Deutz 1012 Spécifications

Service TrainingThis training material is only provided for your use and remains the exclusive property ofLINDE MATERIAL HANDLINGLinde IC-Engined Fork

Page 2Section 4.1Service Training09.044.1.1.1.1 EXPLANATION OF THE ENGINE NUMBER1 Manufacturer's plate with type and engine number2 Engine number

Service TrainingPage 4.2Section 4209.04Fasten gear unit for dismounting and unscrew the hexagonsocket screws.2x unscrew hexagon socket screw (arrows).

Service TrainingPage 4.2Section 4309.04Dismount planetary carrier 2nd stage.The hexagon socket screw is pasted in by means ofLoctite. Heat to unscre

Service TrainingPage 4.2Section 4409.04Pull off casing.Screw mounting rail on casing.Put threaded rod on drive shaft.Renew radial shaft seal (arrow).D

Service TrainingPage 4.2Section 4509.04MOUNTINGPut Loctite on the outer ring of the radial shaft seal, insertit, press in by means of press-in tool 39

Service TrainingPage 4.2Section 4609.04Cover groove nut with Loctite FK2 and tighten with5300+200Nm.Plug in planetary carrier 2, cover screw with Loct

Service TrainingPage 4.2Section 4709.041 Casing with multi-disc brake2 Pinion3 Planetary carrier 1Install casing.NotePinion must be inserted in toothi

Service TrainingPage 4.2Section 4809.044.2.5 TROUBLESHOOTING4.2.5.1 CONNECTING DIAGRAM FOR TROUBLESHOOTINGLEGEND TO DIAGRAMBR Travel control outlet -&

Service TrainingPage 4.2Section 4909.04

Service TrainingPage 4.2Section 5009.044.2.5.2 TOOLS AND AIDS FOR MEASUREMENTSThe tools and gauges used for troubleshooting are similar to the ones in

Service TrainingPage 4.2Section 5109.04ITEM NO. DESCRIPTION1.1 Screw coupling M 14 x 1.51.3 Adapter nipple1.5 Screw coupling M 8 x 11.7 a Banjo bolt M

Service TrainingPage 3Section 4.109.044.1.1.2 CHANGING AND TIGHTENING THE DRIVEBELTCHANGING THE DRIVEBELT- Slacken the alternator and tensioner fasten

Service TrainingPage 4.2Section 5209.044.2.5.3 EXPLANATIONS TO TROUBLESHOOTINGThe functional tests and any ensuing troubleshooting is performed separa

Service TrainingPage 4.2Section 5309.044.2.5.4 HYDRAULIC SPEED CONTROL FOR THE ENGINEThe engine speed control check is first performed, as described b

Service TrainingPage 4.2Section 5409.04Disconnect the speed control linkage, start the engine and move the injectionpump control lever as far as the s

Service TrainingPage 4.2Section 5509.04Valve (20) of lock-outlogic faulty or setting toolow.With accelerator pedals released and engine running, pull

Service TrainingPage 4.2Section 5609.04CSpeed jumps toover 1300 rpm.Nozzle in valve (49) toosmall or clogged.Nozzle in valve (49) toolarge or restrict

Service TrainingPage 4.2Section 5709.04DPressure rises to14 bar minimumEngine speed control isokay.yes noyes noyes noShuttle valve (D) faulty.Enginesp

Service TrainingPage 4.2Section 5809.044.2.5.5 HYDRAULIC BRAKING SYSTEM4.2.5.5.1 FUNCTIONAL TESTTEST CONDITIONS- Truck jacked up and secured so that b

Service TrainingPage 4.2Section 5909.04Install LP gauge with adapter V to port F of power limiter. Start engine and readpressure gauge.Fully depress b

Service TrainingPage 4.2Section 6009.04Disconnect adapter IV at external brake release port R and install LP gaugewith adapter I. Repeat the test.ACon

Service TrainingPage 4.2Section 6109.044.2.5.6 PRESSURE EQUALITY AND START OF CONTROLTEST CONDITIONS- Truck not jacked up.- Pedals properly adjusted.-

Page 4Section 4.1Service Training09.044.1.1.3 ADJUSTING VALVE CLEARANCEThe adjustment can be carried out when the engine is cool or warm after a cooli

Service TrainingPage 4.2Section 6209.04Using adapter V, install LP gauge at port F of power limiter. Start engine andread pressure with the brake rele

Service TrainingPage 4.2Section 6309.04A BΔp = 0 - 0,5 bar.Δp = 0 - 0,5 bar.Slowly depress the F and R accelerator pedals and determine Δp at start of

Service TrainingPage 4.2Section 6409.04CDSet Δp to 11 + 0.1 bar at valve (44) of travel control unit.Δp can be obtained.yesnoRemove adapter III at por

Service TrainingPage 4.2Section 6509.044.2.5.7 HYDROSTATIC TRAVEL DRIVETEST CONDITIONS- Truck jacked up and secured so that both traction wheels can r

Service TrainingPage 4.2Section 6609.04Install LP gauge with adapter V to port F of power limiter. Measure pressurewith engine at idling speed and bra

Service TrainingPage 4.2Section 6709.04yes noABPressure now between17.5 and 20 bar.yes noyes noyes noDCPressure now okay.Pressure now okay.Δp is 6 bar

Service TrainingPage 4.2Section 6809.04CDyes noFully depress the F and R accelerator pedals with the brake pedal released.CAUTION: Rotating wheels.yes

Service TrainingPage 4.2Section 6909.04noyesFnoyesnoyesnoyesGHEΔp between 12 and 14 bar.Install banjo bolts 1.17 with plugs at ports E and F of travel

Service TrainingPage 4.2Section 7009.04HGnoyesnoyesnoyesKVariable-displacementpump defective, repair orrenew.Left or right hydraulicmotor defective, r

