Kalmar TL2 Page 53 Maintenance Manual Download

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1.5

Mechanical components of the

engine

Examine the fan hub (belt driven)

Remove the drive belt, see Chapter

1.7 Cooling system

, para‐

graph

Replace the cooling fan drive belt

Measure the fan hub end clearance. An acceptable value is
max. 0,15 mm (0.006 in).

NOTE

The fan hub must rotate without any wobble or excessive end clear‐

ance.

1 Engine – 1.5 Mechanical components of the engine

TL2 Maintenance Manual

591 003 Default

Summary of Contents for TL2

Page 1: ...Original Instructions Maintenance Manual Terminal Tractor Kalmar TL2 2018 All variants...

Page 2: ......

Page 3: ...e 2 Transmission Maintenance manual 3 Driveline axle 4 Brakes 5 Steering 6 Suspension 7 Load handling 8 Control system 9 Frame body cab and accessories 10 Common hydraulics 11 Common electrics 12 Comm...

Page 4: ......

Page 5: ...Table of content A Foreword 3 Feedback 3 Maintenance manual 4 Reading this manual 7 1 TL2 Maintenance Manual 591 003 Default...

Page 6: ...2 TL2 Maintenance Manual 591 003 Default...

Page 7: ...tant for us to be able to improve the informa tion Copy this form write down your views and send the form to us Thank you for your participation To Cargotec Finland Oy After sales technical support Te...

Page 8: ...n of faults The adjacent sections include a description of the machine structure and functions and some general instructions for locating the faults All subjects in the sections are listed in the foll...

Page 9: ...urposes and thus different information content References between sections within this maintenance manual are indicated with the section and chapter number for example See section 4 Brakes chapter 4 3...

Page 10: ...r delivered to a third party without our explicit permission or used for purposes other than those allowed by us We reserve the right to alter the adjustment values equipment and service and repair in...

Page 11: ...ded are observed Important information The word NOTE is used to emphasise issues concerning safety or the maintenance instructions to which special attention must be paid while working on the machine...

Page 12: ...rder The circuit diagrams use symbols to depict components such as pumps filters valves and sensors An example of a circuit diagram is provided on the following page 3 1 1 2 3 7 4 6 8 7 9 7 69 9 7 10B...

Page 13: ...uipped with a revolving seat 12 Brake light switch 14 Parking brake indicator light switch 15 Shuttle valve 16 Brake pressure quick release valve 17 Rear axle brakes and parking brake spring chamber 1...

Page 14: ...splacement pump in the hydraulic system 14 Pressure return line in the hydraulic system 15 Throttle valve in the hydraulic system 16 Pressure controlled shuttle valve in the hydraulic system 17 Electr...

Page 15: ...n be ordered separately in case extra copies of instruction manuals or spare parts catalogue for the machine are needed later Ordering the manuals The manuals can be ordered from the manufacturer s sp...

Page 16: ...12 A Foreword Reading this manual TL2 Maintenance Manual 591 003 Default...

Page 17: ...Table of content B Safety 3 General safety instructions 3 Safety instructions 4 1 TL2 Maintenance Manual 591 003 Default...

Page 18: ...2 TL2 Maintenance Manual 591 003 Default...

Page 19: ...cing maintenance or adjustments Do not smoke or use an open flame when refueling or servicing the fuel system Avoid skin contact with oils and lubricants Use protective gloves when handling oils and g...

Page 20: ...system has been depressurized when the brake quick release valve does not emit any sound of air flow anymore Depressurizing the hydraulic system 1 Place the machine into service position 2 Note the f...

Page 21: ...g frame of the machine is fully lowered or that it is mechanically supported in its elevated position Set the main switch to vertical position and remove the key from the ignition key lock Be aware of...

Page 22: ...lifting must be performed without a lifting device Keep the object near to your body when lifting Keep your back straight Raise and lower with your legs and arms do not bend your back Do not rotate yo...

Page 23: ...ously exposed to solvents the nervous system may be damaged Symptoms include sleep disorders depression nervousness memory disorder or general tiredness and fatigue Continuous inhalation of petrol and...

Page 24: ...must be off when welding Otherwise strong welding currents can shortcircuit the electronics destroy expensive equipment and cause an explosion or fire Never weld painted surfaces Remove the paint at l...

Page 25: ...pound and when needed antifreeze fluid for exam ple ethylene glycol Coolant must not be drained into the sewer system or directly onto the ground Risks The cooling system is pressurized when the engin...

Page 26: ...ics Risks Sulphuric acid mist is corrosive and it injures the respiratory tract Sulphuric acid is generated when heating certain plastics and paints Isocyanates can be released in the form of steam or...

Page 27: ...njuries if they are accidentally released in an uncontrolled manner Precautions Use safety glasses Lock rings should be of a suitable type and in good condition Follow the instructions in this and oth...

