920937_9350 Maintenance DCE90-180 y DCD70E5

8/13/2019 920937_9350 Maintenance DCE90-180 y DCD70E5

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00

10

20

30

40

50

60

70

80

90

General

Chassis and cab

Electrical system

Engine

Transmission,drive axle, brakes

Steered axle

Hydraulic system

Lifting mast and

fork carriage

Periodic supervision

Technical

HandbookDCD90-180DCD70-32E3 - 70-40E5

This Handbook deals with the designand maintenance of Kalmar forklifttrucks, type DCD.

In addition, it gives details oftroubleshooting and the most commoncorrective maintenance.

Operation and other matters that areprimarily of interest to the operator areincluded in the Instruction Manual.

Kalmar Industries AB

We reserve the right to modifyour design and material specifications without prior notice.

Publ. No. 920 937 9350 02-08AdEra Dokument AB, Vxj 2002


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DCD90-180Technical Handbook Contents 1P.Group 00

935000-11

Group 00

Contents

Safety regulations ..................................................................... 2General ..................................................................................... 5

Applications ......................................................................... 5Design ................................................................................. 6Component units ................................................................. 6Main components ................................................................ 8Supplementary books .......................................................... 9Replacement system Spare parts .................................... 9Tools .................................................................................... 9Tightening torques ............................................................. 10System of units .................................................................. 12


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DCD90-180Technical Handbook

Safety regulations2P.Group 00

935000-11

It is important that you read the instruction manualIncorrect handling can lead to personal injury or damage to prod-ucts and/or property. Therefore, read the instruction book verycarefully before operating the truck. The instruction manual con-tains important information about your Kalmar truck, about theoperation of the truck, about safety during operation and aboutthe trucks daily maintenance. In addition, you will find useful in-formation that will make operations easier for you in your dailywork.Ask your foreman/group leader if there is anything in the manualthat you do not understand or if you feel that information is miss-ing in any area.

The symbol is used on our products in certain cases andthen refers to important information contained in the instructionmanual. Make sure that warning and information symbols are al-ways clearly visible and legible. Replace symbols that have beendamaged or painted over.

Safety regulationsIn this handbook warnings are inserted that apply to your ownsafety. Warnings point out the risk of accident that can cause per-sonal injury.

For technical warnings, that point out the risk of break down, theword IMPORTANT is used:

For information that facilitates the working process or handling,N.B. is used:

N.B. Draws attention to useful information that helps theworking process.

WARNING!

Warns of the risk of serious personal injury, possibledeath and/or serious damage to product or property if theregulations are not followed.

IMPORTANT!Is used to draw attention to such occurrences that can

cause damage to the product or property.


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935000-11

Intended of use

The truck may only be used for the purpose forwhich it was intended, namely, to lift and transportgoods, the weight of which does not exceed themaximum permitted load capacity of the truck.The truck may not, without specific permissionfrom Kalmar, be modified or re-built so that itsfunction or performance is altered.The truck may not be driven on public highways ifit has not been adapted to comply with nationalroad safety regulations.

Operator requirementsThe truck may only be driven by operators whohave been specially trained and who have thecompanys authority to do so.Laws and other regulations relating to driving li-cence, operator ID, log book, etc., must be fol-lowed at all times.The operator must be aware of and follow all localsafety regulations.

Operation of the truck is prohibited:If any of the fitted safety equipment, such as rearview mirrors, headlights, reversing alarm (option-al) does not function correctly.If there is a fault with the brakes, steering or liftequipment.If the truck is fitted with tyres not approved byKalmar.

Operating regulationsBefore starting, always check to ensure that no-body is in the way of the truck or its equipment.Make sure that nobody walks or stands under-neath raised forks or other equipment, whetherthey are loaded or not.The operator must always face the direction of op-eration and take particular care in areas wherepersons or other vehicles are likely to appear inthe vicinity. If visibility is limited by the load, the op-erator should operate the truck in reverse.It is prohibited to transport passengers on thetruck outside the cab or on the load. Passengersmay be transported inside the cab only on condi-tion that it is equipped with a fixed passengerseat.It is prohibited to lift people if the truck is notequipped with an approved lift cage.It is prohibited to exceed the load capacity of thetruck. See capacity plate and loading diagram.It is prohibited to transport loads in the raised po-sition as this entails a risk of the truck tipping. Alltransportation shall take place with the load in thelowered position and with the mast tilted back-wards to the maximum.The operator must adapt the speed of the truck tothe character of the load, conditions of visibility,

the character of the roadway/surface, etc.The operator shall avoid powerful accelerationand braking when turning. In addition, the opera-tor shall always moderate the speed of the truckwhen turning so as to avoid the risk of lateral skid-ding or tipping.

The operator shall take particular care when oper-

ating in the vicinity of electrical power lines, via-ducts, quay-sides, ramps, gates/doors etc.Safety belts must always be worn, if fitted. In theevent of the truck tipping, always remain in thecab and grip the steering wheel securely. Nevertry to jump out of the cab.The parking brake can also be used as an EMER-GENCY BRAKE. However , having been used foremergency braking, the brake linings must be in-spected and replaced if needed. If the parkingbrake has been mechanically released, it mustalways be reset in order for the truck to regainthe parking brake function.

Interrupted operation, parking

Always check that the gear lever is in the neutralposition before turning the ignition key to restart orto reset an emergency stop.Never leave the operators cab without applyingthe parking brake (ON position).Always remove the ignition key if the truck is to beleft unattended.

Other important points to rememberThe trucks hydraulic system includes high pres-sure hydraulic accumulators. Always be extreme-ly careful when working with the hydraulic systemand avoid being unnecessarily close to the hy-draulic equipment, lines and hoses. Before work-

ing on the hydraulic system, the accumulatorsmust be emptied into the tank, with the help of thespecial accumulator evacuation valve.Handle batteries and junction boxes with greatcare. The batteries must always be protected overthe poles and connections.Always rectify any damage or wear and tear thatcan risk personal safety or that can affect thefunctions of the truck or its service life.Trucks with tippable cabs: The cab must alwaysbe tipped over the point of balance. If there is in-sufficient lateral space the cab must always be se-cured against accidental lowering with a brace orsimilar.Avoid touching oils and greases. Avoid inhalingexhaust and oil fumes.Welding painted steel produces poisonous gas-ses. Paint should therefore be stripped beforewelding, good ventilation ensured and/or facemask with filter used.

Operating with attachmentsThe operator must always take the effect of the windinto account when handling containers. Avoid liftingwith a wind strength in excess of 12 m/s (27 mph/40feet per second).Always drive carefully so as to avoid attachmentscolliding with pillars, cables, etc.Carefully study the "Lift methods" section of theinstruction manual.

Safety regulations aimed at reducing the risk of personalinjury and damage to loads or other property.


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935000-11

Tyre changing can be dangerous and should only

be carried out by specially trained personnel usingproper tools and procedures.Failure to comply with these procedures may re-sult in faulty positioning of the tyre and/or rim andcause the assembly to burst with explosive forcesufficient to cause physical injury or death. Neverfit or use damaged tyres or rims.Never attempt to weld on an inflated tyre/rimassembly.Never let anyone assemble or disassemble tyreswithout proper training.Never run the truck on one tyre of a dual assembly.The load capacuty of a single tyre is then danger-ous-ly exceeded and operation in this manner maydamage the rim.Deflation and dismantling Always block the tyre and wheel on the opposite

side of the vehicle before you place the jack inposition. Always crib up the blocks to preventthe jack from slipping.

Always check the tyre/rim assembly for propercomponent seating prior to removal from thetruck.

Always deflate the tyre by removing the valvecore prior to removing the complete assemblyfrom the truck or dismantling any of the compo-nent. Before loosening mounting bolts, run awire through the valve stem to ensure that it isnot blocked. Ice or dirt can prevent all the airfrom escaping. Deflate and remove valve coresfrom both tyres of a dual assembly.

Never position body in front of the rim during de-flation.

