Service Training Linde IC-Engined Fork Truck H 50/60/70/80 D/T H 50/60/70/80 D-02/T-02 H 50/60/70/80 D-03/T-03 Type 353 This training material is only provided for your use and remains the exclusive property of LINDE MATERIAL HANDLING
Service Training 09.06 TABLE OF CONTENT 4 IC-engined fork truck H 50/60/70/80, Type 353 1 4.1 Engine drive 1 4.1.1 Engine model BF6M 1012 E 1 4.1.1.1 Engine specifications 1 4.1.1.1.1 Explanation of the engine number 2 4.1.1.2 Changing and tightening the drivebelt 3 4.1.1.3 Adjusting valve clearance 4 4.1.1.4 Adjusting the injection valve 7 4.1.1.5 Checking the compression pressure 9 4.1.1.6 Cylinder head 10 4.1.1.7 Adjusting the begin of delivery 12 4.1.
09.04 Service Training 4.2.2.2 Operation of control valve block N = Power Limiter 23 4.2.2.3 Braking 24 4.2.2.4 Auxiliary brake 24 4.2.2.5 Lock-out logic - reversing lock 26 4.2.2.6 Flushing of the circuit and housing 28 4.2.3 Hydraulic remote control 30 4.2.3.1 Adjustments 31 4.2.3.1.1 Hydraulic neutral position 31 4.2.3.1.2 Primary adjustment of start of control 31 4.2.3.1.3 Mechanical limitation of the swashplate angle 31 4.2.3.1.
Service Training 09.04 4.3 Chassis 1 4.3.1 Overhead guard - torsion mounting 2 4.3.1.1 Work on the overhead guard 3 4.4 Steering system 1 4.4.1 Power steering circuit diagram 2 4.4.2 Series 304 steering axle 4 4.4.2.1 Description 4 4.4.3 Steering axle removal 5 4.4.3.1 Steering axle installation 6 4.4.4 Steering axle repairs 6 4.4.4.1 Renewing the wheel bearings 7 4.4.4.2 Steering knuckle removal and installation 8 4.4.4.
12.05 Service Training 4.6.7 Electrical system circuit diagram, type 353 -03 LPG 25 4.6.8 Wiring diagram for options, 353 -03 29 4.6.9 Central electrical system 34 4.6.10 Central electrics of series 353 -03 36 4.6.10.1 Relay and fuses of 353 -03 Diesel 36 4.6.10.2 Relay and fuses of 353 -03 LPG 38 4.6.10.3 Relay and fuses for 353 -03 particulate trap 40 4.7 Working hydraulics 1 4.7.1 Working hydraulics circuit diagram 2 4.7.1.1 Explanation of the working hydraulics 3 4.7.
Service Training 12.05 4.9.3 Propellant gas system 33 4.9.3.1 Diagram 33 4.9.3.2 Functional 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.
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Section Service Training 09.04 4 IC-ENGINED FORK TRUCK H 50/60/70/80,TYPE 353 4.1 ENGINE DRIVE 4.1.1 ENGINE MODEL BF6M 1012 E 4.1.1.
Section 4.1 Page 4.1.1.1.1 1 2 Service Training 09.04 2 EXPLANATION OF THE ENGINE NUMBER Manufacturer's plate with type and engine number Engine number stamped on the crankcase NOTE: A second type plate was affixed to the rocker cover by Linde.
Service Training 4.1.1.2 Section 09.04 Page CHANGING AND TIGHTENING THE DRIVEBELT CHANGING THE DRIVEBELT - Slacken the alternator and tensioner fastening screws (2). Turn the tensioning screw (3) anti-clockwise, press the alternator in and remove the drivebelt. Check the pulley for wear, renewing it if necessary. Install a new drivebelt. TIGHTENING THE DRIVEBELT - Turn the tensioning screw (3) clockwise until the required tension is obtained. - Check the tension with a gauge (1), Part No.
Section Page 4.1.1.3 4.1 4 09.04 Service Training ADJUSTING VALVE CLEARANCE The adjustment can be carried out when the engine is cool or warm after a cooling period of at least 30 minutes (oil temperature < 80 °C). Valve clearance: Inlet Outlet 0.3 mm 0.5 mm VALVE CLEARANCE SCHEMATIC Crankshaft position 1 Crankshaft position 2 Turn the engine until the valve inlet and outlet of cylinder 1 are just open. Turn the engine one full revolution (360 °).
Section Service Training 09.06 Page 4.1 5 VALVE CLEARANCE ADJUSTMENT BY MEANS OF A TORQUE ANGLE GAUGE FROM SERIAL NUMBER E1 X353 T 000268 In engines which are equipped with a thrust washer in the valve spring retainer (Fig. A1), the valve clearance can only be adjusted by means of a torque angle gauge.
Section 4.1 Page 6 09.06 Service Training Adjustment of valve clearance - Set torque angle gauge to 0 (zero) (Fig. A4). Take care not to turn the setting screw! - Turn setting screw back (counterclockwise) until reaching the corresponding setting angle. Setting angle of inlet valve: 75° outlet valve: 120° Locknut tightening torque: 20 Nm - Put T-handle on torque angle gauge (Fig. A5). - Support setting screw with T-handle and tighten locknut with socket wrench (open end).
Service Training 4.1.1.4 Section 09.06 Page 4.1 7 ADJUSTING THE INJECTION VALVE CHECKING THE OPENING PRESSURE NOTE: Use only test oil acc. to ISO 4113 or diesel fuel for the test. CAUTION: When checking injection nozzles, take care that the fuel jet does not hit the hands. Due to the high pressure, the fuel can penetrate the skin and cause severe injuries. - Install the injection nozzle on the nozzle tester. - Press the lever down slowly.
Section Page 4.1 8 09.06 Service Training CHECKING FOR LEAKS - Dry the nozzle and nozzle holder - blow dry with an air jet. - Slowly press the tester hand lever down until a pressure approx. 20 bar under the previously obtained opening pressure is reached. - The nozzle does not leak if no drops of fuel show within 10 seconds. If a drop of fuel leaks out, disassemble the injection valve and eliminate the leak by cleaning the injection nozzle. If this does not remedy the leak, renew the injection valve.
Service Training 4.1.1.5 - Section 09.06 Page 4.1 9 CHECKING THE COMPRESSION PRESSURE Remove the injection nozzle. Check the valve clearance. Insert and fasten connector 100110 along with the special seal. Connect a compressometer and crank the engine with the starter. Specified pressure 28 - 33 bar Max.
Section 4.1 Page 10 4.1.1.6 09.06 Service Training CYLINDER HEAD REMOVING THE CYLINDER HEAD - With the engine cool, slacken the cylinder head bolts evenly and in steps in the reverse order as given in the schematic "Cylinder head bolt tightening sequence". DETERMINING THE CYLINDER HEAD GASKET NOTE: by holes.
Service Training 09.06 Section 4.1 Page 11 INSTALLING THE CYLINDER HEAD NOTE: Sealing surfaces for cylinder head gaskets must be clean and free of oil. Pay attention to the fitting sleeve. - Check the cylinder head for warping. Put the cylinder head in place. Check the cylinder head bolts for stretching, see "Visual check". 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.
Section 4.1 Page 12 4.1.1.7 09.06 Service Training ADJUSTING THE BEGIN OF DELIVERY If an injection pump must be replaced, the begin of delivery must be re-adjusted by determining the shim thickness anew. DETERMINING THE SHIM THICKNESS The old injection pump and shim are not required for this procedure.
Service Training 09.96 09.06 Section 4.1 Page 13 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 (mm) Code EK (mm) Code EK (mm) Code EK (mm) Code EK (mm) Code 110.0 110.025 110.05 110.075 110.6 110.625 110.65 110.675 111.2 111.225 111.25 111.275 049 050 051 052 111.8 111.825 111.85 111.875 073 074 075 076 112.4 112.425 112.45 112.475 097 098 099 100 110.1 110.125 110.
Section 4.1 Page 14 Service Training 09.96 09.06 Read the code for the injection pump length (A) on the new injection pump, e.g. 53. The basic dimension of the injection pump (L0) is 109/119 mm. Determine the theoretical thickness of the shim (TS). TS = EK - (L0 + A/100) TS = 111.725 mm - (109 mm + 53/100 mm) or TS = 121.725 mm - (119 mm + 53/100 mm) TS = 2.195 mm Choose the thickness of the shim (SS) according to Table 2. TS 2.195 = SS 2.2 mm Table 2 0.95 1.05 1.15 1.25 1.35 1.45 1.55 1.65 1.75 1.
Service Training 09.96 09.06 Section 4.1 Page 15 INSTALLING THE INJECTION PUMP - - Place the required shim (2) on the roller shaft. Turn the injection pump control lever to the stop position. Set the roller shaft (3) on the base circle. Slightly oil the O-ring and the hole for the ring. Remove the shut-off solenoid and replace by device 100830. Bring the control rod to the stop position with device 100800 and lock it in this position. Insert the injection pump (1).
Section 4.1 Page 16 4.1.8 09.
Service Training 09.96 09.
Section 4.1 Page 18 09.06 4.1.2 ENGINE MODEL BF6M 2012 4.1.2.
Service Training 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Generator Oil filler hole Heater flange Coolant connection-recovery line Fan pulley Fuel lift pump Coolant pump V-belt pulley on crankshaft Belt tensioner pulley Mounting legs Oil pan Oil filling nozzle Öil filter casing with engine oil cooler Oil level dipstick Provisions for attaching a compressor or hydraulic pump Fuel filter cartridge Öil filter cartridge Lifting magnet 09.06 Section 4.
Section 4.1 Page 20 4.1.2.2 Service Training 09.06 ENGINE SPECIFICATIONS Engine model BF6M 2012 E Displacement 6060 cc Power 74.
Service Training 4.1.2.2.1 1 2 09.06 EXPLANATION OF THE ENGINE NUMBER Manufacturer's plate with type and engine number Engine number stamped on the crankcase NOTE: A second type plate was affixed to the cylinder head cover by Linde. EXPLANATION OF THE ENGINE NUMBER B F 6 M 2012 E external cooling series coolant/water number of cylinders aspirated engine turbocharged Section 4.
