Page 1
00
General
Technical
Handbook
DCD90-180
DCD70-32E3 - 70-40E5
This Handbook deals with the design
and maintenance of Kalmar forklift
trucks, type DCD.
10
20
30
40
Chassis and cab
Electrical system
Engine
Transmission,
drive axle, brakes
In addition, it gives details of
troubleshooting and the most common
corrective maintenance.
Operation and other matters that are
primarily of interest to the operator are
included in the Instruction Manual.
Kalmar Industries AB
We reserve the right to modify
our design and material specifications without prior notice.
50
60
70
80
Steered axle
Hydraulic system
Lifting mast and
fork carriage
Publ. No. 920 937 – 9350 02-08
AdEra Dokument AB, Växjö 2002
90
Periodic supervision
Page 2
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DCD90-180
Technical Handbook
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Contents
P.Group 00
1
Group 00
Contents
Safety regulations ..................................................................... 2
General ..................................................................................... 5
Applications ......................................................................... 5
Design ................................................................................. 6
Component units ................................................................. 6
Main components ................................................................ 8
Supplementary books .......................................................... 9
Replacement system – Spare parts .................................... 9
Tools .................................................................................... 9
Tightening torques ............................................................. 10
System of units .................................................................. 12
Page 4
DCD90-180
Technical Handbook
Safety regulations
It is important that you read the instruction manual
Incorrect handling can lead to personal injury or damage to products and/or property. Therefore, read the instruction book very
carefully before operating the truck. The instruction manual contains important information about your Kalmar truck, about the
operation of the truck, about safety during operation and about
the truck’s daily maintenance. In addition, you will find useful information that will make operations easier for you in your daily
work.
Ask your foreman/group leader if there is anything in the manual
that you do not understand or if you feel that information is missing in any area.
The symbol is used on our products in certain cases and
then refers to important information contained in the instruction
manual. Make sure that warning and information symbols are always clearly visible and legible. Replace symbols that have been
damaged or painted over.
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Safety regulations
In this handbook warnings are inserted that apply to your own
safety. Warnings point out the risk of accident that can cause personal injury.
WARNING!
Warns of the risk of serious personal injury, possible
death and/or serious damage to product or property if the
regulations are not followed.
For technical warnings, that point out the risk of break down, the
word IMPORTANT is used:
IMPORTANT!
Is used to draw attention to such occurrences that can
cause damage to the product or property.
For information that facilitates the working process or handling,
N.B. is used:
N.B. Draws attention to useful information that helps the
working process.
Page 5
DCD90-180
Technical Handbook
Safety regulations
Safety regulations aimed at reducing the risk of personal
injury and damage to loads or other property.
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3
Intended of use
z The truck may only be used for the purpose for
which it was intended, namely, to lift and transport
goods, the weight of which does not exceed the
maximum permitted load capacity of the truck.
z The truck may not, without specific permission
from Kalmar, be modified or re-built so that its
function or performance is altered.
z The truck may not be driven on public highways if
it has not been adapted to comply with national
road safety regulations.
Operator requirements
z The truck may only be driven by operators who
have been specially trained and who have the
company’s authority to do so.
z Laws and other regulations relating to driving li-
cence, operator ID, log book, etc., must be followed at all times.
z The operator must be aware of and follow all local
safety regulations.
Operation of the truck is prohibited:
z If any of the fitted safety equipment, such as rear
view mirrors, headlights, reversing alarm (optional) does not function correctly.
z If there is a fault with the brakes, steering or lift
equipment.
z If the truck is fitted with tyres not approved by
Kalmar.
Operating regulations
z Before starting, always check to ensure that no-
body is in the way of the truck or its equipment.
z Make sure that nobody walks or stands under-
neath raised forks or other equipment, whether
they are loaded or not.
z The operator must always face the direction of op-
eration and take particular care in areas where
persons or other vehicles are likely to appear in
the vicinity. If visibility is limited by the load, the operator should operate the truck in reverse.
z It is prohibited to transport passengers on the
truck outside the cab or on the load. Passengers
may be transported inside the cab only on condition that it is equipped with a fixed passenger
seat.
z It is prohibited to lift people if the truck is not
equipped with an approved lift cage.
z It is prohibited to exceed the load capacity of the
truck. See capacity plate and loading diagram.
z It is prohibited to transport loads in the raised po-
sition as this entails a risk of the truck tipping. All
transportation shall take place with the load in the
lowered position and with the mast tilted backwards to the maximum.
z The operator must adapt the speed of the truck to
the character of the load, conditions of visibility,
the character of the roadway/surface, etc.
z The operator shall avoid powerful acceleration
and braking when turning. In addition, the operator shall always moderate the speed of the truck
when turning so as to avoid the risk of lateral skidding or tipping.
z The operator shall take particular care when oper-
ating in the vicinity of electrical power lines, viaducts, quay-sides, ramps, gates/doors etc.
z Safety belts must always be worn, if fitted. In the
event of the truck tipping, always remain in the
cab and grip the steering wheel securely. Never
try to jump out of the cab.
z The parking brake can also be used as an EMER-
GENCY BRAKE. However, having been used for
emergency braking, the brake linings must be inspected and replaced if needed. If the parking
brake has been mechanically released, it must
always be reset in order for the truck to regain
the parking brake function.
Interrupted operation, parking
z Always check that the gear lever is in the neutral
position before turning the ignition key to restart or
to reset an emergency stop.
z Never leave the operator’s cab without applying
the parking brake (ON position).
z Always remove the ignition key if the truck is to be
left unattended.
Other important points to remember
z The truck’s hydraulic system includes high pres-
sure hydraulic accumulators. Always be extremely careful when working with the hydraulic system
and avoid being unnecessarily close to the hydraulic equipment, lines and hoses. Before working on the hydraulic system, the accumulators
must be emptied into the tank, with the help of the
special accumulator evacuation valve.
z Handle batteries and junction boxes with great
care. The batteries must always be protected over
the poles and connections.
z Always rectify any damage or wear and tear that
can risk personal safety or that can affect the
functions of the truck or its service life.
z Trucks with tippable cabs: The cab must always
be tipped over the point of balance. If there is insufficient lateral space the cab must always be secured against accidental lowering with a brace or
similar.
z Avoid touching oils and greases. Avoid inhaling
exhaust and oil fumes.
z Welding painted steel produces poisonous gas-
ses. Paint should therefore be stripped before
welding, good ventilation ensured and/or face
mask with filter used.
Operating with attachments
zThe operator must always take the effect of the wind
into account when handling containers. Avoid lifting
with a wind strength in excess of 12 m/s (27 mph/40
feet per second).
zAlways drive carefully so as to avoid attachments
colliding with pillars, cables, etc.
zCarefully study the "Lift methods" section of the
instruction manual.
Page 6
DCD90-180
Technical Handbook
Safety regulations
Safety instructions for working with tyres
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z Tyre changing can be dangerous and should only
be carried out by specially trained personnel using
proper tools and procedures.
Failure to comply with these procedures may result in faulty positioning of the tyre and/or rim and
cause the assembly to burst with explosive force
sufficient to cause physical injury or death. Never
fit or use damaged tyres or rims.
z Never attempt to weld on an inflated tyre/rim
assembly.
z Never let anyone assemble or disassemble tyres
without proper training.
z Never run the truck on one tyre of a dual assembly.
The load capacuty of a single tyre is then dangerous-ly exceeded and operation in this manner may
damage the rim.
z Deflation and dismantling
– Always block the tyre and wheel on the opposite
side of the vehicle before you place the jack in
position. Always crib up the blocks to prevent
the jack from slipping.
– Always check the tyre/rim assembly for proper
component seating prior to removal from the
truck.
– Always deflate the tyre by removing the valve
core prior to removing the complete assembly
from the truck or dismantling any of the component. Before loosening mounting bolts, run a
wire through the valve stem to ensure that it is
not blocked. Ice or dirt can prevent all the air
from escaping. Deflate and remove valve cores
from both tyres of a dual assembly.
– Never position body in front of the rim during de-
flation.
– Always follow assembly and dismantling proce-
dures outlined in the manufacturer’s instruction
manual, or other reconized industry instruction
manuals. Use proper rubber lubricant.
– Never use a steel hammer to assembling or dis-
mantling rim components – use a lead, brass or
plastic type mallets. The correct tools are available through rim/wheel distributors.
– remove bead seat band slowly to prevent acci-
dents. support the band with your thigh and roll
it slowly to the ground in order to protect back
and toes.
– Disassembly tools apply pressure to rim flanges
to unseat tyre beads. Keep your fingers clear.
Slant disassembly tool about 10 degrees to
keep it firmly in place. Always stand to one side
when applyin g hydraulic pressure. Should the
tool slip off, it may cause fatal injury .
z Rim inspection
– Check rim components periodically for fatigue
cracks. Replace all cracked, badly worn,
damaged and severely rusted components.
– Always select the correct tyre size and construc-
tion matching the manufacturer’s rim or wheel
rating and size.
– Do not use over-size tyres, too large for the
rims, e.g. 14.5 inch tyres with 14 inch rims or
16.5 inch tyres with 16 inch rims.
– Never use damaged, worn or corroded rims/
wheels or fitting hardware. Always verify that the
rim is in a serviceable conditioning.
– Always clean and repaint lightly rusted rims.
– Never use a rim/wheel component that can not
be identified. Check rim parts against multipiece rim/wheel matching charts.
z Assembly and inflation
– It is important that the inflation equipment is
equipped with a water separator to remove
moist-ure from the air line in order to prevent coorosion. Check the separator periodically to ensure that it is working properly.
– Make sure that the lockring is in its right posi-
tion.
– Never mix different manufacurer’s parts since
this is potentially dangerous. Always check
manufacturer for approval.
– Never seat rings with hammering while the tyre
is inflated. Do not hammer on an inflated or partially inflated tyre/rim assembly.
– Always double check to ensure that the rim as-
semblies have been correctly assembled and
that securing studs and nuts are tightened to the
correct torque setting.
