394-02 EU5 Series Service Manual 3948012101EN 04-2020 Motor Doosan

Service Training
IC truck
394-02 EU5 series

02/2020 (H2X394X50001) |=>
H40D-02, H45D-02, H50D-02,

H40T-02, H45T-02, H50T-02
Edition 04/2020
This service document is provided for use only and remains
the exclusive property of Linde Material Handling.
3948012101 EN - 04/2020
History of changes
Edition 02/2020 ● New: Traction hydraulics pump HPV 125 V+

● Changes: Hydraulic circuit diagram
● New: Service plans for diesel and LPG ● Various editorial changes and corrections
● New: Servicing work for diesel
● New: Doosan D24NAP diesel engine Edition 04/2020
● New: Exhaust aftertreatment for the EU V
emissions level ● Various editorial changes and corrections
● New: Multi-cyclone air filter
Service Training - 3948012101 EN - 04/2020 I

Header
Linde − Your Partner
Selling over 100,000 forklift and warehouse But it is only under the toughest conditions that a
trucks per year, Linde ranks as one of the machine can show its true worth. Carefully
world's leading manufacturers. And there are thought-out functionality combined with maxi-
good grounds for its success. Linde products not mum economic efficiency. Linde trucks are
only win over customers with their innovative bursting with ideas. For the benefit of the cus-
technology with a reputation for excellent per- tomer. And to protect the environment.
formance, but in particular with reduced energy
Linde Material Handling GmbH
and operating costs, which are up to 40% lower
Carl-von-Linde-Platz
than those of the competition.
63743 Aschaffenburg
High production quality is also the benchmark Telefon +49 (0) 6021 99-0
for the quality of our services. With ten produc- Telefax +49 (0) 6021 99-1570
tion plants and a dense network of distribution Mail: info@linde-mh.de
partners, we are at your disposal both round the Website: http://www.linde-mh.de
clock and round the world.
Be it leasing, hire or hire purchase — the cost-
benefit ratio is right on target from the very start.
Format of the training manual

This training manual assumes that service train-
ing and a corresponding seminar have already
been completed; this training manual supple-
ments the training already received. It is not
Service Training - 3948012101 EN - 04/2020 III

Header
suitable for self-study without an accompanying

seminar.
This training manual is not organised in such a
way that it sequentially describes the structure of
the truck. In the different chapters, the individual
components of the truck are described as inde-
pendent units one after the other.
The chapters are only based on the structure of
the spare parts list; the content may differ.
The training manual is divided into two-digit
numbered chapters in accordance with the func-
tion group key. The main function groups are lis-
ted below. These main function groups are fur-
ther subdivided; these subgroups are used in
the training manual.
Chapter Contents
00 Product information
10 Internal combustion engine
20 Running gear and drive train
30 Chassis and bodywork
40 Driver's compartment
60 Electrics/electronics
70 Hydraulics
80 Lifting system
90 Business solutions
The introduction is followed by a complete table

of contents for the training manual.
All special tools and measuring instruments
used for this truck can be found in the "Linde
Service Guide", including spare part numbers
and images. The circuit diagrams for the truck
are published separately.
Symbols used
The precautions Danger, Warning, Caution, CAUTION
Note und Environment Note in this manual are
provided to indicate special hazards or unusual indicates hazards that may result in damage to or de-
information requiring special identification: struction of the product.
DANGER
NOTE
indicates hazards that may result in personal injury or
death and/or substantial damage to the product. Identifies technical information requiring special
attention because the connection may not even
be obvious to skilled personnel.
WARNING
indicates hazards that may result in personal injury
and/or substantial damage to the product.
IV Service Training - 3948012101 EN - 04/2020

Header
For your safety other symbols are also used.

ENVIRONMENT NOTE Please note the different symbols.
The information contained herein must be ob-
served, otherwise environmental damage may
occur.
Service Training - 3948012101 EN - 04/2020 V

Header
Identifying components in electrical circuit diagrams

Example: 1 x 1 : 4
1 (function group) X (type of operating material) 1 (sequential number) : 1(pin number)
Examples of the operating materials assigned to the

Code Type of function group
functional groups
Battery, main switch, battery male connector, battery
Nil General
charger
0 Combustion engine Including attached components
Traction motor, drive contactor impulse control system -
1 Drive unit
driving
2 Working hydraulics Lift motor, valve switch
3 Power take-offs Power-assisted steering motor, compressor drive
4 Signalling devices Horn, signal horn, rotating beacon, buzzer
5 Lighting Truck lighting, workplace lighting
6 Measuring and display devices Display unit, battery discharge indicator, hour meter
Special functions (safety func-
7 Dead man switch, emergency off switch, door lock
tions)
8 Automated functions Height preselection, position control
9 Other Heating system, windscreen wipers, fan
Code let-
Type of operating material
ters
A Units
B Sensors, thermoelectric gauges, potentiometers, strain gauges etc.
C Capacitors
D Binary elements, delay devices, storage and memory functions
E Lighting devices, heating devices, fans
F Fuses
G Generators, power supplies
h Visual and audible signalling devices such as signal lights, indicator lights and buzzers
K Contactors, relays
L Coils, inductors
M Motors
N Controllers, amplifiers, regulators
P Display units
R Resistors
S Switches, push buttons
U Voltage transformers
V Semi-conductors
X Terminals, plug connectors
Y Solenoid valves
Z Suppressor circuits
Examples:
1A1 Traction controller N1 Electronic traction control LHC
2B1 Rev sensor 6P2 Instrument panel
4C1 Horn capacitor 1R1 Charging resistor
5E1 Working spotlight S1 Key switch
1F1 Main current fuse U1 Voltage transformer
VI Service Training - 3948012101 EN - 04/2020

Header
Examples:
G1 Truck battery 1V1 MOSFET power module
H1 Indicator lamps 1X1 Plug connector
1K1 Main contactor 1Y4 Exhaust valve
1M
Traction motor 1Z11 Contactor suppressor circuits
1
Service Training - 3948012101 EN - 04/2020 VII

Table of contents
Truck information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
The 394-02 EU5 truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
Safety information for repair and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . 00-4
Internal test specifications / diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6

LHC overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6
LHC basic structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-11
Code lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-11
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-12
CAN box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14
Authorisations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-16
USB-CAN-Box 2 and Bluetooth-CAN-Box 3 software update . . . . . . . . . . . . . . . . . . . 00-16
02 Service
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-1
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-1
Recommendations for consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-1
LPG engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-4
Recommendations for consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-4
Servicing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-6

Diesel service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-6
Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-6
LPG service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-9
Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-9
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-13
Doosan D24NAP diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-14
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-14
Replacing the engine oil and the engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-15
Checking the condition of the V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-18
Replacing the V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-19
Changing the belt tensioner for the V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-20
Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-20
Cleaning the radiator and checking the radiator for leak tightness . . . . . . . . . . . . . . . 02-21
Changing the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-22
Draining water from the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-23
Changing the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-24
Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-25
Cleaning the breather hose for the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-26
Checking the dust discharge valve on the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-26
Cleaning the dust guard prefilter (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . 02-27
Checking the dust discharge valve on the multi-cyclone air filter (special equipment) . 02-27
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Table of contents
Changing the air filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-27

Changing the safety cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-29
Checking the condition and secure attachment of the engine support and engine
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-30
Checking the intake lines and exhaust lines for leak tightness . . . . . . . . . . . . . . . . . . 02-30
CWTA LPG engine (from H2X394G00038) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-32
Changing the engine oil and replacing the engine oil filter . . . . . . . . . . . . . . . . . . . . . 02-32
Replacing the spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-36
Replacing the gas filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-36
Replacing the C-Series evaporator (cannot be dismantled) . . . . . . . . . . . . . . . . . . . . 02-37
Mixture setting and CO testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-43
Checking the LPG system for damage and leak tightness . . . . . . . . . . . . . . . . . . . . . 02-43
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-44
Replacing the pressure hoses in the gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-44
Changing the cooling fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-45
Draining and topping up the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-47
Checking the coolant concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-54
Cleaning the radiator and checking the radiator for leak tightness . . . . . . . . . . . . . . . 02-56
Checking the condition of the V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-57
Removing and installing the V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-58
Removing and installing the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-61
Changing the air filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-62
Replacing the safety cartridge in the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-63
Check the dust discharge valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-65
Cleaning the oil bath air filter and changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-65
Checking the intake lines and exhaust lines for leak tightness . . . . . . . . . . . . . . . . . . 02-66
Running gear and drive train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-67
Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-67
Checking the wheels for damage, foreign objects and wear . . . . . . . . . . . . . . . . . . . . 02-67
Lubricating the steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-68
Checking the mounting of the steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-68
Checking the condition of the antistatic belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-68
Checking the axle clamp mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-70
Checking the mounting of the wheel motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-70
Checking and adjusting the side stops on the drive axle . . . . . . . . . . . . . . . . . . . . . . 02-71
Checking the drive axle bearings for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-71
Checking the mounting of the hydraulic pump on the engine . . . . . . . . . . . . . . . . . . . 02-71
Checking the parking brake for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-73
Chassis and bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-73
Checking the mounting of the chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-73
Checking and lubricating the bearing points and joints . . . . . . . . . . . . . . . . . . . . . . . 02-73
Driver's compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-74
Checking the seat belt for condition and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-74
Checking the pedal group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-75
X Service Training - 3948012101 EN - 04/2020

Table of contents
Checking the swivel bearing of the tilt angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 02-76

Maintaining the heating system and air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . 02-76
Electrics/electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-78
Checking the condition of the electric connections and checking that they are securely
attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-78
Checking the condition and disposing of the starter battery . . . . . . . . . . . . . . . . . . . . 02-78
Checking the axle load sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-80
Calibrating the axle load sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-83
Check the load pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-84
Calibrating the load pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-84
Checking the lift height sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-86
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-87
Checking the oil level in the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-87
Changing the oil in the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-88
Replacing all filters in the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-90
Checking the bleeder valve on the hydraulic tank for correct function . . . . . . . . . . . . 02-93
Checking the hydraulic system for leak tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-94
Checking the tilt cylinder bearings for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-94
Tilt cylinders: Checking the mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-95
Checking the pre-load of the hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-95
Lifting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-96
Safety information for working on the lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-96
Checking the condition of the lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-99
Cleaning and spraying the lift mast chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-100
Checking the mounting, condition and function of the lift mast, lift mast chains, lift
cylinders and end stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-101
Adjusting the lift mast chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-101
Checking the fork arms and arm safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-103
Checking and lubricating the sideshift (special equipment) . . . . . . . . . . . . . . . . . . . . 02-104
Checking the sideshift for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-104
Checking and lubricating the fork prong positioner (special equipment) . . . . . . . . . . . 02-106
Checking the fork prong positioner for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-107

Doosan D24NAP diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Safety information for working on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Glossary of component designations for the Linde Doosan D24NASP diesel engine . 10-2
Identification plate and engine identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Overview of the engine attachment parts and service points . . . . . . . . . . . . . . . . . . . 10-5
Exhaust gases - composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Overview of the sensors and actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Checking the engine power rating in trucks with adjustable hydraulic pump MPR 50 . 10-13
Setpoint values with tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Service Training - 3948012101 EN - 04/2020 XI

Table of contents
Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Instructions for assembling and disassembling the engine . . . . . . . . . . . . . . . . . . . . . 10-15
Crank drive and seals - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Changing the sealing ring for the crankshaft (belt pulley side) . . . . . . . . . . . . . . . . . . 10-18
Crankcase breathing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Cylinder crankcase - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Instructions for changing the flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Crankshaft sensor 0B13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Checking the crankshaft sensor 0B13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Changing the crankshaft sensor 0B13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Changing the ribbed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
Cylinder head, valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
Tips for working on the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
Valve cover - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Removing and installing the valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
Cylinder head - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Changing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Cylinder head seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
Hydraulic tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
Camshaft sensor 0B11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
Checking the camshaft sensor 0B11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
Changing the camshaft sensor 0B11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
Engine oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
Instructions regarding the engine lubrication system after engine repairs . . . . . . . . . . 10-55
Oil pump, oil sump - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
Oil filter support, oil cooler - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
Changing the oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
Engine oil level sensor 0B16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
Engine oil pressure sensor 0B7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61
Changing the engine oil pressure sensor 0B7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
Coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
Instructions for frost protection and coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
Instructions for changing components of the cooling system . . . . . . . . . . . . . . . . . . . 10-66
Checking the cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
Replacing the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
Coolant level sensor 0B19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71
Coolant temperature sensor 0B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
Checking the coolant temperature sensor 0B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
Working on the fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
Fuel system - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
Sanitation regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
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Table of contents
Behaviour during incorrect refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84

Replacing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
Water trap switch 0B36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87
Fuel temperature sensor 0B12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
Checking the fuel temperature sensor 0B12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
Checking the fuel system for leak tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
Fuel preparation, injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
Working on the common rail injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
Replacing the high-pressure fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
Replacing the fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
Fuel quantity regulation valve 0Y11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
Rail pressure sensor 0B35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
Injectors 0Y1...0Y4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100
Checking the injectors 0Y1 to 0Y4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101
Measuring the injectors return flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
Changing the injectors 0Y1 to 0Y4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
Air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
Intake manifold - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
Air volumeter 0B6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
Checking the air volumeter 0B6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113
Vacuum-operated switch S3 for the suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
Charge air pressure and charge air temperature sensor 0B4 . . . . . . . . . . . . . . . . . . . 10-116
Butterfly valve servo motor 0M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117
Checking the butterfly valve servo motor 0M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-118
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121
Safety information for work on the charge air system with exhaust turbocharger . . . . 10-121
Sanitation regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121
Checking charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122
Checking the boost pressure regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122
Checking the charge air system for leak tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
Exhaust turbocharger with attachment parts - assembly overview . . . . . . . . . . . . . . . 10-126
Changing the exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-127
Changing the pressure box on the exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . 10-132
Preheating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
Preheating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
Glow plugs 0R1...0R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
Changing the glow plugs 0R1...0R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
Replacing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
Exhaust after-treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
Diesel particle filter service regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
Diesel particle filter regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142
Diesel particle filter - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145
Changing the diesel particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
Changing the differential pressure sensor 0B15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
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Table of contents
Radiator for exhaust gas recirculation - assembly overview . . . . . . . . . . . . . . . . . . . . 10-150

Exhaust gas recirculation actuator 0M7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
Testing the exhaust gas recirculation actuator 0M7 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
Exhaust gas temperature sensors 0B17 and 0B20 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-154
Checking the exhaust gas temperature sensor 0B17 in the diesel particle filter . . . . . 10-157
Checking the exhaust gas temperature sensor 0B20 in the exhaust manifold . . . . . . 10-160
Changing the exhaust gas temperature sensors 0B17 and 0B20 . . . . . . . . . . . . . . . . 10-162
Differential pressure sensor 0B15 for the diesel particle filter . . . . . . . . . . . . . . . . . . . 10-164
Checking the differential pressure sensor 0B15 for the diesel particle filter . . . . . . . . 10-166
Electrical system, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
Pin assignment of the Doosan engine control unit with 196 contacts . . . . . . . . . . . . . 10-169
Checking the power supply for engine control unit 0N1 . . . . . . . . . . . . . . . . . . . . . . . 10-174
Changing the engine control unit 0N1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175
Removing and installing the starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-176
Starter motor does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-176
Starter motor turns too slowly and does not crank the engine . . . . . . . . . . . . . . . . . . 10-178
Removing and installing three-phase alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
Checking the three-phase generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
Line connectors on the magnet-operated switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181
Self-diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181
Features of self-diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181
Diagnostics functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
Connecting the diagnostic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
Connecting the measurement box for a line test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183
Reading out the error memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
VW CWTA LPG engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188

Description of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
Technical data for the CWTA engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
Overview of the CWTA engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-189
Installation position of the CWTA engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
Lubrication of the CWTA / CKPA engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
Checking the engine power rating in trucks with adjustable hydraulic pump MPR 50 . 10-191
Checking engine power rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-193
Assessing the engine power rating via the engine utilisation . . . . . . . . . . . . . . . . . . . 10-193
Setpoint values with tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
Comparison of emission values (in vol. %) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
Engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
Overview of the cylinder block on the CWTA / CKPA engine . . . . . . . . . . . . . . . . . . . 10-195
Removing and installing the cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
Removing and installing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
V-ribbed belt drive on the CWTA / CKPA engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206
Removing and installing the V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-209
Checking the compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
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Table of contents
Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-214

Overview of the valve train for the CWTA / CKPA engine . . . . . . . . . . . . . . . . . . . . . 10-214
Overview of the chain drive for the CWTA / CKPA engine . . . . . . . . . . . . . . . . . . . . . 10-215
Control housing for the CWTA engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-216
Overview and function of camshaft phasing for the CWTA / CKPA engine . . . . . . . . . 10-217
Removing and installing camshaft phase adjusters with a timing chain . . . . . . . . . . . 10-226
Removing and installing the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-233
Checking the timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-239
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-242
Cooling system for the CWTA / CKPA engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-242
Draining and filling the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-245
Removing and installing the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-249
Removing and installing the coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-250
Engine electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-252
Sensors and actuators for the CWTA engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-252
System overview of camshaft phasing for the CWTA / CKPA engine . . . . . . . . . . . . . 10-253
Three-phase alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-253
Electronic ignition system − overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-255
Gas shortage shut-down device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-257
LPG system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-259

Safety guidelines for LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-259
Safety measures when working on ignition systems . . . . . . . . . . . . . . . . . . . . . . . . . 10-260
Basic rules when working with LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-261
Sealing plastic pipe unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-263
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-264
LPG system - functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-264
Shut-off valve (solenoid valve) with gas filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-265
Technical data for the evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-267
Evaporator connections (using the C-Series evaporator as an example) . . . . . . . . . . 10-268
Operating principle of the evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-269
Overview of the Cobra MD evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-271
Overview of the C-Series evaporator (cannot be dismantled) . . . . . . . . . . . . . . . . . . 10-272
Operating principle of the Cobra MD evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-272
Operating principle of the C-Series evaporator (cannot be dismantled) . . . . . . . . . . . 10-274
Removing and installing the Cobra MD evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . 10-275
Assembling the maintenance kit for the Cobra MD evaporator . . . . . . . . . . . . . . . . . . 10-277
Replacing the C-Series evaporator (cannot be dismantled) . . . . . . . . . . . . . . . . . . . . 10-284
Membrane mixing unit - functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-289
Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-291
LPG system with lambda control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-292
Exhaust gases - composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-292
Description and function of the catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-293
Lambda control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-298
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Mixture setting and CO measurement for the open-loop catalytic converter . . . . . . . . 10-304
Mixture setting and CO measurement for the closed-loop catalytic converter . . . . . . . 10-310
Leakage test on the LPG system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-318
LPG cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-320

The following safety measures must be observed . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-320
Level display with single replacement cylinders(special equipment) . . . . . . . . . . . . . 10-320
LPG tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-332

The following safety measures must be observed . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-332
Performing assembly work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-332
Procedure for bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-337
CNG system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-340

CNG basic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-340
CNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-340
Production, storage and composition of CNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-342
Comparison of emission values (in vol. %) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-343
Safety datasheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-344
Explosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-348
Quality of H gas and L gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-348
CNG-specific components in the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-350
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-350
VW CWTA 3.6 l engine with a regulated catalytic converter . . . . . . . . . . . . . . . . . . . . 10-351
Technical data for the CWTA engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-351
"E-Control" engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-353
CNG mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-353
Operating principle of the Cobra MD evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-356
Operating principle of the C-Series evaporator (cannot be dismantled) . . . . . . . . . . . 10-357
Shut-off system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-360
Shut-off valve (solenoid valve) with gas filter for CNG . . . . . . . . . . . . . . . . . . . . . . . . 10-360
CNG module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-362
Overview of CNG system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-362
Fill valve (1) with integrated non-return valve (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-365
Pressure gauge (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-366
Pressure sensor for the level display (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-366
Mechanical (5) and electromagnetic (6) shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . 10-369
Pressure reducing valve (8) with coolant connection (7) . . . . . . . . . . . . . . . . . . . . . . 10-370
Pressure relief valve 28 bar in the 12-bar range (9) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-371
Burst plug (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-371
Fusible safety plug (13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-371
CNG tank (15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-372
Assembly instructions for Swagelok pipe screw joints . . . . . . . . . . . . . . . . . . . . . . . . 10-373
Mixture setting and CO measurement at the CNG system . . . . . . . . . . . . . . . . . . . . . 10-375
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Table of contents
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-383
Leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-383
Test log after testing the natural gas system for leaks . . . . . . . . . . . . . . . . . . . . . . . . 10-384
Engine electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-385
Electronic ignition system − overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-385
Gas shortage shut-down device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-387
Linde Engine Protection System (LEPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-389

Linde Engine Protection System (LEPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-389

Drive components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Technical data for drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Travel drive - introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Working hydraulics pump MPR50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Hydraulic adjustment with electronic activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
Start of regulation of variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16
Auxiliary brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19
Start of rotation of drive wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
Output unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
Hydraulic fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
Removing and installing the HPV variable displacement pump coupling flange . . . . . 20-26
Hydraulic truck diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
Overview and explanations of diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
Special tools required for the measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31
HPV 125 V+ pressures - measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31
Determining the average wheel speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
Checking the hydrostatic drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
Drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37

Wheel motor HMF 135-2, replacing the tapered roller bearing . . . . . . . . . . . . . . . . . . 20-37
Chassis frame components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-53

Gearbox GR6H − changing the shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-53
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66

Steering system - functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
Linde Curve Assistant (LCA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70
Adjusting the steering stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71
Removing and installing the steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71
Replacing the steering cylinder seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-73
Assembling the steering angle sensor/cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-74
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Removing and installing the axle stub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-76

Special tools for manual assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-76
Process for manual removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-79
Removing the steering pivot pin (pressing out using a fixed press) . . . . . . . . . . . . . . 20-80
Removing the axle stubs from the axle beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-81
Assembly process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-82
Assembling the upper axle stub bearing and wiper . . . . . . . . . . . . . . . . . . . . . . . . . . 20-83
Assembly — axle stub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-85
Assembly — lower axle stub bearing wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-86
Assembling (pre-assembling) the steering pivot pin (pressing in using a fixed press) . 20-87
Assembling the steering pivot pin (pressing in using a fixed press) . . . . . . . . . . . . . . 20-90
Assembling the lower axle stub bearing/flange cover . . . . . . . . . . . . . . . . . . . . . . . . 20-92
Removal/assembly of the wheel hub/wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . 20-93
Removing and installing the track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-96
Press tool - Overview of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-96
Basic device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-98
Basic design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-99
Steering axle 302/303/1602/1603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100
Pressing the track rod pin on the steering cylinder in and out . . . . . . . . . . . . . . . . . . 20-100
Track-rod pin on the steering cylinder - Preparing the press tool . . . . . . . . . . . . . . . . 20-100
Pressing out the track-rod pin on the steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . 20-102
Pressing in the track-rod pin on the steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 20-104
Pressing the track rod pin on the axle stub in and out . . . . . . . . . . . . . . . . . . . . . . . . 20-106
Track-rod pin for the mud flap on the axle stub - Preparing the press tool . . . . . . . . . 20-106
Pressing out the track-rod pin for the mud flap on the axle stub . . . . . . . . . . . . . . . . . 20-107
Pressing in the track-rod pin for the mud flap on the axle stub . . . . . . . . . . . . . . . . . . 20-109
Wheels and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111

Electrostatic charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111
Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112

Brake release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112
Brake cable pulls - Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
Checking the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-123

Mounting the drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Affixing the axle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Gas springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4

Instructions for working with gas springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
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Table of contents
Driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
Seat switch bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
Replacing the seat switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4

Basic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
Physical principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-7
Basic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-7
Simple refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-7
Schematic view of a refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-9
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10
Compressor oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-12
Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-14
Function of the air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-14
How the air conditioner operates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-14
Schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-15
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-15
Condenser with fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-18
Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-19
Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20
Inspection glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22
Expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23
Tubing and hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23
Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-24
Performing work on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-26
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-26
Instructions for working on air conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-27
Emptying an air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-27
Filling the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30
Filling quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-32
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-32
Technical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-32
Procedure for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-33
Checking for leaks in refrigerant circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40
Service and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-43
Repair instructions for the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-43
Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-45
Air conditioning system in the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-47
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-47
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-47
Electric circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-48
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-49
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Operating units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50

Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52
Stop screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52
Joysticks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-53
Joystick variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-53
Joystick interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54
Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-57
Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-59

Display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-59
60 Electrics / electronics
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
Safety information for the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
Cleaning the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
EMC – Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2
Line routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2
Identifying components in electrical circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 60-3
CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-5
CAN bus connection assembly X15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-6
LIN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-7
Pin assignment for the LHC 20 Tricor controller with 154 contacts . . . . . . . . . . . . . . 60-9
Working spotlight position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-14
BlueSpotTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15
TruckSpotTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-16
Sensor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-17
LHC 20 functional overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-17
Actual-value transmitter for speed 1B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-18
Accelerator potentiometer 1B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-19
1B4 hydraulic oil temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20
Steering angle sensor 1B11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20
Suction filter vacuum-operated switch S3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-22
Brake pedal switches 1S1 and S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-23
Water trap sensor 1B13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-24
Single-pedal drive direction switch 1S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-25
Tilt angle sensor 2B3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-26
Seat switch S4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-27
Plug positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-28
Plug positions in the overhead guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-28
Plug positions under the seat cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-29
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Plug positions under the seat cover for the CWTA engine . . . . . . . . . . . . . . . . . . . . . 60-30
Plug positions under the bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-34
Central electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-35

Arrangement of relays and fuses for basic equipment and special equipment . . . . . . 60-35
Arrangement of the adaptor connectors from the console to the truck . . . . . . . . . . . . 60-38
Plug housing X10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-39
Plug housing X11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41
Truck control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-43

Truck control unit overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-43
Overview - Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-45
Heating - sensor overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-46
Linde Hydraulic Control (LHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-47
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-48
Power supply for external components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-48
Enable signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-49
Truck coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-49
LHC controller with ECO mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51
Testing the LHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51
Testing the VW controller and the immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51
Testing the wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-52
Testing sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-55
Assistance systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-56

Assistance systems overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-56
Instructions for adjusting the surround view (Surround View) system . . . . . . . . . . . . . 60-57
Load weight indicator "plus" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-64
Safety guidelines for the load-dependant assistance system (load weight indicator
"plus") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-64
Load-dependant assistance system load weight indicator "plus" . . . . . . . . . . . . . . . . 60-65
Load pressure sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-66
Lift height switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-67
LSP overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-68
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-68
LSP system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71
LSP variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73
LSP display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-75
Rotary push button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-77
Lift height sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80
Load pressure sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-84
Axle load sensor for the 1603 steering axle (LSP active only) . . . . . . . . . . . . . . . . . . 60-85
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Speed sensors at the wheel motors (LSP active only) . . . . . . . . . . . . . . . . . . . . . . . . 60-88

LSP wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-91
LSP diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-92
LSP calibration process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-92
Calibrating the vertical mast position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-92
Calibrating the lift height sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-93
Calibrating the load pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-94
Calibrating the axle load sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-97
Checking the axle load sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-98
Calibrating the pump swivel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100
Checking the lift height sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-101
Replacing the bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-102
Check the load pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-112
Warning messages and error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-113
LSP configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-114
LSP data file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-114
LSP select configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-116
LSP active configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-118
Setting the zero point for the lift height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120
Configuring the lowering limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-122
70 Hydraulics
Clean working in the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
Dirt in the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
Cleaning the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-2
Taking hydraulic oil samples and oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-2
Cleaning work on the Linde control valve - cast valve . . . . . . . . . . . . . . . . . . . . . . . . 70-4
Cleaning instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-29
Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30
Oil volume for the auxiliary hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30
Operating hydraulics circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-32
Function characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-34
Checking the function and safety system of the third auxiliary hydraulics (special
equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-36
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-38
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-38
Depressurisation Auxiliary hydraulics 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-38
Hose layout for pump — control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-39
Hose layout of control pressure supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40
Increasing the volume flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40
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Tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-42

Tilt cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-42
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50
80 Lifting system
Lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
Safety information for working on the lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
Lift mast - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-4
Measuring the lifting speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-4
Removing and installing lift mast model 189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-4
Driving without the lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-7
Setting the tilt angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-7
Removing and installing the outer lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10
Standard lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-11
Sealing the outer lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-11
Duplex/triplex lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-12
Sealing the outer lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-12
Removing and installing the centre lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-13
Sealing the centre lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-13
Assembly parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-15

Support rollers / wear strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-15
Setting the roller play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-15
Roller play - fork carriage in the inner mast, family 189 . . . . . . . . . . . . . . . . . . . . . . . 80-16
Roller play - middle and inside mast profile, Series 189 . . . . . . . . . . . . . . . . . . . . . . . 80-17
Outer Mast Roller Clearance, Type 189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-17
Removing wear strips - Standard lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-18
Removing wear strips - Duplex lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-18
Removing wear strips - Triplex lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-18
Protection elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-22
Line break safety valve in the lift mast (throttle valve) . . . . . . . . . . . . . . . . . . . . . . . . 80-22
Hose reservoir − removal, exchanging hose, sealing, fitting . . . . . . . . . . . . . . . . . . . 80-24
Load support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-28

Sideshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-28
Safety information for working on the sideshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-28
Removing the moveable frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-28
Replacing the upper wear strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-29
Removing the lower slide rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-29
Replacing the cylinder seals, the shafts or the shaft guides . . . . . . . . . . . . . . . . . . . . 80-29
Service Training - 3948012101 EN - 04/2020 XXIII

Table of contents
Releasing air out of the hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30

Malfunctions and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-31
Kaup fork prong positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-32
Description and mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-32
Integrated fork prong positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-34
Installing the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-34
Removing and installing the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-35
Mounting the load backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-36
Course of action after assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-36
Safety information for working on the fork prong positioner . . . . . . . . . . . . . . . . . . . . 80-38
Checking the wear strips for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-38
Removing and installing fork guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-39
Replacing the wear strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40
Checking the slide guides for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40
Removing and installing the fork carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40
Replacing the slide guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-43
Replacing the sideshift reach cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-44
Replacing the fork arm positioning reach cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 80-45
Replacing the reach cylinder seal sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-48
Removing and installing the flow divider (junction) . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50
Errors and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-51
Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-53
Oil flow rates, speeds and operating pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-53
Suspension element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-55

Adjusting the lift mast chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-55
Assembly sequence of the lock nuts on the chain anchor . . . . . . . . . . . . . . . . . . . . . 80-56
90 Special equipment
Reverse proximity warning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
Functionality of ultrasonic sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-6
392/393/394 series: Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-6
Functional test - Specification test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
Specification test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
Setting the zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
Monitoring zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
LHC function (IC trucks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-12
LHC20 (154-pin connection assembly) ► 394-02 (MPR): Speed reduction ON . . . . . . 90-12
XXIV Service Training - 3948012101 EN - 04/2020

Table of contents
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
Diagnostics and parameterising: Ultrasonic ECU 9A7 . . . . . . . . . . . . . . . . . . . . . . . . 90-13
Setting: Ultrasonic sensor ECU(Windows XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-14
Setting the ultrasonic sensor ECU(Windows 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
392/393/394-02/396-03 series: LHC20 software settings: Pathfinder . . . . . . . . . . . . . 90-23
Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-26
394 series: Truck parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-26
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27
392 series: Assembly of ultrasonic ECU 9A7 and display . . . . . . . . . . . . . . . . . . . . . 90-27
392/393/394 series: Assembly of relays and fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 90-28
394 series: Position of the ultrasonic sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29
392/393/394 series: Setting: Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-30
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-32
394 series: Reverse proximity alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-32
Intelligent buckle monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-34

Intelligent buckle monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-34
Reducing the driving speed using the toggle switch . . . . . . . . . . . . . . . . . . . . 90-41

Reducing the driving speed using the toggle switch . . . . . . . . . . . . . . . . . . . . . . . . . 90-41
Reducing the driving speed via the lift height . . . . . . . . . . . . . . . . . . . . . . . . . 90-43

Reducing the driving speed via the lift height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-43
Engine switch-off via seat switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-45

Engine switch-off via seat switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-45
Service work on the trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-49

Service work on the trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-49
Service Training - 3948012101 EN - 04/2020 XXV

Product information 00
Truck information
The 394-02 EU5 truck
The handling characteristics, economic efficien-

cy and operating comfort are again greatly en-
hanced in the 394-02 EU5 truck series.
Due to the implementation of the Doosan
D24NAP diesel engine in the 394-02 series, the
focus was placed on reducing the scope of
maintenance work and maintenance costs over
the life of the truck. This has been primarily ach-
ieved by the omission of typical wearing parts,
such as the toothed belt, or by using more sus-
tainable components.
In addition, the 394-02 series is distinguished by
reduced exhaust emissions and increased envi-
ronmental friendliness, achieved by fulfilling the
"EU V" emissions level.
Fuel consumption and noise emissions have al-
so been reduced, with a simultaneous increase
in driving power. This is made possible by an in-
creased delivery volume from the traction hy-
draulics pump and by the hydraulic oil suction at
the base of the tank.
Service Training - 3948012101 EN - 04/2020 00-1

Truck information
Changes to the "394-02 EU5" series in de-
tail
Doosan D24NAP diesel engine 
Exhaust aftertreatment for the "EU V emissions 

level"
401_20-05
Multi-cyclone air filter 
005_19-12
Traction hydraulic pump V+ 
401_20-06
00-2 Service Training - 3948012101 EN - 04/2020

Truck information
Hydraulic oil suction at the base of the tank 
401_20-07
Hydraulic suction filter 
005_19-08

Truck information
Safety information for repair and maintenance work
Repair and maintenance work may only be car- Battery
ried out by trained service personnel (special- ● Wear protective equipment (industrial gog-
ists) and in accordance with the Linde Service gles, gloves etc.) (electric trucks only).
Guide or training manual. For special trucks, ad- ● Observe the fire protection measures.
ditional qualifications are required, e.g. explo- ● Transport, maintenance and charging may
sion-protected industrial trucks. only be carried out in accordance with instruc-
General tions provided by the battery manufacturer.
● Changes or attachments to the truck may only Devices
be carried out with the manufacturer's permis- ● Lifting devices must have a sufficient load ca-
sion. pacity and be certified appropriately. Observe
● Use only genuine Linde spare parts. Other- the instructions for use.
wise, guarantee and warranty claims will be ● When lifting or pulling, use only the attach-
rendered void and the safety of the truck may ment points on the truck that are provided for
be compromised. this purpose.
● During repair work, any removed components
● Attach the lifting or pulling connection careful-
that are subject to wear or ageing must be re- ly. Check that the bolts and fasteners are se-
placed. Components that are replaced must curely in position. Maintain a safe distance
be filled with or lubricated using the correct lu- from tensioned ropes, slings or chains.
bricant; see "Recommendation for consuma-
● Any steps, ladders or platforms used must
bles".
conform to the relevant regulations.
● Switch on and operate the truck from the driv-
er's compartment only, unless this would pre- Safety equipment

vent the check from being performed. ● Never wear loose clothing or jewellery when
● Never perform repair and maintenance work
working on the truck. Always wear tested
while someone is in the driver's seat, unless safety clothing.
that person is trained in and is assisting with ● When using compressed air or high-pressure
the maintenance procedure.
cleaning equipment, always use protective
● Before opening hydraulic connections, ensure
equipment (mask, industrial goggles etc.).
that the hydraulic system is depressurised.
After completing the repair and maintenance
Secure the truck before starting repair and work:
maintenance work: ● After all repair and maintenance work, per-
● Apply the parking brake and switch off the key
form a functional test of the truck.
switch. ● Inform the operating company of any changes
● Disconnect the battery male connector (elec-
to the driving or braking parameters so that
tric trucks only). the operating company can become familiar
● Secure the truck so that it cannot roll away, with the new handling characteristics before
unless this would prevent the check from be- operating the truck.
ing performed. ● Inform the operating company if the speed re-
● Lift the drive unit and support the truck se- duction function is activated so that the oper-
curely so that the drive wheels can rotate ating company can adapt its hazard assess-
freely. ment to the new operating characteristics.
● Attach a clearly visible warning sign to the
truck, advising that the truck must not be Handling consumables

switched on.
● Secure the truck against being switched on by
unauthorised persons. ENVIRONMENT NOTE

● When carrying out work on the raised fork
Consumables and cleaning materials used dur-
carriage or extended lift mast, always secure ing repair and maintenance work may be harm-
them against unintentional movement. ful to the environment.
Observe the following notes:
● Always handle consumables properly, in ac-
cordance with the manufacturer's instructions.

● Lubricants may be transported and stored on-
ly in approved containers and storage areas.

Truck information
● Keep inflammable lubricants away from hot ● Clean the area around the relevant part be-
objects and naked flames. fore performing lubrication, replacing a filter or
● When topping up consumables, use only carrying out repairs to the hydraulic system.
clean containers. ● When using chain spray, cover over any plas-
● Remove any spilt fluid immediately using a tic panels, as chain spray is difficult to remove
suitable binder. Dispose of the spilt fluid in ac- from plastic panels.
cordance with the applicable regulations.
● Dispose of used or contaminated consuma-
bles in accordance with the applicable regula-
tions.

Internal test specifications / diagnostics

LHC overview
LHC basic structure
1 Joysticks 5a Working hydraulics pump

2 Display 6 Internal combustion engine
3 Lift mast 7 Pedal group
4 Directional control valve block 8 Drive direction switch
5 Traction pump 9 Integral drive control / lift control

LHC modules — the difference between diesel and LPG vehicles
1 LHC LPG/diesel 6 CAN bus

2 Gas shut-off valve 7 VW diagnostics (ISO)
3 Engine control unit 8 Engine control unit
4 LPG engine 9 Diesel engine
5 Throttle bodies servo-motor with potentiome-
ter

Control electronics — overview
1 Joysticks 11 Fuel injection system

2 Display 12 Engine speed transmitter
3 CAN bus I 13 Engine control unit
4 CAN diagnostic connector 14 VW diagnostics
5 Lift mast tilt angle transmitter 15 CAN bus II
6 Lift mast 16 Immobiliser
7 Traction pump 17 Fuel shut-off valve
8 Directional control valve block 18 Pedal group
9 Remote control 19 Drive direction switch
10 Internal combustion engine 20 Integrated traction/lift control — LHC module

LHC 20-system overview
1 Display 5 Immobiliser
2 CAN bus I 6 VW engine control unit
3 CAN diagnostics connector 7 CAN bus II
4 VW diagnostics (ISO) 8 Integrated traction/lift control — LHC module
Display unit — error codes 
The error codes are displayed in text field (1)

(2 x 11 characters) and if the "particulate filter
special equipment" is fitted, the residual capacity
is also displayed.
The sequence in which the error codes are dis-
played depends on the code letters (T before L
before D ... errors) and on the sequence in
which the error numbers are sent on the CAN
bus. If more errors have occurred than can be
shown on the text display, the buttons must be
used for scrolling.
When the "<" symbol is displayed in the text
field, the left-hand button is used for scrolling to
the left and when the ">" symbol is displayed,
the right-hand button is used for scrolling to the
right.
Error code display sequence: T before L before
D before F before R before X before Y before Z.
T Traction
L Lift
D Display
F Particle filter
R Recorder (data logger).
X, Y, Z Customised options 1 to 3

NOTE
Error codes and any error corrections are issued

and analysed using the diagnostic program.

Diagnostics
Code lists
A distinction is made between the following co- function. Warning codes are stored in the error
des as regards the effect on vehicle functions: memory of the relevant control.
States – codes 1 to 99 Errors:

Warnings – codes 100 to 199 An error code affects vehicle function. A function
Errors – codes 200 to 999 may be impaired or completed disabled depend-
ing on the severity of the error. Error codes are
States: stored in the error memory of the relevant con-
trol.
A state code is present during normal operating
conditions and has no effect on vehicle function. The following lists of state, warning and error co-
State codes are not stored in the error memory des are just brief descriptions. A detailed list of
of the relevant control. codes with their possible causes can be found in
the diagnostic software.
Warnings:
A warning code may occur during normal oper-
ating conditions and has no effect on vehicle

Overview
CAN bus connection
The truck diagnostics are performed using a lap-

top (11) on which the diagnostic program and
the corresponding "servicebase" for the truck
are installed. The diagnostic program must be
registered and is then activated by Linde AC
(Application Control).
The laptop (11) is connected to the truck's diag-
nostic connector (4) via the CAN box (5).
The diagnostic connector (4) is connected via
the CAN bus (1) to the display unit (2) and the
truck control unit (3).
Depending on the type of CAN box used (serial
CAN box (5a), USB CAN box (5b), USB CAN
box 2 (5c) or Bluetooth CAN box 3 (5d)), the
connection to the laptop (11) can be made via a

D-sub plug (7), a USB cable (6/7/8/10) or Blue-
tooth (9). In either case, the diagnostic options
are always identical.
NOTE
Connecting via Bluetooth requires a Bluetooth-

enabled laptop or an additional Bluetooth USB
stick.
Serial CAN box to serial port on laptop 
The serial CAN box (3) is connected to the serial

port on the laptop (5) via the connecting cable
(4). The connecting cable (2) is inserted be-
tween the CAN box (3) and the diagnostic con-
nector (1) on the truck.
Serial CAN box to USB port on laptop 
The USB plug on the interface adapter (4) is

connected to the USB port on the laptop (5). The
serial CAN box (3) is connected to the serial
connection on the interface adapter (4). The
connecting cable (2) is inserted between the
CAN box (3) and the diagnostic connector (1) on
the truck.
USB CAN box to USB port on laptop 
The USB CAN box (3), the USB CAN box 2 (4)
or the Bluetooth CAN box 3 is connected to the
USB interface of the laptop (5). The connecting
cable (2) is inserted between the CAN box
(3/4/6) and the diagnostic connector (1) on the
truck.

Bluetooth CAN box 3 to Bluetooth on laptop 
The CAN box 3 is (6) connected to the laptop (5)

via Bluetooth (7). The connecting cable (2) is in-
serted between the CAN box (6) and the diag-
nostic connector (1) on the truck.
Requirements for a Bluetooth connection:
● Bluetooth-enabled laptop or
● Linde Bluetooth stick
CAN box
The CAN box is required for truck diagnostics.
The CAN box provides access to the individual
truck controllers via the CAN bus of the diagnos-
tic connector.
The CAN box contains a computer on which the
relevant software required to control communi-
cation between the diagnostic laptop and the in-
dividual controllers is installed.
Previous CAN box variants:
● Serial CAN box
● USB CAN box
● USB CAN box 2
Currently available CAN box variant:

● Bluetooth CAN box 3
On the left-hand side of the serial CAN box and

the USB CAN box, there is a 4-pin round plug
(6) that is connected to the truck diagnostic con-
nector.
On the right-hand side of the serial CAN box, 
there is a 9-pin Sub-D plug (2) that is used to
connect the diagnostic laptop.

On the right-hand side of the USB CAN box, 
there is a USB cable (1) that is used to connect
the diagnostic laptop.
On the left-hand side of the USB CAN box 2, 

there are three connectors. The middle connec-
tor is an 8-pin round plug (6) and is connected to
the truck diagnostic connector. The lower con-
nector is a USB cable (1) that is used to connect
On the left-hand side of the Bluetooth CAN box 

3, there are three connectors. The middle con-
nector is an 8-pin round plug (6) and is connec-
ted to the truck diagnostic connector. The lower
connector is a USB cable (1) that can be used to
connect the diagnostic laptop.
NOTE
In future, the Bluetooth CAN box 3 will also be

able to be used to connect the diagnostic laptop
via Bluetooth.
Three LEDs indicate the communication state of
the CAN box:
● The LED (8) illuminates once the CAN box
has established a Bluetooth connection with

● The LED (5) illuminates once the CAN box is
supplied with voltage via the diagnostic con-

nector when the truck is switched on.
● The LED (4) or (7) illuminates once data is
transmitted from the truck to the CAN box.

● The LED (3) illuminates once data is transmit-
ted from the diagnostic laptop to the CAN

box.
USB CAN box 2 or Bluetooth CAN box 3: If all
LEDs (4/5/7/8) flash orange and green alternate-
ly, the CAN box is in programming mode.

NOTE
To operate the USB CAN box, the appropriate

driver must be installed on the diagnostic laptop.
The driver can be obtained from the following
sources:
● Linde Extranet → After Sales / Service Fork

Lifts → Software / Download of Service Soft-
ware → Diag_Adapter → CANbox USB II
3903605141 / CANbox USB III 3903605114
● Service Software Stick 7917424003
Authorisations
If different CAN boxes are used interchangeably
or if a CAN box has been replaced, the settings
must be adjusted via the laptop.
NOTE
For a software update, administrative rights are

required. Please contact your system adminis-
trator.
USB-CAN-Box 2 and Bluetooth-CAN- 

Box 3 software update
The flash program and the software for the CAN
box, e.g. "V2.44_Ser_USB_2.bin", are required
to perform a software update on the CAN box.
Both programs can be obtained from the down-
load area on the Extranet.
NOTE
The version number for the flash program and

the software for the CAN box may change. Ver-
sion number "V2.44_Ser_USB_2.bin" is only an
example. The most up-to-date version is always
available on the Extranet.
 Connect the CAN box to the laptop and to the
truck.
 Start the relevant flash program via LMH-
Starter → Settings → CAN-Box Programmer:
● USB-CAN-Box III (Bluetooth) or
● USB-CAN-Box II

 Select the "COM-Port" interface (1) and con- 
firm with Connect (2). "Device Manager" dis-
plays which interface is required. Click on
Open file ... (3) to open the flash program.
 Select the software for the CAN box (4), e.g. 

"CANBox III - V2.68.bin" and click Öffnen (5)
to confirm.
 Tick the fields "Erase before Program", "Verify 

after Program" and "Reset after successful
Program" (6). Click on the Program ... button
(7).
The update for the CAN box software starts. The 

progress is displayed in the "Status" field (8).
Once the update is complete, the message "Ver-
ify operation finished without errors!" appears in
the "Status" field (8).
 The messages "Reset operation finished!"
and "Connection closed!" appear in the "Sta-
tus" field.
 Close the program.
Programming of the CAN box is complete.


Service 02
Consumables
Diesel engine
Recommendations for consumables
ENVIRONMENT NOTE NOTE
Observe the information regarding the use of As the outside temperature falls, the flow char-
consumables. acteristics of the diesel fuel are reduced due to
paraffin segregation. If "summer" diesel fuels are
used at low outside temperatures, it can lead to
Diesel fuel malfunctions. For this reason, cold-resistant
"winter" diesel fuel is available during the colder
Trucks with particle filters
part of the year. This allows reliable operation at
Use only a diesel fuel compliant with EN 590, temperatures down to approx. -22°C.
with a sulphur content ≤ 10 mg/kg and a cetane In winter, use only winter diesel fuel to ensure
number ≥ 51. that the fuel lines do not become blocked with
 If you have any questions, please contact segregated paraffin. Very low temperatures may
your service partner. cause troublesome paraffin segregation even
with winter diesel fuel. Contact your service part-
Trucks without a particle filter ner.
If the only diesel fuel available has a sulphur
content above the value permissible for EN 590, Hydraulic oil
the engine oil change intervals are as follows:
● At a sulphur content more than 10 mg/kg and
NOTE
less than 50 mg/kg = engine oil change inter-
val 1000 operating hours. The working temperature of the oil is the critical
● At a sulphur content more than 50 mg/kg and factor to consider when selecting the correct oil
less than 350 mg/kg = engine oil change infor hydrostatic drive units. The recommenda-
terval 500 operating hours. tions for oils given below can serve only as
● At a sulphur content more than 350 mg/kg = guide values.
engine oil change interval 300 operating Hydraulic oil recommendation for normal use:
hours.
Hydraulic oil ISO - L - HM 68 to ISO 6743 - 4 or
HLP ISO VG 68 to DIN 51524, T.2 (factory fill-
NOTE ing) average constant oil temperature 60°C to
80°C
If the sulphur content of the diesel fuel is more
than 350 mg/kg, an engine oil compliant with Hydraulic oil recommendation for heavy-duty
classification ACEA E6 or API CJ-4 must be use:
used despite the reduced engine oil change in-
tervals. Hydraulic oil ISO - L - HM 100 to ISO 6743 - 4 or
HLP ISO VG 100 to DIN 51524, T.2 for heavy-
CAUTION duty and multi-shift use, operation in hot climate
zones or at high ambient temperatures, average
Damage to the engine may occur. constant oil temperature over 80°C
Use only the specified diesel fuels with the corre-
Hydraulic oil recommendation for normal and
sponding specifications.
heavy-duty use:
The use of organic diesel fuel (RME in accordance
with EN 14214) is not permissible. Hydraulic oil ISO - L - HV 68 to ISO 6743 - 4 or
HVLP ISO VG 68 to DIN 51524, T.3 (multi-grade
oil)
Bio-hydraulic oil
Highly biodegradable hydraulic fluid

02 Service
Consumables
CASTROL Carelube HFS 46
NOTE
or
Panolin HLP Synth 46 If drinking water is not available, use distilled
water.
CAUTION
Bio-oils must not be mixed with mineral oils. Refrigerant for air conditioning
No recommendations for other fluids from other man- R 134a
ufacturers can be made at the present time.
Battery grease
NOTE
Acid-free lubricating grease (battery grease)
If in doubt, the advice of the relevant service
partner is recommended. Recommendations Chain spray
made by representatives from the mineral oil in-
dustry must also be discussed with your service Linde chain spray (see spare parts catalogue for
partner. Manufacturer's approval has been given order no.)
only for the oils specified above. Mixing with or
using other hydraulic fluids may result in costly
damage. Engine oil
When the engine is running, not only is some of
Lubricating grease the engine oil for piston lubrication burnt off
("consumed"), but the temperature stress and
Linde heavy-duty grease, lithium-saponified with the fuel combustion products that enter the oil
EP agents and MoS2. lead to "oil wear", especially affecting chemical
Designation in accordance with DIN 51825- "additives" in the oil. For this reason, the engine
KPF 2N-20 (see spare parts catalogue for order oil must be completely replaced at specified in-
no.) tervals.
Mixing with soap-based types of lubricating Since this "oil wear" depends on the operating
grease other than lithium-saponified is not per- conditions, the fuel quality and the oil quality (the
mitted. performance characteristics of the oil), oil
change intervals vary.
Coolant Lubricating oil may remain in the engine for a
maximum of 12 months. Irrespective of the oil
CAUTION change intervals, the lubricating oil must be
changed at least every 12 months.
Refer to the coolant specifications!
Use only coolant additive TL 774-F (G12+) or TL 774- Only engine oils that comply with the following
G (G12+ +). standards are approved for use in the engine:
● ACEA E6 or API CJ-4 with viscosity
Coolant additive "TL 774-F (G12+)" is added at SAE 10W-30 (factory filling) or SAE 10W-40.
the factory. Depending on the oil quality, different oil change
This additive must be mixed with drinking water intervals must be observed.
(total hardness of the water must not be higher
Engine oil to ACEA E6 or API CJ-4
than 20° on the German degree of hardness
● Oil change every 1000 operating hours or ev-
scale). A maximum of 60% coolant additive can
be used. ery 12 months.
Coolant addi- NOTE

Temperature Drinking water
tive
-25°C 40 % 60 % Note that the engine oil change intervals must
-30°C 45% 55 % be reduced if diesel fuel with an increased sul-
phur content is used.
-35 °C 50 % 50 %
-40 °C 60 % 40 % For forklift trucks with particle filter systems, use
only low-ash oil. The residues from the combus-
tion of oil additives (ash) cannot be regenerated.

Service 02
Consumables
Since a good engine oil is a prerequisite for
problem-free operation and a long service life for NOTE
the engine, always use a high-quality engine oil
Do not add any additive lubricants of any sort to
both when topping up and when changing the the lubricating oils.
oil. Due to their limited viscosity range, single-
grade oils should generally not be used all year Due to the issue of disposal and the special
round. Use these oils only in extreme climate tools and the knowledge required, engine oil
zones. changes and filter changes must be performed
only by your service partner.

02 Service
Consumables
LPG engine
Recommendations for consumables
LPG CAUTION
Approved for the VW engine: Bio-oils must not be mixed with mineral oils.
LPG of 95% propane with the remaining 5% oth- No recommendations for other fluids from other man-
ufacturers can be made at the present time.
er gas up to 80% butane with 20% propane and
other gas fed through a suitable ignition map.
Use only LPG cylinders filled with LPG to NOTE
DIN 51622 or LPG to EN 589 (automotive gas);
gas withdrawal in the liquid phase. If in doubt, we recommend obtaining the advice
of your authorised service partner. Recommen-
dations made by representatives from the miner-
NOTE al oil industry must also be discussed with your
service partner. Manufacturer's approval only
The use of domestic gas cylinders is absolutely exists for the oils specified above. Mixing with or
prohibited. using other hydraulic fluids may result in costly
damage.
Hydraulic oil
Lubricating grease
NOTE Linde heavy-duty grease, lithium-saponified with
EP active ingredients and MoS2. Designation
The working temperature is the critical factor to according to DIN 51825-KPF 2N-20 (order no.:
be considered when selecting the correct oil for
hydrostatic drive units. The recommendations see spare parts catalogue).
for oils given below can only be guide values. Mixing with soap-based lubricating grease types
Hydraulic oil recommendations for normal use: other than lithium-saponified is not permitted.
Hydraulic oil ISO-L-HM 68 to ISO 6743-4 or

HLP ISO VG 68 to DIN 51524, T.2 (factory fill- Coolant
ing) average constant oil temperature 60°C–
CAUTION
80°C.
Hydraulic oil recommendations for heavy-duty Refer to the coolant specifications!
use: Use only coolant additive that complies with VW
standard TL 774-D (G12), TL 774-F (G12+), TL 774-
Hydraulic oil ISO-L-HM 100 to ISO 6743-4 or G (G12++) or TL 774-J (G13).
HLP ISO VG 100 to DIN 51524, T.2 for heavy-
duty and multi-shift use, operation in hot climate Coolant additive "TL 774-F (G12+) "is added at
zones or at high ambient temperatures, average the factory.
constant oil temperature over 80°C.
This additive must be mixed with water (total
Hydraulic oil recommendations for normal and hardness of water must not be more than 20°
heavy-duty use: according to German hardness standards). A
Hydraulic oil ISO-L-HV 68 to ISO 6743-4 or maximum of 60% coolant additive can be used.
HVLP ISO VG 68 to DIN 51524, T.3 (multigrade
oil) Coolant addi-
tive
-25°C 40% 60%
Bio hydraulic oil
-30°C 45% 55%
Highly biodegradable hydraulic fluid -35°C 50% 50%
-40°C 60% 40%
CASTROL Carelube HFS 46
or
Panolin HLP Synth 46

Service 02
Consumables
Depending on the oil quality, different oil change
NOTE intervals must be observed.
If no drinking water is available, distilled water Engine oil that complies with VW standard
must be used. 503 00, 504 00 or 507 00
● Oil change every 1000 operating hours or ev-
Refrigerant for air conditioning ery 12 months.
R 134a Engine oil that complies with VW standard

502 00
● Oil change every 500 operating hours.
Battery grease
Acid-free lubricating grease (battery grease).
NOTE
Chain spray API or ACEA oils are only permitted if they con-
form to the VW standards for the engine men-
Linde chain spray (order no.: see spare parts tioned above.
catalogue).
 When topping up, the various oils may be
mixed with each other; however, the oil
Engine oil change interval is then determined by the oil
of the lowest quality.
When the engine is running, not only is some of
the engine oil for piston lubrication burnt off Since a good engine oil is a pre-requisite for
("consumed"), but the temperature stress and problem-free operation and a long service life for
the fuel combustion products that enter the oil the engine, use only good quality engine oil
lead to "wear", especially affecting chemical "ad- even when topping up and also during oil
ditives" in the oil. For this reason, the entire fill- change. Due to their limited viscosity range, sin-
ing of engine oil must be renewed at specified gle-grade oils should generally not be used all
intervals. year round. These oils should be used only in
extreme climate zones.
Since this "oil wear" depends on the operating
conditions, the fuel quality and the oil quality (the
performance characteristics of the oil), oil NOTE
change intervals vary.
No additional lubricants of any sort should be
The longest time a filling of lubricating oil may mixed in with the lubricating oils.
remain in the engine is 12 months. Irrespective
of the change intervals, the lubricating oil must
be changed at least every 12 months. ENVIRONMENT NOTE
Only engine oils that comply with the following Used oil must be kept away from children until it
standards are approved for use in the engine: is disposed of according to the regulations. Un-
● VW standard 502 00. der no circumstances should oil be allowed to
● VW standard "Longlife" 503 00 with viscosity
penetrate the mains drainage or the ground.
SAE 0W-30. Due to the issue of disposal and the special
● VW standard "Longlife 3" 504 00 (factory fill- tools and knowledge required, engine oil and fil-
ing) with viscosity SAE 5W-30. ter changes may be performed only by your
● VW standard 507 00 with viscosity service partner.
SAE 5W-30, if VW standard 504 00 is met.