Section 4.1 Page 22 4.1.2.3 09.06 REPLACEMENT OF V-RIPPED BELT Fit the V-ripped belt and tension it. Pressh the belt tensioner pulley (1) in direction of the arrow. Fit the V-ripped belt, and finally place it on pulley (2). Loosen the belt tensioner pulley in opposite direction to the arrow until the V-ripped belt is tensioned. If the V-ripped belt is used again, make sure to observe the wear limit.
Service Training 4.1.2.4 09.06 Section 4.1 Page 23 ADJUSTING VALVE CLEARANCE The adjustment can be carried out when the engine is cool or warm after a cooling period of at least 30 minutes (oil temperature < 80 °C). Valve clearance: Inlet Outlet 0.3 +0.1 mm 0.5 +0.1 mm VALVE CLEARANCE SCHEMATIC Crankshaft position 1 Crankshaft position 2 Turn the engine until the valve inlet and outlet of cylinder 1 are just open. Turn the engine one full revolution (360 °).
Section 4.1 Page 24 4.1.2.5 09.06 Service Training CHECKING AND ADJUSTING LEAK-FUEL-FREE INJECTION NOZZLES CHECKING THE OPENING PRESSURE NOTE: Use only test oil acc. to ISO 4113 or diesel fuel for the test. CAUTION: When checking injection nozzles, take care that the fuel jet does not hit the hands. Due to the high pressure, the fuel can penetrate the skin and cause severe injuries. - Install the injection nozzle on the nozzle tester. - Press the lever down slowly.
Service Training CHECK INJECTORS The injectors are not equipped with bores for leak -off fuel. The surplus fuel cannot be discharged and accumulates in the space above the injector needle in the area of the spring of the injector holder. Actuation of the manual lever of the injector tester is no longer possible in this case. For relieving the pressure in the area of the spring, slacken the tensioning nut before each test and re-tighten to the specified torque after the test.
Section 4.1 Page 26 09.06 SETTING OF INJECTORS For a correction of the opening pressure: - Remove injector from nozzle tester 8008. Remove tensioning nut and uninstall all components. Use dolly 110 110 for the injector. Sequence of parts disassembly and re-assembly 1. 2. 3. 4. 5. 6. Tensioning nut Nozzle Adapter Thrust pin Compression spring Shim - Adjust opening pressure by selecting appropriate shim. A thicker shim will increase the opening pressure. Reassemble injector. Tighten tensioning nut.
Service Training LEAK TEST - Dry nozzle and nozzle holder by compressed air. - Press hand lever of tester slowly down until apressure of approx. 20 bar below the previous opening pressure reading is attained. - The nozzle is leak proof if there is no dripping within 10 seconds. - 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! 09.06 Section 4.
Section 4.1 Page 28 09.06 BUZZING AND SPRAY PATTERN TEST - Switch-off pressure gauge of tester. - The buzzing test permits audible checking for ease of movement of the nozzle needle in the nozzle body. New injectors compared to used ones have a different buzzing sound. - This buzzing sound deteriorates by wear in the area of the needle seat. If there is no buzzing of a nozzle despite cleaning, it must be replaced by a new one.
Service Training - Attach new injection lines with sealing rubber elements. Tighten cap screws finger-tight. HINWEIS: When installing the injection lines make sure that sealing cones are exactly aligned one on top of the other. Subsequent bending is not allowed. Injeetion lines must not be re-used. - Tighten bolts of claws. Specified tightening torque: 16 + 5 Nm - Pre-tension cap nuts of injection lines on injection pumps and injection nozzles to a tightening torque of approx. 5 Nm. Then tighten cap nuts.
Section 4.1 Page 30 4.1.2.6 09.06 THERMOSTAT REMOVAL - Drain coolant, collect it, and dispose of it in accordance with legal standards. - Dismantle outlet connecting piece. Remove thermostat. NOTE: Collect coolant and dispose of it in accordance with legal standards. - Attach new sealing ring to thermostat. Insert thermostat together with new sealing ring. NOTE: Mind operating position of thermostat. Arrow (venting notch) points to the top. - Attach outlet connecting piece.
Service Training CHECKING Check thermostat in removed condition. - Measure dimension „a“ on the thermostat. NOTE: „a“ = stroke beginning at approx. 83 ± 2°C (T1) „b“ = stroke ending at approx. 95°C (T2) - Heat up thermostat in the water bath. For a determination of the exact opening point, the temperature reading should take place as closely as possible to the thermostat, however, without contacting the latter. The water must be continuously stirred to arrive at a uniform distribution of temperature.
Section 4.1 Page 32 4.1.2.7 - 09.06 Service Training CHECKING THE COMPRESSION PRESSURE Remove the injection nozzle. Check the valve clearance. Insert and fasten connector 100110 along with the special seal. Connect a compressometer and crank the engine with the starter. Specified pressure 30 - 38 bar Max.
Service Training 4.1.2.8 09.06 Section 4.1 Page 33 CYLINDER HEAD REMOVING THE CYLINDER HEAD - With the engine cool, slacken the cylinder head bolts evenly and in steps in the reverse order as given in the schematic "Cylinder head bolt tightening sequence". DETERMINING THE CYLINDER HEAD GASKET NOTE: For the adjustment of the gap, there are 3 different cylinder head gaskets, which identifiable by holes.
Section 4.1 Page 34 Service Training 09.06 INSTALLING THE CYLINDER HEAD NOTE: Sealing surfaces for cylinder head gaskets must be clean and free of oil. Pay attention to the fitting sleeve. - Check the cylinder head for warping. Put the cylinder head in place. Check the cylinder head bolts for stretching, see "Visual check". 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.
Service Training 09.06 4.1.2.9 INJECTION PUMP 4.1.2.9.1 ADJUSTING THE BEGIN OF DELIVERY Section 4.1 Page 35 If an injection pump must be replaced, the begin of delivery must be re-adjusted by determining the shim thickness anew. DETERMINING THE SHIM THICKNESS The old injection pump and shim are not required for this procedure. Proceed as follows: In the column marked "EP", read the EP code for cylinder 3 on the name plate on the cylinder head cover, e.g.
Section 4.1 Page 36 Service Training 09.06 Read the code for the injection pump length (A) on the new injection pump, e.g. 42. The basic dimension of the injection pump (L0) is 117.5 mm. Determine the theoretical thickness of the shim (TS). TS = EK - (L0 + A/100) TS = 120.875 mm - (117.5 mm + 42/100 mm) TS = 2.955 mm Choose the thickness of the shim (SS) according to Table 2. TS 2.955 = SS 3.
Service Training 4.1.2.9.2 09.06 REPLACEMENT OF THE INJECTION PUMP This repair method is intended for a replacement of the injection pumps only. Commercially available tools: Claw grip wrench Torx tool kit Special tools: Press-on device for control rod Extractor pulling device Extractor pulling device for injection valve 8018 8189 100 830 150 800 110 030 - Remove pressure control valve and inspection cover. Pull off cable connector from cut-off solenoid, governor and temperature sensor.
Section 4.1 Page 38 09.06 - Press control rod into stop position using the knurled lock bolt. - Use press-on device for control rod 100 830. NOTE: Tighten knurled lock bolt finger tight. - Set cylinder of the injection pump to be removed to firing TCD. - Turn crankshaft by approx. 120° opposite to the direction of rotation of the engine. (Zünd OT - firing TCD) NOTE: As viewed in direction of the flywheel. - Remove the corresponding injection line, injection pump and injection valve.
Service Training - Read off ID number for injection pump length (dimension A) for the new injection pump. NOTE: Determining new shim. - Place newly determined shim on roller tappet . - Turn injection pump steering lever to center position more or less. - 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.
Section 4.1 Page 40 09.06 - Put on flange. NOTE: Chamfered end must face injection pump body. - Slightly oil bolts and tighten to a tightening torque of 5 Nm. - Release bolts again by 60°. - Carefully turn injection pump counter clockwise up to a noticeable stop using serrated wrench 8117.
Service Training - Turn bolts in again by 60° and gradually tighten to a tightening torque of 7 Nm, 10 Nm and 30 Nm. NOTE: Start with the outer boit remotest from flywheel. - Turn knurled lock bolt back again. Remove press on device 100 830. 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.
Section 4.1 Page 42 09.06 - Siide sealing ring onto injection valve using some grease and insert injection valve. NOTE: The notch on the injection valve must face away from the claw. Marking faces exhaust gas end. - Mount claws and tum in bolts loosely. - Fit new injection line with sealing rubber. Tighten cap nut 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.
Service Training 4.1.2.10 HEATER FLANGE POSITIVE POLE SCREW OF HEATER FLANGE Special screw TN 0425 8628 NOTE: This special screw must be used only once! MOUNTING Prior to mounting the special screw TN 0425 8628, the heater flange must be removed from the engine, so that countersupporting with a hollow hexagon wrench is possible during the mounting of the special screw. The hollow hexagon wrench (size 5) for counter support must be inserted into the heater flange as shown on the photograph. 09.
Section 4.1 Page 44 09.06 The hollow hexagon wrench must be swivelled in anticlockwise direction.
Service Training The hollow hexagon wrench must be swivelled between the upper and the lower heating coil base to be able to counter-support. When tightening the special screw, always countersupport 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. 09.06 Section 4.
Section 4.1 Page 46 4.1.2.11 09.06 Service Training SPECIAL TOOLS No.
Service Training 09.06 8117 Serrated wrench for tuming injection pump 8189 Torx tool kit 9017 Valve spring assembly lever 9090 Spring clamp pliers 100 110 Connector tor compression tester (by IVEKA Automotive Technologies Schanz GmbH, Talweg 8, D-75417 Mühlacker-Lomersheim) 100 320 Turning gear 100 330 Turning gear 100 400 Dial gauge M2T with locking ring Section 4.
Section 4.1 Page 48 09.06 Service Training 100 750 Measuring bar with spacers tor gauging TDC and piston projection 100 830 Press-on device tor control rod 100 890 Measuring device for base circle measurement 101 910 Tightening angle dial indicator tor main bearing, big-end and flywheel bolts, etc.
