Service Information

Document Title: Function Group: Information Type: Date:

Replacing 843 Service Information 2014/6/26
Profile:

Replacing
Op nbr

14 211 207 Tool for lock strip

Op. No. 84302 Windscreen, replacing

Op. No. 84312 Rear window, replacing
Op. No. 84313 Side window, replacing
Op. No. 84348 Door window, replacing

Removing

1. Poke out and remove the lock strip, see [Invalid linktarget] .

Figure 1
Removing lock strip

2. Push out the window pane.

3. Replace the rubber moulding, if required.

Installing

4. Insert the window pane from the lock strip side.

Begin by correctly positioning the pane at the bottom. Then gradually work the moulding in over the pane
alternating sides and using a small screwdriver.
NOTE!
To facilitate the installation, for example a soap solution may be used.

5. Install the lock strip with the aid of tool 14 211 207, see [Invalid linktarget] .

CAUTION
Turn the hook on the tool in the direction the strip is being installed.
Figure 2
Installing lock strip
 Service Information

Document Title: Function Group: Information Type: Date:

Adjusting possibilities 852 Service Information 2014/6/26
Profile:

Adjusting possibilities

Figure 1
Operator seat, mechanically sprung

1. Back-rest inclination
2. Seat inclination
3. Seat height
4. Longitudinal adjustment
5. Lumbar support
6. Height limiter with locking function;

 maximum height adjustment – lever in the right position

 limited height adjustment – lever in intermediate position
 transporting position, is never used when operating – lever in the left position.

Operator seat, mechanically sprung

The adjusting possibilities are shown in [Invalid linktarget] .

Figure 2
Seat with air suspension

1. Back-rest inclination
2. Seat inclination
 3. Seat height
4. Longitudinal adjustment
5. Lumbar support
6. Height limiter with locking function;

 maximum height adjustment – lever in the right position

 limited height adjustment – lever in intermediate position
 transporting position, is never used when operating – lever in the left position.

Seat with air suspension

The adjusting possibilities are shown in [Invalid linktarget] .
 Service Information

Document Title: Function Group: Information Type: Date:

Air spring for operator 852 Service Information 2014/6/26
seat, replacing
Profile:

Air spring for operator seat, replacing

Op nbr 85202

Removing

1. Disconnect the supply and return air hoses.

Mark the hoses so that they can be reconnected correctly.

2. Loosen and remove the four hexagon socket head bolts (M6) retaining the seat to the attaching bracket.

3. Lift away the seat including the slide rails.

4. Lay the seat on its back and pull to extend the scissors-like linkage.

5. Remove the air hose, the nipple and the nut which locks the air spring.

6. Remove the attaching bolt (hex socket 6 mm) and take out the air spring. See [Invalid linktarget] .

Figure 1

1. Attaching bolt (obscured)

2. Air hose, nipple and nut (obscured)

Installing

7. Install a new air spring.

8. Install the nut and the nipple. Lock with locking fluid medium.

9. Install the air hose.

10. Install the attaching bolt (hex socket).

11. Install the seat and tighten down with the four hexagon socket head bolts.

12. Connect the air hoses.

13. Check the function of the suspension.

 Service Information

Document Title: Function Group: Information Type: Date:

If the back-rest is 852 Service Information 2014/6/26
binding or has excessive
play
Profile:

If the back-rest is binding or has excessive play

Op nbr

1. Slacken both hexagon socket head bolts for the back-rest on the left side of the seat.

2. Install a washer (part No. 14214375-9) on the front hexagon socket head bolt.

3. Turn the washer according to required adjustment, see [Invalid linktarget] .

Figure 1

A. Max. adjustment. Easier (reduced play)

B. Max. adjustment. Harder (reduced play)
C. No adjustment

4. Hold the washer with a 22 mm open end spanner or an adjustable spanner and tighten down the front hexagon
socket head bolt.

5. Tighten down the rear hexagon socket head bolt.

6. If further adjustment is required, install a washer on the right side of the seat as well.
 Service Information

Document Title: Function Group: Information Type: Date:

Maintenance advice 852 Service Information 2014/6/26
Profile:

Maintenance advice
 Make sure that the functions of the seat are not blocked by objects on the floor.
 Check that the parts of the seat belt are not damaged. In case of damage, replace the whole seat belt kit.
 If the air-suspended seat does not retain its set position, check that the air system is not leaking.
 Check for play at the slide rails. Max. 1 mm (0.04 in) longitudinally and max. 1 mm (0.04 in) sideways. If the play
exceeds these values, replace the slide rails. Lubricate the slide rails.
 Check that oil does not leak out of the shock absorber. Replace in case of a leak.
 Check the seat attachment against the floor. Check that none of the bolts are loose.