02 Service
Servicing work
Diesel service plan
Service plan
Note regarding servicing work

Specialist knowledge is required for servicing work. Special tools may also be required.
Contact your service partner.
Preparatory tasks
Clean the truck
Read out and clear the error memory
Calibrate the accelerator potentiometer and the joysticks
Enter the next service interval
Regular Service, at least every 12 months
Internal combustion engine

Replace the engine oil and the engine oil filter
Replace the fuel filter
Clean the breather hose for the fuel tank
Visually inspect the condition of the engine support and engine mount, and check that they are se-
curely attached
Check the condition of the V-ribbed belt
Clean the radiator and check it for leak tightness
Check the coolant concentration
Check the dust discharge valve on the air filter
Check the dust discharge valve on the multi-cyclone air filter
Check the leak tightness of the intake lines and of the exhaust lines
Running gear and drive train
Check the wheels for damage, foreign objects and wear
Check the condition of the antistatic belt
Lubricate the steering axle
Check that the parking brake is working correctly
Chassis and bodywork
Check and lubricate the bearing points and joints
Driver's compartment
Check the condition of the seat belt and check that it is working correctly
Check the pedal group
Electrics/electronics
Check the condition of the electrical connections and check that they are securely attached
Hydraulics
Check the oil level in the hydraulic system
Check that the bleeder valve on the hydraulic tank is working correctly
Check the hydraulic system for leak tightness
Check the pre-load of the hose lines
Lifting system
Check the condition of the lift mast
Clean the lift mast chain and apply chain spray

Service 02
Servicing work
Adjust the lift mast chain
Check and lubricate the sideshift
Check and lubricate the fork prong positioner
Servicing work every 1000 hours, but at least every 3 years

Replace the fuel filter
Clean the breather hose for the fuel tank
curely attached
Replace the cartridge in the air filter
Replace the cartridge in the multi-cyclone air filter
Check the particle filter system and replace the particle filter if necessary
Check the mounting of the axle clamp
Check the side stops of the drive axle
Visually inspect the mounting of the hydraulic pump on the engine
Check the mounting of the steering axle
Visually inspect the mounting of the chassis/counterweight
Service the heating system and air conditioning
Check the condition of the starter battery
Check the axle load sensor
Check the load pressure sensor
Check the lift height sensor
Hydraulics
Check the mounting of the tilt cylinders

02 Service
Servicing work
Lifting system
Check the condition and mounting of the lift cylinders, lift mast chain, chain rollers and end stops, and
check that they are working correctly
Check the mounting of the lift mast
Check the fork arms and fork arm locking devices
Additional servicing work every 3000 hours, but at least every 3 years
(Exceptions in brackets)

Replace the V-ribbed belt
Replace the safety cartridge in the air filter
Check the mounting of the drive wheel unit (only once after 3000 hours)
Check the bearings of the drive axle for wear
Check the swivel bearing of the tilt angle sensor
Calibrate the axle load sensor
Calibrate the load pressure sensor
Hydraulics
Replace all filters in the hydraulic system
Check the tilt cylinder bearings for wear
Lifting system
Check the sideshift for wear
Check the fork prong positioner for wear

Change the coolant
Hydraulics
Change the hydraulic oil
Final tasks
Carry out a functional test, including a test drive
Attach the service sticker

Service 02
Servicing work
LPG service plan
Service plan
Note regarding servicing work

Specialist knowledge is required for servicing work. Special tools may also be required.
Preparatory tasks
Clean the truck
Read out and clear the error memory
Calibrate the accelerator potentiometer and the joysticks
Enter the next service interval

Replace the gas filter
Mount the evaporator using a new repair kit or replace the evaporator
Check the CO level in the exhaust system
Check the LPG system for damage and leak tightness
curely attached
Hydraulics
Lifting system
Check the condition of the lift mast

02 Service
Servicing work

Replace the gas filter
Mount the evaporator using a new repair kit or replace the evaporator
Check the CO level in the exhaust system
Check the LPG system for damage and leak tightness
curely attached
Replace the cartridge in the air filter
Replace the cartridge in the multi-cyclone air filter
Check the mounting of the axle clamp
Check the side stops of the drive axle
Visually inspect the mounting of the hydraulic pump on the engine
Check the mounting of the steering axle
Visually inspect the mounting of the chassis/counterweight
Service the heating system and air conditioning
Check the condition of the starter battery
Check the axle load sensor
Check the lift height sensor
Hydraulics

Service 02
Servicing work
Check the mounting of the tilt cylinders
Lifting system
Check the condition and mounting of the lift cylinders, lift mast chain, chain rollers and end stops, and
check that they are working correctly
Check the mounting of the lift mast
Check the fork arms and fork arm locking devices
(Exceptions in brackets)

Replace the spark plugs
Replace the pressure hoses in the gas system
Replace the V-ribbed belt
Replace the safety cartridge in the air filter
Check the mounting of the drive wheel unit (only once after 3000 hours)
Check the bearings of the drive axle for wear
Check the swivel bearing of the tilt angle sensor
Calibrate the axle load sensor
Calibrate the load pressure sensor
Hydraulics
Replace all filters in the hydraulic system
Check the tilt cylinder bearings for wear
Lifting system
Check the sideshift for wear
Check the fork prong positioner for wear
Hydraulics
Change the oil in the hydraulic system
Additional service work every 9000 hours; no limitation by year

Replace the coolant pump
Change the coolant

02 Service
Servicing work
Final tasks
Carry out a functional test, including a test drive
Attach the service sticker

Service 02
Servicing work
Cleaning the truck
The frequency of cleaning depends on the appli- When cleaning with compressed air, remove
cation conditions of the truck. If highly abrasive stubborn contamination with a cold cleaning sol-
materials, e.g. salt water, fertiliser, chemicals or vent.
cement are used, the truck must be thoroughly
cleaned after each assignment. CAUTION
Deposits and accumulations of combustible ma- Damage to or destruction of truck components!
terials on or in the vicinity of hot parts (e.g. ex-
Water must not be used for cleaning in the area of the
haust pipes) must be removed immediately. central electrical system or switch console. Only use a
Before performing service work, clean the oil fill- dry cloth or clean compressed air for cleaning in this
area.
er openings and their surroundings, as well as
the lubricating nipples.
The following areas must also not be subjected
When cleaning, note the following: to a direct water jet when cleaning (e.g. using
● Wear protective equipment high-pressure cleaning equipment or steam
● Never wash the truck while the engine is run-
cleaners):
● Electrical and electronic components
ning or while the engine is hot
● When using high-pressure cleaners, maintain ● Plug connectors
a minimum distance of 300 mm between the ● Plastic pipes for the air duct
spray pipe and the truck ● Any of the hydraulic and coolant hoses
● Cleaning materials that contain strong sol-
● The areas around hose clips
vents can permanently damage painted and
● Damping mats
plastic surfaces
● Hot steam or cleaning materials with a power-
ful degreasing effect must be used with ex- NOTE

treme caution, because these will affect the
grease filling of bearings with lifetime lubrica- If cleaning using a water jet cannot be avoided,
tion, causing them to leak. Relubrication is not the affected areas must be covered beforehand.
possible. The bearing will be destroyed

02 Service
Servicing work
Doosan D24NAP diesel engine
Checking the engine oil level
ENVIRONMENT NOTE
Observe the information regarding the use of

consumables.
WARNING
When topping up the oil, no oil must drip
onto hot engine parts — risk of fire!
Fill carefully.
CAUTION
Different oil specifications.
Observe the recommendations for consumables.
CAUTION
The oil level must never be above the upper mark.
Drain the engine oil if necessary.
 Park the truck on level ground.

 Open the bonnet.
WARNING
Beware of hot engine and exhaust com-
ponents.
Wear protective equipment.
WARNING
When the engine is hot, the fan may
start automatically.
Do not touch rotating parts.

Service 02
Servicing work
 Take the oil dipstick (2) out of the engine. 
1
 Wipe the oil dipstick using a clean cloth.
 Push the oil dipstick fully back in and remove
it again.
The oil level must be between the marks.
 If necessary, pour in engine oil through the
filling opening until it reaches the upper mark.
 To do so, remove the filler cap (1) from the
filling opening.
Difference in quantity between max. and min.
marks: 4.1 l
 Fit the filler cap and turn to tighten.
 Close the bonnet. 2
d3941502a
Replacing the engine oil and the engine

oil filter
WARNING
Risk of scalding from hot engine oil!
CAUTION
Different oil grades result in different maintenance in-
tervals.
Observe the recommendation for consumables.
ENVIRONMENT NOTE

consumables.
 Place a suitable collection container under the
truck frame.
WARNING
ponents.
WARNING

02 Service
Servicing work
NOTE
Change the engine oil only when the engine is at

operating temperature.
Drain the engine oil.

 Remove the oil drain plug (1). 
 Catch the oil in a suitable container.

 Clean the area around the opening using a
cloth.
 Use a new sealing ring.
 Screw in the oil drain plug (1).
 Tighten the oil drain plug (1). Tightening tor-
que: 30 Nm
1
394-02_01-231
Replacing the engine oil filter

 Use a filter wrench to loosen the engine oil fil- 
ter (1) and unscrew by hand.
 Catch the oil that drains out and dispose of it
with the engine oil filter in an environmentally
friendly manner.
 Coat the sealing ring of the engine oil filter
with oil.
NOTE
The tightening torque varies according to the en-

gine oil filter manufacturer.
Observe the following for Doosan engine oil fil-
ters:
 Tighten the Doosan engine oil filter. Tighten-
ing torque: 16 to 20 Nm
 Tighten the Doosan engine oil filter a further
three-quarter turn using an oil filter wrench.
 Observe the instructions on the engine oil fil-
ter.
 Tighten the engine oil filter according to the
instructions.

Service 02
Servicing work
Topping up the engine oil
 Remove the cover from the oil filling open- 
ing (1).
1
NOTE
At first, add only approx. 5 l of engine oil. Wait

one minute. Then add the rest of the engine oil.
 Pour new engine oil into the filling opening.
Use oil that complies with the recommenda-
tion for consumables.
Filling quantity with filter change: max. 10.5 l
 Pull out the oil dipstick (2) and wipe the dip-
stick clean using a cloth.
2
394-02_01-232
 Use the oil dipstick (2) to check the engine oil 

level after adding oil and top the oil level up to
the "max." level.
2
 Start the engine.
 Check to ensure that no engine oil leaks from
the oil drain plug and the oil filter.
 Allow the engine to warm up to operating tem-
perature.
x
 Stop the engine and wait 10 minutes. ma
min
NOTE
The Check engine oil level error light

on the display unit must go out. See the section
"Checking the display". 394-02_01-233
 Check the oil level.

The oil level must be between "min." and "max."
with a tendency toward the "max." level.
 Top up to "max." with engine oil as necessa-
ry.
 Refit the cover of oil filling opening and allow
it to engage.

02 Service
Servicing work
Checking the display
 Check the display unit (7a). 
The Check engine oil level (8a) error

light on the display unit must go out. The oil level
is indicated reliably in the display unit approx.
10 minutes after the oil is added. 7a
8a
EFF
Display_d0024
Checking the condition of the V-ribbed

belt
WARNING
Rotating parts!
Switch off the engine and remove the
switch key.
NOTE
If the V-ribbed belt is defective or excessively

loose, it will affect the on-board power supply.
WARNING
ponents.
WARNING
 Remove the maintenance cover on the right-

hand side.

Service 02
Servicing work
 Check the V-ribbed belt (1) for excessive 
1
wear, frayed edges, cracks across the belt
and traces of oil.
 Replace the V-ribbed belt if it is damaged.
CAUTION
A special tool and specialist knowledge is required for
this work.
 Refit the side maintenance cover.

 Close the bonnet.
d3941504a
Replacing the V-ribbed belt

Removal 

hand side.
 Position the hexagon wrench on the hexagon
of the belt tensioner (3).
 Turn the belt tensioner (3) anticlockwise and
hold.
The tension of the V-ribbed belt (1) is released.
 Insert a suitable mandril into the latch
holes (2) of the belt tensioner.
The belt tensioner (1) remains in the mounting
position.
 Remove the V-ribbed belt (1).
 Remove the hexagon wrench.
Installation
NOTE
Installation is performed in the reverse se-

quence.
● The belt tensioner works automatically. It re-
quires no adjustment.
 When installing the V-ribbed belt, note the di-
rection of travel.
 Check that the belt is correctly guided into the
belt pulleys.

02 Service
Servicing work
Changing the belt tensioner for the V-
ribbed belt
Removal 
 Remove the V-ribbed belt, see "Replacing the

V-ribbed belt".
 Remove the screw (2).
 Remove the belt tensioner (1).
Installation
NOTE
Installation is carried out in the reverse se-

quence.
The belt tensioner operates automatically. It
does not require setting or adjustment.
Checking the coolant level 
ENVIRONMENT NOTE
Observe information regarding the use of con- 1

sumables.
NOTE 10:30
03.03.2015
If the display (1) in the indicator unit illuminates,
1045,0 h
the coolant level is too low and the coolant must
be topped up. For more information see the sec- EFF
tion entitled "Malfunction displays".
NOTE
Display_0047
The coolant level can also be checked at the ex-
pansion reservoir (3), without having to refer to
the (1) display.
CAUTION
Only use an approved coolant.
Observe the recommendations for consumables.
WARNING
ponents.

Service 02
Servicing work
WARNING
The coolant level must not fall below marking (4)

on expansion reservoir (3).

 If necessary, top up the coolant. To do this,
twist and remove the filler cap (2).
WARNING
The expansion reservoir is pressurised.
Risk of scalding due to hot coolant.
Unscrew the filler cap (2) slowly, and on-
ly if the expansion reservoir is not hot.
 Fit the filler cap and turn to tighten.

Cleaning the radiator and checking the

radiator for leak tightness
NOTE
Only clean the radiator once the engine has

been switched off and allowed to cool.
WARNING
ponents.
WARNING

02 Service
Servicing work
Cleaning the radiator
Cleaning with compressed air 
 Blow out the radiator(1) from the engine side

using compressed air.
 Rinse out the released dirt using a water jet.
Cleaning with cleaner solvent
CAUTION
Humidity must not penetrate the three-phase alterna-
tor.
Therefore, protect it from direct contact with the water
jet.
 Spray the radiator(1) with a conventional

cleaner solvent and leave it to work for ap-
prox. 10 minutes.
 Spray the radiator from the engine side with a
direct water jet until it is clean.
 Warm up the engine.
This evaporates the water residue to prevent the
formation of rust.
Checking the radiator for leak tightness

 Check the connection screw joints, the cool-
ant hoses and the pipe lines on the radiator
for leak tightness.
 Replace porous hoses and re-tighten hose
clips.
Changing the coolant

WARNING
Risk of scalding due to hot coolant!
Allow the engine to cool down before draining the
coolant.
ENVIRONMENT NOTE

consumables.
Draining the coolant

 Open the expansion reservoir.

Service 02
Servicing work
 Remove the screw (1). 
The coolant will drain out.

 Catch the coolant in a suitable container.
 Insert screw (1) and tighten to 3 Nm.
1
 Dispose of the coolant in an environmentally
friendly manner.
394-02_01-222
Topping up the coolant

 Pour new coolant into the expansion reservoir 
using frost protection effective down to −25 C
in accordance with the recommendation for
consumables.
The coolant level must be between "min." (2)
and "max." (1) in the expansion reservoir.
Difference in quantity between "min." and
"max.": approx. 0.75 l
 Close the expansion reservoir.
 Allow the engine to warm up to operating tem-
perature.
 If the coolant level drops below "min.", top up
the coolant to the "max." level.
 Turn off the engine and let it cool down.
 Add more coolant as required.
 Check the coolant level again after approx. 8
operating hours.
 Add more coolant as required.
Draining water from the fuel filter
ENVIRONMENT NOTE

consumables.
 Remove the left-hand side maintenance cov-
er.

02 Service
Servicing work
 Open the drainage screw (1) on the fuel filter 
and drain approx. 100 cm3 into a container
until clean fuel emerges.
ENVIRONMENT NOTE
Dispose of the liquid in an environmentally

friendly manner.
 Tighten the drainage screw again.
d3941503a
Changing the fuel filter
ENVIRONMENT NOTE

consumables.
 Remove the maintenance cover on the left-
hand side.
 Place a suitable container under the fuel fil- 
ter (1).
 Disconnect the electrical connection assem-
bly on the water trap switch (0B36).
 Loosen the fuel filter(1) by turning it anticlock-
wise and remove it.
 Use a filter wrench, if necessary.
 Remove the fuel filter (1) and empty it into the
container.
NOTE
Fill the new fuel filter with clean diesel fuel. Do

not use the diesel fuel from the old fuel filter.
 Coat the sealing ring of the fuel filter (1) with
engine oil.
NOTE
The tightening torque varies according to the

fuel filter manufacturer.
Observe the following for Doosan fuel filters:
 Tighten the Doosan fuel filter to 16 to 20 Nm.

Service 02
Servicing work
 Tighten the Doosan fuel filter a further three-
quarter turn using a filter wrench.
 Reconnect the electrical connection assembly
on the water trap switch (0B36).
 Bleed the fuel system (see "Bleeding the fuel
system").
 Fit the maintenance cover on the left-hand
side.
Bleeding the fuel system
ENVIRONMENT NOTE

consumables.
CAUTION
Air intake can cause operational faults in the fuel in-
jection system.
Therefore, never empty the fuel tank completely. If the
reserve indicator illuminates, top up with fuel.
NOTE
If the fuel tank is inadvertently emptied, the fuel

system must be bled manually.
The pump (1) for bleeding the fuel system is lo- 
cated on the fuel filter at the left-hand side of the
engine compartment.
 Open the bonnet. 1
WARNING
ponents.
WARNING
d3941516
 Actuate the pump piston until you feel great

resistance and it is only possible to pump
slowly.
 Actuate the pump another few times until the
fuel line is filled.

02 Service
Servicing work
Cleaning the breather hose for the fuel
tank
When operating the truck in dusty and dirty con- 
ditions, the breather hose (1) to the fuel tank can
become blocked. It must therefore be cleaned at
regular intervals, depending on how much it is
used.
 Disconnect the hose (1) from the pipe union
at the fuel signal transmitter and blow dry
compressed air through the hose.
 Slide the hose (1) onto the pipe union as far
as the stop.
1
d3941515
Checking the dust discharge valve on

the air filter
The dust discharge valve (1) is largely mainte- 
nance-free.
WARNING
ponents.
WARNING
1 d3941505a
 Squeeze the valve (1) and remove the dust
residue.
 If the valve is damaged, replace it.

Service 02
Servicing work
Cleaning the dust guard prefilter (spe- 
cial equipment)
NOTE
2
The dust collecting tank (1) must never be more
than half full with dust. If there is a heavy accu-
mulation of dust, the tank must be emptied every
day. 1
 Open the dust collecting tank (1) by turning
the tank to the right and lift it off to remove.
 Remove the cover (2).
 Empty the dust collecting tank (1).
 Fit the cover (2).
d3941511
 Replace the dust collecting tank (1) and se-
cure by turning to the left.
Checking the dust discharge valve on

the multi-cyclone air filter (special equip-
ment)
nance-free.
residue.
1
d3941512
Changing the air filter cartridge
NOTE
The air filter cartridge must not be cleaned. If the

air filter vacuum indicator in the display unit
lights up, replace the air filter cartridge.

02 Service
Servicing work
 Open the fastener (1). 
 Turn the air filter cover(2) in an anti-clockwise

direction until the air filter cover(2) is un-
locked.
 Remove the air filter cover (2).
 Remove the air filter cartridge (3). 
CAUTION
Thoroughly clean the inside of the air filter housing.
Do not blow it out with compressed air.
Wipe the housing clean with a clean cloth.
 Insert the new air filter cartridge (3) into the

housing.
Make sure during installation that the air filter
cartridge (3) is not damaged and that the seal is
correctly seated on the filter housing.
 Place the air filter cover (2) on the housing.
 Turn the air filter cover (2) clockwise until the
air filter cover (2) snaps into place.
 Close the fastener (1).

Service 02
Servicing work
Changing the safety cartridge 
NOTE
Check the adhesive label (1) on the air filter cov-

er (2). This indicates whether a safety cartridge
is installed in the air filter.
Replace the safety cartridge:
● After 1000 h/12 months operating time
● If the air filter vacuum display lights up again
immediately after maintenance of the air filter

cartridge
● If the filter cartridge is faulty
CAUTION
Safety cartridges must not be cleaned or reused. Start
the engine only when an air filter cartridge is installed.
The function of the safety cartridge is to prevent the
ingress of dust while the main cartridge is being re-
placed or if a damaged main cartridge is accidentally
used.
 Remove the air filter cover, see "Changing the

air filter cartridge".
 Remove the air filter cartridge (3). 

02 Service
Servicing work
 Remove the safety cartridge (4). 
 Insert the new safety cartridge (4).

 Insert the air filter cartridge.
 Place the air filter cover on the housing.
 Install the air filter cover, see "Changing the
air filter cartridge".
mounting
 Open the bonnet. The elastic bearings used for the engine sus-
pension are subjected to high loads. The service
WARNING life of these bearings is limited depending on the
application conditions.
ponents.  Check the rubber elements for cracks and se-
Wear protective equipment. vere deformation; replace them if necessary.
 Visual inspection: Check all nuts and bolts in
WARNING the engine support and engine mounts for
damage. Check that they are securely attach-
When the engine is hot, the fan may ed.
Checking the intake lines and exhaust lines for leak tightness
 Open the bonnet  Check the condition of the intake air hoses on
the air filter and check the intake air hoses for
WARNING leak tightness.
Beware of hot engine and exhaust com- If you discover leaks, re-tighten the hose clips or
ponents. change the porous pipes.
Wear protective equipment.  Check the inlet manifold and the exhaust
manifold on the cylinder head for leak tight-
WARNING ness.
If you discover leaks, re-tighten the mounting
start automatically. screws or change the seals.
Do not touch rotating parts.  Check the exhaust line connection on the
manifold for leak tightness. If necessary, re-
tighten the mounting screws or change the
seal.

Service 02
Servicing work
 Close the bonnet weight. If necessary, re-tighten the mounting
screws.
 Remove the cover on the counterweight.
 Refit the cover on the counterweight.
 Check the mounting, connections and leak
tightness of the exhaust line in the counter-

02 Service
Servicing work
CWTA LPG engine (from H2X394G00038)
Changing the engine oil and replacing the engine oil filter
(after 12 months at the latest)
WARNING
Risk of scalding from hot engine oil!
CAUTION
Different oil grades result in different maintenance in-
tervals.
Recommendations for consumables must be ob-
served.
ENVIRONMENT NOTE
Observe information regarding the use of con-

sumables.
 Drive the truck over the pit.
 Switch off the engine.
 Close the gas shut-off valve.
 Place a collection container under the truck
chassis.
WARNING
ponents.
WARNING

Service 02
Servicing work
Replacing the engine oil filter
 Place a collection container under the oil filter 
(3).
 Use a 6 AF hexagon socket wrench to loosen
the oil drain plug (8) and unscrew.
 Allow oil to drain from the oil filter.
 Use a 36 AF open-ended spanner to loosen
the bottom part of the oil filter (6) and un- 4
screw.
5
 Pull out the filter insert (4) from the top part of
the oil filter and dispose of it in an environ- 6
mentally friendly manner.
7
 Place a new filter insert over the pipe union 8
on the top part of the oil filter.
 Fit the bottom part of the oil filter (6) with a 3 t3941432
t3941349a
new sealing ring (5).
Tightening torque: 25 Nm
 Fit the oil drain plug (8) with a new sealing
ring (7).
Changing the engine oil
NOTE
Change the engine oil only when the engine is at

operating temperature.
Draining the engine oil 
1 2
 Remove the filler cap (1) from the filling open-
ing.
 Remove the cover on the frame floor.
t3941430

02 Service
Servicing work
 Oil pan, variant 1: From below, unscrew the 
engine-oil drain plug (9) from the oil pan.
 Allow all of the oil to drain off into the collec-
tion container.
 Fit the drain plug (9) with a new sealing ring.
Tightening torque for M14x1.5: 30 Nm
 Fit the cover on the frame floor.
9 t3941433
 Oil pan, variant 2: From below, unscrew the 

engine-oil drain plug (9a) from the oil pan.
 Allow all of the oil to drain off into the collec-
tion container.
 Fit the drain plug (9a) with a new sealing ring.
Tightening torque for M10x1: 14±2 Nm
 Fit the cover on the frame floor.
9a t3941439
Topping up the engine oil 

1 2
 Pour new engine oil into the filling opening in
accordance with the recommendations for
consumables.
Oil pan, variant 1: Filling quantity with filter
change: max. 5.5 l
Oil pan, variant 2: Filling quantity with filter
change: max. 6.8 l
 Using the dipstick (2), check the engine oil
level after adding oil and top up to the max.
mark.
 Fit the filler cap (1) and turn to tighten.
t3941430

Service 02
Servicing work
NOTE
After performing an oil change and a filter

change, carry out an engine test run, checking
the hydraulic pressure display and the leak
tightness of the oil drain plug and oil filter. For an
accurate oil level check (particularly after per-
forming an oil filter change), the engine must be
switched off again and the oil level check carried
out after approx. one minute.
 Check display unit (10) variant 1. 
The Oil display element (11) in the display unit

must go out. The oil level is indicated reliably in
the display unit approx. 10 minutes after the oil
is added.
 Check display unit (10a) variant 2. 
The message "Check the engine oil level" (11a)

in the display unit must go out. The oil level is in-
dicated reliably in the display unit approx. 10 mi-
nutes after the oil is added. 10a
11a
EFF
Display_t0011

02 Service
Servicing work
Replacing the spark plugs
Special tools required 
● Installation tool VWT10118

● Spark plug wrench VW3122B
● Extractor VWT10095A
● Torque wrench 5 - 50 Nm
Removing the spark plugs

 Thoroughly clean the area around the spark
plugs on the cylinder head.
CAUTION
Do not start the engine; the ignition system will be
faulty.
Do not attempt to start the engine without the spark
plugs fitted.
 Place installation tool VWT10118 on the plug

interlocks and carefully pull the connector
plugs off ignition coils 1 to 6 in a downwards
direction.
 Slide on extractor VWT10095 A from the 
straight side of the plug in the direction of the
arrow and pull out ignition coils 1 to 6 together
with the power output stages.
 Use spark plug wrench VW3122B to unscrew
the spark plugs.
Installing the spark plugs

 Check the electrode gap in the new spark
plugs using a feeler gauge.
Setpoint value: 0.8 mm
 Screw in the spark plugs using spark plug
wrench VW3122B and tighten to a tightening
torque of 20 Nm.
 Fit the ignition coils together with power out-
put stage.
Replacing the gas filter

 Close the shut-off valve on the gas cylinder or
gas tank.
 Let the engine run until the gas in the system
has been used up.

Service 02
Servicing work
WARNING
ponents.
WARNING
 Undo the screw (1) and remove it together 

1
with the filter housing (2).
 Remove the filter.
 Clean the housing.
 Insert a new filter and fit the housing.
 Perform a leak test.
2
t3941434
Replacing the C-Series evaporator (can-

not be dismantled)
Replacing the non-regulated evaporator
NOTE
The evaporator cannot be opened or repaired. In

the event of defects, the evaporator must be re-
placed.
gas tank.
has been used up.
WARNING
Beware of hot engine parts and exhaust air compo-
nents.

02 Service
Servicing work
WARNING
When the engine is hot, the fan may start automatical-
ly.

 Disconnect plug 1Y6 (1) from the shut-off
valve and set aside the plug.
 Loosen the pipe (5) from the shut-off valve.
WARNING
If the expansion reservoir is opened, hot steam or hot
coolant can leak out. Risk of scalding!
Cover the filler cap with a cloth. Carefully open the fill-
er cap.
 Open the filler cap (2) of the coolant expan-

sion reservoir.
 Seal the coolant hoses using pinch-off pliers.
 Remove the screw on the safety clip (3). Re-
move the safety clip.
 Disconnect the coolant line (top) and gas pipe
(bottom) from the evaporator and set aside
both components.

 Remove the safety clip (7). Disconnect the
outbound compensation line from the evapo-
rator and set aside the compensation line.

 Loosen the screws (4) on the sheet metal
holder. Pull the evaporator in the drive direc-
tion.

Service 02
Servicing work

 Disconnect the coolant line from the evapora-
tor and set aside the coolant line.
 Remove the evaporator from the truck.

 Remove the banjo bolt on the shut-off valve
(6). Remove the shut-off valve from the evap-
orator.
 Replace the evaporator.
quence.
Tightening torques:
● Banjo bolt on the gas shut-off valve (6):
25 Nm
● Screws on the sheet metal holder (4): 10 Nm
● Screws on the safety clip (3, 8): 3.5 to 4 Nm
 Replace all O-rings on the pipe unions. 
Pipe unions for conveying coolant: blue O-rings

Pipe unions for conveying LPG: black O-rings

02 Service
Servicing work
IMPCO decal information 

 Note the number label on the safety clips.
 Assemble all connections and components.
 Top up the coolant if necessary.
For instructions on how to top up the coolant, re-
fer to the chapter entitled "Draining and filling
the coolant".
Replacing the regulated evaporator
NOTE

placed.
gas tank.
has been used up.
WARNING
nents.
WARNING
ly.

Service 02
Servicing work

WARNING
er cap.

sion reservoir.
both components.

outbound control line from the evaporator and
set aside the control line.

 Remove the screws (4) on the sheet metal
holder.
 Lay aside the holder (9) with the closed-loop
control valve.
 Pull the evaporator in the drive direction.

02 Service
Servicing work


orator.
quence.
Tightening torques:
25 Nm

NOTE
All O-rings on the hose clips must be replaced.

the coolant".

Service 02
Servicing work
Mixture setting and CO testing
NOTE
For more information on mixture setting and CO

testing of the LPG engines, refer to chapter 12
"LPG system with lambda control system".
Checking the LPG system for damage

and leak tightness
NOTE
Check the LPG system for leak tightness at least

once a year. Observe the applicable national
regulations.
Checking the LPG cylinder: 
 Open the shut-off valve on the LPG cylinder.

 Check the LPG cylinder shut-off valve, hose
screw joints and hoses for leak tightness and
damage.
 Check the cylinder selector valve for leak
tightness.
 Check the high-pressure relief valve for leak
tightness.
Also check the second LPG cylinder.
Checking the LPG tank: (special equipment) 
 Open the shut-off valve on the LPG tank.

 Check the shut-off valve on the LPG tank,
hose screw joints and hoses, level display
and filling valve for leak tightness and dam-
age.
 Check the cylinder selector valve (if present)
for leak tightness.
 Check the high-pressure relief valve for leak
tightness.
Also check the second LPG tank (if present).
Checking the engine compartment:
WARNING
ponents.

02 Service
Servicing work
WARNING
 Check the hose and line screw joints, gas fil- 

ter with shut-off valve, evaporator pressure
regulator and gas mixer using a gas detector.
Apply leak spray and see whether any bub-
bles form.
NOTE
Icing and yellow foam deposits on the LPG sys-

tem indicate the presence of leaks.
 Re-tighten leaking screw joints, replace dam-
aged hoses and check for leak tightness
again.
 Eliminate any leaks at the gas filter, evapora-
tor pressure regulator, shut-off valve and gas
mixer. t3941435
mounting
 Open the bonnet. The elastic bearings used for the engine sus-
pension are subjected to high loads. The service
WARNING life of these bearings is limited depending on the
application conditions.
ponents.  Check the rubber elements for cracks and se-
Wear protective equipment. vere deformation; replace them if necessary.
 Visual inspection: Check all nuts and bolts in
WARNING the engine support and engine mounts for
damage. Check that they are securely attach-
When the engine is hot, the fan may ed.
Replacing the pressure hoses in the gas

system
DANGER
The pressure hoses in the gas system age and be-
come brittle.
Replace the hoses in the gas system every 3000 op-
erating hours or every three years.

Service 02
Servicing work
NOTE
All hoses located between the LPG cylinder or

gas tank and the pipe line must be replaced.
Changing the cooling fluid

The cooling system must be filled throughout the
year with a mixture of water and phosphate-free,
glycol-based coolant additive with anti-corrosion
additives to prevent lime scale deposit and dam-
age caused by frost and corrosion, and to raise
the boiling temperature.
WARNING
Never open the filler cap when the en-
gine is hot. Risk of scalding!
Wait until the cooling fluid has cooled
down.
ENVIRONMENT NOTE

sumables.
WARNING
ponents.
WARNING
 Unscrew and remove the filler cap (1).

02 Service
Servicing work
 Place a collection container under the cooling 
fluid hose (5).
 Release the spring band clamp (4).
 Disconnect the cooling fluid hose.
 Drain off all of the cooling fluid.
 Reattach the cooling fluid hose and secure it
using a spring band clamp.
 Dispose of cooling fluid in an environmentally 5
friendly manner.
t3941436
 Add new cooling fluid to the expansion reser- 

voir (2).
The cooling fluid level must be between the min.
and max. marks (3) on the expansion reservoir.
Difference in quantity between min. and max.:
approx. 0.75 l
Filling quantity in the cooling system:
● Without heating system: approx. 10.5 l
● With heating system: approx. 12.0 l
Frost protection should be sufficient for tempera-

tures down to -25°C. For such temperatures, the
mixture ratio required is 40% coolant additive
and 60% drinking water.
Mixture ratio for lower temperatures:
Coolant addi-
tive
-30°C 45% 55 %
-35°C 50 % 50 %
-40°C 60 % 40 %

 Let the engine run.

Service 02
Servicing work
 Loosen the screw (6) on the evaporator until 
the water running out is bubble-free and the
system has been bled.
 Tighten the screw again.
 Check the coolant level.
NOTE
For versions with a heating system, the following

is also required:
6
t3941437
 Remove the filler cap (7) on the right next to 

the wheel arch.
 Use an 8 AF open-ended spanner to loosen
the pipe union (8) through the bore until the
water running out is bubble-free.
 Tighten the pipe union (8).
 Fit the filler cap (7).
Draining and topping up the coolant

Special tools, testing instruments, measur- 
ing devices and other devices required
● Refractometer VWT10007A
● Collection vessel
● Hose clip pliers VWVAS6340

02 Service
Servicing work
Coolant vacuum filler 0009418838 
Container 0009418841 
Draining the coolant - preparations

WARNING
ponents.
WARNING
WARNING
If the expansion reservoir is opened, hot
steam or hot coolant can leak out. Risk
of scalding!
Wait until the coolant has cooled down.
Cover the filler cap with a cloth. Carefully
open the filler cap.

Service 02
Servicing work
 Open the filler cap (1) on the coolant expan- 
sion reservoir (2).

02 Service
Servicing work
 Place a collection container below the coolant

hose (5).
 Loosen the hose clip (4).
 Pull out the coolant hose.
 Allow the residual coolant to drain.
 Reattach the coolant hose and secure it using
a hose clip.
ENVIRONMENT NOTE

consumables.

Service 02
Servicing work
Radiator vacuum filler
The radiator vacuum filler is used to check the
cooling system for leak tightness after a repair
and then to refill it without any bubbles. To con-
nect the radiator vacuum filler to the expansion
reservoir on the cooling system, additional adap-
tors with a coupling nipple may be necessary.
These adaptors are included in the kit
0009418838, but can also be ordered separate-
ly.
Requirements:
● The coolant expansion reservoir must be
emptied
● The container must contain one to two litres
of coolant more than the volume of the cool-

ing system to be filled
● The container on the radiator vacuum filler
must be at the same height as the coolant ex-

pansion reservoir
● The compressed air connection must be be-
tween 6 and 10 bar

● Set the heating control (if present on the
truck) to the "Hot" position, and switch the ig-

nition on if necessary (do not start the engine)
Evacuation, leak test and filling of the cool-

ant system
1. Preparations 
 Place the adaptor (6) on the opening on the

coolant expansion reservoir (2).
 Close shut-off cock V1 and V2. 

02 Service
Servicing work
 Connect the compressed air. The hissing 
noise is normal and is caused by the Venturi
nozzle.
 Bleed the filling hose (7): open shut-off cock 

V2. Dip the filling hose (7) into the coolant to
be added and secure it against slipping.
 Open shut-off cock V1; the filling hose (7) fills 

up with coolant. Only when the filling hose (7)
is free of bubbles, close V1. Excess coolant is
expelled via the hose (8).
2. Evacuating the coolant system 
 Create a vacuum for approx. two minutes.

Shut-off cock V2 is still open.
NOTE
The vacuum in the cooling system will lead to

deformation of the associated hoses.
At a value of between -0.85 and -0.95 bar, the
desired vacuum is reached: the green zone on
the display of the vacuum meter (9).
 Close shut-off cock V2.
 Uncouple the compressed air from the Venturi 
nozzle (10).

Service 02
Servicing work
3. Leak test 
The cooling system remains in a vacuum for one

minute. If the vacuum reduces, this indicates a
leak in the cooling system.
 Monitor the display of the vacuum meter.
If the vacuum remains constant, filling can be-
gin.
4. Filling the coolant system
CAUTION
An insufficient filling quantity can introduce air into the
coolant system.
The supply of coolant to be added must be one to two
litres more than the required coolant volume.
The best filling result can be achieved if the con-

tainer containing the coolant to be added is at
the same height as the expansion reservoir in
the truck.
 Open shut-off cock V1. Coolant flows into the 
cooling system.
 Check the fill level or fill the expansion reser- 

voir to the max. mark.
If there is still a residual vacuum in the cooling
system after filling, the residual vacuum can be
dissipated by opening shut-off cock V2.

02 Service
Servicing work
 Remove the adaptor (6) from the opening on 
the coolant expansion reservoir (2). Seal the
coolant expansion reservoir.
 If it is also necessary to bleed the secondary
cooling circuit, start the engine.
 Compensate for any lowering of the coolant
level in the expansion reservoir by filling with
coolant manually.
Checking the coolant concentration

The cooling system must be filled throughout the
year with a mixture of water and phosphate-free,
glycol-based coolant additive with anti-corrosion
additives to prevent lime scale deposit and dam-
age caused by frost and corrosion, and to raise
the boiling temperature.
WARNING
Never open the filler cap when the en-
gine is hot. Risk of scalding!
Wait until the cooling fluid has cooled
down.
ENVIRONMENT NOTE

sumables.
WARNING
ponents.
WARNING
 Unscrew and remove the filler cap (1).

Service 02
Servicing work
 Check the coolant concentration in the expan- 
sion reservoir (2).
Frost protection should be sufficient for tempera-
tures down to -25°C. For such temperatures, the
mixture ratio required is 40% coolant additive
and 60% drinking water.
Mixture ratio for lower temperatures:
Coolant addi-
tive
-30 °C 45% 55 %
-35 °C 50 % 50 %
-40 °C 60 % 40 %
If the coolant additive level is too low:
 Place a collection container under the cooling 

fluid hose (5).
 Release the spring band clamp (4).
 Disconnect the cooling fluid hose and drain
some cooling fluid from the system.
 Reattach the cooling fluid hose and secure it
using a spring band clamp.
 Dispose of drained cooling fluid in an environ-
mentally friendly manner. 5
t3941436
 Fill the expansion reservoir (2) with coolant 

additive until the correct mixture ratio is
reached.
The cooling fluid level must be between the min.
and max. marks (3) on the expansion reservoir.
 Run the engine until the cooling system has
been bled.
 Check the coolant level.

02 Service
Servicing work
Cleaning the radiator and checking the
radiator for leak tightness
NOTE
Only clean the radiator once the engine has

been switched off and allowed to cool.
WARNING
ponents.
WARNING
Cleaning the radiator

Cleaning with compressed air 
 Blow out the radiator(1) from the engine side

using compressed air.
 Rinse out the released dirt using a water jet.
Cleaning with cleaner solvent
CAUTION
Humidity must not penetrate the three-phase alterna-
tor.
Therefore, protect it from direct contact with the water
jet.
 Spray the radiator(1) with a conventional

cleaner solvent and leave it to work for ap-
prox. 10 minutes.
 Spray the radiator from the engine side with a
direct water jet until it is clean.
 Warm up the engine.
This evaporates the water residue to prevent the
formation of rust.
Checking the radiator for leak tightness

 Check the connection screw joints, the cool-
ant hoses and the pipe lines on the radiator
for leak tightness.
 Replace porous hoses and re-tighten hose
clips.

Service 02
Servicing work
Checking the condition of the V-ribbed
belt
WARNING
Rotating parts!
Switch off the engine and remove the
switch key.
NOTE
If the V-ribbed belt is defective or excessively

loose, it will affect the on-board power supply.
WARNING
ponents.
WARNING

hand side.
 Check the V-ribbed belt (1) for excessive 
wear, frayed edges, cracks across the belt 1
and traces of oil.
 Replace the V-ribbed belt if it is damaged.
t3941431

02 Service
Servicing work
Removing and installing the V-ribbed
belt
Special tools and devices required
● VWT10060A locking pin 
Removing the V-ribbed belt without the air-conditioning compressor
1 Tensioning pulley 4 Crankshaft

2 Three-phase generator 5 Coolant pump
3 V-ribbed belt

Service 02
Servicing work
 Mark the direction of travel of the V-ribbed
belt.

 Place the spanner on the screw of the ten-
sioning pulley (1) and press downwards in the
direction of the arrow until the bores (2) on
the housing align with the tensioning pulley.
Then insert the VWT10060A locking pin into
the bores (2).
 Remove the V-ribbed belt.
Installing the V-ribbed belt without the air-

conditioning compressor
 Check that the guide pulleys run freely.
NOTE
● Before installing the V-ribbed belt, check that
all units (three-phase generator, coolant
pump) are securely mounted.
● Do not bend the V-ribbed belt.
● During the installation process, note the direc-
tion of travel.

 Position the V-ribbed belt as shown.
belt pulleys.
sioning pulley (1) and press downwards
slightly in the direction of the arrow to release
the VWT10060A locking pin from the bores
(2) on the tensioning pulley. Remove the
VWT10060A locking pin.
 Start the engine and check that the belt runs
correctly.

02 Service
Servicing work
Removing the V-ribbed belt with the air-conditioning compressor
1 Tensioning pulley 4 V-ribbed belt

2 Three-phase generator 5 Crankshaft
3 Air-conditioning compressor (special equip- 6 Coolant pump
ment)

belt.

 Place the spanner (1) on the screw of the ten-
sioning pulley and rotate the screw in the di-
rection of the arrow until the VWT10060A
locking pin can be inserted in the tensioning
pulley.
Installing the V-ribbed belt with the air-con-

ditioning compressor

Service 02
Servicing work
NOTE
tion of travel.

belt pulleys.
 Using the spanner (1), lightly push the ten-
sioning pulley in the direction of the arrow to
release the VWT10060A locking pin in the
tensioning pulley. Remove the VWT10060A
locking pin.
correctly.
Removing and installing the coolant

pump
Special tools, testing instruments, measur-
● Refractometer VWT10007 
● VWVAS6340 hose clip pliers
● Torque wrench
● Mandril
Removing the coolant pump
WARNING
er cap.
 Drain the coolant.


02 Service
Servicing work
 Remove the belt pulley for the coolant pump.
To do this, hold the belt pulley in place using
a mandril (commercially available).

 Unscrew the screws (1) for the coolant pump.
Remove the coolant pump (2).
Installing the coolant pump

quence. Please note the following:
 Wet the new O-ring with coolant.
 Insert the coolant pump.
 Tighten the screws for the coolant pump to
8 Nm.
 Install the belt pulley for the coolant pump and
tighten the belt pulley to 20 Nm.
 Fit the V-ribbed belt.
 Add coolant.
the coolant".
Changing the air filter cartridge

(After 1000 operating hours at the latest)
NOTE
The air filter cartridge (1) must not be cleaned.

The air filter cartridge must be replaced when
the vacuum display lights up in the display unit.
 Open the bonnet
WARNING
ponents.
WARNING

Service 02
Servicing work
 Open fasteners (2) and remove air filter cover 
(3).
 Pull out the air filter cartridge (1). 
CAUTION
Clean the inside of the air filter housing thoroughly.
Do not blow it out with compressed air.
Wipe the housing clean with a clean cloth.
 Insert the new air filter cartridge back into the

housing.
When installing, ensure that the air filter car-
tridge is not damaged and that the seal on the
filter housing is securely in place.
 Fit the air filter cover.
 Close the bonnet
Replacing the safety cartridge in the air

filter
NOTE
Note the adhesive label on the housing of the air

filter. The adhesive label indicates whether a
safety cartridge is installed in the air filter.
Replace the safety cartridge:
● After an operating time of three years at the
latest.
● If the air filter vacuum display lights up again
immediately after the filter cartridge has been

serviced.
● If the filter cartridge is faulty.

02 Service
Servicing work
CAUTION
Safety cartridges must not be cleaned or reused. Do
not start the engine without an air filter cartridge.
The function of the safety cartridge is to prevent dust
penetration while the main cartridge is being changed
or if a damaged main cartridge is accidentally used.

 Open the bonnet
WARNING
ponents.
WARNING
 Take off the air filter cover and remove the fil- 
ter cartridge (1).

Service 02
Servicing work
 Pull out the safety cartridge (2). 
 Insert the new safety cartridge.

 Install the filter cartridge and attach the air fil-
ter cover.
Check the dust discharge valve

nance-free.
 Open the bonnet
WARNING
ponents.
WARNING

residue.
Cleaning the oil bath air filter and

changing the oil
Cleaning the oil bath air filter
ENVIRONMENT NOTE

sumables.
 Switch off the engine

02 Service
Servicing work
 Open fasteners (4) on oil tank (3) 
 Move the oil tank downwards to remove, then

empty and clean
 Clean and check seals (2) and change if dam-
aged
 Loosen hose clip on air hose at clean air con-
nection (1) and remove hose
 Detach and clean dust collecting tank (8)
 Detach upper part of filter (7) on overhead
guard
 Wash out upper part of filter and filter insert
holding diesel fuel
The filter and steel mesh inserts can be cleaned
using a steam jet.
 Thoroughly dry the cleaned filter
 Fit upper part of filter and secure air hose us-
ing hose clip
 Fit dust collecting tank (8)
Changing the oil

 Fill the oil tank (3) with engine oil as far as
marking (5)
 Fit the oil tank (3) to the upper part of the filter
(7), ensure that it is correctly positioned, and
secure using fasteners (4)
Checking the intake lines and exhaust lines for leak tightness
 Open the bonnet  Check the inlet manifold and the exhaust
manifold on the cylinder head for leak tight-
WARNING ness.
Beware of hot engine and exhaust com- If you discover leaks, re-tighten the mounting
ponents. screws or change the seals.
Wear protective equipment.  Check the exhaust line connection on the
manifold for leak tightness. If necessary, re-
WARNING tighten the mounting screws or change the
seal.
start automatically.  Close the bonnet
Do not touch rotating parts.  Remove the cover on the counterweight.
 Check the mounting, connections and leak
 Check the condition of the intake air hoses on tightness of the exhaust line in the counter-
the air filter and check the intake air hoses for weight. If necessary, re-tighten the mounting
leak tightness. screws.
If you discover leaks, re-tighten the hose clips or  Refit the cover on the counterweight.
change the porous pipes.

Service 02
Servicing work
Wheel change
DANGER The truck may only be jacked up at these lifting
points at the front left or front right, and at the
Risk of tipping. rear centre.
All tyres on any one axle must be of the same dimen-
sions, from the same manufacturer and of the same  Loosen the wheel fastenings on the wheel in
type and profile. question.
 Lift the truck with a hydraulic jack until the
WARNING wheels are off the ground.
Note the tare weight of the truck.  Support securely using hardwood supports on
Only use hydraulic jacks with a load capacity of at
the chassis or counterweight (removing the
least 5000 kg. load from the hydraulic jacks).
 Unscrew the wheel fastenings.
CAUTION  Change the wheel.
Electrostatic charge.  Position the wheel fastenings and tighten
When using non-marking tyres (light-coloured tyres), them manually.
the electrical potential equalisation must be ensured
with an antistatic belt  Lower the truck.
The antistatic belt must always be in contact with the  Tighten the wheel fastenings crosswise.
ground.
Tightening torque:
 Only position the rear hydraulic jack centrally Front 425 Nm
under the counterweight. Rear 640 Nm
 Position the front hydraulic jack on the left or
right edge of the chassis or on the lift mast.
Checking the wheels for damage, for-

eign objects and wear
 Secure the truck against rolling (apply the
parking brake).
 Place a wheel chock under a wheel that will
not be lifted.
 Lift the truck with a hydraulic jack until the
wheels are off the ground.
 Place a hardwood block underneath.
 Check for free movement of the wheels and
remove anything hindering their movement.

02 Service
Servicing work
The upper edge of the 60 Joule indicator (1) is 
the maximum limit for wear and regrooving. The
decision about whether to regroove the tyres
should be based on the application conditions.
A minimum tread depth is not required with solid
rubber tyres.
It must be ensured that the degree of wear on
the tyres on one axle is the same.
 Change worn or damaged tyres.
Lubricating the steering axle
ENVIRONMENT NOTE NOTE
Observe information regarding the use of con- For lubrication, use lubricating grease in accord-
sumables. ance with the recommendation for consumables.
First lubricate the axle stub bearings at the top
and then at the bottom.
NOTE
 Lubricate the tie rod and axle stub with lubri-
It is better to apply a little grease to the bearings cating grease at the lubricating nipples.
frequently than a lot of grease infrequently.  Lubricate using a grease gun until fresh lubri-
If used in areas with constant exposure to dust, cating grease leaks from the bearing points.
dirt water and, if applicable, road salt or chemi-
cals, weekly lubrication will considerably length-
en the service life of the spherical bearings.
Checking the mounting of the steering axle

 Check that the mounting screws on the steer- Tightening torque between steering cylinder and
ing axle are securely attached. steering axle: 295 Nm.
Tightening torque between steering axle and
counterweight: 195 Nm.
Checking the condition of the antistatic belt

DANGER Under certain circumstances, the truck may be-
come electrostatically charged. To avoid electro-
Risk of fire and explosion possible with electrostatic static charging, an antistatic belt made from con-
discharging.
ductive plastic must be fitted on the frame floor.
Non-marking tyres are not electrically conductive and
must always be earthed with an antistatic belt.
The antistatic belt must always be in contact with the
ground.

Service 02
Servicing work
Information on electrostatic charging: ● If non-marking tyres (light-coloured tyres) are
● The charge level depends on a number of used and the truck is driven in an area with a
factors, such as the type of tyre, air humidity, sealed floor, this electrostatic charging effect
floor covering etc. will frequently occur
● Excessive electrostatic charging is noticeable
● Non-marking tyres are identified by the safety
when the electrostatic charge is discharged to information on the tyre wall.
the ground via the body of a person who  Check that the antistatic belt is securely seat-
touches the truck (electric shock) or when a ed on the frame floor, check the condition and
spark passes from the truck to an earthed check for wear.
part (e.g. a metal shelf)
● With standard types of tyre (black pneumatic  Change the antistatic belt if it is damaged.
or solid rubber tyres), the high graphite con-
tent means that electrostatic charging is rela-
tively rare

02 Service
Servicing work
Checking the axle clamp mounting
 Check each of the 2 mounting screws (M20) 
(1) on the left-hand and right-hand axle
clamps to ensure they are secure.
Tightening torque: 540 Nm.
Checking the mounting of the wheel mo-

tors
 Remove the drive wheels.
 Check the mounting screws (M16) (1) on the 
left-hand and right-hand wheel motors to en-
sure they are secure.
Fit the drive wheels.

Service 02
Servicing work
Checking and adjusting the side stops
on the drive axle
 Check the air gap between the stop (1) and 
chassis (2).
The air gap should not be larger than 1 mm.
Check the air gap on both the left and right of
the axle.
If the air gap is larger, adjust the stop.
 Loosen the hexagon nut (4).
 Adjust the stop with the hexagonal nut (3) un-
til the air gap is 1 mm.
When it is no longer possible to adjust the air
gap, the axle spring element is worn. The spring
element must be replaced.
 Tighten the hexagon nut (4).
Checking the drive axle bearings for

wear
NOTE
The drive axle is supported on both sides of the

chassis by rubber spring elements.
 Remove the drive wheels.
 Using a lamp, check the condition of the rub- 
ber spring elements (1) between the axle,
chassis and plastic stops.
The rubber spring elements must be checked on
both the left and right of the axle. If the axle
spring elements or the plastic stops are worn,
the parts must be replaced.
 Fit the drive wheels.
Checking the mounting of the hydraulic

pump on the engine

02 Service
Servicing work
WARNING
ponents.
WARNING
 Visually inspect the hexagon head screws to

check that they are securely fitted and check
for damage.

Service 02
Servicing work
Checking the parking brake for correct
function
 Drive the truck with maximum load up a gradi-
ent of 15%.
 Place the parking brake lever (2) in a horizon- 
tal position.
The vehicle must remain stationary.
1
 Press the button (1) and release the parking
brake lever (2).
 Move the parking brake downwards by 90°. 2
The vehicle must remain stationary.
d3911394

Checking the mounting of the chassis
WARNING
ponents.
WARNING
 Visually inspect the mounting screws for the

chassis to ensure that it is securely fitted and
check for damage.
Checking and lubricating the bearing

points and joints
ENVIRONMENT NOTE
Observe information regarding working with con-

sumables.

02 Service
Servicing work
 Check and lubricate the following bearings
and mountings:
● Driver's seat guide
● Bearing bolts for the bonnet
● Windscreen wiper bearings (special equip-
ment)
● Door locks and hinges on the weather protec-
tion cab (special equipment)
● Bonnet lock
Checking the seat belt for condition and function
DANGER
Risk of accident or danger to life if the restraint sys-
tem is faulty
Do not operate the industrial truck if the restraint sys-
tem is faulty.
NOTE
For safety reasons, check the condition and

function of the restraint system on a regular ba-
sis (once a month).
Screw connections must be checked on a regu-
lar basis to make sure that they are secure.
The seat belt must be replaced after an acci-
dent.
The driver's seat and the driver's seat mounting
must also be checked after an accident.
 Pull belt (1) completely out and check for fray- 
ing and torn stitching.
 Check that the buckle (3) functions correctly
and that the belt retracts properly.
 Check the covers and fixing points for dam-
age.
Test the automatic blocking mechanism.
 Park the truck on level ground.
 Pull out the belt with a jerk.
The automatic mechanism must block the belt
from being extended from the belt retractor (2).
 Push the driver's seat all the way forwards.
 Fold the seat backrest all the way forwards.
NOTE
When opening the bonnet, remember that the

rear window may have been installed.

Service 02
Servicing work
 Open the bonnet with driver's seat (4) by ap- 
prox. 30°.
WARNING
ponents.
WARNING
The automatic mechanism must block the belt

from being extended from the belt retractor (2).
Checking the pedal group
ENVIRONMENT NOTE

sumables.
 Lift up the bottom plate and secure in place. 
 Unscrew the 4 nuts on the pedal box.

 Check the pedals for ease of movement.
 If necessary, grease the bearings slightly.
 Refit the pedal box.
d3921378

02 Service
Servicing work
Checking the swivel bearing of the tilt
angle sensor
 Remove the panelling from the tilt angle sen-
sor.
 Visually inspect the swivel bearing (1) for 
cracks and wear.
If the swivel bearing is damaged, replace the
swivel bearing.
 Fit the panelling to the tilt angle sensor.
d3931420
Maintaining the heating system and air

conditioning
Maintaining the heating system and air con-
ditioning console
 Open the right-hand driver's doors and pre-
vent from closing
 Remove the cover (1) 
 Remove the filter (2) and clean or replace

 Reinsert the filter and fit the cover
 Unscrew the screws (4)
 Remove the air duct (3)
 Remove the filter (5) and clean or replace
 Reinsert the filter and attach the air duct with
screws
Maintaining the air conditioning

The following maintenance work must be carried
out at the beginning, middle and end of a sea-
son:
 Check the belt tension on the compressor and
check its condition
 Check the refrigerant level and moisture con-
tent in the system

Service 02
Servicing work
The refrigerant must flow bubble-free through
the inspection glass of the dryer when the
engine is running.
When changing a component in the cooling cir-
cuit, the dryer must be changed before refilling.
 Clean the condenser (6) 
The condenser fins must be cleaned gently with-

out applying any high pressure. Otherwise, the
fins will be damaged and impair the air flow.
6 d3941485

02 Service
Servicing work
Checking the condition of the electric connections and checking that they are secure-
ly attached
 Check earth wire for secure attachment.
NOTE
 Check electric wiring for scuffing and secure
Oxidised connections and brittle cables lead to attachment.
voltage drops and thus to difficulties during start-
up and operation.  Remove oxidation residues and replace brittle
cables.
 Check cable terminals for secure attachment
and oxidation residues.
Checking the condition and disposing of the starter battery

When handling starter batteries, the following in-  Due to the possibility of static charges, do not
structions should be observed: rub batteries with dry cloths. Use damp or an-
tistatic cloths instead.
 Wear industrial goggles and a protection suit.
 Before touching the battery, first touch con- Checking the condition
ductive parts of the chassis to discharge any
static charge. WARNING
 Avoid spark formation when connecting/
Battery acid is highly corrosive.
disconnecting.
Wear protective equipment. Avoid all
contact with battery acid. Any spilt bat-
DANGER tery acid should be neutralised immedi-
ately!
Possible risk of explosion when charging the battery
in unventilated areas due to flammable gases.
The battery must only be charged at the charging sta- If clothing, skin or eyes come into contact with
tions and locations provided for this purpose and in battery acid, the affected areas should be rinsed
accordance with regulations. with water immediately. In the event of contact
These stations and locations must fulfil certain crite- with the eyes, consult a doctor immediately!
ria, such as ensuring sufficient ventilation during the  Open the bonnet
charging process.
WARNING
 After charging the battery, leave it standing
for at least eight hours before reconnecting, if Beware of hot engine and exhaust com-
possible. ponents.
 When filling up or recharging, remove any
packaging film beforehand to ensure gas ex-
traction. WARNING
 The gas release openings must not be When the engine is hot, the fan may
sealed, otherwise there is a risk of explosion. start automatically.
 Do not use plastic adhesive tape, especially Do not touch rotating parts.
in the area surrounding the gas release open-
ings.  Inspect battery for cracked housing and acid
leaks.
 Before recharging, first check the battery with-
out electric load to ensure that only intact bat-  Remove any oxidation residues on the battery
teries are charged. terminals and then apply acid-free grease.
 Avoid rubbing textiles against the battery.  Check that the battery-terminal clips are se-
curely fitted.
 Do not open batteries. Electrolyte level cor-
rection not necessary.  Close the bonnet

Service 02
Servicing work
Disposal ping to prevent acid escaping. Leave protective
cap on positive terminal for transport.
Hand in old batteries at the collection point. Nev-
er dispose of old batteries in the household Transport damaged batteries in suitable, acid-re-
waste! sistant containers.
Ensure that all batteries are stored and transpor-

ted upright and safe from short-circuiting or tip-

02 Service
Servicing work
Checking the axle load sensor
Description
After calibrating the reference point for the axle Settings
load sensor, you have to check the axle load ▼
via the rotary push button in the "Settings" → Check axle load
"Check axle load" menu item on the LSP dis-
▼
play.
Perform the Check axle load
operation
If this test is not performed, error T679 appears

on the display unit and the driving speed is limi-
ted to 6 km/h.
Prerequisites
● The truck is in a horizontal position on a level
surface
● There is no load on the truck
● The fork carriage must be raised at least
10 cm and a maximum of 2.0 m above the
ground
● The mast must be vertical
● The seat switch must be actuated
● If an attachment is fitted, it must be activated
on the LSP display. To do this, check the acti-
vated attachment in the "Select attachment"
action menu. If necessary, correct the setting
Menu navigation 
 To perform the test, select the "Check" menu

item (1) using the rotary push button.
 Press the rotary push button.
1 Check
2 Back
3 Check the axle load.

