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Summary of Contents for Kalmar TL2
- Page 1 Terminal Tractor Kalmar TL2 Maintenance Manual 2018 All variants Original Instructions...
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Page 3: Engine
A Foreword B Safety C Preventive maintenance 0 Complete machine 1 Engine Maintenance manual 2 Transmission 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 Common pneumatics D Error codes E Schematics... - Page 5 Table of content A Foreword Feedback Maintenance manual Reading this manual TL2 Maintenance Manual 591 003 Default...
- Page 6 TL2 Maintenance Manual 591 003 Default...
- Page 7 Form for giving feedback It is the goal of Cargotec Oy, to provide everyone working with the maintenance of Kalmar machines with access to the correct infor‐ mation for performing the work safely and efficiently. Your feedback is important for us to be able to improve the informa‐...
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Page 8: Table Of Contents
If the function uses a component that has been described above, the Control system component is presented with a description relevant to the new function only. Frame, body, cab and accessories Common hydraulics Common electrics Common pneumatics TL2 Maintenance Manual 591 003 Default... -
Page 9: Tl2 Maintenance Manual
The information in this manual corresponds to the design and appearance of the machine at the time of delivery. Information in the manuals of the same machine type can differ from each other depending on the machine that the customer has ordered. TL2 Maintenance Manual 591 003 Default... -
Page 10: Tl2 Maintenance Manual
We reserve the right to alter the adjustment values, equipment, and service and repair instructions for the machine without prior notice. Cargotec Oy TL2 Maintenance Manual 591 003 Default... -
Page 11: Tl2 Maintenance Manual
Fig. : This symbol indicates an accessory or optional equipment. The NOTE symbol is clearly distinguished from the text, and it is placed next to the text and picture representing the equipment. TL2 Maintenance Manual 591 003 Default... -
Page 12: Tl2 Maintenance Manual
An example of a circuit diagram is provided on the following page. 19 17 Circuit diagram component list 1. Terminal tractor air filter 2. Pneumatic air compressor 3. Pressure regulator TL2 Maintenance Manual 591 003 Default... -
Page 13: Tl2 Maintenance Manual
60. Parking brake relay valve 64B. Trailer brake control valve for the EC-compliant brake system 65. Parking brake release 68. Parking brake valve for the EC-compliant brake system 69. Air tank (30 litres) for the EC-compliant brake system TL2 Maintenance Manual 591 003 Default... -
Page 14: Tl2 Maintenance Manual
23. Return filter in the hydraulic system 24. Cable in the electric system 25. Indicator light in the electric system 26. Level sensor in the electric system 27. Electric motor 28. Control switch in the electric system TL2 Maintenance Manual 591 003 Default... -
Page 15: Tl2 Maintenance Manual
Ordering the manuals The manuals can be ordered from the manufacturer's spare parts department. Refer to the serial number of the machine when placing the order. TL2 Maintenance Manual 591 003 Default... -
Page 16: Tl2 Maintenance Manual
A Foreword – Reading this manual TL2 Maintenance Manual 591 003 Default... -
Page 17: Tl2 Maintenance Manual
Table of content B Safety General safety instructions Safety instructions TL2 Maintenance Manual 591 003 Default... -
Page 18: Tl2 Maintenance Manual
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Page 19: Tl2 Maintenance Manual
Therefore, it is very important that all persons working with the machine acquaint themselves with and act according to the informa‐ tion in the maintenance manual and the operator's manual. TL2 Maintenance Manual 591 003 Default... -
Page 20: Tl2 Maintenance Manual
Wear appropriate work clothing. Remove any loosely hanging cloth‐ ing, for example a tie or a scarf. Do not wear clothes with wide sleeves, wide trouser legs, and so on. Remove jewellery as it may get caught in moving parts. TL2 Maintenance Manual 591 003 Default... -
Page 21: Tl2 Maintenance Manual
Mechanical or hydraulic tools or lifting devices can tip over or lower accidentally due to a fault or incorrect use. Precautions Use axle stands and supports that are positioned firmly. Use only type approved and inspected lifting tools. TL2 Maintenance Manual 591 003 Default... -
Page 22: Tl2 Maintenance Manual
Noise Noise louder than 85 dB (A) that lasts longer than 8 hours is consid‐ ered harmful to hearing. Tones at high frequencies are more dam‐ TL2 Maintenance Manual 591 003 Default... -
Page 23: Tl2 Maintenance Manual
Machine and vehicle tyres are highly flammable and cause fires that spread explosively. Risks Examples of the causes of ignition include welding, cutting, smok‐ ing, sparks produced by grinding, and flammable materials coming into contact with hot machine parts. TL2 Maintenance Manual 591 003 Default... -
Page 24: Tl2 Maintenance Manual
Open the pipe or hose connection of the damaged pressure line carefully, as liquid or gas under high pressure can flow from the connection. Risks There are injury risks in connection with work on: TL2 Maintenance Manual 591 003 Default... -
Page 25: Tl2 Maintenance Manual
The air conditioning system operates with refrigerant at high pres‐ sure. Escaping refrigerant can cause freeze burns. Heated refrigerant, for example during the repair of leaks in the air conditioning system, produces gases that are very toxic if inhaled. TL2 Maintenance Manual 591 003 Default... -
Page 26: Tl2 Maintenance Manual
If the engine must be operated in enclosed spaces, use an exhaust gas extractor to lead the exhaust gas out. Connect the exhaust gas extractor hose to the exhaust pipe to prevent the exhaust gases from flowing to the workshop. TL2 Maintenance Manual 591 003 Default... -
Page 27: Tl2 Maintenance Manual
Drills, grinders, and other machines with rotating parts can cause severe injuries if clothes or hair get caught and are wound up in the machine. Precautions Clothing on page 5 • TL2 Maintenance Manual 591 003 Default... -