WARNING
If protective bellows is missing, there is risk of pinching in the lever system.
 Service Information

Document Title: Function Group: Information Type: Date:

Operator seat, height 852 Service Information 2014/6/26
adjustment
of attachment
Profile:

Operator seat, height adjustment of attachment

The operator seat is adjustable through its attachment against the floor. Between the slide rails and the attaching bracket
there are spacer sleeves (1) which are 20 mm (0.79 in) high. These sleeves can be moved to adjust the seat height. See
[Invalid linktarget] .

Figure 1
Operator seat, height adjustment

1. Spacer sleeve
 Service Information

Document Title: Function Group: Information Type: Date:

Safety instructions 870 Service Information 2014/6/26
Profile:

Safety instructions
WARNING

 Use tight-fitting protective goggles.

 Use rubber gloves and protect other bare skin (risk of frost-bite).
 Avoid inhalation of refrigerant. Exposure may cause irritation to eyes, nose and throat.
Inhalation of refrigerant in concentrated form may cause the hart to stop.
 Never mix R134a with air in connection with a leakage test. Should something in the system generate a spark and
the system is pressurised, the mixture may ignite.

Only use refrigerant containers approved for this purpose when filling / emptying refrigerant.

 Never fill a refrigerant container to more than 60 % of its gross weight classification. There must be sufficient space
left for the gas to cope with the increase in pressure because of the change in volume arising during temperature
changes, for example caused by exposure to sunlight.
 Never expose a refrigerant container to temperatures above 50 °C (122 °F). Even a correctly filled container may be
at risk of exploding at temperatures above 50 °C (122 °F).
 Always carry out service work in well ventilated areas. R134a vapours are heavier than air and may therefore
accumulate in low lying areas, such as an inspection pit.
 Service Information

Document Title: Function Group: Information Type: Date:

Fan motor, replacing 873 Service Information 2014/6/26
Profile:

Fan motor, replacing

Op nbr 87306

Removing

1. Remove the cover over the heating unit.

2. Remove the attaching plate together with the fan unit, see [Invalid linktarget] .

Figure 1
Attaching plate with fan unit

3. Remove the fan unit from the attaching plate.

4. Remove fan housings (1). See [Invalid linktarget] .

Figure 2
Fan unit

1. Fan housings
2. Engine
3. Fan wheels

5. Loosen and remove the bolts (5 pcs) retaining motor (2).

NOTE!
 There is one bolt at the back of the attaching plate.

6. Remove motor (2) and fan wheels (3).

Installing

7. Install a new motor with fan wheels on the attaching plate.

8. Install the fan unit on the attaching plate.

9. Install the attaching plate together with the fan unit in the machine.

10. Install the cover over the heating unit.

 Service Information

Document Title: Function Group: Information Type: Date:

Heat control valve, 873 Service Information 2014/6/26
replacing
Profile:

Heat control valve, replacing

Op nbr 87308

Removing

1. Remove the cover over the heating unit.

2. Loosen and disconnect the control wire from the valve.

3. Pinch the hoses on either side of the valve with two pairs of pliers, see [Invalid linktarget] .

Figure 1

4. Remove the valve.

Installing

5. Install the new valve and connect the hoses. Remove the pliers.

Figure 2

1. Clip
2. Lever
 6. Install the control wire.
Adjusting: Heat control valve lever (2) must be right up against the stop lug when the temperature control arm is
approximately 2.5 mm (0.1 in) away from its end position. If necessary loosen clip (1) and adjust the position of the
control arm, see [Invalid linktarget] and [Invalid linktarget] .

Figure 3

1. Temperature control in minimum position

Check

7. Set the temperature control to the minimum position, see [Invalid linktarget] . Start and run the engine until warm.
Feel the hoses to the heating unit, [Invalid linktarget] . They must not be warm. Turn off the engine.

Figure 4

1. Hoses to heating unit

8. Install the cover over the heating unit.

 Service Information

Document Title: Function Group: Information Type: Date:

Heater 873 Service Information 2014/6/26
radiator, replacing
Profile:

Heater radiator, replacing

Op nbr 87304

WARNING
If the machine is equipped with AC, take care not to damage any connections to the evaporator.

