Kalmar TL2 User manual
Original Instructions
Maintenance Manual
Terminal Tractor
Kalmar TL2
2018
All variants
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
2 Transmission
Maintenance
manual
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Appendixes
2
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A Foreword
Feedback
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‐
tion.
Copy this form, write down your views, and send the form to us.
Thank you for your participation!
To: Cargotec Finland Oy
After sales, technical support / Terminal tractors
P.O. Box 387
FI-33101 Tampere
FINLAND
From: Company / sender: ..............................................................................................................................
Telephone: ..........................................................................................................................................
E-mail: .................................................................................................................................................
Date: .................................... - .................. - ..................
Manual
information
Name / publication number: ................................................................................................................
Section / page number: ......................................................................................................................
Suggestions,
comments,
remarks, etc.
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Maintenance manual
General
The maintenance manual introduces the machine's maintenance
programme and items to the service personnel.
The manual provides instructions for the service personnel concern‐
ing safe working methods when servicing and adjusting the machine
according to the maintenance programme.
Support from our professional maintenance organisation and follow‐
ing the maintenance instructions described in the manuals are a
prerequisite for safe, reliable, and efficient operation of the machine
throughout its lifecycle.
Contact your superior if some parts of this manual lead to questions
or some important information of maintenance seems to be missing.
Contents
This maintenance manual contains the following information:
A Foreword General information about the purpose and contents of this maintenance
manual, instructions for reading the manual, and a form for giving feedback
B Safety Information regarding safety
C Preventive maintenance Information about preventive maintenance
Maintenance programme
0 Location of faults The adjacent sections include a description of the machine structure and
functions and some general instructions for locating the faults. All subjects in
the sections are listed in the following order:
1.the instructions for the service measures defined in the maintenance
programme
2.ffunction-specific troubleshooting instructions
3.technical information concerning maintenance work
In addition to the general description of the machine operation, the manual
contains a detailed description of the operation of the maintenance item.
The sections describe the components related to the function in question. For
this reason, the most common components are mentioned in several
sections, but they are usually described in connection with the first function to
which the component is related.
If the function uses a component that has been described above, the
component is presented with a description relevant to the new function only.
1 Engine
2 Transmission
3 Driveline/Axle
4 Brakes
5 Steering
6 Suspension and wheels
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
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D Error codes Error codes and instructions for reading the data
E Diagrams Electric, hydraulic, and pneumatic diagrams
F Specifications Technical specifications, conversion tables and unit conversion factors
G Terminology and index General terms and abbreviations, their explanations, and an index of
headings
Division into function groups
The above division of the maintenance manual into function groups
is the same for all machines manufactured by Cargotec Oy. The
groups are indicated by numbers with two digits (for example, 4.3
Power-assisted brake system). Machine specific adaptations of the
function groups are indicated by a third or fourth digit (for example,
4.3.9 Wheel brake or 4.3.9.1 Disc brake).
Certain headings (function groups) are omitted in the documentation
for certain machines if the machine lacks that particular function.
This means that there may be gaps in the function group number‐
ing, for example, 2.7 Cooling system may be included for certain
machines, but may be missing for other machines.
References between different manuals are used since the different
manual types have different purposes and thus different information
content.
References between sections within this maintenance manual are
indicated with the section and chapter number, for example, "See
section 4,
Brakes
, chapter 4.3.9.,
Wheel brake
". A reference within
the same section is indicated by the page number, for example,
"
See Description of the fuel sensor on page 24
".
Conditions
The maintenance instructions described in this manual are based
on the use of generally available standard tools. All lifting devices
required in the maintenance work, for example, slings, straps, and
ratchet blocks, must meet the national standards and regulations for
lifting devices.
Cargotec Oy, will not accept any responsibility for modifications per‐
formed without permission from the manufacturer, or if lifting devi‐
ces, tools, or work methods other than those described in this man‐
ual are used.
Storage
Keep this manual in good condition, and store it in a place where it
is always available to the service personnel.
About the machine
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.
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All information and data in this manual are valid at the time of publi‐
cation.
Copyright
This document may not be copied, presented, or delivered to a third
party without our explicit permission, or used for purposes other
than those allowed by us.
We reserve the right to alter the adjustment values, equipment, and
service and repair instructions for the machine without prior notice.
Cargotec Oy
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Reading this manual
Information on possible safety hazards
This manual includes three types of warnings containing instructions
on how to avoid situations that may compromise safety.
DANGER
Warns about a situation that involves an immediate risk of personal
injury or death unless the safety instructions provided are observed.
WARNING
Warns about a situation that may cause personal injury, death,
and/or substantial damage to the machine or other property unless
the safety instructions provided are observed.
CAUTION
Warns of a situation that may cause moderate personal injury
and/or damage to the product or other property unless the safety
instructions provided are observed.
Important information
The word NOTE is used to emphasise issues concerning safety or
the maintenance instructions to which special attention must be paid
while working on the machine.
An example of how the word NOTE appears is presented below.
NOTE
Calls the reader's attention to an instruction that, for example, empha‐
sises operational safety.
Optional equipment
The machine can be equipped with various accessories or optional
equipment. The equipment is marked with the symbol seen on the
left. The symbol is always accompanied with text representing and/
or describing the equipment.
The NOTE symbol is clearly distinguished from the text, and it is
placed next to the text and picture representing the equipment.