Service TrainingPage 4.2Section 7109.04noyesKnoyesnoyesInstall LP gauge with adapter III to ports YF and ZF of power limiter. Repeat thetest.InoyesLMΔ

Service TrainingPage 5Section 4.109.06VALVE CLEARANCE ADJUSTMENT BY MEANS OF A TORQUE ANGLE GAUGE FROM SERIALNUMBER E1 X353 T 000268In engines which a

Service TrainingPage 4.2Section 7209.04noyesΔp von 10 - 11 bar.Remove adapter III and install adapter II with plug. Connect LP gauge,determine Δp by f

Service TrainingPage 4.2Section 7309.04noyesOnoyesnoyesRemove adapters II with plugs and screw into ports YF and ZF. Determine Δpwith the brake releas

Service TrainingPage 4.2Section 7409.04noyesnoyesRemove adapter II with plug and install them at ports YF and ZF. Determine Δpwith brake released and

Service TrainingPage 4.2Section 7509.04noyesnoyesnoyesInstall HP gauge to HP modulation with screw coupling 1 .1. Plug port BR ontravel control.Start

Service TrainingPage 4.2Section 7609.04QPower unit for forward travelin order.Perform the sarne test with the reverse travel pedaldepressed. The readi

Service TrainingPage 4.2Section 7709.044.2.6 TEST AND ADJUSTMENT INSTRUCTIONS FOR HYDRAULIC PRIMARY ANDSECONDARY CONTROLThe swash plate angle Qmax of

Service TrainingPage 4.2Section 7809.04noyesnoyesΔp 10 - 11 bar.Δp 0 - 0,5 bar.Adjust equal pressure,see "Pressure equalityand start of control&q

Service TrainingPage 4.2Section 7909.04yes noPossible causes:Bypass valve leaking.Combined boost and pressure-relief valve or output device leaking.Co

Service TrainingPage 4.2Section 8009.044.2.6.2 QMAX OF HYDRAULIC MOTORS HMV 105noyesRemove the cover on the bottom of the truck frame. Loosen nut (1)

Service TrainingPage 4.2Section 8109.044.2.6.3 QMIN OF HYDRAULIC MOTORS HMV 105Condition: Qmax of variable displacement pump and the hydraulic motors

Page 6Section 4.1Service Training09.06Adjustment of valve clearance- Set torque angle gauge to 0 (zero) (Fig. A4).Take care not to turn the setting sc

Service TrainingPage 4.2Section 8209.04CHECKING QMIN- Shut off the engine, lock the left wheel, close the valve on 1.32 and put a 5-mm spacer between

Service TrainingSection 4.3Page 14.3 CHASSIS

Service TrainingSection 4.3Page 24.3.1 OVERHEAD GUARD - TORSION MOUNTINGThe overhead guard is fastened to a cross member at the top of the mast so tha

Service TrainingSection 4.3Page 31 Overhead guard pivot articulation on the mast2 Front mounting of tilt cylinders3 Overhead guard4 Rear mounting of t

Service TrainingSection 4.3Page 4- Remove any lateral play in the overhead guard with shims (9).- Install the bearing brackets (7) and torque the scre

Service TrainingSection 4.4Page 14.4 STEERING SYSTEM

Service TrainingSection 4.4Page 24.4.1 POWER STEERING CIRCUIT DIAGRAMB Steering control valve assy. consisting of:14 Pressure-relief valve15 Make-up v

Service TrainingSection 4.4Page 3OPERATION OF THE POWER STEERINGThe oil from the pump (28) enters the steering control valve (B) at port P2, flows thr

Service TrainingSection 4.4Page 44.4.2 SERIES 304 STEERING AXLEEXPLANATION OF THE STEERING AXLE SERIES NUMBER4.4.2.1 DESCRIPTIONThe rear wheels are st

Service TrainingSection 4.4Page 54.4.3 STEERING AXLE REMOVAL- Remove the wheel mounting screws on both wheels.- Jack up and securely block the rear of

Service TrainingPage 7Section 4.109.064.1.1.4 ADJUSTING THE INJECTION VALVECHECKING THE OPENING PRESSURENOTE: Use only test oil acc. to ISO 4113 or di

Service TrainingSection 4.4Page 64.4.3.1 STEERING AXLE INSTALLATION- Mount the two axle blocks (2) on the centre of the axle.NOTE: Axle blocks are not

Service TrainingSection 4.4Page 74.4.4.1 RENEWING THE WHEEL BEARINGS- Jack up the truck.- Remove the wheel.- Remove the cap (8).- Drive out the cotter

Service TrainingSection 4.4Page 84.4.4.2 STEERING KNUCKLE REMOVAL AND INSTALLATION1 Nut2 Thrust washer3 Knuckle body4 Seal5 Taper roller bearing6 King

Service TrainingSection 4.4Page 9STEERING KNUCKLE REMOVAL- Jack up the truck.- Remove the wheels.- Turn the steering until the pin (2) retaining the t

Service TrainingSection 4.4Page 104.4.4.3 STEERING CYLINDER REMOVAL AND INSTALLATIONSTEERING CYLINDER REMOVAL- Jack up and securely block the rear of

Service TrainingSection 4.4Page 11STEERING CYLINDER INSTALLATION- Lift the steering cylinder (8) into the steering axle.NOTE: Support up the steering

Service TrainingSection 4.4Page 124.4.4.4 REPLACING THE STEERING CYLINDER SEALS- Remove the steering cylinder and clamp it in a vise.- Pull the piston

Service TrainingSection 4.4Page 134.4.4.5 STEERING STOP ADJUSTMENT1 Stop screw2 Locknut3 Axle body4 Steering cylinderTo prevent damage to the hydrauli

Service TrainingSection 4.4Page 14

Service TrainingPage 1Section 4.54.5 CONTROLS

Page 8Section 4.1Service Training09.06CHECKING FOR LEAKS- Dry the nozzle and nozzle holder - blow dry with an air jet.- Slowly press the tester hand l