– Never inflate tyres before all side and lockrings
are in place. Check components for proper
assembly after pumping to approximately 5 psi
(=34 kPa, =0.34 bar)
– When adding air to a tyre on an industrial truck,
use a clip-on chuck and stay out of the danger
area. If the tyres has been run flat then the rim
must be dismantled and all parts inspected for
damage.
– Under-inflated tyres have a serious effect on the
stability of the truck and reduces the safe load
handling capacity. Always maintain tyres at the
correct inflation pressures. Check inflation
pressure daily. Do not over-inflate.
– Inspect tyres regulary – every day if possible.
Look for and remove broken glass, torn pieces
of tread, embedded metal chips etc. Inspect for
uneven or rapid tread wear, usually caused by
mechanical irregularities, such as brakes out of
adjustment or excessive toe-in and toe-out. If
discovered, correct the irregularity immediately.
z When installing and tightening trail wheel bolts, ob-
serve the following:
– Ensure that trail wheel or hub mounting surfac-
es and trail wheel fastener mounting surfaces
are clean and free from paint and grease.
– Tighten bolts to specified torque settings. use
staggered sequence; i.e. top bolt, bottom bolt
etc.
Page 7
DCD90-180
Technical Handbook
General
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5
Applications
The Kalmar DCD90-180 range of trucks is based on an entirely
new approach to the design and production of medium-heavy,
diesel-powered forklift trucks. The trucks are durable and safe
and their accessibility for service and maintenance is unexcelled.
Due the their versatility, the trucks can be used in a number of applications, such as:
z Steelworks and heavy engineering industry, where the
trucks handle individual tasks in the handling of mediumheavy goods.
z The forest industry for handling logs by means of a log grap-
ple attachment, sorting of logs at sawmills and handling of
sawn timber in units loads.
z Ports and container terminals for handling medium-heavy
goods and handling empty containers.
z Factories producing houses – lifting of house sections.
KL734
DCD90-180
Page 8
DCD90-180
Technical Handbook
General
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Design – general survey
Kalmar DCD90-180 diesel trucks are of sturdy design for heavy
duty. They are built around a chassis which has high strength and
torsional stiffness and an extremely low centre of gravity.
The operator’s cab is provided with vibration isolation and sound
insulation and offers excellent all-round visibility.
The operator is provided with many facilities for adjusting his
seating attitude. The seat, backrest and springing of the operator’s seat can be adjusted in a wide variety of ways.
The cab is tiltable and offers excellent accessibility to the transmission and pumps. The engine is easily accessible through a
casing, divided in two halves.
The Volvo or Perkins six-cylinder turbocharged engine TD640VE
or TD730VE/TWD731VE, combined with a three-speed gearbox
with torque converter, provides smooth power whenever needed.
The drive axle with hub reductions, the oil-cooled hydraulic brake
system and the pendulum-mounted steered axle with double-acting steering cylinder satisfy very strict demands on strength and
mobility when travelling on irregular surfaces.
The hydraulic system is reliable and has high performance
charged by two or three hydraulic pumps.
For further details, see group 70.
Component units
z Sound-insulated and safety-tested operator’s cab with ex-
cellent all-round visibility. The non-slip, substantial steps provide convenient access to the cab. All models in the series
can be equipped with a rotatable operator’s seat.
z Clearly arranged instrument panel.
z Engine – Volvo TD640VE or TD730VE/TWD731VE six-cyl-
inder, four-stroke, turbocharged diesel engine with direct injection and thermostatically controlled water cooling.
The engine is equipped with:
– Injection pump with centrifugal governor that compensate
for load variations.
– Alternator.
– For alternatives, see separate table.
Page 9
DCD90-180
Technical Handbook
General
z Gearbox with torque converter
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7
– Constant-mesh gearbox in which hydraulically actuated
clutches for the different gears. The clutches are electrically operated.
– Torque converter, which is a hydraulic coupling that ampli-
fies the output torque on an increase in load. Torque conversion takes place smoothly and steplessly throughout
the engine speed range.
– Oil cooler connected to the engine cooling system for
cooling the oil in the gearbox and torque converter.
– Oil pump which supplies oil under pressure to the gearbox
and torque converter.
– Full-flow oil filter for effective cleaning of the gearbox oil.
z Drive axle with two-stage reduction - in the differential and
the hub reductions.
– Oil cooled hydraulic brakes for the foot brake, e.g. Wet
disc brakes.
– Disc type parking brake applied by a sturdy spring and
released by hydraulic oil pressure.
z Hydraulic system with
– Gear type hydraulic pumps connected to take-offs on the
torque converter. One pump for working hydraulics and
one for steering and accumulator charging, which in turn
serves the brake circuits.
– Main valve for controlling the main hydraulics. The valve
is controlled hydraulically from the cab. An electro-hydraulic servo system is available as an option.
– A high pressure filter after each pump for effective clean-
ing of the hydraulic fluid before it is fed to the system.
– Steering valve (Orbitrol) - flow-control valve which sup-
plies hydraulic fluid to the steering cylinder.
z Steered axle with pendulum mounting and double-acting
steering cylinder.
z Sturdy clear-vision mast. Of duplex or triplex design, with or
without free lift.
– Outer mast with hydraulically controlled 5° forward and
10° backward tilting.
– Tilting cylinders with back-pressure valves to prevent the
load from tilting the mast forward.
– Inner mast with support rollers that carry the forces on the
mast. Yoke with guide rollers for the hydraulic hoses and
guide sprockets for the lifting chains.
– Lifting cylinders - two cylinders mounted on the outer
mast.
z Fork carriage designed for optimum visibility and equipped
hydraulic with fork positioning and sideshifting (optional).
Page 10
DCD90-180
Technical Handbook
General
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8
1
23
7
KL734
1. Free -visibility mast, with two lifting cylinders
2. Operator’s cab, rubber suspended cab
3. Engine, six-cylinder diesel engine with
turbo-compressor
4. Steering axle, with pendulum suspension and
double acting steering cylinder
65 4
5. Gearbox, combined with torque converter
6. Drive axle, with hub gearing and oil-cooled
hydraulic brake
7. Fork carriage, hydraulically controlled fork
positioning and sideshift
Main component units
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DCD90-180
Technical Handbook
General
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9
Main components
Alternative drive lines
● = Standard ❍ = Optional
Engine *Turbo **Turbo, intercooler
Volvo TD640VE* 129 kW/690 Nm ●●●●●●●●●●●
Perkins 1006-60T1* 85 kW/465 Nm ❍❍❍❍❍
Volvo TD730VE* 150 kW/800 Nm ❍❍❍❍❍❍❍❍❍❍
Volvo TWD731VE** 167 kW/893 Nm ❍❍❍❍❍❍❍❍❍❍
Perkins 1006-60T2* 114 kW/620 Nm ❍❍❍❍❍❍❍❍❍❍❍
Scania DI9** 167 kW/930 Nm ❍ ❍❍❍❍❍❍❍
Cummins 6BTA5.9-C200** 162 kW/814 Nm ❍❍❍❍❍❍❍❍❍❍❍
Gearbox with powershift, 3+3 gears
Clark 13.7HR 28000
(Volvo TD640VE, TD730VE,
Perkins 1006-60T2, Cummins 6BTA)
Clark 1207 FT 20302
(Perkins 1006-60T1)
Clark 13.7HR 32000
(Volvo TD640VE, TD730VE, Volvo TWD731VE,
Scania DI9, Cummins 6BTA)
Drive axle with Wet Disc Brakes ●●●●●●●●●●●
Pneumatic tyres 10.00x20ÆÆ/16PR
Optional: Semi-solid tyres (Super-Elastic) ❍❍❍❍❍❍❍❍❍❍❍
11.00x20ÆÆ/16PR
12.00x20ÆÆ/20PR
90-6
100-6
100-12
120-6
136-6
120-12
150-12
160-6
160-9
160-12
●●●●●●●●●●●
❍❍❍❍❍
❍❍❍❍❍❍❍❍❍❍❍
●●
●●●●●●●●●
180-6
Supplementary books
In addition to the Instruction Manual and the Technical Handbook, the following books are delivered with every truck.
Spare parts catalogue
Instruction Manual for Volvo Industrial engines
Workshop Manual for Industrial engines
Workshop Manual for the Perkins engine
Replacement system - Spare parts
Kalmar operates a system of replacement parts, repair kits and
gasket sets covering most of the vital components of the truck.
For the contents of these kits, see the Spare parts catalogue.
Tools
Kalmar offers a wide range of tools for truck maintenance work.
For further information, please contact Kalmar’s service depart-
ment.
Page 12
DCD90-180
Technical Handbook
General
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P.Group 00
10
Tightening torques
The tightening torques are applicable to steel bolts and nuts tightened with a torque wrench under the following conditions:
Surface treatment
Condition Lubriation
Bolt Nut
1 untreated untreated oiled
bright galvanised
2
3 hot-dip galvanised bright galvanised dry or oiled
The values specified in Table 1 are applicable to nut-and-bolt
joints, but can also be used for bolts fitted into tapped holes. However, in the latter case, the preloading force will be somewhat
lower, depending on its depth of engagement.
When tightening by machine, the torque specified in Table 1
should be reduced by approx. 5%, due to the increased scatter
and to prevent the bolt from being tightened beyond its yield
point.
Quality 8,8 10,9 12,9
Thread
M fin
M8×1
M10×1,25
M12×1,25
M16×1,5
M18×1,5
bright galvanised
bright galvanised
Tightening torque, Nm
12311
27
54
96
230
330
24
48
85
205
294
untreated
bright galvanised
bright galvanised
Condition
30
61
108
260
373
135
323
466
dry or oiled
39
76
46
91
162
388
559
M20×1,5
M24×2
M30×2
M36×3
460
786
2660
1560
409
700
1388
2367
520
888
1763
3005
647
1100
2200
3730
777
1330
2640
4480
Page 13
DCD90-180
Technical Handbook
General
To reduce the risk of settlement of the material and the
associated reduction in the preloading force if the hardness of the
surface supporting the bolt head or nut is lower than 200 HB, a
washer should be fitted under the bolt head and nut. This is not
applicable if flanged bolts or flanged nuts are used.
When tightening is carried out, the specified torque should be applied without pause, to ensure that the torque wrench will not be
tripped by the static friction before the joint has been tightened to
the specified torque.
