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Service Training

Section

4.9

Page

12

12.05

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.

NOTES:

At this point we would point out that the switchgears of the TSZ are only safe in certain
circumstances from polarity reversal from switching. For instance, an incorrect connection of
the battery to the [truck’s] power supply system must be detected and corrected within a few
seconds, otherwise there is a danger that the electronics will be damaged.

The plug-in connections on the switchgear and on the ignition distributor are made in such a
way that they can only be fitted with the correct polarity (moulded plugs). Therefore no polarity
reversal is to be feared because of these components.

As a rule, electronic ignition systems have higher ignition power than traditional ignition
systems. Electronic ignition systems work in a power range that is potentially lethal if bare
terminals and voltage-carrying parts are touched. This applies both to the low voltage parts
(primary current circuit) and the high voltage parts (ignition circuit) of such equipment.

When working on the ignition system, the ignition must always be switched off or the power
source to be disconnected. Such operations include:

- Changing of parts such as spark plugs, ignition coils or transformers, distributors, cables, etc.

- Connecting of engine test devices such as timing lights, dwell-tachometers, ignition oscillo-

scopes, etc.

If it is necessary to switch on the ignition in order to work on the ignition system or the engine,
dangerous voltages occur in the whole ignition system both in its components and in the wiring
harness, as well as in the diagnostic connector, the tachometer connection, the plug
connections and the test equipment.

So: TAKE CARE WHEN WORKING ON ELECTRONIC IGNITION SYSTEMS!!!

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Summary of Contents for H 50 D

Page 1: ...This training material is only provided for your use and remains the exclusive property of LINDE MATERIAL HANDLING 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 ...

Page 2: ......

Page 3: ...nts 18 4 1 2 2 Engine specifications 20 4 1 2 2 1 Explanation of the engine number 11 4 1 2 3 Replacement of V ripped belt 22 4 1 2 4 Adjusting valve clearance 23 4 1 2 5 Checking and adjusting leak fuel free injection nozzles 24 4 1 2 6 Thermostat 30 4 1 2 7 Checking the compression pressure 32 4 1 2 8 Cylinder head 33 4 1 2 9 Injection pump 35 4 1 2 9 1 Adjusting the begin of delivery 35 4 1 2 9...

Page 4: ... 03 04 38 4 2 4 3 Disc brake repairs 39 4 2 4 4 Reduction gearbox GR 80 06 with multiple disc brake 40 4 2 4 5 Repair on the reducing gear GR 80 06 41 4 2 5 Troubleshooting 48 4 2 5 1 Connecting diagram for troubleshooting 48 4 2 5 2 Tools and aids for measurements 50 4 2 5 3 Explanations to troubleshooting 52 4 2 5 4 Hydraulic speed control for the engine 53 4 2 5 4 1 Functional test 53 4 2 5 4 2...

Page 5: ...12 4 4 4 5 Steering stop adjustment 13 4 5 Controls 1 4 5 1 Accelerator and brake pedal adjustment 2 4 5 2 Speed control 5 4 5 2 1 Speed control up to 10 95 5 4 5 2 2 Speed control from 11 95 7 4 5 3 Medium wheel speed 8 4 5 4 Start of drive wheel rotation 9 4 5 5 Brake shaft stop screws 10 4 5 6 Symmetry of the travel control 11 4 5 6 1 Drive wheel start of rotation 11 4 5 6 2 Engine speed increa...

Page 6: ... 4 8 3 Sealing the lift cylinder 4 4 9 LP gas model H 50 60 70 0 Type 353 1 4 9 1 Drive engine 1 4 9 1 1 Technical data on engine 1 4 9 1 1 1 Technical data on engine up to 12 2004 1 4 9 1 1 2 Technical data on engine from 01 2005 2 4 9 1 2 Note on the engine number 3 4 9 1 3 Changing and tensing V belt 4 4 9 1 4 Checking and setting valve clearance 5 4 9 1 5 Removing and installing the cylinder h...

Page 7: ...unctional description of the propellant gas system 34 4 9 4 Inspections and adjustments 42 4 9 4 1 Ignition system 42 4 9 4 2 Installation of the engine speed control system 46 4 9 4 3 Inspection of the engine speed control system 48 4 9 4 4 Adjustment of the propellant gas mixers 53 ...

Page 8: ...Service Training 12 05 ...

Page 9: ...er 85 kW at 2250 rpm Opening pressure of injection valve 260 bar Compression ratio 17 5 1 Compression 28 33 bar Maximum difference in pressure 4 bar Firing order 1 5 3 6 2 4 Valve clearence cold inlet 0 3 0 1 mm outlet 0 5 0 1 mm Lower idling speed 750 50 rpm Upper idling speed 2300 50 rpm Oil pressure at lower idling speed and 125 C oil temperature min 0 8 bar Count the cylinders beginning at the...

Page 10: ...anufacturer s plate with type and engine number 2 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 E external cooling series coolant water number of cylinders aspirated engine turbocharged ...

Page 11: ...in and remove the drivebelt Check the pulley for wear renewing it if necessary Install a new drivebelt TIGHTENING THE DRIVEBELT Turn the tensioning screw 3 clockwise until the required tension is obtained Check the tension with a gauge 1 Part No 000 941 9435 Tighten the screws 2 again Settings Initialinstallation 400 50 N Check after 15 minutes Operation under load and retighten the belt if necess...

Page 12: ...ature 80 C Valve clearance Inlet 0 3 mm Outlet 0 5 mm adjustable not adjustable VALVE CLEARANCE SCHEMATIC Crankshaft position 1 Turn the engine until the valve inlet and outlet of cylinder 1 are just open Crankshaft position 2 Turn the engine one full revolution 360 NOTE Whenanewrockercoverisinstalled increasethevalveclearanceby0 1mm Adjustthevalve clearance to normal values after 50 service hours...

Page 13: ... oil temperature below 80 C Carry out the preparations e g remove cylinder head cover Turn crankshaft until valve overlap on cylinder no 1 is reached This means Inlet valve starts opening outlet valve closes Crankshaft position 1 in accordance with corresponding adjustment diagram see valve clearance schematic Fix magnet of torque angle gauge on cylinder head Place torque anlge gauge 8190 with scr...

Page 14: ...crew with T handle and tighten locknut with socket wrench open end Observe instructions for tightening Adjust valve clearance for the remaining valves as described above Remove tools Tools required for adjustment Deutz part number 8190 8191 The required special tools may be ordered from the address below Please quote the corresponding ordering number WILBÄR Wilhelm Bäcker GmbH Co KG Postfach 14058...

Page 15: ...sure if necessary by changing the shims Specified pressure New injection nozzles 260 8 bar Pressure for re usability 255 8 bar ADJUSTING THE INJECTION NOZZLE OPENING PRESSURE Clamp the holder 110110 for the injection valve in a vise Place the top part of the injection holder into the holder 110110 and unscrew the union nut Sequence of disassembly 1 Union nut 2 Injection nozzle 3 Intermediate piece...

Page 16: ...hut off the compression tester pressure gauge The buzzing test is an audible test for determining if the needle is moving easily in the nozzle body New injection nozzles have a different buzzing behaviour as opposed to used ones Wear in the area of the needle seat lets the buzzing behaviour deteriorate A nozzle that does not buzz despite cleaning must be replaced A used injection valve must buzz a...

Page 17: ... 33 bar Max difference in pressure 4 bar NOTE The measured compression pressure depends on the RPM of the starter when the measurement is carried out and on the altitude of the place the engine is operated in For this reason it is not possible to define exact limits The compression pressure check is only recommended as a means of comparing all cylinders in relation to each other If the difference ...

Page 18: ... gap there are 3 different cylinder head gaskets which identifiable by holes Place the dial gauge along with spacers 10075C on the sealing surface of the cylinder block and set the dial gauge to 0 Turn the piston to TDC and note the projecting length of the piston at the points of measurement Select the correct cylinder head gasket according to the largest projecting length of the piston Projectin...

Page 19: ... cylinder head bolts for stretching see Visual check Lightly the oil and screw in the cylinder head bolts NOTE Use the cylinder head bolts no more than 5 times Insert the push rods Mount the rocker arm bracket Slightly oil and screw in the long cylinder head bolts Torque the cylinder head bolts as specified and according to the tightening sequence Pre tightening 1st step 30 Nm 2nd step 80 Nm Retig...

Page 20: ...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 L0 of the injection pump from 109 mm to 119 mm The metod of determining the thickness of the shims for the old versions remains the same Proceed as follows In the column marked EP read the EP code for cylinder 3 on the type plate on t...

Page 21: ...775 072 112 375 096 112 975 Take the corrected injection pump installation dimension EK in Table 1a 1b according to the EP code e g 111 725 mm Table 1a EP code beginning with 0 EK Code EK Code EK Code EK Code EK Code mm mm mm mm mm 120 0 120 6 121 2 149 121 8 173 122 4 197 120 025 120 625 121 225 150 121 825 174 122 425 198 120 05 120 65 121 25 151 121 85 175 122 45 199 120 075 120 675 121 275 152...

Page 22: ...Thickness Shim TS Thickness Ts Thickness SS SS mm mm mm mm 0 95 1 049 1 0 2 45 2 549 2 5 1 05 1 149 1 1 2 55 2 649 2 6 1 15 1 249 1 2 2 65 2 749 2 7 1 25 1 349 1 3 2 75 2 849 2 8 1 35 1 449 1 4 2 85 2 949 2 9 1 45 1 549 1 5 2 95 3 049 3 0 1 55 1 649 1 6 3 05 3 149 3 1 1 65 1 749 1 7 3 15 3 249 3 2 1 75 1 849 1 8 3 25 3 349 3 3 1 85 1 949 1 9 3 35 3 449 3 4 1 95 2 049 2 0 3 45 3 549 3 5 2 05 2 149 ...

Page 23: ...110460 and the torque spanner turn the injection pump several times clockwise and anti clockwise by 5 to 15 and determine the average friction torque RM e g 4 8 Nm Turn the injection pump anti clockwise as far as the stop with an average friction torque RM of 4 8 Nm 1 Nm 5 8 Nm and hold it in place Tighten the flange bolts alternately to a torque of 7 Nm 10 Nm and 30 Nm Remove device 100830 and us...

Page 24: ...x socket heads long version E 20 51 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 V belt tension gauge 100 110 Connector for compression pressure tester ...

Page 25: ...on valve 11 mm 110 460 Socket head for turning the injection pump 114 010 Tool for connecting glow plug cables 142 710 Removal tool hook for crankshaft sealing rings 142 890 Assembly tool for rear crankshaft sealing ring 142 900 Assembly tool for crankshaft sealing ring Clamping device for control rod Address your order for special tools to Fa Wilbär P O Box 14 05 80 D 42826 Remscheid 09 96 ...

Page 26: ...Page 18 Section 4 1 Service Training 09 06 4 1 2 ENGINE MODEL BF6M 2012 4 1 2 1 OVERVIEW OF ENGINE COMPONENTS ...

Page 27: ...ulley 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 14 Oil level dipstick 15 Provisions for attaching a compressor or hydraulic pump 16 Fuel filter cartridge 17 Öil filter cartridge 18 Liftingmagnet ...