1. Remove the cover over the heating unit.

2. Remove the attaching plate together with the fan unit, see [Invalid linktarget] .

Figure 1
Attaching plate with fan unit

3. Pinch the heater radiator hoses (1), [Invalid linktarget] , with two pairs of pliers. Disconnect the hoses from the
heater radiator.

Figure 2

1. Heater radiator, hoses

4. Remove the heater radiator and install a new one.

5. Connect the hoses and remove the pliers.

6. Install the attaching plate together with the fan unit.

7. Install the cover over the heating unit.

8. Check and if required, top up the coolant.

 Service Information

Document Title: Function Group: Information Type: Date:

Air conditioning, 874 Service Information 2014/6/26
checking function
Profile:

Air conditioning, checking function

Op nbr 87403

11 666 141 Temperature sensor

11 666 143 Multimeter (Volvo)

1. Close the door and all windows. Start and run the engine until it has reached normal working temperature.

2. Turn the fan switch (4) to position 3 (maximum speed). Set recirculation control (3) to the recirculation position and
heating control (2) to minimum position, see [Invalid linktarget] and [Invalid linktarget] . Start the air conditioning.

Figure 1
Air conditioning, serial No. –2900

1. Measuring point
2. Heating control
3. Recirculation position
4. Switches

3. Run the engine at approx. 1 800 rpm. Measure the temperature at the front right air nozzle on the instrument
panel. Keep measuring for approximately 5 minutes. See [Invalid linktarget] and [Invalid linktarget] .
 Figure 2
Air conditioning, serial No. 2901–, US 60001–

1. Measuring point
2. Heating control
3. Recirculation position
4. Switches

4. At some time during the testing the temperature should drop to around +4 – +9 °C (+39 – +48 °F) at a normal
ambient temperature of 20°C (68 °F) and normal air humidity.
 Service Information

Document Title: Function Group: Information Type: Date:

Air conditioning, 874 Service Information 2014/6/26
description of function
Profile:

Air conditioning, description of function

The air conditioning is filled with refrigerant R134a which is pumped round in the system by the compressor. When the air
conditioning is started, the evaporator becomes cold and the air passing through the evaporator fins is cooled.
The temperature of the evaporator is controlled through a thermostat which via a capillary tube senses the temperature of
the evaporator. When the refrigerant passes through the evaporator it is heated by the hot air which passes between its fins.
Then the refrigerant is pumped via the compressor to the condenser to be cooled. The condenser is positioned in front of
the radiator.

Figure 1
Air conditioning, principle diagram

1. Expansion valve
2. Evaporator
3. Thermostat
4. Compressor
5. Capacitor
6. Receiver drier (no sight glass) (lubricating oil PAG-type) Part No. 1161425

A. Fluid
 B. Gas
C. Gas
D. Fluid

Service points to note

 The service points (connections) in the form of quick-action couplings are positioned on the receiver drier (high
pressure) and behind a plate at the lower, front, right edge of the cab (low pressure).
 There is no sight glass, which means that weighing scales must be used in order to fill the correct amount of R134a.

NOTE!
In order to fill and empty R134a systems, special equipment is required, e.g. FRS-10GS.
Equipment intended for a R12 system must not be used for a R134a system, with the exception of the vacuum pump.
The refrigerants R12 and R134a must not be mixed. Otherwise there is a risk of compressor breakdown.
 Service Information

Document Title: Function Group: Information Type: Date:

Filling and recycling station 874 Service Information 2014/6/26
FRS-10GS
Profile:

Filling and recycling station FRS-10GS

Station 9812443
Technical data

Mains voltage 230 V, 1-phase, 50/60 Hz

Power 205 W
Fuses 2 x 6.3 A glass fuses, 5 x 25 mm (0.2 x 1 in)
Dimensions Depth: 350 mm (14 in)
Width: 320 mm (13 in)
Height: 230 mm (9 in)
Weight 28 kg (62 lb)
Capacity 10 kg/h (22 lb/h) liquid refrigerant R134a at +20 °C) (+68 °F)
Approx. 100 kg/h (220 lb/h) when connected according to the pressure
method
Cleaning Filter replacement at least 6 times a year or after emptying systems 50 times
(Filter part No. 981 2449, positioned inside the front cover)

