Page 1 Service Training Linde IC-Engined Fork Truck H 50/60/70/80 D/T H 50/60/70/80 D-02/T-02 H 50/60/70/80 D-03/T-03 Type 353 This training material is only provided for your use and remains the exclusive property of LINDE MATERIAL HANDLING...
Page 3: Table Of Contents
Service Training 09.06 TABLE OF CONTENT IC-engined fork truck H 50/60/70/80, Type 353 Engine drive 4.1.1 Engine model BF6M 1012 E 4.1.1.1 Engine specifications 4.1.1.1.1 Explanation of the engine number 4.1.1.2 Changing and tightening the drivebelt 4.1.1.3 Adjusting valve clearance 4.1.1.4 Adjusting the injection valve 4.1.1.5...
Page 4 Service Training 09.04 4.2.2.2 Operation of control valve block N = Power Limiter 4.2.2.3 Braking 4.2.2.4 Auxiliary brake 4.2.2.5 Lock-out logic - reversing lock 4.2.2.6 Flushing of the circuit and housing 4.2.3 Hydraulic remote control 4.2.3.1 Adjustments 4.2.3.1.1 Hydraulic neutral position 4.2.3.1.2 Primary adjustment of start of control 4.2.3.1.3...
Page 5 Service Training 09.04 Chassis 4.3.1 Overhead guard - torsion mounting 4.3.1.1 Work on the overhead guard Steering system 4.4.1 Power steering circuit diagram 4.4.2 Series 304 steering axle 4.4.2.1 Description 4.4.3 Steering axle removal 4.4.3.1 Steering axle installation 4.4.4 Steering axle repairs 4.4.4.1 Renewing the wheel bearings 4.4.4.2...
Page 6 Service Training 12.05 4.6.7 Electrical system circuit diagram, type 353 -03 LPG 4.6.8 Wiring diagram for options, 353 -03 4.6.9 Central electrical system 4.6.10 Central electrics of series 353 -03 4.6.10.1 Relay and fuses of 353 -03 Diesel 4.6.10.2 Relay and fuses of 353 -03 LPG 4.6.10.3 Relay and fuses for 353 -03 particulate trap Working hydraulics...
Page 7 Service Training 12.05 4.9.3 Propellant gas system 4.9.3.1 Diagram 4.9.3.2 Functional description of the propellant gas system 4.9.4 Inspections and adjustments 4.9.4.1 Ignition system 4.9.4.2 Installation of the engine speed control system 4.9.4.3 Inspection of the engine speed control system 4.9.4.4 Adjustment of the propellant gas mixers...
Page 8 Service Training 12.05...
Page 9: Ic-Engined Fork Truck H 50/60/70/80, Type
Section Service Training Page 09.04 IC-ENGINED FORK TRUCK H 50/60/70/80, TYPE 353 ENGINE DRIVE 4.1.1 ENGINE MODEL BF6M 1012 E 4.1.1.1 ENGINE SPECIFICATIONS Engine model BF6M 1012 E Displacement 4790 cc Power 85 kW at 2250 rpm Opening pressure of injection valve 260 bar Compression ratio 17,5 : 1...
Page 10: Explanation Of The Engine Number
EXPLANATION OF THE ENGINE NUMBER Manufacturer's plate with type and engine number Engine number stamped on the crankcase NOTE: A second type plate was affixed to the rocker cover by Linde. EXPLANATION OF THE ENGINE NUMBER B F 6 M 1012...
Page 11: Changing And Tightening The Drivebelt
Section Service Training Page 09.04 4.1.1.2 CHANGING AND TIGHTENING THE DRIVEBELT CHANGING THE DRIVEBELT - Slacken the alternator and tensioner fastening screws (2). - Turn the tensioning screw (3) anti-clockwise, press the alternator in and remove the drivebelt. - Check the pulley for wear, renewing it if necessary. - Install a new drivebelt.
Page 12: Adjusting Valve Clearance
Section Service Training 09.04 Page 4.1.1.3 ADJUSTING VALVE CLEARANCE The adjustment can be carried out when the engine is cool or warm after a cooling period of at least 30 minutes (oil temperature < 80 °C). Valve clearance: Inlet 0.3 mm Outlet 0.5 mm VALVE CLEARANCE SCHEMATIC...
Page 13 Section Service Training Page 09.06 VALVE CLEARANCE ADJUSTMENT BY MEANS OF A TORQUE ANGLE GAUGE FROM SERIAL NUMBER E1 X353 T 000268 In engines which are equipped with a thrust washer in the valve spring retainer (Fig. A1), the valve clearance can only be adjusted by means of a torque angle gauge.
Page 14 Section Service Training 09.06 Page Adjustment of valve clearance - Set torque angle gauge to 0 (zero) (Fig. A4). Take care not to turn the setting screw! - Turn setting screw back (counter- clockwise) until reaching the corresponding setting angle. Setting angle of inlet valve: 75°...
Page 15: Adjusting The Injection Valve
Section Service Training Page 09.06 4.1.1.4 ADJUSTING THE INJECTION VALVE CHECKING THE OPENING PRESSURE NOTE: Use only test oil acc. to ISO 4113 or diesel fuel for the test. CAUTION: When checking injection nozzles, take care that the fuel jet does not hit the hands. Due to the high pressure, the fuel can penetrate the skin and cause severe injuries.
Page 16 Section Service Training 09.06 Page CHECKING FOR LEAKS - Dry the nozzle and nozzle holder - blow dry with an air jet. - Slowly press the tester hand lever down until a pressure approx. 20 bar under the previously obtained opening pressure is reached.
Page 17: Checking The Compression Pressure
Section Service Training Page 09.06 4.1.1.5 CHECKING THE COMPRESSION PRESSURE - Remove the injection nozzle. - Check the valve clearance. - Insert and fasten connector 100110 along with the special seal. - Connect a compressometer and crank the engine with the starter. Specified pressure 28 - 33 bar Max.
Page 18: Cylinder Head
Section Service Training 09.06 Page 4.1.1.6 CYLINDER HEAD REMOVING THE CYLINDER HEAD - With the engine cool, slacken the cylinder head bolts evenly and in steps in the reverse order as given in the schematic "Cylinder head bolt tightening sequence". DETERMINING THE CYLINDER HEAD GASKET NOTE: For the adjustment of the gap, there are 3 different cylinder head gaskets, which identifiable...
Page 19 Section Service Training Page 09.06 INSTALLING THE CYLINDER HEAD NOTE: Sealing surfaces for cylinder head gaskets must be clean and free of oil. Pay attention to the fitting sleeve. - Check the cylinder head for warping. - Put the cylinder head in place. - Check the cylinder head bolts for stretching, see "Visual check".
Page 20: Adjusting The Begin Of Delivery
Section Service Training 09.06 Page 4.1.1.7 ADJUSTING THE BEGIN OF DELIVERY If an injection pump must be replaced, the begin of delivery must be re-adjusted by determining the shim thickness anew. DETERMINING THE SHIM THICKNESS The old injection pump and shim are not required for this procedure. NOTE: From 4/95, the mounting depth of the injection pump has been increased by 10 mm so that the EP code changes from 70 to 170 and the basic dimension L...
Page 21 Section Service Training 09.96 Page 09.06 Take the corrected injection pump installation dimension (E ) in Table 1a/1b according to the EP code, e.g. 111.725 mm. Table 1a: EP code beginning with '0' Code Code Code Code Code (mm) (mm) (mm) (mm) (mm)
Page 22 Section Service Training 09.96 09.06 Page Read the code for the injection pump length (A) on the new injection pump, e.g. 53. The basic dimension of the injection pump (L ) is 109/119 mm. Determine the theoretical thickness of the shim (T - (L + A/100) = 111.725 mm - (109 mm + 53/100 mm) or T...
Page 23 Section Service Training 09.96 Page 09.06 INSTALLING THE INJECTION PUMP - Place the required shim (2) on the roller shaft. - Turn the injection pump control lever to the stop position. - Set the roller shaft (3) on the base circle. - Slightly oil the O-ring and the hole for the ring.
Page 24: Special Tools
Section Service Training 09.06 Page 4.1.8 SPECIAL TOOLS E 14 Torx socket heads, long version E 20 Socket head, 15 mm, long version for injection valve (union nut) 2461 Compression pressure tester 7532 Torque spanner 7773 A Socket spanner 1/4 " 8189 Torx tool kit 91 107...
Page 25 Section Service Training 09.96 Page 09.06 100 400 Dial gauge M2T with locking ring 100 750 Dial gauge with spacers for measuring TDC and projecting length of piston 110 110 Holder for injection valve, 11 mm 110 460 Socket head for turning the injection pump 114 010 Tool for connecting glow plug cables 142 710...
Page 26: Engine Model Bf6M 2012
Section Service Training 09.06 Page 4.1.2 ENGINE MODEL BF6M 2012 4.1.2.1 OVERVIEW OF ENGINE COMPONENTS...
Page 27 Section Service Training Page 09.06 1 Generator 2 Oil filler hole 3 Heater flange 4 Coolant connection-recovery line 5 Fan pulley 6 Fuel lift pump 7 Coolant pump 8 V-belt pulley on crankshaft 9 Belt tensioner pulley 10 Mounting legs 11 Oil pan 12 Oil filling nozzle 13 Öil filter casing with engine oil cooler...
Page 28: Engine Specifications
Section Service Training 09.06 Page 4.1.2.2 ENGINE SPECIFICATIONS Engine model BF6M 2012 E Displacement 6060 cc Power 74.9 kW at 2200 rpm Opening pressure of injection valve 260 bar Compression ratio 19 : 1 Compression 30 - 38 bar Maximum difference in pressure 4 bar Firing order 1 - 5 - 3 - 6 - 2 - 4...
Page 29: Explanation Of The Engine Number
EXPLANATION OF THE ENGINE NUMBER Manufacturer's plate with type and engine number Engine number stamped on the crankcase NOTE: A second type plate was affixed to the cylinder head cover by Linde. EXPLANATION OF THE ENGINE NUMBER B F 6 M 2012...
Page 30: Replacement Of V-Ripped Belt
Section Service Training 09.06 Page 4.1.2.3 REPLACEMENT OF V-RIPPED BELT Fit the V-ripped belt and tension it. Pressh the belt tensioner pulley (1) in direction of the arrow. Fit the V-ripped belt, and finally place it on pulley (2). Loosen the belt tensioner pulley in opposite direction to the arrow until the V-ripped belt is tensioned.
Page 31: Adjusting Valve Clearance
Section Service Training Page 09.06 4.1.2.4 ADJUSTING VALVE CLEARANCE The adjustment can be carried out when the engine is cool or warm after a cooling period of at least 30 minutes (oil temperature < 80 °C). Valve clearance: Inlet +0.1 Outlet +0.1 VALVE CLEARANCE SCHEMATIC...