Quality 8,8 10,9 12,9
Tightening torque, Nm
Condition
Thread
M
12311
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4
5
6
8
10
12
16
20
24
30
Quality 8,8 10,9 12,9
Thread
UNC
1/4
5/16
3/8
7/16
1/2
3,2
6,4
11
26
52
91
220
430
750
1480
12311
12,5
25
44
70
107
2,9
5,7
9,8
24
47
81
198
386
668
1317
Tightening torque, Nm
11,1
22,3
39
62
95
3,6
7,2
12,5
30
59
103
250
49
848
1672
Condition
14,1
28,3
50
79
121
4,6
9,1
16
38
74
128
313
620
1050
2080
17,6
35
62
100
151
5,5
11
19
45
89
154
375
732
1270
2500
20
42
73
118
178
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
153
210
370
594
889
1260
1760
2320
3060
136
187
390
528
791
1120
1565
2065
2720
173
237
418
671
1005
1424
1990
2620
3455
216
298
524
839
1260
1780
2490
3280
4320
255
353
619
990
1480
2100
2940
3870
5100
Page 14
DCD90-180
Technical Handbook
General
Quality 8,8 10,9 12,9
Tightening torque, Nm
Condition
Thread
UNF
12311
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1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
13
26
47
75
114
164
227
396
629
937
1350
1860
2500
3260
11
23
42
66
101
145
202
352
560
834
1200
1655
2225
2900
14
29
53
85
128
185
256
447
710
1058
1525
2100
2825
3680
19
37
67
107
162
231
321
559
889
1320
1900
2630
3530
4610
System of units
The SI system of units is employed in this handbook:
The conversion factors are as follows:
Pressure
megapascal bar Kilogram-force per
square centimetre,
kpf/cm²
Atmosphere, at
Pound-force
per square
inch,
psi
22
44
79
126
191
273
379
661
1050
1560
2250
3110
4170
5450
1
0,1
0,098
Torque
Newtonmeter
Nm
1
9,81
Power
Kilowatt
kW
1
0,735
10
1
0,98
10,2
1,02
1
Kilogram force-metre
kgf m
0,102
1
Horsepower (metric)hpHorsepower
1,36
1
145
14.5
14.2
Pound-force foot
lbf ft
0.74
7.23
hp
1.34
0.986
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DCD90-180
Technical Handbook
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Contents
P.Group 10
1
Group 10
Chassis and cab
Specifications ........................................................................... 2
Chassis...................................................................................... 3
Description ........................................................................... 3
Operator’s cab ........................................................................... 4
Description ........................................................................... 4
Steering column .............................................................. 7
Pump and cylinder for cab tilting ..................................... 8
Accelerator pedal with change-over switches for
forward and reverse ........................................................ 9
Gear selector type RMH ................................................ 10
Hydraulic weight indicator ............................................. 11
Service ............................................................................... 12
Changing the fresh air filter ........................................... 12
Check and lubrication of brake pedal ............................ 12
Windscreen wipers ........................................................ 13
Air conditioning unit ................................................................. 14
Description ......................................................................... 14
Service ............................................................................... 17
Checking the air conditioning unit ................................. 17
Page 16
DCD90-180
Technical Handbook
Specifications
Air conditioner
z Cab unit
Circulated air flow 500-600 m
Electric power consumption approx 350 W
z Compressor
Max. speed 4000 r/min
Refrigerant R134a *)
Electric power consumption approx 50 W
Oil capacity Zexel PAG SP-20 1.5 dl
z Condenser
Electric power consumption 250 W
z Cooling effect 6-8,5 kW
z Heating effect approx 11 kW
*) Refrigerant R12 is no longer in production due to legislation
3
/h
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Page 17
DCD90-180
Technical Handbook
1
Chassis
Description
9350
00-11
P.Group 10
3
Chassis
The chassis consists of:
z A unit construction frame built up around two beams with a
minimum of welds for best possible strength.
z Mountings for the drive axle, steered axle, mast, lifting cylin-
ders and transmission.
z The necessary counterweights to provide a very low centre
of gravity. Moreover, the steered axle is designed to serve as
an additional counterweight.
z The hydraulic oil tank and the fuel tank are produced as sep-
arate units and are bolted to the side of the chassis. The
tanks have a low profile, which contributes to the good visibility.
1. Hydraulic tank
2. Counterweights
3. Service hatch for the battery
4. Fuel tank
2
3
4
Chassis 90-180
Page 18
DCD90-180
Technical Handbook
Operator’s cab
Description
Operator’s cab
The operator’s cab is a separate structure and rests on the chassis on rubber dampers. The operator’s seat, steering wheel and
hydraulic control levers can be adjusted for best possible operator comfort. Effective insulation minimises the vibrations and
sound level in the cab.
The standard heating system consists of a fan and heater for
heating the air in the cab by recirculation. Fresh air is drawn in
through a ventilation air filter. Full air conditioning, with cooling,
heating and dehumidification, is available to special order.
9350
00-11
P.Group 10
4
1
2
3
1. Steering column with instrument panel and switches, ECS-terminal (option)
2. Air filter
3. Heating system
4. Electrical central unit
4
Page 19
DCD90-180
Technical Handbook
31 4 5 2 6
Operator’s cab
Description
9350
00-11
P.Group 10
5
KL735
1
23
4
F
N
R
R
145
23
L
0
a
bc
d
7
KL743
1. Gear selector
FORWARD/NEUTRAL/REVERSE 1/2/3
2. Lever DIRECTION INDICATORS/HORN
FRONT WINDSCREEN WASHER/
FRONT WIPERS/MAIN BEAM
3. Instrument panel
4. Steering wheel panel
5. Starting switch
6. Control lever, hydraulic functions
a. Lift, b. Tilt, c. Sideshift, d. Fork positioning
8 9 10 11 12 13 14
7. Electrical central unit with fuses and relays
8. Brake pedals, normal driving brake
9. Release clutch
10. Accelerator pedal
11. Steering wheel adjustment
12. Stop control
13. Parking brake
14. Operator’s seat
Page 20
DCD90-180
Technical Handbook
Operator’s cab
Description
9350
00-11
P.Group 10
6
66
21
24
25
26
27
28
22
29
1
23
4
30
23
32
31
54
55 56 60 59
F
N
R
33
34
KL581
39
38
37
36
35
40 41 42 43 44 45 52 53
46
47 48 49 50 51
R
1
2
3
4
5
KL580
KL582
L
0
57 58 64 61 62 63
21. Pressure gauge, gearbox oil pressure
22. Fuel gauge
23. Temperature gauge, engine coolant temperature
24. Switch, working lights
25. Switch, working lights
26. Switch, working lights
27. Switch, flashing beacon
28. Switch, hazard warning lights
29. Switch, driving lights
30. Spare
31. Spare
32. Spare
33. Spare
34. Switch, compressor air conditionin
1)
g
35. Control, recirculation/fresh air
36. Control, defrost/cab
37. Switch, fan
38. Control, heat
39. Control, cold
KL675
1)
40. Spare
41. Spare
42. Warning lamp, battery charging
43. Warning lamp, low engine oil pressure
44. Warning lamp, low gearbox oil pressure
45. Warning lamp, low brake pressure
(accumulator pressure)
46. Warning lamp, low engine coolant level
47. Indicating lamp, preheating
48. Warning lamp, high engine coolant temperature
49. Warning lamp, high gearbox oil temperature
50. Spare
51. Warning lamp, parking brake ON
52. Spare
53. Spare
54. Spare (Green lamp TWIST-LOCKS LOCKED)
55. Spare (Orange lamp ALIGNMENT)
56. Spare (Red lamp TWIST-LOCKS UNLOCKED)
57. Spare (LOCK/UNLOCK TWIST-LOCKS)
58. Spare (LENGT ADJUSTMENT 20-40’)
1)
1)
1)
59. Indicating lamp, headlights
60. Indicating lamp, direction indicators
61. ECS terminal
1)
62. Switch, windscreen wiper, rear
63. Switch, windscreen wiper, roof
64. Spare
65. Fuses
66. Hour meter
1)
Optional
1)
1)
Page 21
DCD90-180
Technical Handbook
Operator’s cab
Description
Steering column
Surrounding the steering column are multi-function levers for
gear changing, indicators, windshield wipers, etc., as well as the
instrument panel with the ECS terminal. At the very foot of the
steering column is the steering valve (Orbitrol), activated by the
steering wheel via an angled gear. The steering column is
equipped with an adjustment handles for the alteration of steering
wheel height and rake.
9350
00-11
P.Group 10
7
1
23
4
1
F
N
R
R
1
2
3
4
5
L
0
2
3
KL580A
4
1. Gear lever
2. Multi-function lever
3. ECS terminal
4. Steering wheel adjustment
handles
5. Angled gear
6. Orbitrol steering valve
KL588
6
5
Steering column
Page 22
DCD90-180
Technical Handbook
Operator’s cab
Description
Pump and cylinder for cab tilting
A hydraulic cylinder is provided for tilting the cab. The hydraulic
fluid pressure for this purpose is generated by a manually operated pump. The pump is fitted with a reversing valve for upward or
downward tilting.
9350
00-11
P.Group 10
8
1
2
3
2
4
1. Cab tilting cylinder
2. Manual pump
3. Vibration damper
4. Cab tilting cylinder
Pump and cylinder for cab tilting
Page 23
DCD90-180
Technical Handbook
Operator’s cab
Description
9350
00-11
P.Group 10
9
3
1
1. Push-button, reverse gear
2. Push-button, forward gear
3. Microswitch
4. Engagemant and disenagagement of the
foot operated gear changing system
4
2
Accelerator pedal with change-over switches for forward and reverse
Page 24
DCD90-180
Technical Handbook
Operator’s cab
Description
9350
00-11
P.Group 10
10
Gear selector type RMH
Page 25
DCD90-180
Technical Handbook
Operator’s cab
Description
1
9350
00-11
P.Group 10
11
4
3
2
1. Indicator scale in the cab
2. Tank connection to the brake valve connecting block
3. Foot switch for weighing
4. Connection to the main valve LIFT section
Hydraulic weight indicator
Page 26
DCD90-180
Technical Handbook
Operator’s cab
Service
Changing the fresh air filter
(every 200 hours or when needed)
1. Remove the filter casing retaining bolts and remove the filter
element.