Fig. : This symbol indicates an accessory or optional
equipment.
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Function descriptions
The function descriptions are presented as circuit diagrams and
equipment position drawings that describe the function and the
associated components.
The function descriptions describe the function in a logical order.
The circuit diagrams use symbols to depict components such as
pumps, filters, valves, and sensors.
An example of a circuit diagram is provided on the following page.
3.1
1
2
3
74
6
8
79
769
9
7
10B
11
12
11B
64B
15
16
19 17
16
18
19
59
65
60
14
7
68
Circuit diagram component list
1. Terminal tractor air filter
2. Pneumatic air compressor
3. Pressure regulator
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3.1 Air drier
4. Air drier water separator container (6 litres)
6. Charging valve that fills the pneumatic system with compressed
air if the engine is not working or the compressor cannot be used
7. Drain valve
8. Four-circuit protection valve
9. Air tanks (2 x 30 litres)
10B. Pressure switch and measurement sensor
The measurement sensor is available as an option.
11. Front pedal valve
11B. The rear pedal valve and shuttle valve in tractors equipped
with a revolving seat
12. Brake light switch
14. Parking brake indicator light switch
15. Shuttle valve
16. Brake pressure quick release valve
17. Rear axle brakes and parking brake spring chamber
18. Front axle brakes
The parking brake spring chamber is an option.
19. Pressure measurement fitting
59. Parking brake solenoid valve
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
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Explanation of the function description symbols
The following symbols are used in function descriptions. The sym‐
bols are based on standard symbols used in the electric and
hydraulic diagrams.
1.Pneumatic air compressor
2.Air filter
3.Four-circuit protection valve in the pneumatic system
4.Air tank
5.Brake pedal valve in the pneumatic system
6.Pressure switch in the pneumatic system
7.Service brake and parking brake chamber in the pneumatic
system
8.Solenoid valve in the pneumatic system
9.Level valve in the pneumatic system
10.Air spring in the pneumatic system
11.Cylinder in the pneumatic system
12.Palm type couplings in the pneumatic system
13.Variable-displacement pump in the hydraulic system
14.Pressure/return line in the hydraulic system
15.Throttle valve in the hydraulic system
16.Pressure-controlled shuttle valve in the hydraulic system
17.Electrically controlled solenoid valve in the hydraulic system
18.Electrically controlled directional valve in the hydraulic system
19.Load control valve in the hydraulic system
20.Throttle valve in the hydraulic system
21.Pressure switch in the hydraulic system
22.Cylinder in the hydraulic system
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
A
B
ab
M
11
12
1
2
3
4
5
6
7
8
10
15
16
17
18
13
14
9
19
20
21
22
23
24
25
26
27
28
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Manual package
The following manuals are included in the machine delivery as
ordered:
•Operator's manual
•Maintenance manual
•Spare parts catalogue
Each manual can be ordered separately, in case extra copies of
instruction manuals or spare parts catalogue for the machine are
needed later.
Ordering the manuals
The manuals can be ordered from the manufacturer's spare parts
department.
Refer to the serial number of the machine when placing the order.
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B Safety
General safety instructions
General
Everyone performing maintenance and adjustment procedures on
the machine must follow the safety instructions included in this man‐
ual.
Maintenance must be carried out only by professional and trained
personnel.
Training on maintenance and occupational safety issues can be
ordered from our service centre if necessary.
Remember:
•Follow the safety instructions included in this manual.
•Obtain the training required by the job and, if necessary, ask
your work instructor for guidance on the issues regarding
safety at work.
•Follow local laws, safety instructions, and regulations.
•Do the job with equipment and tools that you have been trained
to use safely and properly.
•Always stop the engine before commencing maintenance or
adjustments.
•Do not smoke or use an open flame when refueling or servicing
the fuel system.
•Avoid skin contact with oils and lubricants. Use protective
gloves when handling oils and greases during maintenance.
•When working, use suitable protective clothing, which does not
easily get caught in the machine components and which pro‐
vides good protection against oil and liquid splashes during
maintenance.
•Work carefully but efficiently, and do not take any risks.
In this publication, Cargotec Oy has documented and warned about
situations and risks that may occur in connection with operation as
well as service and repairs of the machine under normal conditions.
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.
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Safety instructions
General
Read the safety instructions before starting servicing or other work
on the machine, and follow them strictly to keep operational safety
at the intended level.
Service position
The machine's service position is used during service, maintenance,
and other procedures during which the machine must be stationary.
Service position:
•The machine is parked with the parking brake engaged.
•The lifting frame is lowered to the ground level.
•The engine is switched off.
•The main power is not switched on.
Depressurizing the brake system
1.Place the machine in service position.
2.Depressurize the brake system
Switch the parking brake on and off several times with the
parking brake switch. The system has been depressurized
when the brake quick release valve does not emit any sound of
air flow anymore.
Depressurizing the hydraulic system
1.Place the machine into service position.
2.Note the following when opening the pipe and hose connec‐
tions:
If any pipe or hose connections of the hydraulic system are
opened during service, first ensure that opening them does not
cause any personal injuries or material damage resulting from
lowering of the load or a machine component.
DANGER
Working under the cab without the mechanical safety stop that pre‐
vents the cab from lowering is strictly prohibited!
Clothing
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.
4B Safety – Safety instructions
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Table of contents
Other Kalmar Tractor manuals