Page 32: Checking And Adjusting Leak-Fuel-Free Injection Nozzles
Section Service Training 09.06 Page 4.1.2.5 CHECKING AND ADJUSTING LEAK-FUEL-FREE INJECTION NOZZLES CHECKING THE OPENING PRESSURE NOTE: Use only test oil acc. to ISO 4113 or diesel fuel for the test. CAUTION: When checking injection nozzles, take care that the fuel jet does not hit the hands. Due to the high pressure, the fuel can penetrate the skin and cause severe injuries.
Page 33 Section Service Training Page 09.06 CHECK INJECTORS The injectors are not equipped with bores for leak -off fuel. The surplus fuel cannot be discharged and accumulates in the space above the injector needle in the area of the spring of the injector holder. Actuation of the manual lever of the injector tester is no longer possible in this case.
Page 34 Section Service Training 09.06 Page SETTING OF INJECTORS For a correction of the opening pressure: - Remove injector from nozzle tester 8008. Remove tensioning nut and uninstall all components. Use dolly 110 110 for the injector. Sequence of parts disassembly and re-assembly 1.
Page 35 Section Service Training Page 09.06 LEAK TEST - Dry nozzle and nozzle holder by compressed air. - Press hand lever of tester slowly down until apressure of approx. 20 bar below the previous opening pressure reading is attained. - The nozzle is leak proof if there is no dripping within 10 seconds.
Page 36 Section Service Training 09.06 Page BUZZING AND SPRAY PATTERN TEST - Switch-off pressure gauge of tester. - The buzzing test permits audible checking for ease of movement of the nozzle needle in the nozzle body. New injectors compared to used ones have a different buzzing sound.
Page 37 Section Service Training Page 09.06 - Attach new injection lines with sealing rubber elements. Tighten cap screws finger-tight. HINWEIS: When installing the injection lines make sure that sealing cones are exactly aligned one on top of the other. Subsequent bending is not allowed. Injeetion lines must not be re-used.
Page 38: Thermostat
Section Service Training 09.06 Page 4.1.2.6 THERMOSTAT REMOVAL - Drain coolant, collect it, and dispose of it in accordance with legal standards. - Dismantle outlet connecting piece. Remove thermostat. NOTE: Collect coolant and dispose of it in accordance with legal standards. - Attach new sealing ring to thermostat.
Page 39 Section Service Training Page 09.06 CHECKING Check thermostat in removed condition. - Measure dimension „a“ on the thermostat. NOTE: „a“ = stroke beginning at approx. 83 ± 2°C (T1) „b“ = stroke ending at approx. 95°C (T2) - Heat up thermostat in the water bath. For a determination of the exact opening point, the temperature reading should take place as closely as possible to the thermostat, however, without contacting...
Page 40: Checking The Compression Pressure
Section Service Training 09.06 Page 4.1.2.7 CHECKING THE COMPRESSION PRESSURE - Remove the injection nozzle. - Check the valve clearance. - Insert and fasten connector 100110 along with the special seal. - Connect a compressometer and crank the engine with the starter. Specified pressure 30 - 38 bar Max.
Page 41: Cylinder Head
Section Service Training Page 09.06 4.1.2.8 CYLINDER HEAD REMOVING THE CYLINDER HEAD - With the engine cool, slacken the cylinder head bolts evenly and in steps in the reverse order as given in the schematic "Cylinder head bolt tightening sequence". DETERMINING THE CYLINDER HEAD GASKET NOTE: For the adjustment of the gap, there are 3 different cylinder head gaskets, which identifiable...
Page 42 Section Service Training 09.06 Page INSTALLING THE CYLINDER HEAD NOTE: Sealing surfaces for cylinder head gaskets must be clean and free of oil. Pay attention to the fitting sleeve. - Check the cylinder head for warping. - Put the cylinder head in place. - Check the cylinder head bolts for stretching, see "Visual check".
Page 43: Injection Pump
Section Service Training Page 09.06 4.1.2.9 INJECTION PUMP 4.1.2.9.1 ADJUSTING THE BEGIN OF DELIVERY If an injection pump must be replaced, the begin of delivery must be re-adjusted by determining the shim thickness anew. DETERMINING THE SHIM THICKNESS The old injection pump and shim are not required for this procedure. Proceed as follows: In the column marked "EP", read the EP code for cylinder 3 on the name plate on the cylinder head cover, e.g.
Page 44 Section Service Training 09.06 Page Read the code for the injection pump length (A) on the new injection pump, e.g. 42. The basic dimension of the injection pump (L ) is 117.5 mm. Determine the theoretical thickness of the shim (T - (L + A/100) = 120.875 mm - (117.5 mm + 42/100 mm)
Page 45: Replacement Of The Injection Pump
Section Service Training Page 09.06 4.1.2.9.2 REPLACEMENT OF THE INJECTION PUMP This repair method is intended for a replacement of the injection pumps only. Commercially available tools: Claw grip wrench 8018 Torx tool kit 8189 Special tools: Press-on device for control rod 100 830 Extractor pulling device 150 800...
Page 46 Section Service Training 09.06 Page - Press control rod into stop position using the knurled lock bolt. - Use press-on device for control rod 100 830. NOTE: Tighten knurled lock bolt finger tight. - Set cylinder of the injection pump to be removed to firing TCD.
Page 47 Section Service Training Page 09.06 - Read off ID number for injection pump length (dimension A) for the new injection pump. NOTE: Determining new shim. - Place newly determined shim on roller tappet - Turn injection pump steering lever to center position more or less.
Page 48 Section Service Training 09.06 Page - Put on flange. NOTE: Chamfered end must face injection pump body. - Slightly oil bolts and tighten to a tightening torque of 5 Nm. - Release bolts again by 60°. - Carefully turn injection pump counter clockwise up to a noticeable stop using serrated wrench 8117.
Page 49 Section Service Training Page 09.06 - Turn bolts in again by 60° and gradually tighten to a tightening torque of 7 Nm, 10 Nm and 30 Nm. NOTE: Start with the outer boit remotest from flywheel. - Turn knurled lock bolt back again. Remove press on device 100 830.
Page 50 Section Service Training 09.06 Page - Siide sealing ring onto injection valve using some grease and insert injection valve. NOTE: The notch on the injection valve must face away from the claw. Marking faces exhaust gas end. - Mount claws and tum in bolts loosely. - Fit new injection line with sealing rubber.
Page 51: Heater Flange
Section Service Training Page 09.06 4.1.2.10 HEATER FLANGE POSITIVE POLE SCREW OF HEATER FLANGE Special screw TN 0425 8628 NOTE: This special screw must be used only once! MOUNTING Prior to mounting the special screw TN 0425 8628, the heater flange must be removed from the engine, so that countersupporting with a hollow hexagon wrench is possible during the mounting of the special screw.
Page 52 Section Service Training 09.06 Page The hollow hexagon wrench must be swivelled in anticlockwise direction.
Page 53 Section Service Training Page 09.06 The hollow hexagon wrench must be swivelled between the upper and the lower heating coil base to be able to counter-support. When tightening the special screw, always counter- support with the hollow hexagon wrench (in direction of the arrow), in order to avoid bending of the heating coil.
Page 54: Special Tools
Section Service Training 09.06 Page 4.1.2.11 SPECIAL TOOLS Designation 8002 Hydraulic pressure pump for cooler leak test 8005 Compression tester (by IVEKA Automotive Technologies Schanz GmbH, Talweg 8, D-75417 Mühlacker-Lomersheim) 8008 Nozzle tester 8012 Socket SW 15, long design for injection valve (union nut) 8018 Clay-grip wrench a/flats 17 for injection lines 8024...
Page 55 Section Service Training Page 09.06 8117 Serrated wrench for tuming injection pump 8189 Torx tool kit 9017 Valve spring assembly lever 9090 Spring clamp pliers 100 110 Connector tor compression tester (by IVEKA Automotive Technologies Schanz GmbH, Talweg 8, D-75417 Mühlacker-Lomersheim) 100 320 Turning gear 100 330...
Page 56 Section Service Training 09.06 Page 100 750 Measuring bar with spacers tor gauging TDC and piston projection 100 830 Press-on device tor control rod 100 890 Measuring device for base circle measurement 101 910 Tightening angle dial indicator tor main bearing, big-end and flywheel bolts, etc.
Page 57 Section Service Training Page 09.06 120 680 Extractor for sealing ring beneath injector 121 410 Sleeve for fitting valve stem seal 130 300 Piston ring pliers 130 440 Trapezoidal groove wear gauge 130 660 Piston ring compressor Ø 98 mm Address your order for special tools to: Fa.
Page 58 Section Service Training 09.06 Page...
Page 59: Transmission
Service Training Page Section TRANSMISSION...
Page 60: Hydrostatic Transmission
Page Service Training Section 4.2.1 HYDROSTATIC TRANSMISSION The transmission is composed of separate components consisting of a high pressure axial variable- displacement pump with integrated control elements and 2 high pressure axial variable-displacement motors. Each hydraulic motor is bolted to a 2-stage planetary hub reduction gear via an intermediate housing that contains the disc brake so forming a compact drive unit for each traction wheel.
Page 61: Schematic Diagram Of The Drive
Service Training Page Section 4.2.1.1 SCHEMATIC DIAGRAM OF THE DRIVE 1 Gear pump, 23 cc, due to transmission ration 8 Disc brake 1 engine revolution = 27 cc 9 Axial piston motor HMV 105 S 2 Engine KHD BFM 6 1012 E 10 Suction filter 3 Axial piston pump BPV 100 S 11 Oil tank...
Page 62: Transmission Specifications
Page Service Training Section 4.2.1.2 TRANSMISSION SPECIFICATIONS VARIABLE DISPLACEMENT PUMP Type: BPV 100 S Definition of type designation: = Series = Pump = Variable-displacement 100 = Max. delivery in cc/rev. = Swashplate Number of pistons: Piston diameter: 22.5 mm Max. swashplate angle: 18 °...
Page 63 Service Training Page Section WHEEL DRIVES Two wheel drives bolted to frame Each unit consists of: 1 variable-displacement hydraulic motor HMV 105 S Definition of type designation: = High pressure = Motor = Variable displacement 105 = Max. displacement in cc/rev. = Swashplate Number of pistons: Piston diameter:...
Page 64: Hydraulic Circuit Diagram
Page Service Training Section 4.2.1.3 HYDRAULIC CIRCUIT DIAGRAM WORKING HYDRAULICS Control valve block consisting of: Way valve (auxiliary hydraulics) Shuttle valve Way valve (auxiliary hydraulics) Pressure holding valve Way valve - tilting Way valve - lifting Pressure reducing valve Restrictor Restrictor 2/2-way valve (pressure balance) Maximum pressure valve, 265 bar...
