Kalmar Technical Handbook ContChamp DC 4160-4560 4 This Handbook deals with the design and maintenance of Kalmar LMV container machines. In addition, it gives details of trouble- shooting and the most common orrective maintenance, Operation and other matters that are primarily of interest to the operator are included in the Operator's Manual Kalmar LMV We reserve the right to modify our design and material specifications without prior notice. Publ. Nr 820 937-9070 90-12 ‘AdEra Dokument AB, Vaxjo 1990 00 10 20 General Chassis and cab Electrical system 30 40 50 60 Engine Transmission, © drive axle, brakes Steering axle 70] Hydraulic system 80 | ~ Boom and attachment 90! Periodic supervisionRevision 1 — Technical Handbook DC 4160-4560 Group Page Edition Note 2044 95-12 Contents 20 A0B118.010005 95-12 Manual electric gear-changing system, Clark 34000/36000 20 -A08899.010006 95-12 Automatic gear-changing system, Clark 34000/36000 7 4 95-12 Contents 70 A10205.020001 95-12 -——‘Hydraulic system 70 A10205.010002 95-12 Hydraulic system, vertical lit 70 A10206.010002 95-12 WDB brake system, without external cooling 70 A10206.020002 95-12 += WDB brake system, with external cooling so 4 95-12 Contents 80 A05434.010003 95-12 ‘Hydraulic circuit, combination attachment 80 A02864.010002 95-12 Electrical circuit, bottom-ift 80 A04454.010003 95-12 Electrical circuit, top-lit 80 —A11452.010002 ——-95-12_-—_EElectro-hydraulic servo system for the RC model (combination) 80 —A11454.010002 95-12 _——_Electro-hydraulic servo system for the RRC model (combination) vertical lit 80 A11451.010002 95-12 _—_EElectro-hydraulic servo system for the RS model (container) 80 —-A11453.010002 95-12 -—_Electro-hydraulic servo system for the RS model (container) vertical lift 80 ——A11455.030001 95-12 -—_EElectro-hydraulic servo system for the FSS model (container)DC 4160-4560 Technical Handbook Contents Group 00 General Safely rules 2 Applications 4 Design - Overview 4 ‘Component units. 6 ‘Supplementary books Replacement system — Spare parts 7 Tools 7 Tightening torque: ‘System of unitsDC 4160-4560 Technical Handbook General Safety rules * Follow the local safety regulations. ‘+ Before starting, check that nobod accessories. the way of the truck and its * The truck should be driven only by specially trained operators who are authorised to do so by the work supervisor. + Warning! Only authorized and qualified personnel may work with the safety system. + Warning! If the overload safety system override function has been used, there is a risk of forward tipping. The truck should be operated with extreme care to prevent accidents, * 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. + Do not exceed the lifting capacity of the truck. * Great care must be exercised at all times when driving the machine. Always remember the great height and width of the machine so that collision with beams, cables etc. is avoided, * Its prohibited to start liting a container if the red warning light TWIST-LOCK UNLOCKED is lit or if any of the yellow warning lights TWIST-LOCK UNLOCKED or ALIGNMENT are unit, N.B. the ALIGNMENT warning light goes out once the lit has begun. * Ifthe safety system warning lamps for container coupling are not functioning, the system must be immediately repaired. To use a truck with faulty warning lamps is a great safety risk. * Do not drive the truck with load raised high above the ground, since the truck may overtum. The transport must be carried out with the load as close to the truck as possible, i.e. with the boom. retracted as far as possible without obstructing vision. * Never run hands or fingers along any tubes, pipes or hoses whilst investigating for possible leaks as ‘Some of these lines (diesel fuel, hydraulic, steering, etc.) operate at extremely high pressures and even the most minute of leaks can cause oil or fluid to penetrate the skin. Avoid staying close to pressurized components or hoses. * Always apply the parking brake before leaving the cab. Always remove the key if the truck is left unattended, * The parking brake may also be used as EMERGENCY BRAKE (see Brake system). * 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 usetil life of the truck or to the safety of the personnel. * Follow the safety rules whenever carrying out service work on the air conditioner. The refrigerant is injurious to the skin and eyes. Only authorised personnel may empty or top up the refrigerant. * The brake system is equipped with accumulators charged to a pressure of up to 210 bar. To prevent Accidents when working on the brake system, never disconnect any component without previously relieving the accumulator pressure by means of the accumulator discharge valve. Never carry out any service work on the boom or attachmentt when the engine is running.DC 4160-4560 33V Adjustment ranges Starting current 100 - 400 mA Ditference between starting and closing current 0-850 mA Max. current adjusted individually for each function Fuse 3A Converter Ambient temperature, 24 V version -30°C to 450°C Max. control pressure output Pla urease se ‘ete Recommended inlet pressure + 1.0-2.0MPa Recommended retum pressure P.=0.1-02MPa Solenoid coil resistance R,=2700 Inductance L=032H ‘Maximum output flow ha = approx. 10 Vin Leakage in neutral position from Sto R 4, <0.20 min Weight 0.9 kgDC 4160-4560 Technical Handbook 190709 Specifications Automatic electric gear-changing system Fuse SA Outputs: All outputs ara short-circuit protected and can withstand a load of 1A. However, the total output must not exceed 4A. 9 outputs for gear selection. ‘Output for engine control. Qutput for lock-up. Output for fault indication. Inputs: 8 Inputs for gear selection control. Input for manual gear-changing. Input for lock-up. Input for kick-down. 2 inputs for fault indication, one of which can be used for monitoring the engine speed. Input for tacho pulses from the output shaft. Heat dissipation 15WDC 4160-4560 Electrical system — Technical Handbook Description i ‘The system voltage is 24V and the supply is taken from two 12V batteries connected in series and charged by an alternator across electronic rectifying and voltage stabilisation circuits. ‘The negative and positive poles are both connected across a main switch. The negative pole is then connected to the chas- sis. Always open the main switch whenever work is to be carried out on the electrical system, if the truck is to remain idle for some time and whenever welding work is to be carried out on the truck. ‘Warning lamps and instruments are clearly arranged on the instrument panel, to the left of the driver. The panel is hinged, and a circuit board with relays, fuses and terminal blocks is located below it. mE —t iy ye Oy 24 volt battery 4 —Main switchDC 4160-4560 Electrical system pens Technical Handbook Description P. 1. Relay, preheating 2. Sensor, pressure gauge, oll pressure engine 3. Sensor, warning lamp low oil pressure engine 4. Sensor, warring lamp lowcoolant level '5. Sensor, temperature gauge coolant temperature (in e 6. Sensor, waming lamp high coolant temperature (in T-connection) 7. Allamator 8. Starter motor ‘9. Sensor, warning lamp low oil pressure and pressure gauge oll pressure gearbox 10. Sensor, warning lamp low oil pressure gearbox 11. Sensor, pressure gauge oll pressure gearbox Electrical components of the Volvo TD 100 G engineDC 4160-4560 Electrical system Technical Handbook Service 20-6 Tor: Checking the electrolyte level of the batteries ‘The batteries are fitted behind a cover on the left-hand side of the truck. The electrolyte level should be about 10 mm above the cells. Top up with de-ionized water as necessary. ‘The batteries supplied with the truck are of sealed-for-life type, i.e. they need not normally be topped up during the life of the battery. However, we would advise you to check the electrolyte level once or twice a year and, if necessary, top up with deionised water. Relay box in cab ~ fuses Fuse Rating No. Circuit protected A St Wiper motor front, direction indicators, seat buzzer, parking brake sensor 10 S2 Ignition key, preheater, starter motor, air conditioner, cab lighting 10 S3____Container attachment, container panel 10 7-812 $13-818 $4 Electric gear-changing 5 $5 Warning lamps, instrument illumination, relay for coolant level 5 $6 —_Brake lights, reversing lights, reversing alarm 15, S7 —_ Fan, compressor for ait conditioner, condenser 15, $8 Container lighting $9 Working lights (15 A for 4 lamps) Hazard beacon 10 S10 Working lights, standard (15 A for4 lamps) 10, S11 Horn, screenwash motor, wiper rear and root, wiper front, intermittent relay $12 Driving lights (main fuse), rear lights (main fuse), position lights $13 Main beam, right-hand S14 Main beam, left-hand S15 Dipped beam, right-hand $16 Dipped bear, left-hand S17 Rear light, left-hand S18 Rear light, right-hand aannaaad Bulbs Rating Description Watts Base. instruments 3 BA7s Indicating lamps 12 Wex4,6d Cab lighting 10 $85 Rear lights, red 5 BAISs Brake lights 24 BAI5s Direction indicators 21 BAI5s Position lights 5 sv8,5 Driving lights 7570 PASt-3B (fulV/dipped beam) Reversing lights, white 70 Pk22s Working lights 70 P25 Hazard beacon 70 Pk22sDC 4160-4560 Electrical system Technical Handbook Service Rel: 305 Reversing light 314 Parking brake, disengagement 315 High power (Starting switch) 316 Wiper motor, front 320 Electric stop ') 321-1. Intermittent relay wiper front 321-2. Intermittent relay wiper rear") 322 Coolant level 323 Pulse relay, direction indicators 330 Starting block 331 Propulsion forward 332 Propulsion reverse 334 Release clutch at automatic gearbox ") 960 _ Reversing block *) Optional equipment Fuses for preheater element Fitted on the engine -50A Starting from another battery ‘+ Make sure that the auxiliary batteries are connected in series, 50 that 24 V will be supplied. Note: Do not disconnect the truck- battery cables. * Connect the jumper cables in the following orders: 1. Red cable (+) to auxiliary battery 2. Red cable (+) to truck battery 3, Black cable (-) to auxiliary battery 4. Black cable (-) to a location some distance away from the truck battery, such as the negative cable connection on CAUTION Batteries emit oxyhydrogen which is a very explosive gas. A spark ‘eccurring when auxiliary starting cables are incorrectly connected may the main switch. be sufficient for a battery to explode * Start the engine and cause damage. Do not disturb the jumper cables while starting, as sparks ‘may otherwiswe be caused. Do not lean over either battery. ‘+ Disconnect the jumper cables in exactly the reverse order.DC 4160-4560 Electrical system 8070 95-08 208 Technical Handbook Service Publ. er] p, Cable markings Al cables are marked with a number for identifying the terminal Points as follows: P = Pressure Cable ‘Destination T= Temperature ai a Coolant level Goes from 1 (657) Punsto Fuel level terminal component block 27 657 Terminal 1 in block 27 If there is a dot in the destination number it describes a terminal block. If the cable has a jumper, ¢.9. a common cable for supplying ‘several functions, a capital letter is added to the cable number. Variable sensor Cable Destination 103A (26.1) ; Goes trom “LSpans te Terminal 1 in block 26 terminal terminal block 10 block 26 Terminal 3 in block 10 Connected to ‘supply the next function Relay marking 2Ooe8 BSOS; a, Terminal blocks 6, 7,8, 9, 19, 20, 21, 22, 28. To steering wheel panel 17, 18. Engine transmitters 10. Roof panel 23. Working lights 11. Lamps front lat 24. To cabin roof 12, Lamps front right 25. To chassis 18. Wiper motor rear 26. To cabin undemeath side, front wiper motor 14, Lamps rear right, reversing alarm 27. Wipers front, air conditioner 18. Lamps rear left 30, 31. Container attachment 16. Gearbox valve housing 29, 32, 33, 34, 35, 36, 37, 38, 39, 40. OptionsAppendix Technical Handbook Catalogue of Components Catalogue of Components Classification Components are classed in the following groups: 30-99 Battery, fuse holder, etc. 100 Switch. 200 Making/Breaking contacts (sensors, etc). 300 Relays. 400 Light bulbs. 500 _ Indicating/Warning lamps. 600-664 Switching devices (solonoid valves, wiper motor, starter motor). 665-684 Semiconductor components (thyristor, transistors). 685-699 Other control system components (not contactors). 700 Instruments, sensors (analog types of tachometers, etc.) 800-900 Other components. 1000 Cable mats Component list 30 Battery 190 Switch, highflow gear 32 Printed circuit board, Junction box 191. Switch, gear selector forward 37. Earthing terminal on chassis 182 Switch, gear selector rear 39. Terminal, negative terminal 195 Switch, gear shift 51 Fuse holder, 1-pol 442 Switch, foot 52. Fuse holder, 2-pole 143. Switch, seat heater 56 Fuse holder, 6-pole 144 Battery disconnecting switch 59 Fuse holder, 12-pole 145. Switch, AT-regulator 62 Battery connector, 2-pole 147 Switch, direction indicators 64 Battery connector, 4-pole ‘Switch, hom 72 Outlet 2-pole ‘Switch, main key switch 77 Outlet, 7-pole . intermittent wiper 78 Outlet, extra, 7-pole 156 Switch, cab heating 157. Switch, seat tit 100 Switch, light 158. Switch, rear fog light 101 Switch, main/dipped beam 160 Switch, combi forward'reverse 102 Switch, fog light 161 Switch, combi- horn, light main/dipped beam, 103 Switch, distance light washer, wiper (intermittent), direction indicator 104 Switch, mast lights 165 Switch, seat heater 18 See 166. Switch, interlocking of turntable toh, q 167 Switch, pneumatic springing 107 Switch, parking brake 168 Switch, interlocking of seat 108 Switch, central lubricator 169 Switch, reversible seat 109. Switch, hazard lights 170. Switch, evaporator (LPG) 110 Switch, rotating hazard beacon 471 Switch, fith wheel up/down 111 Switch, window regulator 172. Switch, fifth wheel forward/reverse 142 Switch, air conditioner (AC) 475 Switch, cab hoist up 143. Switch, aternative steering 176 Switch, cab hoist down 114 Switch, reading light 480 Switch, WD 145. Switch, instrument illumination 190 Switch, air conditioner 116 Switch, interior lighting 195. Switch, joy-stick X 117 Switch, heating 196 Switch, joy-stick X+¥ 118 Switch, heater fan 197 Switch, length’sideways driving 119. Switch, wiper 199. Switch, option 120 Switch, washer 123 Switch, observation mirror 200 Contact, breaking, waming lamp, parking brake 125 Switch, exhaust brake 201 Contact, breaking, waming lamp, brake 126 Switch, ditt. block 202 Contact, breaking, waming lamp, oil pressure engine 128 Switch, power take off side 204 Contact, breaking, pressure accumulatortank 129 Switch, power take off rear 205 Contact, breaking, interior lightingAppendix Technical Handbook Catalogue of Components ery 206 207 208 214 215 216 217 218 219 220 223 224 229 230 231 235 239 240 242 243 244 250 251 260 261 262 263 264 265 299 300 301 302 303 304 305 306 307 308 310 311 312 313 314 315 316 317 318 319 Contact, breaking, glove Contact, making, dif. interlock Contact, making, warning lamp temperature brake cooling 