Page 1 Handbook Engine Transmission,drive 180-250 axle, brakes This Handbook deals with the design and maintenance of Kalmar LMV forklift trucks, type DCD. In addition, it gives details of troubleshooting and the most common Steered axle corrective maintenance. Operation and other matters that are primarily of interest to the operator are included in the Instruction Manual.
Page 3: Table Of Contents
DCD 180-250 9213 97-11 Contents Technical Handbook Publ. Gr. P. Contents Group 00 Safety regulations..............2 Applications ................5 Design – gerneral survey ............6 Component units ..............6 Main components ..............9 Supplementary books .............. 9 Replacement system – Spare parts ......... 9 Tools ..................
Page 4: Safety Regulations
Therefore, read the instruction book very carefully before operating the truck. The instruction manual con- tains important information about your Kalmar LMV truck, about the operation of the truck, about safety during operation and about the truck’s daily maintenance. In addition, you will find use- ful information that will make operations easier for you in your dai- ly work.
Page 5 Never try to The truck may not, without specific permission from jump out of the cab. Kalmar LMV, be modified or re-built so that its func- tion or performance is altered. The parking brake can also be used as an EMER- GENCY BRAKE.
Page 6 Safety regulations DCD 180-250 9213 97-11 Technical Handbook Publ. Gr. P. Safety instructions for working with tyres Tyre changing can be dangerous and should only Rim inspection be carried out by specially trained – Check rim components periodically for fatigue personnel using proper tools and procedures.
Page 7: Applications
Publ. Gr. P. Applications The Kalmar LMV DCD 180-250 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 unex- celled.
Page 8: Design - Gerneral Survey
Publ. Gr. P. Design – general survey Kalmar LMV DCD 180-250 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.
Page 9 General DCD 180-250 9213 97-11 Technical Handbook Publ. Gr. P. Hydraulic system with – Gear type hydraulic pumps connected to take-offs on the torque converter. One pump for lifting and one for the other functions in the main hydraulics and also for the foot brake cooling circuit.
Page 10 General DCD 180-250 9213 97-11 Technical Handbook Publ. Gr. P. KL741 1. Free -visibility mast, with two lifting cylinders 5. Gearbox, combined with torque converter 2. Operator’s cab, rubber suspended cab 6. Drive axle, with hub gearing and oil-cooled hydraulic brake 3.
Page 11: Main Components
For the contents of these kits, see the Spare parts catalogue. Tools Kalmar LMV offers a wide range of tools for truck maintenance work. For further information, please contact Kalmar LVM’s service de- partment.
Page 12: Tightening Torques
9213 97-11 Technical Handbook Publ. Gr. P. Tightening torques (According to Kalmar LMV K Standards 20060.0001) The tightening torques are applicable to steel bolts and nuts tigh- tened with a torque wrench under the following conditions: Surface treatment Condition Lubrication...
Page 13 General DCD 180-250 00 11 9213 97-11 Technical Handbook Publ. Gr. P. To reduce the risk of settlement of the material and the associa- ted reduction in the preloading force if the hardness of the surfa- ce supporting the bolt head or nut is lower than 200 HB, a washer should be fitted under the bolt head and nut.
Page 14: System Of Units
General DCD 180-250 00 12 9213 97-11 Technical Handbook Publ. Gr. P. Quality 10,9 12,9 Tightening torque, Nm Condition Thread 5/16 7/16 9/16 1050 1058 1320 1560 1 1/8 1350 1200 1525 1900 2250 1 1/4 1860 1655 2100 2630...
Page 15 DCD 180-250 9213 97-11 Contents Technical Handbook Publ. Gr. P. Group 10 Chassis and cab Specification ................2 Chassi Description ................3 Chassis................3 Operator’s cab..............4 Steering column .............. 7 Pump and cylinder for cab tilting ........8 Service Changing the fresh air filter ..........
Page 16: Specifications
DCD 180-250 Specifications 9213 97-11 Technical Handbook Publ. Gr. P. Air conditioner Cab unit Circulated air flow 500-600 m Electric power consumption approx 350 W Compressor Max. speed 4000 r/min Refrigerant R134a *) Electric power consumption approx 50 W Oil capacity Zexel PAG SP-20 1.5 dl...
Page 17: Chassi Description
DCD 180-250 Chassi 9213 97-11 Description Technical Handbook Publ. Gr. P. Chassis Low-level located tilting cylinders The chassis consists of: Tiltable operator’s cab A unit construction frame built up around two box- sections for best possible strength. Mountings for the drive axle, steered axle, mast, lifting cylin- ders and transmission.
Page 18: Operator's Cab
DCD 180-250 Operator’s cab 9213 97-11 Description Technical Handbook Publ. Gr. P. 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.
Page 19 DCD 180-250 Operator’s cab 9213 97-09 Description Technical Handbook Publ. Gr. P. KL742 10 11 KL743 1. Gear selector 7. Electrical central unit FORWARD/NEUTRAL/REVERSE 1/2/3 with fuses and relays 2. Lever DIRECTION INDICATORS/HORN 8. Brake pedals, normal driving brake FRONT WINDSCREEN WASHER/ 9.
Page 20 DCD 180-250 Operator’s cab 9213 97-09 Description Technical Handbook Publ. Gr. P. KL581 37 38 39 35 36 40 41 42 43 44 45 47 48 49 50 51 KL582 54 55 56 60 59 KL580 57 58 64 62 63 21.
Page 21: Steering Column
DCD 180-250 Operator’s cab 9213 97-11 Description Technical Handbook Publ. Gr. P. 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.
Page 22: Pump And Cylinder For Cab Tilting
DCD 180-250 Operator’s cab 9213 97-11 Description Technical Handbook Publ. Gr. P. Pump and cylinder for cab tilting On trucks equipped with low-level tilt cylinders, a hydraulic cylin- der is provided for tilting the cab. The hydraulic fluid pressure for this purpose is generated by a manually operated pump.
