DOWNLOAD PDF Kalmar LMV Reach Stacker DC 2,5-8 Technical Handbook Manual EN

Technical Handbook

00

General

10

Chassie and cab

20

Electrical system

30

Engine

DC 2,5 - 8 40

Transmission, drive axle and brakes

This manual deals with the design and maintenance of Kalmar LMV fork lift trucks in the serie DC 2,5 - 8 tonnes The manual also gives you basic knowledge of troubleshooting and repair work.

Operation and other matters mainly of interest to operators are dealt with in the Instruction Manual Kalmar LMV

We reserve the right to alter design and material specification without notice

Publ. No. 920 937-9083 95-12 TEKNIFO, Växjö 1995

50

60

Steering axle

70

Hydraulic system

80

Lifting mast and fork carriage

90

Periodic supervision

DC 2,5 - 8

Contents

Technical Handbook

9083 95-12 00 1 Gr. P Publ.

Group 00

General Safety rules __________________________________________________ 3 Applications __________________________________________________ 4 Design – General survey ________________________________________5 Component units ______________________________________________6 Supplementary books __________________________________________8 Replacement system – Spare parts _______________________________ 8 Tools _______________________________________________________8 Main components _____________________________________________8 Tightening torques ____________________________________________ 9 System of units ______________________________________________ 11

DC 2,5 - 8

General

Technical Handbook

9083 95-12 00 3 Gr. P Publ.

Safety rules General •

Follow the local safety regulations.

•

Before starting, check that nobody is in the way of the truck and its accessories.

•

The truck should only be driven by specially trained operators who are authorised to do so by the work supervisor.

•

The truck must not be used if its brakes, steering or lifting equipment is faulty. Neither must it be used if it has been repaired, modified or adjusted without the approval of the work supervisor.

•

It is not permissible to carry passengers on the truck.

•

Do not exceed the lifting capacity of the truck (See the Load diagram in the cab).

•

It is not permissible to use the truck for lifting personnel, unless the truck is equipped with an approved personnel cage.

•

Do not drive the truck with a heavy load raised high above the ground level, since the truck may overturn.

•

Always apply the parking brake before leaving the cab.

•

To prevent accidents when work is being carried out on the brake system, never disconnect any component without previously depressurising the accumulator, e.g. by applying the brakes repeatedly until they are no longer operative.

•

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.

•

The hydraulic pressure regulating valve for the hoisting function is scaled and for reasons of safety the pressure setting must not be altered. The guarantee is void if the seal is broken.

Toxic fumes are emitted when welding painted items. Therefore, remove the paint surface thoroughly before starting to weld, and also ensure that ventilation is adequate or wear a face mask with a filter for protection against chlorine.

•

Safety rules for trucks with LPG engines •

Filling of the LPG tanks should only be carried out by specially trained personnel who have been assigned to this task.

•

Personnel engaged on filling the LPG tanks shall wear protective clothing.

•

Changing of the LPG tanks should be carried out only at places allocated for this purpose.

•

The engine must be stopped, the parking brake must be applied and the operator must have climbed out of the truck before the work of changing of the tanks is started.

•

Never change LPG tanks or park an LPG-driven truck in areas where there is intense heat, naked flames or similar potential fire hazards. Neither should this be done in the vicinity of pits, stairways and similar areas.

•

Before use, inspect all LPG tanksfor: -

Dents, scratchers or other damage to the tank.

-

Damage to or dirt in valves and liquid level gauges.

-

Signs of leakage at valves or threaded connections.

If defects or damage is detected, don’t use the LPG tank before the necessary repairs have been carried out.

•

After having parked an LPG-driven truck indoors overnight or for a longer period of time with the LPG tank fitted, always close the shut-off valve of the tank.

DC 2,5 - 8 Technical Handbook

9083 95-12 00 4 Gr. P Publ.

General

Applications 2,5 – 8 t with diesel or LPG engine •

Engineering industry, iron foundries and steelworks – where the trucks maintain the flow of materials in production, stores and warehouses.

•

Harbours and terminals – handling of piece goods.

•

Sawmills and factories for making houses – handling of timber.

•

Ro/Ro vessels – trucks of Ro/Ro design are used as service trucks for handling piece goods, slings, mooring lines, decks and forks for larger trucks.

DC 2,5 - 3,5

DC 5 - 5,5

DC 6 - 8

K346

Models

DC 2,5 - 8 Technical Handbook

General

9083 95-12 00 5 Gr. P Publ.

Design – General survey The various trucks in the Kalmar LMV 2.5, 3, 4, 4,5 5, 5.5, 6, 7, 7.5 and 8 tonnes range differ principally in their wheelbases, wheel sizes, engines and masts, i.e. that which is dependent on the lifting capacity for which the truck has been designed.

The truck is built up around an all-welded, unit construction chassis of high strength and torsional stiffness.

The operator's cab is provided with vibration isolation and sound insulation and satisfies with a comfortable margin the demands made on a safety cab in various standards and regulations.

The operator is provided with many facilities for adjusting his driving positions. The operator's seat has progressive springing and hydraulic shock absorbers, and its seat, backrest and springing can be adjusted in many different ways.

The engine powering the 2,5–7 tonnes truck is a four-cylinder Perkins diesel or LPG engine, whereas the 7.5-8 tonnes truck is powered by a Perkins six-cylinder diesel or LPG engine. The torque converter and the power-shift gearbox ensure smooth power transmission.

The hydraulic system serves the steering, braking, lifting and other control systems. The hydraulic system comprises of two hydraulic pumps.

The drive axle with hub reductions and the Kalmar LMV steering axle with pivot suspension satisfy strict demands on strength and mobility when the truck is used on an uneven surface.

The tilting cab design facilitates excellent access to vital components for servicing.

The entire drive system, including engine, torque converter, gearbox and propeller shaft are thus easily accessible from above.

DC 2,5 - 8 Technical Handbook

9083 95-12 00 6 Gr. P Publ.

General

Operator’s Cab Rubber suspended safety cab

Mast Clear-view mast with or without free lift

Engine 4- or 6 cylinder diesel or LPG engine

Accumulators Data Plate

For brakes and steering

Steering axle

Fork Carriage

With pivot suspension and double-acting steering cylinder

With manually operated sliding forks or hydraulic fork-spreading and side shift

Gearbox Drive Axle With hub gearing and hydraulic wetdisc brakes K326

Component units •

Operator's cab – safety cab with sound insulation.

•

Engine – four- or six-cylinder diesel or LPG engine.

– Exhaust gas emission control system for effective cleaning of the exhaust gases without loss of power.

•

Gearbox with torque converter.

– Gearbox – hydraulically actuated gear-changing with constant-mesh gears.

– Torque converter – increases the output torque as the speed of the truck decreases. The reduction ratio is adjusted smoothly and steplessly within the speed range of the torque converter.

– Gearbox valve, electrically operated by means of the lever in the cab.

'

– Adjustable inching.

Combined with torque converter. Two speeds in each direction.

DC 2,5 - 8

General

Technical Handbook

9083 95-12 00 7 Gr. P Publ.

– Oil cooler – for cooling the torque converter oil.

– Oil pump – integrated into the gearbox for supplying oil under pressure to various points in the gearbox.

– Full-flow oil filter – for effective cleaning of the gearbox oil.

•

Drive axle – with hub reductions and brake system.

– Oil-cooled disc brakes in each hub.

•

Parking brake – On older models the parking brake consists of a disc brake on the ingoing shaft of the drive axle. Later models however are equipped with a small wet-disc brake integrated with the drive axle.

•

Steering – Orbitrol valve – flow-control valve for metering the hydraulic oil flow to the steering cylinder. With overflow valve – for adjusting the hydraulic oil pressure to suit the steering system.

– Steering cylinder – double-acting, for distinct transmission of the steering wheel travel.

– Steering axle with pivot suspension.

•

Mast of clear-vision type as standard – telescopic mast consisting of: – Outer mast – with hydraulically controlled 5° forward and 10° backward tilting. For heights of lift greater than 5 m, the angle of tilt is restricted to 3° and 5° respectively.

– Tilting cylinders – with back-pressure valves, to prevent the load from tilting the mast forward.

– Inner mast – of frame construction with rollers designed to take up the lateral forces. Yoke with guide sprockets for the lifting chains and hydraulic hoses.

The locations of the guide sprockets and rollers provide the best possible visibility for the operator.

– Lifting cylinders – two cylinders mounted on the reverse side of the outer mast. This arrangement assures the operator of good forward visibility through the mast.

– FLEYER type lifting chains.

•

Fork carriage – clear-vision model with hydraulic sideshift and fork positioning.

Fork levelling is available to special order.

•

Hydraulic pumps (dual pump) – one gear pump for supplying the steering system, the brake system and the accumulator and a second for supplying the working hydraulics.

•

Main valve – with four sections for hydraulic control of lifting, tilting, sideshifting and fork positioning. The main valve is actuated through a hydraulic servo system.

•

Hydraulic accumulator – of diaphragm type, charged from one part of the dual pump and supplying the brake system and the steering system.

DC 2,5 - 8

9083 95-12 00 8 Gr. P Publ.

General

Technical Handbook

Main components 2,5 – 3,5 Engine Perkins 1004-4 Perkins 1004-4THR Perkins 1006-6 Deutz BF4M Deutz BF6M Perkins 4.236, LPG Perkins 6.3544, LPG Perkins 1006-6, LPG Gearbox Graziano Voith PST1 Voith C 845 Borg Warner PR2 Clark 12.6 HR-18213-1 Drive axle Kalmar LMV BL 55 Kalmar LMV BL 75 Kalmar LMV BL 40 Kalmar LMV BL 80 Kalmar LMV BL 100

■

2,5 – 8 4 – 5,5 6–7 ■

7,5 – 8

■ ■ ❒

❒

❒

❒

❒

❒

❒

❒ ❒ ❒

■ ■ ■

■

■

■

■ ❒

■

■

■ ■

■ ■

■ ■

■

❒ = Alternativ

Supplementary books In addition to the Instruction Manual for the DC 2.5–8 and the Technical Handbook for the DC 2.5–8, the following books are delivered with every truck: •

Spare parts catalogue for the DC 2.5–8

•

PERKINS Handbook for the 1004-4 or 1006-6 engine or the PERKINS Handbook for the G.4.236 or G.6.3544 LPG engine.

•

PERKINS Workshop manual for diesel (LPG) engines

•

Borg Warner PR2 Industrial Transmission Service Manual

•

Clark Transmission HR 18 000

Replacement system – Spare parts Kalmar LMV operates a system of replacement parts, repair kits end seal kits which covers most of the vital components of the truck.

The scopes of these kits are described in the Accessory catalogue (920936.2013).

Tools Kalmar LMV offers a broad range of tools for maintenance work on forklift trucks.

For further information, please get in touch with the Service Department of Kalmar LMV.

DC 2,5 - 8

9083 95-12 00 9 Gr. P Publ.

General

Technical Handbook

Tightening torques (According to Kalmar LMV K Standard 20060.0001) The tightening torques are applicable to steel bolts and nuts tightened with a torque wrench under the following conditions: 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.

Surface treatment Condition

Lubrication Bolt

Nut

1

Untreated

Untreated

Oiled

2

Bright galvanised Bright galvanised Bright galvanised

Untreated Bright galvanised Hot-dip galvanised

Dry or oiled

3

Hot-dip galvanised Untreated

Dry or oiled

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 and the bolt head and nut. This is not applicable if flanged bolts or flanged nuts are used.

When tightening is carried out, the specified torque should be applied without pause, to ensure that the torque wrench will not be tripped by the static friction before the joint has been tightened to the specified torque.

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

Bolt strength grade

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

103 250 490 848 1672

128 313 610 1050 2080

154 375 732 1270 2500

36

2570

2288

2904

3620

4340

DC 2,5 - 8

General

Technical Handbook Bolt strength grade

8.8

10.9

12.9

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

153 210 370 594 889 1260 1760 2320 3060

136 187 390 528 791 1120 1565 2065 2720

173 237 418 671 1005 1424 1990 2620 3455

216 298 524 839 1260 1780 2490 3280 4320

255 353 619 990 1480 2100 2940 3870 5100

10.9

12.9

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

Bolt strength grade

8.8

Tightening torque, Nm Condition Thread M fine

1

2

3

1

1

M 8x1 M10x1.25 M12x1.25 M16x1.5 M18x1.5

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

M20x1.5 M24x2 M30x2 M36x3

460 786 1560 2660

409 700 1388 2367

520 888 1763 3005

647 1100 2200 3730

777 1330 2640 4480

9083 95-12 00 10 Gr. P Publ.

DC 2,5 - 8

9083 95-12 00 11 Gr. P Publ.

General

Technical Handbook Bolt strength grade

8.8

10.9

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

164 227 396 629 937 1350 1860 2500 3260

145 202 352 560 834 1200 1655 2225 2900

185 256 447 710 1058 1525 2100 2825 3680

231 321 559 889 1320 1900 2630 3530 4610

273 379 661 1050 1560 2250 3110 4170 5450

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

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

Pressure Megapascal MPa

Bar

Kilogram-force per square centimetre, kgf/cm2

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 Newton-metre 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

DC 2,5 - 8

Contents

Technical Handbook

9083 97-03 10 1 Gr. P Publ.

Group 10

Chassis and cab Technical specifications _________________________________________ 3 Air conditioner _____________________________________________3 Description __________________________________________________ 4 Chassis __________________________________________________ 4 Operator’s cab _____________________________________________5 Instruments and Controls _____________________________________ 6 Instruments and Controls (optional) _____________________________ 8 Operator’s seat ____________________________________________ 10 Air conditioning unit ________________________________________ 11 Compressor ___________________________________________ 12 Condenser ____________________________________________ 12 Liquid reservoir and filter dryer _____________________________ 12 Expansion valve ________________________________________ 12 Evaporator ____________________________________________ 12 Tilting the cab _____________________________________________13 Hand operated pump ____________________________________ 13 Electrically operated pump (option) _________________________ 13 Pump and cylinder for hoisting the cab (option) ___________________ 14 Service instructions ___________________________________________ 15 Changing the fresh air filter __________________________________ 15 Checking the air conditioning unit _____________________________ 15 General instructions for work on the air conditioning system. ________ 16 Leakage in the system ______________________________________ 16 Compressor oil ____________________________________________ 17

DC 2,5 - 8

Technical specifications

Technical Handbook

Technical specifications Air conditioner •

Cab unit – heat output – cooling output – circulated air flow – electric power consumption (fan)

•

Compressor – speed – refrigerant – electric power consumption (clutch) – oil (Suniso 5GS)

•

8100 W (7000 kcal/h) 4060 W (3500 kcal/h) 6 m3/h 150 W (12.5 A at 12 V)

9000 rpm max.

R-134A 48 W (4 A –12 V) 1.3 dl

Condenser – electric power consumption (fan)

160 W (13.4 A at 12 V)

9083 97-03 10 3 Gr. P Publ.

DC 2,5 - 8 Technical Handbook

Description

Description Chassis The chassis consists of an all-welded frame, with mudguards, tanks and counter weights bolted to the frame.

The hydraulic oil tank is located on the right-hand side of the chassis. The fuel tank and the starting battery are located on the left-hand side.

The power unit, i.e. the engine and transmission, is supported by sturdy rubber anti-vibration mountings. These contribute to smooth, silent and vibration-free operation.

The space below the operator’s cab, offers excellent accessibility for service work when the cab is raised.

The counterweights fitted to the truck are designed to conform to the safety regulations applicable on various markets or as specified in the order.

K347

9083 97-03 10 4 Gr. P Publ.

DC 2,5 - 8 Technical Handbook

Description

9083 97-03 10 5 Gr. P Publ.

Operator’s cab

K348

2 - 3,5 The operator’s cab is a separate structure and rests on the chassis on rubber dampers. The cab is of safety design, and great consideration has been given to ergonomic factors, such as correct seat position, convenient locations of controls, and the effectiveness and sound level of the heating and ventilation system.

The cab is equipped as standard with a hydraulic tilting cylinder. In this case the cab is tilted manually with the aid of a hand operated pump. The truck can be supplied as an option with electrically initiated tilting of the cab, whereby the tilting cylinder is supplied by the hydraulic system of the truck and is operated by the two buttons located on the left side of the truck.

Another option is to fit the truck with a hoisting cab which is powered by a hydraulic lifting cylinder and appertaining pump. The lifting cylinder is supplied by the hydraulic system of the truck and is operated by controls located by the right-hand steps. The cylinder can be operated manually by a pump if the hydraulic system is out of action. The engine, power transmission and the hydraulic system are easily accessible when the cab is hoisted.

The height and slope of the steering wheel can be adjusted by means of adjusting levers on the steering column.

The control levers are located by the seat and can adjusted to a comfortable working position with a locking lever.

Movement of the control levers is transmitted via hydraulic servo to the main valve.

DC 2,5 - 8

9083 97-03 10 6 Gr. P Publ.

Description

Technical Handbook

Instruments and Controls

3

2

4

5

1

13

12

11

6 10

7

8

9 K523

1.

2.

3.

4.

5.

6.

Direction- and gear selector, FORWARD/ NEUTRAL/REVERSE Control lever DIRECTION INDICATOR, HORN, WINDSCREEN WIPERS, WINDSCREEN WASHER and DIP SWITCH Indicating lamps Emergency shutdown Instrument panel Control levers, hydraulic system a. Lift/Lower b. Tilt c. Side shift d. Fork positioning e. Fork levelling*)

7.

8.

9.

10.

11.

12.

13.

Fuses Parking brake Operator’s seat Accelerator Brake pedal Steering wheel adjustment Heater (Air conditioning)*)

*) Optional equipment **) Not used on diesel- and LPG trucks

DC 2,5 - 8

9083 97-03 10 7 Gr. P Publ.

Description

Technical Handbook

14 15 16 17 18

19 20 21 22 23

24 25 26 27 28

40

41

42

29 30 31 32 33 34

43

35 36 37 38 39

K343

44 14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

Charging –**) Direction indicators Parking brake Low engine oil pressure High engine coolant temperature Low gearbox oil pressure High gearbox oil temperature Head lamps Dipped lamps Low brake pressure Preheating Low engine coolant level -**) –**) Switch, driving lights and instrument illumination *) Switch, Working light Switch, Working light *) Switch, Flashing beacon *)

33.

Switch, rear wiper - Off - Intermittent wiping (10 seconds)*) - Continuous wiping

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

Switch, roof wiper *) Switch, fan speed I and II –**) Switch, air condition *) Switch, hazard flashers Main key-switch Vacant Hour-meter Fuel gauge (not on LPG-trucks) Temperature gauge Interior lighting

*) Optional equipment **) Not used on diesel- and LPG trucks

DC 2,5 - 8

9083 97-03 10 8 Gr. P Publ.

Description

Technical Handbook

Instruments and Controls (optional) 3

2

4

5

1

13

11

10

6

12

7

8

K300

1.

2.

3.

4.

5.

6.

9

Direction- and gear selector, FORWARD/ NEUTRAL/REVERSE Control lever DIRECTION INDICATOR, HORN, WINDSCREEN WIPERS, WINDSCREEN WASHER and DIP SWITCH Indicating lamps Emergency shutdown Instrument panel Control levers, hydraulic system a. Lift/Lower b. Tilt c. Side shift d. Fork positioning e. Fork levelling*)

7.

8.

9.

10.

11.

12.

13.

Fuses Parking brake Operator’s seat Accelerator Brake pedal Steering wheel adjustment Heater (Air conditioning)*)

*) Optional equipment **) Not used on diesel- and LPG trucks

DC 2,5 - 8

9083 97-03 10 9 Gr. P Publ.

Description

Technical Handbook

14 15 16 17 18

19 20 21 22 23

29 30 31 32 33 34

24 25 26 27 28

40

41

42

43 35 36 37 38 39

44 K301

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

Charging –**) Direction indicators Parking brake Low engine oil pressure High engine coolant temperature Low gearbox oil pressure High gearbox oil temperature Head lamps Dipped lamps Low brake pressure Preheating Low engine coolant level -**) –**) Switch, driving lights and instrument illumination *) Switch, Working light Switch, Working light *)

32.

33.

Switch, Flashing beacon *) Switch, rear wiper - Off - Intermittent wiping (10 seconds)*) - Continuous wiping

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

Switch, roof wiper *) Switch, fan speed I and II –**) Switch, air condition *) Switch, hazard flashers Main key-switch Vacant Hour-meter Fuel gauge (not on LPG-trucks) Temperature gauge Interior lighting

*) Optional equipment **) Not used on diesel- and LPG trucks

DC 2,5 - 8

Description

Technical Handbook

Operator’s seat All the trucks can be obtained fitted with a reversible or rotating operator’s seat. In such versions, the seat is integrated with the steering column on a console together with the foot pedals so that the driving controls form a single unit.

The reversible seat is hydraulically powered and is operated via an extra control lever. The rotating seat is locked in position with an hydraulically actuated plunger in the base plate. To turn the seat, the operator must first build up sufficient hydraulic pressure by pressing the brake pedal, release the locking plunger by pressing a catch pedal with the other foot, and finally turn the operator console with the control lever (the catch pedal should be pressed down throughout the whole procedure).

!

CAUTION Never adjust a reversible seat while the machine is in motion

Control lever for reversible operator’s seat.

Hydraulic catch for the operator’s seat

K349

9083 97-03 10 10 Gr. P Publ.

DC 2,5 - 8

9083 97-03 10 11 Gr. P Publ.

Description

Technical Handbook

Air conditioning unit Trucks are equipped as standard only with a heater and fan. An air conditioner is available as an optional equipment.

The air conditioning system, comprising the components illustrated below, serves to maintain the climate in the operator’s cab as comfortable as possible.

The air conditioning system •

heats the air when it is cold

•

dehumidifies the air when it is damp

•

removes impurities from the air

•

cools the air when it is hot.

The air conditioner is controlled by means of switches on the instrument panel and controls on the fan casing below the instrument panel.

Refrigerant phases High-pressure, gaseous High-pressure, liquid Low-pressure, liquid (from expansion valve to operator coil) ○ ○ ○ ○ ○ ○ ○ ○ ○

K350

Low pressure, gaseous

DC 2,5 - 8 Technical Handbook

Description

Compressor The system is powered by the compressor which functions as a pump, drawing in cold low-pressure gas from the evaporator, compressing and heating it, and discharging it as high-pressure gas to the condenser.

The compressor is directly driven by the engine through V-belts. The operating and idling functions are controlled by an electro-magnetic clutch which, in turn, is thermostatically operated by a sensor 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 the hot high-pressure gas from the compressor into liquid form. The tubes and fins of the condenser coil absorb the heat which is then dissipated by the fan.

Liquid reservoir and filter dryer The function of the liquid reservoir and integral filter dryer is to collect the liqiud refrigerant and to bind any humidity present. The reservoir, which is located in the condenser housing, also serves as an expansion vessel in the cooling circuit.

Having flowed through the dryer in the bottom of the liquid reservoir, the refrigerant passes through a riser tube which is fitted with a sight glass to enable the liquid to be inspected for bubbles.

Expansion valve The expansion valve throttles the flow, allowing an optimized quantity of refrigerant to flow to the evaporator.

Evaporator The heat required for evaporation is obtained from the cab air which is conveyed through the evaporator coil by means of a fan. Thus, the cab air is cooled, distributed and returned to the interior.

The refrigerant now reverts to its gaseous state and returns from the evaporator to the compressor suction, thereby completing the cycle.

9083 97-03 10 12 Gr. P Publ.

DC 2,5 - 8

Description

Technical Handbook

9083 97-03 10 13 Gr. P Publ.

Tilting the cab Hand operated pump The truck is equipped as standard with manual tilting of the cab which is operated by a hydraulic cylinder with the aid of a hand operated pump that is located by the steps on the left side of the truck.

The engine compartment is easily accessible for servicing when the cab is tilted.

NOTE. Ensure for the sake of safety that the cab is tilted to its full extent, ie, past its point of balance. The cab will move by its own weight for the last part of its travel.

A

B

K521

Electrically operated pump (option) The truck can be equipped as an optional feature with an electrically operated pump to tilt the cab. Electric tilting of the cab is controlled by two push buttons located by the steps on the lefthand side of the truck.

The engine compartment is easily accessible for servicing when the cab is tilted.

NOTE. Ensure for the sake of safety that the cab is tilted to its full extent, ie, past its point of balance. The cab will move by its own weight for the last part of its travel.

K522

DC 2,5 - 8 Technical Handbook

Description

Pump and cylinder for hoisting the cab (option)

Safety pin

Lifting control lever

Safety pin

K327

The cab can be hoisted with the aid of a hydraulic cylinder, operated via a control valve located underneath the steps on the right side. The cylinder can also be pumped by hand if the hydraulic system is not in action (see further in the Instruction Manual).

All essential components are accessible for service when the cab is hoisted, eg, engine, gearbox, pumps, hydraulic filter, parking brake, main valve, steering valve.

The cab can also be slewed outwards to facilitate replacement of the engine if required.

!

Warning!

• Never go under the cab unless it is secured by the safety pins.

There is a serious danger of injury if the cab is not secured.

•

It is absolutely forbidden to drive the truck with the cab in the hoisted mode. The truck can tip over.

•

The weight of the cab must be supported if the cylinder should become loose from the cab. The cab must not be allowed to be held only by the safety stay.

9083 97-03 10 14 Gr. P Publ.

DC 2,5 - 8 Technical Handbook

Service instructions

9083 97-03 10 15 Gr. P Publ.

Service instructions Changing the fresh air filter (every 500 hours or as required) 1.

Remove the filter casing retaining bolts and remove the filter element.

2.

Fit a new filter element.

Checking the air conditioning unit It 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.

K352

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.

Start the engine and start the air conditioner.

2.

After 10 minutes of operation, check that no air bubbles are visible in the sight glass of the filter dryer. (Air bubbles should occur only when the compressor is started and stopped.)

If air bubbles are visible, the system, should be topped up by a service man.

3.

Check that the condenser is not clogged. If necessary, clean the condenser fins with compressed air.

4.

Change the filter dryer if flakes of rust are visible in the sight glass.

5.

Change the fresh air filter whenever necessary.

6.

Check the V-belt tension and the compressor mounting.

7.

Check that the magnetic coupling engages and disengages satisfactorily.

8.

Check that the condensate drain from the cooling element is not clogged.

9.

Check that there is no leakage.

!

CAUTION • 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.

•

Never carry out welding on a charged refrigeration system or in its vicinity.

•

Always discharge the refrigerant whenever repair work is to be carried out on the air conditioner.

Refilling of the system with type R-134A should be carried out by a service man.

DC 2,5 - 8 Technical Handbook

Service instructions

General instructions for work on the air conditioning system.

1.

Special equipment is necessary for carrying out service work on the air conditioning system.

2.

Great care and extreme cleanliness must be observed whenever work is carried out on the air conditioning system.

3.

The refrigerant must be emptied whenever any repair work is started on the air conditioning system. Observe scrupulously the safety instructions. Use the filling equipment for emptying the system and follow the special instructions for this purpose (see the section entitled Leakage in the system).

4.

After discharging the refrigerant from the system, care must be taken when breaking the joints, since some parts of the system may still be pressurised.

5.