Page 2Section 4.5Service Training4.5.1 ACCELERATOR AND BRAKE PEDAL ADJUSTMENTACCELERATOR PEDALS- Bring both accelerator pedals to the same level, posi

Service TrainingPage 3Section 4.5

Page 4Section 4.5Service TrainingBOWDEN CABLE FOR THE PARKING BRAKE- Depress the brake pedal until the flat spring (1) engages.- Set the lever on the

Service TrainingPage 5Section 4.54.5.2 SPEED CONTROL4.5.2.1 SPEED CONTROL UP TO 10/95ADJUSTMENT INSTRUCTIONS FOR DIMENSION X (LOWER IDLING SPEED)- Ret

Page 6Section 4.5Service TrainingADJUSTMENT INSTRUCTIONS FOR DIMENSION Y (UPPER IDLING SPEED)- Fully depress the brake pedal and lock it.- Start the e

Service TrainingPage 7Section 4.54.5.2.2 SPEED CONTROL FROM 11/95From 11/95 the speed control lever has been provided with an overload protection. The

Page 8Section 4.5Service Training4.5.3 MEDIUM WHEEL SPEEDCONDITIONS- Jack up and securely block the truck so that the wheels can turn freely.- Acceler

Service TrainingPage 9Section 4.54.5.4 START OF DRIVE WHEEL ROTATIONThe start of wheel rotation is set by means of setscrew (3) such that wheel rotati

Page 10Section 4.5Service Training4.5.5 BRAKE SHAFT STOP SCREWS- Connect a low pressure gauge to port BR on the travel control unit.- Slacken the clam

Service TrainingPage 11Section 4.54.5.6 SYMMETRY OF THE TRAVEL CONTROL4.5.6.1 DRIVE WHEEL START OF ROTATIONADJUSTMENT REQUIREMENTS- Pedal adjustment i

Service TrainingPage 9Section 4.109.064.1.1.5 CHECKING THE COMPRESSION PRESSURE- Remove the injection nozzle.- Check the valve clearance.- Insert and

Page 12Section 4.5Service Training4.5.6.2 ENGINE SPEED INCREASETEST REQUIREMENTS- Truck blocked up and secured so that both wheels are free to rotate.

Service TrainingPage 13Section 4.54.5.7 PRESSURE DIFFERENCE DPTEST REQUIREMENTS- Truck blocked up.- Engine and travel hydraulics at operating temperat

Page 14Section 4.5Service Training4.5.8 MODIFICATION OF ENGINE ACCELERATIONIn special cases it may be necessary to adapt the operating characteristics

Service TrainingPage 1Section 4.64.6 ELECTRICAL SYSTEM

Page 2Section 4.6Service Training4.6.1 WIRING DIAGRAMA1 Glow duration unitF1 Fuse for glow duration unit, 80 AF11 Fuse for indicator instrument, 5 AF1

Page 3Section 4.6Service TrainingCIRCUIT DIAGRAMM H 50/60/70/80, TYPE 353

Service TrainingPage 5Section 4.605.00

Page 6Section 4.6Service Training05.004.6.2 WIRING DIAGRAM FOR OPTIONS5E2 Dip beam, right5E3 Dip beam, left5E4 Side light, front right5E5 Side light,

Page 7Section 4.6Service Training05.00678954312CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50/60/70/80, TYPE 353

Page 10Section 4.1Service Training09.064.1.1.6 CYLINDER HEADREMOVING THE CYLINDER HEAD- With the engine cool, slacken the cylinder head bolts evenly a

Service TrainingPage 9Section 4.605.004.6.3 WIRING DIAGRAM, 353 -02A1 Glow duration unit 55-60F1 Fuse for glow duration unit, 80 A 1F11 Fuse for poten

Page 10Section 4.6Service Training05.00V1/2/3 Decoupling diodes 26, 28, 40X1 Connector 15 pins 11 - 17, 30 - 42, 74X2 Connector 12 pins 4 - 22, 30 - 3

Page 11Section 4.6Service Training05.00CIRCUIT DIAGRAMM H 50/60/70/80 -02, TYPE 353

Service TrainingPage 13Section 4.605.004.6.4 WIRING DIAGRAM FOR OPTIONS, 353 -025E2 Dip beam, right 255E3 Dip beam, left 285E4 Side light, front right

Page 14Section 4.6Service Training05.005S11 Light switch 27 - 335S12 Hazard warning light switch 44 - 515S13 Directional indicator switch 46 - 489S1 F

Page 15Section 4.6Service Training05.00CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50/60/70/80 -02, TYPE 353

Service TrainingPage 17Section 4.609.044.6.5 WIRING DIAGRAM, 353 -03 DIESELA1 Control device for heater flange 53-581B11 Cooling water temperature sen

Service TrainingPage 11Section 4.109.06INSTALLING THE CYLINDER HEADNOTE: Sealing surfaces for cylinder head gaskets must be clean and free of oil. Pay

Page 18Section 4.6Service Training09.04S7 Temperature switch for richer fuel mixture 9S8 Horn button 77S14 Brake pedal switch (start inhibit) 19S18 Co

Page 19Section 4.6Service Training09.04CIRCUIT DIAGRAMM H 50/60/70/80 -03, TYPE 353 DIESEL

Section 4.6Page 20Service Training09.04

Service TrainingPage 21Section 4.609.044.6.6 WIRING DIAGRAM FOR OPTIONS, 353 -035E2 Dip beam, right 275E3 Dip beam, left 305E4 Side light, front right

Page 22Section 4.6Service Training09.049S1 Front wiper switch 93 - 999S2 Rear/roof wiper switch 135 - 1429S3 wiper switch, wash 101 - 1089S5,6 Spotlig

Page 23Section 4.6Service Training09.04CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50/60/70/80 -03, TYPE 353 DIESEL