Page 23: Changing The Fresh Air Filter
DCD 180-250 Operator’s cab 9213 97-11 Service Technical Handbook Publ. Gr. P. Changing the fresh air filter (every 1000 hours) Remove the filter casing retaining bolts and remove the filter element. Fit a new filter element.
Page 24: Air Conditioning Unit Description
DCD 180-250 Air conditioning unit 9213 97-11 Description Technical Handbook Publ. Gr. P. Air conditioning unit The air conditioning unit consists of the parts shown in the illu- stration and its function is to maintain the climate in the ope- rator’s cab as comfortable as possible.
Page 25 DCD 180-250 Air conditioning unit 9213 97-09 Description Technical Handbook Publ. Gr. P. 1. Liquid receiver/filter dryer A High-pressure gas 2. Evaporator B High-pressure liquid 3. Fan C Low-pressure liquid 4. Expansion valve D Low-pressure gas 6. Condenser E Warm air in cab 7.
Page 26: Compressor
DCD 180-250 Air conditioning unit 9213 97-11 Service Technical Handbook Publ. Gr. P. 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.
Page 27: Checking The Air Conditioning Unit
DCD 180-250 Air conditioning unit 9213 97-11 Service Technical Handbook Publ. Gr. P. 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.
Page 28: Condenser Unit
DCD 180-250 Air conditioning unit 9213 97-09 Service Technical Handbook Publ. Gr. P. IN CAB UNIT CONDENSER UNIT GL 1,5 SV 1,5 RD 1,5 BR 1,5 BR 1,5 GL 1,5 VT 1,5 HIGH 1. Fan switch 2. Cooler on/off 3. Anti-freeze thermostat 4.
Page 29 DCD 180-250 9213 97-11 Contents Technical Handbook Publ. Gr. P. Group 20 Electrical system Specifications ................2 Electrical system ..............3 Description ................3 Checking the electrolyte level of the batteries....5 Fuses ................5 Bulbs ................5 Relays ................6 Starting from another battery ...........6 Cable markings ..............7 Manual electric gear-changing system Clark 32000, fixed operator’s seat...
Page 30: Specifications
DCD 180-250 Specifications 9213 97-11 Technical Handbook Publ. Gr. P. Alternator rating 1540 W Starting battery, voltage 2 x 12 V capacity 135 Ah earthing negative...
Page 31: Electrical System
DCD 180-250 Electrical system 9213 97-11 Description Technical Handbook Publ. Gr. P. 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.
Page 32 DCD 180-250 Electrical system 9213 97-11 Description Technical Handbook Publ. Gr. P. 1. Transmitter, warning lamp low oil pressure and gearbox oil pressure instrument 2. Transmitter, warning lamphigh oil temp and gearbox oil temperature instrument 3. Fuse 4. Relay preheater element 5.
Page 33: Checking The Electrolyte Level Of The Batteries
DCD 180-250 Electrical system 9213 97-11 Description Technical Handbook Publ. Gr. P. Electrical system N.B. The electrical system operates at 24 V. The source of power The starting batteries accompanying supply are two 12 V batteries which are charged by an alternator.
Page 34: Relays
DCD 180-250 Electrical system 9213 97-11 Description Technical Handbook Publ. Gr. P. Relays Reversing light 313-1 Brake light (rear-front) ²) 313-3 Direction indicators (right-left) ²) 313-4 Direction indicators (left-right) ²) 313-5 Rear light (rear-front) ²) 313-6 Dipped beam (front-rear) ²) 313-7 Reversing light (rear-front) ²)
Page 35: Cable Markings
DCD 180-250 Electrical system 9213 97-11 Description Technical Handbook Publ. Gr. P. Cable markings All cables are marked with a number for identifying the terminal points as follows: P = Pressure Cable Destination T = Temperature η = Coolant level...
Page 36 DCD 180-250 Manual electric gear-changing system 9213 97-11 Description Technical Handbook Publ. Gr. P. 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.
Page 37 DCD 180-250 Manual electric gear-changing system 9213 97-11 Description Technical Handbook Publ. Gr. P. Clark 32000 Manual electric gearchanging Fixed operator’s seat...
Page 38: Manual Electric Gear-Changing System Clark 32000 Rotatable Operator's Seat
DCD 180-250 Manual electric gear-changing system 9213 97-11 Description Technical Handbook Publ. Gr. P. Manual electric gear-changing system Clark 32000 Rotatable operator’s seat A06526.0100 The content of this diagram can also be found integrated in the general electric diagrams DCD 90-450 in this manual.
Page 39 DCD 180-250 Manual electric gear-changing system 9213 97-11 Description Technical Handbook Publ. Gr. P. Clark 32000 Manual electric gearchanging otatable operator’s seat...
Page 40: Description
DCD 180-250 Safety interlock system 9213 97-11 Description Technical Handbook Publ. Gr. P. Safety interlock for container handling The safety interlock comprises two solwnoid valves which are activated by switches or sensors on the container attachment. The valves interrupt the servo supply from control levers to main valves in two cases: 1.
Page 41 DCD 180-250 Safety interlock system 9213 97-11 Description Technical Handbook Publ. Gr. P. Safety interlock, circuit diagram, cabin circuits...
Page 65 DCD 180-250 9213 97-11 Contents Technical Handbook Publ. Gr. P. Group 30 Volvo TWD 731 VE Specifications ................3 EngineTWD 731 VE Description ................4 Overviewl................. 4 Cooling system..............6 Fuel system ..............8 Lubrication system ............10 Combusting air system..........12 Service ................
Page 66 DCD 180-250 9213 97-11 Technical Handbook Publ. Gr. P. Volvo TWD 731 VE...
Page 67: Specifications
DCD 180-250 Specifications 9213 97-11 Technical Handbok Publ. Gr. P. Manufacturer, type TWD 731 VE Coolant volume, l Rating ISO 3046 kW (Hk) 167 (227) at r/min 2200 Torque ISO 3046, Nm at r/minl 1200 Number of cylinders Swept volume, l...