After connections have been broken, the openings must immediately be blanked off with sealing plugs, to prevent the ingress of dirt and moisture into the system. The dryer will be saturated after 30 minutes if the connections are left open.

Always take all precautions necessary to prevent moisture from entering into the system. Moisture may cause frosting and acidification of the refrigerant, thus giving rise to corrosion.

6.

Whenever work is carried out on the system, the filter dryer must always be changed.

Leakage in the system 1.

Switch off the system.

2.

Examine the system and locate the leakage. Special leakage testing equipment can be used for this purpose.

3.

Attend to any fault and seal off the leaks by replacing defective gaskets, hoses, etc.

4.

After all faults have been corrected, fill the system with R-134A refrigerant up to the correct level in the refrigerant receiver, as described below.

5.

The work described below presupposes that special filling equipment is available.

6.

Connect the blue hose of the suction pressure gauge to the service valve on the suction side of the compressor (marked S, SUC or SUCTION).

7.

Connect the red hose of the discharge pressure gauge to the service valve on the discharge side of the compressor (marked D, DIS or DISCHARGE).

8.

Connect the yellow filling and vacuum hose to the refrigerant cylinder that contains R-134A.

9.

Start the engine of the vehicle and adjust its speed to at least 1000 rpm, but preferably higher. Switch on the air conditioner for cooling, and set the cooling thermostat and fan to MAX.

10.

Open the valve on the suction side of the compressor, which will then draw refrigerant from the cylinder.

11.

Check the sight glass on the refrigerant receiver. The liquid will initially contain a large number of bubbles. The longer the compressor is left running, the smaller the number of bubbles and the clearer will be the liquid.

If the bubbles should suddenly disappear, this probably indicates that the cooling thermostat has tripped. If so, by-pass the thermostat by connecting a cable directly from the battery, or wait until the thermostat has closed again.

When all bubbles have disappeared, check the pressure on the pressure gauge and raise the pressure by a further 0.1 MPa, so that the system will contain a reserve of refrigerant.

9083 97-03 10 16 Gr. P Publ.

DC 2,5 - 8

Service instructions

Technical Handbook

9083 97-03 10 17 Gr. P Publ.

12.

The system is now filled with the refrigerant. Shut off the valve on the suction side and then shut off the valve on the cylinder. Disconnect the service hoses and fit the protective caps.

13.

If the system is overfilled, the pressure and temperature will slowly increase until the thermostat opens the circuit to the compressor solenoid. This is due to the fact that the refrigerant is circulated in the system without being evaporated or condensed in the condenser. No cooling will therefore take place in the cooling element and a large amount of heat will be generated in the condenser. In addition, numerous bubbles will be visible in the sight glass. Correct this by releasing some of the refrigerant until the cooling elements start cooling again and bubbles are no longer visible in the sight glass.

14.

If the system contains insufficient refrigerant, bubbles will be visible in the sight glass. Top up with the refrigerant as described in 10 and 11 above.

Compressor oil 1.

The compressor is filled with oil at the factory. Under normal conditions, the oil need neither be changed nor topped up.

2.

In the event of loss of refrigerant, some oil loss may also occur, since about 25% of the oil volume circulates with the refrigerant.

The following grades of oil may be used: Sunrico No. 5G Texaco Capella E

DC 2,5 - 8

Contents

Technical Handbook

9083 95-12 20 1 Gr. P Publ.

Group 20

Electrical system Technical specifications _________________________________________ 3 Description __________________________________________________ 4 Service instructions ____________________________________________ 5 Electrical system ___________________________________________ 5 Checking the electrolyte level of the battery ______________________ 5 Starting from an auxiliary battery _______________________________ 5 Fuses ____________________________________________________ 6 Relays ___________________________________________________6 Connectors ________________________________________________6 Light Bulbs ________________________________________________8 Earthing terminals on chassis _________________________________8 Sensors and symbols in circuit diagrams _________________________ 9 Cable marking _____________________________________________9 Circuit designations _________________________________________ 9 Components ____________________________________________ 9 Connectors _____________________________________________9 Cables ________________________________________________10 Electrical circuit diagram: Warning lamps, steering panel ___________ 11 Text in diagrams ___________________________________________ 12 Catalogue of Components _______________________________ Appendix Diagrams DC 2,5-8 Standard and rotatable operator´s seat, outer circuits __________________________________ A07261.0300/03 DC 2,5-8 Standard and rotatable operator´s seat, inner circuits __________________________________ A07261.0400/03 DC 4-8 Reversible operator´s seat, outer circuits _____ A07265.0100/02 DC 4-8 Reversible operator´s seat, inner circuits ______ A07265.0200/03 DC 2,5-8 Standard and rotatable operator´s seat, outer circuits, LPG _____________________________ A07262.0300/01 DC 4-8 Reversible operator´s seat, outer circuits, LPG _ A07266.0100/01 DC 2,5-3,5 Standard, outer circuits, 12 V ____________ A10698.0100/02 DC 2,5-3,5 Standard, inner circuits, 12 V ____________ A10699.0100/02

DC 2,5 - 8 Technical Handbook

Technical specifications

9083 95-12 20 3 Gr. P Publ.

Technical specifications Alternator rating

Starting battery,

type - power

770 W (1260 W on trucks with air conditioner)

Current

55/90 A

voltage

24 V (2 x 12 V connected in series)

capacity

105 Ah

earthing

Negative

DC 2,5 - 8

9083 95-12 20 4 Gr. P Publ.

Description

Technical Handbook

Description The source of power supply consists of two 12 V batteries connected in series which are charged by an alternator across electronic rectifying and voltage stabilising circuits.

The instruments panel of the truck includes gearbox oil temperature and oil pressure warning lamps and an operating hour meter.

The arrangement of the electrical system is shown schematically on the general arrangement of the system, whereas the individual components are shown on the detailed wiring diagram.

Reversible operator´s seat

Standard and rotatable operator´s seat

2

3 4

1

3 1

5

6 7

1. Horn 2. Limit switch 3. Transmitter 4. Junction box 5. Resistor 6. Batteries 7. Main switch 8. Alternator

8 K353

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 20 5 Gr. P Publ.

Service instructions B A

Electrical system The electrical system operates at 24V. The battery is charged by an alternator. The negative pole is connected to the chassis via a main switch.

Checking the electrolyte level of the battery The battery is located on the left-hand side of the truck and is accessible after the cab has been lifted.

K336

The electrolyte level should be about 10 mm about the cells. Top up with de-ionized water as necessary.

Note.

The original batteries are of maintenance-free type. This means that the no water has been added under normal conditions during the life of the battery.

However, we recommend you to check the electrolyte level once or twice a year. Whenever necessary, top up with de-ionized water.

Starting from an auxiliary battery

!

Caution!

Batteries contain a highly explosive mixture of hydrogen and oxygen. Sparks may be caused if the jumper cables are connected incorrectly, and the battery may explode, causing injury.

Before connection, make sure that the main switch (for the battery) is in position OFF.

•

Connect the battery poles as below: 1. Positive to positive 2. Negative on the auxiliary battery to the chassis not to close to the discharged battery.

•

Set the main switch in position ON

•

Start the truck

•

Disconnect the auxiliary battery. Start with the connection to the chassis.

DC 2,5 - 8 Technical Handbook

9083 95-12 20 6 Gr. P Publ.

Service instructions

Fuses

Relay No.

Circuit

Fuses for the electrical system are located under the right-hand forward side window and are easily accessible from the right-hand door of the truck.

335-1

Gear-changing (Clark)

335-2

Gear-changing (Borg-Warner)

313 - 1

Rear lights (rear-front)

313 - 2

Braking lights (rear-front)

313 - 3

Direction indicators (right-left)

313 - 4

Direction indicators (left-right)

313 - 5

Gear-changing (front-rear)

313 - 6

Gear-changing (rear-front)

313 - 7

Reversing alarm (reverseforward)

Block No. Protected Circuit

Rating (A)

11

Ignition key, Preheating

25

(25*)

12

Buzzer (seat), Cab heater*,

10

(10*)

13

Main fuse light • Rear lights • Working lights • Roading lights

15

(25*)

14

Wiper motor, front

10

(10*)

313 - 8

Dipped beam (front-rear)

15

Wiper motor, rear

10

(10*)

313 - 9

Main beam (front-rear)*

16

Washer, horn

10

(10*)

313 - 10

Reversing lights (front-rear)

21

Radio/recorder*, Comm.radio*, Flashing beacon* 10

313 - 11

Working lights (front-rear)

(10*)

Reversing lights, Reversing alarm, Électrical gear-changing 10

(10*)

Fan heating, Wipermotor roor*, Air condition* 10

(15*)

Elect.stop, Brake lights, Instruments, Direction indicators, Indicating lamps 10

Connectors on the truck are marked from 1 upwards. The illustration shows the location of connectors in the junction box, and which connectors are used.

(10*)

Connector No. Function

25

Rear lights

10

(10*)

26

Working lights

10

(10*)

56 - 1

22 23

56 - 2 24

Connectors

* Option

Relays The illustration shows the arrangement of relays in the relays in the junction box, which is located under the front side window (below the fuse boxes). The junction box is located in the rear left corner of the cab if the truck is fitted with a reversible operator´s cab.

1.

Main beam. front

2.

Wiper motor, front

3.

24V/12V converter

4.

Option

5.

Wiper motor rear, Cab heater

6.

Frame, rear

7.

Shiftronic*

8.

Fan heating, Thermostat AC

9.

Multi-switch lever, Gear lever

10.

Indicating lamps

Relay No.

Circuit

11.

Indicating lamps, Switches

305

Reversing lights

12.

Roof connector

314

Parking brake, Release clutch

13.

Instrument panel

315

Main relay (functions after the key)

14.

Shiftronic*

316

Wiper motor front

15.

Sensors, below the cab

321-1

Intermittent wiping front*

16.

Manoeuvre panel (switches)

321-2

Intermittent wiping rear*

17.

Manoeuvre panel (switches)

323

Flasher relay

18.

Manoeuvre panel (switches)

328

Gear-changing (Borg-Warner)

19.

Motor

330

Start locking relay

20.

Gearbox

331

Electrical gear-changing (forward)

21.

Working lights

332

Electrical gear-changing (reverse)

DC 2,5 - 8 Technical Handbook

Service instructions

Standard machine

K1071

Machine with reversible operator´s seat

K1072

9083 95-12 20 7 Gr. P Publ.

DC 2,5 - 8 Technical Handbook

Service instructions

Light Bulbs Designation

Power (Watt)

Socket

Headlight

70

H3 PK22s

Reversing light

70

H3 PK22s

Direction indicators, front

21

BA15s

Direction indicators, rear

21

BA15s

Rear lights

5

BA15s

Brake lights

21

BA15s

Inner lighting

2x10

SV8.5-8

Indicating lamps 24V

1,2

W2x4,6d

Indicating lamps 12 V

1,2

W2x4,6d

Earthing terminals on chassis The table below shows where the various earthing terminals are located on the truck.

Circuit designation 37 - 1 37 - 2 37 - 3 37 - 4 37 - 5 37 - 6 37 - 7 37 - 8 37 - 9 37 - 10 37 - 12 37 - 13

Location Junction box Adjoining front wiper motor Adjoining horn underneath cab On chassis from battery negative pole Earth on engine stop-valve Earth on engine block Earth for seat buzzer Adjoining rear wiper motor Earth for options on roof Earth , adjoining switch 251 (reversible operator’s seat Earthing of cab on junction box

9083 95-12 20 8 Gr. P Publ.

DC 2,5 - 8 Technical Handbook P=Pressure T=Temperature η=Coolant level b=Fuel level

Service instructions

9083 95-12 20 9 Gr. P Publ.

Sensors and symbols in circuit diagrams The figure shows the significance of the various sensor symbols used in circuit diagrams concerning the truck.

Cable marking Each cable on the truck is marked with a consecutive number (does not apply to coloured cable). Each cable number is unique, ie, it is not used on any other cable.

V=OFF/ON G=Variable sensor K354

Circuit designations The following rules apply for designations used in the electrical circuit diagram of the truck:

Components •

All components have a number, together with any text.

•

A particular components always has the same number, regardless of the circuit or truck model/variant.

Example:

•

100 308 403

Switch, lights Relay, brake lights Bulb, load lamp

In some cases the same component is used in different places on the truck, eg, relay for the intermitted wiper (321) front and rear. In such cases the component number has a suffix -1, -2, -3, etc.

See further under the heading Component designations.

Connectors Connectors are each marked with a separate consecutive number.

DC 2,5 - 8

Service instructions

Technical Handbook Cables •

Each cable is identified at both ends. The identification consists of the cable number (does not apply to coloured cable, see below) and additional information in brackets on the circuit diagram indicating where the other end of the cable is connected.

-

If the other end is connected to a connector and pin, it is noted inside inverted commas. The number of the connector and pin are separated by a dot.

-

If the other end is connected to a component, the number of the component is noted within brackets.

K355

Example: A 454 ("32.2") Cable number 454 goes to connector 32 pin 2.

The cable is connected to the positive side of the consumer.

B 161 ("5.9")

Cable number 161 goes to connector 5 pin 9.

The cable is connected to the negative side of the consumer.

C 462 (230)

Cable 462 goes to seat switch terminal (component 230).

The cable is connected to the positive side of the consumer

NOTE. Only the cable number is marked on the cable. Information in brackets is on the electrical circuit diagram only.

•

Colour of the cable is noted in the circuit diagram with the following abbreviations.

PU GN Y W BI Gr SB BN

= = = = = = = =

Purple Green Yellow White Blue Grey Black Brown

R LBN OR VO P I LBL LGN

= = = = = = = =

Red Light brown Orange Violet Pink Grey Light blue Light green

9083 95-12 20 10 Gr. P Publ.

DC 2,5 - 8

9083 95-12 20 11 Gr. P Publ.

Service instructions

Technical Handbook

Electrical circuit diagram: Warning lamps, steering panel Lamp No. 1.

Colour

Function

Red

Charging

2.

1

Not used

3.

Green

Direction indicators

4.

Red

Parking brake

5.

Red

Engine oil pressure

6.

Red

Engine temperature

7.

Red

Gearbox oil pressure (Not Voith)

8.

Red

Gearbox temperature

9.

Blue

Headlight, main beam

10.

Yellow

Hedlight, dipped beam

11.

Red

Low brake pressure

12.

Green

Pre-heater

13.

Red

Low coolant level

14.

Not used

15.

Not used

2

3

4

5

6 - 10

11 12 13 14 15

K592

Connector A

Connector B

1.

+ 24 V across key

1.

- side lamp 6

2.

- side lamp 1

2.

- side lamp 11

3.

- side lamp 8

3.

+ side lamp 12

4.

Not connected

4.

Not connected

5.

- side lamp 14

5.

+ direction indicator L

6.

Not connected

6.

+ direction indicator R

7.

Not connected

7.

- side lamp 13

8.

- side lamp 4

8.

+ side lamp 9

9.

- side lamp 5

9.

- side lamp 15

10.

0 Volt (negative for 24 V)

10.

+ side lamp 10

DC 2,5 - 8 Technical Handbook

Service instructions

Text in diagrams A07261.0300/03 A Common cabling to seat, extra heating and radio converter.

Common cabling to engine, gear box and chassis.

B. Option - Reversing interlock.

A07261.0400/03 A. Only at Borg Warner gear box.

Only at Clark gear box.

A07265.0100/02 A. Common cabling to engine, gear box and chassis.

B. Option - Reversing interlock.

A07265.0200/03 A. Only at Borg Warner gear box.

Only at Clark gear box.

A07262.0300/01 A. Common cabling to seat, extra heating and radio converter.

Common cabling to engine, gear box and chassis.

B. Option - Reversing interlock.

A07266.0100/01 A. Common cabling to engine, gear box and chassis.

B. Option - Reversing interlock.

9083 95-12 20 12 Gr. P Publ.

Komponentförteckning/List of Components/Komponentenverzeichnis/ Liste de composants Nr/No/

Svenska

English

Deutsch

Francaise

30 32 37 39 51 52 56 59 62 64 72 77 78 100 101 102 103 104 105 106 107 108 109 110 111 112

Batteri Kretskort elcentral Terminal stomanslutning Terminal minusanslutning Säkringshållare 1-polig Säkringshållare 2-polig Säkringshållare 6-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)

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, 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)

Batterie Leiterplatte, Elektrozentrale Terminal, masseanschluss Terminal, Minus-Anschluss Sicherungshalter, 1polig Sicherungshalter, 2polig Sicherungshalter, 6polig Sicherungshalter, 12polig Batteriestecker, 2polig Batteriestecker, 4polig Buchse 2polig Buchse 7polig Buchse Extra, 7-polig Schalter, Beleuchtung Schalter, Umschalter Fern-/Abblendlicht Schalter, Nebelscheinwerfer Schalter, Fernscheinwerfer Schalter, Ladescheinwerfer Schalter, Arbeitsbeleuchtung Schalter, Containerbeleuchtung Schalter, Feststellbremse Schalter, Zentralschmierung Schalter, Warnblinkanlage Schalter, Rundum-Kennleuchte Schalter, Fensterheber Schalter, Klimaanlage (AC)

Switch, alternative steering Switch, reading light Switch, instrument illumination Switch, interior lighting Switch, heating Switch, heater fan Switch, wiper Switch, washer Switch, observation mirror Switch, exhaust brake Switch, diff. block Switch, power take off side Switch, power take off rear

Schalter, Lenkung Alt. Schalter, Leselampe Schalter, Instrumentenbeleuchtung Schalter, Innenbeleuchtung Schalter, Heizung Schalter, Lüftermotor Heizung Schalter, Scheibenwischer Schalter, Waschanlage Schalter, Rückspiegel Schalter, Motorbremse Schalter, Differentialsperre/Bremse Schalter, Nebenantrieb Seite Schalter, Nebenantrieb hinten

Batterie Circuit imprimé, centrale électrique Borne, mis á la masse Borne, connexion moins Porte-fusible, 1 pôle Porte-fusible, 2 pôles Porte-fusible, 6 pôles Porte-fusible, 12 pôles Connecteur de charge de batterie, 2 pôles Connecteur de charge de batterie, 4 pôles Prise, 1 pôle Prise, 7 pôles Prise supplémentaire, 7 pôles Interrupteur, feux Interrupteur, commutation route-croisement Interrupteur, feux de brouillard Interrupteur, feux longue porte´e Interrupteur, feux de travail Interrupteur, feux de travail Interrupteur, élairage conteneur Interrupteur, frein de stationnement Interrupteur, graissage centralise´ Interrupteur, feux de de´tresse Interrupteur, gyrophares Interrupteur, lève-glace Interrupteur, groupe de refroidissement climatisation, (AC) Interrupteur, type commande de direction Interrupteur, éclairage lecture Interrupteur, éclairage des instruments Interrupteur, éclairage inte´rieur Interrupteur, chauffage Interrupteur, motoventilateur chauffage Interrupteur, essuie-glace Interrupteur, lave-glace Interrupteur, rétroviseur Interrupteur, ralentisseur sur échappement Interrupteur, blocage de différentiel/frein Interrupteur, prise de puissance latérale Interrupteur, prise de puissance arrière

113 Strömställare styrning alt 114 Strömställare låsbelysning 115 Strömställare instr belysning 116 Strömställare innerbelysning 117 Strömställare värme 118 Strömställare fläktm värme 119 Strömställare vindrutetorkare 120 Strömställare spolare 123 Strömställare backspegel 125 Strömställare avgasbroms 126 Strömställare diff spärr/broms 128 Strömställare kraftuttag sida 129 Strömställare kraftuttag bak Date: 1998-03-09 Document No: P00022.0100 Issue: 05 Signature: RKO Change No: 980576

Anm.

Page 1 of 13

File:

G:\PRODUTV\ECS\PROD\P0002201\P0002201.DOC

Komponentförteckning/List of Components/Komponentenverzeichnis/ Liste de composants Nr/No/

Svenska

English

Deutsch

Francaise

130 131 132 135 142 143 144 145 147 149 150 152 156 157 158 160

Strömställare hög/lågväxel Strömställare färdväljare fram Strömställare färdväljare bak Strömställare växelväljare Strömställare fot Strömställare sitsvärme Batterifrånskiljare Strömställare AT-regulator Strömställare körvisare Strömställare signalhorn Strömställare startlås/ellas Strömställare intervalltorkare Strömställare kupevärmare Strömställare stoltilt Strömställare dimbakljus Strömställare komb fram/back

Switch, high/low gear Switch, gear selector forward Switch, gear selector rear Switch, gear shift 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, combi-forward/reverse

Schalter, Rangegetriebe Hoch/Niedrig Schalter, Fahrtrichtungswähler vorwärts Schalter, Fahrtrichtungswähler rückwärts Schalter, Schalthebel Fußschalter Schalter, Sitzheizung Batterietrennschalter Schalter, Abgasdruckregler Schalter, Fahrtrichtungsanzeiger Schalter, Signalhorn Schalter, Startschloß/E-Sperre Schalter, Intervallwischer Schalter, Kabinenheizung Schalter, Kippen des Sitzes Schalter, Nebelschlußleuchte Schalter, Kombi - vorn/rückwärts

161

Strömställare komb signal, ljus hel/halv spol,torkare m intervall körvisare

Schalter, combi-horn, light main/dipped beam, washer, wiper (intermittent), direction indicator

Schalter, Kombi-Signal, Beleuchtung Fern/Abblendlicht, Waschanlage, Intervallwischer, Fahrtrichtungsanzeiger

Interrupteur, petite/grande vitesse Interrupteur, marche avant Interrupteur, marche arrière Interrupteur, sélecteur de vitesse Interrupteur, pédale Interrupteur, chauffage d’assise Interrupteur, général Interrupteur, régulateur AT Interrupteur, clignotants Interrupteur, avertisseur sonore Interrupteur, contacteur antivol/verrou électrique Interrupteur, balayage intermittent Interrupteur, chauffage habitacle Interrupteur, basculement du siège Interrupteur, feux de brouillard arrière Interrupteur, sélecteur marche avant/marche arrière Interrupteur, avertisseur, feux de route et de croisement, lave-glace,essuie-glace a` balayage intermittent, clignotants

163 165 166 167 168 169 170 171 172

Strömställare start på 2-an Strömställare stolvärme Strömställare låsning vändskiva Strömställare luftfjädring Strömställare låsn stol Strömställare stolsvändning Strömställare förångare (LPG) Strömställare v-skiva upp/ner Strömställare v-skiva fr/back

Switch, start 2nd gear Switch, seat heater Switch, interlocking of turntable Switch, pneumatic springing Switch, interlocking of seat Switch, reversible seat Switch, evaporator (LPG) Switch, fifth wheel up/down Switch, fifth wheel forward/reverse

Schalter, Start 2-gang Schalter, Sitzheizung Schalter, Sperren Sattelkupplung Schalter, Luftfederung Schalter, Sitzverriegelung Schalter, Drehen des Sitzes Schalter, Verdampfer (LPG) Schalter, Sattelkupplung, aufwärts/abwärts Schalter, Sattelkupplung, vorn/hinten

173

Strömställare v-skiva skevning

Switch, fifth wheel, levelling

Schalter, Sattelkupplung, Niveauausgleich

Interrupteur, démarrage 2-trans.

Interrupteur, chauffage du siège Interrupteur, verrouillage de la sellette Interrupteur, suspension pneumatique Interrupteur, verrouillage du siège Interrupteur, pivotement du siège Interrupteur, évaporateur (GPL) Interrupteur, sellette montée/descente Interrupteur, sellette marche avant/marche arrière Interrupteur, sellette marché, corr-niveau

175 176

Strömställare hyttlyft upp Strömställare hyttlyft ner

Switch, cab hoist up Switch, cab hoist down

Schalter, Kabinenhub, aufwärts Schalter, Kabinenhub, abwärts

Interrupteur, élevation de cabine, montée Interrupteur, élevation de cabine, descente

180

Strömställare fyrhjulsdrift

Switch, 4-WD

Schalter, Vierradantrieb (4WD)

Interrupteur, 4 roues motrices

190 191

Strömställare klimatanläggning Strömställare recirkulation

Switch, air conditioner Switch, re-circulation

Schalter, Frischluftheizung Schalter, Re-zirkulation

Interrupteur, climatisation Interrupteur, re-circulation

Date: Document No: Issue: Signature: Change No:

1998-03-09 P00022.0100 05 RKO 980576

Anm.

Page 2 of 13

File:

G:\PRODUTV\ECS\PROD\P0002201\P0002201.DOC

Komponentförteckning/List of Components/Komponentenverzeichnis/ Liste de composants Nr/No/

Svenska

English

Deutsch

Francaise

195 196 197 198 199 1001 1002 1003 1004 1005

Switch, joy-stick X Switch, joy-stick X+Y Switch, length/sideways driwing Switch, equalizing fifth wheel Switch, option Switch, TW Switch, unlocking of TW Switch, locking of TW Switch, stop at 30 -35’ Switch, overriding of the safety system

Schalter, Joy-stick X Schalter, Joy-stick X+Y Schalter, Längs-/Querfahren Schalter, Ausgleich der Sattelkupplung Schalter, Option Schalter, TW Schalter, Lösen der TW Schalter, Verriegelung der TW Schalter, Stopp bei 30-35’ Schalter, ûberbrückung des sicherheitssystem

Interrupteur, Joy-stick X Interrupteur, Joy-stick X+Y Interrupteur, sens longitudinal/transversal Interrupteur, équililbré de la selette Interrupteur, option Interrupteur, TW Interrupteur, deverroulliage TW Interrupteur, verroulliage TW Interrupteur, arrêt á 30-35’ Interrupteur, Dérivation du système de sécurité

1006 1007 1008

Strömställare joy-stick X Strömställare joy-stick X+Y Strömställare längs/tvärskörning Strömställare flytläge skevning Strömställare option 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

Switch, front legs down Switch, rear legs down Switch, clamping/-releasing legs

Schalter, vorderes Bein ab Schalter, hinteres Bein ab Schalter, Klemmen/Lösen der Beine

Interrupteur, béquille avant baisse Interrupteur, béquille arrière baisse Interrupteur, serrage/-deserrage béquilles

200

Brytkontakt lampa park broms

Contact, breaking,warning lamp,parking brake

Unterbrecherkontakt,Warnlampe,Feststellbremse

201 202

Brytkontakt lampa färdbroms Brytkontakt lampa oljetryck motor

Unterbrecherkontakt,Warnlampe,Betriebsbremse Unterbrecherkontakt,Warnlampe,Öldruck Motor

204

Brytkontakt tryck ackumulator

Contact, breaking, warning lamp, brake Contact, breaking, warning lamp, oil pressure engine Contact, breaking, pressure accumulatortank

205 206

Brytkontakt innerbelysning Brytkontakt handskfack belysning

Contact, breaking, interior lighting Contact, breaking, glove

Unterbrecherkontakt, Innenbeleuchtung Unterbrecherkontakt, Handschuhfachbeleuchtung

207 208 214 215 216 217 218 219 220 221

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

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

Schließkontakt, Differentialsperre Schließkontakt, Warnlampe, Temperatur,Spulenkreis Bremsen Schließkontakt, Overdrive Schließkontakt, Temperatur Motor Schließkontakt, Bremslicht Schließkontakt, Rueckfahrscheinwerfer Schließkontakt, Abgasdruckregler Schließkontakt, Kontrollampe Luftfilter Unterbrecherkontakt, Antrieb Schließkontakt, Temperatur Getriebe

222

Slutkontakt lampa temp moment - förstärkare

223

Släpkontakt signal

Contact, making, warning lamp temperature torque amplifier.