Page 28: ...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 Valve clearence cold inlet 0 3 0 1 mm outlet 0 5 0 1 mm Lower idling speed 800 rpm Upper idling speed 2300 50 rpm Oil pressure at lower idling speed and 125 C oil temperature min 0 8 bar Count the cylinders beginning at the flywheel end ...

Page 29: ...facturer s plate with type and engine number 2 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 E external cooling series coolant water number of cylinders aspirated engine turbocharged ...

Page 30: ...nsioner pulley in opposite direction to the arrow until the V ripped belt is tensioned If the V ripped belt is used again make sure to observe the wear limit Measure the distance a between the lug of the movable tensioningarmandthestopofthe fixedtensionerhousing Ifthedistance a islessthan3mm theV rippedbeltmust be replaced The V ripped belt is equipped with a spring loaded belt tensioner pulley th...

Page 31: ...olution 360 NOTE When a new rocker cover is installed increase the valve clearance by 0 1 mm Adjust the valve clearance to normal values after 50 service hours ADJUST CHECK THE VALVE CLEARANCE Unscrew the venting valve and swivel it to the side Dismount the cylinder head cover Crankshaft position as shown in adjusting diagram Prior to a valve clearance adjustment the motor must havecooleddownforat...

Page 32: ... the nozzle tester Press the lever down slowly Read the pressure at the start of fuel ejection and adjust the pressure if necessary by changing the shims NOTE Aftercheckingandadjustment thepressureinthespringchamberintheinjectionnozzlemust be reduced to zero before the injection nozzles are installed in the engine in order to prevent possible starting difficulties of the engine CAUTION During the ...

Page 33: ...ecified torque after the test Slacken tensioning nut by approx 180 and re tighten Use dolly 110 110 for injector Specified tightening torque 30 40 Nm Connect injector to nozzle tester 8008 Caution Beware of injection nozzle jet The fuel penetratesdeeplyintotheskinandmaycause blood poisoning With pressure gauge switched on slowly press lever of nozzle tester 8008 down The pressure at which the gaug...

Page 34: ...nts Use dolly 110 110 for the injector Sequence of parts disassembly and re assembly 1 Tensioning nut 2 Nozzle 3 Adapter 4 Thrust pin 5 Compression spring 6 Shim Adjust opening pressure by selecting appropriate shim A thicker shim will increase the opening pressure Re assemble injector Tighten tensioning nut Specified tightening torque 30 40 Nm Check injector on nozzle tester 8008 once again ...

Page 35: ...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 If there is dripping dismantle the injector and clean to remedy the leak If this does not work replace the nozzle by a new one No reworking allowed ...

Page 36: ...ea of theneedleseat Ifthereisnobuzzingofanozzledespite cleaning it must be replaced by a new one A used injector must produce an audible buzzing sound upon rapid actuation of the hand lever and provide for a weil atomised spray pattern The spray pattern may differ noticeably from that of a new injector RE INSTALLATION OF INJECTORS Place new slightly greased sealing rings onto injectors and install...

Page 37: ...t sealing cones are exactly aligned one on top of the other Subsequent bending is not allowed Injeetion lines must not be re used Tighten bolts of claws Specified tightening torque 16 5 Nm Pre tensioncapnutsofinjectionlinesoninjectionpumps and injection nozzles to a tightening torque of approx 5 Nm Then tighten cap nuts Specified tightening torque 25 3 5 Nm NOTE Use claw grip wrench 8018 ...

Page 38: ...smantleoutletconnectingpiece Removethermostat NOTE Collect coolant and dispose of it in accordance with legal standards Attach new sealing ring to thermostat Insert thermostat together with new sealing ring NOTE Mind operating position of thermostat Arrow venting notch points to the top Attach outlet connecting piece Required tightening torque 30 Nm ...

Page 39: ...tion of the exact opening point the temperature reading should take place as closely as possible to the thermostat however without contacting the latter The water must be continuously stirred to arrive at a uniform distribution of temperature The rate of rise of temperature should not exceed 1 C min at a maximum otherwise opening will be delayed correspondingly Measure dimension b on the thermosta...

Page 40: ...0 38 bar Max difference in pressure 4 bar NOTE The measured compression pressure depends on the RPM of the starter when the measurement is carried out and on the altitude of the place the engine is operated in For this reason it is not possible to define exact limits The compression pressure check is only recommended as a means of comparing all cylinders in relation to each other If the difference...

Page 41: ...he gap there are 3 different cylinder head gaskets which identifiable by holes Place the dial gauge along with spacers 100750 on the sealing surface of the cylinder block and set the dial gauge to 0 Turn the piston to TDC and note the projecting length of the piston at the points of measurement Compare the largest value with the table and determine the corresponding cylinder head gasket Projecting...

Page 42: ... cylinder head bolts for stretching see Visual check Lightly the oil and screw in the cylinder head bolts NOTE Use the cylinder head bolts no more than 5 times Insert the push rods Mount the rocker arm bracket Slightly oil and screw in the long cylinder head bolts Torque the cylinder head bolts as specified and according to the tightening sequence Pre tightening 1st step 30 Nm 2nd step 80 Nm Retig...

Page 43: ...302 119 275 231 119 875 255 120 475 279 121 075 303 119 3 232 119 9 256 120 5 280 121 1 304 119 325 233 119 925 257 120 525 281 121 125 305 119 35 234 119 95 258 120 55 282 121 15 306 119 375 235 119 975 259 120 575 283 121 175 307 119 4 236 120 0 260 120 6 284 121 2 308 119 425 237 120 025 261 120 625 285 121 225 309 119 45 238 120 05 262 120 65 286 121 25 310 119 475 239 120 075 263 120 675 287 ...

Page 44: ...ss Shim TS Thickness Ts Thickness SS SS mm mm mm mm 0 95 1 049 1 0 2 45 2 549 2 5 1 05 1 149 1 1 2 55 2 649 2 6 1 15 1 249 1 2 2 65 2 749 2 7 1 25 1 349 1 3 2 75 2 849 2 8 1 35 1 449 1 4 2 85 2 949 2 9 1 45 1 549 1 5 2 95 3 049 3 0 1 55 1 649 1 6 3 05 3 149 3 1 1 65 1 749 1 7 3 15 3 249 3 2 1 75 1 849 1 8 3 25 3 349 3 3 1 85 1 949 1 9 3 35 3 449 3 4 1 95 2 049 2 0 3 45 3 549 3 5 2 05 2 149 2 1 3 5...

Page 45: ...Press on device for control rod 100 830 Extractor pulling device 150 800 Extractor pulling device for injection valve 110 030 Remove pressure control valve and inspection cover Pull off cable connector from cut off solenoid governor andtemperaturesensor Swivelholdingplatesideways Remove engine cut off device or lock cover Press control rod into stop position using the stop lever Insert press on de...

Page 46: ...iring TCD Turncrankshaftbyapprox 120 oppositetothedirection of rotation of the engine Zünd OT firing TCD NOTE As viewed in direction of the flywheel Removethecorrespondinginjectionline injectionpump and injection valve NOTE Use claw grip wrench 8018 for the injection line Use extractor pulling device 150 800 with puller 110 030 for injection valve if jammed Pull out O ring if necessary using extra...

Page 47: ...ned shim on roller tappet Turn injection pump steering lever to center position more or less Apply AP 1908 compound to location hole in crankcase and to O rings of injection pump Mount injection pump and insert injection pump steering lever carefully into control rod NOTE The roller tappet for the respective injection pump must be on the base circle of the camshaft ...

Page 48: ...t 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: ...Turn knurled lock bolt back again Remove press on device 100 830 NOTE Check smooth movement of control rod from stop position to start position Actuate cut off lever to this end Mount new O ring NOTE Slightly oil O ring Press control rod into stop position using the cut off lever and retain Install engine shut off device Tighten bolts Plug in cable connector Specified tightening torque 21 Nm ...

Page 50: ... must face away from the claw Marking faces exhaust gas end Mount claws and tum in bolts loosely Fitnewinjectionlinewithsealingrubber Tightencapnut finger tight NOTE Sealing cones must be exactly in line when mounting the injection line Re bending is not allowed Injection lines must not be used twice Tighten bolt of claws Specified tightening torque 16 5 Nm ...

Page 51: ...ust 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 The hollow hexagon wrench size 5 for counter support must be inserted into the heater flange as shown on the photograph ...

Page 52: ...Page 44 Section 4 1 Service Training 09 06 The hollow hexagon wrench must be swivelled in anticlockwise direction ...

Page 53: ...led 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 Tightening torque for special screw 38 Nm ...

Page 54: ...ssion tester by IVEKA Automotive Technologies Schanz GmbH Talweg 8 D 75417 Mühlacker Lomersheim 8008 Nozzle tester 8012 Socket SW15 longdesignforinjectionvalve unionnut 8018 Clay grip wrench a flats 17 for injection lines 8024 Valve sealing pliers 8113 Torx wrench sockets E14 8114 Torx wrench sockets E20 long version 8115 V belt tension gauge ...

Page 55: ...ump 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 Turning gear 100 400 Dial gauge M2T with locking ring ...

Page 56: ...or 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 110 030 Extractor for injectors to be used with tool 150 800 110 110 Dolly for injector a flats 11 110 470 Assembly tool tor control rod sleeves 110 500 Special wrench for injection line ...

Page 57: ...or 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 Wilbär P O Box 14 05 80 D 42826 Remscheid ...

Page 58: ...Page 50 Section 4 1 Service Training 09 06 ...

Page 59: ...Service Training Page 4 2 Section 1 4 2 TRANSMISSION ...

Page 60: ...for the power steering system A gear pump serving as delivery pump is driven via an auxiliary power take off on the engine With the proven double pedal control a travel control unit is used to select the travel directions the control pressures for regulating the variable displacement pump primary control and the variable displacement motors secondarycontrol aswellasforadjustingthespeedoftheengine ...

Page 61: ...tion 1 engine revolution 27 cc 2 Engine KHD BFM 6 1012 E 3 Axial piston pump BPV 100 S 4 Axial piston pump MPF 55 S 5 Gear pump 27 cc 6 Traction wheels 7 Planetary hub reduction gearbox i 17 45 8 Disc brake 9 Axial piston motor HMV 105 S 10 Suction filter 11 Oil tank A Feed B Working hydraulics C Steering hydraulics ...

Page 62: ... 330 bar H 50 60 390 bar H 70 80 Boost control pressure 17 5 bar Max speed 2250 RPM Qmax at nmax 225 l min Qmax of feed pump 60 l min Type of control hydraulic Operation hydraulic remote control Start end of control 4 10 bar Overload protection hydraulic power control load sensing Pump drive Curved teeth coupling TANDEM PUMP 1 pump for working hydraulics Type MPF 55 S Definition of type designatio...

Page 63: ... Motor V Variable displacement 105 Max displacement in cc rev S Swashplate Number of pistons 9 Piston diameter 21 mm Swashplateangle displacement max 20 8 105 cc min 8 40 cc Start end of delivery 7 bar 10 bar 1 oil pressure operated disc brake mounted on extended engine shaft fully encapsulated running in oil required only as parking brake and emergency brake 1 planetary hub reduction gearbox i 17...