Page 68: Enginetwd 731 Ve Description
DCD 180-250 Engine TWD 731 VE 9213 97-11 Description Technical Handbook Publ. Gr. P. Overview The TWD 731 VE 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.
Page 69 DCD 180-250 Engine TWD 731 VE 9213 97-11 Description Technical Handbook Publ. Gr. P. 1. Fan hub 2. Gear driven coolant pump 3. Lift eyelet 4. Twin fuel filters of throw-away type 5. Turbo-charger 6. Air cooled exhaust manifold 7. Lift eyelet 8.
Page 70: Cooling System
DCD 180-250 Engine TWD 731 VE 9213 97-11 Description Technical Handbook Publ. Gr. P. Cooling system The engine is liquid-cooled and equipped with a closed cooling system consisting of the following main components: Coolant pump Radiator Thermostat Radiator fan Coolant passages...
Page 71 DCD 180-250 Engine TWD 731 VE 9213 97-11 Description Technical Handbook Publ. Gr. P. 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 that requires no external pipes on the engine.
Page 72: Fuel System
DCD 180-250 Engine TWD 731 VE 9213 97-11 Description Technical Handbook Publ. Gr. P. 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.
Page 73 DCD 180-250 Engine TWD 731 VE 9213 97-11 Description Technical Handbook Publ. Gr. P. 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.
Page 74: Lubricating System
DCD 180-250 Engine TWD 731 VE 9213 97-11 Description Technical Handbook Publ. Gr. P. 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.
Page 75: Lubrication System
DCD 180-250 Engine TWD 731 VE 9213 97-11 Description Technical Handbook Publ. Gr. P. 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.
Page 76: Combustion System
DCD 180-250 Engine TWD 731 VE 9213 97-11 Description Technical Handbook Publ. Gr. P. 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.
Page 77 DCD 180-250 Engine TWD 731 VE 9213 97-11 Description Technical Handbook Publ. Gr. P. 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.
Page 78: Quality Of Diesel Fuel
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 LMV part No. 923.110.0003) to the coolant, if the above mixture is not used in the cooling system.
Page 79: Changing Oil And Oil Filter
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 LMV filters. Checking the V-belt tension 1. Check at regular intervals that the V-belts are correctly tensioned.
Page 80: Checking And Adjusting The Valve Clearances
DCD 180-250 Engine TWD 731 VE 9213 97-11 Service Technical Handbook Publ. Gr. P. Checking and adjusting the valve clearances N.B. Never attempt to check the valve clearances when the engine is running. The engine must be stationary but may be cold or hot.
Page 81: Preventive Maintenance On Turbo-Charger
DCD 180-250 Engine TWD 731 VE 9213 97-11 Service Technical Handbook Publ. Gr. P. 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.
Page 83 DCD 180-250 9213 97-11 Contents Technical Handbook Publ. Gr. P. Group 40 Transmission, drive axle, brakes Specification ................2 Transmission Description ................3 Torque converter ............. 3 Gearbox................3 Oil circuit................5 Service ................. 6 Oil level check ..............6 Changing gearbox oil and filter........
Page 84: Specification
DCD 180-250 Specifications 9213 97-09 Technical Handbook Publ. Gr. P. Torque converter and gearbox Model Clark - 13.7 HR 32312 Number of gears 3F – 3R Oil capacity, total system, l Oil grade API-CD, Engine oil, see also Group 90 Oil operating temperature, °C...
Page 85: Transmission Description
DCD 180-250 Transmission 9213 97-11 Description Technical Handbook Publ. Gr. P. The transmission consists of a torque converter integrated with the gearbox, and a propeller shaft, driven axle with differential, hub reductions and brakes. The torque converter and gearbox run together, using a common hydraulic system.
Page 86 DCD 180-250 Transmission 9213 97-09 Description Technical Handbook Publ. Gr. P. 1. Turbine wheel 2. Pump impeller 3. Stator 4. Torque converter 5. Oil filter 6. Oil pump 7. Clutch disc Gearbox Clark 32000...
Page 87: Oil Circuit
DCD 180-250 Transmission 9213 97-11 Description Technical Handbook Publ. Gr. P. Oil circuit The function of the oil is: – to transmit the engine output to the gearbox. The torque converter can multiply the engine torque by up to three times, but at the expense of the speed rotation.
Page 88: Service
DCD 180-250 Transmission 9213 97-11 Service Technical Handbook Publ. Gr. P. Oil level check (transmission, incl. converter) Check the oil level daily with the engine at idling speed and the oil temperature between 82 and 93°C. Maintain the oil level at the FULL mark.
Page 89: Checking Pressures In The Clark 32000 Gearbox
DCD 180-250 Transmission 9213 97-11 Service Technical Handbook Publ. Gr. P. Checking pressures in the Clark 32000 gearbox The pressure should always be checked when the oil is at the normal working temperature of 82–93°C and the gearbox is in neutral.
Page 90: Drive Axle Rockwell Description
DCD 180-250 Drive axle Rockwell 9213 97-11 Description Technical Handbook Publ. Gr. P. The drive axle features two-stage reduction (differential and hub). Rockwell planetary axles permit the bevel or hypoid gearing of the carrier and the axle shafts to carry only a nominal torsional load while at the same time providing the highest practical gear reduction ratio at the wheels.
Page 91 DCD 180-250 Drive axle Rockwell 9213 97-11 Description Technical Handbook Publ. Gr. P. 1. Spider 5. Ring gear cog/hub 2. Sunwheel Planet wheel 3. Floating ring gear 6. Wheel hub 4. Planet spur gear 7. Axle shaft Hub reduction 1. Crown wheel 2.