Page 28: Tl2 Maintenance Manual
Deflate the tyre before starting to work with the wheel. • Check that tyres, rims, and lock rings are intact. Never repair • damaged tyres, rims, or lock rings. Use a protective screen, hearing protection and safety glasses. • Fig. : Protective screen TL2 Maintenance Manual 591 003 Default... -
Page 29: Tl2 Maintenance Manual
Table of content C Preventive maintenance For the service personnel Maintenance programme Initial maintenance Scheduled maintenance TL2 Maintenance Manual 591 003 Default... -
Page 30: Tl2 Maintenance Manual
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Page 31: C Preventive Maintenance
Absolute cleanliness should be observed especially during regular maintenance of the hydraulic and fuel systems to to make sure that the operation of the machine is reliable. TL2 Maintenance Manual 591 003 Default... -
Page 32: Tl2 Maintenance Manual
If you notice any defects, inform your supervisor or the person responsible for the maintenance of the machine immediately..The defects must be repaired before you continue to use the machine. Store the reports carefully so that they are easily available when needed. TL2 Maintenance Manual 591 003 Default... -
Page 33: Maintenance Programme
Examine the universal joints and tighten the mounting see: 3 Driveline / axle Change the wheel hub oil see: 4 Brakes Maintenance item Reference 4 Brakes Examine and, if necessary, adjusting the brake system see: TL2 Maintenance Manual 591 003 Default... -
Page 34: Scheduled Maintenance
Note Reference 1.7 Cooling system Examine the radiator see: 1.7 Cooling system Examine the radiator hoses see: 1.7 Cooling system Examine the cooling fan see: 1.6 Intake and exhaust Examine intake see: system piping TL2 Maintenance Manual 591 003 Default... -
Page 35: Tl2 Maintenance Manual
1.5 Mechanical Engine steam cleaning 2000 see: components of the engine 1.5 Mechanical Examine crankcase 2000 see: components of the engine breather tube 1.5 Mechanical Examine vibration 2000 see: components of the engine damper, rubber TL2 Maintenance Manual 591 003 Default... -
Page 36: Driveline/Axle
3.3 Drive axle Examine the wheel end oil see: level 3.3 Drive axle Examine the differential oil see: level Visually examine the axle see: 3.3 Drive axle 3.3 Drive axle Examine the breather 2000 see: TL2 Maintenance Manual 591 003 Default... -
Page 37: Brakes
Tighten the axle mounting see: screws 6.2 Suspension Tightening the front spring see: mounting screws 6.3 Tyres and rims Tighten the wheel mounting see: nuts 6.3 Tyres and rims Examine the tyre pressure see: TL2 Maintenance Manual 591 003 Default... -
Page 38: Tl2 Maintenance Manual
Replace the filter element of The filter must be replaced see: control, cleaning and the return filter earlier if the restriction hydraulic oil indicator is lit. 10.3 Tanks and Change the hydraulic oil 2000 see: accumulators TL2 Maintenance Manual 591 003 Default... -
Page 39: Tl2 Maintenance Manual
12.5 Filters, air dryer Replace the drying filter 1000 see: and pressure release element of the air dryer 12.5 Filters, air dryer Operation 1000 see: and pressure release pressure regulator adjust the pressure level TL2 Maintenance Manual 591 003 Default... -
Page 40: Tl2 Maintenance Manual
C Preventive maintenance – Maintenance programme Lubrication 4,5,6 4,5,6 Explanation of the symblos: Manual lubrication (at intervals of 250 running hours). If the machine is equipped with central lubrication, check only. TL2 Maintenance Manual 591 003 Default... -
Page 41: Steering
Lubricating the fifth wheel joints (2 pcs.) Holland FW 35 Lubricating the lifting cylinder ends (4 pcs.) 9 Frame, body, cab, and accessories Lubricating the cab tilt latch Lubricating the cab door locks (2 pcs.) Lubricating the cab door hinges TL2 Maintenance Manual 591 003 Default... -
Page 42: Tl2 Maintenance Manual
C Preventive maintenance – Maintenance programme TL2 Maintenance Manual 591 003 Default... -
Page 43: Tl2 Maintenance Manual
Table of content 0 Complete machine Locating faults and malfuctions Example of troubleshooting Troubleshooting cables Troubleshooting hoses TL2 Maintenance Manual 591 003 Default... -
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Page 45: Complete Machine
Check that all oil and fluid levels are normal. Engine oil • Coolant • Fuel • Hydraulic oil • Check the appropriate function description for Sections 1–12 on page and the system in the enclosed circuit diagrams. See TL2 Maintenance Manual 591 003 Default... -
Page 46: Example Of Troubleshooting
Use the function description and diagrams to check the control signals for the function to find where in the function chain that control signal or reaction is incorrect. on page 5 For more information about cables and hoses, see on page 6 . TL2 Maintenance Manual 591 003 Default... -
Page 47: Troubleshooting Cables
Use a multimeter to measure the cable resistance between the cable and the machine frame. The cable is intact if the multimeter shows constant resist‐ ance. TL2 Maintenance Manual 591 003 Default... -
Page 48: Troubleshooting Hoses
Check the hoses and hose connections of the function you are troubleshooting for abrasions, crushing, and leaks. Replace all damaged hoses and connectors with similar parts available from our spare parts department. TL2 Maintenance Manual 591 003 Default... -
Page 49: Tl2 Maintenance Manual
Table of content 1 Engine 1.2 Fuel system 1.5 Mechanical components of the engine 1.6 Intake and exhaust system 1.7 Cooling system 1.8 Lubrication system TL2 Maintenance Manual 591 003 Default... -
Page 50: Tl2 Maintenance Manual
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Page 51: Engine
Put a container below the filter. Clean the filter and the area around it. Remove the spin-on fuel filter with the fuel filter wrench. Clean the filter sealing surface of the filter bracket. TL2 Maintenance Manual 591 003 Default... -
Page 52: Tl2 Maintenance Manual
Start the engine and check for leaks. NOTE It is not necessary to vent air from the high pressure system before starting the engine. NOTE Replace the suction-side and the pressure-side fuel filters at the same time. TL2 Maintenance Manual 591 003 Default... -