Contact, brush, horn

Schließkontakt, Warnlampe Temperatur Drehmomentwandler Schließkontakt, Signal

Contact à ouverture, voyant, frein de stationnement Contact à ouverture,voyant,frein de service Contact à ouverture,voyant,pression d’huile moteur Contact à ouverture,pression réservoir accumulateur Contact à ouverture, éclairage intérieur Contact à ouverture, éclairage de la boite à gants Contact à fermeture, blocage du différentiel Contact à fermeture, voyant température circuit d’arrosage des freins Contact à fermeture, overdrive Contact à fermeture, température du moteur Contact à fermeture, feux stop Contact à fermeture, feux de recul Contact à fermeture, régulateur AT Contact à fermeture, témoin filtre à air Contact à ouverture, transmission Contact à fermeture, température de la bôite de vitesses Contact à fermeture, voyant température convertisseur Curseur, avertisseur

Date: Document No: Issue: Signature: Change No:

Unterbrecherkontakt,Druck Akkumulatorbehälter

1998-03-09 P00022.0100 05 RKO 980576

Anm.

Page 3 of 13

File:

G:\PRODUTV\ECS\PROD\P0002201\P0002201.DOC

Komponentförteckning/List of Components/Komponentenverzeichnis/ Liste de composants Nr/No/

Svenska

English

Deutsch

Francaise

224 228 229 230 231

Slutkontakt insprutningspump Slutkontakt hyttlåsning Slutkontakt stolslåsning Brytkontakt stol Slutkontakt fotkontroll stolvändning

Contact, making, injection pump Contact, making, cab locking Contact, making, seat locking Contact, breaking, seat Contact, making, seat rotation, foot switch

Schließkontakt, Einspritzpumpe Schließkontakt, Kabinenverriegelung Schließkontakt, Sitzsperre Unterbrecherkontakt, Sitz Endkontakt, Drehen des Sitzes, Fußschalter

232

Brytkontakt lampa luftanslutning släp

Contact, breaking, warning lamp air connection

233

Slutkontakt lampa låsning vändskiva

Contact, warning, interlocking of turntable

Unterbrecherkontakt, Warnlampe, Luftanschluß Anhänger Endkontakt, Warnanzeige, Sperren Sattelkupplung

235

Slutkontakt sidoskjutning stol

Contact, making, side shifting of seat

Endkontakt, Seitl. Sitzverstellung

239 240 241

Brytkontakt termisk Slutkontakt termisk Brytkontakt lampa luftmatning släp

242

Slutkontakt lampa oljetryck v-låda

Unterbrecherkontakt, thermisch Schließkontakt, thermisch Unterbrecherkontakt, Warnlampe Förderluft Anhänger Schließkontakt, Warnlampe, Öldruck Getriebe

243

Brytkontakt tryck kylmedia AC

244 250 251 260 261 262 263

Slutkontakt hydraulik aktiverad Brytkontakt nödstopp Slutkontakt vändbar förarstol Slutkontakt lyft steg 1 Slutkontakt lyft steg 2 Slutkontakt tilt Slutkontakt gaffelspridning

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, breaking, emergency stop Contact, making, VBFS Contact, making, hoist step 1 Contact, making, hoist step 2 Contact, making, tilting Contact, making, fork positioning

264 265 266 267 299 300 301 302 303 304 305 306

Slutkontakt sidoföring Slutkontakt stativ in/ut Brytkontakt hyttdörr Slutkontakt bromstryck Slut/brytkontakt option Relä hel/halvljus Relä dimljus Relä fjärrljus Relä lastljus Relä arbetsljus Relä backljus Relä helljus

Contact, making, sideshift Contact, making, lifting mast in-out Contact, breaking cab door Contact, making, brake pressure 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

Schließkontakt, Seitenverschiebung Schließkontakt, Hubgerüst ein-aus Unterbrecherkontakt, Kabinetür Schließkontakt, Bremsdruck Schließ-Unterbrecherkontakt, (option) Relais, Fem-/Abblendlicht Relais, Nebelscheinwerfer Relais, Fernscheinwerfer Relais, Ladescheinwerfer Relais, Arbeitsbeleuchtung Relais, Rückfahrscheinwerfer Relais, Fernlicht

Contact à fermeture, pompe d’injection Contact à fermeture, verrouillage de la cabine Contact àfermeture, verrouillage du siège Contact à ouverture, siège Contact à fermeture, pivotement du siège contact au plancher Contact à ouverture, voyant connexion pneumatique remorque Contact à ouverture, voyant verrouillage sellette , Contact à ouverture, de´placement latéral du siège Contact à ouverture, thermique Contact à fermeture, thermique Contact à ouverture, témoin air d’alimentation remorque Contact à fermeture, voyant, pression d’huile boîte de vitesses Contact à ouverture, pression frigorigène (climatisation) Contact à fermeture, hydraulique actionnée Contact à ouverture, arrêt d’urgence Contact à fermeture, siège pivotant Contact à fermeture, élévation e´tape 1 Contact à fermeture, élévation e´tape 2 Contact à fermeture, inclinaison Contact à fermeture, écartement des bras de fourche Contact à fermeture, déplacement latéral Contact à fermeture, mat de lev. ext-ret.

Contact à ouverture, portiere de cabine Contact à fermeture, pression de frein Contact à fermeture/ouverture, (option) Relais, route-croisement Relais, feux antibrouillard Relais, feux longue portée Relais, projecteur de chargement Relais, projecteur de travail Relais, feux de recul Relais, feux de route

Date: Document No: Issue: Signature: Change No:

Unterbrecherkontakt, Druck Kühlmittel (Klimaanlage) Schließkontakt, Hydraulik aktiviert Unterbrecherkontakt, Notaus Schließkontakt, drehbarer Fahrersitz Schließkontakt, Hub Stufe 1 Schließkontakt, Hub Stufe 2 Schließkontakt, Neigung Schließkontakt, Gabelverstellung

1998-03-09 P00022.0100 05 RKO 980576

Anm.

Page 4 of 13

File:

G:\PRODUTV\ECS\PROD\P0002201\P0002201.DOC

Komponentförteckning/List of Components/Komponentenverzeichnis/ Liste de composants Nr/No/

Svenska

English

Deutsch

Francaise

307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325

Relä halvljus Relä bromsljus Relä parkeringsbroms Relä körvisare vä Relä körvisare hö Relä startelement Relä vändbar förarstol Relä parkeringsbroms Relä startlås Relä torkare Relä strålkastartorkare Relä AT-regulator Relä varningsblinkers Relä elektrisk stopp Relä intervalltorkare Relä kylvätskenivå Relä blinkers Relä rangespärr Relä blinkande bromsljus (back)

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, starting 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)

Relais, Abblendlicht Relais, Bremslicht Relais, Standlicht Relais, Fahrtrichtungsanzeiger, L Relais, Fahrtrichtungsanzeiger, R Relais, Startelement Relais, drehbarer Fahrersitz Relais, Feststellbremse Relais, Startschloß Relais, Wischer Relais, Scheinwerferwischer Relais, Abgasdruckregler Relais, Warnblinker Relais, elektrischer Stopp Relais, Intervallwischer Relais, Kühlflüßigkeitsstand Relais, Blinker Relais, Rangesperre Relais, blinkendes Bremslicht (beim Zurücksetzen)

326 327 328 329 330 331 332 333 334 335

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)

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)

Relais, blinkendes Bremslicht (Rund-um) Relais, Wechsel neutral Relais, Wechselschaltung Relais, Wechsel hoch niedrig Relais, Startsperre Relais, Antrieb vorn (LPG, Diesel) Relais, Antrieb hinten (LPG, Diesel) Zeitrelais, Vorwärmautomatik Relais, Auskuppeln/Antriebsabschaltung Relais, Schaltventil 1 Getriebe (Diesel, LPG)

336

Relä växelventil 2:a (diesel, gas)

Relay, gear change valve 2-gear (diesel,LPG)

Relais, Schaltventil 2 Getriebe (Diesel, LPG)

337 338 339 340 341 342 343

Relä drivriktning motor Relä kylfläkt drivmotor Relä kylfläkt elskåp Tidrelä fördröjt tillslag Tidrelä fördröjt frånslag Relä drivning 2/4 hjul Relä dimbakljus

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

Relais, Antriebsrichtung Motor Relais, Lüfter Antriebsmotor Relais, Lüfter Schaltschrank Zeitrelais, verzögerte Einschaltung Zeitrelais, verzögerte Ausschaltung Relais, 2-Rad/4-Rad-Antrieb Relais, Nebelschlußleuchte

Relais, feux de croisement Relais, feux stop Relais, feux de stationnement Relais, clignotant supplémentaire, ga.

Relais, clignotant supplémentaire, dr.

Relais, élément de démarrage Relais, siège pivotant Relais, frein de stationnement Relais, démarreur antivol Relais, essuie-glace Relais, essuie-phare Relais, régulateur AT Relais, feux de détresse Relais, arrêt électrique Relais, balayage intermittent Relais, niveau radiateur Relais, clignotants Relais, blocage doubleur Relais, feux stop clignotants (en marche arrière) Relais, feux stop clignotants (gyrophare) Relais, changement neutre Relais, changement de rapports Relais, petite/grande vitesse Relais, blocage démarrage Relais, marche avant Relais, marche arrière Relais, temporise´, préchauffage automatique Relais, débrayage/arrêt d’entraînement Relais, distributeur de changement, boîte à 1 rapport (gazole, GPL) Relais, distributeur de changement, boîte à 2 rapports (gazole, GPL) Relais, sens de marche moteur Relais, moteur du ventilateur Relais, boîtier électrique du ventilateur Relais, temporise´, mise en marche temporiseé Relais, temporise´, arrêt temporisée Relais, commutation 2/4 roues motrices Relais, feux de brouillard arrière

Date: Document No: Issue: Signature: Change No:

1998-03-09 P00022.0100 05 RKO 980576

Anm.

Page 5 of 13

File:

G:\PRODUTV\ECS\PROD\P0002201\P0002201.DOC

Komponentförteckning/List of Components/Komponentenverzeichnis/ Liste de composants Nr/No/

Svenska

English

Deutsch

Francaise

344 345 346 347 348 349 350 351 352 353 354 355 356

Relä momentförstärkare Relä låsning vändskiva Relä frikoppling stollåsning Relä stolvändning/ljussignal Relä fläktmotor värmare Relä fartreglage Relä pumpkontaktor/pumpkontroll Relä hyttlyft upp Relä hyttlyft ner Relä säkerhetsslinga Relä styrsystem Relä sensorstyrning Skiftrelä längskörning/tvärskörning

Relay, torque amplifier Relay, interlocking of turntable Relay, releasing of seat interlocking Relay, multifunction, seat rotation/light signal 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

Relais, Drehmomentwandler Relais, Sperren der Sattelkupplung Relais, Freigabe Sitzverriegelung Relais, Multifunktion, Sitzdrehen/Lichtsignal Relais, Gebläsemotor Heizung Relais, Geschwindigkeitsregelung Relais, Pumpenkontrolle Relais, Kabinenhub, aufwärts Relais, Kabinenhub, abwärts Relais, Sicherheitsschleife Relais, Signal Lenkung Relais, Sensorsteuerung Schaltrelais, Längs-/Querfahren

357 360 365 366 367 368 3001 3002 3003 3004 3005

Relä roterande varningsljus Relä startsolenoid Relä fönsterhiss upp Relä fönsterhiss ner Relä styrning Relä lågt bromstryck Relä rotation Relä tilt Relä sidoföring Relä längdinställning Relä twist lock

Relay, hazard beacon Relay, starting solenoid Relay, electrical screen elevator up Relay, electrical screen elevator down Relay, steerin Relay, low brake pressure Relay, rotation Relay, tilt Relay, side shifting Relay, length adjustment Relay, twist lock

Relais, rotierende Rund-um-Kennleuchte Relais, Anlaßermagnet Relais, elektrischer Fensterheber aufwärts Relais, elektrischer Fensterheber abwärts Relais, Lenkung Relais, niedrieger Bremsdruck Relais, rotation Relais, neigung Relais, seitenverstellung Relais, längeneinstellung Relais, twist lock

Relais, convertisseur de couple Relais, verrouillage de la sellette Relais, déverrouillage du siège Relais, multifonction siège/appel de phare Relais, chauffage du moteur de ventilateur Relais, commande de vitesse Relais, commande de pompe Relais, élevation de cabine, montée Relais, élevation de cabine, descente Relais, boucle de sécurité Relais, signal système de commande Relais, commande capteurs Relais, de commutation, sens longitudinal/transversal Relais, gyrophare Relais, solénoîde démarreur Relais, montée du lève-glace électrique Relais, descente du lève-glace électrique Relais, direction Relais, pression de frein petite Relais, rotation Relais, inclinaison Relais, translation laterale Relais, dispersion Relais, twist lock

375 376 377 378 379 380 381 399 400L 400R 401L 401R 402 403

Huvudkontaktor reglersystem Kontaktor fram reglersystem Kontaktor bak reglersystem Kontaktor by-pass reglersystem Kontaktor pumpmotor Kontaktor Kontaktor återladdning Relä option G-lampa vä fram G-lampa hö fram G-lampa vä bak G-lampa hö bak G-lampa fjärrljus G-lampa lastljus

Main contactor, operating control Contactor, forward operating control Contactor, reversing operating control Contactor, ”by-pass” operating control Contactor, pump motor Contactor Contactor, recharging Relay, option Light bulb, roading light left hand front Light bulb, roading light left hand rear Light bulb, roading light left hand front Light bulb, roading light left hand rear Light bulb, distance light Light bulb, mast light

Hauptschütz, Regelsystem Schütz, vom Regelsystem Schütz, hinten Reglersystem Schütz, Bypass Reglersystem Schütz, Pumpenmotor Schütz Schütz, Aufladung Relais, Option Glühlampe, Scheinwerfer links vorn Glühlampe, Scheinwerfer rechts vorn Glühlampe, Scheinwerfer links hinten Glühlampe, Scheinwerfer rechts hinten Glühlampe, Fernscheinwerfer Glühlampe, Ladescheinwerfer

Contacteur principal, système de régulation Contacteur, régulation avant Contacteur, régulation arrière Contacteur, système de régulation by-pass Contacteur, moteur de la pompe Contacteur Contacteur, recharge Relais, option Ampoule, projecteur avant gauche Ampoule, projecteur avant droite Ampoule, projecteur arrière gauche Ampoule, projecteur arrière droite Ampoule, feux longue portée Ampoule, projecteur de chargement

Date: Document No: Issue: Signature: Change No:

1998-03-09 P00022.0100 05 RKO 980576

Anm.

Page 6 of 13

File:

G:\PRODUTV\ECS\PROD\P0002201\P0002201.DOC

Komponentförteckning/List of Components/Komponentenverzeichnis/ Liste de composants Nr/No/

Svenska

English

Deutsch

Francaise

404 405 406L 406R 408L 408R 410L 410R 411L 411R 412L 412R 413L

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

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 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)

Ampoule, projecteur de travail Ampoule, feux de recul Eclairage conteneur gauche Eclairage conteneur droite Ampoule, feux de stationnement, avant gauche Ampoule, feux de stationnement, avant droite Ampoule, feu stop, avant gauche Ampoule, feu stop, avant droite Ampoule, feu stop, arrière gauche Ampoule, feu stop, arrière droite Ampoule, feu arrière gauche Ampoule, feu arrière droite Ampoule, feu arrière, avant gauche

413R

G-lampa bak ljus hö fram (VBFS)

Light bulb, rear light,right-hand forward (VBFS)

416-1 416-2

G-lampa sidomarkering vä fram G-lampa sidomarkering vä bak

Light bulb, side position light, left-hand forward Light bulb, side position light, left-hand rear

417-1

G-lampa sidomarkering hö fram

Light bulb, side position light, right -hand forward

417-2

G-lampa sidomarkering hö bak

Light bulb, side position light, right-hand rear

420 421 422 423 426 427 428 429 431 432 433 434 435 436 437 440 445

G-lampa positionsljus vänster G-lampa positionsljus höger G-lampa körvisare vä fram G-lampa körvisare hö fram G-lampa körvisare vä bak G-lampa körvisare hö bak 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 värmereglage belysning G-lampa körvisare vä (extra)

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, heating control light Light bulb, extra direction indicator left

Glühlampe, Arbeitsbeleuchtung Glühlampe, Rückfahrscheinwerfer Containerbeleuchtung links Containerbeleuchtung rechts Glühlampe, Standlicht, links vorn Glühlampe, Standlicht, rechts vorn Glühlampe, Bremslicht, links vorn Glühlampe, Bremslicht, rechts vorn Glühlampe, Bremslichts, links hinten Glühlampe, Bremslicht, rechts hinten Glühlampe, Rücklicht, links hinten Glühlampe, Rücklicht, rechts hinten Glühlampe, Rücklicht, links vorn (drehbarer Fahrersitz) Glühlampe, Rücklicht, rechts vorn (drehbarer Fahrersitz) Glühlampe, seitliche Begrenzungsleuchte, links vorn Glühlampe, seitliche Begrenzungsleuchte, links hinten Glühlampe, seitliche Begrenzungsleuchte, rechts vorn Glühlampe, seitliche Begrenzungsleuchte, rechts hinten Glühlampe, Positionsleuchte links Glühlampe, Positionsleuchte rechts Glühlampe, Fahrtrichtungsanzeiger links Glühlampe, Fahrtrichtungsanzeiger rechts vorn Glühlampe, Fahrtrichtungsanzeiger links hinten Glühlampe, Fahrtrichtungsanzeiger rechts hinten Glühlampe, Rundum-Kennleuchte Glühlampe, Zigarettenanzünder-Beleuchtung Glühlampe, Instrumentenbeleuchtung Glühlampe, Handschuhfachbeleuchtung Glühlampe, Einstiegbeleuchtung Glühlampe, Innenbeleuchtung Glühlampe, Leselampe Glühlampe, Identifikationsleuchte Glühlampe, ID-Beleuchtung/Dachschild Glühlampe, Beleuchtung für Heizungsbedieung Glühlampe, Fahrtrichtungsanzeiger links, Extra

Date: Document No: Issue: Signature: Change No:

1998-03-09 P00022.0100 05 RKO 980576

Anm.

Ampoule, feu arrière, avant droite Ampoule, feu de position latérale avant gauche Ampoule, feu de position latérale arrière gauche Ampoule, feu de position latérale avant droite Ampoule, feu de position arrière droite Ampoule, feu de position gauche Ampoule, feu de position droite Ampoule, clignotant avant gauche Ampoule, clignotant avant droite Ampoule, clignotant arrière gauche Ampoule, clignotant arrière droite Ampoule, gyrophare Ampoule, éclairage allume-cigares Ampoule, éclairage des instruments Ampoule, éclairage de la boïte à gants Ampoule, éclairage de l’emmarchement Ampoule, éclairage intérieur Ampoule, éclairage de lecture Ampoule, éclairage de plaque Ampoule, éclairage commande chauffage Ampoule,clignotant supplémentaire gauche Page 7 of 13

File:

G:\PRODUTV\ECS\PROD\P0002201\P0002201.DOC

Komponentförteckning/List of Components/Komponentenverzeichnis/ Liste de composants Nr/No/

Svenska

English

Deutsch

Francaise

446 451 452 464 500 501 503 504 505 506 507 508 509 510 512 514 519 524 528 547 549 550 551 552 554 555 556 560 561 569 590 599

G-lampa körvisare hö (extra) G-lampa dimbakljus vänster G-lampa dimbakljus höger G-lampa belysning elcentral Kont lampa körvisare Kont lampa körvisare (extra) Varn lampa oljetryck motor Kont lampa helljus 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 förvärmning Varn lampa centralvarning Varn lampa oljetryck v-låda Varn lampa hyttlåsning Varn lampa temp v-låda Varn lampa bromstryck Varn lampa temp spolkrets bromsar Varn lampa temp kylvatten mot Varn lampa låsning vändskiva Varn lampa temp drivmotor el Varn lampa temp pumpmotor el Kont lampa elvärme Kont lampor kompl 15 st Kont lampa option

Light bulb, extra direction indicator right Light bulb, fog light rear left Light bulb, fog light rear right Light bulb, electrical box lighting Indicating lamp, direction indicator Indicating lamp, direction indicator extra Warning lamp, oil pressure engine Indicating lamp, main beam 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, preheating 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 Warning lamp, temperature, drive motor Warning lamp, temperature, pump motor Indicating lamp, electric heater Indicating lamps complete (15pcs) Indicating lamp, option

Glühlampe, Fahrtrichtungsanzeiger, rechts, Extra Glühlampe, Nebelschlußleuchte links Glühlampe, Nebelschlußleuchte rechts Glühlampe, Beleuchtung Elektrozentrale Kontrollampe, Fahrtrichtungsanzeiger Kontrollampe, Fahrtrichtungsanzeiger, Extra Warnlampe, Öldruck Motor Kontrollampe, Fernlicht Warnlampe, Ladestrom Warnlampe, Ladestrom Extra Warnlampe, Betriebsbremse Warnlampe, Feststellbremse Warnlampe, Kühlflüssigkeitsstand Kontrollampe, Differentialsperre Warnlampe, Temperatur Drehmomentwandler Kontrollampe, Overdrive Kontrolleuchte, Abblendlicht Kontrollampe, Luftfilter Kontrollampe, Vorwärmung Warnleuchte, Zentrales Warnsystem Warnlampe, Öldruck Getriebe Warnlampe, Kabinenverriegelung Warnlampe, Temperatur Getriebe Warnlampe, Bremsdruck Warnlampe, Temperatur Spülkreis Bremsen Warnlampe, Temperatur Kühlwasser Motor Warnleuchte, Sperren der Sattelkupplung Warnleuchte, Temperatur Antriebsmotor, el.

Warnleuchte, Temperatur Pumpenmotor el.

Kontrolleuchte, Elektroheizung Kontrollampen komplett (15 stück) Kontrollampe, Option

Ampoule, clignotant supplémentaire droite Ampoule, feu de brouillard arrière gauche Ampoule, feu de brouillard arrière droite Ampoule, éclairage centrale électrique Témoin, clignotants Témoin, clignotant supplémentaire Voyant, pression d’huile moteur Témoin, feux de route Voyant, charge Voyant, charge supplémentaire Voyant, frein de service Voyant, frein de stationnement Voyant, niveau liquide de refroidissement Témoin, blocage du différentiel Voyant, température du convertisseur Témoin, overdrive Témoin, feu de croisement Témoin, filtre à air Témoin, préchauffage Voyant, signalisation centralisée Voyant, pression d’huile de la boîte Voyant, verrouillage de la cabine Voyant, température de la boîte de vitesses Voyant, pression de freinage Voyant, température circuit de freins Voyant, température refroidissement moteur Voyant, verrouillage de la sellette Voyant, temp.moteur propulsion, élect.

Voyant, temp.moteur pompe, élect.

Témoin, chauffage électrique Témoins, ensemble (15) Témoin, 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

Magnetventil, Motorbremse Magnetventil, Differentialsperre Magnetventil, Bremse Magnetventil, Heizung Magnetventil, Nebenantrieb Seite Magnetventil, Nebenantrieb hinten Magnetventil, 2-Rad/4-Rad-Antriebe

Electrovanne, ralentisseur sur échappement Electrovanne, blocage du différentiel Electrovanne, frein Electrovanne, chaleur Electrovanne, prise de force latérale Electrovanne, prise de force arrière Electrovanne, 2/4 roues motrices

600 M-ventil avgasbroms 601 M-ventil diff spärr 602 M-ventil broms 603 M-ventil värme 604 M-ventil kraftuttag sida 605 M-ventil kraftuttag bak 606 M-ventil 2/4 hjulsdrift Date: 1998-03-09 Document No: P00022.0100 Issue: 05 Signature: RKO Change No: 980576

Anm.

Page 8 of 13

File:

G:\PRODUTV\ECS\PROD\P0002201\P0002201.DOC

Komponentförteckning/List of Components/Komponentenverzeichnis/ Liste de composants Nr/No/

Svenska

English

Deutsch

Francaise

607 608 609 610 611 613 614 615 617 620 621 622 623 624 625 626 630 631 632 633 634 635 636 637 638 639 640 641 642 643 644 645

M-ventil hög/låg växel Pumpaggregat hyttlyft Ställmotor gaspådrag M-ventil hydraulsystem allm M-ventil flödesbegränsning M-ventil momentförstärkare M-ventil rangespärr M-ventil hjulvridning M-ventil AT-regulator by-pass 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 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

Solenoid valve, high/low gear Pump unit, cab hoist Regulating motor, throttle Solenoid valve, hydraulics, general Solenoid valve, flow restriction Solenoid valve, torque amplifier Solenoid valve, ranging interlock Solenoid valve, wheel turning Solenoid valve, AT-regulator ”by-pass” 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, 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

Magnetventil, Wechsel hoch/niedrig Pumpenanlage, Kabinenhub Stellmotor, Gasgeben Magnetventil, hydraulische Anlage allgemein Magnetventil, Fließbegrenzung Magnetventil, Drehmomentwandler Magnetventil, Rangesperre Magnetventil, Radeinschlag Magnetventil, Abgasdruckregler ”Bypass” Magnetventil, Sattelkupplung, aufwärts Magnetventil, Sattelkupplung, abwärts Magnetventil, Sattelkupplung, vorn Magnetventil, Sattelkupplung, hinten Magnetventil, Niveauausgleich rechts Magnetventil, Niveauausgleich links Magnetventil, Abgasdruckregler Magnetventil, Getriebe Vorwärtsgang Magnetventil, Getriebe Rückwärtsgang Magnetventil, Getriebe Schaltstufe I Magnetventil, Getriebe Schaltstufe II Magnetventil, Getriebe Schaltstufe III Magnetventil, Anliegedruck Magnetventil, Lenkung Magnetventil, Ausgleich der Sattelkupplung Magnetventil, Abstellung Einspritzpumpe Magnetventil, Sperren LS Orbitrol Magnetventil, LPG Magnetventil, Verdampfer (LPG) Magnetventil, Feststellbremse Magnetventil, Sitzsperre (VBFS) Magnetventil, Sperren Sattelkupplung Magnetkupplung, Kompressor Klimaanlage

646 647 648 6001 6002 6003

M-ventil stolsvändning M-ventil stolstilt M-ventil luftfjädring M-ventil, blockering höger M-ventil, blockering vänster M-ventil, inkoppling av hydraulik till topplyft

Solenoid valve, seat rotation Solenoid valve, seat tilt Solenoid valve, pneumatic springing Solenoid valve, blocking right Solenoid valve, blocking left Solenoid valve, activation of toplift hydraulics

Magnetventil, Drehen des Sitzes Magnetventil, Kippen des Sitzes Magnetventil, Luftfederung Magnetventil, Blockierung rechts Magnetventil, Blockierung links Magnetventil, Aktivierung von Oberhubhydraulik

Electrovanne, petite/grande vitesse Groupe pompe-moteur, élevation de cabine Moteur de commande de gaz Electrovanne,système hydraulique, général Electrovanne, limiteur de débit Electrovanne, convertisseur de couple Electrovanne, blocage du doubleur Electrovanne, pivotement roues Electrovanne, by-pass du régulateur AT Electrovanne, sellette, montée Electrovanne, sellette, descente Electrovanne, sellette, marche avant Electrovanne, sellette, marche arrière Electrovanne, corr.-niveau droits Electrovanne, corr.-niveau gauche Electrovanne, régulateur AT Electrovanne, boîte de vitesses marche avant Electrovanne, boîte de vitesses marche arrière Electrovanne, boîte vitesses rapport I Electrovanne, boîte de vitesses rapport II Electrovanne, boîte de vitesses rapport III Electrovanne, pression de serrage Electrovanne, direction Electrovanne, équilibré de la selette Electrovanne, arrêt de la pompe d’injection Electrovanne, verrouillage de LS Orbitrol Electrovanne, GPL Electrovanne, évaporateur (GPL) EElectrovanne, frein de stationnement Electrovanne, verrouillage du siège (VBFS) Electrovanne, verrouillage de la sellette Coupleur magnétique, compresseur climatisation Electrovanne, pivotement du siège Electrovanne, basculement du siège Electrovanne, suspension pneumatique Electrovanne, blocage droit Electrovanne, blocage gauche Electrovanne, alimentation hydraulique du levage supèrieur

Date: Document No: Issue: Signature: Change No:

1998-03-09 P00022.0100 05 RKO 980576

Anm.