Figure 1

1. Service connection for changing oil in filling and recycling station

2. Draining valve for oil separator
3. Refrigerant, in – blue
4. Refrigerant, in – yellow
5. Refrigerant, out – red
6. Connection, rubber container for non-condensable gases, and for vacuum pump hose
7. Sight glass
8. Indicating lamp, high pressure alarm
9. Low-pressure gauge
10. High-pressure gauge
 11. Switch, vent for non-condensable gases
12. Switch, start / stop
13. Blind plugs (connections) for connecting hoses
14. Compartment for weighing scales

Weighing scales 981 2444

Technical data

Max. weight 100 kg (220 lb)

Accuracy 20 g (0.7 oz)
Mains voltage 230 V, 50/60 Hz, or with battery
6F22U 9V (inside cover on side)

Figure 2
Weighing scales 9812444

1. Controlled 230 V socket for connecting filling and recycling station

2. Push button for rough setting, kilogram
3. Push button for fine setting, gram
4. Push button for emptying / filling
5. Push button for connecting controlled 230 V socket 1
6. Push button, off
7. Push button, on and zero setting of weighing scales
8. Indicating lamp, emptying
9. Indicating lamp, filling
10. DISPLAY UNIT
11. Indicating lamp controlled 230 V socket, marked 230 VAC
 Service Information

Document Title: Function Group: Information Type: Date:

Refrigerant R134a, 874 Service Information 2014/6/26
vacuum-pumping including
filling
Profile:

Refrigerant R134a, vacuum-pumping including filling

Op nbr 87405

999 8237 Oil hose

981 1207 Leak detector

981 2443 Station FRS-10GS

981 2446 Nipples, 2 pcs

981 2447 Nipple for oil hose

981 2444 Weighing scales FRV-100VBE

981 2445 Vacuum pump Royal 2

981 2452 Vacuum pump hose

Vacuum pumping

1. Connect yellow hose (Y2) with vacuum gauge between vacuum pump and outlet No. 6 on the filling and recycling
station, see [Invalid linktarget] .
 Figure 1
Vacuum pumping

2. Connect yellow hose (Y1) to the receiver drier on the machine and open the valve, see [Invalid linktarget] .

3. Start the vacuum pump.

4. Open the breather valve on the vacuum pump and vacuum-pump for 5–10 minutes. Close the valve and vacuum-
pump for approximately a further 50 minutes.

CAUTION
The air conditioning should be vacuum-pumped to make sure that all moisture is removed from the system. As it
takes approx. 50 minutes to vacuum-pump, the time could be used for filling lubricating oil (PAG type), see [Invalid
linktarget] . Open the valve and allow the measured amount of oil to be sucked into the system. See ”Refrigerant
R134a, emptying”, point 15, see [Invalid linktarget] .
 Figure 2
Filling lubricating oil

1. 9812447 Nipple
2. Oil hose 9998237

5. Turn off the vacuum pump. Remove the yellow hoses.

6. Test for leakage while there is a partial vacuum in the system. The partial vacuum in the system must not change
more than 0.01 MPa (0.1 bar) (1.5 psi) (during a period of approximately 10 minutes. If the partial vacuum changes
more, it is an indication that there is a leak in the system. Rectify any leaks.

Filling

7. Connect red hose to the receiver drier and yellow hose to the container, see [Invalid linktarget] .

Figure 3
Filling refrigerant
 8. Place the container upside down on the weighing scales.

9. Set the weighing scales to zero.

10. Start the filling and recycling station.

11. Open the valve on the container.

12. Fill the system with approximately 200 gram (7 oz) of refrigerant.
Turn off the filling and recycling station and close the valve on the container.
Wipe off any oil and blow with compressed air in the "sniffing holes" on the couplings.

Leakage check

13. Test for leakage using a leak detector and rectify any leaks, see [Invalid linktarget] .
In case of a major leak, pump out the system and rectify, see [Invalid linktarget] .

Figure 4
Leakage check

14. Open the container valve and start the filling and recycling station.
Fill according to the air conditioning specifications, total weight 2.0 +0.1 kg (4.4 +0.2 lb).

15. Close the valve on the container and turn off the filling and recycling station.

Checking pressure

16. Start the engine (and run it at approx. 1800 rpm) and start the air conditioning. Check that the low-pressure gauge
on the filling and recycling station shows 1–3 bar (14.5–44 psi) and that the high-pressure gauge shows 8–14 bar
(116–203 psi) at an ambient temperature of approximately 20 °C (68 °F).
Stop the engine.