Page 53: Mechanical Components Of The Engine
Replace the cooling fan drive belt . graph 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. TL2 Maintenance Manual 591 003 Default... -
Page 54: Tl2 Maintenance Manual
For cogged belts, make sure that the belt tension gauge is positioned so that the center tensioning leg is placed directly over the high point (hump) of a cog. Other positioning will result in incorrect measurement. TL2 Maintenance Manual 591 003 Default... -
Page 55: Tl2 Maintenance Manual
If any of these conditions are identified, contact an authorized repair location to replace the vibration damper. For vibration damper location, refer to engine drawings. TL2 Maintenance Manual 591 003 Default... -
Page 56: Tl2 Maintenance Manual
If any of the above conditions exist, replace the crankcase breather tube. Contact an authorized repair location. If equipped, inspect the crankcase breather catch bottle for the following conditions: Cracks • Holes • General damage • TL2 Maintenance Manual 591 003 Default... -
Page 57: Tl2 Maintenance Manual
Do not use pneumatic tools to remove the breather cover cap‐ screws. Damage to the rocker cover can result. Remove the filter cover. NOTE Make note of the locations of the crankcase ventilation filter cover studs during dissassembly. TL2 Maintenance Manual 591 003 Default... -
Page 58: Tl2 Maintenance Manual
Some solvents are flammable and toxic and could cause severe injury. When using solvents, acids, or alkaline materials for cleaning, fol‐ low the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. TL2 Maintenance Manual 591 003 Default... -
Page 59: Tl2 Maintenance Manual
The gasket must be fully seated around the entire perimeter of the rocker lever cover groove. Apply clean 15W-40 engine oil to the o-rings on the crankcase ventilation filter. Install the filter onto the rocker lever cover. TL2 Maintenance Manual 591 003 Default... -
Page 60: Tl2 Maintenance Manual
One or two capscrews directly mount the breather tube connection to the rocker lever cover. Remove the cap‐ screws to disconnect the breather tube connection from the rocker lever cover. TL2 Maintenance Manual 591 003 Default... -
Page 61: Tl2 Maintenance Manual
Capscrew mounted rocker lever cover Examine the gasket for cracks on the sealing surface. NOTE Examine the gasket while it is installed in the valve cover. Once the gasket is removed from the cover it must be replaced. TL2 Maintenance Manual 591 003 Default... -
Page 62: Tl2 Maintenance Manual
If both of the number 1 cylinder rocker levers are loose, pro‐ ceed to the next step; If the number 1 cylinder rocker levers are not loose, rotate the crankshaft 360 degrees and proceed to the next step. TL2 Maintenance Manual 591 003 Default... -
Page 63: Tl2 Maintenance Manual
NOTE The clearance is correct when some resistance is “felt” when the feeler gauge is slipped between the crosshead and the rocker lever socket. TL2 Maintenance Manual 591 003 Default... -
Page 64: Tl2 Maintenance Manual
Install the rocker lever cover over the mounting capscrews. Install the isolators and mounting nuts. Tighten the mounting nuts. Tightening torque 24 Nm (212 in- lb). Stud mounted rocker lever cover Capscrew mounted rocker lever cover TL2 Maintenance Manual 591 003 Default... -
Page 65: Tl2 Maintenance Manual
Steam is the best method of cleaning a dirty engine or a piece of equipment. If steam is not available, use a solvent to wash the engine. Protect all electrical components, openings, and wiring from the full force of the cleaner spray nozzle. TL2 Maintenance Manual 591 003 Default... -
Page 66: Intake And Exhaust System
If needed, disassemble and clean. Examine air compressor mounting NOTE Depending on the application, it is possible engines will not be equip‐ ped with an air compressor. TL2 Maintenance Manual 591 003 Default... -
Page 67: Tl2 Maintenance Manual
Wear appropriate eye and face protection when using compressed air. Stop the engine. Open the drain valve on the wet tank to release the system air pressure Remove the air compressor discharge line from the air com‐ pressor. TL2 Maintenance Manual 591 003 Default... -
Page 68: Tl2 Maintenance Manual
Examine the air cleaner restriction CAUTION Never operate the engine without an air cleaner. Intake air must be filtered to prevent dirt and debris from entering the engine and caus‐ ing premature wear. TL2 Maintenance Manual 591 003 Default... -
Page 69: Tl2 Maintenance Manual
The red flag (A) in the window gradually rises as the cartridge loads with dirt. When air restriction is indicated the air filter must be replaced. After changing or replacing the cartridge, reset the indica‐ tor by pushing the reset button (B). TL2 Maintenance Manual 591 003 Default... -
Page 70: Cooling System
On applications that do not use a coolant recovery system, the top tank of the radiator is used to check and top off the coolant level. Never remove the radiator cap when the cooling system is hot. TL2 Maintenance Manual 591 003 Default... -
Page 71: Tl2 Maintenance Manual
Use a refractometer to examine the antifreeze concentration. CAUTION Never mix more than 60% concentrated coolant with water. A greater concentration provides reduced cooling effect with the risk for overheating and reduced frost protection. TL2 Maintenance Manual 591 003 Default... -
Page 72: Tl2 Maintenance Manual
Isolate the engine from the vehicle cooling system by closing coolant flow valves to the equipment heating systems before initiating repair. This will prevent the heater circuit from drain‐ ing, minimizing the chance for air pockets to be present during TL2 Maintenance Manual 591 003 Default... -
Page 73: Tl2 Maintenance Manual
An air vent port connection, which connects to the top tank/ • coolant recovery tank of the cooling system, is located next to the water outlet This provides adequate venting for a maximum fill rate of 19 liters (5 gal) per minute. TL2 Maintenance Manual 591 003 Default... -
Page 74: Tl2 Maintenance Manual