Page 9 of 13

File:

G:\PRODUTV\ECS\PROD\P0002201\P0002201.DOC

Komponentförteckning/List of Components/Komponentenverzeichnis/ Liste de composants Nr/No/

Svenska

English

Deutsch

Francaise

6004 6005 6006 6007 6008 6009 6010 6011 6012 6013 6014 6015

M-ventil, sänk M-ventil, lyft M-ventil, bom ut M-ventil, bom in M-ventil, vridning medsols M-ventil, vridning motsols 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, lower Solenoid valve, lift Solenoid valve, boom out Solenoid valve, boom in Solenoid valve, rotation clockwise Solenoid valve, rotation counter-clockwise 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

Magnetventil, Senken Magnetventil, Heben Magnetventil, Ausleger aus Magnetventil, Ausleger ein Magnetventil, Rotation im Uhrzeigersinn Magnetventil, Rotation entgenen Uhrzeigersinn Magnetventil, Neigung aus Magnetventil, Neigung ein Magnetventil, Neigung Magnetventil, vorderes Bein ab Magnetventil, hinteres Bein ab Magnetventil, Klemmen/-Lösen der Beine

Electrovanne, descente Electrovanne, levage Electrovanne, fléche sortie Electrovanne, fleche rentrée Electrovanne, rotation horaire Electrovanne, rotation anti-horaire Electrovanne, inclinaison sortie Electrovanne, inclinaison rentrée Electrovanne, inclinaison Electrovanne, béquille avant baisse Electrovanne, béquille arrière baisse Electrovanne, serrage/deserrage béquilles

Thermostat, air condition Wiper motor forward Wiper motor rear Wiper motor roof Wiper motor roof (option) 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 Compressor Control unit, termostat AC Speed control (EC) Pump, central lubrication Drive motor (EC) Pump, emergency steering Electric brake

Thermostat, Klimaanlage Scheibenwischermotor vorn Scheibenwischermotor hinten Scheibenwischermotor Dach Scheibenwischermotor Dach (Option) Motor für Scheibenwaschanlage Motor für Scheinwerfer Motor für Scheinwerferreinigungsanlage Anlasser Lüfter Antriebsmotor (EC) Lüfter Schaltschrank (EC) Gebläsemotor (Heizung) Generator, Extra Generator ohne angebauten Reglerschalter Generator mit angebauten Reglerschalter Fensterhebermotor Reglerschalter Dosierpumpe, Klimaanlage Umwälzpumpe, Klimaanlage Diode Kompressor Reglereinheit, Thermostat AC Geschwindigkeitsregler (EC) Pumpe, Zentralschmierung Antriebsmotor (EC) Pumpe, Notlenkung E-Bremse

Thermostat, climatisation Moteur essuie-glace avant Moteur essuie-glace arrière Moteur essuie-glace pavillon Moteur essuie-glace pavillon (option) Moteur lave-glace Moteur projecteurs Moteur lave-phares Démarreur Moteur du ventilateur (EC) Boîtier électrique du ventilateur (EC) Moteur du ventilateur (chauffage) Alternateur supplémentaire Alternateur sans régulateur de charge Alternateur avec régulateur de charge Moteur lève-glaces Régulateur de charge Pompe de dosage, climatisation Pompe de circulation, climatisation Diode Compresseur Unité de régulation, Thermostat AC Régulation de la vitesse (EC) Pompe, graissage centralisé Moteur d’entraînement (EC) Pompe, direction de secours Frein électrique

649 Termostat klimatannläggning 650-1 Torkarmotor fram 650-2 Torkarmotor bak 650-3 Torkarmotor tak 650-4 Torkarmotor tak (option) 651 Vindrutespolarmotor 652 Strålkastarmotor 653 Strålkastarspolarmotor 654 Startmotor 655 Kylfläkt drivmotor (EC) 656 Kylfläkt elskåp (EC) 657 Fläktmotor värme 658 Generator (extra) 659 Generator utan laddregulator 660 Generator med laddregulator 661 Fönsterhissmotor 662 Laddregulator 663 Doseringspump klimatanläggning 664 Cirk pump klimatanläggning 665 Diod 670 Kompressor 685 Reglerenhet termostat AC 690 Fartreglafe (EC) 693 Pump centralsmörjning 695 Drivmotor (EC) 696 Pumpaggregate nödstyrning 697 Elbroms Date: 1998-03-09 Document No: P00022.0100 Issue: 05 Signature: RKO Change No: 980576

Anm.

Page 10 of 13

File:

G:\PRODUTV\ECS\PROD\P0002201\P0002201.DOC

Komponentförteckning/List of Components/Komponentenverzeichnis/ Liste de composants Nr/No/

Svenska

English

Deutsch

Francaise

698 699 700 701 702 703 704 705 706

Pumpmotor (EC) M-ventil option Hastighetsmätare Mätare oljetemp v-låda Klocka Varvtalsmätare Tryckluftsmätare Mätare oljetryck v-låda Termometer temp kylvätska motor

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

Pumpenmotor (EC) Magnetventil (option) Tachometer Meßinstrument, Öltemperatur Getriebe Uhr Drehzahlmesser Druckluftmesser Meßinstrument, Öldruck Getriebe Thermometer, Temperatur Kühlflüssigkeit Motor

707 708 709 710 712 715 720 753 754 756

Bränslemätare Timräknare Kapacitetsmätare batteri Tidur motor/kupevärmare Mätare oljetryck motor Extra instrument allm Givare vändbar förarstol Varvtalsgivare motor Givare lufttryck Temperatur kylvätska motor

Fuel gauge Hour meter Capacity gauge, battery Timer, engine- and cab heater Motor oil pressure gauge Extra instrument, general Transmitter, revolving driver´s seat (VBFS) Transmitter, engine revolution Transmitter, air pressure Transmitter, engine coolant temperature

Kraftstoffanzeiger Betriebsstundenzähler Kapazitätsmesser Schaltuhr, motor- und Kabinenheizung Maßinstrument, Öldruck Motor Zusatzinstrument, allgemein Geber, drehbarer Fahrersitz (VBFS) Drehzahlgeber Motor Geber, Luftdruck Temperaturgeber, Kühlflüssigkeit Motor

757 758 759 760

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

761

Givare rev-spärr/aut-vxl motor

Kraftstoffstandgeber Drehzahlgeber Getriebe Flüssigkeitsstandanzeiger, Kühlflüssigkeit Geber Umkehrsperre/automatische Schaltung Transmission Geber Umkehrsperre/automatische Schaltung Motor

762 763 764 765 766 767 768 770 771 773 774 775

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 rattutslag Givare vinkel Givare närvaro Givare utomhustemp Givare temp klimatanläggning

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, steering wheel angle Transmitter, angle Transmitter, presence Transmitter, ambient temperature Transmitter, temperature air condition

Moteur de la pompe (EC) Electrovanne, (option) Compteur de vitesse Thermomètre, huile de la boîte Montre Compte-tours Manomètre, air Manomètre, huile de la boîte Thermomètre, temp. liquide refroidissement moteur Jauge de carburant Compteur horaire Indicateur de capacité, batterie Minuterie, chauffage moteur et habitacle Minuterie, prèssion d’huile moteur Instruments supplémentaires, général Capteur, siège de conduite pivotant (VBFS) Capteur de régime moteur Capteur, pression d’air Capteur de température, liquide de refroidissement Capteur de niveau de carburant Capteur de régime boîte de vitesses Indicateur de niveau, liquide de refroidissement Capteur blocage marche arrière/ changement automatique transmission Capteur blocage marche arrière/ changement automatique moteur Capteur, temp. circuit refroidiss. freins Capteur, niveau huile hydraulique Capteur, pression servo de la boîte Capteur, pression d’huile de la boîte Capteur, température d’huile de la boîte Capteur, pression d’huile moteur Capteur, pression d’huile hydraulique Capteur, braquage Capteur, angle Capteur, présence Capteur, température extérieure Capteur, de températeur, climatisation

Date: Document No: Issue: Signature: Change No:

Geber, Temperatur Spülkreis Bremsen Geber, Hydraulikölfüllstand Geber, Servodruck, Getriebe Geber, Öldruck Getriebe Geber, Öltemperatur Getriebe Geber, Öldruck Motor Geber, Öldruck, Hydraulik Geber, lenkradeinschlag Geber, Winkel Geber, Präsenz Geber, Außentemperatur Geber, Temperatur, Klimaanlage

1998-03-09 P00022.0100 05 RKO 980576

Anm.

Page 11 of 13

File:

G:\PRODUTV\ECS\PROD\P0002201\P0002201.DOC

Komponentförteckning/List of Components/Komponentenverzeichnis/ Liste de composants Nr/No/

Svenska

English

Deutsch

Francaise

776 777 778 7200

Givare temp hydraulolja Givare läge Givare drivbrytning Givare, axeltryck höger

transmitter, hydraulic temperature Transmitter, position Transmitter, drive break Sensor, axle pressure right

Geber, Temperatur, Hydrauliköl Geber, Position Geber, Antriebsabschaltung Drucksensor, Achsdruck rechts

7201

Givare, axeltryck vänster

Sensor, axle pressure left

Drucksensor, Achsdruck links

779 780

Reglersystem återladdning (EC) Reglersystem åkmotor (EC)

Control system, recharging (EC) Control system main motor (EC)

Steuersystem, Aufladung (EC) Regelsystem, Fahrmotor (EC)

781

Reglersystem pumpmotor (EC)

Control system pump motor (EC)

Regelsystem Pumpenmotor (EC)

782 783 784 785 789 790 795 799 800 802 803 804 805 806 807 808 810 815 820 822 823 824 825 826 830 835 840 850

Logik interface 2 drivmotorer Logik interface gaspådrag Logik interface bromsregl Logik interface styrsystem Givare allmän Elektronisk kontrollenhet ECU Display Logik allm (option) Sttartelement Eluppvärmd backspegel Eluppvärmd stol Cigarettändare Elvärme hytt Aggregat klimatanläggning Potentiometer Eluppvärmd lufttorkare Kondensor AC Manöverspak Motstånd Signalfilter Signalomvandlare höger Signalomvandlare vänster Reglage spakstyrning Ventil spakstyrning Tändspole Tändstift Strömfördelare Signalhorn

Logic (interface) two main motors (EC) Logic (interface) throttle Logic (interface) brake control Logic (interface) control system Transmitter, common Electronic Control Unit ECU Display 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 Control lever Resistor Signal filter Signal amplifier, right Signal amplifier, left Controls, (steering with control levers).

Valve, (steering with control levers).

Ignition coil Ignition plug Distributor Horn

Logik (Schnittstelle) zwei Antriebsmotoren Logik (Interface) Gasgeben Logik (Interface) Bremssteuerung Logik (Interface) Lenkung Geber, allgemein Elektrinikkontrolleinheit ECU Display Logik, allgemein (option) Startelement Elektrisch beheizter Rückspiegel Elektrisch beheizter Sitz Zigarettenanzünder Elektrische Heizung Kabine Aggregat, Klimaanlage Potentiometer Elektrisch beheizer Lufttrockner Kondensor Klimaanlage Bedienungshebel Widerstand Signalfilter Signalverstärker, rechts Signalverstärker, links Regler, Hebelsteuerung Ventil, Hebelsteuerung Zündspule Zündkerze Stromverteiler Signalhorn

Capteur, température huile hydraulique Capteur, position Capteur, arrêt d’entraînement Capteur de pression, arbre du vérin du levage droit Capteur de pression, arbre du vérin du lévage gauche Système de régulation de recharge (EC) Système de régulation moteur d’avancement (EC) Système de régulation moteur de la pompe (EC) Interface deux moteurs de propulsion Interface d’accélérateur Interface de commande de frein Interface de système de commande Capteur, général Unite de control électronique ECU Afficheur Circuit logique, général (option) Réchauffeur de démarrage Rétroviseur à chauffage électrique Siège à chauffage électrique Allume-cigares Chauffage électrique cabine Groupe climatisation Potentiomètre Séchage à l’air, à chauffage électrique Condenseur climatisation Levier de commande Résistance Filtre de signal Amplificateur de signaux, droit Amplificateur de signaux, gauche Commande, leviers Distributeur, leviers Bobine d’allumage Bougie Distributeur Avertisseur sonore

Date: Document No: Issue: Signature: Change No:

1998-03-09 P00022.0100 05 RKO 980576

Anm.

Page 12 of 13

File:

G:\PRODUTV\ECS\PROD\P0002201\P0002201.DOC

Komponentförteckning/List of Components/Komponentenverzeichnis/ Liste de composants Nr/No/

Svenska

English

Deutsch

Francaise

853 900 901 902 903 905 906 910 940 950 955 960

Summer Radio/bandspelare Spänningsomvandlare Högtalare Antenn radio Kommunikationsradio Antenn kommunikationsradio Spänningsomvandlare 80V/24V Logik batterivakt Logik transistortändning Logik övervarvningsskydd (LPG) Logik rev-spärr/aut-vxl

Summer Radio/Kassettengerät Spannungsumwandler Lautsprecher Antenne, Radio CB-Funk Antenne, CB-Funk Spannungsumwandler 80 V/24 V Logik Batteriewächter Logik Transistorzündung logik Überdrehungsschutz (LPG) Logikeinheit Umkehrsperre/automatische Schaltung

961 962

Motor/kupevärmare Logik slitageind kol elmotor

Buzzer Radio/tape recorder Voltage converter Loud speaker Aerial, radio Communication radio Aerial, communication radio Voltage converter 80 V / 24 V Logic switch , battery watch Logic transistor ignition Logic overspeed protection (LPG) Logic unit, reversing interlock/automatic gear changing Engine- and cab heater Logic indication of wear, brush electrical motor

965

Backvarnare

Reversing alarm

Rückfahrwarner

Signal sonore Radio/lecteur Convertisseur de tension Haut-parleur Antenne radio Radiotéléphone Antenne radiotéléphone Convertisseur de tension 80 V/24 V Circuit logique de surveillance batterie Circuit logique allumage transistorisé Circuit logique protection de surrégime (GPL) Unité logique blocage de marche arrière/ changement automatique Chauffeur moteur et habitacle Circuit logique indicateur d’usure des balais, moteur électrique Avertisseur de recul

Date: Document No: Issue: Signature: Change No:

Motor- und Kabinenheizung Logik Verschleißanzeige Kohle, Elektromotor

1998-03-09 P00022.0100 05 RKO 980576

Anm.

Page 13 of 13

File:

G:\PRODUTV\ECS\PROD\P0002201\P0002201.DOC

DC 2,5 - 8

Contents

Technical Handbook

9083 95-12 30 1 Gr. P Publ.

Group 30

Engine Technical specifications _________________________________________ 3 Diesel engine, standard ______________________________________ 3 Diesel engine, option ________________________________________4 LPG engine _______________________________________________ 5 Description __________________________________________________ 7 Diesel engine ______________________________________________7 Cooling system __________________________________________8 Air cleaner _____________________________________________10 Unikat catalytic exhaust gas cleaner _________________________ 10 Fuel system ____________________________________________ 11 Lubrication system ______________________________________ 13 LPG engines Perkins LPG 4.236 and 1006-6 LPG ________________ 15 Cooling and lubrication systems ____________________________ 15 Fuel system ____________________________________________ 15 Service instructions ___________________________________________ 17 Quality of diesel oil _________________________________________ 17 Quality of coolant __________________________________________ 17 Draining water from the fuel tank ______________________________ 17 Inspection of the air cleaner and changing the filter element _________ 17 Changing the lubricating oil filter ______________________________ 18 Checking the V-belt tension __________________________________ 18 Checking the valve clearances ________________________________ 19 Cleaning the feed pump strainer ______________________________ 19 When changing the fuel injectors ______________________________ 19 Changing the fuel filter ______________________________________ 20 Checking the gas supply if an LPG engine fails to start. ____________ 20 Maintenance of the emission control system _____________________ 20

DC 2,5 - 8 Technical Handbook

Technical specifications

Technical specifications Diesel engine, standard 2,5 - 7 ton

7,5 - 8 ton

Manufacturer and type designation

Perkins 1004-4

Perkins 1004-4THR

Rating ISO 3046/2534

57 kW

75 kW

Rated speed

2200 rpm

2200 rpm

Max torque

262 Nm at 1400 rpm 3

368 Nm at 1300 rpm

Numbers of cylinders - Swept volume

4 st - 3990 cm

4 st - 3990 cm3

Compression ratio

16,5:1

16,1:1

Thermostat begins to open at:

77 - 85 °C

77 - 85 °C

Thermostat fully open at:

92 - 98 °C

92 - 98 °C

Engine type

4 - stroke

4 - stroke

Idling speed

600 - 700 rpm

600 - 700 rpm

Direct injection

Direct injection

(should be set so that the engine runs smoothly) Fuel injection Injection angle, opening pressure and injector nozzels

See Perkins Workshop Manual

Cylinder bore

100 mm

100 mm

Piston stroke

127 mm

127 mm

- Intake

0,20 mm (cold engine)

0,20 mm

- Exhaust

0,45 mm (cold engine)

0,45 mm

1-3-4-2

1-3-4-2

Valve clearances

Firing order Stall speed

See group 40, Technical specifications

Lubrication oil filter

Full-flow, disposable paper filter with by-pass valve

Lubricating oil pressure

0,2 - 0,41 MPa

0,2 - 0,41 MPa

Lubricating oil - Grade - Viscocity

API-CD See Group 90, Oil- and lubricant recommendations

9083 95-12 30 3 Gr. P Publ.

DC 2,5 - 8 Technical Handbook

9083 95-12 30 4 Gr. P Publ.

Technical specifications

Diesel engine, option 4 - 7 ton

7,5 - 8 ton

7,5 - 8 ton

Manufacturer and type designation

Deutz BF4M

Deutz BF6M

Perkins 1006-6

Rating ISO 3046/2534

59 kW

85 kW

86 kW

Rated speed

2300 rpm

2200 rpm

2100 rpm

Max torque

300 Nm at 1500 rpm 3

450 Nm at 1500 rpm

407 Nm at 1250 rpm 6 st - 5980 cm3

Numbers of cylinders Swept volume

4 st - 3192 cm

Compression ratio

17,5:1

17,5:1

16,5:1

Thermostat begins to open at:

83 °C

83 °C

77 - 85 °C

Thermostat fully open at:

95 °C

95 °C

92 - 98 °C

Engine type

4 - stroke

4 - stroke

4 - stroke

Idling speed (should be set so that the engine runs smoothly)

600 - 700 rpm

600 - 700 rpm

600 - 700 rpm

Fuel injection

Direct injection

Direct injection

Direct injection

Injection angle, opening pressure and injector nozzels

See Deutz Workshop Manual

See Deutz Workshop Manual

See Perkins Workshop Manual

Cylinder bore

94 mm

94 mm

100 mm

Piston stroke

155 mm

155 mm

127 mm

Valve clearances - Intake (cold engine) - Exhaust (cold engine)

0,3 +0,1 mm 0,5 +0,1 mm

0,3 +0,1 mm 0,5 +0,1 mm

0,20 mm 0,45 mm

Firing order

1-3-4-2

1-5-3-6-2-4

1-5-3-6-2-4

Stall speed Lubrication oil filter Lubricating oil pressure Lubricating oil - Grade - Viscocity

6 st - 4788 cm

3

See group 40, Technical specifications Full-flow, disposable paper filter with by-pass valve 0,08 MPa (varm engine)

0,08 - 0,20 MPa (varm engine)

0,20 - 0,41 MPa

API-CD See Group 90, Oil- and lubricant recommendations

DC 2,5 - 8 Technical Handbook

9083 95-12 30 5 Gr. P Publ.

Technical specifications

LPG engine 2,5 - 7 ton

7,5 - 8 ton

Manufacturer and type designation

Perkins 4.236

Perkins 1006-6

Rating ISO 3046/2534

57 kW

92,5 kW

Rated speed

2600 rpm

2600 rpm

Max torque

262 Nm at 1400 rpm 3

397 Nm at 1500 rpm 6 st - 5980 cm3

Number of cylindrar - Swept volume

4 st - 236 in

Compression ratio

7,0:1

7,5:1

LPG system - Spark plug electrode gap - Distributor contact gap - Ignition point, when the engine is stationary at 2000 rpm

IMPCO 0,5 mm Breakerless 10° before TDC 30° before TDC

IMPCO 0,7 mm Breakerless 20° before TDC

Thermostat begins to open:

77 - 85 °C

77 - 85 °C

Thermostat fully open at:

92 - 98 °C

92 - 98 °C

Engine type

4 - stroke

4 - stroke

Idling speed (should be set so that the engine runs smoothly)

600 - 700 rpm

600 - 700 rpm

Injection angle, opening pressure and injector nozzels

See Perkins Workshop Manual

Cylinderbore

98,43 mm

100 mm

Piston stroke

127 mm

127 mm

Valve clearances - Intake (cold engine) - Exhaust (cold engine) Firing order

0,30 mm 0,38 mm 1-3-4-2

0,30 mm 0,38 mm 1-4-2-6-3-5

Stall speed

See Group 40 Technical specifications

Lubrication oil filter

Full-flow, disposable paper filter with by-pass valve

Lubricating oil pressure

0,2 - 0,41 MPa

Lubricating oil - Grade - Viscocity

API-CD See Group 90, oil- and lubricant recommendations

LPG, tank - Type - Weight of empty tank - Weight of LPG

0,2 - 0,41 MPa

T16,5 25,5 kg max 16,5 kg

DC 2,5 - 8 Technical Handbook

Description

9083 95-12 30 7 Gr. P Publ.

Description Diesel engine The engine is a Perkins 1000 diesel engine. The engines are four-stroke, directinjection, four/six cylinder diesel engine.

The engine in Perkins 1000 - serie provide lower fuel consumption, more effective combustion and cleaner exhaust emissions than their predecessors.

The four-cylinder 1004 - 4 engine is supplied as standard for 2,5 - 7 tonnes trucks, while the four-cylinder 1004 - 4THR engine is installed as standard in 7,5 - 8 tonnes trucks.

All 2,5 - 8 tonnes trucks are available with LP - Gas engines.

1004-4

1006-6 K356

DC 2,5 - 8 Technical Handbook

Description

9083 95-12 30 8 Gr. P Publ.

Cooling system The radiator is comprised of two systems of cooling cells operating in parallel. One system cools the engine coolant (water) while the other cools the gearbox oil.

Engine coolant is circulated by a pump fitted at the front of the engine, towards the radiator. The radiator also operates as an expansion vessel which is equipped with a sensor to activate a warning lamp on the instrument panel in the event of low coolant level.

The cooling system is pressurized, which increases the boiling point of the coolant.

The filler cap on the radiator should therefore be opened with caution when the engine is warm.

The pump bearings are permanently lubricated and require no maintenance.

K357

Cooling system, Perkins

DC 2,5 - 8

9083 95-12 30 9 Gr. P Publ.

Description

Technical Handbook

1.

Coolant filling

5.

Cylinder cooling

2.

Thermostat housing

6.

Cylinder head cooling

3.

Coolant pump

7.

4.

Oil cooler

Heat exchanger with return lead to thermostat housing

Coolant chart, Deutz

K1367

Cold-starting device The engine is equipped with an electric heater element which is switched on by means of the starting key. The element should be switched on for at least 20 seconds at ambient temperatures below +5˙C.

!

CAUTION Never use ether when using the cold starting device, since an explosion may otherwise occur. Ether should on no condition be used, it can otherwise cause damage to pistons, piston rings, etc.

DC 2,5 - 8 Technical Handbook

Description

9083 95-12 30 10 Gr. P Publ.

Air cleaner The engine is equipped with Donaldsson air cleaner or as specified by the customer.

K358

Unikat catalytic exhaust gas cleaner The truck can be equipped with an exhaust gas cleaner.

The exhaust gas cleaner is designed to remove unburned fuel, carbon monoxide and other combustible substances from the exhaust gases. The substances are burned catalytically as the hot exhaust gases flow through a bed of platinum-coated metalic catalyst. The temperature necessary for starting and maintaining the catalytic process is provided by the exhaust gases, without loss of engine power.

K359

DC 2,5 - 8 Technical Handbook

9083 95-12 30 11 Gr. P Publ.

Description Fuel system

The fuel system consists of the fuel tank with its fuel gauge, water collector, feed pump with pre-filter, fine filter and injection pump with cold-starting device.

When the engine is started, the feed pump draws fuel from the tank through the pre-filter and then delivers it through the fine filter to the injection pump. The injection pump then delivers the fuel at high pressure to the injectors. Any excess fuel supplied by the feed pump will also flow through the fine filter but will then be returned to the fuel tank through the return line (see diagram below).

K360

Fuel tank and pipes Perkins 1004-4

Return

1. Fuel tank 2. Feed pump 3. Fuel filter 4. Injection pump K361

5. Injector 6. Intake air 7. Heater 8. Water collector Fuel system, Perkins 1004-4

DC 2,5 - 8 Technical Handbook

K1366

Description

9083 95-12 30 12 Gr. P Publ.

1.

Fuel tank

8.

Lead to injection valve

2.

Lead to fuel pump

9.

Injection valve

3.

Fuel pump

10.

Fuel leakage lead

4.

Lead to fuel filter

11.

5.

Fuel filter

Banjo screw and pressure maintenance valve

6.

Lead to injection pump

12.

Return lead to fuel tank

7.

Injection pump

13.

Maintain greatest possible distance

Fuel system, Deutz

DC 2,5 - 8

9083 95-12 30 13 Gr. P Publ.

Description

Technical Handbook

Lubrication system The engine lubrication system consists of an oil sump, oil pump, oil cleaner, reducing valve and the oilways connecting the main oilway with the various lubrication points.

The pistons, cylinder liners and gudgeon pin bearings are oilsplash and oil-mist lubricated, as are the cams and rockers.