Section 4.6Page 24Service Training09.04CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50/60/70/80 -03, TYPE 353 DIESEL

Service TrainingPage 25Section 4.609.044.6.7 ELECTRICAL SYSTEM CIRCUIT DIAGRAM, TYPE 353 -03 LPGA1 Ignition control device 33-36B1 Actual speed transm

Page 26Section 4.6Service Training09.04T1 Ignition coil 30-32V1/3 Decoupling diodes 17, 237V4 Decoupling diode 13X1 15-pin plug 9-28X2 12-pin plug 3-2

Page 27Section 4.6Service Training09.04CIRCUIT DIAGRAMM H 50/60/70/80 -03, TYPE 353 LPG

Page 12Section 4.1Service Training09.064.1.1.7 ADJUSTING THE BEGIN OF DELIVERYIf an injection pump must be replaced, the begin of delivery must be re-

Section 4.6Page 28Service Training09.04

Service TrainingPage 29Section 4.609.044.6.8 WIRING DIAGRAM FOR OPTIONS, 353 -035E2 Dip beam, right 265E3 Dip beam, left 295E4 Side light, front right

Page 30Section 4.6Service Training09.045S13 Directional indicator switch 52 - 559S1 Front wiper switch 93 - 999S2 Rear/roof wiper switch 135 - 1429S3

Page 31Section 4.6Service Training09.04CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50/60/70/80 -03, TYPE 353 LPG

Section 4.6Page 32Service Training09.04CIRCUIT DIAGRAMM FOR OPTIONAL EQUIPMENT H 50/60/70/80 -03, TYPE 353 LPG

Service TrainingPage 33Section 4.609.04

Page 34Section 4.6Service Training09.044.6.9 CENTRAL ELECTRICAL SYSTEMThe whole electrical system ist mounted on the left side of the truck behind a c

Service TrainingPage 35Section 4.609.04TOP VIEW OF FUSE BOXES I - IVThe fuse box I ist standard version, the boxes II, III and IV are fitted dependin

Page 36Section 4.6Service Training09.044.6.10 CENTRAL ELECTRICS OF SERIES 353 -034.6.10.1 RELAY AND FUSES OF 353 -03 DIESEL0 Relay for UPA1 Indicator

Service TrainingPage 37Section 4.609.04TOP VIEW OF FUSE BOXES I - IIIFuse outputFuse inputFuse outputFuse inputFuse box I1 Ignition starter, display (

Service TrainingPage 13Section 4.109.06EKCode EKCode EKCode EKCode EKCode(mm) (mm) (mm) (mm) (mm)110.0 110.6 111.2 049 111.8 073 112.4 097110.025 110.

Page 38Section 4.6Service Training09.044.6.10.2 RELAY AND FUSES OF 353 -03 LPG1 Relay K3 for LPG cut-off2 Relay K2 for starter3 Relay K4 load relay4 I

Service TrainingPage 39Section 4.609.04TOP VIEW OF FUSE BOXES I - IVFuse outputFuse inputFuse box I1 Indicating device, ignition starter switch (F11)

Page 40Section 4.6Service Training09.04Fuse inputFuse output4.6.10.3 RELAY AND FUSES FOR 353 -03 PARTICULATE TRAPTOP VIEW OF FUSE BOXES1 Diagnostic pl

Service TrainingSection 4.7Page 14.7 WORKING HYDRAULICS

Service TrainingSection 4.7Page 24.7.1 WORKING HYDRAULICS CIRCUIT DIAGRAM9 2/2-way valve (pressure balance)10 Maximum pressure valve, 265 bar11 Tilt c

Service TrainingSection 4.7Page 34.7.1.1 EXPLANATION OF THE WORKING HYDRAULICSWhen the control levers are in the neutral position and the pump output

Service TrainingSection 4.7Page 44.7.2 TILT CYLINDER1 Bearing bracket2 Screw3 Eyebolt4 Bearing pin5 Locknut6 Piston rod7 Rear bearing pin8 Retaining s

Service TrainingSection 4.7Page 54.7.2.1 TILT CYLINDER REMOVAL, INSTALLATION, ADJUSTMENT, SEALINGTILT CYLINDER REMOVAL- Tilt the mast forward as far a

Service TrainingSection 4.7Page 6SEALING THE TILT CYLINDERSEALING THE PISTON RODCondition: Cylinder removed- Clamp the cylinder with the eyebolt of th

Service TrainingSection 4.7Page 7RENEWING THE PISTON SEALSCondition: Cylinder removed- Clamp the cylinder with the eyebolt of the cylinder barrel (8)

Page 14Section 4.1Service Training09.06Read the code for the injection pump length (A) on the new injection pump, e.g. 53.The basic dimension of the i

Service TrainingSection 4.7Page 8

Service TrainingPage 1Section 4.84.8 MAST

Page 2Section 4.8Service Training4.8.1 MAST REMOVAL- Remove the forks.- Lower the fork carriage.- Tilt the mast fully forward.- Disconnect the hoses (

Service TrainingPage 3Section 4.84.8.2 LIFT CYLINDER REMOVAL, INSTALLATION- Start the engine, operate the lift hydraulics and raise the fork carriage

Page 4Section 4.8Service Training4.8.3 SEALING THE LIFT CYLINDER1 Piston rod diam. 68 - H 50/60 only2 Wiper3 Cylinder head4 Grooved ring5 Opening for

Service TrainingPage 5Section 4.8SEALING THE H 50/60/70/80 LIFT CYLINDERCondition: Cylinder removed- Hold the cylinder at the 42 mm hexagon head (11).