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 fiter Contact, breaking, drive cut off Contact, making, temperature gear box Contact, making, warning lamp temperature torque amplifier. Contact, brush, hom Contact, making, injection pump Contact, making, cab locking Contact, making, seat locking Contact, breaking, seat Contact, making, seat rotation, foot switch Contact, breaking, waming lamp air connection Contact, warning, interlocking of turntable Contact, making, side shifting of seat Contact, breaking, thermic Contact, making, thermic Contact, breaking, waming lamp air supply to trailer Contact, making, waming 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, titing Contact, making, fork positioning Contact, making, sideshitt Contact, making, iting mast in-out Contact, makingrbraking option Relay, main/dipped beam Relay, fog light Relay, distance light Relay, mast light Relay, working light Relay, reversing light, Relay, main beam Relay, dipped beam Relay, brake light Relay, parking light Relay, direction indicator left Relay, direction indicator right Relay, element preheater Relay, rotating driver's seat (VBFS) Relay, parking brake Relay, starting key Relay, wiper Relay, roading lights wiper Relay, AT-regulator Relay, hazard blinkers 320 Relay, electical stop 321 Relay, intermittent wiper 922 Relay, coolant level 323. Relay, blinkers 324 Relay, range interlock 325 Relay, flashing brake lights (reversing) 326. Relay, flashing hazard lights (reversing) 327 Relay, gear neutral 328 Relay, gear shitt 329 Relay, high/low gear 330 Relay, start intertock 331 Relay, forward driving 332. Relay, reversing driv 333. Time relay, automatically preheating 334 Relay, free wheeVdrive disconnection 335 Relay, gear change valve 1-gear (diesel,LPG) 396 Relay, gear change valve 2-gear (diesel, PG) 837 Relay, motor drive direction 338 Relay, cooling fan drive motor 339 Relay, cooling fan electrical box 340 Time relay, start delay 341 Time relay, stop delay 342. Relay, switching 2/4WD 343 Relay, fog light rear 344 Relay, torque amplifier 345. Relay, interlocking of turntable 346 Relay, releasing of seat interlocking ‘347 Relay, mutitunction, seat rotatior/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 Relay, hazard beacon Relay, starting solenoid Relay, electrical screenelevator up Relay, electrical screenelevator down 375. Main contactor, operating control 376 Contactor, forward operating control 377 Contactor, reversing operating control 378 Contactor, “by-pass” operating control 379 Contactor, pump motor 380 Contactor 381 Contactor, recharging 399. Relay, option 400L. Light bulb, roading light left hand front 400R Light bulb, roading light left hand rear 401L Light bulb, roading light left hand front 401R Light bulb, roading light left hand rear 402 Light bulb, distance light 403. Light bulb, mast light 404 Light bulb, working light 405. Light bulb, rear light 406L Container light left-hand 406R Container light right-hand 408L. Light bulb, parking light, left-hand forward SRSSSRRBRER EEAppendix Technical Handbook Catalogue of Components 408R Light bulb, parking light, right-hand forward 4101 Light bulb, brake light, left-hand forward ‘410R Light bulb, brake light, right-hand forward 441L. Light bulb, brake light, le (hand rear 411 Light bulb, brake light, right-hand rear 412L Light bulb, rear light, left-hand rear 412R Light bulb, rear light right-hand rear 4131 Light bulb, rear light, left-hand forward (VBFS) ‘41R Light bulb, rear light, right-hand forwward (VBFS) 416-1 Light bulb, side position light, left-hand forward 416-2 Light bulb, side position light, left-hand rear 417-1 Light bulb, side position light, right-hand forward 417-2 Light bulb, side position light, right-hand rear 420 421 422 423 426 427 428 429 432 433 434 435 436 437 440 445 451 Light bulb, position light, left-hand Light bulb, position light, right-hand Light bulb, direction indicator le-hand forward ction indicator right-hand forward Light bulb, Light bulb, direction indicator let-hand rear Light bulb, direction indicator right-hand rear Light bulb, flashing beacon lamp Light bulb, cigarett lighter illumination Light bulb, instrument illumination Light bub, glove pocket light, Light bulb, step-in lighting Light bulb, interior lighting Light butb, reading lighting Light bulb, identification light Light bulb, identification lighroot sign Light bulb, heating control light Light bul, extra direction indicator left Light bulb, extra direction indicator right Light bulb, fog light rear lett Light bulb, fog light rear right Light bulb, electrical box lighting Indicating lamp, direction indicator Indicating lamp, direction indicator extra Warming lamp, oil pressure engine Indicating lamp, main beam Waming lamp, loading Waming lamp, loading extra Waming lamp, brake ‘Warming lamp, parking brake ‘Waring lamp, coolant level Indicating lamp, dif. interlock Warning lamp, temperature converter Indicating lamp, overdrive clutch Indicating lamp, dipped lights Indicating lamp, air fiter Warning lamp, central warning Indicating lamp, preheating Warning lamp, oll pressure gear box Warming lamp, cab lock Waming lamp, temperature gear box Waming lamp, brake pressure ‘Waming lamp, temperature cooling system brakes. ‘Waming lamp, temperature coolant engine Warming lamp, interlocking of tumtable ‘Waming lamp, temperature, drive motor Warning lamp, temperature, pump motor 569 590 599 600 601 602 604 605 606 607 608 609 610 en 613 614 Indicating lamp, electric heater Indicating lamps complete (15 pes) Indicating lamp, option Solenoid valve, exhaust brake Solenoid valve, ditt. interlock ‘Solenoid valve, brake Solenoid valve, power take off, side Solenoid valve, power take off, rear Solenoid valve, 2/4WD Solenoid valve, high/low gear Pump unit, cab hoist Regulating motor, throttle ‘Solenoid valve, hydraulics, general Solenoid valve, flow restriction Solenoid valve, torque amplifier Solenoid valve, ranging interlock Solenoid valve, wheel turning Solenoid valve, AT-regulator “by-pass” Solenoid valve, fith whee! up Solenoid valve, fith wheel down ‘Solenoid vaive, fifth wheel foward Solenoid valve, fifth wheel rear Solenoid valve, AT-reguiator 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, stop injection pump ‘Solenoid valve, LPG ‘Solenoid valve, evaporator (LPG) Solenoid valve, parking brake ‘Solenoid valve, seat locking (VBFS) Solenoid valve, fith wheel locking Magnetic clutch, compressor AC ‘Solenoid valve, seat tilt Solenoid valve, pneumatic springing Thermostat, air condition ‘650-4 Wiper motor root (option) 651 Washer motor Light motor Light washer motor ‘Starter motor ae tan, main motor (EC) fan, electrical box (EC) feat fan Alternator extra Altemator without loading regulator Alternator with loading regulator ‘Screenelevator motor Loading regulator Dosage pump, air condition Circulating pump, air condition Diode SsAppendix rn Technical Handbook Catalogue of Components é 670 Compressor 804 Cigarett lighter 685 Control unit, termostat AC 805 Electrical heating cab 690 Speed control (EC) 806 Aggregate, air conditioner 683 Pump, central lubrication 807 Potentiometer 695. Drive motor (EC) 808 Electrical heater air dryer 697 Electric brake 810 Condensor AC 698 Pump motor (EC) 820 Resistor 699 Solenoid valve, option 825 Controls, (steering with control levers). 826. Valve, (steering with control levers). 700 Speedometer 830 Ignition coil 701 Gear box oil temperature gauge 835. Ignition plug 702 Clock 840. Distributor 703 Engine rev meter 850 Hom 704 Air pressure gauge, 853 Buzzer 705 Gearbox oll pressure gauge, 706 Temperature gauge, engine coolant 900 Radiofape recorder 707 Fuel gauge 901 Voltage converter 708 Hour meter 902 Loud speaker 709 Capacity gauge, battery 903 Aerial, radio 710 Timer, engine- and cab heater 905 Communication radio 712 Motor oil pressure gauge 906 Aerial, communication radio 715 Extra instrument, general 910 Voltage converter 80 V / 24 V 753 Transmitter, engine revolution 940 Logic switch watch 754 Transmitter, air pressure 950 Logic transistor ignition 756 Transmitter, engine coolant temperature 955 Logic overspeed protection (LPG) ‘757 Transmitter, fuel level 960 Logic unit, reversing interlock/automatic gear 758 Transmitter, gear box revolution changing 759 Transmitter, coolant level 961 Engine- and cab heater 760 Transmitter, reversing interlock / automatic 962 Logic indication of wear, brush electrical motor gear changing system (on gear box output 965 Reversing alarm shaft) 761. Transmitter, reversing interlock / automatic gear changing system (engine speed) 762 Transmitter, brake flushing circuit 763 Transmitter, hydraulic fluid level 764 Transmitter, gearbox servo pressure 765. Transmitter, oll pressure gear box 766 Transmitter, oil temperature gear box 767 Transmitter, ol pressure engine 768 Transmitter, hydraulic pressure 770 Transmitter, steering wheel angle 74 Transmitter, angle 773 Transmitter, presence 774 Transmitter, ambient temperature 775 Transmitter, temperature air condition 776 Transmitter, hydraulic temperature 777 Transmitter, position 778 Transmitter, drive break 779 Control system, recharging (EC) 780 Control system main motor (EC) 781 Control system pump motor (EC) 782 Logic (interface) two main motors (EC) 783 Logic (intertace) throttle 784 Logic (intertace) brake control * 785 Logic (interface) control system 795 Display 788. Logic, general (option) 800 Start element 802 Electrical heated observation mirror 803 Electrical heated seatDC 4160-4560 Electro-hydraulic servo system ails Technical Handbook Description General ‘The electro-hydraulic servo system consists of the following ‘components: * Control units + Converters on the main valves In addition there are relays, solenoid valves and sensors in the system. This is made clear in the circuit diagrams for respective units. Control lever ‘Switches for hydraulic functions, Converter for main valvesDC 4160-4560 Electro-hydraulic servo system a race Description Technical Handbook Current collector Potentiomenter s + +48.V supply from Output signal to control unit control unit pressure plate Mounting for the ball-coupling Current collector Control lever ‘The control lever is adevice used to control electrical signals. ‘The controls are used to actuate electro-hydraulic converters which, in tum, deliver the hydraulic servo signals which operate the spools of the hydraulic system valves. The head of the control lever is equipped with four fingertip controlled potentiometers. ‘The lever is mounted on a powerful rotation-lockes ball coupling conneted with a pressure plate of case hardened steel, which in tum activates four hardened push rods. The push rods are ‘fetumed to a neutral position - the central position of the lever ~ by means of retum springs. ‘The operative part consists of one potentiometer for each direction of travel. The potentiometer winding is fixed in the ut whereas the current collectors are attached to the movable push rods. During operation, the positive supply from the control unit is taken from the potentiometers via the collectors. When the lever is in neutral, the collector is clear of the potentiometer track and the circuit is open. ‘The potentiometer setting and thus also the output signal varies in proportion to the movement of the lever when the unit is ‘operated. Following ampilfication and square-wave modulation in the control unit, the output signal is used to contro! the hydraulic servo pressure from the converter. Press button Potentiometer Ball couplingDC 4160-4560 Electro-hydraulic servo system 90709012, 20-11 Technical Handbook Description Control units 1 and 2 ‘The IPS 302 is an electronic control unit which incorporates @ voltage stabiliser and is used to supply the control lever units. Stabilised BV d.c. is supplied to the potentiometers in the control units. An 80 - 100 mA signal is returned to the control unit from the appropriate potentiometer, depending on the lever movement, n the control unit, the signal is modulated to a square-wave form, is amplified to approx. 400mA and is used as a control signal for the electro-hydraulic converters. Square- ‘wave modulation is required to ensure accuracy of the conver- ters. ‘Compensation for changes in the resistance of the converter solenoid coil due to temperature variations and supply voltage variations is provided automatically by means of a current- sensing feedback loop. Each function can be regulated by means of two potentiome- ters, one of which determines the starting point of the curve and the other its slope and end point. (The settings are adjusted at the factory.) "MIN" regulates the starting point of the curve "MAX" regulates the slope and end point unit, Voltageoor DC 4160-4560 Electro-hydraullc servo system Technical Handbook Description Converters Solenoid Pilot valve Push button, manual operation Inlet servo pressure! | Retum servo Pressure ‘A given control current is results In a definite servo Pressure at the spool actuator Converter The converter Is an electrically controlled pressure raducing valve for the remote control of hydraulic functions. The output signal is a proportional hydraulic servo pressure which is used {to control the spools of the main valves. ‘The converter consists of a solenoid and a pilot valve. itis, ‘connected to the main valve spool actuator block. ‘The solenoid exerts a proportional force on the pilot valve. The ‘end of the unit is provided with a vent screw and a pushbutton for emergency manual operation. ‘The control pressure output delivered by the pilot valve to the spool actuator of the main valve is practically proportional to the input current. ‘The solenoid is supplied with square-wave modulated d.c. to ‘minimise the hysteresis effect and ensure maximum accuracy. ‘The pilot valve is closed in the neutral position. ‘Servo Presgure.ae Cont Gontgol current 0 100 200 200 400 600 600 700 80 Voltage U,V 24 6 8 10 12 14 16 8m 2 Equivalent voltage across 27 9 solenoid coil Servo pressure as function of Input currentDC 4160-4560 Electro-hydraulic servo system aaa Technical Handbook Play between current collector and winding Contact pin Mounting screw for potentiometer Coordinate control-lever unit Service Publ [or[P. Preventive maintenance of control lever unit or replacement of potentiometers ‘Since the lever are operated continuously when the truck is in ‘service, the control lever unit is subjected to a certain amount of wear. A number of simple checks may be carried out, mainly on the potentiometers and current collectors, to prevent faults and consequent damage due to wear. In the event of severe wear, the entire potentiometer module should be replaced. Coordinate lever unit 1. Isolate the power supply by opening the main switch. 2. ‘Remove the gai 3. Release the control lever unit by removing the four Allen- screws in the mounting plate. 