Service 02
Servicing work
The following user notification appears: "Park 
the truck on level, even ground without a load,
lift the load support and move the mast into a
vertical position" (1).
 Follow the instructions.
 After following the instructions, select the
"Yes" menu item (2) using the rotary push
button.
The axle load sensor is tested automatically.
The test can still be cancelled at this point by us-
ing the "Back" button or selecting the "No" menu
item (3).
If the test is successful, the following user notifi- 

cation is displayed: "Axle load testing was suc-
cessful." (1).
 Acknowledge the user notification by pressing
the rotary push button.
If the automatic test procedure finds that a test 

condition has been violated, the following error
message appears: "Axle load testing value" (1).
 Acknowledge the error message by pressing

02 Service
Servicing work
A user notification (1) appears. The user notifi- 
cation provides information about why the test
failed.
 Establish the correct testing conditions. Re-
peat the test on the axle load sensor.
If the automatic test procedure finds a deviation
that is too far from the preset values, the follow-
ing user notification appears: "Implausible axle
load value. Please notify service."
The "Load rating assistant" function is automati-
cally deactivated.

Service 02
Servicing work
Calibrating the axle load sensor
 Lower the truck until the wheels on the steer-
NOTE ing axle are back on the ground.
Calibrate the axle load sensor when the truck is
not carrying a load. Calibrating the reference for the axle load
sensor
NOTE
NOTE
To ensure that calibration is performed correctly,
the attachment being used must be selected To calibrate the "reference point for the axle
correctly in the LSP display under "Settings - load sensor", somebody has to sit on the driver's
Load rating assistant". seat. This allows the driver's weight to be recor-
ded. If a seat switch bridge has been fitted, this
must be removed. The seat switch must be func-
Calibrating the zero point for the axle load tional.
sensor
 Switch on the truck.
 Park the truck on an even surface (± 1°).
 Actuate the parking brake.
In order to perform the calibration, the following
 Switch off the truck. requirements must be met:
● The driver must be in the operating position
 Lift the truck at the rear using a hydraulic jack
until the wheels on the steering axle are off (seat switch actuated)
● The seat belt must be fastened (special
the ground.
equipment)
 Prop up the chassis of the truck. ● The parking brake must be applied
 Lower the truck using a hydraulic jack. ● The truck must be at a standstill
● The accelerator must be in the neutral posi-
tion
NOTE
● The joystick must be in the neutral position
Alternatively, the truck can be raised at the rear  Start the diagnostic program.
using a crane with sufficient load capacity until
the wheels on the steering axle are lifted off the  Raise the fork arms without a load until the
ground. fork arms are no longer touching the ground
 Switch on the truck. (maximum 300 mm).
 Actuate the joystick until the lift mast is exact-
requirements must be met: ly vertical (tilt of 0°).
● The parking brake must be applied  Start the "Axle load sensor reference" calibra-
● The truck must be at a standstill tion process via the diagnostic program.
● The accelerator must be in the neutral posi-  Perform the "Axle load sensor reference" cali-
tion bration via the diagnostic program.
 Start the diagnostic program. NOTE

 "Calibrate the zero point for the axle load sen-
Following calibration, the axle load sensor must
sor" via the diagnostic program. be checked via the "Check axle load" menu item
 Switch off the truck. in the LSP menu to ensure that the axle load
sensor is functioning correctly.

02 Service
Servicing work
 Read off the weight indicator in the LSP dis-
NOTE play.
Check the load pressure sensor when the truck The weight indicator in the LSP display must
is not carrying a load. show approx. 0 kg (±50 kg).
 Switch on the truck. If the value displayed deviates from this value,
 Lift the fork carriage. the load pressure sensor must be calibrated.
Calibrating the load pressure sensor

The load pressure sensor is calibrated via the di-
agnostic program. An automatic process for cali-
brating the load pressure sensor is stored in the
truck control unit.
NOTE
The load pressure sensor is calibrated when the

truck is not carrying a load. The lowering limit
must be permanently deactivated during the cali-
bration process.
The "Lowering limit" sub-menu can be found un- 
der the "Mast positioning" main menu on the
LSP display.
1 Lift height
2 Tilt angle
3 Lift limits
4 Lowering limit
5 Mast positioning

Service 02
Servicing work
 Deactivate the lowering limit in the "Lowering 
limit" sub-menu (5) ("Off").
NOTE

the attachment being used must be selected
correctly in the LSP display under "Settings -
Load rating assistant".
 Bring the hydraulic oil to operating tempera-
ture (restrict the pressure via the pressure re-
lief valve for approximately two minutes).
 Start the diagnostic program.
 Move the mast to a vertical position (tilt ap-
prox. 0°).
 Raise the mast to approx. 500 mm below the
upper mechanical stop (without a load).
requirements must be met:
● The seat switch must be activated
equipment)
● The parking brake must be applied
● The truck must be at a standstill
tion
 Start the"Load pressure sensor calibration"

process via the diagnostic program.
 Actuate the joystick for lifting and extend the
lift mast to the maximum lift height until the
pressure relief valve responds audibly for ap-
prox. two to three seconds.
NOTE
The maximum lift height, the number of lifting

stages and the position of the lifting stage transi-
tions are stored automatically in the truck control
unit.
 Move the joystick for lifting into the neutral po-
sition.
 Actuate the joystick for lowering. Lower the lift
mast.

02 Service
Servicing work
NOTE
When the lift mast is lowered, the speed of the

lowering procedure is automatically reduced dur-
ing the lifting stages and between the individual
lifting stages.
 Move the joystick for lowering back into the
neutral position only when the lift mast is fully
lowered.
The truck control unit calculates and records the
heights of the lifting stage transitions and the
maximum lift height. These values are stored in
the truck control unit.
NOTE
If the joystick is moved into the neutral position

during the lifting operation or lowering proce-
dure, the calibration process is interrupted and
must be restarted.
Checking the lift height sensor

 Switch off the truck.
 Check the condition of the lift height sensor,
electrical supply line, steel cable, bellows, ca-
ble holder and cable protection device and
check for damage.
 Check that the steel cable for the lift height
sensor can move freely.
 Replace any damaged parts.

Service 02
Servicing work
Hydraulics
Checking the oil level in the hydraulic system
ENVIRONMENT NOTE

consumables.
NOTE
Oil specification: Refer to the recommendations

for consumables.
 Fully lower the fork carriage.
WARNING
ponents.
WARNING
Variant 1:
 Unscrew the breather filter (1) together with 
the oil dipstick (2) on the left-hand side of the
engine compartment.
NOTE
The tank is pressurised. A small amount of air

will escape.
 Screw the breather filter complete with oil dip-
stick back in fully and then unscrew it again.
The oil level must be between the two marks (3)
on the dipstick.
 Top up the hydraulic oil to the upper mark if
necessary.
Difference in quantity between max. and min.
marks: approx. 3 l

02 Service
Servicing work
Variant 2:
the oil dipstick (2a) on the left-hand side of 1
the engine compartment. 2a
4
5
NOTE
The tank is pressurised. A small amount of air

will escape.
NOTE
The oil dipstick (2a) has two markings, which are

valid for the different lift heights.
 Check the corresponding marking.
d3941513
● Marking (5) for lift heights up to 5800 mm
● Marking (4) for lift heights of 5800 mm to
7715 mm
 Screw in the breather filter together with the
oil dipstick completely and then unscrew it
again.
The oil level must be within the corresponding
markings on the dipstick.
 Top up the hydraulic oil to the relevant mark-
ing as required.
Difference in quantity between the markings: ap-
proximately 1.25 l
Changing the oil in the hydraulic system

CAUTION
The oil must have an optimal purity level at all times.
Measures must be taken to ensure this.
When servicing the truck after 6000 operating hours,
it is therefore absolutely essential that the hydraulic oil
is changed before changing the suction filter.
ENVIRONMENT NOTE

sumables.
Draining the hydraulic oil via the drain plug

 Drive the truck over the pit.
 Fully lower the fork carriage and lift mast.
 Place a collection container under the left side
of the truck floor.

Service 02
Servicing work
WARNING
ponents.
WARNING

the oil dipstick (2).
 Unscrew the hydraulic oil drain plug on the
hydraulic oil tank.
 Allow all the oil to drain out. Clean the area
around the oil drain thoroughly.
 Assemble the drain plug.
 Then replace the suction filter, as described in
the section entitled "Replacing all filters in the
hydraulic system".
Extracting the hydraulic oil

 Fully lower the fork carriage and lift mast.
WARNING
ponents.
WARNING

02 Service
Servicing work
the oil dipstick (2). 4 1
2
 Turn the filter cover (4) in an anti-clockwise 3
direction and unscrew it.
 Slowly remove the filter cartridge.
This will allow the oil to flow back into the con-
tainer.
 Pull the filter cartridge out completely.
 Extract the oil using a suitable oil pump.
 Then replace the suction filter, as described in
the section entitled "Replacing all filters in the
hydraulic system".
d3941487
Refilling/topping up the hydraulic oil

 Add hydraulic oil via the filling opening. 
Total filling quantity: approx. 28.0 l

 Check the oil level using the dipstick (2) and
add more oil until the upper marking (3) on
the dipstick is reached.
 Allow the engine to idle (do not start driving)
for 3 minutes in the upper range (parking
brake applied and accelerator pedal de-
pressed).
 Check the oil level again.
NOTE
The hydraulic system will bleed itself automati-

cally when the engine is running.
Replacing all filters in the hydraulic sys-

tem
ENVIRONMENT NOTE

sumables. Dispose of the filter cartridges in an
environmentally friendly manner.
Feed and pressure filters

 Fully lower the lift mast
 Unscrew the side maintenance cover on the
left

Service 02
Servicing work
 Undo both mounting screws (1) on the filter 
carrier
 Swing out the filter carrier
 Place a collection vessel underneath
 Loosen the pressure filter housing (2) and the
feed filter housing (3) at the hexagonal sec-
tion
 Unscrew the filter housing manually and pull
out the filter cartridges from the base
 Apply oil to the seals on the new filter car-
tridges
 Attach the filter cartridges to the base on the
filter top
 Screw on the filter housing and tighten it by
hand
Variant 1 tightening torque: 10+5 Nm; then loosen by a ¼ turn

(in combination with 0009830836, 0009830846, 0009830619 & 0009830632)
Variant 2 tightening torque: 10+5 Nm

(in combination with 0009831512, 0009831513, 0009831514 & 0009831515)
 Fold the filter carrier up and screw in place

 Check the filter flange for leak tightness dur-
ing a test run.
 Mount the side maintenance cover
Suction filter
CAUTION
It must be ensured that the oil always has an optimum
purity level.
When servicing the device after 6000 operating hours,
it is therefore absolutely essential to change the hy-
draulic oil before changing the suction filter.
WARNING
ponents.
WARNING

02 Service
Servicing work
 Open the breather filter (5) 
This allows the air to escape so that the oil will

not overflow when the filter cartridge is inserted.
 Turn the filter cover (4) in an anti-clockwise
direction and unscrew it
 Slowly remove the filter cartridge
This will allow the oil to flow back into the con-
tainer.
 Pull the filter cartridge out completely
 Carefully insert a new filter cartridge into the
filter cover
Ensure that it is correctly centred in the filter
end.
 Clean the filter cover seal and coat with oil
 Refit the filter cover (4) and turn it in a clock-
wise direction
 Tighten the filter cover.
 Screw the breather filter on
The hydraulic system will bleed itself automati-
cally when the engine is running.
 Check the filter cover for leak tightness during
a test run.
Breather filter
NOTE
In the event of heavy dust accumulation, it may

be necessary to change the filter earlier.
WARNING
ponents.
WARNING

Service 02
Servicing work
 Unscrew the filter (5) for the hydraulic oil tank 
from the filler neck
 Remove the dipstick (6) from the breather fil-
ter and attach it to the new filter
 Screw in the filter and tighten
Checking the bleeder valve on the hy-

draulic tank for correct function
NOTE
The breather filter for the hydraulic oil tank is fit-

ted with a bleeder valve that allows a small
amount of pressure in the tank.
ENVIRONMENT NOTE

sumables.
 Open the bonnet
WARNING
ponents.
WARNING

02 Service
Servicing work
 Close the breather filter (1) or check whether 
the breather filter is seated securely
 Start the engine
 Extend the lift mast several times to the stop
and lower it again
 Switch off the engine. Open the breather filter
(1) on the hydraulic oil tank
It must be possible to hear air escaping from the
tank. If air cannot be heard escaping, replace
the breather filter.
Checking the hydraulic system for leak tightness

 Open the bonnet.  Check all connections between the oil tank,
the drive motors, the pumps and the control
WARNING valves for leak tightness.
Beware of hot engine and exhaust com-  Tighten connections if necessary.

ponents.  Check the lift cylinder, tilt cylinder and steer-
Wear protective equipment. ing cylinder for leak tightness.
 Replace any porous hoses.
WARNING
 Inspect the lines for chafing and replace, if
When the engine is hot, the fan may necessary.
 Close the floor plate.
 Raise and secure the floor plate.
Checking the tilt cylinder bearings for

wear
NOTE
The tilt cylinders are mounted in rubber bearings

on both sides.

Service 02
Servicing work
 Unscrew screw (1) on washer (2). 
 Visually check the rubber bearings for cracks.

The rubber must not exhibit any cracks.
 Check the rubber bearings on each tilt cylin-
der at the front and rear.
If the rubber bearings are worn or damaged, the
pats must be replaced.
Tilt cylinders: Checking the mounting

 Check the 4 tilt cylinder mounting screws
(M16) for firm seating.
 Check the 2 eye bolt clamping screws (M12)
for firm seating.
Checking the pre-load of the hose lines 
The pre-load of the double hoses must be

5-10 mm per metre, based on the initial length.
 Adjust the pre-load by sliding the hoses in the
retaining clips to the measurement specified.
d3921519

02 Service
Servicing work
Lifting system
Safety information for working on the lift mast
DANGER
Risk of crushing when the lift mast or fork carriage is
raised.
No work may be carried out on the lift mast or at the
front of the truck unless the following protection meas-
ures are observed.
Use a safety chain with a sufficient load capacity for
the lift mast in question.
NOTE
A special tool may be necessary for the follow-

ing protection measures.
Securing the lift mast against tilting back- 

wards
The lift mast must be secured against acciden-
tally tilting backwards.
 Tilt the mast fully forwards.
 Pull the key out of the key switch.
 Apply the parking brake.
 Disconnect the battery male connector (elec-
tric trucks only).
 Insert a hardwood block.
Securing the lift mast against tilting for- 

wards
When working on the tilt cylinders, the lift mast
must be secured against unintentionally tilting
forwards.
 Set the lift mast to vertical.
tric trucks only).
 Loop a round sling around the crossmember.
 Attach a round sling to the crane hook. Adjust
the tension of the round sling using the crane.
NOTE
Use a suitable mounting aid.

Service 02
Servicing work
Standard lift mast
Function:: When raising the inner mast, the
chain rollers are moved upwards with the chains
so that the fork carriage is lifted with a transmis-
sion ratio of 2:1 due to the chain deflection.
Securing the 
raised standard lift mast 1
 Extend the lift mast.
 Place the chain around the cross beams of
the outer mast (1) and around the cross
beams of the inner mast (2), and connect
them to one another.
 Beware of the hose lines on the cross beam
of the outer mast.
 Lower the inner mast to the end of the chain.
Duplex lift mast

2
Function:: The fork carriage is raised to the spe-
cial free lift height via the chain guide pulley of d3921482
the centre cylinder.
Here, it moves twice as fast as the centre cylin-
der.
The inner mast is then lifted by the two outer cyl-
inders, taking the fork carriage with it.
The centre cylinder is positioned on the extenda-
ble inner mast.
Securing the 
raised duplex lift mast 1
of the outer mast.
 Lower the lift mast to the end of the chain.
 Lower the fork carriage as far as it will go.
Triplex lift mast

2 d3921483
cial free lift height via the chain guide pulley of
Two lift cylinders then raise the inner mast.
Once the inner mast is fully extended, two addi-
tional lift cylinders lift the middle mast, which is

02 Service
Servicing work
lifted together with the inner mast and the fork
carriage.
ble inner mast.
Securing the raised triplex lift mast 
 Extend the lift mast (lift 1 and lift 2).

 Place the chain over the cross beams of the
middle mast (1) and over the cross beams of
the inner mast (2), and connect them to one
another.
of the outer mast.

 Extend the lift mast further (lift 3). 1
outer mast (1) and over the cross beams of
the middle mast (2) and connect them to one
another.
of the outer mast.
2
d3921484

Service 02
Servicing work
Checking the condition of the lift mast
 Switch off the truck.  Check the condition of the end stops.
 Check the condition of the lift mast, the guide  Check that the locking rings for the mountings
surfaces, the rollers and the chains, and of the piston rods at the top of the lift mast are
check for damage. seated correctly.
NOTE NOTE
Individual plastic links that are damaged or miss- Change any damaged parts. Contact your serv-
ing do not impair the function or service life. ice partner.
 Check the mounting of the chains on the
chain anchor.

02 Service
Servicing work
Cleaning and spraying the lift mast 
chain
DANGER
Lift mast chains are safety elements. Incorrect clean-
ing materials may cause direct damage to chains.
Do not use cold cleaning solvent, chemical cleaners
or fluids that are corrosive or contain acid or chlorine.
If the lift mast chain is so dusty that penetration

of the lubricating oil cannot be guaranteed, the
chain must be cleaned.
 Place a collection container under the lift
mast.
 Clean lift mast chain with paraffin derivatives, d3941343
such as benzine.
Take note of the manufacturer's safety informa-
tion. When cleaning with a steam jet, do not use
additives.
 After cleaning, immediately apply compressed
air to the chain to remove any water that re-
mains on the surface and in the chain joints.
The chain must be moved several times during
this process.
 Immediately apply Linde chain spray to chain,
moving chain while doing so.
NOTE
Chain spray must not be used on industrial

trucks that are used in the food production in-
dustry. Instead, use a low-viscosity oil approved
for use in the food industry.

Service 02
Servicing work
Checking the mounting, condition and
function of the lift mast, lift mast chains,
lift cylinders and end stops
 Clean the lift mast guides and chain. 
 Check the chain for condition and wear, espe-

cially around the guide pulleys.
 Check the mounting of the chain to the chain
anchor.
 Replace damaged chains.
NOTE
Individual plastic links that are damaged or miss-

ing do not impair function or service life.
 Check the condition and mounting of the lift
mast, guide surfaces and rollers.
Tightening torque between lift mast and drive
axle:
● 4 mounting screws (M16) at top: 275 Nm
● 2 mounting screws (M20) at bottom: 385 Nm
 Check the condition, mounting and correct

function of the end stops.
 Check the mounting of the lift cylinders.
 Check that the locking ring of the piston rod
mounting at the top of the lift mast is seated
correctly.
Adjusting the lift mast chain

Standard lift mast
NOTE
The lift mast chain stretches over time during

operation and therefore has to be readjusted on
the right and left sides.
 Lower lift mast completely.

02 Service
Servicing work
 Loosen locknut (1). 
 Adjust chain at adjustment nut (2) of chain an-

chor. 2
The lower guide roller on the fork carriage may
only protrude max. 30 mm from the inner lift 1
mast guide rail.
 Tighten the locknut (1).
 Also adjust second chain.
CAUTION
When extending the lift mast, it must not touch the
end stops.
Fully extend the lift mast and check clearance to end
stops.
d3941365
Apply chain spray.
NOTE
In the case of trucks that are used in the food

production sector, chain spray should not be
used. Instead, use a low-viscosity oil licensed for
use in the food industry.
 Apply Linde chain spray to guide surfaces
and chain.
Duplex lift mast or triplex lift mast
NOTE

operation and therefore has to be readjusted.
 Lower the lift mast and fork carriage com-
pletely.
 Loosen lock nut (4). Adjust chain at adjust- 
ment nut (3) of chain anchor.
only protrude max. 30 mm from the inner lift
mast guide rail.
CAUTION
end stops.
stops. 3
4 d3921486

Service 02
Servicing work
Apply chain spray.
NOTE

and chain.
Checking the fork arms and arm safety 

devices
 Check the fork arms (1) for visible deforma- 3
tion, wear and damage.
 Check that the screws (2) on the arm safety
device and fork arm latch (3) are properly
positioned and show no signs of damage.
 Replace faulty parts.
2
2 d3911398

02 Service
Servicing work
Checking and lubricating the sideshift
(special equipment)
ENVIRONMENT NOTE

sumables.
 Check the hydraulic lines for abrasion spots
and replace them if necessary.
 Check the hydraulic connections and mount-
ing elements for secure attachment and wear.
Tighten or replace them as necessary.
 Check the cylinder for damage and leak tight-
ness.
NOTE
Grease the sideshift after cleaning each time it is

cleaned. Use lubricating grease as set out in the
recommendation for consumables. It is better to
apply a little grease to the bearing points fre-
quently than a lot of grease infrequently.
 Move the fork arms so that the lubricating nip- 
ples (1) can be accessed.
 Lower the sideshift until the fork arms touch
the ground.
 Apply lubricating grease to the lubricating nip-
ples (1) for the support rollers on the fork car-
riage, until grease escapes at the side.
ples (2) for the wear strips on the fork car-
riage at the top until grease escapes at the
side.
1 2 1 d3931430
Checking the sideshift for wear

 Dismantle and clean the sideshift.

Service 02
Servicing work
 Dismantle the slide guides from the upper 
guide (1).
 Measure the wall thickness of the slide guide
(3).
If the wall thickness is less than 2.5 mm, change
the slide guides.
On the 394-02 series H50/600 and the 388-01 

series E50/600, an additional wear strip is fitted
to the bottom of the fork carriage.
If the wall thickness is less than 3 mm, this wear
strip must be replaced.
 Lubricate the slide guides (and the wear
strip).
 Reassemble the sideshift.
 Tilt the lift mast forwards and lower the fork
arms until they touch the ground in order to
relieve the sideshift frame of the weight of the
forks.
 Lubricate the sideshift at the lubricating nip-
ples (2) and (4).

02 Service
Servicing work
Checking and lubricating the fork prong
positioner (special equipment)
ENVIRONMENT NOTE

sumables.
 Check the hydraulic lines for abrasion spots
and replace the lines if necessary.
 Check the hydraulic connections and mount-
ing elements for secure attachment and wear.
Tighten or replace them as necessary.
 Check the cylinder for damage and leak tight-
ness.
NOTE
Grease the fork prong positioner after each

cleaning procedure. Use lubricating grease as
set out in the recommendation for consumables.
It is better to apply a little grease to the sliding
blocks frequently than to apply a lot of grease in-
frequently.
 Move the fork arms so that the lubricating nip- 
ples (1) can be accessed.
 Lower the fork prong positioner until the fork 1
arms touch the ground.
ples (1) for the wear strips on the fork car- 2
riage at the top and bottom until grease es-
capes at the side.
ples (2) for the wear strips on the guides at
the top and bottom until grease escapes at
the side. 2
1
d3941489

Service 02
Servicing work
Checking the fork prong positioner for
wear
Checking the wear strips for wear 
 Move the fork arms fully outwards.

 Check the top, bottom, left and right wear
strips for wear.
NOTE
The wear strips must be replaced if one or more

of the specified dimensions (wear limit values in
mm) is less than permitted.
Checking the slide guides for wear 
 Using a feeler gauge at the indicated position,

check the upper and lower slide guides for
wear.
NOTE
The slide guides must be replaced when the

play between the fork carriage and the locking
plate of the slide guides is less than 0.5 mm.
Checking and adjusting the play between the 

fork carriage and the clamp unit
 Check the torque of the screw (1). Setpoint 1
value: 5 - 8 Nm.
 Tighten the screw (1) to a torque of 5 Nm -
8 Nm.
3 2
 Move the fork carriage into both sides and
check that it moves freely.
393-02_08-067

02 Service
Servicing work

Internal combustion engine 10

Safety information for working on
the engine
WARNING
Due to the close proximity of parts, the following must
be taken into consideration for all assembly opera-
tions:
 There is a risk of injury from maintenance points
that are difficult to access.
 Many parts of the engine become hot during oper-
ation — risk of burns! Use the safety equipment
available.
 Take care to allow sufficient clearance around all
hot or moving components.
 All types of lines, even electric cables, must be
routed such a way that the original line routing is
restored.
 Fuel, engine oils or coolant additives are harmful to
health. Observe the safety information from the
manufacturer.
 Regularly check the tools in use for damage and
safety risks.
 To prevent injuries and skin contact, wear protec-
tion goggles and protective gloves for all assembly
operations on the fuel system.
 Never leave objects such as cleaning cloths or
tools in the engine compartment.

Introduction
Glossary of component designations for the Linde Doosan D24NASP diesel engine
Code Designation
0B4 Sensor for charge air pressure and charge air temperature
0B6 Air volumeter
0B7 Sensor for engine oil pressure
0B10 Coolant temperature sensor
0B11 Camshaft sensor
0B12 Fuel temperature sensor
0B13 Crankshaft sensor
0B15 Differential pressure sensor for diesel particle filter
0B16 Engine oil level sensor
0B17 Exhaust gas temperature sensor
0B19 Coolant level sensor
0B20 Exhaust gas temperature sensor
0B35 Rail pressure sensor
0B36 Water trap switch
0K1 Starter motor relay
0K2 Engine control unit relay
0K4 Relay for terminal 15
0M1 Butterfly valve servo motor
0M7 Exhaust gas recirculation actuator
0N1 Engine control unit
0R1 Glow plug 1st cylinder
0R2 Glow plug 2nd cylinder
0R3 Glow plug 3rd cylinder
0R4 Glow plug 4th cylinder
7S1 Regeneration start button
0Y1 Injector 1st cylinder
0Y2 Injector 2nd cylinder
0Y3 Injector 3rd cylinder
0Y4 Injector 4th cylinder
0Y11 Closed loop control valve for fuel quantity
70 A fuse
F1
(pre-heating relay)
20 A fuse
F11
(engine control unit relay)
5 A fuse
F12
(terminal 15)
S3 Vacuum-operated switch

Identification plate and engine identifica- 
A
tion
The identification plate (A) is located on the front 1 2 3 4
of the engine.
Information about the engine is also engraved or
stamped at the indicated location (B) on the cyl-
inder block. This information is required when
ordering parts.
1 Engine type
2 Engine serial number
3 Manufacturer's label text
4 Data matrix code
5 Version 5
6 Year of production (manufacturer code)
7 Exhaust emissions rating B
2 6
1 7
394-02_01-312

Technical data
Manufacturer Doosan
Industrial diesel engine D24NAP
Four-cycle series, inline, water-cooled, model with turbo-
Engine type
charger and intercooler, common rail injection technology,
controlled exhaust gas recirculation
Displacement 2393 cm3
Ratio of bore to stroke 90 mm/ 94 mm
Compression 17:1
Ignition sequence 1-3-4-2
Direction of rotation (as seen on flywheel) Anti-clockwise
Bottom camshaft, maintenance-free, driven by spur gears,
Engine control unit
Maintenance-free valve train via hydraulic tappets
Combustion method Direct injection
Position of cylinder 1 Opposite the power release side (front)
Engine weight (dry) 236 kg
Performance data
Engine power rating Pnominal = 55 kW
Revolution speed nnominal = 2300 rpm
Maximum torque Mdmax = 250 Nm at 1600 rpm
Lower idle speed (engine installed in the
n = 950 rpm
truck)
Operating data, temperatures
Opening start at 82°C
Thermostat
Fully open at 97°C (max. 8 mm)
Electrical equipment
Engine control unit Bosch ECU EDC17C87
Starter motor 12 V, 2.7 kW
Three-phase generator 12 V, 110 Ah
Air-conditioning compressor Belt driven, regulated
Consumables
Lubricating oil
Engine oil (quality) SAE API CJ or ACEA E6
Engine oil (viscosity) 10W-30 or 10W-40
Engine oil quantity 8.5 l (with filter change)
Engine oil pressure at idle speed 1.5 bar
Engine oil pressure at maximum load 4...5.5 bar
Coolant
Composition 40% anti-freeze and 60% water, set to −25°C
Coolant quality TL 774-F (G12+) or TL 774-G (G12++)
Diesel fuel
Diesel fuel Diesel fuel in accordance with EN 590
Biodiesel fuel NOT approved

Overview of the engine attachment
parts and service points
Outlet side
8
3
6
7
394-02_01-177
1 Oil filling opening 5 Starter motor

2 Identification plate 6 Air conditioning compressor
3 Exhaust turbocharger 7 Oil pan
4 Oil dipstick 8 Three-phase generator

Inlet side
1 2
4
6
5
394-02_01-178
1 Crankcase breather filter 5 High-pressure fuel pump (consisting of pri-

2 High-pressure rail ming pump, fuel quantity adjustment unit and
3 Coolant pump high-pressure pump)
4 Automatic tensioner arm with guide pulley 6 Engine oil cooler
7 Oil filter (not mounted directly on the engine)
Exhaust gases - composition

Exhaust gases - introduction impact, it is important to improve the exhaust
emission characteristics of the spark-ignition en-
Fuel combustion in the working cylinders of an gine. All measures for reducing the harmful
engine is incomplete to a greater or lesser ex- emissions that are restricted under various legis-
tent. The lower the level of combustion, the lation are aimed at keeping harmful emissions to
greater the emission of harmful substances in a minimum while achieving the lowest possible
the exhaust gas. Fuel combustion is never com- fuel consumption, high drive power and good
plete - not even when there is an excess of at- driving characteristics.
mospheric oxygen. To reduce the environmental

In addition to a high percentage of harmless ele- combining with blood haemoglobin. NO2 is a
ments, the exhaust gas emitted from a spark-ig- red-brown gas with a sharp pungent smell. It irri-
nition engine also contains components that are tates the lungs by attacking the tissue. In combi-
known to be harmful to the environment, at least nation with unsaturated hydrocarbons, nitrogen
in higher concentrations. The harmful proportion oxides cause smog to form when exposed to
accounts for approximately one percent of the sunlight. NO and NO2 are both known as nitro-
exhaust gas and is made up of carbon monoxide gen oxides (NOx).
(CO), nitrogen oxides (NOx) and hydrocarbons
Hydrocarbons (HC): The exhaust gas contains
(HC). The main problems, depending on the air-
quite different hydrocarbons:
fuel ratio, are the opposing concentrations of CO
and HCs on the one hand and NOx on the other. Saturated hydrocarbons (paraffins) are virtually
odourless and have a narcotic effect with slight
Exhaust gases - characteristics irritation of the mucous membrane.
Unsaturated hydrocarbons (olefins, acetylenes)
The principal components of exhaust gas are ni-
have a slightly sweetish smell and can cause ir-
trogen, carbon dioxide and steam. They are
ritation of the mucous membrane to some ex-
non-toxic.
tent. They play an essential part in the formation
Carbon monoxide (CO) : Carbon monoxide is a of smog as they react in sunlight in the presence
colourless, odourless gas. It has a far greater af- of NO to form oxidants that irritate the mucous
finity to haemoglobin (red blood pigment) than membrane, and ozone is created at the same
oxygen, and therefore to poisoning the body. time.
Nitrogen oxides (NO, NOX) : Nitrogen oxide NO Aromatic hydrocarbons have a characteristic
is a colourless gas that oxidises in the air to be- smell. They are pungent-smelling nerve poisons
come NO2. It is known as a serious haemotoxin that have a narcotic effect and irritate the eyes
because it causes the rapid onset of paralysis by and nose even in very low concentrations.
Technical features
● Common rail injection system with solenoid
valves
● Diesel particle filter with upstream oxidation
catalytic converter
● Electronically controlled exhaust gas recircu-
lation valve
● Exhaust turbocharger with charge pressure
regulation by wastegate
● EGR radiator

Full load characteristic curve for the 2.4 ltr 
common rail engine
55 kW in accordance with Directive
2016/1628 stage V
Engine speed
Power [kW] Torque [Nm]
[rpm]
1600 41.9 250
2300 55 229
1 Power [kW]
2 Speed [rpm]
3 Power performance curve
4 Torque performance curve
5 Torque [Nm]


Overview of the sensors and actuators
Inlet side
0B35
0B4 0M1
0M7
0B7
0Y11
394-02_01-179
0B4 Sensor for charge air pressure and charge 0B7 Sensor for engine oil pressure
air temperature 0B35 Rail pressure sensor

0M1 Butterfly valve servo motor 0Y11 Closed loop control valve for fuel quantity
0M7 Actuator for exhaust gas recirculation (EGR)
NOTE
The following sensors are not included in the

graphic:
● Air volumeter 0B6

● Differential pressure sensor 0B15
● Fuel temperature sensor 0B12
● Exhaust gas temperature sensor 0B17
● Water trap switch 0B36

Outlet side
0Y3 0Y4
0Y2
0Y1
0B10
0B20
0B11
0B16
0B13
394-02_01-180
0B10 Coolant temperature sensor 0B16 Level sensor for engine oil
0B11 Camshaft sensor 0B20 Exhaust gas temperature sensor
0B13 Crankshaft sensor 0Y1...0Y4 Injectors for cylinders 1...4
Explanation of the sensors

The engine control unit detects the sensor sig-
nals and outputs appropriate signals to activate
the actuators. If the actuators return a signal, the
engine control unit also detects this signal, e.g.
butterfly valve servo motor.

Based on these signals, the engine control unit
calculates the following:
● Injection timing and duration for best perform-
ance
● Timing of the diesel particle filter regeneration
● Exhaust gas recirculation
Checking the engine power rating in trucks with adjustable hydraulic pump MPR 50
To save energy (fuel), the engine speed is in- ted. The engine power rating cannot be checked
creased to 2300 rpm during lifting using the with a retroactively adjusted pump, since the
working pump MPR 50. electronic control can no longer function proper-
ly.
To achieve the same lifting speed of approx.
0.5 m/s, the delivery volume per rotation must The magnetic current delivery volume character-
be increased. istic curve which has been set ex works is stored
in the electronic control. This characteristic
Therefore with the change of the pump swivel
curve is the basis for activating the MPR and the
angle of the MPR 50 up to the power limit of the
engine.
internal combustion engine, the engine speed
"n" is kept low (fuel consumption) and the pump The characteristic curve cannot be adjusted to
swivel angle (determines the delivery volume be correct. If it is adjusted retrospectively, acti-
per rotation "V") is kept at the maximum. This is vation will no longer function correctly. If adjust-
carried out with a programmed characteristic ment improves one function, another function
curve specified in the LHC 20. will be unintentionally and simultaneously im-
paired.
If the engine is loaded beyond its power limit,
the LHC 20 detects this using crankshaft sensor It is not in the interests of our customers to per-
0B13. form adjustments to the MPR without detailed
knowledge of the system.
The LHC 20 reacts by reducing the load using
pump MPR (large pump swivel angle): smaller The engine power rating must be checked ac-
pump swivel angle but also reduced delivery vol- cording to the described procedure in the "effi-
ume per rotation. ciency" setting.
The engine speed is now increased to keep the The truck must also be at operating temperature
maximum lifting speed constant. Volumetric flow (as described in the text: hydraulic oil at a mini-
in l/min remains the same. mum of 60°C). The steering must be in a
straight-ahead position and lifting set to 100%.
The diagnostic software assesses the perform-
ance based on the current for the pump swivel All of these points influence the engine speed
angle and the engine speed. This cannot be as- and the requested volume flow rate (and there-
sessed subjectively. fore the requested power).
The engine power rating can only be checked as
described here if the MPR 50 is correctly adjus-
Setpoint values with tolerance
Conditions for checking the engine power rating:

● Hydraulic oil temperature: 60°C
● Mode: Efficiency
● Steering angle setting: straight
● Lifting: 100%
● Pressure setting for the pressure relief valve
○ Working hydraulics H40 = 250 bar

○ Working hydraulics H45/50 = 275 bar
Engine speed differential be-

Engine code letter / version /
Engine utilisation: tween setpoint and actual forced
power
down
No suppression of revolution
DM02VB / DM02-MFF01 / 55 kW <100%
speed

Crankgear
Instructions for assembling and disassembling the engine
WARNING CAUTION
Risk of injury if incorrect procedures are followed If during engine repairs you find large quantities of
when working on the engine! metal chips or abrasion, this may indicate damage to
Observe safety information for repair and mainte- the crankshaft or connecting rod bearings.
nance work and safety information for working on the To prevent consequential damage, perform the follow-
engine. ing tasks after repair:
 Carefully clean the oil channels
 Change the oil cooler
NOTE
 Replace the oil filter.
● To perform assembly work, the engine must
be secured to the engine holder and gearbox
holder VAS 6095 with the universal mounting
VAS 6095/1.
● All bearing surfaces and running surfaces
must be oiled before assembly operations.

Crank drive and seals - assembly overview
12 13
11
10
9 3 2
5
6
7 4
394-02_01-298
1 Crankshaft housing 8 Control housing cover

2 Screws 9 Mounting screw for crankshaft pulley
3 Adaptor 10 Crankshaft pulley
4 Flywheel 11 Oil seal for engine oil (front)
5 Protective dust cap 12 Control disc
6 Oil seal for engine oil (rear) 13 Crankshaft
7 Cylinder block (base)
Crankshaft housing (1) and cylinder block

(base) (7)
 Apply TB1217H on the mounting surface of
the crankshaft housing and of the cylinder
block (base).
 Observe the relevant quantity specifications
for the different application areas in accord-
ance with the manufacturer's specifications.
Adaptor (3)
Screws (2) and flywheel (4)
 Tighten the screws using the angular method.
Protective dust cap (5)
Oil seal for engine oil (rear) (6)
 Note the installation position of the seal.
 Use the assembly device to fit the seal.
Control housing cover (8)

 Apply TB1217H to the mounting surface, cov-
ering an area with a diameter of ∅2.5 mm
±0.5 mm.
Crankshaft pulley (10) and bolts for the crank-
shaft pulley (9)
 Apply blue LOCTITE 587 to the bolts.
Oil seal for engine oil (front) (11)
 Always replace an oil seal after removing it.
Control disc (12)
 Always install a control disc using a parallel
key.
 Do not damage the teeth of the control disc.
Assembling the crankshaft (13)
 Apply sufficient engine oil to the bearing
points.
 Observe the order of assembly for the bear-
ings.
NOTE
Engine oil must not be applied to the mounting

positions of the cylinder blocks and bearings.

Changing the sealing ring for the crank-
shaft (belt pulley side)
WARNING
Observe the safety information for repair and mainte-
nance work and the safety information for working on
the engine.

Assembly and disassembly device for front oil 
seal 860104–02047
394-02_01-311
Torque wrench up to 50 Nm 
Torque wrench up to 300 Nm
Dismantling
 Dismantle the V-ribbed belt. See "Replacing 393_01-1158
the V-ribbed belt".

 Dismantle the belt tensioner. See "Changing 
the belt tensioner for the V-ribbed belt".
 Remove the crankshaft belt pulley (2).
394-02_01-305

 Remove the crankshaft sensor 0B13 (5).

 Remove the screw (3). 9
3
 Remove the auxiliary wheel (9).
 Remove the 16 screws (8).
8
 Remove the control housing cover (6).
4
7 5
6
394-02_01-306
 Dismantle the oil seal from the control disc 

cover using the assembly and disassembly
device (10) and a rubber mallet. 10
Installation
quence. Observe the following:
11
 Place the control disc cover (6) on a stable
work surface with the assembly side facing
down.
 Push the seal (11) onto the short end of the
assembly and disassembly device (10). 6
 Drive the sealing ring into the control housing
cover using a rubber mallet.
394-02_01-307
Tightening torque for the screws (8): 22 Nm
Tightening torque for the screw (1): 255 Nm
Crankcase breathing
1 2
3
394-02_01-279
In internal combustion engines, air flows be-

tween piston rings and the cylinder liner as a re-
sult of pressure differences between the com-
bustion space and crankcase. These air flows

are known as blow-by gases. These oil-contain-
ing gases are fed back into the intake area via
the crankcase breather so as not to harm the
environment.
The gases flow into the oil separator (2). There,
the larger oil drops are deposited and gather on
the base. The oil can drip into the cylinder head
through the openings (3).
The pressure regulating valve (1) regulates the
pressure for bleeding the crankcase. The pres-
sure regulating valve consists of a membrane
and a compression spring. When the blow-by
gases are introduced, the pressure regulating
valve (1) limits the vacuum in the crankcase. If
the vacuum in the crankcase is too high, the en-
gine seals could be damaged.
● If there is a slight vacuum in the intake chan-
nel, the force of the compression spring
opens the pressure regulating valve (1).
● If there is a high vacuum in the intake chan-
nel, the pressure regulating valve (1) closes.
When the pressure regulating valve (1) opens, 
the gases flow through the crankcase breathing 4
hose (4) back into the intake system.
The crankcase breathing system does not re-
quire any maintenance.
394-02_01-278

Cylinder crankcase - assembly overview
Camshaft (1), intermediate wheel (2), oil 
pump (4), crankshaft pulley (6)
 Tighten the screw joints (3) and (5) to the de-
fined tightening torques.
Camshaft (1) 
 Before installation, apply the recommended

engine oil to the running surfaces in the cylin-
der block and to the camshaft.
Tightening torque for the screw joint of the cam-
shaft: 22 Nm
1
394-02_01-285
Intermediate wheel (2) 
 Before installation, apply the recommended

engine oil to the liner in the intermediate
wheel.
2
Play between the intermediate wheel and the
crankshaft pulley: 0.087 mm to 0.2 mm.
Play between the intermediate wheel and the
camshaft pulley: 0.087 mm to 0.211 mm.
Tightening torque: 43 Nm (3) 3
394-02_01-286

Oil pump (4) 
Play between the crankshaft pulley and the oil

pump impeller: 0.06 mm to 0.259 mm
Tightening torque: 22 Nm (5)
394-02_01-287
Oil pan (7) 
 Clean the sealing face before installation.

 Install with sealant TB1217H.
Sealant with Ø 3 mm ±0.5 mm
Tightening torque: 29 Nm (8)
8 7
394-02_01-288
High-pressure fuel pump (9) 
 Replace the O-rings before installation.

Play between the crankshaft pulley and the high-
pressure fuel pump wheel: 0.06 mm to
0.259 mm
394-02_01-289

Control disc (10) 
 Slide the control disc onto the crankshaft, en-

suring that it is correctly positioned.
Fastening the control disc in place with the con-
trol disc cover
10
394-02_01-290
Control housing cover (11) 
 Clean the sealing faces before installation.

11
5 394-02_01-291
Instructions for changing the flywheel

WARNING
NOTE
Risk of injury if incorrect procedures are followed
when working on the engine! When assembly work is being performed, the
engine must be secured on the engine holder
Observe safety information for repair and mainte-
nance work and safety information for working on the
and gearbox holder VAS 6095 with the universal
engine. mounting VAS 6095/1.

Crankshaft sensor 0B13
0B13
394-02_01-213
The crankshaft sensor (0B13) is located on the

end face of the engine, close to the crankshaft
belt pulley (1).
Pin assignment 
Pin Connection
A020 Signal +
A021 Signal −
A057 Ground (GND)
A020 A021 A057

Function
The crankshaft sensor (0B13) is designed as an
inductive sensor. It senses the crankshaft posi-
tion. It senses the engine speed, based on the
sensing of the crankshaft position. The engine 394-02_01-214
control unit (0N1) uses the signals from the
crankshaft sensor (0B13) and camshaft sensor
(0B11) to determine the piston position for each
cylinder and hence the respective injection tim-
ing.

Checking the crankshaft sensor 0B13
Special tools, testing instruments, measuring 
devices and other devices required
● Wiring harness for 196–pin KMC/Doosan
0009419980
● Four measurement boxes 0009418413
● Four cover plates for KMC/Doosan 196-pin/
plug A or plug K
● Multimeter
● Wiring diagram
Checking the electrical connection assem-

bly
 Switch off the ignition.
bly for crankshaft sensor 0B13.
Check the electrical connection assembly for:
● Bent connections
● Corrosion
● Contamination
● Moisture
If no fault is detected, check the cables for con-

tinuity.
Checking the cables for continuity

 Connect the wiring harness 0009419980,
measurement boxes 0009418413 and cover
plates for KMC/Doosan 196-pin/plug A or plug
K. See "Connecting the measurement adapter
for a line test".
NOTE
Use suitable probes, as otherwise the electrical

connection assemblies may stretch, which can
cause loose connections.
 Check the continuity of the cables at pins
A020 and A057.
A021 and A057.
If no fault is detected, test using an oscilloscope.
Checking the crankshaft sensor 0B13 using

an oscilloscope
 Switch on the engine.
 Connect the oscilloscope to crankshaft sensor
0B13 and camshaft sensor 0B11.

Connection diagram
Oscilloscope connection
+ - Signal Earth
A20 A21 A52 A51
Crankshaft sensor 0B13 Crankshaft sensor 0B13 Camshaft sensor 0B11 Camshaft sensor 0B11
 Use current probes to check the signals.

 Compare the display on the oscilloscope with
the template shown in the "Troubleshooting
Guide".
If a fault is detected in the signals, conduct me-
chanical testing.
Mechanical testing
 Check the control disc (1) for the following: 
● Secure positioning
● Damage
● True running
● Metal chips on the control disc or the trans-
mitter
 Rectify any detected faults.
Courses of action
 Repeat all tests.
 Perform the courses of action as per the fol-
lowing table. 1
394-02_01-392
No fault X X
Line test
Fault X
Oscilloscope No fault X X
Error status
test Fault X
Mechanical No fault X X X
testing Fault
Replace the Replace engine
Course of ac- Replace defec-
crankshaft sen- control unit
tion tive lines.
sor 0B13. 0N1.
Changing the crankshaft sensor 0B13

WARNING
when working on the engine!
engine.

Removal 

bly (1).
 Remove the crankshaft sensor 0B13.
Installation
 Replace all the seals on the crankshaft posi-
tion sensor 0B13.
Changing the ribbed belt pulley

Required special tools, testing instruments,
measuring devices and other tools
Torque wrench (40 Nm to 300 Nm) 
Removal 
 Remove the ribbed belt (1); see "Changing

the V-ribbed belt".
 Remove the nut (2). 1
 Remove the ribbed belt pulley (3).
Installation 2
 Installation is carried out in the reverse se-
Tightening torque for the nut (2): 255 Nm
3
394-02_01-337

Cylinder head, valve train
Tips for working on the cylinder head
WARNING
NOTE
Risk of injury if the engine is handled incorrectly!
If the cylinder head has been removed or ex-
Observe safety information for repair and mainte- changed, replace all coolant.
engine.

Valve cover - assembly overview
1 Crankcase breathing 5 Oil seal

2 Screw 6 Filler cap of the oil filling opening
3 Valve cover 7 Pressure regulating valve for the crankcase
4 Screw breathing
1 Crankcase breathing
2 Screw
Tighten in sequence.
3 Valve cover
Replace all seals.
4 Screw
5 Oil seal
Replace all seals.
6 Filler cap of the oil filling opening
7 Pressure regulating valve for the crankcase
breathing

Removing and installing the valve cover 
Special tools, testing instruments, measuring

● Torque wrench (5 to 50 Nm)
● Torque wrench (up to 10 Nm) 393_01-1167
Removal
 Open two clips (1). 
2
 Remove the hose (2) of the crankcase breath-
ing system.
 Remove the return line (see the section "Re-
1
placing the fuel return line").
1
394-02_01-270
 Loosen ten (3) screw joints. 

3 4
 Mark the installation position of the injection
lines (4) and the high-pressure line (5).
 Remove the high-pressure line (5).
 Remove four injection lines (4).
NOTE
Do not reuse injection lines and high-pressure

lines. 6 5 3 394-02_01-271
 Remove two screws (8). 

7
 Remove the high-pressure rail (7).
8 394-02_01-272

 Remove ten screws (9). 
10
 Remove the service flap (10).
9
394-02_01-273
 Disconnect four electrical connections (12). 

11 12
 Loosen four screws (13).
CAUTION 13
The oil seals on the valve cover may be stuck on the
injectors and can be damaged during removal.
Remove the injectors carefully.
 Remove four injectors (11) by carefully turn-

ing them to the left and right.
394-02_01-274
NOTE
Do not reuse copper sealing rings on the injec-

tors.
 Disconnect the electrical connections of the 
power strip by removing the four nuts (14).
14
 Unscrew four glow pencils (15).
15
394-02_01-275

 Remove twelve screws (16). 
17
 Remove the valve cover (17).
16
394-02_01-276
Installation
NOTE

quence.
 Tighten the twelve screws (16) in sequence.
 Tighten four glow pencils (15). Tightening tor-
que: 9 to 12 Nm
 Tighten four nuts (14) on the power strip.
Tightening torque: 1.3 to 2.0 Nm
 Ensure that the oil sealing rings (18) on the 
valve cover do not fall out. If necessary, use
new oil sealing rings. 18
 Coat the oil sealing rings (18) with engine oil
before inserting the injectors (11).
 Use new copper sealing rings on the injec-
tors.
CAUTION
The threads in the cylinder head and the injector
seats can be damaged if the screws (13) are tight- 394-02_01-277
ened without the injectors (1) being correctly fitted.
Tighten the screws (13) slowly and only until hand
tight. When tightening, ensure that the injectors (11)
do not tilt or slip out of their seats.
 Tighten four screws (13) on the injectors (11).

Tightening torque: 43±3.4 Nm
 Tighten ten screws (9) in sequence. Tighten-
ing torque: 10 Nm
NOTE
It is easier to install the injection lines (4) and the

high-pressure line (5) if the high-pressure rail (7)
is not seated very firmly.

 Screw two screws (8) in slightly by hand.
CAUTION
If the injection lines (4) and the high-pressure line (5)
are bent by force, they can be damaged irreversibly.
The screw joints will then leak.
The injection lines (4) and high-pressure line (5) must
not be bent or installed under tension.
 First, screw on the screw joints of the high-

pressure pump and high-pressure rail until
hand tight.
 Then screw on the screw joints on the injec-
tors until hand tight.
 Tighten two screws (8). Tightening torque:
22 Nm
 Tighten the screw joints on the high-pressure
pump and high-pressure rail: tightening tor-
que: 29 Nm
 Tighten the screw joints on the injectors.

Cylinder head - assembly overview
1 Belt tensioner for ribbed belts 8 High-pressure rail

2 Coolant pump 9 High-pressure fuel lines
3 Three-phase generator 10 Intake manifold with butterfly valve
4 Ribbed belt 11 Exhaust turbocharger
5 Coolant hose 12 Exhaust gas recirculation radiator
6 Exhaust gas recirculation valve 13 Exhaust manifold
7 Oil lines 14 Thermostat housing

Changing the cylinder head 
● Torque wrench (up to 10 Nm)

● Torque wrench (5 Nm to 50 Nm)
● Pliers for spring band clamps VWVAS6340
(not pictured)
● Knife edge 500 mm
WARNING
engine.
Removal
NOTE
● All cable ties that are removed during removal
must be refitted in the same position during
installation.
● Replace all removed seals.
● Switch off the ignition.
● Disconnect the electrical earth wire from the
battery.
● Drain the oil. Collect the oil in a suitable ves-
sel.
 Remove the three-phase generator. See "Re-
moving and installing three-phase generator".
 Remove the coolant pump. See "Replacing
the coolant pump".
Removing the coolant hose 
 Remove the two screws (1).

1
 Remove the two spring band clamps (2).
 Loosen the coolant hose (4) from the exhaust
gas recirculation valve.
 Remove the coolant hose (4) and the two
supports (3).
2 3 4 2 394-02_01-354

Removing the exhaust gas recirculation 
valve
 Remove two oil lines (5) between the oil filter
(6) and the oil cooler (7).
 Collect escaping oil in a suitable container.
bly (8).
bly (9).
 Remove the spring band clamp (10). 
 Pull out the hose (11) from the exhaust gas

recirculation valve.
 Disconnect the three mountings (14) for elec- 

tric cables from the exhaust gas recirculation
valve (21).
 Remove the four screws (12).
 Remove the exhaust gas recirculation valve
(13).
 Remove the high-pressure rail. See "Chang-
ing the glow plugs 0R1 to 0R4".
 Remove high-pressure lines. See "Changing
the injectors 0Y1 to 0Y4".

Removing the intake manifold and the throttle valve housing
15 Hose clip 20 Screw

16 Hose 21 Throttle valve housing
17 Electrical connection assembly 22 Intake manifold
18 Electrical connection assembly 23 Screw
19 Mounting for electrical connection assembly 24 Screw

 Pull out the hose (16) including the hose clip
(15).
 Disconnect the two electrical connection as-
semblies (17, 18).
 Loosen the six mountings (19) for electric ca-
bles from the throttle valve housing (21) and
from the intake manifold (22).
NOTE
Some mountings (19) for electric cables are con-

cealed by other components in the diagram.
NOTE
Not all screws (24) are shown in the diagram.

See "Intake manifold - assembly overview" for
an illustration of all screws.
 Remove the intake manifold (22) and the
throttle valve housing (21).

WARNING
Risk of injury due to the heavy weight of the intake
manifold and the throttle valve housing!
Enlist the help of a second person if necessary.
If no second person is available:
 If necessary, remove three screws (23) before dis-
assembling the intake manifold (22).
 Remove the throttle valve housing (21).
 Remove the exhaust turbocharger. See

"Changing the exhaust turbocharger".
Removing the exhaust gas recirculation radiator
25 Spring band clamp 29 Nut

26 Screw 30 Sheet metal
27 Sheet metal 31 Exhaust gas recirculation radiator
28 Screw 32 Hose
 Loosen the two spring band clamps (25).

 Pull out the two hoses (32).
 Secure the sheet metal (27) to prevent any
load being placed on the wiring loom (32).

 Remove the three nuts (29). 
 Remove the sheet metal (30).

 Remove the exhaust gas recirculation radiator
(31).
Removing the exhaust manifold
34 Screw 38 Sheet metal

35 Sheet metal 40 Exhaust manifold
36 Sheet metal 0B20 Exhaust gas temperature sensor
37 Screw
 Remove the exhaust gas temperature sensor

(0B20). See "Changing the exhaust gas tem-
perature sensors 0B17 and 0B20".
 Remove the two sheet-metal parts (35, 36).

 Remove the two screws (37). 
39 40 39
 Remove the sheet metal (38).
 Remove the eight screws (39).
 Remove the exhaust manifold (40).
39 394-02_01-358
Removing the thermostat housing 
 Remove the coolant temperature sensor

(0B10).
 Remove the spring band clamp (41).
 Pull out the hose (42).
 Remove the two nuts (43).
 Rotate the support (45) out of the working
area.
NOTE
Do not damage the wiring loom when rotating

the support (45).
 Remove the thermostat housing (46).
Removing the adaptor-connector support 

bly (47).
 Remove the four mechanical mountings (48).
 Remove the electrical connection assembly
(49) from the adaptor-connection support
(50).

 Remove the two screws (51). 
 Remove the adaptor-connector support (50).
50
51
394-02_01-359
Removing the valve cover 

53 52
 Remove the 20 screws (52). 52
 Remove the valve cover (53).
NOTE
See also "Removing and installing the valve

cover".
52 52 394-02_01-360
Removing the tappet drive and rocker lev- 

ers 54
55 54
 Remove the ten screws (54). 54
 Remove the tappet drive and rocker arms
(55).
394-02_01-361

Removing the tappets 
56
 Remove the eight tappets (56).
394-02_01-362
Removing the cylinder head 

57
 Remove the cylinder head (58).
58
 Remove the cylinder head seal (59).
NOTE
The cylinder head seal (59) is not visible in the

diagram. 59
Installation
57
CAUTION
394-02_01-363
Assembly errors and damage to components lead to

engine malfunctions!
 Always replace the cylinder head seal (59).
 Always replace the socket head screws (57).
 Do not apply oil to the socket head screws (57).
 Handle seals with care. Damaged seals lead to
leakages.

 Carefully remove the seal remains from the
cylinder head (58) and the crankcase. When
doing so, avoid scores and scratches.
 Carefully clean the crankcase and the cylin-
der head at the mounting surfaces.
Check the following before assembly:

 Check the surface of the crankcase and of the
cylinder head for flatness using a knife edge.