2. Wash the filter insert with water and detergent or by using a
high pressure washer. Replace the insert if necessary.
3. Reinstall the filter insert.
9350
00-11
P.Group 10
12
2
1
3
4
1. Brake pedal
2. Lubricating nipple
3. Locking screw
4. Shaft
Check and lubrication of brake pedal
(every 1000 hours)
1. Check and tighten the locking screws 3, so that the brake
pedal is securely fitted in the console.
2. Lubricate the brake pedal shaft through the nipples 2.
Page 27
DCD90-180
Technical Handbook
Operator’s cab
Service
9350
00-11
P.Group 10
13
Windscreen wipers
The wiper arms are fixed to the wiper motor shafts via conical
splines. The shafts are manufactured of hardened steel and the
wiper arm mounting of soft, pressed metal. When fitting, the nuts
must be tightened so hard that the splines are pressed well into
the mounting and function as a carrier.
Removal
1. Remove the wiper arms by loosening the nuts and thereafter
tapping and carefully rocking the arms to and fro.
Fitting
1. Check to ensure that the splines on the motor shaft are free
from the softer material from the wiper arm mounting.
1
If this is not the case, clean the splines so that they can
pressed fully into the wiper arm mounting.
2. Fit the wiper arms onto the motor shafts and tighten the nuts
to a torque of 16-20 Nm.
Hold the wiper arm to take up the torque pressure so that it
is not transferred to the motor, which could result in damage
.
IMPORTANT!
2
3
The nuts must be tightened sufficiently hard, otherwise
the shafts may start to slip inside the wiper arm mounting,
resulting in damage.
1. Wiper arm fitting
2. Securing nut, wiper arm
3. Grooved cone on motor shaft
4. Wiper motor
4
Page 28
DCD90-180
Technical Handbook
1
Air conditioning unit
Description
Air conditioning unit
The air conditioning unit consists of the parts shown in the illustration and its function is to maintain the climate in the ope-rator’s cab as comfortable as possible. The air conditioning unit:
z heats the air when it is cold
z dehumidifies the air when it is humid
z removes impurities from the air
z cools the air when it is warm
The equipment is steered by switches and controls on the instrument panel.
5
6
4
9350
00-11
P.Group 10
14
1. Heating control
2. Heat exchanger
3. Vapourizer
4. Expansion valve
5. To condenser
6. To compressor
7. Heating valve
8. From engine
9. To engine
10. Fan
11. Fan
12. Fan control
13. Fresh air filter
14. Air disperser
15. Control defrost/cab
16. Defroster outlet
3
8
9
7
2
15 16
12
14
10
11
13
The heating and ventilating system
Page 29
DCD90-180
Technical Handbook
Air conditioning unit
Description
9350
00-11
P.Group 10
15
F
2
4
D
C
E
E
3
7
A
B
6
1. Liquid receiver/filter dryer
2. Evaporator
3. Fan
4. Expansion valve
6. Condenser
7. Compressor
1
G
A High-pressure gas
B High-pressure liquid
C Low-pressure liquid
D Low-pressure gas
E Warm air in cab
F Cooled air to the cab
G Outside air for removing heat
Page 30
DCD90-180
Technical Handbook
Air conditioning unit
Description
Compressor
The air conditioning system is driven by the compressor. This
performs as a pump, drawing cold, low-pressure gas from the
evaporator, compressing it and thereby raising its temperature,
and discharging it at high pressure to the condenser.
The compressor is driven by V-belts directly from the diesel engine. Switching between operation and idling is controlled by an
electro-magnetic clutch which, in turn, is controlled by a thermostat whose sensor is located between the fins of the evaporator
coil. The thermostat switches off the compressor at low temperatures, to prevent icing of the evaporator.
Condenser
The function of the condenser is to convert the hot high-pressure
gas from the compressor into liquid form. The tubes and fins of
the condenser coil absorb heat, which is then removed by the air
delivered by the fan.
The temperature of the refrigerant in the condenser varies from
about +50°C to +70°C. The pressure varies between 12 and 20
bar, depending on the ambient temperature and the flow of air
through the condenser. When the refrigerant is condensed into
liquid form, it is transferred under pressure to the liquid receiver/
filter dryer.
9350
00-11
P.Group 10
16
Liquid receiver with filter-dryer
The function of the liquid receiver with integrated filter dryer is to
collect the liquid coolant, bind the moisture, and to filter and remove impurities. The receiver, which is located in the condenser
housing, also serves as the expansion vessel in the refrigeration
circuit.
After flowing through the dryer in the bottom of the liquid receiver,
the refrigerant flows through a riser tube. A sight glass enables
the operator to check that the liquid flows without the presence of
any bubbles, and that the system is filled with a sufficient amount
of refrigerant.
Expansion valve
The expansion valve throttles the flow and passes an optimised
quantity of refrigerant that the evaporator is capable of evaporating.
The expansion valve is also the part of the circuit which separates
the high- pressure side from the low-pressure side. The refrigerant flows to the expansion valve under high pressure and leaves
it under low pressure.
The amount of refrigerant which passes the evaporator varies,
depending on the thermal load. The valve operates from ’fully
open’ to ’fully closed’ and in-between searches for a point to give
optimum evaporation.
Evaporator
The heat necessary for evaporating the refrigerant is extracted
from the cab air which is circulated by a fan through the evaporator coil. The cab air is thus cooled, and is distributed and returned
to the cab.
In the evaporator, the refrigerant reverts to the gaseous state and
returns to the compressor suction, thereby completing the cycle.
Page 31
DCD90-180
Technical Handbook
WARNING!
z If the refrigerant hose should fail or if
other refrigerant leakage should occur, switch off the air conditioner immediately.
z Refrigerant is injurious to the skin and
eyes.
z Never release refrigerant in an en-
closed space. If released into a service pit, for instance, the gas may
cause asphyxia.
z It is forbidden by law to discharge re-
frigerants into the air intentionally.
z Never carry out welding on a charged
refrigeration system or in its vicinity.
z Only authorised service mechanics
are allowed to drain off and fill refrigerant in the air conditioning system.
Only the prescribed refrigerant may be
used when refilling.
Air conditioning unit
Service
The liquid refrigerant should be completely evaporated before it
is allowed to flow from the evaporator. The refrigerant is still cold
even when it has completely evaporated. The cold vapour which
flows through what remains of the evaporator continues to
absorb heat, and then becomes overheated. This means that the
temperature of the refrigerant has risen to above the point where
it evaporates without changing the pressure.
In an evaporator which operates at a suction pressure of 2 bar,
the liquid refrigerant will have a temperature of –1.1°C. When the
refrigerant is subsequently evaporated through heat absorption
in the evaporator, the temperature of the gas will rise at the evaporator outlet to +1.6°C. This represents a difference of 2.7°C between the evaporation temperature and the temperature at the
outlet. This is called overheating.
All expansion valves should be adjusted at the plant in such a
way that maximum evaporation with overheating is performed in
the air conditioning system.
Checking the air conditioning unit
If the unit is in continuous operation, this check should be carried
out every week from early spring to late autumn and during extended periods of high humidity during the winter.
If the unit is used very little during cold and dry winter periods, the
compressor should be run for a few minutes every week, to lubricate the rubber hoses, couplings, seals and shaft seal.
9350
00-11
P.Group 10
17
1. Start the engine and start the air conditioner.
At an outdoor temperature below 0°C, the system cannot
start since the low-pressure relay breaks contact.
2. After 10 minutes of operation, check that no bubbles are
visible in the sight glass of the filter-dryer. (Bubbles should
occur only when the compressor is started and stopped.)
If there are any air bubbles, subsequent filling should be performed by an authorised service mechanic.
3. Check that the condenser is not clogged. If necessary, clean
the condenser fins with compressed air.
4. Change the fresh air filter as necessary.
5. Check the V-belt tension and the compressor mounting.
6. Check that the magnetic coupling engages and disengages
satisfactorily.
7. Check that the condensate drain from the cooling element is
not clogged. Check for leakage.
Page 32
DCD90-180
Technical Handbook
IN CAB CLIMATE UNIT CONDENSER UNIT
Air conditioning unit
Service
9350
00-11
P.Group 10
18
A
RD 1,5
1
2
3
GL 1,5
L
SV 1,5
M
H
RD 1,5
C
4
R
4
R
GL 1,5
M
5
BR 1,5
RD 1,5
8
30
85
87
86
BR 1,5
M
9
M
6
BR 1,5
VT 1,5
7
HIGH
LOW
10
1. Fan switch
2. Cooler on/off
3. Anti-freeze thermostat
4. Resistor
5. Fan motor
6. Indicator lamp – cold (in push button)
7. High-/low-pressure monitor
8. Relay
9. Condenser fan
10. Compressor
Circuit diagram in cab climate unit/condenser unit
Page 33
DCD90-180
Technical Handbook
9350
00-11
Contents
P.Group 20
1
Group 20
Electrical system
Specifications .............................................................................2
Electrical system ........................................................................3
Description ............................................................................3
Service ..................................................................................6
Checking the electrolyte level of the batteries..................6
Fuses ...............................................................................6
Bulbs ................................................................................6
Relays ..............................................................................7
Starting from another battery ...........................................7
Cable markings ................................................................8
Diagrams
Gear changing systems.........................................................9
Clark 18000/20000, fixed operator’s seat .....................10
Clark 18000/20000, rotatable operator’s seat ...............12
Clark 28000/32000, fixed operator’s seat .....................14
Clark 28000/32000, rotatable operator’s seat ...............16
Engine shut down at low/high coolant temperature
Engine with stop solenoid ..............................................18
Engine with fuel shut off valve........................................19
Engine shut down, connected to the operator’s seat
Electrically controlled extra hydraulic function.....................21
Safety interlock system .......................................................22
Component list DCD90-450
Wiring diagram, truck body ............................... A08334.1000
Wiring diagram, inner, standard ........................ A08333.1000
Wiring diagram, inner, rotatable operator’s seat
..................................................................... A08333.1100
Safety interlock system, empty container attachment, Volvo
..................................................................... A28047.0600
Safety interlock system, empty container attachment, Perkins
.................................................................. A28047.0700
Page 34
DCD90-180
Technical Handbook
Specifications
Alternator rating Perkins: 1260 W
Volvo: 1540 W
Starting battery, voltage 2 x 12 V
capacity 140 Ah
earthing negative
9350
00-11
P.Group 20
2
Page 35
DCD90-180
Technical Handbook
IMPORTANT!