Always follow assembly and dismantling proce-dures outlined in the manufacturer s instructionmanual, or other reconized industry instructionmanuals. Use proper rubber lubricant.

Never use a steel hammer to assembling or dis-mantling rim components use a lead, brass or

plastic type mallets. The correct tools are avail-able through rim/wheel distributors. remove bead seat band slowly to prevent acci-

dents. support the band with your thigh and rollit slowly to the ground in order to protect backand toes.

Disassembly tools apply pressure to rim flangesto unseat tyre beads. Keep your fingers clear.Slant disassembly tool about 10 degrees tokeep it firmly in place. Always stand to one sidewhen applyin g hydraulic pressure. Should thetool slip off, it may cause fatal injury .

Rim inspection Check rim components periodically for fatigue

cracks. Replace all cracked, badly worn,damaged and severely rusted components.

Always select the correct tyre size and construc-tion matching the manufacturer s rim or wheelrating and size.

Do not use over-size tyres, too large for the

rims, e.g. 14.5 inch tyres with 14 inch rims or16.5 inch tyres with 16 inch rims. Never use damaged, worn or corroded rims/

wheels or fitting hardware. Always verify that therim is in a serviceable conditioning.

Always clean and repaint lightly rusted rims. Never use a rim/wheel component that can not

be identified. Check rim parts against multi-piece rim/wheel matching charts.

Assembly and inflation It is important that the inflation equipment is

equipped with a water separator to removemoist-ure from the air line in order to prevent co-orosion. Check the separator periodically to en-sure that it is working properly.

Make sure that the lockring is in its right posi-tion.

Never mix different manufacurer s parts sincethis is potentially dangerous. Always checkmanu-facturer for approval.

Never seat rings with hammering while the tyreis inflated. Do not hammer on an inflated or par-tially inflated tyre/rim assembly.

Always double check to ensure that the rim as-semblies have been correctly assembled andthat securing studs and nuts are tightened to the

correct torque setting. Never inflate tyres before all side and lockringsare in place. Check components for properassembly after pumping to approximately 5 psi(=34 kPa, =0.34 bar)

When adding air to a tyre on an industrial truck,use a clip-on chuck and stay out of the dangerarea. If the tyres has been run flat then the rimmust be dismantled and all parts inspected fordamage.

Under-inflated tyres have a serious effect on thestability of the truck and reduces the safe loadhandling capacity. Always maintain tyres at thecorrect inflation pressures. Check inflationpressure daily. Do not over-inflate.

Inspect tyres regulary every day if possible.Look for and remove broken glass, torn piecesof tread, embedded metal chips etc. Inspect foruneven or rapid tread wear, usually caused bymechanical irregularities, such as brakes out ofadjustment or excessive toe-in and toe-out. Ifdiscovered, correct the irregularity immediately.

When installing and tightening trail wheel bolts, ob-serve the following: Ensure that trail wheel or hub mounting surfac-

es and trail wheel fastener mounting surfacesare clean and free from paint and grease.

Tighten bolts to specified torque settings. usestaggered sequence; i.e. top bolt, bottom boltetc.

Safety instructions for working with tyres


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General5P.Group 00

935000-11

ApplicationsThe Kalmar DCD90-180 range of trucks is based on an entirelynew approach to the design and production of medium-heavy,diesel-powered forklift trucks. The trucks are durable and safeand their accessibility for service and maintenance is unexcelled.Due the their versatility, the trucks can be used in a number of ap-plications, such as:

Steelworks and heavy engineering industry, where thetrucks handle individual tasks in the handling of medium-heavy goods.The forest industry for handling logs by means of a log grap-ple attachment, sorting of logs at sawmills and handling ofsawn timber in units loads.Ports and container terminals for handling medium-heavygoods and handling empty containers.Factories producing houses lifting of house sections.

KL734

DCD90-180


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General6P.Group 00

935000-11

Design general surveyKalmar DCD90-180 diesel trucks are of sturdy design for heavyduty. They are built around a chassis which has high strength andtorsional stiffness and an extremely low centre of gravity.The operator s cab is provided with vibration isolation and soundinsulation and offers excellent all-round visibility.The operator is provided with many facilities for adjusting hisseating attitude. The seat, backrest and springing of the opera-tor s seat can be adjusted in a wide variety of ways.The cab is tiltable and offers excellent accessibility to the trans-mission and pumps. The engine is easily accessible through acasing, divided in two halves.The Volvo or Perkins six-cylinder turbocharged engine TD640VEor TD730VE/TWD731VE, combined with a three-speed gearboxwith torque converter, provides smooth power whenever needed.The drive axle with hub reductions, the oil-cooled hydraulic brakesystem and the pendulum-mounted steered axle with double-act-ing steering cylinder satisfy very strict demands on strength and

mobility when travelling on irregular surfaces.The hydraulic system is reliable and has high performancecharged by two or three hydraulic pumps.For further details, see group 70.

Component unitsSound-insulated and safety-tested operator s cab with ex-cellent all-round visibility. The non-slip, substantial steps pro-vide convenient access to the cab. All models in the seriescan be equipped with a rotatable operator s seat.Clearly arranged instrument panel.Engine Volvo TD640VE or TD730VE/TWD731VE six-cyl-inder, four-stroke, turbocharged diesel engine with direct in-

jection and thermostatically controlled water cooling.The engine is equipped with: Injection pump with centrifugal governor that compensate

for load variations. Alternator. For alternatives, see separate table.


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General7P.Group 00

935000-11

Gearbox with torque converter Constant-mesh gearbox in which hydraulically actuated

clutches for the different gears. The clutches are electri-cally operated.

Torque converter, which is a hydraulic coupling that ampli-fies the output torque on an increase in load. Torque con-

version takes place smoothly and steplessly throughoutthe engine speed range. Oil cooler connected to the engine cooling system for

cooling the oil in the gearbox and torque converter. Oil pump which supplies oil under pressure to the gearbox

and torque converter. Full-flow oil filter for effective cleaning of the gearbox oil.

Drive axle with two-stage reduction - in the differential andthe hub reductions. Oil cooled hydraulic brakes for the foot brake, e.g. Wet

disc brakes. Disc type parking brake applied by a sturdy spring and

released by hydraulic oil pressure.

Hydraulic system with Gear type hydraulic pumps connected to take-offs on the

torque converter. One pump for working hydraulics andone for steering and accumulator charging, which in turnserves the brake circuits.

Main valve for controlling the main hydraulics. The valveis controlled hydraulically from the cab. An electro-hy-draulic servo system is available as an option.

A high pressure filter after each pump for effective clean-ing of the hydraulic fluid before it is fed to the system.

Steering valve (Orbitrol) - flow-control valve which sup-

plies hydraulic fluid to the steering cylinder.

Steered axle with pendulum mounting and double-actingsteering cylinder.

Sturdy clear-vision mast. Of duplex or triplex design, with orwithout free lift. Outer mast with hydraulically controlled 5 forward and

10 backward tilting. Tilting cylinders with back-pressure valves to prevent the

load from tilting the mast forward. Inner mast with support rollers that carry the forces on the

mast. Yoke with guide rollers for the hydraulic hoses andguide sprockets for the lifting chains.

Lifting cylinders - two cylinders mounted on the outermast.

Fork carriage designed for optimum visibility and equippedhydraulic with fork positioning and sideshifting (optional).


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General8P.Group 00

935000-11

1. Free -visibility mast, with two lifting cylinders2. Operator s cab, rubber suspended cab3. Engine, six-cylinder diesel engine with

turbo-compressor4. Steering axle, with pendulum suspension and

double acting steering cylinder

5. Gearbox, combined with torque converter6. Drive axle, with hub gearing and oil-cooled

hydraulic brake7. Fork carriage, hydraulically controlled fork

positioning and sideshift

Main component units

KL734

2 31

6 5 4

7


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General9P.Group 00

935000-11

Main components

Supplementary books

In addition to the Instruction Manual and the Technical Hand-book, the following books are delivered with every truck.