Page 64: ...holding valve 6 Way valve tilting 7 Way valve lifting 8 Pressure reducing valve 8a Restrictor 8b Restrictor 9 2 2 way valve pressure balance 10 Maximum pressure valve 265 bar 11 Tilt cylinder 12 Slow down valve 13 Lift cylinder B STEERING CONTROL VALVE ASSEMBLY 14 Pressure relief valve 15 Make up valve 16 Shock valve 17 Steering control valve C STEERING CYLINDER D SHUTTLE VALVE E OIL COOLER F COOL...

Page 65: ...PV 100 ASSY 19 Variable displacementpump 20 3 2 way valve Reversing lock 21 3 3 way valve 22 Control piston 22a Nozzles 1 44 mm 23 4 3 way valve pilot valve 24 Servo piston 25 Combined feed and pressure relief valve 330 20 bar H 50 60 390 20 bar H 70 80 26 Boost pressure valve 17 5 bar L WORKING HYDRAULICS PUMP 27 Axial piston pump MPF 55 M POWER STEERING PUMP 28 Gear pump 27 cc rev N POWER LIMITE...

Page 66: ...rictor 46 4 2 way valve brake actuation 47 2 2 way valve 48 4 3 way valve direction of travel 49 3 2 way valve signal for engine speed Q HYDRAULIC DRIVE UNIT ASSEMBLY 50 Pressure relief valve 50a Restrictor 51 3 3 way valve 52 Hydraulic motors 53 4 2 way valve pilot valve 53a Restrictor 53b Restrictor 54 Disc brakes 55 Control piston R 3 2 WAY VALVE EXTERNAL BRAKE RELEASE S OIL TANK 56 Suction fil...

Page 67: ...Seite 9 Abschnitt 4 2 Service Training HYDRAULIKSCHALTPLAN H 50 60 70 80 TYP 353 ...

Page 68: ...Abschnitt 4 2 Seite 10 Service Training 05 00 HYDRAULIKSCHALTPLAN H 50 60 70 80 D 02 BAUREIHE 353 ...

Page 69: ...Seite 11 Abschnitt 4 2 Service Training 05 00 HYDRAULIKSCHALTPLAN H 50 60 70 80 T 02 BAUREIHE 353 ...

Page 70: ......

Page 71: ...Service Training Page 4 2 Section 13 05 00 ...

Page 72: ...reducing valve 8 2 2 way valve pressure balance 9 Maximum pressure valve 265 5 bar 10 Shuttle valve 11 Pressure holding valve 12 Tilt cylinder 13 Slow down valve 14 Lift cylinder H 50 H 60 15 Line breakage protection 16 Lift cylinder H 70 H 80 C STEERING CONTROL VALVE ASSEMBLY 17 Pressure relief valve 18 Make up valve 19 Shock valve 20 Steering control valve D STEERING CYLINDER E BOOST PRESSURE PU...

Page 73: ...y valve pilot valve 29 Servo piston 30 Combined feed and pressure relief valve pressure relief valve 285 15 bar H50 pressure relief valve 305 15 bar H60 pressure relief valve 360 15 bar H70 80 pressure relief valve 420 15 bar H80 900 31 Boost pressure valve 17 5 bar J WORKING HYDRAULICS PUMP 32 Axial piston pump MPF 55 K POWER STEERING PUMP 33 Gear pump 27 cc rev L POWER LIMITER 34 6 2 way valve 3...

Page 74: ...on 46 2 2 way valve 12 bar 47 4 3 way valve direction of travel 48 Way valve direction of travel single pedal optional equipment N OIL COOLER O OIL FILTER 49 Filling device P HYDRAULIC DRIVE UNIT ASSEMBLY 50 Pressure relief valve 51 Restrictor 52 3 3 way valve 53 Hydraulic motor HMV 105 54 4 2 way valve pilot valve 55 Control piston 56 Disc brakes Q 3 2 WAY VALVE EXTERNAL BRAKE RELEASE R OIL TANK ...

Page 75: ...Page 17 Section 4 2 Service Training 09 04 HYDRAULIC CIRCUIT DIAGRAMM H 50 60 70 80 D 03 TYPE 353 ...

Page 76: ...Section 4 2 Page 18 Service Training 09 04 ...

Page 77: ...Service Training Page 4 2 Section 19 09 04 ...

Page 78: ... pressure When an accelerator pedal is depressed way valve 48 determines the direction of travel while valve 49 and pressure reducing valve 43 establish the pilot pressures controlling engine speed and pump output Whenthestrokeoftheacceleratorpedalcreatesadifferentialpressureof4barbetweenYandZ thepump begins delivery and the truck starts to move At the same time a pressure of 7 bar goes from valve...

Page 79: ...late angle maximum rpm II Operation Brake 43 Pressure regulating valve swashplate angle 44 Pressure relief valve 11 bar 45 Restrictor for differential pressure 46 4 2 way valve braking 47 2 2 way valve 12 bar brake protection 48 4 3 way valve travel direction 49 3 2 way valve signal for maximum rpm ...

Page 80: ...Service Training Page 4 2 Section 22 09 04 ...

Page 81: ...of valve 29 is determined by the differential pressure between Y and Z If due to the selection of a travel direction a higher pressure exists at Z valve 29 is shifted to position a and the higher pressure Y goes to the pressure reducing valve 30 At the same time the pressure applied through valve 40 which is switched to position b by the feed pressure goes to the hydraulic motor remote control thr...

Page 82: ... motors stroke up from Qmin to Qmax increasing the torque at the traction wheels Any additional power requirements by the working and steering hydraulics cannot be served by the power limiter This overloads the engine and if the power requirement continues reduces its speed If the engine speed drops until the differential pressure between Y and Z is reduced to 4 bar the pump will downstroke to zer...

Page 83: ... isusedtomeasureadifferentialpressure whose size is proportional to the flow i e it varies with engine speed The nearly constant pressure upstream of the restrictor goes into the spring chamber of valve 18a whereas the speed dependent pressure is applied against the spring pressure When the engine speed reaches approx 2250 rpm valve 18a opens and sends the working pressure applied at port M throug...

Page 84: ... the inertia of the truck drives the engine via the hydraulic motors and pump and lets the engine overspeed during braking the braking distance would be very long The specified braking delay is achieved through the auxiliary braking and during reversing the reversing lock also becomes effective EXPLANATION When the pilot pressure for pump and engine control is preselected at Y by depressing the re...

Page 85: ... 21 to valve 20 shifting it to position a The pressure now goes through the shifted valve to port N spring chamber of engine speed control cylinder J pushing it against the speed signal applied at port V3 so that the injection pump is set to lower idling speed This pressure is also sent to port N at control valve block N shifting valve 40 to position a The 17 5 bar pressure from the feed oil passa...

Page 86: ...ists between valve 50 and low pressure Due the size of the nozzle 50a the quantity of oil emitted is fixed to 3 litres per hydraulic motor The quantity of oil leaving at the low pressure side is replaced by cool oil flowing in through the feed valves This method togetherwiththeleakagecausedbythehighpressure allowstheentirecirculatingoiltobereplacedseveral times per minute HOUSING FLUSHING The cool...

Page 87: ...Service Training Page 4 2 Section 29 09 04 ...

Page 88: ...ic pin 7 Position mark 8 Grooved nut 9 Setscrew 10 Springs 11 Nut 12 Threaded pin 13 Spring plate 14 Servo piston 15 Bleed screw 16 Reversal lock up to 4 94 16 1 Setscrew 16 2 Sealing nut 16 3 Screw 16 4 O ring 16 5 Adjustment spring 16 6 Valve piston 16 7 Valve spring from 5 94 16 1 1 Screw 16 1 2 Valve spring 16 1 3 Shims 16 1 4 O ring 16 5 Valve piston ...

Page 89: ...tric pin 6 back half way from the noted spanner position Lock the hexagonal nut 5 Manually bring the engine to maximum speed The wheels should not rotate Repeat the adjustment if necessary 4 2 3 1 2 PRIMARY ADJUSTMENT OF START OF CONTROL Let the engine run at low idle speed and slacken the grooved nut 8 By turning the setscrew 9 the pressure springs 10 are either tensioned or relieved so that the ...

Page 90: ...4 HYDRAULIC REMOTE CONTROL HPV 105 02 SERVO CONTROL 1 Control piston 2 Lever 3 Spring plate 4 Spring 5 Shims REVERSE LOCK OUT 6 Valve spool 7 Spring 8 Control circuit nozzles HYDRAULIC ZERO POSITION 9 Pilot 10 Pilot casing setscrew 11 Spring 12 Locknut ...

Page 91: ...ing screw 10 until the wheels start to turn Mark the spanner position Turn the adjusting screw back until the wheels start turning in the opposite direction Mark the spanner position Turn the adjusting screw 10 back to half of the marked position Tighten the locknut 12 Bring the engine up to maximum speed manually The wheels should not turn START OF PRIMARY CONTROL Connect a low pressure gauge to ...

Page 92: ...5 94 Valve adjustment with shims 16 1 3 Start the engine and carry out the test as for the version up to 4 94 NOTE Insert the shims Reversal lock is advanced Remove the shims Reversal lock is retarded 4 2 3 1 6 REDUCING THE TRUCK SPEED The maximum truck speed can be reduced as desired by the customer For this purpose it is only necessary to reduce the travel of the control piston 14 which reduces ...

Page 93: ... 09 04 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: ...Service Training Page 4 2 Section 36 09 04 4 2 4 1 REDUCTION GEARBOX WITH DISC BRAKE GR 80 02 03 04 ...

Page 95: ...rust washer 19 Grooved nut 20 Centring ring 21 Planet carrier II 22 Taper roller bearing 23 O ring 24 Retaining ring 25 Planet spider II 26 Cylindrical roller bearing 27 Wheel bolt 28 Wheel hub 29 Taper roller bearing 30 Shaft sealing ring 31 Cheese head screw 32 Axle flange 32a Cheese head screw 33 Ball 34 Sintered metal filter ventilation DISC BRAKE 35 Ball bearing 36 Brake piston 37 O ring 38 D...

Page 96: ... planet carrier items 10 to 17 Remove the retaining rings 24 from the planet carrier 21 journal Press the planetary gears 25 off the journal with a mounting iron or a puller Heat the grooved nut 19 and remove with a suitable spanner and torque converter NOTE The nut 19 is torqued to 2100 Nm and secured with Loctite Pull the planet carrier along with the centring ring 20 and wheel hub 28 from axle ...

Page 97: ...the pinion 44 onto the hydraulic motor output shaft Mark the position of the roll pin 50 in relation to the holes in the disc carrier 38 Introduce the disc carrier into the housing 46 and slide the discs with 2 small screwdrivers bit for bit over the toothing of the pinion 44 The disc carrier must always be pressed in further The mounting depth of the disc carrier is correct if the inlet of the re...