Page 6Section 4.8Service Training

Service TrainingSection 4.9Page 112.054.9 LP GAS MODEL H 50/60/70/0, TYPE 3534.9.1 DRIVE ENGINE4.9.1.1 TECHNICAL DATA ON ENGINE4.9.1.1.1 TECHNICAL DAT

Service TrainingSection 4.9Page 212.054.9.1.1.2 TECHNICAL DATA ON ENGINE FROM 01/2005Engine type Perkins KVT 1000.6 EGSITList of components YF 80929Po

Service TrainingSection 4.9Page 312.05BREAKDOWN OF THE ENGINE NUMBERYA 80929 U 660 0739 WYear of manufactureEngine serial numberCountry of manufacture

Service TrainingPage 15Section 4.109.06INSTALLING THE INJECTION PUMP- Place the required shim (2) on the roller shaft.- Turn the injection pump contro

Service TrainingSection 4.9Page 412.05CHANGING THE V-BELT- Remove cover (1) on the rear panel.- Open engine cover- Loosen hexagon nut (3) on adjusting

Service TrainingSection 4.9Page 512.054.9.1.4 CHECKING AND SETTING VALVE CLEARANCEThe valve clearance is to be checked and adjusted only with the engi

Service TrainingSection 4.9Page 612.054.9.1.5 REMOVING AND INSTALLING THE CYLINDER HEADREMOVING THE CYLINDER HEAD- Loosen cylinder head screws uniform

Service TrainingSection 4.9Page 712.05- Insert new cylinder head seal without additionalsealant (B).NOTICE: Before installation of the cylinderhead, c

Service TrainingSection 4.9Page 812.05- If there is no torque measuring tool (1) available,mark the position of each individual screw on thecylinder h

Service TrainingSection 4.9Page 912.054.9.2 ELECTRICAL SYSTEM4.9.2.1 ELECTRONIC IGNITION SYSTEM4.9.2.1.1 ELECTRONIC IGNITION SYSTEM UP TO 12/2004The m

Service TrainingSection 4.9Page 1012.05COMPONENTS OF A TRANSISTOR IGNITION SYSTEM1 Battery2 Ignition starting switch3 Ignition coil4 Switchgear5 Trans

Service TrainingSection 4.9Page 1112.05INDUCTIVE ACTIVATION OF THE IGNITIONPermanent magnet (1) and induction winding (2) form thestator. The rotor, w

Service TrainingSection 4.9Page 1212.05FUNCTIONING OF THE TRANSISTOR COIL IGNITION (TSZ)The a.c. control voltage delivered by the induction generator

Service TrainingSection 4.9Page 1312.05

Page 16Section 4.1Service Training09.064.1.8 SPECIAL TOOLSE 14 Torx socket heads, long versionE 2051 Socket head, 15 mm, long version for injection va

Service TrainingSection 4.9Page 1412.054.9.2.1.2 ELECTRONIC IGNITION SYSTEM FROM 01/2005FUNCTIONAL DIAGRAM1 Ignition switch2 Battery3 Ignition electro

Service TrainingSection 4.9Page 1512.05DESCRIPTIONThe engine is equipped with an integrated electronic ignition system without contact breaker points.

Service TrainingSection 4.9Page 1612.05TRANSMISSION OF THE PULSESThe purpose of the advance angle sensor (generator)is to generate a pulse whenever it

Service TrainingSection 4.9Page 1712.05CHECKING THE IGNITION TIMINGA timing light is required for measuring the ignition point. It must be connected b

Service TrainingSection 4.9Page 1812.05FIRING POINT CHARACTERISTIC CURVE FOR 1006-EGSIMARKING THE FIRING POINTThe firing point is fixed by the ignitio

Service TrainingSection 4.9Page 1912.054.9.2.1.2.1 MECHANICAL IGNITION TIMINGSPECIAL TOOLS REQUIREDTiming pin for ignition systemPart no. 000 008 61

Service TrainingSection 4.9Page 2012.05CHECKING THE MECHANICAL IGNITION TIMING ARRANGEMENT IN SITU- Set cylinder 1 of the internal-combustion engine a

Service TrainingSection 4.9Page 2112.05ADJUSTING THE TOOTHED DISC IN SITU- Set cylinder 1 of the internal combustion engine at topdead centre on the

Service TrainingSection 4.9Page 2212.05INSTALLING THE IGNITION CONTROL UNITNOTE: Prior to installing the ignition control unit, setcylinder 1 of the i

Service TrainingSection 4.9Page 2312.054.9.2.2 ELECTRONIC ENGINE-SPEED CONTROLFUNCTION OF THE CONTROL SYSTEMWith gas-propellant trucks, the engine spe

Service TrainingPage 17Section 4.109.06100 400 Dial gauge M2T with locking ring100 750 Dial gauge with spacers for measuring TDC and projectinglength

Service TrainingSection 4.9Page 2412.05BLOCK DIAGRAM OF THE ENGINE SPEED REGULATOR1 Perkins gas engine2 Flywheel with starter ring gear3 Speed indicat

Service TrainingSection 4.9Page 2512.05NOMINAL VALUE TRANSMITTERThe nominal value transmitter (5) is adjusted, via a hydraulic modulator (4), in accor

Service TrainingSection 4.9Page 2612.054.9.2.3 ELECTRICAL SYSTEM CIRCUIT DIAGRAM4.9.2.3.1 ELECTRICAL SYSTEM CIRCUIT DIAGRAM UP TO 12/2004A1 Ignition c

Page 27Section 4.6Service Training12.05CIRCUIT DIAGRAM H 50/60/70/80 T, TYPE 353, UP TO 12/2004

Service TrainingSection 4.9Page 2912.05

Service TrainingSection 4.9Page 3012.054.9.2.3.2 ELECTRICAL SYSTEM CIRCUIT DIAGRAM FROM 01/2005A1 Ignition control device 49-66B1 Actual speed transmi

Page 31Section 4.6Service Training12.05CIRCUIT DIAGRAM H 50/60/70/80 T, TYPE 353, FROM 01/2005

