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Service Training
Linde IC engined truck

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Series 359

H100-600, H120-1200, H120600, H140-1200, H140-600,
H160-1200, H160-600, H180600
Edition 06/2007
This service document is provided for use only and remains
the exclusive property of Linde Material Handling.
394 804 2401 EN – 06/2007
Header
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Structure of training document
This training document is based on the relevant
seminar held at our Linde training centres or at
the authorised dealer’s premises and is designed
to supplement it. The training document taken
by itself without an accompanying seminar is not
suitable for self-study.
This training document is divided into numbered
sections from 0 to 10, with the content being
identical in all training documents. The sections
are only guided by the organisation of the spare
parts list and may differ from the content . The
circuit diagrams for the truck can be found in
section 10 in the Appendix.
Section

Content

0

Product information

1

Motor

2

Gearbox

3
4

Chassis
Undercarriage

5

Controls

6

Electrics / Electronics

Symbols used

Content
Hydraulics

7
8

Load lift system

9

Special equipment and accessories

10

Circuit diagrams

The training document is not organised so that it
successively describes the structure of the truck
but is based on a modular concept. This means
that in the different sections the individual vehicle
components are described as independent units
one after the other. This is another reason why a
course at one of our training centres is essential.
The introduction is followed by a complete contents list for the training document. This is supplemented by an index at the end of the training
document.
Here we should like to inform you that a list of all
special tools and measuring instruments used
for this truck can be called up referred to type,
including spare part number, usage and graphics,
in the documentation software "Truck Expert".

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The precautions Danger, Warning, Caution,
Note und Environment Note in this manual are
provided to indicate special hazards or unusual
information requiring special identification:
DANGER

Section

indicates hazards that may result in personal injury or
death and/or substantial damage to the product.

WARNING
indicates hazards that may result in personal injury
and/or substantial damage to the product.

NOTE

Identifies technical information requiring special
attention because the connection may not even
be obvious to skilled personnel.
ENVIRONMENT NOTE

The information contained herein must be observed, otherwise environmental damage may
occur.
For your safety other symbols are also used.
Please note the different symbols.

CAUTION
indicates hazards that may result in damage to or
destruction of the product.

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Service Training – 394 804 2401 EN – 06/2007
Table of contents
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0

Product information
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1
The BR 359 truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
VDI datasheet H100-600, H120-600, H140-600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
VDI datasheet H150-600, H160-600, H180-600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
VDI datasheet H120-1200, H140-1200, H160-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . 0-12

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-15
LTC basic structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-15
CAN bus communication — overview and installation position . . . . . . . . . . . . . . . . . . . 0-16
Error code lists

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-17

Indicator unit — error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-17
LTC traction control codes, version1.X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-18

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LTC lift control codes, 0.040 version, LTC module N1 . . . . . . . . . . . . . . . . . . . . . . . . . 0-21
LTC lift control codes, Version 0.040, LTC module N2 . . . . . . . . . . . . . . . . . . . . . . . . . 0-24
Cummins diesel engine fault codes

1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-26

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Engine

Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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Description of the drive

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
View of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Engine identification

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Engine data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Injection pump plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Engine control unit data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Installing, removing and checking the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Rocker levers and pushrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Installing, removing and checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Front crankshaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Renewing the oil sump seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Removing and refitting the injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Removing, installing and checking the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Installing, removing and checking the exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . 1-32

Service Training – 394 804 2401 EN – 06/2007

III
Table of contents
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2

Axles
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Technical data for traction drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Schematic view of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Linde Truck Control (LTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Traction drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Travel drive − introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Variable displacement pump controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Motor variables controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Pedal group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
HPV 210-02 variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Electro-hydraulic remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Variable pump advance start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

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Variable motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Variable motor HMV 210-02 and HMV 280-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Output unit function characteristics
Reduction gearbox

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Reduction gearbox GR 26-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

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Braking process - function characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Retarder valve block components

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Retarder valve block function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Brake release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Towing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Checking the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Hydraulic fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Function characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Checking the hydraulic fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

4

Chassis,bodywork and fittings
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Function characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
stub axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Wheel hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Adjusting the inner steering stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Adjusting the outer steering stop

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Removing and installing the steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

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Service Training – 394 804 2401 EN – 06/2007
Table of contents
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Sealing the steering cylinder

5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Controls
Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Indicator unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6

Electrics/Electronics
Central electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Arrangement of relays and fuses for basic equipment and special equipment . . . . . . . . . 6-1

Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Testing the electronic controllers and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Testing the LTC (vehicle and lift controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Checking wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Testing sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

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Checking actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Testing the indicator unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

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Hydraulics

Regulating pump HPR 210-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Technical data for regulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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HPR 210-02 regulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Load sensing regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Operating hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Working hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Hose layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Hose layout, supply, valve block, working hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Hose layout — lifting/lowering

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Tilting hose layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Hose layout for sideshift and fork positioner

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Measurements and settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Checking the maximum working pressure and LS pressure . . . . . . . . . . . . . . . . . . . . . 7-14
Checking and adjusting delta pressure P to LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Service Training – 394 804 2401 EN – 06/2007

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Table of contents
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Tilting the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Cabin tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Operation of the cab tilt device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

Annex
10 Circuit diagrams
Hydraulic circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Wiring diagram part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Wiring diagram Part 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

Wiring diagram Part 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

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Wiring diagram part 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Wiring diagram part 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Wiring diagram Part 6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

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Wiring diagram part 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Wiring diagram Part 8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18

Wiring diagram part 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20

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Wiring diagram part 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22