Service Training 120 680 Extractor for sealing ring beneath injector 121 410 Sleeve for fitting valve stem seal 130 300 Piston ring pliers 130 440 Trapezoidal groove wear gauge 130 660 Piston ring compressor Ø 98 mm Address your order for special tools to: Fa. Wilbär, P.O. Box 14 05 80, D-42826 Remscheid 09.06 Section 4.
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Service Training 4.2 TRANSMISSION Page Section 4.
Page Section 4.2.1 4.2 2 Service Training HYDROSTATIC TRANSMISSION The transmission is composed of separate components consisting of a high pressure axial variabledisplacement pump with integrated control elements and 2 high pressure axial variable-displacement motors. Each hydraulic motor is bolted to a 2-stage planetary hub reduction gear via an intermediate housing that contains the disc brake so forming a compact drive unit for each traction wheel.
Page Service Training 4.2.1.1 1 2 3 4 5 6 7 Section SCHEMATIC DIAGRAM OF THE DRIVE Gear pump, 23 cc, due to transmission ration 1 engine revolution = 27 cc Engine KHD BFM 6 1012 E Axial piston pump BPV 100 S Axial piston pump MPF 55 S Gear pump, 27 cc Traction wheels Planetary hub reduction gearbox i = 17.45 8 9 10 11 A B C Disc brake Axial piston motor HMV 105 S Suction filter Oil tank Feed Working hydraulics Steering hydraulics 4.
4.2 Page 4.2.1.2 Service Training 4 Section TRANSMISSION SPECIFICATIONS VARIABLE DISPLACEMENT PUMP Type: Definition of type designation: Number of pistons: Piston diameter: Max. swashplate angle: Max. operating pressure: Boost/control pressure: Max. speed: Qmax at nmax: Qmax of feed pump: Type of control: Operation: Start/end of control: Overload protection: Pump drive: BPV 100 S B = Series P = Pump V = Variable-displacement 100 = Max. delivery in cc/rev. S = Swashplate 9 22.
Page Service Training Section WHEEL DRIVES Two wheel drives bolted to frame Each unit consists of: 1 variable-displacement hydraulic motor HMV 105 S Definition of type designation: H = High pressure M = Motor V = Variable displacement 105 = Max. displacement in cc/rev. S = Swashplate Number of pistons: 9 Piston diameter: 21 mm Swashplate angle/displacement: max. 20.8 °/105 cc min.
4.2 Page Section 4.2.1.
Page Service Training G Section BOOST PRESSURE PUMP 18 18a 18b 18c Gear pump, 23 cc/rev.; i = 1.18, resulting in 27 cc/rev. Way valve - auxiliary braking Restrictor Restrictor H ENGINE J ENGINE SPEED CONTROL CYLINDER K VARIABLE-DISPLACEMENT PUMP BPV 100, ASSY. 19 Variable-displacement pump 20 3/2-way valve Reversing lock 21 3/3-way valve 22 Control piston 22a Nozzles, 1.
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HYDRAULIKSCHALTPLAN H 50/60/70/80, TYP 353 Service Training Seite Abschnitt 9 4.
10 Seite 05.00 Service Training HYDRAULIKSCHALTPLAN H 50/60/70/80 D-02, BAUREIHE 353 4.
05.00 HYDRAULIKSCHALTPLAN H 50/60/70/80 T-02, BAUREIHE 353 Service Training Seite Abschnitt 11 4.
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Page 4.2 Section 14 09.
Service Training 09.04 F ENGINE G ENGINE SPEED CONTROL CYLINDER H VARIABLE-DISPLACEMENT PUMP HPV 105-02, ASSY.
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09.04 HYDRAULIC CIRCUIT DIAGRAMM H 50/60/70/80 D-03, TYPE 353 Service Training Page Section 17 4.
4.2 18 Section Page 09.
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Page 4.2 Section 20 4.2.2 09.04 Service Training OPERATION OF THE HYDROSTATIC TRANSMISSION The oil flow (20 L/min at nmin1, 60 L/min at nmax) generated by boost pressure pump G goes through filter O to control valve block N entering it at port E1 and leaving at port E, from where it goes to port E of the travel control unit P.
Service Training Travel Control Unit I Operation Travel direction, swashplate angle, maximum rpm II Operation Brake 43 44 45 46 47 48 49 Pressure regulating valve - swashplate angle Pressure-relief valve, 11 bar Restrictor - for differential pressure 4/2-way valve - braking 2/2-way valve, 12 bar - brake protection 4/3-way valve - travel direction 3/2-way valve - signal for maximum rpm 09.04 Page 4.
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Service Training 4.2.2.2 09.04 Page 4.2 Section 23 OPERATION OF CONTROL VALVE BLOCK N = POWER LIMITER Remote control Travel control unit Feed pump Feed Travel control unit Engine speed HMV control cylinder HMV Travel control unit HMV The feed pressure oil flows via E1 and E through control valve block N, goes through travel control unit P from port E to F and returns to the control valve block through port F. The feed pressure valve (26) stabilizes a pressure of 17.
Page 4.2 Section 24 09.04 Service Training POWER LIMITER, ANTI-STALL DEVICE The drive is provided with a power limiter to prevent any overload on the engine by the travel drive. This device controls the swashplate angle of the variable-displacement pump and the variable-displacement motors depending on the high pressure so that the product of flow volume Q x working pressure P does not exceed the available engine power at any time.
Service Training 09.04 Page 4.2 Section 25 EXPLANATION Tank Feed The oil flow from the feed pump (18) goes through restrictor (18c) and is fed through port P3 into the oil circuit. Way valve (18a) is kept closed by a spring. Restrictor (18c) is used to measure a differential pressure whose size is proportional to the flow, i.e. it varies with engine speed.
Page 4.2 Section 26 09.04 Service Training at the pressure balance in the working hydraulics way valve block. This causes the pressure balance to close, thus increasing the pressure of the oil flow of the working hydraulic pump (27). The power required from the engine prevents the rpm from rising too high during braking. 4.2.2.5 LOCK-OUT LOGIC - REVERSING LOCK When the direction of travel is reversed quickly, the differential pressure changes from Y/Z to Z/Y faster than the pump can follow.
Service Training 09.04 Page 4.2 Section 27 at piston (24) continues through open valve (21) to valve (20), which is shifted to position (b) by the 5 bar spring and the feed pressure in the spring chamber. This connects the spring chamber of control cylinder J via port N to the tank. HP Forward Power Limiter Travel Control Unit HP Reverse Power Limiter When the travel direction is reversed quickly, the pressure in spring chamber (a) of the servo piston (24) drops to 17.
Page 4.2 Section 28 4.2.2.6 09.04 Service Training FLUSHING OF THE CIRCUIT AND HOUSING In order to prevent extremely high oil temperatures in the closed circuit, the drive is provided with circuit flushing through an output control device. The temperature in the hydraulic units and the tank is also approximated by flushing the pump and the motor housing. CIRCUIT FLUSHING Each hydraulic motor has an output control device consisting of valve (50), nozzle (50a) and valve (51).
Service Training 09.04 Page 4.
Page 4.2 Section 30 4.2.3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Service Training 09.04 HYDRAULIC REMOTE CONTROL Cover Pilot housing Control pilot Control lever Hexagonal nut Eccentric pin Position mark Grooved nut Setscrew Springs Nut Threaded pin Spring plate Servo piston Bleed screw 16 Reversal lock up to 4/94: 16.1 16.2 16.3 16.4 16.5 16.6 16.7 Setscrew Sealing nut Screw O-ring Adjustment spring Valve piston Valve spring from 5/94: 16.1.1 16.1.2 16.1.3 16.1.4 16.
Service Training 4.2.3.1 09.04 Page 4.2 Section 31 ADJUSTMENTS CONDITIONS - Jack up and securely block the truck so that both traction wheels can rotate freely. - Hydraulic oil at operating temperature. 4.2.3.1.1 - HYDRAULIC NEUTRAL POSITION Hold the eccentric pin (6) with a socket head spanner. Slacken the hexagonal nut (5). Start the engine and let it idle. Gently turn the eccentric pin (6) with the socket head spanner until the traction wheels cease to rotate.
Page 4.2 Section 32 4.2.3.1.4 HYDRAULIC REMOTE CONTROL HPV 105 -02 SERVO CONTROL 1 2 3 4 5 Service Training 09.
Service Training 09.04 Page 4.2 Section 33 ADJUSTMENTS TEST CONDITIONS - Jack the truck up and secure it safely, so that both drive wheels can spin freely. - Truck is at operating temperature. - Travel and braking actuation correctly set. HYDRAULIC ZERO POSITION TEST Test Findings Evaluation Start engine. Release brake, bring engine up to full speed manually. Wheels stop. Zero position in order. Wheel/s turn. Zero position not in order.
Page 4.2 Section 34 4.2.3.1.5 Service Training 09.04 REVERSAL LOCK (LOGIC LOCK OUT) UP TO 4/94 - Slacken the sealing nut (16.2). - Using a socket head spanner, screw in the setscrew (16.1) as far as possible and then screw out again 2 1/2 to 3 turns. - Start the engine, release the brake and fully depress the forward accelerator pedal. The engine and wheels must accelerate to full speed.
Service Training 4.2.4 1 2 3 09.04 Page 4.2 Section 35 WHEEL DRIVE Reduction gearbox Disc brake 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.
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Page 4.2 Section 38 4.2.4.2 09.04 Service Training SERVICING THE REDUCTION GEARBOX (GR 80 -02/-03/-04) CONDITIONS - Jack up the truck and block it up securely. - Remove the traction wheel. - Place an oil pan under the gearbox. REPLACING THE SEALING RING (3) - Tighten the cover (2) using a bar (support on 2 wheel mounting bolts). Remove retaining ring (1). Remove the bar, take the cover (2) off the ring gear (4) and remove the O-ring (3). Installation is the reverse of removal.
Service Training 4.2.4.3 09.04 Page 4.2 Section 39 DISC BRAKE REPAIRS CONDITIONS - Jack up the truck and block it up safely. - Remove the traction wheel. - Place an oil pan under the gearbox. DISC BRAKE REMOVAL - Drive a pedestrian pallet truck under the gearbox, raise the gearbox and place a suitable wooden support under it in the centre. - Drive a wooden wedge under the mounting of the manifold to prevent the motor from tipping. - Unscrew the M16x40 mounting screws (32a).