4. Mark and loosen the electrical cables from undemeath by pulling off the flat pin connectors with flat-nosed pliers or similar. N.B. Incorrect connection of plus and minus will result In the spark-suppression diodes In the lever unit being burnt out. 5. Remove the locking ring and thereafter remove the plastic cover. itis now possible to check all components. 6. Clean the potentiometer tracks and current collectors with a soft brush. If the potentiometers have been in service for a Jong time, turn the track through 10 - 15° so that the current collector will be in contact with the new section of the track. 7. Lubricate the potentiometer track with Shell Fluid No. 12 or ‘equivalent to proiong the usetu! life of the potentiometer. 8. Itnecessary, adjust the clearance between the current collector and the winding to about 2mm by means of the Potentiometer mounting screw (see figure). If the screw is adjusted up too far, the function will start when the lever is in ‘neutral position. The idle travel of the lever should be 2 - 3°. 9. Check that there is no play between the current collector and the contact pin. Adjust as necessary. 10. If the contact arm and potentiometer are very wor, replace both of them.DC 4160-4560 Technical Handbook Electro-hydraulic servo system See Service Converter ‘The useful life of the converters is normally the same as that of ‘other hydraulic components. No maintenance in the true sense is required, but check at regular intervals that the mounting ‘screws have not worked loose. Control units 1 and 2 (IPS 302) ‘The control units need no actual maintenance. To change the Circuit board, proceed as follows: 1. Isolate the power supply by opening the main switch. 2, Remove the two screws retaining the plastic cover and remove the cover. 3. Remove the four screws retaining the black light-alloy cover ‘and remove the cover. 4. Remove the screw securing the bottom of the circuit board to the cooling and mounting rail. 5. Withdraw the ciroult board by hand, taking care not to damage the components. The board is a relatively tight fit in the edge connector. 6. Fit the new circuit board. Ensure that itis located in the guides on the sides of the case and that the bottom connec- tor engages. Press down the board firmly and refit the screw. 7. Retit the cover. Cables and wiring Long experience has shown that most electrical faults are due to defective cables. So check the following at regular intervals: 1, Check that none of the cables is physically damaged. 2. Check that none of the connections has worked loose. 3. Check that there is no risk of short-circuits due to water leakage into sensitive parts. Check in particular the connec- tions to the converters.DC 4160-4560 Electro-hydraulic servo system a Technical Handbook Service Trimming of the electro-hydraulic servo system using a measuring Instrument ‘Trimming may be necessary for a number of reasons, such as after replacement of the circuit board, replacement of tha alternator or battery which will ater the supply voltage, replace- ‘ment of a converter, etc. ‘The most reliable method of trimming is to use a universal meter with a range of 0 - 1000mA. Connect the universal meter between the control unit and the converter for the relevant function. This requires a special cable which allows the univer- ‘sal meter to be connected in series. The connection points are ‘shown in the circuit diagram. 1. Check the system specificatio - Supply voltage at least 24 V — Supply voltage to control lever units approx. 8 V — Hydraulic servo pressure 30-40 bar 2. Remove the plastic cover from the control units.Use the ‘rimming potentiometers on the top of the units. Each con- verter corresponds to one group (see figure). Each group consists of an LED, and MIN and MAX potentiometers. The LED will light up when the corresponding function is in operation. When the starting value P1 is adjusted by means of the MIN potentiometer, the entire pressure curve will be displaced in Parallel, As a result, the final pressure P2 will change as much ‘as P1 (see the graph below) and the idle travel of the lever will increase or decrease. ‘The MAX potentiometer alters only the slope of the pressure curve, ie. the starting pressure will remain unaltered when the MAX potentiometer is adjusted, but the slope of the curve and the final pressure will change (see the Potentiometer function graph). 3. Start the machine and run the engine up to operating speed. ‘The engine must be at normal operating temperatura before measurement is started. 4. Connect the universal meter to the appropriate function. 5. Move the lever slowly in the direction corresponding to the ‘elevant function until the corresponding LED lights up. ‘Move the lever further in the same direction until the hydrau- lic function just begins to move. Read the universal meter. 6. Release the lever to the neutral position. 7. Move the lever in the same direction again until the LED lights up. 8. Tum the MIN potentiometer until the reading of the universal meter is the same as that in point 5. above. The starting point of the curve is now preset. The control lever should have the required idle travel from the neutral position, 9. Move the lever to the limit of its travel in the direction corres- Ponding to the relevant function.DC 4160-4560 Electro-hydraullc servo system 42° Lamp panel Angle iron Pivoted joint sensor 0 activator Sensor ci 3] Steered axle At a distance greater 5 mm the sensor signal is interruptedDC 4160-4560 Technical Handbook Page 23-30 Empty LG 1907085-08 20231 (pub. Tar,DC 4160-4560 Automatic electric gear changing system Technical Handbook Description Automatic gear-changing system ‘The automatic electric gear-changing system is based on a control unit incorporating a microprocessor. See also circuit diagram, page 37. The contro! unit has connections for + Gear-changing control + Display + Solenoid valves on the transmission = Speed sensor on the torque converter and transmission Control unit ‘The control unit is simple to program, even while the truck is in operation. It measures the speed of rotation with high accuracy and stability, and it has fully programmable outputs for gear selection. Green POWER LED ‘The LED is alight when power supply is available to the control unit, SHIFTRONIC 1 - connection to transmission valve housing. 2. - connection to the gear selector in the cab. P3_- connection to the display in the cab. 4 - connection to the programming terminal. Automatic gear-changing ‘The control unit (Shiftronic) continuously senses the speed of the output shaft and selects a suitable gear in accordance with the programmed table. Hysteresis is also programmed into the table to prevent excessively frequent gear-changing. ‘The control unit changes up to the gear selected by the driver by means of the gear-selector control. Safety functions ‘These functions are always active. Reversing protection: in the neutral position, the contro! Unit inhibits gear engagement if the speed of the output shaft is in excess of a programmed limit (REV PROT). Display shows REV. Speed sensor: When the speed exceeds a certain minimum value (SENS CHECK), a check is made to ensure that the tachometer pulses are received regularly If the rate should suddenly change, this is interpreted as the sensor being inope- rative. The transmission is shifted to neutral and the fault output is activated. The display shows SENS. Short-circuit protection: if any of the outputs is short- circuited, all outputs will be de-energised so that improper gear ‘engagement will not be initiated. The display shows AMD.DC 4160-4560 Automatic electric gear changing system Technical Handbook Description [sezmesoe 20 32 P1= Connection Pin Eunction 1. Output signal to gearbox output speed sensor 2 Earthing 3. Output signal gear selector 47 . aoa 12. Output signal inching 14, _ Input signal from gearbox output speed sensor 19. Output signal to engine speed sensor. 20. Input signal from engine speed sensor. P2- Connection Pin Function 4. +24 supply to the control unit 2 Earthing 3. Input signal from gear selector ao 5 6° fe a ae) Co Is} Programming unitDC 4160-4560 ae Technical Handbook (emo Tarl EmptyDC 4160-4560 Technical Handbook Manual electric gear-changing system Diagram Publ Manual electric gear-changing system ‘The manual electric gear-changing system is electro-hyrdaulic and controls the transmission by means of solenoid valves. Oil under pressure is supplied to the solenoid valves from the oil ump built into the transmission. ‘An inductive sensor senes the speed of the propeller shat and applies a signal to reversing interlock which prevents reversing at speeds above 3 kmih, See the circuit diagram. Manual electric gear-changing system Clark 34000/36000 A081 18.0100 05 Gearbox control valve Employed gear Activated solenoids To seat buzzer switch To starter motor (50) From starter switch From altemator (D+) To parking brake warning lamp Gear selector ‘Speed sensor on gearbox output shaft (output speed) Valve cover with control valves Electrical central unit ‘Switch at parking brake - ON when brake is released ‘Switch at inching — OFF when inching . Relays Wiper motor Starting interlock Stop SELTONOOM> Beene 3 Reversing lights Inching Reverse gear 10. Forward gear 11. Reverse interlock, which prevents gear-changing at speeds above 3 kmh, SPNOnEe Cable colours Svart = Black Brun = Brown Vit =WhiteDC 4160-4560 Technical Handbook Automatic electric gear-changing system Diagram Publ 1Gr1F. Automatic electric gear-changing system Clark 34000/36000 A08899.0100 06 Gearbox control valve Employed gear Activated solenoids To seat buzzer switch Relay 9 and 10 are not mounted Jumper between 86 and 87 To starter motor (50) From starter switch From alternator (D+) To parking brake waming lamp Control unit Display Gear selector Speed sensor in torque converter housing (engine speed) Speed sensor on gearbox output shaft (output speed) Valve cover with control valves Electrical central unit Switch at parking brake ~ ON when brake is released Switch at inching - OFF when inching 0. Relays Wiper motor Starting interlock Stop AONaeron moow> Reversing lights Inching . Reverse gear 10, Forward gear 11. Reverse interlock, which prevents gear-changing at speeds above 3 km/h. Oeroase Cable coloursjgiooroe | 80vf7 : = z I + S35 Gove a - 7 WH DANTE 20 WHITES] gevre. ore vay 71axyn 803 TORINO [nora Seo eee FET ST Sern ee a= 1 z 9 . 7 = z T3 SP Qual wl ec DINOYLITHS = * [oareroteraorar a EET, Sa See oe pe iz i 7 7 7 =o a T mis z[walmaruaty DC 4160-4560 Coca Technical Handbook contents (put Ter.) Group 30 Engine Specifications 2 Engine, 3 Description. 3 General, 3 Cooling system. 5 Fuel system 7 Lubrication system 70 Combusting air system. 12 Air cleaner 12 ‘Turbocharger 13 Air pre-heating 14 Service. 15 Quality of diesel fuel. 15, ‘Coolant quality 15 Lubrication oil quality 15, Draining the water from the fuel tank 15 Inspection of air cleaner and changing the filter element. 15 ‘Changing oil and oil filter 16 Checking V-belt tension 16 ‘Changing and adjusting the valve clearances 17 ‘Changing the fuel filters 7 Preventive maintenance on turbo-charger 18 Maintenance of exhaust-gas cleaner 18DC 4160-4560 Technical Handbook Specifications Manufacturer, type Coolant volume, | Rating, ISO 3046/2534, kW (hp) at rimin Torque, ISO 3046, Nm at r/min Number of cylinders ‘Swept volume, litres. Valve clearance, engine cold or at operating temp., intet, mm exhaust, mm Idling speed, r/min (adjust so that the engine funs smoothly) Injection pump timing ‘Thermostat, starts to open at °C fully open at °C Lubricating oit fitter with by-pass valve Lubricating oil pressure, kPa running speed idling speed Lubricating oll grade viscosity Volume, | Volvo TD 100 G 46 180/230 2200 1057 1400 9.60 04 0.70 525 20° +0.5° BTDC 78 90 Full-flow, disposable paper elements 350 150 min. API-CD, CD+ ‘see figura below 21 *) Engine wear may increase if these oils are used at temperatures above +15 °C and +30 °C respectively. **) Synthetic or semi-synthetic oil. N.B. Use only SAE 5W/30 oilDC 4160-4560 Engine 4 Technical Handbook Description 2 General ‘The engines powering ContChamp DC 4160-4560 is a 6- r, inline, 4-stroke diesel engine with overhead valves. ‘The engine Is turbocharged, i.e. combustion air is supplied under pressure. As a result, the quantity of fuel injected can be increased, which increases the engine output. The turbocharger Is driven by the exhaust gases and uses energy that would otherwise be lost. ‘The engine is pressure-lubricated and incorporates an oll pump which delivers oi to all lubrication points. A full-flow oil fter effectively cleans the lubricating oil. The fuel system is protected against impurities by replaceable filters. Th has replaceable wet cylinder liners. The engine has separate, mutually interchangeable cylinder heads for each cylinder. Turbocharger Hydraulic pump a Alternator ‘for brake system Oil cooler Intake-side of the Volvo TD 100 G engine|DC 4160-4560 Engine Technical Handbook Description Exhaust-side of Volvo TD 100 G engineDC 4160-4560 Engine yo eee 30-5 Technical Handbook Description é Cooling system The engine is liquid-cooled and equipped with a closed cooling system consisting of the following main components: Coolant pump Radiator ‘Thermostat (3 pes.) Radiator fan Coolant passages Engine oil cooler Gearbox oil cooler ‘The coolant flows through a longitudinal passage into the ‘engine block. The opening into the cooling jacket of each cylinder is individually sized to ensure that each cylinder will be ‘supplied with the same rate of coolant flow. ‘The coolant flows in the separate retum lines converge into a ‘common pipe in the thermostat housing. The coolant then flows to the coolant pump and then into the engine and to the oll cooler. ‘When the engine has reached its normal operating temperature, the thermostat will open the circuit to the radiator. ‘The piston-type thermostat is capable of passing a high coolant flow rate at a minimum of pressure drop, thus contributing to favourable coolant circulation in the engine. ‘The cootant pump is gear-driven, and the pump impeller is ‘made of plastic. Radiator Coolant pump Thermostat housingDC 4160-4560 Engine Sa Description Technical Handbook The cooling system is equipped with a sensor which activates the “Low coolant level” warning lamp on the instrument panel. ‘The engine lubricating oil is cooled efficiently and reliably in a ‘separately mounted tubular oil cooler. The gearbox oil is also cooled by the engine coolant, but in a separate shelland-tube cooler. Piston thermostat From radiator Engine warm Pump and thermostatDC 4160-4560 Technical Handbook Engine 070 BO Description Fuel system ‘The fuel circulates in two circuits - the high-pressure circuit and the low-pressure circuit. When the engine is started, the feed ump draws fuel from the tank and dalivers it at relatively low pressure through fine fitters up to the injection pump. This then delivers fuel at high pressure to the injectors which supply the fuel in atomised form to the engine combustion chambers. Excess