Section 9Page 32Service Training

Service TrainingSection 4.9Page 3312.054.9.3 PROPELLANT GAS SYSTEM4.9.3.1 DIAGRAM1 Drive motor2 Intake manifold3 Mixer4 Vacuum conductMixer - gas shut

Page 18Section 4.1Service Training09.064.1.2 ENGINE MODEL BF6M 20124.1.2.1 OVERVIEW OF ENGINE COMPONENTS

Service TrainingSection 4.9Page 3412.054.9.3.2 FUNCTIONAL DESCRIPTION OF THE PROPELLANT GAS SYSTEMThe various stages of the gas system are described b

Service TrainingSection 4.9Page 3512.05STOPPINGBy switching off the ignition, the throttle valve in the propellant gas mixer (3) is closed. At the sam

Service TrainingSection 4.9Page 3612.05VAPORISOR - PRESSURE REGULATOR MODEL E1 LPG intake2 Cooling water intake/outlet3 Connection for compensating li

Service TrainingSection 4.9Page 3712.05OPERATION OF THE VAPORISORThe LPG must be moved in gaseous form to process it with the intake air in the mixer

Service TrainingSection 4.9Page 3812.05MAINTENANCE ON VAPORISORMaintenance on the vaporisor should include the checking of the secondary valve actuati

Service TrainingSection 4.9Page 3912.05PROPELLANT GAS MIXERThe correct proportions for the gas-air mixture are important for problem-free running of t

Service TrainingSection 4.9Page 4012.05It works as follows:When the engine starts, a vacuum is passed through the connection (4) to the gas shutoff va

Service TrainingSection 4.9Page 4112.05FUNCTIONING OF THE VACUUM-CONTROLLED SHUTOFF VALVEWhen the engine is off, the shutoff valve is in closed positi

Service TrainingSection 4.9Page 4212.054.9.4 INSPECTIONS AND ADJUSTMENTS4.9.4.1 IGNITION SYSTEMCHECKING THE FIRING POINTNOTE: The firing point can onl

Service TrainingSection 4.9Page 4312.05INSPECTION OF THE IGNITION SYSTEMIGNITION CABLEResistance 2.5 – 4 kΩ depending on the length of the cableResist

Service TrainingPage 19Section 4.109.061 Generator2 Oil filler hole3 Heater flange4 Coolant connection-recovery line5 Fan pulley6 Fuel lift pump7 Cool

Service TrainingSection 4.9Page 4412.05SWITCHGEAR A1TEST CONDITION- Ignition coil in orderTESTING- Pull out plug from TSZ switchgear and press wire fu

Service TrainingSection 4.9Page 4512.05- Draw out the high-voltage transmission line terminal 4 from the ignition distributor and earth it with anemer

Service TrainingSection 4.9Page 4612.054.9.4.2 INSTALLATION OF THE ENGINE SPEED CONTROL SYSTEMTARGET VALUE TRANSMITTER1. Install terminal nut (6) on p

Service TrainingSection 4.9Page 4712.05ACTUAL VALUE TRANSMITTERWARNING: For adjusting or installation work on actual value transmitter B1 and with X/B

Service TrainingSection 4.9Page 4812.054.9.4.3 INSPECTION OF THE ENGINE SPEED CONTROL SYSTEMBefore starting these checks:- Jack the truck up securely

Service TrainingSection 4.9Page 4912.05ENGINE SPEED CONTROL SYSTEM CONNECTION PLANX/B1 Rotation speed actual value transmitter B1X/B2 Rotation speed n

Service TrainingSection 4.9Page 5012.05

Service TrainingSection 4.9Page 5112.05ELECTRONIC CONTROL SYSTEMENGINE SPEED REGULATOR SUPPLY VOLTAGE- Connect voltmeter between the connections X/N2:

Service TrainingSection 4.9Page 5212.05- Voltage measurement between connections X/B2:2 and X/B1:2. (Voltage value of the basic setting). Theplugs rem

Service TrainingSection 4.9Page 5312.054.9.4.4 ADJUSTMENT OF THE PROPELLANT GAS MIXERSASSEMBLY- Close throttle valve manually.- Adjust limit stop scre

Page 20Section 4.1Service Training09.064.1.2.2 ENGINE SPECIFICATIONSEngine model BF6M 2012 EDisplacement 6060 ccPower 74.9 kW at 2200 rpmOpening press

Service TrainingSection 4.9Page 5412.05ADJUSTING THE CO CONTENTPrerequisites for adjustment:- Firing point checked and if necessary corrected: desired

Linde Material Handling63701 AschaffenburgPostfach 10 01 36Telefon (0 60 21) 99-0Telefax (0 60 21) 99-15 70http://www.linde.de/linde-staplereMail: ser

Service TrainingPage 21Section 4.109.064.1.2.2.1 EXPLANATION OF THE ENGINE NUMBER1 Manufacturer's plate with type and engine number2 Engine numbe

Service Training09.06TABLE OF CONTENT4 IC-engined fork truck H 50/60/70/80, Type 353 14.1 Engine drive 14.1.1 Engine model BF6M 1012 E 14.1.1.1 Engine

Page 22Section 4.1Service Training09.064.1.2.3 REPLACEMENT OF V-RIPPED BELTFit the V-ripped belt and tension it.Pressh the belt tensioner pulley (1) i

Service TrainingPage 23Section 4.109.064.1.2.4 ADJUSTING VALVE CLEARANCEThe adjustment can be carried out when the engine is cool or warm after a cool

Page 24Section 4.1Service Training09.064.1.2.5 CHECKING AND ADJUSTING LEAK-FUEL-FREE INJECTION NOZZLESCHECKING THE OPENING PRESSURENOTE: Use only test

Service TrainingPage 25Section 4.109.06CHECK INJECTORSThe injectors are not equipped with bores for leak -off fuel.The surplus fuel cannot be discharg