80°C (176°F). Turn the engine OFF. Allow the coolant temperature to drop to 50° C (122° F) before draining the cooling system. Drain the cooling system. Repeat the procedure with good quality plain water. TL2 Maintenance Manual 591 003 Default... -
Page 75: Tl2 Maintenance Manual
The illustration is for reference only. If applicable, open the manual bleed valve before filling the cooling system. Once properly filled, make sure to close the manual bleed valve. TL2 Maintenance Manual 591 003 Default... -
Page 76: Tl2 Maintenance Manual
Use compressed air to blow out the dirt and debris. Measurements Air pressure: Examine for bent or broken fins. Examine for radiator core and gasket leaks. If the radiator must be replaced, refer to the equipment manu‐ facturer's replacement procedures. TL2 Maintenance Manual 591 003 Default... -
Page 77: Tl2 Maintenance Manual
Make the pressure-test to the radiator cap. Refer to the OEM service manual for radiator cap test procedures. The pressure cap must get sealed within 14 kPa [2 psi] of the value specified on the cap, or it must be replaced. TL2 Maintenance Manual 591 003 Default... -
Page 78: Tl2 Maintenance Manual
A bent or damaged fan blade can fail during operation and cause personal injury or property damage. Replace original equipment fan that is damaged with a fan of the identical part number. Refer to the vehicle or equipment manufacturer's specifica‐ tions for capscrew torque. TL2 Maintenance Manual 591 003 Default... -
Page 79: Tl2 Maintenance Manual
The belt should be centered on, or close to the middle of, the pulley. Misaligned belts, either too far forward or back‐ ward, can cause belt wear, belt roll-offs, or increase uneven tensioner bushing wear. TL2 Maintenance Manual 591 003 Default... -
Page 80: Tl2 Maintenance Manual
NOTE Always replace the belt when a tensioner is replaced. However, it is not always necessary to replace a tensioner when a belt is replaced. Tensioner cap Tensioner arm Spring case Tensiner pulley TL2 Maintenance Manual 591 003 Default... -
Page 81: Tl2 Maintenance Manual
Belt damage can be caused by: Incorrect tension • Incorrect size or length • Pulley misalignment • Incorrect installation • Severe operating environment • Oil or grease on the side of the belts. • TL2 Maintenance Manual 591 003 Default... -
Page 82: Tl2 Maintenance Manual
Water pump pulley Refrigerant compressor pulley .Alternator pulley Tensioner idler pulley NOTE Some engine driven belts are installed/supplied by the vehicle's origi‐ nal equipment manufacturer (OEM). See the OEM service manual for removal and installation instructions. TL2 Maintenance Manual 591 003 Default... -
Page 83: Tl2 Maintenance Manual
NOTE Make a diagram of the belt arrangement prior to removing the drive belt. This aids in installation and proper routing of the cooling fan drive belt. TL2 Maintenance Manual 591 003 Default... -
Page 84: Tl2 Maintenance Manual
The dirt can be removed with a suitable tool to examine for wear. Clean, examine, and reuse all pulleys in the front end acces‐ sory drive if not damaged, rather than replacing. Pulleys dam‐ aged from embedded debris must be replaced. TL2 Maintenance Manual 591 003 Default... -
Page 85: Tl2 Maintenance Manual
Operate the engine and check for belt squeal. Excessive belt squeal indicates belt slippage. If belt squeal is present, check the routing of the belt to make sure that the belt is installed correctly on each pulley. TL2 Maintenance Manual 591 003 Default... -
Page 86: Lubrication System
Turn OFF the engine. Put a container below the oil drain hole. Remove the oil drain plug. Drain the oil immediately to make sure all the oil and contaminants are removed from the engine. TL2 Maintenance Manual 591 003 Default... -
Page 87: Tl2 Maintenance Manual
Remove the filter with an oil filter wrench. Clean the gasket surface of the filter head. NOTE The O-ring may be stuck on the filter head. Make sure it is removed before installing the new filter. TL2 Maintenance Manual 591 003 Default... -
Page 88: Tl2 Maintenance Manual
Install the filter onto the oil filter head. Tighten the filter until the gasket contacts the filter head surface. Tighten 3/4 to 1 turn after the gasket makes contact with the filter head. TL2 Maintenance Manual 591 003 Default... -
Page 89: Tl2 Maintenance Manual
Table of content 2 Transmission 2.3 Mechanical transmission 2.6 Lubrication system 2.7 Cooling system TL2 Maintenance Manual 591 003 Default... -
Page 90: Tl2 Maintenance Manual
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Page 91: Tl2 Maintenance Manual
Dented, worn, or out-of-phase driveline U-joints and slip • fittings Clogged or dirty breather • Transmission fluid for evidence of engine coolant • Tighten the transmission mounting screws The transmission bracket is mounted on the tractor frame with four mounting screws. TL2 Maintenance Manual 591 003 Default... -
Page 92: Tl2 Maintenance Manual
The amount of dust and dirt determines the frequency of breather cleaning. Be careful when cleaning the transmission exterior. Spraying steam, water, or cleaning solution directly at the breather may force the water or cleaning solution into the transmission. TL2 Maintenance Manual 591 003 Default... -
Page 93: Tl2 Maintenance Manual
Use a thin 14 mm wrench or a deep 22 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. TL2 Maintenance Manual 591 003 Default... -
Page 94: Tl2 Maintenance Manual
Cold examination procedure determines if the transmission has enough oil to be operated safely until a hot examination can be made. Hot examination procedure determines if the transmission has cor‐ rect oil level with normal operating temperature. TL2 Maintenance Manual 591 003 Default... -
Page 95: Tl2 Maintenance Manual
COLD EXAMINATION band. Refer to the previous fig‐ ure. Make a hot examination at the first opportunity after normal operating temperature (71 - 93°C) is reached. TL2 Maintenance Manual 591 003 Default... -
Page 96: Tl2 Maintenance Manual
Replace the transmission oil filters The oil filters are located at the bottom of the transmission. There are two filters, prefilter and oil filter. It is easier to replace the filters one by one. TL2 Maintenance Manual 591 003 Default... -