Page 92: Wdb-System
DCD 180-250 Drive axle Rockwell 9213 97-11 Description Technical Handbook Publ. Gr. P. WDB-system The wet disc brake system is maintenance free, being immune to wear. Neither are the brakes prone to the fading which normally occurs under tough operating conditions. Furthermore, adjustment of the brakes is not required.
Page 93: Parking Brake System
DCD 180-250 Drive axle Rockwell 9213 97-11 Description Technical Handbook Publ. Gr. P. Parking brake system The parking brake, which is of the disc type, is mounted on the drive axle input shaft. The brake is operated by a heavy-duty spring in the parking brake cylinder and is released by hydraulic pressure of min 100 bar, counteracting the spring force.
Page 94: Service
DCD 180-250 Drive axle Rockwell 9213 97-11 Service Technical Handbook Publ. Gr. P. Changing the drive axle oil IMPORTANT: To assure that the wheel ends of planetary axles with a common wheel end/housing bowl oil level are initially lubricated, fill each wheel end directly with oil before vehicle is put back into operation.
Page 95: Parking Brake
DCD 180-250 Drive axle Rockwell 9213 97-11 Service Technical Handbook Publ. Gr. P. Parking brake – replacement of brake linings 1. Check the wheels so that the truck stands absolutely still. 2. Release the parking brake. 3. Dismantling the caliper assembly by knocking out the mounting shafts from the lugs.
Page 96: Drive Axle Kessler
DCD 180-250 Drive axle Kessler 9213 97-11 Description Technical Handbook Publ. Gr. P. Downshifting in the drive axle is in two stages: in the differential, and in the hub reduction. This gives a minimum of stresses in the power transmission system since the final torque is achieved first at the driven wheels.
Page 97: Hub Reduction
DCD 180-250 Drive axle Kessler 9213 97-11 Description Technical Handbook Publ. Gr. P. Hub reduction The hub reduction consists of a cylindrical planetary gear in each hub. The planetary gear comprises a sun gear, 4 planet gears, and a ring gear that surrounds the planet gears. When the drive axle, and thereby the sun gear, rotates, the rotational movement is transmitted to the planet gears.
Page 98: Service Brake
DCD 180-250 Drive axle Kessler 9213 97-11 Description Technical Handbook Publ. Gr. P. Service brake The service brake consists of oil-cooled discs that are alternately fixed to and rotating with the hub. Hydraulic pressure is applied to activate a piston in each hub, the discs are then pressed together, and the wheels are braked.
Page 99: Parking Brake System
DCD 180-250 Drive axle Kessler 9213 97-11 Description Technical Handbook Publ. Gr. P. Parking brake The parking brake is a disc brake that acts on the drive axle’s input shaft and is applied by means of a powerful spring in a spring brake cylinder.
Page 100: Service
DCD 180-250 Drive axle Kessler 9213 97-11 Service Technical Handbook Publ. Gr. P. Changing the drive axle oil IMPORTANT: To assure that the wheel ends of planetary axles with a common wheel end/housing bowl oil level are initially lubricated, fill each wheel end directly with oil before vehicle is put back into operation.
Page 101: Installation Of Disc Brake
DCD 180-250 Drive axle Kessler 9213 97-11 Service Technical Handbook Publ. Gr. P. Installation of disc brake 1. Insert the brake discs (4) and (5) alternately in the brake housing (2). 2. Measure the clearance A. 3. Fit the piston (3) in the brake spider (1).
Page 102 DCD 180-250 Drive axle Kessler 9213 97-11 Service Technical Handbook Publ. Gr. P. 8. Check to marke sure the brake carrier (1) is free from scratches. Lubricate all internal surfaces, fit the brake piston (3), and align it to the tapped holes.
Page 103: Installing The Brake On The Axle
DCD 180-250 Drive axle Kessler 9213 97-11 Service Technical Handbook Publ. Gr. P. Installing the brake on the axle 1. Check the sealing surfaces for the O-ring and apply a coat of LOCTITE 270 to the contact surfaces on the b rake spider.
Page 104 DCD 180-250 Drive axle Kessler 9213 97-11 Service Technical Handbook Publ. Gr. P. 8. Align and centre the discs (4) using the tool. Apply pressure to the discs with the help of the brake’s hydraulic system. 9. Fit the wheel hub onto the axle’s splines. Release the brake pressure.
Page 105 DCD 180-250 Drive axle Kessler 9213 97-11 Service Technical Handbook Publ. Gr. P. Installation of hub reduction 1. Press the spacer washer (1) onto the spindle and seal with LOCTITE 270. 2. Push the sun gear (2) onto the spindle and secure with the lock ring (3).
Page 106 DCD 180-250 Drive axle Kessler 9213 97-11 Service Technical Handbook Publ. Gr. P. 3. Push the needle bearing into the planet gear (4). The outer cardboard sleeve in which the bearings are packed will then Outer cardboard Inner slide off.
Page 107: Dismantling The Planet Gear
DCD 180-250 Drive axle Kessler 9213 97-11 Service Technical Handbook Publ. Gr. P. Dismantling the planet gear 1. Tap the safety pin out from the inside. 2. Press the planet gear shafts out from the outside and inwards in the planetary gear carrier.
Page 109 DCD 180-250 9213 97-11 Contents Technical Handbook Publ. Gr. P. Group 60 Steering axle Specifications ................2 Steering axle Description ................3 Service ................. 4 Replacement of steering cylinder ........4 Replacement of steered wheel bearings ......4 Replacement of knuckle pin bearings ......6 Inspection of dismountable rims........
Page 110: Specifications
DCD 180-250 Specifications 9213 97-11 Technical Handbook Publ. Gr. P. Tightening torques DCD 180-200 Wheel nuts, Nm 400 (41 kpm) Steered wheel bearing nuts, Nm Mounting screw M20, steering cylinder oiled bolt Nuts for lower knuckle-pin bearings, Nm Nuts for upper knuckle-pin bearings, Nm...