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.
Electrical system
Description
The system voltage is 24V and the supply is taken from two 12V
batteries connected in series and charged by an alternator
across electronic rectifying and voltage stabilisation circuits. .
The positive pole is connected across a main switch. The negative pole is then connected to the chassis.
Warning lamps and instruments are clearly arranged on the instrument panel. The central electrical unit with fuses and relays
is located on the lower section of the cab’s rear wall.
9350
00-11
P.Group 20
3
1. Main switch
2. Battery
1
2
Page 36
DCD90-180
Technical Handbook
Electrical system
Description
9350
00-11
P.Group 20
4
1. Transmitter, warning lamp low oil pressure and gearbox oil pressure instrument
2. Transmitter, warning lamp low oil temperatur and gearbox oil temperatur instrument
3. Fuse
4. Relay preheater element
5. Transmitter, coolant temp instrument
6. Transmitter, high coolant temp instrument
7. Transmitter, engine oil pressure instrument
8. Transmitter, low engine oil pressure warning lamp
9. Starter motor
10. Transmitter, low coolant level warning lamp
11. Engine wiring
Electrical components, Volvo engine
Page 37
DCD90-180
Technical Handbook
12 34 5 67
Electrical system
Description
9350
00-11
P.Group 20
5
11
98
10
1. Sensor, coolant temperature
2. Sensor, engine temperature (cold start)
3. Stop solenoid valve
4. Solenoid valve, disconnection cold start
5. Resistor for stop solenoid valve
6. Resistor for pre-heating glowplug
7. Main fuse electrical system 2 x 50 A
8. Sensor, warning lamp low gearbox oil pressure
9. Glowplug, inlet air pre-heating
10. Sensor, instrument gearbox oil temperature
11. Sensor, warning lamp low engine oil pressure
Electrical components , Perkins engine
Page 38
DCD90-180
Technical Handbook
N.B.
The starting batteries accompanying
the truck are of the maintenance-free
type, which implies that it should not
be necessary to top-up with electrolyte during the life of the batteries.
However, the level of the electrolyte
should preferably be checked once or
twice a year. Fill as required by adding
de-ionized water.
S1-6 7-12 13-18 19-24
Electrical system
Service
Electrical system
The electrical system operates at 24 V. The source of power supply are two 12 V batteries which are charged by an alternator. The
negative pole is connected to the chassis.
The positive pole is connected to a main switch A.
IMPORTANT!
When working with the electrical system, when carrying
out welding on the truck or at long time parking, always
isolate the batteries.
A Main switch
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.
Relay box in cab – fuses
Fuse Rating
No. Circuit protected A
S1 Wiper motor front, direction indicators,
seat buzzer, parking brake sensor ........................... 10
S2 Ignition key, pre-heater, starter motor,
cab lighting (Air conditioner 25 A
S3 Container attachment, safety interlock ..................... 15
S4 Electric gear-changing ............................................ 5
S5 Warning lamps, instrument illumination, relay,
coolant level .............................................................. 5
S6 Brake lights, reversing lights, reversing alarm ......... 15
S7 Fan (Air conditioner
1)
) .............................................. 25
S8 Spare (Working lights, container
S9 Working lights (15 A for 4 lamps
Hazard beacon ........................................................ 10
S10 Working lights, standard (15 A for 4 lamps) ............ 10
S11 Horn, screenwash motor, wiper rear and roof,
wiper front, intermittent relay .................................... 10
S12 Driving lights (main fuse), rear lights
(main fuse), position lights ...................................... 15
S13 Main beam, right-hand (Main beam, front 10A
S14 Main beam, left-hand (Main beam, rear 10A
S15 Dipped beam, right-hand (Dipped beam, front
S16 Dipped beam, left-hand (Dipped beam, rear
S17 Rear light, left-hand (Rear light, front
S18 Rear light, right-hand (Rear light, rear
S19 ECU 1
S20 ECU 4
1)
................................................................... 10
1)
................................................................... 10
S21 Voltage converter 24/12 ............................................. 5
S22-24 Spare........................................................................... -
1)
Optional equipment
2)
Rotatable operator’s seat
Bulbs
1)
).......................... 15
1)
) ......................... 15
1)
)
2)
2)
2)
) .................... 5
2)
) ................... 5
9350
00-11
P.Group 20
6
2)
) ...... 5
) ......... 5
2)
) ...... 5
) ......... 5
Rating
Description Watts...................................... Base
B
Instruments 3 ............................................. BA7s
Indicating lamps 1,2 .................................... W2x4,6d
Cab lighting 10............................................ S8,5
Rear lights, red 5 ........................................... BA15s
Brake lights 21 ......................................... BA15s
Direction indicators 21 ......................................... BA15s
Position lights 5 ............................................SV8,5
Driving lights 75/70 .................................. P43t-38
(full/dipped beam)
Reversing lights, white 70......................................... PK22s
Working lights 70 ......................................... PK22s
Hazard beacon 70 ......................................... PK22s
Page 39
DCD90-180
Technical Handbook
Electrical system
Service
Relays
9350
00-11
P.Group 20
7
305 Reversing light
313-1 Brake light (rear-front)
313-3 Direction indicators (right-left)
313-4 Direction indicators (left-right)
313-5 Rear light (rear-front)
313-6 Dipped beam (front-rear)
313-7 Reversing light (rear-front)
313-8 Main beam (front-rear)
313-9 Shifting (rear-front)
313-10 Shifting (front-rear)
2)
2)
2)
2)
2)
2)
2)
2)
2)
314 Parking brake, disengagement
315 High power (Starting switch)
316 Wiper motor, front
320 Electric stop (ECS 07)
322-1 Coolant level
322-2 Coolant level (ECS 07)
323 Pulse relay, direction indicators
328 Lever steering (ECS 04)
1)
1)
1)
330 Starting block
331 Propulsion forward
332 Propulsion reverse
334 Release clutch at automatic gearbox (ECS 01)
368 Low brake pressure (ECS 07)
1)
399 Spare
Miscellaneous
321-1 Intermittent relay wiper front
321-2 Intermittent relay wiper rear
960 Reversing block
1)
Optional equipment
2)
Rotatable operator’s seat
1)
1)
A
WARNING!
Batteries emit oxyhydrogen which
is an explosive gas. A spark, for
example from incorrectly connected
starting cables, could cause a battery
to explode and result in serious injury
and damage.
Main fuse
for electrical system
Fitted on the engine
2 x 50 A
Starting from another battery
z Make sure the auxiliary batteries are connected in series, so
that 24 V will be supplied.
Note: Do not disconnect the truck-battery cables
z Connect the jumper cables in the following order:
1. Red cable (+) to auxiliary battery
2. Red cable (+) to truck battery
3. Black cable (–) to auxiliary battery
4. Black cable (–) to a location some distance away from
the truck battery, such as the negative cable connection on
the chassis.
z Start the engine
Do not disturb the jumper cables while starting, as sparks
may otherwise be caused. Do not lean over either battery.
z Disconnect the jumper cables in exactly the reverse order.
Page 40
DCD90-180
Technical Handbook
Electrical system
Service
Cable markings
All cables are marked with a number for identifying the terminal
points as follows:
9350
00-11
P.Group 20
8
P = Pressure
T = Temperature
η = Coolant level
o = Fuel level
V = ON/OFF
G = Variable sensor
Cable Destination
103A
271
(26.1)
Goes from Runs to
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, e.g. a common cable for supplying several functions, a capital letter is added to the cable number.
Cable Destination
Goes from Runs to
terminal terminal
block 10 block 26
Terminal 3
in block 10
(657)
Terminal 1 in block 26
Connected to
supply the next function
Jumper
Page 41
DCD90-180
Technical Handbook
Diagrams
Gear changing systems
Manual electrical gear-changing system
The manual electric gear-changing system is electro-hydraulic
and controls the transmission by means of solenoid valves. Oil
under pressure is supplied to the solenoid valves from the oil
pump built into the transmission.
An inductive sensor senses the speed of the propeller shaft and
applies a signal to a speed monitor which prevent gear-changing
at speeds above 3 km/h.
See the circuit diagrams on the following pages.
9350
00-11
P.Group 20
9
Page 42
DCD90-180
Technical Handbook
Diagrams
Gear changing systems
Manual electric gear-changing system
Clark 18000/20000 Fixed operator’s seat
A09509.0400
This diagram can also be found integrated in the general electric
diagrams DCD90-450 in this Handbook.
A. Gearbox control valve
B. Employed gear
C. Avtivated solenoids
D. To seat buzzer switch
F. To starter motor (50)
G. From start switch
H. From alternator (D+)
J. To parking brake warning lamp
3. Gear selector
5. Speed sensor on gearbox output shaft (output speed)
6. Valve cover with solenoid valves
7. Electrical central unit
8. Switch at parking brake – ON when brake is released
9. Switch at inching – OFF when inching
10. Relays
3. Wiper motor
4. Starting interlock
5. Stop
6. –
7. Reversing lights
8. Inching
9. Reverse gear
10. Forward gear
11. Reversing interlock
9350
00-11
P.Group 20
10
Cable colours
Svart = Black
Grå =Grey
Röd=Red
Blå =Blue
Gul = Yellow
Grön= Green
Brun = Brown
Vit = White
Rosa = Pink
Page 43
DCD90-180
Technical Handbook
D
9
8
10
Diagrams
Gear changing systems
9350
00-11
P.Group 20
11
J
G
H
F
11
7
5
6
3
C
A
B
Clark 18000/20000
Manual electric gear-changing system
Fixed operator’s seat
Page 44
DCD90-180
Technical Handbook
Diagrams
Gear changing systems
Manual electrical gear-changing system
Clark 18000/20000 Rotatable operator’s seat
A09510.0400
This diagram can also be found integrated in the general electric
diagrams DCD90-450 in this Handbook.