Page 97: Tl2 Maintenance Manual
Remove the screws of the oil filter lid and remove the filter. Install the filter cartridge and its seals as shown in the figure. Tighten the lid screws. Start the engine. Check the connections for oil leaks. TL2 Maintenance Manual 591 003 Default... -
Page 98: Tl2 Maintenance Manual
Transmission oil cooler is fitted at the engine radiator. The circula‐ tion of oil to the cooler is controlled automatically. Cooling hose from the transmission to cooler Cooling hose from the cooler to transmission TL2 Maintenance Manual 591 003 Default... -
Page 99: Tl2 Maintenance Manual
Table of content 3 Driveline / axle 3.2 Propeller shaft 3.3 Drive axle TL2 Maintenance Manual 591 003 Default... -
Page 100: Tl2 Maintenance Manual
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Page 101: Tl2 Maintenance Manual
Tightening torque 160 Nm (118 ft-lb). Each end of the propeller shaft has four mounting plates with two mounting screws. Examine the universal joints for: Visible wear in the joints • Radial and lateral play (free movement) • TL2 Maintenance Manual 591 003 Default... -
Page 102: Tl2 Maintenance Manual
Examine to ensure that air escapes through the breather (A). Clean the breather as necessary. NOTE Do not blow the air with high pressure. Do not blow the air from the breather towards the axle casing. TL2 Maintenance Manual 591 003 Default... -
Page 103: Tl2 Maintenance Manual
Let the oil drain to the correct level. If the oil level is below the bottom of the fill plug hole: • Add the specified oil. Install and tighten (70-90 Nm) the oil level inspection plug (A). TL2 Maintenance Manual 591 003 Default... -
Page 104: Tl2 Maintenance Manual
The oil level is correct when the oil stops flowing. Install and tighten (70-90 Nm) the oil level inspection plug (A). Wipe the excess oil off the outer surface of the axle. TL2 Maintenance Manual 591 003 Default... -
Page 105: Tl2 Maintenance Manual
Table of content 4 Brakes 4.3 Power assisted brake system TL2 Maintenance Manual 591 003 Default... -
Page 106: Tl2 Maintenance Manual
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Page 107: Tl2 Maintenance Manual
Use a wrench to turn the adjusting nut (A) clockwise until the brake shoes contact the drum. Then turn the adjusting nut (A) counterclockwise 3/4 turn. Test the vehicle before you return it to service. NOTE Do not use electric or pneumatic wrench. TL2 Maintenance Manual 591 003 Default... -
Page 108: Tl2 Maintenance Manual
4 Brakes – 4.3 Power assisted brake system Lubricate the s-cam and slack adjusters Lubricate the s-cam through the grease fitting (A). Lubricate the slack adjuster through grease fitting(B). TL2 Maintenance Manual 591 003 Default... -
Page 109: Tl2 Maintenance Manual
Table of content 5 Steering 5.2 Power assisted system 5.2.1 Front axle Wheel alignment TL2 Maintenance Manual 591 003 Default... -
Page 110: Tl2 Maintenance Manual
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Page 111: Tl2 Maintenance Manual
If the cross tube is bent or cracked: Replace it. • If the clamps are damaged: Replace them. • If either clamp has become welded to the cross tube: • Replace the entire cross tube assembly. TL2 Maintenance Manual 591 003 Default... -
Page 112: Tl2 Maintenance Manual
– There are deep cracks or breaks in the cup, the cone CR ACK WEAR GROOVE inner race or the roller surfaces. – There are bright wear marks on the outer surface of the WEAR MARKS roller cage. TL2 Maintenance Manual 591 003 Default... -
Page 113: Tl2 Maintenance Manual
The full weight of the vehicle must be on the axle assembly. Clean all grease fittings before you lubricate the king pins. Lubricate the king pins through the top (A) and bottom (B) grease fittings. TL2 Maintenance Manual 591 003 Default... -
Page 114: Tl2 Maintenance Manual
Align the point‐ ers with the marks on the tires. Measure and record the dis‐ tance between the pointers. Repeat Step 6 for the front of the tires. TL2 Maintenance Manual 591 003 Default... -
Page 115: Tl2 Maintenance Manual
Fig. : Top view (front side of the vehicle is above the stops. illustration) Tighten the nut and bolt on each end of the cross tube to the specified torque. Refer to the Torque specifications. Repeat Steps 1 - 8 to measure the toe dimension. TL2 Maintenance Manual 591 003 Default... -
Page 116: Tl2 Maintenance Manual
5 Steering – Wheel alignment TL2 Maintenance Manual 591 003 Default... -
Page 117: Tl2 Maintenance Manual
Table of content 6 Suspension 6.2 Suspension 6.3 Tyres and rims TL2 Maintenance Manual 591 003 Default... -
Page 118: Tl2 Maintenance Manual
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Page 119: Tl2 Maintenance Manual
Loosen each mounting nut (B). Tighten each mounting nut (B) until the nut touches the side plate. Do not bend the side plates. TL2 Maintenance Manual 591 003 Default... -
Page 120: Tl2 Maintenance Manual
Examine the tightness of the nuts after operating the machine for 1 day, at the latest. Examine the trye pressure Tyre pressure is checked when the tyre is cold. F Technical data . For correct tyre pressure, see Section TL2 Maintenance Manual 591 003 Default... -
Page 121: Load Handling
Table of content 7 Load handling 7.2 Lifting/lowering 7.9 Load carrying TL2 Maintenance Manual 591 003 Default... -
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Page 123: Tl2 Maintenance Manual
Do a functional test for load handling control in the cab. For Kalmar T2 Operator's correct instruments and controls, see Manual , Section 4 Instruments and controls , Chapter 4.6 Con‐ trol lever . TL2 Maintenance Manual 591 003 Default... -
Page 124: Tl2 Maintenance Manual
48.0mm with a 2" pin and at least 86.0mm with a 3.5" pin. Worn components must be replaced immediately. The locking jaws and slide must always be replaced as a pair. TL2 Maintenance Manual 591 003 Default... - Page 125 9 Frame, body, cab and accessories 9.1 Controls and instrumentation 9.4 Heating, ventilation and air conditioning 9.4.1 Air conditioner 9.5 Wiper / washer system 9.10 Structure and mounting of the cab 9.10.1 Cab mounting and suspension TL2 Maintenance Manual 591 003 Default...