 Check the condition of the threaded holes for
screwing the cylinder head in place for signs
of damage.
If any damage is found:
 Have the engine repaired.
If no damage is found:
Installing the cylinder head

 Determine the piston that is located at top
dead centre.
 Measure the projection between the top of the
piston and the cylinder-block surface.
 Use the following table to determine the class
of cylinder head seal.
Piston projection
Class of cylinder head seal
Setpoint value: 0.50 ±0.16 mm
Number of semi
Smallest measured Greatest measured
Marking circles on the iden- Thickness [mm]
value [mm] value [mm]
tification mark
A 1 1.02±0.05 0.34 0.45
B 2 1.12±0.05 0.45 0.55
C 3 1.22±0.05 0.55 0.66
 Assemble the cylinder head seal in the cor-

rect position on the cylinder block.
Assembling the cylinder head seal 

60 61
Observe the following: the identification mark
(60) and marking (61) must be legible from the
62
top.
 Align the cylinder head seal (59) using the fol- 64 65
lowing points:
● Tappet bore holes
● Thread of the socket head screws
● Openings of the cylinder head seal
63
 Assemble the cylinder head (58). 394-02_01-364
 Align the cylinder head (58) according to the 60 Identification mark on the cylinder head seal
list above. (59)
61 Class of cylinder head seal (59)
62 Side for intake manifold (22)
63 Side for exhaust manifold (40)
64 Side for coolant pump
65 Side for flywheel

Assembling the socket head screws
13 17 64
9 18
5
14
1 10
4
6
8 2
12
3
16 7
11
15
65
394-02_01-365
1 to 18 Tightening sequence 65 Side for flywheel

64 Side for coolant pump
The socket head screws (57) are assembled in

four stages. Adhere to the sequence shown for
each stage.
NOTE
Do not mix up the tightening sequence (1...18)

and the position numbers (1...18).
Procedure for assembling the socket head
screws (57):
1 Tighten hand-tight
2 Tighten to a tightening torque of 39 Nm
3 Angle tightening: 90°
Installing the tappets

 Apply engine oil to both ends of the tappets.
 Position the tappet in the tappet bore hole
with one or two light blows from a rubber mal-
let.
Installing the valve cover

 First, tighten the screws (52) hand-tight.

 Tighten the screws (52) in sequence. Tighten-
ing torque: 10 Nm
Tightening torques
Position
Component Tightening torque [Nm]
number
(1) Screws for the coolant-hose support 10
(12) Screws for the exhaust gas recirculation valve 22
(23) Screws for the throttle valve housing 22
(28) Screws for the exhaust gas recirculation radiator 30
(29) Nuts for the exhaust gas recirculation radiator 22
(33, 36) Screws for the heat shield on the exhaust manifold 12
(38) Screws for the exhaust manifold 30
(42) Nuts for the thermostat housing 22
(43) Screws for the thermostat housing 22
(51) Screws for the adaptor-connector support 43
(52) Screws for the valve cover 10
(54) Screws for the tappet drive 20 to 24
(57) Screws for the cylinder head 39

Cylinder head seal 
A
There are three different thicknesses of cylinder
B
head seal. If the cylinder head has been planed, C
the piston may project further than usual. The
cylinder head seal can be recognised as it is
marked with a different number of notches.
 Select the required thickness from the table
depending on the piston projection.
394-02_01-263
Piston projection
Cylinder head seal
0.50 ±0.16 mm
Marking Thickness [mm] From [mm] To [mm]
A 1.02±0.05 0.34 0.45
B 1.12±0.05 0.45 0.55
C 1.22±0.05 0.55 0.66

Valve train 
1 2
Spur gears drive the camshaft (6) located below 3
the gears to control the engine. The camshaft
uses the valve tappets (5) to move eight push- 4
rods (4). Rocker levers (1) actuate the 16
valves (3). Valve springs (2) ensure that the
valves (3) remain in their valve seats when not
5
being actuated. This closes the combustion
space. 6
If irregular engine operation or problems with the
engine control unit occur, the valve springs (2)
must be checked for changes in length and
394-02_01-264
shape (perpendicularity).

Hydraulic tappet
5 2
394-02_01-265
1 Piston 4 High-pressure chamber

2 Hydraulic tappet housing 5 Oil reservoir chamber
3 Ball head
Maintenance-free hydraulic tappets on the rock-

er levers adjust the valve clearance. The oil res-
ervoir chamber (5) is completely filled with en-
gine oil.
NOTE
During removal, observe the following:
● The chamber must be installed with the open-

ing pointing away from the rocker lever.
● Do not set the hydraulic tappet down on its
head after removal. If you do so, engine oil
will leak out. After the motor has been started,
the oil reservoir chamber (5) fills up very slow-
ly with engine oil. This produces a loud clack-
ing noise.

Camshaft sensor 0B11
0B11
1
394-02_01-211
The camshaft sensor (0B11) is located on the

outlet side of the engine, behind the starter mo-
tor (1).
Pin assignment 
PIN Connection
A051 Ground (GND)
A052 Signal
A037 Supply voltage (5 V)
A051 A052 A037

Function
The camshaft sensor (0B11) is designed as a
Hall sensor. It scans a sprocket on the camshaft
and senses the camshaft position. The engine
control unit (0N1) uses the signals from the cam- 394-02_01-212
shaft sensor (0B11) and crankshaft sensor
(0B13) to determine the piston position for each
cylinder and hence the respective injection tim-
ing.

Checking the camshaft sensor 0B11
0009419980
plug A or plug K
● Multimeter
● Wiring diagram

bly
bly for camshaft sensor 0B11.
● Corrosion
● Contamination
● Moisture
If no fault is detected, check the power supply.

Checking the power supply 
 Connect the electrical connection assembly

for camshaft sensor 0B11.
A051 A052 A037
for a line test".
Pin Connection
A037 Power supply (5 V)
A051 Ground (GND)
A052 Signal
394-02_01-343
 Connect the multimeter for voltage measure-

ment to the pins A037 and A051.
 Switch on the ignition. Setpoint value: 5 V.
tinuity.

for a line test".
NOTE

A037 and A051.
A052 and A051.
If no fault is detected, test using an oscilloscope.
Checking the camshaft sensor 0B11 using

an oscilloscope
for crankshaft sensor 0B13.
 Connect the oscilloscope to crankshaft sensor
0B13 and camshaft sensor 0B11.

Connection diagram
Connection to the oscilloscope
+ - Signal Earth
A20 A21 A52 A51
Crankshaft sensor 0B13 Crankshaft sensor 0B13 Camshaft sensor 0B11 Camshaft sensor 0B11
 Use current probes to check the signals.

 Compare the display on the oscilloscope with
the template shown in the "Troubleshooting
Guide" for series 394-02D EU5.
Courses of action
 Perform the courses of action as per the fol-
lowing table.
No fault X X X
Voltage test
Fault
No fault X X
Error status Line test
Fault X
Oscilloscope No fault X X
test Fault X
Replace the
Course of ac- Replace the en- Replace the
camshaft sen-
tion gine control unit line
sor
Changing the camshaft sensor 0B11

Removal 

bly (1).
 Remove the camshaft sensor 0B11.
NOTE
To aid clarity, the starter motor is not shown in

the graphic.
Installation
 Replace all the seals on the camshaft sensor
0B11.

Lubrication
Engine oil circuit
14
13 13 13 13
12 12 12
11 11 11 11 11
10 10 10 10 10
9 9 9 9
7 7 7 7
8
6 5
4
2
1
3
394-02_01-295
1 Oil pump 8 Control housing

2 High-pressure relief valve 9 Piston
3 Bypass valve in the oil cooler 10 Main bearing (crankshaft)
4 Oil cooler 11 Big end bearing
5 Oil filter 12 Camshaft bearing
6 Bypass valve in the oil filter 13 Rocker lever and hydraulic tappet
7 Spray nozzles for cooling the pistons 14 Turbocharger
Colour key for engine oil

Cooled, filtered
Cooled, unfiltered
Uncooled, unfiltered
This engine is force-lubricated by a mechanical

oil pump (1). The oil pump (1) initially transports
oil from the oil pan into the high-pressure relief
valve (2). The high-pressure relief valve (2) is a
safety valve. This valve prevents engine compo-
nents being damaged as a result of excessively
high oil pressure, for example at low outside
temperatures and at high revolution speeds. The
oil then flows through the oil cooler (4) and the
oil filter (5). The bypass valves (3, 6) on the oil

cooler (4) and on the oil filter (5) ensure that the
oil pressure is maintained if the oil cooler (4) and
oil filter (5) are blocked.
Oil is directed through the cylinder block to lubri-
cate the main bearings (10), the big end bear-
ings (11), the camshaft bearings (12) and the
rocker lever with hydraulic tappet (13). The tur-
bocharger (14) is also connected to the engine
lubrication system. In the cylinder block, the oil
is distributed into oil channels. In the control
housing (8), the oil is distributed around the spur
gears. Each cylinder has a spray nozzle (7) for
cooling the piston crown. The oil filter (5) cleans
the engine oil. The oil cooler (4) cools the oil to a
temperature that is suitable for operation. The oil
flows back into the oil pan from the engine com-
ponents that have been supplied with oil.

Instructions regarding the engine lubrication system after engine repairs
WARNING
NOTE
when working on the engine! When assembly work is being performed, the
engine must be secured to the engine holder
and gearbox holder VAS 6095 with the universal
engine. mounting VAS 6095/1.
CAUTION
If during engine repairs you find large quantities of
metal chips or abrasion, this may indicate damage to
the crankshaft or connecting rod bearings.
To prevent consequential damage, perform the follow-
ing tasks after repair:
 Carefully clean the oil channels
 Change the oil cooler
Oil pump, oil sump - assembly overview

WARNING
engine.
Requirement
 Remove the V-ribbed tensioner.
 Remove the crankshaft belt pulley.
 Remove the belt tensioner.
 Remove the control housing cover.
 Remove the control wheel.

Oil pump (1) 
Play between the crankshaft pulley and the oil

pump impeller: 0.06 mm to 0.259 mm
394-02_01-303
Oil pan (4) 
 Clean the sealing face before installation.

Sealant with Ø 3 mm ±0.5 mm
Two oil drain plugs (5)
Level sensor for engine oil (6)
3
6
5 5 4
394-02_01-304

Oil filter support, oil cooler - assembly overview
1 Engine oil filter 4 Screws

2 Support for the engine oil filter 5 Support for the oil cooler
3 Engine oil supply and engine oil drain
WARNING
engine.
Engine oil filter (1)

Tightening torque for the engine oil filter (1):
20 Nm
Support for the engine oil filter (2)

Engine oil supply and engine oil drain (3)
Screws (4)
 After dismantling the support for the oil cooler
(5), replace the sealing rings between the
support for the oil cooler and the cylinder
block.
The sealing rings are not shown in the graphic.
Tightening torque for the screws (4): 16 Nm to
20 Nm
Changing the oil pan

WARNING
engine.

● Flexible-head wrench, size 12
● Silicone sealant TB1217H
● Manual drill with plastic brush insert
● Protection goggles
● Blunt scraper
394-02_01-253

Removal 
 Drain the engine oil, see "Changing the en-

gine oil and engine oil filter".
bly from the engine oil level sensor (0B16).
 Remove the oil pan (2).
NOTE 1
If necessary, loosen the oil pan by striking lightly

with a rubber mallet. 0B16 2
 Use a flat scraper to remove any residual
sealant from the cylinder block. 394-02_01-238
 Clean the sealing face on the cylinder block.

This must be free from oil and grease.
WARNING
Danger of injury.
Wear eye protection.
 Use a rotating plastic brush to remove any re- 

sidual sealant from the oil pan.
 Clean the sealing face of the oil pan.
This must be free from oil and grease.
Installation
 Before installing the oil pan, check the sealant
is within its shelf life date.
393_01-1202
 Cut off the tube nozzle at the first marking 

(nozzle diameter approx. 3 mm).
 Apply sealant with a thickness of 3 ± 0.5 mm
to the clean sealing face of the oil pan.
NOTE
If the bead of sealant is too thick, surplus seal-

ant will fall into the oil pan. This can block the
strainer in the oil pump suction line.
 Place the oil pan on the cylinder block within
5 minutes.
393_01-1203

NOTE
When installing the oil pan on the removed en-

gine, ensure that the oil pan is flush with the cyl-
inder crankcase on the flywheel side.
 Tighten the 26 screws across diagonals.
 Allow 25 minutes for the sealant to dry com-
pletely.
 Refill the engine with oil, see "Changing the
engine oil and engine oil filter".
Engine oil level sensor 0B16
0B16
394-02_01-215
The engine oil level sensor (0B16) is designed

as an ultrasonic sensor. It is located in the oil
pan.

Pin assignment 
Pin Connection
Vbat Supply from the battery
K070 Ground (GND)
K069 Signal
K069 K070 Vbat
Function
The engine oil level sensor (0B16) senses the oil
level in the oil pan. The signal is transmitted via
the engine control unit (0N1) to the display unit.
If the oil level is too low, the engine oil level indi- 394-02_01-216
cator lights up. Depending on the configuration,
the truck can then move only at creep speed
(approx. 2 km/h).
The engine oil level sensor (0B16) measures the
filling level from 18 mm to 118 mm.
The operating temperature range is from −40°C
to +160°C.
Engine oil pressure sensor 0B7
0B7
394-02_01-217
The engine oil pressure sensor (0B7) is located

on the inlet side of the engine.

Pin assignment 
Pin Connection
A036 Signal
A035 Ground (GND)
Function
The engine oil pressure sensor (0B7) senses the
oil pressure of the engine. The engine control
unit (0N1) takes the sensor signal from engine
oil pressure sensor (0B7). If the engine oil pres- 394-02_01-240
sure is too low, the engine oil pressure indicator
lights up and a buzzer sounds. The engine oil
pressure sensor (0B7) measures from 0.5 bar to
1 bar. Pressures > 1 bar are not sensed.
Changing the engine oil pressure sen-

sor 0B7
WARNING
Risk of scalding from hot surfaces!
Allow the engine to cool down.
Remove the engine oil pressure sensor 0B7.
Required special tools, testing instruments, 

393_01-1158
Removal 
0B7
bly (1) on the engine oil pressure sen-
sor (0B7).
 If necessary, use a cloth to collect the engine 1
oil at the engine oil pressure sensor (0B7).
 Remove the engine oil pressure sensor (0B7).
Installation
NOTE

quence.
394-02_01-243
 Tightening torque for 0B7: 22 Nm.

Cooling
Coolant circuit
7 6
10
8 4
9
1
2 3
394-02_01-266
1 Radiator 6 EGR radiator

2 Coolant pump 7 EGR valve
3 Engine block 8 Thermostat
4 Cylinder head 9 Bypass
5 Engine oil cooler 10 Heat exchanger for the cab heating
The coolant flows from the engine block (3) into

the cylinder head (4). The coolant absorbs heat
from the combustion chamber and engine oil.
When the coolant reaches a temperature ≥
82°C, it flows through the opened thermostat (8)
into the radiator (1). This is where the heat
transfer takes place.
At a coolant temperature < 82°C the coolant
flows through the bypass (9), since the thermo-
stat(8) is closed. The coolant flows back to the
coolant pump (2).
The coolant for the heat exchanger for the cab
heating (10) is taken from the thermostat hous-
ing between the cylinder head (4) and the ther-
mostat (8). After the coolant has passed through
the heat exchanger (10), it flows directly to the
coolant pump (2) and is fed back into the coolant
circuit.

The coolant flows sequentially through the fol-
lowing components:
● EGR radiator (6)
● EGR valve (7)
● Engine oil cooler (5)
The coolant is fed from the EGR radiator (6) and

the EGR valve (7) via the thermostat (8).
From the engine oil cooler (5), the coolant flows
directly to the coolant pump (2) and back into
the coolant circuit.
Once the coolant has cooled back down, it flows
from the radiator (1) back to the coolant pump
(2).

Instructions for frost protection and coolant
NOTE
● Engine coolant level must be within the mark-
ings on the expansion reservoir.
● Always firmly close the cover on the expan-
sion reservoir.
● Only G12++ according to TL 774-G may be
used as a coolant additive.
● The coolant additive G12++ must only be
mixed with G12+.
● The coolant additive must be mixed with
drinking water (total hardness of water must
not be more than 20° according to German
hardness standards) If no drinking water is
available, distilled water must be used
● Coolant additives endorsed according to
"TL 774-G" or according to "TL 774-F" pre-
vent frost damage, corrosion damage and
lime scale deposits, and also raise the boiling
temperature. Therefore, the cooling system
must be filled with anti-freeze and corrosion
inhibitor all year round.
● Particularly in tropical countries, the coolant
increases operational safety by increasing the
boiling point when the engine is under heavy
load.
● Frost protection must be ensured down to
around -25°C (in countries with an Arctic cli-
mate, down to around -35°C).
● In hot countries or even during warm sea-
sons, the coolant concentration must not be
reduced by adding water The percentage of
coolant additive must be at least 40%
● If greater frost protection is required for cli-
matic reasons, the percentage of G12++ can
be increased to up to 60% (frost protection
down to about -40°C). Otherwise, the frost
protection is reduced and the cooling effect
will be impaired.
● Use refractometer VWT10007A as a means
of determining the current frost protection
density.
● If the radiator, heat exchanger, cylinder head
or cylinder head seal have been replaced,
used coolant should not be reused.
Recommended mixture ratios
Frost protec- G12+ or G12+

Drinking water
tion down to +
-25°C Approx. 40% Approx. 60%

Instructions for changing components of
the cooling system
WARNING
Risk of scalding by coolant.
When the engine is hot, the cooling system is pres-
surised.
 Be sure to release the pressure before performing
repairs if necessary.
 Observe safety information for repair and mainte-
nance work and safety information for working on
the engine.
Pliers for spring band clamps VWVAS6340 
Hose connections are secured with spring band

clamps or clamping clips.
Coolant hoses on the engine must be secured
only with spring band clamps. 393_01-1234
 Replace clamping clips with spring band

clamps.
 Use the pliers for spring band clamps
VWVAS6340 for fitting spring band clamps.
 When installing coolant hoses, ensure that
they are not tensioned and do not come into
contact with other components.
 Take note of the marking on the coolant con-
nection and hose.
 Test the cooling system for leaks using cool-
ing system testing instrument V.A.G 1274 and
adapters V.A.G 1274/8 and V.A.G 1274/9.
Checking the cooling system for leaks 

measuring devices and other devices:
● Cooling system testing instrument V.A.G
1274 B
● Adapter for cooling system testing instrument
V.A.G 1274/8 and V.A.G 1274/9

Test conditions
● Engine at normal operating temperature
Test procedure
WARNING
Hot steam may escape when opening the expansion
reservoir.
Wear goggles and protective clothing to prevent eye
injuries and scalding. Cover the filler cap with a cloth
and open it cautiously.

 Open the coolant expansion reservoir's filler
cap.
 Screw adapter for cooling system testing in-
strument V.A.G 1274/8 into the coolant ex-
pansion reservoir.
 Clamp connection piece V.A.G 1274 B/1 into
the adapter for cooling system testing instru-
ment V.A.G 1274/8.
 Via the connection hose provided, connect
connection piece V.A.G 1274 B/1 with cooling
system testing instrument V.A.G 1274 B
 Use the hand pump of the testing instrument
to generate overpressure of approx. 1.0 bar.
DANGER
Risk of scalding!
Before disconnecting cooling system testing instru-
ment V.A.G 1274 B from the supply hose or connec-
tion piece V.A.G 1274 B/1, the existing pressure in
the system must be discharged. To do this, press the
pressure relief valve on cooling system testing instru-
ment V.A.G 1274 B until the pressure gauge displays
the value "0".
If pressure decreases:
 Identify location of leak and rectify.
Check high-pressure relief valve in the filler cap
 Screw filler cap into the adapter for cooling
system testing instrument V.A.G 1274/9.
 Screw connector V.A.G 1274 B/1 into the
adapter for cooling system testing instrument
V.A.G 1274/9.
 Via the connection hose provided, connect
connection piece V.A.G 1274 B/1 with cooling
system testing instrument V.A.G 1274 B.
 Use the hand pump of the cooling system
testing instrument to generate overpressure
of approx. 1.6 bar.
The high-pressure relief valve must not open
yet.
If the high-pressure relief valve opens prema-
turely:
 Change filler cap.
 Raise pressure to more than 1.6 bar.
The high-pressure relief valve must open.
If the high-pressure relief valve does not open:
 Change filler cap.

Replacing the coolant pump
WARNING
Risk of scalding due to hot coolant!
Allow the engine to cool down before draining the
coolant.
ENVIRONMENT NOTE

consumables.

 Allow the coolant to drain.

 Screw in the screw (1) and tighten. Tightening
torque: 29±3 Nm
1
394-02_01-222

Removal
 Loosen four screws (7) on the belt pulley (6).
NOTE
It is easier to loosen the screws of the belt pulley

if the V-ribbed belt is still in place and under ten-
sion.
 Position the hexagon wrench on the hexagon
of the belt tensioner (10).
 Turn the belt tensioner (10) anticlockwise and
hold.
The tension of the V-ribbed belt (5) is released.
 Insert a suitable mandril into the latch
holes (9) of the belt tensioner.
The belt tensioner (10) remains in the mounting
position.
 Remove the V-ribbed belt (5).
 Remove the hexagon wrench.
 Remove four screws (7) from the belt pul-
ley (6).
 Remove the belt pulley (6).

 Remove the screw (1) of the three-phase
generator (11).
 Fold back the three-phase generator (11).
 Unscrew two screws (4) and remove the
screws, along with the support.
 Open three clips (2, 3, 8) and remove the ho-
ses.
 Press the coolant hose clip out of the 
bore (5).
5 1
 Remove eight screws (3).

2
 Remove the support (2).
 Remove two nuts (4).
3 3
 Remove the coolant pump (1).
Installation
NOTE
3
quence.
 When installing the V-ribbed belt, note the di- 3 4 394-02_01-224
rection of travel.
belt pulleys.
 Replace the seal.
 Tighten the screws to secure the coolant
pump. Tightening torque: 20 Nm
 Tighten the nuts to secure the coolant pump.
 Tighten the screw to secure the three-phase
generator. Tightening torque: 40 Nm

Coolant level sensor 0B19
0B19
394-02_01-208
The coolant level sensor (0B19) is located in the

expansion reservoir. It is connected to the dis-
play unit (6P1).
Pin assignment 
Pin Connection
:1 Supply
:3 Ground (GND)
Function
The coolant level sensor (0B19) is designed as
an NO switch. The coolant level sensor (0B19)
reports a low coolant level directly to the display
unit (6P1) by closing.
1 3
394-02_01-239

Coolant temperature sensor 0B10
0B10
394-02_01-209
The coolant temperature sensor (0B10) is loca-

ted on the outlet side of the engine in the ther-
mostat housing.
Pin assignment 
Pin Connection
A099 Ground (GND)
A100 Temperature signal
Function
The coolant temperature sensor (0B10) senses
the temperature of the engine coolant. It is de-
signed as a thermocouple temperature sensor. A099 A100
The temperature difference between the meas-
urement point and the comparison point gener-
ates a thermoelectric voltage. The engine con-
trol unit (0N1) senses the resulting temperature
signal. 394-02_01-210

Checking the coolant temperature sen-
sor 0B10
0009419980
plug A or plug K
● Multimeter
● Wiring diagram

bly
 Disconnect electrical connection assembly for
the coolant temperature sensor 0B10.
● Corrosion
● Contamination
● Moisture
If no fault is detected, check the electrical resist-

ance.

Checking the electrical resistance 
 Connect the multimeter for resistance meas-

uring to the pins A099 and A100.
 Measure the resistance of the coolant temper-
ature sensor 0B10.
PIN Connection
A099 Ground (GND) A099 A100
A100 Signal
If the measured value is endless, there is a short

circuit in coolant temperature sensor 0B10.
 Replace the coolant temperature sensor
0B10.
If no fault is detected, check the electrical volt-
394-02_01-319
age.
Checking the electrical voltage

for a line test".
 Disassemble the coolant temperature sensor
0B10. See "Replacing the coolant tempera-
ture sensor 0B10".
 Switch on the ignition.
 Check the coolant temperature sensor 0B10
using a known temperature.
Temperature [°C] Electrical voltage [mV]

−35 4819
0 4112
10 3744
20 3315
30 2855
80 1011
125 369
If the setpoint value is not reached:

 Replace the coolant temperature sensor
0B10.
If the setpoint value is reached, check the cables
for continuity.
 Assemble the coolant temperature sensor
0B10. See "Replacing the coolant tempera-
ture sensor 0B10".

for a line test".
NOTE

A099 and A100.
If no fault is detected in the electric cables:
 Replace engine control unit 0N1.

Fuel supply
Working on the fuel supply
WARNING WARNING
Risk of injury if incorrect procedures are followed Risk of burns due to very hot fuel.
when working on the engine!  In extreme cases, the temperature of the fuel lines
Observe safety information for repair and mainte- and/or the fuel can be as high as 100°C. Before
nance work and safety information for working on the undoing any fuel line connections, allow the fuel to
engine. cool, as there is a risk of serious scalding.
 Wear protective gloves.
WARNING  Wear protection goggles.
The following must be observed when working on fil-

led or partially filled fuel tanks: WARNING
Before starting work, a switched-on exhaust gas ex-
traction system must be placed in the vicinity of the Risk of injury from fuel under high pressure.
assembly opening of the fuel tank in order to extract The fuel lines are pressurised! Before loosening hose
fuel gases released from the exhaust gas hose. If no connections, place a cleaning cloth around the con-
exhaust gas extraction system is available, a radial nection point. Reduce the pressure by carefully re-
fan (motor outside the air flow) with a delivery volume moving the hose.
greater than 15 m3/h can be used.
Do not damage fuel hoses in the engine compart-
Avoid skin contact with fuel! Wear fuel-resistant ment.
gloves!
Fuel system
2 3 4
5
1
9 6
8 5 10 11 3 5
394-02_01-338
1 High-pressure fuel pump 6 Injector 0Y1-0Y4

2 Fuel supply line 7 Engine control unit 0N1
3 Rail pressure sensor 0B35 8 Fuel tank
4 High-pressure rail 9 Fuel filter
5 Fuel return line

10 Connections for the sensors on the engine 11 Connections for the actuators on the engine
control unit 0N1 control unit 0N1
Function Components
The compression stroke of the piston compress- The low-pressure system includes:
es the air that is drawn in. The air heats up. The ● Fuel return lines (5)
heated air ignites the diesel fuel (compression- ● Fuel tank (8)
ignition engine). ● Fuel filter (9)
The higher the storage volume, the slower the

The high-pressure system includes:
system. Therefore, a reservoir is connected be-
● High-pressure fuel pump (1)
hind the high-pressure fuel pump (1), the high-
pressure rail (4). ● Fuel supply lines (2)
● Rail pressure sensor 0B35 (3)

From the high-pressure rail (4), the fuel enters
● High-pressure rail (4)
the combustion chamber via the injectors
0Y1-0Y4 (6). In order to achieve the best engine ● Four injectors 0Y1-0Y4 (6)
performance, the engine control unit 0N1 (7) de- ● Engine control unit 0N1 (7)
termines the timing of the injection, the quantity

of fuel and the fuel pressure, depending on the
working conditions.
The fuel system consists of a low-pressure sys-
tem, a high-pressure system and the engine
control unit 0N1 (7).

Fuel system - assembly overview
1 Fuel tank 4 Supply line

2 Fuel filter 5 Return line
3 Switch for water trap 0B36 6 Bleed line
CAUTION
Dirt must not be allowed to enter the removed return
lines or the connections of the injectors.
 Observe the cleanliness rules.
 Observe the instructions for working on the fuel
system.
 Protect the opened fuel connections via suitable
means to prevent the ingress of dirt.

394-02_01-323
High-pressure fuel pump (7) 
Tightening torque (8): 22 Nm

Play between the auxiliary wheel and the pinion
gear of the high-pressure fuel pump: 0.087 mm
to 0.2 mm

394-02_01-324
High-pressure rail (9) 

10
394-02_01-325
Fuel line (10) 
 Always replace the fuel line after disassem-

bly.

11
394-02_01-326
Fuel return line (11) 
 Avoid oil leaks after assembly.

12
12
13
394-02_01-327
Injectors (12) 
 Replace all seals before assembly.

Tightening torque: 40 Nm to 46 Nm (13)
Sanitation regulations
When working on the fuel supply/injection sys- ● Only install clean parts: Leave spare parts in
tem, the following "regulations" regarding clean- their packaging until immediately prior to in-
liness must be carefully observed: stallation. Never use parts that were stored
● Before opening any connection point, clean it unpackaged (e.g. in toolboxes etc.).
thoroughly and all around it. ● Any transport or protective packaging and
● Place parts that have been removed on a locking caps must only be removed immedi-
clean pad and cover the parts Never use lint- ately prior to installation.
ing cloths!
● If repairs to components that have been re-
moved are not performed straight away, cover

up or seal the parts carefully.

● When the system is open: if at all possible, do contact with coolant hoses, clean the hoses
not use compressed air. Avoid moving the immediately. Damaged hoses must be re-
truck if possible. placed.
● Care should also be taken that no fuel runs
on to the coolant hoses. If fuel comes into
Behaviour during incorrect refuelling

CAUTION
Incorrect refuelling can cause damage to the fuel sup-
ply system!
Incorrect refuelling can cause irreversible damage to
the high-pressure components, in particular the high-
pressure fuel pump.
 Fill the tank only with a diesel fuel listed in the
"Recommendations for consumables".
 If incorrect refuelling is identified, do not start the
engine.
Lack of lubrication by the diesel fuel can cause

seizure of valves in the high-pressure fuel pump.
Particles that have eroded from moving parts
may cause further damage within the mechani-
cal pressure regulating valve on the high-pres-
sure rail and within the injectors.
Step Description Yes No

Go to Go to
► Has the engine been started with incorrect fuel?
step 1 step 2
1 Engine has been started with incorrect fuel
► Empty the fuel tank as far as possible via the filler neck using the
VAS 5190 fuel suction device.
► Disconnect the fuel supply line from the high-pressure fuel pump to the
fuel filter on the fuel filter.
► Lead the free end of the fuel supply line into a suitable container.
► Perform the actuator test whilst simultaneously activating the high-pres-
sure fuel pump.
The high-pressure fuel pump is now activated.
► If necessary, repeat this process until the fuel tank is completely emp-
tied.
► Remove the flange cover from the fuel tank.
► Inspect the fuel tank for chips according to the manufacturer's specifi-
cations and completely empty it of fuel.
► Perform a visual inspection for coarse impurities and chips on the
screen filter.
Go to Go to
► Are chips present?
step 3 step 4
2 Engine has not been started with incorrect fuel
► Empty the fuel tank as far as possible via the filler neck using the
VAS 5190 fuel suction device.
► Disconnect the fuel supply line from the high-pressure fuel pump to the
fuel filter on the fuel filter.
► Lead the free end of the fuel supply line into a suitable container.

► Perform the actuator test whilst simultaneously activating the high-pres-
sure fuel pump.
► The high-pressure fuel pump is now activated.
► If necessary, repeat this process until the fuel tank is completely emp-
tied.
► Fill the fuel tank with 5 litres of diesel fuel.
► Completely empty the fuel tank again as described above.
► Reconnect the fuel supply line to the fuel filter.
► Completely fill the truck fuel tank.
► Perform a test drive.
3 Chips present in the fuel tank and screen filter
► Clean the fuel tank according to the manufacturer's specifications.
► Clean the screen filter according to the manufacturer's specifications.
► Replace the following high-pressure components:
● High-pressure fuel pump
● High-pressure lines
● Including the high-pressure rail
○ Injectors
○ Fuel return lines
○ Fuel filter
► Bleed the fuel system.
4 No chips present in the fuel tank and screen filter
► Replace the high-pressure fuel pump.
► When checking for chips, perform the following step only if the high-
pressure fuel pump is defective!
► See illustration "394-02_01-256" at the end of this section.
► Remove the two screws (1).
► Remove the fuel quantity regulation valve (0Y11).
► Check the fuel quantity regulation valve (0Y11) for chips.
► Check the high-pressure fuel pump (2) for chips.
Go to Go to
► Are chips present?
step 5 step 6
5 Chips present in the high-pressure fuel pump
► Replace the following high-pressure components:
● High-pressure fuel pump
● High-pressure lines
● Including the high-pressure rail
○ Injectors
○ Fuel return lines
○ Fuel filter

6 No chips present in the high-pressure fuel pump
► Replace the fuel filter.
Fuel quantity regulation valve on the high-pres- 

sure fuel pump 0Y11
Screws (1)
High-pressure fuel pump (2) 1
Fuel quantity regulation valve (0Y11)
2
1 394-02_01-256
Replacing parts of the fuel supply sys-

tem
Spring band clamp pliers VWVAS6340 
Hose connections are secured with spring band

clamps or clamping clips.
Only spring band clamps may be used to secure
fuel hoses on the engine. 393_01-1234
 Replace clamping clips with spring band

clamps.
 Use spring band clamp pliers VWVAS6340 to
fit spring band clamps.

Water trap switch 0B36
0B36
394-02_01-197
The water trap switch (0B36) is located on the

fuel filter (1).
Pin assignment 
Pin Connection
K044 Signal
K048 Ground (GND)
Function
K048 K044
The water trap switch (0B36) senses condensa-
tion water within the fuel filter (1). The engine
control unit (0N1) senses the signal. If the con-
densation water level reaches a pre-determined
level, the "Water in the fuel filter" indicator light 394-02_01-198
illuminates and a buzzer sounds.

Fuel temperature sensor 0B12
0B12
1
394-02_01-195
The fuel temperature sensor (0B12) is located

on the fuel filter (1).
Pin assignment 
Pin Connection
K028 Signal
K032 Ground (GND)
Function K032 K028

The fuel temperature sensor (0B12) senses the
fuel temperature at the fuel filter (1). The engine
control unit (0N1) senses the resulting tempera-
ture signal. To comply with exhaust emission
limits and to operate the engine under the best 394-02_01-196
conditions, the fuel temperature is critical for the
timing and duration of injection.

Checking the fuel temperature sensor
0B12
0009419980
plug A or plug K
● Multimeter
● Wiring diagram

bly
bly for fuel temperature sensor 0B12.
● Corrosion
● Contamination
● Moisture

ance.


uring to the pins K032 and K028.
 Measure the resistance of the fuel tempera-
ture sensor 0B12.
PIN Connection K032 K028

K028 Signal
K032 Ground (GND)

circuit in the fuel temperature sensor 0B12.
 Replace the fuel temperature sensor 0B12.
394-02_01-394
age.

for a line test".
 Disassemble the fuel temperature sensor
0B12. See "Replacing the fuel temperature
sensor 0B12".
 Check the fuel temperature sensor using a
known temperature.
Electrical volt- Electrical volt-

Temperature age [mV] age [mV]
[°C] (manufacturer: (manufacturer:
Bosch) Parker)
−40 4868 4876
0 4102 4121
20 3293 3324
40 2377 2404
80 1000 1019
140 265 275

 Replace the fuel temperature sensor 0B12.
for continuity.
 Assemble fuel temperature sensor 0B12. See
"Replacing the fuel temperature sensor
0B12".

for a line test".
NOTE

K032 and K028.
Checking the fuel system for leak tight-

ness
WARNING
Risk of injury from fuel spraying out!
The high-pressure fuel pump compresses the fuel to
1800 bar.
 If the fuel lines need to be pressurised after a re-
pair, exit the danger area.
 Then perform testing.
 After assembly, clean all fuel connections us-

ing brake cleaner, and then dry them.
 Bleed the fuel system; see "Bleeding the fuel
system".
 Check the entire fuel system for leak tight-
ness.
 Perform a visual inspection.
If there is any leakage despite the correct tight-
ening torque, replace the affected component.
 Warm up the truck.
 Check the high-pressure area for leak tight-
ness again.

Fuel preparation, injection
Working on the common rail injection system
WARNING
engine.
WARNING
Risk of injury due to high pressure and high tempera-
ture in the high-pressure rail!
 Connect a laptop with the diagnostic program in-
stalled on it.
 Use the diagnostic program to check the tempera-
ture and pressure in the high-pressure rail.
CAUTION
Damage to the common rail injection system can lead
to engine damage.
To prevent consequential damage, observe the fol-
lowing information for the repair:
 Avoid damage to the high-pressure rail.
 Protect all engine components against the ingress
of dirt during work on the common rail injection
system.
 Always replace loose high-pressure lines.
Replacing the high-pressure fuel pump

CAUTION
Risk of irreparable damage to the high-pressure fuel
pump due to ingress of dirt and dry running.
If dirt particles enter the high-pressure fuel pump, or
the high-pressure fuel pump runs dry, it may be dam-
aged.
 After replacing the high-pressure fuel pump, fill it
with fuel before starting the engine for the first
time.
 Do not remove the sealing plug until immediately
prior to installing the fuel lines.
 Protect the opened fuel ports by suitable means to
prevent the ingress of dirt.

● Sealant TB121H
● Protection goggles
393_01-1158
Removal 
1
 Observe cleanliness rules and instructions for 0Y11
working on the fuel system. 4
Removing the V-ribbed belt
 Remove the V-ribbed belt, see "Replacing the
V-ribbed belt". 3
Disconnecting the electrical connection assem-
blies and lines
 Disconnect the electrical connection assem- 2
bly (1) from the fuel quantity regulation valve
(0Y11).
NOTE 394-02_01-258
Make sure that the electrical connection assem-

bly is not damaged during the disconnection
process. Otherwise the entire wiring harness
must be replaced.
 Remove the fuel supply line (3).
 Remove the fuel return line (2), see the sec-
tion "Replacing the fuel return line".
 Remove the high-pressure line (4).
Removing the crankshaft pulley and belt ten- 
sioner
 Remove the crankshaft pulley (8).
 Remove the belt tensioner (5).
 Remove the two screws (9). 7
 Remove the crankshaft sensor (0B13).
8
9 0B13 394-02_01-259

Removing the control housing cover 

 Remove the control housing cover (11).
 Remove any residual sealant from the control 10
housing cover (11)
WARNING 11
Danger of injury.
Wear eye protection.
 Clean the sealing face of the control housing

cover (11)
394-02_01-260
Removing the crankshaft pulley 
 Remove the crankshaft pulley (12).
12
394-02_01-261
Removing the high-pressure fuel pump 
 Remove the three screws (14).

 Remove the high-pressure fuel pump (13).
 Remove the collar from the high-pressure fuel
pump (13).
NOTE 13
The collar is located on the control side of the
engine. It holds the high-pressure fuel pump (13)
in position.
14
 Remove the O-ring from the collar.
Installation
394-02_01-262
NOTE

quence.

Installing the high-pressure fuel pump
NOTE
Always replace the O-ring on the collar. Do not

re-use it.
 Tighten the nut to secure the collar. Tighten-
ing torque: 80±0.5 Nm
CAUTION
Before installing the high-pressure fuel pump, check
the installation position of the drive wheel. The mark-
ing on the drive wheel must point to the cylinder
block. The direction of the pin must be opposite that
of the idling gear.
CAUTION
The marking on the idling gear must be between the
drive wheel markings on the high-pressure fuel pump.
The play in the idling gear and in the drive wheel for
the high-pressure fuel pump must not exceed be-
tween 0.087 and 0.2 mm.
 Tighten the screws to secure the high-pres-

sure fuel pump. Tightening torque: 22 Nm
Installing the crankshaft pulley
NOTE
Pay attention to the installation position when in-

stalling the crankshaft pulley. Do not damage
the teeth of the crankshaft pulley.
Installing the control housing cover
NOTE
Observe the following when installing the control

housing cover:
 Before installing the control housing cover,
check that the sealant is within its shelf life
date.
 Apply sealant with a thickness of 2.5±0.5 mm
to the clean sealing face of the control hous-
ing cover.
NOTE
If the bead of sealant is too thick, surplus seal-

ant will fall into the camshaft drive.
 Take care not to damage the shaft seal.
 Use a rubber mallet to gently hammer the
shaft seal into the control housing cover.

 Do not drive the shaft seal too far into the
control housing cover.
NOTE
Always replace the shaft seal. Do not re-use it.

 Using a mandrel, align the control housing
cover on the cylinder block.
 Tighten the 16 screws to secure the control
housing cover. Tightening torque: 22 Nm
NOTE
Place the control housing cover on the cylinder

block within 5 minutes.
 Allow 25 minutes for the sealant to dry com-
pletely.
 Install the crankshaft sensor (0B13).
Installing the crankshaft pulley
 Tighten the screw to secure the crankshaft
pulley. Tightening torque: 255 Nm
NOTE
Take care not to damage the shaft seal.

Installing the V-ribbed belt
 Install the V-ribbed belt, see "Replacing the V-
ribbed belt".
Replacing the fuel return line

 If necessary, fold back the three-phase gener-
ator: see the section entitled "Replacing the
coolant pump".
 Open the clip (3). 
1 2
 Remove two cable ties (3, 4).
 Disconnect the connector to the high-pres-
sure fuel pump (5).
3
 Remove the clip (6).
4
6 5 394-02_01-269

Disconnect the fuel return line from the injectors 
7 A B
NOTE 8 A
7
First, release all safety clips (8) before discon-
necting the individual fuel return line connec-
tions (2).
 Push the two brackets (7) downwards (A) and
simultaneously pull the safety clip (8) upwards
to release it (B).
 Hold the fuel return line connection by the
brackets (7) and pull it up and off the injectors
(C).
 Once all four fuel return line connections (2)
7 C
have been disconnected, remove the fuel re-
turn line (1). C
7
NOTE

quence.
394-02_01-267
 To connect the fuel return line, position the 

fuel return line connections (2) on the injec- D
tors. 7 D
 Hold the fuel return line connection by the 7
brackets (7) and press downwards (D). Simul-
taneously push the safety clip (8) downwards
until it locks (E).
 Replace two cable ties (3, 4).
E
8
394-02_01-268

Fuel quantity regulation valve 0Y11
0Y11
394-02_01-182
The fuel quantity regulation valve (0Y11) is loca-

ted on the high-pressure fuel pump.
Pin assignment 
Pin Connection
A006 Signal
Function
The fuel quantity regulation valve (0Y11) only A007 A006
lets as much fuel into the high-pressure fuel
pump as is required to build up the required rail
pressure. The engine control unit (0N1) picks up
the signal from the rail pressure sensor (0B35) 394-02_01-183
and uses the signal to control the fuel quantity
regulation valve (0Y11).

Rail pressure sensor 0B35
0B35
394-02_01-184
The rail pressure sensor(0B35) is located in the

rail (1) on the inlet side of the engine.
Pin assignment 
Pin Connection
A063 Ground (GND)
A062 Signal
A063 A052 A042

Function
The rail pressure sensor (0B35) measures the
pressure in the rail (1). The engine control unit
(0N1) senses this signal. If the measured pres-
sure deviates from the target value, the engine 394-02_01-185
control unit (0N1) slows down the engine speed
as necessary. To ensure that the rail pressure
returns to the pressure value required for correct
operation of the engine, the engine control unit
(0N1) activates the fuel quantity regulation valve
(0Y11).
This is dependent amongst other things on the:
● Engine temperature
● Fuel temperature
● Engine speed
● Engine load
● Condition of the injectors – dirty or defective.

Injectors 0Y1...0Y4
0Y3 0Y4
0Y2
0Y1
394-02_01-186
The injectors (0Y1...0Y4) are Bosch solenoid

valve injectors type "CRI2-18 OHW". They are
installed in line on the cylinder head.
Each cylinder has one injector: injector (0Y1) is
seated on the first cylinder, injector (0Y4) is
seated on the fourth cylinder.

Pin assignment 
Injector 0Y1
PIN Connection
A064 Signal +
A085 Signal − 0Y1 A064 A085
Injector 0Y2
PIN Connection
A024 Signal +
A045 Signal −
Injector 0Y3
PIN Connection 0Y2 A024 A045
A022 Signal +
A043 Signal −
Injector 0Y4
PIN Connection
A066 Signal +
A087 Signal −
0Y3 A022 A043
Function
During the delivery phase, the injectors
(0Y1...0Y4) atomise the fuel in the combustion
chamber in several stages at a pressure of up to
1800 bar. The atomisation is performed at the
command of the engine control unit and in con-
junction with the exhaust gas sensor values. If
0Y4 A066 A087
the engine speed is reduced, no fuel is injected
into the combustion chamber.
394-02_01-187
Checking the injectors 0Y1 to 0Y4

WARNING
engine.

0009419980
plug A or plug K
● Multimeter
● Wiring diagram

bly
bly of the injectors (0Y1...0Y4).
● Corrosion
● Contamination
● Moisture

ance.

 Set the multimeter to resistance measuring.

 Measure the resistance of the injector(0Y1) at
A064 and A085.
Injector 0Y1 0Y1 A064 A085
PIN Connection
A064 Signal +
A085 Signal −

A024 and A045.
Injector 0Y2
PIN Connection
0Y2 A024 A045
A024 Signal +
A045 Signal −

A022 and A043.
Injector 0Y3
PIN Connection
A022 Signal +
A043 Signal − 0Y3 A022 A043

A066 and A087.
Injector 0Y4
PIN Connection
A066 Signal +
A087 Signal −
If the measured value is endless, there is a short 0Y4 A066 A087
circuit in the injector.

 Replace the injector.
If the measured value is not endless, check the
cables for continuity. 394-02_01-353

for a line test"
NOTE


A064 and A085.
A024 and A045.
A022 and A043.
A066 and A087.
Further troubleshooting
 Swap the electrical connection assembly with
that of a different injector.
If the fault also migrates:
 Replace the injector.
If the fault does not migrate, check the electrical
connection assembly on engine control unit 0N1
for:
● Corrosion
● Contamination
● Moisture
If a fault is detected:
 Rectify the fault.
If no faults are found:
 Check the injectors for mechanical defects.
 To do this, check the return flow measure-
ment. See "Measuring the return flow volume
of the injectors"
 Check the encoding of the injectors.

Measuring the injectors return flow 
Special tools, testing instruments and measur-

ing devices required:
● Injector testing instrument 0009418523
● Adaptor 0009419077
Prerequisites for the measurement:

● Engine at operating temperature with a cool-
ant temperature of > 80°C
Installing the injector testing instrument

 Disconnect the return lines from the individual
injectors.
 Connect one adaptor 0009419077 to each of
the return connections of the individual injec-
tors.
 Attach the silicone hoses between the adap-
tors and the individual measuring cylinders.
 Start the engine and bleed the individual
measurement wires
NOTE
When bleeding, ensure that the testing instru-

ment is positioned in such a way that the meas-
urement wires are always at a positive gradient.
 Once all measurement wires are full of bub-
ble-free diesel, discharge the diesel from the
individual measuring cylinders. To do this, pull
out the silicone hoses from the lower end of
the individual measuring cylinders and collect
the diesel in a suitable container.
ENVIRONMENT NOTE

consumables.
 Reconnect the silicone hoses filled with diesel
to the testing instrument.
 Perform the measurement at a low idling
speed of 1000 rpm for a duration of 2 mi-
nutes.
NOTE
During measurement, bubble-free diesel must

flow into the measuring device.
 Compare the filling levels of the individual re-
turn flow volumes in the measuring cylinders
of the testing instrument and assess these
levels against the examples provided.

Example images for functioning and defec-
tive injectors
Injectors OK: five scale lines after 2 minutes of 
run time at a low idling speed of 1000 rpm.
394-02_01-367
Defective injectors: fuel injection quantity of all 

injectors is too low. Only four scale lines after
2 minutes of run time at a low idling speed of
1000 rpm.
394-02_01-368
Individual injector faulty: fuel injection quantity 

on 4th cylinder too low. Only four scale lines af-
ter 2 minutes of run time at a low idling speed of
1000 rpm. All other cylinder fuel injection quanti-
ties are correct.
394-02_01-369
Changing the injectors 0Y1 to 0Y4 

● Torque wrench (5 Nm to 50 Nm) 393_01-1167

WARNING
Observe the safety information for working on the fuel
supply and follow the cleanliness rules.
Removal
 Loosen the air hoses on the turbocharger.
 Remove the coolant hose and the air hoses
from the sheet metal holder.
 Remove the two screws from the sheet metal
holder.
 Remove the sheet metal holder.
 Remove the fuel return lines; see "Replacing
the fuel return line".
NOTE
Reuse the fuel return line.

 Open the clip (1). 
2
 Remove the hose (2) of the crankcase breath-
ing system.
 Remove the return line (see the section "Re-
1
placing the fuel return line").
1
394-02_01-331
 Loosen the nine screw joints (3). 

3 4
 Remove the four high-pressure lines (4).
NOTE
Do not reuse a high-pressure line.
394-02_01-330

 Remove the ten screws (5). 
6
 Remove the service flap (6) (crankcase
breathing). 5
394-02_01-332
 Disconnect the four electrical connections (8). 

7 8
 Loosen four screws (10).
 Remove the four tensioning stabilisers (9).
10
CAUTION
9
The oil sealing rings (11) on the valve cover may be
stuck on the injectors and can be damaged during re-
moval.
Remove the injectors carefully.
Replace all the seals (injectors and service flaps).
 Remove the four injectors (7) by carefully

394-02_01-333
turning them to the left and right.
NOTE
Do not reuse any seals or sealing rings on the

injectors.
Installation
NOTE

quence.
 Ensure that the oil sealing rings (11) on the
valve cover do not fall out.

 Use new oil sealing rings. 
 Coat the oil sealing rings (11) with engine oil

before inserting the injectors (7). 11
 Use new copper sealing rings on the injec-
tors.
 Tighten the four screws (10) on the tensioning
stabilisers (9). Tightening torque: 43±3 Nm
 Tighten the ten screws (5) in sequence. Tight-
ening torque: 10 Nm
394-02_01-334
CAUTION
If the high-pressure lines (4) are bent by force, they
can be damaged irreversibly. The screw joints will
then leak.
Do not bend the high-pressure lines (4). Install them
so that they are not under tension.
Replace the high-pressure lines every time they are
loosened.
 First, screw on the screw joints on the high-

pressure rail until they are hand-tight.
 Then screw on the screw joints on the injec-
tors until they are hand-tight.
 Tighten the screw joints on the high-pressure
rail: tightening torque: 30 Nm
 Tighten the screw joints on the injectors.
 Bleed the fuel supply system; see "Bleeding
the fuel system".
 Check the entire fuel system and the connec-
tions of the return lines for leak tightness.

Air intake
Intake manifold - assembly overview
5 3
8
4
1
2
6
7
9
10
11
13
12
394-02_01-341
1 Butterfly valve housing 8 Electric cable

2 Coolant hose 9 Seal
3 Fuel return line 10 Intake manifold
4 Fuel supply line 11 Screw
5 High-pressure rail 12 Screw
6 EGR valve
7 Oil lines between the oil cooler and the oil fil-
ter housing

13 Cylinder head
Preparatory tasks
 Remove the butterfly valve housing (1).
 Remove the coolant hose (2).
 Remove the fuel return line (3).
 Remove the fuel supply line (4).
 Remove the EGR valve (6).
 Remove two oil lines (7) between the oil filter
housing and the oil cooler.
 Remove the electric cable (8).
Assembly overview
 Install the seal (9), ensuring that it is correctly
positioned.
 Fit the intake manifold (10) on the cylinder
head (13) with 13 screws (11, 12).
Tightening torque for the screws (11, 12): 22 Nm
Air volumeter 0B6
0B6
394-02_01-188
The air volumeter (0B6) is located on the air fil-

ter housing next to the vacuum-operated switch
(S3) for the air filter vacuum indicator. The arrow
(←) indicates the direction of flow of air and
therefore the installation position.

Pin assignment 
Pin Connection
Air volumeter input sig-
K086
nal
K079 Supply voltage (5 V)
K087 Ground (GND)
Intake air temperature K076 K087 K079 K086
K076
input signal
Function
The air volumeter (0B6) is a thermal sensor. It 394-02_01-189
measures the resistance of two wires which act
as resistor elements. As these wires heat up,
their specific resistances change.
The engine control unit (0N1) uses the differ-
ence between the resistance values to calculate
the following variables:
● Intake air temperature
● Mass flow
● Air humidity
These variables are required by the engine con-

trol unit (0N1) to determine the injection timing
and injection duration, which in turn determine
the fuel quantity. The air volumeter (0B6) must
operate correctly in order to ensure compliance
with exhaust gas regulations. If the engine is
turned off but the key switch is switched on, the
air volumeter (0B6) cleans itself occasionally by
heating up for a brief period.
The air volumeter (0B6) measures air flow from
0.65 bar to 1.1 bar.
The operating temperature range is from -40°C
to +125°C.

Checking the air volumeter 0B6
0009419980
plug A or plug K
● Multimeter
● Wiring diagram

bly
bly for air volumeter 0B6.
● Corrosion
● Contamination
● Moisture


for air volumeter 0B6.
plates for KMC/Doosan 196-pin/plug A or plug K076 K087 K079 K086
for a line test".
Pin Connection
Air volumeter input sig-
K086
nal
394-02_01-393
K079 Supply voltage (5 V)
K087 Ground (GND)
Intake air temperature
K076
input signal

ment to the pins K079 and K087.
 Check the power supply of air volumeter 0B6.
Setpoint value: 5 V
tinuity.

for a line test".
NOTE

K076 and K087.
K079 and K087.
K086 and K087.
If no fault is detected in the lines:
 Replace air volumeter 0B6.

Vacuum-operated switch S3 for the suction filter
S3
394-02_01-190
The vacuum-operated switch (S3) for the air fil-

ter vacuum indicator is located on the air filter
housing next to the air volumeter (0B6). The
vacuum-operated switch (S3) is located behind
the air filter.
Pin assignment
Pin Connection
Connection K66 on
1
LHC (N1)
2 Ground (GND)
Function
The vacuum-operated switch (S3) closes at a
vacuum of 0.054 bar. The signal is transmitted
to the display unit via the engine control
unit (0N1). The vacuum increases if the air filter
is clogged. If the vacuum is too high, the air filter
vacuum indicator (H7) lights up on the display
unit.

Charge air pressure and charge air temperature sensor 0B4
1
0B4
394-02_01-191
The charge air pressure and charge air tempera-

ture sensor (0B4) is located on the butterfly
valve (1).
Pin assignment 
Pin Connection
A095 Ground (GND)
Temperature input sig-
A061
nal
Charge pressure input A095 A061 A038 A101
A101
signal
Function
The charge air pressure and charge air tempera- 394-02_01-192
ture sensor (0B4) senses the charge air pres-
sure and temperature before the inlet to the in-
take manifold. Depending on the air tempera-
ture, the engine control unit (0N1) regulates the
injection timing and duration as well as the posi-
tion of the EGR valve. The measured charge
pressure value also influences the injection tim-
ing and duration. If the charge pressure is too
high, the wastegate is opened accordingly.

The charge air pressure and charge air tempera-
ture sensor (0B4) measures from 0.5 bar to 4
bar.
The operating temperature range is from -40°C
to +130°C.
Butterfly valve servo motor 0M1
0M1
394-02_01-193
The butterfly valve servo motor (0M1) and the

butterfly valve (1) are located before the intake
manifold.
Pin assignment 
Pin Connection
A008 Engine signal +
A009 Engine signal −
A098 Signal
A009 - A008
A097 Ground (GND)

A016 A097 A098
Function
The engine control unit (0N1) continually sends
signals to the butterfly valve servo motor (0M1). 394-02_01-194
The butterfly valve servo motor (0M1) adjusts

the butterfly valve (1). This regulates the amount

of air flowing from the intercooler into the inlet
manifold.
Checking the butterfly valve servo motor

0M1
0009419980
plug A or plug K
● Multimeter
● Wiring diagram
Checking the butterfly valve servo motor

0M1 for visible damage
 Check the butterfly valve servo motor 0M1 for
externally visible signs of damage.
If a fault is detected:
 Replace the butterfly valve servo motor 0M1.
If no fault is detected, test the electrical connec-
tion assembly.

bly
bly for butterfly valve servo motor 0M1.
● Corrosion
● Contamination
● Moisture
If no fault is detected, check the teach status of

the butterfly valve servo motor 0M1.
Checking the teach status of the butterfly

valve servo motor 0M1
 Connect a laptop with the diagnostic program
installed on it.
 Check that the butterfly valve servo motor
0M1 was correctly taught after the last re-
placement.


If no fault is detected, check the limit positions.
Checking the limit positions

 Connect a laptop with the diagnostic program
installed on it.
 Activate teach mode for butterfly valve servo
motor 0M1.
 Check the 0% position.
 Check the 100% position.
If the setpoint values are not reached:
 Replace the butterfly valve servo motor 0M1.

for a line test".
K032 K028
Pin Connection
A008 Servo motor signal +
A009 Servo motor signal −
A016 Power supply (5 V)
A098 Signal
A097 Ground (GND)

394-02_01-394
ment to the pins A016 and A097.
 Switch on the ignition. Setpoint value: 5 V
tinuity.

for a line test".
NOTE

A008 and A097.

A009 and A097.
A098 and A097.

Charging
Safety information for work on the charge air system with exhaust turbocharger
WARNING  Spring band clamp pliers VWVAS6340 are
recommended for fitting spring band clamps.
when working on the engine!  Replace all self-securing nuts.
Observe safety information for repair and mainte-  Do not lift the exhaust turbocharger by the
nance work and safety information for working on the wastegate.
engine.
 Before installing the exhaust turbocharger, fill
Comply with the following safety information for it by pouring engine oil into the pipe connec-
working on the charge air system with exhaust tion, thereby preventing a dry start.
turbocharger:  Comply with the engine oil specification.
 The charge air system must be leak-tight.  After installing the exhaust turbocharger, al-
 The air filter must be clean, see "Changing low the engine to idle for approx. 2 minutes to
the air filter cartridge" and "Replacing the ensure the oil supply to the exhaust turbo-
safety cartridge in the air filter". charger.
 During the repair, clean any oil from pipe un-

ions and hose ends. NOTE
 All hose connections of the charge air system Always secure any testing instruments and
must be secured with spring band clamps or measuring devices used during test drives. Do
hose clips. not operate these devices whilst the truck is in
motion.
 Hose clip pliers VAS 6362 are recommended
for fitting hose clips.
Sanitation regulations
CAUTION ● If repairs to components that have been re-
moved are not performed straight away, cover
If mechanical damage is found on the exhaust turbo- up or seal the parts carefully.
charger, for example a destroyed compressor impel- ● Only install clean parts: Leave spare parts in
ler, changing the turbocharger alone is not enough. their packaging until immediately prior to in-
To avoid consequential damage, please perform the
following tasks:
stallation. Never use parts that have been
picked up unpackaged
 Check air filter housing, air filter insert and the in-
take hoses for contamination.
● Remove any transport packaging or protec-
tive packaging and locking caps only immedi-
 Test entire charge air gap and the intercooler for ately prior to installation.
foreign objects.
● During the repair, clean any oil from pipe un-
If foreign objects are found in the charge air system, ions and hose ends.
the charge air gap must be cleaned and the intercool-
er must be changed if applicable.
● During assembly, do not use any media con-
taining oil, silicone or grease.
● Do not use compressed air when the system
● Before opening any connection point, clean it
is open. Do not move the truck.
thoroughly and all around it.
● Place parts that have been removed on a
clean pad and cover the parts Never use lint-
ing cloths.