The reducing valve reduces the oil pressure in the system to between 0.2 and 0.41 MPa (2.0 and 4.2 kgf/cm2) at normal engine speed and normal operating temperature.

The diagram below shows the lubrication principles, the locations of the lubrication points and the runs of the oilways.

K362

Rocker assembly Drain

Drain

Tappets

1. Camshaft bearings

1. Bore Timing gears

Small end

Tappets

2. Camshaft bearings

Splash 2. Bore

3. Bore

Small end

3. Camshaft bearings

4. Bore

Small end

Splash

Splash

Splash

Splash

1. Big end

2. Big end

3. Big end

4. Big end

1. Main bearing

2. Main bearing

3. Main bearing

Idler gear

Fuel pump gear hub

Small end

Splash

4. Main bearing

5. Main bearing

Oil pressure gauge

Main oil gallery Lub. oil pump

Relief valve

Lub. oil filter

Sump strainer

K363

Lubrication system, Perkins 1004-4

DC 2,5 - 8 Technical Handbook

K1365

9083 95-12 30 14 Gr. P Publ.

Description

1.

Oil sump

14.

Rocker arm

2.

Suction lead

15.

Return lad to oil sump

3.

Oil pump

16.

Pressure gauge sensor

3a.

Control valve

17.

3b.

Pressure relief valve

Oil lead to exhaust-powered turbocharger

4.

Oil cooler

18.

Exhaust-powered turbocharger

5.

Oil filter

19.

6.

Main oil pipe

Oil lead to compressor or hydraulic pump

7.

Main bearing

20.

Compressor

8.

Crankshaft bearing

21.

Hydraulic pump

9.

Camshaft bearing

22.

Return lead from compressor or hydraulic pump

10.

Lead to nozzle

23.

Lead to balance shafts (2 off)

11.

Piston cooling nozzle

24.

Balance shafts

12.

Rocker, with impulse lubrication of rocker arms

25.

Return lead from turbocharger to crankcase

13.

Push-rod, oil duct for lubrication of rocker arms Lubrication system, Deutz

DC 2,5 - 8 Technical Handbook

Description

9083 95-12 30 15 Gr. P Publ.

LPG engines Perkins LPG 4.236 and 1006-6 LPG LPG trucks are powered by the well-proven Perkins petrol engine, converted for running on LPG. The engine is equipped with an evaporator, valves, adjusting devices, etc. in the fuel system.

The crankcase and cylinder block are integrated into one casting and the cylinder liners are of dry type. The pistons are of light alloy.

The connecting rods, crankshaft and camshaft are drop forged, and hardened and tempered for high strength. The crankshaft and camshaft are both journalled in five bearings.

The forced lubrication system of the engine is equipped with a full-flow filter.

Cooling and lubrication systems The cooling and lubrication systems are exactly the same as those of the diesel engine.

Fuel system The main components of the fuel system are the LPG tank with shut-off valve and level gauge, and filter, evaporator, solenoid valve and gas mixer.

As soon as the starting key is turned, a vacuum valve will open and the LPG will flow from the tank to the evaporator. When the engine has started, LPG in gas form will flow from the evaporator to the intake system of the engine. The engine is equipped with an electric choke throttle.

The flow of gas to the engine cylinders is controlled by means of the accelerator pedal. The idling flow and the air/gas mixture are preset on delivery by means of adjusting screws on the evaporator, and this adjustment is of decisive importance to the non-polluting characteristics of the LPG engine.

The evaporator is equipped with two adjusting screws which are preset by Kalmar LMV. The screws should be adjusted only by personnel who have access to correct measuring instruments. Incorrect adjustment may also cause excessively high CO content.

CAUTION The engine must not be run so that it will stop when the main valve is closed.

During cold weather, the fuel lines may then freeze when the main valve is opened and LPG flows to the evaporator.

DC 2,5 - 8 Technical Handbook

9083 95-12 30 16 Gr. P Publ.

Description 1

Vacuum

2 3

4

5

1.

Damper housing

2.

Air-gas mixer

3.

Revs regulator

4.

Liquefied petroleum gas tank

5.

Safety valve

6.

Valve with filter

7.

Evaporator

6

K364

7

IMPCO fuel system, LPG engine

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 30 17 Gr. P Publ.

Service instructions Quality of diesel oil If light diesel oil is used to achieve environmental benefits, the engine manufacturer’s recommendations must be followed, e.g. concerning lubricant additive.

If this is not observed, the injection pump may be damaged.

It should also be noted that light diesel oil contains a certain proportion of paraffin (kerosene) and causes a reduction in the engine output.

Quality of coolant It is recommended that the coolant used in the summer as well as in the winter should consist of a mixture of 60% of water and 40% of glycol.

It is recommended that the coolant should be changed once a year.

Unless a special anti-freeze is used in the cooling system, an anti-corrosion additive should always be mixed into the coolant.

Draining water from the fuel tank Drain any water from the fuel tank by backing off the plug on the underside of the tank.

Retighten the plug as soon as the fuel flowing out is free from water and other impurities.

Inspection of the air cleaner and changing the filter element 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 cumbustion 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.

Main filter element Safety filter element Dust receiver

2.

Clean the outside of the air cleaner.

3.

Remove and clean the dust receiver.

4.

Release and carefully remove the main filter element. Do not remove the safety filter element.

5.

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.

6.

Change the safety filter element: – after the main filter element has been changed five times – at least every other year – if the engine has been run with the main element damaged.

K365

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.

DC 2,5 - 8

Service instructions

Technical Handbook

9083 95-12 30 18 Gr. P Publ.

Changing the lubricating oil filter 1.

Place a tray under the filter to avoid oil spillage.

2.

Remove the filter canister and discard it. The filter is of disposable type. Use filter tongs. Check that the adapter is firmly positioned in the filter head.

3.

Clean the filter connection.

4.

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

5.

Lubricate the canister seal with clean oil.

6.

Fit the new filter and tighten it – by hand only. Do not use filter tongs.

7.

If the engine oil has been changed, run the engine and check that there is no leakage at the filter.

Adapter

NOTE The canister incorporated a valve to ensure that no oil will run out of the canister. Always use a genuine Kalmar LMV filter.

K368

6 - cyl

NOTE: Use only a genuine Kalmar LMV filter element, to prevent the risk of serious damage to the engine.

Checking the V-belt tension

K366

1.

Press down the belt between the alternator and the crankshaft with your thumb.

2.

The deflection of the belt should be approx. 10 mm. Adjust the tension, if necessary, by adjusting the position of the alternator.

DC 2,5 - 8 Technical Handbook

9083 95-12 30 19 Gr. P Publ.

Service instructions

Checking the valve clearances The valve clearances should be in accordance with the values in the Technical specifications and in the table below.

Note: No. 1 cylinder is at the front of the engine, nearest to the Vbelt drive.

1.

Turn the crankshaft in its normal direction of rotation until the inlet valve of No. 4 cylinder (four-cylinder engine) or No. 6 cylinder (six-cylinder engine) has just opened and the exhaust valve of the same cylinder has not yet closed fully.

Check the valve clearences at No. 1 cylinder and adjust as necessary.

Four-cylinder engine cold

K082

Six-cylinder Four-cylinder Six-cylinder engine LPG engine LPG engine cold or hot cold cold

Inlet

0,20

0,20

0,30

0,30

Exhaust

0,45

0,45

0,38

0,38

2.

Check the other valves in accordance with the table.

Four-cylinder engine

Six-cylinder engine

1 3 4 2

1 5 3 6 2 4

... when the inlet and 4 2 1 3 exhaust valves of these cylinders are moving simultaneuosly

6 2 4 1 5 3

Check the valve clearance at the cylinder...

Cover Gasket Strainer

Cleaning the feed pump strainer

K367

1.

Remove the cover and gasket.

2.

Carefully lift out the strainer and wash the strainer and cover with paraffin (kerosene).

3.

Check that the strainer and gasket are in good condition.

4.

Refit the strainer, gasket and cover.

5.

Using the handle, check that the pump operates satisfactorily.

NOTE Depending on the position in which the crankshaft has stopped, the pump will draw fuel during different parts of the stroke. If the pump draws unsatisfactorily, turn the crankshaft and try pumping again. Resistance is felt in the handle when the pump is drawing fuel.

When changing the fuel injectors Note the marking of the injector. For further particulars, see the Perkins Workshop Manual.

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 30 20 Gr. P Publ.

Changing the fuel filter

Retaining bolt Four-cylinder engine - single filter Six-cylinder engine - duplex filter K369

1.

Clean the outside of the filter.

2.

Remove the retaining bolt, at the same time your holding the filter from below.

3.

Remove and discard the filter element.

4.

Clean the filter head and bottom strainer, using diesel oil.

5.

Fit new seals, if necessary.

6.

Fit the bowl, with the filter element, to the filter head and ensure that the element seals against the seal.

7.

Tighten the retaining bolt.

8.

Release the air bleed screw and pump by means of the hand pump until fuel which is free from air bubbles flows through the air bleed screw. Tighten the air bleed screw.

Checking the gas supply if an LPG engine fails to start.

1.

Check operation of the gas supply system as follow: – Disconnect the gas hose of the mixer.

– Choke, and run the starter motor.

2.

The evaporator should then blow an abundant amount of gas.

!

CAUTION Warning for naked flame. Serious risk of explosion.

Maintenance of the emission control system The catalytic converter can be easily cleaned and remounted in the event of excessive soot.

DC 2,5 - 8

Contents

Technical Handbook

9083 95-12 40 1 Gr. P Publ.

Group 40

Transmission, drive axle, brakes Technical specifications _________________________________________ 3 Description __________________________________________________ 5 Torque converter ___________________________________________ 5 Gearbox __________________________________________________ 7 Oil circuit _________________________________________________9 Voith automatic transmission _________________________________13 Drive axle ________________________________________________14 Drive axle with separate parking brake _______________________ 14 Drive axle with integrated parking brake ______________________ 15 Foot brake _______________________________________________ 16 Drive axle with separate parking brake _______________________ 16 Drive axle with integrated parking brake ______________________ 17 Parking brake _____________________________________________18 Separate parking brake ___________________________________ 18 Integrated parking brake __________________________________ 19 Electronic reversing interlock _________________________________20 Service instructions ___________________________________________ 21 Checking the gearbox oil level ________________________________ 21 Borg Warner, Clark ______________________________________ 21 Voith, Graziano Voith _____________________________________ 21 Oil change and filter replacement – gearbox _____________________ 21 Borg Warner ___________________________________________ 21 Clark _________________________________________________ 22 Voith _________________________________________________ 22 Graziano Voith __________________________________________ 23 Checking the pressure - gearbox ______________________________ 24 Borg Warner ___________________________________________ 24 Clark HR 18000 ________________________________________ 25 Voith _________________________________________________ 26 Electrical connections - gearbox ______________________________ 28 Borg Warner ___________________________________________ 28 Clark _________________________________________________ 28 Voith _________________________________________________ 29 Changing the air filter - Voith automatic transmission ______________ 29 Changing the oil – drive axle, hub reductions ____________________ 30 Separate parking brake _____________________________________ 30 Replacing the parking brake pads. __________________________ 30 Mechanical disengagement of the parking brake, older models ____ 30 Parking brake integrated with drive axle ________________________ 31 Mechanical disengagement of the parking brake, later models ____ 31 Testing of electronic reversing interlock _________________________ 31 Dismantling/Reassembly of BL55 and BL75 _____________________ 32 Dismantling/Reassembly of BL40 _____________________________ 34 Dismantling/Reassembly of BL80 _____________________________ 36 Dismantling/Reassembly of BL100 ____________________________ 38

DC 2,5 - 8

9083 95-12 40 3 Gr. P Publ.

Technical specifications

Technical Handbook

Technical specifications Gearbox, standard

2,5 - 3,5 LB

Manufacturer,

Graziano Voith

Voith

Borg Warner

Clark

type designation

PST1

C 845

PR2

12,6 HR 18213-1

Number of gears

1F - 1R

2F - 2R

2F - 2R

2F - 2R

Torque converter, type

Free weeling stator

Fixed stator with converter lock-up

Free weeling stator

Fixed stator

approx. 10 approx. 9

approx. 10 approx. 9

approx. 9,5 approx. 7,5

approx. 10,5 approx. 8,5

82-93

82-93

82-93

82-93

Max permissible temp at outlet to oil cooler °C

120

120

120

120

Pressure

See Service instructions

Lubricating oil

See Group 90, Oil and lubricant recommendations

Oil volume on filling when new changing the oil and filter Operating temperature, torque converter

Stall speed

l l °C

rpm

1725±50

4 - 5,5 t

6-8t

1640 ± 50

1700±50

Drive axle with separate parking brake

2,5 - 5,5 t

6-8t

Manufacturer, type designation

Kalmar LMV, BL 55

Kalmar LMV, BL 75

Foot brake system

Hydraulic, wet disc brakes

Parking brake system

Hydraulic with disc brake on the drive axle input shaft.

Grade of oil Viscosity

API GL-5 See Group 90, Oil- and lubricant recommendations.

Oil capacity, (hub reduction incl.) l

5,5

Torques, Nm Mounting to the chassis Wheel nuts Hub reduction, bearing nut

1950 ± 50

9,0

See Group 00, Tightening torques See Group 00, Tightening torques Tighten the nut until the hub begins to bind. Then back off the nut until it runs freely, but without play.

DC 2,5 - 8

9083 95-12 40 4 Gr. P Publ.

Technical specifications

Technical Handbook Drive axle with integrated parking brake

2,5 - 3,5 LB

4-8t

4 - 8 t (truck with 6-cylinder engine)

Manufacturer, type designation

Kalmar LMV, BL 40

Kalmar LMV, BL 80

Kalmar LMV, BL 100

Foot brake system

Hydraulic, wet disc brakes

Parking brake system

Hydraulic with disc brake on the drive axle input shaft.

Grade of oil Viscosity

API GL-5 See Group 90, Oil- and lubricant recommendations.

Oil capacity, (hub reduction incl.) l

6,2

Torques, Nm Mounting to the chassis Wheel nuts Hub reduction, bearing nut

Tightening torque Bolt joint between drive axle and chassis

650 Nm

Wheel nuts

2.5 - 5.5 t

490 Nm

6-8t

590 Nm

8,6

13,5

See Group 00, Tightening torques See Group 00, Tightening torques Tighten the nut until the hub begins to bind. Then back off the nut until it runs freely, but without play.

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 40 5 Gr. P Publ.

Description The transmission consists of a torque converter integrated with the gearbox, and a propeller shaft and drive axle with differential, hub reductions and wet disc brake..

K370

Torque converter Stator

Pump impeller Torque converter

Turbine wheel

The hydraulic torque converter can be regarded as a hydraulic coupling located between the output shaft of the engine and the input shaft of the gearbox. The output torque of the torque converter increases as the speed of the truck decreases.

The most important components of the torque converter are the pump impeller, turbine wheel and stator. When the truck pulls away from rest – when load is applied – the flow of oil from the pump impeller will drive the turbine wheel and thus the gearwheels of the gearbox.

Borg Warner PR2 and Graziano Voith PST1 are equipped with a free-wheel stator whereas the Clark and Voith C 845 have a fixed stator. Moreover, the Voith C845 has converter lock-up, i.e. the pump impeller and stator are locked at a certain speed. The torque converter then acts as a solid coupling between the engine and gearbox.

To be able to operate, the torque converter must be supplied with oil under pressure, and this is obtained from a hydraulic pump built into the torque converter. This pump also supplies oil to the gearbox.

K371

Gearbox Borg Warner PR2 with torque converter

Since the power losses in the torque converter cause appreciable heating of the circulating oil, an oil cooler is provided to dissipate this heat. This cooler is connected in series with the normal cooling system of the engine.

DC 2,5 - 8 Technical Handbook

9083 95-12 40 6 Gr. P Publ.

Description

1. Elastic coupling 2. Gear wheel at input shaft 3. Gear whell at pumpshaft 4. Direct connection 5. Turbine wheel 6. Clutch FORWARD 7/8. Gear wheel FORWARD 9. Clutch REVERSE 10/11/12. Gear wheel REVERSE 13. Output shaft 14. Power take-off P. Pump impeller T. Turbine wheel L. Stator K372

Voith C845 automatic transmission

DC 2,5 - 8 Technical Handbook

Description

9083 95-12 40 7 Gr. P Publ.

Gearbox Gear-changing is elctrical and is carried out by means of solenoid valves.

The gearbox is of the constant-mesh type. Gear-changing is carried out by the clutch plates being hydraulically actuated for the required ratio or for forward/reverse.

The gearbox is as standard provided with elecrical inching facilities, actuated by the brake pedal. This facility is used, for instance, for lifting.

A manually operated friction clutch (soft inching) is available as an optional extra feature, whereby an extra brake pedal is fitted in the cab. The pedal on the right operates as a normal brake while the one on the left provides an inching function at the beginning when pressed. After 15° of its movement down the pedal is interconnected mechanically with the one on the right to operate the brake.

K373

Borg Warner PR2 valve assembly

Graziano Voith PST1 BL40 BL80 BL100

Voith C845

BL55 Clark HR 18000

BL75

K1382

Borg Warner PR2

DC 2,5 - 8

9083 95-12 40 8 Gr. P Publ.

Description

Technical Handbook

1.st gear Input

Output 2.nd gear

Clark HR 18000 gearbox

K375

T

P

B

S FS

Pump P

Pump impeller F

Forward gear

T

Turbine wheel

Reverse gear

S

Stator

FS Free wheel K1356

B

F Graziano Voith PST1 gearbox

DC 2,5 - 8

9083 95-12 40 9 Gr. P Publ.

Description

Technical Handbook

Oil circuit The function of the oil is: •

to transmit the engine output to the gearbox. The torque converter can multiply the engine torque by up to three times. But this is at the expense of the engine speed

•

to apply the clutches in the gearbox. All gearwheels are always in engagement with one another

•

to dissipate the heat from the torque converter

•

to lubricate the gearbox and torque converter

•

to transport any solid particles to the filter.

Temperature transmitter

Oil cooler

Lubricating oilway Disengagement plunger Forward/Reverse change over-valve 1st/2nd change-over valve

Safety valve Torque converter 1st Pump

2nd

Level plugs

Suction strainer

K376

Filter Clutch pressure control valve

Oil sump

Diagrammatic arrangement of oil circuit, Clark gearbox

DC 2,5 - 8 Technical Handbook

9083 95-12 40 10 Gr. P Publ.

Description

Forward

Reverse Gearbox valve housing

1st speed forward engaged

FWD

REV

2nd

1st 1st

2nd Reverse

2nd speed reverse engaged

Forward

FWD

REV

2nd

1st 1st

K377

2nd

Diagrammatic arrangement of oil flow in the Clark HR 18000 gearbox

Open

Gearbox filter

Lube priority valves

Pump

Converter valve

Cooler by-pass valve

High

Reverse

Low

High

Forward

Clutch/acc. pressure Pump pressure Reverse High Lube CCT Converter charge

Inching spool in high position

Inching and accumulator control

High- and low spool in high position

Forward- and reverse spool in Forward position

Accumulator in Forward position

High- and low valve

Low

Selector valve

Regulator and accumulator

Technical Handbook

Closed

To converter

From converter

K378

Cooler

Forward and high solenoids energised and dumping oil

DC 2,5 - 8

Description 9083 95-12 40 11 Gr. P Publ.

Diagrammatic arrangement of oil flow in the Borg Warner PR2 gearbox with electric gear changing

DC 2,5 - 8

9083 95-12 40 12 Gr. P Publ.

Description

Technical Handbook

4,5 bar

Pressure drop max. 1.5 bar

13

2,5 bar

12

9

8 7 10 11 6

9 bar

4

3 5 2 1

K1358

1.

Suction filter

8.

Cooler

2.

Pump

9.

Pressure limiting valve

3.

Oil filter with bypass

10.

Inching valve

4.

Pressure limiting valve

11.

Direction selector

5.

Regulating valve

12.

Shock valve

6.

Throttle valve

13.

Lubrication relief valve

7.

Torque converter

Diagrammatic arrangement of oil flow in the Graziano Voith PST1 gearbox

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 40 13 Gr. P Publ.

Voith automatic transmission The Voith-Certomatic C845 is a fully automatic, two-speed transmission.

The engine power is transmitted through the torque converter in 1st gear and purely mechanically in 2nd gear, when the converter impeller and turbine are locked to provide direct drive (known as converter lock-up).

The torque converter delivers a high starting torque and has a high efficiency throughout the speed range. Above around 60% of maximum speed, power is transmitted mechanically. This ensures high efficiency at high speeds.

The transition from hydrodynamic to mechanical power transmission takes place fully automatically and smoothly.

1.

2.

3.

4.

5.

6.

7.

K379

Input shaft Output shaft Electric cables Connection for hydraulic inching Pump connection Oil filler pipe and dipstick Fine filter connection Voith C 845 automatic transmission

DC 2,5 - 8 Technical Handbook

Description

Drive axle Reduction in the drive axle takes place in two stages, i.e. in the differential and in the hub reductions.

This arrangement minimises the stresses in the power transmission, since step-up to the final torque only occurs at the driven wheels.

Due to the close tolerances maintained in production, the sound level is very low.

Drive axle with separate parking brake

K380

9083 95-12 40 14 Gr. P Publ.

DC 2,5 - 8 Technical Handbook

Description

9083 95-12 40 15 Gr. P Publ.

Drive axle with integrated parking brake

Integrated parking brake

K1353

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 40 16 Gr. P Publ.

Foot brake The trucks are fitted with wet disc brakes that are maintenance free and with stand severe loading over long periodes.

The brakes reqires no adjustments, there is no wear of brake components and no fading The truck is braked by hydraulically applied wet disc brakes in each hub. With help of hydraulic pressure the oilcooled discs are pressed together and give an effective braking action.

The brake system is entirely enclosed and no water or impurities are allowed to penetrate in. The heat that is generated is led away by the discs working in a hydraulic oil bath, connected to a special cooling circuit.

Drive axle with separate parking brake 2

3

4

1

5

6

7

1. To vehicle hydraulic system 2. Hydraulic piston 3. Disc arrangement 4. Hub to spindle seal 5. Cooling oil from vehicle hydraulic system 6. Cooling oil cavity K093

7. Lubricating oil cavity

Foot brake

DC 2,5 - 8 Technical Handbook

9083 95-12 40 17 Gr. P Publ.

Description

Drive axle with integrated parking brake

3

2

1 7

6 4

5

1. To vehicle hydraulic system 2. Hydraulic piston 3. Disc arrangement 4. Hub to spindle seal 5. Cooling oil from vehicle hydraulic system 6. Cooling oil cavity 7. Lubricating oil cavity

K1359

Foot brake

DC 2,5 - 8

9083 95-12 40 18 Gr. P Publ.

Description

Technical Handbook

Parking brake Separate parking brake The parking brake is actuated by means of a manual hydraulic valve. When the valve is open to the tank, the parking brake is applied by a heavy spring in the parking brake cylinder. To release the parking brake, the supply line from the accumulator to the brake cylinder is opened by means of the parking brake valve. The hydraulic oil pressure then overcomes the spring force and the brake is released.

1 3 2

4 5

K381

1.

Brake cylinder

2.

Brake lining

3.

Brake arm

4.

Mounting bracket

5.

Rubber damper

Separate parking brake

DC 2,5 - 8

9083 95-12 40 19 Gr. P Publ.

Description

Technical Handbook

Integrated parking brake The parking brake that is integrated with the drive axle is controlled via a manual hydraulic valve. When the valve is open to the reservoir the brake is applied by a powerful spring in the parking brake cylinder. The pressure lead from the accumulator to the hydraulic piston is opened via the parking brake valve causing the spring to be counteracted, thus releasing the brake.

1

1.

Differential housing

2.

Spring

3.

Brake discs

2

3

K1359

K1384

Integrated parking brake

DC 2,5 - 8

9083 95-12 40 20 Gr. P Publ.

Description

Technical Handbook

Electronic reversing interlock The reversing interlock prevents changing between forward and reverse unless the truck is stationary or almost stationary.

The reversing interlock consists of an inductive sensor and associated electronics.

The parking brake disc is fitted with a screw. When the disc rotates, the screw gives rise to a signal every time it passes the sensor.

The gearbox valves will be blocked via the electronics and the FORWARD and REVERSE relays, and changing between forward and reverse is impossible. When the speed is sufficiently low, the relevant relay will be energised and gear-changing will again be possible.

The gap between the sensor and the screw must be 2–5 mm.

Battery bracket

2-5 mm Inductive sensor Screw Relay

Brake disc Driven axle input shaft

K382

102 57 Valve FORWARD 227 + 225

56

FORWARD relay 86 85

Forward/reverse selector

R F

36

+24V

-

+ 226

Valve REVERSE

K394

85 1

REVERSE relay

2251

86

2261

-24V

2 3 4 5 6 7 Reversing interlock

8

+

355

Sensor

DC 2,5 - 8

9083 95-12 40 21 Gr. P Publ.

Service instructions

Technical Handbook

Service instructions N.B. When changing a Borg Warner gearbox the torque converter must also always be changed. Please note that the torque converter is supplied separately.

Checking the gearbox oil level Borg Warner, Clark •

Use the dipstick to check the oil level – the oil at normal working temperature – the engine at a speed of 500–600 rpm (Clark)

Voith, Graziano Voith •

The filler pipe includes a dipstick.

•

Always check the oil level with the transmission at normal operating temperature, with the engine running at idling speed and forward or reverse gear engaged (the torque converter filled with oil). The level should be between the MIN and MAX marks on the dipstick. If the oil level is too low, the transmission may overheat or the gear-changing performance may be incorrect.

Oil change and filter replacement – gearbox Borg Warner This should be carried out when the oil is hot.

1.

Remove the gearbox drain plug, drain the oil and clean the suction strainer.

2.

Remove the oil filter.

3.

Fit a new filter.

4.

Fit and tighten the drain plug.

5.

Fill with oil to the MIN. mark on the dipstick.

6.

Start the engine and let it idle until the oil has reached working temperature.

7.

Top-up with additional oil to the MAX. mark. Check the level when the engine is stationary, immediately after it has been stopped.

Filter

Drain plug and suction strainer Dipstick K383

Borg Warner PR 2 gearbox

DC 2,5 - 8

Service instructions

Technical Handbook

9083 95-12 40 22 Gr. P Publ.

Clark This should be carried out when the oil is hot.

1.

Remove the gearbox drain plugs and drain the oil.

2.

Remove the gearbox suction strainer, withdraw the strainer and clean it.

Note If the strainer is covered with metallic particles, the reason must be determined before the gearbox is filled with new oil.

Dipstick

Filter

Drain plug

3.

Replace the suction strainer seal, fit the strainer and check that there is no leakage round the seal.

4.

Remove the oil filter.

5.

Fit the new filter.

6.

Fit and tighten the drain plugs.

7.

Fill with oil to the MIN. mark on the dipstick.

8.

Start the engine and let it run at 500–600 rpm until the oil has reached the operating temperature.

9.

Top-up with additional oil to the MAX. mark on the dipstick, allowing the engine to idle during this procedure.

N.B. In the event of gearbox damage, always replace the oil cooler – the cause of the damage may be a faulty oil cooler.

K384

Voith Dipstick

1.

Run the transmission so that it is at normal operating temperature before changing the oil.