Page 4.2 Section 40 4.2.4.4 1 2 3 4 5 6 7 8 9 Service Training 09.
Service Training 4.2.4.5 REPAIR ON THE REDUCING GEAR GR 80 -06 DISMOUNTING Jack up truck and dismount wheel. Unscrew the hexagon socket screw. Loosen gear unit from oil motor and remove it. Put appropriate device under oil motor in retainer of motor carrier (cramped working conditions) in order to avoid tilting. 09.04 Page 4.
Page 4.2 Section 42 09.04 Fasten gear unit for dismounting and unscrew the hexagon socket screws. 2x unscrew hexagon socket screw (arrows). Remove casing.
Service Training Dismount planetary carrier 2nd stage. The hexagon socket screw is pasted in by means of Loctite. Heat to unscrew. Pull out planetary carrier with 4 gearwheels. Loosen groove nut. 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. 09.04 Page 4.
Page 4.2 Section 44 09.04 Pull off casing. Screw mounting rail on casing. Put threaded rod on drive shaft. Renew radial shaft seal (arrow). Dismount securing ring. The radial shaft seal is pasted in with Loctite.
Service Training 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. 09.04 Page 4.
Page 4.2 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.
Service Training 1 Casing with multi-disc brake 2 Pinion 3 Planetary carrier 1 Install casing. Note Pinion must be inserted in toothing of multidisc brake. Adjustment by turning the lower gear casing. Assemble and install in truck. 09.04 Page 4.
Page 4.2 Section 48 09.04 Service Training 4.2.5 TROUBLESHOOTING 4.2.5.
Service Training 09.04 Page 4.
Page 4.2 Section 50 4.2.5.2 Service Training 09.04 TOOLS AND AIDS FOR MEASUREMENTS The tools and gauges used for troubleshooting are similar to the ones in the catalogue "Special Tools and Instruments". The part names are the same as those in the catalogue under the same consecutive number. All parts contained in the test box are also identified by "1." in the description of the troubleshooting. The rest of the designation corresponds to the identification of the test box manufacturer.
Service Training 09.04 ITEM NO. DESCRIPTION 1.1 1.3 1.5 1.7 a 1.7 b 1.12 1.13 1.17 1.18 1.19 1.24 1.31 1.32 Screw coupling M 14 x 1.5 Adapter nipple Screw coupling M 8 x 1 Banjo bolt M 14 x 1.5 with plug and M 8 x 1 bore Banjo bolt M 14 x 1.5 with M 8 x 1 bore Low pressure gauge 0 - 40 bar High pressure gauge 0 - 600 bar Banjo bolt M 18 x 1.5 with plug Banjo bolt M 18 x 1.5 with M 14 x 1.5 bore Banjo bolt M 18 x 1.5 with M 14 x 1.
Page 4.2 Section 52 4.2.5.3 09.04 Service Training EXPLANATIONS TO TROUBLESHOOTING The functional tests and any ensuing troubleshooting is performed separately for each main group. The following components and functions are affected: 4.2.5.4 4.2.5.5 4.2.5.6 4.2.5.7 Hydraulic speed control for the engine Hydraulic braking system Pressure equality and start of control Hydrostatic travel drive Before commencing with the activities described below, first check the oil level and top up, if required.
Service Training 4.2.5.4 09.04 Page 4.2 Section 53 HYDRAULIC SPEED CONTROL FOR THE ENGINE The engine speed control check is first performed, as described below, merely as a functional test. If any malfunctions are detected during the test, a detailed troubleshooting must be carried out subsequently. 4.2.5.4.
Page 4.2 Section 54 Service Training 09.04 Disconnect the speed control linkage, start the engine and move the injection pump control lever as far as the stop by hand. yes Engine speed of 2250 + 50 rpm is obtained. no Adjust engine speed or put the injection pump governor or engine in order. Repeat the test. Connect LP gauge with adapter V to port F of power limiter. Start engine and read pressure. yes Pressure 17,5 - 21 bar. no See troubleshooting "Hydrostatic travel drive".
Service Training A 09.04 Page 4.2 Section 55 B Valve (20) of lock-out logic faulty or setting too low. yes Speed control cylinder extends fully. Engine accelerates to 2250 + 50 rpm. no With accelerator pedals released and engine running, pull the lift lever fully back and hold it there. yes Speed control cylinder extends fully. Engine accelerates to rated speed. no Loosen banjo bolt at port N of speed control cylinder. With the engine running, pull the lift lever fully back and hold there.
Page 4.2 Section 56 Service Training 09.04 C Release accelerator pedal and then depress it about 1/3 of pedal stroke. Speed jumps to over 1300 rpm. yes No increase in speed or increase too low. yes Jump in speed to 1100 - 1300 rpm. yes Nozzle in valve (49) too small or clogged. Nozzle in valve (49) too large or restrictor in supply line clogged. Fully depress one accelerator pedal and wait until full engine or wheel speed is reached.
Service Training 09.04 Page 4.2 Section 57 D With accelerator pedals released, pull the lift lever fully back and hold there. yes Engine speed of 2250 + 50 rpm is reached no 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. Shuttle valve (D) faulty. yes Pressure rises to 14 bar minimum no Pressure reducing valve (8) of control valve faulty.
Page 4.2 Section 58 09.04 4.2.5.5 HYDRAULIC BRAKING SYSTEM 4.2.5.5.1 FUNCTIONAL TEST Service Training TEST CONDITIONS - Truck jacked up and secured so that both traction wheels can rotate freely. Pedals properly adjusted. Brake pedal locked in the "brake applied" position Hydraulic oil at operating temperature TEST Test Symptoms Start engine and attempt to turn right or left traction wheel with wheel nut spanner and extension. Traction wheels cannot be turned.
Service Training 09.04 Page 4.2 Section 59 Install LP gauge with adapter V to port F of power limiter. Start engine and read pressure gauge. yes Minimum pressure 17.5 bar obtained. no Check "Hydrostatic travel drive". Install LP gauge with adapter IV to external release port R. Start engine and read pressure with the brake released. yes Minimum pressure 17.5 bar obtained. no Fully depress brake pedal with engine running and observe pressure gauge. yes Pressure drops to approx. 0 bar.
Page 4.2 Section 60 Service Training 09.04 A Disconnect adapter IV at external brake release port R and install LP gauge with adapter I. Repeat the test. 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. yes Pressure 17.5 bar minimum. no Connecting oil passage in valve (46) clogged; clean it. Brake shaft adjusted incorrectly; correct the adjustment. Valve (46) faulty; repair valve or renew travel control unit.
Service Training 4.2.5.6 09.04 Page 4.2 Section 61 PRESSURE EQUALITY AND START OF CONTROL TEST CONDITIONS - Truck not jacked up. Pedals properly adjusted. Brake released. Engine and travel drive at operating temperature. 4.2.5.6.1 FUNCTIONAL TEST - Driver seated on driver's seat - Start engine Test Symptoms Beurteilung Sensitively depress F or R accelerator pedal (fine control range) until truck starts. Truck starts slowly without jerking. Start of control okay. Truck jerks.
Page 4.2 Section 62 Service Training 09.04 Using adapter V, install LP gauge at port F of power limiter. Start engine and read pressure with the brake released. yes Pressure = 17.5 - 21 bar. no 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. yes Δp = 5 bar or more. no See "Hydrostatic travel drive".
Service Training 09.04 A Page 4.2 Section 63 B yes Δp = 0 - 0,5 bar. no Remove adapter III at ports YF and ZF and install LP gauge with adapter II at ports YF and ZF. Repeat the test. See "Hydrostatic travel drive". yes Δp = 0 - 0,5 bar. no Adjust Δp by turning rear (looking in direction of travel) bushing or renew travel control unit. Slowly depress the F and R accelerator pedals and determine Δp at start of control (start of wheel rotation). yes Δp at start of control = 4 + 0,5 bar.
Page 4.2 Section 64 Service Training 09.04 D C Set Δp to 11 + 0.1 bar at valve (44) of travel control unit. yes Δp can be obtained. no Remove adapter III at ports YF and ZF and install LP gauge with adapter II to ports YF and ZF. With F and R accelerator pedals depressed to the stop, set Δp to 11 + 0.1 bar. Fault in hydraulic remote control. Repair or renew remote control. yes Δp obtained. no Fault in travel control unit. Repair or renew the unit. Fully depress the F or R accelerator pedal.
Service Training 4.2.5.7 09.04 HYDROSTATIC TRAVEL DRIVE TEST CONDITIONS - Truck jacked up and secured so that both traction wheels can rotate freely. Hydraulic neutral in order. Engine cover raised. Floor plate removed. Pedals properly adjusted. Brake pedal locked in the "applied" position. Front cover removed. Engine and travel drive at operating temperature. Page 4.
Page 4.2 Section 66 Service Training 09.04 Install LP gauge with adapter V to port F of power limiter. Measure pressure with engine at idling speed and brake pedal released. Pressure between 17.5 and 20 bar. Pressure under 17.5 bar. Pressure over 20 bar. Check boost pressure valve (26) and increase spring tension, if necessary. Repeat the test. yes Pressure now between 17.5 and 20 bar. Setting of boost pressure valve (26) too high. Adjust or renew the valve.
Service Training A 09.04 Page 4.2 Section 67 B Leak in remote control for left or right hydraulic motor. Locate and remedy the fault or renew the control. yes Pressure now between 17.5 and 20 bar. no Disconnect HP lines of right hydraulic motor, repeat the test. Fault in right hydraulic motor. Repair or replace motor. yes Pressure now okay. no Disconnect the HP lines of left hydraulic motor, repeat the test. Fault in left hydraulic motor. Repair or replace motor. yes Pressure now okay.
Page 4.2 Section 68 Service Training 09.04 C D Install banjo bolt 1.17 with plug at ports E and F of the travel control unit. Repeat the test. Fault in travel control unit. Possible causes: Valve (47) sticking in open position. Setting of valve (46) (brake shaft) incorrect. Valve (44) (11 bar) dirty or setting incorrect. yes Δp is 12 bar minimum. Valve (33) (13 bar) dirty or setting incorrect. Clean or correct the setting.