fuel which is circulated in the low-pressure system is also cleaned in the fine fiters and is returned through a spill valve back to the tank. ‘The fuel system includes the following components: Fuel tank - a separate unit located on the left-hand side of the truck. The fuel volume in the tank can be read on a gauge on the instrument panel. Feed pump - of piston type, supplies fuel at a certain pressure and flow rate to the injection pump. Splll valve - which restricts the fuel feed pressure and provides Continuous venting of the fuel system. Excess fuel flows through the injection pump before returning to the tank, thus cooling the fuel in the fuel chamber of the pump, which contributes to more uniform distribution of the fuel to the various cylinders. Fuel filter Spill valve Injector Fuel tank Feed pump Injection pump Solenoid valve (option) Suction strainerDC 4160-4560 Engine Technical Handbook Description oe Tele Fuel filters - two filters connected in parallal and with a com- ‘mon cover. The filters are of disposable type, with the filter ‘elements made of spirally wound paper. Fuel fitter Injectors - each with a nozzle holder and a nozzle. When the {uel pressure has risen to the preset value, the needle will lit and atomised fue! will be injected into the combustion chamber through accurately calibrated holes in the nozzle sleeve. - Supply pipe coupling . Spill fuel pipe connection Spacers for adjusting the opening pressuré |. Compression spring 5. Thrust pin . Nozzle sleeve NeedleDC 4160-4560 Engine — Technical Handbook Description ¢- Injection pump - located on the left-hand side of the engine and driven by gears. The pump is equipped with an RSV ‘governor which has a steep control characteristic at low engine speeds. As a result, the engines appear more powerful and have a higher tractive effort at low speeds. . Link piece . Control screw Locking ring Link arm . Dowel Lead cam 10. Sipper 41. Control arm 42, Govemor arm 18. Cover 14. Link rod 15. Adjustment nut 16. Spring cup 15 17. Govemor spring Aa 18. Governer weight 19. Bell crank 17 20. Locking washer 21. Control axle 18 22. Housing SPENoMseno 3 2XNweaaW® eo RSV centrifugal governorDC 4160-4560 Technical Handbook Engine Description Piston cooling Lubrication system The engine is pressure-lubricated, and the oil is supplied by a pump in the oil sump. All lubricating oil flows through a double fulllow filters. ‘The lubricating oil is cooled in an externally mounted tubular oi! cooler by the engine coolant. ‘The lubricating system includes the following main components: ‘Ol pump - of gear type, which draws oil through a coarse strainer that arrests larger particles. The pump delivers oil through the lubricating oil fiters to the various passages of the lubsicating system. Piston cooling - reduces substantially the piston temperature which, in tur, contributes to a longer life of the piston rings, reduces the risk of carbon deposits and lowers the oil consump- tion. ‘The pistons are cooled by oil which is sprayed by nozzles into the underside of each piston and into the cooling passages when the piston is at the bottom dead centre. Cooling is controlled by a piston cooling valve which shuts off the cooling oil supply at low engine speeds. This ensures that the lubricating oll flow will be a maximum when the engine is started and when itis running at idling speed. The valve also restricts the pressure of the piston cooling oil at high engine speeds, to make more oil available for lubrication. |. Oil pump . Reducing valve . By-pass valve Oil under pressure to the lubrication system . Piston cooling valve . Oil under pressure for piston cooling . Oil cooler . By-pass filter Oil fiter Lubrication system of the TD 100 G engineDC 4160-4560 Engine Technical Handbook Description ea Ter Réducing valve - located just before the filter. The valve will ‘open if the lubricating oll pressure Is too high and will return ‘excess oil back to the sump. ll fiter - of fulltlow type, with a filter element of pleated fitter paper. To protect the engine against insufficient lubricating oil, a by-pass valve is fitted in the oil iter bracket. The valve will open it the lubricating oil pressure should rise above a certain pressu- ‘a due to clogging of the filter. When the valve is open, unfite- ‘ed oil will flow to the engine. The filters are of disposable type and should be scrapped after use. Crankcase ventilation - prevents pressurising of the crank- case and collects fuel vapour, steam and other gaseous pro- ducts of combustion. Crankcase ventilation is provided by a pipe connected to the crankcase inspection cover on the right- hand side of the engine, between the starter motor and the oil filter. oe”, Full-fow fitter Lubrication system of the TD 100 G engineDC 4160-4560 Technical Handbook Engine oe 370 90-1230 Combustion air system Large quantities of alr are necessary for burning the fuel supp- lied to the engine. Free, unrestricted flow of fresh air and exhaust gases is therefore essential to allow the engine to run efficiently. Alr cleaner ‘The intake air is cleaned in a two-stage air cleaner, the first stage of which collects coarse particles by cyclone action, and the particles are then collected in a dust receiver. The second ‘stage consists of a filter element - the main filter element. A safely filter element is located on the inside of the main ele- ‘ment. The safety element prevents the ingress of impurities into the engine while the main element is being changed and if the main element should sustain damage while the engine is unning, @.g. due to incorrect installation. Air intake Dust receiver Alr cleanerDC 4160-4560 Engine Gam Technical Handbook Description Pub [Gr P. Turbocharger ‘The turbocharger supplies more air to the combustion cham- bers than the engine would be capable of drawing naturally. This enables the engine to bum more fuel which, in tum, increa- ses the engine output. The turbocharger consists of a turbine wheel and a centrifugal ‘compressor impeller, each with a separate casing but mounted ‘on a common shaft. ‘The exhaust gases provide the energy necessary for driving the turbine wheel which, in turn, drives the compressor. ‘The turbocharger is lubricated and cooled by the lubricating oil from the engine. |. Mounting bolts for the ‘compressor casing . Circlip |. O-ring |. Thrust bearing . Bearing housing . Bearing bushes . Citctip . Oil thrower ring 1. Turbina casing |. Turbine wheel |. Piston ring seals . Heat shield . Thrust washer . Spacer ring . Oil deflector plate . Piston ring seals ”. Holder for piston ring seals |. Compressor impeller . Cover |. Compressor casing ‘Turbo charger of the TD 100 G engineDC 4160-4560 Engine — Technical Handbook Description P. Air pre-heating Before the air is admitted into the combustion chamber, it flows across an electrically heated starting element. This has a high rating of 4 kW and heats the intake air sufficiently for the engine to start at low ambient temperatures. The starting element i ‘switched on with the starting key.DC 4160-4560 Technical Handbook Engine '9070 90-12-30 Service Main fier element Quality of diesel fuel Diesel fuel conforming to DIN 51601, CEC-ERF-D1 or ASTM- 0975-No.2 should be used. The fuel should have the lowest possible sulphur content. N.B. When light diese! (e.g. Dipolar) Is used, follow the ‘engine manufacturer's recommendations concerning the addition of extra lubricant, etc., since the injection pump may otherwise be damaged. Also note that light diesel Includes a certain percentage of paraffin (kerosene), which Feduces the engine output. Coolant quality ‘Throughout the year, the coolant should consist of a mixture of 60% of water and 40% of ethylene glycol. The coolant should bbe changed and the cooling system should be flushed once a 923.110.0003) to the coolant, if the above mixture is not used in the cooling system. N.B. Never add a corrosion inhibitor if the cooling system contains glycol, since this would cause foaming which seriously impairs the cooling capacity Lubricating oll quality ‘See Group 90, Periodic supervision. Draining the water from the fuel tank Drain any water from the fuel tank by removing the drain plug. Immediately refit the drain plug as soon as the tlow of fuel is free from water and other impurities. Inspection of the air cleaner and changing the filter element Check the indicator when the engine is running. Itt shows red, the main fiter element must be changed. The collecting elficien- y of the filter element will not be improved if th changed too early. But if changing of the filter element is de- layed, smoke emission from the engine will increase, the engine ‘may lose power due to insufficient supply of combustion air, and engine damage may occur in certain cases. ‘The air pipe from the air cleaner to the engine should be check- €@d for tightness from time to time. Minor leakage, such as that caused by loose hose clips, and damaged or porous hoses may cause dust to be drawn into the engine, which will give rise to costly engine wear. ‘Change the filter element as follows: 1. The engine must not be running, 2. Clean the outside of the air cleaner. 3. Remove and clean the dust receiver. 4. Release and caretully remove the main filter element. Do not temove the safety filter element.DC 4160-4560 Technical Handbook Engine Service Publ, [GcTP. 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 ~ atleast every other year - if the indicator shows red after the main element has been changed - ifthe engine has been run with the main element damaged The safaty fitter 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 refiting it, carefully check that the main filter element is undamaged. Changing the oll and oll filter N.B. Before draining the oll, make sure that It Is at normal working temperature. 1, Remove the drain plug from the underside of the sump and drain the oil. 2. Clean the area round the filters and place a tray under the filters to collect any spillage. 3. Remove and discard the filter canisters, which are of dispo- sable type. 4, Pour clean oil into the centre of the new filters, wait until the oil has seeped through the filter paper and top up until the fitters are full 5. Lubricate the canister seals with oll. 6. Fit the new fiters and tighten them - by hand only. 7. Fill the engine with oil (see Group 90, Lubrication chart). 8. Run the engine and check that no oil leaks at the fitters. 9. Stop the engine and check the oil level after a few minutes. ‘Top up as necessary to the MAX level on the dipstick. N.B. To avold serious damage to the engine, use only genuine Kalmar LMV filters. Checking the V-belt tension 1. Check at regular intervals that the V-belts are correctly tensioned. It should not be possible to depress the V-belt more than 10 - 12 mm mid-way between the pulleys. 2. The engines are equipped with an automatic belt tensioner which maintains the belt tension constant. N.B. If the belt drive cons! both belts. of two belts, always changeDC 4160-4560 Technical Handbook Service Checking and adjusting the valve clearances N.B. Never attempt to check the valve clearances when the engine is running. The engine must be stationary but may be cold or hot. 1. Tum the crankshaft in its normal direction of rotation until the inlet valve of No. 6 cylinder has just opened and the exhaust valve of the same cylinder has not yet closed fully. Check the valve clearances on No. 1 cylinder and adjust as neces- sary. Valve clearances Engine TD 100G Inlet 0.40 mm. Exhaust 0.70 mm 2. Check the other valves in accordance with the table below. Check the valve clearances : of cylinder No. 153624 «when the inlet and exhaust valves of the following cylinders are just changing over (are moving simultaneously) 624153 Changing the fuel filters 1. Clean the outsides of the filters. 2. Remove the filters and discard them. 3. Clean the fitter head. 4, Check that the new filters are perfectly cle Seals are in good con ‘and that the 5. Fit the new filter canisters and tighten them by hand until the seal is in contact with the seating surface. Then tighten them a further half a tum,DC 4160-4560 Technical Handbook CAUTION. Never run the engine with the air inlet or exhaust pipes disconnected from the turbo- charger, since personnel could then sustain injuries. Note! Adjustments on the injection pump are to be performed by authorized personnel only. Engine Radial roller bearing, ‘Tapered roller bearings for axial thrust Differential assemblyDC 4160-4560 Drive axle = Technical Handbook Description WDB-system ‘The wet disc brake system is maintenance free, being immune to wear. Neither are the brakes prone to the fading which ‘normally occurs under tough operating conditions. Furthermore, adjustment of the brakes is not required. ‘The brakes consist of a series of stationary and rotary discs arranged altemately. The stationary discs are anchored (spli- ined) to the brake housing. The friction discs fit between the stationary discs and revolve with the wheel hub. Hydraulic pressure supplied by the accumulator when the brake pedal is operated moves a large hydraulic piston outwards which in turn pushes the discs together to slow the rotation of the re-volving friction discs. This slows the motion of each wheel hub and stops the vehicle. The systemis fully enclosed, thereby effectively excluding all dirt and contamination. ‘A cooling circuit is provided to dissipate the heat produced when braking. The cooling circuit uses fluid from the general hydraulic system, which means that the total volume of hydraulic fluid in the truck participates in the cooling process. ‘Two different systems — with or without external fan-cooled fluid cooler are available, see further Group 70. Hydraulic system. Brake pressure from foot brake Hydraulic piston Hub to Disc arrangement spindle seal To vehicle hydraulic system Cooling fluid trom a= vehicle hydraulic is system Cooling tluid Lubricating cavity fluid cavity Wet-disc brakeDC 4160-4560 Drive axle Technical Handbook Description (it “Tere Parking brake system The parking brake, which is of the disc type, is mounted on the drive axle input shaft. The brake is operated by a heavy-duty spring in the parking brake cylinder and is released by hydraulic pressure, counteracting the spring force. The brake cylinder and the caliper assembly form an integral unit. The hydraulic press- ture is applied via the parking brake control lever in the opera- tor’s cab. ‘The parking brake can also be used as an emergency brake. Emergency braking causes heavy wear to the brake pads. ‘Therefore the brake pads have to be changed after two ‘emergency brake operations. Ny ie fe a Dee Pe Vin 9 Sa Cylinder and caliper assembly Piston Spring cap Brake linings Seal, large Back up ring, large Seal, small Backup ring, small 10, Stud 1 PeENgagpo 13. Locking pin 14. Washer 15. Spring Parking brakeDC 4160-4560 Technical Handbook Drive axle oll Drive axle mounting bolts ———_—. Tightening torque, see Specifications Service Changing the drive axle oll IMPORTANT: To assure that the wheel ends of planetary axles with a common wheel end/housing bow! oil laval are initially lubricated, fill each wheel end directly with oil before vehicle is ut back into operation. DO NOT FILL THE AXLE THROUGH ‘THE DRIVE UNIT OR HOUSING BOWL ONLY. 1. Drive the truck forward until the oil drain plug on one of the wheel hub reductions is at its lowest point of travel. 