Page 65 Service Training Page Section BOOST PRESSURE PUMP Gear pump, 23 cc/rev.; i = 1.18, resulting in 27 cc/rev. 18a Way valve - auxiliary braking 18b Restrictor 18c Restrictor ENGINE ENGINE SPEED CONTROL CYLINDER VARIABLE-DISPLACEMENT PUMP BPV 100, ASSY. Variable-displacement pump 3/2-way valve Reversing lock 3/3-way valve...
Page 66 Page Service Training Section High-pressure modulator Nozzles Pressure-relief valve 3/2-way valve Nozzle By-pass valve PRESSURE FILTER 10 microns TRAVEL CONTROL UNIT ASSEMBLY Pressure reducing valve Pressure-relief valve Restrictor 4/2-way valve - brake actuation 2/2-way valve 4/3-way valve - direction of travel 3/2-way valve - signal for engine speed HYDRAULIC DRIVE UNIT ASSEMBLY Pressure-relief valve...
Page 71 Service Training Page 05.00 Section...
Page 72 Page Service Training 09.04 Section HYDRAULIC CIRCUIT DIAGRAM, TYPE 353 -03 WORKING HYDRAULICS Control valve block consisting of: Way valve (auxiliary hydraulics) Way valve (auxiliary hydraulics) Way valve (tilting) Way valve (lifting) Restrictor Pressure reducing valve 2/2-way valve (pressure balance) Maximum pressure valve, 265 Shuttle valve Pressure holding valve...
Page 73 Page Service Training 09.04 Section ENGINE ENGINE SPEED CONTROL CYLINDER VARIABLE-DISPLACEMENT PUMP HPV 105-02, ASSY. Variable-displacement pump 3/2-way valve Reversing lock 3/3-way valve Control piston 4/3-way valve - pilot valve Servo piston Combined feed and pressure-relief valve - pressure-relief valve 285 bar (H50) - pressure-relief valve 305 bar (H60)
Page 74 Page Service Training 09.04 Section Pressure-relief valve 13 bar High-pressure modulator 3/2-way valve By-pass valve TRAVEL CONTROL UNIT ASSEMBLY 3/2-way valve - signal for engine speed Pressure reducing valve Pressure-relief valve 11 bar Restrictor 4/2-way valve - brake actuation 2/2-way valve 12 bar 4/3-way valve - direction of travel Way valve - direction of travel (single pedal) (optional equipment) OIL COOLER...
Page 77 Page Service Training 09.04 Section...
Page 78: Operation Of The Hydrostatic Transmission
Page Service Training 09.04 Section 4.2.2 OPERATION OF THE HYDROSTATIC TRANSMISSION The oil flow (20 L/min at n 1, 60 L/min at n ) generated by boost pressure pump G goes through filter O to control valve block N entering it at port E1 and leaving at port E, from where it goes to port E of the travel control unit P.
Page 79 Page Service Training 09.04 Section Travel Control Unit Operation Travel direction, swashplate angle, maximum rpm Operation Brake Pressure regulating valve - swashplate angle Pressure-relief valve, 11 bar Restrictor - for differential pressure 4/2-way valve - braking 2/2-way valve, 12 bar - brake protection 4/3-way valve - travel direction 3/2-way valve - signal for maximum rpm...
Page 80 Page Service Training 09.04 Section...
Page 81: Operation Of Control Valve Block N = Power Limiter
Page Service Training 09.04 Section 4.2.2.2 OPERATION OF CONTROL VALVE BLOCK N = POWER LIMITER Remote control Travel control unit Feed pump Feed Travel control unit Engine speed Travel control unit control cylinder The feed pressure oil flows via E1 and E through control valve block N, goes through travel control unit P from port E to F and returns to the control valve block through port F.
Page 82: Braking
Page Service Training 09.04 Section POWER LIMITER, ANTI-STALL DEVICE The drive is provided with a power limiter to prevent any overload on the engine by the travel drive. This device controls the swashplate angle of the variable-displacement pump and the variable-displacement motors depending on the high pressure so that the product of flow volume Q x working pressure P does not exceed the available engine power at any time.
Page 83 Page Service Training 09.04 Section EXPLANATION Tank Feed The oil flow from the feed pump (18) goes through restrictor (18c) and is fed through port P3 into the oil circuit. Way valve (18a) is kept closed by a spring. Restrictor (18c) is used to measure a differential pressure whose size is proportional to the flow, i.e.
Page 84: Lock-Out Logic - Reversing Lock
Page Service Training 09.04 Section at the pressure balance in the working hydraulics way valve block. This causes the pressure balance to close, thus increasing the pressure of the oil flow of the working hydraulic pump (27). The power required from the engine prevents the rpm from rising too high during braking.
Page 85 Page Service Training 09.04 Section at piston (24) continues through open valve (21) to valve (20), which is shifted to position (b) by the 5 bar spring and the feed pressure in the spring chamber. This connects the spring chamber of control cylinder J via port N to the tank.
Page 86: Flushing Of The Circuit And Housing
Page Service Training 09.04 Section 4.2.2.6 FLUSHING OF THE CIRCUIT AND HOUSING In order to prevent extremely high oil temperatures in the closed circuit, the drive is provided with circuit flushing through an output control device. The temperature in the hydraulic units and the tank is also approximated by flushing the pump and the motor housing.
Page 87 Page Service Training 09.04 Section...
Page 88: Hydraulic Remote Control
Page Service Training 09.04 Section 4.2.3 HYDRAULIC REMOTE CONTROL 1 Cover 16 Reversal lock 2 Pilot housing 3 Control pilot up to 4/94: 16.1 Setscrew 4 Control lever 16.2 Sealing nut 5 Hexagonal nut 16.3 Screw 6 Eccentric pin 16.4 O-ring 7 Position mark 16.5...
Page 89: Adjustments
Page Service Training 09.04 Section 4.2.3.1 ADJUSTMENTS CONDITIONS - Jack up and securely block the truck so that both traction wheels can rotate freely. - Hydraulic oil at operating temperature. 4.2.3.1.1 HYDRAULIC NEUTRAL POSITION - Hold the eccentric pin (6) with a socket head spanner. - Slacken the hexagonal nut (5).
Page 90: Hydraulic Remote Control Hpv
Page Service Training 09.04 Section 4.2.3.1.4 HYDRAULIC REMOTE CONTROL HPV 105 -02 SERVO CONTROL HYDRAULIC ZERO POSITION 1 Control piston 9 Pilot 2 Lever 10 Pilot casing (setscrew) 3 Spring plate 11 Spring 4 Spring 12 Locknut 5 Shims REVERSE LOCK-OUT 6 Valve spool 7 Spring 8 Control circuit nozzles...
Page 91 Page Service Training 09.04 Section ADJUSTMENTS TEST CONDITIONS - Jack the truck up and secure it safely, so that both drive wheels can spin freely. - Truck is at operating temperature. - Travel and braking actuation correctly set. HYDRAULIC ZERO POSITION TEST Test Findings...
Page 92: Reversal Lock (Logic Lock Out)
Page Service Training 09.04 Section 4.2.3.1.5 REVERSAL LOCK (LOGIC LOCK OUT) UP TO 4/94 - Slacken the sealing nut (16.2). - Using a socket head spanner, screw in the setscrew (16.1) as far as possible and then screw out again 2 1/2 to 3 turns.
Page 93: Wheel Drive
Page Service Training 09.04 Section 4.2.4 WHEEL DRIVE 1 Reduction gearbox 2 Disc brake 3 Hydraulic motor The reduction gearbox and the disc brake can be serviced without removing the complete wheel drive from the truck. Proceed according to the following instructions.
Page 94: Reduction Gearbox With Disc Brake (Gr 80 -02/-03/-04)
Page Service Training 09.04 Section 4.2.4.1 REDUCTION GEARBOX WITH DISC BRAKE (GR 80 -02/-03/-04)
Page 95 Page Service Training 09.04 Section REDUCTION GEARBOX 1 Retaining ring 19 Grooved nut 2 Cover 20 Centring ring 3 O-ring 21 Planet carrier II 4 Ring gear 22 Taper roller bearing 5 Straight pin 23 O-ring 6 Plug 24 Retaining ring 7 Sealing ring 25 Planet spider II 8 Cheese head screw...
Page 96: Servicing The Reduction Gearbox (Gr 80 -02/-03/-04)
Page Service Training 09.04 Section 4.2.4.2 SERVICING THE REDUCTION GEARBOX (GR 80 -02/-03/-04) CONDITIONS - Jack up the truck and block it up securely. - Remove the traction wheel. - Place an oil pan under the gearbox. REPLACING THE SEALING RING (3) - Tighten the cover (2) using a bar (support on 2 wheel mounting bolts).
Page 97: Disc Brake Repairs
Page Service Training 09.04 Section 4.2.4.3 DISC BRAKE REPAIRS CONDITIONS - Jack up the truck and block it up safely. - Remove the traction wheel. - Place an oil pan under the gearbox. DISC BRAKE REMOVAL - Drive a pedestrian pallet truck under the gearbox, raise the gearbox and place a suitable wooden support under it in the centre.
Page 98: Reduction Gearbox Gr 80 -06 With Multiple Disc Brake
Page Service Training 09.04 Section 4.2.4.4 REDUCTION GEARBOX GR 80 -06 WITH MULTIPLE DISC BRAKE 1 Wheel hub 10 Planetary carrier I 2 Shaft seal 11 Sun gear 3 Tapered roller bearing 12 Internal gear 4 Plug 13 Circlip 5 Pretensioning ring 14 Pretensioning plate 6 Slotted nut 15 Brake springs...
Page 99: Repair On The Reducing Gear Gr
Page Service Training 09.04 Section 4.2.4.5 REPAIR ON THE REDUCING GEAR GR 80 -06 DISMOUNTING Jack up truck and dismount wheel. Unscrew the hexagon socket screw. Loosen gear unit from oil motor and remove it. Put appropriate device under oil motor in retainer of motor carrier (cramped working conditions) in order to avoid tilting.
Page 100 Page Service Training 09.04 Section Fasten gear unit for dismounting and unscrew the hexagon socket screws. 2x unscrew hexagon socket screw (arrows). Remove casing.
Page 101 Page Service Training 09.04 Section Dismount planetary carrier 2nd stage. The hexagon socket screw is pasted in by means of Loctite. Heat to unscrew. Pull out planetary carrier with 4 gearwheels. Loosen groove nut. +200 Tightening torque 5300 The groove nut is pasted in with Loctite. Heat to loosen groove nut.
Page 102 Page Service Training 09.04 Section Pull off casing. Screw mounting rail on casing. Put threaded rod on drive shaft. Renew radial shaft seal (arrow). Dismount securing ring. The radial shaft seal is pasted in with Loctite. Dismounting sequence: 1 Casing with multi-disc brake 2 Planetary carrier 2 3 Groove nut 4 Taper roller bearing...