Service Training E 09.04 Page 4.2 Section 69 F yes Motor now reaches maximum speed at each side. no See "Hydraulic speed control". At max. speed, determine Δp between ports E and F. yes Δp between 12 and 14 bar. no Install banjo bolts 1.17 with plugs at ports E and F of travel control unit. Repeat test with engine idling. Reconnect lines to ports E and F and adjust valve (44) (11 bar) at full throttle to a Δp of 11 - 12 bar. yes Δp between 12 and 14 bar. no Set valve (33) to 13 bar.
Page 4.2 Section 70 Service Training 09.04 G H Read pressure at port F when accelerator pedals are depressed. yes Pressure drops clearly under 17.5 bar. no Disconnect the right or left hydraulic motor, repeat the test. Variable-displacement pump defective, repair or renew. yes Pressure at port F still drops to below 17.5 bar. no Left or right hydraulic motor defective, repair or renew. Check the braking system, see "Hydraulic braking system". Repeat the test. yes Wheels now turning.
Service Training I 09.04 Page 4.2 Section 71 K yes Δp 0 - 0,5 bar. no Check for equal pressure, see "Pressure equality and start of control". yes Equal pressure can be achieved. no 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. yes Δp now 0 - 0,5 bar. no Install LP gauge with adapter III to ports YF and ZF of power limiter.
Page 4.2 Section 72 L Service Training 09.04 M Determine Δp by fully depressing the F and R accelerator pedals consecutively with the brake released. Remote control servo piston sticking or control cylinder of cradle defective. yes Δp von 10 - 11 bar. no Remove adapter III and install adapter II with plug. Connect LP gauge, determine Δp by fully depressing the F and R accelerator pedals with the brake released and engine running. Leak in hydraulic remote control.
Service Training 09.04 Page 4.2 Section 73 O yes Average wheel speed of 155 - 165 rpm achieved on both sides. no Install LP gauge with adapter III to ports Y and Z of remote control and determine Δp with the brake released. yes Δp 0 bar to max. 0,5 bar. no Remove adapters III and screw in adapters II with plugs. Install LP gauges and determine Δp with the brake released. Leak in remote control. Remedy fault or renew remote control. yes Δp now 0 bar to max. 0,5 bar.
Page 4.2 Section 74 P Service Training 09.04 Q Fully depress the F and R accelerator pedals with the brake released and the engine running. Read Δp when pedals are fully depressed. yes Δp of 11 - 11 bar obtained to both sides. no Remove adapter III and screw in adapter II with plug. Determine Δp with the brake released and pedals fully depressed. Leak in the remote control unit. Repair or renew the unit. yes Δp of 10 - 11 bar now achieved.
Service Training 09.04 Page 4.2 Section 75 S R yes Average wheel speed of 155 - 165 rpm obtained to both sides. no 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. Check maximurn swivel angle of BPV, see "Mechanical limitation of swivelling angle". Check the minimum swivelling angle of the HMV, see "Qmin of hydraulic motors HMV 105". yes Δp 10 - 11 bar.
Page 4.2 Section 76 Service Training 09.04 Q HP 330 + 20 bar on H 50/60, 390 + 20 bar on H 70/80. LP minimum 17.5 bar. HP far below specifications, LP at least 17.5 bar. HP and LP pulsate or LP drops below 12 bar and HP does not rise. Power unit for forward travel in order. Internal leak, possible causes: Combined boost and prsssure-relief valve, bypass valve leaking. Output device faulty. External leaks in power unit for reverse travel.
Service Training 4.2.6 09.04 Page 4.2 Section 77 TEST AND ADJUSTMENT INSTRUCTIONS FOR HYDRAULIC PRIMARY AND SECONDARY CONTROL The swash plate angle Qmax of the variable-displacement pump or the Qmax/Qmin of the hydraulic motors need only be checked if required in "Hydrostatic travel drive" of the troubleshooting. The following tests and adjustments must only be performed by qualified skilled staff.
Page 4.2 Section 78 4.2.6.1 Service Training 09.04 QMAX OF VARIABLE DISPLACEMENT PUMP BPV 100 Start the engine and determine Δp between ports Y and Z. yes Δp 0 - 0,5 bar. no Adjust equal pressure, see "Pressure equality and start of control". Fully depress F and R accelerator pedals and determine Δp when fully depressed. yes Δp 10 - 11 bar. no Adjust correctly, see "Pressure equality and start of control". Determine average wheel speed with accelerator pedals fully depressed.
Service Training 09.04 Page 4.2 Section 79 A yes Speed now 68 - 65 rpm. no Qmax of pump in order. 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.
Page 4.2 Section 80 4.2.6.2 Service Training 09.04 QMAX OF HYDRAULIC MOTORS HMV 105 Lock the right traction wheel. Start engine, release brake, fully depress one accelerator pedal and measure speed of left wheel. Qmax of left motor okay. yes Wheel speed 116 - 130 rpm. no Remove the cover on the bottom of the truck frame. Loosen nut (1) and turn stop screw (2) out.
Service Training 4.2.6.3 09.04 Page 4.2 Section 81 QMIN OF HYDRAULIC MOTORS HMV 105 Condition: Qmax of variable displacement pump and the hydraulic motors is in order. Connect LP gauge with adapter V to port F on the power limiter and connect adapter 1.31. Fully depress F and R pedals and determine the Δp between ports F and X with pedals fully depressed. Δp to both sides under 4 bar. Δp to one side 10 -11 bar, to the other side under 4 bar.
Page 4.2 Section 82 Service Training 09.04 CHECKING QMIN - Shut off the engine, lock the left wheel, close the valve on 1.32 and put a 5-mm spacer between injection pump lever and stop screw for maximum engine speed. - Start the engine, fully depress an accelerator pedal (engine speed reaches approx. 1200 rpm) and measure the speed of the right wheel. - Now open the valve on 1.32 and measure the wheel speed again (hydraulic motor now goes from Qmax to Qmin).
Service Training 4.3 CHASSIS Section Page 4.
Section Page 4.3.1 4.3 2 Service Training OVERHEAD GUARD - TORSION MOUNTING The overhead guard is fastened to a cross member at the top of the mast so that it follows the mast when tilted. At the rear supports, the overhead guard is guided in two adjustable rollers. This type of roof construction increases the torsion stiffness of the mast and it is called a torsion mounting.
Service Training 1 2 3 4 5 6 Section Page 4.3 3 Overhead guard pivot articulation on the mast Front mounting of tilt cylinders Overhead guard Rear mounting of tilt cylinders Roller mount Overhead guard guide roller 4.3.1.1 WORK ON THE OVERHEAD GUARD DISASSEMBLY - Slacken the fastening screws on the left and right roller mounts (5) and slide the mount outward in the area of the bearing holes. - Dismantle the left and right bearing bracket (7). - Take off the overhead guard by lifting it up.
Section Page 4.3 4 Service Training - Remove any lateral play in the overhead guard with shims (9). - Install the bearing brackets (7) and torque the screws (10) to 80 Nm. - Using a mounting iron, position the left and right roller mounts (4) without play on the overhead guard tube sections and handtighten the mount fastening screws. - 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.
Service Training 4.4 STEERING SYSTEM Section Page 4.
Section Page 4.4.1 4.4 Service Training 2 POWER STEERING CIRCUIT DIAGRAM B Steering control valve assy.
Service Training Section Page 4.4 3 OPERATION OF THE POWER STEERING The oil from the pump (28) enters the steering control valve (B) at port P2, flows through the steering control valve (17), leaves the valve through port T1 and goes back to the tank through the oil cooler (E). Turning the steering wheel closes the P2-T2 connection and the oil coming from P2 is fed to the steering cylinder via port R or L. The maximum pressure on the primary side is set to 150 bar.
Section Page 4.4.2 4.4 Service Training 4 SERIES 304 STEERING AXLE EXPLANATION OF THE STEERING AXLE SERIES NUMBER 304 D 11 5053 Series number Month built Year built Axle type 4.4.2.1 DESCRIPTION The rear wheels are steered by means of a double-acting hydraulic cylinder mounted to the steering cylinder and the two steering knuckles with two track rod links (fixed length). The motion of the steering wheel activates the steering control valve controlling the oil flow to the steering cylinder.
Service Training 4.4.3 - STEERING AXLE REMOVAL Remove the wheel mounting screws on both wheels. Jack up and securely block the rear of the truck. Remove the rear wheels. Support the steering axle (1). Remove the mounting screws (4). Remove the plate (3). 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. Section Page 4.
Section Page 4.4.3.1 4.4 6 Service Training STEERING AXLE INSTALLATION - Mount the two axle blocks (2) on the centre of the axle. NOTE: Axle blocks are not symmetrical, wide section must be shown up! - Place the steering axle (1) into the counterweight from below. Raise the steering slightly until the two axle blocks (2) contact the counterweight and underpin it. - Coat the mounting screws (4) with Loctite 270. - Fasten the two plates (3) and axle blocks (2) with screws (4).
Section Service Training 4.4.4.1 Page 4.4 7 RENEWING THE WHEEL BEARINGS - Jack up the truck. Remove the wheel. Remove the cap (8). Drive out the cotter pin (7). Loosen and remove the 55 mm nut (6). Drive out the wheel hub (1) out from the inside with a plastic hammer. Renew the outer bearing ring of taper roller bearings (2) and (5) and also the shaft seal (3). Pull the taper roller bearing (2) from the knuckle (4) and renew it.
Section Service Training 8 Page 4.4.4.2 1 2 3 4 5 4.
Service Training STEERING KNUCKLE REMOVAL - Jack up the truck. - Remove the wheels. - Turn the steering until the pin (2) retaining the track rod (3) is positioned in the counterweight recess. - Drive out the roll pins (6). - Place the special tool (4) on the jack (5) and position it under the pin (2). - Support the knuckle (7) against the counterweight with a pipe (1). - Operate the jack (7) and press out the pin (2).
Section 4.4 Page 10 4.4.4.3 Service Training STEERING CYLINDER REMOVAL AND INSTALLATION STEERING CYLINDER REMOVAL - Jack up and securely block the rear of the truck so that the wheels can turn freely. - Remove the dowel pins (3) from pin (2). - Turn the steering wheel clockwise or anti-clockwise until the steering cylinder is extended as far as possible. - Remove the four mounting screws (9) at the steering cylinder (7).