Page 98: ...C BRAKE 1 Wheel hub 2 Shaft seal 3 Tapered roller bearing 4 Plug 5 Pretensioning ring 6 Slotted nut 7 Planetary carrier II 8 Drain plug 9 Planetary gears 10 Planetary carrier I 11 Sun gear 12 Internal gear 13 Circlip 14 Pretensioning plate 15 Brake springs 16 Brake piston 17 Brake discs 18 Pinion ...

Page 99: ...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: ...Service Training Page 4 2 Section 42 09 04 Fastengearunitfordismountingandunscrewthehexagon socket screws 2x unscrew hexagon socket screw arrows Remove casing ...

Page 101: ...sted in by means of Loctite Heat to unscrew Pull out planetary carrier with 4 gearwheels Loosen groove nut Tightening torque 5300 200 Nm The groove nut is pasted in with Loctite Heat to loosen groove nut Groove nut spanner for gear unit GR 80 06 Purchse order number 399 900 70 79 Required to unscrew groove nut ...

Page 102: ...ting 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 5 Casing ...

Page 103: ...45 09 04 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: ... Section 46 09 04 Cover groove nut with Loctite FK2 and tighten with 5300 200 Nm 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: ...Section 47 09 04 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: ... outlet speed control cylinder and remote control inlet for hydraulic motors N Reversing lock outlet inlet of speed control cylinder and power limiter P3 Hydraulic oil filter inlet P4 Hydraulic oil filter outlet V Travel control outlet speed control cylinder inlet X Power limiter inlet of remote control for hydraulic motors Y Z Travel control outlet YF ZF power limiter Y Z Power limiter outlet inl...

Page 107: ...Service Training Page 4 2 Section 49 09 04 ...

Page 108: ...re the same as those in the catalogue under the same consecutive number All parts contained in the test box are also identified by 1 in the description of the troubleshooting The rest of the designation corresponds to the identification of the test box manufacturer Example Text box designation banjo bolt 7 a troubleshooting designation banjo bolt 1 7 a 1 1 1 3 1 5 1 7 a 1 7 b 1 12 1 13 1 17 1 18 1...

Page 109: ...ar 1 13 High pressure gauge 0 600 bar 1 17 Banjo bolt M 18 x 1 5 with plug 1 18 Banjo bolt M 18 x 1 5 with M 14 x 1 5 bore 1 19 Banjo bolt M 18 x 1 5 with M 14 x 1 5 bore 1 24 Cover plate 50 x 38 1 31 Round connector 1 32 Banjo bolt with shut off valve ADAPTER NO CONSISTING OF I Adapter nipple 1 3 Screw coupling 1 1 II Banjo bolt 1 7 a Screw coupling 1 5 III Banjo bolt 1 7 b Screw coupling 1 5 IV ...

Page 110: ... breather valve The installation points for pressure gauges or plugs are shown in the line hook up diagram In some test steps the hydraulic motors must be disconnected In this case proceed as follows Loosen the high pressure flange fastening screws of the hydraulic motor to be disconnected by about 5 turns pull back the hoses slide the cover plate 1 24 50 x 38 between the motor flange surface and ...

Page 111: ... injection pump lever pedals as far as the stop Engine Then with the pedal released speed reaches the upper move the lift lever to the Lift idling speed of 2250 50 RPM position hold there and and then drops to the lower then release the lever idling speed of 750 50 RPM Release the brake fully depress the F and R accelerator pedals consecutively and release them Caution Rotating wheels If these res...

Page 112: ...test Connect LP gauge with adapter V to port F of power limiter Start engine and read pressure Pressure 17 5 21 bar econnectspeedcontrollinkage releasebrakeandfullydepressoneaccelerator pedal CAUTION Rotating wheels Re apply brake and fully depress one accelerator pedal yes no yes no See troubleshooting Hydro static travel drive no yes Engine speed of 2250 50 rpm is obtained B A Speed control cyli...

Page 113: ...nder and repeat test Shuttle valve D faulty yes no B A no yes no yes no yes C Speed control cylinder extends fully Engine accelerates to 2250 50 rpm Speed control cylinder extends fully Engine accelerates to rated speed Speed control cylinder extends fully Engine accelerates to rated speed Pressure rise is directly proportional to stroke of pedal up to 14 bar minimum Connect LP gauge with screw co...

Page 114: ...tor pedal and wait until full engine or wheel speed is reached Then depress the accelerator pedal for the opposite direction Engine speed drops to low idling rpm and only starts to rise when wheels turn in new direction yes yes yes yes no Jump in speed to 1100 1300 rpm No increase in speed or increase too low D Valve 20 malfunctioning Release accelerator pedal and then depress it about 1 3 of peda...

Page 115: ...lvefaulty Pressure balance faulty Remedy the fault or renew control unit Engine speed of 2250 50 rpm is reached With accelerator pedals released pull the lift lever fully back and hold there Install LP gauge with screw coupling 1 1 to port VS of working hydraulics control valve speed control signal Start engine pull the lift lever fully back and hold there Fully extend the lift cylinder and then m...

Page 116: ...Traction wheels can be try to turn right or left turned traction wheel again After this test lower the truck and check the braking behaviour of the rolling vehicle Perform this check by fully depressing the brake pedal when an accelerator pedal is fully depressed The wheels must lock without the truck pulling to one side If the result of the test is not as described determine the cause by troubles...

Page 117: ...it Remove adapter IV Reconnect external brake release port R and close the grummet Start engine release brake and fully depress F and R accelerator pedals Disc brake of rotating wheel not functioning correctly Remove and eliminate fault Braking system okay Traction wheels rotating yes no yes no yes no yes no Check Hydrostatic travel drive A Install LP gauge with adapter IV to external release port...

Page 118: ...peat the test A Connecting oil passage in valve 46 clogged cleanit Brakeshaftadjusted incorrectly correct the adjustment Valve 46 faulty repairvalveorrenew travel control unit yes no Pressure 17 5 bar minimum Leak in right or left disc brake Repair the brake NOTE Oil will leak out at gearbox breather of wheel drive with the faulty brake ...

Page 119: ...ver seated on driver s seat Start engine Test Symptoms Beurteilung Sensitively depress F or Truck starts slowly Start of control okay R accelerator pedal without jerking fine control range until truck starts Truck jerks Start of control not okay Perform troubleshooting acc to following procedures 4 2 5 6 2 TROUBLESHOOTING Jack up and secure the truck so that both traction wheels can rotate freely ...

Page 120: ...ing travel control shaft into noticeable neutral position Tighten the clamping screw Determine Δp between ports YF and ZF no no no yes yes yes See Hydrostatic travel drive Δp 0 0 5 bar A B 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 Install LP gauge with adapter III at por...

Page 121: ...yes yes no yes no See Hydrostatic travel drive 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 direction of travel bushing or renew travel control unit Fully depress the F and R accelerator pedals consecutively and determine Δp Δp 11 0 1 bar yes no C D Adjust start of control see Primary adjustment o...

Page 122: ...and ZF With F and R accelerator pedals depressed to the stop set Δp to 11 0 1 bar Average wheel speed 155 165 rpm In order yes See Hydrostatic travel drive no Δp obtained yes no Fully depress the F or R accelerator pedal Measure the rotation of the left and right wheel and calculate the average wheel rpm Faultinhydraulicremote control Repair or renew remote control Fault in travel control unit Rep...

Page 123: ...DITIONS 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 position Front cover removed Engine and travel drive at operating temperature ...

Page 124: ...rts E and F of the power limiter and install LP gauge with adapter I directly to ports E and F Determine the Δp between ports E and F at idling speed Pressure now between 17 5 and 20 bar yes no B A Δp over 12 bar Read pressure at port F Boost pump 18 defective replace pump Check boost pressure valve 26 and increase spring tension ifnecessary Repeat the test Pressure between 17 5 and 20 bar Setting...

Page 125: ...hydraulic motor Repair or replace motor Disconnect the HP lines of left hydraulic motor repeat the test Disconnect HP lines of right hydraulic motor repeat the test Fault in right hydraulic motor Repair or replace motor Leakinremotecontrolfor left or right hydraulic motor Locate and remedythefaultorrenew the control Install a second LP gauge with adapter V at port E of power limiter Determine Δp b...

Page 126: ...ar minimum Install banjo bolt 1 17 with plug at ports E and F of the travel control unit Repeat the test Clean and re install nozzles in ports YF and ZF Repeat the test See Hydraulic speed control no yes Pressure at one gauge rises quickly to value obtained at port F while pressure at second gauge lags for a long time Valve 33 13 bar dirty or setting incorrect Clean or correct the setting Faultint...

Page 127: ...termine Δp between ports E and F See Hydraulic speed control Motor now reaches maximum speed at each side Δp between 12 and 14 bar Wheels rotate both in forward and reverse direction when pedals are depressed Reconnect lines to ports E and F and adjust valve 44 11bar atfullthrottle to a Δp of 11 12 bar Set valve 33 to 13 bar Release the brake and depress the F and R accelerator pedals consecutivel...

Page 128: ...ll LP gauge with adapter III to ports Y and Z of hydraulic remote control Start engine and read Δp with the brake released Pressure at port F still drops to below 17 5 bar Disconnect the right or left hydraulic motor repeat the test Read pressure at port F when accelerator pedals are depressed Pressure drops clearly under 17 5 bar Check the braking system see Hydraulic braking system Repeat the te...

Page 129: ... 0 5 bar Check or renew travel control unit Equal pressure can be achieved Check for equal pressure see Pressure equality and start of control 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 control Repair or renew the remote control Power limiter defective nozzles in ports YF ZF maybe clogged...

Page 130: ...mote control servo piston sticking or control cylinder of cradle defective Determine Δp by fully depressing the F and R accelerator pedals consecutively with the brake released Leak in hydraulic remote control Repair fault or renew remote control Install adapter III with LP gauge at ports ZF and YF of power limiter fully depress F and R pedals with brake released and engine running and determine Δ...

Page 131: ...ew in adapters II with plugs Install LP gauges and determine Δp with the brake released Install LP gauge with adapter III to ports Y and Z of remote control and determine Δp with the brake released Average wheel speed of 155 165 rpm achieved on both sides Leak in remote control Remedy fault or renew remote control Leak in power limiter control block Remedy fault or renew control block Travel contr...

Page 132: ...mine the average wheel speed Δp now 10 11 bar Remove adapter III and screw in adapter II with plug Determine Δp with the brake released and pedals fully depressed Δp of 11 11 bar obtained to both sides Fully depress the F and R accelerator pedals with the brake released and the engine running Read Δp when pedals are fully depressed Leak in the remote control unit Repair or renew the unit Leak in c...

Page 133: ...the Δp between ports F and X with the F and R pedals fully depressed 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 Fault in power limiter Eliminate the fault or renew it Oil leak in the remote control for hydraulic motors Locate and remedy fault see Qmin of hydraullc motors ...

Page 134: ...s in power unit for reverse travel Disconnect the left hydraulic motor repeat the test no yes Fault in right motor eliminate fault or renew the motor no yes HP and LP now in order HP and LP now in order HP far below specifications LP at least 17 5 bar Disconnect the right hydraulic motor repeat the test HP and LP pulsate or LP drops below 12 bar and HP does not rise HP 330 20 bar on H 50 60 390 20...