Page 28: ...el Risks Dismantling wheels tyres rims or lock rings can be thrown Tyre pressures tyres rims or lock rings can be thrown Precautions Deflate the tyre before starting to work with the wheel Check that...

Page 29: ...Table of content C Preventive maintenance 3 For the service personnel 3 Maintenance programme 5 Initial maintenance 5 Scheduled maintenance 6 1 TL2 Maintenance Manual 591 003 Default...

Page 30: ...2 TL2 Maintenance Manual 591 003 Default...

Page 31: ...se only recommended fluids and original equipment and spare parts available from our spare parts department Following the maintenance programme defined in this maintenance manual is a prerequisite for...

Page 32: ...plicable instructions Tilting the cab For different maintenance procedures it is necessary to tilt the cab to maintenance position For correct procedure see Operator s Manual Section 6 Inspection and...

Page 33: ...s of the engine 2 Transmission Maintenance item Reference Tightening the transmission mounting screws see 2 3 Mechanical transmission Change transmission oil see 2 6 Lubrication system Replace the tra...

Page 34: ...d hydraulic oil Scheduled maintenance General The 500 hour maintenance is to be performed at 500 1 000 1 500 hours and so on The 1 000 hour maintenance is to be performed at 1 000 2 000 3 000 hours an...

Page 35: ...nd connections 500 see 11 3 Batteries Examine the engine coolant antifreeze 500 see 1 7 Cooling system Examine the radiator pressure cap 500 see 1 7 Cooling system Examine the cooling fan belt tension...

Page 36: ...smission oil filters 1000 see 2 6 Lubrication system Change transmission oil and examine oil level 1000 see 2 6 Lubrication system Clean and examine the transmission exterior 1000 see 2 3 Mechanical t...

Page 37: ...al steering gear Maintenance item Service interval hours Note Reference Examine the tie rod assembly 1000 see 5 2 Power assisted system Examine axle bearings 1000 see 5 2 Power assisted system Lubrica...

Page 38: ...operation of the air conditioner 500 Air conditioner needs to be serviced annually see 9 4 1 Air conditioner 10 Common hydrauliucs Maintenance item Service interval hours Note Reference Examine the h...

Page 39: ...12 Common pneumatics Maintenance item Service interval hours Note Reference Replace the drying filter element of the air dryer 1000 see 12 5 Filters air dryer and pressure release Operation of the air...

Page 40: ...13 14 3 8 Explanation of the symblos Manual lubrication at intervals of 250 running hours If the machine is equipped with central lubrication check only 12 C Preventive maintenance Maintenance program...

Page 41: ...ating the steering cylinder ends 4 pcs 6 Suspension 9 Lubricating the rear axle rocker bearing 2 pcs 7 Load handling 10 Lubricating the lifting frame bearing 2 pcs 11 Fifth wheel grease nipples jaws s...

Page 42: ...14 C Preventive maintenance Maintenance programme TL2 Maintenance Manual 591 003 Default...

Page 43: ...Table of content 0 Complete machine 3 Locating faults and malfuctions 3 Example of troubleshooting 4 Troubleshooting cables 5 Troubleshooting hoses 6 1 TL2 Maintenance Manual 591 003 Default...

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Page 45: ...to locate any malfunctions in the steering and other systems the person must be able to read the machine circuit diagrams in a professional manner Follow the troubleshooting sequence indicated in the...

Page 46: ...stem of the function 3 Start the troubleshooting by checking the component or actua tor receiving the signal 4 If the actuator is not defective continue by checking the com ponent that should send the...

Page 47: ...nections and any joints of the suspected cable 2 Check the cable as follows a Disconnect the connector from both the control unit and component b Connect the other end of the cable to a point on the f...

Page 48: ...or pneumatic diagram for the item you are troubleshooting see Section E Diagrams Check the con nections and any joints of the suspected hose 3 Check the hoses as follows a Start the troubleshooting i...

Page 49: ...of content 1 Engine 3 1 2 Fuel system 3 1 5 Mechanical components of the engine 5 1 6 Intake and exhaust system 18 1 7 Cooling system 22 1 8 Lubrication system 38 1 TL2 Maintenance Manual 591 003 Def...

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Page 51: ...HAZARD Fuel in contact with the skin may cause injury Avoid skin contact with the fuel Use protective gloves CAUTION Take care to ensure absolute cleanliness Impurities in fuel cause damage to the sy...

Page 52: ...seal or filter can 8 Use a priming device to pump fuel into the fuel system WARNING The fuel pump high pressure fuel lines and fuel rail contain very high pressure fuel Never loosen any fittings while...

Page 53: ...7 Cooling system para graph Replace the cooling fan drive belt 2 Measure the fan hub end clearance An acceptable value is max 0 15 mm 0 006 in NOTE The fan hub must rotate without any wobble or exces...