Service Training Section 4.4 Page 11 STEERING CYLINDER INSTALLATION - Lift the steering cylinder (8) into the steering axle. NOTE: Support up the steering cylinder with wooden blocks. Steering cylinder holes have different diameters: diam. 24 mm at top, diam. 26 mm at bottom. - Insert the track rod (3) into the fork on the steering cylinder (8) and bring them into alignment. - Insert a centring pin (2) through the track rod (3) and fork on the piston rod of the steering cylinder (8).
Section 4.4 Page 12 4.4.4.4 - - Service Training REPLACING THE STEERING CYLINDER SEALS Remove the steering cylinder and clamp it in a vise. Pull the piston rod (1) out to one side as far as possible. Drive in the guide bushing (5) approx. 1 - 2 mm. Loosen the retaining ring (9) with a 2.5 mm drift punch through hole (3) and remove with a screwdriver.
Service Training 4.4.4.5 1 2 3 4 Section 4.4 Page 13 STEERING STOP ADJUSTMENT Stop screw Locknut Axle body Steering cylinder To prevent damage to the hydraulic cylinder, check and adjust, if necessary, the left and right-hand steering stop after repairing a steering knuckle, track rod or steering cylinder. - Loosen the locknut (2) and screw out the M12x60 stop screw (1) approximately 10 turns. Start the engine and turn the steering wheel until the hydraulic cylinder is fully extended.
Section 4.
Service Training 4.5 CONTROLS Section Page 4.
4.5 Section 2 Page 4.5.1 Service Training ACCELERATOR AND BRAKE PEDAL ADJUSTMENT ACCELERATOR PEDALS - Bring both accelerator pedals to the same level, position bracket (1) on the leg spring (2) and secure them with screws. - With the aid of the spacer (WM 6), adjust the hexagonal screws (3) and (7) to a clearance of 48 mm from the pedal and lock them with locknuts. - Position the travel control 55 mm (WM 6) from the side of the pedal and secure it with screws.
Service Training Section Page 4.
Section Page 4.5 4 Service Training BOWDEN CABLE FOR THE PARKING BRAKE - Depress the brake pedal until the flat spring (1) engages. - Set the lever on the control unit cover to the "Brake engaged" position. - Remove any play in the brake cable (2) at the lower end by clamping the nipple (3).
Service Training 4.5.2 SPEED CONTROL 4.5.2.1 SPEED CONTROL UP TO 10/95 Section 09.96 Page 4.5 5 ADJUSTMENT INSTRUCTIONS FOR DIMENSION X (LOWER IDLING SPEED) - Retract the speed control cylinder (1) and slacken screw (4). Shift the adjusting lever (3) outward as far as possible on lever (2). - 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.
Section 4.5 Page 6 09.96 Service Training ADJUSTMENT INSTRUCTIONS FOR DIMENSION Y (UPPER IDLING SPEED) - Fully depress the brake pedal and lock it. - Start the engine. - Depress the accelerator pedal until the speed control cylinder is fully extended. - Slacken nut (4) and slide the adjusting lever (3) on lever (2). - Adjust dimension Y to 0.1 mm. - Tighten screw (4). - Check dimension Y with a 0.1 mm feeler gauge.
Service Training 4.5.2.2 Section 09.96 Page 4.5 7 SPEED CONTROL FROM 11/95 From 11/95 the speed control lever has been provided with an overload protection. The adjustment procedure is as follows. - With the control cylinder (1) retracted, slide the retainer (2) on the lever (7) as far as possible away from the engine and tighten both the cheese head screws (3). - 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).
4.5 Section 8 Page 4.5.3 09.96 Service Training MEDIUM WHEEL SPEED CONDITIONS - Jack up and securely block the truck so that the wheels can turn freely. - Accelerator pedals and engine speed control correctly adjusted. - Engine runs at 2250 - 2300 rpm with the accelerator pedals fully depressed. CHECK - Start the engine, release the brake and fully depress the right-hand accelerator pedal. - In this position measure the speed of the left and right wheel and calculate the average of both speeds.
Service Training 4.5.4 Section 09.96 Page 4.5 9 START OF DRIVE WHEEL ROTATION The start of wheel rotation is set by means of setscrew (3) such that wheel rotation starts directly after the engine rpm increases or shortly thereafter. In no case should the start of wheel rotation begin before the engine speed starts to increase. ADJUST CONDITIONS - Pedal adjustment is in order. Block up the truck so that both drive wheels can turn freely. Engine and travel drive warmed up to operating temperature.
Section 4.5 Page 10 4.5.5 09.96 Service Training BRAKE SHAFT STOP SCREWS - Connect a low pressure gauge to port BR on the travel control unit. - Slacken the clamping screw on the brake lever and turn the brake shaft (5) clockwise as far as the stop. - Loosen locknut (2). - Start engine. Slowly screw in setscrew (1) while at the same time holding brake shaft (5) clockwise against the stop until the brake shaft has less clearance.
Service Training 4.5.6 SYMMETRY OF THE TRAVEL CONTROL 4.5.6.1 DRIVE WHEEL START OF ROTATION 09.96 Section 4.5 Page 11 ADJUSTMENT REQUIREMENTS - Pedal adjustment is in order. - Truck blocked up and secured so that both drive wheels can turn freely. - Engine and traction hydraulics at operating temperature. - Floor plate removed. - Symmetry of speed control is in order. CHECK - Start the engine and release the brake. - Slowly push down the forward pedal until the wheels begin to rotate.
Section 4.5 Page 12 4.5.6.2 09.96 Service Training ENGINE SPEED INCREASE TEST REQUIREMENTS - Truck blocked up and secured so that both wheels are free to rotate. - Brake applied. - Pedal adjustment is in order. TEST - Sit down on the driver's seat. - Start the engine. Test Symptoms Assessment Gently push forward and reverse pedal until engine speed increases. Speed increase with pedal stroke equal. Symmetry in order. Speed increase with pedal stroke not equal. No symmetry.
Service Training 4.5.7 09.96 Section 4.5 Page 13 PRESSURE DIFFERENCE DP TEST REQUIREMENTS - Truck blocked up. Engine and travel hydraulics at operating temperature. Pedal adjustment is in order. Symmetry of travel control is in order. Two low pressure gauges connected to ports Y and Z of travel control unit with screw couplings 1.1 (refer to "Aids and Tools for Measurements"). TEST Test Symptoms Assessment Start the engine. Release the brake.
Section 4.5 Page 14 4.5.8 Service Training 09.96 MODIFICATION OF ENGINE ACCELERATION In special cases it may be necessary to adapt the operating characteristics of the engine to the service conditions of the truck, e.g. very sensitive driving at creep speed without accelerating the engine, or frequent hill starts with a load at high engine speed. Both possibilities can be adjusted as described below.
Service Training 4.6 ELECTRICAL SYSTEM Section Page 4.
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CIRCUIT DIAGRAMM H 50/60/70/80, TYPE 353 Service Training 4.
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1 2 6 3 05.00 4 7 CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50/60/70/80, TYPE 353 Service Training 5 8 Page Section 9 7 4.
Section Service Training 05.00 4.6.3 WIRING DIAGRAM, 353 -02 A1 Glow duration unit 55-60 F1 F11 F12 1 14 9F14 9F16 Fuse for glow duration unit, 80 A Fuse for potential 30, S1, 10 A Fuse glow duration unit/ shut-off magnet 10 A Fuse for horn, 10 A Fuse for working lights switch illumination/Heater 15 A Fuse for UPA, max.
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09.04 Page Section CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50/60/70/80 -03, TYPE 353 LPG Service Training 31 4.
32 Page 09.04 Service Training CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50/60/70/80 -03, TYPE 353 LPG 4.
Service Training 09.04 Section 4.
Section 4.6 Page 34 4.6.9 Service Training 09.04 CENTRAL ELECTRICAL SYSTEM The whole electrical system ist mounted on the left side of the truck behind a cover of the second foothold.
Service Training 09.04 Section 4.6 Page 35 TOP VIEW OF FUSE BOXES I - IV The fuse box I ist standard version, the boxes II, III and IV are fitted depending on the special equipment. Fuse output Fuse input Fuse output Fuse input EXAMPLE FOR A FUSE APPLICATION 5 F 31 : 2 Fuse output No.
Section 4.6 Page 36 Service Training 09.04 4.6.10 CENTRAL ELECTRICS OF SERIES 353 -03 4.6.10.
Service Training 09.
Section 4.6 Page 38 4.6.10.2 09.
Service Training 09.
Section 4.6 Page 40 4.6.10.3 1 2 3 4 5 6 Service Training RELAY AND FUSES FOR 353 -03 PARTICULATE TRAP Diagnostic plug 6X8 Signal transmission connector 7X9 Relay 7K12, 12V/20 A Relay 7K9, 12 V/70 A Relay 7K11, 12 V/70 A Control device for particulate trap 7A1 TOP VIEW OF FUSE BOXES Fuse input Fuse output 1 2 3 4 5 09.
Service Training 4.7 WORKING HYDRAULICS Section Page 4.
Section Page 4.7.1 1 2 3 4 5 6 7 8a 8b 4.
Service Training 4.7.1.1 Section Page 4.7 3 EXPLANATION OF THE WORKING HYDRAULICS When the control levers are in the neutral position and the pump output is nill, way valves (2), (4), (6) and (7) and also the pressure balance (9) are closed. Port P1 is connected via the pressure-reducing valve (8) to port VS.
Section 4.7 Page 4 4.7.
Service Training 4.7.2.1 Section Page 4.7 5 TILT CYLINDER REMOVAL, INSTALLATION, ADJUSTMENT, SEALING TILT CYLINDER REMOVAL - Tilt the mast forward as far as possible. Unscrew and remove the bearing bracket (1) on the cross member of the outer upright. Press the piston rod (6) and pin (4) up and out of the lower bearing half, but leave it in the bearing. Slacken the fastening screws (11) on the left and right roller mount (12) and slide outward. Lift the overhead guard approx.