Page 111: Steering Axle Description
DCD 180-250 Steering axle 9213 97-11 Description Technical Handbook Publ. Gr. P. The steered axle is supported by a pendulum suspension and is operated by a double-acting steering cylinder. The mechanism includes the smallest possible number of moving parts to minimise the number of service points and to simplify maintenance.
Page 112: Replacement Of Steering Cylinder
DCD 180-250 Steering axle 9213 97-11 Service Technical Handbook Publ. Gr. P. Replacement of steering cylinder 1. Disconnect the hydraulic connections from the steering cylinder, and protect the open ends of the cylinder and hoses by means of caps or plugs.
Page 113 DCD 180-250 Steering axle 9213 97-09 Service Technical Handbook Publ. Gr. P. 1. Rubber element 2. Steering cylinder 3. Spindle 4. Locking screw 5. Lubricating nipple 6. Upper bearing 7. Wiper 8. Knuckle pin 9. Protective ring 10. Sealing ring 11.
Page 114: Replacement Of Knuckle Pin Bearings
DCD 180-250 Steering axle 9213 97-11 Service Technical Handbook Publ. Gr. P. 4. Tap the inner race of the inner bearing onto the wheel axle, using a suitable tube. Pack the inner race with grease. 5. Lift the hub onto the axle, fit the inner race of the outer bearing position and pack it with grease.
Page 115 DCD 180-250 Steering axle 9213 97-11 Service Technical Handbook Publ. Gr. P. Assembly 1. Tap the outer race of the upper bearing into the steering cradle from below, using a piece of tube. 2. Fit the screw back into the drift holes. Seal with sealing compound.
Page 116: Inspection Of Dismountable Rims
Inspection of dismountable rims Due to special operating conditions for dismountable rims, theres is a risk of excessive wear of the lock ring groove in the rim bead, the lock ring itself and the 45° face on the beadseat or loose flange.
Page 117: Inspection Procedure
Information on the minimum diameter of your rim bead can be recieved from Kalmar LMV. High stress areas, how to identify rim damage 1. High stress areas are marked with B on the illustration 2.
Page 118: Safety Test When Changing Tyres
Safety test when changing tyres The test is intended for detecting cracks in wheels. Cracks can lead to safety risks if they are not detected and remedied. Potential cracks that cause air leakage are not detected in the test described here. The test is carried out in two steps 1.
Page 119 DCD 180-250 9213 97-11 Contents Technical Handbook Publ. Gr. P. Group 70 Hydraulic system Specifications ................. 2 Main hydraulics Description ................3 General survey ............... 3 Hydraulic system, supply ..........4 Lifting ................5 Lowering brake valve ............6 Tilting................6 Fork spreading ..............
Page 120 DCD 180-250 Specifications 9213 97-11 Technical Handbook Publ. Gr. P. For different pressure settings, see the hydraulic plate on each truck Hydraulic fluid Volume, litres 270 (28-1200) 350 (20–25–1200) Grade of fluid Use a hydraulic fluid for mobile applications from a reputable oil company.
Page 121: Main Hydraulics Description
DCD 180-250 Main hydraulics 9213 97-11 Description Technical Handbook Publ. Gr. P. General survey The hydraulic system consists of the following sub-systems. Main hydraulics with the following functions: – Lifting – Tilting – Sideshifting Steering system Driving brake system for wet brakes with: –...
Page 122: Hydraulic System, Supply
DCD 180-250 Main hydraulics 9213 97-11 Description Technical Handbook Publ. Gr. P. The fluid is cleaned through a high pressure filter upstream after each pump. In its standard version, the hydraulic system is equipped with a servo-operated main valve. A pressure reducing valve in the valve block delivers 35 bar servo pressure for the control-lever valves.
Page 123: Lifting
DCD 180-250 Main hydraulics 9213 97-11 Description Technical Handbook Publ. Gr. P. Lifting The lifting cylinders are supplied from a single-acting valve spool in the main valve. The lifting speed is determined by the position of the lift control lever. The flow of fluid from the hydraulic pumps can be changed by altering the engine speed, which thus provides an additional means of controlling the lifting speed.
Page 124: Lowering Brake Valve
DCD 180-250 Main hydraulics 9213 97-11 Description Technical Handbook Publ. Gr. P. Lowering brake valve The lowering brake valves are screwed into the connecting pipes at the bottom of the cylinders. They are preset and no adjustment facilities are provided.
Page 125: Fork Spreading
DCD 180-250 Main hydraulics 9213 97-11 Description Technical Handbook Publ. Gr. P. Fork spreading The main valve opens and closes the supply of fluid to the two hydraulic cylinders at the forks. After sideshifting of one fork to right position, the fork spreading lever is used to move the other fork to intended fork distance.
Page 126: Checking The Hydraulic Hoses
DCD 180-250 Main hydraulics 9213 97-11 Service Technical Handbook Publ. Gr. P. WARNING! The hydraulic system includes a high- pressure accumulator. Open the accumulator eva- cuating valve to release pressure before working on the hydraulic system. Take great care during all work on the hydraulic system. Avoid being close to pressurized hydraulic components and hoses.
Page 127: Checking The Pressure And Settings
DCD 180-250 Main hydraulics 9213 97-11 Service Technical Handbook Publ. Gr. P. Checking the pressure and settings 1. Start the engine and allow it to idle. When making the following pressure tests, use a pressure gauge with a sufficiently long hose to enable reading from the cab.
Page 128: Steering System Description
DCD 180-250 Steering system 9213 97-11 Description Technical Handbook Publ. Gr. P. Steering system The steering system comprises the steering valve and the steering cylinder. The system is supplied with fluid from the valve block adjoining the main valve. An adjustable pressure limiting valve provides the control pressure.
Page 129 DCD 180-250 Steering system 9213 97-11 Description Technical Handbook Publ. Gr. P. Orbitrol steering valve The steering valve is of the closed centre, non-reaction type with load sensing signal connection to the valve block. The load signal gives load-dependent control of the fluid pressure from the valve block to the steering valve.