Page 54: ...nt Oil or grease on the side of the belts 3 Measure the belt tension in the center span of the pulleys An alternate method deflection method can be used to check belt tension by applying 110 N 25 lbf...

Page 55: ...mper location refer to engine drawings Examine the vibration damper viscous 1 Examine the vibration damper for evidence of fluid loss dents and wobble Examine the vibration damper thickness for any de...

Page 56: ...e crankcase breather tube outlet with detergent and warm water NOTE If a crankcase breather tube heater option is installed the crankcase breather heater must be removed prior to submerging the crankc...

Page 57: ...tive battery cable first and attach the negative battery cable last 1 Disconnect the battery cables Refer to the original equipment manufacturer OEM service manual 2 Remove any fasteners securing the...

Page 58: ...und replace the gasket Do not stretch the new gasket during installation NOTE Exposure to oil can cause the gasket to swell which can make it dif ficult to install the gasket back into the groove If t...

Page 59: ...sket tab end Finish by pushing in the sides see illustration 2 Gently push the gasket down into the groove Do not use a finger to trace the gasket around into the groove during instal lation as this w...

Page 60: ...ive battery cable last Remove 1 Disconnect the batteries See equipment manufacturer serv ice information 2 Prior to removing any components use compressed air to remove any loose debris from around th...

Page 61: ...oil drain line is internal to the breather connection tube C 5 Remove the mounting nuts and isolators from the rocker lever cover 6 Remove the rocker lever cover 7 Examine the gasket for cracks on the...

Page 62: ...be less than 60 C 140 F Use the barring tool to rotate the crankshaft until the number 1 cylinder is at top dead center TDC 2 The TDC indicator is on the vibration damper Align the vibration damper s...

Page 63: ...Intake 0 152 MIN 0 006 0 381 MAX 0 015 Exhaust 0 381 MIN 0 015 0 762 MAX 0 030 NOTE Examing the overhead setting is usually performed as part of a trou bleshooting procedure and resetting is not requ...

Page 64: ...rocker levers E exhaust I intake Four cylinder 2E 3I 4E and 4I Six cylinder 2E 3I 4E 5I 6I and 6E 9 If the measurements are out of specification set the valve lash Install 1 Install the rocker lever...

Page 65: ...tion 6 Connect the breather tube connection to the rocker lever cover 7 Tighten the capscrews Tightening torque 10 Nm 89 in lb 8 Connect the batteries See equipment manufacturer service information 9...

Page 66: ...piping 1 Examine the air intake piping for wear points and damage to piping loose clamps punctures that may damage the engine 2 Replace damaged pipes 3 Tighten loose clamps 8 Nm to prevent the air sys...

Page 67: ...m 33 ft lb 5 Operate the engine and examine for correct compressor oper ation 6 Examine for air oil and coolant leaks Examine air compressor discharge lines WARNING FLYING MATERIAL HAZARD Flying debri...

Page 68: ...al carbon deposit is less than 2 mm 1 16 in 7 Clean or replace any lines or connections that exceed this specification 8 Examine any air driers splitter valves pressure relief valves and alcohol injec...

Page 69: ...ble to the turbocharger air inlet in order to obtain a true indica tion of restrictions Vacuum Indicator Vacuum switches actuate a warning light on the instrument panel when the air restriction become...

Page 70: ...engine to cool below 50 C 120 F before add ing coolant On applications that use a coolant recovery system examine to make sure the coolant is at the appropriate level on the coolant recovery tank for...

Page 71: ...d coolant to the tank be careful to keep the fluid free of any impurities Impurities in coolant damage the coolant pump and impair engine coolant circulation The right coolant mix and type can be foun...

Page 72: ...ump and localized boiling CAUTION Do not relieve the system pressure while hot in order to top off immediately before returning the vehicle to service The system will not be able to generate the press...

Page 73: ...ves See equipment manufacturer service information for complete cooling system drain information 7 Examine for damaged hoses and loose or damaged hose clamps Replace as required 8 Examine the radiator...

Page 74: ...ned ON 6 With the cooling system fill cap removed Operate the engine at LOW IDLE for 2 minutes Turn the engine OFF and add plain water to bring the level back to FULL Start the engine NOTE After start...

Page 75: ...y be equipped with a manual bleed valve which is to be opened to make sure of a proper fill The upper radiator pipe is a common location for bleed valves The illustration is for reference only 1 Remov...

Page 76: ...harge coolant into the environment Use an appropriate container and deliver the coolant to a hazardous waste collection point CAUTION Wear appropriate eye and face protection when using compressed air...

Page 77: ...malfunctioning cap may result in the loss of coolant and the engine running hot 1 Make sure that the correct radiator pressure cap is being used 2 Examine the rubber seal of the pressure cap for damag...

