carried out can be determined on the basis of the operating hour meter readings. When carrying out a 1000-hour service, it is advisable to work in the following order: 1.

Every 1000 hours

2.

Every 500 hours

General survey chart Maintenance intervals, hours Operating time

1000

500

Note

200

Oil change, engine

400

Filter change, engine

500

1000





1500 2000

Guarantee service after 50 hours. Work in accordance with list below:









...

WARRANTY SERVICE at 50 working hours 1. 2. 3. 4.

500 hours service according to Technical Handbook, group 90 Perform and fill in control chart in the Warranty certificate Changing of oil in engine, gearbox and drive axle. Changing filter in engine, gearbox and hydraulic system, (all filters incl. WDB, servo filter etc) 5. Valve clearance adjustment (engine) 6. Check all bolt joints (see also SI94-003)

Periodic supervision Lubrication


8

9

Group 90

TDCE01 04GB P. 4

10 11

6, 7

12 13

KL1318

17

16 15

14

5

19

1

4 3 2



IMPORTANT! If the truck s tands unused outdoors , with the hydraulic pi s ton rods expos ed, all pis ton rods must be gr eas ed to prevent corros ion.

A fter they have been washed with deg reas ing agent, all pis tons s hould be moved back wards and forwards s everal times to obtain a new protective film of oil.

DCE80-100E Technical Handbook Item No.

Periodic supervision Lubrication

Description

Interval

operating hours 200/ 400

500

1000

Group 90

TDCE01 04GB P. 5

No. of Remarks lub. points

1

Cylinder bearing, tilt cylinders

L

4

2

Mast suspension

L

2

3

Cylinder bearing

L

4

4

Support rollers, mast and carriage

5

Sliding plates

Relieve the mast of load when lubricating

18

outer - innermast inneremast - carriage carriage - sidelift

L L L

4 4 8

Use skylift or similar. Lubricate all sliding surfaces with lubricating agent. Use a brush and distribute evenly. Operate the mast to max lifting height. Every 500 hours, check bolted joints and the wear of the sliding plates . If the remaining thickness of any plate is less than 3 mm it must be replaced, see Technical Handbook.

6

Engine oil

x

7

Oil filter, engine

x

8

x) Oil change every 200 hours 1) 2

x) Filter change every 400 hours

Steered wheel bearings

2

9

Knuckle pin bearing

4

Dismantle, clean, inspect and pack with grease every 4000 hours

10

Gearbox oil

11

Gearbox, oil filter

x

12

Drive axle

C

13

Propeller shaft

L

14

Hydraulic fluid filter

15

Hydraulic fluid

16

Breather filter, hydraulic reservoir

17

Linkage, steered axle

18

Hinges, doors and hatches

19

Brake pedals

x x

1

x) Oil change. Check level while idling

1

x) Filter change

3

x) Oil change, differential and hubs. First oil change after 200 h, thereafter every 1000 h. Drain the oil at working temperature Check the levels after refill

3 x x

L

2

x) Filter change

1

Oil change every 2000 hours

1

x) Filter change

4 L CL

1)

Dismount doors and hatches 2

Check and retighten the pedal axle locking screws. Lubricate axle nipples

The interval is greatly dependent on the fuel and lubricant quality as well as the operating conditions. If intervals longer than 200 hours are desired, the condition of the oil must be checked by the company making the oil, by means of regular lubricant tests.

For volumes, see Technical Data. For lubricating oil grades, see Oil and lubricant recommendations L=Lubricate C=Check

Periodic supervision Lubrication, Standard side-lift


Group 90

TDCE01 04GB P. 6

4 4 1

1

3

3



7 8

5

6

KL1599

Twist-locks

6





Hook coupling

Hook coupling , locking plate

DCE80-100E Technical Handbook Pos No.

Periodic supervision Lubrication, Standard side-lift

Description

Interval 500

1000

Group 90

TDCE01 04GB P. 7

No. of Remark lub. points

1

Sliding surfaces, length adjustment

L

Brush onto all sliding surfaces with the attachment in the fully extended position

2

Sliding surfaces, sideshift

L

Brush onto all sliding surfaces with the sideshift to the limit in each direction

3

Cylinders, sideshift

L

2

4

Cylinders, length adjustment

L

4

5

Locking cylinders

L

4

6

Lifting pin twist connection

L

4

7

Twist-lock

L

8

Contact pin Axel, hook coupling

9

C

Check that the sensors are undamaged and free from grease. Check the function, see group 80.

4

Disassemble and check the twist-locks every 5000 h. See group 80. Same procedure should be used at suspected damage to the twist-locks.

L

4

Check that the sensors are undamaged and free from grease. Check the function, see group 80.

L

2

Disassemble and check the hooks every 5000 h. See group 80. Same procedure should be used at suspected damage to the hooks.

L = Lubricate C = Check

Periodic supervision Lubrication, C-hook Side-lift


TDCE01 04GB P. 8

Group 90

1 3

2

4 9

1 4

9



5

8



7

C arri ag e with hydraulic levelling

8



Carriage without hydraulic levelling

6

DCE80-100E Technical Handbook Pos nr

Periodic supervision Lubrication, C-hook Side-lift

Benämning

Intervall 500

1

Cylinders, side locking plates

1000

Antal smörjpkt

L

4

Group 90

TDCE01 04GB P. 9

Anm

Check that the sensors are free from grease and that the sensor faces are undamaged Check the function, see group 80

2

Cylinder, sideshift

L

2

3

Cylinders, length adjustment

L

4

4

Hooks

L

2

Disassemble and check the hooks every 5000 h. See Technical Handbook group 80. Same procedure should be used at suspected damage.