Section Page 4.7 Service Training 6 SEALING THE TILT CYLINDER 1 2 3 4 5 6 7 8 9 Bearing Setscrew Piston Guide ring Piston seal Rod seal Bushing - piston stroke limiter Cylinder barrel Piston rod 10 11 12 13 14 15 16 17 18 Guide ring Sealing ring Support ring Cylinder head Rod seal O-ring Wiper Hexagonal nut Eyebolt SEALING THE PISTON ROD Condition: Cylinder removed - Clamp the cylinder with the eyebolt of the cylinder barrel (8) in a vise.
Service Training Section Page 4.7 7 RENEWING THE PISTON SEALS Condition: Cylinder removed - Clamp the cylinder with the eyebolt of the cylinder barrel (8) in a vise. Open the flanged retainer for the cylinder head (13) and screw the cylinder head out of the barrel. Pull the piston rod assembly out of the barrel. 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.
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Service Training 4.8 MAST Section Page 4.
Section Page 4.8.1 4.8 Service Training 2 MAST REMOVAL - Remove the forks. Lower the fork carriage. Tilt the mast fully forward. Disconnect the hoses (6) on the fitting (7). Unscrew the overhead guard bearings on the left and right and slide the overhead guard back. Remove the left and right tilt cylinder pivots, tilt the cylinder up and secure it. 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.
Service Training 4.8.2 Section Page 4.8 3 LIFT CYLINDER REMOVAL, INSTALLATION - Start the engine, operate the lift hydraulics and raise the fork carriage (8) approx. 1 metre. - Pry out the retaining ring (1) of the cylinder to be removed. - Block up the inner upright (2), operate the lowering control lever until the inner upright is supported by the block and continue to operate the lever until the piston rod of the cylinder to be removed is fully lowered.
Section Page 4.8.3 1 2 3 4 5 6 7 8 9 10 11 4.8 Service Training 4 SEALING THE LIFT CYLINDER Piston rod diam. 68 - H 50/60 only Wiper Cylinder head Grooved ring Opening for socket spanner Bleed screw O-ring Cylinder barrel Guide bushing Stop screw Hexagon head 42 mm H 70/80, DEVIATION FROM H 50/60 12 13 14 15 16 Piston head with tang (top piston head) Retaining ring Piston rod - tube diam.
Service Training Section Page 4.8 5 SEALING THE H 50/60/70/80 LIFT CYLINDER Condition: Cylinder removed - Hold the cylinder at the 42 mm hexagon head (11). - Slightly heat the cylinder head (3) in the area of the thread and unscrew from the cylinder barrel (8) with a suitable socket spanner. - Pull the piston rod (1) or (14) out of the barrel (8) and inspect for damage. - Remove the cylinder head seals (3).
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Section Service Training 12.05 4.9 LP GAS MODEL H 50/60/70/0,TYPE 353 4.9.1 DRIVE ENGINE 4.9.1.1 TECHNICAL DATA ON ENGINE 4.9.1.1.1 TECHNICAL DATA ON ENGINE UP TO 12/2004 Engine type Perkins 1006.6 T List of components YF 80929 Power 72 kW Compression rating: 13 bar wear limit: 10 bar Max. admissible pressure difference 2 bar Rated speed 2100 rpm Idling speed 800 rpm Max.
Section 4.9 Page 4.9.1.1.2 2 Service Training 12.05 TECHNICAL DATA ON ENGINE FROM 01/2005 Engine type Perkins KVT 1000.6 EGSIT List of components YF 80929 Power 72 kW Compression rating: 13 bar wear limit: 10 bar Max. admissible pressure difference 2 bar Rated speed 2100 rpm Idling speed 800 rpm Max.
Section Service Training 4.9.1.2 12.05 Page 4.9 3 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).
Section Page 4.9.1.3 4.9 4 12.05 CHANGING AND TENSING V-BELT CHANGING THE V-BELT - Remove cover (1) on the rear panel. Open engine cover Loosen hexagon nut (3) on adjusting rail. Loosen fixing screw (4). Press alternator (5) against the engine. Turn support with LP gas tanks towards the back on the side. - Remove the cover on the counterweight. - Unscrew screws (6 of them) from counterweight on radiator cover. - Remove cover plate (8) upwards from radiator.
Service Training 4.9.1.4 Section 12.05 Page CHECKING AND SETTING VALVE CLEARANCE The valve clearance is to be checked and adjusted only with the engine cold. - Remove valve cover. - Turn the engine with screwdriver through opening in the middle housing on toothed flywheel ring until the valves on the 6th cylinder overlap. In this position, check the valve clearance of the first cylinder and adjust if necessary. - Turn the flywheel further until the valves of the 2nd cylinder overlap.
Section Page 4.9.1.5 4.9 6 12.05 Service Training REMOVING AND INSTALLING THE CYLINDER HEAD REMOVING THE CYLINDER HEAD - Loosen cylinder head screws uniformly and gradually in an alternating spiral sequence, as shown in the diagram. - Check cylinder head screws, with a ruler (1), for deformation of the screw shaft (2). - Check the screw for a visible reduction of thread size close to the screw shaft (3).
Service Training Section 12.05 Page - Insert new cylinder head seal without additional sealant (B). NOTICE: Before installation of the cylinder head, clean the thread holes in the engine block. - In order to keep the cylinder head seal in the correct position for assembly of the cylinder head, screw two 1/2 UNF stud bolts into the motor block (C). - Lightly oil the cylinder head screw thread and tighten to 110 Nm in accordance with diagram.
Section Page 4.9 8 12.05 - If there is no torque measuring tool (1) available, mark the position of each individual screw on the cylinder head in relation to a corner point (A). - Mark the correct angle (in a clockwise direction) on the top of each screw in accordance with length (S, M or L). - Tighten the screws in the correct order until they are adjusted in accordance with the marks made on the cylinder head.
Section Service Training 12.05 4.9.2 ELECTRICAL SYSTEM 4.9.2.1 ELECTRONIC IGNITION SYSTEM 4.9.2.1.1 ELECTRONIC IGNITION SYSTEM UP TO 12/2004 4.9 Page 9 The motor is equipped with a Bosch contactless transistor-coil ignition (TSZ [German abbreviation]) . Control of the spark ignition without mechanical contact provides the following advantages: - Ignition electronics and ignition generator work with no wear and consequently need no maintenance whatsoever.
Section 4.9 Page 10 12.05 Service Training COMPONENTS OF A TRANSISTOR IGNITION SYSTEM 1 2 3 4 5 6 7 Battery Ignition starting switch Ignition coil Switchgear Transmitter Ignition distributor Spark plug(s) FUNCTIONING OF THE IGNITION SYSTEM The ignition system consists of the following components: Battery (1) as the energy source.
Service Training 12.05 Section 4.9 Page 11 INDUCTIVE ACTIVATION OF THE IGNITION Permanent magnet (1) and induction winding (2) form the stator. The rotor, which rotates against the stator, is positioned on the timer core (4) located on the ignition distributor shaft. The core and rotor are made of soft magnetic steel and have pointed extensions (stator arms and rotor arms). As the rotor turns, the air gap (3) between stator arms and rotor arms periodically changes.
Section 4.9 Page 12 12.05 Service Training 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.
Service Training 12.05 Section 4.
Section 4.9 Page 14 4.9.2.1.2 ELECTRONIC IGNITION SYSTEM FROM 01/2005 FUNCTIONAL DIAGRAM 1 2 3 4 5 6 7 12.
Service Training 12.05 Section 4.9 Page 15 DESCRIPTION The engine is equipped with an integrated electronic ignition system without contact breaker points. Due to its design, the ignition system is reliable, non-adjustable and has the following advantages: - No centrifugal advance. Permanent stability of the ignition timing curve. High secondary voltage. No wear of the controller due to a magnetic pickup without mechanical contact.
Section 4.9 Page 16 12.05 Service Training TRANSMISSION OF THE PULSES The purpose of the advance angle sensor (generator) is to generate a pulse whenever it passes a tooth. The electronic controller receives a unique pulse whenever a specially formed tooth passes the generator. This allows the top dead centre point (TDC) to be determined accurately. ADVANCE ANGLE SENSOR This sensor is a magnetic pickup mounted adjacent to the teeth of the toothed disc.
Service Training 12.05 Section 4.9 Page 17 CHECKING THE IGNITION TIMING A timing light is required for measuring the ignition point. It must be connected between the ignition coil and spark plug of the number 1 cylinder. For the check, the ignition coil must be unscrewed from the bracket of the number 1 plug. 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.
Section 4.9 Page 18 Service Training 12.05 MARKING THE FIRING POINT The firing point is fixed by the ignition electronics and can only be adjusted in the direction of "retarded" with appropriate resistors (see circuit diagram). 1 2 Firing point mark on housing Firing point mark on flywheel FIRING POINT CHARACTERISTIC CURVE FOR 1006-EGSI (white (yellow) (blue) Firing Point (° BTDC) (green) (red Eng.
Service Training The firing point caracteristic curve is controlled by a resistor. The picture besides shows the position of the resistor in the truck. 4.9.2.1.2.1 MECHANICAL IGNITION TIMING SPECIAL TOOLS REQUIRED Timing pin for ignition system Part no. 000 008 61 00 Torx driver for ignition system ET-Nr. 276 10 122 12.05 Section 4.
Section 4.9 Page 20 12.05 Service Training CHECKING THE MECHANICAL IGNITION TIMING ARRANGEMENT IN SITU - Set cylinder 1 of the internal-combustion engine at top dead centre on the compression stroke. - Pull off the connector of the ignition control unit (1). - Unscrew and remove the ignition control unit (1). - Push the timing pin Ø 3 mm (5) through the hole (4) in the toothed disc (3) into the hole in the housing (2).
Service Training ADJUSTING THE TOOTHED DISC IN SITU - Set cylinder 1 of the internal combustion engine at top dead centre on the compression stroke. - Pull off the connector of the ignition control unit (1). - Unscrew and remove the ignition control unit (1). - Loosen the screw (6). - Rotate the toothed disc (2) until the hole in the toothed disc (4) aligns with the hole in the housing (2). - Insert the 3mmtiming pin (5) . - Tighten the screw (9 Nm).