Page 130: Steering Valve
DCD 180-250 Steering system 9213 97-11 Description Technical Handbook Publ. Gr. P. Item 12 – assembly pattern Tightening torquet: 30±5 Nm 1. Dust cover 2. Body – spool – sleeve 3. Ball 4. Threaded bush 5. O-ring 6. Guide ring 17.
Page 131: Brake System Description
DCD 180-250 Brake system 9213 97-11 Description Technical Handbook Publ. Gr. P. Brakesystem – WDB-system The foot brake system is known as the wet disc brake system, in which each hub is equipped with a multiple-disc assembly. The disc assembly comprises stationary discs arranged alternately with a number of rotating discs.
Page 132: Checking The Braking System
DCD 180-250 Brake system 9213 97-11 Service Technical Handbook Publ. Gr. P. Checking the braking system The figures in the following text refer to the picture on page xx and Hydraulic circuit diagram. The checks are to be made with the hydraulic system at the working temperature.
Page 133: Parking Brake System
DCD 180-250 Parking brake system 9213 97-11 Description Technical Handbook Publ. Gr. P. Parking brake The parking brake consists of a disc brake with a brake cylinder on the drive axle input shaft. The brake is applied by a heavy spring in the brake cylinder.
Page 134: Hydraulic Pumps Description
DCD 180-250 Hydraulic pumps 9213 97-11 Description Technical Handbook Publ. Gr. P. Hydraulic pump The hydraulic pump is of the gear type and is directly driven by the engine via splines. The pump spindles are mounted in plain bearings which are lubricated by the hydraulic fluid flowing through the pump.
Page 135 DCD 180-250 Hydraulic pumps 9213 97-11 Service Technical Handbook Publ. Gr. P. Hydraulic pumps General instructions are given below for service operations that should be carried out on the pumps and how much wear is acceptable on the various components before a particular component must be replaced.
Page 136 DCD 180-250 Hydraulic pumps 9213 97-11 Service Technical Handbook Publ. Gr. P. Permissible wear of the pump components 9. Pump body The pump pressure presses the pump gears towards the walls of the body on the low-pressure side, and since the shafts and bearings wear, the pump gears will rub against the body.
Page 137: Accumulator Description
DCD 180-250 Accumulator 9213 97-11 Description Technical Handbook Publ. Gr. P. Accumulator The hydraulic system is connected to membrane type accu- mulators which are pre-charged with nitrogen at a pressure of 70 bar. The membrane is forced upward causing the pressure of the nitrogen to increase as the accumulator becomes charged with hydraulic fluid.
Page 138: High Pressure Filter
DCD 180-250 High pressure filter 9213 97-11 Description, service Technical Handbook Publ. Gr. P. High pressure filter Two high pressure filters located immediately after the pumps are used to clean the fluid. The filter head is equipped with a by-pass valve which opens at 5 bar.
Page 139: Main Valve
DCD 180-250 Main valve 9213 97-11 Description Technical Handbook Publ. Gr. P. Valve block Several hydraulic functions are concentrated to a valve block which is connected directly to the main valve. . Valve block, main functions: (Numbering is the same as in the Hydraulic Circuit Diagrams) 1.
Page 140: Main Valve Description
DCD 180-250 Main valve 9213 97-11 Description Technical Handbook Publ. Gr. P. Main valve The main valve, in its standard version, is actuated via a hydraulic servo. The valve consists of the following main components: Inlet section Control sections, corresponding to the number of functions of...
Page 141 DCD 180-250 Main valve 9213 97-11 Description Technical Handbook Publ. Gr. P. Main valve with hydraulic servo control The main valve has incorporated hydraulic actuators for setting the control valve spools. The actuators include springs which centre the spool when the actuators are not pressurized.
Page 142 DCD 180-250 Main valve 9213 97-11 Description Technical Handbook Publ. Gr. P. Control valve for servo control of the main valve The control valves are integrated into a block, and the number of valves corresponds to the number of functions of the truck.
Page 143 DCD 180-250 Main valve 9213 97-11 Service Technical Handbook Publ. Gr. P. Main valve The main valve is precision made and must be treated with great care so that its performance will not be impaired. The following rules apply whenever service work is carried out.
Page 144: Hydraulic Cylinders Service
DCD 180-250 Hydraulic cylinders 9213 97-11 Service Technical Handbook Publ. Gr. P. Repairs to leaking hydraulic cylinders – replacing the seal WARNING! Never use compressed air for remo- ving the piston from the cylinder. You could sustain serious injuries. General instruction applicable to all cylinders If necessary, see Group 80 for instructions on the dismantling of the fork carraige and mast.
Page 145: Lubrication Of Single Acting Cylinders
DCD 180-250 Hydraulic cylinders 9213 97-11 Service Technical Handbook Publ. Gr. P. Lubrication of single acting cylinders 1. This type of cylinders have no oil supply on the piston side. If the cylinders are operated in a limited stroke (1), there is a risk of corrosion damage to the upper part of the cylinder in- ner surface (4).
Page 146: Lifting Cylinder
DCD 180-250 Hydraulic cylinders 9213 97-11 Service Technical Handbook Publ. Gr. P. Lifting cylinder 1. The cylinder head is threaded into the cylinder pipe, and a C-spanner must be used for fitting and removing it. 2. When reassembling an overhauled cylinder, after the piston...
Page 147: Steering Cylinder
DCD 180-250 Hydraulic cylinders 9213 97-11 Service Technical Handbook Publ. Gr. P. Steering cylinder 1. The steering cylinder has a double-acting piston, with the piston seal in the centre. 2. A cylinder head which is secured to the cylinder pipe by a locking ring is provided at each end.