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Page 126: Tl2 Maintenance Manual
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Page 127: Frame, Body, Cab And Accessories
Controls and instrumentation Examine the operation of the equipment in the cab Do a functional test for the equipment in the cab. For correct Kalmar T2 Operator's Manual , instruments and controls, see Section 4 Instruments and controls . -
Page 128: Heating, Ventilation And Air Conditioning
Some bubbles can Too little refrigerant and/or be seen every few a leak in the system. seconds. Switch the air conditioner immediately, contact service personnel qualified service refrigeration equipment. TL2 Maintenance Manual 591 003 Default... -
Page 129: Tl2 Maintenance Manual
The liquid is clear, Too much refrigerant. and bubbles cannot Contact service personnel be seen when the qualified service engine speed refrigeration equipment. changed. TL2 Maintenance Manual 591 003 Default... -
Page 130: Wiper / Washer System
Fill the washer fluid reservoir Remove the reservoir cap (A) and fill the reservoir with recom‐ mended fluid. Examine the frost resistance of the fluid if the machine is used in cold conditions. TL2 Maintenance Manual 591 003 Default... -
Page 131: Structure And Mounting Of The Cab
Under 2 seconds— Valve is damaged or filter is clogged. • Over 10 seconds — Valve is damaged or filter is clog‐ • ged. Replace the valve if the valve is damaged or the filter is clog‐ ged. TL2 Maintenance Manual 591 003 Default... -
Page 132: Tl2 Maintenance Manual
9 Frame, body, cab and accessories – 9.10 Structure and mounting of the cab TL2 Maintenance Manual 591 003 Default... -
Page 133: Common Hydraulics
Table of content 10 Common hydraulics 10.3 Tanks and accumulators 10.5 Hoses, pipes and valves 10.6 Temperature control, cleaning and hydraulic oil TL2 Maintenance Manual 591 003 Default... -
Page 134: Tl2 Maintenance Manual
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Page 135: Tl2 Maintenance Manual
Be careful not to discharge oil into the environment. Use an appro‐ priate container, and deliver the oil to a hazardous waste collection point. Take care to ensure absolute cleanliness. Impurities in oil cause damage to the system. TL2 Maintenance Manual 591 003 Default... -
Page 136: Tl2 Maintenance Manual
Examine to ensure that air escapes through the breather hose (A). If the hose is clogged, replace the hose. NOTE Do not blow the air with high pressure. Do not blow the air from the breather towards the hydraulic tank. TL2 Maintenance Manual 591 003 Default... -
Page 137: Tl2 Maintenance Manual
The condition and tightness 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 wheel floating. TL2 Maintenance Manual 591 003 Default... -
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Take care to ensure absolute cleanliness. Impurities in oil cause damage to the system. Remove the cover (B). Replace the filter element (A). Close the cover (B). TL2 Maintenance Manual 591 003 Default... -
Page 139: Common Electrics
Table of content 11 Common electrics 11.3 Batteries 11.4 Alternator TL2 Maintenance Manual 591 003 Default... -
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Ensure that the batteries are fastened securely. Clean the batteries externally. Clean battery terminals and cable lugs to remove the oxide layer, if necessary. Use protective grease on the cable lugs. TL2 Maintenance Manual 591 003 Default... -
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(-) battery cable first and attach the negative (-) battery cable last. Remove and inspect the battery cables and connections (A) for cracks or corrosion. Replace broken terminals, connectors, or cables. TL2 Maintenance Manual 591 003 Default... -
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If the connections are corroded, use a battery brush or wire brush to clean the connections until shiny. Make sure all debris is removed from the connecting surfaces. Install the cables and tighten the battery connections. Coat the terminals with grease to prevent corrosion. TL2 Maintenance Manual 591 003 Default... -
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Examine the alternator Clean the alternator externally. Examine that the alternator is securely fastened. Examine the fastening and condition of the alternator cables. Be careful not to ground or short-circuit the wires with each other. TL2 Maintenance Manual 591 003 Default... -
Page 145: Common Pneumatics
Table of content 12 Common pneumatics 12.2 Tanks and accumulators 12.5 Filters, air dryer and pressure release TL2 Maintenance Manual 591 003 Default... -
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The air tanks are located under the chassis. 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. TL2 Maintenance Manual 591 003 Default... -
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The air dryer is fitted with a replaceable element, which includes a coarse filter and drying agent that binds humidity. The air dryer is located on the front left corner. Remove the drying filter element (B). Install new drying filter element. TL2 Maintenance Manual 591 003 Default... -
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Table of content D Error codes Engine Engine error codes (Cummins) Transmission TL2 Maintenance Manual 591 003 Default... -
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Intake Manifold Pressure Sensor Circuit - data incorrect Intake Manifold Temperature Sensor #1 Circuit - shorted hig Intake Manifold Temperature Sensor #1 Circuit - shorted low Intake Manifold Temperature #1 High - Critical Intake Manifold Temperature High – Warning TL2 Maintenance Manual 591 003 Default... -
Page 152: Tl2 Maintenance Manual
Speed Low – Warning Engine Brake Driver #1 Circuit - shorted low Accelerator Pedal Idle Validation Circuit - data incorrect Accelerator Pedal Idle Validation Circuit - out of calibration Accelerator Pedal Idle Validation Circuit - shorted TL2 Maintenance Manual 591 003 Default... -
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Injector Solenoid Valve Cylinder #3 Circuit – open circuit Injector Solenoid Valve Cylinder #4 Circuit - grounded circuit Injector Solenoid Valve Cylinder #4 Circuit – open circuit Injector Solenoid Valve Cylinder #5 Circuit – grounded circuit TL2 Maintenance Manual 591 003 Default... -
Page 154: Tl2 Maintenance Manual
1077 Fuel Pump Control Module, Idle Validation Error 1077 Fuel Pump Control Module, Fuel Shutoff Error 1077 Fuel Pump Control Module, Self-Test Error 1077 Fuel Pump Control Module, Fueling or Engine Speed Mismatch 1077 TL2 Maintenance Manual 591 003 Default... -