2.

Set the forward/reverse selector to the neutral position and stop the engine.

3.

Remove the drain plug (8) and drain the oil.

4.

Check that the O-ring on top of the strainer (drain plug) is in good condition.

5.

Screw out the fine filter, clean it carefully and blow it dry with compressed air. Fit a new sealing ring.

6.

Fill the transmission with 8 l of ATF. N.B. Never use engine oil.

Note Motoroil may not be used Drain plug

Filter K1449

7.

Raise the driven wheels, start the engine and engage a gear.

8.

Check the oil level on the dipstick. Top up with oil until the level is between the MIN and MAX marks on the dipstick.

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 40 23 Gr. P Publ.

Graziano Voith

Filter

1.

Run the transmission so that it is at normal operating temperature before changing the oil.

2.

Set the forward/reverse selector to the neutral position and stop the engine.

3.

Remove the drain plug (8) and drain the oil.

4.

Check that the O-ring on top of the strainer (drain plug) is in good condition.

5.

Screw out the fine filter, clean it carefully and blow it dry with compressed air. Fit a new sealing ring.

6.

Fill the transmission with 8 l of ATF. N.B. Never use engine oil.

Note Motoroil may not be used

Dipstick

K385

Drain plug

7.

Raise the driven wheels, start the engine and engage a gear.

8.

Check the oil level on the dipstick. Top up with oil until the level is between the MIN and MAX marks on the dipstick.

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 40 24 Gr. P Publ.

Checking the pressure - gearbox Borg Warner Pressure Borg Warner PR2 electric gear changing Speed

1300 rpm

Inlet cooler, MPa

0.7 – 5.6 Converter pressure 3.4 - 8.4 bar

Main pressure 6.3 - 10.5 bar

Reverse low

Drain plug

Reverse high Clutch pressure 4.5 - 5.6 bar

Forward low Forward high

High and low valves on the valve body

When fitting the valve housing it is important that the bolts are tightened in a particular sequence, see illustration.

Tightening torque 2.3 - 3.0 kpm

K386

Checking the pressure in a Borg Warner PR2 gearbox

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 40 25 Gr. P Publ.

Clark HR 18000

Measurement tapping for the supply pressure to the torque converter.

The pressure should be at least 1.76 bar at 2000 rpm and not more than 4.92 at maximum engine speed in neutral gear.

Control valve clutch pressure.

Measurement tapping for the oil temperature from the torque converter.

This shows red at a temperature of 121 °C. Converter outlet to the oil cooler.

Oil inlet from the oil cooler Oil drain plug.

Measurement tapping for all clutch pressures. This should be 12.7 - 15.4 bar with the parking brake applied, the oil at a temperature of 82 - 93 °C and the engine idling. If the pressures varies by more than 0.4 bar between the various gears, this is an indication of leakage and it must be remedied.

Forward clutch

2:nd gear

1:st gear

Reverse clutch

Suction strainer Measurement tapping for the lubrication oil pressure. The pressure here should be between 1.1 bar and 1.7 bar at 2000 rpm at an oiltemperature of 82 - 93 °C. Torque converter outlet to the oil cooler.

K387

Checking the pressure in a Clark HR 18000 gearbox

DC 2,5 - 8 Technical Handbook

9083 95-12 40 26 Gr. P Publ.

Service instructions

Voith Check the pressure at an engine speed of 1500 rpm and an oil temperature of 80°C.

Pressure Voith C 845 automatic transmission Speed 1500 r/m Main pressure, bar Neutral First gear Second gear Torque converter, First gear bar Converter lock-up Forward gearl, bar First/second Reverse gear, bar First/second

2 ± 0,5 14 ± 1 8,7 ± 0,5 3,7 ± 0,2 3,8 ± 0,2 14 ± 1 / 8,7 ± 0,5 14 ± 1 / 8,7 ± 0,5

Adjusting screw, traction/engine brake May be adjusted only by a trained mechanic

1. System pressure Neutral First Second

2. Torque converter First 3. Converter lock-up pressure in 2nd gear 4. Forward gear, First/Second

5. Reverse gear First/Second 6. Adjusting screw, speed for changing between Ist and 2 nd. The basic setting between the screw head and the locknut is 4.4 mm. A screw displacement of 1 mm gives approx.

100 r/min. May be adjusted only by a trained mechanic.

DC 2,5 - 8

9083 95-12 40 27 Gr. P Publ.

Service instructions

Technical Handbook

Graziano Voith Check the pressure at an engine speed of 2000 rpm and an oil temperature of 80°C. Pressure Graziano Voith PST1 Main pressure Pressure torque converter

in out

Lubricating pressure

min 8,5 bar

max 9,5 bar

min 4,0 bar min 2,0 bar

max 5,0 bar max 3,0 bar

0,8-1,0 bar

4

5

3

6

2

1

K1357

1.

Main pressure

2.

Pressure, torque converter

3.

Pressure, inching

4.

Pressure, front axle

5.

Pressure, rear axle

6.

Lubricating pressure

DC 2,5 - 8

Blue

9083 95-12 40 28 Gr. P Publ.

Service instructions

Technical Handbook

Electrical connections - gearbox White Red

Borg Warner Energised cables in different gears Gear

Cable

Forward 1

Red

Forward 2

Red/white

Reverse 1

Blue

Reverse 2

Blue/white

Neutral

De-energised

Checking the gear-changing coils •

Connect 24 V across one coil at a time and check that the solenoid is energised by listening for a distinct clicking sound.

K389

Clark Energised cables in different gears Gear

Cable/colour

Forward 1

4/yellow + 6/blue

Forward 2

6/blue

Reverse 1

4/yellow + 7/brown

Reverse 2

7/brown

Neutral

De-energised

Checking the gear-changing coils •

Blue Brown Yellow Orange

K390

Connect 24 V across one coil at a time and check that the solenoid is energised by listening for a distinct clicking sound.

DC 2,5 - 8

Service instructions

Technical Handbook

Voith Energized cables, see illustrtion.

Note!

The voltage over the coil is 24 V.

Green/Yellow Blue

Brown

Forward Reverse -12 V earth

Changing the air filter - Voith automatic transmission

K391

Change the air filter every 500 hours.

•

Air filter

K392

Remove the old filter and screw in the new filter.

9083 95-12 40 29 Gr. P Publ.

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 40 30 Gr. P Publ.

Changing the oil – drive axle, hub reductions 1.

Drain the oil when it is warm. The drain plugs of the hub reductions should face downwards. Drain the oil through the differential drain plug.

2.

Refit the drain plugs, tighten them and fill with new oil. Start with the hub reductions and then the differential. For oil capacities, see the Technical specification.

Oil filling plug

K1360

Separate parking brake Adjustment If braking is weak, adjust with the adjusting nut A.

NOTE! The total clearance between disc and brake pads should be about 2 mm.

Brake disc Brake pad

Replacing the parking brake pads.

A

1.

Remove the brake pad retaining bolts.

2.

Fit new pads and bolt them in position.

3.

Use nut A to adjust the clearance between the disc and the brake pads.

Mechanical disengagement of the parking brake, older models The parking brake will be automatically applied by a powerful spring in the brake cylinder if the hydraulic pressure should fall below a certain level.

Block the wheels to prevent the truck from rolling, before disengaging the brake.

K316

1.

Loosen the adjusting nut A until the brake pads are released.

2.

After correcting the fault, adjust the parking brake with the adjusting nut A.

DC 2,5 - 8

Service instructions

Technical Handbook

9083 95-12 40 31 Gr. P Publ.

Parking brake integrated with drive axle Mechanical disengagement of the parking brake, later models The parking brake will be automatically applied by a powerful spring if the hydraulic pressure should fall below a certain level.

1.

Chock the wheels before disengaging the parking brake.

2.

Release the parking brake. If the parking brake control is not released, the fluid in the brake cylinder will drain to the hydraulic reservoir. If this should happen, screw out the piston, disconnect the hydraulic hose and fill with hydraulic fluid.

3.

Tighten the innermost nut on the release piston 3 to 4 turns.

Tighten the nut another turn or so if the parking brake does not disengage.

K1363

Release piston

!

4.

Warning Remember when moving the truck in this condition that the brakes are out of action.

Restore the release piston when the necessary work is done.

K1364

Testing of electronic reversing interlock

102

Fram/back väljare

57

Ventil FRAM 227

-

Relä FRAM 86

56

85

R

+ 225

F

36

1.

Connect –24 V to pin 4 of the reversing interlock unit.

2.

Connect +24 V to pin 3 of the reversing interlock unit.

Check that the green LED lights up.

3.

Connect the inductive sensor to the interlock unit, with + (blue) to pin 7 and – (brown) to pin 8.

4.

Connect +24 V to pin 6. Check that the orange LED lights up. Connect a voltmeter between pin 4 (–) and pin 1 (+) and check that the reading is 24 V.

5.

Disconnect the supply from pin 6 and connect it instead to pin 5. Check that the yellow LED lights up. Connect a voltmeter between pin 4 (–) and pin 1 (+) and check that the reading is 24 V.

6.

Remove the voltmeter and other connections, except those specified in items 1, 2 and 3 above.

7.

Move the sensor quickly back and forth over some metallic object and check that the green LED is extinguished.

Connect +24 V to pin 6 and 5 and check in the same way that the yellow and orange LEDs respectively are extinguished.

+24V

+ 226

1

2

3

4

2251

-

85

2261

-24V 86

5

6

7

8

Vakt rev. spärr Ventil BACK

K394

Relä BACK

+

355

Induktiv givare

DC 2,5 - 8 Technical Handbook

Service instructions

Dismantling/Reassembly of BL55 and BL75 The dismantling instructions describe dismantling of the brake completely.

Depending on where leakage occurs the dismantling should be discontinued when this point is reached. The truck shall be jacked up and securely supported, with the wheels removed and the brake system depressurized.

•

Take off the cover (51) and gasket (50) from the planetary housing (47).

•

Loosen the planetary housing (47) and remove it. The planetary gearing (54) follows with it.

•

Unscrew the nuts (31) and carefully remove the ring gear (28).

•

Remove the hub (23) taking care not to damage the sealing ring (20).

Note The sealing ring is sensitive to damage and must therefore be handled with care when dismantling and reassembling.

•

Remove the retaining ring (15C) and seal (15B).

•

Loosen and remove the housing cover (15A).

•

Remove the O-ring (10), brake discs (13) and clutch drive plates (12).

•

Loosen the housing screws (2) and remove the housing from the drive axle.

•

Remove the O-ring (4).

The piston must also be removed from the housing to charge the piston seals if they are suspected of being damaged.

Reassembly Ensure that all parts are undamaged before reassembling the brake. In particular check O-rings and other seals for damage. Replace worn parts.

•

Position O-ring (4) on the drive axle (1).

•

Fit the housing against the drive axle.

•

Fix the fitting tool on the axle boss.

•

Put the brake discs and pressure plates in the housing. Begin and end with a brake disc. (BL 55 has 5 brake discs and 4 pressure plates, BL75 has 7 brake discs and 6 pressure plates.)

•

Lubricate and fit the O-ring in the housing cover. Apply gasket sealant on the cover and fit onto the housing. Secure the screws with Loctite, or similar sealant.

•

Apply pressure to the piston and ensure that the pressure remains unaltered throughout the rest of the assembling procedure

•

Fit sealing ring (20) in the hub. Secure the screws with Loctite, or similar sealant.

Note The sealing ring must be fitted facing the right way. The ring will otherwise be damaged and leakage will occur.

-

On BL 55 the opening of the sealing ring shall be positioned so that the "spring" is visible from above (see arrow).

-

On BL 75 one side of the sealing ring is marked "Oil side". Position so that the text is visible from above (see arrow).

• •

Fit the hub in the housing.

Fit the ring wheel in the hub and tighten it with the nut (31).

•

Fit the planetary housing and insert shaft.

•

Finally, fit the spacer, gasket and planetary housing cover.

9083 95-12 40 32 Gr. P Publ.

DC 2,5 - 8 Technical Handbook

K1352

Service instructions

9083 95-12 40 33 Gr. P Publ.

BL55 och BL75

DC 2,5 - 8 Technical Handbook

Service instructions

Dismantling/Reassembly of BL40 The dismantling instructions describe dismantling of the brake completely. Depending on where leakage occurs the dismantling should be discontinued when this point is reached. The truck shall be jacked up and securely supported, with the wheels removed and the brake system depressurized.

•

Take off the cover (57) and gasket (56) from the planetary housing (51).

• •

Loosen the planetary housing (51) and remove it. The planetary gearing (38) follows with it.

Remove the axle nut (37) and locking ring (26) and carefully take off the ring wheel (35).

•

Remove the hub (23). Be careful with the seal (24) when removing the hub.

Note The sealing ring is sensitive to damage and must therefore be handled with care when dismantling and reassembling.

•

Remove the seal (24).

• •

Loosen and remove the housing cover (21).

Remove the O-ring (20), friction discs (18) and steel discs (17).

•

Unscrew the disc housing screws (6) and take away the disc housing from the drive axle cover.

•

Remove the O-ring (8).

The piston must also be removed from the housing to charge the piston seals if they are suspected of being damaged.

Reassembly Ensure that all parts are undamaged before reassembling the brake. In particular check O-rings and other seals for damage. Replace worn parts.

•

Position O-ring (8) on the drive axle.

•

Fit the housing (9) against the drive axle.

• •

Fix the fitting tool on the axle boss.

Place the friction discs and steel discs in the disc housing. Begin and end with a steel disc.

(On the BL40 there are three friction discs and four steel discs on each side.)

•

Lubricate and fit the O-ring (20) in the housing cover. Apply gasket sealant on the cover and fit onto the housing. Secure the screws with Loctite, or similar sealant.

•

Apply pressure to the piston and ensure that the pressure remains unaltered throughout the rest of the assembling procedure

• •

Remove the fitting tool.

Fit the seals (25) in the hub.

Note The sealing ring must be fitted facing the right way. The ring will otherwise be damaged and leakage will occur.

-

Place the seals back to back so that the inner seal lies with its opening facing downwards and the outer seal lies with its opening facing upwards (the ”spring” shall be visible on the outer seal).

• •

Fit the hub in the housing.

Fit the ring wheel in the hub and secure it with the axle nut (36) and locking ring (26).

•

Push the O-ring (33) on the hub.

•

Mount the planetary housing and seal the screws (54) with Loctite.

•

Mount the axle (40) and sun gear (47).

•

Finally, mount the seal (56) and planetary housing cover (57).

9083 95-12 40 34 Gr. P Publ.

DC 2,5 - 8

9083 95-12 40 35 Gr. P Publ.

Service instructions

Technical Handbook

6

9

21

17

20

17

18

8

26 33 24

35 37 28

56

54

25

47

48

57 38 51

K1355

BL40

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 40 36 Gr. P Publ.

Dismantling/Reassembly of BL80 The dismantling instructions describe dismantling of the brake completely. Depending on where leakage occurs the dismantling should be discontinued when this point is reached. The truck shall be jacked up and securely supported, with the wheels removed and the brake system depressurized.

• Take off the cover (62) and gasket (61) from the planetary housing (56).

• Loosen the planetary housing (56) and remove it. The planetary gearing (43) follows with it.

• Remove the axle nut (42) and locking ring (41) and carefully take off the ring wheel (40).

•

Remove the hub (37). Be careful with the slide ring seal (27) when taking off the hub.

N.B. The slide ring seal is sensitive to damage and must therefore be handled carefully when dismantling and assembling.

For satisfactory operation of the seal it is essential that a thin coat of oil is maintained all the time between the glide rings. This can appear to be a form of sweating but must be regarded as leakage.

•

Take out the glide ring seal (27) from the cover (23) and hub (37).

• • • • • •

Loosen and remove the housing cover (23).

Remove O-ring (22), friction discs (21) and steel discs (20).

Unscrew the screws (16) and take out the plunger.

Unscrew the nipples (6, 7, and 10).

Remove the disc housing (12).

Remove the O-ring (11).

Reassembly Ensure that all parts are undamaged before reassembling the brake. In particular check O-rings and other seals for damage. Replace worn parts.

• Position O-ring (11) on the drive axle.

• Fit the housing (12) against the drive axle.

• Tighten the nipples (6, 7 and 10) and fit the plunger (15).

• •

Fix the fitting tool on the axle boss.

Place the friction discs and the steel discs in the disc housing. Begin and end with a steel disc. (On the BL80 there are five friction discs and six steel discs on each side.)

•

Lubricate and fit the O-ring (22) in the housing cover. Apply gasket sealant on the cover and fit onto the housing. Secure the screws with Loctite, or similar sealant.

Apply pressure to the piston and ensure that the pressure remains unaltered throughout the rest of the assembling procedure Remove the fitting tool.

Mount the glide ring seal (27) in the cover (23) and in the hub (37).

Fit the seals (30, 31) in the hub.

• • • •

N.B. The seals must be fitted facing the right way. Otherwise they will be damaged and oil will leak out.

-

• • • • • •

Place the seals back to back so that the inner seal (31) lies with its opening facing downwards and the outer seal (30) lies with its opening facing upwards (the ”spring” shall be visible on the outer seal).

Fit the hub in the housing.

Fit the ring wheel (40) in the hub and secure it with the axle nut (42) and locking ring (41).

Push the O-ring (38) on the hub.

Mount the planetary housing and seal the screws (57) with Loctite.

Mount the axle (46) and sun gear (52).

Finally, mount the seal (61) and planetary housing cover (62).

DC 2,5 - 8

9083 95-12 40 37 Gr. P Publ.

Service instructions

Technical Handbook

6 12

23

21

20

22

20

11 10

15

7 10

31 16 38 40 42

41 37

30

27 46

52

62

61

K1354

43 56

57

BL80

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 40 38 Gr. P Publ.

Dismantling/Reassembly of BL100 The dismantling instructions describe dismantling of the brake completely. Depending on where leakage occurs the dismantling should be discontinued when this point is reached. The truck shall be jacked up and securely supported, with the wheels removed and the brake system depressurized.

• Remove the cover (53) and O-ring (52) from the planet holder (50).

•

Release the planet holder (50) and take it out. The planetary gear (41) will come with it.

•

Take out the axle (40) and the sun gear (45).

•

Remove the axle nut (38) and locking ring (39) and carefully take off the ring wheel (37).

•

Remove the hub (34). Be careful with the slide ring seal (23) when taking off the hub.

N.B. The slide ring seal is sensitive to damage and must therefore be handled carefully when dismantling and assembling.

For satisfactory operation of the seal it is essential that a thin coat of oil is maintained all the time between the glide rings. This can appear to be a form of sweating but must be regarded as leakage.

•

Take out the glide ring seal (23) from the cover (20) and hub (34).

• • • • • •

Loosen and remove the housing cover (20).

Remove O-ring (19), friction discs (18) and steel discs (17).

Unscrew the screws (60) and take out the plunger (16).

Unscrew the nipples (7, 8, and 10).

Remove the disc housing (13).

Remove the O-ring (12).

Reassembly Ensure that all parts are undamaged before reassembling the brake. In particular check O-rings and other seals for damage. Replace worn parts.

• Position O-ring (12) on the drive axle.

• Fit the housing (13) against the drive axle.

• Tighten the nipples (7, 8 and 10) and fit the plunger (16).

• •

Fix the fitting tool on the axle boss.

Place the friction discs and the steel discs in the disc housing. Begin and end with a steel disc. (On the BL100 there are five friction discs and six steel discs on each side.)

•

Lubricate and fit the O-ring (19) in the housing cover. Apply gasket sealant on the cover and fit onto the housing. Secure the screws with Loctite, or similar sealant.

Apply pressure to the piston and ensure that the pressure remains unaltered throughout the rest of the assembling procedure Remove the fitting tool.

Mount the glide ring seal (23) in the cover (20) and in the hub (34).

Fit the seals (26, 27) in the hub.

• • • •

N.B. The seals must be fitted facing the right way. Otherwise they will be damaged and oil will leak out.

-

Place the seals back to back so that the inner seal (27) lies with its opening facing downwards and the outer seal (26) lies with its opening facing upwards (the ”spring” shall be visible on the outer seal).

• • •

Fit the hub in the housing.

Fit the ring wheel (37) in the hub and secure it with the axle nut (38) and locking ring (39).

Push the O-ring (56) on the planet holder (50).

•

Mount the plant holder (59) in the hub.

•

Finally fit the O-ring (52) and the cover (53).

DC 2,5 - 8

9083 95-12 40 39 Gr. P Publ.

Service instructions

Technical Handbook

7 13

20

18

17

19

12

16

17

8

10 8

27 60

38

39 38

34

37 26

23 40

45

56

41

50 52 53

K1353

BL100

DC 2,5 - 8

Contents

Technical Handbook

9083 95-12 60 1 Gr. P Publ.

Group 60

Steering axle Technical specifications _________________________________________ 3 Description __________________________________________________ 5 Service instructions ____________________________________________ 6 Checking the alignment of the steered wheels ____________________ 6 Checking the steering axle ____________________________________ 6 Replacing the steering cylinder ________________________________ 7 Dismantling _____________________________________________ 7 Replacing the knuckle pin bearings and wheel bearings _____________ 8 Dismantling the wheel bearings _____________________________ 8 Dismantling the knuckle pin bearings _________________________ 8 Assembling the knuckle pin bearings _________________________ 9 Assembling the wheel bearings _____________________________ 9 Adjusting the wheel bearings _______________________________ 9

DC 2,5 - 8 Technical Handbook

9083 95-12 60 3 Gr. P Publ.

Technical specifications

Technical specifications Max. deviation of steered wheel alignment ±2 mm (parallellism) Max. axial play of the knuckle pins 0.2 mm Wheel nut tightening torque 2.5 - 5.5 t 490 Nm 6-8t

590 Nm

DC 2,5 - 8 Technical Handbook

Description

9083 95-12 60 5 Gr. P Publ.

Description The steering axle is of Kalmar LMV design and manufacture. The suspension is of pendulum type and consists of a cradle, steering cylinders, connecting rods and knuckle pins.

The steering cylinder is double-acting (see also Group 70, HYDRAULIC SYSTEM).

K395

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 60 6 Gr. P Publ.

Service instructions Checking the alignment of the steered wheels 1.

Make a chalk mark (A in the illustration) in the middle of each steered wheel tyre.

2.

Measure the distance between the two chalk marks.

3.

Drive the truck forward so that the two chalk marks point to the rear.

4.

Measure again the distance between the marks. If the difference in the distance is greater than 2 mm, this is due to deformed steering links, which must be replaced. It is not possible to adjust them.

K396

Checking the steering axle

K397

1.

Remove one steered wheel and check the axial clearance in the knuckle pin. The maximum recommended clearance is 0.2 mm.

2.

Check the clearance at the steering piston rods and the knuckle pins.

3.

Check the steering cylinder piston rod for scoring and deformation and check the condition of the hydraulic hoses.

4.

Replace demaged parts.

5.

Fit the steered wheels and retighten the wheel nuts.

6.

Check the setting of the steered wheels.

7.

Check that the wheels follow the steering wheel movements and that the steering wheel movements feel normal.

DC 2,5 - 8

Service instructions

Technical Handbook

9083 95-12 60 7 Gr. P Publ.

Replacing the steering cylinder Dismantling

K395

1.

Lift the steered wheel end of the truck and fit blocks under it to make it safe.

2.

Disconnect the hydraulic hoses from the steering cylinder and fit protective caps/plugs to the cylinder and hose connections.

3.

Remove the grub screws from the ends of the steering cylinder piston rods.

4.

Remove the pins from the piston rod forks.

5.

Remove the bolts securing the cylinder.

6.

Remove the cylinder.

DC 2,5 - 8

9083 95-12 60 8 Gr. P Publ.

Service instructions

Technical Handbook

Replacing the knuckle pin bearings and wheel bearings To replace the knuckle pin bearings, the wheel bearings must also be removed.

Dismantling the wheel bearings 1.

Lift the steered-wheel end of the truck, fit blocks under the truck and dismantle the relevant steered wheel.

2.

Clean the area around the knuckle pin.

3.

Remove the protective cover, bearing nut, washer and inner part of the outer bearing.

4.

Remove the hub.

5.

Remove the inner part of the inner bearing.

Dismantling the knuckle pin bearings 6.

Remove the steering link.

7.

Remove the circlip at the bottom of the knuckle pin. Save the shims that are inside the circlip.

8.

Hammer the knuckle pin downwards, using a heavy lead mallet. The bearing holder, lower bearing and inner race of the upper bearing will be removed together with the knuckle pin.

9.

Remove the inner races from the knuckle pin.

10.

Turn the knuckle pin outwards and remove it.

11.

Knock the bearing out of the steering cradle using a drift in the holes.

Steering link Upper bearing

Holes for drift

Sealing washer Sealing ring Pin

Inner bearing Hub

Washer Sealing ring Lower bearing Bearing holder Shims Circlip

K399

Outer bearing Washer Bearing nut Protective cover

DC 2,5 - 8

Service instructions

Technical Handbook

9083 95-12 60 9 Gr. P Publ.

Assembling the knuckle pin bearings 1.

Tap the outer race of the upper bearing into the steering cradle from below, using a piece of tube.

2.

Insert the knuckle pin in position. Place the sealing washer on the knuckle pin and tap on the inner race.

3.

Replace the entire bearing holder or solely its needle bearing.

4.

Fit the washer and sealing ring.

5.

Tap the bearing holder, with the lower bearing, into the knuckle pin. Press the whole knuckle pin upwards until the play is taken up.

6.

Fit shims so that the axle clearance of the knuckle pin will not exceed 0.2 mm (see the figure "Knuckle pin").

7.

Fit the circlip.

8.

Fit the steering link.

Assembling the wheel bearings 9.

Replace the sealing ring.

10.

Remove the bearing races from the hub and fit new ones. Note that the bearings should be mounted so that the tapers point in opposite directions, with the large diameters away from the centre of the hub.

11.

Tap the inner race of the inner bearing onto the stub axle.

12.

Pack carefully with grease and fit the hub.

13.

Tap the inner part of the outer bearing onto the stub axle.

14.

Pack carefully with grease.

15.

Fit the washer and bearing nut. Tighten the bearing nut as far as it will go and then back it off about 1/8 of a turn. The wheel bearings should neither be preloaded nor have clearance.

16.

Pack the protective cover with grease and fit it.

17.

Fit the wheel.

Adjusting the wheel bearings 1.

Lift the truck and fit blocks under it. Rotate the two steered wheels and check whether the wheel bearings are in good condition

2.

Remove the protective cover.

3.

Turn the bearing nut clockwise as far as it will go and then back it off about 1/8 of a turn. The wheel bearings should neither be preloaded nor have clearance.

4.

Turn the steered wheel and check that the bearing resistance feels normal.

5.

Lock the bearing nut using a split pin.

DC 2,5 - 8

Contents

Technical Handbook

9083 95-12 70 1 Gr. P Publ.