Section 4.9 Page 22 12.05 INSTALLING THE IGNITION CONTROL UNIT NOTE: Prior to installing the ignition control unit, set cylinder 1 of the internal combustion engine at top dead centre on the compression stroke. - Push timing pin (9) through the recess in the hub into the hole in the housing. - Check by inserting the 3mm timing pin (5) through the toothed disc into the housing. - Check the O-ring on the flange and replace, if necessary. - Place the ignition control unit (1) in the mounting position.
Service Training 4.9.2.2 12.05 Section 4.9 Page 23 ELECTRONIC ENGINE-SPEED CONTROL FUNCTION OF THE CONTROL SYSTEM With gas-propellant trucks, the engine speed is kept constant, up to the performance limits of the engine, with the electronic control system, in spite of varying loads caused by the drive and lift hydraulics. Thus the engine power corresponds to the appropriate r.p.m., according to the pedal setting (transmission).
Section 4.9 Page 24 Service Training 12.
Service Training 12.05 Section 4.9 Page 25 NOMINAL VALUE TRANSMITTER The nominal value transmitter (5) is adjusted, via a hydraulic modulator (4), in accordance with the pedal position and the actuation of the operating hydraulics. This adjustment changes the nominal value transmitter (5) into a proportional electrical signal. A conductive plastic potentiometer is built into the nominal value transmitter (5) with an electrically active adjustment range of 44 °.
Section 4.9 Page 26 Service Training 12.05 4.9.2.3 ELECTRICAL SYSTEM CIRCUIT DIAGRAM 4.9.2.3.
12.05 CIRCUIT DIAGRAM H 50/60/70/80 T, TYPE 353, UP TO 12/2004 Service Training 4.
Service Training 12.05 Section 4.
Section 4.9 Page 30 4.9.2.3.2 Service Training 12.
12.05 CIRCUIT DIAGRAM H 50/60/70/80 T, TYPE 353, FROM 01/2005 Service Training 4.
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Service Training 4.9.3 PROPELLANT GAS SYSTEM 4.9.3.1 DIAGRAM 1 2 3 4 5 6 7 8 Drive motor Intake manifold Mixer Vacuum conduct Mixer - gas shutoff valve Vacuum conduct Intake manifold shutoff valve Gas conduit Vaporisor - Mixer Vacuum conduct Mixer - secondary stage of vaporisor Cooling water conduit Vaporisor heating 12.05 Section 4.
Section 4.9 Page 34 4.9.3.2 12.05 Service Training FUNCTIONAL DESCRIPTION OF THE PROPELLANT GAS SYSTEM The various stages of the gas system are described below with their operating positions: OFF POSITION - Ignition start switch (11) open. Electromagnetic shutoff valve (12) in open position. Vacuum-controlled shutoff valve (14) closed. Throttle valve in mixer (3) closed. ON POSITION - Ignition start switch (11) closed. Electromagnetic shutoff valve (12) in closed position.
Service Training 12.05 Section 4.9 Page 35 STOPPING By switching off the ignition, the throttle valve in the propellant gas mixer (3) is closed. At the same time, the distributor valve (11) switches to open position, and the low pressure still present in the system is thereby led through the conduct (5) of the secondary diaphragm in the vaporisor (9) by the engine runoff in the intake manifold.
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Service Training 12.05 Section 4.9 Page 37 OPERATION OF THE VAPORISOR The LPG must be moved in gaseous form to process it with the intake air in the mixer as a flammable mixture. This is achieved by means of the vaporisor, which is heated by the engine cooling water. It works as follows: The IMPCO vaporisor is a combined two-stage regulator with vaporisor.
Section 4.9 Page 38 12.05 Service Training MAINTENANCE ON VAPORISOR Maintenance on the vaporisor should include the checking of the secondary valve actuating lever (1). The Impco maintenance kits are used for two different vaporisor types (series E and EP). As a result, a check must be carried out, and, if necessary, the actuating lever (1) has to be bent accordingly.
Service Training 12.05 Section 4.9 Page 39 PROPELLANT GAS MIXER The correct proportions for the gas-air mixture are important for problem-free running of the engine. For this purpose, a mixer valve (the mixer) serves for the correct dosing of gas and air.
Section 4.9 Page 40 12.05 Service Training It works as follows: When the engine starts, a vacuum is passed through the connection (4) to the gas shutoff valve and opens the valve. This enables LPG to flow to the vaporisor and from there to reach the mixer via connection (6) in a gaseous state.
Service Training 12.05 Section 4.9 Page 41 FUNCTIONING OF THE VACUUM-CONTROLLED SHUTOFF VALVE When the engine is off, the shutoff valve is in closed position. No LPG can flow to the vaporisor. When the engine is started, a vacuum is present in the intake section, which develops through the intake stroke of the engine. This vacuum is passed through a tube connection from the mixer via connection (11) to the top of the diaphragm (9) in the shutoff valve.
Section 4.9 Page 42 12.05 4.9.4 INSPECTIONS AND ADJUSTMENTS 4.9.4.1 IGNITION SYSTEM CHECKING THE FIRING POINT NOTE: The firing point can only be checked and adjusted dynamically using a strobe light. - Let the engine warm up. - Stop engine and switch off ignition. - Connect strobe lamp according to manufacturer’s instructions. - Start engine. - Let engine run at idling speed of 800 rpm. - Shine the strobe light at the firing point mark 18 ° before TDC on the flywheel (2) (vertically from above).
Service Training 12.05 INSPECTION OF THE IGNITION SYSTEM A1 E1 Transistor-coil ignition (TSZ) switchgear Ignition distributor with induction-type pulse generator G2 S1 T1 Battery Ignition starting switch Ignition coil IGNITION CABLE Resistance 2.
Section 4.9 Page 44 12.05 Service Training SWITCHGEAR A1 TEST CONDITION - Ignition coil in order TESTING - Pull out plug from TSZ switchgear and press wire fuse. - Connect voltmeter to the plug between contact 4 (+) and 2 (-). - Switch ignition on. Target value: about the same as battery voltage, otherwise determine interruption on the basis of wiring diagram and remove it. - Switch ignition off. - Insert the plug back into the TSZ switchgear.
Service Training 12.05 Section 4.9 Page 45 - Draw out the high-voltage transmission line terminal 4 from the ignition distributor and earth it with an emergency cable. - Plug two electric cables into the sockets of the two-pin plug of the induction transmitter, and tap the plus and minus sides of a 1.5 volt battery with their ends. For each tap a spark should be produced on cable 4. Change the polarity in the battery if necessary.
Section 4.9 Page 46 4.9.4.2 12.05 Service Training INSTALLATION OF THE ENGINE SPEED CONTROL SYSTEM TARGET VALUE TRANSMITTER 1. Install terminal nut (6) on piston rod of adjustment cylinder (8) (terminal nut must make contact with adjustment cylinder housing). 2. Align red marking (5) on the target value transmitter (1) in line with the red marking on the housing. 3. Install target value transmitter (1) and tighten screws (2) on terminal flange (3) hand-tight only. 4.
Service Training 12.05 Section 4.9 Page 47 ACTUAL VALUE TRANSMITTER WARNING: For adjusting or installation work on actual value transmitter B1 and with X/B1 plugs disconnected (see engine speed control connection plan), the engine may in no circumstances be started. Otherwise the engine races (no actual value signal for speed control N2 ). - Loosen nuts (2) and (3) to adjust [the transmitter].
Section 4.9 Page 48 4.9.4.3 12.05 Service Training INSPECTION OF THE ENGINE SPEED CONTROL SYSTEM Before starting these checks: - Jack the truck up securely so that both drive wheels can turn freely. - Lock brake pedal in “brake locked” position. - Engine is warmed up.
Service Training 12.05 Section 4.9 Page 49 ENGINE SPEED CONTROL SYSTEM CONNECTION PLAN X/B1 Rotation speed actual value transmitter B1 X/B2 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.
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Service Training 12.05 Section 4.9 Page 51 ELECTRONIC CONTROL SYSTEM ENGINE SPEED REGULATOR SUPPLY VOLTAGE - Connect voltmeter between the connections X/N2:3 and X/N2:25 on the disconnected plug X/N2. - Switch ignition on. - The meter should show 12 V (= supply voltage) from engine speed regulator N2. NOTE: If this value is not obtained, check cabling (+) and (-) supply line. - Plug X/N2 plug back into the engine speed regulator N2.
Section 4.9 Page 52 12.05 Service Training - Voltage measurement between connections X/B2:2 and X/B1:2. (Voltage value of the basic setting). The plugs remain connected. Insert the measuring prods at the indicated measuring points. For this purpose, the rubber bush must be removed from plug X/B1. Meter shows voltage of 750 ± 10 mV. - Start engine. - Press an accelerator pedal fully down until the end stop. The voltage on the meter must likewise steadily rise from 750 ± 10 mV to 2 V.
Service Training 4.9.4.4 1 2 3 4 5 12.05 Section 4.9 Page 53 ADJUSTMENT OF THE PROPELLANT GAS MIXERS Operating magnet Full load mixture adjustment screw Idling mixture adjustment screw Mixer Connecting rod 6 7 8 9 Lock nut Lever Limit stop Limit stop screw ASSEMBLY - Close throttle valve manually. - Adjust limit stop screw (9) so that with the throttle valve at the limit stop (8) closed, it approaches the assembly, and then turn back 1 more turn.
Section 4.9 Page 54 12.05 Service Training ADJUSTING THE CO CONTENT Prerequisites for adjustment: - Firing point checked and if necessary corrected: desired value 18 ± 2 ° before TDC (from 01/2005: 8 ± 2 ° before TDC). - With truck warmed up, hydraulic oil at 60 – 70 °C, operating hydraulics pressure relief valve set to 265 bar. - Parking brake locked in braked position. Adjustment: - Turn idling mixture adjustment screw (3) to its limit stop and then unscrew by three turns. - Connect CO meter.
Linde Material Handling 63701 Aschaffenburg Postfach 10 01 36 Telefon (0 60 21) 99-0 Telefax (0 60 21) 99-15 70 http://www.linde.de/linde-stapler eMail: service.training@linde-fh.de 353 804 2401.