Page 135: ...d hydraulic test box adapter No 1 31 and 1 32 tachometer for diesel engine tachometer for wheel speed Test conditions for all the activities described below Truck jacked up and secured so that the traction wheels can rotate freely Floor plate removed Traction motor and travel hydraulics at operating temperature Engine speed reaches 2250 2350 rpm when the brake is released and the accelerator pedal...

Page 136: ...etermine average wheel speed with accelerator pedals fully depressed Under 58 rpm Over 58 rpm 58 65 rpm RPM too high Check Qmax of hydraulic motors Qmax of pump okay RPM too low Check adjustment of servo piston Repeat test 4 2 6 1 QMAX OF VARIABLE DISPLACEMENT PUMP BPV 100 A Start the engine and determine Δp between ports Y and Z Fully depress F and R accelerator pedals and determine Δp when fully...

Page 137: ...79 09 04 yes no Possible causes Bypass valve leaking Combined boost and pressure relief valve or output device leaking Control piston faulty Control piston of hydraulic remote control sticking A Qmax of pump in order Speed now 68 65 rpm ...

Page 138: ...stop screw 2 in until a noticeable resistance is felt and turn a further 1 2 turn at this point Repeat the test Wheel speed 116 130 rpm Lock the right traction wheel Start engine release brake fully depress one accelerator pedal and measure speed of left wheel no yes Speed now okay Qmax of left motor okay Check the right motor by locking the left wheel Remove left motor and bring remote control in...

Page 139: ... 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 Δp to one side 10 11 bar to the other side under 4 bar Δp between ports F and X 10 bar or more Check and adjust if necessary Qmin of hydraulic motors acc to following instructions Valve 40 in power limiter sticking in the lock position Valve...

Page 140: ...eed must be higher by a factor of 2 62 than when the valve is closed Example Wheel speed Required speed with valve close x factor at Qmin with valve open 60 rpm x 2 62 157 rpm The required speed can be adjusted with the stop screw 4 Tolerance range 0 10 rpm Turning screw in decreases rpm Turning screw out increases rpm In the secondary control the engine speed is a little lower depending on the op...

Page 141: ...Service Training Section 4 3 Page 1 4 3 CHASSIS ...

Page 142: ...d 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: ...verhead 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 Dismantle the left and right bearing bracket 7 Take off the overhead guard by lifting it up ASSEMBLY Place the overhead guard along with the mounted bearings 8 into the outer mast mounting ...

Page 144: ...80 Nm Usingamountingiron positiontheleftandrightrollermounts 4 withoutplayontheoverheadguardtube sections and handtighten the mount fastening screws Start the engine and tilt the mast forward and backward This will adjust the rollers at the widest section of the overhead guard practically without any play Torque the roller mount fastening screws to 80 Nm ...

Page 145: ...Service Training Section 4 4 Page 1 4 4 STEERING SYSTEM ...

Page 146: ... POWER STEERING CIRCUIT DIAGRAM B Steering control valve assy consisting of 14 Pressure relief valve 15 Make up valve 16 Shock valve 17 Steering control valve C Steering cylinder E Oil cooler F Cooler bypass valve 1 bar 28 Gear pump 27 cc rev ...

Page 147: ...ough 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 The maximum pressure on the primary side is set to 150 bar When the steering wheel is not operated the secondary valves 16 limit the restoring force and the peak pressures connected therewith to 220 bar The make up valves 15 ensure that the steerin...

Page 148: ...trol valve controlling the oil flow to the steering cylinder The axle body is mounted to the frame with shock mounts allowing the axle to swing on uneven ground The steering cylinder is mounted on the axle body with dowel pins and four bolts The track rod links have covered joint bearings on both ends and they are joined to the piston rod and steering knuckle with press in pins and roll pins These...

Page 149: ...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 Slowly lower the steering axle 1 with the axle block 2 Place an oil pan underneath Disconnect the tubes on both sides of the steering cylinder ...

Page 150: ...nd underpin it Coat the mounting screws 4 with Loctite 270 Fasten the two plates 3 and axle blocks 2 with screws 4 Torque the screws 4 to 395 Nm 39 5 mkp Connect the tubes on both sides of the steering cylinder Eliminate any air in the steering by turning the steering wheel through its full travel cycle about 10 times Mount the wheels Lower the truck Tighten opposite wheel mounting screws to a tor...

Page 151: ...ew it Fill the wheel bearing chambers around the taper roller bearing with grease as illustrated Position the wheel hub on the knuckle and drive on the bearing 5 Put the thrust washer 9 in place fit the screw 6 and tighten it to 150 Nm Turn the screw back to the nearest cotter pin hole and secure with a cotter pin Fill the cap 8 with lithium based grease Part No 733 740 0160 place it on the wheel ...

Page 152: ...e Training Section 4 4 Page 8 4 4 4 2 STEERING KNUCKLE REMOVAL AND INSTALLATION 1 Nut 2 Thrust washer 3 Knuckle body 4 Seal 5 Taper roller bearing 6 King pin 7 Knuckle 8 Taper roller bearing 9 Seal 10 Spacer ...

Page 153: ...e jack 5 NOTE The pin will drop when pressed out of the bearing seat It can be driven out with a drift punch and hammer Remove the knuckle 7 STEERING KNUCKLE INSTALLATION Place the steering knuckle 7 into the axle body Oil the kin pin 10 insert it from below and drive it in with a plastic hammer Press the pin 10 in fully with a jack 5 Fitthewasher 8 screwonthenut 9 andtightento600 Nm Filllithium b...

Page 154: ...the steering cylinder 7 Pull the steering cylinder 7 to the rear and so that the pin is positioned under the counterweight recess NOTE Support up the steering cylinder with wooden blocks Position the pipe 1 over the pin collar and support it against the counterweight recess Place the jack 5 on the ground put the press out pin 4 on the piston of the jack 5 and bring them in line Operate the jack 5 ...

Page 155: ... pin 4 into the fork on the piston rod of the steering cylinder 8 from below Place a jack 6 on the ground under the pin 4 Operate the jack and press in the pin 4 Remove the pipe 1 and centring pin 2 and secure with a roll pin Press the second pin in as describe above and secure with a roll pin Screw the union nuts for the two hoses 7 and 9 onto the fittings on the steering cylinder and tighten the...

Page 156: ... O rings 4 grooved ring 7 wiper 8 and guide band 6 out of the guide bushing Renew the O rings grooved ring wiper and guide band making sure that each sealing element is positioned correctly see detail A Remove the sealing ring 2 from the piston rod and replace with a new one Remove the second retaining ring 9 Remove the guide bushing 5 and renew the sealing elements Slightly grease or oil the guid...

Page 157: ...le track rod or steering cylinder Loosen the locknut 2 and screw out the M12x60 stop screw 1 approximately 10 turns Start the engine and turn the steering wheel until the hydraulic cylinder is fully extended Screw in the stop screw until it contacts the axle 3 Turn the steering wheel until the steering cylinder 4 is centred screw in the stop screw 1 2 to 3 turns and lock it with the nut 2 NOTE Adj...

Page 158: ...Service Training Section 4 4 Page 14 ...

Page 159: ...Service Training Page 1 Section 4 5 4 5 CONTROLS ...

Page 160: ...djusting lever 4 on the travel control shaft shaft is in the neutral position when delivered BRAKE PEDAL Slide the stop 8 for the non depressed pedal full up in the elongated holes Slide the adjusting lever 5 onto the brake shaft of the control Using a flat 10 mm spanner turn the shaft clockwise as far as the stop and clamp the adjusting lever in this position Slide the stop 8 in the elongated hol...

Page 161: ...Service Training Page 3 Section 4 5 ...

Page 162: ...OWDEN 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: ...N 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 Tighten the screw 4 Slacken nut 6 and adjust dimension X to 0 1 mm by turning the ball cup 5 Lock the nut 6 against the ball cup 5 Check dimension X with a 0 1 mm feeler gauge 09 96 ...

Page 164: ...D 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 Tighten screw 4 Check dimension Y with a 0 1 mm feeler gauge 09 96 ...

Page 165: ...ad screws 3 Move the lever as far as the low idle stop 6 by rotating the threaded rod 5 and lock the threaded rod with the nut 4 Start the engine and fully extend the control cylinder 1 by operating the accelerator NOTE The brake pedal must be held in the fully depressed position Loosen both cheese head screws 3 Slide the retainer 2 on the lever 7 as far as the upper idle stop and fix with the che...

Page 166: ...orrectly 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 In this position measure the speed of the left and right wheel and calculate the average of both speeds Perform the same measurement with the left accelerator pedal depressed Specified speed 155 165 rpm 09 96 ...

Page 167: ...der CHECK Start the engine and release the brake pedal Depress the accelerator pedal for forward travel gently until the engine speed rises and the wheels start to rotate If the start of wheel rotation follows directly or at the same time as the increase in speed the adjustment is in order If the wheels rotate before the engine speed rises correct the setting as follows Loosen locknut 4 and adjust...

Page 168: ...s far as the stop Loosen locknut 2 Startengine Slowlyscrewinsetscrew 1 whileatthesametimeholdingbrakeshaft 5 clockwiseagainst the stop until the brake shaft has less clearance Now gently screw out setscrew 1 while holding the brakeshaft clockwise against the stop until the maximum pressure is obtained Then screw out setscrew a further turn and tighten locknut 2 Adjust the brake pedal as described ...

Page 169: ...the neutral position to start of rotation Depress the reverse pedal until the start of rotation and also measure the pedal stroke Thepedalstrokefromneutraltothestartofrotationshouldbeequalforforwardandreverse Anynoticeable difference should be corrected as follows Stop the engine Open the engine cover and remove the floor plate Slacken the clamping screw on the travel control lever Using a size 10...

Page 170: ...dal adjustment is in order TEST Sit down on the driver s seat Start the engine Test Symptoms Assessment Gently push forward and Speed increase with pedal Symmetry in order reverse pedal until engine stroke equal speed increases Speed increase with pedal No symmetry stroke not equal Adjust by turning in direc tion of travel the front bushing on travel control unit 09 96 ...

Page 171: ...ssessment Start the engine Dp between ports Y and Z Adjustment of pressure Release the brake rises to 11 0 1 bar relief valve 34 in order Alternately depress forward and reverse pedal as far as Dp between ports Y and Z Adjustment of pressure possible does not rise to 11 0 1 bar relief valve 34 not in or is larger order Adjust as follows Slacken locknut 7 at pressure relief valve 34 If Dp was too l...

Page 172: ...7 mm engine acceleration Pressure at control cylinder approx 6 bar approx 5 bar approx 7 bar at the start of acceleration Modification of control cylinder Remove Insert 1 mm shim 1 mm shim from control in control cylinder cylinder Dp Y Z at start of traction approx 4 bar wheel rotation Low engine idle speed approx 800 rpm approx 820 rpm approx 750 rpm Adjustment of accelerator The adjustment range...

Page 173: ...Service Training Page 1 Section 4 6 4 6 ELECTRICALSYSTEM ...