5

Spring loaded contact pin, alignment against upper container

C

2

Check that the sensors are free from grease and that the sensor faces are undamaged Check the function, see group 80

6

Spring loaded contact pin, alignment against lower container

C

7

Cylinders, levelling

L

8

Support wheels

L

9

Sliding surfaces, length adjustment

L

Check that the sensors are free from grease and that the sensor faces are undamaged Check the function, see group 80 4 K

4

Brush onto all sliding surfaces with the sidelift in the fully extended position

L=Lubricate C=check


Periodic supervision Daily

DAILY SUPERVISION

Or when refuelling

Check

Group 90

TDCE01 04GB P. 10

Refill as required

Brakes

Operation

Steering

Operation

All instruments: Direction indicators, horn, brake lights, headlights

Operation

Lift mast: Lifting chains Links, suspension

Damage?

All hydraulic functions, e.g.: Lift, tilt, sideshift, length adjustment

Operation Run every function to its end position in order to lubricate the cylinders and prevent corrosion

Engine, gearbox, drive axle, hydraulic hoses

Noises? Oil leakage?

Fuel

Amount • The gauge reading should never drop to Drain condensate from the fuel prefilter (if applicable)

Engine oil

Level

•

Air cleaner

•

Indicator

Coolant

•

Level

•

Hydraulic oil

•

Level

•

Gearbox oil

•

Level

Windscreen washer

•

Fluid level

Wheels

•

Tyre pressure

Sidelift attachment

•

Check that all sensors are undamaged and free from grease.

•

Check the function, see group 80.

DCE80-100E


Technical Handbook

Group 90

TDCE01 04GB P. 11

Every 500 hours Item

Unit

Action

Remarks

1

Truck

Wash

Note! Do not use high-pressure on bearings or bearing housings

2

Radiator

Clean the fins of the radiator with water and detergent

Note! Do not use high-pressure.

3

Engine

Check the oil and coolant connections for leakage

4

Air cleaner

Change the filter element if the indicator shows red.

5

Battery cables, terminals and fuses

Clean the terminals and apply petroleum jelly. If necessary, replace cables and terminals.

6

Turbo charger

Check for leakage.

7

Exhaust system

Check for leakage.

8

V-belts

Check the belt tension

See Group 30

9

Brakes

Check for oil leakage. Test brake performance. Functional test WDB incl parking brake.

See Group 70

10

Steering axle

Check for play and damage

11

Steered and driven wheels

Check the wheel alingment. Check for damage to rims and tyres. Tighten the wheel nuts

See Group 40 resp 60 Specifications

12

Drive axle and propeller shaft

Check oil level Tighten bolt joints Check for leakage

See Group 40 Specifications

13

Transmission

Check for oil leakage.

14

Mast and carriage

Check for hose damage. Check hose stretching Check sliding plates and support wheels. Check tilt cylinders for cracks Check bolted joints

See Group 80

15

Chains

Wash, check and adjust length.

See group 80

See Group 30

See Group 30

Lubricate 16

Sidelift

Check that all sensors are undamaged and free from grease. Check for damage. Check function, see group 80

17

(Air conditioner)

Check the performance

18

Lubrication points, oil and filter changes in accordance with the Lubrication chart.

19

Measures according to Daily supervision

See Group 10


Periodic supervision Group 90

TDCE01 04GB P. 12

IMPORTANT! A lways attend to any damag e, wear or faults that are im portant to the perfor mance of the truck and its s ervic e life or the s afety of the pers onnel.

DCE80-100E


Technical Handbook

Group 90

TDCE01 04GB P. 13

Every 1000 hours Item

Unit

Action

Remarks

1

Cabin filter element

Change filter element

See Group 10

2

Engine

Check valve clearances, cooling system, starter motor, alternator and fuses

See engine maufacurer’s Workshop Manual and Group 30

3

Fuel tank

Drain

4

Fuel filter

Change the filter. Bleed the fuel system.

5

Injectors

Check

6

V-belts

Check and change as necessary.

7

Batteries

Check

8

Wheels

Check for damage

9

Propeller shaft

Check the bolted joints and check the universal joints for play

10

Transmission and drive axle

Clean the breather filter

11

Lifting chains

Check

12

Painting and safety marking

Touch up

13

All functions

Test-drive and check

14

(Air conditioner)

Check the refrigerant level

15

Check accumulator pre-charging pressure

16

Lubrication points, oil and filter changes in accordance with the Lubrication chart.

17

500 hours service

See engine maufacurer’s Workshop Manual

See Group 40

See Group 80

See Group 70

IMPORTANT! A lways attend to any damag e, wear or faults that are im portant to the perfor mance of the truck and its s ervic e life or the s afety of the pers onnel.

Oil and lubricant recommendations


Group 90

 

     



 



         



 

 

 

 

    

  

TDCE01 04GB P. 14

 

         

      

Grease Use EP universal grease to NLGI Grade 2 with 3–5% molybdenum disulphide additive for all lubrication points, including wheel bearings.

Grease for Plastic plates Use grease recommended by Kalmar. Ordered from Kalmar’s Spares department. 0,65 kg cartridge for grease gun Art. no 923110.0360 5 kg can Art. no 923595.0003

IMPORTANT! A ny devi ations from the above table mus t be supported by wri tten approval from K almar.

Coolant for air conditioning unit ZXL100 Seltec PAG oil

Tdce01_04gb Manual Dce 80-100e

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