Page 78: ...rivets bent or loose blades 2 Examine the fan to make sure it is securely mounted Tighten the capsrews if necessary CAUTION Do not straighten a bent fan blade or continue to use a damaged fan A bent o...

Page 79: ...t see ANReplace the cooling fan drive belt 4 After replacing the belt if the tensioner arm stops are still in contact with the spring case stop replace the tensioner 5 With the belt removed examine th...

Page 80: ...the bracket NOTE Most belt tensioners are mounted to the water inlet connection Some belt tensioners are mounted to a separate mounting bracket and use internal fasteners for clearance Examine for re...

Page 81: ...Install the drive belt see Chapter 1 7 Cooling system para graph Replace the cooling fan drive belt 4 Connect the battery cables Refer to the OEM service manual 5 Operate the engine and check for leak...

Page 82: ...cooling fan drive belt General Due to the number of drive belt arrangements this procedure does not cover all available cooling fan drive belt routing To make sure the cooling fan drive belt is route...

Page 83: ...he tensioner to wind the spring tighter CAUTION The belt tensioner is spring loaded and must be pivoted away from the drive belt Pivoting in the wrong direction can result in damage to the belt tensio...

Page 84: ...eplaced 3 Inspect the belt grooves for Embedded debris Uneven excessive rib wear Exposed belt cords 4 Inspect the backside of the belt for Glazing high heat Embedded debris Exposed belt cords If any o...

Page 85: ...er pump pulley at this time 2 Pivot the tensioner in the direction of the spring tang and install the drive belt slipping the belt over the water pump pul ley last 3 Slowly release the tensioner to ap...

Page 86: ...engine oil Drain WARNING Used engine oil may be carcinogenic and cause reproductive toxic ity Avoid inhalation of vapors ingestion and prolonged contact with used engine oil If not reused dispose of i...

Page 87: ...s after starting If not turn OFF the engine immediately to avoid engine damage Make sure that the correct oil level is in the oil pan 5 Turn OFF the engine Wait approximately 5 minutes to let the oil...

Page 88: ...Be careful that no debris is poured into the filter If using an oil supply with a metallic or plastic seal under the cap be careful to peel the seal back Puncturing the seal with a knife or sharp obj...

Page 89: ...Table of content 2 Transmission 3 2 3 Mechanical transmission 3 2 6 Lubrication system 6 2 7 Cooling system 10 1 TL2 Maintenance Manual 591 003 Default...

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Page 91: ...ansmission at regular intervals Intervals must be specified according to severity of service and operating conditions 2 Examine the transmission for Loose bolts transmission and mounting components Fl...

Page 92: ...nd nut 5 Tighten the locking nuts F Tightening torque 58Nm 6 Loosen the screw D and nut E 7 Examine the distance of the coil spring If the distance is not 63 5mm repeate the points 2 6 8 Remove the sc...

Page 93: ...mm socket to remove or replace the breather Pliers or a pipe wrench may crush or damage the stem and produce metal chips which could enter the transmission 2 Transmission 2 3 Mechanical transmission 5...

Page 94: ...t the correct level according to the dipstick 3 Start the engine and let it run idle so that the torque converter and oil cooler are filled up 4 Stop the engine and examine the filter connections for...

Page 95: ...rake 2 Run the engine at idle 500 800 rpm for approximately 1 minute 3 Shift to D Drive and then to R Reverse to clear the hydraulic system of air 4 Shift to N Neutral and allow the engine to remain a...

Page 96: ...engine to idle 500 800 rpm 6 With the engine running remove the dipstick from the tube and wipe clean 7 Insert the dipstick into the tube until it seats and remove 8 Examinate fluid level Repeat the...

Page 97: ...the filter 3 Remove the screws of the oil filter lid and remove the filter 4 Install the filter cartridge and its seals as shown in the figure 5 Tighten the lid screws 6 Start the engine Check the con...

Page 98: ...the engine radiator The circula tion of oil to the cooler is controlled automatically B B A A A Cooling hose from the transmission to cooler B Cooling hose from the cooler to transmission 10 2 Transmi...

Page 99: ...Table of content 3 Driveline axle 3 3 2 Propeller shaft 3 3 3 Drive axle 4 1 TL2 Maintenance Manual 591 003 Default...

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Page 101: ...ounting screws A 16 pcs Tightening torque 160 Nm 118 ft lb Each end of the propeller shaft has four mounting plates with two mounting screws 2 Examine the universal joints for Visible wear in the join...

Page 102: ...acked parts 4 Replace all worn or damaged parts 5 Make sure that there is no looseness at the pivot points Make sure that the pivot points are lubricated 6 Make sure that all the parts move freely thr...