Spare parts catalogueInstruction Manual for Volvo Industrial enginesWorkshop Manual for Industrial enginesWorkshop Manual for the Perkins engine

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

ToolsKalmar offers a wide range of tools for truck maintenance work.

For further information, please contact Kalmar s service depart-ment.

Alternative drive lines= Standard = Optional

9 0

- 6

1 0 0

- 6

1 0 0

- 1 2

1 2 0

- 6

1 3 6

- 6

1 2 0

- 1 2

1 5 0

- 1 2

1 6 0

- 6

1 6 0

- 9

1 6 0

- 1 2

1 8 0

- 6

Engine *Turbo **Turbo, intercoolerVolvo TD640VE* 129 kW/690 Nm

Perkins 1006-60T1* 85 kW/465 Nm

Volvo TD730VE* 150 kW/800 Nm

Volvo TWD731VE** 167 kW/893 Nm

Perkins 1006-60T2* 114 kW/620 Nm

Scania DI9** 167 kW/930 Nm

Cummins 6BTA5.9-C200** 162 kW/814 Nm

Gearbox with powershift, 3+3 gearsClark 13.7HR 28000(Volvo TD640VE, TD730VE,Perkins 1006-60T2, Cummins 6BTA)

Clark 1207 FT 20302(Perkins 1006-60T1)

Clark 13.7HR 32000(Volvo TD640VE, TD730VE, Volvo TWD731VE,Scania DI9, Cummins 6BTA)

Drive axle with Wet Disc Brakes

Pneumatic t yres 10.00x20/16PR11.00x20/16PR12.00x20/20PR

Optional: Semi-solid tyres (Super-Elastic)


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General10P.Group 00

935000-11

Tightening torquesThe tightening torques are applicable to steel bolts and nuts tight-ened 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. How-

ever, in the latter case, the preloading force will be somewhatlower, depending on its depth of engagement.When tightening by machine, the torque specified in Table 1should be reduced by approx. 5%, due to the increased scatterand to prevent the bolt from being tightened beyond its yieldpoint.

Surface treatment

Condition LubriationBolt Nut

1 untreated untreated oiled

2bright galvanisedbright galvanisedbright galvanised

untreatedbright galvanisedbright galvanised

dry or oiled

3 hot-dip galvanised bright galvanised dry or oiled

Quality 8,8 10,9 12,9

Tightening torque, NmCondition

ThreadM fin 1 2 3 1 1

M81M101,25M121,25M161,5M181,5

275496

230330

244885

205294

3061

108260373

3976

135323466

4691

162388559

M201,5M242M302M363

460786

26601560

409700

13882367

520888

17633005

647110022003730

777133026404480


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General11P.Group 00

935000-11

To reduce the risk of settlement of the material and theassociated reduction in the preloading force if the hardness of thesurface supporting the bolt head or nut is lower than 200 HB, awasher should be fitted under the bolt head and nut. This is notapplicable if flanged bolts or flanged nuts are used.When tightening is carried out, the specified torque should be ap-plied without pause, to ensure that the torque wrench will not betripped by the static friction before the joint has been tightened tothe specified torque.

Quality 8,8 10,9 12,9


ThreadM 1 2 3 1 1

4568

10

3,26,4112652

2,95,79,82447

3,67,2

12,53059

4,69,1163874

5,511194589

1216202430

91220430750

1480

81198386668

1317

10325049

8481672

128313620

10502080

154375732

12702500

Quality 8,8 10,9 12,9


ThreadUNC 1 2 3 1 1

1/45/163/87/161/2

12,5254470

107

11,122,3396295

14,128,35079

121

17,63562

100151

204273118178

9/165/83/47/8

11 1/81 1/41 3/81 1/2

153210370594

8891260176023203060

136187390528

7911120156520652720

173237418671

10051424199026203455

216298524839

12601780249032804320

255353619990

14802100294038705100


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General12P.Group 00

935000-11

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

Pressure

Torque

Quality 8,8 10,9 12,9


ThreadUNF 1 2 3 1 1

1/45/163/87/161/2

13264775114

11234266

101

14295385

128

193767

107162

224479

126191

9/165/83/47/8

11 1/81 1/41 3/81 1/2

164227396629

9371350186025003260

145202352560

8341200165522252900

185256447710

10581525210028253680

231321559889

13201900263035304610

273379661

1050

15602250311041705450

megapascal bar Kilogram-force persquare centimetre,kpf/cm Atmosphere, at

Pound-forceper squareinch,psi

10,10,098

1010,98

10,21,021

14514.514.2

Newton-meterNm

Kilogram force-metrekgf m

Pound-force footlbf ft

19,81

0,1021

0.747.23

Power

KilowattkW

Horsepower (metric)hp

Horsepowerhp

10,735

1,361

1.340.986


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935000-11

Group 10

Chassis and cab

Specifications ........................................................................... 2Chassis...................................................................................... 3

Description ........................................................................... 3Operators cab ........................................................................... 4

Description ........................................................................... 4Steering column .............................................................. 7Pump and cylinder for cab tilting ..................................... 8Accelerator pedal with change-over switches forforward and reverse ........................................................ 9Gear selector type RMH................................................ 10Hydraulic weight indicator ............................................. 11

Service ............................................................................... 12Changing the fresh air filter ........................................... 12Check and lubrication of brake pedal ............................ 12Windscreen wipers ........................................................ 13

Air conditioning unit ................................................................. 14Description ......................................................................... 14Service ............................................................................... 17

Checking the air conditioning unit ................................. 17


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Specifications2P.Group 10

935000-11

Air conditionerCab unitCirculated air flow 500-600 m 3 /hElectric power consumption approx 350 W

CompressorMax. speed 4000 r/minRefrigerant R134a *)Electric power consumption approx 50 WOil capacity Zexel PAG SP-20 1.5 dl

CondenserElectric power consumption 250 W

Cooling effect 6-8,5 kWHeating effect approx 11 kW

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


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ChassisDescription 3P.Group 10

935000-11

ChassisThe chassis consists of:

A unit construction frame built up around two beams with aminimum of welds for best possible strength.Mountings for the drive axle, steered axle, mast, lifting cylin-

ders and transmission.The necessary counterweights to provide a very low centreof gravity. Moreover, the steered axle is designed to serve asan additional counterweight.The hydraulic oil tank and the fuel tank are produced as sep-arate units and are bolted to the side of the chassis. Thetanks have a low profile, which contributes to the good visi-bility.

Chassis 90-180

1

2

3

1. Hydraulic tank2. Counterweights3. Service hatch for the battery4. Fuel tank

4


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Operators cabDescription 4P.Group 10

935000-11

Operator s cabThe operators cab is a separate structure and rests on the chas-sis on rubber dampers. The operators seat, steering wheel andhydraulic control levers can be adjusted for best possible opera-tor comfort. Effective insulation minimises the vibrations andsound level in the cab.The standard heating system consists of a fan and heater forheating the air in the cab by recirculation. Fresh air is drawn inthrough a ventilation air filter. Full air conditioning, with cooling,heating and dehumidification, is available to special order.