Page 174: ...icator light H12 Flasher indicator light H13 Fuel level warning light H24 Fan H25 Preheating H26 Soot filter warning light 4H7 Horn K2 Starter relay K3 Signal transmission relay preheating M1 Starter 3 1 kW P1 Hour meter 6P3 Composite instrument R1 Glow plugs S1 Preheat starter switch S2 Engine temperature switch S3 Oil temperature switch S4 Oil pressure switch S5 Suction filter vacuum switch S6 F...

Page 175: ...Page 3 Section 4 6 Service Training CIRCUIT DIAGRAMM H 50 60 70 80 TYPE 353 ...

Page 176: ......

Page 177: ...Service Training Page 5 Section 4 6 05 00 ...

Page 178: ...H11 Directional indicator rear right 5H12 13 Switch lighting 1 2 W 9H1 9H6 Switch lighting 1 2 W 5K1 Direction indicator switch 9K1 Intermittent relay front wiper 9K2 Intermittent relay rear roof wiper 9K3 Rear wiper motor relay 9M1 Wiper motor front 9M2 Washer front 9M3 Wiper motor roof 9M4 Wiper motor rear 9M5 Washer rear roof 4S15 Revolving light switch 5S11 Light switch 5S12 Hazard warning lig...

Page 179: ...Page 7 Section 4 6 Service Training 05 00 6 7 8 9 5 4 3 1 2 CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50 60 70 80 TYPE 353 ...

Page 180: ......

Page 181: ...rning light 32 H5 Engine oil pressure warning light 34 H6 Suction filter vacuum indicator light 36 H12 Flasher indicator light 46 H13 Fuel level warning light 38 H24 Fan 40 H25 Preheating 42 H26 Soot filter warning light 44 4H7 Horn 74 K2 Starter relay 4 17 K3 Signal transmission relay preheating 55 K4 Additional relay potential 15 14 M1 Starter 4 P1 Hour meter 24 6P3 Composite instrument 22 48 R1...

Page 182: ... 4 X5 Connector 2 pins 9 59 X6 Connector 6 pins 1 5 10 60 64 X7 Connector 2 pins 17 X8 Connector 1 pin 1 X10 Connector 3 pins 21 25 5X13 Connector 1 pin 47 7X8 Connector 1 pin 44 7X9 Connector 6 pins 12 17 72 Y1 Shutoff magnet 50 52 Y2 Magnet for richer fuel mixture 6 CABLE COLOURS BK black BN brown BU blue GN green GY gray OG orange RD red VT violet WH white YE yellow ...

Page 183: ...Page 11 Section 4 6 Service Training 05 00 CIRCUIT DIAGRAMM H 50 60 70 80 02 TYPE 353 ...

Page 184: ......

Page 185: ...r UPA potential 15 20 A 7 62 9F16 Fuse single pedal model 5 A 2 9F21 Fuse front windscreen wiper 15 A 56 87 9F22 Fuse rear roof windscreen wiper 15 A 123 9F23 Fuse for UPA potential 30 20 A 9 9F24 26 Fuses spotlight 15 A 12 18 20 5H8 Directional indicator front left 46 5H9 Directional indicator rear left 43 5H10 Directional indicator front right 49 5H11 Directional indicator rear right 51 5H12 13 ...

Page 186: ...ector 6 pins 56 100 116 9X3 Connector 6 pins 73 76 9X4 Connector 9 pins 56 100 112 123 9X5 Connector 2 pins 129 9X6 Connector 4 pins 13 20 9X7 Connector 6 pins 10 12 9X8 Connector 6 pins 16 18 9X9 Connector 6 pins 20 22 9X10 Connector 3 pins 1 3 9X11 Connector 3 pins 2 9X12 Connector 3 pins 1 3 9X13 Connector 4 pins 109 111 9X14 Connector 4 pins 102 104 9X15 Connector 2 pins 126 1Y1 Solenoid valve...

Page 187: ...Page 15 Section 4 6 Service Training 05 00 CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50 60 70 80 02 TYPE 353 ...

Page 188: ......

Page 189: ...t 26 H2 Electrical control warning light 28 H3 Engine temperature warning light 31 H4 Hydraulic oil temperature warning light 33 H5 Engine oil pressure warning light 35 H6 Suction filter vacuum indicator light 37 H12 Flasher indicator light 47 H13 Fuel level warning light 39 H24 Fan 41 H25 Preheating 43 H26 Soot filter warning light 45 4H7 Horn 77 K2 Starter relay 6 19 K3 Heater flange relay 58 60...

Page 190: ...pins 8 22 31 39 50 58 X3 Connector 1 pin 3 X4 Connector 2 pins 3 6 X5 Connector 1 pin 6 X6 Connector 6 pins 3 10 63 65 X7 Connector 2 pins 19 X8 Connector 1 pin 11 X10 Connector 3 pins 222 23 26 5X13 Connector 1 pin 48 7X8 Connector 1 pin 45 7X9 Connector 6 pins 14 19 65 75 9X11 Connector 3 pins 68 Y1 Shutoff magnet 50 52 Y2 Magnet for richer fuel mixture 8 CABLE COLOURS BK black BN brown BU blue ...

Page 191: ...Page 19 Section 4 6 Service Training 09 04 CIRCUIT DIAGRAMM H 50 60 70 80 03 TYPE 353 DIESEL ...

Page 192: ...Section 4 6 Page 20 Service Training 09 04 ...

Page 193: ...e pedal model 2 9F20 Fuse for magnetic protective switch 129 131 9F21 Fuse front windscreen wiper 66 99 9F22 Fuse rear roof windscreen wiper 141 9F23 Fuse for UPA potential 30 10 9F24 26 Fuses spotlight 13 20 22 5H8 Directional indicator front left 53 5H9 Directional indicator rear left 50 5H10 Directional indicator front right 56 5H11 Directional indicator rear right 58 5H12 13 Switch lighting 34...

Page 194: ... pins 112 126 134 9X3 Connector 6 pins 85 87 9X4 Connector 9 pins 66 112 115 125 134 9X5 Connector 2 pins 147 9X6 Connector 4 pins 13 22 9X7 Connector 6 pins 11 13 9X8 Connector 6 pins 18 20 9X9 Connector 6 pins 22 24 9X10 Connector 4 pins 3 5 9X11 Connector 3 pins 4 9X12 Connector 3 pins 3 5 9X13 Connector 4 pins 122 124 9X14 Connector 4 pins 115 117 9X15 Connector 2 pins 144 1Y1 Solenoid valve s...

Page 195: ...Page 23 Section 4 6 Service Training 09 04 CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50 60 70 80 03 TYPE 353 DIESEL ...

Page 196: ...Section 4 6 Page 24 Service Training 09 04 CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50 60 70 80 03 TYPE 353 DIESEL ...

Page 197: ...icator 16 H2 Electronic control warning light 17 H3 Engine temperature indicator 18 H4 Hydraulic fluid temperature indicator 19 H5 Oil pressure indicator 20 H6 Suction filter vacuum indicator 21 H12 Turn signal indicator 26 H13 Fuel remaining indicator 22 4H7 Horn 28 K2 Relay for starter motor 3 9 K3 Propellant gas control relay 39 41 K4 Auxiliary relay for terminal 15 8 11 N2 Engine speed regulat...

Page 198: ...ode 13 X1 15 pin plug 9 28 X2 12 pin plug 3 22 39 50 X6 6 pin plug 1 3 7 X7 2 pin plug 9 X10 3 pin plug 13 15 7X4 3 pin plug 38 9X11 3 pin plug 35 Y1 Speed operating magnet 49 Y2 Propellant gas shutoff valve 41 CABLE COLOURS BK black BN brown BU blue GN green GY grey OG orange RD red VT violet WH white YE yellow ...

Page 199: ...Page 27 Section 4 6 Service Training 09 04 CIRCUIT DIAGRAMM H 50 60 70 80 03 TYPE 353 LPG ...

Page 200: ...Section 4 6 Page 28 Service Training 09 04 ...

Page 201: ...ingle pedal model 4 74 9F20 Fuse for magnetic protective switch 129 131 9F21 Fuse front windscreen wiper 99 9F22 Fuse rear roof windscreen wiper 141 9F23 Fuse for interior lights 66 9F24 26 Fuses spotlight 12 19 21 5H8 Directional indicator front left 52 5H9 Directional indicator rear left 49 5H10 Directional indicator front right 55 5H11 Directional indicator rear right 57 5H12 13 Switch lighting...

Page 202: ...X2 Connector 6 pins 66 112 126 134 9X3 Connector 6 pins 85 87 9X4 Connector 9 pins 112 115 125 134 9X5 Connector 2 pins 147 9X6 Connector 4 pins 12 21 9X7 Connector 6 pins 10 12 9X8 Connector 6 pins 17 19 9X9 Connector 6 pins 21 23 9X10 Connector 3 pins 3 5 9X11 Connector 3 pins 3 5 9X12 Connector 3 pins 3 5 9X13 Connector 4 pins 122 124 9X14 Connector 4 pins 115 117 9X15 Connector 2 pins 144 1Y1 ...

Page 203: ...Page 31 Section 4 6 Service Training 09 04 CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50 60 70 80 03 TYPE 353 LPG ...

Page 204: ...Section 4 6 Page 32 Service Training 09 04 CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50 60 70 80 03 TYPE 353 LPG ...

Page 205: ...Service Training Page 33 Section 4 6 09 04 ...

Page 206: ... on the left side of the truck behind a cover of the second foothold 8 Interval relay 9K2 9 Flasher relay 5K1 I Fuse box II Fuse box III Fuse box IV Fuse box 1 Preheating relay 2 Distributor plug plus 3 Preheating fuse 80 A 4 Starter relay 5 Signal converter preheating 6 Windsccreen wiper relay 7 Interval relay 9K1 ...

Page 207: ...USE 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 5 F 31 2 Fuse output No of fuse Fuse Functional group lights ...

Page 208: ...RIES 353 03 4 6 10 1 RELAY AND FUSES OF 353 03 DIESEL 0 Relay for UPA 1 Indicator relay 5K1 2 Wiper relay 9K3 3 Interval relay 9K1 9K2 4 Relay K4 load relay 5 Starter relay K2 6 Control device for heater flange A1 7 Plus distributor 8 Plug for interfaces 9 Minus distributor ...

Page 209: ...ng 9F14 20 A 5 Horn 4F15 10 A 6 Single pedal model 9F16 5 A Fuse box II 1 Front wiper Interior lights 9F21 15 A 2 Windscreen wiper rear roof 9F22 15 A 3 Spare fuse 9F23 20 A 4 Working light 9F24 15 A 5 Working light 9F25 15 A 6 Working light 9F26 15 A Fuse box III 1 Turn signal system 5F31 15 A 2 Turn signal system 5F32 15 A 3 Side marker left side 5F33 5 A 4 Side marker right side 5F34 5 A 5 Dip ...

Page 210: ...PG 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 10 Plug connector 5X1 5X2 5X3 9X1 9X6 7X4 9X4 11 Minus distributor ...