Page 103: ...the container 4 Install the oil drain plug B Fill 1 Remove the inspection plug A 2 Fill the wheel hub with recommended oil until some oil flows from the hole A The oil level is correct when the oil s...

Page 104: ...d out tightening torque 70 90 Nm 4 Install and tighten 70 90 Nm the plug B when all the oil has drained out 5 Remove the oil level inspection plug A in the differential 6 Fill the differential with re...

Page 105: ...Table of content 4 Brakes 3 4 3 Power assisted brake system 3 1 TL2 Maintenance Manual 591 003 Default...

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Page 107: ...thickness of 8 mm the bands must be replaced Examine the slack adjuster NOTE If the brake system has automated slack adjuster the adjustment pro cedure is not necessary 1 Raise the wheel off the groun...

Page 108: ...m and slack adjusters 1 Lubricate the s cam through the grease fitting A 2 Lubricate the slack adjuster through grease fitting B B B A A 4 4 Brakes 4 3 Power assisted brake system TL2 Maintenance Manu...

Page 109: ...Table of content 5 Steering 3 5 2 Power assisted system 3 5 2 1 Front axle 3 Wheel alignment 6 1 TL2 Maintenance Manual 591 003 Default...

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Page 111: ...Examine that the tie rod nut is installed and secured with a cotter pin If the cotter pin is missing tighten the tie rod end nut and install a new cotter pin Do not loosen the tie rod end nut to inser...

Page 112: ...bearings If any of the following conditions exist you must replace the bear ing WORN SURFACE WORN RADIUS The center of the large diameter end of the rollers is worn level or below the outer surface WE...

Page 113: ...s 1 Park the vehicle on a level surface Block the wheels to pre vent the vehicle from moving Set the parking brake 2 Verify that the tires touch the ground Do not raise the vehicle The full weight of...

Page 114: ...le from moving Set the parking brake ON 2 Use jacks to lift vehicle so that front tires are off the ground Support the front axle with safety stands 3 Use paint or chalk to mark the center area of bot...

Page 115: ...on each end of the cross tube b Turn the cross tube until the specified toe distance is obtained c The threaded portion of the tie rod end must be installed into the cross tube beyond the point where...

Page 116: ...8 5 Steering Wheel alignment TL2 Maintenance Manual 591 003 Default...

Page 117: ...Table of content 6 Suspension 3 6 2 Suspension 3 6 3 Tyres and rims 4 1 TL2 Maintenance Manual 591 003 Default...

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Page 119: ...ate makes even contact with the bottom axle 3 Starting with the front outside nut use a crossing pattern to tighten the nut in two even steps to the final torque 610 Nm 450 ft lbs Tighten the front sp...

Page 120: ...bricate the threads lightly 2 Fasten the nuts and tighten them to 600 Nm in the order described in the figure Examine the tightness of the nuts after operating the machine for 1 day at the latest Exam...

Page 121: ...Table of content 7 Load handling 3 7 2 Lifting lowering 3 7 9 Load carrying 4 1 TL2 Maintenance Manual 591 003 Default...

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Page 123: ...oom 1 Do a functional test for load handling control in the cab For correct instruments and controls see Kalmar T2 Operator s Manual Section 4 Instruments and controls Chapter 4 6 Con trol lever 7 Loa...

Page 124: ...between the fifth wheel and the lift boom the top surface jaws and slide of the fifth wheel the joints in the locking mechanism of the hitch Examine of the kingpin 1 Examine the wear of the kingpin l...

Page 125: ...9 1 Controls and instrumentation 3 9 4 Heating ventilation and air conditioning 4 9 4 1 Air conditioner 4 9 5 Wiper washer system 6 9 10 Structure and mounting of the cab 7 9 10 1 Cab mounting and su...

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Page 127: ...f the equipment in the cab 1 Do a functional test for the equipment in the cab For correct instruments and controls see Kalmar T2 Operator s Manual Section 4 Instruments and controls 9 Frame body cab...

Page 128: ...according to the following instructions Examine the amount of refrigerant 1 Start the engine and run the engine at maximum speed 2 Switch the air conditioner to maximum blowing and maximum cooling 3 S...

Page 129: ...refrigerant The liquid is clear and bubbles cannot be seen when the engine speed is changed Too much refrigerant Contact service personnel qualified to service refrigeration equipment 9 Frame body ca...

Page 130: ...wiper motor can be damaged 1 Pay attention to the condition of the blades Worn or damaged blades clean the glass poorly and scratch the glass Fill the washer fluid reservoir 1 Remove the reservoir cap...

Page 131: ...Decrease the rod D length by placing the rod deeper into the upper sleeve A To lower ride level Increase the rod length by reducing the insertion of the rod in the sleeve NOTE One inch 25 4 mm of clea...

Page 132: ...8 9 Frame body cab and accessories 9 10 Structure and mounting of the cab TL2 Maintenance Manual 591 003 Default...