Checking charge air system
WARNING
engine.
During testing, observe the following: 
 Observe the manufacturer's specifications for

maintenance and repair.
 During the repair, clean any oil from pipe un-
ions and hose ends.
 Secure all hose connections on the boost
pressure system using spring band clamps or
using hose connections with plug connectors.
 Use the pliers for spring band clamps to fit the
spring band clamps.
NOTE
The charge air system must be leak-tight.

394-02_01-293
Checking the boost pressure regulation

● Manual vacuum pump with accessories
VWVAS6213
Test conditions
● The fuses must be OK.
● Battery voltage must be at least 11.5 V.
● All electrical consumers must be switched off
● The earth connections must be OK.
● There must be no leaks on the induction side
or the exhaust side.

● No errors on the engine/fuel injection system
or compression pressure.
● There must be no errors logged in the error
memory.
● The coolant temperature must be at least
80°C.
Test procedure
 Perform the actuator test and activate the
boost pressure regulator valve 0Y7.

NOTE
● Activation of the valve can also be tested by
touch.
● In the activation, the linkage of the pressure
box must move back and forth to regulate
boost pressure on the exhaust turbocharger.
If the valve fails to activate:
 Continue the actuator test through to the end.
 During the actuator test, observe the linkage
of the exhaust turbocharger.
NOTE
Upon activation, the linkage of the pressure box

for boost pressure regulation on the exhaust tur-
bocharger must move back and forth.
 Check whether the boost pressure regulator
valve 0Y7 clicks.
NOTE
Activation of the valve can also be tested by

touch.
 Continue the actuator test through to the end.
 Stop the test function.
If the linkage does not move, even though the
solenoid valve operates:
 Pull out the vacuum hose on the pressure box
for boost pressure regulation.
 Connect the manual vacuum pump
VWVAS6213 to the pressure box for boost
pressure regulation and check that the link-
age moves freely.
If the linkage does not move freely:
 The exhaust turbocharger is faulty; replace
the exhaust turbocharger.
If the linkage does not move because the sole-
noid valve is not working:
 Check boost pressure regulator valve 0Y7.

Checking the charge air system for leak
tightness
● Testing instrument for charge air systems
0009419841
● Level adapter V.A.G 1687/10
Test procedure
 Observe the safety measures before starting
assembly work.
 Remove the intake hose (1) from the air filter. 
 Insert the level adapter 1687/10 into the in-

take hose (1) and secure it with a clip.
Prepare the testing instrument for charge air 

systems 0009419841 as follows:
 Unscrew the pressure regulating valve (2)
completely and close the valves (3) and (4).
NOTE
To enable the pressure regulating valve (2) to be

turned, the turning knob must be pulled up-
wards.

 Connect the testing instrument for charge air 
systems 0009419841 to the level adapter
1687/10 as shown.
 Connect the compressed air hose (1) (com- 

pressed air supply) to the testing instrument
for charge air systems 0009419841.
NOTE
Drain any water in the inspection glass via the

drainage screw (6).
 Open the valve (3).
 Use the pressure regulating valve (2) to ad-
just the pressure to 0.5 bar.
CAUTION
Setting the pressure too high can damage the engine.
The test pressure must not exceed 0.5 bar.
 Open the valve (4) and wait until the test cir-
cuit is filled. If necessary, readjust the pres-
sure to 0.5 bar.
 Use leak detection spray or the ultrasonic
measuring device V.A.G 1842 to check the
charge air system for leaks.
NOTE
Before removing the testing instrument for

charge air systems 0009419841, release the
pressure from the test circuit by pulling out the
intake hose from the level adapter 1687/10.

Exhaust turbocharger with attachment parts - assembly overview
1 Fresh air inlet 11 Seal

2 Bypass hose to the cylinder head 12 Turbine housing
3 Pressure box (wastegate) 13 Clip
4 Compressed air outlet 14 Banjo bolt with seal (19 Nm)
5 Banjo bolt with seal (19 Nm) 15 Screw (10 Nm)
6 Seal 16 Oil supply line
7 Exhaust gas inlet 17 Oil return line
8 Screw with washer 18 Screw (10 Nm)
9 Heat shield 19 Compressor housing
10 Exhaust gas outlet 20 Seal

21 Bypass hose from the wastegate
WARNING
Observe the safety instructions for repair and mainte-
nance work, for working on the engine and for work-
ing on the charge air system with exhaust turbocharg-
er.
CAUTION
Component damage due to bending.
If the oil return line is bent, micro-cracks may have
formed. These micro-cracks can lead to leakage.
 Before installing the exhaust turbocharger, check
the oil return line and the decoupling elements.
 If the oil return line is damaged, replace it.
NOTE
Before installing the exhaust turbocharger, re-

place all seals and self-locking nuts. To prevent
damage, ensure the seals are fitted in the cor-
rect position.
Changing the exhaust turbocharger

WARNING
engine.

● Hose clip pliers
CAUTION
If mechanical damage is found on the exhaust turbo-
charger, it is not enough simply to replace the exhaust
turbocharger. To avoid consequential damage, per-
form the following tasks:
 Check the air filter housing for foreign objects, see
"Changing the air filter cartridge".
 Check the air filter cartridge for foreign objects, see
"Changing the air filter cartridge".
 Check the intake hoses for foreign objects.
 Clean the entire charge air line. 394-02_01-254
 Check the intercooler for foreign objects, and re-

place it if necessary.

Removal 

 Remove the two screws (1) from the thermal
insulation plate (2).
 Remove the thermal insulation plate (2).
 Open the three clips (3...5) and remove the 

hoses.

 Remove the three nuts (7). 
NOTE
The three nuts and the exhaust pipe are not

shown in the graphic.
 Remove the banjo bolt (8).
 Remove the four nuts (6).
 Lift the exhaust turbocharger (10) upwards
and out of the engine compartment.
CAUTION
Damage to components when lifting the turbocharger.
Due to its heavy weight, it is difficult to handle the tur-
bocharger. Unless care is taken, it can be damaged
during removal.
 Lift the exhaust turbocharger only by the compres-
sor housing.
 Do not lift the exhaust turbocharger by the waste-
gate.
 Do not bend the exhaust gas temperature sensor
(0B20) behind the exhaust turbocharger.
Installation
CAUTION
Component damage due to bending.
If the oil return line is bent, micro-cracks may have
formed. These micro-cracks can lead to leakage.
 Before installing the exhaust turbocharger, check
the oil return line and the decoupling elements.
 If the oil return line is damaged, replace it.
NOTE
Before installing the exhaust turbocharger, re-

place all seals and self-locking nuts. To prevent
damage, ensure the seals are fitted in the cor-
rect position.

 Fit the oil return line (13) to the exhaust turbo- 
charger.
 Tighten the two screws (14) to secure the oil
return line (13) to the exhaust turbocharger.
NOTE
Always replace the oil supply line.

 Fill the exhaust turbocharger on the pipe con-
nection with engine oil to prevent a dry start.
 Fit the oil supply line (12) to the exhaust tur-
bocharger.
 Tighten the banjo bolt (11) to secure the oil
return line (12) to the exhaust turbocharger.
 Position the exhaust turbocharger in the en-
gine compartment.
CAUTION
Do not damage the exhaust turbocharger when instal-
ling it.
 Lift the exhaust turbocharger only by the compres-
sor housing.
 Do not lift the exhaust turbocharger by the waste-
gate.
 Do not bend the exhaust gas temperature sensor
(0B20) behind the exhaust turbocharger.

 Using the four nuts (6), attach the exhaust tur- 
bocharger to the exhaust manifold (15).
 Tighten the four nuts (6) securing the exhaust
turbocharger to the exhaust manifold (15).
 Using the three nuts (7), attach the exhaust
turbocharger to the exhaust pipe.
NOTE
The three nuts and the exhaust pipe are not

shown in the graphic.
 Tighten the three nuts (7) securing the ex-
haust turbocharger to the exhaust pipe. Tight-
ening torque: 22 Nm
 Fit the oil return line (13) to the cylinder block.
 Tighten the two screws (9) to secure the oil
return line (13) to the cylinder block. Tighten-
ing torque: 10 Nm
 Fit the oil supply line (12) to the cylinder
block.
 Tighten the banjo bolt (8) to secure the oil re-
turn line (12) to the cylinder block. Tightening
torque: 19 Nm
 Install the hoses (17) and close the 

clips (3...5).

 Fit the thermal insulation plate (2) to the ex- 
haust turbocharger.
 Attach the thermal insulation plate (2) with the
two screws (1).
NOTE
After installing the exhaust turbocharger, allow

the engine to idle for approx. 2 minutes to en-
sure the oil supply to the exhaust turbocharger.
 Read the error memory of the engine control
unit and clear any relevant entries as neces-
sary.
Changing the pressure box on the ex-

haust turbocharger
WARNING
engine.

● Hose clip pliers
394-02_01-254

Removal 

 Remove the two screws (1) from the thermal
insulation plate (2).
 Remove the thermal insulation plate (2).
 Remove the hose (7).
 Note the dimension (A).
 Hold the knurled nut (6) in place and loosen
the nut (5).
 Remove the two nuts (4).
 Turn the knurled nut (6) anticlockwise until the
pressure box (4) is loose.
 Remove the pressure box (4).
Installation
 Restore the dimension (A).
 Tighten the two nuts (4). Tightening torque:
22 Nm
 Hold the knurled nut (6) in place and tighten
the nut (5). Tightening torque: 22 Nm
 Fit the hose (7).
 Start the engine and check the function of the
pressure box (4).
 If necessary, loosen the nut (5) and turn the
knurled nut (6) until the wastegate is working.
Then re-tighten the nut (5).
 Mark the position of the nut (5) and the
knurled nut (6) permanently with suitable
paint.
 Fit the thermal insulation plate (2).

Preheating system
Preheating system
WARNING
Observe the safety information for repair and mainte-
nance work and the safety information for working on
the engine.
If the coolant temperature is less than 10 °C, the

engine must be pre-heated. The preheating
process lasts approx. 20 seconds.
Glow plugs 0R1...0R4
0R4 0R3 0R2 0R1

394-02_01-218
The glow plugs (0R1...0R4) with post-heating

capability are fitted as standard. They are
screwed into the inlet side of the engine behind
the high-pressure rail. A conductor rail (1) con-
nects the glow plugs (0R1...0R4) to each other.
The power supply is connected to the second
glow plug (0R2). The glow plugs (0R1...0R4) are
earthed via the engine block.
Function
The engine control unit (0N1) activates the glow
plug relay (0K1). The glow plug relay (0K1) pro-
vides the power supply for pre-heating and post-
heating the glow plugs (0R1...0R4). Pre-heating
begins after the key switch has been switched
on.
Post-heating is performed:
● If the engine is in the cold start phase
● If the exhaust gas temperature is too low
● If the emission limits are not satisfied
● If the engine temperature drops due to a low
load.

Changing the glow plugs 0R1...0R4
WARNING
engine.

393_01-1158
Removal 
Removing the injection lines and high-pressure 1 2

line 3
 Undo the screw joint (2) on the injectors
(0Y1...0Y4).(1).
 Undo the five screw joints (9) on the high-
pressure rail(8). 9
 Remove the injector lines (3).
8
 Remove the screw (7) on the high-pressure
line (6). 4
 Undo the screw joint (5) on the high-pressure
fuel pump (4). 7
 Remove the high-pressure line (6). 6 5 394-02_01-250
Removing the high pressure rails 
 Remove two screws (2) from the high-pres- 1

sure rail (1).
2 394-02_01-251

Removing the glow plugs 0R1...0R4 
2 3
NOTE
The power supply is connected to the glow plug 0R4

(0R2).
 Remove the nut (2).
 Disconnect the power supply.
 Remove the conductor rail (3).
 Remove the glow plug (0R4).
NOTE
The removal process for the glow plugs

(0R1...0R3) is exactly the same.
394-02_01-252
Installation
NOTE

quence.
Installing glow plugs 0R1...0R4
 Tighten the glow plugs (0R1...0R4). Tighten-
ing torque: 12 Nm
 Tighten the nuts to fasten the conductor rail.
Installing the high-pressure rail
 Tighten the two screws to secure the high-
pressure rail. Tightening torque: 22 Nm
Installing the fuel and high-pressure lines
CAUTION
There may be leakage from the high-pressure rail.
Pay attention to the installation position of all the
lines. Do not bend them. Install them so that they are
not under tension. Always replace the lines, fittings
and clips.
 Attach the injection lines to the injectors

(0Y1...OY4).
 Attach the injection lines to the high-pressure
rail.
 Tighten the screw joint to attach the injection
lines to the injectors (0Y1...0Y4). Tightening
torque: 22 Nm
 Tighten the screw joints to attach the injection
lines to the high-pressure rail. Tightening tor-
que: 22 Nm

 Attach the high-pressure line to the high-pres-
sure rail.
 Attach the high-pressure line to the high-pres-
sure fuel pump.
 Tighten the screw joint to attach the high-
pressure line to the high-pressure rail. Tight-
ening torque: 22 Nm
 Tighten the screw joint to attach the high-
pressure line to the high-pressure fuel pump.

Exhaust system
Replacing parts of the exhaust system
WARNING
NOTE
when working on the engine! ● After completing assembly work the exhaust
system, make sure that the exhaust system is
not distorted and has sufficient clearance
engine. from the body. If necessary, align the silencer
and exhaust pipe so that there is sufficient
clearance from the body at all points and the
load on the suspension system is distributed
equally.
● Replace the self-securing nuts.
Exhaust gas recirculation
3 2
4 5
394-02_01-281
1 Engine 4 Turbocharger
2 EGR radiator 5 Intercooler
3 EGR valve 6 Thermostat
Coolant circulation of the engine

Exhaust-gas flow
Air flow
Function
To reduce the nitrogen oxides (NOx), the engine
is fitted with an exhaust gas recirculation sys-
tem.
The EGR system consists of the EGR valve (3)
and the EGR radiator (2). The EGR system is
connected to both the coolant circulation and the

exhaust-gas flow. The cooling circuit is descri-
bed in the section on "Coolant circulation". A
portion of the hot exhaust gas flows through the
EGR system as required, where it is cooled. The
cooled exhaust gases are mixed into the charge
air. This gas mixture is supplied to the engine for
combustion.
This reduces the oxygen content in the combus-
tion chamber and less fuel is injected. The com-
bustion temperature falls. This reduces the pro-
portion of nitrogen oxides in the exhaust gases.
The consequence of this is an increase in the
soot particles in the exhaust gases.
The EGR valve (3) closes depending on the
amount of accumulated soot in the diesel parti-
cle filter and the regeneration type. This stops
the exhaust gas recirculation. See the section
entitled "Regeneration of the diesel particle fil-
ter".

Exhaust after-treatment 
In the Doosan D24NAP engine, the soot particle

emissions are reduced by the internal engine ac-
tions as well as by a diesel particle filter (2). The
diesel particle filter (2) is installed in a housing
together with the oxidation catalytic converter (1)
close to the engine behind the engine cooler.
The temperature required for operation is
reached more quickly due to the proximity to the
engine. To ensure that this temperature is
reached even faster, heat management is per-
formed by the butterfly valve. This heat manage-
ment enables a reliable DPF regeneration by in-
creasing the exhaust gas temperature to the re-
quired level. This requires a sufficient oxygen
content in the exhaust gas. In order to keep the
particle quantity low, a high exhaust gas temper-
ature is required, especially in conditions with a
low load.
System overview
1 Oxidation catalytic converter 0B17 Exhaust gas temperature sensor down-

2 Diesel particle filter stream of the diesel particle filter
3 Display unit 0B20 Exhaust gas temperature sensor in the ex-
4 Diesel engine haust manifold
5 Turbocharger 0N1 Engine control unit
0B6 Air volumeter
0B15 Differential pressure sensor for diesel particle
filter

Oxidation catalytic converter
To ensure that the temperature required for op-
eration is reached quickly, the oxidation catalytic
converter is made from a metal alloy with good
thermal conductivity. On this metal body, there is
a carrier layer made of aluminium oxide. To ena-
ble the catalysis, platinum is applied by means
of vapour deposition.
Function
The oxidation catalytic converter transforms a
large proportion of the hydrocarbons (HC) and
the carbon monoxide (CO) into steam and car-
bon dioxide.
Diesel particle filter 
The diesel particle filter consists of a monolithic

body made of aluminium titanate (6). This body
is subdivided into numerous small segmented
channels (7) which are closed off alternately
(asymmetric cell technology). This results in a
large, open face with intake ports and outlet
ports separated by filter walls.
Function
The exhaust gas, which contains soot, flows
through the porous filter walls of the input chan-
nels. In the process the soot particles, in con-
trast to the gaseous components of the exhaust,
are withheld in the input channels.
Diesel particle filter service regeneration

Service regeneration is required at least every Performing service regeneration
1000 hours. Service regeneration is required at
an earlier time if the DPF has not been regener- WARNING
ated and soot accumulation exceeds 121%. If
soot accumulation reaches 151%, the DPF can Risk of fire from diesel particle filter becoming very
hot during service regeneration.
only be manually cleaned or replaced.
 Keep the diesel particle filter away from highly
flammable materials.
Checking the diesel particle filter  Do not use corrosion protection media for exhaust
pipes or heat shields on the diesel particle filter.
Test conditions These substances can ignite if the engine is hot.
● Fuses OK
● Battery voltage at least 11.5 V
● Earth connections OK NOTE

● No error entry in the error memory
In the event of danger, stop the service regener-
ation.

Prerequisites for performing service regenera- The engine speed increases automatically.
tion
Service regeneration is completed after a maxi-
● Truck is at a standstill in an outside area (in-
mum of 50 minutes. The engine returns to idle
creased exhaust load)
speed.
● No flammable materials are present in the vi-  Let the engine run a while so that the fan can
cinity of the exhaust system cool the engine compartment.
Exhaust gas temperature up to 650°C The idle speed is increased to 1500 rpm for ap-
● Engine at normal operating temperature prox. 100 seconds.
● Coolant ≥ 40°C
● Engine is idling CAUTION

● Diagnostic software started
The engine may be damaged by oil dilution.
 Follow the instructions given in the "Linde Fuel is post-injected during service regeneration. This
Service Guide". post-injection dilutes the engine oil.
 Replace the engine oil and the engine oil filter after
 If the DPF cannot be regenerated, clean or service regeneration.
replace the DPF.
Diesel particle filter regeneration

The diesel particle filter must be regenerated to
prevent it from becoming clogged with soot parti-
cles and to ensure that its functionality is not im-
paired in any way. During the regeneration
process, the soot particles collected in the diesel
particle filter are burned.
The regeneration types and their characteristics
are shown in the following tables.
Stage legend
Stage Regeneration type Message
1 Passive None
Particle filter regeneration
required!
2 Active, continuous, started automatically
If the engine is cold, also:
Warm up engine!
Particle filter regeneration
required!
3 Active, started manually
If the engine is cold, also:
Warm up engine!
4 Standstill regeneration, started manually None
Service regeneration, started by diagnostic
5 None
software
Display and effect

Indicator light
Soot accumu- Reduction in
Stage Buzzer
lation performance
"Particle filter "Service inter-
"Malfunction"
warning" val exceeded"
1 ≤ 99% Off Off Off Off No
2 100 to 105% Off Off Off Short interval No
3 106 to 110% Flashing Off Off Short interval No

Indicator light
Soot accumu- Reduction in
Stage Buzzer
lation performance
"Particle filter "Service inter-
"Malfunction"
warning" val exceeded"
Creep speed;
Flashes slow- truck func-
4 111 to 120% Flashing On Short interval
ly tions cannot
be accessed
Creep speed;
≥ 121 to Flashes quick- truck func-
5 Flashing On Short interval
151% ly tions cannot
be accessed
Intervention by the truck control unit

Main injection Low injection Butterfly Second post-
Stage EGR valve Post-injection
delayed pressure valves injection
1 No No Closed Open No No
2 Yes Yes Open Closed Yes Yes
Passive regeneration (depending on load)

Passive regeneration occurs in the background
without any visualisation or message for the op-
erator.
Active, continuous regeneration (automati-

cally started)
During operation with the engine at operating
temperature, the particles that are produced are
continuously burned.
Continuous regeneration happens predominant-
ly at high engine loads, for example during load-
ing and unloading at exhaust gas temperatures
of 450 to 500°C. In the process, a reaction with
nitrogen dioxide transforms the soot particles in-
to carbon dioxide.
Active regeneration (started manually by

the operator)
If the engine does not reach a sufficient temper-
ature during operation, the continuous regenera-
tion process cannot start.
If continuous regeneration does not reach the
temperature required to burn the soot particles,
thermal management is initiated to increase the
exhaust gas temperature.

The following courses of action to increase the
exhaust gas temperature are initiated:
● Exhaust gas recirculation is stopped The
EGR valve remains closed

● Fuel injection quantity, start of injection and
injection duration are altered up to the point of

the second post-injection
Thermal management starts automatically. Dur-
ing thermal management, the truck can be driv-
en as normal.
Standstill regeneration (started by the oper-

ator)
If the engine does not reach a sufficient temper-
ature during operation, the active regeneration
process cannot start.
The truck must be parked. Standstill regenera-
tion must be initiated by the operator. The truck
experiences a power reduction. It drives only at
creep speed.
Service regeneration (started by the service

partner)
If the DPF has not been regenerated and stage
5 is reached, service regeneration must be initi-
ated.
Service regeneration must be activated and car-
ried out in the diagnostic software.
Service regeneration is similar to thermal man-
agement.
Ash content in the diesel particle filter

During each regeneration process, soot particles
are burned to ash. As such, depending on use
(fuel consumption), the diesel particle filter is fil-
led with ash as the number of operating hours
rises. If the soot accumulation reaches 151%,
the DPF must be cleaned or replaced.
 See also the section entitled "Diesel particle
filter service regeneration".

Diesel particle filter - assembly overview
2 4
12
11
5
10 6
7 7
8
394-02_01-257
1 Clip 8 Differential pressure sensor for diesel particle

2 Support (rotated 90°) filter (0B15)
3 Diesel particle filter 9 Exhaust gas temperature sensor (0B17) in
4 Support (rotated 90°) the diesel particle filter (180° mirror image)
5 Exhaust gas outlet 10 Oxidation catalytic converter
6 Clip 11 Exhaust gas inlet
7 Clip 12 Seal
NOTE
To prevent leaks, always replace the clips and

seals on the diesel particle filter.

Changing the diesel particle filter
1 Pipe clip 9 Support

2 Pipe 10 Screw
3 Pipe clip 11 Exhaust gas temperature sensor 0B17
4 Pipe 12 Pipe clip
5 Pressure pipe 13 Diesel particle filter
6 Nut 14 Oxidation catalytic converter
7 Exhaust gas temperature sensor 15 Exhaust gas outlet
8 Electrical connection assembly

WARNING
Risk of burns from hot surfaces!
 Allow the engine to cool down.
 Use personal protective equipment.
CAUTION
The diesel particle filter and diesel oxidation filter
must not be damaged.
Handle the diesel particle filter and diesel oxidation fil-
ter with the necessary care.
NOTE
If necessary, replace the diesel particle filter be-

fore the service limit (10,000 hours).
Reasons:
● Ash accumulation too high
● Soot accumulation too high (>151%)
Removal
 Loosen the pipe clip (1).
 Remove the pipe (2) and the pipe clip (1).
 Loosen the pipe clip (3).
 Remove the pipe (4) and the pipe clip (3).
0B17 (11); see "Changing the exhaust gas
temperature sensors 0B17 and 0B20".
 Remove the two pressure pipes (5); see
"Changing the differential pressure sensor
0B15".
bly (8) from the differential pressure sensor
0B15.
 Remove the support (9).
 Remove the four nuts (6).
 Remove the exhaust aftertreatment system
(7) from the truck.
 Remove the two pipe clips (12).
 Remove the diesel particle filter (13) from the
oxidation catalytic converter (14).
 Remove the diesel particle filter (13) from the
container part for the exhaust gas outlet (15).

Installation
 Replace the clips (3, 12), including the seals.
CAUTION
Component damage during installation of the diesel
particle filter!
Do not bend the exhaust gas temperature sensor
0B17.
After fitting a used diesel particle filter:

 Perform a service regeneration on the diesel
particle filter.
Changing the differential pressure sen-

sor 0B15
WARNING
Risk of burns from hot surfaces!
 Allow the engine to cool down.
 Use personal protective equipment.
CAUTION
Dirt must not enter the open pressure pipes: risk of
faulty analyses of the differential pressure!
 Observe the notes and instructions for working on
the exhaust system.
 Use suitable means to protect the opened exhaust
gas connections against the ingress of dirt.
CAUTION
Impairment of the function due to damage!
Handle the diesel oxidation filter and diesel particle fil-
ter with the corresponding level of care.
Do not bend electric cables and pressure pipes.

Removal 
 Loosen the two pipe clips (1).

 Remove the two hoses (2) from the differen-
tial pressure sensor 0B15.
bly (3).
 Remove the differential pressure sensor
0B15.
Installation
2 3 1 4 1 2
Installation is carried out in the reverse se- 0B15
quence. Observe the following: 394-02_01-342
 Replace the hoses and the pipe clips with

new ones during installation.

Radiator for exhaust gas recirculation - assembly overview
3
2
7
1
4 6
5
10
10
9
394-02_01-242
1 Coolant hose 7 Seal

2 Screw (22 Nm) 8 Pipe for exhaust gas recirculation
3 Seal with decoupling element; do not bend the de-
4 Radiator for exhaust gas recirculation coupling element – risk of crack formation
5 Screw (30 Nm) 9 Coolant hose
6 Screw (30 Nm) 10 Clip
 Observe the safety measures before com-

mencing assembly work. NOTE
 Observe the cleanliness rules. Replace the seals (3, 7).

Exhaust gas recirculation actuator 0M7
0M7
394-02_01-199
The exhaust gas recirculation actuator (0M7) is

located on the exhaust gas recirculation valve.
The EGR valve is integrated in the intake mani-
fold.
Pin assignment 
Pin Connection
A067 Engine signal +
A088 Engine signal −
A079 Signal
A088 - A067
A078 Ground (GND)

A040 A078 A079
Function
The engine control unit (0N1) controls the ex-
haust gas recirculation actuator (0M7). The ex- 394-02_01-200
haust gas recirculation actuator (0M7) opens

and closes the EGR valve as needed. The throt-
tle valve position is reported back to the engine
control unit (0N1). The opening and closing of
the exhaust gas recirculation actuator (0M7)
conducts exhaust gases back into the engine.
This reduces the combustion temperature. The
concentration of nitrogen oxides is reduced.

Testing the exhaust gas recirculation
actuator 0M7
NOTE
The exhaust gas recirculation is tested during

the "actuator test" diagnostics function. This pro-
cedure activates the exhaust gas recirculation
actuator (0M7) in phases so that the extreme
values for exhaust gas recirculation can be read
out.
● Multimeter
● Test adapter 000 973 43 14
● Wiring diagram
Test conditions
● The fuses must be OK.
● Earth connections must be OK.
● There must be no leaks on the induction side
or exhaust side.
● No errors on the engine/fuel injection system
or compression pressure.
● There must be no errors saved in the error
log; read the error log.

● The coolant temperature must be at least
60°C.
Test procedure
 Connect the diagnostic program and start the
diagnostic software.
 Perform the actuator test and activate the ex-
haust gas recirculation actuator (0M7).
NOTE
Activation of the valve can also be tested by

touch.
 End the diagnostics function.
If the valve does not activate:
 Disconnect connection assembly from the ex-
haust gas recirculation actuator (0M7).

Check the power supply 

 Connect the multimeter to the following con-
tacts of the plug and to the engine earth to
perform a voltage measurement.
● A040 + engine earth A088 - A067
● A040 + A078
→ Setpoint value: at least 4.8 to 5.2 V A040 A078 A079
 Connect test adapter 000 973 43 14 to the
control unit wiring harness. 394-02_01-200
The engine control unit is not connected when A040 Supply voltage (5 V)
carrying out this step. A067 Engine signal +
A078 Ground (GND)
 Check the wires between the test adapter and A079 Signal
the plug for open circuits using the wiring dia- A088 Engine signal −
gram.
→ Line resistance: max. 2.0 Ω
 Also check the wires for short circuits against
each other, to the battery earth/engine earth
and to the battery positive terminal. Setpoint
value: R = infinite (no connection)
If no error was detected in the wires when a volt-
age was present between A040 + engine earth
and A040 + A078:
 Replace the exhaust gas recirculation actua-
tor (0M7).
 Perform adaptation of the exhaust gas recir-
culation actuator (0M7).
 Check the engine control unit error memory
and clear the error memory if necessary.
If no error was detected in the wires when no
voltage was present between A040 + engine
earth and A040 + A078:
 Pull out the connector plugs from all compo-
nents attached to this power supply lead.
 Check the power supply to these components
and perform a wiring test.
If no fault is detected in the wiring and there was
no voltage at the components:
 Replace the engine control unit (0N1).

Exhaust gas temperature sensors 0B17
and 0B20
Exhaust gas temperature sensor 0B17
0B17
1
394-02_01-201
The exhaust gas temperature sensor (0B17) is

located in the diesel particle filter (1).
Pin assignment 0B17 
PIN Connection
K047 Signal
K050 Ground (GND)
K047 K050
394-02_01-202

Exhaust gas temperature sensor 0B20
0B20
394-02_01-203
The exhaust gas temperature sensor (0B20) is

located behind the turbocharger (1) in the ex-
haust manifold.
Pin assignment 0B20 
PIN Connection
A033 Earth (GND)
A059 Signal
Function
A033 A059
The exhaust gas temperature sensors
(0B17, 0B20) sense the exhaust gas tempera-
tures in the exhaust manifold and in the diesel
particle filter by changes in resistance. They are
designed as PT200 sensors. At 0°C the resist- 394-02_01-204
ance is ≈ 200 Ω.
The exhaust gas temperature sen-
sors (0B17, 0B20) measure temperatures from
−40°C to +800°C.
The temperature recorded in the exhaust mani-
fold is used to calculate the optimum fuel injec-
tion quantity. The engine can then operate within
the optimum temperature range and efficiency

range. In addition, the delta of the two tempera-
tures provides information about the condition of
the diesel oxidation catalytic converter.
The temperature recorded in the diesel particle
filter allows the condition of the diesel particle fil-
ter to be monitored and the optimum conditions
for regeneration of the diesel particle filter to be
determined.

Checking the exhaust gas temperature
sensor 0B17 in the diesel particle filter
0009419980
plug A or plug K
● Multimeter
● Wiring diagram

bly
bly for exhaust gas temperature sensor 0B17.
● Corrosion
● Contamination
● Moisture

ance.


uring to the pins K047 and K050.
 Measure the resistance of exhaust gas tem-
perature sensor 0B17.
K047 K050
PIN Connection
K047 Signal
K050 Ground (GND)

circuit in the exhaust gas temperature sensor 394-02_01-302
0B17.
 Replace the exhaust gas temperature sensor
0B17.
age.

for a line test".
 Disassemble the exhaust gas temperature
sensor 0B17. See "Changing the exhaust gas
temperature sensor 0B17".
 Check the exhaust gas temperature sensor
0B17 using a known temperature.

−40 683
0 787
50 909
100 1022
200 1226
400 1562
600 1825
800 2036

0B17.
for continuity.
 Assemble the exhaust gas temperature sen-
sor 0B17. See "Changing the exhaust gas

for a line test".
NOTE

K047 and K050.

Checking the exhaust gas temperature
sensor 0B20 in the exhaust manifold
0009419980
plug A or plug K
● Multimeter
● Wiring diagram

bly
bly for exhaust gas temperature sensor 0B20.
● Corrosion
● Contamination
● Moisture

ance.


uring to the pins A033 and A059.
 Measure the resistance of exhaust gas tem-
perature sensor 0B20.
A033 A059
PIN Connection
A033 Earth (GND)
A059 Signal

circuit in the exhaust gas temperature sensor 394-02_01-301
0B20.
0B20.
age.

for a line test"
 Disassemble the exhaust gas temperature
sensor 0B20. See "Changing the exhaust gas
 Check the exhaust gas temperature sensor
0B20 using a known temperature.

−40 584
0 674
50 728
100 881
200 1064
400 1370
600 1615
800 1815

0B20.
for continuity.
 Assemble the exhaust gas temperature sen-
sor 0B20. See "Changing the exhaust gas

for a line test".
NOTE

A033 and A059.
Changing the exhaust gas temperature

sensors 0B17 and 0B20
WARNING
Risk of burns from hot engine components!
Always use sufficient safety equipment and personal
protective equipment when working on a hot engine!
 Before starting work, make sure that the engine
and its components have cooled down sufficiently.
 Observe the safety instructions in the section enti-
tled "Safety information for working on the engine".

● Size 10 open-ended spanner attachment for
torque wrench
Removing the exhaust gas temperature 

sensor 0B17
 Document the line routing and the mounting
type for subsequent restoration.
bly (2).
(1).
Installing the exhaust gas temperature sen-

sor 0B17

 Restore the line routing of the electric cable
and its mounting type.
 Coat the thread of the exhaust gas tempera-
ture sensor with ceramic paste.
Removing the exhaust gas temperature 

sensor 0B20
 Remove the exhaust turbocharger; see the
section entitled "Changing the exhaust turbo-
charger".
 Document the line routing and the mounting
type for subsequent restoration. 3
bly (4).
 Remove the exhaust gas temperature sensor.
Installing the exhaust gas temperature sen-

sor 0B20 4
Tightening torque: 44 Nm 394-02_01-292
To install, follow the removal steps in the re-

verse order, taking the following into account:
 Restore the line routing of the electric cable
and its mounting type.
 Coat the thread of the exhaust gas tempera-
ture sensor (4) with ceramic paste.
 Install the exhaust turbocharger.

Differential pressure sensor 0B15 for the diesel particle filter
0B15
1
394-02_01-205
The differential pressure sensor (0B15) for the

diesel particle filter is located on the diesel parti-
cle filter(1).
Pin assignment 
Pin Connection
K042 Power supply (5 V)
K015 Ground (GND)
K016 Signal
3
K016 K015 K042
394-02_01-206

Function
The differential pressure sensor (0B15) for the 
diesel particle filter records the pressures before
(1) and after (2) the diesel particle filter (3). The
1 2
difference is transmitted to the engine control
unit (0N1).
diesel particle filter measures pressures from
0.04 bar to 5 bar.
diesel particle filter measures the filling level of
the diesel particle filter and determines the opti-
mal conditions for diesel particle filter regenera-
tion.
0B15 3
394-02_01-207

Checking the differential pressure sen-
sor 0B15 for the diesel particle filter
0009419980
plug A or plug K
● Multimeter
● Wiring diagram

Checking the electrical connection assem- 
bly
bly for the differential pressure sensor 0B15
(3).
● Corrosion
● Contamination
● Moisture
1 3 0B15 2
394-02_01-316

for differential pressure sensor 0B15.
1
K. See "Connecting the measurement adapter K016 K015 K042
for a line test".
PIN Connection
K015 Ground (GND)
K016 Signal
K042 Power supply (5 V)
 Connect the multimeter for voltage measure- 394-02_01-406

ment to the pins K042 and K015.
 Switch on the ignition. Setpoint value: 5 V
tinuity.

for a line test".
NOTE


K016 and K015.
K042 and K015.
If no fault is detected in the electric cables,
check the differential pressure sensor 0B15.
Checking the differential pressure sensor

0B15
for a line test".
 Check the pressure pipes for leakage and
blockages.
If no fault is found:
 Check the sensor to ensure that the pressure
pipes (1) and (2) are correctly connected.
If no fault is found:
 Keep the engine idling.
 Connect the multimeter for voltage measure- 
ment to the pins K015 and K016. Setpoint val-
ue: 0.3 to 4.5 V
 Replace the differential pressure sensor
0B15.
3
If the setpoint value is reached: K016 K015 K042

394-02_01-314

Electrical system, engine
Pin assignment of the Doosan engine control unit with 196 contacts
A 105 pin K 91 pin
In the mating direction ↑front

196 pin measurement adapter 
Use the measurement adapter with part number

0009419980 to check all inputs and outputs of
the LHC 20.
NOTE
It is not permitted to puncture the cable insula-

tion in order to test the cables, signals and pow-
er supplies. The resulting contact resistances
cause truck malfunctions.
Pin Function
A001
A002
A003
A004
A005
A006 0Y11 fuel quantity closed loop control valve (control)
A007 0Y11 fuel quantity closed loop control valve (12 V supply voltage)
A008 0M1 butterfly valve servo motor (engine signal (POS))
A009 0M1 butterfly valve servo motor (engine signal (NEG))
A010
A011 Feedback from glow plug relay
A012
A013
A014 0B7 engine oil pressure sensor (5 V supply voltage)
A015

Pin Function
A016 0M1 butterfly valve servo motor (5 V supply voltage)
A017
A018
A019
A020 0B13 crankshaft sensor (signal (POS))
A021 0B13 crankshaft sensor (signal (NEG))
A022 0Y3 injector 3rd cylinder (POS)
A023
A024 0Y2 injector 2nd cylinder (POS)
A025
A026
A027
A028
A029
A030
A031
A032
A033 0B20 exhaust gas temperature sensor (ground (GND)
A034
A035 0B7 engine oil pressure sensor (ground (GND)
A036 0B7 engine oil pressure sensor (signal)
A037 0B11 camshaft sensor (5 V supply voltage)
A038 0B4 charge air pressure and charge air temperature sensor (5 V supply voltage)
A039
A040 0M7 actuator for the exhaust gas recirculation (5 V supply voltage)
A041
A042 0B35 rail pressure sensor (5 V supply voltage)
A043 0Y3 injector 3rd cylinder (NEG)
A044
A045 0Y2 injector 2nd cylinder (NEG)
A046
A047
A048
A049
A050
A051 0B11 camshaft sensor (ground (GND)
A052 0B11 camshaft sensor (signal)
A053
A054
A055
A056
A057 0B13 crankshaft sensor (ground (GND)
A058
A059 0B20 exhaust gas temperature sensor (signal)
A060
A061 0B4 charge air pressure and charge air temperature sensor (temperature signal)
A062 0B35 rail pressure sensor (signal)
A063 0B35 rail pressure sensor (ground (GND)

Pin Function
A064 0Y1 injector 1st cylinder (POS)
A065
A066 0Y4 injector 4th cylinder (POS)
A067 0M7 actuator for exhaust gas recirculation (engine signal (POS))
A068
A069
A070
A071
A072
A073
A074
A075
A076
A077
A078 0M7 actuator for exhaust gas recirculation (ground (GND)
A079 0M7 actuator for exhaust gas recirculation (signal)
A080
A081
A082
A083
A084
A085 0Y1 injector 1st cylinder (NEG)
A086
A087 0Y4 injector 4th cylinder (NEG)
A088 0M7 actuator for exhaust gas recirculation (engine signal (NEG))
A089
A090
A091
A092
A093 Glow plug relay
A094
A095 0B4 charge air pressure and charge air temperature sensor (ground (GND)
A096
A097 0M1 butterfly valve servo motor (ground (GND)
A098 0M1 butterfly valve servo motor (signal)
A099 0B10 coolant temperature sensor (ground (GND)
A100 0B10 coolant temperature sensor (signal)
A101 0B4 charge air pressure and charge air temperature sensor (charge pressure signal)
A102
A103
A104
A105
K001 Terminal 30 (supply voltage) from 0K2 relay Doosan engine control unit
K002 Ground
K004 Ground
K006 Ground

Pin Function
K007
K008
K009
K010
K011 Regeneration start button
K012
K013
K014
K015 0B15 differential pressure sensor for diesel particle filter (ground (GND)
K016 0B15 differential pressure sensor for diesel particle filter (signal)
K017
K018
K019
K020
K021
K022
K023 Diesel particle filter regeneration lamp
K024
K025
K026
K027
K028 0B12 fuel temperature sensor (signal)
K029
K030 CAN1 (POS)
K031 CAN1 (NEG)
K032 0B12 fuel temperature sensor (ground (GND)
K033
K034
K035
K036
K037
K038
K039
K040
K041
K042 0B15 differential pressure sensor for diesel particle filter (5 V supply voltage)
K043
K044 0B36 water trap switch (signal)
K045
K046
K047 0B17 exhaust gas temperature sensor after oxi-cat (signal)
K048 0B36 water trap switch (ground (GND)
K049
K050 0B17 exhaust gas temperature sensor after oxi-cat (ground (GND)
K051
K052
K053
K054

Pin Function
K055
K056
K057
K058
K059
K060
K061
K062
K063
K064
K065
K066
K067
K068
K069 0B16 engine oil level sensor (signal)
K070 0B16 engine oil level sensor (ground (GND)
K071
K072
K073
K074
K075 Terminal 15 (battery positive ignition)
K076 0B6 air volumeter (intake air temperature signal)
K077
K078
K079 0B6 air volumeter (5 V supply voltage)
K080
K081
K082
K083
K084
K085
K086 0B6 air volumeter (signal)
K087 0B6 air volumeter (ground (GND)
K088 Main relay
K089
K090
K091
K092
K093
K094

Checking the power supply for engine 
control unit 0N1
WARNING
engine.

0009419980
plug A or plug K
● Multimeter
● Wiring diagram
Measuring procedure
 Connect the measurement adapter, measure-
ment boxes and cover plates. See "Connect-
ing the measurement adapter for a line test".
 Use the multimeter for voltage measurement
to measure between the following bushes on
the measurement boxes. Setpoint value: 12 V
First measurement: K03 and K02
Second measurement: K05 and K02
Third measurement: K01 and K02
Other actions
If the measured value deviates from the setpoint
value in no more than two measurements:
 Replace the corresponding cable between the
engine control unit and the main relay.
value in all measurements:
 Turn the ignition and starting switch to switch
setting "I".
 Listen to see whether the main relay
switches.
If you do not hear a switching noise from the
main relay:
 Replace the 7.5 A fuse.
 Repeat the test.
If you do not hear a switching noise:
 Replace the ignition and starting switch.

If you hear a switching noise from the main re-
lay:
 Replace the main relay.
 Repeat the measuring procedure.
value in all measurements:
Changing the engine control unit 0N1

WARNING
engine.
Removal
 Disconnect the earth connection from the bat-
tery.
 Loosen the two interlocks (1) on the electrical 
connection assemblies (2).
 Disconnect the two electrical connections (2)
from the engine control unit 0N1 (4).
 Remove the support bracket (3). 
 Remove the engine control unit 0N1 (4).
Installation
 Connect the diagnostic device.
 Check the error memory.
If the error memory cannot be deleted:
 Perform further troubleshooting.

Removing and installing the starter mo-
tor
Removal 
 Observe the safety information.

 Observe the cleanliness rules. 4
 Disconnect battery with ignition switched off.
 Remove the electric cable (4) from the bolt.
 Remove the nuts (1). 1
 Remove the starter motor (2).
2
Installation
3
quence. Observe the following: 394-02_01-297
 Tightening torque for the nuts (1): 43 Nm ±4.3

 Connect the battery with the ignition switched
off.
Starter motor does not turn

WARNING
engine.

● Multimeter
● Wiring diagram
First test 

setting "I".
ment between terminal 50 (2) (with connector
plug attached) and the battery earth/engine
earth.
 Measure the voltage. Setpoint value: at least
8.0 V.
If the setpoint value is reached at terminal 50
(2):
 Measure the voltage between the connection
for field winding (3) and the battery ground/
engine ground.
8.0 V
If the setpoint value is reached at the field wind-
ing (3):
 Repair the starter motor.
If the setpoint value is not reached at the field
winding (3):
 Replace the magnet-operated switch.
If the setpoint value is not reached at terminal 50
(2):
 Check the wire between the ignition and start-
ing switch and the starter motor for open cir-
cuits using the wiring diagram. Line resist-
ance: max. 2.0 Ω
If the setpoint value for the line resistance is
reached:

 Replace the ignition and starting switch.
 Replace the wire between the ignition and
starting switch and the starter motor.
Second test
setting "I".
ment between terminal 30 (1) (with connector
plug attached) and the battery earth/engine
earth.
8.0 V.
bly at the positive terminal (+) of the battery.
bly at terminal 30 (1).
 Check the wire between the positive terminal
(+) of the battery and terminal 30 (1) for open
circuits. Line resistance: max. 2.0 Ω
 Replace the wire between the positive termi-
nal (+) of the battery and terminal 30 (1).
Starter motor turns too slowly and does not crank the engine
Test conditions  In doing so, do not release the earthing strap
● Battery charged and checked on the starter motor.
● Ribbed belt tension and generator mounting
 After cleaning, tighten the connections.
are OK
● All electrical consumers are switched off  Connect the earthing strap to the battery.
Test procedure  Actuate the ignition and starting switch.
 Actuate the ignition and starting switch. If the starter motor still does not crank the en-
gine:
If the starter motor does not crank the engine:
 Replace the starter motor.
 With the ignition switched off, disconnect the
earthing strap from the battery.
 Clean the connections on the starter motor
and the earthing strap between the engine
and the starter motor.

Removing and installing three-phase al-
ternator
Torque wrench (5 to 50 Nm)
393_01-1158
Removal 
 Observe the safety information.

 Disconnect the battery with the ignition
switched off.
 Remove the V-ribbed belt (4); see "Replacing
the V-ribbed belt".
 Remove the earth cable (3).
bly (1).
 Remove the screws (5).
 Remove the three-phase generator (6).
Installation
Checking the three-phase generator


Multimeter 
Checking the indicator light 

1
The indicator light for the battery (1) must light
up.
 Switch on the engine.
The indicator light for the battery (1) must go off.
Checking the open-circuit voltage
 Disconnect the electrical connection between
the battery and earth.
EFF
 Connect the multimeter to the battery. Set-

point value: 12.2 V to 12.5 V
 Replace the battery.
394-02_01-346
If the setpoint value is reached:

 Establish an electrical connection between
the battery and earth.
Checking the charging voltage without any elec-
trical consumers
Setpoint value for the charging voltage: greater
than the open-circuit voltage
 Replace the three-phase generator.
If the setpoint value is reached:
Checking the charging voltage with electrical
consumers

 Switch on the ventilation at the highest power
setting.
 Switch on the heating system.
 Switch on the rear window heating, if present.
Setpoint value for the charging voltage: greater
than the open-circuit voltage
 Replace the three-phase generator.
Line connectors on the magnet-operated switch
1 Terminal 30, from the battery 3 Lid for the field winding connection
2 Terminal 50, from the ignition switch
Self-diagnostics
Features of self-diagnostics
The engine control unit (0N1) must be encoded des and saves them until the error memory con-
during initial commissioning of the engine. tent is deleted. See "Error code list".
The engine control unit (0N1) contains an error If errors that affect the engine are detected, the
memory. indicator light flashes.
If faults occur in the monitored sensors or com- The saved errors can be read using the diagnos-
ponents, these errors are saved in the error tic software.
memory along with details of the type of error.
 Once the errors have been rectified, clear the
After analysing the information, the engine con- error memory.
trol unit (0N1) differentiates the various error co-

Diagnostics functions
Querying the control unit version
 Query the control unit version and encoding
using the diagnostic software.
Diagnostics functions in the diagnostic soft-

ware
NOTE
Please see the following table for the prerequi-

sites under which the required diagnostics func-
tions can be selected.
Requirement
Diagnostics functions Engine is stationary, ig-
Engine is idling Engine in load operation
nition is switched on
Control unit versions Yes Yes Yes
Error memory contents Yes1) Yes Yes
Encoding Yes No No
Measured values Yes Yes Yes
1)Perform only with ignition switched on, if the

engine does not start.
Connecting the diagnostic system

● PC with diagnostic software
● Measurement adapter 0009419980
● Multimeter
● Wiring diagram
Requirements
● Fuses OK
● Battery voltage at least 11.5 V
● Earth connections OK
● Cold engine
Procedure
 Connect the PC.
 Start the diagnostic software.
 Follow the instructions given in the diagnostic
software.

Connecting the measurement box for a 
line test
● Wiring harness for 196-pin KMC/Doosan
0009419980
plug A or plug K
● Multimeter
● Wiring diagram
The wiring harness 0009419980, measurement

box 0009418413 and the cover plates are used
to test the lines between the corresponding com-
ponents and the engine control unit (0N1).
The contacts on the control unit (0N1) are dis-
tributed to two different wiring harnesses. See
"Pin assignment of the Doosan engine control
unit with 196 contacts".

Connection diagram
9 10
1
9 11
2
5
12
3
9
4 13
9
6
7 8 0N1
394-02_01-377
1 Electrical connection assembly between wir- 7 Electrical connection assembly between wir-
ing harness and measurement box ing harness and engine control unit 0N1
2 Electrical connection assembly between wir- 8 Electrical connection assembly between wir-
ing harness and measurement box ing harness and engine control unit 0N1
3 Electrical connection assembly between wir- 9 Measurement box
ing harness and measurement box 10 Cover plate
4 Electrical connection assembly between wir- 11 Cover plate
ing harness and measurement box 12 Cover plate
5 Housing 13 Cover plate
6 Electrical connection assembly between wir- 0N1 Engine control unit
ing harness and wiring loom of the engine
control unit 0N1

Procedure 
Requirements
● Ignition is switched off

bly between the engine control unit (0N1) and
the wiring loom.
between the plug (6) of the wiring harness
and the wiring loom of the engine control unit
0N1.
 Connect the electrical connection assemblies
between the plugs (7, 8) and the engine con-
trol unit 0N1.
 Connect the electrical connection assembly 
between the plugs (1...4) with one measure-
ment box (9) each.

 Assemble the cover plates (10...13) on the 
measurement boxes.
NOTE
The number of the plugs (1...4) must match the

numbers of the cover plates.
Reading out the error memory

Procedure for reading the error memory
 Run the engine at idling speed.
 Connect the diagnostic system and start the
 Select the diagnostics function "Error memory
contents".
 Select the diagnostics function "Read out the
error memory".
Only if engine does not start:
 If no errors are stored in the engine control
unit, "0 errors detected" appears on the dis-
play unit.
 If errors are stored in the engine control unit,
they are displayed one below the other on the
display unit.
 Rectify any displayed errors using the error
table. Then, clear the error memory.
Static errors

If one or more static errors are present in the da-
ta storage, these errors must be rectified by per-
forming guided diagnostics in consultation with
the customer.
Sporadic errors
If only sporadic errors or notes are saved in the
error memory and no customer complaint is
made in connection with an electronic truck sys-
tem, clear the error memory.
 Select the test plan once again.
 Close the guided diagnostics.
All error memories are now read again.
The window that now appears confirms that all
sporadic errors have been deleted. The diagnos-
tics log is sent automatically "online".
The truck system test is ended.

VW CWTA LPG engine

Description of the drive
Technical data for the CWTA engine
Manufacturer VW
Engine type CWTA
Number of cylinders 6 in V-type arrangement ,10.6°
Bore/stroke: 89 mm/96.5 mm
Nominal capacity Pnominal = 56 kW ±5% at 2700 rpm
Compression 9.7:1
Nominal speed nnominal = 2700rpm
Lower idling, truck nlower idling, truck = 1000 rpm
Maximum revolution speed when driving nmax, driving = 2700rpm
Maximum revolution speed when lifting nmax, lifting = 2300rpm
Maximum permissible revolution speed when tow-
nmax = 3200rpm
ed
Maximum torque Maximum torquemax = 224 Nm at 1400rpm
Hydraulic valve-clearance compensation, 4
Valve clearance
valves per cylinder
Via maintenance-free chain and two adjustable
Valve train camshafts, via roller cam followers at inlet and
outlet
Ignition Electronic ignition sequence
Ignition sequence 1-5-3-6-2-4
Weight 156 kg
Installed tilt (as seen on flywheel) 8° to the right
Direction of rotation (as seen on flywheel) Left
Maximum permissible engine oil temperature in
135°C
the oil sump
Maximum permissible coolant temperature upon
110°C
discharge from engine in continuous operation
Maximum permissible suction vacuum at Pnominal
at the measurement port for the "suction vacuum" 65 mbar
sensor
Maximum permissible exhaust gas back pressure
250 mbar
at Pnominal (guarantee for VW)
Maximum permissible slope from installation posi-
30°
tion in all directions
Thermostat opening temperature 80°C ± 2°C
Thermostat full opening 95°C
Fuel LPG, LPG with 95% propane and 5% other gases

VW CWTA LPG engine
Overview of the CWTA engine
1 Ignition coils with spark plug connectors and 10 Coolant pump

spark plugs 0T1-0T6 11 Oil dipstick (Linde MH version)
2 Hall sensor for camshaft phasing (intake 12 Impco intake manifold
0B10 and outlet 0B13) 13 MAP sensor
3 Control valves for camshaft phasing (intake 14 Oil filler neck
0Y7 and outlet 0Y8) 15 Crankshaft
4 Coolant temperature transmitter 0B1 16 Oil level sensor 0B16
5 Engine oil cooler 17 Oil drain plug
6 Engine speed sensor 0B2 18 Oil sump Superb
7 Engine oil filter 19 Exhaust manifold
8 Oil pressure switch 0S1 20 Support for heat shield
9 Coolant regulator

VW CWTA LPG engine
Installation position of the CWTA engine
A 8° to the right when facing the flywheel

VW CWTA LPG engine
Lubrication of the CWTA / CKPA engine
Oil circulation
1 Camshaft phase adjuster 7 Suction line

2 Camshaft bearing 8 Oil sump
3 Hydraulic tappet rod 9 Oil filter
4 Chain tensioner 10 Oil cooler
5 Chain tensioner 11 Crankshaft bearing
6 Oil pump 12 Spray nozzles for piston lubrication
Checking the engine power rating in trucks with adjustable hydraulic pump MPR 50
To save energy (fuel), the engine speed is no This is carried out with a programmed character-
longer raised to 2800 rpm with the new working istic curve specified in the LHC 20.
pump MPR 50 during lifting, but instead load-de-
If the engine is loaded beyond its power limit the
pendent to approx. 1600 to 2300 rpm (to 2500
LHC 20 recognises this via actual value trans-
rpm with LPG) .
mitter for speed 1B1.
To achieve the same lifting speed of approx. 0.5
The LHC 20 reacts by reducing the load via
m/s, the delivery volume per rotation must be in-
pump MPR (larger pump swivel angle) → smaller
creased.
pump swivel angle, but also reduced delivery
Therefore with the change of the pump swivel volume per rotation.
angle of the MPR 50 up to the power limit of the
To keep the lifting speed constant, the engine
internal combustion engine, the engine speed
speed is now increased. Volumetric flow in l/min
"n" is kept low (fuel consumption) and the pump
remains the same.
swivel angle (delivery volume per rotation "V") is
kept at the maximum.

VW CWTA LPG engine
Power is assessed in "Pathfinder" via the current will no longer function correctly. If a function is
for the pump swivel angle and the engine speed. improved through adjusting, another is uninten-
tionally worsened at the same time.
This cannot be assessed subjectively.
It is not in the interests of our customers to per-
The checking of the engine power rating descri-
form adjustments to the MPR without detailed
bed here is only possible with a correctly adjus-
knowledge of the system.
ted MPR 50. The engine power rating cannot be
checked with a retroactively adjusted pump, The engine power rating should be checked ac-
since the electronic control can no longer func- cording to the described procedure in the "effi-
tion properly. ciency" setting.
The magnetic current delivery volume character- The truck must also be at operating temperature
istic curve which has been set ex works is stored (as described in the text: hydraulic oil minimum
in the electronic control. This is the basis for ac- 60°C) The steering must be in a straight-ahead
tivating the MPR and the internal combustion position. Lifting adjusted to 100%.
engine.
All of these points influence the engine speed
The characteristic curve cannot be set correctly; and the requested volumetric flow (and therefore
if this is adjusted retrospectively, the activation the requested power).

VW CWTA LPG engine
Checking engine power rating
To check the engine power rating of the internal value. The pressure speed falls with tolerance,
combustion engine, the engine was loaded in for example from 2800 to 2700 rpm. This means
trucks of the 39x series with fixed displacement that the internal combustion engine is OK. If the
pump. This means that the lift mast was lifted at number of revolutions falls below the tolerance
normal operating temperature (approx. 60°C hy- limit, the engine is not OK. Many technicians tra-
draulic oil temperature) up to the end stop. Maxi- ditionally have able to perform this test without
mum pressure results in the process. This is implements including by audible detection (hear-
limited to the preset value by the pressure relief ing/sensation/subjective).
valve. This may vary depending on the lift mast
With the introduction of the adjustable working
design (standard, duplex, triplex) and tonnage.
hydraulics pump, testing in this manner is no
The pressure places strain on the engine. The longer possible.
engine speed has been forced down to a certain
Assessing the engine power rating via

the engine utilisation
The procedure "lifting to the end stop" is the
same. "Pathfinder": "Inputs and outputs" - win-
dow: "Engine utilisation". This is shown in per-
cent.
The engine utilisation is calculated via the estab-
lished (VW control unit) available engine torque
and the actual requested torque.
Selected examples (values in the respective test
may differ):
Lifting without load

Actual torque 170 Nm
Available torque 250 Nm
Engine utilisation 68%
Lifting with nominal load

Lifting at the stop

Example: Engine power rating too low
Lifting at the stop*

tween setpoint and actual 300 rpm
forced down

VW CWTA LPG engine
*Engine with reduced power due to a mechani-
cal or electronic fault.
Setpoint values with tolerance
Conditions for checking the engine power rating:

● Hydraulic oil temperature: 60° C
● Pressure setting of the pressure limit valve;
working hydraulics H40 = 250 bar; H45/50 =

275 bar
Number of revolutions differential

Engine code letters Engine utilisation:
setpoint - actual forced down
No suppression of the number of
BMF / CWTA <95%
revolutions
Comparison of emission values (in vol. %)
1 Diesel engine CO Carbon monoxide

2 Diesel engine with diesel particle filter HC Hydrocarbons
3 LPG engine with unregulated catalytic con- NOx Nitrogen oxide
verter PM Particles (soot)
4 LPG engine with regulated catalytic converter
5 CNG engine with regulated catalytic convert-
er

VW CWTA LPG engine
Engine block
Overview of the cylinder block on the CWTA / CKPA engine
Removing and installing the cylinder

head cover

Special tools required

● Pliers for spring band clamps VWVAS6340
● Torque wrench (5-50 Nm)
Removing the cylinder head cover

 Replace the cylinder head cover if it is dam-
aged or leaking.
 All cable ties that are loosened or cut off dur-
ing removal must be reattached at the same
place during the installation process.
negative terminal from the battery.
 Remove the suction pipe.