Page 211: ...F15 5 A 6 Single pedal model 9F16 5 A Fuse box II 1 Windscreen wiper front 9F21 15 A 2 Windscreen wiper rear roof 9F22 15 A 3 Interior light 9F23 5 A 4 Working light 9F24 15 A 5 Working light 9F25 15 A 6 Working light 9F26 15 A Fuse box III 1 Turn signal system 5F31 15 A 2 Turn signal system 5F32 15 A 3 Side marker left side 5F33 5 A 4 Side marker right side 5F34 5 A 5 Dip beam left side 5F35 10 A...

Page 212: ...SES FOR 353 03 PARTICULATE TRAP TOP VIEW OF FUSE BOXES 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 1 Fuse 7F15 5A 2 Fuse 7F16 30 A 3 Fuse 7F17 4 Fuse 7F18 5 Fuse 7F19 ...

Page 213: ...Service Training Section 4 7 Page 1 4 7 WORKING HYDRAULICS ...

Page 214: ...ure valve 265 bar 11 Tilt cylinder 12 Slow down valve 13 Lift cylinder 27 Axial piston pump MPF 55 D Shuttle valve 1 Control valve assembly consisting of 2 Way valve auxiliary hydraulics 3 Shuttle valve 4 Way valve auxiliary hydraulics 5 Pressure holding valve 6 Way valve tilting 7 Way valve lifting 8a Restrictor 8b Restrictor ...

Page 215: ...e of the safety valve 10 is reached the maximum pressure valve opens and lets oil flow to port T3 Due to the differential pressure resulting at restrictor 10a the load pressure becomes greaterthantheresponsepressureofthemaximumpressurevalveandthepressurebalanceismodulated so that only so much oil flows as is required for the maintenance of the differential pressure at restrictor 10a Any excess oil...

Page 216: ...ction 4 7 Page 4 4 7 2 TILT CYLINDER 1 Bearing bracket 2 Screw 3 Eyebolt 4 Bearing pin 5 Locknut 6 Piston rod 7 Rear bearing pin 8 Retaining screw 9 Overhead guard 10 Support 11 Screw 12 Roller mount with roller 13 Hoses ...

Page 217: ... for the pin 7 and drive the pin 7 out from the inside Lift off the cylinder assembly TILT CYLINDER INSTALLATION Insert the tilt cylinder along with the pin 4 fitted in the eyebolt 3 into the front bearing half Align the cylinder barrel eyebolt with the hole of the rear pivot install the pin 7 and tighten the retaining screw 8 Connect the hoses 13 Install the front bearing bracket 1 and tighten th...

Page 218: ... damage Remove the cylinder head seals and clean the cylinder head Install new cylinder head seals Grease the seals slightly slide the cylinder head on the piston rod screw into the barrel and tighten to 300 350 Nm drive in the flanged retainer Screw the eyebolt 18 with nut 17 back into the piston rod Re assemble the cylinder and adjust the eyebolt 18 according to the adjustment procedures and loc...

Page 219: ...l Remove the setscrew 2 Screw the piston 3 off the piston rod Remove the seals Thoroughly clean the inside of the piston and cylinder barrel and inspect for damage Install new seals Screw the piston onto the piston rod and torque to 500 550 Nm Secure the piston with the setscrew 2 Grease the seals slightly and insert the piston rod and piston into the cylinder barrel Screw in the cylinder head 13 ...

Page 220: ...Service Training Section 4 7 Page 8 ...

Page 221: ...Service Training Page 1 Section 4 8 4 8 MAST ...

Page 222: ...lt the cylinder up and secure it Attach a rope to the top cross member of the outer upright and hook on a crane Be sure that the load capacity of the crane and rope is sufficient Remove the mast pivot bearing pillows and lift the mast out of the pivots Installation is the reverse of removal Bleed the lift cylinders when taking the truck into operation again 7 Fitting 8 Fork carriage 9 Cylinder mou...

Page 223: ...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 Disconnect the hose 6 at the base of the cylinder Remove the bracket 4 on the outer upright 3 Tiltthecylinder 5 slightlytotheside slingaropearoundthecylinderandliftthecylinderoutofthemount 9 with a suitable hoist crane or fork truck Installat...

Page 224: ...er head 4 Grooved ring 5 Opening for socket spanner 6 Bleed screw 7 O ring 8 Cylinder barrel 9 Guide bushing 10 Stop screw 11 Hexagon head 42 mm H 70 80 DEVIATION FROM H 50 60 12 Piston head with tang top piston head 13 Retaining ring 14 Piston rod tube diam 77 mm 15 Stop screw bottom piston head 16 Bottom stop sleeve ...

Page 225: ... install a new seal kit consisting of O ring 7 grooved ring 4 and wiper 2 Insert the piston rod into the cylinder barrel CoatthecylinderheadthreadwithLoctiteNo 270andscrewitontothecleanthreadofthecylinderbarrel Install the lift cylinder on the mast and eliminate any air in the cylinder when taking into operation REMARK H 70 60 ONLY The H 70 80 piston rod 14 consists of a barrel with a piston head ...

Page 226: ...Page 6 Section 4 8 Service Training ...

Page 227: ...ession rating 13 bar wear limit 10 bar Max admissible pressure difference 2 bar Rated speed 2100 rpm Idling speed 800 rpm Max running torque 355 Nm 1250 rpm Ignitiontiming 18 2 before TDC at 800 rpm Cylinder 1 Cylinder gear side Firing sequence 1 5 3 6 2 4 Spark plug Champion C6 BYC Speed limiting device 3200 rpm Valve clearance cold Intake 0 20 0 05 mm Outlet 0 45 0 05 mm Coolant Water Thermostat...

Page 228: ...ax admissible pressure difference 2 bar Rated speed 2100 rpm Idling speed 800 rpm Max running torque 355 Nm 1250 rpm Ignitiontiming 18 2 before TDC at 800 rpm Cylinder 1 Cylinder gear side Firing sequence 1 5 3 6 2 4 Spark plug Bosch FR 56 Speed limiting device 3200 rpm Valve clearance cold Intake 0 20 0 05 mm Outlet 0 45 0 05 mm Coolant Water Thermostat Wax Opening temperature 80 C Opening comple...

Page 229: ... component list number Motor type six cylinder aspirating engine If you require replacement parts service or information on your engine you will need to quote the full motor number to your Perkins representative 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 ...

Page 230: ... fan In this position the V belts can be removed NOTE Only change V belts in pairs Fit new V belts and fasten fan Replace cover plate 8 on radiator cladding TENSING THE V BELT Turn alternator 5 until the correct V belt tension is obtained Re tighten fastening screw 4 and hexagon nut 3 Check V belt tension adjust tension if necessary Test with meter Place meter 7 on V belt 6 and take measurement Me...

Page 231: ... of the 4th cylinder overlap Check the valves on the 3rd cylinder and adjust if necessary Turn the flywheel further until the valves of the 1st cylinder overlap Check the valves on the 6th cylinder and adjust if necessary Turn the flywheel further until the valves of the 5th cylinder overlap Check the valves on the 2nd cylinder and adjust if necessary Turn the flywheel further until the valves of ...

Page 232: ...isible reduction of thread size close to the screw shaft 3 If the check on the cylinder head screws gives cause to reject them deformed or stretched screws are to be replaced INSTALLING THE CYLINDER HEADS Clean the sealing face of the cylinder head and engine block No residue of sealant must remain on the sealing faces Check cylinder head for distortion WARNING The sealing face of the cylinder hea...

Page 233: ...der head seal in the correct position for assembly of the cylinder head screw two 1 2 UNF stud bolts into the motor block C Lightly oil the cylinder head screw thread and tighten to 110 Nm in accordance with diagram Tighten cylinder head screws in the order shown in the diagram taking account of the length Tighten short screws S another 150 Tighten medium length screws M another 180 Tighten long s...

Page 234: ...n 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 Tighten the screws in the correct order until they are adjusted in accordance with the marks made on the cylinder head WARNING It is not necessary to tighten the cylinder head screws when the motor is warm or after 50 hours of operation ...

Page 235: ...ut the entire service life of the ignition distributor Great ignition reliability at high speed and optimum power consumption at low speeds as a result of control of the dwell angle and the absence of contact bounce The principal characteristic of this ignition system is the ignition pulse generator which replaces the cam controlled contact breaker The ignition pulse generator has the job of gener...

Page 236: ...primary current flows from the battery through the ignition starting switch 2 when switched on and the primary winding of the ignition coil 3 back through the switchgear 4 The activation of the interruption of the primary current by the switchgear is controlled by an induction pulse generator 5 in the ignition distributor 6 At the moment when the primary current is interrupted a high voltage is in...

Page 237: ...ion winding GENERATION OF THE TRANSMITTER VOLTAGE The approach of the stator arm and the rotor arm increases the magnetic flux This change in flux induces a voltage in the induction winding this voltage rises to a peak value which is reachedjustbeforethearmscomeoppositeeachother Asthe timer core continues to turn the arms move apart and the transmitter voltage changes direction The pulse transmitt...

Page 238: ...polarity reversal is to be feared because of these components As a rule electronic ignition systems have higher ignition power than traditional ignition systems Electronic ignition systems work in a power range that is potentially lethal if bare terminals and voltage carrying parts are touched This applies both to the low voltage parts primary current circuit and the high voltage parts ignition ci...

Page 239: ...Service Training Section 4 9 Page 13 12 05 ...

Page 240: ...raining Section 4 9 Page 14 12 05 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: ...s are conducted to the ignition coils in the firing order and from there to the respective spark plugs The main feature of this ignition system is the electronic controller which receives all pulses and signals and after processing them performs or initiates the following functions The control of the primary circuit of the ignition coils is by means of the ignition electronics A regulation of the ...

Page 242: ...ctronic controller as information on engine speed and position of the crankshaft NOTE The position of the generator in relation to the toothed disc can not be changed IGNITION COIL The ignition coil is largely identical with coils of conventional ignition systems in construction and in operation A single coil which is plugged on the plug without a high tension lead and screwed to an angle bracket ...

Page 243: ...umber 1 cylinder For the check the ignition coil must be unscrewed from the bracket of the number 1 plug The removed coil is then connected using a spare ignition cable to the spark plug the timing light can then be attached to this cable NOTE A conventional spark plug HT lead is required for this test The firing point is 8 2 BTDC at an idle speed of 750 50 rpm CONNECTING DIAGRAM FOR SPARK PLUG CA...

Page 244: ...the direction of retarded with appropriate resistors see circuit diagram 1 Firing point mark on housing 2 Firing point mark on flywheel Eng speed rpm 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 27k white 5 5 4 2 4 9 12 15 17 18 18 16k yellow 2 2 1 1 6 10 12 15 17 18 18 9k1 blue 1 1 2 4 8 11 13 16 18 19 19 4k7 green 4 4 5 7 10 12 14 17 19 20 20 white yellow blue green red Firing Point BTDC ...

Page 245: ...ITION TIMING SPECIAL TOOLS REQUIRED Timing pin for ignition system Part no 000 008 61 00 Torx driver for ignition system ET Nr 276 10 122 The firing point caracteristic curve is controlled by a resistor The picture besides shows the position of the resistor in the truck ...

Page 246: ...tion 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 PushthetimingpinØ3mm 5 throughthehole 4 in the toothed disc 3 into the hole in the housing 2 NOTE The mechanical adjustment is correct if both holes align when the engine is set at TDC ...