Page 133: ...Table of content 10 Common hydraulics 3 10 3 Tanks and accumulators 3 10 5 Hoses pipes and valves 5 10 6 Temperature control cleaning and hydraulic oil 6 1 TL2 Maintenance Manual 591 003 Default...

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Page 135: ...il tank be careful to keep the oil free of other fluids or impurities Impurities damage the hydraulic system Filter the oil before adding it into the tank Change the hydraulic oil CAUTION Avoid skin c...

Page 136: ...uring the oil level examination or oil change 1 Examine that the breather hose A is intact along its entire length Replace a damaged hose 2 Use a screwdriver or other suitable tool to examine that the...

Page 137: ...of the hydraulic hoses and connections must always be checked during maintenance Components that have deteriorated must be replaced Pay special attention to the components of the steering and fifth w...

Page 138: ...the environment Use an appro priate container and deliver the oil and the used filter to a hazard ous waste collection point Take care to ensure absolute cleanliness Impurities in oil cause damage to...

Page 139: ...Table of content 11 Common electrics 3 11 3 Batteries 3 11 4 Alternator 6 1 TL2 Maintenance Manual 591 003 Default...

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Page 141: ...illed in the eyes flush immediately with large quantities of water and consult a doctor Do not smoke or use an open flame near the batteries While working on the batteries remove your watch rings and...

Page 142: ...el in the cells The level must be about 10 mm above the top of the battery plates add liquid if necessary Add distilled water only Also check that the air holes in the filler plugs are not clogged Exa...

Page 143: ...the connections until shiny Make sure all debris is removed from the connecting surfaces 4 Install the cables and tighten the battery connections 5 Coat the terminals with grease to prevent corrosion...

Page 144: ...Section 4 11 is lit if the battery volt age is higher than the voltage supplied by the alternator If the indi cator light is lit while the engine is running the alternator has a mal function Examine...

Page 145: ...Table of content 12 Common pneumatics 3 12 2 Tanks and accumulators 3 12 5 Filters air dryer and pressure release 4 1 TL2 Maintenance Manual 591 003 Default...

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Page 147: ...located under the chassis 1 Drain the water from the reservoirs by pulling the cord A attached to the valve ring at the bottom of the reservoir The exiting compressed air forces the water out A A 12...

Page 148: ...tem The air dryer is equipped with an overflow valve If the dryer ele ment is fully clogged it is bypassed and the air flows directly to the air tanks through the valve Adjust the pressure level 1 Con...

Page 149: ...Table of content D Error codes 3 Engine 3 Engine error codes Cummins 3 Transmission 8 1 TL2 Maintenance Manual 591 003 Default...

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Page 151: ...lidation switch data incorrect 93 2 Water in Fuel Indicator High 5 1 7 9 e c n a n e t n i a M Water in Fuel Sensor Circuit shorted hig 9 h 7 3 Water in Fuel Sensor Circuit shorted low 97 4 Engine Oil...

Page 152: ...68 18 Battery 1 Voltage High Warning 168 16 Fuel Temperature High Warning 174 16 Fuel Temperature Sensor Circuit data out of range 174 11 Engine Oil Temperature Sensor Circuit shorted hig 1 h 75 3 Eng...

Page 153: ...orted high 632 3 Fuel Shutoff Valve Supply Voltage error 632 11 SAE J1939 Multiplexing PGN Timeout Error 639 3 SAE J1939 Multiplexing Configuration Error 639 13 SAE J1939 datalink cannot transmit 639...

Page 154: ...on Sensor 1 Crankshaft Supply Voltage Circuit shorted low 1043 4 Accelerator Pedal Position Sensor Supply Voltage Circuit shorted high 1043 3 Accelerator Pedal Position Sensor Supply Voltage Circuit s...

Page 155: ...ltiple Unit Synchronization Switch Circuit data incorrect 1377 2 Low Oil Level in the Centinel makeup oil tank 1380 17 Fuel Supply Pump Inlet Pressure Sensor Circuit shorted hig 1 h 381 3 Fuel Supply...

Page 156: ...Transmission Error code table 8 D Error codes Transmission TL2 Maintenance Manual 591 003 Default...

Page 157: ...D Error codes Transmission 9 TL2 Maintenance Manual 591 003 Default...

Page 158: ...10 D Error codes Transmission TL2 Maintenance Manual 591 003 Default...

Page 159: ...Table of content E Schematics 3 Hydraulic 3 Electric 4 Pneumatic 5 1 TL2 Maintenance Manual 591 003 Default...

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Page 161: ...E Schematics Hydraulic E Schematics Hydraulic 3 TL2 Maintenance Manual 591 003 Default...

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Page 163: ...Electric 4 E Schematics Electric TL2 Maintenance Manual 591 003 Default...