VW CWTA LPG engine

 Push the extractor VWT10095A in the direc-
tion of the arrow starting from the straight side
of the connector. Remove the ignition coils
with the power output stages.
NOTE
Seal the intake channels in the suction pipe and

the cylinder head using a clean cloth.
 Unplug/disconnect and expose all other elec-
trical cables from the cylinder head cover.

 Loosen the screws for the cylinder head cover
starting from the outside and working inwards
((17)-(1)).
 Unscrew the screws and remove the cylinder
head cover.
Installing the cylinder head cover


 At the points indicated (arrows) on the cover,
apply sealant VWD454300A2.

VW CWTA LPG engine

 Position the cylinder head cover and screw it
in place evenly, starting with the screws on
the inside and working outwards ((1)...(17)).
 Install the suction pipe.
The rest of the installation is carried out in the
reverse order.
the coolant".
NOTE
Ensure that the fuel hoses are securely attach-

ed.
Tightening torques
Screw the cylinder head cover on the cylinder
head to 10 Nm.

VW CWTA LPG engine
Removing and installing the cylinder
head
Overview of the cylinder head
1 10 Nm with spacer and sealing ring 17 23 Nm

2 Seal for the cylinder head cover 18 Runner
3 Lifting eye 19 23 Nm
4 23 Nm 20 Lifting eye
5 23 Nm 21 23 Nm
6 10 Nm 22 Pipe connection
7 Suction pipe support 23 O-ring
8 10 Nm 24 Sealing ring
9 Pipe connection 25 Cylinder head seal
10 Seal/sealing ring 26 Cylinder head
11 Chain tensioner, 50 Nm 27 Cylinder head bolt
12 Cover 28 Support
13 Sealing ring 29 10 Nm
14 8 Nm 30 Filler cap
15 8 Nm 31 Cylinder head cover
16 Coolant pipe

VW CWTA LPG engine
Check the cylinder head for distortion

Testing instruments and measuring devices re-
quired
● 500 mm knife edge VWVAS6075
● Feeler gauge
Maximum permissible distortion: 0.05 mm
Removing the cylinder head

● Camshaft guide VWT10068A 
● Torque wrench (5-50 Nm) 
● Torque wrench (40-200 Nm)
● Pliers for spring band clamps VWVAS6340 
● Extractor VWT10095A 

VW CWTA LPG engine
● Polydrive wrench VW3452 
Alternatively: triple-square screwdriver, size 12

(commercially available)
● Counter hold tool VWT10172
● Sealant VWD176501A1
● Loctite FK3
Requirements:
The engine should be no more than hand hot.
WARNING
er cap.
 To remove the pressure in the cooling sys-

tem, open the filler cap on the expansion res-
ervoir and then close it again.
 Remove the coolant reservoir.
 Remove the coolant regulator housing.
NOTE
Before pulling out the connection plugs, make a

note of which components they belong to.
 Disconnect the following connection assem-
blies:
● Coolant temperature transmitter.
● Pump for coolant return.
● Injection vales for cylinders 1-6

1 0B10 phase sensor for intake side
2 0Y7 valve in the intake for camshaft phasing
3 0B13 phase sensor for outlet
4 0Y8 valve in the outlet for camshaft phasing
 Unplug/disconnect and expose all of the other

required electrical cables from the cylinder
head.
 Disconnect all connection cables, coolant and
vacuum hoses from the cylinder head.

VW CWTA LPG engine

 Rotate the crankshaft in the running direction
of the engine to the TDC mark for cylinder 1.
Use the counter hold tool (VWT10172).
 Remove cylinder head cover.

 The cams (A) of cylinder 1 must point towards
each other.

 Remove the chain tensioner for the camshaft
roller chain (arrow).

 Unscrew the two screws (5) from sealing
flange. Then unscrew all screws (arrows)
from the cover.
 Unscrew the mounting screws (arrows) from
the cover. Remove the covers for the timing
chain and the control housing.
 Before removing it, mark the camshaft roller
chain (e.g. using ink, mark an arrow showing
the direction of travel).
 First remove the outlet camshaft adjuster.
 Remove the camshaft phase adjuster togeth-
er with the camshaft roller chain from the in-
take camshaft.

VW CWTA LPG engine

CAUTION
The camshafts are hollow and can be damaged if
they are rotated incorrectly.
 Remove the camshaft guide during tightening or
loosening tasks.
 Rotate only at the specified points (arrows) using a
wrench with a width across flats of 27 mm.

 Loosen the screws on the camshaft phase
adjusters (10) and (6).
 Remove the two camshaft phase adjusters.
 Loosen screws on the runner (7). Remove the
runner.
 Remove the clipped-in runner (11).
 Remove the guide roller (8) for the chain
wheel (9).
 Remove the chain wheel (9).
 Place the timing chain to one side.

 Unscrew the screws (arrows) from the control
housing. Pull the control housing downwards
and off the camshaft.

 Loosen and unscrew the cylinder head bolts
in the sequence 1-20, starting from the out-
side and working inwards.
Depending on the type of cylinder head bolt in
use, use the Polydrive wrench VW3452 or triple-
square screwdriver, size 12.
 With assistance from another mechanic, care-
fully lift off the cylinder head.
Use the existing suspension eyes for this pur-
pose.
 To prevent dirt and emery residues from get-
ting into the cylinders, seal the cylinders with
a clean cloth.

VW CWTA LPG engine
 Avoid getting dirt and emery residues into the
coolant.
 Carefully grind down the sealing faces of the
cylinder head and cylinder block. Take care
not to create any long scratches or scores (if
using abrasive paper, the grit size must not
be finer than 100).
 Test the cylinder head for distortion.
Installing the cylinder head
NOTE
An Impco LPG system is fitted at the engine in-

let. For this reason, the cylinder head has no
threads for fuel injectors, rendering it unsuitable
for interchange with the cylinder head fitted to a
car.
● When installing a replacement cylinder head,
oil all contact faces between support ele-

ments, roller cam followers and the cams on
the camshafts before assembling the cylinder
head cover.
● Check the torque at the nuts of the camshaft
bearings.
● The plastic washers provided for protecting
the open valves must not be removed until

immediately before the cylinder head is
placed in position.
● If the cylinder head is replaced, all of the cool-
ant must be changed.

 Carefully remove emery residues and swarf,
as well as the clean cloths.
If the piston for cylinder 1 is not in the TDC posi-
tion:

Use the counter hold tool (VWT10172).
 Use the vibration damper mounting screw to
turn the crankshaft in the running direction of
the engine to the TDC mark for cylinder 1 (ar-
row).
 At the same time, a second mechanic guides
the timing chain by hand.
NOTE
Do not remove the new cylinder head seal from

its packaging until immediately before installa-
tion. Handle the new seal with care. If it is dam-
aged it will leak.

VW CWTA LPG engine
 Place the new cylinder head seal in position.
The marking (spare part number) must be
legible.

 Insert the dowel sleeves into the cylinder
block in bores 12 and 20.

 Move the camshaft in the cylinder head to
TDC for cylinder 1.
The cams (A) of cylinder 1 must point towards
each other.

 It must be possible to insert camshaft guide
VWT10068A into both shaft slots.
 Prepare the cylinder head seal for assembly.

VW CWTA LPG engine

NOTE
The longer cylinder head bolts are inserted into

the central holes in the cylinder head.
 Place the cylinder head in position, insert the
new cylinder head bolts, and hand-tighten
them.
 Tighten the cylinder head bolts in four stages
in the tightening sequence 1-20 as described
below, starting from the inside and working
outwards:
1. Pre-tighten all bolts to 15 Nm.
2. Tighten all bolts to 30 Nm.
3. Using a rigid wrench, tighten the bolts by an-
other 90° (¼ turn).
4. Using a rigid wrench, tighten the bolts by an-
other 90° (¼ turn).

 Oil the sealing rings on the camshaft. Install
the control housing. During this process, the
timing chain must be placed over the valves
for camshaft phasing.

 Secure the chain wheel (9) with the guide roll-
er (8) on the cylinder head.

VW CWTA LPG engine

 Position the timing chain so that it is "taut" on
the chain wheel. Now screw on the runner
(arrow).
The rest of the assembly process is carried out
in the reverse sequence.
 Install the camshaft phase adjuster with the
timing chain for the camshaft drive.
 Install the cylinder head cover.
 Top up with new coolant.
the coolant".
V-ribbed belt drive on the CWTA / CKPA engine

ment)

VW CWTA LPG engine
Assembly overview of the V-ribbed belt drive without air-conditioning compressor
1 25 Nm 11 10 Nm
2 Three-phase generator 12 20 Nm
3 Support for ancillary equipment 13 V-ribbed belt roller for coolant pump
4 23 Nm 14 50 Nm
5 23 Nm 15 Tensioning pulley for the V-ribbed belt
6 Guide pulley 16 Sealing flange
7 40 Nm 17 8 Nm
8 V-ribbed belt 18 Coolant pump
9 Vibration damper 19 Cylinder block
10 Tighten seven screws to 60 Nm + ½ a turn
(180°)

VW CWTA LPG engine
Assembly overview of the V-ribbed belt drive with air-conditioning compressor
1 25 Nm 12 Tighten seven screws to 60 Nm + ½ a turn

2 Three-phase generator (180°)
3 Support for ancillary equipment 13 10 Nm
4 23 Nm 14 20 Nm
5 23 Nm 15 V-ribbed belt roller for coolant pump
6 Air-conditioning compressor 16 50 Nm
7 Three screws: 25 Nm 17 Tensioning pulley for the V-ribbed belt
8 Guide pulley 18 Sealing flange
9 40 Nm 19 8 Nm
10 V-ribbed belt 20 Coolant pump
11 Vibration damper 21 Cylinder block

VW CWTA LPG engine
Removing and installing the V-ribbed
belt
Special tools and devices required
Removing the V-ribbed belt without the air-conditioning compressor
1 Tensioning pulley 4 Crankshaft

2 Three-phase generator 5 Coolant pump
3 V-ribbed belt

VW CWTA LPG engine
belt.

sioning pulley (1) and press downwards in the
direction of the arrow until the bores (2) on
the housing align with the tensioning pulley.
Then insert the VWT10060A locking pin into
the bores (2).
Installing the V-ribbed belt without the air-

conditioning compressor
NOTE
tion of travel.

belt pulleys.
sioning pulley (1) and press downwards
slightly in the direction of the arrow to release
the VWT10060A locking pin from the bores
(2) on the tensioning pulley. Remove the
VWT10060A locking pin.
correctly.

VW CWTA LPG engine
Removing the V-ribbed belt with the air-conditioning compressor

ment)

belt.

 Place the spanner (1) on the screw of the ten-
sioning pulley and rotate the screw in the di-
rection of the arrow until the VWT10060A
locking pin can be inserted in the tensioning
pulley.
Installing the V-ribbed belt with the air-con-

ditioning compressor

VW CWTA LPG engine
NOTE
tion of travel.

belt pulleys.
 Using the spanner (1), lightly push the ten-
sioning pulley in the direction of the arrow to
release the VWT10060A locking pin in the
tensioning pulley. Remove the VWT10060A
locking pin.
correctly.
Checking the compression pressure

● Spark plug wrench VW3122B

● Torque wrench (5–50 Nm)
● Compression-pressure testing instrument
VWVAG1763
Test conditions
● Engine oil temperature not less than 30°C.
● All electrical consumers, such as the lights or
the rear window heating, must be switched
off.
● If the truck is fitted with air conditioning, it
must be switched off.
Test procedure
 Open the diagnostic software (IMPCO). Start
the compression test in the guided diagnos-
tics.
 Unplug the connection plugs for the ignition
coils 1–6. Use installation tool VWT10118 to
release the plug interlocks.
 Place installation tool VWT10118 on the lock-
ing button (arrow) and carefully remove the
connection plug.

VW CWTA LPG engine
 Push the extractor VWT10095 A in the direc- 
tion of the arrow starting from the straight side
of the connector. Remove the ignition coil and
power output stage.
 Use spark plug wrench VW3122B to remove
the spark plugs.
 Briefly start the engine so that combustion
residues dissipate.
 Check the compression pressure using test-
ing instrument VWVAG1763.
NOTE
Use the testing instrument in accordance with

the operating instructions for the device.
 Keep the starter motor turning until the testing
instrument shows no further increase in pres-
sure.
Values for compression pressure

New: 11–13 bar
Wear limit: 8 bar
Permissible pressure difference across all of the
cylinders: 3 bar
 Fit the spark plugs using spark plug wrench
VW3122B.
Tightening torque of the spark plugs: 20 Nm
 Fit the ignition coils together with power out-
put stage. Install the connection plugs.
 Deactivate the compression test in the diag-
nostic software.
 Clear the error in the error memory of the "IM-
PCO" controller if necessary.

VW CWTA LPG engine
Valve train
Overview of the valve train for the CWTA / CKPA engine
1 Tighten to 5 Nm + 1/8 of a turn (45°) 12 Valves

2 Sealing rings 13 Dowel sleeve
3 Control housing 14 Cylinder head
4 Tighten to 8 Nm + ¼ of a turn (90°) 15 Seal for the valve stem
5 Camshaft phasing for the outlet side 16 Support element
6 Timing chain for the camshaft 17 Safety clip
7 Camshaft phasing for the intake side 18 Roller cam follower
8 Tighten to 60 Nm + ¼ of a turn (90°) 19 Valve spring
9 Cylinder head height: minimum height a = 20 Valve spring seat
139.9 mm 21 Valve cone piece
10 Guide pulley (drive chain wheel for high-pres- 22 Intake camshaft
sure pump not available at Linde) 23 Bearing cover for the camshaft
11 Bearing shaft 24 Outlet camshaft

VW CWTA LPG engine
Overview of the chain drive for the CWTA / CKPA engine
1 Drive for the outlet camshaft with camshaft 5 Gear for the crankshaft
phase adjuster 6 Guide pulley (drive chain wheel for high-pres-
2 Hydraulic chain tensioner sure pump not available at Linde)
3 Drive for the oil pump 7 Drive for the intake camshaft with camshaft
4 Hydraulic chain tensioner phase adjuster

VW CWTA LPG engine
Control housing for the CWTA engine
1 Runner 5 3.8 Nm
2 Control housing 6 Tighten to 8 Nm + ½ a turn (180°).
3 0Y7 valve in the intake for camshaft phasing 7 Seal
Checking the strainer of the control housing

for contamination

 Unclip the strainer (2) from the back of the
control housing (1).
 Remove any contamination present.

VW CWTA LPG engine
Overview and function of camshaft
phasing for the CWTA / CKPA engine
Overview of camshaft phasing
● Camshaft phase adjuster for the outlet cam- 

shaft (1) with an advance angle of 22°
● 0Y8 solenoid valve (2) for camshaft phasing
on the outlet side
● 0Y7 solenoid valve (3) for camshaft phasing
on the intake side
● Camshaft phase adjuster for the intake cam-
shaft (4) with an advance angle of 52°
● Hall sensor as a phase sensor (5) 
● Trigger wheel (6)

The position of the intake camshaft is detected
via the intake phase sensor (0B10).
The position the outlet camshaft is detected via
the outlet phase sensor (0B13).

VW CWTA LPG engine
Both of the camshaft phase adjusters operate 
hydraulically. The camshaft phase adjusters are
connected via the control housing to the engine
oil cycle.
● Oil channels to the ring canal of the camshaft
(7)
● Control housing (8)
Function of camshaft phasing
9 Intake camshaft 0B6 Transmitter for intake air pressure/tempera-

10 Outlet camshaft ture
0Y7 Solenoid valve for intake camshaft phasing 0B1 Transmitter for coolant temperature
0Y8 Solenoid valve for outlet camshaft phasing 0N1 Engine control unit
11 Oil pump 0B13 Outlet camshaft phase sensor
0B2 Transmitter for engine speed 0B10 Intake camshaft phase sensor
The camshaft phasing system operates at an oil

pressure of above 0.7 bar.
If the camshaft phasing system is not operating
correctly or the engine is not running smoothly,
this may be due to clogged oil channels in cam-
shaft phase adjusters.

VW CWTA LPG engine
 Check that the oil pressure is 0.7 bar.
 If the oil pressure is different, check the cam-
shaft phase adjusters for dirt or foreign ob-
jects, and remove the dirt or foreign objects.
 Clean and flush the lubrication system.
The process of adjusting the camshafts depends
on the load characteristics of the engine. The
load characteristics of the engine are deter-
mined by the engine speed (0B2), the intake air
pressure/temperature (0B6) and the engine tem-
perature (0B1). The position of the crankshaft
and the camshafts with the phase sensors
(0B10) and (0B13) is also relevant.
Adjusting the camshafts increases performance
and torque. In addition, it saves fuel and reduces
exhaust emissions.
The process of camshaft phase adjustment is
performed continuously via two camshaft phase
adjusters.
To adjust the camshafts, the engine control unit
(0N1) actuates the electromagnetic valves (0Y7)
and (0Y8). The solenoid valves then open the oil
channels in the control housing. The engine oil
passes via the control housing and the camshaft
into the camshaft phase adjusters. The camshaft
phase adjusters rotate independently and adjust
the camshafts according to the specifications
from the engine control unit.
The maximum adjustment of the camshafts is
52° for the intake camshaft and 22° for the outlet
camshaft.
Design of the camshaft phase adjuster on

the intake side
● Internal rotor (12) 
● Oil channels (13)

● External rotor (14)
The housing with the external rotor is secured to
the chain wheel. The internal rotor is secured to
the camshaft.
The maximum advance angle is 52°. The intake
camshaft is adjusted across the entire engine
speed range using the adjustment map values
stored in the engine control unit.

VW CWTA LPG engine
"Pre-injection adjustment" of the intake camshaft
15 Ring canals 19 Engine oil pressure

16 Front-side bores 20 Oil return
0Y7 Solenoid valve 21 Oil channel for pre-injection adjustment
17 Control piston 22 Control housing
18 Oil return
If the camshaft phasing fails, the camshaft

phase adjuster is pressed by the oil pressure in-
to the basic position of 25° beyond TDC.
For the purpose of exhaust gas recirculation and
torque multiplication, the intake camshaft is ad-
justed to the "intake valves open before TDC"
position. To initiate the adjustment process, the
engine control unit actuates the solenoid valve
(0Y7) for camshaft phasing.
Once activated, the valve moves the control pis-
ton (17). In the control housing, the oil channel
for pre-injection adjustment (21) is opened in ac-
cordance with the advance angle. The pressur-
ised engine oil flows via the control housing into
ring canal (15) of the camshaft.
For pre-injection adjustment, the oil flows via the
five front-end bores (16) of the camshaft into the
five chambers in the camshaft phase adjuster for

VW CWTA LPG engine
pre-injection adjustment. Here, the oil pushes
against the blades of the internal rotor.
The rotor rotates in the opposite direction to the
control housing and causes the camshaft to ro-
tate with it. As a result, the camshaft rotates in
the opposite direction of rotation to the crank-
shaft and the intake valves open earlier.
"Post-injection adjustment" for the intake camshaft
15 Ring canals 20 Oil return

16 Front-side bores 21 Oil channel for post-injection adjustment
0Y7 Solenoid valve 22 Control housing
17 Control piston 23 Blind hole for the mounting screw
18 Oil return 24 Interior blades
19 Engine oil pressure
If the camshaft phasing fails, the camshaft

phase adjuster is pressed by the oil pressure in-
to the basic position of 25° beyond TDC.
When idling and when a high output is required
from the engine, the intake camshaft is rotated
such that the intake valves open late, i.e. be-
yond TDC. The engine control unit actuates the
solenoid valve (0Y7) for post-injection adjust-
ment of the intake camshaft.
The solenoid valve (0Y7) opens the channel for
post-injection adjustment by moving the control

VW CWTA LPG engine
piston (17). As a result, oil flows via the control
housing (22) into the ring canal in the camshaft.
The oil flows via bores in the camshaft into the
blind hole in the mounting screw (23).
From here, the oil flows via the five bores in
camshaft phase adjuster into the oil chamber
behind the blades of the internal rotor for post-
injection adjustment. The oil pushes the internal
rotor and the camshaft in the direction of rotation
of the crankshaft. The valves open later.
At the same time as the channel for post-injec-
tion adjustment is opening (21), the control pis-
ton (17) opens the channel for pre-injection ad-
justment to allow the oil to return (20), thus re-
leasing the pressure from this channel. The rota-
tion in the "post-injection" direction pushes the
oil out of the oil chamber for pre-injection adjust-
ment. The oil then drains via the channel for pre-
injection adjustment.
Controlling continuous adjustment
The regulation allows continuous adjustment be-

tween the pre-injection and post-injection of the
intake camshaft, with the total adjustment travel
mounting to a maximum crank angle of 52°. Us-
ing the signals from the hall sensor, the engine

VW CWTA LPG engine
control unit detects the current position of the in-
take camshaft.
The camshafts are adjusted using the adjust-
ment map values for the engine stored in the en-
gine control unit (0N1). Once actuated by the
engine control unit, the solenoid valve (0Y7)
moves the control piston, e.g. in the direction of
pre-injection adjustment. The pressurised oil
flows via the control housing into the camshaft
phase adjuster and pushes the camshaft in the
"pre-injection" direction.
The movement of the control piston in the "pre-
injection" direction automatically opens the
channel for post-injection adjustment in the di-
rection of the oil flow. Once the required ad-
vance angle has been reached, the solenoid
valve (0Y7) moves the control piston to a posi-
tion in which both chambers of the phase adjust-
er are pressurised.
If the timing is shifted in the "post-injection" di-
rection, the process happens in the reverse se-
quence.
Design of the camshaft phase adjuster on

the outlet side
● Internal rotor (25) 
● Wider blades (26)

● Oil channels (27)
● External rotor (28)
In contrast to the closed-loop adjustment of the
intake camshaft, the engine control unit actuates
the outlet camshaft into just two positions: a ba-
sic position and idling position.
The maximum advance angle is 22°. The design
of the camshaft phase adjuster for the outlet
camshaft is identical to that of the camshaft
phase adjuster for the intake camshaft. Howev-
er, the internal blades are wider because the ad-
justment travel is just 22°.

VW CWTA LPG engine
Adjusting the outlet camshaft
29 Blades 35 Oil return

30 Internal rotor 36 Oil channel for the basic position
31 External rotor 37 Blind hole for the mounting screw
0Y8 Solenoid valve 38 Control housing
32 Control piston 39 Ring canals
33 Oil return 40 Front-side bores
The outlet camshaft sits in its basic position at

speeds above idle speed and when the engine
is being started.
The outlet valves then close just before TDC. In
this position, the outlet camshaft is in the power,
torque and exhaust gas recirculation operating
statuses.
The solenoid valve (0Y8) is not actuated in
these operating statuses. In the basic position,
the outlet camshaft closes the valves just before
TDC. The engine control unit does not actuate
the solenoid valve (0Y8). This means that the
solenoid valve (0Y8) sits in a position in which
the channel for post-injection adjustment is ex-
posed.

VW CWTA LPG engine
The pressurised engine oil flows via the oil chan-
nels (36) in the control housing into a ring canal
(39) in the outlet camshaft. From here, the oil
flows through the front-side bores (40) in the
camshaft into the oil chamber of the camshaft
phase adjuster.
Here, the oil pushes against the blades (29) of
the internal rotor (30). The blades (29) rotate to
the stop and cause the camshaft to rotate with
them. The camshaft remains in this position as
long as the solenoid valve (0Y8) is not actuated.
Idling control
30 Internal rotor 35 Oil return

31 External rotor 36 Oil channel for the basic position
0Y8 Solenoid valve 37 Blind hole for the mounting screw
0N1 Engine control unit 38 Control housing
32 Control piston 39 Ring canals
33 Oil return 40 Front-side bores
When idling and at speeds of up to approx. 1200

rpm, the outlet camshaft is adjusted in the "pre-
injection" direction.
The engine control unit actuates the solenoid
valve (0Y8). As a result, the control piston (32)
moves and exposes a different channel in the
control housing.

VW CWTA LPG engine
The engine oil now flows into the other ring ca-
nal on the camshaft and via the drilled camshaft
into the camshaft phase adjuster. Here the oil
pushes against the blades of the internal rotor
(30). The blades are rotated against the running
direction of the engine and cause the camshaft
to rotate with them.
The outlet valves open and close earlier. The oil
in the chamber upstream of the blades flows
back via the bore in the camshaft phase adjuster
and the blind hole in the screw (37).
The oil then flows to the ring canal in the cam-
shaft (39) and to the solenoid valve (0Y8). In the
solenoid valve (0Y8), the oil flows via the return
line into the timing chain housing
Removing and installing camshaft

phase adjusters with a timing chain


● VWT10068A camshaft guide
● VWT10172 counter hold tool with
VWT10172/1 bolt
● VWD 176501A1 sealant
Removing the camshaft phase adjusters
WARNING
For all assembly work in the engine compartment, the
close proximity of the parts mean that the following in-
structions are relevant: Restore the original wiring
guide (e.g. for fuel, hydraulics, electrics, activated car-
bon canister system, coolant and refrigerant, brake
fluid, vacuum).
Take care to allow sufficient clearance around all hot
or moving components.


VW CWTA LPG engine
NOTE
Before pulling out the plugs, make a note of

which components they belong to.

blies:


 Unscrew the screws (arrows) from the cover.
Prise off the cover.

 Rotate the crankshaft using the VWT10172
counter hold tool in the running direction of
the engine to the OT mark for cylinder 1 (ar-
row).

VW CWTA LPG engine

each other.

 Loosen the screw for the camshaft phase ad-
juster for the outlet side by approx. one turn.
To do this, hold the spanner flats of the cam-
shaft using an open-ended spanner.

 Loosen the screw for the camshaft phase ad-
juster for the intake side by approx. one turn.
To do this, hold the spanner flats of the cam-
shaft using an open-ended spanner.

 Insert the VWT10068A camshaft guide into
both shaft slots. If necessary, slightly rotate
the camshafts back and forth using an open-
ended spanner.

VW CWTA LPG engine

 Remove the chain tensioner for the timing
chain (arrow).
 Mark the chain links that sit opposite the

markings (arrows) on the camshaft phase ad-
justers. Marking the timing chain will facilitate
the installation process.
 Completely unscrew the screws for the cam-
shaft phase adjusters. Remove the camshaft
phase adjusters.
NOTE
The bottom cover holds the timing chain on the

chain wheel of the oil pump. The timing chain
must not skip.
Installing the camshaft phase adjusters

Requirement:
● The crankshaft is at the OT position.
● The camshafts are fixed in place using the
VWT10068A camshaft guide
First install the camshaft phase adjuster for the
intake camshaft as follows:

VW CWTA LPG engine
NOTE
● The camshaft phase adjusters are locked in
the "quiescent state". This ensures that the
trigger wheel does not twist when the timing is
adjusted. If the interlock is not engaged
(locked) in the "quiescent state", rotate the
adjuster by hand in both directions until it
locks. If this is not possible, replace the cam-
shaft phase adjuster.
● Because of the dowel pin, the camshaft
phase adjusters can be attached to the hold-
ing fixture of the camshafts only in one posi-
tion (arrows).
 Attach the camshaft phase adjuster for the in-
take side, with the timing chain fitted, to the
camshaft. During the assembly process, note
the following:
● The timing chain must not "sag" at the fixed
chain wheel.
● With the timing chain stretched "taut", the 
camshaft phase adjuster must be easy to fit
and to tighten by hand.
● The arrow (2) on camshaft phase adjuster for 

the intake side 24 E must align with the right-
hand notch (1) on the control housing. Refer
to the marks on the control housing.
 Tighten the screw for the camshaft phase ad-
juster by hand.
 Starting from the tooth that aligns with the ar-
row (2) and the notch (1), count exactly 16
chain pins to the right on the timing chain.
Mark this chain pin with a coloured marker
pen.

VW CWTA LPG engine

 Insert the camshaft phase adjuster for the
outlet side 32 A into the timing chain of the
camshafts. The 16 chain pins counted out be-
fore must sit between the teeth at the 24 E
and 32 A arrow markings.
 Position the camshaft phase adjuster for the
outlet side 32 A with the timing chain fitted on
the camshafts on the outlet camshaft. During
the assembly process, note the following:
● The arrow (2) on camshaft phase adjuster for 

the outlet side 32 A must align with the right-
hand notch (1) on the control housing. Refer
to the marks on the control housing.
NOTE
The camshaft phase adjuster for the outlet side

must be easy to fit on the outlet camshaft. If nec-
essary, slightly rotate the camshaft back and
forth.
 Remove the VWT10068A camshaft guide.

 Install the chain tensioner for the timing chain
(arrow) and tighten the chain tensioner to a
torque of 50 Nm.

VW CWTA LPG engine
 Rotate the engine in the running direction of

the engine by two turns and check the timing.
If the marking (arrows) do not line up:

CAUTION
loosening tasks.
NOTE
● Replace all of the screws for the chain
wheels.
 Screw in the new screws for the camshaft
phase adjusters for the intake side and outlet
side to 60 Nm + ¼ of a turn (90°).
 Clean the sealing faces for the rear cover. Ap-
ply the VWD 176501A1 sealant to the sealing
face.

VW CWTA LPG engine

 Fit the cover. Tighten the screws (arrows) in a
crosswise pattern to 8 Nm.
The rest of the assembly process is carried out
in the reverse sequence.
Removing and installing the camshaft



● VWT10068A camshaft guide
● VWT10172 counter hold tool
● VWD 176501A1 sealant
● VWG 052723A2 solid lubricant paste
● Loctite FK3
Removing the camshaft
WARNING
For all assembly work in the engine compartment, the
close proximity of the parts mean that the following in-
structions are relevant: Restore the original wiring
guide (e.g. for fuel, hydraulics, electrics, activated car-
bon canister system, coolant and refrigerant, brake
fluid, vacuum).
Take care to allow sufficient clearance around all hot
or moving components.


VW CWTA LPG engine
NOTE
Before pulling out the plugs, make a note of

which components they belong to.

blies.

 Expose the electrical wiring harness.

 Unscrew the cover (arrows) from the cylinder
head.
WARNING
Parts can drop into the chain case.
Carefully cover the bottom chain case.

Use the VWT10172 counter hold tool.

VW CWTA LPG engine

 It must be possible to insert the VWT10068A
camshaft guide into both shaft slots.

 Remove the chain tensioner for the timing
chain on the camshafts (arrow).

CAUTION
loosening tasks.

 Loosen the screws on the camshaft phase
adjusters (1) and (2).
 Remove the two camshaft phase adjusters.

VW CWTA LPG engine

 Unscrew the control housing (2) with the four
screws (1) from the cylinder head. Pull the
control housing downwards from the cam-
shafts in the direction of the arrow.
 Place the timing chain to one side.

Intake camshaft(A)
 Remove the bearing covers (1) and (13).
 Remove the bearing cover (7).
 Loosen and remove the bearing covers (5)
and (9) crosswise and in an alternating order.

Outlet camshaft (B)
 Remove the bearing cover (8).
 Loosen the bearing covers (6) and (10) cross-
wise and in an alternating order.
Next steps for both camshafts

 Carefully take out the camshafts and place
them on a clean surface.
 Remove the roller cam followers together with
the support elements and place them on a
clean pad.
NOTE
Ensure that the roller cam followers and support

elements are not interchanged.
Installing the camshaft
Requirement:

VW CWTA LPG engine

When installing the camshafts, the cams for cyl-
inder 1 (A) must face upwards.

 Lightly coat the contact face of the bearing
covers (7) and (8) with the VWG 052723A2
solid lubricant paste before installing the bear-
ing covers.
 Insert the support elements into the cylinder
head. Place the relevant roller cam followers
onto the valve stem ends and support ele-
ments.

 Ensure that all of the roller cam followers (1)
are correctly positioned on the valve stem
ends and clipped onto the correct support ele-
ments (2).
 Oil the camshaft treads.
 Carefully place the corresponding camshaft
into the camshaft bearings on the cylinder
head. In doing so, note the marking on the
camshafts.

 Note the installation position of the bearing
covers.
The tips of the bearing covers (arrow A) for the
intake and outlet camshafts face outwards.
Intake camshaft (A)

VW CWTA LPG engine

 Screw on the bearing covers (5) and (9)
crosswise and in an alternating order and
tighten to 5 Nm + 1/8 of a turn (45°).
 Screw on the bearing cover (7) and tighten to
5 Nm + 1/8 of a turn (45°).
Outlet camshaft (B)


 Screw on the bearing cover (8) and tighten to
5 Nm + 1/8 of a turn (45°).
Next steps for both camshafts


both shaft slots.
 Before installation, check the strainer for the
control housing for contamination.
 Before installing the control housing, oil the
sealing rings on the camshafts.
 Oil the contact face of the sealing rings in the
control housing. Slowly slide the control hous-
ing over the sealing rings on the camshafts.

VW CWTA LPG engine

 Install the control housing. Insert the screws
(arrows) with Loctite FK3.
 Install the camshaft phase adjuster with the
timing chain for the camshaft drive.
 Clean the sealing face on the cover as well as
on the cylinder head.
 Replace the sealing rings on the cover.
 Coat the sealing face on the cover with the
VWD 176501A1 sealant and install the cover
immediately.
NOTE
The VWD 176501A1 sealant hardens quickly.


 Insert all of the screws (arrows) and lightly
tighten them initially.
 Then tighten the screws to 8 Nm.
 Install the chain tensioner for the timing chain
for the camshafts and tighten the chain ten-
sioner to 50 Nm.
Checking the timing

VWT10068A camshaft guide 
VWT10172 counter hold tool 
Checking the timing


VW CWTA LPG engine

 Rotate the crankshaft using the VWT10172
counter hold tool in the running direction of
the engine to the TDC mark for cylinder 1.

each other.

both shaft slots.
NOTE
Due to the function of the camshaft phase ad-

justers, the grooves on the camshafts may not
be exactly horizontal. Therefore, if necessary,
rotate the camshafts to insert the VWT10068A
camshaft guide.

CAUTION
loosening tasks.

VW CWTA LPG engine
Check the setting marks on the camshaft phase

adjuster against the marks on the control hous-
ing:
● The arrows on the camshaft phase adjusters
must align with the right-hand notches on the
control housing.
NOTE
● A slight offset between marking 32 A and the
notch is permissible.

 The distance between the markings on the
camshaft phase adjuster must be exactly 16
chain pins on the timing chain for the cam-
shafts.
If the marks do not line up:
 Adjust the timing.
If the marks do line up:

VW CWTA LPG engine
Markings on the control housing

(A) view of the flywheel-side
(B) view of the vibration damper side
The notches (arrows) are the reference points
for the markings on the camshaft phase adjust-
ers.
Cooling
Cooling system for the CWTA / CKPA engine

ment)

VW CWTA LPG engine
Assembly overview for the cooling system
1 Coolant temperature sensor 12 Coolant regulator

2 O-ring 13 Coolant pipe
3 Retaining clips 14 Sealing ring
4 10 Nm 15 8 Nm
5 Retaining clips 16 Belt pulley
6 To top of radiator 17 20 Nm
7 Non-return valve 18 Coolant pump
8 O-ring 19 10 Nm
9 Electric coolant pump 20 Pipe connection
10 5 Nm 21 Seal
11 O-ring
Electric coolant pump

VW CWTA LPG engine
The electrical coolant pump prevents the coolant 
from being heated after the engine has been
switched off. The pump starts to operate at a
coolant temperature of 95°C. The pump
switches off again when the temperature falls
below 90°C.

Mounting position of the electrical coolant pump
The electrical coolant pump (9) is mounted on
the support for ancillary equipment.

 To remove the coolant pump, the support (ar-
row) for ancillary equipment must be removed
from the cylinder.

VW CWTA LPG engine
Connection diagram for coolant hoses
1 Expansion reservoir 7 Engine

2 Radiator 8 Engine oil cooler
3 Heat exchanger for heating system and air 9 Coolant regulator
conditioning unit 10 Coolant pump
4 Bleeder screw 11 Cylinder head
5 Non-return valve 12 Evaporator
6 Electric coolant pump
Draining and filling the coolant

● Refractometer VWT10007A 
WARNING
Wait until the cooling fluid has cooled down. Cover
the filler cap with a cloth. Carefully open the filler cap.

VW CWTA LPG engine

sion reservoir (2).

 Place a collection container under the coolant
hose (5).
 Remove the coolant hose.
 Allow the residual coolant to drain.
 Reattach the coolant hose and secure it using
a hose clip.
NOTE
Observe disposal specifications for the coolant.

VW CWTA LPG engine
Topping up the coolant
NOTE
● Only G 12 plus plus according to TLVW774G
may be used as a coolant additive.
● Only distilled water may be used as mixing
water.
● G12 plus plus must not be mixed with G11.
Otherwise, the coolant goes brown and must
be changed.
● Coolant additives prevent freezing, corrosion-
related damage and lime scale deposits. They
also increase the boiling temperature. There-
fore, the cooling system must be filled with
coolant and corrosion inhibitor all year round.
● Particularly in tropical countries, the coolant
guarantees operational safety by increasing
the boiling point when the engine is under
heavy load.
● Frost protection must be ensured down to
-25°C (in countries with an Arctic climate,
down to -35°C).
● Do not change the concentration of the cool-
ant by topping it up. The percentage of cool-
ant additive must be at least 40%.
● If stronger frost protection is required for cli-
matic reasons, the percentage of coolant ad-
ditive can be increased up to 60% (frost pro-
tection down to -40 °C). At a higher proportion
than this, the cooling effect deteriorates, and
the frost protection reduces again.
● If the radiator, heat exchanger, cylinder head
or cylinder head seal have been replaced,
used coolant must not be reused.
Coolant mixture ratios
Frost protection down to Level of frost protection G 12 plus plus Distilled water
-25°C 40% 3.6 l 5.4 l
-35 °C 50% 4.5 l 4.5 l
NOTE
Depending on the truck equipment, the coolant

volume may deviate from this value.

VW CWTA LPG engine

 Add new coolant to the expansion reservoir
(2).
The coolant level must be between the min. and
max. marks (3) on the expansion reservoir.
 Start the engine and keep the engine speed
at approx. 2000 rpm for three minutes.
 Run the engine until the fan starts up.

 Loosen the screw (6) on the evaporator until
the water running out is bubble-free and the
system has been bled.
 Tighten the screw again.
WARNING
er cap.
 Check the coolant level. Top up the coolant if 6

necessary.
When the engine is at operating temperature,
the coolant level must be at the max. mark. t3941437
When the engine is cold, the coolant level must

be between the min. and max. marks.
NOTE
For versions with a heating system, the following

is also required:

VW CWTA LPG engine

 Remove the filler cap (7) on the right next to
the wheel arch.
 Use an 8 AF open-ended spanner to loosen
the pipe union (8) through the bore until the
water running out is bubble-free.
 Tighten the pipe union (8).
 Fit the filler cap (7).
Removing and installing the coolant

pump
● Refractometer VWT10007 
● Torque wrench
● Mandril
Removing the coolant pump
WARNING
er cap.

 Remove the belt pulley for the coolant pump.
To do this, hold the belt pulley in place using
a mandril (commercially available).

VW CWTA LPG engine

 Unscrew the screws (1) for the coolant pump.
Remove the coolant pump (2).
Installing the coolant pump

quence. Please note the following:
 Wet the new O-ring with coolant.
 Insert the coolant pump.
 Tighten the screws for the coolant pump to
8 Nm.
 Install the belt pulley for the coolant pump and
tighten the belt pulley to 20 Nm.
 Fit the V-ribbed belt.
 Add coolant.
the coolant".
Removing and installing the coolant reg-

ulator
● Hose clamp pliers VWVAS6340 
Removing the coolant regulator


 Set aside the electrical connection assembly
(A).
 Remove the coolant hoses from the engine oil
cooler (arrows) and set aside the coolant ho-
ses.

VW CWTA LPG engine

 Loosen bolts (arrows). Remove the coolant
pipe union along with the coolant hose.
 Remove the coolant regulator from the cool-
ant pipe.
Installing the coolant regulator


NOTE
A metal sleeve (arrow) must be present in the

coolant pipe union. If the metal sleeve is miss-
ing, the coolant pipe union must be replaced.
 Clean the sealing face for the sealing ring.
 Insert the coolant regulator into the coolant
pipe.
NOTE
Change seals and sealing rings.


 Check that the edges on the coolant regulator
(2) align with the housing (1) (arrows).
 Wet the new sealing ring with coolant and
place the sealing ring on the coolant pipe un-
ion.
 Attach the coolant pipe union along with the
sealing ring. Tighten the screws crosswise in
an alternating order to 5 Nm.

 Install the coolant hoses (arrows) and the
electrical connection assembly (A).
 Add coolant.

VW CWTA LPG engine
Engine electrics
Sensors and actuators for the CWTA engine
0N1 Control unit for the gas system 6X2 Diagnostic connector
0K3 Supply relay LHC20 Electronic controller
1Y6 Gas shut-off valve 0B19 Level sensor for coolant
0T1-0T6 Ignition coil for cylinders 1 - 6 0B16 Level sensor for engine oil
0M2 Servo motor for butterfly valves 0S1 Pressure switch for engine oil
0Y3 Closed-loop control valve (only for a closed- 0B21 Lambda probe (only for a closed-loop evapo-
loop evaporator) rator and USA)
0Y7 Inlet for camshaft phasing valve 0B11 Lambda probe (only for a closed-loop evapo-
0Y8 Outlet for camshaft phasing valve rator)
0B11 Lambda probe for heating system (only for a 0B6 Transmitter for pressure/temperature of in-
closed-loop evaporator) take air
0B21 Lambda probe for heating system (only for a 0B1 Transmitter for coolant temperature
closed-loop evaporator and USA) 0B13 Phase sensor for camshaft outlet
0M1 Electrical coolant pump 0B10 Phase sensor for camshaft inlet
0K4 Relay for electrical coolant pump 0M2 Servo motor for butterfly valves, with dual po-
H14 Engine lamp tentiometer
6P1 Display unit 0B2 Transmitter for engine speed

VW CWTA LPG engine
System overview of camshaft phasing for the CWTA / CKPA engine
0N1 Control unit for the gas system 0B6 Transmitter for pressure/temperature of in-
0Y7 Inlet for camshaft phasing valve take air
0Y8 Outlet for camshaft phasing valve 0B2 Transmitter for engine speed
6X2 Diagnostic connector 0B13 Phase sensor for camshaft outlet
0B1 Transmitter for coolant temperature 0B10 Phase sensor for camshaft inlet
Three-phase alternator
To change the three-phase alternator the free-
wheel belt pulley must be removed and refitted
Removing and installing a free-wheel belt

pulley
Special tool required 
● Multi-point adapter VW3400
Removing the free-wheel belt pulley

 Remove the ribbed V-belt.
 Remove the dust protection cap from the free-
wheel belt pulley.

VW CWTA LPG engine
 Insert a 6 mm AF cap screw into the drive
shaft of the three-phase alternator.
 Restrain the multi-point adapter VW3400 us- 
ing a size-17 box-end wrench. Loosen the
free-wheel belt pulley by rotating the three-
phase alternator drive shaft clockwise.
Installing the free-wheel belt pulley

 Insert multi-point adapter VW3400 in the free-
wheel belt pulley.
 First screw the free-wheel belt pulley by hand
on to the drive shaft of the three-phase alter-
nator until it reaches the stop.
 Restrain the multi-point adapter VW3400 us-
ing a size-17 box-end wrench. Tighten the
free-wheel belt pulley using a torque wrench
to rotate the three-phase alternator anticlock-
wise.
 Fit the protective cap on to the free-wheel belt
pulley.
 Fit the ribbed V-belt.

VW CWTA LPG engine
Electronic ignition system − overview
1 IMPCO ignition control unit 9 Spark plugs

2 Error light 10 Coolant temperature sensor
3 Battery 11 Engine speed sensor
4 Fuse 12 Camshaft phase sensor, 2 x
5 Ignition and starting switch 13 Suction pipe temperature sensor
6 Shut-off valve 14 Butterfly valve servo motor with potentiome-
7 Diagnostic connector ter
8 Ignition coils

VW CWTA LPG engine
Properties of ignition system
● A sensor for measuring the suction pipe tem-
perature is mounted in the suction connection
● Shut-off due in the event of gas shortage
● The gas shut-off valve (6) is activated by the
ignition control unit, not by the LHC controller
● The speed signal is sent from the LHC con-
troller to the ignition control unit via the CAN
bus. The speed controller in the ignition con-
trol unit adjusts the butterfly valve via the but-
terfly valve servo motor in combination with a
monitoring potentiometer
● Error display in the display unit
Now in LPG trucks from series 39x-02: If an en- 
gine fault occurs, the "engine malfunction" error
light (2) illuminates in the display unit instead of
the "preheating indicator" error light (1).
Diagnostics for ignition control unit and wir- 

ing harnesses
The IMPCO ignition control unit and the wiring
harnesses can be checked using measuring
adaptor 0009734313 in connection with adaptor
7917299010.
The diagnostic program (servicebase "IMPCO"
with diagnostics cable 3003652504) offers the
following functions:
● Change parameters
Sensors and actuators are displayed, e.g.

temperature sensor and camshaft phase ad-
juster.
● For diagnostics purposes, switch off individual
ignition coils while the engine is running

● Change the ignition timing (ignition map)
This may be necessary depending on the pro-

pane/butane mixture used; see vapour pres-
sure curve.
● Calibrate components
● Errors are displayed
Current errors are also indicated by an error

light in the driver's cab.
The error history can be read out.

VW CWTA LPG engine
NOTE
Error "359 - engine run-on too long" is only indi-

cated in the error history, and is indicated by a
flashing error light.
Gas shortage shut-down device
1 Signal lights in the display unit (error light for 3 Traction controller and lift control LHC (N1)
engine control unit and warning light for gas 4 Gas shut-off valve (1Y6)
system) 5 Ignition coils (0T1) to (0T6)
2 Ignition and starting switch (S1) 6 Ignition control unit E-Control (0N1)
Function
If the ignition and starting switch (2) is used to
switch off the gas engine, the LHC (3) shuts
down all lifting and traction functions. The igni-
tion control unit (6) can, however, take up to a
maximum of 65 seconds to switch off power to
the ignition coils (5). The gas shut-off valve (4) is
immediately closed by the ignition control unit
(6) when the ignition and starting switch (2) is
switched off.
Depending on the temperature of the gas, the
engine can run on for 2 seconds up to a maxi-
mum of 20 seconds after being switched off.
If the engine runs on for longer than 20 seconds,
the gas shortage shut-down device is defective.

VW CWTA LPG engine
A possible cause is leakage at the gas shut-off
valve. The signal lights (1) illuminate. In such in-
stances, the shut-off cock on the gas cylinder
must be closed immediately.
The diagnostics program shows the error "359 -
engine run-on too long".
Signal light in the display unit 
 Rectify the error.

 Switch the ignition off and on.
 Delete the error memory in the diagnostic pro-
gram.
After the engine has run on for 65 seconds, the
ignition control unit switches off the power to the
10:30
ignition coils. In this case, the engine is shut 01.01.2018
down even if there is a leakage at the gas shut-
12345,6 h
off valve.
EFF
393-02_01-047

LPG system
Safety guidelines for LPG
Always observe the "Use of LPG" (DGUV 79) CAUTION
accident prevention regulations published by the
main trade association of commercial employ- LPG will cause frostbite if it comes into
ers' liability insurance associations, or the na- contact with skin!
tional guidelines. Use personal protective equipment.
LPG includes the flammable gases PROPANE,

BUTANE and mixtures of these substances. The lines and related equipment for gas in the
LPG is stored in LPG cylinders or LPG tanks liquid phase and LPG containers must not be
and is kept there ready to drive internal combus- exposed to an impermissible impact of heat.
tion engines. The pressure of these gases in the 2. Removable LPG tanks (LPG cylinders) must
container depends on the outside temperature be positioned on the industrial truck such that
and can reach up to 25 bar or more. they are lying with the collar opening facing
downwards. Upon installation and removal, the
DANGER gas outlet connection of the cylinder valve must
be sealed with a lock nut that has been securely
LPG becomes gaseous as soon as it es-
tightened using a wrench.
capes; this means that a hazardous, po-
tentially explosive atmosphere will be Before the LPG cylinders are connected, their
created immediately.
pipe connections must be checked for perfect
No open flames (stoves, storm lanterns, condition.
spark-forming activities etc.) and no
smoking in storage rooms and when After removal, the cylinder cap must immediately
working on the LPG system! be screwed onto the cylinders fitted with a lock
nut.
Obligations of the owner and employees 3. The valves must be opened slowly! Striking
tools must not be used to aid opening and clos-
The owner must ensure that industrial trucks are ing. Risk of explosion from discharge spark.
only operated or maintained by persons trained
in the operation or maintenance of such industri-
al trucks and who can be expected to perform NOTE
their duties reliably. The LPG systems in indus-
trial trucks may be operated only if they are in In the event of fires involving LPG, use only car-
good condition. bon dioxide dry-powder fire extinguishers or car-
bon dioxide gas extinguishers. In the United
The owner must draw up operating instructions Kingdom, only carbon dioxide dry-powder fire
for industrial trucks in an understandable form extinguishers may be used to extinguish fires.
and language, containing all information re-
4. Leaking gas cylinders must not be reused.
quired for safe operation. The operating instruc-
Taking all precautions into account, leaking gas
tions must be made known to operators and
cylinders must immediately be discharged out-
maintenance staff.
side and marked as leaking If damaged gas cyl-
They must be accessible to operators and main- inders are supplied, the provider or a represen-
tenance staff at the site of operation at all times tative (service-station attendant etc.) must be
and be observed by such persons. immediately notified of the damage present,
where possible in writing
A. In operation 5. The condition of the entire LPG system must
be monitored continuously, checking in particu-
1. Before releasing the pipe or hose connec- lar for leak tightness, to ensure that it is safe to
tions, the cylinder and main shut-off valves must operate. Operating the industrial truck when the
be closed. The connecting nuts on the cylinders gas system is leaking is not permitted. When
must only be released slowly and, at first, only checking for leak tightness, soapy water, a solu-
very slightly; otherwise, the gas remaining in the tion of Nekal or other foaming products must be
line will spurt out used. It is not permitted to inspect the gas sys-
tem using a naked flame for illumination.

LPG system
6. Frozen system parts must be thawed out us- 4. The special regulations governing the storage
ing only hot water, hot sandbags or similar. Nak- of compressed gas containers must be observed
ed flames, red-hot objects etc. can cause explo- without fail, in addition to country-specific regula-
sions. tions where applicable. For example, com-
pressed gas tanks must not be stored:
7. When replacing individual system parts, the
manufacturers' installation instructions must be ● in rooms below ground level
observed. The cylinder and main shut-off valves ● on stairwells
must be closed when doing so. ● in hallways/landings
8. The electrical system on an industrial truck ● in confined yards or passageways/thorough-
with an LPG engine must be monitored continu- fares or in their immediate vicinity
ously. Sparks may cause explosions if system ● on steps of outdoor installations
parts containing gas are leaking. If an industrial ● on specially marked escape routes
truck with an LPG engine is decommissioned for ● in garages
a long period, the storage room must be thor- ● in workrooms.
oughly ventilated before the industrial truck is
commissioned again. Please also take into account the ""General re-
quirements on compressed gas tanks - opera-
9. Explosions involving gas cylinders or LPG tion of compressed gas tanks"" based on the
systems must be immediately reported to the Pressure Equipment Directive 2014/68/EU or
employers' liability insurance association and corresponding national regulations.
the responsible industrial inspectorate, even if
no injuries occur. Damaged parts must be stored 5. Electric hand lamps used in these rooms must
carefully until the conclusion of the investigation. be equipped with an enclosed sealed cover and
a strong protective cage.
10. Industrial trucks with an LPG engine may be
operated in entirely or partially closed rooms on- 6. When working in maintenance workshops, the
ly if no dangerous concentrations of exhaust cylinder and main shut-off valves must be closed
components hazardous to health can accumu- and the LPG cylinders protected from impact of
late in the air. heat. Before work breaks and the end of the
day's work, a responsible person must check
that all valves, in particular cylinder valves, are
B. In storage rooms and maintenance work- closed. Do not perform any work involving fire, in
shops particular welding and cutting jobs, near the LPG
1. The cylinder and main shut-off valves must be cylinders. LPG cylinders, even when empty,
closed as soon as industrial trucks are put into must not be stored in workshops.
storage. 7. Storage rooms and maintenance workshops
2. Industrial trucks with LPG systems must be must be well ventilated. It must be borne in mind
parked only in sufficiently well-ventilated areas that LPG is heavier than air and collects at floor
above ground level. They must not be parked level, in inspection pits and in other depressions
near entrances to rooms below ground level. in the ground, where it can produce a potentially
Sufficient space must be maintained around explosive gas and air mixture.
parked industrial trucks; such areas must not in-
clude cellar openings or access points, pits or DANGER
similar cavities, drains without liquid traps, venti- Exhaust gases are poisonous.
lation shafts and light wells or combustible mate-
Storage rooms must be sufficiently venti-
rial. lated!
3. Removable LPG containers may only be
changed in storage rooms if there is no possibili-
ty of a hazardous explosive atmosphere being
produced.
Safety measures when working on ignition systems

To prevent personal injury and/or destruction of structions when working on ignition system
the ignition system, comply with the following in- units:

LPG system
 Connect and disconnect ignition system lines,  Before carrying out any electric or spot weld-
including high-voltage lines and testing instru- ing, completely disconnect the battery and the
ment lines, only when the ignition is switched connections to the control units. The earth
off. electrode must be positioned as close as pos-
sible to the welding point.
 Use a quick charger as a starting aid only for
up to 1 minute at a maximum of 16 volts.
 The engine must be washed only when the ig-
nition is switched off.
Basic rules when working with LPG

1
Close the shut-off cock on the LPG cylinder when no more gas is required.
.
2
Do not smoke or use an open flame.
.
3 Before commencing work and once the work is complete, ventilate the engine compartment using
. compressed air.
4
Disconnect the negative terminal of the battery.
.
5
Avoid spark formation in the vicinity.
.
WARNING
Observe the "safety guidelines for LPG"!
NOTE
In certain countries, there is a legal requirement

for LPG tanks to be cleaned with an inert gas,
e.g. nitrogen.
Material characteristics
● LPG is a liquefied gas consisting of a pro-
pane/butane mixture with a variety of compo-
sitions.
● When propane/butane ignite:
Ignition temperature: 430°C
Mixture ratio: 2-11% propane with 89-98% air
● Propane/butane is compressed 260 times in
the cylinder.
● The thermal expansion of propane/butane in
enclosed containers and when 100% full is
7 bar/1°C rise in temperature.
Example:
An LPG container has been incorrectly filled to
100% instead of to 80%. The temperature of the
LPG increases by 3° Celsius and thus the pres-
sure in the container increases to 21 bar.

LPG system
● Propane/butane is invisible and heavier than
air.
● Propane/butane displaces air and causes suf-
focation in rooms in deeper locations.
● Boiling points: propane: -42°C/butane: -2°C
WARNING
Risk of freezing due to extreme cold.
This is caused by the discharge (expan-
sion) of propane/butane when changing
from a fluid to a gas.
Wear protective gloves.
Propane/butane vapour pressure curve 
The vapour pressure curve shows the tempera-

ture dependency for different propane/butane
mixtures.
(1) Vapour pressure

(2) Temperature
(3) Propane
(4) Butane
Different mixture ratios of propane
(3) to (4)
and butane.
NOTE
Depending on the propane/butane mixture ratio,

it may be necessary to change the ignition tim-
ing and the full load setting to achieve the de-
crease in speed required.
Adjusting the ignition timing

The ignition timing can be adjusted in the diag- Error codes + parameters
nostic program. ▼
Select the "Impco" servicebase. General
▼
Fuel type
Mixture ratio of propane/butane

The composition ratio of the propane/butane
mixture varies considerably in different coun-
tries.
Country Propane/butane ratio

Summer Winter
Belgium 30/70 50/50
Germany predominantly propane
Denmark 50/50 70/30
Austria 20/80 80/20
Netherlands 30/70 70/30

LPG system
Ask the gas supplier about the mixture ratio if
necessary.
Using LPG cylinders 
● LPG cylinders may only be filled up to 80% of

their volume. A gas blanket of 20% is required
in order to compensate for the thermal expan-
sion of the LPG. If the cylinder is overfilled,
overpressure will occur. This overpressure is
released via a pressure relief valve and poses
a danger to the environment due to a risk of
explosion.
● Only authorised persons are permitted to fill
LPG cylinders in Germany.
● The use of typical household bottles (camping
gas) is forbidden.
● Use replacement cylinders (with a capacity of 1 LPG (maximum 80% of the entire volume)
11 kg) made of steel in accordance with 2 Gas blanket (20% of the entire volume)
EN 1442.
● Bottles made of plastic or with a plastic coat-
ing cannot be used in conjunction with an ul-
trasonic sensor.
● Problems with dirt/rust can be avoided by us-
ing a second, larger filter.
DANGER
Risk of explosion when using double LPG cylinders.
Replacement cylinders made from aluminium or com-
posite materials may only be used when fitted with an
additional safety valve.
Sealing plastic pipe unions

Use pourable plastic Loctite 5331, spare part
number 737 920 01 01, to seal plastic pipe un-
ions.
NOTE
Do not use Teflon tape to seal plastic pipe un-

ions. Using Teflon tape can result in malfunc-
tions caused by small Teflon shreds, which are
formed during installation or when the Teflon
hardens.