VI

Service Training – 394 804 2401 EN – 06/2007

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XXX

  • 1. W IE Service Training Linde IC engined truck P V E R Series 359 H100-600, H120-1200, H120600, H140-1200, H140-600, H160-1200, H160-600, H180600 Edition 06/2007 This service document is provided for use only and remains the exclusive property of Linde Material Handling. 394 804 2401 EN – 06/2007
  • 2. Header g Structure of training document This training document is based on the relevant seminar held at our Linde training centres or at the authorised dealer’s premises and is designed to supplement it. The training document taken by itself without an accompanying seminar is not suitable for self-study. This training document is divided into numbered sections from 0 to 10, with the content being identical in all training documents. The sections are only guided by the organisation of the spare parts list and may differ from the content . The circuit diagrams for the truck can be found in section 10 in the Appendix. Section Content 0 Product information 1 Motor 2 Gearbox 3 4 Chassis Undercarriage 5 Controls 6 Electrics / Electronics Symbols used Content Hydraulics 7 8 Load lift system 9 Special equipment and accessories 10 Circuit diagrams The training document is not organised so that it successively describes the structure of the truck but is based on a modular concept. This means that in the different sections the individual vehicle components are described as independent units one after the other. This is another reason why a course at one of our training centres is essential. The introduction is followed by a complete contents list for the training document. This is supplemented by an index at the end of the training document. Here we should like to inform you that a list of all special tools and measuring instruments used for this truck can be called up referred to type, including spare part number, usage and graphics, in the documentation software "Truck Expert". W IE V E R P The precautions Danger, Warning, Caution, Note und Environment Note in this manual are provided to indicate special hazards or unusual information requiring special identification: DANGER Section indicates hazards that may result in personal injury or death and/or substantial damage to the product. WARNING indicates hazards that may result in personal injury and/or substantial damage to the product. NOTE Identifies technical information requiring special attention because the connection may not even be obvious to skilled personnel. ENVIRONMENT NOTE The information contained herein must be observed, otherwise environmental damage may occur. For your safety other symbols are also used. Please note the different symbols. CAUTION indicates hazards that may result in damage to or destruction of the product. II Service Training – 394 804 2401 EN – 06/2007
  • 3. Table of contents g 0 Product information Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1 The BR 359 truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 VDI datasheet H100-600, H120-600, H140-600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 VDI datasheet H150-600, H160-600, H180-600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9 VDI datasheet H120-1200, H140-1200, H160-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . 0-12 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-15 LTC basic structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-15 CAN bus communication — overview and installation position . . . . . . . . . . . . . . . . . . . 0-16 Error code lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-17 Indicator unit — error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-17 LTC traction control codes, version1.X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-18 W IE LTC lift control codes, 0.040 version, LTC module N1 . . . . . . . . . . . . . . . . . . . . . . . . . 0-21 LTC lift control codes, Version 0.040, LTC module N2 . . . . . . . . . . . . . . . . . . . . . . . . . 0-24 Cummins diesel engine fault codes 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-26 V E R Engine Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 P Description of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 View of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Engine identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Engine data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Injection pump plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Engine control unit data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Installing, removing and checking the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Rocker levers and pushrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Installing, removing and checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 Front crankshaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 Renewing the oil sump seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 Removing and refitting the injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 Removing, installing and checking the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 Installing, removing and checking the exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . 1-32 Service Training – 394 804 2401 EN – 06/2007 III
  • 4. Table of contents g 2 Axles Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Technical data for traction drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Schematic view of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Linde Truck Control (LTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Traction drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Travel drive − introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Variable displacement pump controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Motor variables controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Pedal group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 HPV 210-02 variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Electro-hydraulic remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Variable pump advance start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 W IE Variable motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Variable motor HMV 210-02 and HMV 280-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Output unit function characteristics Reduction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 V E R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Reduction gearbox GR 26-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 P Braking process - function characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Retarder valve block components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Retarder valve block function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 Brake release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 Towing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 Checking the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 Hydraulic fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 Function characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 Checking the hydraulic fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 4 Chassis,bodywork and fittings Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Function characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 stub axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Wheel hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Adjusting the inner steering stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Adjusting the outer steering stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Removing and installing the steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 IV Service Training – 394 804 2401 EN – 06/2007
  • 5. Table of contents g Sealing the steering cylinder 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Controls Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Indicator unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 6 Electrics/Electronics Central electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Arrangement of relays and fuses for basic equipment and special equipment . . . . . . . . . 6-1 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Testing the electronic controllers and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Testing the LTC (vehicle and lift controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Checking wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Testing sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 W IE Checking actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Testing the indicator unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 7 V E R Hydraulics Regulating pump HPR 210-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Technical data for regulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 P HPR 210-02 regulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Load sensing regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Operating hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Working hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Hose layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Hose layout, supply, valve block, working hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Hose layout — lifting/lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Tilting hose layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Hose layout for sideshift and fork positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Measurements and settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Checking the maximum working pressure and LS pressure . . . . . . . . . . . . . . . . . . . . . 7-14 Checking and adjusting delta pressure P to LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Service Training – 394 804 2401 EN – 06/2007 V
  • 6. Table of contents g Tilting the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Cabin tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Operation of the cab tilt device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Annex 10 Circuit diagrams Hydraulic circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Wiring diagram part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Wiring diagram Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Wiring diagram Part 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 W IE Wiring diagram part 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Wiring diagram part 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Wiring diagram Part 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 V E R Wiring diagram part 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Wiring diagram Part 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 Wiring diagram part 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 P Wiring diagram part 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 VI Service Training – 394 804 2401 EN – 06/2007