Page 148: Tilting Cylinder
DCD 180-250 Hydraulic cylinders 9213 97-11 Service Technical Handbook Publ. Gr. P. Tilting cylinder 1. Both ends of the tilting cylinder are fitted with a clevis mount. The piston rod clevis is threaded onto the piston rod and is secured by locknuts and locking plate.
Page 149: Fork Spreading And Sideshifting Cylinder
DCD 180-250 Hydraulic cylinders 9213 97-11 Service Technical Handbook Publ. Gr. P. Fork spreading and sideshifting cylinder 1. Both ends of the fork spreading and side shifting cylinder are fitted with a clevis. The piston rod clevis is threaded onto the piston rod.
Page 150: Hydraulic Diagram Components
DCD 180-250 Hydraulic diagram 9213 97-11 Components Technical Handbook Publ. Gr. P. Hydraulic circuit diagram Components A06195.0100 1. Accumulator charging valve 2. Pressure limiting valve, steering system 3. Differential valve, gives max. 11 bar difference between LS-signal of the steering valve and the pump pressure 4.
Page 151 4YFPRS +& 7YTTPIQIRX ,]HVEYPMG ']PMRHIVW 8IGLRMGEP ,ERHFSSO %PP 8VYGOW...
Page 153 All trucks 9279 02-09 Contents Technical Handbook Publ. Gr. P. Contents Clean hydraulics ................ 3 Measures to prevent pollution of the hydraulic system....4 Fault finding for leakage ............6 The function and removal of seals..........7 Piston rod seals ..............7 Support ring and O ring ............
Page 155: Clean Hydraulics
Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Clean hydraulics Hydraulic systems are extremely sensitive to impurities - a hy- draulic system is just as sensitive as a diesel engine’s fuel sys- tem, with its pumps, filters and lines. It is therefore extremely important that hydraulic systems are kept clean and free from impurities.
Page 156: Measures To Prevent Pollution Of The Hydraulic System
Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Gasses The most common gas that occurs as an impurity in a hydraulic system is air. Unlike fluids, gasses can be compressed. If air is allowed to enter a hydraulic system, this compression will be ex- perienced as a “sponginess”...
Page 157 Never fit components where the protective plugs have fallen out - impurities may have entered the system IMPORTANT! If there is the slightest doubt about the purity of the hy- draulic fluid - send a fluid sample to the manufacturer of the fluid, or to Kalmar Service...
Page 158: Fault Finding For Leakage
Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Fault finding for leakage 1. All fault finding should take place with the minimum hydraulic pressure required to actually discover the leakage. High pres- sure will tighten all seals and make it more difficult to discover any leakage.
Page 159: The Function And Removal Of Seals
Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. The function and removal of seals Piston rod seals The piston rod seal is the seal that sits in a groove in the hydraulic cylinder head forming a seal against the piston rod. This seal is very exposed as it performs both dynamic and static sealing func- tions, i.e., it is seals against the moving surface of the piston rod whilst the sealing surface against the cylinder head is static.
Page 160 Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Piston rod seal type TICLA is of compact design with integrated support ring. It has an inner sealing lip against the piston rod and an outer sealing lip which seals with press fit against the cylinder head.
Page 161: Support Ring And O Ring
Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. The compressible piston rod seal consists of a solid rubber profile and gives a greater sealing area than V seals. Use a screwdriver to remove the seal, see illustration. Lever out and twist up the seal.
Page 162: Wiper
Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Wiper The task of the wiper is to scrape the piston rod clean and prevent øD+10 any impurities being drawn into the cylinder pipe. The wiper must be fitted with a special tool. This tool must have a greater outer diameter than the wiper, so that the pressure against the wiper ceases just as the wiper is pressed into posi- tion.
Page 163: Single Action V Type Piston Seals With Support Ring
Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Single action V type piston seals with support ring On single action V seals it is always the long side that seals against the static and the short side that seals against the moving surface.
Page 164: Double Action Piston Seals
Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Double action piston seals Double action seals function with pressure from both directions, e.g., in a steering cylinder. The whole of the surface within the cylinder pipe is the sealing surface, it is therefore extremely important that this surface is not damaged in any way.
Page 165: Lubrication
Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Lubrication 1. Within the actual hydraulic system - never anything other than the normal hydraulic fluid used in the hydraulic system. 2. On the cylinder head thread - use copper paste (e.g., Moly- cote CU 7439).
Page 166: Dismantling The Steering Cylinder
Hydraulic Cylinders All trucks 9279 02-09 Service Technical Handbook Publ. Gr. S. Dismantling the steering cylinder On the steering cylinder, it can be very difficult to remove the pis- ton from the cylinder as the O ring in the cylinder head sticks in the locking ring groove of the cylinder pipe.
Page 168 [[[OEPQEVMRHGSQ % 4EVXIO 'SQTER] /EPQEV -RHYWXVMIW 7ZIVMKI %& 7) 0NYRKF] 7[IHIR XIP JE\ ...
Page 169 DCD 180-250 9213 97-11 Contents Technical Handbook Publ. Gr. P. Group 80 Lifting mast and fork carriage Specifications ................2 Lifting mast and fork carriage ..........3 Description ................3 Service ................. 4 Inspection of lifting chains ..........4 Inspection of the lifting mast..........5 Wear inspection –...
Page 170: Specifications
DCD 180-250 Specifications 9213 97-11 Technical Handbook Publ. Gr. P. Permissible wear of forks 10% at point a (see instructions) Lifting chains Max. permissible wear Clearance between the forks 25 mm and ground when the forks are in the lowest position...
Page 171: Lifting Mast And Fork Carriage
Publ. Gr. P. Lifting mast The mast on Kalmar LMV forklift trucks is of very sturdy design. The number of welds has been kept down to a minimum, to ensure the highest possible strength. The stresses on the mast components are low. Both duplex and triplex masts are of free- vision type.
Page 172: Inspection Of Lifting Chains
1635 • ”Kette austauschen” (Replace the chain) This type of tape may be ordered from Kalmar LMV. 2. Check that no pins are loose in the outer washers. 3. Check that there are no visible cracks in any of the links.