Page 26Section 4.1Service Training09.06SETTING OF INJECTORSFor a correction of the opening pressure:- Remove injector from nozzle tester 8008. Removet

Service TrainingPage 27Section 4.109.06LEAK TEST- Dry nozzle and nozzle holder by compressed air.- Press hand lever of tester slowly down until apress

Page 28Section 4.1Service Training09.06BUZZING AND SPRAY PATTERN TEST- Switch-off pressure gauge of tester.- The buzzing test permits audible checking

Service TrainingPage 29Section 4.109.06- Attach new injection lines with sealing rubber elements.Tighten cap screws finger-tight.HINWEIS: When install

Page 30Section 4.1Service Training09.064.1.2.6 THERMOSTATREMOVAL- Drain coolant, collect it, and dispose of it in accordancewith legal standards.- Dis

Service TrainingPage 31Section 4.109.06CHECKINGCheck thermostat in removed condition.- Measure dimension „a“ on the thermostat.NOTE: „a“ = stroke begi

Service Training09.044.2.2.2 Operation of control valve block N = Power Limiter 234.2.2.3 Braking 244.2.2.4 Auxiliary brake 244.2.2.5 Lock-out logic -

Page 32Section 4.1Service Training09.064.1.2.7 CHECKING THE COMPRESSION PRESSURE- Remove the injection nozzle.- Check the valve clearance.- Insert and

Service TrainingPage 33Section 4.109.064.1.2.8 CYLINDER HEADREMOVING THE CYLINDER HEAD- With the engine cool, slacken the cylinder head bolts evenly a

Page 34Section 4.1Service Training09.06INSTALLING THE CYLINDER HEADNOTE: Sealing surfaces for cylinder head gaskets must be clean and free of oil. Pay

Service TrainingPage 35Section 4.109.064.1.2.9 INJECTION PUMP4.1.2.9.1 ADJUSTING THE BEGIN OF DELIVERYIf an injection pump must be replaced, the begin

Page 36Section 4.1Service Training09.06Read the code for the injection pump length (A) on the new injection pump, e.g. 42.The basic dimension of the i

Service TrainingPage 37Section 4.109.064.1.2.9.2 REPLACEMENT OF THE INJECTION PUMPThis repair method is intended for a replacement of the injection pu

Page 38Section 4.1Service Training09.06- Press control rod into stop position using the knurledlock bolt.- Use press-on device for control rod 100 830

Service TrainingPage 39Section 4.109.06- Read off ID number for injection pump length (dimensionA) for the new injection pump.NOTE: Determining new sh

Page 40Section 4.1Service Training09.06- Put on flange.NOTE: Chamfered end must face injection pumpbody.- Slightly oil bolts and tighten to a tighteni

Service TrainingPage 41Section 4.109.06- Turn bolts in again by 60° and gradually tighten to atightening torque of 7 Nm, 10 Nm and 30 Nm.NOTE: Start w

Service Training09.044.3 Chassis 14.3.1 Overhead guard - torsion mounting 24.3.1.1 Work on the overhead guard 34.4 Steering system 14.4.1 Power steeri

Page 42Section 4.1Service Training09.06- Siide sealing ring onto injection valve using some greaseand insert injection valve.NOTE: The notch on the in

Service TrainingPage 43Section 4.109.064.1.2.10 HEATER FLANGEPOSITIVE POLE SCREW OF HEATER FLANGESpecial screw TN 0425 8628NOTE: This special screw mu

Page 44Section 4.1Service Training09.06The hollow hexagon wrench must be swivelled inanticlockwise direction.

Service TrainingPage 45Section 4.109.06The hollow hexagon wrench must be swivelled betweenthe upper and the lower heating coil base to be able tocoun

Page 46Section 4.1Service Training09.064.1.2.11 SPECIAL TOOLSNo. Designation8002 Hydraulic pressure pump for cooler leak test8005 Compression tester(b

Service TrainingPage 47Section 4.109.068117 Serrated wrench for tuming injection pump8189 Torx tool kit9017 Valve spring assembly lever9090 Spring cla

Page 48Section 4.1Service Training09.06100 750 Measuring bar with spacers tor gauging TDC and pistonprojection100 830 Press-on device tor control rod1

Service TrainingPage 49Section 4.109.06120 680 Extractor for sealing ring beneath injector121 410 Sleeve for fitting valve stem seal130 300 Piston rin

Page 50Section 4.1Service Training09.06

Service TrainingPage 4.2Section 14.2 TRANSMISSION

Service Training12.054.6.7 Electrical system circuit diagram, type 353 -03 LPG 254.6.8 Wiring diagram for options, 353 -03 294.6.9 Central electrical

Service TrainingPage 4.2Section 24.2.1 HYDROSTATIC TRANSMISSIONThe transmission is composed of separate components consisting of a high pressure axial

Service TrainingPage 4.2Section 34.2.1.1 SCHEMATIC DIAGRAM OF THE DRIVE1 Gear pump, 23 cc, due to transmission ration1 engine revolution = 27 cc2 Engi

Service TrainingPage 4.2Section 44.2.1.2 TRANSMISSION SPECIFICATIONSVARIABLE DISPLACEMENT PUMPType: BPV 100 SDefinition of type designation: B = Serie

Service TrainingPage 4.2Section 5WHEEL DRIVESTwo wheel drives bolted to frameEach unit consists of:1 variable-displacement hydraulic motor HMV 105 SDe

Service TrainingPage 4.2Section 64.2.1.3 HYDRAULIC CIRCUIT DIAGRAMA WORKING HYDRAULICS1 Control valve block consisting of:2 Way valve (auxiliary hydra

Service TrainingPage 4.2Section 7G BOOST PRESSURE PUMP18 Gear pump, 23 cc/rev.; i = 1.18, resulting in 27 cc/rev.18a Way valve - auxiliary braking18b