Page 247: ...onnect the battery Set cylinder 1 of the internal combustion engine at top dead centre on the compression stroke Remove the cover on the timing case Push timing pin 8 through the gear wheel and the recess in the hub into the hole in the housing Remove the four screws 7 with the help of the special tool 10 Unscrew the three M8 nuts on the flange of the ignition timing unit 1 and remove ignition con...

Page 248: ...timing pin 5 through the toothed disc into the housing Check the O ring on the flange and replace if neces sary Place the ignition control unit 1 in the mounting posi tion Be sure to push the pin through the slot in the gear wheel Fasten the flange by means of the M8 nuts and tighten the nuts to 22 Nm Pushthegearwheelagainstthehubandfastenthegear wheelwiththehelpofthespecialscrews 7 Tightenthe scr...

Page 249: ...n ADVANTAGES OF THE CONTROL SYSTEM The control system has an electronic regulator with proportional integral and differential operation The following advantages follow from these properties in comparison with proportional regulators alone No pressure on the drive motor i e maximum idling speed rated speed resulting in a reduction of noise and gas consumption Regulation of idling speed i e no need ...

Page 250: ... indicator 4 Speed setting cylinder hydraulically controlled 5 Nominal value transmitter rotary potentiometer 6 Nominal value signal processing 7 Actual value signal processing 8 Nominal value actual value comparison 9 PID regulator 10 Output stage 11 Engine speed regulator 12 Modulator proportional magnet 13 Propellant gas mixer with throttle valve ...

Page 251: ...e regulating difference the speed regulator 11 changes the setting of the throttle valve via the modulator 12 Thus the nominal value speed set is kept constant irrespective of the engine load In addition the two stop positions of the throttle valve are indicated via the magnet current capture of the PID regulator 9 PID REGULATOR The nominal value and actual value are compared and the difference is...

Page 252: ...or 21 H12 Turn signal indicator 26 H13 Fuel remaining indicator 22 4H7 Horn 28 K2 Relay for starter motor 3 9 K3 Propellant gas control relay 38 41 N2 Engine speed regulator 44 50 M1 Starter motor 3 P1 Operating hours counter 15 6P3 Indicator equipment 15 27 S1 Ignition starter switch 9 2 S2 Engine temperature switch 18 S3 Oil temperature switch 19 S4 Oil pressure switch 20 S5 Suction filter vacuu...

Page 253: ...Page 27 Section 4 6 Service Training 12 05 CIRCUIT DIAGRAM H 50 60 70 80 T TYPE 353 UP TO 12 2004 ...

Page 254: ......

Page 255: ...Service Training Section 4 9 Page 29 12 05 ...

Page 256: ...ing 39 H26 Particles filter warning 41 4H7 Horn 47 K2 Relay for starter motor 4 11 K3 Propellant gas shutoff relay 69 72 K4 Auxiliary relay terminal 15 9 17 N2 Engine speed regulator 74 78 M1 Starter motor 3 4 P1 Operating hours counter 21 6P3 Indicator equipment 20 46 1R1 Resistor 51 53 S1 Ignition starter switch 11 15 S2 Engine temperature switch 27 S3 Oil temperature switch 29 S4 Oil pressure s...

Page 257: ...Page 31 Section 4 6 Service Training 12 05 CIRCUIT DIAGRAM H 50 60 70 80 T TYPE 353 FROM 01 2005 ...

Page 258: ...Section 9 Page 32 Service Training ...

Page 259: ...EM 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 Vaporisor heating ...

Page 260: ...9 A vacuum also passes through conduit 6 in the secondary stage of the vaporisor 9 and activates the secondary valve via a diaphragm Now depressurised gas flows through the open valve in gaseous form through the conduit 6 to the mixer where it is mixed with the air and led as an ignitable mixture through the intake manifold 2 to the individual cylinders OPERATION Inoperation thepositionofthethrott...

Page 261: ...s the secondary valve in the vaporisor shuts off the gas flow and causes the engine to stop with no run on and no uncontrolled burning in the outlet By closing the throttle valve the vacuum is also filled in the conduit 4 the vacuum regulated shutoff valve 14 closes and the LPG path to the vaporisor 9 is cut off After the engine stops and the steel cylinder valves close some liquid gas remains in ...

Page 262: ...ted gas 1 LPG inlet 2 Primary valve 3 Primary diaphragm 4 Secondary diaphragm 5 Manual actuator 6 Actuating lever 7 Spring of secondary diaphragm 8 Vacuum connection 9 Evaporated gas outlet exit 10 Secondary valve 11 Evaporation chamber 12 Water chamber 13 Compensating hole 14 Drilled hole 15 Primary valve springs 16 Primary diaphragm pivot 17 Secondary diaphragm connecting pin ...

Page 263: ...linked to the atmospheric pressure via the compensating hole 14 The secondary valve 10 can be activated mechanically by the manual actuator 5 for a cold start With the motor running throttle valve of mixer open a vacuum is created in the gas conduct to the mixer and this vacuum opens the secondary valve 10 so that the LPG can flow through the open primary valve 2 into the vaporisor The secondary v...

Page 264: ...cordingly To carry out the check and the bending adjustment proceed as follows After assembly of the maintenance kit check the position of the connecting pin 4 using a setting bar 3 and a feeler gauge A setting bar is placed over the housing 5 The spring 2 pushes the valve into its closed position The distance between the connecting pin 4 and the setting bar 3 must be 1 mm If necessary the actuati...

Page 265: ...or this purpose a mixer valve the mixer serves for the correct dosing of gas and air 5 Full load mixture adjustment screw 6 Gas intake from vaporisor 7 Transmission tube vacuum to diaphragm 8 Idling mixture adjustment screw 1 Mixture outlet to engine 2 Air intake from air filter 3 Vacuum connection magnet valve sec ondary diaphragm 4 Vacuum connection shutoff valve ...

Page 266: ...turewhichflowspastthealmost closedthrottlevalveinidlingmodeisconstant Inidling mode part of the inflowing air is conducted to the air inlet valve The idling setting is controlled using the idling mixture adjustment screw 8 by which the gas air mixture in idling mode is thinned or enriched MIXTURE ADJUSTMENT FOR FULL LOAD This setting controls the mixing proportions if the gas regulator valve is op...

Page 267: ... top of thediaphragm 9 intheshutoffvalve Thepressuredifferencebetweenthetopandbottomofthediaphragm 9 creates an upward displacement of the diaphragm The diaphragm 9 thereby activates the lever 8 whichactsonthevalveshaft 7 Thevalveshaft 7 isdisplacedupwardsandtherebyopenstheplatevalve 4 againsttheinitialtensionoftheleafspring 5 LPGcannowflowthroughthefilterplate 1 tothevaporisor 6 LPG outlet filter...

Page 268: ...the correct setting the marking on the flywheel must be flush with notch 1 on the housing ADJUSTING THE FIRING POINT Loosen clamping screw 3 on ignition distributor 4 to the point where it can just be turned manually Shine the strobe light on the markings Twist the ignition distributor so that the 18 marking on the flywheel is flush with the notch on the housing Turning clockwise Earlier ignition ...

Page 269: ...gnition coil to the central connection of the distributor head 22 26 kΩ IGNITION COIL T1 Measure primary resistance between terminal 1 and 15 Target value 0 6 1 0 Ω Measure secondary resistance between terminal 4 and 15 Target value 6 10 kΩ G2 Battery S1 Ignition starting switch T1 Ignition coil A1 Transistor coil ignition TSZ switchgear E1 Ignition distributor with induction type pulse generator ...

Page 270: ...ess 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 Switch ignition off Insert the plug back into the TSZ switchgear Take the plug out of the induction transmitter ignition distributor ...

Page 271: ...rminal 5 is to be inspected and if necessary corrected If there is still no spark formation the switchgear is defective Induction transmitter Test conditions TSZ switchgear in order Ignition coil in order Lines between switchgear and ignition distributor in order Testing Remove the plug of the TSZ switchgear and take a measurement of the resistance between terminals 5 and 6 of the plug Target valu...

Page 272: ... tighten screws 2 on terminal flange 3 hand tight only 4 Attach connection rods 7 to adjustment cylinder 8 Preset measurement a to 6 mm 5 Connect voltmeter between plug X B2 2 and X B1 2 With the plugs still connected insert test prods on the back into the indicated measuring points For this purpose the rubber coating must be removed from plug X1 Switch ignition on Twist target value transmitter 1...

Page 273: ...d Otherwise the engine races no actual value signal for speed control N2 Loosen nuts 2 and 3 to adjust the transmitter Insertsensorgaugethroughtheopeningontheintermediatehousing betweentoothedring 4 andactual value transmitter B1 The correct distance measurement X between toothed ring 4 and actual value transmitter B1 must be 0 5 0 3 mm Attachnut 3 onactualvaluetransmitterB1backontheassemblyandsec...

Page 274: ...TEM 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 Connection plan for engine speed control Electrical system circuit diagram ...

Page 275: ...Rotation speed nominal value transmitter B2 X2 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 PlugX B1maynotbedisconnectedatthefromtheactualvaluetransmitterduringthestarting procedure since otherwise the engine races ...

Page 276: ...Service Training Section 4 9 Page 50 12 05 ...

Page 277: ...earth of truck Switch ignition on Meter should show 5 V midpoint voltage NOTE If the meter shows no voltage value or an incorrect value the cabling on plug X B1 and the supply voltage from N2 must be checked or speed regulator N2 replaced Reconnect plug X B1 NOMINALVALUETRANSMITTER Connect meter for voltage measurement between connections X B2 1 and X B1 2 The plugs remain connected Plug in the me...

Page 278: ...ach test cable of a meter on the connections X B1 2 and X B1 1 and take a resistance measurement Target value 1 kΩ 100 Ω Switch meter to a c voltage and to set to 100 V measuring range Disconnect speed regulator N2 Turn engine with starter motor and read off voltage on meter Target value 5 15 V Connect tachometer Manually draw out operating magnet axis by about 1 3 and start engine Set an engine s...

Page 279: ...en turn back 1 more turn Move lever 7 on shaft and clamp at an angle of 30 3 Install mixer Press throttle valve manually onto the limit stop and adjust connecting rod 5 between magnet 1 and lever 7 to an initial tension of 1 mm and press on ball grip of lever 6 Lock rod 5 with nuts 6 1 Operating magnet 2 Full load mixture adjustment screw 3 Idling mixture adjustment screw 4 Mixer 5 Connecting rod ...

Page 280: ...full load mixture adjustment screw 2 in the middle between L and R the screw is located at the gas intake in the mixer Connect CO meter With the footbrake on bring the engine to maximum running speed activate tilt control lever fully to the limitstopandholdthere atthesametimeturnthesteeringtothelimitstoptoo andhold therebyapplying a load to the engine Determine CO value of the engine under this lo...

Page 281: ......

Page 282: ...Linde Material Handling 63701Aschaffenburg Postfach100136 Telefon 06021 99 0 Telefax 06021 99 1570 http www linde de linde stapler eMail service training linde fh de 353 804 2401 0906 ...

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