Page 173: Inspection Of The Lifting Mast
2. Check the fork suspension for play. Wear at “a” must not exceed 10% 3. If the forks need repairing, get in touch with Kalmar LMV or of the original dimension service personnel authorised by Kalmar LMV, who will decide whether the forks can be repaired.
Page 174: Dismantling The Fork Carriage, Duplex
DCD 180-250 Lifting mast and fork carriage 9213 97-11 Service Technical Handbook Publ. Gr. P. Dismantling the fork carriage, duplex 1. Disconnect all the hose connections between the hydraulic cylinders of the fork carriage and the hydraulic system. Fit protective caps/plugs to all hydraulic cylinder and hose connections.
Page 175: Adjusting The Rollers In The Fork Carriage And Inner Mast
DCD 180-250 Lifting mast and fork carriage 9213 97-11 Service Technical Handbook Publ. Gr. P. Adjusting the rollers in the fork carriage and inner mast 1. Remove the fork carriage. 2. Use a drift to tap out the tubular dowel from the inside.
Page 176: Adjusting The Support Rollers In The Fork Carriage And Inner Mast
DCD 180-250 Lifting mast and fork carriage 9213 97-11 Service Technical Handbook Publ. Gr. P. Adjusting the support rollers in the fork carriage and inner mast Support rollers of the same type are fitted between the inner mast and the fork carriage and between the inner mast and the outer mast.
Page 177: Checking Lateral Support Roller Alignment
DCD 180-250 Lifting mast and fork carriage 9213 97-11 Service Technical Handbook Publ. Gr. P. Checking lateral support roller alignment To ensure correct function, the lateral support rollers must be both parallel and at right-angles to their respective contact surfaces.
Page 178: Replacing The Bearings Of The Fork Support Rollers
Replacing the bearings of the fork support rollers 1. Remove the circlip securing the bearing. 2. Remove the support roller using an extractor. 3. Remove the internal circlips and press out the bearing. 4. Fit a new bearing and fit the circlips. 5.
Page 179: Lifting Mast And Fork Carraige For High Lifting
12 plates in the fork carriage. Note! The lubricating agent should be of a brand approved by Kalmar LMV, or other with same specification. The use of any other lubricants could lead to excessive wear and that the Kalmar LMV guarantee is jeopardized.
Page 180 Sliding plates Sliding plates...
Page 181 DCD 180-250 9213 97-11 Contents Technical Handbook Publ. Gr. P. Group 90 Periodic supervision Periodic supervision ..............3 General survey ..............3 General survey chart ............4 Warranty service ..............3 Lubrication chart ..............4 Daily supervision ..............6 Every 200 hours ..............7 Every 600 hours ..............
Page 182 DCD 180-250 Empty page 9213 97-11 Technical Handbook Publ. Gr. P.
Page 183: General Survey
DCD 180-250 Periodic supervision 9213 97-11 Technical Handbook Publ. Gr. P. General survey To extend the service life of the truck and to prevent the risk of faults causing injury to personnel or damage to equipment, the truck must be subjected to regular periodic supervision.
Page 184 DCD 180-250 Periodic supervision 9213 97-11 Technical Handbook Publ. Gr. P. NOTE! After they have been washed with degreasing If the truck is standing unused outdoors, with agent, all pistons should be moved backwards the piston rods protruding, all piston rods and forwards several times to obtain a new pro- must be greased to prevent corrosion.
Page 185: Lubrication Chart
DCD 180-250 Periodic supervision 9213 97-11 Technical Handbook Publ. Gr. P. LUBRICATION CHART Item Description Interval No. of Remarks operating hours lub. points 1000 Cylinder bearing, tilt cylinders Chain wheels Lifting chains Brush or spray with thin engine oil Support rollers, forks...
Page 186: Daily Supervision
DCD 180-250 Periodic supervision 9213 97-11 Technical Handbook Publ. Gr. P. DAILY SUPERVISION DAILY SUPERVISION Or when Check Refill if required refueling Brakes Function Steering Function All instruments. Function Blinkers, brake lights, horn, Headlights, reflectors Lifting chains Damage Links, suspension...
Page 187 DCD 180-250 Periodic supervision 9213 97-11 Technical Handbook Publ. Gr. P. Every 200:e hours Item Unit Action Remarks Truck Wash Note! Do not use high- pressure on bearings or bearing housings Radiator Clean the fins of the Note! Do not use radiator with water and detergent high-pressure.
Page 188: Every 600 Hours
DCD 180-250 Periodic supervision 9213 97-11 Technical Handbook Publ. Gr. P. Every 600 hours Item Unit Action Remark Air cleaner Change the filter element if the indicator shows red. See Group 30 Turbo charger Check for leakage. See Group 30 Exhaust system Check for leakage.
Page 189: Every 1000 Hours
DCD 180-250 Periodic supervision 9213 97-11 Technical Handbook Publ. Gr. P. Every 1000 hours Item Unit Action Remarks Cabin filter element Change filter element See Group 10 Engine Check valve clearances, See Volvo cooling system, starter motor, Workshop Manual alternator and fuses...
Page 190: Oil And Lubricant Recommendations
Use EP universal grease to NLGI Grade 2 with 3–5% molyb- denum disulphide additive for all lubrication points, including wheel bearings. Lubricant for sliding plates Use lubricant approved by Kalmar LMV. Order from Kalmar LMV Spare parts department 0.65 kg cartridge for greasegun Art.no. 923110-0360 5 kg can Art.no.
Page 191 Publ. Gr. P. Gearbox oil IMPORTANT! On delivery from Kalmar LMV, the gearbox is filled with API-CD SAE 10W/30 motor oil. The gearbox must not be re-filled with ATF oil. If another recommended oil is chosen, ensure that the gearbox is completely drained of old oil before re-filling with the new oil.

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