Service TrainingPage 4.2Section 831 High-pressure modulator32 Nozzles33 Pressure-relief valve40 3/2-way valve41 Nozzle42 By-pass valveO PRESSURE FILTE

Seite 9Abschnitt 4.2Service TrainingHYDRAULIKSCHALTPLAN H 50/60/70/80, TYP 353

Abschnitt 4.2Seite 10Service Training05.00HYDRAULIKSCHALTPLAN H 50/60/70/80 D-02, BAUREIHE 353

Seite 11Abschnitt 4.2Service Training05.00HYDRAULIKSCHALTPLAN H 50/60/70/80 T-02, BAUREIHE 353

Service Training12.054.9.3 Propellant gas system 334.9.3.1 Diagram 334.9.3.2 Functional description of the propellant gas system 344.9.4 Inspections a

Service TrainingPage 4.2Section 1305.00

Service TrainingPage 4.2Section 1409.04HYDRAULIC CIRCUIT DIAGRAM, TYPE 353 -03A WORKING HYDRAULICS1 Control valve block consisting of:2 Way valve (aux

Service TrainingPage 4.2Section 1509.04F ENGINEG ENGINE SPEED CONTROL CYLINDERH VARIABLE-DISPLACEMENT PUMP HPV 105-02, ASSY.24 Variable-displacement p

Service TrainingPage 4.2Section 1609.0437 Pressure-relief valve 13 bar38 High-pressure modulator39 3/2-way valve40 By-pass valveM TRAVEL CONTROL UNIT

Page 17Section 4.2Service Training09.04HYDRAULIC CIRCUIT DIAGRAMM H 50/60/70/80 D-03, TYPE 353

Section 4.2Page 18Service Training09.04

Service TrainingPage 4.2Section 1909.04

Service TrainingPage 4.2Section 2009.044.2.2 OPERATION OF THE HYDROSTATIC TRANSMISSIONThe oil flow (20 L/min at nmin1, 60 L/min at nmax) generated by

Service TrainingPage 4.2Section 2109.04Travel Control UnitI OperationTravel direction, swashplate angle, maximum rpmII OperationBrake43 Pressure regul

Service Training12.05

Service TrainingPage 4.2Section 2209.04

Service TrainingPage 4.2Section 2309.04The feed pressure oil flows via E1 and E through control valve block N, goes through travel control unit Pfrom

Service TrainingPage 4.2Section 2409.04POWER LIMITER, ANTI-STALL DEVICEThe drive is provided with a power limiter to prevent any overload on the engin

Service TrainingPage 4.2Section 2509.04EXPLANATIONFeedThe oil flow from the feed pump (18) goes through restrictor (18c) and is fed through port P3 in

Service TrainingPage 4.2Section 2609.04at the pressure balance in the working hydraulics way valve block. This causes the pressure balance toclose, th

Service TrainingPage 4.2Section 2709.04at piston (24) continues through open valve (21) to valve (20), which is shifted to position (b) by the 5 barsp

Service TrainingPage 4.2Section 2809.044.2.2.6 FLUSHING OF THE CIRCUIT AND HOUSINGIn order to prevent extremely high oil temperatures in the closed ci

Service TrainingPage 4.2Section 2909.04

Service TrainingPage 4.2Section 3009.044.2.3 HYDRAULIC REMOTE CONTROL1 Cover2 Pilot housing3 Control pilot4 Control lever5 Hexagonal nut6 Eccentric pi

Service TrainingPage 4.2Section 3109.044.2.3.1 ADJUSTMENTSCONDITIONS- Jack up and securely block the truck so that both traction wheels can rotate fre

Service TrainingPage 1Section 4.109.044 IC-ENGINED FORK TRUCK H 50/60/70/80, TYPE 3534.1 ENGINE DRIVE4.1.1 ENGINE MODEL BF6M 1012 E4.1.1.1 ENGINE SPEC

Service TrainingPage 4.2Section 3209.044.2.3.1.4 HYDRAULIC REMOTE CONTROL HPV 105 -02SERVO CONTROL1 Control piston2 Lever3 Spring plate4 Spring5 Shims

Service TrainingPage 4.2Section 3309.04ADJUSTMENTSTEST CONDITIONS- Jack the truck up and secure it safely, so that both drive wheels can spin freely.-

Service TrainingPage 4.2Section 3409.044.2.3.1.5 REVERSAL LOCK (LOGIC LOCK OUT)UP TO 4/94- Slacken the sealing nut (16.2).- Using a socket head spanne

Service TrainingPage 4.2Section 3509.044.2.4 WHEEL DRIVE1 Reduction gearbox2 Disc brake3 Hydraulic motorThe reduction gearbox and the disc brake can b

Service TrainingPage 4.2Section 3609.044.2.4.1 REDUCTION GEARBOX WITH DISC BRAKE (GR 80 -02/-03/-04)

Service TrainingPage 4.2Section 3709.04REDUCTION GEARBOX1 Retaining ring2 Cover3 O-ring4 Ring gear5 Straight pin6 Plug7 Sealing ring8 Cheese head scre

Service TrainingPage 4.2Section 3809.044.2.4.2 SERVICING THE REDUCTION GEARBOX (GR 80 -02/-03/-04)CONDITIONS- Jack up the truck and block it up secure

Service TrainingPage 4.2Section 3909.044.2.4.3 DISC BRAKE REPAIRSCONDITIONS- Jack up the truck and block it up safely.- Remove the traction wheel.- Pl

Service TrainingPage 4.2Section 4009.044.2.4.4 REDUCTION GEARBOX GR 80 -06 WITH MULTIPLE DISC BRAKE1 Wheel hub2 Shaft seal3 Tapered roller bearing4 Pl

Service TrainingPage 4.2Section 4109.044.2.4.5 REPAIR ON THE REDUCING GEAR GR 80 -06DISMOUNTINGJack up truck and dismount wheel.Unscrew the hexagon so