Page 103 Page Service Training 09.04 Section MOUNTING Put Loctite on the outer ring of the radial shaft seal, insert it, press in by means of press-in tool 399 900 70 75 or hammer in. Heat taper roller bearing and insert it. Screw in groove nut with chamfer pointing downwards.
Page 104 Page Service Training 09.04 Section Cover groove nut with Loctite FK2 and tighten with 5300 +200 Plug in planetary carrier 2, cover screw with Loctite FK2 and tighten with a tightening torque of 23 Nm. Plug in planetary carrier 1. Plug in pinion.
Page 105 Page Service Training 09.04 Section 1 Casing with multi-disc brake 2 Pinion 3 Planetary carrier 1 Install casing. Note Pinion must be inserted in toothing of multi- disc brake. Adjustment by turning the lower gear casing. Assemble and install in truck.
Page 106: Troubleshooting
Page Service Training 09.04 Section 4.2.5 TROUBLESHOOTING 4.2.5.1 CONNECTING DIAGRAM FOR TROUBLESHOOTING LEGEND TO DIAGRAM Travel control outlet -> brake inlet Power limiter outlet -> inlet of travel control and remote control for hydraulic motors Power limiter inlet Travel control outlet -> speed control cylinder and remote control inlet for hydraulic motors Reversing lock outlet ->...
Page 107 Page Service Training 09.04 Section...
Page 108: Tools And Aids For Measurements
Page Service Training 09.04 Section 4.2.5.2 TOOLS AND AIDS FOR MEASUREMENTS The tools and gauges used for troubleshooting are similar to the ones in the catalogue "Special Tools and Instruments". The part names are the same as those in the catalogue under the same consecutive number. All parts contained in the test box are also identified by "1."...
Page 109 Page Service Training 09.04 Section ITEM NO. DESCRIPTION Screw coupling M 14 x 1.5 Adapter nipple Screw coupling M 8 x 1 1.7 a Banjo bolt M 14 x 1.5 with plug and M 8 x 1 bore 1.7 b Banjo bolt M 14 x 1.5 with M 8 x 1 bore 1.12 Low pressure gauge 0 - 40 bar...
Page 110: Explanations To Troubleshooting
Page Service Training 09.04 Section 4.2.5.3 EXPLANATIONS TO TROUBLESHOOTING The functional tests and any ensuing troubleshooting is performed separately for each main group. The following components and functions are affected: 4.2.5.4 Hydraulic speed control for the engine 4.2.5.5 Hydraulic braking system 4.2.5.6 Pressure equality and start of control 4.2.5.7...
Page 111: Hydraulic Speed Control For The Engine
Page Service Training 09.04 Section 4.2.5.4 HYDRAULIC SPEED CONTROL FOR THE ENGINE The engine speed control check is first performed, as described below, merely as a functional test. If any malfunctions are detected during the test, a detailed troubleshooting must be carried out subsequently. 4.2.5.4.1 FUNCTIONAL TEST TEST CONDITIONS...
Page 112 Page Service Training 09.04 Section Disconnect the speed control linkage, start the engine and move the injection pump control lever as far as the stop by hand. Adjust engine speed or put Engine the injection pump governor + 50 speed of 2250 or engine in order.
Page 113 Page Service Training 09.04 Section Speed control Valve (20) of lock-out cylinder extends fully. logic faulty or setting too Engine accelerates to low. + 50 2250 rpm. With accelerator pedals released and engine running, pull the lift lever fully back and hold it there. Speed control cylinder extends fully.
Page 114 Page Service Training 09.04 Section Release accelerator pedal and then depress it about 1/3 of pedal stroke. Speed jumps to Nozzle in valve (49) too over 1300 rpm. small or clogged. Nozzle in valve (49) too No increase in speed large or restrictor in or increase too low.
Page 115 Page Service Training 09.04 Section With accelerator pedals released, pull the lift lever fully back and hold there. Engine speed of 2250 + 50 rpm is reached Install LP gauge with screw coupling 1.1 to port VS of working hydraulics control valve (speed control signal).
Page 116: Hydraulic Braking System
Page Service Training 09.04 Section 4.2.5.5 HYDRAULIC BRAKING SYSTEM 4.2.5.5.1 FUNCTIONAL TEST TEST CONDITIONS - Truck jacked up and secured so that both traction wheels can rotate freely. - Pedals properly adjusted. - Brake pedal locked in the "brake applied" position - Hydraulic oil at operating temperature TEST Test...
Page 117 Page Service Training 09.04 Section Install LP gauge with adapter V to port F of power limiter. Start engine and read pressure gauge. Minimum pressure Check "Hydrostatic travel 17.5 bar obtained. drive". Install LP gauge with adapter IV to external release port R. Start engine and read pressure with the brake released.
Page 118 Page Service Training 09.04 Section Disconnect adapter IV at external brake release port R and install LP gauge with adapter I. Repeat the test. Connecting oil passage in valve (46) Leak in right or left disc brake. Repair clogged; clean it. Brake shaft adjusted Pressure 17.5 bar the brake.
Page 119: Pressure Equality And Start Of Control
Page Service Training 09.04 Section 4.2.5.6 PRESSURE EQUALITY AND START OF CONTROL TEST CONDITIONS - Truck not jacked up. - Pedals properly adjusted. - Brake released. - Engine and travel drive at operating temperature. 4.2.5.6.1 FUNCTIONAL TEST - Driver seated on driver's seat - Start engine Test Symptoms...
Page 120 Page Service Training 09.04 Section Using adapter V, install LP gauge at port F of power limiter. Start engine and read pressure with the brake released. Pressure = 17.5 - 21 bar. See "Hydrostatic travel drive". Install a second LP gauge with adapter V at port E of power limiter. Start the engine, release the brake and determine Δp between ports E and F.
Page 121 Page Service Training 09.04 Section Δp = 0 - 0,5 bar. Remove adapter III at ports YF and ZF and install LP gauge with adapter II at ports YF and ZF. Repeat the test. Adjust Δp by turning rear (looking in See "Hydrostatic travel Δp = 0 - 0,5 bar.
Page 122 Page Service Training 09.04 Section Set Δp to 11 + 0.1 bar at valve (44) of travel control unit. Δp can be obtained. Remove adapter III at ports YF and ZF and install LP gauge with adapter II to ports YF and ZF. With F and R accelerator pedals depressed to the stop, set Δp to 11 + 0.1 bar.
Page 123: Hydrostatic Travel Drive
Page Service Training 09.04 Section 4.2.5.7 HYDROSTATIC TRAVEL DRIVE TEST CONDITIONS - Truck jacked up and secured so that both traction wheels can rotate freely. - Hydraulic neutral in order. - Engine cover raised. - Floor plate removed. - Pedals properly adjusted. - Brake pedal locked in the "applied"...
Page 124 Page Service Training 09.04 Section Install LP gauge with adapter V to port F of power limiter. Measure pressure with engine at idling speed and brake pedal released. Pressure between Pressure under 17.5 bar. Pressure over 20 bar. 17.5 and 20 bar. Check boost pressure valve Setting of boost pressure (26) and increase spring...
Page 125 Page Service Training 09.04 Section Leak in remote control for left or right hydraulic Pressure now between motor. Locate 17.5 and 20 bar. remedy the fault or renew the control. Disconnect HP lines of right hydraulic motor, repeat the test. Fault in right hydraulic Pressure now okay.
Page 126 Page Service Training 09.04 Section Install banjo bolt 1.17 with plug at ports E and F of the travel control unit. Repeat the test. Fault in travel control unit. Possible causes: Valve (47) sticking in open Valve (33) (13 bar) dirty position.
Page 127 Page Service Training 09.04 Section Motor now See "Hydraulic speed reaches maximum speed control". at each side. At max. speed, determine Δp between ports E and F. Δp between 12 and 14 bar. Install banjo bolts 1.17 with plugs at ports E and F of travel control unit. Repeat test with engine idling.
Page 128 Page Service Training 09.04 Section Read pressure at port F when accelerator pedals are depressed. Pressure drops clearly under 17.5 bar. Disconnect the right or left hydraulic motor, repeat the test. Pressure at Variable-displacement Left or right hydraulic port F still drops to below pump defective, repair or motor defective, repair or 17.5 bar.
Page 129 Page Service Training 09.04 Section Δp 0 - 0,5 bar. Check for equal pressure, see "Pressure equality and start of control". Equal pressure can be achieved. Remove adapter III and install adapter II with plug. Connect LP gauge and determine Δp with the brake released and engine running. Leak in hydraulic remote Δp now 0 - 0,5 bar.
Page 130 Page Service Training 09.04 Section Determine Δp by fully depressing the F and R accelerator pedals consecutively with the brake released. Remote control servo piston sticking or control Δp von 10 - 11 bar. cylinder cradle defective. Remove adapter III and install adapter II with plug. Connect LP gauge, determine Δp by fully depressing the F and R accelerator pedals with the brake released and engine running.
Page 131 Page Service Training 09.04 Section Average wheel speed of 155 - 165 rpm achieved on both sides. Install LP gauge with adapter III to ports Y and Z of remote control and determine Δp with the brake released. Δp 0 bar to max. 0,5 bar. Remove adapters III and screw in adapters II with plugs.
Page 132 Page Service Training 09.04 Section Fully depress the F and R accelerator pedals with the brake released and the engine running. Read Δp when pedals are fully depressed. Δp of 11 - 11 bar obtained to both sides. Remove adapter III and screw in adapter II with plug. Determine Δp with the brake released and pedals fully depressed.
Page 133 Page Service Training 09.04 Section Average wheel speed of 155 - 165 rpm obtained to both sides. Connect LP gauge with adapter lll to port X at the power limiter and a second LP gauge to F. Determine the Δp between ports F and X with the F and R pedals fully depressed.
Page 134 Page Service Training 09.04 Section HP and LP HP 330 + 20 HP far below pulsate or LP drops below on H 50/60, 390 + 20 bar on specifications, LP at least H 70/80. LP minimum 12 bar and HP does 17.5 bar.
Page 135: Test And Adjustment Instructions For Hydraulic Primary And Secondary Control
Page Service Training 09.04 Section 4.2.6 TEST AND ADJUSTMENT INSTRUCTIONS FOR HYDRAULIC PRIMARY AND SECONDARY CONTROL The swash plate angle Q of the variable-displacement pump or the Q of the hydraulic motors need only be checked if required in "Hydrostatic travel drive" of the troubleshooting. The following tests and adjustments must only be performed by qualified skilled staff.