2, Remove the oil plug and drain the oil. Refit the plug. 3, Repeat the procedure on the other wheel. 4, Remove the drain plug from the bottom of the differential and drain the oil. Refit and tighten the drain plug. 5. Fill each reduction with fresh oil. The level indicator shall be horisontal as shown on figure. Remove the filler plug and top up with oll. Refit and tighten the filler plug Volume: See ‘Specifications. 6. Remove the level plug from the differential and fill he differential with oll. Refit and tighten the level plug. Volume: See specifications. Rim clamp nuts Tightening torque, see SpecificationsDC 4160-4560 Technical Handbook The parking brake can also be used as an EMERGENCY BRAKE. NOTE! After two emergency brake operations the brake pads has to be changed. Drive axle oe Service (as Tere] Parking brake - initial adjustment Note! The spring cap (3) has a clock-wise thread and the stud (10) has an antl- clockwise thre Never try to screw the spring cap (3) in with springs in compres- sion as the threads may be damaged. 1. Ensure that the spring cap (3) Is fully engaged in the housing (1). 2. Apply hydraulic pressure. 3. Tum the nut (11) against the washer. 4, Release the hydraulic pressure. 5. Tum the spring cap (3) until the total clearance between the disc and the lining (2) is 0.5 mm. 6. Apply the hydraulic pressure. 7. Back up the nut (11) and lock it with the pin (13). The brake is now ready tor operation. 1. Cylinder and caliper assembly 2. Piston 3. Spring cap 4. Brake linings 6. Seal, large 7. Back up ring, large 8. Seal, small 8. Backup ring, small 10. Stud 11. Lock nut 12. Washer 13. . Locking pin 414. Washer 18. Spring Compensation of lining wear 1. Apply pressure. 2. Tum the nut (11) against the washer (12). 3. Release the pressure 4, Tum the spring cap (3), until the total clearance between the disc and the linings (4) is reduced to 0,5 mm, 5. Apply pressure. 6. Back up the nut (11) and lock it with pin (13). The brake is ow operational again with maximum torque.DC 4160-4560 a Technical Handbook Contents Group 60 Steered axle Specifications Steering axle. Description. Service, ieplacement of steering cylinder placement of knuckle pin bearings Replacement of steering wheel bearings Miscellanous Nona noonDC 4160-4560 — {9070 90-12 Technical Handbook Specifications Tightening torques. ‘Wheel nuts, Nm 402 (41 kpm) ‘Steered wheel bearing nuts Against stop (slacken 1/8 turn attr lightening) ‘Nuts for lower knuckle-pin bearings, Nm Against stop ‘Nuts for upper knuckle-pin bearings, Nm Against stopDC 4160-4560 Steering axle rae Technical Handbook Description ‘The steering axle is supported by a pendulum suspension and is operated by a double-acting steering cylinder. The ‘mechanism includes the smallest possible number of moving Parts to minimise the number of service points and to simplify maintenance. ‘The mounting in the chassis comprises entirely maintenanca- free rubber elements. The rear suspension is fitted with a pivoted joint. This is used to indicate a too low loading of the steering axle, i.e. the risk of tipping forwards. When only the ‘weight of the steering axle remains a "gap" is created which is indicated by a sensor. See further description under Group 20, ‘overload indication system. ‘The knuckle pins and wheel axles are mounted in taper roller bearings. The hydraulic circus of the steering system are described in Group 70. Pivoted joint bearing £ Rubber element Bay > Stoong eye | } Upper { Knuckle pin Lower bearing Link lever Steering axlerT DC 4160-4560 Steering axle (9070 80-1260 4 (pus TorTP} Technical Handbook Service Replacement of steering cylinder 1. Disconnect the hydraulic connections {rom the steering Locking washer. rom the stoning Steering cylinder cylinder, and protect the open ends of the cylinder hoses by means of caps or plugs. 2. Release and remove the piston rod pivot spindles. 3. Remove the bolts retaining the cylinder on the steering cradle. 4, Remove the cylinder. 5. Fit the new cylinder and coat the mounting bolts with LOCTITE. 6. Connect the piston rod ends to the link levers. Secure the pivot spindles by means of the locking washers. 7. Connect the hydraulic hoses. Replacement of knuckle pin bearings Dismanting |. Jack up the steered wheel end of the truck and block it up ina safe manner. Lock with 2. Remove the retaining ring from the steered wheel and Loctite remove the wheel. Note. A trolley with a rest for holding the wheel securely will be needed for handling purposes. 3. Secure a sling around the hub neck and lift until the hub is held in position. Note. Use a trolley, pallet truck or the like provided with a rest. ‘4. Remove the protective cover from the upper bearing of the knuckle pin. 5. Release the tabs of the tab washer. Remove the upper bearing nut and remove the tab washer and plain washer. 6. Remove the protective cover from the lower bearing, remove the split pin from the bearing nut and remo rut. The inner race of the bearing is loose and can be removed. 7. Remove the knuckle pin by tapping it upwards. The inner ‘ace of the upper bearing will accompany the pin. 8. Use a trolley to lift out the wheel axle. 9. Remove the wipers {rom the steering cradle. 10. Remove the outer bearing races from the steering cradle by means of an intemal puller. Note. if a suitable puller Is not available, lugs for a pulling tool may be welded to the inner race. The race will then shrink and will be easier to remove.DC 4160-4560 Steering axle Technical Handbook Service Hub . Outer bearing ~~~ -/ 4_--- Whee! nutRamee DC 4160-4560 Steering axle (9070 90-12 60-8 Technical Handbook Service Publ_TGel Assembly 1. Pack the outer races of the bearings with grease and press them into the steering cradle. Note that these are taper bearings. Fit the inner races so that the larger inside diameter taces outwards. ‘Around plate should be made for each bearing size for pressing in the races. A heavy hammer can then be used to hammer the plate for driving in the race. Don't hammer the bearings directly since they may not enter straight and may become jammed in the housing. 2. Fit new wipers to the steering cradle, using a suitable ring to tap them in. Tapping the wipers in with a hammer will damage them. 3. Lift the wheel axle into position by means of a hand trolley or hoist. ‘4, Insert the knuckle pin, fit the spacer and lower bearing inner race (packed with grease), and fit the bearing nut. 5. Tighten the lower bearing nut to stop and secure it with a spit pin. 6. Fit the upper bearing Inner race (packed with grease), the plain washer and the tab washer in position. Grease the tab washer to ensure that it will not be damaged by the bearing rut 7. Pack both bearings fully with grease and check that they tum freely. 8. Tighten the upper bearing nut to stop. Release the liting device as the nut is tightened to ensure that the lifting ‘device does not prevent tightening. 9. Tum the wheel axle to check that it moves freely. 10. Coat the covers with sealing compound, pack them with (grease and top up with grease through the grease nipple when the cover is in position and the sealing compound has dried. Replacement of steered wheel bearings Dismantiing 1. Jack up the steered wheel end of the truck and block it up ina safe manner. 2. Remove the retaining ring from the steered wheel and remove the wheel. Note. A trolley with a rest for holding the wheel ‘securely will be needed for handling purposes. 3. Remove the hub cover. 4. Secure a lifting sling to the hub, preterably using one of the ‘hub bolts. Fit a nut to secure the bolt. Use a hand trolley, Pallet truck or the like for lifting the hub.DC 4160-4560 Steoring axle co Carer Technical Handbook Service Publ. Tar]. 5. Remove the tab washer, locknut and bearing nut. The plain washer is loose. 6. Remove the hub off the wheel axle by means of the hand truck. The inner race of the outer bearing will accompany the hub. 7.. Withdraw the inner race of the inner bearing from the wheel axle. 8. Remove the seal, but leave the spacer in position. Assembly 1. Pack the outer races of the bearings with grease and press them into the hub. Note that these are taper bearings. Fit the inner races so that the larger inside diameter faces outwards. A round plate should be made for each bearing size for pressing in the races. A heavy hammer can then be used to hammer the plats for driving in the race. Don't hammer the bearings directly since they may not enier straight and may become jammed in the housing. 2. Press a new seal into the hub. Use a suitable round plate {or this purpose. Tapping the seal itself with a hammer will damage it. 3. Clean the spacer and pack it with grease, 4. Tap the inner race of the inner bearing onto the wheel axle, using a suitable tube. Pack the inner race with grease. 5. Lift the hub onto the axle, fit the inner race of the outer bearing position and pack it with grease. 6. Fit the plain washer and bearing nut with the flat surtace facing inwards. Tighten the bearing nut to press the bearing home, and release the nut 1/8 of a tum. 7. Fitthe tab washer and locknut. Grease the tab washer to prevent damage by the nut. Tighten the locknut and lock both the bearing nut and the locknut with the tabs. 8. Pack the outer bearing with grease, pack the bearing cover with grease and fit it into position. Top up with grease through the grease nipple. Miscellaneous ‘The steered wheel alignment is not adjustable. If the link levers have been deformed so that the wheel alignment has been disturbed, the link levers must be replaced. NOTE. The orientation of the link levers must be correct, ‘since they will otherwise be damaged by the wheels when 1@ correct orientation rg of the levers Is shown In the figure.DC 4160-4560 Technical Handbook ‘Kalmar 9070 95-19 70-1 Contents L pup, Torte] Group 70 Hydraulic system Specifications Main hydraulics Desoription ———— Principle of the electro-hydraulic servo system — Main hydraulics, feed Servo circuits Litt oo Telescoping of boom Over-centre valve Service Hydraulic fuid Hydraulic oil fier Breatherfiter High pressure fiter for the servo hydraulics 40 Steering system 1 Description Steering valve 12 Priority valve 98g Cooomervanwe Hydraulic pumps 15 Description 15 Service 16 Main vaive 18 Description 18 Service 19 Main valve, adjusting the supply pressure 19 Main valve, adjustment of load damping setting. 19 Brake system 20 Description 20 WDB brake system without extemal cooling 20 Cooling circuit 21 Main components of the brake system 24 WDB brake system with extemal cooling 23 Cooling circuit 24 Brake pump. a Hydraulic accumulators 28 ‘Accumulator charging vaive 28 Hydraulic brake pedal 29 Parking brake 30 Parking brake valve 30 Air-cooled oil cooler 31 Service 32 ‘Adjusting the WDB brake sytem 32 Air-cooled oil cooler 35 Accumulators 35 Hydraulic cylinders 36 Service 36 Repairs to leaking hydraulic cylinders 36 Lifting cylinder — 37 Telescoping cylinder, main boom — 38 Damping cylinders, attachment 39 Side-shifting cylinders 40 Locking cylinders, twist-ocks “4 Steering cylinder 42 Diagrams Hydraulic system ‘A10205.0200 01 Hydraulic system, vertical it ‘A10205.0100 02 WDB brake system without external cooling ‘A10206.0100 02 WDB brake system with external cooling A10206.0200 02DC 4160-4560 corr '90-1270, Ton T Technical Handbook Specifications Main hydraulics Hydraulic pressure, approx. MPa See the rating plate in the hydraulic compartment Hydraulic fluid volume (incl 6% Lubrizol for the WDB system) ' 600 Fitter type High pressure fiter mesh n 10 iting speed ms 0.25 -0.15 without load - with rated load Lowering speed ms 0.20-0.30 without load - with rated load Grade of fluid Use a hydraulic tluid for mobile applications trom a reputable oil company Viscosity ‘SH 32 at normal operating temperatures ‘SH 46 at moderately high operating temperatures ‘SH 68 at high operating temperatures See also Group 30 Electro-hydraulic servo system ‘Accumulator pressure (servopressure) Bar 30-40 ‘Nitrogen pre-charging pressure Bar 50 High-pressure filter mesh » 10 Opening press. of by-pass valve for high-pressure filter Bar 35 WOB brake system with external cooling ‘Accumulator pre-charging pressure Bar 95 Set pressure, brake pump Bar 200 Set pressure, accumulator charging valve Bar 175 Pressure trom brake pedal Bar 130 Cooling oil circuit, pump pressure Bar 15 WOB brake system without external cooling Accumulator, pre.charging pressure Bar 95 Set pressure, accumulator charging valve Bar 175 Pressure from brake pedal Bar 130 Steering system Max. hydraulic oll prassure Bar 175 ‘Shock valve opening pressure Bar 240DC 4160-4560 Technical Handbook Main hydraulics 7OO2 70S Description Publ [orl General The hydraulic system consists of the following sub-systems. + Main hydraulics comprising = Servo system supplying the electro-hydraulic system. + Telescoping of the main boom = Litingylowering of the main boom + Rotation of attachment ~ Length adjustment of the top-lift frame + Sideshifting Locking/unlocking twist-4ocks = Control of trailer arms + Foot-brake system - the truck may be equipped with one of the following two systems = WDB hydraulically operated, oil-cooled mul-disc brake ‘system without extemal cooling - WDB hydraulically operated, oilcooled multi-disc brake system with external cooling * Parking brake system consisting of a disc brake on the drive axle input shaft. Applied by spring force and released hy- drautically. + Steering system Principle of the electro-hydraulic servo system The main hydraulics are controlled by means of an electrohy- draulic servo system, the basic arrangement of which is shown diagrammatically on the next page. Each function of the hydraulic system is controlled by a total of three individual sub-systems - electric servos, hydraulic servos and main hydraulics. ‘The contro! unit in the electrical system is supplied at the battery voltage of 24V. The contro! unit delivers a pulsed d.c. output to the coordinate lever's potentiometer for each function. ‘The signal is modulated by the amount of movement of the lever and Is returned to the control unit for ampiitication. \@ amplified signal is then fed to the converters - one for each lit and lower and a further two for boom out and in. The converters are electrically controlled pressure reduction valves which converts the electrical signal to a proportional hydraulic. servo pressure. The servo pressure, in turn, actuates the operating spool of the main valve and thereby controls the main flow. Main valve 2 has no converter but retains the servo pressure from the converter for main valve 1. (If the truck is equipped with a vertical lift then main valve 2 Is also equipped with a converter). ‘The pressure regulating valve for the servo circuit receives its pressures from pump A or C and delivers 30-35 bar servo pressure to the converter. An accumulator on the valve ensures that servo pressure is available even if the engine should temporarily stop.DC 4160-4560 Technical Handbook Main hydraulics rn | Description a Tal] Main hydraulics, feed ‘The truck's main hydraulics are fed by three different pumps. Pump 2, a single pump, feeds one main valve for lit and boom extension together with a pressure regulator valve for the hydraulic servo, Pump 3, the inner section of a double pump, feeds the other main valve for lit and boom extension. Pump 4, the outer section of the double pump, feeds the steering system and the attachment via a priority valve together with a pressure regulator valve for the hydraulic servo. The priority valve ensures that the requirements of the steering system are always satisfied first and feeds the remaining flow to the different functions of the attachment. Both main valves are connected in parallel, both for the servo and the main flow, which makes maximum use of the pump's capacity for lit and boom extension. ‘The pumps draw hydraulic fluid from the hydraulic tank which is located on the right hand side of the truck. The pressurized fluid travels from the pumps to high pressure filters for cleaning before circulating in the system. ‘The hydraulic system is controlled from the cab by means of a coordinate lever for boom functions and a collection of switches for the attachment functions. 