A. Gearbox control valve
B. Employed gear
C. Avtivated solenoids
D. To seat buzzer switch
F. To starter motor (50)
G. From start switch
H. From alternator (D+)
J. To parking brake warning lamp
3. Gear selector
5. Speed sensor on gearbox output shaft (output speed)
6. Valve cover with solenoid valves
7. Electrical central unit
8. Switch at parking brake – ON when brake is released
9. Switch at inching – OFF when inching
10. Relays
3. Wiper motor
4. Starting interlock
5. Stop
6. –
7. Reversing lights
8. Inching
9. Reverse gear
10. Forward gear
11. Reversing interlock
12. PCB 2 – rotatable opertor’s seat
9350
00-11
P.Group 20
12
Cable colours
Svart = Black
Grå =Grey
Röd=Red
Blå =Blue
Gul = Yellow
Grön= Green
Brun = Brown
Vit = White
Rosa = Pink
Page 45
DCD90-180
Technical Handbook
10
Diagrams
Gear changing systems
9350
00-11
P.Group 20
13
12
10
D
9
8
GHJ
F
11
7
5
6
3
C
B
A
Clark 18000/20000
Manual electric gear-changing system
Rotatable operator’s seat
Page 46
DCD90-180
Technical Handbook
Diagrams
Gear changing systems
Manual electrical gear-changing system
Clark 28000/32000 Fixed operator’s seat
A06526.0200
This diagram can also be found integrated in the general electric
diagrams DCD90-450 in this Handbook.
A. Gearbox control valve
B. Employed gear
C. Avtivated solenoids
D. To seat buzzer switch
F. To starter motor (50)
G. From start switch
H. From alternator (D+)
J. To parking brake warning lamp
3. Gear selector
5. Speed sensor on gearbox output shaft
6. Valve cover with solenoid valves
7. Electrial central unit
8. Switch at parking brake – ON when brake is released
9. Switch at inching – OFF when inching
10. Relays
3. Wiper motor
4. Starting interlock
5. Stop
6. –
7. Reversing lights
8. Inching
9. Reverse gear
10. Forward gear
11. Reversing interlock
9350
00-11
P.Group 20
14
Cable colours
Svart = Black
Grå =Grey
Röd=Red
Blå =Blue
Gul = Yellow
Grön= Green
Brun = Brown
Vit = White
Rosa = Pink
Page 47
DCD90-180
Technical Handbook
D
9
8
10
Diagrams
Gear changing systems
9350
00-11
P.Group 20
15
J
G
F
H
K
11
7
5
6
C
3
A
B
Clark 28000/32000
Manual electric gear-changing system
Fixed operator’s seat
Page 48
DCD90-180
Technical Handbook
Diagrams
Gear changing systems
Manual electrical gear-changing system
Clark 28000/32000 Rotatable operator’s seat
A06526.0100
This diagram can also be found integrated in the general electric
diagrams DCD90-450 in this Handbook.
A. Gearbox control valve
B. Employed gear
C. Avtivated solenoids
D. To seat buzzer switch
F. To starter motor (50)
G. From start switch
H. From alternator (D+)
J. To parking brake warning lamp
3. Gear selector
5. Speed sensor on gearbox output shaft (output speed)
6. Valve cover with solenoid valves
7. Electrical central unit
8. Switch at parking brake – ON when brake is released
9. Switch at inching – OFF when inching
10. Relays
3. Wiper motor
4. Starting interlock
5. Stop
6. –
7. Reversing lights
8. Inching
9. Reverse gear
10. Forward gear
11. Reversing interlock
12. PCB 2 – rotatable opertor’s seat
9350
00-11
P.Group 20
16
Cable colours
Svart = Black
Grå =Grey
Röd=Red
Blå =Blue
Gul = Yellow
Grön=Green
Brun = Brown
Vit = White
Rosa = Pink
Page 49
DCD90-180
Technical Handbook
D
9
12
10
10
Diagrams
Gear changing systems
9350
00-11
P.Group 20
17
H
J
F
G
K
8
11
7
5
13
C
3
A
B
6
Clark 28000/32000
Manual electric gear-changing system
Rotatable operator’s seatl
Page 50
DCD90-180
Technical Handbook
Diagrams
Engine stop high/low temp
9350
00-11
P.Group 20
18
Engine stop at high/low coolant temperature
Engine with stop solenoid
Page 51
DCD90-180
Technical Handbook
Diagrams
Engine stop high/low temp
9350
00-11
P.Group 20
19
Engine stop at high/low coolant temperature
Engine with fuel shut off valve
Page 52
DCD90-180
Technical Handbook
Diagrams
Automatic engine stop, operator’s seat
9350
00-11
P.Group 20
20
ter the operator has left the cabin. After 5 min the eng-
The engine is automatically shut down a certain time af-
ine rpm is reduced to idle speed.
340. Time relay, after set time restart is permitted
Engine stop, operator’s seat
Page 53
DCD90-180
Technical Handbook
Diagrams
El-operated extra hydraulic function
9350
00-11
P.Group 20
21
1. Control section in the main valve, extra function
199. Push-button for extra function in the 4th or 5th control
lever
Electrically operated extra hydraulic function
1
Page 54
DCD90-180
Technical Handbook
WARNING!
The truck must not be operated with
by-passed safety interlock system!
Diagrams
Safety interlock system
Safety interlock for container handling
The safety interlock comprises three solenoid valves which are
activated by switches or sensors on the container attachment.
The valves interrupt the servo supply from control levers to main
valve in two cases:
1. Interrupt LIFT if not every twist-locks is either open or locked.
This prevents lifting of a container if accidentally only one
side of the container has been properly locked with the twistlocks.
2. Interrupt locking of the twist-locks if the attachment is not fully aligned onto the container, i.e. all corners are not close up
to the container.
In case of emergency, the safety interlock system is possible to
by-pass with a key operated switch.
N.B. The operator is responsible for by-passing with the key.
When the key is turned to ON-position, the safety interlock
system is out of function!
9350
00-11
P.Group 20
22
Page 55
DCD90-180
Technical Handbook
Diagrams
Safety interlock system
Safety interlock system
Volvo engine: A28047.0600
Perkins engine: A28047.0700
1. Switch, twist-locks
2. Switch, length adjustment 20–40’
3. Indicating lamp TWIST-LOCKS LOCKED
4. Indicating lamp ALIGNMENT
5. Indicating lamp TWIST-LOCKS OPEN
6. Terminal in chassis
7. Terminal in fork carriage
8. Sockets in the electrical central unit
9. Key operated by-pass switch
10. Solenoid valves, cut off servo pressure for twist-locks if there
is no alignment signal
11. Solenoid valve cuts off servo pressure for lift if twist-locks are
neither unlocked nor locked
12. Attachment electrical system
13. Sensor TWIST-LOCKS LOCKED
14. Sensor TWIST-LOCKS OPEN
15. Sensor ALIGNMENT
16. Indicating lamp, lights up when the system is by-passed with
key switch 9
9350
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P.Group 20
23
Page 56
Page 57
Page 58
Page 59
Page 60
Page 61
Page 62
Page 63
Page 64
Page 65
Page 66
Page 67
Page 68
Page 69
Page 70
Page 71
Page 72
Page 73
Page 74
Page 75
Page 76
Page 77
Page 78
Page 79
DCD90-180
Technical Handbook
Contents
Group 30
Volvo TD640VE
Specifications............................................................. 3
Engine TD640VE ....................................................... 4
Description............................................................ 4
Volvo TD730VE/TWD731VE
Specifications............................................................. 7
Engine TD730VE/TWD731VE ................................... 8
Description............................................................ 8
Overview.......................................................... 8
Cooling system .............................................. 10
Fuel system ................................................... 12
Lubrication system......................................... 15
Combusting air system .................................. 17
Service................................................................ 19
Coolant quality............................................... 19
Lubrication oil quality ..................................... 19
Draining the water from the fuel tank............. 19
Inspection of air cleaner and changing
the filter element ............................................ 19
Changing the oil and oil filter ........................ 20
Checking V-belt tension................................. 20
Checking and adjusting the valve clearances21
Changing the fuel filters................................. 21
Preventive maintenance on turbo-charger .... 22
9350
02-08
P.Group 30
Perkins 1006-60T
Specifications ............................................................. 40
Engine Perkins 1006-60T ........................................... 41
Description ............................................................ 41
General ............................................................ 41
Cooling system................................................. 42
Fuel system...................................................... 43
Service .................................................................. 44
Coolant quality ................................................. 44
Lubrication oil quality........................................ 44
Draining the water from the fuel tank ............... 44
Inspection of air cleaner and changing
the filter element............................................... 44
Changing the oil and oil filter ........................... 45
Checking V-belt tension ................................... 46
Checking and adjusting the valve clearances.. 46
Changing the fuel filters ................................... 47
Preventive maintenance on turbo-charger ....... 48
Cummins 6BTA5.9
See Cummins Operation and Maintenance Manual and
also Shop Manual
1
Volvo TAD720VE
Specifications........................................................... 24
Engine TAD720VE................................................... 25
Description.......................................................... 25
Overview........................................................ 25
Cooling system .............................................. 27
Fuel system ................................................... 29
Lubrication system......................................... 31
Combusting air system .................................. 33
Service................................................................ 35
Coolant quality............................................... 35
Lubrication oil quality ..................................... 35
Draining the water from the fuel tank............. 35
Inspection of air cleaner and changing
the filter element ............................................ 35
Changing the oil and oil filter ........................ 36
Checking V-belt tension................................. 36
Checking and adjusting the valve clearances37
Changing the fuel filters................................. 38
Preventive maintenance on turbo-charger .... 38
Page 80
DCD90-180
Technical Handbook
Volvo TD640VE
9350
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P.Group 30
2
Page 81
DCD90-180
Technical Handbook
Specifications
Manufacturer, type TD640VE
Coolant volume, l 37
9350
02-08
P.Group 30
3
Rating ISO 3046 kW (Hp)
at r/min
Torque ISO 3046, Nm
at r/min
Number of cylinders 6
Swept volume, l 5.48
Valve clearance, engine cold
inlet, mm
exhaust, mm
Idle speed, r/min
(adjust so that the engine
runs smoothly)
Injection pump, timing 13°±0,5° BTDC
Thermostat,
starts to open at °C
fully open at °C
Lubricating oil filter Full flow, disposable paper el-
Lubricating oil pressure, kPa
running speed
idling speed
129 (175)
2400
690
1500
0.40
0.55
650±50
75
88
ement with by-pass valve
300–500
min 150
Lubricating oil grade
viscosity
Volume, incl filter, l 16
See Group 90
Page 82
DCD90-180
Technical Handbook
Engine TD640VE
Description
The TD640VE engine is a 6-cylinder, 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 by an oil pump which delivers
oil to all lubrication points. A full-flow oil filter effectively cleans the
lubricating oil. The fuel system is protected against impurities by
replaceable filters. The engine has replaceable wet cylinder liners
and two cylinder heads, each covering three cylinders.