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Auxiliary Pressure Sensor Input # 2 Circuit – shorted low 1387 Auxiliary Equipment Sensor Input # 2 (OEM Pressure Sensor) Engine Protection – Warning 1387 Additional OEM/Vehicle Diagnostic Codes have been logged. Check other ECM's for DTC's. 1484 TL2 Maintenance Manual 591 003 Default... -
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D Error codes – Transmission Transmission Error code table TL2 Maintenance Manual 591 003 Default... -
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D Error codes – Transmission TL2 Maintenance Manual 591 003 Default... -
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D Error codes – Transmission TL2 Maintenance Manual 591 003 Default... -
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Table of content E Schematics Hydraulic Electric Pneumatic TL2 Maintenance Manual 591 003 Default... -
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E Schematics – Hydraulic Schematics Hydraulic TL2 Maintenance Manual 591 003 Default... -
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E Schematics – Electric Electric TL2 Maintenance Manual 591 003 Default... -
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E Schematics – Pneumatic Pneumatic TL2 Maintenance Manual 591 003 Default... -
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E Schematics – Pneumatic TL2 Maintenance Manual 591 003 Default... -
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Table of content F Technical data Specifications and dimensional drawing Specifications Oil, grease and fluid volumes and quality Tightening torques, units of measurement and conversion tables TL2 Maintenance Manual 591 003 Default... -
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Page 175: F Technical Data
[2621.09] 98 [2489.2] R 56.7 [1440.26] TO REAR AXLE BRKT 187.4 [4760] [243.94] UP 5.49 [139.57] DOWN 126.42 [3211.05] 63.56 [1614.39] UP 46.37 [1177.88] DOWN 74.02 [1880] 46.39 0.98 80.43 REAR [2946.4] [25.01] [1178.25] [2043] TL2 Maintenance Manual 591 003 Default... -
Page 176: Specifications
Model Allison 3000im Operating Automatic transmission with torque converter principle Front axle Hande 5.5 Front axle Hande 5.5 Rated axle 5500 kg load Brake Size 410 mm x 160 mm Steering Mechanical steering arm TL2 Maintenance Manual 591 003 Default... -
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Front axle Leaf springs, attached with pivot pins to the tractor frame and with clamps to the axle. Rear axle On the standard tractors, the rear axle is bolted rigidly to the tractor frame. TL2 Maintenance Manual 591 003 Default... -
Page 178: Tl2 Maintenance Manual
The flow for the steering is determined by the load information coming from the steering device. If steering is not in operation, no hydraulic oil flow is directed to the steering cylinders. Steering 100 bar hydraulics pressure value TL2 Maintenance Manual 591 003 Default... -
Page 179: Tl2 Maintenance Manual
8.0 bar. Compressor Approximately 500 litres per minute (Depends output on engine type and RPM). Compressed 3 tanks: 89 litres. air tank volume TL2 Maintenance Manual 591 003 Default... -
Page 180: Oil, Grease And Fluid Volumes And Quality
ASTM4985 or ASTM D6210 Diesel fuel NOTE Never fill the fuel tank to more than 90% of the capacity. Diesel fuel Fuel tank volume 300 l Fuel quality High-quality ultra-low sulphur diesel fuel Classification EN590 TL2 Maintenance Manual 591 003 Default... -
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GL-5 Cab tilt hydraulics Cab tilt pump hydraulic oil Cab tilt pump reservoir volume 1,9 l Hydraulic oil quality Hydraulic oil, Dextron III Ambient temperature -30 °C - +10 °C Classification ISO VG 32 TL2 Maintenance Manual 591 003 Default... -
Page 182: Tl2 Maintenance Manual
ESSO Beacon EP1, MOBIL Mobilgrease HP222, Shell Alvania EP1, CASTROL APS 2. Classification NLGI 1 Temperatures below -10 °C, use NLGI 0 Pneumatic system Air system pressure Nominal air pressure 8,3 - 8,9 bar TL2 Maintenance Manual 591 003 Default... -
Page 183: Tightening Torques, Units Of Measurement And Conversion Tables
1.36 = Nm x 0.102 = kg·m x 7.22 = lb·ft Pressure (Pa = N/ m x 4.0 = in. H x 0.249 = kPa x 0.30 = in. Hg x 3.38 = kPa TL2 Maintenance Manual 591 003 Default... -
Page 184: Tl2 Maintenance Manual
Flow factor l / min (dm / min) x 0.264 = US gal / min x 3.785 = l/min Conversion table, length Unit mile 0.01 0.00001 0.3937 0.03281 0.01094 0.000006 0.001 39.37 3.2808 1.0936 0.00062 TL2 Maintenance Manual 591 003 Default... -
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35.315 1.30796 1000 0.001 61.024 0.035315 0.001308 16.387 0.000016 0.01638 0.000578 0.000021 28316.8 0.028317 28.317 1728 0.03704 764529.8 0.76453 764.53 46656 1 gal (US) = 3785.41 cm = 231 in = 0.83267 gal (UK) TL2 Maintenance Manual 591 003 Default... -
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100000 14.5037 2088.6 Pa=N/ m 0.00001 0.001 0.001 0.00015 0.02086 0.01020 0.01 1000 0.14504 20.886 lbf/in 0.07032 0.0689 6894.76 6.89476 lbf/ft 0.00047 0.00047 47.88028 0.04788 0.00694 kg/cm = 735.56 Torr (mmHg) = 0.96784 atm TL2 Maintenance Manual 591 003 Default... -
Page 187: Tl2 Maintenance Manual
Table of content G Appendixes Warranty information Garantiehinweise Información sobre la garantía Information sur la garantie Garanti information Takuutodistus TL2 Maintenance Manual 591 003 Default... -
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Page 189: Warranty Information
General This warranty book is a valuable document that will help the owner to gain maximum use of the Kalmar product to which the warranty applies. The product is supplied by Cargotec, which is the legal entity responsible under this warranty. -
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Warranty coverage for large components (e.g. engines, transmis‐ sions, generators, inverters, electrical drive- and hoist motors) is based on original component manufacturer’s warranty terms and conditions.Contact your local Kalmar repre-sentative with any ques‐ tions regarding component warranties. Governing law This warranty shall be governed and interpreted in accordance with the laws of Finland, excluding, however, the provisions contained in the Finnish Act (796/1988) on International Sales of Goods. -
Page 192: Garantiehinweise
Betriebsanleitung und im Wartungshandbuch genau zu beachten. Im Rahmen der Wartung und Reparatur dieses Produkts dür‐ • fen nur solche Ersatzteile verwendet werden, die die Kalmar Spezifikationen erfüllen. Ausgewechselte Teile sind für eine Überprüfung aufzubewah‐ • ren, bis über den Garantieanspruch entschieden wurde. -