1. Hydraulic tank 2 Hydraulic pump 3 Hydraulic pump 4 Hydraulic pump 5. High pressure filter 6 Pressure reducing valve servo 30-35 bar 7. Priority valve 8. Steering valve 10. Main valve 1 a.UFT1 b. EXTENSION 1 11. Converters 12. Main valve 2 a. UFT2 b. EXTENSION 2 17. Main valve, attachment a. Rotation b. Tit ¢. Side shitt d. Feed, other functions 18. Coordinate lever 19. Control unit 1 20. Control unit 2 21. Switch panel ‘The position numbers correspond to next picture and the hydraulic system diagram Electro-hydraullcal system, principalDC 4160-4560 Main hydraulics — Technical Handbook Description 1. Hydraulic fluid tank. 2. Hydraulic pump, LIFT 1, BOOM EXTENSION 1, SERVO 8. Hydraulic pump, LIFT 2, BOOM EXTENSION 2 4. Hydraulic pump, STEERING BOOM, SERVO, ATTACHMENT 5. High pressure filter 7. Priority valve, steering system 10. Main valve for LIFT 1, BOOM EXTENSION 1 12. Main valve for LIFT 2, BOOM EXTENSION 2 Main hydraulics, feedDC 4160-4560 Technical Handbook Main hydraulics '9070 90-12 70 6 | Description = 1. Main valve 2. Main valve 3. Pressure reduction valve with accumulator for servo pressure 4. High pressure fitter 5. Converter The illustration shows a servo system for a machine with overload indication system. One set of converters feed both main valves. Servo circuitDC 4160-4560 Technical Handbook Main hydraulics Roce Description (publ TonT 1, Tank connection 2. Solenoid valve 3. Chech valves 4. Cut-off piston A. Feed from pump B. Outlet to cylinder Electrical controlled seat valve Litt ‘The double-acting cylinders are, at the piston end equipped with flange-mounted 2-way cut-off valves, consisting of: = Body, equipped with a spring- and pressure-loaded piston = Shuttle valve = Magnet valve = Cover ‘When the itt cylinder is in the lowest position and the iit lever ‘not activated, the cut-off piston is held in the closed position by ‘means of spring pressure and by the cut-off pressure through the solenoid valve. When litting, hydraulic fluid is fed to inlet A, the solenoid valve opens and dispreses the cut-off pressure to the tank, The pressure on the piston is thereby relieved, which ‘opens and releases hydraulic fluid through outlet 6 to the lift cylinder. The opening pressure is 2.5 bar. ‘The valve holds the load by means of the fluid pressure from the lift cylinder to outlet B. The pressure flows via the chech valve, through the solenoid valve as cut-off pressure and presses the piston to the closed position. ‘The cut-oft valves prevent communication between the lift cylinders, which in tum prevents twisting of the boom with uneven loads. The lift cylinders are connected in parallel and fed from both ‘main valves with the combined capacity of the two hydraulic pumps. Litt systemDC 4160-4560 Technical Handbook Over-centre valve Main hydraulics Description ‘The extension cylinder is ted with hydraulic pressure from one section of each main valve. The flow from two hydraulic pumps Is thereby utilized. ‘An over-centre valve is located in each of the feed lines. These Prevent the boom retracting too quickly due to the weight of the toad. They also act as a safeguard against hose fractures, Over-centre valve ‘The over-centre valve contains a counter-pressure valve that ‘opens with the pilot pressure from the piston rod side of the extension cylinder. A shuttle valve allows a free flow of hydraulic fluid to the extension cylinder with the BOOM OUT. For BOOM IN the pressure on the piston rod side must increas. to at least 1.3 times the pressure created by the loaded piston. Then the over-centre valve is opened by the pilot pressure and the hydraulic fluid on the piston side can pass on the tank. ‘Over-center valve Main valve Telescoping of boomDC 4160-4560 Technical Handbook ree [9070 90-12 70 9 jervice L Pu Torl Hydraulic fluid ‘The hydraulic-fluid tank is located on the right-hand side of the truck. ‘Check the fluid level on the fluid sight-glass, with all hydraulic pistons in the bottom positions. Top up the hydraulic tluid as necessary. See the Specification for the oil grades. I the truck has an oil-cooled wet disc brake system, any hydraulic oil used for topping-up should contain 6% of Lubrizo! ‘additive which is necessary for good performance of the brake system. ‘The additive is not consumed during normal operation and ‘must only be added at oil change and refill. Lubrizol may be ordered from Kalmar LMV Service department. CAUTION! Hydraulic fluld with Lubrizol additive Is chemically aggressive. Avold extended contact with the skin, Hydraulic oil filter ‘The high pressure filter for the hydraulic oll must be changed at the intervals specified in the lubrication chart. in addition, the filter must always be changed whenever work has been carried out on the hydraulic system. 1. Clean the outside of the filter and the area around it. 2, Place a vessel under the filter to collect any spillage. 3. Remove the fter bowl. Use an open-ended or ring spanner. ‘4, Remove the filter cartridge. 5. Replace the O-ring between the fiter head and the bow! and the O-rings on the adapter. The O-rings are packed together with the fiter cartridge. 6. Lubricate the O-ring for the filter head with hydraulic oil. 7. Remove the filter cartridge from its package and fit in immediately. 8. Carefully clean the filter bowl and fill it half-tull with hydraulic oil. 9. Fit the bowl and tighten it. 10. Start the engine to purge the system of air, and check that the filter does not leak. Breather filter ‘Change the breather filters every 1000 hours. In dusty Conditions, replacement may be necessary more frequently. A clogged breather filter will cause pump cavitation and drastically reduce the hydraulic pumps life time.DC 4160-4560 Technical Handbook Main hydraulics Sor RIE 70-10 Service High-pressure filter for the servo hydraulics ‘The high-pressure filter mounted adjacent to the main valve and at the attachment main vaive filters the circulating servo oil to Protect the components downstream of the filter and prevent maloperation. Aby-pass valve opens at 3.5 bar if the filter should become clogged. ‘The fitter contain a cartridge which should be changed every 1000 hours of operation. 1. Unscrew the bottom section of the housing and withdraw the cartridge downwards. 2. Fit a new cartridge, check the O-ring and refit he bottom section of the housing. Hydraullc-fluld filter for the brake cooling circuit (only brake systems with external cooling) Change the fiter every 1000 hours of operation. (Option: Two filters. Change both filters every 1000 hours of operation.)DC 4160-4560 Technical Handbook 1. Steering cylinder 2. Steering valve 3. Valve, block 4. Priority valve 5. Test outlet, steering pressure 6. Feed from pump Description Steering system ‘The steering system is supplied from hydraulic pump C, which also supplies the main hydraulics for the attachment. A priority valve ensures that the steering valve will always be supplied with a sufficient amount of fluid. Any remaining fluid is routed to the main hydraulics. ‘certain signal pressure at connection CF in the priority valve is always in communication with pressure connection P of the steering valve. As soon as the steering wheel is operated, a load signal LS will immediately be applied to the priority valve which changes over and supplies a sulficient quantity of fluid to the steering valve. ‘The pressure in the steering system is determined by a relief valve in the priority valve. Steoring systemDC 4160-4560 Technical Handbook 1. Double shock valve with suction valve 2. Check valve Steering valve and valve block ‘Adjusting screw for double shock valve under the plug Valve block OVPK Steering system Description Steering valve ‘The steering : - ve Is of the closed-center, non-reaction type with a load signal connection to the priority valve. The load signal ensures load-depandent control of the flow from the priority valve to the steering valve, The closed-center feature means that the valve shuts off the flow between the pump and ‘the tank when the valve is in the neutral position. This is neces- ‘Sary to enable a signal pressure to be connected to the steering valve, ‘The steering valve consists of a gear pump and a distribution valve. When the steering valve is turned, fluid is supplied from the steering pump across the gear pump to the distribution valve, which ensures that the flow will be supplied to the port corresponding to the direction in which the steering valve has been tumed. The gear pump ensures that the flow supplied to the cylinder will be proportional to the angle through which the ‘steering wheel has been turned. if the flow from the ‘steering pump should cease, ‘steering valve will automatically per- form as a manual pump, i.e. some degree of emergency contro will still be available. Shock valve A valve block with builtin double shock and suction valves is connected to the steering valve. The shock valves, opening at 240 bar, prevent pressure surges caused by blows against the steered wheels from being propagated to the steering valve. ‘The suction valves open to prevent vacuum on the opposite side of the piston, which could lead to cavitation.DC 4160-4560 Steering system amy Technical Handbook Description tem 12 - assembly configuration mas 1. Dust seal ce 2! Housing - spo! - sleeve Tightening torque: 30 +5 Nm 3. Ball 4, Threaded bush 5. O-ting 6. Guide ring 7. Front bearing race 8. Needle thrust bearing 9. Rear bearing race 18. O-ring 10. Ring 19. End cover 11. Dowa} 20. Washer 12. Neutral position springs, 1 set 21. Pin 22. Bolt with drilled head 23, Locking wire 24. Nameplate 16. Distributor plate 25. Selt-tapping screw 17. Gear set 26. Spacer Steering valveDC 4160-4560 Steering system Technical Handbook Description Priority vaive ‘The priority valve distributes the oil flow from the pump so that the steering valve will always be supplied with an adequate flow. certain pressure is always supplied from connection CF to the steering valve. When the steering wheel is operated, a load signal LS will be fed back to the priority valve to reset the valve ‘spool. When the steering wheel valve is not operated, the entire pump flow is diverted to the main hydraulics. ‘The valve spool is stabilised by an internal connection PP to the supply line of the steering valve. ‘Supply from pump Plugged connection PP_ connected internally (see diagram below ) Load signal connection: {from steering valve Supply to Supply to steering valve main Rygrauies (ptorty fon) Priority valveDC 4160-4560 Hydraulic pumps a Technical Handbook Description Publ Tonle. Hydraulic pumps. The hydraulic pump for the main hydraulics is a single and a double gear pump which is direct-driven by means of splines from the torque converter. The pump shafts are mounted in slidingcontact bearings which ara lubricated by the hydraulic oll {lowing through the pump. Gap between gear teeth Hydraulic pump 1. Splines 2. Drive shaft and gear set 3. Gear housing 1 4. Thrust plate 5. Sealing 6. Driven gear set 7. Gear housing 2 8. Connection shaft ‘Twin hydraulic pumpDC 4160-4560 Technical Handbook Hydraulic pumps Service Pua TocTp, Hydraulic pumps General instructions are given below for the service work that should be carried out on the pumps and how much wear is acceptable on the various components before a particular component must be replaced. 1. If different sections of the pump must be prised apart, take ‘great care not to damage any of the machined surfaces. It ‘great force is used, the parts may be damaged. 2. Itis very important to blow all parts clean and wipe them with a lint-ree linen cloth before assembling. 3. Ifthe parts are difficult to fit during assembly, tap them gently with a soft mallet — never use a steel hammer. 4. The gears are carefully matched, and they must therefore be kept together as a unit during dismantling. Treat them with extreme care, so that the shafts and the teeth will not be ‘damaged. Avoid touching the shaft ends. 5. Never hammer a sliding contact or rolling-contact bearing into place. Always use a press or some other suitable tool. 6. Before assembly, fll all ports with hydraulic oil, so that the Pump will be thoroughly lubricated right from the start. All Pumps must rotate in the appropriate direction, since the Pressure will otherwise damage the seals. 7. Acold pump must not draw wamn oil, since it may otherwise seize. 8. After starting, run the pump without load and with the engine funning at idling speed for at least two minutes. During this tun-in period, check that the pump does not run hot.DC 4160-4560 Technical Handbook Hydraulic pumps — 7-47 Service Permissible wear of the pump components 9. Pump body ‘The pump pressure presses the pump gears towards the walls of the body on the low-pressure side, and since the shafts and bearings wear, the pump gears will ub against the body. If the pump body has worn more than 0.13 mm, it must be ‘changed. Check by placing a straight-edge inside the pump body, and use a feeler gauge to measure the wear. 10, Driven gear ‘The driven gear must be replaced if any type of scoring or wear Is found on the shaft ends or teeth. 11, Driving gear Fit a new driving gear if wear can be felt on the sealing surfaces. 