Page 136: Q Max
Page Service Training 09.04 Section 4.2.6.1 OF VARIABLE DISPLACEMENT PUMP BPV 100 Start the engine and determine Δp between ports Y and Z. Adjust equal pressure, Δp 0 - 0,5 bar. see "Pressure equality and start of control". Fully depress F and R accelerator pedals and determine Δp when fully depressed.
Page 137 Page Service Training 09.04 Section Possible causes: Bypass valve leaking. Speed now 68 - 65 rpm. Combined boost and pressure-relief valve or output device leaking. Control piston faulty. Control piston of hydraulic remote control sticking. of pump in order.
Page 138: Qmax
Page Service Training 09.04 Section 4.2.6.2 OF HYDRAULIC MOTORS HMV 105 Lock the right traction wheel. Start engine, release brake, fully depress one accelerator pedal and measure speed of left wheel. Wheel speed of left motor okay. 116 - 130 rpm. Remove the cover on the bottom of the truck frame.
Page 139: Qmin
Page Service Training 09.04 Section 4.2.6.3 OF HYDRAULIC MOTORS HMV 105 Condition: Q of variable displacement pump and the hydraulic motors is in order. Connect LP gauge with adapter V to port F on the power limiter and connect adapter 1.31. Fully depress F and R pedals and determine the Δp between ports F and X with pedals fully depressed.
Page 140 Page Service Training 09.04 Section CHECKING Q - Shut off the engine, lock the left wheel, close the valve on 1.32 and put a 5-mm spacer between injection pump lever and stop screw for maximum engine speed. - Start the engine, fully depress an accelerator pedal (engine speed reaches approx. 1200 rpm) and measure the speed of the right wheel.
Page 141: Chassis
Service Training Section Page CHASSIS...
Page 142: Overhead Guard - Torsion Mounting
Section Service Training Page 4.3.1 OVERHEAD GUARD - TORSION MOUNTING The overhead guard is fastened to a cross member at the top of the mast so that it follows the mast when tilted. At the rear supports, the overhead guard is guided in two adjustable rollers. This type of roof construction increases the torsion stiffness of the mast and it is called a torsion mounting.
Page 143: Work On The Overhead Guard
Service Training Section Page 1 Overhead guard pivot articulation on the mast 2 Front mounting of tilt cylinders 3 Overhead guard 4 Rear mounting of tilt cylinders 5 Roller mount 6 Overhead guard guide roller 4.3.1.1 WORK ON THE OVERHEAD GUARD DISASSEMBLY - Slacken the fastening screws on the left and right roller mounts (5) and slide the mount outward in the area of the bearing holes.
Page 144 Section Service Training Page - Remove any lateral play in the overhead guard with shims (9). - Install the bearing brackets (7) and torque the screws (10) to 80 Nm. - Using a mounting iron, position the left and right roller mounts (4) without play on the overhead guard tube sections and handtighten the mount fastening screws.
Page 145: Steering System
Service Training Section Page STEERING SYSTEM...
Page 146: Power Steering Circuit Diagram
Section Service Training Page 4.4.1 POWER STEERING CIRCUIT DIAGRAM Steering control valve assy. consisting of: Steering cylinder Pressure-relief valve Oil cooler Make-up valve Shock valve Cooler bypass valve, 1 bar Steering control valve Gear pump, 27 cc/rev...
Page 147 Service Training Section Page OPERATION OF THE POWER STEERING The oil from the pump (28) enters the steering control valve (B) at port P2, flows through the steering control valve (17), leaves the valve through port T1 and goes back to the tank through the oil cooler (E). Turning the steering wheel closes the P2-T2 connection and the oil coming from P2 is fed to the steering cylinder via port R or L.
Page 148: Series 304 Steering Axle
Section Service Training Page 4.4.2 SERIES 304 STEERING AXLE EXPLANATION OF THE STEERING AXLE SERIES NUMBER 5053 Series number Month built Year built Axle type 4.4.2.1 DESCRIPTION The rear wheels are steered by means of a double-acting hydraulic cylinder mounted to the steering cylinder and the two steering knuckles with two track rod links (fixed length).
Page 149: Steering Axle Removal
Service Training Section Page 4.4.3 STEERING AXLE REMOVAL - Remove the wheel mounting screws on both wheels. - Jack up and securely block the rear of the truck. - Remove the rear wheels. - Support the steering axle (1). - Remove the mounting screws (4). - Remove the plate (3).
Page 150: Steering Axle Installation
Section Service Training Page 4.4.3.1 STEERING AXLE INSTALLATION - Mount the two axle blocks (2) on the centre of the axle. NOTE: Axle blocks are not symmetrical, wide section must be shown up! - Place the steering axle (1) into the counterweight from below. Raise the steering slightly until the two axle blocks (2) contact the counterweight and underpin it.
Page 151: Renewing The Wheel Bearings
Service Training Section Page 4.4.4.1 RENEWING THE WHEEL BEARINGS - Jack up the truck. - Remove the wheel. - Remove the cap (8). - Drive out the cotter pin (7). - Loosen and remove the 55 mm nut (6). - Drive out the wheel hub (1) out from the inside with a plastic hammer. - Renew the outer bearing ring of taper roller bearings (2) and (5) and also the shaft seal (3).
Page 152: Steering Knuckle Removal And Installation
Section Service Training Page 4.4.4.2 STEERING KNUCKLE REMOVAL AND INSTALLATION 1 Nut 6 King pin 2 Thrust washer 7 Knuckle 3 Knuckle body 8 Taper roller bearing 4 Seal 9 Seal 5 Taper roller bearing 10 Spacer...
Page 153 Service Training Section Page STEERING KNUCKLE REMOVAL - Jack up the truck. - Remove the wheels. - Turn the steering until the pin (2) retaining the track rod (3) is positioned in the counterweight recess. - Drive out the roll pins (6). - Place the special tool (4) on the jack (5) and position it under the pin (2).
Page 154: Steering Cylinder Removal And Installation
Section Service Training Page 4.4.4.3 STEERING CYLINDER REMOVAL AND INSTALLATION STEERING CYLINDER REMOVAL - Jack up and securely block the rear of the truck so that the wheels can turn freely. - Remove the dowel pins (3) from pin (2). - Turn the steering wheel clockwise or anti-clockwise until the steering cylinder is extended as far as possible.
Page 155 Service Training Section Page STEERING CYLINDER INSTALLATION - Lift the steering cylinder (8) into the steering axle. NOTE: Support up the steering cylinder with wooden blocks. Steering cylinder holes have different diameters: diam. 24 mm at top, diam. 26 mm at bottom. - Insert the track rod (3) into the fork on the steering cylinder (8) and bring them into alignment.
Page 156: Replacing The Steering Cylinder Seals
Section Service Training Page 4.4.4.4 REPLACING THE STEERING CYLINDER SEALS - Remove the steering cylinder and clamp it in a vise. - Pull the piston rod (1) out to one side as far as possible. - Drive in the guide bushing (5) approx. 1 - 2 mm. - Loosen the retaining ring (9) with a 2.5 mm drift punch through hole (3) and remove with a screwdriver.
Page 157: Steering Stop Adjustment
Service Training Section Page 4.4.4.5 STEERING STOP ADJUSTMENT 1 Stop screw 2 Locknut 3 Axle body 4 Steering cylinder To prevent damage to the hydraulic cylinder, check and adjust, if necessary, the left and right-hand steering stop after repairing a steering knuckle, track rod or steering cylinder. - Loosen the locknut (2) and screw out the M12x60 stop screw (1) approximately 10 turns.
Page 158 Section Service Training Page...
Page 159: Controls
Section Service Training Page CONTROLS...
Page 160: Accelerator And Brake Pedal Adjustment
Section Service Training Page 4.5.1 ACCELERATOR AND BRAKE PEDAL ADJUSTMENT ACCELERATOR PEDALS - Bring both accelerator pedals to the same level, position bracket (1) on the leg spring (2) and secure them with screws. - With the aid of the spacer (WM 6), adjust the hexagonal screws (3) and (7) to a clearance of 48 mm from the pedal and lock them with locknuts.
Page 161 Section Service Training Page...
Page 162 Section Service Training Page BOWDEN CABLE FOR THE PARKING BRAKE - Depress the brake pedal until the flat spring (1) engages. - Set the lever on the control unit cover to the "Brake engaged" position. - Remove any play in the brake cable (2) at the lower end by clamping the nipple (3).
Page 163: Speed Control
Section Service Training 09.96 Page 4.5.2 SPEED CONTROL 4.5.2.1 SPEED CONTROL UP TO 10/95 ADJUSTMENT INSTRUCTIONS FOR DIMENSION X (LOWER IDLING SPEED) - Retract the speed control cylinder (1) and slacken screw (4). Shift the adjusting lever (3) outward as far as possible on lever (2).
Page 164 Section Service Training 09.96 Page ADJUSTMENT INSTRUCTIONS FOR DIMENSION Y (UPPER IDLING SPEED) - Fully depress the brake pedal and lock it. - Start the engine. - Depress the accelerator pedal until the speed control cylinder is fully extended. - Slacken nut (4) and slide the adjusting lever (3) on lever (2). - Adjust dimension Y to 0.1 mm.
Page 165: Speed Control From 11/95
Section Service Training 09.96 Page 4.5.2.2 SPEED CONTROL FROM 11/95 From 11/95 the speed control lever has been provided with an overload protection. The adjustment procedure is as follows. - With the control cylinder (1) retracted, slide the retainer (2) on the lever (7) as far as possible away from the engine and tighten both the cheese head screws (3).
Page 166: Medium Wheel Speed
Section Service Training 09.96 Page 4.5.3 MEDIUM WHEEL SPEED CONDITIONS - Jack up and securely block the truck so that the wheels can turn freely. - Accelerator pedals and engine speed control correctly adjusted. - Engine runs at 2250 - 2300 rpm with the accelerator pedals fully depressed. CHECK - Start the engine, release the brake and fully depress the right-hand accelerator pedal.
Page 167: Start Of Drive Wheel Rotation
Section Service Training 09.96 Page 4.5.4 START OF DRIVE WHEEL ROTATION The start of wheel rotation is set by means of setscrew (3) such that wheel rotation starts directly after the engine rpm increases or shortly thereafter. In no case should the start of wheel rotation begin before the engine speed starts to increase.
Page 168: Brake Shaft Stop Screws
Section Service Training Page 09.96 4.5.5 BRAKE SHAFT STOP SCREWS - Connect a low pressure gauge to port BR on the travel control unit. - Slacken the clamping screw on the brake lever and turn the brake shaft (5) clockwise as far as the stop. - Loosen locknut (2).
Page 169: Symmetry Of The Travel Control
Section Service Training 09.96 Page 4.5.6 SYMMETRY OF THE TRAVEL CONTROL 4.5.6.1 DRIVE WHEEL START OF ROTATION ADJUSTMENT REQUIREMENTS - Pedal adjustment is in order. - Truck blocked up and secured so that both drive wheels can turn freely. - Engine and traction hydraulics at operating temperature. - Floor plate removed.