1. Steering column with instrument panel and switches, ECS-terminal (option)2. Air filter3. Heating system4. Electrical central unit

1

2

3

4


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Operator s cabDescription 5P.Group 10

935000-11

1

2

3

4

N

R

F

1 4 5

2 3

R

0

L

KL735

8 9 10 11 12 13 14

3 1 4 5 2 6

a b c d

1. Gear selectorFORWARD/NEUTRAL/REVERSE 1/2/3

2. Lever DIRECTION INDICATORS/HORNFRONT WINDSCREEN WASHER/FRONT WIPERS/MAIN BEAM

3. Instrument panel4. Steering wheel panel5. Starting switch6. Control lever, hydraulic functions

a. Lift, b. Tilt, c. Sideshift, d. Fork positioning

7. Electrical central unit with fuses and relays8. Brake pedals, normal driving brake9. Release clutch10. Accelerator pedal11. Steering wheel adjustment12. Stop control13. Parking brake14. Operator s seat

KL743

7


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935000-11

KL581

21 22 23

2425

2627

37 38 39

3132

33

2829

30

34 35 36

KL582

40 41 42 43 44 45 52 53

47 48 49 50 51

46

KL675

KL580

54 55 56 6059

57 58 64 61 62 63

1

2

3

4

N

R

F

1

4 5

2 3

R

0

L

21. Pressure gauge, gearbox oil pressure22. Fuel gauge23. Temperature gauge, engine coolant temperature24. Switch, working lights25. Switch, working lights26. Switch, working lights27. Switch, flashing beacon28. Switch, hazard warning lights29. Switch, driving lights30. Spare31. Spare32. Spare33. Spare34. Switch, compressor air conditionin g 1)35. Control, recirculation/fresh air36. Control, defrost/cab37. Switch, fan38. Control, heat39. Control, cold 1)

40. Spare41. Spare42. Warning lamp, battery charging43. Warning lamp, low engine oil pressure44. Warning lamp, low gearbox oil pressure45. Warning lamp, low brake pressure

(accumulator pressure)46. Warning lamp, low engine coolant level47. Indicating lamp, preheating48. Warning lamp, high engine coolant temperature49. Warning lamp, high gearbox oil temperature50. Spare51. Warning lamp, parking brake ON52. Spare53. Spare54. Spare (Green lamp TWIST-LOCKS LOCKED) 1)55. Spare (Orange lamp ALIGNMENT) 1)56. Spare (Red lamp TWIST-LOCKS UNLOCKED) 1)57. Spare (LOCK/UNLOCK TWIST-LOCKS) 1)58. Spare (LENGT ADJUSTMENT 20-40 ) 1)59. Indicating lamp, headlights60. Indicating lamp, direction indicators61. ECS terminal 1)62. Switch, windscreen wiper, rear63. Switch, windscreen wiper, roof64. Spare65. Fuses66. Hour meter

1) Optional

66


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935000-11

Steering columnSurrounding the steering column are multi-function levers forgear changing, indicators, windshield wipers, etc., as well as theinstrument panel with the ECS terminal. At the very foot of thesteering column is the steering valve (Orbitrol), activated by thesteering wheel via an angled gear. The steering column isequipped with an adjustment handles for the alteration of steeringwheel height and rake.

KL580A

1

2

3

4

N

R

F

1

4 5

2 3R

0

L

Steering column

12

3

6

5

KL588

4

1. Gear lever2. Multi-function lever3. ECS terminal4. Steering wheel adjustment

handles5. Angled gear6. Orbitrol steering valve


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935000-11

Pump and cylinder for cab tiltingA hydraulic cylinder is provided for tilting the cab. The hydraulicfluid pressure for this purpose is generated by a manually opera-ted pump. The pump is fitted with a reversing valve for upward ordownward tilting.

1. Cab tilting cylinder2. Manual pump3. Vibration damper4. Cab tilting cylinder

Pump and cylinder for cab tilting

1 2

3

24


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935000-11

1

2

34

1. Push-button, reverse gear2. Push-button, forward gear3. Microswitch4. Engagemant and disenagagement of the

foot operated gear changing system

Accelerator pedal with change-over switches for forward and reverse


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935000-11

Gear selector type RMH


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Operator s cabService 12P.Group 10

935000-11

Changing the fresh air filter(every 200 hours or when needed)1. Remove the filter casing retaining bolts and remove the filter

element.2. Wash the filter insert with water and detergent or by using a

high pressure washer. Replace the insert if necessary.3. Reinstall the filter insert.

Check and lubrication of brake pedal(every 1000 hours)

1. Check and tighten the locking screws 3, so that the brakepedal is securely fitted in the console.

2. Lubricate the brake pedal shaft through the nipples 2.

1. Brake pedal2. Lubricating nipple3. Locking screw4. Shaft

1 2

34


27/242


Operator s cabService 13P.Group 10

935000-11

Windscreen wipersThe wiper arms are fixed to the wiper motor shafts via conicalsplines. The shafts are manufactured of hardened steel and thewiper arm mounting of soft, pressed metal. When fitting, the nutsmust be tightened so hard that the splines are pressed well intothe mounting and function as a carrier.

Removal1. Remove the wiper arms by loosening the nuts and thereafter

tapping and carefully rocking the arms to and fro.

Fitting1. Check to ensure that the splines on the motor shaft are free

from the softer material from the wiper arm mounting.If this is not the case, clean the splines so that they canpressed fully into the wiper arm mounting.

2. Fit the wiper arms onto the motor shafts and tighten the nutsto a torque of 16-20 Nm.Hold the wiper arm to take up the torque pressure so that itis not transferred to the motor, which could result in damage

.

2

3

4

1. Wiper arm fitting2. Securing nut, wiper arm

3. Grooved cone on motor shaft4. Wiper motor

1

IMPORTANT!The nuts must be tightened sufficiently hard, otherwisethe shafts may start to slip inside the wiper arm mounting,resulting in damage.


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Air conditioning unitDescription 14P.Group 10

935000-11

Air conditioning unitThe air conditioning unit consists of the parts shown in the illu-stration and its function is to maintain the climate in the ope-ra-tor s cab as comfortable as possible. The air conditioning unit:

heats the air when it is cold

dehumidifies the air when it is humidremoves impurities from the aircools the air when it is warm

The equipment is steered by switches and controls on the instru-ment panel.

1. Heating control2. Heat exchanger3. Vapourizer4. Expansion valve5. To condenser6. To compressor7. Heating valve8. From engine9. To engine10.Fan11. Fan12. Fan control13. Fresh air filter14. Air disperser15. Control defrost/cab16. Defroster outlet

The heating and ventilating system

1

3

4

5

6

27

9

8

10

15 16

11

13

1412


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935000-11

1. Liquid receiver/filter dryer2. Evaporator3. Fan4. Expansion valve6. Condenser7. Compressor

A High-pressure gasB High-pressure liquidC Low-pressure liquidD Low-pressure gasE Warm air in cabF Cooled air to the cabG Outside air for removing heat

F

E

C

E

D

2

3

4

A B7

6 G 1


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935000-11

CompressorThe air conditioning system is driven by the compressor. Thisperforms as a pump, drawing cold, low-pressure gas from theevaporator, compressing it and thereby raising its temperature,and discharging it at high pressure to the condenser.The compressor is driven by V-belts directly from the diesel en-gine. Switching between operation and idling is controlled by anelectro-magnetic clutch which, in turn, is controlled by a thermo-stat whose sensor is located between the fins of the evaporatorcoil. The thermostat switches off the compressor at low tempera-tures, to prevent icing of the evaporator.

CondenserThe function of the condenser is to convert the hot high-pressuregas from the compressor into liquid form. The tubes and fins ofthe condenser coil absorb heat, which is then removed by the airdelivered by the fan.The temperature of the refrigerant in the condenser varies from

about +50 C to +70 C. The pressure varies between 12 and 20bar, depending on the ambient temperature and the flow of airthrough the condenser. When the refrigerant is condensed intoliquid form, it is transferred under pressure to the liquid receiver/ filter dryer.

Liquid receiver with filter-dryerThe function of the liquid receiver with integrated filter dryer is tocollect the liquid coolant, bind the moisture, and to filter and re-move impurities. The receiver, which is located in the condenserhousing, also serves as the expansion vessel in the refrigerationcircuit.After flowing through the dryer in the bottom of the liquid receiver,the refrigerant flows through a riser tube. A sight glass enablesthe operator to check that the liquid flows without the presence ofany bubbles, and that the system is filled with a sufficient amountof refrigerant.

Expansion valveThe expansion valve throttles the flow and passes an optimisedquantity of refrigerant that the evaporator is capable of evaporat-ing.The expansion valve is also the part of the circuit which separatesthe high- pressure side from the low-pressure side. The refriger-ant flows to the expansion valve under high pressure and leaves

it under low pressure.The amount of refrigerant which passes the evaporator varies,depending on the thermal load. The valve operates from fullyopen to fully closed and in-between searches for a point to giveoptimum evaporation.