12. Pressure plates The pressure plates seal at the sides of the pump section. Wear of the pressure plats will cause internal leakage. The maximum permissible wear is 0.05 mm. Fit new pressure plats if the existing ones are scored, worn or pitted. Check the centres of the pressure plates where the teeth mesh. Wear here indicates that there are impurities in the oil. Pitting Indicates cavitation or gas formation. Discolouration of the Pressure plates indicates overheating. 13. Dowels la dowel or its hoe has been damaged, the dowel and possibly the section containing the dowel hole must be changed. f more than reasonable force must be used for pressing in a dowel, this may be due to inadequately deburred or fouled Parts, deformation of the dowel or poor fit of the dowel hoe. 14, Sliding-contact bearings and roller bearings it new pump gears are fitted, the bearings must be a hard press fit, Roller gearings must be a light press fit, and itis acceptable itthey can be pressed in by hand. it a bearing can drop out of its seat, the hole is too large. 15. Seals Replace all rubber and plastic seals, including all O-rings, seals at the pressure plates, shaft seals and gaskets.DC 4160-4560 Technical Handbook Inlet section Return to tank 1. No-load relief valve 2. Regulator (shunt valve) 3. Main pressure limiting valve 4. Spool for lit 5. Load signal valve Main valve Main valve Gia Description (era “TorT Main valve ‘The main valve is a load-sensing, pressure-compensated directior rol valve of modular type. In the hydraulic sys- tem the two units, each one comprising: + Inlet section = Control seetion = Combined control and outlet section ‘The inlet section is provided with a flow regulator (shunt valve), main pressure limiting valve, a no-load relief valve and a redu- cing valve for the no-load relief signal line. ‘The main pressure limiting valve is pilot-controlled and opens the connection to the tank by moving the spool when the preset pressure is reached. ‘The no-load relief valve returns the oil flow to the tank and minimises the pressure losses whan all the spools are in the eutral position. The pressure drop between the tank inlet P ‘and the tank connection T is only approx. 4 bar, The operation of the valve is such that, as soon as a function is actuated, the flow to the no-load reliet signal line will be interrupted. The no- load relief valve then closes, and the regulator (shunt) at the ‘same time takes over and builds up a pump pressure of approx. 13 bar higher than the highest load pressure. The control section is equipped with a check valve in the supply passage to prevent inadvertent lowering of the load when several functions are operated simultaneously. The control section incorporates a valve for transmitting the load ‘signal to the regulator (shunt valve) in the inlet section of the main valve. The load signal valve employs the load pressure to control a spool which, in tum, is supplied with oil from the supply passage {or controling the shunt valve. The design permits the Circulation of a small constant flow in the load signal circuit, thereby ensuring a supply of warm oil for fast and accurate control. ‘The outlet section has a tank connection and connections for the load-sensing and no-load reliet signals. ‘The valve spools are spring-centered and mechanically control- led. In the hydraulic system with electro-hydraulic servo, the spools are controled by hydraulic servo pressure using electro- hydraulic converters.DC 4160-4560 Technical Handbook Main valve ig Service (ew Torte EPs ote 2 Return ff Supply. Measurement tapping Locknut Adjustment of main pressure limiting valve Adjustment of load damping setting Main valve ‘The main valves are of precision type and must be handled with great care to safeguard their good performance. The following rules apply to service work: 1. Never use the spool ends or housings for clamping or ripping when ifting a valve block. 2. Never subject spool ends or housings to blows or shocks. Rough treatment may deform the spool, which will ead to Immediate seizure. 3. Protect the valves from moisture and dirt. Take particular ‘care to prevent dirt from entering the connection ports. Protect the ports and other joint faces to prevent scoring and bruising. Keep unconnected ports plugged with plastic lugs or the like. 4. When fitting pipes and hose couplings, observe meticulous cleanliness. Make sure that no swart, flakes of paint or other impurities enter the valve. To avoid unnecessary stresses in the valve, do not overtighten the couplings. Main valve - adjusting the supply pressure ‘The supply pressure to the main valve is determined by the main pressure limiting valve. ‘This is focatad in the Inlat section (see figure). When adjusting: + Release the locknut and turn the adjusting screw the projec- ting pin with a drilled hole. + Check the pressure by connecting a pressure gauge to the ‘measurement tapping on the relevant inlet section. Main valve - adjustment of load damping setting ‘The load damping can be set by means of the nut on the end cover of the combined control and outlet section. + Anti-clockwise adjustment reduces the damping and results in “harder loading. - Clockwise adjustment increases the damping and results in “softer” loading. = The damping should be adjusted to achieve “soft” loading, but without making operation sluggish.DC 4160-4560 Technical Handbook Brake system Description WDB brake system without external cooling This system is known as the wet disc brake system, in which assembly comprises stationary discs arranged atternately with a ‘number of rotating discs. The disc assembly is compressed by hydraulic pressure to provide effective braking action. The assembly Is submerged in a hydraulic oil bath to dissipate the heat generated by braking. A separate cooling circuit is provi- ded to coo! the hydraulic oll, The advantages of the wet disc brake system include the fact that no adjustment is needed, and that no fading or wear occur. Moreover, the enclosed oil bath keeps the system completely free from water and impurities. The wet disc brake system comprises three separate hydraulic Circuits, |.e. the foot-brake circuit, the cooling circuit and the parking brake circuit. ‘All circuits are supplied with hydraulic fluid under pressure from the variable displacement hydraulic pump. The brake circuits are supplied from two hydraulic accumulators and the cooling circuit is supplied directly from the pump. ‘The pump feeds a charging valve which ensures that a mini- ‘mum pressure will always be maintained in the accumulators. During the charging proces: harging valve serves as a Priority valve, so that a certain residual flow will be supplied to the cooling circuit. If the engine runs at no load, the residual flow may be so small that the flow in the cooling circuit engine will temporarily stop. When the accumulator has been charged {0 full pressure, the charging valve transfers the entire pump flow to the cooling circuit.DC 4160-4560 Technical Handbook Brake system 9070 90-12 70 21] Description Cooling circuit When the accumulators are charged, alls fed to the cooling oil cavities in the drive axle. A by-pass valve between the supply and return lines ensures that the cooling oil pressure will not exceed 1,5 bar, in order to protect the drive axle. ‘The supply fluid, and optionally also the retum fluid, is thorough- ly filtered. Since the suction and retum lines of the cooling system ara both connected to the tank, the total hydraulic oil volume of the truck will be involved in cooling, which contributes to the excellent cooling capacity of the system. Main components of the brake system The figures refer to the hydraulic diagram for the WDB brake system without external cooling. 1. The variable displacement hydraulic pump, which generates the brake pressure and is driven by a power take-off on the engine. 3. Accumulator charging valve set to 175 bar and serving as a ‘st priority to the brake system. ‘The remaining flow is delivered to the cooling circuit. 6. Accumulators which are charged by the accumulator char- ging valve, are pre-charged with nitrogen and ensure that be available in the brake even if the engine should temporarily stop. 9. Parking brake vaive which supplies fluid at a reduced pressure from the accumulator to the parking brake cylinder when the parking brake is released. Sensor 7 switches on the parking brake warning lamp when the parking brake is applied, and sensor 8 initiates a signal to a buzzer in the cab to indicate that the operator has left the seat without applying the parking brake. 14, Right-hand front brake pedal. Supplies oil at a reduced Pressure from the accumulator to the drive axle disc brake assembly. This pedal is used as a normal foot brake. 18. Left-hand front brake pedal. Apart from the normal braking function, the pedal disengages the transmission via connec- tion 12 at a given brake pressure. 17, Parking brake cylinder. Actuated by a heavy spring when the brake is applied, i.e. when the oil has been discharged through the parking brake valve. The brake is released by hydraulic oil from the parking brake valve. 21. Disc assemblies in the wheel hubs.DC 4160-4560 Brake system Technical Handbook Description 1. Hydraulic pump 2. Test outlet, pump pressure 3. Accumulator charging valve 4, Test outlet, charging pressure, 175 bar 5. Accumulator pressure release valve 6. Accumulator, 95 bar precharge 10. Connecting bar 18. Cooling circuit fiter. peo oe Brake system without external coolingDC 4160-4560 Technical Handbook Brake system Description WDB brake system with external cooling ‘This systam is known as the wet disc brake system, in which ‘each hub is equipped with a muttiple-disc assembly. The disc assembly comprises stationary discs arranged alternately with a ‘umber of rotating discs. The disc assembly is compressed by hydraulic pressure to provide etective braking action. The assembly is submerged in a hydraulic oll bath to dissipate the heat generated by braking. A separate cooling circuit is provi- ded to coo! the hydraulic oll. The advantages of the wet disc brake system include the fact that no adjustment is needed, and that no fading or wear occur. Moreover, the enclosed oil bath keeps the system completely {ree from water and impurities. ‘The wet disc brake system comprises three separate hydraulic Circuits, i. the foot-brake circuit, the cooling circuit and the parking brake circuit. All circuits are supplied with hydraulic fluid under pressure from the variable displacement hydraulic pump. The brake circuits are supplied from two hydraulic accumulators and the cooling Circuit is supplied directly {rom the pump. The cooling circuit ‘drives the cooling circuit circulation pump and the cooling fan which is connected directly to the pump. A charging valve ensures that a minimum pressure will always be maintained in the accumulators. During the charging pro- cess, the charging valve serves as a priorily valve, so that a certain residual flow will be supplied to the cooling circuit. If the engine runs at no load, the residual flow may be so small that the flow in the cooling circuit motor will temporarily stop. When the acounulator has been charged to full pressure, the charging valve transfers the entire pump flow to the cooling circuit motor. The variable delivery pump is controlled by a load signal either {from the charging valve or fram the supply line to the cooling circuit motor. The load signal controls the pump regulator, 60 that the pump will deliver a constant flow, regardless of the engine speed.DC 4160-4560 Technical Handbook Coy Brake system 190709012 70-24 Description Publ. TorTP. Cooling circuit “The circulation pump draws hydraulic oil directly from the tank and delivers it to the drive axle. A by-pass valve between the supply and return lines ensures that the cooling oil pressure will not excead 15 bar, in order to protect tha drive axle. ‘The variable displacement pump continuously receives a load signal from the cooling motor circuit, which maintains a constant flow in the cooling circuit, regardiass of tha engine spea ‘The cooling oil flows from the dirve axle to a cooler with a by- ‘pass function controlled by a bi-metal thermostat. The oil temperature thus determines the proportion of the oil flowing through the cooler. ‘The supply fluid, and optionally also the return fluid, is thorough- ly filtered. Since the suction and retum fines of the cooling system are both connected to the tank, the total hydraulic oil ‘volume of the truck will be involved in cooling, which contributes to the excellent cooling capacity of the system. Main components of the brake system ‘The figures refer to the hydraulic diagram for the WDB brake system without external cooiing. 1. The variable displacement hydraulic pump, with pressure and flow compensation, which generates the brake pressu- re and is driven by a power take-off on the engine, ‘3. Accumulator charging valve set to 175 bar and serving as a Priority valve which gives first priority to the brake system. ‘The remaining flow is delivered to the cooling circuit motor. ‘9. Accumulators which are charged by the accumulator char- ing valve, are pre-charged with nitrogen and ensure that Pressure will be available in the brake circuit and cooling Circuit evan if the engine should temporarily stop. 12.Parking brake valve which supplies fluid at a reduced pressure from the accumulator to the parking brake cylinder when the parking brake is released. Sensor 10 switches on the parking brake warning lamp when the parking brake is applied, and sensor 11 initiates a signal to a buzzer in the cab to indicate that the operator has left the seat without applying the parking brake, 17. Right-hand front brake pedal. Supplies oil at a reduced Pressure from the accumulator to the drive axle disc brake assembly. This pedal is used as a normal foot brake. 18. Left-hand front brake pedal. Apart from the normal braking inction, the pedal disengages the transmission via connec- tion 15 at a given brake pressure. 20. Parking brake cylinder. Actuated by a heavy spring when the brake is applied, i.e. when the oil has been discharged through the parking brake valve. The brake is released by hydraulic oil from the parking brake valve. 27. Disc assemblies in the wheel hubs.DC 4160-4560 Technical Handbook Brake system The cooling circuit consists of the following components: 4. Orifice plate which supplies the hydraulic motor of the, cooling pump with fluid at a pressure of 40-50 bar. 21. Hydraulic pump motor supplied from the brake system pump across the charging valve and orifice plate 4. 22. Cooling fluid circulation pump which draws fluid directly from the tank. The pump is flange-mounted directly on the hydraulic pump motor. 23. Fan-cooled air/fluid cooler with thermostatically controlled by-pass valve, which ensures that the hydraulic oil will ‘quickly be warmed up to the working temperature. The valve is fully open when the fluid temperature is below 40°C. The by-pass valve also protects the cooler against excessive pressure. The valve is set to open at approx. 