Page 170: Engine Speed Increase
Section Service Training 09.96 Page 4.5.6.2 ENGINE SPEED INCREASE TEST REQUIREMENTS - Truck blocked up and secured so that both wheels are free to rotate. - Brake applied. - Pedal adjustment is in order. TEST - Sit down on the driver's seat. - Start the engine.
Page 171: Pressure Difference Δp
Section Service Training 09.96 Page 4.5.7 PRESSURE DIFFERENCE DP TEST REQUIREMENTS - Truck blocked up. - Engine and travel hydraulics at operating temperature. - Pedal adjustment is in order. - Symmetry of travel control is in order. - Two low pressure gauges connected to ports Y and Z of travel control unit with screw couplings 1.1 (refer to "Aids and Tools for Measurements").
Page 172: Modification Of Engine Acceleration
Section Service Training 09.96 Page 4.5.8 MODIFICATION OF ENGINE ACCELERATION In special cases it may be necessary to adapt the operating characteristics of the engine to the service conditions of the truck, e.g. very sensitive driving at creep speed without accelerating the engine, or frequent hill starts with a load at high engine speed.
Page 173: Electrical System
Section Service Training Page ELECTRICAL SYSTEM...
Page 174: Wiring Diagram
Section Service Training Page 4.6.1 WIRING DIAGRAM Glow duration unit Preheat/starter switch Engine temperature switch Fuse for glow duration unit, 80 A Oil temperature switch F11 Fuse for indicator instrument, 5 A Oil pressure switch F13 Fuse for glow duration unit/soot filter power Suction filter vacuum switch supply, 5 A Fuel level warning switch...
Page 177 Section Service Training 05.00 Page...
Page 178: Wiring Diagram For Options
Section Service Training 05.00 Page 4.6.2 WIRING DIAGRAM FOR OPTIONS 4S15 Revolving light switch Dip beam, right Dip beam, left 5S11 Light switch 5S12 Hazard warning light switch Side light, front right Side light, front left 5S13 Directional indicator switch Front wiper switch - continuous Side light, rear left Side light, rear right...
Page 181 Section Service Training 05.00 Page 4.6.3 WIRING DIAGRAM, 353 -02 Glow duration unit 55-60 Fuse for glow duration unit, 80 A Fuse for potential 30, S1, 10 A Fuse glow duration unit/ shut-off magnet 10 A 4F15 Fuse for horn, 10 A 9F13 Fuse for working lights switch illumination/Heater 15 A...
Page 182 Section Service Training 05.00 Page V1/2/3 Decoupling diodes 26, 28, 40 Connector 15 pins 11 - 17, 30 - 42, 74 Connector 12 pins 4 - 22, 30 - 38, 51 Connector 2 pins 1, 4 Connector 2 pins 9, 59 Connector 6 pins 1, 5, 10, 60 - 64 Connector 2 pins...
Page 185: Wiring Diagram For Options
Section Service Training 05.00 Page 4.6.4 WIRING DIAGRAM FOR OPTIONS, 353 -02 Dip beam, right Dip beam, left Side light, front right Side light, front left Side light, rear left Side light, rear right License plate light 9E1-9E6 Spotlight 10 - 22 9E13 Interior light 5F31,32...
Page 186 Section Service Training 05.00 Page 5S11 Light switch 27 - 33 5S12 Hazard warning light switch 44 - 51 5S13 Directional indicator switch 46 - 48 Front wiper switch 82 - 87 Rear/roof wiper switch 118 - 124 wiper switch, wash 90 - 96 9S5,6 Spotlight switch...
Page 189: Wiring Diagram, 353 -03 Diesel
Section Service Training 09.04 Page 4.6.5 WIRING DIAGRAM, 353 -03 DIESEL Control device for heater flange 53-58 1B11 Cooling water temperature sensor Fuse MTA Fuse for heater flange Fuse for potential 30, S1 Fuse for heater flange control device/ shut-off magnet 4F15 Fuse for horn 9F13...
Page 190 Section Service Training 09.04 Page Temperature switch for richer fuel mixture Horn button Brake pedal switch (start inhibit) Coolant level sensor 22-24 V1/3 Decoupling diodes 29,41 Connector 15 pins 12-19, 31-43, 77 Connector 12 pins 8-22, 31-39, 50-58 Connector 1 pin Connector 2 pins 3, 6 Connector 1 pin...
Page 193: Wiring Diagram For Options
Section Service Training 09.04 Page 4.6.6 WIRING DIAGRAM FOR OPTIONS, 353 -03 Dip beam, right Dip beam, left Side light, front right Side light, front left Side light, rear left Side light, rear right License plate light 5E10 Position light, right 5E11 Position light, left 9E1-9E6...
Page 194 Section Service Training 09.04 Page Front wiper switch 93 - 99 Rear/roof wiper switch 135 - 142 wiper switch, wash 101 - 108 9S5,6 Spotlight switch 13 - 24 Travel direction switch, single-pedal model 2 - 5 1V11 Free-wheeling diode 1V12 Free-wheeling diode Connector 15 pins...
Page 197: Electrical System Circuit Diagram, Type 353 -03 Lpg
Section Service Training 09.04 Page 4.6.7 ELECTRICAL SYSTEM CIRCUIT DIAGRAM, TYPE 353 -03 LPG Ignition control device 33-36 Actual speed transmitter 47,48 Set speed transmitter 46-48 Ignition distributor 29-34 Spark plugs 29-33 Fuse 70 A MTA Fuse class 30, S1 10 A 4F15 15 A audible warning device fuse 7F12 Fuse for Lambda control, 10 A 9F13 Fuse for switch illumination of...
Page 198 Section Service Training 09.04 Page Ignition coil 30-32 V1/3 Decoupling diodes 17, 23 Decoupling diode 15-pin plug 9-28 12-pin plug 3-22, 39-50 6-pin plug 1,3,7 2-pin plug 3-pin plug 13-15 3-pin plug 9X11 3-pin plug Speed operating magnet Propellant gas shutoff valve CABLE COLOURS black brown...
Page 201: Wiring Diagram For Options
Section Service Training 09.04 Page 4.6.8 WIRING DIAGRAM FOR OPTIONS, 353 -03 Dip beam, right Dip beam, left Side light, front right Side light, front left Side light, rear left Side light, rear right License plate light 5E10 Position light, right 5E11 Position light, left 9E1-9E6...
Page 202 Section Service Training 09.04 Page 5S13 Directional indicator switch 52 - 55 Front wiper switch 93 - 99 Rear/roof wiper switch 135 - 142 wiper switch, wash 101 - 108 9S5,6 Spotlight switch 11 - 22 Travel direction switch, single-pedal model 2 - 5 1V11 Free-wheeling diode...
Page 205 Section Service Training 09.04 Page...
Page 206: Central Electrical System
Section Service Training 09.04 Page 4.6.9 CENTRAL ELECTRICAL SYSTEM The whole electrical system ist mounted on the left side of the truck behind a cover of the second foothold. 1 Preheating relay 8 Interval relay 9K2 2 Distributor plug (plus) 9 Flasher relay 5K1 3 Preheating fuse 80 A 4 Starter relay...
Page 207 Section Service Training 09.04 Page TOP VIEW OF FUSE BOXES I - IV The fuse box I ist standard version, the boxes II, III and IV are fitted depending on the special equipment. Fuse output Fuse input Fuse output Fuse input EXAMPLE FOR A FUSE APPLICATION 31 : 2 Fuse output...
Page 208: Central Electrics Of Series
Section Service Training 09.04 Page 4.6.10 CENTRAL ELECTRICS OF SERIES 353 -03 4.6.10.1 RELAY AND FUSES OF 353 -03 DIESEL 0 Relay for UPA 5 Starter relay K2 1 Indicator relay 5K1 6 Control device for heater flange A1 2 Wiper relay 9K3 7 Plus distributor 3 Interval relay 9K1/9K2 8 Plug for interfaces...
Page 209 Section Service Training 09.04 Page TOP VIEW OF FUSE BOXES I - III Fuse output Fuse input Fuse output Fuse input Fuse box I Ignition starter, display (F11) 15 A Supply of glow time control device (F12) 10 A Switch illumination, heating* (9F13) 15 A Seat heating* (9F14) 20 A...
Page 210: Relay And Fuses Of 353 -03 Lpg
Section Service Training 09.04 Page 4.6.10.2 RELAY AND FUSES OF 353 -03 LPG 1 Relay K3 for LPG cut-off 2 Relay K2 for starter 3 Relay K4 load relay 4 Indicator relay 5K1 5 Relay 9K1 for interval 6 Relay 9K2 for interval 7 Relay 9K3 for wiper 8 Relay for plus distributor 9 Fuse 70 A MTA...
Page 211 Section Service Training 09.04 Page TOP VIEW OF FUSE BOXES I - IV Fuse output Fuse input Fuse output Fuse input Fuse box I Indicating device, ignition starter switch (F11) 10 A Catalyst* (7F12) 10 A Switch illumination for working lights* (9F13) Heating*, revolving light* (9F14) 20 A Horn (4F15)
Page 212: Relay And Fuses For 353 -03 Particulate Trap
Section Service Training 09.04 Page 4.6.10.3 RELAY AND FUSES FOR 353 -03 PARTICULATE TRAP 1 Diagnostic plug 6X8 2 Signal transmission connector 7X9 3 Relay 7K12, 12V/20 A 4 Relay 7K9, 12 V/70 A 5 Relay 7K11, 12 V/70 A 6 Control device for particulate trap 7A1 TOP VIEW OF FUSE BOXES Fuse input...
Page 213: Working Hydraulics
Service Training Section Page WORKING HYDRAULICS...
Page 214: Working Hydraulics Circuit Diagram
Section Service Training Page 4.7.1 WORKING HYDRAULICS CIRCUIT DIAGRAM 9 2/2-way valve (pressure balance) 1 Control valve assembly consisting of: 10 Maximum pressure valve, 265 bar 2 Way valve (auxiliary hydraulics) 11 Tilt cylinder 3 Shuttle valve 12 Slow down valve 4 Way valve (auxiliary hydraulics) 13 Lift cylinder 5 Pressure holding valve...
Page 215: Explanation Of The Working Hydraulics
Service Training Section Page 4.7.1.1 EXPLANATION OF THE WORKING HYDRAULICS When the control levers are in the neutral position and the pump output is nill, way valves (2), (4), (6) and (7) and also the pressure balance (9) are closed. Port P1 is connected via the pressure-reducing valve (8) to port VS.