EvaporatorThe heat necessary for evaporating the refrigerant is extractedfrom the cab air which is circulated by a fan through the evapora-tor coil. The cab air is thus cooled, and is distributed and returnedto the cab.In the evaporator, the refrigerant reverts to the gaseous state andreturns to the compressor suction, thereby completing the cycle.


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Air conditioning unitService 17P.Group 10

935000-11

The liquid refrigerant should be completely evaporated before itis allowed to flow from the evaporator. The refrigerant is still coldeven when it has completely evaporated. The cold vapour whichflows through what remains of the evaporator continues toabsorb heat, and then becomes overheated. This means that thetemperature of the refrigerant has risen to above the point where

it evaporates without changing the pressure.In an evaporator which operates at a suction pressure of 2 bar,the liquid refrigerant will have a temperature of 1.1 C. When therefrigerant is subsequently evaporated through heat absorptionin the evaporator, the temperature of the gas will rise at the evap-orator outlet to +1.6 C. This represents a difference of 2.7 C be-tween the evaporation temperature and the temperature at theoutlet. This is called overheating.All expansion valves should be adjusted at the plant in such away that maximum evaporation with overheating is performed inthe air conditioning system.

Checking the air conditioning unitIf the unit is in continuous operation, this check should be carriedout every week from early spring to late autumn and during ex-tended periods of high humidity during the winter.If the unit is used very little during cold and dry winter periods, thecompressor should be run for a few minutes every week, to lubri-cate the rubber hoses, couplings, seals and shaft seal.

1. Start the engine and start the air conditioner.At an outdoor temperature below 0 C, the system cannotstart since the low-pressure relay breaks contact.

2. After 10 minutes of operation, check that no bubbles arevisible in the sight glass of the filter-dryer. (Bubbles shouldoccur only when the compressor is started and stopped.)If there are any air bubbles, subsequent filling should be per-formed by an authorised service mechanic.

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

4. Change the fresh air filter as necessary.5. Check the V-belt tension and the compressor mounting.6. Check that the magnetic coupling engages and disengages

satisfactorily.7. Check that the condensate drain from the cooling element is

not clogged. Check for leakage.

WARNING!

If the refrigerant hose should fail or if

other refrigerant leakage should oc-cur, switch off the air conditioner im-mediately.Refrigerant is injurious to the skin andeyes.Never release refrigerant in an en-closed space. If released into a serv-ice pit, for instance, the gas maycause asphyxia.It is forbidden by law to discharge re-frigerants into the air intentionally.Never carry out welding on a chargedrefrigeration system or in its vicinity.Only authorised service mechanicsare allowed to drain off and fill refrig-erant in the air conditioning system.

Only the prescribed refrigerant may beused when refilling.


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Air conditioning unitService 18P.Group 10

935000-11

LMHC

A

1

2

3

R D

1 , 5

GL 1,5SV 1,5RD 1,5 4 4

R R

R D

1 , 5

M

M M

BR 1,5

BR 1,5

VT 1,5

7

B R

1 , 5

8

30

85

87

86GL 1,5

10

LOW

IN CAB CLIMATE UNIT CONDENSER UNIT

1. Fan switch2. Cooler on/off3. Anti-freeze thermostat4. Resistor5. Fan motor6. Indicator lamp cold (in push button)7. High-/low-pressure monitor8. Relay9. Condenser fan

10. Compressor

5

6

9

Circuit diagram in cab climate unit/condenser unit

HIGH


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935000-11

Group 20

Electrical system

Specifications .............................................................................2Electrical system ........................................................................3

Description ............................................................................3Service ..................................................................................6

Checking the electrolyte level of the batteries..................6Fuses ...............................................................................6Bulbs ................................................................................6Relays ........................................................................... ...7Starting from another battery ...........................................7Cable markings ................................................................8

DiagramsGear changing systems.........................................................9

Clark 18000/20000, fixed operators seat .....................10Clark 18000/20000, rotatable operators seat ...............12Clark 28000/32000, fixed operators seat .....................14Clark 28000/32000, rotatable operators seat ...............16

Engine shut down at low/high coolant temperatureEngine with stop solenoid ..............................................18Engine with fuel shut off valve........................................19

Engine shut down, connected to the operators seatElectrically controlled extra hydraulic function.....................21Safety interlock system .......................................................22Component list DCD90-450Wiring diagram, truck body ............................... A08334.1000Wiring diagram, inner, standard ........................ A08333.1000Wiring diagram, inner, rotatable operators seat

..................................................................... A08333.1100Safety interlock system, empty container attachment, Volvo

..................................................................... A28047.0600Safety interlock system, empty container attachment, Perkins

.................................................................. A28047.0700


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935000-11

Alternator rating Perkins: 1260 WVolvo: 1540 W

Starting battery, voltage 2 x 12 Vcapacity 140 Ahearthing negative


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Electrical systemDescription 3P.Group 20

935000-11

The system voltage is 24V and the supply is taken from two 12Vbatteries connected in series and charged by an alternatoracross electronic rectifying and voltage stabilisation circuits. .The positive pole is connected across a main switch. The nega-tive pole is then connected to the chassis.Warning lamps and instruments are clearly arranged on the in-strument panel. The central electrical unit with fuses and relaysis located on the lower section of the cabs rear wall.

IMPORTANT!Always open the main switch when-ever work is to be carried out on theelectrical system, if the truck is to

remain idle for some time and when-ever welding work is to be carried outon the truck.

1. Main switch2. Battery

1

2


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935000-11

1. Transmitter, warning lamp low oil pressure and gearbox oil pressure instrument2. Transmitter, warning lamp low oil temperatur and gearbox oil temperatur instrument3. Fuse4. Relay preheater element5. Transmitter, coolant temp instrument6. Transmitter, high coolant temp instrument7. Transmitter, engine oil pressure instrument8. Transmitter, low engine oil pressure warning lamp9. Starter motor10. Transmitter, low coolant level warning lamp11. Engine wiring

Electrical components, Volvo engine


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935000-11

1. Sensor, coolant temperature2. Sensor, engine temperature (cold start)3. Stop solenoid valve4. Solenoid valve, disconnection cold start5. Resistor for stop solenoid valve6. Resistor for pre-heating glowplug7. Main fuse electrical system 2 x 50 A8. Sensor, warning lamp low gearbox oil pressure9. Glowplug, inlet air pre-heating10. Sensor, instrument gearbox oil temperature11. Sensor, warning lamp low engine oil pressure

1 2 3 4 5 6 7

98

Electrical components , Perkins engine

11

10


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Electrical systemService 6P.Group 20

935000-11

Electrical systemThe electrical system operates at 24 V. The source of power sup-ply are two 12 V batteries which are charged by an alternator. Thenegative pole is connected to the chassis.The positive pole is connected to a main switch A.