LPG system
Functions
LPG system - functions
1 LPG cylinder 12 Internal combustion engine

2 Pressure relief valve 13 Butterfly valve servo motor potentiometer
3 Display 14 Exhaust camshaft phasing solenoid valve
4 Electromagnetic shut-off valve with filter 15 Vacuum line
5 Coolant breather 16 Exhaust camshaft phase sensor
6 Evaporator/pressure regulator 17 Intake camshaft phase sensor
7 Ignition switch 18 Intake camshaft phasing solenoid valve
8 Air filter 19 VW speed sensor for the ignition control unit
9 Mixer 20 Impco engine control unit
10 Butterfly valve 21 Ignition coils
11 Butterfly valve servo motor
Evaporator − method of operation Inactive position function

The LPG must be converted into a gaseous ● Ignition and starting switch (7) open.
state so that it can be mixed in the mixer with ● Electromagnetic shut-off valve (4) closed.
the induction air to form a combustible mixture. ● Butterfly valve (10) in the mixer (9) closed.
This conversion is achieved in the evaporator,
which is heated by the engine coolant.
Operating position function
The method of operation is as follows:
● Ignition and starting switch (7) closed.
The IMPCO evaporator is a combined two-stage ● Electromagnetic shut-off valve (4) closed.
regulator with an evaporator. It receives LPG via
the solenoid valve and cleaning filter at tank
pressure, and reduces the LPG pressure in two
stages to a value somewhat lower than atmos-
pheric pressure (vacuum).

LPG system
Start Switching off
During the start procedure, the ignition control When the ignition switch (7) is switched off, the
unit (20) receives a speed signal from the speed electromagnetic shut-off valve (4) is closed by
sensor (19) and opens the electromagnetic shut- the ignition control unit (20). At the same time,
off valve (4). At the same time, the LTC control the LTC (15) activates the actuator solenoid (11)
unit (15) activates the actuator solenoid (11) to and the butterfly valve (10) is moved to the stop
open the butterfly valve (10). The open butterfly screw.
valve permits the vacuum from the engine to act
A speed of 700 ±100 rpm must be set using the
on the mixer piston (9) for the secondary mem-
stop screw, so this action does not close the but-
brane of the evaporator/pressure regulator (6)
terfly valve. All driving and operating functions
and opens the secondary valve.
are switched off by the LTC (15).
Now gas released from pressure flows through
The ignition control unit (20) also enables the re-
the secondary valve to the mixer. Here the gas
lease of ignition sparks to the cylinders. The en-
is mixed with air and is fed into the cylinders as
gine is allowed to run on for a short time to burn
a combustible mixture.
off the gas remaining in the LPG system.
Operation Should the engine (12) run on for more than

20 seconds, the ignition control unit (20) detects
During operation, the butterfly valve position is a leaking electromagnetic shut-off valve (4). The
varied by the LTC traction controller (15) default warning lamp (3) lights up. The ignition con-
pending on the speed and load on the engine. trol unit (20) blocks the release of ignition sparks
The resulting increase or decrease in vacuum for 65 seconds after the ignition switch (7) is
acts on the secondary membrane in the evapo- switched off. This time must be sufficient for the
rator,which in turn affects the gas flow rate and LPG cylinder to be closed off.
the mixture ratio in the mixer (9).
If a fault is present, the fault warning lamp (3)
If the vacuum increases due to a clogged air fil- lights up again every time the truck is started. It
ter, this pressure counteracts the opening pres- can be switched off only by repairing the fault
sure on the secondary membrane in the evapo- and deleting the error display in the electronic
rator (6). This causes the closed loop control control diagnostic software.
valve in the evaporator (6) to partly close, the
gas flow rate to be reduced and thereby pre-
vents over-enrichment of the mixture.
Shut-off valve (solenoid valve) with gas 

filter
The shut-off valve has three basic functions:
1. Filtering
The dirt particles and rust particles commonly
found in replacement cylinders are filtered here
to ensure that the shut-off function of the valve
functions correctly. If dirt reaches the tappet of
the shut-off valve, the shut-off valve cannot
close properly. This is reported to the driver as
an error: (diagnostic software; error code 359)
See description: Gas shortage shut-down device
2. Shut-off and opening of the gas flow:
The shut-off valve must be closed when the in-
ternal combustion engine is not running. When
starting up and during operation of the engine,
the shut-off valve is actuated by the IMPCO con-
troller and the gas flow to the evaporator is

LPG system
opened. This allows the empty evaporator to fill
with gas. If only the ignition is switched on, the
shut-off valve remains closed.
3. Gas shortage shut-down device:
When the engine is switched off, it continues to
run for approx. 2-3 seconds. This ensures that
the remaining gas between the shut-off valve
and the combustion chamber is burned off with-
out a trace. This function is called gas shortage
shut-down.
Components of the shut-off valve 
At an LPG temperature of approx. 102°C, olefins

(similar to paraffin) form in the LPG. These ole-
fins settle on the tappet (3) and the valve can no
longer shut off tightly. An adaptor (1) with high
thermal conductivity prevents the olefins from
settling on the tappet (3).
The paper filter (2) with integrated magnet keeps
metallic dirt in the filter.
Due to the hexagonal profile of the piston (3),
the contact face on the cylinder is flat.
The brass washer (4) prevents delayed shut-off
1 Adaptor
caused by residual magnetism on the coil. 2 Paper filter with integrated magnet
3 Piston
When the temperature rises in the gas system,
4 Brass washer
the pressure rises. The coil (5) also opens the 5 Coil
valve in the event of high temperature and pres-
sure.
In the shut-off valve There is a protection diode 
for the relay.
CAUTION
The diode can be destroyed by faulty polarisation
when connecting the lines.
Positive and negative connections must not be inter-
changed.

LPG system
Technical data for the evaporator
Manufacturer: IMPCO
Cobra MD and C-Series (cannot
Product:
be dismantled)
Fuel: LPG CNG
Maximum inlet pressure: 30 bar 30 bar
Minimum inlet pressure: 2 bar 2 bar
Nominal operating pressure,
150 to 250 mbar 150 to 250 mbar
stage 1:
Nominal outlet pressure: -3.7 mbar -3.7 mbar
Maximum evaporator perform-
15 kg/h (based on propane)
ance:
Maximum gas flow: Dependent on gas composition and gas pressure
Required filter rating of the gas: 40 microns 40 microns
Heat source: Cooling-water circuit for the engine
Minimum cooling-water tempera-
80°C 80°C
ture:
For maximum evaporator per-
90 to 95°C
formance:

LPG system
Evaporator connections (using the C-Series evaporator as an example)
1 Front C Hot-water channel, inlet/outlet

2 Top D Gas outlet
3 Rear E Test connection for first evaporator chamber
4 Underside (1/8" NPT)
A Gas inlet (1/4"-18 NPT) F M6 mounting screws (2x), depth: 16 mm
B Compensation lines for the open-loop evapo-
rator/control lines for the closed-loop evapo-
rator (three options)

LPG system
Operating principle of the evaporator
1 Coolant 3 Gas (gaseous)

2 Gas (liquid)

LPG system
1 Gas inlet 4 Gas outlet

2 Coolant 5 Coolant
3 Compensation connection (open-loop)/
control connection (closed-loop)
A 1. evaporation stage
B Evaporator
C 2. evaporation stage

LPG system
Overview of the Cobra MD evaporator
1 Primary valve 7 Pressure relief valve, 1.7 bar

2 Secondary membrane 8 Bore
3 Spring 9 Primary membrane
4 Lever 10 Evaporator chamber
5 Connection for the compensation line (open- 11 Heating channel
loop)/control line (closed-loop) 12 Valve pin with spring
6 Secondary valve 13 Expansion bore

LPG system
Overview of the C-Series evaporator (cannot be dismantled)
1 Primary valve 6 Secondary valve

2 Secondary membrane 7 Bore
3 Spring (serves as a pressure relief valve at 8 Primary membrane
1.7 bar) 9 Evaporator chamber
4 Arm 10 Heating channel
5 Connection for the compensation line (open- 11 Valve pin with spring
loop)/control line (closed-loop) 12 Expansion hole
Operating principle of the Cobra MD

evaporator
Inactive position of evaporator
In the inactive position (engine switched off) the
primary valve (1) is open, and the secondary
valve (6) is closed by the spring (3). The secon-
dary valve (6) prevents discharge of gas when
the engine is switched off.

LPG system
Operating position of evaporator 
The primary valve (1) is controlled by the pres-

sure in the evaporator chamber (10), which acts
on the primary membrane (9). This pressure is
fed through the bore (8) into the chamber in front
of the membrane. The valve pin (12) transmits
the movement to the primary valve (1) (face
valve). The spring underneath the valve pin (12)
generates the back pressure. A vacuum created
via the expansion bore is present at the back
face of the primary membrane (9).
When the engine is running (throttle valve on the
mixer is open), a vacuum is created in the mixer
line, which opens the secondary valve (6), allow-
ing LPG to flow through the open primary valve
(1) into the evaporator. The secondary valve (6)
is activated by the secondary membrane (2).
Reducing the LPG pressure (approx. 10 bar in
the LPG cylinder) to atmospheric pressure cau-
ses the LPG to evaporate and consequently cool
down. To compensate for the cooling and to ac-
celerate evaporation, the evaporator is heated.
For this purpose, coolant is directed through the
heating channel (11) of the evaporator. Depend-
ing on the setting of the butterfly valve (which in
turn depends on the accelerator pedal position),
the secondary membrane (2) is pulled forward to
a lesser or greater extent, thereby controlling the
opening of the secondary valve (6).
Depending on the speed and the loading of the
engine, the vacuum at the back face of the sec-
ondary membrane (2) in the secondary part of
the evaporator is increased or reduced. This
process changes the rate of flow of gas through
the secondary valve (6).
If the vacuum increases due to a clogged air fil-
ter, this vacuum counteracts the opening pres-
sure of the secondary membrane (2) via the
connection (5). This process causes the secon-
dary valve (6) to close to a certain degree, which
reduces the rate of flow of gas and prevents the
mixture becoming over-rich.
Function of the pressure relief valve at 1.7

bar:
If the pressure in the evaporator chamber (10) is
above 1.7 bar, the pressure relief valve (7)
opens and blows gas into the atmosphere via a
hose. This arrangement prevents a permanent
leakage at the evaporator housing. If escaping
gas is detected at the hose, it may be the case
that the seal on primary valve is faulty. If escap-
ing gas is detected at the hose, the gas cylinder

LPG system
must be locked via the shut-off cock. The evapo-
rator must then be repaired or replaced.
Operating principle of the C-Series

evaporator (cannot be dismantled)
Inactive position of evaporator 
In the inactive position (engine switched off), the

primary valve (1) is open and the secondary

When the engine is running (butterfly valve on 

the mixer is open), a vacuum is created in the
mixer line. This vacuum opens the secondary
valve (6), allowing gas to flow through the open
primary valve (1) into the evaporator. The sec-
ondary valve (6) is activated by the secondary
membrane (2).
Reducing the LPG pressure (approx. 10 bar in
the LPG cylinder) to atmospheric pressure cau-
ses the LPG to evaporate and consequently cool
down. To compensate for the cooling and to ac-
celerate evaporation, the evaporator is heated.
For this purpose, coolant is directed through the
heating channel (10) of the evaporator. Depend-
ing on the setting of the butterfly valve (which in
turn depends on the accelerator pedal position),
the secondary membrane (2) is pulled forward to
a lesser or greater extent, thereby controlling the
opening of the secondary valve (6).
engine, the vacuum at the back face of the

LPG system
secondary membrane (2) in the secondary part
of the evaporator is increased or reduced. This
process changes the rate of flow of gas through
reduces the rate of flow of gas and prevents the
Pressure limit via spring at 1.7 bar:

above 1.7 bar, the secondary valve (6) opens
because the pre-load force of the spring (3) is
designed for a pressure of up to 1.7 bar. This ar-
rangement prevents a permanent leakage at the
evaporator housing. If over-enrichment of the
engine is detected (engine does not run smooth-
ly or stutters), the gas cylinder must be locked
via the shut-off cock. The evaporator must then
be replaced.
Removing and installing the Cobra MD

evaporator

gas tank.
has been used up.
WARNING
nents.
WARNING
ly.
 Disconnect plug 1Y6 from the shut-off valve

and set aside the plug.
 Loosen the pipe line from the shut-off valve.

LPG system
WARNING
Wait until the cooling fluid has cooled down. Cover
the filler cap with a cloth. Carefully open the filler cap.
 Open the filler cap of the coolant expansion

reservoir.
 Loosen all of the hose lines from the evapora-
tor and set aside the hose lines.
 Remove the screws that secure the evapora-
tor to the sheet metal holder. Remove the
evaporator from the truck.
 Remove the screw on the shut-off valve. Re-
move the shut-off valve from the evaporator.
For information on repairing the evaporator, re-
fer to the instructions in the chapter entitled:
"Service instructions for the Cobra MD evapora-
tor"
quence.
 Attach all of the connections and compo-
nents.
the coolant".

LPG system
Assembling the maintenance kit for the Cobra MD evaporator
2 Screw 12 Seal for housing plate

3 Secondary cover 13 Primary valve pin
4 Secondary membrane 14 Housing plate
5 Screw 15 Screw plug
6 Secondary lever 16 Primary spring
7 Secondary pin 17 External locking ring
8 Secondary seat 18 Primary membrane
9 Spring 19 Cover
10 Housing 20 Screw
11 Screw

LPG system
NOTE
The instructions for how to assemble the mainte-

nance kit show a similar evaporator.
The maintenance kit contains the spare parts for 
the maintenance work.
For the German market, additional spare
screws, a test tag and a lid for the primary but-
ton in the respective colour for the year are pro-
vided.
 Remove six screws (2) from the secondary 

cover (3)
NOTE
Make sure that during subsequent assembly

work, the same screws are screwed back into
their original tapped holes.
 Carefully undo the secondary cover. Using a 

screwdriver handle or some other suitable
tool, tap all around the edge of the cover
 Carefully lift off the secondary cover (3) and 

secondary membrane (4) from the evaporator
NOTE
When lifting these parts off, take care not to

damage the lever attached to the stage valve.
Push the cover and the membrane forwards until
the lever slips out of the slot on the tappet on the
membrane.
 Do not damage the lever

LPG system
 Only once the tappet has been disengaged 
from the valve lever should the cover and
membrane be fully lifted off
 Undo the screw (5) of the secondary pin (7) 
NOTE
Look out for the spring (9) that is compressed

under the lever and ensure it is not lost.
 Remove the secondary lever (6) and secon- 

dary pin (7) from the support mounting, and
remove the spring (9)
NOTE
Do not lose these parts as they will be required

for subsequent reassembly.
 Use side cutters to cut off the soft nose on the 

secondary seat (8) on the upper face of the
secondary lever (6), and remove the secon-
dary seat. Put the secondary lever aside for
subsequent reassembly

LPG system
 Turn the evaporator/pressure regulator 
around and remove the seven screws (20)
from the primary pressure stage cover (19).
Here again, make sure that during subse-
quent assembly work, the same screws are
screwed back into their original tapped holes.
Then lift off the cover (19)
 Remove the primary membrane (18) 
 Loosen the housing plate and the seal from 

the housing (10). Remove the locking ring
(17) and the primary spring (16) on the pri-
mary valve pin (13)
 Turn the housing cover around and remove 

the primary valve pin (13) and the seal (12).
Thoroughly clean the housing cover to ensure
a good sealing effect

LPG system
 Check the guide hole in the cleaned housing 
plate (14) for wear and roundness. The play
between the new primary valve pin (13) and
guide hole (15) must not exceed 0.3 mm
 Hold the primary valve pin in position and ro- 

tate the housing plate (14). Position the pri-
mary spring (16) on the valve pin and secure
it with a new locking ring (17)
 Place a new seal (12) on the flat side of the 

housing plate (14). This seal must be posi-
tioned the right way up
NOTE
Note the small matching holes in the seal and

housing cover.
 Place the new primary membrane (18) from 

the repair kit on the evaporator housing. The
spacing of the screw holes ensures that the
membrane is correctly aligned
 Carefully place the cover (19) over the mem-
brane. Insert the screws (20) through the cov-
er and the housing plate and screw them into
the evaporator housing until they are hand-
tight

LPG system
 Working across diagonals, tighten the screws 
(20) to 4.1 ± 0.3 Nm
 Use side cutters to cut off the soft nose on the 

secondary seat (8) from the secondary lever
(6). Remove the seat and place the valve lev-
er on one side for subsequent reassembly
 Push the nose of the new secondary seat (8) 

through the hole in the end of the secondary
lever (6)
 Pick up the parts of the secondary valve that
were previously set aside. Push the secon-
dary pin (7) through the holes in the secon-
dary lever (6)
 Insert the spring (9) into its holding fixture on 

the evaporator housing

LPG system
 Position the secondary lever and the pin on 
the spring (9). Press down until the pin is firm-
ly seated
 Insert the screws (5) and tighten them to a 

torque of 4.1 ± 0.3 Nm. Check the height of
the secondary lever. Use a knife edge to
check that the end of the secondary lever is
0.8 mm below the level of the casting. The
lever height can be adjusted by carefully
bending the end of the lever
 Adjust the secondary membrane (4) and sec-
ondary lever (6) so that they are aligned flush
with each other. After fitting, the end of the
lever must be inserted into the slot on the bot-
tom of the new membrane. The spacing of the
screw holes ensures the correct positioning of
the secondary membrane
 Position the secondary cover (3) and screw in 
the screws that were previously removed
 Working across diagonals, tighten the screws 

(2) to a torque of 3.0 to 4.2 Nm

LPG system
Replacing the C-Series evaporator (can-
not be dismantled)
Replacing the non-regulated evaporator
NOTE

placed.
gas tank.
has been used up.
WARNING
nents.
WARNING
ly.

WARNING
er cap.

sion reservoir.
both components.

LPG system

outbound compensation line from the evapo-
rator and set aside the compensation line.

 Loosen the screws (4) on the sheet metal
holder. Pull the evaporator in the drive direc-
tion.


orator.
quence.
Tightening torques:
25 Nm

LPG system
 Replace all O-rings on the pipe unions. 
Pipe unions for conveying coolant: blue O-rings

Pipe unions for conveying LPG: black O-rings
IMPCO decal information 

the coolant".
Replacing the regulated evaporator
NOTE

placed.
gas tank.
has been used up.

LPG system
WARNING
nents.
WARNING
ly.

WARNING
er cap.

sion reservoir.
both components.

outbound control line from the evaporator and
set aside the control line.

LPG system

 Remove the screws (4) on the sheet metal
holder.
 Lay aside the holder (9) with the closed-loop
control valve.
 Pull the evaporator in the drive direction.


orator.
quence.
Tightening torques:
25 Nm

NOTE
All O-rings on the hose clips must be replaced.

LPG system

the coolant".
Membrane mixing unit - functions

CA100 mixer
1 Hose connection for vacuum control at the 6 Butterfly valve

membrane 7 Intake air inlet
2 Spring 8 Membrane
3 Gas regulator valve 9 Idle mixture adjustment screw
4 CNG connection inlet 10 Air flow
5 Full-load mixture adjustment screw
The correct ratio of the gas/air mixture is impor-

tant for proper operation of the engine. A mixing
valve (mixing unit) ensures proper metering of
gas and air.

LPG system
Basic setting of the adjustment screws
Idle mixture adjustment screw (9) completely 
screwed in (closed).
Full-load mixture adjustment screw (5) to posi- 

tion (R) as in Rich.
Method of operation 
When the engine starts (butterfly valve (6)

open), there is a vacuum in the chamber below
the membrane (8); this vacuum is created by the
intake stroke of the engine's piston. This vac-
uum is transmitted via a communication hose (1)
to the top of the membrane (8) and moves it
against the force of the spring (2), pushing the
gas regulator valve (3) upwards. This is possible
until the gas regulator valve (3) is fully open.
The vacuum varies depending on the engine
speed and the position of the butterfly valve (6).
The gas regulator valve (3) is connected to the
membrane (8) and is designed such that, re-
gardless of the position of the membrane (8), the
correct amount of gas is always metered and
mixed with the incoming air. Two limiting mixture
settings are provided on the mixing unit.
Idling mixture setting

The adjustment of the air-gas mixture at the low-
er idling speed is controlled by the idle mixture
adjustment screw (9). The air-gas mixture (10)
flows past the slightly open butterfly valve into
the intake channel. The idle mixture adjustment

LPG system
screw (9) can be used to regulate and set the ra-
tio of the air-gas mixture. If the adjustment screw
(9) is unscrewed, the air-gas mixture becomes
leaner, and if it is screwed in, this makes the
mixture increasingly richer. The maximum per-
missible value of carbon monoxide (CO) in the
exhaust gas after the catalytic converter of 0.1%
vol. must be observed.
Full-load mixture setting

This setting controls the mixture ratio when the
gas regulator valve (3) is open. The setting be-
comes active only when the engine is approach-
ing full load. Adjustment of the full-load mixture
adjustment screw (5) is possible only when the
engine is under full load at the limiting speed
(nominal speed).
The composition of the mixture between idling
and full-load conditions is controlled by the de-
sign of the gas regulator valve. The gas regula-
tor valve (3) is designed such that, at low load,
the mixture is lean and becomes increasingly
rich as the load and engine speed increase.
The diagnostic program can be used to set the
ignition timing according to the propane/butane
mixture used.
Speed control
The speed control ensures that the engine
speed remains constant when the accelerator
pedal is kept in the same position. As such, the
engine speed is only determined by the position
of the accelerator pedal and is independent of
the load (e.g. uphill drive).
To do this, the desired speed (voltage V) is 
transferred from the LTC controller (2) to the ig-
nition control unit 0N1 (1) via the CAN bus.

LPG system
A DC motor (3) adjusts the throttle valve via 
gears and thus sets the speed. The position of
the throttle valve is monitored by two potentiom-
eters that operate in opposite directions.
Installation drawing: 
(1) Mixing unit

(2) Seal
(3) Pipe
(4) O-ring
(5) Butterfly valve with servo motor
(6) Seal
NOTE
Adjustments to the throttle-valve servo motor via

potentiometer (0M1) are not possible and also
are not necessary.
If there is an error at the throttle-valve servo mo-
tor, at the potentiometers, at the ignition control
unit or at the cable connections, the spiral-
wound filament lights up in the display unit as an
error display.
In the diagnostic program in the "IMPCO" serv-
icebase, the exact error texts can be called up.
Check the potentiometer:
Inputs + Outputs
▼
Butterfly valve
▼
Butterfly valve potentiometer
LPG system with lambda control system

Exhaust gases - composition
Exhaust gases - introduction pollutants in the exhaust gas. There is no such
thing as a complete combustion of fuel, even if
The fuel combustion in the cylinders of an en- there is excess oxygen in the air. To reduce the
gine is more or less incomplete. The more in- pollution of the environment, the exhaust gas
complete the burning, the greater the amount of characteristics of the spark ignition engine must

LPG system
be improved. All measures for reducing pollutant come NO2. It is known as a serious haemotoxin
emissions limited by different laws and regula- because it causes the rapid onset of paralysis by
tions have the aim of achieving a minimum of combining with blood haemoglobin. NO2 is a
pollutant emissions with as much fuel economy red-brown gas with a sharp pungent smell. It irri-
as possible, with high performance and good tates the lungs by attacking the tissue. In combi-
driving characteristics. nation with unsaturated hydrocarbons, nitrogen
oxides cause smog to form when exposed to
In addition to a high percentage of unharmful
sunlight. NO and NO2 are both known as nitro-
matter, the exhaust gas of a spark ignition en-
gen oxides (NOx).
gine contains also contains components consid-
ered to be harmful for the environment at least in Hydrocarbons (HC): The exhaust gas contains
higher concentrations. The harmful part makes quite different hydrocarbons:
up about one percent of the exhaust gases and
Saturated hydrocarbons (paraffins) are almost
it consists of carbon monoxide (CO), nitrogen
odourless, have a narcotic effect and cause a
oxides (NOx) and hydrocarbons (HC). The great-
light irritation of mucous membranes.
est problems posed hereby are the opposite
concentrations of CO and HC on the one hand Unsaturated hydrocarbons (olefins, acetylenes)
and NOx on the other, dependent on the air-to- have a slightly sweetish smell and can cause ir-
fuel ratio. ritation of the mucous membrane to some ex-
tent. They play an essential part in the formation
Exhaust gases - characteristics of smog as they react in sunlight in the presence
of NO to form oxidants that irritate the mucous
The major components of the exhaust gases are membrane, and ozone is created at the same
nitrogen, carbon dioxide and water vapour. time.
These are non-poisonous.
Aromatic hydrocarbons have a characteristic
Carbon monoxide (CO) : Carbon monoxide is a odour. They are nerve toxins with a narcotic ef-
colourless, odourless gas. It has a far greater affect, have a pungent smell and irritate eyes and
finity to haemoglobin (red blood pigment) than nose even at very low concentrations.
oxygen, and therefore to poisoning the body.
Nitrogen oxides (NO, NOX) : Nitrogen oxide NO
is a colourless gas that oxidises in the air to be-
Description and function of the catalytic

converter
All Linde LPG trucks are equipped with a catalyt-
ic converter as standard. The catalytic converter
is used as part of the exhaust after-treatment
system to treat the toxic and potentially deadly
carbon monoxide emissions and to reduce these
emissions so that the CO emission levels at the
exhaust pipe are considerably below the levels
required by law.
This means that, even if a sub-optimal mixture
ratio of air and LPG is present in the combustion
chamber, the setpoint values required by law for
CO of 0.1 vol. % can be achieved.

LPG system
DANGER
In the event of a fault (for example with the evapora-
tor), CO emissions up to 1000 times higher than nor-
mal (level required by law) may occur. CO levels as
high as this can lead to immediate death. Carbon
monoxide (CO) is odourless and colourless.
CO emissions must be tested at the exhaust pipe on
a regular basis; these tests are required by law.
Faults must be rectified immediately!
Essentially, distinction is drawn between three

options for reducing exhaust emissions:
● Measures implemented within the engine
● Measures implemented when preparing the
mixture by regulating the mixture ratio of

gas/air
● Exhaust gas after-treatment by the catalytic
converter
Schematic view of an open-loop catalytic converter
Red Gas 6 IMPCO control unit

Blue Air 7 Gas pipe
1 Air filter 8 Compensation line
2 Gas tank 9 Silencer with built-in catalytic converter
3 Pressure relief valve 10 Butterfly valve
4 Gas shut-off valve 11 Mixer
5 Evaporator
NOTE
The following diagram shows 394-02 CWTA as

an example.

LPG system
Installation situation 
12 Suction pipe
Schematic view of a closed-loop catalytic converter
394-02, 396-03 8 Compensation line

Red Gas 9 Silencer with built-in catalytic converter
Blue Air 10 Butterfly valve
1 Air filter 11 Mixer
2 Gas tank 12 Lambda probe
3 Pressure relief valve 13 Vacuum line of the mixer
4 Gas shut-off valve 14 Combined vacuum line that controls the evaporator
5 Evaporator membrane
6 IMPCO control unit 15 0Y3 pulse valve "Pierburg"
7 Gas pipe 16 Nozzle
NOTE
The following diagram shows 394-02 CWTA as

an example.

LPG system
Installation situation 
18 Suction pipe
Structure of the control system 
7 Gas pipe: evaporator → mixer

8 Compensation pipe with vacuum: air filter →
mixer
13 Vacuum line with very low vacuum inlet
14 Combined vacuum line that controls the
evaporator membrane
15 0Y3 pulse valve "Pierburg"

LPG system
Schematic view of a closed-loop catalytic converter (US version)
394-02, 396-03 9 Silencer with built-in catalytic converter

Red Gas 10 Butterfly valve
Blue Air 11 Mixer
1 Air filter 12 Lambda probe
2 Gas tank 13 Vacuum line of the mixer
3 Pressure relief valve 14 Combined vacuum line that controls the evaporator
4 Gas shut-off valve membrane
5 Evaporator 15 0Y3 pulse valve "Pierburg"
6 IMPCO control unit 16 Nozzle
7 Gas pipe 17 Lambda probe downstream of the catalytic con-
8 Compensation line verter

LPG system
Lambda control system
1 Temperature sensor for cooling water 10 Gas cylinder/gas tank

2 Lambda probe 11 Shut-off valve and filter
3 Three-way catalytic converter 12 Evaporator
4 Speed sensor 13 Actuator for butterfly valve
5 Ignition coil 14 Pulse valve
6 Control unit 15 Mixer
7 Diagnostic cable 3003652504 16 Pressure and temperature sensor
8 Error light in display unit/switch panel 17 Air filter
9 Diagnostic program, "IMPCO" servicebase 18 Phase sensor
Lambda control system − Description

In combination with the catalytic converter, the
lambda control system represents the most ef-
fective exhaust gas cleaning process for the
spark-ignition engine currently available.
Use of a three-way catalytic converter is espe-
cially effective. A three-way catalytic converter is
able to reduce hydrocarbons, carbon monoxide
and nitrogen oxide by more than 90% if the en-
gine is operated within a very narrow range of
deviation (± 1%) from the stoichiometric air/fuel
ratio lambda = 1.
The stoichiometric air/fuel ratio is the mass ratio
theoretically required for complete combustion,
which is 14 kg of air to 1 kg of LPG. The air/fuel
ratio (lambda) indicates the extent to which the

LPG system
actual air/fuel mixture deviates from what is re-
quired in theory.
Lambda = induced air mass : theoretical air
mass
The lambda control system regulates the fuel
quantity in such a way that the air/fuel mixture
enables almost complete combustion.
Lambda probe − Structure and position 
The lambda probe monitors the exhaust-gas

flow of all cylinders evenly in the exhaust pipe.
The ceramic sensor is contained in a housing
that protects it from any mechanical impacts.
The housing also assists in mounting the ceram-
ic sensor. The outer part of the ceramic body
lies in the exhaust gas flow; the inner part is in
contact with the ambient air.
1 Contact part
Lambda probe − Functional description 2 Ceramic support
3 Ceramic sensor
From approx. 300°C and above, the ceramic 4 Pipe protection, exhaust side
5 Electrical connection
material used is conductive to oxygen ions. If the 6 Disc spring
oxygen content on each side of the sensor is dif- 7 Protective sleeve, air side
ferent, an electrical voltage is generated be- 8 Housing (-)
tween the two end surfaces. This is a measure- 9 Electrode (+)
ment of the difference in the oxygen content on 10 Electrode (-)
each side of the sensor. The residual oxygen
content in the exhaust gas of an internal com-
bustion engine is predominantly determined by
the air/fuel ratio of the mixture supplied to the
engine. Even when operating on excess-fuel de-
livery, the exhaust gas still contains residual
oxygen. This dependency allows the oxygen
content in the exhaust gas to be used as an in-
dex of the air/fuel ratio. The voltage generated
by the lambda probe on the basis of the oxygen
content in the exhaust gas reaches
800-1000 mV with a rich mixture (lambda < 1),
whereas a lean mixture (lambda > 1) only gener-
ates around 100 mV. The transition from the rich
range to the lean range occurs at 450-500 mV.
In addition to the oxygen content of the exhaust
gas, the temperature of the ceramic body also
plays a key role, as it influences the conductivity
to oxygen ions. This means the progression of
the generated voltage is heavily influenced not
only by the air/fuel ratio, but also by the temper-
ature. The stated values therefore apply for a
working temperature of approx. 600°C. Howev-
er, the reaction time for a change in voltage
when the mixture composition is changed is also
heavily dependent on temperature. If the reac-
tion times can be measured in seconds when
the ceramic is at a temperature of below 350°C,
the sensor reacts in less than 1 ms at the opti-
mum operating temperature of 600°C. Once the

LPG system
engine has been started, the lambda control
system is therefore switched off until the mini-
mum operating temperature of approx. 350°C
has been reached. Until this time, the engine is
controlled using the basic settings. Excessive
temperatures shorten the service life. Therefore,
the lambda probe must be installed such that
sustained full-load operation does not cause the
temperature to exceed 900°C-1000°C. 1200°C
is permissible for short periods.
Lambda probe − Heated 
With this probe, the ceramic temperature is de-

termined at low engine loads (low exhaust-gas
temperatures) by the electrical heater and at
high loads by the exhaust-gas temperature. The
heated lambda probe can be installed at a great-
er distance from the engine so that no problems
occur, even during extended periods of driving
under full load. The external heating system en-
sures that the ceramic is heated up quickly so 1 Probe housing
2 Ceramic support tube
that it achieves its operating temperature within 3 Connection cable
15-60 seconds of starting the engine, at which 4 Pipe protection with slots
point the lambda control system is activated. 5 Active ceramic sensor
6 Contact part
7 Protective sleeve
8 Heating element
9 Terminal connections for the heating element
Lambda control system − Functional description
1 0Y3 pulse valve "Pierburg" 3 Air connection (atmospheric pressure)

2 Evaporator connection (secondary mem- 4 Connection for vacuum of butterfly valve
brane)
The lambda probe delivers a voltage signal to

the electronic control unit (200 - 800 mV), which
actuates the pulse valve (1) with a PWM (Pulse
Width Modulation) signal. The pulse valve cau-
ses the mixture to become richer or leaner. For
this purpose, a control threshold of approx.
500 mV is programmed in the control unit. If the

LPG system
voltage returned by the lambda probe is less
than this value (mixture too lean), more LPG is
added. If this value is exceeded (mixture too
rich), the pulse valve reduces the LPG quantity.
The change in the LPG quantity is achieved us-
ing the pulse valve, which actuates the secon-
dary membrane of the evaporator according to
the PWM (Pulse Width Modulation) signal from
the control unit. If more LPG is required (richer
mixture), the evaporator connection is closed.
This means that only the small vacuum of intake
air acts on the secondary side of the evaporator.
This opens the secondary valve fully.
If less LPG is required (leaner mixture), the vac-
uum connection (4) is opened. This creates a
large vacuum at the secondary membrane,
which causes the secondary valve to close fur-
ther. Less LPG is then able to flow to the mixer
and the mixture becomes leaner.
However, changes in the air/fuel ratio must not
be made abruptly; otherwise, the truck would
jerk when operated. For this reason, the elec-
tronic control unit includes an integrator that
slowly changes the mixture composition by
means of a time function. Between the moment
when a fresh mixture is created in the LPG mix-
er and the time when the lambda probe records
the combusted mixture, a certain amount of time
elapses (dead time). This is due to the transit
time of the mixture to the engine, the time for the
operating cycle of the engine, the transit time for
the combusted exhaust gases from the engine
to the lambda probe, and the response time of
the lambda probe. The result of this dead time is
that it is not possible to maintain a constant pre-
cise mixture. Instead, the air/fuel ratio constantly
fluctuates by a few tenths of a percent around
lambda = 1. When the integrator is correctly
tuned, however, the average value of the air/fuel
ratio remains exactly within the catalytic convert-
er window, which is the range in which the cata-
lytic converter achieves its highest conversion
rate.
Lambda control system − Tasks of the con-

trol unit
The control unit
● activates the pulse valve
● Carries out not only the Lambda 1 control, but
also ignition control
● Detects the load state of the engine via a tem-
perature sensor and a pressure sensor. This
is important when determining the ignition tim-
ing and the mixture composition

LPG system
● Stores and evaluates data. This allows
changes (wear or damage) to be identified
and measures to be introduced
● Reads out the current lambda value and dis-
plays it on a screen
NOTE
Apart from the basic settings, no adjustment

work on the gas system or the ignition system is
necessary.
Lambda probe − Control range 
Three-way catalytic converter

The three-way catalytic converter is capable of
simultaneously removing a high proportion of all
three harmful components (CO, HC, NO).
1 Lambda control range

2 Voltage curve of the Lambda probe
3 Lambda air-fuel ratio
4 Exhaust emissions and probe voltage

LPG system
Three-way catalytic converter − Structure
1 Sheet-metal housing 5 Lambda probe

2 Carrier 6 Electronic control unit
3 Active catalytic layer 7 Control valve at the evaporator/pressure reg-
4 Three-way catalytic converter (NOx, HC, CO) ulator
Metallic monoliths require a carrier layer made 

from aluminium oxide ("washcoat"). This carrier
layer increases the effective area of the catalytic
converter by a factor of 7000.
In three-way catalytic converters, the effective
catalytic layer created on top of this consists of
platinum and rhodium. Platinum accelerates the
oxidation of hydrocarbons (HC) and carbon
monoxide (CO); rhodium accelerates the reduc-
tion of nitrogen oxide (NOx).
The precious-metal content of a catalytic con-
verter is approx. 2 to 3 grams.
1 Platinum and rhodium coating
Three-way catalytic converter − Operating 2 Ceramic or metal carrier body
conditions
Significant conversion of harmful substances
does not commence until the operating tempera-
ture exceeds 250°C. The ideal operating condi-
tions are in the temperature range of approx.
400°C-800°C. Thermal ageing due to the sinter-
ing of the precious metals and the carrier layer is

LPG system
significantly higher in the range of
800°C-1000°C, leading to a reduction in the ac-
tive surface area.
The operating time in this temperature range
has a major influence in this regard. At tempera-
tures in excess of 1000°C, thermal ageing in-
creases very sharply, leading to the catalytic
converter becoming completely ineffective.
An engine malfunction, e.g. misfiring, can in-
crease the temperature of the catalytic converter
to above 1400°C. Such temperatures completely
destroy the catalytic converter because the carri-
er material melts. Engine oil residues (due to a
high level of engine oil consumption) can also
destroy (poison) the catalytic converter.
Mixture setting and CO measurement

for the open-loop catalytic converter
Applies only to trucks with an open-loop catalytic
converter.
Regularity of the mixture setting

● With the annual gas system check (mainte-
nance of the gas system)
● When repairing the gas system (evaporator or
mixer)
● If necessary, in accordance with the legally
required half-yearly CO testing in the exhaust
tailpipe (in Germany)
Mixture setting
Requirements:
● Air filter, engine oil, valve clearance, com-
pression and ignition timing are OK/at set-

point values:
Setpoint ignition timing in ° of the crank angle before TDC

394 - 3.2 l (BMF) 394 - 3.6 l (CWTA)
391 series 392/393 series
series series
LPG not controlled 22 ± 2 22 ± 2 20 ± 2 17 ± 2
LPG controlled 16 ± 2 16 ± 2 20 ± 2 15 ± 2
CNG controlled 22 ± 2 20 ± 2 22 ± 2 22 ± 2
The ignition timings can be found in the diagnos-

tic software.
● IMPCO ignition system OK
● Idle speed 1000 rpm/the engine load setpoint
values can be found in the workshop litera-
ture/Pathfinder
● "Zero point calibration" performed with fresh
air using the exhaust gas measuring device

LPG system
● Truck at operating temperature with a coolant
temperature of > 80°C
● No errors in the truck or in the diagnostic soft-
ware:
Warning light for the engine control unit not illu- 
minated
Error light for the gas system not illuminated 
Basic setting of the mixer (from the factory) 
The mixture ratio of air/LPG is set on the mixer

using the adjustment screw for idle speed (9)
and the adjustment screw for full load (6).
NOTE
Always use the basic setting set out below first!

Adjustment screw for idle speed (9)
For the basic setting, the adjustment screw for
idle speed is screwed in completely. The air by-
pass is closed. When the adjustment screw for
idle speed is rotated in an anti-clockwise direc-
tion, a bypass to the air intake opens.

LPG system

Adjustment screw for full load (6)
In the basic setting, the adjustment screw for full
load is set to the (R) position ("Rich"). The ad-
justment screw for full load is located in the gas
intake.
Testing the engine power rating 
 Connect the diagnostic software.

 Open the servicebase of the respective truck
type with a CAN box.
The engine utilisation is shown in the diagnostic
program in the following window:
Inputs + outputs
▼
Driving
▼
Engine load
Prerequisites for testing the engine power rat-

ing:
● Pressure setting of the pressure relief valve:
the values can be found in the diagnostic soft-
ware
 Test the engine load
To test the engine power rating, the engine must
be definitively loaded. The load is applied by lift-
ing to the mechanical stop. The opening pres-
sure of the pressure relief valve is referred to
here as the "full load".
Assessing the engine power rating via the en-
gine utilisation
 Establish full load by lifting at the stop.
The engine utilisation is calculated from the
known level of engine torque available (VW con-
trol unit) and the measured level of torque re-
quested.
The engine utilisation is given as a percentage.
Examples (values may vary):

LPG system
Lifting without a load
Measured torque 170 Nm
Lifting with a nominal load

Lifting at the stop


forced down

cal or electronic fault
Setpoint values with tolerance:

Engine code letter Engine utilisation: tween setpoint and actual forced
down
BMF / CWTA 96-100% 200 rpm
Measuring the carbon monoxide CO emis-

sions in the exhaust gas (testing at the ex-
haust tailpipe)

NOTE
Use a suitable CO measuring device, e.g. the

"IMR 1500". Not all CO measuring devices are
suitable for performing the measurement. Some
devices are too slow for the measuring process
or have a CO measurement range that is too
small. If an error occurs in the gas system, CO
values can reach > 8 vol. %.
 Perform a fresh air calibration on the measur-
ing device.
CO measurement at the lower idling speed
 Perform a CO measurement at the lower
idling speed.

LPG system
Setpoint value for the CO = < 0.05 vol. %
 Correct the setting using the adjustment 
screw for the idle speed (unscrew the adjust-
ment screw).
 Continuously measure the CO value using the
measuring device and correct the setting until
the setpoint value is reached.
Measuring the CO content under full load
Full load means that the internal combustion en-
gine must be definitively loaded. "Lift up to the
mechanical stop."
 Measure the CO content under full load.
Setpoint value for the CO = < 0.05 vol. %
 Correct the settings using the adjustment 
screw for full load: direction of rotation to-
wards the (L) position ("Lean").
 Continuously measure the CO value using the
measuring device and correct the setting until
the setpoint value is reached.
 At the same time, check the engine power rat-
ing in the diagnostic software under "Engine
load" (the engine power rating must corre-
spond to the setpoint value).
NOTE
For 393-01 only: If the mast is at the stop and

the lifting joystick is then actuated while the en-
gine is operating at idle speed, the engine may
cut out in certain cases. This is not a reason for
a complaint provided that the setpoint lifting
speed is achieved.
Measuring the CO upstream of the catalytic

converter
In the event of an error, the mixture ratio of air
and LPG may be too "rich" (excess gas). This
problem can be detected as e.g. higher fuel con-
sumption.

LPG system
To facilitate the optimum mixture ratio of air and 
LPG in the combustion chamber, the CO content
must be measured upstream of the catalytic
converter. A measurement port (1) is installed in
the exhaust pipe for this purpose. An optimum
mixture ratio guarantees a low CO value and low
fuel consumption.
Advantages of CO measurement upstream of
the catalytic converter:
● The optimum combustion behaviour is ach-
ieved
● The function of the catalytic converter can be
checked via the measurement

● Any faults in the exhaust system can be de-
tected, such as a defective lambda sensor (ig-

nition map shifted)
Setpoint values: 0.1 vol. % must also not be ex-
ceeded before the exhaust after-treatment (up-
stream of the catalytic converter).
Adjustment instructions and test instructions

for the IMPCO mixture preparation system
on LPG trucks
In the case of the IMPCO mixture preparation
system, you have to differentiate between
"open-loop" and "closed-loop" catalytic convert-
ers in relation to the adjustment work and
checks required.
The closed-loop system (lambda control system)
can be recognised from its exterior by the lamb-
da probe upstream of the catalytic converter and
by the electro-pneumatic closed-loop control
valve in the control line on the pressure regula-
tor/evaporator.
During the CO measurement, a distinction is
made between:
● Testing the mixture setting in the gas system
(CO measurement upstream of the measure-

ment connection for the catalytic converter)
NOTE
This measurement/adjustment work must essen-

tially be performed after any repairs to the gas
system.
● Testing the emitted CO emissions (catalytic
converter function is checked/testing at the
exhaust tailpipe)
The measurements upstream and downstream
of the catalytic converter are necessary for test-
ing the catalytic converter.
Testing at the exhaust tailpipe is sufficient to test
the statutory specifications of the DGUV V 79

LPG system
(previously BGV D34) standard during the half-
yearly exhaust-gas check. The half-yearly ex-
haust-gas check takes place between the pre-
scribed yearly gas system checks.
Mixture setting and CO measurement

for the closed-loop catalytic converter
Applies only to trucks with a closed-loop catalyt-
ic converter.
In the 396 T series, a system to control the 
air/gas mixture preparation is installed. This sys-
tem can also be installed in all other series at
the customer's request. With this system, the ex-
haust gas is measured by the lambda sensor
(22) and the information forwarded to the IM-
PCO control unit.
The image shows the electro-pneumatic closed- 

loop control valve fitted in the 391 evo / 392-02 /
393-02 / 394-02 and 396-03 series.
The control unit sends signals to the electro-
pneumatic closed-loop control valve, thereby re-
ducing the levels of HC and NOx in the exhaust
gas. The levels of CO are higher in the closed-
loop system (upstream of the catalytic converter)
than in the open-loop system.
Regularity of mixture setting

● With the annual gas system check (mainte-
nance of the gas system)
● When repairing the gas system (evaporator or
mixer)
● If necessary, in accordance with the statutory
(in Germany) prescribed semi-annual CO
testing in the exhaust tailpipe
Requirements
pression and ignition timing are OK / at set-
point values:
Setpoint ignition timing in ° of crank angle before TDC

394 - 3.2 l (BMF) 394 - 3.6 l (CWTA)
391 series 392 / 393 series
series series
LPG controlled 16 ± 2 16 ± 2 20 ± 2 15 ± 2
CNG controlled 22 ± 2 20 ± 2 22 ± 2 22 ± 2

tic software.

LPG system
● Idle speed 1000 rpm / engine load setpoint
values can be found in the workshop manual /
Pathfinder
air using exhaust gas measuring device
ware:
Warning light for engine control unit not illumina- 
ted
Error light for gas system not illuminated 
The mixture ratio of air / LPG is set on the mixer

using the adjustment screw for idle speed (6)
and the adjustment screw for full load (5) (depic-
tion is of CA 55 mixer).
NOTE
Always use the basic settings set out below first!

LPG system
391 evo, 392-02, 393-02: Adjustment screw for 
idle speed (6)
 For the basic setting, completely screw in the
adjustment screw for idle speed.
391 evo, 392-02, 393-02: Adjustment screw for 

full load (6)
 For the basic setting, set the adjustment 

screw for full load to position (R) "Rich".
394-02: Adjustment screw for idle speed (7) 

adjustment screw for idle speed.
394-02, 396-03: Adjustment screw for full load 

(6)

LPG system
 For the basic setting, set the adjustment 
screw for full load to position (R) "Rich".
Calibrating the IMPCO control unit

 Open servicebase "IMPCO" with the IMPCO 

diagnostic cable.
 Open the "Error codes + parameters" window.
Select the "General" tab.
Error codes + parameters

▼
General
Fuel type
 Adjust the fuel type. If L-gas is used at the

factory: Select "Propane (L)".
 Open the "Guided diagnostics" window. Se-
lect "Mixture setting" and confirm the selec-
tion.
Guided diagnostics
▼
Mixture setting
The control system is deactivated by confirming

the selection (clicking). The lambda probe then
measures the actual non-regulated emissions
upstream of the catalytic converter. In addition,
the adjustment is deleted.
 Change window: "Inputs+outputs". Select
"Mixture setting" and confirm the selection.
Inputs+outputs
▼
Mixture setting

LPG system
The following values must be shown in the dis- 
play fields (1...3).
● (1)Closed Loop (active/inactive): Inactive
● (2) Setting mode: Setting
● (3) Adaption Mode: Deleted
Performing the mixture setting when idling

 Correct the settings at the adjustment screw 
for idle speed (7) until the bar in the diagnos-
tic software is in the middle under the "Mix-
ture" point (4).
 Check the CO level on the measuring device.
The value of < 0.1% vol. must not be exceeded.
Performing the mixture setting under full

load
 Lift up to the mechanical stop and use the lift-
ing hydraulics to place the engine under load.
Setpoint speed 391 evo: 2100 rpm
Setpoint speed 392-02/393-02: 2700 rpm
Setpoint speed 394-02: 2800-100 rpm
Setpoint speed 396-03: 2200 rpm
 Correct the settings at the adjustment screw 
for full load (6) until the bar in the diagnostic
software is in the middle under the "Mixture"
point (4).
The value of < 0.1% vol. must not be exceeded.
 Change window: "Guided diagnostics". Con-
firm with "OK". The control system is then re-
activated and the adjustment is saved.
Guided diagnostics
▼
Mixture setting
 After measuring and activating the control

system, check the mixture controller (4) and
the CO values again on the measuring de-
vice.

LPG system
 Secure the adjustment screws with sealing
varnish.
 Check the engine power rating.

Inputs+outputs
▼
Driving
▼
Engine load
Prerequisites for checking the engine power rat-

ing:
The values can be found in the diagnostic
software
 Check the engine load.
To check the engine power rating, the engine
must be definitively loaded. The load is applied
by lifting to the mechanical stop. The opening
pressure of the pressure relief valve is referred
to here as the "full load".
gine utilisation
quested.



LPG system
Lifting at the stop


forced down


down
LPG 90-100% 200 rpm
Measuring carbon monoxide CO emissions

in the exhaust gas

NOTE

suitable for carrying out the measurement.
Some devices are too slow for the measuring
process or have a CO measurement range that
is too small. If an error occurs in the gas system,
CO values can reach > 8 vol. %.
ing device.
idling speed.
Setpoint value for CO = < 0.1 vol. %
mechanical stop."

LPG system
NOTE

the lifting joystick is then actuated from the idling
position, the engine may sometimes cut out.
This is not a reason for a complaint provided
that the setpoint lifting speed is achieved.
Measuring the CO upstream of the catalytic converter

sumption.
converter. A measurement port (Pfeil)(1) is in-
stalled in the exhaust pipe for this purpose. An
optimum mixture ratio guarantees a low CO val-
ue and low fuel consumption.
ieved.
checked via the measurement.


nition map shifts).
If the measurement needs to be performed up-
stream of the catalytic converter, please note
the following:
The closed-loop control valve can only bring
about reductions in the air / gas combustion

LPG system
mixture; it cannot supplement the mixture. For
this reason, the following values are expected
when measuring the CO content upstream of the
catalytic converter:
Lambda control active: CO 0.5 - 1.0 vol. %
Lambda control inactive, adaption mode: CO 1.5
- 2.0 vol. %
Leakage test on the LPG system

A leak test must be carried out after mainte-
nance and repair work on the LPG system.
Required testing equipment

- Gas leak detector (e.g. IMR 50 from IMR®) 
- Leak detection spray or soapy water
Test procedure
DANGER
Exhaust gases are toxic.
LPG trucks must only be repaired, serv-
iced and tested in well ventilated work-
places!

 Blow out the engine compartment with com-
pressed air.
 Open the extraction valve from the LPG tank.
 Switch on the gas leak detector and calibrate
it in the fresh air. Follow the procedure in the
operating instructions for the gas leak detec-
tor.
 Using the probe, slowly scan the gas hoses
and pipes, the valves and the evaporator all
the way from the opened LPG tank to the
evaporator.
NOTE
LPG is heavier than air. Run the probe under-

neath the components.
 If a leak is detected, immediately close the
LPG tank and ventilate the truck.

LPG system
 Apply leak detection spray to the LPG system 
(alternatively, use soapy water) and locate the
leak.
 Repair or replace faulty components. Then
perform the gas leakage test using the gas
leak detector again.
 Using the probe, slowly scan the gas hoses
and pipes, the valves and the evaporator all
the way from the opened LPG tank to the
evaporator.
 If a leak is detected, immediately switch off
the engine, close the LPG tank and ventilate
the truck.
 Apply leak detection spray to the LPG system
(alternatively, use soapy water) and locate the
leak.
 Repair or replace faulty components. Then
perform the gas leakage test using the gas
leak detector again.
The leakage test is complete when no more
leaks can be found with the engine running.

LPG cylinder
The following safety measures must be observed
● An area of 10 m x 10 m must be sealed off
NOTE around the truck tank and information decals
on the potential dangers provided. Inside the
● In Germany, operations on the LPG tank must sealed-off space, there must be no areas be-
only be carried out by "authorised personnel" low ground level, such as cellar openings,
in accordance with the German Ordinance on pits, drains, ventilation shafts or light wells.
Industrial Safety and Health (BetrSichV). ● Avoid allowing excessive amounts of gas to
● In other countries, other national safety regu- escape.
lations may apply. These must be observed. ● Use a gas detector.
● Switch off mobile phones.
WARNING
● Once the work is complete, carry out a leak
Observe the "safety guidelines for LPG"! test.
Safety measures
● Wear protective gloves to prevent frostbite.
● All work must only be carried out in an open
space in an explosion-protected area, e.g. at
an LPG refuelling station.
Level display with single replace-

ment cylinders
(special equipment)
LPG trucks can be fitted with single replacement
cylinders with an ultrasonic sensor to display the
fuel level in the replacement cylinders.
The ultrasonic sensor is pre-calibrated for a 300
x 620 mm standard cylinder (11 kg filled weight)
with a propane/butane mixture containing 95 %
propane (customary in Germany). For all other
cylinders with significantly different propane con-
tent, the sensor must be calibrated in accord-
ance with the following instructions.
Description of the ultrasonic sensor

The ultrasonic sensor determines the content in
reclined LPG cylinders made of steel and alumi-
nium. It enables an exact level display and level
monitoring. The sensor was developed specifi-
cally for application in LPG-powered forklift
trucks.
Factory setting
The sensor in each truck is mechanically preset
for the subsequent country-specific replacement
cylinders on delivery, though not electrically.
Due to warehousing requirements for the

LPG cylinder
various cylinder types necessary in this respect,
this cannot be performed ex works.
The sensor is electrically preset in the truck or in
the replacement part delivery for replacement
cylinders with a diameter of 300 mm. For a full
replacement cylinder with this diameter and a
gas proportion of 95% propane according to DIN
51622, the sensor indicates a fill level of 100%.
Use-specific special cases

- If cylinders with a diameter of more than 300
mm are used, the sensor in drive mode initially
indicates a fill level of 100% for a longer period
of time. Only after approx. 30 minutes is the gas
consumption signalled via the display unit (first
luminous bar goes out).
- If gas mixtures with a propane proportion sig-
nificantly below 95% are used, despite a fill
weight of 11 kg the sensor will indicate a fill level
of less than 100% in certain circumstances.
In both cases the sensor should be recalibrated
to the country or customer-specific cylinder ge-
ometry or gas mixture.
When using replacement cylinders with the
same diameter but with a different length to
standard cylinders, the display properties for the
fill level cannot be influenced by calibrating.
Sensor maintenance
The contact area (arrow) of the sensor must be 
kept clean. In the case of heavy contamination
of the contact area, this must be cleaned care-
fully with a soft cloth with water or soapy water.
CAUTION
The sensor can be damaged.
No abrasive mechanical or chemical stress on the
contact area.

LPG cylinder
Notes on positioning the sensor
1 Welding seam 4 Relaxed state

2 Float/pipe 5 Operating state with LPG cylinder fitted
3 Cylinder's longitudinal axis
Factory setting:
The sensor is mechanically preset for the subse-
quent country-specific replacement cylinders on
delivery.
 Assembly sensor: Writing always in drive di-
rection
Angle deviation from the cylinder's longitudinal
axis/crosswise to the cylinder's longitudinal axis
Maximum deviation: ±1°
Horizontal position of the sensor: In cylinder's
longitudinal axis
Minimum distance of the midpoint of the sensor
to the central axis: ±3 mm
Horizontal position of the sensor: Crosswise to
the cylinder's longitudinal axis
Maximum deviation from the central axis: ±3 mm

LPG cylinder
Checking the horizontal position of the sensor 
 Apply a thin layer of grease (arrow) to the

coupler surface of the ultrasonic sensor.
 Fasten replacement cylinder corresponding to
the variant to the swivel bracket. (There must
not be any welded seams of the replacement
cylinder in the area of the coupler surface).
NOTE
● BR392: Close bracket and open it again.
Oval grease impression (arrow) must be located 

centrally (±3 mm crosswise to the cylinder) on
the cylinder.
 Remove grease; do not use aggressive clean-
ing agents.
The vertical position of the sensor is ensured by 

the design of the bracket and the use of appro-
priate discs between the sensor and console
and no other method of correction should be
used. The correct replacement cylinder position
is also achieved via plastic spacer 3925711422
or 3915711400. For production-related reasons,
these can be installed on delivery in a duplicate
state. In this case, dismantle to one element and
readjust the overall height of the spring elements
009652627 and the lock position. The bracket
cover must not be supported on the lock bolt;
otherwise the lock's ease of movement is not
ensured.
Impression dimension of the sensor
After fitting the cylinder the sensor should be ac-
tivated min. 4 mm (steel) or min. 6 mm (alumini-
um).
Overall
Condition
height
relaxed 47 ±0.5 mm
Steel cylinder fitted 33 - 43 mm
Aluminium cylinder fitted 33 - 39 mm

LPG cylinder

 Assembly of the cylinder: Central support of
the bottle and distance of the sensor (deter-
mine extent of impression with plasticine and
measurements).
● 4 hexagon head screws M12*40-8.8-A2C; 

part number: 9008311302 (1)
● 8 washers 13-ST50-A2C; part number:
9309412022 (2)
 Ensure that the plug connector is in the cor-
rect position (right plug retaining plate for the
standard console).
Fitting the gas cylinder


 When fitting the gas cylinder, contact with the
sensor must be initially avoided.
 After closing the swivel bracket, the sensor
must be pressed down to the specified level.
 The minimum distance to welded seams must
be adhered to.
 Using a gas cylinder with a plastic net to pro-
tect the cylinder prevents the sensor from be-
ing connected to the cylinder. Therefore the
net must not be used in connection with the
sensor.