The low emission engine has a new design of combustion chamber, injection equipment and charge air cooler (intercooler) which
satisfy future emission requirements from both the USA (California) and Europe. The new engines represent a considerable improvement, not only in terms of exhaust gas emissions, but also
in terms of power and torque curves.
In addition, all Volvo engines comply with the EC OFF-ROAD and
EPA 1/CARB 1 exhaust smoke requirements.
9350
02-08
P.Group 30
4
12 3 4
56 7 8 9
1. Oil filler cap
2. Oil dipstick
3. Fresh air intake
4. Air filter
5. Starter motor
KL1448b
6. Oil cooler
7. Oil filter, full flow
8. Oil filter, by-pass
9. Compressor, air conditioning system
Intake side of the Volvo TD640VE engine
Page 83
DCD90-180
Technical Handbook
Engine TD640VE
Description
9350
02-08
P.Group 30
5
10
11 12
KL1448a
13 14 15 16 17 18 19 20 22
10. Outlet coolant
11. Fuel filters
12. Expansion tank, cooling system
13. Fan hub
14. Gear wheel driven coolant pump
15. Coolant inlet
16. Alternator
17. Fuel feed pump
18. Injection pump
19. Fuel lines for tank connection
20. Smoke limiter
21. Control motor, electrically controlled
accelerator (Optional, ECS)
22. Flywheel housing SAE 2
21
Exhaust side of the engine Volvo TD640VE
Page 84
DCD90-180
Technical Handbook
Volvo TD730VE/TWD731VE
9350
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P.Group 30
6
Page 85
DCD90-180
Technical Handbook
Manufacturer, type Volvo TD730VE Volvo TWD731VE
Coolant volume, l 40 41
Specifications
9350
02-08
P.Group 30
7
Rating ISO 3046 kW (Hk)
at r/min
Torque ISO 3046, Nm
at r/minl
Number of cylinders 6 6
Swept volume, l 6.73 6.73
Valve clearance, engine cold
inlet, mm
exhaust, mm
Idle speed, r/min
(adjust so that the engine
runs smoothly)
Injection pump, timing 10°±0.5° BTDC 10°±0.5° BTDC
Thermostat,
starts to open at °C
fully open at °C
Lubricating oil filter Full flow, disposable paper el-
Lubricating oil pressure, kPa
running speed
idling speed
150 (231)
2200
800
1400-1500
0.40
0.55
650±50 650±50
75
88
ement with by-pass valve
300–500
min 150
167 (231)
2200
893
1300-1400
0.40
0.55
75
88
Full flow, disposable paper element with by-pass valve
300–500
min 150
Lubricating oil grade
viscosity
Vol u m e , l 19 1 9
See Group 90 See Group 90
Page 86
DCD90-180
Technical Handbook
Engine TD730VE/TWD731VE
Description
Overview
The TD730VE/TWD731VE engine is a 6-cylinder, inline, 4-stroke,
low emission diesel engine with overhead valves. The engine is
turbocharged, i.e. combustion air is supplied under pressure. As
a result, the quantity of fuel injected can be increased, which increases the engine output. The turbocharger is driven by the exhaust gases and uses energy that would otherwise be lost.
In order to further increase the engine efficiency, the engine is
equipped with a water to air intercooler. (Only TWD731VE)
The engine is pressure-lubricated by an oil pump which delivers
oil to all lubrication points. A full-flow oil filter effectively cleans the
lubricating oil. The fuel system is protected against impurities by
replaceable filters. The engine has replaceable wet cylinder liners
and two cylinder heads, each covering three cylinders.
The low emission engine has a new design of combustion chamber, injection equipment and charge air cooler (intercooler) which
satisfy future emission requirements from both the USA (California) and Europe. The new engines represent a considerable improvement, not only in terms of exhaust gas emissions, but also
in terms of power and torque curves.
In addition, all Volvo engines comply with the R24 exhaust smoke
requirements.
9350
02-08
P.Group 30
8
Page 87
DCD90-180
Technical Handbook
1. Fan hub
2. Gear driven coolant pump
3. Lift eyelet
4. Twin fuel filters of throw-away
type
5. Turbo-charger
6. Exhaust manifold
7. Lift eyelet
8. Coolant pipe, inlet
9. Pump coupling guard
10. Smoke limiter
11. Oil cooler
12. Fuel shut off valve
13. Injection pump
14. Relay for inlet manifold heater
15. Cable iron
16. Lift eyelet
17. Coolant pipe, outlet
18. Flywheel housing SAE 2
19. Starter motor
20. Crankcase ventilation
21. Full-flow filter of spin-on type
22. By-pass filter of spin-on type
23. Vibration damper
24. Automatic belt tensioner
25. Intercooler
Engine TD730VE/TWD731VE
Description
TWD731VE
1 2
8910 11 12 13
4
3
25
9350
02-08
P.Group 30
9
5
6 7
TD730VE
Engine Volvo TD730VE/TWD 731 VE
Page 88
DCD90-180
Technical Handbook
Engine TD730VE/TWD731VE
Description
Cooling system
The engine is liquid-cooled and equipped with a closed cooling
system consisting of the following main components:
z
Coolant pump
z
Radiator
z
Expansion tank
z
Thermostat
z
Radiator fan
z
Coolant passages
z
Engine oil cooler
z
Gearbox oil cooler
z
Intercooler (only TWD-engine)
The coolant flows through a longitudinal passage into the engine
block. The opening into the cooling jacket of each cylinder is individually sized to ensure that each cylinder will be supplied with
the same rate of coolant flow.
The coolant flows in the separate return lines converge into a
common pipe in the thermostat housing. The coolant then flows
to the coolant pump and then into the engine and to the oil cooler.
When the engine has reached its normal operating temperature,
the thermostat will open the circuit to the radiator.
The piston-type thermostat is capable of passing a high coolant
flow rate at a minimum of pressure drop, thus contributing to favourable coolant circulation in the engine.
The coolant pump is fitted on the transmission cover and is driven
by a gear wheel from the transmission wheel.
The intercooler (TWD engine) is connected to the cooling system
by a pipe from the coolant pump. The outlet from the intercooler
is connected to the oil cooler.
9350
02-08
P.Group 30
10
1. Filler cap
2. Pipe thermostat housing- upper expansion tank
3. Piston thermostat
4. Distribution channel
5. Cylinder head
6. Oil cooler
7. Cylinder lining
8. Coolant pump
9. Pipe to the suction side of the pump
10. Radiator
11. Intercooler (only TWD-engine)
Page 89
DCD90-180
Technical Handbook
Engine TD730VE/TWD731VE
Description
The cooling system is equipped with a sensor which activates the
”Low coolant level” warning lamp on the instrument panel.
The engine lubricating oil is cooled efficiently and reliably in a
plate oil cooler. The gearbox oil is also cooled by the engine coolant, but in a separate shell-and-tube cooler.
9350
02-08
P.Group 30
11
Thermostat function during heating-up period
Thermostat function, full coolant circulation
Page 90
DCD90-180
Technical Handbook
Engine TD730VE/TWD731VE
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
pump draws fuel from the tank and delivers it at relatively low
pressure through fine filters up to the injection pump. This then
delivers fuel at high pressure to the injectors which supply the fuel
in atomised form to the engine combustion chambers.
Excess fuel which is circulated in the low-pressure system is also
cleaned in the fine filters and is returned through a spill valve back
to the tank.
The fuel system includes the following components:
Fuel tank - a separate unit located on the left-hand side of the
truck. The fuel volume in the tank can be read on a gauge on the
instrument panel.
Feed pump - of piston type, supplies fuel at a certain pressure
and flow rate to the injection pump.
Spill 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.
.
9350
02-08
P.Group 30
12
Normal operation
Shut down
1. Coarse filter
2. Fuel shut off valve
8
3. Feeder pump
4. Fine filter
5. Fuel tank
6. Check valve
7. IInjection pump
8. Overflow valve
8
Bränslesystem, principschema
Page 91
DCD90-180
Technical Handbook
Engine TD730VE/TWD731VE
Description
Fuel shut off valve
At normal operation, the solenoid in the shut off valve is activated
and fuel is fed to the injection pump.
When the starting key is turned to 0, the solenoid valve is deactivated and the flow is reversed. Thereby the feeder pump drains
the fuel from the injection pump resulting in engine shut down.
The check valve prevents return fuel from flowing into the injection pump.
9350
02-08
P.Group 30
13
T. Inlet from fuel tank
F. Outlet to fuel pump
P. Inlet from fuel filter
I. Outlet to injection pump
Normal operationShut down
Fuel shut off valve
Page 92
DCD90-180
Technical Handbook
Engine TD730VE/TWD731VE
Description
Fuel filters - two filters connected in parallel and with a common
cover. The filters are of disposable type, with the filter elements
made of spirally wound paper.
9350
02-08
P.Group 30
14
Fuel filter
Injectors - each with a nozzle holder and a nozzle. When the fuel
pressure has risen to the preset value, the needle will lift and atomised fuel will be injected into the combustion chamber through
accurately calibrated holes in the nozzle sleeve.