A Main switchChecking the electrolyte level of the batteriesThe batteries are fitted behind a cover on the left-hand side of thetruck. The electrolyte level should be about 10 mm above thecells. Top up with de-ionized water as necessary.Relay box in cab fusesFuse RatingNo. Circuit protected A

S1 Wiper motor front, direction indicators,seat buzzer, parking brake sensor ........................... 10

S2 Ignition key, pre-heater, starter motor,cab lighting (Air conditioner 25 A 1)).......................... 15

S3 Container attachment, safety interlock ..................... 15S4 Electric gear-changing ............................................ 5S5 Warning lamps, instrument illumination, relay,

coolant level .............................................................. 5S6 Brake lights, reversing lights, reversing alarm ......... 15S7 Fan (Air conditioner 1)) .............................................. 25S8 Spare (Working lights, container 1)) ......................... 15S9 Working lights (15 A for 4 lamps 1))

Hazard beacon ........................................................ 10

S10 Working lights, standard (15 A for 4 lamps) ............ 10S11 Horn, screenwash motor, wiper rear and roof,wiper front, intermittent relay .................................... 10

S12 Driving lights (main fuse), rear lights(main fuse), position lights ...................................... 15

S13 Main beam, right-hand (Main beam, front 10A 2)) ...... 5S14 Main beam, left-hand (Main beam, rear 10A 2)) ......... 5S15 Dipped beam, right-hand (Dipped beam, front 2)) ...... 5S16 Dipped beam, left-hand (Dipped beam, rear 2)) ......... 5S17 Rear light, left-hand (Rear light, front 2)) .................... 5S18 Rear light, right-hand (Rear light, rear 2)) ................... 5S19 ECU 1 1) ................................................................... 10S20 ECU 4 1) ................................................................... 10S21 Voltage converter 24/12 ............................................. 5S22-24 Spare........................................................................... -1) Optional equipment 2) Rotatable operator s seatBulbs

RatingDescription Watts ...................................... Base

Instruments 3 ............................................. BA7sIndicating lamps 1,2. ................................... W2x4,6dCab lighting 10 ............................................ S8,5Rear lights, red 5 ...........................................BA15sBrake lights 21 ......................................... BA15sDirection indicators 21.........................................BA15s

Position lights 5 ............................................SV8,5Driving lights 75/70 .................................. P43t-38(full/dipped beam)Reversing lights, white 70.........................................PK22sWorking lights 70 .........................................PK22sHazard beacon 70.........................................PK22s

N.B.The starting batteries accompanyingthe truck are of the maintenance-freetype, which implies that it should notbe necessary to top-up with electro-lyte during the life of the batteries.However, the level of the electrolyteshould preferably be checked once ortwice a year. Fill as required by addingde-ionized water.

IMPORTANT!When working with the electrical system, when carryingout welding on the truck or at long time parking, alwaysisolate the batteries.

S1-6 7-12 13-18 19-24


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935000-11

Relays305 Reversing light313-1 Brake light (rear-front) 2)313-3 Direction indicators (right-left) 2)313-4 Direction indicators (left-right) 2)313-5 Rear light (rear-front) 2)313-6 Dipped beam (front-rear) 2)313-7 Reversing light (rear-front) 2)313-8 Main beam (front-rear) 2)313-9 Shifting (rear-front) 2)313-10 Shifting (front-rear) 2)314 Parking brake, disengagement315 High power (Starting switch)316 Wiper motor, front320 Electric stop (ECS 07) 1)322-1 Coolant level322-2 Coolant level (ECS 07) 1)323 Pulse relay, direction indicators328 Lever steering (ECS 04) 1)

330 Starting block331 Propulsion forward332 Propulsion reverse334 Release clutch at automatic gearbox (ECS 01) 1)368 Low brake pressure (ECS 07) 1)399 Spare

Miscellaneous321-1 Intermittent relay wiper front321-2 Intermittent relay wiper rear 1)960 Reversing block1) Optional equipment2)

Rotatable operator s seat

Main fusefor electrical systemFitted on the engine2 x 50 A

Starting from another batteryMake sure the auxiliary batteries are connected in series, sothat 24 V will be supplied.

Note: Do not disconnect the truck-battery cablesConnect the jumper cables in the following order:1. Red cable (+) to auxiliary battery2. Red cable (+) to truck battery3. Black cable ( ) to auxiliary battery4. Black cable ( ) to a location some distance away fromthe truck battery, such as the negative cable connection onthe chassis.

Start the engineDo not disturb the jumper cables while starting, as sparksmay otherwise be caused. Do not lean over either battery.

Disconnect the jumper cables in exactly the reverse order.

WARNING!

Batteries emit oxyhydrogen whichis an explosive gas. A spark, forexample from incorrectly connectedstarting cables, could cause a batteryto explode and result in serious injuryand damage.


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935000-11

Cable markingsAll cables are marked with a number for identifying the terminalpoints as follows:

Cable Destination

Goes from Runs toterminal componentblock 27 657

Terminal 1in block 27

If there is a dot in the destination number it describes a terminalblock.

If the cable has a jumper, e.g. a common cable for supplying se-veral functions, a capital letter is added to the cable number.

Cable Destination

Goes from Runs toterminal terminalblock 10 block 26

Terminal 3in block 10

Connected tosupply the next function

P = PressureT = Temperature = Coolant levelo = Fuel level

V = ON/OFFG = Variable sensor

Jumper

271 (657)

103A (26.1)Terminal 1 in block 26


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DiagramsGear changing systems 9P.Group 20

935000-11

Manual electrical gear-changing systemThe manual electric gear-changing system is electro-hydraulicand controls the transmission by means of solenoid valves. Oilunder pressure is supplied to the solenoid valves from the oilpump built into the transmission.An inductive sensor senses the speed of the propeller shaft andapplies a signal to a speed monitor which prevent gear-changingat speeds above 3 km/h.See the circuit diagrams on the following pages.


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935000-11

Manual electric gear-changing systemClark 18000/20000 Fixed operator s seat

A09509.0400This diagram can also be found integrated in the general electric

diagrams DCD90-450 in this Handbook.

A. Gearbox control valveB. Employed gearC. Avtivated solenoidsD. To seat buzzer switchF. To starter motor (50)G. From start switchH. From alternator (D+)J. To parking brake warning lamp

3. Gear selector5. Speed sensor on gearbox output shaft (output speed)6. Valve cover with solenoid valves7. Electrical central unit8. Switch at parking brake ON when brake is released9. Switch at inching OFF when inching10. Relays

3. Wiper motor4. Starting interlock5. Stop6. 7. Reversing lights8. Inching9. Reverse gear

10. Forward gear11. Reversing interlock

Cable coloursSvart = BlackGr = GreyRd = RedBl = BlueGul = YellowGrn = GreenBrun = BrownVit = WhiteRosa = Pink


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935000-11

F

G H

J

1 1

7

1 0

D

8

9

3

A B

C

6

5

Clark 18000/20000Manual electric gear-changing system

Fixed operators seat


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935000-11

Manual electrical gear-changing systemClark 18000/20000 Rotatable operator s seat




3. Gear selector5. Speed sensor on gearbox output shaft (output speed)

6. Valve cover with solenoid valves7. Electrical central unit8. Switch at parking brake ON when brake is released9. Switch at inching OFF when inching10. Relays

3. Wiper motor4. Starting interlock5. Stop6. 7. Reversing lights8. Inching9. Reverse gear10. Forward gear

11. Reversing interlock12. PCB 2 rotatable opertor s seat



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935000-11

3

9

1 1

8

C

6

B A

7

5

F

G

H

J

1 0

1 2

D

1 0


Rotatable operator s seat


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935000-11

Manual electrical gear-changing systemClark 28000/32000 Fixed operator s seat


diagrams DCD90-450 in this Handbook.A. Gearbox control valveB. Employed gearC. Avtivated solenoidsD. To seat buzzer switchF. To starter motor (50)G. From start switchH. From alternator (D+)J. To parking brake warning lamp

3. Gear selector5. Speed sensor on gearbox output shaft6. Valve cover with solenoid valves7. Electrial central unit8. Switch at parking brake ON when brake is released9. Switch at inching OFF when inching10. Relays


11. Reversing interlock



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935000-11

Manual electrical gear-changing systemClark 28000/32000 Rotatable operator s seat




3. Gear selector5. Speed sensor on gearbox output shaft (output speed)6. Valve cover with solenoid valves7. Electrical central unit8. Switch at parking brake ON when brake is released9. Switch at inching OFF when inching10. Relays


11. Reversing interlock12. PCB 2 rotatable opertor s seat

Cable coloursSvart = BlackGr = GreyRd = RedBl = BlueGul = YellowGrn = GreenBrun = Brown

Vit = WhiteRosa = Pink


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935000-11


Rotatable operator s seatl


50/242


DiagramsEngine stop high/low temp 18P.Group 20

935000-11

Engine stop at high/low coolant temperatureEngine with stop solenoid


51/242


DiagramsEngine stop high/low temp 19P.Group 20

935000-11

Engine stop at high/low coolant temperatureEngine with fuel shut off valve


52/242


DiagramsAutomatic engine stop, operator s seat 20P.Group 20

935000-11

Engine stop, operator s seat

3 4 0

. T i m e r e

l a y , a

f t e r s e

t t i m e r e s

t a r t

i s p e r m

i t t e d

T h e e n g

i n e

i s a u

t o m a

t i c a

l l y s

h u

t d o w n a c

e r t a

i n t i m e a

f -

t e r t h e o p e r a

t o r

h a s

l e f t t h e c a

b i n

. A f t e r

5 m

i n t h e e n g -

i n e

r p m

i s r e

d u c e

d t o i d l e s p e e

d .