Group 70

Hydraulic system Technical specifications _________________________________________ 3 Description __________________________________________________ 5 Lifting and lowering _________________________________________ 8 Lowering brake valve ________________________________________8 Tilting ____________________________________________________ 9 Back-pressure valve _________________________________________ 9 Free lift __________________________________________________ 10 Fork positioning ___________________________________________ 11 Sideshift _________________________________________________ 11 Fork levelling _____________________________________________11 Servo circuit for power hydraulics _____________________________ 12 Steering _________________________________________________ 15 Steering valve ____________________________________________ 18 Hydraulic accumulator ______________________________________ 23 Accumulator charging valve __________________________________ 23 Charging the accumulator (twin pump only) ______________________ 24 Parking brake _____________________________________________25 Hydraulic pumps __________________________________________ 25 Main valve _______________________________________________ 26 Reducing valve (dual pump only) ______________________________ 27 Control valve _____________________________________________28 Tilting the cab _____________________________________________29 Cab hoist (optional) ________________________________________ 30 Trucks with reversible operator’s seat (optional) __________________ 31 Change-over valve _________________________________________ 32 Service instructions ___________________________________________ 33 Checking the hydraulic hoses ________________________________ 33 Checking the hydraulic pressure – main system __________________ 33 Hydraulic oil filter __________________________________________ 33 Breather filter _____________________________________________33 Changing the hydraulic oil ___________________________________ 34 Main valve _______________________________________________ 34 Supply pressure to the main valve _____________________________ 34 Accumulator charging ______________________________________ 35 Checking the pressure limits and tightness ___________________ 35 Adjusting the MAX pressures ______________________________ 35 Hydraulic pumps __________________________________________ 37 Repairs to leaking hydraulic cylinders – replacing the seal __________ 37 General instructions applicable to all cylinders. ________________ 37 Lifting cylinder __________________________________________ 38 Steering cylinder ________________________________________ 39 Tilting cylinder __________________________________________ 40 Fork positioning and sideshifting cylinders ____________________ 41 Cab hoisting cylinder _____________________________________ 42 Hydraulic charts DC 2,5-8, Twin pump with separate chargin valve _____ 229859.0100/02 DC 2,5-8, Twin pump with integrated chargin valve ____ 229859.0200/02 DC 2,5-8, Triple pump (truck with drive axle BL55 or BL75) ______________________________________ 229859.0300/01 DC 2,5-8, Triple pump (truck with drive axle BL40, BL80 or BL100) _____________________________________ 229859.0300/02

DC 2,5 - 8

Technical specifications

Technical Handbook Truck model Volume of hydraulic oil Grade of oil Viskositet

2,5-3,5/500 L

Lifting speed, at rated m/s load – unloaded Lowering speed, at rated m/s load – unloaded (Lowering brake valve setting)

4-4,5-500

5-5,5/500

9083 95-12 70 3 Gr. P Publ.

6-8/600

43 80 105 150 Use a hydraulic oil for mobil applications from a reputable oil company.

SH 32 – for normal operating temperatures SH 46 – for moderately high operating temperatures SH 68 – for high operating temperatures 0,4–0,5 0,5–0,45

Main system Pump capacity litres/min 38 50 at 1000 r/min (engine) Max hydraulic pressure MPa Duplex standard 15,0 19,0 16,0 16,5 17,0 18,5 Duplex free visibility 15,0 19,0 16,0 16,5 17,0 18,5 Triplex 15,5 20,0 16,5 17,0 18,0 19,0 Hydraulic oil filter Return filter Mesh µ 10 Back-pressure valve MPa 5,0 tilt cylinders, opening pressure (lift height above 4000 mm) Steering and brake system: up to and including T32 011.0513 (diesel); T32 031.0045 (LPG) Pump capacity litres/min 20 26,5 at 1000 r/min (engine) Max hydraulic pressure MPa 14,0 14,0 14,0 Opening pressure, MPa 12,5 15,0 20,0 relief valve Steering valve, orbitrol volume 125 160 315 per steering wheel turn cm3 Pre-loading pressure MPa 5 nitrogen in the accumulator Accumulator charging MPa 13 valve setting Pressure, brake system MPa 6,0 Pressure, servo system MPa 3,5 Pressure, Rotatable MPa 3,5 operator’s seat Steering system: From T32 100.0008 (diesel); T32 300.0001 (LPG) Pump capacity litres/min 20 26,5 at 1000 r/min (engine) Max hydraulic pressure MPa 14,0 14,0 14,0 Opening pressure, MPa 12,5 15,0 20,0 relief valve Steering valve, orbitrol volume 125 160 315 per steering wheel turn cm3 Brake system: From. T32 100.0008 (diesel); T32 300.0001 (LPG) Pre-loading pressure MPa nitrogen in the accumulator 5,0 Accumulator charging MPa valve setting 8,0 Pressure, brake system MPa 6,0 Pressure, Rotatable MPa 8,0 operator’s seat

19,5 19,5 20,0

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 70 5 Gr. P Publ.

Description The standard version of the hydraulic system comprises the following functions: steering, braking, lifting and tilting. The trucks are often equipped to order with a fork carriage for sideshifting or for fork positioning and sideshifting. Moreover, they can be equipped with a levelling function for one fork. The main valves of the hydraulic system are operated from the control levers via a hydraulic servo system.

In trucks fitted with clamping/rotating units or other accessories, one or two of the above functions are normally replaced by these special functions. Special functions can normally be obtained without the need for modifying the ordinary hydraulic system. If necessary, the trucks are equipped with a main valve with five functions.

Dual pump (up to 921231) Serial numbers up to and including T32011.0513 (Diesel) T32031.0045 (LPG)

Accumulator Charging valve

To steering To cab hoist

Tank retur Hydraulic pumps

Main valve

K400

DC 2,5 - 8 Technical Handbook

Description

9083 95-12 70 6 Gr. P Publ.

The hydraulic system includes a twin pump or a triple pump that supplies fluid from the reservoir to the subsystems, ie, steering and brakes.

In both versions, the innermost pump supplies the main valve of the power hydraulics.

In machines equipped with twin pump, the outer pump supplies fluid to a charging valve which in turn supplies both the orbitrol steering valve and the accumulator tank of the brakes system.

Dual pump with integrated charging valve (from. 930101) Serial numbers up to and including T32011.0513 (Diesel) T32031.0045 (LPG)

Accumulator

To steering valve

Tank retur

Hydraulic pumps

Main valve

K1065

DC 2,5 - 8 Technical Handbook

9083 95-12 70 7 Gr. P Publ.

Description

Triple pump with separate charging valve Serial numbers from

T32100.0008 (Diesel) T32300.0001 (LPG)

Accumulator

Steering valve

Charging valve

Tank retur

Main valve Hydraulic pumps

K1057

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 70 8 Gr. P Publ.

Lifting and lowering Lifting and lowering of the fork carriage are carried out using the lift lever.

The lifting speed is determined by the position of the lift lever.

The oil flow from the hydraulic pump can be changed by altering the engine speed, which gives an additional means of controlling the lift speed.

During lowering, the fork carriage and the load force the oil from the lift cylinders into the tank. A lowering brake valve in the return line from the cylinders restricts the lowering speed and also limits the oil flow in the event of a hose failure.

The lifting cylinders are filled with oil on the piston-rod side to prevent corrosion. This oil is not pressurised but is drawn into the cylinders and fed back to the tank in step with the piston movements.

To tank

To lifting cylinder

To lifting cylinder

K401

Duplex standard mast

Lowering brake valve Outer sleeve

Throttling slot

The lowering brake valve is a combined check and throttling valve. It controls the flow rate in the return direction, but provides unrestricted flow in the supply direction.

The outer sleeve is rotatable and is used for adjusting the throttling slot and thus the fork carriage lowering speed.

A

K402

B

Lowering brake valve

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 70 9 Gr. P Publ.

Tilting The return lines from the tilting cylinders contain a backpressure valve that opens at a pressure of 5 MPa. The backpressure valve prevents the load from moving the tilting cylinders.

K403

Tilting system

Back-pressure valve The back-pressure valve is a pilot-controlled pressure-limiting valve with check valve. For this valve to open, the pressure in the tilt-out circuit must be higher than 5 MPa. This prevents inadvertent tilting forward caused by heavy load on the forks. The valve setting is not adjustable.

Permanently preset insert 5 MPa

K404

Back-pressure valve

DC 2,5 - 8 Technical Handbook

9083 95-12 70 10 Gr. P Publ.

Description

Free lift The duplex and triplex mast assemblies can both be equipped with free-lift cylinders for lifting the fork carriage without increasing the total height. This is known as free lift.

Trucks with lifting heights up to 6.5 m are equipped as standard with an area-controlled system. In this case, the free-lift cylinders have a larger area than the main lifting cylinders. A higher force therefore acts on the free-lift cylinders, and they are consequently the first to move. The main lifting cylinders will start to move only after the free-lift cylinders have reached the limit of their travel.

As option (trucks with lifting heights in excess of 6.5 m) the trucks can be equipped with a system where, the hydraulic fluid flow to the cylinders is positively controlled by solenoid valves.

Lifting cylinder

Free-lifting cylinder

Hose reel alternative

Freely-suspended hose alternative

Swivel

K405

Fork positioning/sideshifting cylinders

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 70 11 Gr. P Publ.

Fork positioning The main valve opens and closes the supply of oil to the two hydraulic cylinders at the forks. A flow distributor, located between the valve and the cylinders, ensures that the forks move equal distances, even if the resistance on the forks should be different.

When the distance between the forks is reduced, the flow distributor ensures that equal quantities of oil will be supplied to the piston rod sides of the two cylinders.

When the distance between the forks is increased, the flow distributor controls the oil returning from the cylinders.

Sideshift In trucks fitted with fork positioning and sideshift, the same hydraulic cylinders are used for fork positioning and sideshifting. When the sideshifting lever is moved, the hydraulic valve for sideshifting will supply oil to the piston rod side of one of the sideshifting cylinders and to the piston side of the other cylinder.

Fork levelling On trucks fitted with fork levelling function, one of the forks is supported by a hydraulic cylinder that moves the fork vertically.

To sideshifting cylinders

To fork leveling cylinder

To fork positioning cylinders

To sideshifting cylinders K406

Fork positioning/Sideshifting/Fork levelling

DC 2,5 - 8 Technical Handbook

9083 95-12 70 12 Gr. P Publ.

Description

Servo circuit for power hydraulics The power hydraulics are controlled with the aid of a hydraulic servo system.

Servo pressure in machines with a twin pump is 3.5 MPa. The pressure is obtained via a pressure reducing valve fitted in the supply line between the accumulator and the control valve block.

Servo pressure in machines with a triple pump is 8.0 MPa and it is obtained directly from the accumulator.

Dual pump (up to 921231) Serial numbers up to and including T32011.0513 (Diesel) T32031.0045 (LPG)

Reducing valve

Return block

K1068

DC 2,5 - 8 Technical Handbook

9083 95-12 70 13 Gr. P Publ.

Description

Dual pump with integrated charging valve (from. 930101) Serial numbers up to and including T32011.0513 (Diesel) T32031.0045 (LPG)

Reducing valve

Connector

K1069

DC 2,5 - 8 Technical Handbook

9083 95-12 70 14 Gr. P Publ.

Description

Triple pump with separate charging valve Serial numbers from

T32100.0008 (Diesel) T32300.0001 (LPG)

Connector

K1070

DC 2,5 - 8

9083 95-12 70 15 Gr. P Publ.

Description

Technical Handbook

Steering The steering orbitrol valve is supplied differently depending on whether the machine is equipped with a twin or triple pump in the hydraulic system.

•

In conjunction with a twin pump the orbitrol valve is supplied with a flow of fluid from the charging valve of the accumulator (see illustration below).

•

In conjunction with a triple pump the orbitrol valve is supplied directly from the middle pump (see illustration to the right).

Dual pump (up to 921231) Serial numbers up to and including T32011.0513 (Diesel) T32031.0045 (LPG)

Steering valve

Charging valve

Cooling circuit, brake

Choke

Steering cylinder

K407

To tank

DC 2,5 - 8 Technical Handbook

Description

9083 95-12 70 16 Gr. P Publ.

Dual pump with integrated charging valve (from. 930101) Serial numbers up to and including T32011.0513 (Diesel) T32031.0045 (LPG)

Steering valve

Steering cylinder

K1066

DC 2,5 - 8 Technical Handbook

Description

9083 95-12 70 17 Gr. P Publ.

The steering valve feeds a preset volume of oil per steering wheel turn and controls the quantity of oil and oil flow to the steering cylinder. When the steering wheel is not moved, the steering cylinder cannot move, because the two steering cylinder outlets on the steering wheel valve are blocked.

Triple pump with separate charging valve Serial numbers from

T32100.0008 (Diesel) T32300.0001 (LPG)

Steering valve

Steering cylinder

K1058

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 70 18 Gr. P Publ.

Steering valve

Danfoss symbol

There are different types of steering valve depending on whether the hydraulic system is equipped with a twin or triple pump.

ISO - symbol

Distribution valve

•

On machines with twin pump the steering valve is of the closed centre-nonreaction type, which means that it is closed to the flow of fluid between the pump and reservoir in the neutral mode.

•

On machines with triple pump the steering valve is of the open centre-nonreaction type, which means that it is open to the flow of fluid between the pump and reservoir in the neutral mode.

The steering valve consists of a gear pump and a distribution valve. When the steering wheel is turned, oil is supplied to the gear pump which determines the quantity of oil that will flow to the steering cylinder. The direction of oil flow is determined by the distribution valve. Everything takes place proportionally to the steering wheel travel.

Gear pump Danfoss OSPB steering valve

K409

Valve block

A valve block incorporating an overflow valve and double safety valve is connected to the steering valve. The safety valve relieves high pressure surges in the steering cylinder, which may be caused, for instance, by blows against the steered wheels and which may give rise to hose failure. Vacuum on the opposite side of the piston that could lead to cavitation is prevented by opening of the make-up valves (check valves) in the combined safety and make-up valves.

The overflow valve limits the maximum steering pressure.

1

Steering valve

2 3

Double safety valve with make-up valve

2.

Overflow valve

3.

Check valve

B

Adjusting screw for the overflow valve under the plug

C

Adjusting screw for the double safety valve under the plug

Steering valve with valve block

K410

B K411

1.

C Valve block

DC 2,5 - 8 Technical Handbook

9083 95-12 70 19 Gr. P Publ.

Description

Item 12 - assembly pattern

Tightening torque: 30+ 5 Nm 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

K412

Dust cover Body – spool valve – sleeve Ball Threaded bush O-ring Guide ring Front bearing race Needle bearing holder Rear bearing race Ring Pin Neutral position springs, 1 set Shaft Spacer

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

O-ring Distribution plate Gear set O-ring End plate Washer Pin Screw with drilled head Locking wire Nameplate Self-tapping screw Spacer Spacer Danfoss OSPB steering valve

DC 2,5 - 8

9083 95-12 70 20 Gr. P Publ.

Description

Technical Handbook

Driving brake system When using the driving brakes, hydraulic fluid from the accumulator is supplied to the brake cylinders. The gearbox is disengaged via solenoid valves at a pre-determined brake pressure (electrically controlled inching).

The driving brake can be complemented as optional extra equipment with "soft inching". In such cases the operator’s station is provided with an extra pedal located to the left on the normal brake pedal. The pedal is connected, to the gearbox and also to the normal brake pedal.

As the operator presses the pedal, the gearbox is activated to start a soft disengagement, without actuating the brakes. The normal brake is applied with electrically controlled inching after pressing the pedal down about 15°.

Dual pump (up to 921231) Serial numbers up to and including T32011.0513 (Diesel)

T32031.0045 (LPG)

Parking brake valve

Steering valve Brake valve

Charging valve

K413

By-pass

Foot brake and inching

DC 2,5 - 8 Technical Handbook

9083 95-12 70 21 Gr. P Publ.

Description

Dual pump with integrated charging valve (from. 930101) Serial numbers up to and including T32011.0513 (Diesel) T32031.0045 (LPG)

Brake pedal

Parking brake valve

K1067

Foot brake and inching

DC 2,5 - 8 Technical Handbook

9083 95-12 70 22 Gr. P Publ.

Description

Triple pump with separate charging valve Serial numbers from

T32100.0008 (Diesel) T32300.0001 (LPG)

Brake pedal Parking brake valve

Charging valve

K1052

Foot brake and inching

DC 2,5 - 8

9083 95-12 70 23 Gr. P Publ.

Description

Technical Handbook

Hydraulic accumulator The task of the accumulator is to pressurise the foot brake, parking brake and the steering system.

The accumulator is of diaphragm type and is pressurised with nitrogen (see figure). During charging, the nitrogen is compressed and, during braking, it will force the hydraulic oil into the system.

Pre-loading with nitrogen

Charging

Max. charging

Discharging

!

CAUTION Before starting work on the steering system, always ensure that the accumulator has been discharged. Discharge the accumulator by repeatedly applying and releasing the parking brake until the brake action ceases.

Nitrogen

Accumulator charging valve

K414

Up to and including serial nr T32011.0513 diesel T32031.0045 LPG

The accumulator charging valve is different in the twin and triple pump systems.

Charging valve, Up to Serial No. T32011.0513 Diesel T32031.0045 LPG

3

The function of the accumulator charging valve is to maintain the pressure in the accumulator between the MAX and MIN pressure limits.

2

The valve contains

1

1.

An adjustable relief valve for limiting the MAX pressure.

2.

A pilot-controlled sequence valve which enables the hydraulic oil to be recirculated to the tank when the accumulator is fully charged.

3.

A check valve which ensures that the flow in the supply pipe will always be from the pump to the accumulator.

K415

From serial number

T32100.0008 diesel T32300.0001 LPG

Charging valve, from Serial No. T32100.0008 Diesel T32300.0001 LPG

P

P1

The object of the accumulator valve is to maintain the right pressure in the accumulator.

The valve includes

1

T K1062

1.

Adjustable bypass valve with check valve to limit MAX. pressure.

2.

Check valve that allows flow in one direction only in the supply line from pump to accumulator.

2

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 70 24 Gr. P Publ.

Charging the accumulator (twin pump only)

1

Charging the accumulator consists in principle of three stages, as follows.

1.

3

Valve 2 is set, in its rest mode, at one of its limits, ie, where flow to the reservoir is completely cut off. Valve 1 is coupled to the pilot circuit of valve 2.

As soon as the pump starts to build up the pressure in the pilot circuit of valve 2, the slide moves upwards. A pressure is also build up at the same time on the opposite side of the slide (from valve 1). This pressure holds against the slide, causing it to set in the middle position.

2

To prevent the flow of all fluid from the hydraulic system to the accumulator during the charging sequence, the flow from the pump is distributed so that some of the fluid is used to charge the accumulator while the rest is directed back to the reservoir. This form of distribution facilitates the transfer of extra flow to the power hydraulics as required.

1

The pump now charges the accumulator via check valve 3.

The spring force of valve 1 is greater than the accumulator pressure and thus keeps the pilot lead to valve 2 open.

2

2.

When pressure in the accumulator overrides the spring force of the valve 1, the slide switches over to open a connection to the reservoir for the pilot lead of valve 2. The slide in valve 2 now moves upwards and opens the lead from the pump directly to the reservoir, whereby the system transfers to circulation pumping.

3.

The brake and steering system consume pressure from the accumulator, causing pressure to fall to MINIMUM (18% of MAX.). The spring force of valve 1 then overrides the accumulator pressure and swithes the valve so that connection to the reservoir closes and the pilot lead to the valve 2 and switches the valve so that connection to the reservoir closes and the pilot lead to valve 2 opens.

3

2

1

3 3

2

Pilot pressure moves valve 2 to the middle position and the accumulator begins to charge again (sequence 1).

1 K416

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 70 25 Gr. P Publ.

Parking brake On older models the parking brake consists of a disc brake on the ingoing shaft of the drive axle. Later models however are equipped with a small wet-disc brake integrated with the drive axle. Both types are applied by a powerful spring in the hydraulic cylinder of the parking brake. The brake is released by hydraulic pressure supplied from the accumulator of the hydraulic system.

Belleville washers K417

Brake cylinder

Hydraulic pumps The hydraulic system is pressurised by either two or three gear pumps, The pumps are integral and are driven by a drive shaft connected to the torque converter.

K418

Dual pump

Driven gear

Inlet

Body

Outlet

Driving gear K1061

Triple pump

K419

Gap between gear teeth

DC 2,5 - 8

9083 95-12 70 26 Gr. P Publ.

Description

Technical Handbook

Main valve The cast main valve consists of the following sections: •

Inlet section

•

Control sections, corresponding to the number of functions of the truck

•

Outlet sections

The inlet section has two alternative pump connections, but the connection which is in the same plane as the control ports is normally plugged. The supply is connected to the end wall of the inlet section.

The inlet section includes an adjustable, sealed main pressure limiting valve.

The control section is equipped with a spring-centred control spool valve. Each end of the spool valve is provided with a controller that displaces the spool valve in proportion to the hydraulic pressure.

K420

1. Pump connection 2. Free passage 3. Check valve in the supply port 4. Main pressure limiting valve 5. Tank port 6. Supply port 7. Servo-operated control spool valve

The supply port is fitted with a check valve which prevents undesirable lowering of the load when several functions are operated simultaneously.

The outlet section has two tank connections.

To hydraulic reservoir

From lifting cylinder

Fork positioning

Tilting

Side shifting

From hydraulic pump

To lifting cylinder Measurement tapping for pressure

K421

Adjustment screw for pressure

DC 2,5 - 8 Technical Handbook

Description

Reducing valve (dual pump only) The reducing valve is connected into the supply line from the accumulator, and its function is to reduce the main pressure to a servo pressure of 3.0 MPa, which is used for controlling the main valve. The valve maintains the preset pressure constant, regardless of variations in the supply pressure.

The valve contains a precisions-ground, directly-actuated reducing spool valve.

When port P is pressurised, the spool valve moves against the force of the presetting spring and opens the tank return T. The resulting pressure in port S is supplied to the servo circuit. Positive overlap between ports P and T minimises the oil consumption.

The adjusting screw is set to 3.0 MPa and is sealed. A measurement tapping is provided immediately adjacent to port S, and this can be used for checking the servo pressure.

S = Servo pressure P = Pressure supply T = Tank return K422

9083 95-12 70 27 Gr. P Publ.

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 70 28 Gr. P Publ.

Control 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 minimise the internal leakage.

The control forces are low, and the valve travel is proportional to the lever travel, which ensures smooth operation of the main hydraulics.

Adjusting screw for level travel

Pressure reducing valve

K423

Control valve

Dual pump: 3,5 MPa Triple pump: 8,0 MPa

K424

Servo actuation of the main valve on a truck with rotatable operator's seat

DC 2,5 - 8 Technical Handbook

9083 95-12 70 29 Gr. P Publ.

Description Tilting the cab

The cab can be tilted with the aid of a separate hydraulic system consisting of a tilting cylinder and a hand-operated pump to facilitate the servicing of items that are located underneath the cab. As an optional feature the hand pump can be replaced with an electric pump, powered directly by the batteries of the truck and operated via push buttons on the pump.

See the instruction manual with regard to operation.

Hand pump

Tilting cylinder

K1060

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 70 30 Gr. P Publ.

Cab hoist (optional) The cab hoist system consists of a lifting cylinder, controls and a hand-operated pump. The lifting cylinder is connected via controls to the hydraulic system of the truck. The hand pump is connected in parallel with the hydraulic system to facilitate operation when hydraulic power is not in action.

When hoisting the cab with the hand pump, the direction of flow of the hydraulic fluid is regulated by moving the control valve to"Hoist" and "Lower" respectively.

For operation, see the Instruction Manual.

Charging valve

Control lever

Hoisting cylinder Hand pump

K446

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 70 31 Gr. P Publ.

Trucks with reversible operator’s seat (optional) On trucks fitted with a reversible operator’s seat, the operator platform including steering console and pedals, is mounted on a special hydraulically powered base.

Rotation of the base is operated via controls on the seat.

Steering is switched over automatically with the aid of a shuttle valve in the steering system when the seat is reversed.

Control lever for reversible operator’s seat

Hydraulic catch for the operator’s seat

K349

DC 2,5 - 8 Technical Handbook

9083 95-12 70 32 Gr. P Publ.

Description

Change-over valve A change-over valve is connected into the lines between the steering valve and the steering cylinder, and its function is to reverse the supply and return lines when the operator’s seat is turned. This ensures that the direction of steering will always be the same, regardless of the direction in which the operator’s seat is facing. Forward is always in the direction in which the operator is facing.

The change-over valve is a four-way, double-acting directional control valve with three positions, and the valve is spring-centred to the 0 position.

The valve is mechanically connected to a cam in the pivot of the operator’s seat frame. When the frame is between the forward-facing and rearward-facing positions, the valve is in its 0 position, i.e. the supply to the steering cylinder is shut off.

Double-acting 4-way 3-position

Spring centring

To tank and brake cooling circuit To steering cylinder

Change-over valve

From steering pump/ charging valve

K426

Change-over valve for truck with a rotatable operator's seat

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 70 33 Gr. P Publ.

Service instructions During all work on the hydraulic system, observe the greatest cleanliness, since the presence of foreign matter can easily result in a valve seizing, or other disturbances.

!

CAUTION! Before carrying out any work on the steering system, check that the accumulator has been discharged. Discharge the accumulator by repeatedly applying and releasing the parking brake until the brake action ceases.

Checking the hydraulic hoses Check hydraulic hoses and hose connections for leakage and cracking or wear. Replace the hoses if there is the slightest indication of weakness. If necessary, tighten the connections.

Checking the hydraulic pressure – main system 1.

Connect a pressure gauge with a range of 0–25 MPa (0– 250 kp/cm2) to the test connection of the main hydraulic system. Ensure that the pressure gauge hose is sufficiently long for the pressure gauge to be read from the inside of the cab.

2.

Start the engine and let it run in the mid-speed range.

3.

Tilt the mast backwards, let the fork carriage run to the end position. Read the hydraulic oil pressure. The correct hydraulic oil pressure is shown in the Technical specification section.

NOTE For the pressure in circuits on trucks fitted with other lifting masts, refer to the relevant delivery specifications.

4.

Change the pressure setting, if required. The adjusting screw is located on the main valve.

!

N.B. Don't exceed the value in the table, since this may jeopardize the safety of the machine.

Hydraulic oil filter

K427

Hydraulic oil filter

The hydraulic system includes a return filter which should be changed every 1000 hours of operation. The filter is of spin-on type. To change the filter, screw off the old filter element, discard it, clean the filter head and screw on a new filter.

Breather filter The hydraulic tank is fitted with a breather filter which prevents airborne impurities from entering the tank. The filter should be changed every 1000 hours of operation. The filter is of spin-on type. To change the filter, screw off the old filter element, discard it and screw on a new filter.

DC 2,5 - 8 Technical Handbook

9083 95-12 70 34 Gr. P Publ.

Service instructions Changing the hydraulic oil

The hydraulic oil should be changed every 2000 hours of operation, but at least once a year.

1.

Discharge the accumulator by repeatedly applying the parking brake.

2.

Remove the drain plug from the hydraulic tank and drain the oil. Replace the drain plug and tighten it.

3.

Fill the tank with new hydraulic oil (6% Lubrizol). The capacity is shown in the Technical specification.

Breather filter

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 must be observed whenever carrying out service work.

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 spool valve ends and covers against blows. The spool valve may be bent if carelessly handled, and it will then immediately jam.