17. Disconnect the filling and recycling station from the machine.

18. Test the function of the air conditioning according to [Invalid linktarget] .
 Service Information

Document Title: Function Group: Information Type: Date:

Refrigerant, 874 Service Information 2014/6/26
emptying
Profile:

Refrigerant, emptying
Op nbr 87402

999 8237 Oil hose

981 2443 Station FRS-10GS

981 2446 Nipples, 2 pcs

981 2447 Nipple for oil hose

981 2444 Weighing scales FRV-100VBE

981 2445 Vacuum pump Royal 2

981 2452 Vacuum pump hose

981 1207 Leak detector

1. Make the service connections for the AC system accessible on the machine.

2. Connect the yellow hose to the receiver drier on the machine, see [Invalid linktarget] .

Figure 1
Connecting hose to receiver drier

3. Connect the blue hose to the low-pressure outlet under the cab, see [Invalid linktarget] .
Connect the red hose to the container for R134a, see [Invalid linktarget] .
 Figure 2
Connecting hose at low-pressure outlet

4. Place the container on a weighing scales and set the weighing scales to zero, if the amount of refrigerant is to be
checked. See [Invalid linktarget] . Press button 7 on the weighing scales to set it to zero.

Figure 3
Emptying

1. Valve

5. Open valve (1) on the container.

6. Open the valves at the connections to:

 container, red hose

 low-pressure outlet, blue hose
 high-pressure outlet, yellow hose.

CAUTION
 Note that the valves are to be screwed clockwise.

7. Press button 5 to switch on voltage to the weighing scale socket 1. The lamp 230 VAC lights up, see [Invalid
linktarget] .

Figure 4
Switching on voltage

8. Start the station with button (12), see [Invalid linktarget] .

Figure 5
Filling and recycling station

9 Low-pressure gauge
12 Switch, start / stop

9. When low-pressure gauge (9), see [Invalid linktarget] , shows 0 pressure or a partial vacuum, the system has been
emptied.

10. Stop the filling and recycling station.

11. Close the valve on the container.

12. Close the valves at the three connections.

CAUTION
The valves are to be screwed counter-clockwise.
 13. Disconnect the hoses from the three connections on the machine and reconnect them to the respective "blind"
plugs (connections) on the filling and recycling station.

14. The refrigerant circuit can now be opened without releasing any refrigerant.

WARNING
The filling and recycling station contains pressurised oil.

Draining lubricating oil (PAG type)

15. Carefully open valve (2), see [Invalid linktarget] , on the oil separator on the station. Screw the valve inward. Drain
off any lubricating oil (PAG type) into a graduated measuring glass. Close the valve on the oil separator when all oil
has run out.

CAUTION
Top up the air conditioning with the same amount of oil as was drained off. If no lubricating oil (PAG type) runs out,
there is no need to fill any oil in the air conditioning.

Figure 6
Draining AC compressor oil
 Service Information

Document Title: Function Group: Information Type: Date:

Protection against 880 Service Information 2014/6/26
electromagnetic
interference
Profile:

Protection against electromagnetic interference

This machine has been tested according to the EU directive about electromagnetic interference which can lead to risk of
accidents.
It is therefore of great importance that the use inside as well as outside the machine and the installation of electronic
additional equipment, e.g. communication equipment, which may cause interference with the electronic system on the
machine, is carried out paying attention to these aspects in order to maintain safety.

Figure 1

A. Radio aerial
B. Telephone aerial
C. Two-way radio

Never use communication equipment, e.g. a mobile telephone, which is not correctly installed in the cab, while the machine
is running. Its signals may interfere with important electronics in the electrical system of the machine. The communication
equipment must be connected to the electrical system of the machine and connected to an external, permanent aerial
according to the instructions of the manufacturer.
All installation of electronic additional equipment must therefore be carried out according to the manufacturer"s instructions
and by competent personnel.

CAUTION
Only CE marked equipment may be installed. Leads to/from radio transmitter / telephone must not be routed close to leads
for the gear-shifting electronics. Supply and return leads should be laid together.

Voltage supply to the above optional equipment is taken from connector CRC (14 V) in the overhead panel and in the
instrument panel from a loose lead in the cable harness routed from the ceiling to connector CP (24 V).
Figure 2

D Radio
E Cable harness in right post
F Loose lead in cable harness from ceiling to connector CP.
Cable red marked +12V.
G Voltage converter
H Connector CRC
I Telephone / two-way radio
 Thank you for your purchase.
Have a nice day.

file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/6/26 14:43:09]