Page 216: Tilt Cylinder
Section Service Training Page 4.7.2 TILT CYLINDER 1 Bearing bracket 8 Retaining screw 2 Screw 9 Overhead guard 3 Eyebolt 10 Support 4 Bearing pin 11 Screw 5 Locknut 12 Roller mount with roller 6 Piston rod 13 Hoses 7 Rear bearing pin...
Page 217: Tilt Cylinder Removal, Installation, Adjustment, Sealing
Service Training Section Page 4.7.2.1 TILT CYLINDER REMOVAL, INSTALLATION, ADJUSTMENT, SEALING TILT CYLINDER REMOVAL - Tilt the mast forward as far as possible. - Unscrew and remove the bearing bracket (1) on the cross member of the outer upright. - Press the piston rod (6) and pin (4) up and out of the lower bearing half, but leave it in the bearing. - Slacken the fastening screws (11) on the left and right roller mount (12) and slide outward.
Page 218 Section Service Training Page SEALING THE TILT CYLINDER 10 Guide ring 1 Bearing 11 Sealing ring 2 Setscrew 12 Support ring 3 Piston 13 Cylinder head 4 Guide ring 14 Rod seal 5 Piston seal 15 O-ring 6 Rod seal 16 Wiper 7 Bushing - piston stroke limiter 17 Hexagonal nut...
Page 219 Service Training Section Page RENEWING THE PISTON SEALS Condition: Cylinder removed - Clamp the cylinder with the eyebolt of the cylinder barrel (8) in a vise. - Open the flanged retainer for the cylinder head (13) and screw the cylinder head out of the barrel. - Pull the piston rod assembly out of the barrel.
Page 220 Section Service Training Page...
Page 221: Mast
Section Service Training Page MAST...
Page 222: Mast Removal
Section Service Training Page 4.8.1 MAST REMOVAL - Remove the forks. - Lower the fork carriage. - Tilt the mast fully forward. - Disconnect the hoses (6) on the fitting (7). - Unscrew the overhead guard bearings on the left and right and slide the overhead guard back. - Remove the left and right tilt cylinder pivots, tilt the cylinder up and secure it.
Page 223: Lift Cylinder Removal, Installation
Section Service Training Page 4.8.2 LIFT CYLINDER REMOVAL, INSTALLATION - Start the engine, operate the lift hydraulics and raise the fork carriage (8) approx. 1 metre. - Pry out the retaining ring (1) of the cylinder to be removed. - Block up the inner upright (2), operate the lowering control lever until the inner upright is supported by the block and continue to operate the lever until the piston rod of the cylinder to be removed is fully lowered.
Page 224: Sealing The Lift Cylinder
Section Service Training Page 4.8.3 SEALING THE LIFT CYLINDER H 70/80, DEVIATION FROM H 50/60 1 Piston rod diam. 68 - H 50/60 only 2 Wiper 12 Piston head with tang (top piston head) 3 Cylinder head 4 Grooved ring 13 Retaining ring 14 Piston rod - tube diam.
Page 225 Section Service Training Page SEALING THE H 50/60/70/80 LIFT CYLINDER Condition: Cylinder removed - Hold the cylinder at the 42 mm hexagon head (11). - Slightly heat the cylinder head (3) in the area of the thread and unscrew from the cylinder barrel (8) with a suitable socket spanner.
Page 226 Section Service Training Page...
Page 227: Lp Gas Model H 50/60/70/0, Type
Section Service Training 12.05 Page LP GAS MODEL H 50/60/70/0, TYPE 353 4.9.1 DRIVE ENGINE 4.9.1.1 TECHNICAL DATA ON ENGINE 4.9.1.1.1 TECHNICAL DATA ON ENGINE UP TO 12/2004 Engine type Perkins 1006.6 T List of components YF 80929 Power 72 kW Compression rating: 13 bar wear limit: 10 bar...
Page 228: Technical Data On Engine From 01/2005
Section Service Training 12.05 Page 4.9.1.1.2 TECHNICAL DATA ON ENGINE FROM 01/2005 Engine type Perkins KVT 1000.6 EGSIT List of components YF 80929 Power 72 kW Compression rating: 13 bar wear limit: 10 bar Max. admissible pressure difference 2 bar Rated speed 2100 rpm Idling speed...
Page 229: Note On The Engine Number
Section Service Training 12.05 Page 4.9.1.2 NOTE ON THE ENGINE NUMBER The engine number is printed on a plate, which is affixed to the side of the injection pump (1) or at the back, on the cylinder block (2). BREAKDOWN OF THE ENGINE NUMBER 80929 660 0739 Year of manufacture...
Page 230: Changing And Tensing V-Belt
Section Service Training 12.05 Page 4.9.1.3 CHANGING AND TENSING V-BELT CHANGING THE V-BELT - Remove cover (1) on the rear panel. - Open engine cover - Loosen hexagon nut (3) on adjusting rail. - Loosen fixing screw (4). - Press alternator (5) against the engine. - Turn support with LP gas tanks towards the back on the side.
Page 231: Checking And Setting Valve Clearance
Section Service Training 12.05 Page 4.9.1.4 CHECKING AND SETTING VALVE CLEARANCE The valve clearance is to be checked and adjusted only with the engine cold. - Remove valve cover. - Turn the engine with screwdriver through open- ing in the middle housing on toothed flywheel ring until the valves on the 6 cylinder overlap.
Page 232: Removing And Installing The Cylinder Head
Section Service Training 12.05 Page 4.9.1.5 REMOVING AND INSTALLING THE CYLINDER HEAD REMOVING THE CYLINDER HEAD - Loosen cylinder head screws uniformly and gradually in an alternating spiral sequence, as shown in the diagram. - Check cylinder head screws, with a ruler (1), for deformation of the screw shaft (2).
Page 233 Section Service Training 12.05 Page - Insert new cylinder head seal without additional sealant (B). NOTICE: Before installation of the cylinder head, clean the thread holes in the engine block. - In order to keep the cylinder head seal in the correct position for assembly of the cylinder head, screw two 1/2 UNF stud bolts into the motor block (C).
Page 234 Section Service Training 12.05 Page - If there is no torque measuring tool (1) available, mark the position of each individual screw on the cylinder head in relation to a corner point (A). - Mark the correct angle (in a clockwise direction) on the top of each screw in accordance with length (S, M or L).
Page 235: Electrical System
Section Service Training 12.05 Page 4.9.2 ELECTRICAL SYSTEM 4.9.2.1 ELECTRONIC IGNITION SYSTEM 4.9.2.1.1 ELECTRONIC IGNITION SYSTEM UP TO 12/2004 The motor is equipped with a Bosch contactless transistor-coil ignition (TSZ [German abbreviation]) . Control of the spark ignition without mechanical contact provides the following advantages: - Ignition electronics and ignition generator work with no wear and consequently need no maintenance whatsoever.
Page 236 Section Service Training 12.05 Page COMPONENTS OF A TRANSISTOR IGNITION SYSTEM 1 Battery 2 Ignition starting switch 3 Ignition coil 4 Switchgear 5 Transmitter 6 Ignition distributor 7 Spark plug(s) FUNCTIONING OF THE IGNITION SYSTEM The ignition system consists of the following components: Battery (1) as the energy source.
Page 237 Section Service Training 12.05 Page INDUCTIVE ACTIVATION OF THE IGNITION Permanent magnet (1) and induction winding (2) form the Ignition distributor with induction-type stator. The rotor, which rotates against the stator, is positioned pulse generator on the timer core (4) located on the ignition distributor shaft. The core and rotor are made of soft magnetic steel and have pointed extensions (stator arms and rotor arms).
Page 238 Section Service Training 12.05 Page FUNCTIONING OF THE TRANSISTOR COIL IGNITION (TSZ) The a.c. control voltage delivered by the induction generator is converted into rectangular pulses in the switchgear. These pulses control the switching on and off of the primary coil current and thus the induction of the high voltage in the secondary winding of the ignition coil.
Page 239 Section Service Training 12.05 Page...
Page 240: Electronic Ignition System From 01/2005
Section Service Training 12.05 Page 4.9.2.1.2 ELECTRONIC IGNITION SYSTEM FROM 01/2005 FUNCTIONAL DIAGRAM 1 Ignition switch 2 Battery 3 Ignition electronic unit 4 Ignition coil 5 Spark plugs 6 Pickup 7 Toothed disc...
Page 241 Section Service Training 12.05 Page DESCRIPTION The engine is equipped with an integrated electronic ignition system without contact breaker points. Due to its design, the ignition system is reliable, non-adjustable and has the following advantages: - No centrifugal advance. - Permanent stability of the ignition timing curve. - High secondary voltage.
Page 242 Section Service Training 12.05 Page TRANSMISSION OF THE PULSES The purpose of the advance angle sensor (generator) is to generate a pulse whenever it passes a tooth. The electronic controller receives a unique pulse when- ever a specially formed tooth passes the generator. This allows the top dead centre point (TDC) to be determined accurately.
Page 243 Section Service Training 12.05 Page CHECKING THE IGNITION TIMING A timing light is required for measuring the ignition point. It must be connected between the ignition coil and spark plug of the number 1 cylinder. For the check, the ignition coil must be unscrewed from the bracket of the number 1 plug.
Page 244 Section Service Training 12.05 Page MARKING THE FIRING POINT The firing point is fixed by the ignition electronics and can only be adjusted in the direction of "retarded" with appropriate resistors (see circuit diagram). 1 Firing point mark on housing 2 Firing point mark on flywheel FIRING POINT CHARACTERISTIC CURVE FOR 1006-EGSI (white...
Page 245: 4.9.2.1.2.1 Mechanical Ignition Timing
Section Service Training 12.05 Page The firing point caracteristic curve is controlled by a resistor. The picture besides shows the position of the resistor in the truck. 4.9.2.1.2.1 MECHANICAL IGNITION TIMING SPECIAL TOOLS REQUIRED Timing pin for ignition system Part no. 000 008 61 00 Torx driver for ignition system ET-Nr.
Page 246 Section Service Training 12.05 Page CHECKING THE MECHANICAL IGNITION TIMING ARRANGEMENT IN SITU - Set cylinder 1 of the internal-combustion engine at top dead centre on the compression stroke. - Pull off the connector of the ignition control unit (1). - Unscrew and remove the ignition control unit (1).
Page 247 Section Service Training 12.05 Page ADJUSTING THE TOOTHED DISC IN SITU - Set cylinder 1 of the internal combustion engine at top dead centre on the compression stroke. - Pull off the connector of the ignition control unit (1). - Unscrew and remove the ignition control unit (1). - Loosen the screw (6).
Page 248 Section Service Training 12.05 Page INSTALLING THE IGNITION CONTROL UNIT NOTE: Prior to installing the ignition control unit, set cylinder 1 of the internal combustion engine at top dead centre on the compression stroke. - Push timing pin (9) through the recess in the hub into the hole in the housing.