Supply pressure to the main valve

K428

Hydraulic oil tank

The supply pressure to the main valve should be in accordance with the section entitled Technical specification. The pressure is determined by the main pressure limiting valve which is located on the inlet section. When carrying out adjustment, connect a pressure gauge as described in the section entitled Checking the hydraulic pressure – main system, and turn the adjusting screw until the correct pressure is obtained.

Adjustment screw for pressure

K421

Measurement tapping for pressure

Main valve

DC 2,5 - 8 Technical Handbook

9083 95-12 70 35 Gr. P Publ.

Service instructions Accumulator charging

Up to and including serial number T32011.0513 diesel T32031.0045 LPG Measurement tapping

Checking the pressure limits and tightness

X

1.

Connect a pressure gauge to measurement tapping M1 on the accumulator charging valve.

2.

Start the engine.

3.

Depressurise the system by repeatedly applying and releasing the parking brake until the brake action ceases.

4.

Let the pump charge the accumulator to MAX pressure.

Read the pressure gauge.

5.

Stop the engine and check that the pressure in the accumulator is maintained.

3 2

1

Adjusting the MAX pressures

1.

2.

3.

K415

Relief valve for MAX pressure Pilot-controlled sequence valve for recirculation to the tank Check valve Accumulator charging valve

Adjustment screw

1.

Connect a pressure gauge to the measurement tapping M1 on the accumulator charging valve.

2.

With the engine not running, discharge the accumulator to the tank by repeatedly applying and releasing the parking brake until the brake action ceases.

3.

Set the MAX pressure as follows: •

Back off the locknut on adjusting screw 1 (see the figure showing the accumulator charging valve).

•

Turn the adjusting screw half a turn clockwise or anticlockwise. Turn it clockwise to increase the pressure and anti-clockwise to reduce the pressure.

•

Start the engine, wait until the accumulator is charged and read the new MAX pressure on the pressure gauge.

If necessary, adjust further. NOTE: If the pressure is to be raised, turn the adjusting screw clockwise while the engine is still running. If the pressure is to be reduced, stop the engine, discharge the accumulator, turn the adjusting screw anti-clockwise, start the engine and then read the new pressure. Tighten the locknut on the adjusting screw.

The MIN-pressure is automatically set to 18% of the MAXpressure.

Measurement tapping

K448

Accumulator charging valve

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 70 36 Gr. P Publ.

Accumulator charging From serial number T32100.0008 diesel Measurement tapping

T32300.0001 LPG

Checking the pressure limits and tightness

P

P1

1.

Connect a pressure gauge to measurement tapping M1 on the accumulator charging valve.

2.

Start the engine.

3.

Let the pump charge the accumulator to MAX pressure.

Read the pressure gauge.

4.

Stop the engine and check that the pressure in the accumulator is maintained.

Adjusting the MAX pressures

T

K1062

Connect a pressure gauge to the measurement tapping M1 on the accumulator charging valve.

2.

With the engine not running, discharge the accumulator to the tank by repeatedly applying and releasing the parking brake until the brake action ceases.

3.

Set the MAX pressure as follows: •

Back off the locknut on adjusting screw 1 (see the figure showing the accumulator charging valve).

•

Turn the adjusting screw half a turn clockwise or anticlockwise. Turn it clockwise to increase the pressure and anti-clockwise to reduce the pressure.

•

Start the engine, wait until the accumulator is charged and read the new MAX pressure on the pressure gauge.

If necessary, adjust further. NOTE: If the pressure is to be raised, turn the adjusting screw clockwise while the engine is still running. If the pressure is to be reduced, stop the engine, discharge the accumulator, turn the adjusting screw anti-clockwise, start the engine and then read the new pressure. Tighten the locknut on the adjusting screw.

Accumulator charging valve

Adjustment screw

Measurement tapping

K1064

1.

Accumulator charging valve

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 70 37 Gr. P Publ.

Hydraulic pumps If a fault should occur on one of the hydraulic pumps, consult the Service Department at Kalmar LMV.

Repairs to leaking hydraulic cylinders – replacing the seal

Screwdriver

General instructions applicable to all cylinders.

If necessary, see Group 80 for instructions on the dismantling of the fork carriage and mast.

!

Seal

K136

Scraper ring

Example of cylinder head

CAUTION Don’t use compressed air for removing the piston from the cylinder, since serious injuries may result.

1.

Remove the relevant hydraulic cylinder from the truck. 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 future. Use a screwdriver or the like to remove the seal from the piston side. Use the screwdriver as shown in the figure.

Sealing rings Backing rings Guide rings

Clean all components very thoroughly.

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.

K137

Piston seals

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.

DC 2,5 - 8

9083 95-12 70 38 Gr. P Publ.

Service instructions

Technical Handbook

Lifting cylinder 1.

The cylinder head is threaded into the cylinder tube, and a C spanner must be used for fitting and removing it.

2.

When assembling an overhauled cylinder, after the piston has been fitted into the cylinder and the cylinder head is to be tightened, it is extremely important to ensure that the piston rod is well centred in the cylinder head, so that the cylinder head threads will not be damaged. Lubricate these threads with molybdenum disulphide (Molykote) grease.

Duplex

Free lift

K429

Triplex

Lifting cylinder

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 70 39 Gr. P Publ.

Steering cylinder 1.

The steering cylinder has a double-acting piston, with the piston seal in the centre.

2.

A cylinder head which is screwed into the cylinder tube is provided at each end.

3.

The piston is shrink fit on the piston rod, mid-way along the length of the piston rod.

K430

Steering cylinder

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 70 40 Gr. P Publ.

Tilting cylinder 1.

The cylinder end of the tilting cylinder is equipped with a mounting lug. The piston rod fork is threaded onto the piston rod and is locked by means of a nut.

2.

The cylinder head is threaded into the cylinder tube, and a C spanner must be used for fitting and removing it.

K431

Tilting cylinder

DC 2,5 - 8

Service instructions

Technical Handbook

9083 95-12 70 41 Gr. P Publ.

Fork positioning and sideshifting cylinders 1.

The cylinder has a welded piston rod lug and a lug bearing at each end.

2.

The piston head is threaded onto the piston rod and is removable, to allow for replacing the seals. The piston head is locked onto the piston rod by means of a split pin.

When fitting and removing the piston head, use a chain wrench or, if necessary, a large pipe wrench.

K432

Sideshifting and fork positioning cylinder

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 70 42 Gr. P Publ.

Cab hoisting cylinder The cab cylinder mounting varies for different truck models but in other aspects the cab hoisting cylinder is the same for all variants of the truck in series 2.5 - 8.

K447

Cab hoisting cylinder

DC 2,5 - 8 Technical Handbook

Service instructions

Hydraulic chart 1.

Brake cylinder

2.

Brake

3.

Parking brake

4.

Accumulator tank

5.

Steering valve

6.

Steering cylinder

7.

Rotatable operator´s seat

8.

Accumulator charging valve

9.

Cab hoist cylinder

10.

Main valve

11.

Hydraulic pumps

12.

Hand pump (cab hoist)

13.

Return filter

14.

Hydraulic tank

15.

Lifting cylinder

16.

Free lift cylinder

17.

Tilting cylinder

18.

Fork positioning and sideshift cylinder

19.

20.

Servo pressure reduce valve High pressure filter

21.

Parking brake cylinder integrated with drive axle

22.

Parking brake valve

23.

Pressure limiting valve (integrated with steering axle)

24.

Shock valve (integrated with steering axle)

9083 95-12 70 44 Gr. P Publ.

DC 2,5 - 8

Contents

Technical Handbook

9083 95-12 80 1 Gr. P Publ.

Group 80

Lifting mast and fork carriage Technical specifications _________________________________________ 3 Description __________________________________________________ 5 Service instructions ____________________________________________ 6 Inspection of lifting chains ____________________________________6 Inspection of lifting mast _____________________________________ 7 Wear inspection – forks ______________________________________ 7 Lubricating the hose guide pulley ______________________________7 Dismantling the fork carriage __________________________________8 Dismantling the lifting mast ___________________________________ 9 Mast and carriage with guide pulley _____________________________ 9 Replacement of upper support rollers in forks __________________9 Replacing bushes in fork lower support rollers __________________9 Replacing support roller bearings in the fork carrige and inner mast _________________________________________ 10 Adjusting the play of a support roller _________________________ 10 Mast and carriage with glide plates ____________________________ 11 Lubrication of glide plates _________________________________11 Checking for wear _______________________________________11 Replacing the glide plates _________________________________11

DC 2,5 - 8 Technical Handbook

9083 95-12 80 3 Gr. P Publ.

Technical specifications

Technical specifications Forks Thickness

mm

Max. permissible wear at point "a" Lifting chains Pitch mm Max. permissible extension (to be measured in accordance with the service instructions) Clearance between the forks and the mm ground when the forks are in the lowest position

2,5–4 t

4,5–5,5 t

6–8 t

45

60

60

10%

25.4 3%

10

DC 2,5 - 8

Description

Technical Handbook

9083 95-12 80 5 Gr. P Publ.

Description Kalmar LMV fork lift trucks may be fitted with one of a number of different types of lifting mast and fork carriage.

This manual deals mainly with free-vision duplex masts with fork positioning and sideshifting carriages.

Mast •

Free-vision duplex mast with two lifting cylinders.

•

Free-vision duplex mast with free lift.

•

Free-vision triplex mast with free lift.

Fork carriages •

Carriage with manually adjustable forks (standard).

•

Fork positioning and sideshifting carriage.

•

Fork positioning and sideshifting carriage, with fork systems having a separate trolley for each fork.

The carriages may also be equipped with levelling facilities acting on one fork.

The lifting mast and fork carriage may be equipped with guide pulleys or glide plates.

K433

DC 2,5 - 8 Technical Handbook

9083 95-12 80 6 Gr. P Publ.

Service instructions

Service instructions Inspection of lifting chains To increase safety, the lifting chains should be inspected regularly in accordance with the six points below. This may be carried out during every 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.

The chain extension should not exceed 3% Measure the extension across the 25 links that usually break first at the guide sprocket. 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.

A special wear measurement tape may be used for chains of up to 1 1/2" pitch.

The tape is marked: •

“Zulässige Verlängerung” (Permissible extension)

•

“Kette austauschen” (Replace the chain)

This type of tape may be ordered from Kalmar LMV.

P-measure

New chain measures over 25 links

Inch

mm

mm

Max. permitted measures over 25 links 3%-elongation mm

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

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

476,25 635 793,75 952,5 1270 1587,5

490 654 817 981 1308 1635

K434

2.

Check that no pins are loose in the outer washers.

3.

Check that there are no visible cracks in any of the links.

4.

Check that there is no mechanical damage.

5.

Check that the chain is not corroded.

6.

Check that the chain bends easily around the guide sprocket and does not jam when bent.

After inspection, oil the chains with light oil or spray of the type containing a penetrant.

Note If the lifting chain does not pass the inspection, replace the whole of it.

Lifting chains must not be joined or re-riveted.

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 80 7 Gr. P Publ.

Inspection of lifting mast 1.

Inspect the lifting mast for damage or wear on the outer or inner masts.

Investigate whether any wear on the lifting mast has been caused by the support rollers.

Run the fork carriage up and down the mast and listen for any unusual sounds from the bearings.

Check that the hose quide pulley runs easily and that is does not damage the hoses.

Run the fork 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 appropriate hose connections.

Drive the truck onto a flat surface and move the mast into the vertical position. Lower the forks to the bottom position. Check that there is a space of 10 mm between the bottoms of the forks and the ground. If the clearance is less than 10 mm, adjust the lifting chains equally.

2.

3.

4.

5.

6.

Careful inspection may considerably extend the service lift of the forks.

!

CAUTION Never carry out service work on a lifting mast when the engine is running.

Wear inspection – forks 1.

Wear at a must not exceed 10% of the original dimention

K435

Inspection of forks wear

2.

3.

Hose guide pulley 4.

5.

Bush

Inspect the forks for cracks and deformation and check the thickness of the fork.

• Fork wear must not exceed 10% (calculated from the original dimension and measured 150 mm from the heel of the fork).

• Cracks visible to the naked eye are not permissible.

Pay special attention to the heels of the forks.

Superficial cracks are generally not longer than about 5 mm. If superficial cracks are detected, grind down the area by about 0.5 mm. Carry out magnetic particle examination if the crack is still visible. (This work must be carried out by an approved company.)

Check the fork suspension for play.

If the forks need repairing, get in touch with Kalmar LMV or service personnel authorised by Kalmar LMV, who will decide whether the forks can be repaired.

Superficial cracks and wear must not be remedied by welding.

Forks that have been straightened must be heat treated again.

NOTE The forks must be inspected at least once a year by a qualified person who is trained for the job.

Lubricating the hose guide pulley Dismantle, inspect, lubricate and refit the bush of the hose guide pulley.

Ka37

Carry out this work at intervals in accordance with Group 90, Periodic supervision.

DC 2,5 - 8 Technical Handbook

9083 95-12 80 8 Gr. P Publ.

Service instructions

Dismantling the fork carriage 1.

Disconnect all the hose connections between the hydraulic cylinders of the fork carriage and the hydraulic system. Fit protective caps/plugs to all hydraulic cylinder and hose connections.

N.B. Never use rags, cotton waste or wooden plugs. Use only protective caps and plugs of plastic or metal.

2.

Raise the fork carriage a little.

3.

Fit blocks under the lower cross-member of the fork carriage.

4.

Lower the fork carriage so that is rests with the bottom cross-member on the blocks and with the forks on the ground.

5.

Remove the pin from the chain mounting and secure the chain with a rope, so that itt cannot run off the guide sprocket.

6.

Start the engine and raise the inner mast so that it is clear of the fork carriage.

7.

Reverse the truck away from the fork carriage.

Guide sprocket

Hose guide pulley

Inner mast Outer mast

Tilt cylinders

Lifting chain Fork carriage

Fork positioning/ sideshifting cylinders

support rollers

Bottom crossmember of fork carriage K438

Lifting mast with fork carriage

DC 2,5 - 8 Technical Handbook

Service instructions

9083 95-12 80 9 Gr. P Publ.

Dismantling the lifting mast 1.

Remove the fork carriage as described under the heading "Dismantling the fork carriage".

2.

Disconnect the hydraulic hoses from the lifting cylinder.

Cap/plug all connections.

3.

Set the tilt control lever to the vertical position and secure a sturdy lifting chain to the lifting lugs on the mast.

4.

Disconnect the tilt cylinder pistons at the outer mast.

5.

Disconnect the locking plates under the mast suspension and lift the mast.

Observe great care and pay attention to the risk of being injured by crushing.

6.

Fit blocks under the lifting cylinders, disconnect the piston mounting of the lifting cylinders and draw out the inner mast.

Mast and carriage with guide pulley Replacement of upper support rollers in forks 1.

Remove the circlip securing the bearing.

2.

Remove the support roller using an extractor.

3.

Fit a new bearing.

4.

Press the support roller on and fit the circlip.

NOTE This only applies to 6–8 tonne trucks.

Replacing bushes in fork lower support rollers

K436

Support rollers on the lifting mast

1.

Remove the circlip and locking bolt securing the roller shaft.

2.

Tap out the shaft and fit a new bush.

3.

Fit the support roller and secure the shaft.Replacing support roller bearings in the fork carriage and inner mast

DC 2,5 - 8

Service instructions

Technical Handbook

9083 95-12 80 10 Gr. P Publ.

Replacing support roller bearings in the fork carrige and inner mast

Schims

K439

1.

Dismantle the fork carriage/inner mast.

2.

Remove the circlip securing the ball bearing.

3.

Remove the support roller using an extractor.

4.

Fit the new ball bearing and check that the fit between the outer race and the support roller is good.

5.

Press on the wheel and fit the circlip.

Dismantling a support roller

Schims

Adjusting the play of a support roller When the support rollers are mounted in position, they are fitted with shims on the outside and the inside.

If the clearance between the mast and the support roller or between the fork carriage and the support roller should become excessive, remove the support roller and move a suitable number of shims to the inside.

Schims

K440

Support rollers on the lifting mast

DC 2,5 - 8

9083 95-12 80 11 Gr. P Publ.

Service instructions

Technical Handbook

Mast and carriage with glide plates The mast and carriage can be fitted with glide plates instead of guide pulleys. Two types of glide plates are available: •

Glide plate made of Oilon (plastic)

•

Glide plate made of spring steel

Lubrication of glide plates Lubricate the glides plates at the first two servicing opportunities, and then as required. Use the lubricant below: •

Gleitmo 850 for Oilon plates

•

Molycote for spring steel plates

Checking for wear Check the degree of wear by measuring the amount of play against the glide surface. Replace the plates when the play exceeds 3 mm.

Replacing the glide plates •

Dismantle the fork carriage/inner mast.

•

Loosen and remove the locking bracket.

•

Remove the glide plates.

•

Ensure that the spacers and holders are undamaged.

•

Put the new plates in the holders.

•

Lock the plates with the locking bracket.

•

Reassamble the fork carriage/inner mast.

Glide plates

Glide plates

Glide plates

Glide plates

K445

DC 2,5 - 8

Contents

Technical Handbook

9083 95-12 90 1 Gr. P Publ.

Group 90

Periodic supervision Periodic supervision ___________________________________________ 3 General __________________________________________________ 3 General survey chart ________________________________________3 Daily supervision ___________________________________________ 4 Every 200 hours ____________________________________________ 5 Every 500 hour _____________________________________________6 Every 1000 hours ___________________________________________ 7 Lubrication Chart ___________________________________________ 8 Oil and lubricant recommendations ____________________________ 10 Lubrication grease ______________________________________ 10 Hydraulic oil ___________________________________________ 10 Gearbox oil ____________________________________________ 10 Drive axle oil ___________________________________________ 10 Engine oil _____________________________________________10

DC 2,5 - 8

9083 95-12 90 3 Gr. P Publ.

Periodic supervision

Technical Handbook

Periodic supervision 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.

Special procedures are required on trucks used under difficult conditions, such as in difficult terrain or for the transport of hot goods. These procedures are not dealt with here.

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 600 hours

2.

Every 200 hours

The same procedure also applies to work carried out in a 600-hour service.

General survey chart Maintenance intervals, hours Operating time, hours

1000

600

200

200 400 600 800 1000 1200 1400 ...

2000 ...

Remarks

Guarantee service after 200 hours. Comprises: • Work in accordance with list below

Warranty service at 200 working hours 1.

200 hours service according to Technical Handbook, group 90

2.

Changing of oil in engine and gearbox

3.

Changing filter in engine, gearbox and hydraulic system (all filters including WDB, servo filter etc)

4.

Valve clearance adjustment (engine)

5.

Check all bolt joints (see also SI94-003)

6.

Fill in date and signature in the warranty card

DC 2,5 - 8 Technical Handbook

Periodic supervision

9083 95-12 90 4 Gr. P Publ.

Daily supervision ACTION

Alternatively when refuelling

Check

Brakes

Function

Steering

Function

Topping-up when necessary

All instruments: Direction indicators, brake lights,

Function

horn, lights, reflectors Lifting chains

Damage

Links, suspension Lift, tilt, sideshifting

Function

fork positioning Engine, gearbox, drive axle

Unusual sounds?

Hydraulic hoses

Oil leakage?

Fuel

Quantity Fuel gauge must never show 0

1

Engine oil

Level

Coolant

Level

Battery

Level

Windscreen washer

Liquid level

Hydraulic oil

Level

Wheels

Tyre pressure 1) 0,8 MPa

) Unless otherwise specified

If special antifreeze coolant is used in the radiator, anticorrosion additive should be mixed with the coolant

DC 2,5 - 8 Technical Handbook

9083 95-12 90 5 Gr. P Publ.

Periodic supervision

Every 200 hours Item Unit

Action

1

Outside of the truck

Wash with high-pressure unit Inspect the roof of the cab, lubricate the hinges

2

Radiator

If necessary, flush the outside of the radiator with water and detergent

3

Engine

Change the oil and replace the oil filter1) PERK 1 ) Every 200 hours

4

Engine and coolant connections

Check the tightness

5

Air cleaner

Check the filter and shake it clean.

Replace if necessary.

6

Battery leads, terminals and fuses

Clean the terminals and apply petroleum jelly

7

V-belts

Check the tension

8

Lifting mast and fork carriage

Check for damage. Tighten the nuts

9

Steering

Check for play, etc.

10

Steered wheels and driven wheels

Tighten the wheel nuts. Inspect the tyres and wheels for damage

11

Steering, propeller shaft and tilt cylinders

Lubricate

12

Drive axle and propeller shaft

Check the oil level, check for leakage.

Tighten the bolted joint of the axle.

13

Gearbox

Check the oil level and mounting, check for leakage

14

(Exhaust gas emission control system)

Inspect the catalyst.

Top up with catalyst if necessary

Guarantee service at 200 hours

Reference Remarks

N.B. Not under high pressure

PERK = Perkins Workshop Manual for Diesel (LPG)Engines 4.236 alt 6.3544

DC 2,5 - 8 Technical Handbook

9083 95-12 90 6 Gr. P Publ.

Periodic supervision

Every 500 hour Item Unitt

Action

1

Engine, diesel and LPG

Adjust the idling. Inspect the engine and alternator mountings.

2

Engine, LPG

Overhaul the ignition system and the LPG system, and replace wear parts as necessary

3

Air cleaner

Replace the filter element

4

Exhaust gas emission system

Check the tightness

5

Steered wheels

Check the parallelism, deformation.

Inspect bearing clearances and adjust if necessary

6

Hydraulic hoses on the mast

Check that the hoses guide pulley runs freely and that the hoses are undamaged

7

Forks

Inspect for wear

8

Gearbox

Change the oil after the first 500 h Replace the filter every 500 h

9

Battery

Top up the batteries with water twice a year

10

200 h service

Note!

Always attend to damage, wear and faults which may be of importance to the performance and service life of the truck or to personal safety.

Reference Remarks

DC 2,5 - 8 Technical Handbook

9083 95-12 90 7 Gr. P Publ.

Periodic supervision

Every 1000 hours Item Unit

Action

Reference Remarks

1

Engine, diesel and LPG

Inspect the valve clearance, cooling system, starter system, starter motor, alternator and fuses

PERK

2

Engine LPG

Clean the filter in the evaporator

PERK

3

Fuel tank

Drain

4

Fuel filter, diesel

Replace the fine filter. Clean the pre-filter.

Bleed the fuel system Clean the strainer

PERK

PERK.

Fuel filter, LPG 5

Injectors

Check the opening pressure, tightness and shape of the jet if necessary

6

V-belts

Replace all

7

Batteries

Check

8

Wheels

Inspect for damage

9

Hydraulic system Steering system pump

Replace all filters (change the oil every 2000 h) Clean the filter element

10

Gear-changing

Check the clearance

11

Drive axle and propeller shaft

Tighten the bolted joints.

Check for leakage.

12

Differential

Tighten the bolted joint

13

Drive axle Hub reduction

Change the oil Clean the breather filter

14

Seat bearing (rotatable seat)

Lubricate

15

Anti-slip covering on the steps and the cab floor

Inspect and replace any worn parts of the anti-slip covering

16

Paintwork and safety markings

Touch up

17

Fresh air filter

Replace the filter

18

(Air conditioner)

Check the performance

19

Hose guide pulley

Dismantle and lubricate

20

Gearbox

Change the oil and replace the filter Clean the suction filter

21

Brakes

Check the discs

22

500 and 200 hour service

Note!

Always attend to damage, wear and faults which may be of importance to the performance and service life of the truck or to personal safety.

Add 6 % Lubrizol See Group 70

DC 2,5 - 8

9083 95-12 90 8 Gr. P Publ.

Periodic supervision

Technical Handbook

Lubrication Chart 1

8 2 3 4

5 6 7

11

10

9

10

18, 19

17 16 15

12

21

8

14

13 20

20

13

14

K337

Note!

If the truck is left unused outdoors with the piston rods extended they must be lubricated with grease to prevent corrosion.

After washing with degreasing agent all pistons should be run back and forth a few times to renew the protective film of lubricant.

DC 2,5 - 8 Technical Handbook

9083 95-12 90 9 Gr. P Publ.

Periodic supervision

Item Designation No.

Hours of operation

No. of lubr. points

1

Cylinder bearing (no lubrication)

K

2

Hose reel

3

Chain wheel

4

Chains

5

Wheels and supporting rollers

S

*)

6

Fork spread guides

S

1

7

Cylinder bearing

S

4

8

Glide plates

K

4

9

Gearbox, oil

K

10

Gearbox oil filter

11

Engine oil

12

Engine oil filter

13

Comments

4

Not to be lubricated

*)

2

*) Dismantle, clean and pack with grease, remount

S

2

S

2

*) Varies with type of mast

1

*) Change the oil

1

*) Change the filter

*)

1

*) Oil change every 200 hours1)

*)

1

*) Filter change every 200 hours

Steer wheel bearing

2

14

Knuckle pin bearing

4

Dismantle, clean, inspect, pack with grease and refit every 2000 hours

15

Drive axle

K

1

*) Change the oil, incl. hub gearing

16

Universal shaft

S

17

Hydraulic filter

18

Hydraulic fluid + Lubrizol 6 %

19

Venting filter hydraulic reservoir

20

Linkage

21

Hinges, doors and covers

S = Lubricate

*)

Brush or spray with thin engine oil

*)

*)

3 *)

1

K

*) Change filter Change the fluid every 2000 hours

*) S

1

*) Change filter

4 S

Lift off doors and covers

K = Check

For quantities, see ”Technical Data”.

For lubricant grades, see ”Kalmar LMV Lubricant Recommendations”.

1)

The interval is greatly dependet 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.

Volumes, see Technical specification

DC 2,5 - 8

Periodic supervision

Technical Handbook

Oil and lubricant recommendations Engine oil Quality:

API-CD oil for turbo engines from a reputable oil company.

Viscosity:

See diagram below -30

-20

-10

10

20

SAE 10W/30

-25°C

SAE 5W/30

±0°C

SAE 30 +10°C

-4

40

°C

*

-10°C

-10°C SAE 20W/30

-22

30

SAE 15W/40

-15°C

**

0

14

32

50

*

SAE 40 68

86

* 104

°F

K038

*)

The use of these oils at temperatures above + 15 °C and + 30 °C includes a risk for engine wear.

**)

Refers to synthetic or semi-synthetic oil.

N.B. Only SAE/30 must be used.

Lubrication grease Use a multipurpose grease of type EP NLGI-Grade 2 with 3-5 % Molybden disulphide for all lubricating points, wheel bearings included.

Hydraulic oil Quality:

Hydraulic oil from a well known oil company.

Viscosity:

ISO VG 32 at normal operating temperature ISO VG 46 at increased operating temperature ISO VG 68 at high operating temperature

Engine oil with a viscosity of SAE 10 may also be used.

To avoid the brakes from hacking 6 % LUBRIZOL should be added to the hydraulic oil. The addmixture is not consumed at normal operating and should only be added after oil changing. LUBRIZOL can be ordered from Kalmar LMV spare part service.

Gearbox oil Quality:

Clark, Borg Warner:

Viscosity:

Engine oil API-CD, C-3 SAE 5W;10W; 20W

N.B. Never mix engine oil with ATF oil.

Voith:

ATF-oil

Drive axle oil Quality:

API GL-5.

Viscosity:

SAE 80W/90 or 80W/140.

9083 95-12 90 10 Gr. P Publ.