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Page 167: ...Pneumatic E Schematics Pneumatic 5 TL2 Maintenance Manual 591 003 Default...

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Page 171: ...6 E Schematics Pneumatic TL2 Maintenance Manual 591 003 Default...

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Page 173: ...chnical data 3 Specifications and dimensional drawing 3 Specifications 4 Oil grease and fluid volumes and quality 8 Tightening torques units of measurement and conversion tables 11 1 TL2 Maintenance M...

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Page 175: ...ommon units and their abbreviations as well as conversion tables for the SI units and length area volume weight mass and pressure measure ments Dimensional drawing 103 19 2621 09 98 2489 2 187 4 4760...

Page 176: ...W 220 hp 2000rpm Torque ISO 3046 952 Nm 1400 rpm Engine speeds Idle speed 700 rpm Maximum speed 2500 Alternator 70 A Starting batteries 2 x 12 V Transmission Model Allison 3000im Operating principle A...

Page 177: ...make contact with the brake drum and generate brake torque Service brake Dual circuit drum brakes Parking brake Spring loaded drum brake at the rear axle controlled with an electric switch in the cab...

Page 178: ...le stage Hydraulics Operating principle The pressure and volume flow required by the terminal tractor hydraulic system is generated by a fixed pump which is actuated by the PTO on the transmission A p...

Page 179: ...ntrol valve at the compressor directs the compressor output to the by pass line when the system pressure exceeds 8 0 bar Compressor output Approximately 500 litres per minute Depends on engine type an...

Page 180: ...er mix more than 60 concentrate in the coolant Cummins engine cooling fluid specification Cooling fluid quantity 30 3 l Cooling fluid quality 50 concentrated coolant and 50 water The fluids must be th...

Page 181: ...ple ESSO Beacon EP1 MOBIL Mobilgrease HP222 Shell Alvania EP1 or CASTROL APS 2 Classification NLGI 1 Temperatures below 10 C use NLGI 0 Rear axle Rear axle lubrication oil Differential oil volume 13 l...

Page 182: ...Summer mixture 1 6 Air conditioner Air conditioner refrigerant Refrigerant quantity 900 g Refrigerant quality R134A Lubrication grease General lubrication grease Lubrication grease quality EP multipur...

Page 183: ...ca Inch in Foot ft Yard yd Mile mile Centimetre cm Metre m Kilometre km Conversion table SI units SI unit Conversion factor Other than SI Conversion factor SI Torque Nm x 10 2 kg cm x 0 8664 lb in Nm...

Page 184: ...kJ J x 0 239 calorie x 4 19 J Speed and acceleration m s2 x 3 28 ft s2 x 0 305 m s2 m s x 3 28 ft s x 0 305 m s km h x 0 62 mph x 1 61 km h Horsepower torque Bhp x 5252 rpm TQ lb ft TQ x rpm 5252 bhp...

Page 185: ...0 a 0 01 100 0 0001 1 1076 4 119 58 ft2 0 092903 0 000929 1 0 1111 144 000 yd2 0 83613 0 008361 9 1 1296 00 in2 6 4516 0 000645 0 006943 0 000771 1 1 ha 100 a 1 mile2 259 ha 2 59 km2 Conversion table...

Page 186: ...Unit kp cm2 bar Pa N m2 kPa lbf in2 lbf ft2 kp cm2 1 0 98067 98066 5 98 0665 14 2233 2048 16 bar 1 01972 1 100000 100 14 5037 2088 6 Pa N m2 0 00001 0 001 1 0 001 0 00015 0 02086 kPa 0 01020 0 01 100...

Page 187: ...content G Appendixes 3 Warranty information 3 Garantiehinweise 6 Informaci n sobre la garant a 10 Information sur la garantie 14 Garanti information 18 Takuutodistus 21 1 TL2 Maintenance Manual 591 00...

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Page 189: ...parts must be kept available for inspection until the warranty claim is finally settled All defects under this warranty must be claimed in writing to an authorized dealer or service agent of Cargotec...

Page 190: ...er costs for example all duties are to be carried by the client When parts are required to be returned to Cargotec the right to accept return cost in advance is reserved What the warranty does not cov...

Page 191: ...two months Any reported defect shall be inspected and confirmed by technical personnel from an authorized dealer or service agent of Cargotec if not otherwise agreed in writing Major component warran...

Page 192: ...wendet werden die die Kalmar Spezifikationen erf llen Ausgewechselte Teile sind f r eine berpr fung aufzubewah ren bis ber den Garantieanspruch entschieden wurde Alle w hrend der Garantiefrist auftret...

Page 193: ...rgenom men werden sind von einem autorisierten H ndler oder einer Kun dendienststelle auszuf hren und bed rfen der schriftlichen Geneh migung von Cargotec Alle Arbeiten sind ge m den von Cargotec fest...