1. Supply pipe coupling
2. Spill fuel pipe connection
3. Spacers for adjusting the opening pressure
4. Compression spring
5. Thrust pin
6. Nozzle sleeve
7. Needle
Injector
Page 93
DCD90-180
Technical Handbook
Engine TD730VE/TWD731VE
Description
Lubricating system
The engine is pressure-lubricated, and the oil is supplied by a
pump in the oil sump. All lubricating oil flows through a full-flow
filter. One part of the oil flows through a by-pass filter for separation of extremely small particles.
The lubricating oil is cooled in a plate oil cooler by the engine
coolant.
The lubricating system includes the following main components:
Oil pump - of gear type, which draws oil through a coarse strainer
that arrests larger particles. The pump delivers oil through the lubricating oil filters to the various passages of the lubricating system.
Piston cooling – reduces substantially the piston temperature
which, in turn, contributes to a longer life of the piston rings, reduces the risk of carbon deposits and lowers the oil consumption.
The pistons are cooled by oil which is sprayed by nozzles into the
underside of each piston and into the cooling passages when the
piston is at the bottom dead centre.
Cooling is controlled by a piston cooling valve which shuts off the
cooling oil supply at low engine speeds. This ensures that the lubricating oil flow will be a maximum when the engine is started
and when it is running at idling speed. The valve also restricts the
pressure of the piston cooling oil at high engine speeds, to make
more oil available for lubrication.
9350
02-08
P.Group 30
15
1. Oil pump
2. Reducing valve
3. By-pass valve
4. Oil under pressure to
the lubrication system
5. Piston cooling valve
6. Oil under pressure for
piston cooling
7. Oil cooler
8. By-pass filter
9. Oil filter
Lubricating system
Page 94
DCD90-180
Technical Handbook
Engine TD730VE/TWD731VE
Description
Reducing valve – located just before the filter. The valve will
open if the lubricating oil pressure is too high and will return
excess oil back to the sump.
Oil filter – of full-flow type, with a filter element of pleated filter
paper. To protect the engine against insufficient lubricating oil, a
by-pass valve is fitted in the oil filter bracket. The valve will open
if the lubricating oil pressure should rise above a certain pressure
due to clogging of the filter. When the valve is open, unfiltered oil
will flow to the engine. The filter is of disposable type and should
be scrapped after use.
By-pass filter – approx. 5% of the oil passes through the by-pass
filter with very low speed. The low speed allows very small particles to be separated. The filter insert is of the disposable type.
Crankcase ventilation – prevents pressurising of the crank-case
and collects fuel vapour, steam and other gaseous products of
combustion. Crankcase ventilation is provided by a pipe connected to the crankcase inspection cover on the right-hand side of the
engine, between the starter motor and the oil filter.
9350
02-08
P.Group 30
16
1. Piston cooling valve
2. By-pass valve (safety valve)
3. Reducer valve
4. Oil cooler
5. Full-flow filter
6. By-pass filter
7. Oil pump
8. Suction strainer
9. Oil sump
Lubrication system
Page 95
DCD90-180
Technical Handbook
Engine TD730VE/TWD731VE
Description
Combustion system
Large quantities of air are necessary for burning the fuel supplied
to the engine. Free, unrestricted flow of fresh air and exhaust gases is therefore essential to allow the engine to run efficiently.
Air cleaner
The intake air is cleaned in a two-stage air cleaner, the first stage
of which collects coarse particles by cyclone action, and the particles are then collected in a dust receiver. The second stage consists of a filter element - the main filter element. A safety filter
element is located on the inside of the main element. The safety
element prevents the ingress of impurities into the engine while
the main element is being changed and if the main element
should sustain damage while the engine is running, e.g. due to
incorrect installation.
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2
3
KL 1632
1
1. To engine
2. Air restriction indicator
3. Dust exit
Air cleaner
Page 96
DCD90-180
Technical Handbook
1. Exhaust gases to silencer
2. Air to the engine intercooler
3. Exhaust gases from the engine
4. Intake air
Engine TD730VE/TWD731VE
Description
Turbocharger
The turbocharger supplies more air to the combustion chambers
than the engine would be capable of drawing naturally. This enables the engine to burn more fuel which, in turn, increases the engine output.
The turbocharger consists of a turbine wheel and a centrifugal
compressor impeller, each with a separate casing but mounted
on a common shaft.
The exhaust gases provide the energy necessary for driving the
turbine wheel which, in turn, drives the compressor.
The turbocharger is lubricated and cooled by the lubricating oil
from the engine.
Intercooler (Only TWD731VE)
In intercooling, the air that has been compressed and heated by
the turbo is cooled in an intercooler.
The intercooler increases the oxygen supply for combustion so
allowing the injected fuel to be burnt more effectively whilst reducing guel consumption as well as the level of exhaust emission.
Intercooling also reduces the thermal stressed on the engine, increasing durability and reducing oil consumption
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Turbo charger
Inlet manifold heater
Before the air is admitted into the combustion chamber, it flows
across an electrically heated starting element. This has a high
rating of 3 kW and heats the intake air sufficiently for the engine
to start at low ambient temperatures. The heater element is energised when the starting key is turned. Suitable preheating time is
about 50 seconds.
1. Air from turbocompressor
2. Engine cooling system
3. Air to combustion chamber
1. Heater element
Page 97
DCD90-180
Technical Handbook
Engine TD730VE/TWD731VE
Service
Coolant quality
Throughout the year, the coolant should consist of a mixture of
60% of water and 40% of ethylene glycol. The coolant should be
changed and the cooling system should be flushed once a year.
Always add a corrosion inhibitor (Kalmar part No. 923.110.0003)
to the coolant, if the above mixture is not used in the cooling system.
N.B. Never add a corrosion inhibitor if the cooling system
contains glycol, since this would cause foaming which seriously impairs the cooling capacity.
Lubricating oil quality
See Group 90, Periodic supervision.
Draining the water from the fuel tank
Drain any water from the fuel tank by removing the drain plug. Immediately refit the drain plug as soon as the flow of fuel is free
from water and other impurities.
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1
1. Main filter element
2. Safety filter element
2
KL1637
Inspection of the air cleaner and changing the
filter element
Check the indicator when the engine is running. If it shows red,
the main filter element must be changed. The collecting efficiency
of the filter element will not be improved if the element is changed
too early. But if changing of the filter element is delayed, smoke
emission from the engine will increase, the engine may lose power due to insufficient supply of combustion air, and engine damage may occur in certain cases.
The air pipe from the air cleaner to the engine should be checked
for tightness from time to time. Minor leakage, such as that
caused by loose hose clips, and damaged or porous hoses may
cause dust to be drawn into the engine, which will give rise to
costly engine wear.
Change the filter element as follows:
1. The engine must not be running.
2. Clean the outside of the air cleaner.
3. Remove the cover.
4. Release and carefully remove the main filter element. Do not
remove the safety filter element.
5. Fit a new main filter element. Carefully check that it is not
damaged. Note on the safety filter element when the main element was replaced.
6. Change the safety filter element:
– after the main filter element has been changed five times
– at least every other year
– if the indicator shows red after the main element has been
changed
– if the engine has been run with the main element dam-
aged
The safety filter element must not be cleaned and reused. The
engine must not be run without the main filter element. If the main
element must be cleaned and refitted in emergency cases, don’t
use compressed air to clean it, since the filter element may be
damaged. Before refitting it, carefully check that the main filter element is undamaged.
Page 98
DCD90-180
Technical Handbook
Engine TD730VE/TWD731VE
Service
Changing the oil and oil filter
N.B. Before draining the oil, 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 fil-
ters to collect any spillage.
3. Remove and discard the filter canisters, which are of dispos-
able type.
4. Pour clean oil into the centre of the new filters, wait until the
oil has seeped through the filter paper and top up until the filters are full.
5. Lubricate the canister seals with oil.
6. Fit the new filters 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 thefilters.
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 avoid serious damage to the engine, use only genuine Kalmar filters.
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Checking the V-belt tension
1. Check at regular intervals that the V-belts are correctly ten-
sioned. 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 consists of two belts, always change
both belts.
Page 99
DCD90-180
Technical Handbook
Engine TD730VE/TWD731VE
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 and cold.
1. Turn 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 necessary.
Valve clearance
Engine TD730VE/TWD731VE
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Inlet
Exhaust
2. Check the oter valves in accordance with the table below.
Check the valve clearance of cylinders No...
...when the inlet and exhaust valves of the following cylinders are just
changing over
(are moving simultaneously)
0.40 mm
0.55 mm
153624
624153
Changing the fuel filters
1. Clean the outsides of the filters.
2. Remove the filters and discard them.
3. Clean the filter head.
4. Check that the new filters are perfectly clean and that the
seals are in good condition.
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 turn.
Page 100
DCD90-180
Technical Handbook
WARNING!
Never run the engine with the air inlet
or exhaust pipes disconnected from
the turbocharger, since personnel
could then substain injuries.
IMPORTANT!
Adjustments on the injection pump are
to be performed by authorized personnel only.
Engine TD730VE/TWD731VE
Service
Preventive maintenance on the turbocharger
The turbocharger may be damaged and, in the worst case, may
break down if the engine is not properly serviced.
1. Check that the engine air inlet system is in good condition,
i.e. that the air cleaner is clean, that none of the hoses are
worn and that hose connections are not defective, which
would allow oil to seep past the seals on the compressor side
and be entrained by the inlet air. The latter may lead to high
exhaust gas temperatures and overheating of the turbine
shaft bear-ing. If corrective action is then not taken, the turbocharger may break down.
2. Change the lubricating oil and filter at the specified intervals.
Check at regular intervals that the lubricating oil lines to the
turbocharger are in good condition and do not leak. Also
check regularly that the oil pressure is not too low, since this
could quickly lead to damage to the turbocharger.
3. Ensure that the fuel system is serviced at the specified inter-
vals. Inadequate fuel supply caused by clogged fuel filters or
incorrect setting of the injection pump reduces the turbocharger speed which, in turn, results in a lower engine output.
4. Check that there are no restrictions in the crankcase ventila-
tion. If the vent is blocked, pressure may build up and may
force oil into the inlet air system of the turbocharger and
engine.
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