Page 249: Electronic Engine-Speed Control
Section Service Training 12.05 Page 4.9.2.2 ELECTRONIC ENGINE-SPEED CONTROL FUNCTION OF THE CONTROL SYSTEM With gas-propellant trucks, the engine speed is kept constant, up to the performance limits of the engine, with the electronic control system, in spite of varying loads caused by the drive and lift hydraulics. Thus the engine power corresponds to the appropriate r.p.m., according to the pedal setting (transmission).
Page 250 Section Service Training 12.05 Page BLOCK DIAGRAM OF THE ENGINE SPEED REGULATOR 1 Perkins gas engine 7 Actual value signal processing 2 Flywheel with starter ring gear 8 Nominal value / actual value comparison 3 Speed indicator 9 PID regulator 4 Speed setting cylinder (hydraulically controlled) 10 Output stage 5 Nominal value transmitter (rotary potentiometer)
Page 251 Section Service Training 12.05 Page NOMINAL VALUE TRANSMITTER The nominal value transmitter (5) is adjusted, via a hydraulic modulator (4), in accordance with the pedal position and the actuation of the operating hydraulics. This adjustment changes the nominal value transmitter (5) into a proportional electrical signal.
Page 252: Electrical System Circuit Diagram Up To 12/2004
Section Service Training 12.05 Page 4.9.2.3 ELECTRICAL SYSTEM CIRCUIT DIAGRAM 4.9.2.3.1 ELECTRICAL SYSTEM CIRCUIT DIAGRAM UP TO 12/2004 Ignition control device 33-35 V1-3 Decoupling diodes 16,18, Actual speed transmitter 47,48 Decoupling diode Set speed transmitter 46-48 15-pin plug 9-28 Ignition distributor 29-34 12-pin plug 3-21,...
Page 255 Section Service Training 12.05 Page...
Page 256: Electrical System Circuit Diagram From 01/2005
Section Service Training 12.05 Page 4.9.2.3.2 ELECTRICAL SYSTEM CIRCUIT DIAGRAM FROM 01/2005 Ignition control device 49-66 Resistor 51-53 Actual speed transmitter 74-75 Ignition starter switch 11-15 Set speed transmitter 75-77 Engine temperature switch Oil temperature switch Spark plug cylinder 1 Oil pressure switch Spark plug cylinder 2 Suction filter vacuum switch...
Page 259: Propellant Gas System
Section Service Training 12.05 Page 4.9.3 PROPELLANT GAS SYSTEM 4.9.3.1 DIAGRAM 1 Drive motor 2 Intake manifold 3 Mixer 4 Vacuum conduct Mixer - gas shutoff valve 5 Vacuum conduct Intake manifold shutoff valve 6 Gas conduit Vaporisor - Mixer 7 Vacuum conduct Mixer - secondary stage of vaporisor 8 Cooling water conduit...
Page 260: Functional Description Of The Propellant Gas System
Section Service Training 12.05 Page 4.9.3.2 FUNCTIONAL DESCRIPTION OF THE PROPELLANT GAS SYSTEM The various stages of the gas system are described below with their operating positions: OFF POSITION - Ignition start switch (11) open. - Electromagnetic shutoff valve (12) in open position. - Vacuum-controlled shutoff valve (14) closed.
Page 261 Section Service Training 12.05 Page STOPPING By switching off the ignition, the throttle valve in the propellant gas mixer (3) is closed. At the same time, the distributor valve (11) switches to open position, and the low pressure still present in the system is thereby led through the conduct (5) of the secondary diaphragm in the vaporisor (9) by the engine runoff in the intake manifold.
Page 262 Section Service Training 12.05 Page VAPORISOR - PRESSURE REGULATOR MODEL E 1 LPG intake 2 Cooling water intake/outlet 3 Connection for compensating line 4 Outlet for evaporated gas 1 LPG inlet 2 Primary valve 3 Primary diaphragm 4 Secondary diaphragm 5 Manual actuator 6 Actuating lever 7 Spring of secondary diaphragm...
Page 263 Section Service Training 12.05 Page OPERATION OF THE VAPORISOR The LPG must be moved in gaseous form to process it with the intake air in the mixer as a flammable mixture. This is achieved by means of the vaporisor, which is heated by the engine cooling water. It works as follows: The IMPCO vaporisor is a combined two-stage regulator with vaporisor.
Page 264 Section Service Training 12.05 Page MAINTENANCE ON VAPORISOR Maintenance on the vaporisor should include the checking of the secondary valve actuating lever (1). The Impco maintenance kits are used for two different vaporisor types (series E and EP). As a result, a check must be carried out, and, if necessary, the actuating lever (1) has to be bent accordingly.
Page 265 Section Service Training 12.05 Page PROPELLANT GAS MIXER The correct proportions for the gas-air mixture are important for problem-free running of the engine. For this purpose, a mixer valve (the mixer) serves for the correct dosing of gas and air. 1 Mixture outlet to engine 5 Full load mixture –...
Page 266 Section Service Training 12.05 Page It works as follows: When the engine starts, a vacuum is passed through the connection (4) to the gas shutoff valve and opens the valve. This enables LPG to flow to the vaporisor and from there to reach the mixer via connection (6) in a gaseous state.
Page 267 Section Service Training 12.05 Page FUNCTIONING OF THE VACUUM-CONTROLLED SHUTOFF VALVE When the engine is off, the shutoff valve is in closed position. No LPG can flow to the vaporisor. When the engine is started, a vacuum is present in the intake section, which develops through the intake stroke of the engine.
Page 268: Inspections And Adjustments
Section Service Training 12.05 Page 4.9.4 INSPECTIONS AND ADJUSTMENTS 4.9.4.1 IGNITION SYSTEM CHECKING THE FIRING POINT NOTE: The firing point can only be checked and ad- justed dynamically using a strobe light. - Let the engine warm up. - Stop engine and switch off ignition. - Connect strobe lamp according to manufacturer’s instruc- tions.
Page 269 Section Service Training 12.05 Page INSPECTION OF THE IGNITION SYSTEM Transistor-coil ignition (TSZ) switchgear Battery Ignition distributor with induction-type pulse Ignition starting switch generator Ignition coil IGNITION CABLE Resistance 2.5 – 4 kΩ depending on the length of the cable Resistance of the cable from terminal 4 of the ignition coil to the central connection of the distributor head: 22 –...
Page 270 Section Service Training 12.05 Page SWITCHGEAR A1 TEST CONDITION - Ignition coil in order TESTING - Pull out plug from TSZ switchgear and press wire fuse. - Connect voltmeter to the plug between contact 4 (+) and 2 (-). - Switch ignition on. Target value: about the same as battery voltage, otherwise determine interruption on the basis of wiring diagram and remove it.
Page 271 Section Service Training 12.05 Page - Draw out the high-voltage transmission line terminal 4 from the ignition distributor and earth it with an emergency cable. - Plug two electric cables into the sockets of the two-pin plug of the induction transmitter, and tap the plus and minus sides of a 1.5 volt battery with their ends.
Page 272: Installation Of The Engine Speed Control System
Section Service Training 12.05 Page 4.9.4.2 INSTALLATION OF THE ENGINE SPEED CONTROL SYSTEM TARGET VALUE TRANSMITTER 1. Install terminal nut (6) on piston rod of adjustment cylinder (8) (terminal nut must make contact with adjustment cylinder housing). 2. Align red marking (5) on the target value transmitter (1) in line with the red marking on the housing. 3.
Page 273 Section Service Training 12.05 Page ACTUAL VALUE TRANSMITTER WARNING: For adjusting or installation work on actual value transmitter B1 and with X/B1 plugs disconnected (see engine speed control connection plan), the engine may in no circum- stances be started. Otherwise the engine races (no actual value signal for speed control N2 ). - Loosen nuts (2) and (3) to adjust [the transmitter].
Page 274: Inspection Of The Engine Speed Control System
Section Service Training 12.05 Page 4.9.4.3 INSPECTION OF THE ENGINE SPEED CONTROL SYSTEM Before starting these checks: - Jack the truck up securely so that both drive wheels can turn freely. - Lock brake pedal in “brake locked” position. - Engine is warmed up. APPLIANCES AND MEASURING TOOLS - Digital meter - Tachometer...
Page 275 Section Service Training 12.05 Page ENGINE SPEED CONTROL SYSTEM CONNECTION PLAN X/B1 Rotation speed actual value transmitter B1 X/B2 Rotation speed nominal value transmitter B2 Fuse F13, starting relay K2 X/Y1 Operating magnet Y1 X/N2 Speed regulator N2 NOTE: Plug X2 is in the central electrical system behind the covering of the second step. WARNING: Plug X/B1 may not be disconnected at the from the actual value transmitter during the starting procedure, since otherwise the engine races.
Page 276 Section Service Training 12.05 Page...
Page 277 Section Service Training 12.05 Page ELECTRONIC CONTROL SYSTEM ENGINE SPEED REGULATOR SUPPLY VOLTAGE - Connect voltmeter between the connections X/N2:3 and X/N2:25 on the disconnected plug X/N2. - Switch ignition on. - The meter should show 12 V (= supply voltage) from engine speed regulator N2. NOTE: If this value is not obtained, check cabling (+) and (-) supply line.
Page 278 Section Service Training 12.05 Page - Voltage measurement between connections X/B2:2 and X/B1:2. (Voltage value of the basic setting). The plugs remain connected. Insert the measuring prods at the indicated measuring points. For this purpose, the rubber bush must be removed from plug X/B1. Meter shows voltage of 750 ±...
Page 279: Adjustment Of The Propellant Gas Mixers
Section Service Training 12.05 Page 4.9.4.4 ADJUSTMENT OF THE PROPELLANT GAS MIXERS Operating magnet Lock nut Full load mixture adjustment screw Lever Idling mixture adjustment screw Limit stop Mixer Limit stop screw Connecting rod ASSEMBLY - Close throttle valve manually. - Adjust limit stop screw (9) so that with the throttle valve at the limit stop (8) closed, it approaches the assembly, and then turn back 1 more turn.
Page 280 Section Service Training 12.05 Page ADJUSTING THE CO CONTENT Prerequisites for adjustment: - Firing point checked and if necessary corrected: desired value 18 ± 2 ° before TDC (from 01/2005: 8 ± 2 ° before TDC). - With truck warmed up, hydraulic oil at 60 – 70 °C, operating hydraulics pressure relief valve set to 265 bar.
Page 282 Linde Material Handling 63701 Aschaffenburg Postfach 10 01 36 Telefon (0 60 21) 99-0 Telefax (0 60 21) 99-15 70 http://www.linde.de/linde-stapler 353 804 2401.0906 eMail: service.training@linde-fh.de...

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