53/242


DiagramsEl-operated extra hydraulic function 21P.Group 20

935000-11

Electrically operated extra hydraulic function

1

1. Control section in the main valve, extra function199. Push-button for extra function in the 4th or 5th control

lever


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DiagramsSafety interlock system 22P.Group 20

935000-11

Safety interlock for container handlingThe safety interlock comprises three solenoid valves which areactivated by switches or sensors on the container attachment.The valves interrupt the servo supply from control levers to mainvalve in two cases:1. Interrupt LIFT if not every twist-locks is either open or locked.

This prevents lifting of a container if accidentally only oneside of the container has been properly locked with the twist-locks.

2. Interrupt locking of the twist-locks if the attachment is not ful-ly aligned onto the container, i.e. all corners are not close upto the container.

In case of emergency, the safety interlock system is possible toby-pass with a key operated switch.N.B. The operator is responsible for by-passing with the key.When the key is turned to ON-position, the safety interlocksystem is out of function!

WARNING!

The truck must not be operated withby-passed safety interlock system!


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DiagramsSafety interlock system 23P.Group 20

935000-11

Safety interlock systemVolvo engine: A28047.0600Perkins engine: A28047.07001. Switch, twist-locks2. Switch, length adjustment 20 40

3. Indicating lamp TWIST-LOCKS LOCKED4. Indicating lamp ALIGNMENT5. Indicating lamp TWIST-LOCKS OPEN6. Terminal in chassis7. Terminal in fork carriage8. Sockets in the electrical central unit9. Key operated by-pass switch10. Solenoid valves, cut off servo pressure for twist-locks if there

is no alignment signal11. Solenoid valve cuts off servo pressure for lift if twist-locks are

neither unlocked nor locked

12. Attachment electrical system13. Sensor TWIST-LOCKS LOCKED14. Sensor TWIST-LOCKS OPEN15. Sensor ALIGNMENT16. Indicating lamp, lights up when the system is by-passed with

key switch 9


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935002-08

Group 30

Volvo TD640VESpecifications............................................................. 3Engine TD640VE....................................................... 4

Description............................... ............................. 4

Volvo TD730VE/TWD731VESpecifications............................................................. 7Engine TD730VE/TWD731VE................................... 8

Description............................... ............................. 8Overview.......................................................... 8

Cooling system .............................................. 10Fuel system ................................................... 12Lubrication system......................................... 15Combusting air system.................................. 17

Service..................................... ........................... 19Coolant quality............................................... 19Lubrication oil quality ..................................... 19Draining the water from the fuel tank............. 19Inspection of air cleaner and changingthe filter element ............................................ 19Changing the oil and oil filter ........................ 20Checking V-belt tension................................. 20Checking and adjusting the valve clearances21Changing the fuel filters................................. 21Preventive maintenance on turbo-charger .... 22

Volvo TAD720VESpecifications........................................................... 24Engine TAD720VE................................................... 25

Description............................... ........................... 25Overview........................................................ 25Cooling system .............................................. 27Fuel system ................................................... 29Lubrication system......................................... 31Combusting air system.................................. 33

Service..................................... ........................... 35Coolant quality............................................... 35Lubrication oil quality ..................................... 35Draining the water from the fuel tank............. 35Inspection of air cleaner and changingthe filter element ............................................ 35Changing the oil and oil filter ........................ 36Checking V-belt tension................................. 36Checking and adjusting the valve clearances37Changing the fuel filters................................. 38

Preventive maintenance on turbo-charger .... 38

Perkins 1006-60TSpecifications ............................................................. 40Engine Perkins 1006-60T........................................... 41

Description ............................................................ 41General ............................................................ 41Cooling system................................................. 42Fuel system...................................................... 43

Service .................................................................. 44Coolant quality ................................................. 44

Lubrication oil quality........................................ 44Draining the water from the fuel tank ............... 44Inspection of air cleaner and changingthe filter element............................................... 44Changing the oil and oil filter ........................... 45Checking V-belt tension ................................... 46Checking and adjusting the valve clearances.. 46Changing the fuel filters ................................... 47Preventive maintenance on turbo-charger ....... 48

Cummins 6BTA5.9

See Cummins Operation and Maintenance Manual andalso Shop Manual


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DCD90-180Technical Handbook 2P.Group 30

935002-08

Volvo TD640VE


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935002-08

Manufacturer, type TD640VE

Coolant volume, l 37

Rating ISO 3046 kW (Hp)at r/min

129 (175)2400

Torque ISO 3046, Nmat r/min

6901500

Number of cylinders 6

Swept volume, l 5.48

Valve clearance, engine coldinlet, mmexhaust, mm

0.400.55

Idle speed, r/min

(adjust so that the engineruns smoothly)

65050

Injection pump, timing 130,5 BTDC

Thermostat,starts to open at Cfully open at C

7588

Lubricating oil filter Full flow, disposable paper el-ement with by-pass valve

Lubricating oil pressure, kParunning speedidling speed

300500min 150

Lubricating oil gradeviscosity

See Group 90

Volume, incl filter, l 16


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Engine TD640VEDescription 4P.Group 30

935002-08

The TD640VE engine is a 6-cylinder, inline, 4-stroke dieselengine with overhead valves. The engine is turbocharged, i.e.combustion air is supplied under pressure. As a result, thequantity of fuel injected can be increased, which increases theengine output. The turbocharger is driven by the exhaust gasesand uses energy that would otherwise be lost.

The engine is pressure-lubricated by an oil pump which deliversoil to all lubrication points. A full-flow oil filter effectively cleans thelubricating oil. The fuel system is protected against impurities byreplaceable filters. The engine has replaceable wet cylinder linersand two cylinder heads, each covering three cylinders.The low emission engine has a new design of combustion cham-ber, injection equipment and charge air cooler (intercooler) whichsatisfy future emission requirements from both the USA (Califor-nia) and Europe. The new engines represent a considerable im-provement, not only in terms of exhaust gas emissions, but alsoin terms of power and torque curves.In addition, all Volvo engines comply with the EC OFF-ROAD andEPA 1/CARB 1 exhaust smoke requirements.

Intake side of the Volvo TD640VE engine

1. Oil filler cap2. Oil dipstick3. Fresh air intake4. Air filter5. Starter motor

6. Oil cooler7. Oil filter, full flow8. Oil filter, by-pass9. Compressor, air conditioning system

1 2 3 4

5 6 7 8 9


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Engine TD640VEDescription 5P.Group 30

935002-08

Exhaust side of the engine Volvo TD640VE

11 12

13 14 15 16 17 18 19 20 22

10. Outlet coolant

11. Fuel filters12. Expansion tank, cooling system13. Fan hub14. Gear wheel driven coolant pump15. Coolant inlet16. Alternator17. Fuel feed pump18. Injection pump19. Fuel lines for tank connection20. Smoke limiter21. Control motor, electrically controlled

accelerator (Optional, ECS)22. Flywheel housing SAE 2

10

21


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DCD90-180Technical Handbook 6P.Group 30

935002-08

Volvo TD730VE/TWD731VE


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Manufacturer, type Volvo TD730VE Volvo TWD731VE

Coolant volume, l 40 41

Rating ISO 3046 kW (Hk)at r/min

150 (231)2200

167 (231)2200

Torque ISO 3046, Nmat r/minl

8001400-1500

8931300-1400

Number of cylinders 6 6

Swept volume, l 6.73 6.73

Valve clearance, engine coldinlet, mmexhaust, mm

0.400.55

0.400.55

Idle speed, r/min

(adjust so that the engineruns smoothly)