Page 194: ...eser Garantie deutlich aufgef hrten Haftungsbestimmungen von Cargotec hinaus gehen M ngelanzeige Der Besitzer hat festgestellte M ngel schriftlich bei Cargotec oder einem autoririerten H ndler oder ei...

Page 195: ...Gesetz zum Internationalen Warenhandel 796 1988 stipulierten Bestimmun gen Wird ein Teil dieser Garantie aufgrund eines geltenden Gesetzes nicht auf der Basis des finnischen Rechts behandelt oder ausg...

Page 196: ...el mantenimiento y en las repara ciones del producto Las piezas que se hayan cambiado deben estar disponibles para su inspecci n hasta que se resuelva cualquier reclama ci n sobre la garantia Todos lo...

Page 197: ...ve a cabo bajo las condiciones de esta garant a debe ser acometido por un proveedor o agente de servi cios que cuente con una autorizaci n escrita de Cargotec Este tipo de trabajos deben llevarse a ca...

Page 198: ...sus piezas que ampl en la respon sabilidad de Cargotec m s all de las condiciones claramente expresadas en esta garant a Comunicaci n de defectos Es responsabilidad del propietario del producto comun...

Page 199: ...s interna cionales Si debido a una norma obligatoria de alguna legislaci n aplicable alguna parte de esta garant a no debiera regirse e in terpretarse de acuerdo con la legislaci n finlandesa esto no...

Page 200: ...ants remplac s doivent tre conserv s pour inspection jusqu au r glement final de la demande en gar antie Selon cette garantie toutes les r clamations concernant les d fauts doivent tre effectu es par...

Page 201: ...agr par crit par Cargo tec Tous ces travaux devront tre effectu s selon les instructions de Cargotec et durant les heures de travail normales Lorsque cette mesure est applicable Cargotec livrera les p...

Page 202: ...ment dans cette garantie Rapport des d fauts C est la responsabilit du propri taire du produit de signaler par crit toute non conformit du produit Cargotec ou un distribu teur agr ou un service d ent...

Page 203: ...ns toute loi applica ble une partie de cette garantie ne peut pas tre r gie par et inter pr t e conform ment la l gislation finlandaise cette exception n affecte en aucun cas l applicabilit de la l gi...

Page 204: ...li gen till Cargotecs auktoriserade terf rs ljare eller ser vice partner inom nedan angiven tid Det ligger garen att kunna dokumentera att f ruts ttningarna f religger f r garantins till mplighet Till...

Page 205: ...laktig till f ljd av en olycksh n delse efter leverans till ursprunglig k pare felaktigt eller ej auktori serat underh ll verbelastning v rdsl shet eller felaktig lagring hantering eller anv ndning c...

Page 206: ...tillverkargaranti och garen m ste kon takta dem direkt betr ffande garantiarbete Cummins Allison Volvo Siemens ABB och Control Techniques Drive Service Garantins t ckning f r stora komponenter t ex mo...

Page 207: ...valtuutetulta j lleenmyyj lt tai huoltoedusta jalta allamainittujen aikam rien sis ll Tuotteen omistajan velvollisuuteen kuuluu varmistaa ett yll olevat ehdot t yttyv t Takuun laajuus Viitaten t m n...

Page 208: ...letun kuljetusehdon takia b vahingoittuu ensimm iselle ostajalle toimituksen j lkeen onnettomuuden seurauksena sopimattomasta tai luvattomasta k y t st ylikuormituksesta huolimattomasta tai sopimattom...

Page 209: ...et on teht v Cargotecille tai Cargotecin valtuuttamalle j lleenmyyj lle tai huoltoedustajalle kahden kuukau den kuluessa vian havaitsemisesta Cargotecin valtuuttama j lleenmyyj tai huoltoedustaja tark...

Page 210: ...24 G Appendixes Takuutodistus TL2 Maintenance Manual 591 003 Default...

Page 211: ...system 1 18 Lifting lowering 7 3 Load carrying 7 4 Load handling 7 3 Locating faults and malfuctions 0 3 Lubrication system 1 38 Lubrication system 2 6 Maintenance manual A 4 Maintenance programme C 5...

Page 212: ...26...

Page 213: ...MyParts you can now order over 50 000 Kalmar Genuine Parts on line 24 7 at parts mykalmar com You will also be able to check on parts availability for your all Kalmar equipment in one place To regist...

Page 214: ......

Page 215: ......

Page 216: ...approximately EUR 3 4 billion in 2014 and it employs approximately 11 000 people Cargotec s class B shares are quoted on NASDAQ OMX Helsinki Ltd under symbol CGCBV www cargotec com Kalmar 415 East Dun...

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Kalmar TL2, Maintenance Manual

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