Page 193: Tl2 Maintenance Manual
Cargotec gelieferten Ersatzteilen Mängel auftreten; (e) die in einer Art und Weise benutzt, gewartet oder unterhalten wurden, die nicht den Vorschriften in den Betriebs- und Wartungsanleitun‐ gen von Cargotec entsprechen; oder (f) wenn die oben beschriebe‐ TL2 Maintenance Manual 591 003 Default... -
Page 194: Tl2 Maintenance Manual
Die Gewährleistung für große Bauteile (z. B. Motoren, Getriebe, Generatoren, Umrichter, elektrische Antriebs- und Hebe-motoren) basiert auf den Original-Garantiebedingungen des jeweiligen Hers‐ tellers. Setzen Sie sich bitte mit Ihrem örtlichen Kalmar-Vertreter in Kontakt, wenn Sie Fragen zur Garantie bzgl. einzelner Bauteile haben. -
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Wird ein Teil dieser Garantie aufgrund eines geltenden Gesetzes nicht auf der Basis des finnischen Rechts behandelt oder ausgelegt, so beeinträchtigt dies in keiner Weise die Anwendbarkeit des finni‐ schen Rechts auf andere Teile dieser Garan-tie. TL2 Maintenance Manual 591 003 Default... -
Page 196: Información Sobre La Garantía
En los casos en los que resulte necesario, y conforme a las • condiciones de la entrega, deberá efectuarse una inspec-ción de la entrega por la línea de productos de Kalmar o por el rep‐ resentante autorizado de los productos Kalmar. El producto debe manejarse y conservarse siguiendo estricta‐... -
Page 197: Tl2 Maintenance Manual
Cargotec; (e) se haya utilizado, conservado o reparado de una forma no compatible con el manual de instrucciones y las instrucciones de mantenimiento de Cargotec; o que (f) las condi‐ TL2 Maintenance Manual 591 003 Default... -
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Por favor, contacte con su representante local de Kalmar para cualquier consulta referente a la gar-antía de un component. -
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Page 200: Information Sur La Garantie
Une inspection doit être effectuée à la livraison par les respon‐ • sables de la gamme de produits Kalmar ou par le représentant des produits Kalmar agréé, lorsque cette mesure est requise conformément aux conditions de livraison. Le produit doit être utilisé et entretenu conformément aux •... -
Page 201: Tl2 Maintenance Manual
Cargotec; ou (f) les conditions de l’applicabilité de la garantie, telles que décrites ci-dessus, n’ont pas été remplies. Cette garantie ne couvre pas les réglages mécaniques ordinaires tels que décrits et expliqués dans le manuel d’utilisation et les TL2 Maintenance Manual 591 003 Default... -
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Pour toute ques-tion concernant la garantie d'un quelconque composant, contactez votre représentant local Kalmar. Loi directrice Cette garantie doit être régie et interprétée conformément à la légis‐ lation finlandaise, exception faite, cependant, des provisions conte‐ TL2 Maintenance Manual 591 003 Default... -
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être régie par et inter‐ prétée conformément à la législation finlandaise, cette exception n’affecte en aucun cas l’applicabilité de la législation finlandaise aux autres parties de cette garantie. TL2 Maintenance Manual 591 003 Default... -
Page 204: Garanti Information
Garanti information Allmänt Denna Garantibok är en värdehandling som skall hjälpa ägaren att få största utbyte av sin Kalmar-produkt (produkten) som garantin avser. Produkten är levererad av Cargotec som är juridiskt ansvarig enhet för denna garanti. Innan produkten tas i bruk måste följande beaktas: Läs noga ige‐... -
Page 205: Tl2 Maintenance Manual
Oberoende av föregående villkor, förblir Cargotecs obligatoriska ansvar, enligt varje tillämplig lagstiftning avseende produkt ansvar, som kan träda i kraft, oförändrat. Cargotec åtar sig inte något ans‐ var för utfästelser eller garantier avseende produkten eller dess TL2 Maintenance Manual 591 003 Default... -
Page 206: Tl2 Maintenance Manual
Garantins täckning för stora komponenter (t.ex. motorer, transmis‐ sioner, generatorer, växelriktare, elektriska driv- och spelmotorer) baseras på den ursprungliga komponenttillverkarens garantivillkor. Kontakta din lokala Kalmar-representant om du har frågor som rör komponentgarantier. Tillämplig lag Denna garanti skall tolkas och tillämpas i enlighet med finsk lag, dock med undantag av villkoren i den finska lagen (796/1988) om internationell försäljning av varor. -
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G Appendixes – Takuutodistus Takuutodistus Yleistä Tämä takuutodistus on dokumentti, jonka tarkoituksena on auttaa Kalmar tuotteen omistajaa saamaan täysi hyöty hankkimastaan koneesta. Tuotteen on toimittanut Cargotec, joka vastaa tästä takuusitoumuksesta. Ennen tuotteen käyttöönottoa huomaa seuraava: Lue huolellisesti tuotteen mukana toimitettu käyttö- ja huolto-ohjekirja. Jos kirjaa ei ole toimitettu tai jos sitä... -
Page 208: Tl2 Maintenance Manual
Kaikissa olosuhteissa Cargotecin vastuu mistä tahansa vahingosta rajoittuu tuotteen ostohintaan. Huolimatta edellämainituista ehdoista Cargotecin lainmukainen tuo‐ tevastuu säilyy muuttumattomana. Cargotec ei hyväksy mitään vel‐ voiteitta koskien tuotteeseen liittyvien osien ja komponenttien TL2 Maintenance Manual 591 003 Default... -
Page 209: Tl2 Maintenance Manual
Suomen lain (796/1988) ehdot kansainvälisestä tavara-kaupasta. Jos jokin pakottava sääntö sovellettavassa laissa vaatii ettei tämän takuun jotain kohtaa voida tulkita Suomen lain mukai-sesti, se ei millään tavoin vaikuta Suomen lain sovellettavuuteen muissa tämän takuun kohdissa. TL2 Maintenance Manual 591 003 Default... -
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G Appendixes – Takuutodistus TL2 Maintenance Manual 591 003 Default... - Page 211 Index Air conditioner 9 - 4 Propeller shaft 3 - 3 Alternator 11 - 6 Reading this manual A - 7 Appendixes G - 3 Safety B - 3 Batteries 11 - 3 Safety instructions B - 4 Brakes 4 - 3 Scheduled maintenance C - 6 Cab mounting and suspension 9 - 7 Schematics E - 3...
- Page 213 With Kalmar 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.
- Page 216 +1-785-242-2200 Published by Kalmar, part of Cargotec. Copyright ©Cargotec 2015. All rights reserved. No part of this publication may be copied or reproduced without permission of the copyright owner. The content of this document is provided “as is”, without warranties of any kind with regards to its accuracy or reliability and excluding all implied warranties.
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