65050 65050

Injection pump, timing 100.5 BTDC 100.5 BTDC

Thermostat,starts to open at Cfully open at C

7588

7588

Lubricating oil filter Full flow, disposable paper el-ement with by-pass valve

Full flow, disposable paper el-ement with by-pass valve

Lubricating oil pressure, kParunning speedidling speed

300500min 150

300500min 150

Lubricating oil gradeviscosity

See Group 90 See Group 90

Volume, l 19 19


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Engine TD730VE/TWD731VEDescription 8P.Group 30

935002-08

OverviewThe TD730VE/TWD731VE engine is a 6-cylinder, inline, 4-stroke,low emission diesel engine with overhead valves. The engine isturbocharged, i.e. combustion air is supplied under pressure. Asa result, the quantity of fuel injected can be increased, which in-creases the engine output. The turbocharger is driven by the ex-haust gases and uses energy that would otherwise be lost.In order to further increase the engine efficiency, the engine isequipped with a water to air intercooler. (Only TWD731VE)The engine is pressure-lubricated by an oil pump which deliversoil to all lubrication points. A full-flow oil filter effectively cleans thelubricating oil. The fuel system is protected against impurities byreplaceable filters. The engine has replaceable wet cylinder linersand two cylinder heads, each covering three cylinders.The low emission engine has a new design of combustion cham-ber, injection equipment and charge air cooler (intercooler) whichsatisfy future emission requirements from both the USA (Califor-nia) and Europe. The new engines represent a considerable im-provement, not only in terms of exhaust gas emissions, but alsoin terms of power and torque curves.In addition, all Volvo engines comply with the R24 exhaust smokerequirements.


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Cooling systemThe engine is liquid-cooled and equipped with a closed coolingsystem consisting of the following main components:

Coolant pumpRadiator

Expansion tankThermostatRadiator fanCoolant passagesEngine oil coolerGearbox oil coolerIntercooler (only TWD-engine)

The coolant flows through a longitudinal passage into the engineblock. The opening into the cooling jacket of each cylinder is indi-vidually sized to ensure that each cylinder will be supplied withthe same rate of coolant flow.

The coolant flows in the separate return lines converge into acommon pipe in the thermostat housing. The coolant then flowsto the coolant pump and then into the engine and to the oil cooler.When the engine has reached its normal operating temperature,the thermostat will open the circuit to the radiator.The piston-type thermostat is capable of passing a high coolantflow rate at a minimum of pressure drop, thus contributing to fa-vourable coolant circulation in the engine.The coolant pump is fitted on the transmission cover and is drivenby a gear wheel from the transmission wheel.The intercooler (TWD engine) is connected to the cooling systemby a pipe from the coolant pump. The outlet from the intercooleris connected to the oil cooler.

1. Filler cap2. Pipe thermostat housing- upper expansion tank3. Piston thermostat4. Distribution channel5. Cylinder head6. Oil cooler

7. Cylinder lining8. Coolant pump9. Pipe to the suction side of the pump10. Radiator11. Intercooler (only TWD-engine)


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

Thermostat function, full coolant circulation

Thermostat function during heating-up period


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935002-08

Fuel systemThe fuel circulates in two circuits - the high-pressure circuit andthe low-pressure circuit. When the engine is started, the feedpump draws fuel from the tank and delivers it at relatively lowpressure through fine filters up to the injection pump. This thendelivers fuel at high pressure to the injectors which supply the fuelin atomised form to the engine combustion chambers.Excess fuel which is circulated in the low-pressure system is alsocleaned in the fine filters and is returned through a spill valve backto the tank.The fuel system includes the following components:

Fuel tank - a separate unit located on the left-hand side of thetruck. The fuel volume in the tank can be read on a gauge on theinstrument panel.

Feed pump - of piston type, supplies fuel at a certain pressureand flow rate to the injection pump.

Spill valve - which restricts the fuel feed pressure and providescontinuous venting of the fuel system. Excess fuel flows throughthe injection pump before returning to the tank, thus cooling thefuel in the fuel chamber of the pump, which contributes to moreuniform distribution of the fuel to the various cylinders..

Brnslesystem, principschema

1. Coarse filter2. Fuel shut off valve3. Feeder pump4. Fine filter5. Fuel tank6. Check valve7. IInjection pump8. Overflow valve

8

8

Shut down

Normal operation


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Fuel shut off valveAt normal operation, the solenoid in the shut off valve is activatedand fuel is fed to the injection pump.When the starting key is turned to 0, the solenoid valve is deacti-vated and the flow is reversed. Thereby the feeder pump drainsthe fuel from the injection pump resulting in engine shut down.The check valve prevents return fuel from flowing into the injec-tion pump.

T. Inlet from fuel tankF. Outlet to fuel pumpP. Inlet from fuel filterI. Outlet to injection pump

Fuel shut off valve

Normal operationShut down


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Fuel filters - two filters connected in parallel and with a commoncover. The filters are of disposable type, with the filter elementsmade of spirally wound paper.

Injectors - each with a nozzle holder and a nozzle. When the fuelpressure has risen to the preset value, the needle will lift and at-omised fuel will be injected into the combustion chamber throughaccurately calibrated holes in the nozzle sleeve.

Fuel filter

1. Supply pipe coupling2. Spill fuel pipe connection3. Spacers for adjusting the opening pressure4. Compression spring5. Thrust pin6. Nozzle sleeve7. Needle

Injector


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Lubricating systemThe engine is pressure-lubricated, and the oil is supplied by apump in the oil sump. All lubricating oil flows through a full-flowfilter. One part of the oil flows through a by-pass filter for separa-tion of extremely small particles.The lubricating oil is cooled in a plate oil cooler by the enginecoolant.The lubricating system includes the following main components:

Oil pump - of gear type, which draws oil through a coarse strainerthat arrests larger particles. The pump delivers oil through the lu-bricating oil filters to the various passages of the lubricating sys-tem.

Piston cooling reduces substantially the piston temperaturewhich, in turn, contributes to a longer life of the piston rings, re-duces the risk of carbon deposits and lowers the oil consumption.The pistons are cooled by oil which is sprayed by nozzles into theunderside of each piston and into the cooling passages when thepiston is at the bottom dead centre.Cooling is controlled by a piston cooling valve which shuts off thecooling oil supply at low engine speeds. This ensures that the lu-bricating oil flow will be a maximum when the engine is startedand when it is running at idling speed. The valve also restricts thepressure of the piston cooling oil at high engine speeds, to makemore oil available for lubrication.

1. Oil pump2. Reducing valve3. By-pass valve4. Oil under pressure to

the lubrication system5. Piston cooling valve6. Oil under pressure for

piston cooling7. Oil cooler8. By-pass filter9. Oil filter

Lubricating system


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Reducing valve located just before the filter. The valve willopen if the lubricating oil pressure is too high and will returnexcess oil back to the sump.Oil filter of full-flow type, with a filter element of pleated filterpaper. To protect the engine against insufficient lubricating oil, aby-pass valve is fitted in the oil filter bracket. The valve will openif the lubricating oil pressure should rise above a certain pressuredue to clogging of the filter. When the valve is open, unfiltered oilwill flow to the engine. The filter is of disposable type and shouldbe scrapped after use.By-pass filter approx. 5% of the oil passes through the by-passfilter with very low speed. The low speed allows very small parti-cles to be separated. The filter insert is of the disposable type.Crankcase ventilation prevents pressurising of the crank-caseand collects fuel vapour, steam and other gaseous products ofcombustion. Crankcase ventilation is provided by a pipe connect-ed to the crankcase inspection cover on the right-hand side of theengine, between the starter motor and the oil filter.

1.

920937_9350 Maintenance DCE90-180 y DCD70E5

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Transcript of 920937_9350 Maintenance DCE90-180 y DCD70E5