2 bar 24, Filter with by-pass. Ifthe fiter should become clogged so that the pressure exceeds 0.6 bar, the by-pass valve will open automatically. 25. Cooling fluid by-pass valve which supplies oil at a maximum pressure of 1.5 bar to the drive axle. 26. Temperature sensor. Lights up the warning lamp for high cooling oil temperature if the temperature should exceed 115°C.DC 4160-4560 Brake system 9070 90" 5 Technical Handbook Description P. 1. Adjustable hydraulic pump 2. Test outlet, pump pressure 200 bar 3. Accumulator charging valve 4. Nozzle, determines cooling circuit motor speed 5. Shuttle valve 6. Test outlet, pressure to cooling circuit ‘motor, 40-60 bar 7. Test outlet, charging pressure 175 bar 8. Accumulator pressure release valve 9. Accumulators, 95 bar precharge 13, Connecting bar 21. Cooling circuit motor 22. Cooling circuit pump with integrated fan 23. Air cooler 24, Cooling circuit fier SJ Brake system with external coolingcr DC 4160-4560 Brake system [9070 90-12-7027] Technical Handbook Description Pub Tar]. Brake pump oe 1. Set screw for stroke limiting 2. Adjusting spool 3. Slipper plate 4. Driven shatt 5. Swash-plate 6. Cylinder block 7. Compression spring 8. Valve plate 9. Piston ‘The brake pump is a variable-displacement piston pump with nine pistons mounted in a rotating cylinder block. The piston strokes are determined by the angle of an inclined swashplate. The pistons are secured to a slipper plate which rotates with the swashplate. The swept volume of the piston and the space in the piston are fillad with oll during the suction stroke. The oll is discharged during the delivery stroke through a valve plate and gives a balancing opposing force from the swash-plate and a lubricating oil film which prevents wear. The piston heads incorporate ortice where oil is discharged. ‘The swashplate has an adjusting spool which sets the pump. ‘The spool is controlled: = at WOB-system without external cooling: directly by the pressure in the output line, see hydraulic chart. ~ at WDB-system witht external cooling: flow and pressure controlled by a regulator. ‘The adjusting spool alters the slope of the swashplate and thus also the total flow delivered by the pistons. This design results in the flow being automatically adjusted to the system demand, while the preset pressure is maintained constant. ‘The adjustment is stepless, and the flow is a maximum at ‘maximum slope of the swashplate and is zero when the swashplate is vertical. ANON ORS 8 \ pee connection, only WDB-system with external cooling. 10. Regulator 11. LS-connection 12. Flow regulator 13. Pressure regulator 14. Set screw 415. Suction line 16. Pressure line Brake pumpDC 4160-4560 Brake system 170 80-1270. Technical Handbook Description Hydraulic accumulators ‘The brake system is equipped with two accumulators which nsure that hydraulic fluid under pressure will always be availa- ble for the brake system. ‘The accumulators are of piston type and are precharged with nitrogen to a pressure of 96 bar for the WOB system. ‘An accumulator consists of a cylinder made of pressure-vessel steel, an aluminium piston which is free to move along the entire cylindar length, and two end covers - for the gas supply at the top and for connection to the hydraulic system at the bot- tom. The latter is of safaty type and is impossible to remove unless the gas pressure has been completely relieved. ‘The hydraulic connection is connected to the brake system and to the tank. The tank connection can be opened by means of the accumulator discharge valve, the key for which is suspen- ded adjacent to the vaive. Gas connection ‘Accumulator charging valve ‘The function of the accumulator charging valve Is to divert the pump flow to the accumulator whenever the latter needs char- ‘ing. This ensures that the brake system's given priority and is first to receive oil. ‘During charging, the pump delivers oil through a check valve to the accumulator. A restriction limits the flow to a maximum of approx. 17 Vin. A the same time, pitt oll pressure is supplied ‘across the pilot valve to the main valve, where itis added tothe spring force and keeps the main valve closed. ‘When the accumulator has been charged, the oil pressure from the accumulator overcomes the spring force inthe pilot valve which changes over and relieves the pilot pressure to the tank. ‘The main valve changes over and opens the connection to the cooling circuit motor. ‘The difference between the prassures at which charging is started and stopped is determined by the itference in area between the pressure and tank connections of the valve, and Fiydraulic connection fmeuris to about 18% fhe pressure at wich charging ‘stopped, i.e. about 27 at a pressure of 150 bar and about Accumulator | 39 bar at 165 bar. Charging pressure >) PSL YB a oe + ISVTESAQ™L 290 WSLSAST3 Of se yoy oun seme An (A) & exUPAN AY ONLADOOTWEE w+ swag o1n SREB as oe 4 29 nan vos sau 3668 RST soruscsowal Bowe MOORS “LPPSIN OTA In HOB BBLARR Oe = ET ln TOM wep fer meine 1 iS ‘OAYSS13 230 W3ISASTS I SYSNT 8 Sis0rE PT ISOSOPE| RO aT eg oe) oe =a LlDC 4160-4560 [9070 95.09 90-1 Technical Handbook Contents C Pup Tor LP Group 90 Periodic supervision General survey 3 General survey chart 4 Daily supervision i0 Every 200 hours "1 Every 600 hours 12 Every 1000 hours. 13, Oil and lubricant recommendationsDC 4160-4560 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 regula- tions 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 deait 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: 4. Every 1000 hours 2. Every 600 hours 3. Every 200 hours ‘The same procedure also applies to work carried out in a 600- hour service. General survey chart Maintenance intervals, hours Operating ‘Anm time, hours 00? 600 200 200 © Warranty service after 200 400 © hours. Comprises: 600 . © *Work in accordance 800 © with list below 1000 . . . +1200 . 4400 ° 1600 . . 2000 . . . 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 fier in engine, gearbox and hydraulic system, {all fiters incl. WOB, servo filter etc) Valve clearance adjustment (engine) Check all bolt joints (see also SI94-003) Fill in date and signature in the warranty cardDC 4160-4560 Technical Handbook Periodic supervision ere LUBRICATION CHARTDC 4160-4560 Technical Handbook LUBRICATION CHART Description Periodic supervision Remarks [Boom mounting Liting cylinder Top and bottom Sti plates, Doom Brush on by hand, withthe boom in the fully extended position Rotator mounting Damper cylinders Rotator reduction gear Check the lvel. Top up tothe red point Jon te sight glasses Propelier shaft Gearbox oit %) Change the oi. Check the level at idling speed [Gearbox titer X) Change the fiter Engine otter x) Change the fiter every 400 h Engine ol X) Change the oil every 200") Drive axle Hydraulic ot Hyaraulc ol titer X) Change the fiter Breather fiters, hydraulic tank | Change fiter every 2000 Cooking oi fiter, hydraulic brake system x} Change the fiter Link overs Steered wheel bearings Knuckle pin bearings Remove, clean, inspect and pack with grease [every 2000 Rotator bearings 2 nipples on each side Pinion and ring gear Brush on with grease [Boor and panel hinges Lit off the doors and panels *) The interval is greatly dependent on the fuel and lubricant quality as well as the operating condilions. If intervals longer than 200 hours are desired, the condition of the oll must be checked by the company making the oi, by means of regular lubricant tos. LeLubricate ‘= Check NOTE! After they have been washed with degreasing Ifthe truck is standing unused outdoors, with agent, all pistons should be moved backwards and forwards several times to obtain a new protective oil film. the piston rods protruding, all piston rods ‘must be greased to prevent corrosion.DC 4160-4560 Technical Handbook Periodic supervision LUBRICATION CHART, CONTAINER UNITDC 4160-4560 Technical Handbook Periodic supervision LUBRICATION CHART CONTAINER UNIT Description Siding surfaces, length adjustment Brush onto al sting surfaces wit ihe frame in the fully extended position Suding surtaces, sideshiting [Brush onto all siding surtaces withthe frame sideshifted tothe limit in each direction [Chain length adjustment Brush with ol, not grease | Sideshiting cytinder [Chain sprocket, length adjustment Ptanetary gear [Check sight glass level, top up as necessary. ) Fist ol change after 500 hours, xx) thereafter change oll every 1000 hours (volume: 1.5 tives) Locking cylinder Lit pinion twist connection Lubricate with grease Lit pinion sing surtace Lubricate with grease (Contact pin Lubricate with grease Twistlock axle Lubricate G=CheckDC 4160-4560 Technical Handbook Periodic supervision LUBRICATION CHART, COMBI-LIFT UNITDC 4160-4560 Technical Handbook Periodic supervision LUBRICATION CHART, COMBI-LIFT UNIT Description Remarks Sting surtaces, length agjustment [Brush onto all siding surfaces withthe trame in the fully extended position Sding surtaces, sideshiting Jerush onto all siding surtaces withthe frame sideshities tothe limit in each direction [Chain, length adjustment Brush with oi, not grease Sideshiting cylinder 5. | Chain sprocket, length adjustment 6 [Planetary gear c x Xx [Check sight olass level, top up as nesessary. Xx} Fist oll change alter 500 hours, xx) every 1000 hours (volume 1.5 res) 7 [Locking cylinder U 8 Lit pinion twist connection L Lubsicate with grease 9 [Lit pinion siding surtace t Lubricate wih grease 10 |Contact pin L Lubricate with grease 11 [Twist lock ante 5 12 |Cytinder, lowering/ralsing L 19 | Arm bearing t 14 {Siding surtaces, height adjustment L Lubricate all siding surfaces with the legs Inthe maximum extended postion 18 [uit shoe mounting L 16 | Grip cylinder L 17 [Arm boating t 16 [Cylinder neight aqustment 19 [um shoe LeLubeleate = Check Lubricate all moving parts with ol to prevent the build up of rust. [Oo not use greaseDC 4160-4560 Technical Handbook Perlodic supervision Daily supervision area DAILY SUPERVISION Orwhen Refill it refueling Check required Brakes ‘Operation Steering Operation Rear steered axle suspension Check that the rear (On machines equipped with suspensionis clean overload indicating system) Allinstruments. Blinkers, brake lights, horn Operation Headights, reflactors Boom, pivot suspension and sliding plates Damage ‘Attachment and rotator ‘Operation Engine, gearbox, drive axle Noises? Hydraulic hoses Oilleakage? Fuel “Amount ‘The fuel meter . Must never show 0 Engine olf Level ‘Air cleaner Indicator ° Goolant . Level ° Hydraulic fluid ° Level Oo Gearbox oil ° Level ° Wipers. . Fluid tevel . Wheels ° Damages? ° ‘Tyre pressure 0,9 MPaDC 4160-4560 Technical Handbook Periodic supervision Every 200 hours lem Unit Action Remarks 1 Truck Wash 2 Radiator Clean the fins of the Note! Do not use radiator with water and detergent high-pressure. 3 Engine Check the oi and coolant connections for leakage 4 Aircleaner Empty the dust receiver. Check the indicator. Replace if required. ‘See Group 30. 5 Brakes Check for oil leakage. Test brake performance. See Group 70. 6 Battery cables, ‘Clean the terminals and apply terminals and petroleum jelly. f necessary, fuses replace cables and terminals. 7 Vibelts ‘Check the belt tension 8 Telescope boom and Check for damage. Retighten attachment the bolted joints. Check sliding- plates for wear. Apply special lubricant. See Group 80 9 Steering axle Check for play, damage 10 Steered and driven _Tighten the wheel nuts See Group 40 resp wheels Inspect tyres and rims for 60 Specifications possible damage. 11 Drive axle and Tighten bolt joints ‘See Group 40 propelier shaft Check for leakage ‘Specifications 12 Gearbox Check for oil leakage. 13. (Air conditioner) Check the performance ‘See Group 10 14° (Exhaust gas Inspect the catalyst and ‘See Group 30 ‘emission control top up as necessary. system) 15 Lubrication points, oil and filter changes in accordance with the Lubrication chart. 16 For optional equipment, pls. refer to special instructions issued. N.B. Always attend to any damage, wear or faults that are important to the perfor-mance of the truck and its service life or the safety of the personnel.DC 4160-4560 Technical Handbook Periodic supervision Every 600 hours = Item Unit Action Remark 1 Aircleaner Change the fiter element if the indicator shows red. See Group 30 2 Turbo charger Check for leakage. See Group 30 3 Exhaust system Check for leakage. 4 Steered wheels ‘Check the wheel alignment, ‘See Group 60 and check for deformation or bearing play. 5 Telescope boom Check that the hose and attachment guide pulleys run freely and that the hoses are in {good condition. 6 Lubrication points, oil 7 and filter changes in accordance with the Lubrication chart. 200 hours service N.B. Always attend to any damage, wear or faults that are important to the performance of the truck and its service life or the safety of the personnel,DC 4160-4560 Technical Handbook Periodic supervision Every 1000 hours tem Unit Action Remarks 1 Fresh-airfilter Change fiter element ‘See Group 10 2 Engine Check valve clearances, See Volvo cooling system, starter motor, Workshop Manual altemator and fuses and Group 30 3 Fuel tank Drain 4 Fuel fiter Change the fiter. Bleed the fuel system. 5 Injectors Check See Volvo Workshop Manual 6 Vbelts Check and change as necessary. 7 Batteries Check. 8 Wheels Check for damage 9 Propeller shaft Check the bolted joints and See Group 40 ‘check the universal joints for play 10 Gearbox and Clean the breather drive axle 11. Brakes Check See Group 70 12. Painting and Touch up safety marking 13 _Allfunctions Test-drive and check 14 (Airconditioner) Check the refrigerant level 15 Lubrication points, oil and fiter changes in accordance with the Lubrication chart. 16 Hydraulic pressure Check and adjust if necessary. 17. 600 and 200 hours service N.B. Always attend to any damage, wear or faults that are important to the performance of the truck and its service life or the safety of the personnel.DC 4160-4560 Technical Handbook ; . [Horo a05- 90-18 Periodic supervision — Oil and lubricant recommendations Engine oll Grade: API - CD cil for turbocharged engines, from a reputable oil company. Visoosity: See the chart below *) Ifthese olls are used at temperatures above +15°C or +30°C, engine wear may increase. **) Synthetic or semi-synthetic oil N.B, Only SAE SW/30 may be used. Transmission Grade: ‘API - CD Engine oil, C-3 N.B. Never top up with ATF oil Viscosity: Above -23°C: SAE 10 Above 0°C: SAE 30 Drive axle oil Grade: APIGLS Viscosity: SAE 8OW-140 Hydraulic fluid Grade: Hydraulic fluid for mobile applications from a reputable oil company. Engine oil with a viscosity of SAE 10 can also be used. Viscosity: ‘SHS 32 at normal working temperatures. Additive 6% LUBRIZOL. Grease Use EP universal grease to NLGI Grade 2 with 3-5% molybde- ‘num disulphide additive forall lubrication points, including whee! bearings.