LPG cylinder
NOTE
For special cylinders, adhere to the manufactur-

er's installation instructions.
Calibrating
NOTE
A sensor must only be calibrated during its initial

commissioning (truck delivery, replacement sen-
sor) if a special case as described under "Signal
output - use-specific special cases" applies:
- Using cylinders with a diameter other than 300
mm
- Using gas mixtures with a propane proportion
other than 95%
To avoid incorrect calibration
● Only full LPG cylinders are to be used for cali-
bration.
● Variations and sloping positions are to be
avoided during the calibration process.
● Differences in temperature from the sensor
and the LPG cylinder are to be avoided during
the calibration process.
● The contact of the wire for calibration is to be
closed again after triggering the calibration
process
Procedure:
Sensor no. 7917415518 (see back of sensor for
part number):
1. Prepare full replacement cylinder. Ensure the
maximum fill level of the replacement cylinder in
advance, for example by weighing (e.g. Germa-
ny: 11 kg full weight plus the weight of an empty
cylinder).
2. Park truck on level ground.
3. Check bracket for correct disc thickness un-
der the sensor and correct positioning of the
sensor; correct if necessary.
4. Fit full replacement cylinder, secure and close
bracket.
5. Wait for temperature adjustment between re-
placement cylinder and ultrasonic sensor as well
as calming of the LPG surface. Wait at least 10
minutes.
6. Switch on the ignition.
7. Open plug X14.
8. Close plug X14 after two seconds.
For sensor no. 7917415613 also:

LPG cylinder
9. Switch off the ignition.
10. Open plug X14.
11. Switch on the ignition (display value in the
display now oscillates continuously between
"empty" and "full").
NOTE
The sensor has thus set the fill level of the fitted
replacement cylinder equal to 100% and saves it
permanently for this cylinder diameter and the
gas mixture.
Reset
Reset means that the last measured and saved
value of the previously fitted replacement cylin-
der is reset to zero. A reset is carried out for ex-
ample for quick function checking of the sensor
on the vehicle with a second cylinder (no influ-
ence on the calibration value of the factory set-
ting).
Replacement cylinder: Fill level of the replace-
ment cylinder at least 50% or greater!
Sensors: Only possible with 7917415613
Reset sensor no. 7917415613:
1. Prepare a replacement cylinder with more
than 50% fill level; ensure in advance by weigh-
ing, for example.
2. Park truck on level ground.
3. Check bracket for correct disc thickness un-
der sensor as well as correct positioning of the
sensor; correct if necessary.
4. Fit replacement cylinder, secure and close
bracket.
5. Wait for temperature adjustment between re-
placement cylinder and ultrasonic sensor as well
as calming of the LPG surface. Wait at least 10
minutes.
6. Switch on the ignition.
7. Open plug X14.
After a 30-second waiting period, the sensor
should issue a fill level signal corresponding to
the fill level of the replacement cylinder.

LPG cylinder
Electrical testing
The sensor's power supply (power ON) must be
ensured with measurements. The use of test
adapter number 7917299006 and adapter cable
harness number 3003810300 is recommended.
The sensor must not be opened for trouble-
shooting. Due to its internal design it is very like-
ly that it will suffer irreparable damage when
opened.
The ultrasonic sensor is an active sensor. The
output signal is a power source with 0.5 to 4.5 V.
0 to 0.3 V = line connector to earth or sensor de-
fective.
4.7 to 5.0 V = line breakage or sensor defective.
Voltage values on PIN : 3 and display in the display

Full Empty Error
Status dis-
1 2 3 4 5 6 7 8 11
play
Switch-on
> 4.70
threshold (in 4.12 3.56 2.98 2.42 1.84 1.28 0.70 0.30
<0.30
V)
With a hysteresis of 0.1 V, the individual sta-

tuses are switched off again.
 Ignition "ON"
 After fitting the bottle, the measured value
must appear after 30 seconds – 2 minutes. If
the sensor head and the bottle have a smooth
surface, contact is made with the signal volt-
age faster.
Error D192
If no bottle is inserted or the LPG cylinder is not
positioned correctly, the ultrasonic sensor re-
ceives no echo. It first displays the value of the
last measurement.
After 10 minutes, the sensor then switches the
output signal back and forth between 0.5 (status
8) and 1.5 V (status 6). This occurs at a frequen-
cy of 0.25 Hz.
The status "no echo" (0.25 Hz/0.5; 1.5 V) must
be detected after 20 seconds at the latest and is
indicated in the display with error D192.
In addition, status 10 is displayed in the fuel tank
gauge (all LEDs off). → The fuel tank gauge is
no longer activated.
If the signal 0.25 Hz/0.5; 1.5 V is no longer sent,
this must be identified after 20 seconds at the
latest. Error D192 is no longer displayed and
the fuel tank gauge is no longer activated.
Sensor defective or defective signal

LPG cylinder
After 10 minutes the sensor also switches the
output signal back and forth between 0.5 and
1.5 V at a frequency of 0.25 Hz.
Error overview
Error Cause Suggested solution

Switch on the ignition, check
Sensor not correctly connected
fuse and wiring
New cylinder with <50% content
fitted or calibration performed Fit bottle with content >50%
with cylinder content <50%
No operation/display possible Clean/de-ice coupler surface
(display indicates "empty") Coupler surface contaminated/
carefully; switch ignition off and
iced over
back on again
Problem is caused by container,
Significant deposits/contamina- fill level cannot be displayed on
tion in the replacement cylinder this container, perform work with
another container
Replacement cylinder fitted with
Fit completely filled replacement
similar fill level as previous cylin-
cylinder, check fill level by weight
der
Maximum forklift truck tilt excee- Move truck from tilt of <5° or <8°
ded when switching on the igni- incline; switch ignition off and
tion back on again
Replacement cylinder fitted with Fit replacement cylinder with
Display value not correct <50% content >50% content
Deviation from the calibration
value, e.g. due to:
Different replacement cylinder di-
ameter
Carrying out calibration
Different gas mixture to usual
gas mixture
Calibration previously performed
incorrectly
Display value continuously "null" Plug X14 is open Closing the connection
Fit completely filled replacement
No replacement cylinder fitted
cylinder, check fill level by weight
Move truck from tilt of <5° or <8°
Exceeding the maximum tilt incline; switch ignition off and
back on again; wait 30 seconds
Continuous fluctuation of the dis-
Carefully clean/de-ice contact
play value in the first quarter (be- Contact area contaminated/iced
area; switch ignition off and back
tween 0.5 V and 1.5 V at 0.25 over
on again
Hz)
Sensor positioned incorrectly Check and correct positioning
another container
play value in the first half imme-
diately after switching the ignition Sensor defective Change the sensor
on (between 0.5 V and 1.5 V at
0.25 Hz).

LPG cylinder
play value over the entire range Close the connection, recalibra-
Plug X14 is open
(between 0.5 and 1.5 V at 0.25 tion necessary
Hz)
Replacement cylinder installed Fit container correctly and se-
the wrong way round, removal cure; pay attention to positioning
from gas phase pins in the bracket cover
Forklift truck does not move al- Valve/extraction pipe installed fill level cannot be displayed on
though display value still indi- the wrong way round this container, perform work with
cates a fill level another container
another container
No supply voltage Restore supply voltage
Wiring/connection assembly de- Check wiring/connection assem-
fective bly
Sequence not followed Recalibration
Position replacement cylinder
Replacement cylinder not placed
correctly and secure in place;
correctly
switch ignition on again
Calibration unsuccessful No (full) replacement cylinder Fit completely filled replacement
placed cylinder, check fill level by weight
Carefully clean/de-ice contact
Contact area contaminated/iced
area; switch ignition off and back
over
on again
another container
Flow chart
Error: No display value or

incorrect display value
│
———
Output value 1.5 or 2.5 V Sensor defective
—
│
Place completely filled
bottle and secure
│
Wait 10 minutes
Carry out reset
——— ——— ——— ———

│ ———
— — — —
Output value over 90% │ │ │
(>4.1 V) 1 2 3

LPG cylinder
│
Sensor OK
1
│
No output value (0 V)
Switch on the ignition.
│
Output value over 90% — Yes
(4.1 V) — │
│ │
No
│ │
│
Check wiring
│
│ │
Output value over 90% — Yes │
(4.1 V) — │
│ │
No
│ │
│
Sensor defective
│
│ │
——— │
Sensor OK
—
2
│
Output value "empty"
│
- Check contact area and
cleanliness
- Check positioning of
Sonatic© FLT relative to
the bottle
│
(4.1 V) — │
│ │
No
│ │
Put on and secure other │
full bottle │

LPG cylinder
│ │
│
Wait 10 minutes
│
│ │
Output value over 90% — Yes │
(4.1 V) — │
│ │
No
│ │
│
Sensor defective
│
│ │
——— │
Sensor OK
—
3
│
Output value incorrect
Carrying out calibration
│
(4.1 V) — │
│ │
No
│ │
│
Sensor defective
│
│ │
——— │
Sensor OK
—

LPG tank
The following safety measures must be observed
● An area of 10 m x 10 m must be sealed off
NOTE around the truck tank and information decals
on the potential dangers provided. Inside the
● In Germany, operations on the LPG tank must sealed-off space, there must be no areas be-
only be carried out by "authorised personnel" low ground level, such as cellar openings,
in accordance with the German Ordinance on pits, drains, ventilation shafts or light wells.
Industrial Safety and Health (BetrSichV). ● Avoid allowing excessive amounts of gas to
● In other countries, other national safety regu- escape.
lations may apply. These must be observed. ● Use a gas detector.
● Switch off mobile phones.
WARNING
● Once the work is complete, carry out a leak
Observe the "safety guidelines for LPG"! test.
Safety measures
● Wear protective gloves to prevent frostbite.
● All work must only be carried out in an open
space in an explosion-protected area, e.g. at
an LPG refuelling station.
Performing assembly work

DANGER
Risk of explosion to LPG tank
 LPG tank components must only be
changed for genuine spare parts.
Damaged components must not be
installed. Follow the assembly instruc-
tions to ensure the safety of the LPG
tank.
 Welding on the LPG tank is strictly
prohibited.
 No design-related changes or signifi-
cant modification must be made to the
LPG tank.
 LPG tanks are pressurised environ-
ments; equalise pressure before
opening.

LPG tank
Description of the instrument panel
Connections 4 V MAX 80%

A Extraction valve Tank must only be filled to max. 80%
B Level display 5 Gross volume in litres
C Safety valve/pressure relief valve, discharges into 6 PT39BARPS 0-27BAR
the open above 27 bar Test pressure = 39 bar / max. permissible pres-
D 80% filling stop valve sure = 27 bar
or filling valve, in association with manual outlet 7 LPG = LPG product group
valve 8 T-20°/65°C
E Manual outlet valve Minimum temperature = -20°C / maximum temper-
ature = 65°C
Markings 9 Instrument panel material code (e.g. 1234)
1 Manufacturer 10 Mark and number of the independent test centre
e.g. WvM = Witte van Moort 11 Design approval number
2 Production date YY - MM
3 Model and tank number, e.g. N 002170
Tools required 
● Protective gloves
● Gas detector / test spray
● Torque wrench up to 120 Nm such as SW 32
compass wrench
● Torque wrench 10 Nm.
Removing the 80% filling stop valve

 Completely empty the LPG tank. With the
shut-off valve open, empty the LPG tank until
the engine turns off.
 Close the extraction valve and remove the
LPG tank from the truck.
 Secure the LPG tank in position so that the in-
strument panel is facing upwards. This is nec-
essary so that the floats do not collide with
the extraction pipe during assembly/disas-
sembly!

LPG tank
 Equalise the pressure in the LPG tank. To do
so, open the extraction valve max. 1 turn. Gas
can escape.
DANGER
Risk of explosion.
Observe safety measures when working on the LPG
tank.
 Close the extraction valve again.

 Make sure that the surrounding area and any
tools are clean. No dirt must enter the tank.
 Unscrew the four M6 hexagon socket head 
screws of the level display. Unscrew the final
screw slowly to allow any remaining pressure
to dissipate. Then carefully remove the level
display with the sealing ring and floats.
NOTE
Even if you are only changing the 80% filling

stop valve, the level display must always be re-
moved as well. Otherwise, the floats of the level
display and the 80% filling stop valve can collide
and may be damaged.
 Loosen the 80% filling stop valve using the
SW 32 compass wrench.
 Carefully unscrew the 80% filling stop valve. 
(1) Level display 
(2) 80% filling stop valve

LPG tank
New level display
1 Flat gasket, approval 67R-01 2 Identifier: 97100X M.YY ∅YYY 52°
NOTE
The flat seal must be replaced during the instal-

lation process.
Key to identifier (2):

X Last number from the SRG order number
M.Y Production date (month.year)
Values for M:
1 January
2 February
3 March
4 April
5 May
6 June
7 July
8 August
9 September
O October
N November
D December
YYY Tank ∅ D
Installation position: 

LPG tank
Order number
WvM order For tank ∅ D
Linde number SRG L (mm) R (mm)
number (mm) YYY
x
0009823711 4879711004 78991 320 160 145
0009823712 4879711005 78992 360 180 165
0009823713 4879711003 78990 300 150 135
0009823714 4879711002 78993 270 135 120
Scope of delivery for gauge:
● 0009823709 insert from SRG 
● 0009013203 button head screw (2x),

CH-6-32x5/16-A2
● 9045316132 socket head screw (4x),
M6x20-8.8-A2C
NOTE
The "TOP" mark on the insert is no longer in

use. Ensure that the components are installed
correctly.
Installing the 80% filling stop valve

 Remove any dirt in the tank.
 Check the level display for damage and dirt;
change if necessary.
 Clean the instrument panel and the O-ring
groove of the level display.
 Assemble the level display with the new seal-
ing ring. Carefully insert the level display with-
out bending the float rod. Note the correct ori-
entation of the level display.
 Working across diagonals, hand-tighten the 4
M6x20 screws for fastening the level display.
Then tighten them across diagonals to a tor-
que of 10 Nm.
 Check the thread for the 80% filling stop
valve.
 Check the rod and floats of the new 80% fill-
ing stop valve for damage (bending).
 The thread of the 80% filling stop valve is al-
ready provided with sealant. Screw in the
80% filling stop valve.

LPG tank
 Tighten the 80% filling stop valve to 
100+30 Nm. The tolerance of +30 Nm enables
the level display to be positioned precisely at
the top.
WARNING
The 80% filling stop valve prevents overfilling.
Correct functionality can be ensured only when the
level display is precisely aligned.
 Attach the wire connections.

 Fill up the LPG tank to check for leaks.
 Check the connections/instruments for leaks
using the gas detector and leak detection
spray. To do so, pressurise the tank for 10 mi-
nutes and check for leaks during that time.
 Bleed the tank, as described in the following
section. Then install the LPG tank and start
up the forklift truck.
NOTE
● Repairs must be logged.
● Repair operations and tank numbers must be
saved for at least 10 years and must be avail-
able for consultation.
Procedure for bleeding

Bleeding can be required in the following cases:
● If refuelling takes too long.
● If a fuel level of 80% can no longer be
reached.
● Always after repair work.
 The LPG tank must be at least 25% full. The

filled LPG tank is removed in order to carry
out bleeding.
DANGER
Risk of explosion to LPG tank.
 Bleeding may only take place in a
suitable location.

LPG tank
When the LPG tank is in its installation position, 
the immersion tube is pointing downwards.
Therefore, the removed LPG tank is placed in 

the installation position onto a work surface and
marked with an arrow pointing downwards (see
photo).
 The LPG tank must be turned into the bleed- 

ing position for bleeding. In other words, the
arrow must point vertically upwards.

LPG tank
 In this position, the immersion tube is pointing 
vertically upwards and the air, which is lighter
than propane/butane, is able to escape.
 Slowly open the extraction valve so that the
line breakage protection is not activated. Do
not open the extraction valve fully as this
helps to keep the volumetric flow to a mini-
mum (gas volume).
WARNING
Risk of frostbite due to extreme cold.
This is caused by the discharge (expan-
sion) of propane/butane when changing
from a fluid to a gas.
Wear protective gloves.
 Allow the air to escape from the tank for ap- 

prox. 3 minutes via the extraction valve. Es-
caping gas can be detected by its smell and
by using a gas detector.
An indeterminate amount of gas can flow into
the extraction pipe when the LPG tank is turned
to the bleeding position. For this reason, first gas
then air and then gas again is able to escape af-
ter the extraction valve is opened. Never empty
the tank to a fuel level of less than 10%.
 Reinstall the tank and fill up to a max. fuel lev-
el of 80%.
 Check the connections/instruments for leaks
using the gas detector and leak detection
spray. To do so, pressurise the tank for 10 mi-
nutes and check for leaks during that time.
NOTE
For LPG tanks with front-end instruments, pro-

ceed in the same manner as described above.

CNG system
CNG basic principles
CNG
Properties of CNG Comparison of fuels
CNG is a naturally occurring substance with a CNG Propane Petrol
varied composition. The principal component is Lower explo-
usually methane. Methane (also called mine gas 5% 2% 0.6%
sion limit
and marsh gas) is produced by decomposition
Upper explo-
processes. In the CNG used for technical appli- 16% - -
sion limit
cations, the methane content is usually more
than 80%. Ignition tem-
595°C 460°C 220°C
perature
Methane is the simplest of all hydrocarbons and Minimum igni-
belongs to the alkane or paraffin group. 0.3 mJ 0.26 mJ 0.24 mJ
tion energy
● Flammable Vapour densi-
● Forms an explosive mixture with air ty compared 0.55 1.6 3.5
● Colourless and odourless. Odour is therefore to air
added by the gas producer
● Lighter than air The energy density of CNG is very high. Its calo-
rific value is dependent on its composition and is
CNG or a CNG substitute can also be produced
about three times greater than that of hydrogen.
synthetically from other fuels (coal, lignite, pet-
CNG is used mainly for heating and electricity
rol). However, the procedures are complex and
generation. In some countries (such as Italy, Ar-
expensive and are used only in a few countries.
gentina and Germany), it is also used as fuel for
vehicles.
Advantages of CNG
Calorific value Hu in
Low fuel costs Fuel (gas type)
MJ/kg
●
● Clean exhaust gases Methane 50.0

● No soot particles Propane 46.4
● Can be used in enclosed spaces Butane 49.5
● Can be used in underground areas
Due to its relatively high density, LPG is consid-
Material characteristics of natural gas ered the more dangerous medium. Moreover,
the lower explosion limit of butane, for instance,
Density under normal is substantially lower than that of CNG.
0.718 kg/m3
conditions
If LPG is released in its liquid state, the rate of
Density ratio to air (air escape by mass is more than ten times that for
0.555
= 1) an escape of LPG in its gaseous state, virtually
Ignition limits 4-16 vol.% regardless of the pressure and through an aper-
Ignition temperature 595°C ture of the same cross-section. For this reason,
Boiling temperature -162°C the statutory regulations are considerably stricter
Critical temperature -82.6°C and more extensive for the storage of LPG than
for the storage of CNG.
Critical pressure 46 bar
If there LPG is released in its liquid state, there
CNG is mixed with sulphur compounds to en- is a risk of freezing (interaction of Joule-Thom-
sure an odour is given off before explosive son effect and evaporation effect). The tempera-
CNG/air mixtures can form. ture at the discharge point may reach a level as
low as -80°C.
For CNG, the pressure in the gas system is so
high (up to 220 bar at ambient temperature) that
if there is an uncontrolled release of gas, even

CNG system
without any ignition, catastrophic damage can combustion. Due to its non-polar characteristics,
occur due to the effect of the pressure. it is hardly soluble in water, at only 3.5 ml/
100 ml. However, it dissolves well in ethanol and
Characteristics of pure methane diethyl ether. Methane can react explosively with
oxygen, air and chlorine. In chlorination, methyl
Methane is a colourless and odourless gas with chloride, methylene chloride, chloroform and
a density (0.722 g/dm3 at 20°C) that is less than carbon tetrachloride are produced. In oxidation
that of air. Methane is flammable and burns with on the other hand, the molecule is broken down
a bluish, non-sooty flame. It does not support completely to produce water and carbon dioxide.

CNG system
Production, storage and composition of CNG
Production and storage Ethane (C2H6) 9.2%
Key producer nations (correct as of 2011): Propane (C3H8) 2.6%
● USA Butane (C4H10) 0.7%
● Russia CO2 1.6%
● Canada N2 0.8%
● Iran H2S -
● Qatar
Netherlands
When produced, natural gas contains water va-
Methane (CH4) 82.0%
pour and in some cases sulphur (organic com-
pounds or hydrogen sulphide). Due to the risk of Ethane (C2H6) 2.7%
corrosion, natural gas must be dried and desul- Propane (C3H8) 0.4%
phurised before being fed into the pipeline net- Butane (C4H10) 0.2%
work. Natural gas is mainly transported via pipe CO2 0.7%
lines from the depots to the consumers. It can N2 14.0%
be stored in large quantities in caverns or in
H2S -
aquifer tanks underground.
For short-term fluctuations in demand, natural Lacq (F)
gas is stored above ground in containers, from
Methane (CH4) 71.3%
which it can be brought into the network much
more quickly than from underground storage. Ethane (C2H6) 4.1%
Propane (C3H8) 2.9%
Composition Butane (C4H10) 1.5%
CO2 -
The composition of natural gas can vary signifi- N2 1.0%
cantly between the individual producing areas.
H2S 18.3%
The following summary provides examples of
the composition of natural gas in different pro-
ducing areas. Wolfersberg
Methane (CH4) 93.9%
Ethane (C2H6) 1.4%
NOTE
Propane (C3H8) 2.1%
The higher the methane content of the natural Butane (C4H10) 1.9%
gas, the higher its energy content. CO2 0.3%
Russia N2 0.4%
Methane (CH4) 98.4% H2S -
Ethane (C2H6) 0.5%
Wustrow
Propane (C3H8) 0.2%
Methane (CH4) 37.0%
Butane (C4H10) 0.1%
Ethane (C2H6) 2.5%
CO2 0.1%
Propane (C3H8) -
N2 0.8%
Butane (C4H10) -
H2S -
CO2 0.3%
North Sea N2 60.2%
Methane (CH4) 84.8% H2S -

CNG system
Comparison of emission values (in vol. %)
1 Diesel engine CO Carbon monoxide

2 Diesel engine with diesel particle filter HC Hydrocarbons
3 LPG engine with unregulated catalytic con- NOx Nitrogen oxide
verter PM Particles (soot)
4 LPG engine with regulated catalytic converter
5 CNG engine with regulated catalytic convert-
er

CNG system
Safety datasheet
In accordance with EC directive (91/155/ Danger symbol F+
EEC)/§14 Ordinance on Hazardous Substances R rates R 12
Trade name: natural gas dried
Butane
Issue date: Nov. 1995
Revised: May 2003 CAS no./EINECS no. 106-97-8/203-448-7
Mol. % <1
1. Name of substance and company desig- Mass % <3
nation Danger symbol F+
R rates R 12
Natural gas dried (acc. to
Trade name: DVGW Worksheet G 260, Pentane
2nd gas family)
CAS no.: 68410 - 63 - 9 CAS no./EINECS no. 109-66-0/203-692-4
EINECS no.: 270 - 085 - 9 Mol. % < 0.5
Energy source, raw mate- Mass % <2
Purpose:
rial Danger symbol F
GASAG R rates R 11
Berliner Gaswerke Aktien-
gesellschaft Nitrogen
10769 Berlin
Tel.: +49 (0)30 7872 -0 CAS no./EINECS no. 7727-37-9/231-783-9
Mol. % < 15
2. Composition/information on components Mass % < 25
Mixture of hydrocarbons and inert gases whose Carbon dioxide

proportions can vary within the following approx-
imate boundaries. The information in mol. % are CAS no./EINECS no. 124-38-9/204-696-9
only slightly different from the information in vol.
Mol. % <6
%.
Mass % < 18
Methane
CAS no./EINECS no. 74-82-8/200-812-7 3: Possible dangers

Mol. % 80 - 99 The use of natural gas is harmless when gas
Mass % 70 - 98 systems are operated without faults. Work on
Danger symbol F+ these systems may only be carried out by spe-
R rates R 12 cialist staff. In the case of breakdowns (for ex-
ample a line leak), natural gas can escape unin-
tentionally.
Ethane
Designation of the dangers
CAS no./EINECS no. 74-84-0/200-814-8 ● Forms mixtures that may ignite with air
Mol. % < 12 ● Extremely flammable gas
Mass % < 18
Special danger instructions for people and the
Danger symbol F+
environment
R rates R 12
● Slightly anaesthetising gas
Propane ● In high concentrations, risk of suffocation ex-
ists
CAS no./EINECS no. 74-98-6/200-827-9
Mol. % <4 4. First-aid procedures
Mass % <8
General information
● Natural gas is not poisonous

CNG system
After inhaling ● On entering the danger area, specialist staff
● Quick exit from the danger area should wear respiratory protection that is in-
dependent of circulating air unless the gas
● If breathing stops, deliver mouth-to-mouth re- concentration has been measured and the at-
suscitation or use a respirator mosphere declared harmless.
● Call emergency doctor ● Provide sufficient ventilation
● Only use oxygen outside of the danger area
Cleaning procedure
After skin contact ● Form a safety zone
● No treatment required ● Sufficiently ventilate area and check for es-
After eye contact caping gas in the danger area with suitable
measuring device before re-entering
● Non-irritant, no treatment required
After swallowing 7. Handling and storage
● Not applicable
Handling
5. Fire fighting measures Natural gas is transported in closed systems

(pipe lines, containers).
Stop gas escaping
Storage
Suitable extinguishing agents
Containers with natural gas may not be stored
● Dry extinguishing agents near materials supporting combustion.
● Carbon dioxide
Storage spaces must be ventilated. Facilities,
● Water with suitable extinguishing technology
devices or containers are to be kept tightly
(spray jet)
closed
Unsuitable extinguishing agents
Note for fire protection and explosion protection
● Foam
When handling and storing natural gas, explo-
Special hazards sion-protection measures should be taken (ven-
In closed rooms, do not extinguish flames before tilation, preventing ignition sources, designation
the escaping gas is stopped, otherwise there is of explosion protection zones).
a danger of a flammable mixture forming. Fire class: C
As a result of incomplete combustion, carbon Note explosion protection directives from the
monoxide (CO) can be produced (danger of poi- employers' liability insurance association in the
soning). chemical industry.
Special protective equipment
● Respiratory protection equipment independ- 8. Exposure controls and personal protec-
ent of circulating air tive equipment
Additional information Reference is made to BGR 104
● Remove ignition sources
Personal protective equipment
● Form a safety zone
● Cool environment with water During work on gas systems or containers, pre-
cautions are to be taken against injuries (see
BGR 102).
6. Procedures in case of unintentional re-
lease Respiratory protection
Stop gas escaping In the case of a fire or a lack of oxygen content

in the air of 17 vol.%, use respiratory protection
Avoid ignition sources that is independent of circulating air
Precautionary measures concerning people Limiting and monitoring environmental exposure
● Evacuate people and keep unauthorized per- None
sonnel away
● Close off danger area and surroundings, re-
main in the open air with the wind away from
you in the case of escaping gas

CNG system
9. Physical and chemical characteristics ● Not mutagenic (not damaging to genetic
make-up)
The physical and chemical characteristics are ● Not teratogenic (not damaging to fruit)
dependent on the composition of the natural
gas. This can vary within a relatively broad
range. In the following table, bands are therefore 12. Ecological information
indicated for the physical and chemical charac- 12.1. Stability/degradability
teristics.
Stability in water
Condition gaseous
The observed hydrocarbons do not hydrolyse in
Colour colourless water.
odourless, if necessary
odorised acc. to Stability in the ground
Smell
DVGW Worksheet G The degradation behaviour of natural gas in the
280 ground is not well known.
Boiling point -195°C up to -155°C Photolysis
Ignition temperature when mixed with air
(acc. to DIN 51794) 575°C up to 640°C The observed hydrocarbons, methane, ethane,
propane and butane are primarily broken down
Ignition limits in air at
through indirect photolysis.
20°C (acc. to DIN 4 vol.% up to 17 vol.%
51649) Their by-products are carbon dioxide and water.
Minimum ignition ener- 12.2. Behaviour in parts of the environment
0.25 mJ
gy at 20°C
Density at 0°C 0.7 kg/m3 to 1.0 kg/m3 Distribution between parts of the environment
Relative density (air = The calculation according to Mackay, level I, for
0.55 to 0.75
1) distribution to the air, biota, sediment, soil and
Solubility in water at 0.03 m3/m3 to 0.08 water parts of the environment shows that the
20°C m3/m3 hydrocarbons, methane, ethane, propane, and
butane fall 100% into the air category.
10. Stability and reaction Organic accumulation
Conditions/substances to be avoided Organic accumulation is not well known for the

observed hydrocarbons methane, ethane, pro-
Flammable mixtures coming into contact with ig- pane, butane and pentane.
nition sources, reaction with materials support-
ing combustion 12.3. Eco-toxic effects
Dangerous reactions/decomposition products Toxicity with fishes, invertebrate water animals,

aquatic plants, organisms in the soil, terrestrial
Carbon monoxide (CO) can occur as a result of plants and other terrestrial non-mammals includ-
incomplete combustion (danger of poisoning) ing birds
Not toxic
11. Toxicology information
Hazard to water
In accordance with the EC directive for the clas-
sification, packaging and marking of dangerous Not hazardous to water
materials, the hydrocarbons contained in natural BSB value, CSB value
gas observed in accordance with the statements
in "2. Composition/information on components" Not applicable
are: 12.4. Other effects
● Not poisonous For methane (CH4), the greenhouse effect GWP
● Not an irritant amounts to 21 kg of CO2/kg of gas.
● Not sensitizing
● Not carcinogenic
● Not toxic for reproduction

CNG system
PG n. a.
NOTE
EmS no. 2-02
Mass-based greenhouse effect (Global Warming
Potential) of methane over a period of 100 Air transport ICAO/IATA
years. The GWP value of 21 means that 1 kg of
CH4 has an effect on the climate 21 times that of Natural gas, com-
1 kg CO2. Correct technical name
pressed
Class 2.1
13. Information for disposal
● Only permitted in freight planes
Small quantities of natural gas/air mixture can ● Maximum quantity of 150 kg
be delivered harmlessly into the atmosphere
(establish protection zone).
● Packaging Directive 200
15. Directives
NOTE
Identification code
At the opening where gas can escape, an explo-
sion protection zone must be identified, the size Danger sym-
of which, if in doubt, must be determined based highly flamma-
bol/danger F+
on a calculation or measurement of the gas con- ble
designation:
centration.
highly flamma-
We should point out that the sample collection R rates: R 12
ble
for BGR 104 is not always applicable in the case Must not fall
of a deliberate gas release. S2 into the hands
The deliberate release of a dangerous quantity of children
of natural gas (in the context of BGR 104) is not Store contain-
permissible in enclosed spaces. er in a well
S9
ventilated
Large quantities of natural gas/air mixture can
place
be removed by controlled burning if necessary.
S rates Keep away
from ignition
14. Transport information S 16
sources - no
Natural gas is transported in pipe lines or also in smoking
steel bottles or other containers. Take meas-
ures against
Transport by land according to provisions of S 33
electrostatic
ADR/RlD/GGVSE charging
Natural gas, com-
Designation of the National directives
pressed, with high
goods
methane content, ADR Employers' Liability Insurance Association Direc-
Class/figure letter 2/1F tive 104 (BGR 104)
UN no. 1971 Ordinance on Hazardous Substances (Gef-
Warning board/danger StoffV) 5
23
no.
§ 22 Youth Employment Protection Act
No. 2.1 Flammable (JarbschG)
Danger slip
gases
Dangerous Goods Act (GGVS/ADR ordinance)
Maritime transport lMDG/GGV maritime on electrical systems in potentially explosive
areas (ATEX from 01.07.2003) in combination
Natural gas, com- with the ordinance pertaining to the Equipment
Correct technical name Safety Act (ordinance on bringing into use
pressed
Class 2.1 equipment and protection systems for potentially
explosive areas - explosion protection ordinance
UN no. 1971
- 11th Ordinance to the Equipment Safety Act)
Marine pollutant No

CNG system
16: Other information It does not provide any assurance on the char-
acteristics of the described product.
The "employers' liability insurance association
directives for health and safety at work" from the HEDSET (Harmonized Electronic Data Set) Ex-
main trade association of the commercial em- isting Substances Regulation
ployers' liability insurance associations BGV D No 793/93 (EEC) of 23 March 1993rd "Natural
2, "working on gas systems" and BGV C 6, "sys- gases, dried" EINECS no 270-085-9, CAS no
tems for public gas supply" must be complied 6841 0-63-9
with in their respective valid version, including
their instructions for execution. Kyoto Agreement, Second Assessment report of
the IPCC (Intergovernmental Panel on Climate
Further Information and Change)
The information listed only describes the safety
requirements for the product and is based on
current knowledge.
Explosion protection
The entire gas system must be leak-tight.
The installation of the gas system and all of its
components must always be carried out in ac-
cordance with the manufacturer's specifications.
Escaping gas, e.g. when draining the gas sys-
tems, must be drained safely, i.e. the system
may only be drained out in the open.
A safety distance of at least 10 m from sources
of ignition must be maintained.
If gas is escaping, mark out a prohibited area of 
10x10 m with hazard tape and warning signs.
Quality of H gas and L gas

Distinction in gas quality
CNG is available in two qualities in Germany: H
gas, which is mainly produced in Russia and
Norway, and L gas which comes from Germany
and is usually available in Bremen, Lower Saxo-
ny and North Rhine-Westphalia.

CNG system
H gas and L gas
H gas (high calorific gas) has a proportion of
methane between 87 and 99.1 percent by vol-
ume (vol. %), whilst for L gas (low calorific gas)
it is generally only between 79.8 and 87 vol. %.
Moreover, H gas has a lower proportion of nitro-
gen (N2) and carbon dioxide (CO2).
The gas quality is classified according to DVGW
Worksheet G260.
Calorific value and knock resistance

The higher the proportion of methane, the higher
the calorific value. H gas therefore has a much
higher energy content than L gas:
13.1-13.63 kWh/kg compared to
10.66-11.26 kWh/kg. At 120 octane, H gas has a
lower knock resistance than L gas, and you can
travel significantly further on a full tank. Both H
gas, as well as the somewhat cheaper L gas,
are suitable as fuel. Modern engines adjust
themselves automatically to the particular gas
quality.
Schematic view of the load diagram for H gas
1 Torque [Nm] 3 Speed [rpm]

2 Power [kW]

CNG system
CNG-specific components in the truck
Overview
1 BMF VW engine 3.2 l / CWTA 3.6 l 5 CNG modules

2 "E-Control" engine control unit 6 Shut-off valves 1Y12 and 1Y13
3 CA100 mixer (CNG version)
4 Cobra MD evaporator (BMF engine) / C-Ser-
ies (CWTA engine)

CNG system
VW CWTA 3.6 l engine with a regulated catalytic converter
Special features:
● Engine oil level sensor 0B16 (TOG)
● Lambda 1 control system
● Water-cooled 6-cylinder in-line engine with
"E-Control" engine control unit (electronic ig-

nition system)
● Direct valve activation via timing chain-driven,
overhead camshafts (two pieces)

● Maintenance-free valve train via hydraulic
tappets.
Technical data for the CWTA engine

Manufacturer VW
Engine type CWTA
Number of cylinders 6 in V-type arrangement, 10.6°
Bore / stroke: 89 mm / 96.5 mm
Nominal capacity Pnominal = 56 kW ±5% at 2700 rpm
Compression 9.7:1
Nominal speed nnominal = 2700 rpm
Lower idling, truck nlower idling, truck = 1000 rpm

CNG system
Maximum revolution speed when driving nmax, driving = 2700 rpm
Maximum revolution speed when lifting nmax, lifting = 2300 rpm
Maximum permissible revolution speed when tow-
nmax = 3200 rpm
ed
Maximum torque Maximum torquemax = 224 Nm at 1400 rpm
Hydraulic valve-clearance compensation, 4
Valve clearance
valves per cylinder
Via maintenance-free chain and two adjustable
Valve train camshafts, via roller cam followers at inlet and
outlet
Ignition Electronic ignition sequence
Ignition sequence 1-5-3-6-2-4
Weight 156 kg
Installed tilt (as seen on flywheel) 8° to the right
Direction of rotation (as seen on flywheel) left
Maximum permissible engine oil temperature in
135°C
the oil sump
Maximum permissible coolant temperature upon
110°C
discharge from engine in continuous operation
Maximum permissible suction vacuum at Pnominal
at the measurement port for the "suction vacuum" 65 mbar
sensor
Maximum permissible exhaust gas back pressure
250 mbar
at Pnominal (guarantee for VW)
Maximum permissible slope from installation posi-
30°
tion in all directions
Thermostat opening temperature 80°C ± 2°C
Thermostat full opening 95°C
Fuel CNG, all globally approved natural gas qualities

CNG system
"E-Control" engine control unit 
The "E-Control" engine control unit contains the

● Ignition control
The ignition control unit regulates the ignition

timing depending on the speed and tempera-
ture, and the fuel quality (see diagnostic pro-
gram).
● Lambda 1 control system
The fuel composition of 13.5:1 is controlled by

lambda 1.
● Engine speed control
The speed is monitored and controlled by the 1 "E-Control" engine control unit
throttle valve position. 2 LHC Linde control unit
● Diagnostics and parameters
Controller diagnostics can be performed via

the 4-pin LPG diagnostics cable.
● CAN connection to LHC
The engine control unit is connected to the

LHC via the CAN bus. The inputs and outputs
to and from the controller can be checked us-
ing the LPG measurement box.
CNG mixer
CA100 Mischer
1 Hose connection for vacuum control at the 6 Butterfly valve

membrane 7 Intake air inlet
2 Metering spring 8 Membrane
3 Gas regulator valve 9 Idling adjustment screw
4 CNG connection inlet 10 Air flow
5 Full-load adjustment screw

CNG system
The CNG mixer mixes air and gas at the opti-
mum lambda 1 mixture ratio.
Mixture ratio 1:13.5 (1 part CNG, 13.5 parts air)
NOTE
Spare part number for CA100 mixer (CNG ver-

sion):
● BMF engine 3945701718

● CWTA engine 3945701722
NOTE
The mixers for CNG and LPG are identical in

terms of their basic design and function. A differ-
ent membrane (8) is fitted in the CNG mixer.
Basic setting of the adjustment screws

Idling adjustment screw (9) completely screwed 
in (closed).
Full-load adjustment screw (5) in the middle po- 

sition ("Lean").

CNG system
Membrane up to serial number H2X394G00037
IMPCO CNG CNG repair kit 3945729002 for

regulated catalytic converter with VW BMF 3.2 l
engine
Membrane from serial number H2X394G00038
IMPCO CNG CNG repair kit 3945729005 for

regulated catalytic converter with VW CWTA 3.6
l engine

CNG system
Operating principle of the Cobra MD
evaporator
Evaporator for CNG
The evaporator in the CNG truck is always
equipped with a pulse valve. Together with the
controller and the lambda sensor, this is how the
mixture formation is controlled.
The maintenance of the CNG evaporator, the
maintenance kit and the components to be re-
placed are identical to the LPG version.


When the engine is running (butterfly valve on
valve (6), allowing CNG to flow through the open
membrane (2).
Since CNG has a lower energy density at stand-
ard atmospheric pressure in comparison with
other fuels, natural gas is compressed to ap-
prox. 200 bar to ensure an adequate amount of
energy within a reasonable volume within the
truck. The CNG is kept in a gaseous physical
condition. The CNG tank is filled via a CNG fill-
ing station. The pressure of the CNG is lowered
from 200 bar to approx. 10 bar via a pressure re-
ducing valve that is cooled with coolant. The

CNG system
pressure in the evaporator is then lowered by
the primary valve (1) from 10 bar to atmospheric
pressure.
Depending on the setting of the butterfly valve
(which in turn depends on the accelerator pedal
position), the secondary membrane (2) is pulled
forward at varying strengths, thereby controlling
the opening of the secondary valve (6).
process changes the flow rate of gas through
reduces the flow rate of gas and prevents the
Function of the pressure relief valve at 1.7

bar:
above 1.7 bar, the pressure relief valve (7)
opens and blows gas into the atmosphere via a
hose. This arrangement prevents a permanent
leakage at the evaporator housing. If escaping
gas is detected at the hose, it may be the case
that the seal on primary valve is faulty. If escap-
ing gas is detected, the gas cylinder must be
locked via the shut-off cock. The evaporator
must then be repaired or replaced.
Operating principle of the C-Series

evaporator (cannot be dismantled)
Evaporator for CNG 
NOTE
The yellow "Only natural gas" label refers to

CNG-optimised evaporator 0009822614 for the
VW CWTA 3.6 l engine. The label must always
be present, and remain visible even after a re-
placement.
The evaporator in the CNG truck is always
equipped with a pulse valve. Together with the
controller and the lambda sensor, this is how the
mixture formation is controlled.

CNG system
The main difference to a normal C-Series evap- 
orator is the countersunk labyrinth seal inside
the evaporator housing. This optimisation ach-
ieves better flow characteristics and a higher
flow rate of CNG for the VW CWTA 3.6 l engine.


When the engine is running (butterfly valve on 

valve (6), allowing gas to flow through the open
membrane (2).
Since CNG has a lower energy density at stand-
ard atmospheric pressure in comparison with
other fuels, natural gas is compressed to ap-
prox. 200 bar to ensure an adequate amount of
energy within a reasonable volume within the

CNG system
truck. The CNG is kept in a gaseous physical
condition. The CNG tank is filled via a CNG fill-
ing station. The pressure of the CNG is lowered
from 200 bar to approx. 10 bar via a pressure re-
ducing valve that is cooled with coolant. The
pressure in the evaporator is then lowered by
the primary valve (1) from 10 bar to atmospheric
pressure.
Depending on the setting of the butterfly valve
(which in turn depends on the accelerator pedal
position), the secondary membrane (2) is pulled
forward at varying strengths, thereby controlling
the opening of the secondary valve (6).
process changes the flow rate of gas through
reduces the flow rate of gas and prevents the
Pressure limit via spring at 1.7 bar:

above 1.7 bar, the secondary valve (6) opens
because the pre-load force of the spring (3) is
designed for a pressure of up to 1.7 bar. This ar-
rangement prevents a permanent leakage at the
evaporator housing. If over-enrichment of the
engine is detected (engine does not run smooth-
ly or stutters), the gas cylinder must be locked
via the shut-off cock. The evaporator must then
be replaced.

CNG system
Shut-off system
1Y6 Shut-off valve with filter in 10-bar low-pres- 1Y12, 1Y13 Tank shut-off valve in the high-pressure
sure range (same component as in LPG en- range (maintenance-free)
gine)
NOTE
The shut-off valves are activated only when the

engine is running or during the start phase.
Shut-off valve (solenoid valve) with gas 

filter for CNG
The shut-off valve has three basic functions:
1. Filtering
The dirt particles found in the gas are filtered
here to ensure that the shut-off function of the
valve functions correctly. If dirt reaches the tap-
pet rod of the shut-off valve, the shut-off valve
cannot close properly. This is reported to the
driver as an error: (diagnostic software; error
code 359) See description: Gas shortage shut-
down device
2. Shut-off and opening of the gas flow:

CNG system
The shut-off valve must be closed when the in-
ternal combustion engine is not running. When
starting up and during operation of the engine,
the shut-off valve is activated by the E-Control
controller and the gas flow to the evaporator is
opened. This allows the empty evaporator to fill
with gas. If only the ignition is switched on, the
shut-off valve remains closed.
3. Gas shortage shut-down:
When the engine is switched off, it continues to
run for approx. 2-3 seconds. This ensures that
the remaining gas between the shut-off valve
and the combustion chamber is burned off with-
out a trace. This function is called gas shortage
shut-down.
Components of the shut-off valve 
At an LPG temperature of approx. 102°C, olefins

(similar to paraffin) form in the LPG. These ole-
fins settle on the tappet rod (3) and the valve
can no longer shut off tightly. An adaptor (1) with
high thermal conductivity prevents the olefins
from settling on the tappet rod (3).
NOTE
In the case of CNG-version trucks, such dirt is

not an issue.
The paper filter (2) with integrated magnet keeps 1 Adaptor
metallic dirt in the filter. 2 Paper filter with integrated magnet
3 Piston
Due to the hexagonal profile of the piston (3), 4 Brass washer
the contact face on the cylinder is flat. 5 Coil
The brass washer (4) prevents delayed shut-off

caused by residual magnetism on the coil.
When the temperature rises in the gas system,
the pressure rises. The coil (5) also opens the
valve in the event of high temperature and pres-
sure.
In the shut-off valve there is a protection diode 
for the relay.
CAUTION
The diode can be destroyed by faulty polarisation
when connecting the lines.
Positive and negative connections must not be inter-
changed.

CNG system
CNG module
Overview of CNG system
Diagram of CNG system
1 CNG tank 2x 75 l 9 Pressure sensor for level display

2 "E-Control" controller 10 Pressure reducing valve
3 Servo motor for butterfly valves 11 Electromagnetic shut-off valve
4 Ignition system 12 Evaporator with pulse valve
5 Lambda probe 13 Mixer
6 Fill connection 14 Gas engine
7 Non-return valve 15 Intake air
8 Electric tank valve with fusible safety plug

CNG system
Overview of CNG system
1 Fill valve 9 Pressure relief valve (low-pressure range)

2 Integrated non-return valve 10 Low-pressure gas connection, about 10 bar
3 Pressure gauge 11 Pressure relief valve - burst plug, 330 bar
4 Electrical pressure sensor 12 Burst pipe protection
5 Mechanical shut-off valve 13 Fusible safety plug 110°C
6 Electromagnetic shut-off valve 14 Display unit 6P1
7 Cooling water connection 15 Fuel tank, 200 bar at 15°C, 250 bar at 65°C
8 Pressure reducing valve 16 "E-Control" controller

CNG system
Overview of CNG module
1 Fill valve 8 Pressure reducing valve

2 Integrated non-return valve 9 Pressure relief valve (low-pressure range)
3 Pressure gauge 11 Pressure relief valve - burst plug, 330 bar
5 Mechanical shut-off valve 13 Fusible safety plug 110°C
6 Electromagnetic shut-off valve 15 Fuel tank, 200 bar at 15°C, 250 bar at 65°C

CNG system
Fill valve (1) with integrated non-return
valve (2)
Characteristics 
● Compatible with all couplings suitable for

NGV1 connecting nipple
● Optional, integrated 50 micron dirt filter (1)
● Integrated non-return valve with high flow
● Seal-saving design
● Quiet refuelling
Technical data
Pressure range
● PN = 200 bar
● PS = 260 bar
● PT = 390 bar
● Compatible with NGV1-P30
Temperature range
● -80°C to +120 C
Design
● All parts made of rustproof stainless steel,
with protective dust cap.
● Seals resistant to CNG.
External testing
● ECE R1 10 available
Protective dust cap 
NOTE
When the truck is in use, the dust cap must be

attached to the fill valve.
During maintenance on the fill valve, check the
following:
● Cleanliness. No dirt in the valve or on the cap.
● Protective dust cap present and secured with
pull tab on the valve.

● No visible damage

CNG system
Pressure gauge (3) 
The pressure gauge is needed to monitor the fill

level when refuelling.
The ignition must be switched off during refuel-
ling. When it is switched off, the level display will
not be visible on the display unit. The pressure
gauge can be used to determine the fill level.
When carrying out maintenance work, check the
following on the pressure gauge:
1 Functional check:
- Cylinder shut off: display 0 bar
- Compare with level display in the display
unit. Example: 220 bar means that the cylin-
der is full
- Example: 110 bar corresponds to approx.
50%; 55 bar corresponds to approx. 25%
2 Check for damage or contamination.
Pressure sensor for the level display (4) 
NOTE
The pressure sensor sends the fuel level to the

display unit.
Pin assignment
Pin 1 Earth (-)

Pin 2 Sensor signal output
Pin 3 Power supply (+)
Technical data
Pressure measuring
0 to 200 bar
range
Over pressure safe 800 bar
Burst pressure 1700 bar
Compressed natural
Measuring medium
gas (CNG)
Housing, parts that
Oil-tight, non-corrosive,
come into contact with
CrNi steel
the measuring medium
IP 69K when connec-
Protection class ted, in accordance with
IEC 60 529
Ambient temperature -20 - +80°C
0.5 V at 0 bar up to 3.7
Output signal V at 200 bar, increas-
ing linearly
Characteristic curve
≤ 0.5%
deviation
Supply voltage 7.8 V to 30 V

CNG system
Installation position Any
Permissible exposure 20 g, in accordance
to vibration with IEC 60068-2-6
Permissible exposure 500 g, in accordance
to jolts with IEC 60068-2-27
30 V, 80 MHz - 4.2
Interference fields GHz, testing in accord-
ance with EN 12895
Insulation 500 V DC
Short circuit resistance S+ to UB-
Authorisation ECE-R110 (CNG)
CE labelling Present
Suitable for sink opera-
< 10 mA
tion
WIKA product no. 7506566
Electrical testing
 The power supply must be ensured with
measurements.
 If possible, use measuring adaptor
7917299006 and adaptor wiring harness
3003810300.
The sensor must not be opened for trouble-
shooting. The pressure sensor for the level dis-
play is an active sensor.
Value of the output signal:

0.5 V to 3.7 V Tank empty (0 bar) to tank full (200 bar)
4.5 V (= 250 bar) is the maximum possible pressure in the intact system
> 4.7 V (> 262.5 bar) overpressure, which is displayed as an error
0 V to 0.3 V Short circuit to earth or sensor defective
5.0 V Line breakage or sensor defective
NOTE
To ensure a correct level display, the character-

istic curve must always be set to "CNG" on the
display of CNG trucks. This setting can be im-
plemented using the diagnostic software.
Voltage values on pin:2 of the sensor plug and 
the condition display on the display unit
Switch-on threshold
Condition display
(V)
1 3.38
2 2.92
3 2.48
4 2.04
5 1.60
6 1.16
7 0.80

CNG system
8 0.30
> 4.70
11
< 0.30
At a hysteresis of 0.1 V, the individual statuses

are switched off again.
Output signal characteristic curve 
Input signal of the pressure sensor in the display 

unit

CNG system
Mechanical (5) and electromagnetic (6)
shut-off valve
Mechanical shut-off valve (5) 
During maintenance, check the following:

● With the engine running, close the shut-off
valve – the engine will stop.

● Check for damage or contamination.
Also carry out this check during repair work.
Electromagnetic shut-off valve (6) 
During maintenance, check the following:

● Check for damage or contamination.
Also carry out this check during repair work.
Tank shut-off valves 1Y12 and 1Y13 
Tank shut-off valves 1Y12 and 1Y13 work in the

>220 bar high-pressure range with low magnetic
forces. For this reason, small diameters (bores)
are required.

CNG system
Pressure reducing valve (8) with coolant connection (7)
1 Connection for stainless steel tube, dia. 5 Pipe union ¼-18NPT(m)-1/8NPT(f),

6x1 mm, with Swagelok terminal screw joint 0009524411 (2x)
2 Pipe union ¼ NPT-M14x1.5, 0009512129 6 Angled pipe adaptor 1/8NPT-3/8,
3 High-pressure regulator, 3925702002 0009560109 (2x) for cooling water
4 High-pressure relief valve with cap
¼-18NPTF, 0009441357
The pressure reducing valve reduces the pres- 

sure from approx. 200 bar (in the tank) to a con-
stant 10 bar. It is held at a constant temperature
level with cooling water.

CNG system
Pressure relief valve 28 bar in the 12- 
bar range (9)
No maintenance or testing is required.
NOTE
The cap must always be present. If the cap is

not present, this is an indication that the valve
has tripped.
Burst plug (11) 
The burst plug is a pressure relief valve up to

330 bar.
Fusible safety plug (13) 
The fusible safety plug blows at a temperature of

110°C.
NOTE
After the fusible safety plug has blown, it must

be replaced.

CNG system
CNG tank (15)
2014/68/EU or equivalent national regulations.
Operating pressure 200 bar at 15°C

Volume 2x 75 litres
Inspection interval 5 years

CNG system
Assembly instructions for Swagelok pipe
screw joints
NOTE
Before assembly, make sure that the pipe is

clean, free from burrs and undamaged.
Initial assembly (olives still loose)
NOTE
These instructions apply to conventional pipe

screw joints and pipe screw joints with the new
rear clamping ring geometry.
 Insert the pipe into the Swagelok pipe screw 
joint.
 Ensure that the pipe rests firmly on the shoul-
der of the pipe screw joint body and the union
nut is finger-tightened.
 Due to the variation in pipe diameters, a com-
mon starting point is desirable. For this rea-
son, tighten the union nut until the pipe no
longer turns by hand, or allows no more axial
movement in the fitting.
 Mark the union nut at the 6 o'clock position. 

CNG system
 Firmly hold the screw joint body and tighten 
the union nut with 1¼ revolutions up to the 9
o'clock position.
 Carry out a leak test.
Re-assembly (olives secure on the pipe) 
Screw joint in released state.
 Move the pipe with the pre-assembled clamp- 

ing ring into the body, until the front clamping
ring is secured.
 Finger-tighten the union nut. Then tighten by 

an additional ¼ revolution.
 Carry out a leak test.

CNG system
Mixture setting and CO measurement at
the CNG system
Requirements
pression and ignition timing are OK / at set-
point values:
Setpoint ignition timing in ° of the crank angle before TDC

394 - 3.2 l (BMF) 394 - 3.6 l (CWTA)
391 series 392 / 393 series
series series
LPG controlled 16 ± 2 16 ± 2 20 ± 2 15 ± 2
CNG controlled 22 ± 2 20 ± 2 22 ± 2 22 ± 2

tic software.
● Idle speed 1000 rpm / the engine load set-
point values can be found in the workshop lit-
erature/Pathfinder
air using the exhaust gas measuring device
ware:
Warning light for the engine control unit not illu- 
minated
Error light for the gas system not illuminated 

CNG system
The mixture ratio of air / LPG is set on the mixer

using the idling adjustment screw (7) and the
full-load adjustment screw (6) (depiction is of CA
55 mixer).
NOTE
Always use the basic settings set out below first!
391 evo: Idling adjustment screw (7) 

idling adjustment screw.
391 evo: Full-load adjustment screw (6) 
 For the basic setting, set the full-load adjust- 

ment screw to the middle position "Rich".

CNG system
394-02: Idling adjustment screw (7) 

idling adjustment screw.
394-02: Full-load adjustment screw (6) 
 For the basic setting, set the full-load adjust- 

ment screw to the middle position "Lean".
Calibrating the E-Control control unit

 Open "IMPCO" servicebase with the IMPCO 
diagnostic cable.
 Open the "Error codes + parameters" window.
Select the "General" tab.

▼
General
Fuel type
 Set the fuel type. If H gas is used at the facto-

ry: Select "Butane (H)".
 Open the "Guided diagnostics" window. Se-
lect "Mixture setting" and confirm the selec-
tion.

CNG system
Guided diagnostics
▼
Mixture setting
Confirmation (click) deactivates the control sys-

tem. The lambda probe then measures the ac-
tual non-regulated emissions upstream of the
catalytic converter. In addition, the adaptation is
deleted.
 Change window: "Inputs + outputs". Select
"Mixture setting" and confirm the selection.
Inputs + outputs
▼
Mixture setting
The following values must be shown in the dis- 

play fields (1...3).
● (1) Closed Loop (active/inactive): Inactive
● (2) Adjust Mode: Adjustment
● (3) Adaptation Mode: Deleted
Executing the mixture setting at idling

 Correct the settings at the idling adjustment 
screw (7) until the bar in the diagnostic soft-
ware is in the middle under the "Mixture" point
(4).
The value of < 0.1 vol. % must not be exceeded.
Executing the mixture setting under full load

 Lift up to the mechanical stop and use the lift-
ing hydraulics to place the engine under load.
Setpoint speed 391 evo: 2100 rpm
Setpoint speed 394-02: 2800-100 rpm

CNG system
 Correct the settings at the full-load adjustment 
screw (6) until the bar in the diagnostic soft-
ware is in the middle under the "Mixture" point
(4).
The value of < 0.1 vol. % must not be exceeded.
 Change window: "Guided diagnostics". Con-
firm with "OK". The control is then re-activa-
ted and the adaptation is saved.
Guided diagnostics
▼
Mixture setting
 After measuring and activating the control,

check the mixture controller (4) and the CO
values again on the measuring device.
 Secure the adjustment screws with sealing
varnish.
 Check the engine power rating.

Inputs + outputs
▼
Driving
▼
Engine load
Prerequisites for testing the engine power rat-

ing:
the values can be found in the diagnostic soft-
ware
 Check the engine load.
To test the engine power rating, the engine must
be definitively loaded. The load is applied by lift-
ing to the mechanical stop. The opening pres-
sure of the pressure relief valve is referred to
here as the "full load".
gine utilisation

CNG system
quested.


Lifting at the stop


forced down


down
CNG 90-100% 200 rpm

CNG system
Measuring carbon monoxide CO emissions
in the exhaust gas

NOTE

suitable for performing the measurement. Some
devices are too slow for the measuring process
or have a CO measurement range that is too
small. If an error occurs in the gas system, CO
values can reach > 8 vol. %.
ing device.
idling speed.
mechanical stop."
NOTE

the lifting joystick is then actuated while the en-
gine is operating at idle speed, the engine may
cut out in certain cases. This is not a reason for
a complaint provided that the setpoint lifting
speed is achieved.

CNG system
Measuring the CO upstream of the catalytic converter

sumption.
converter. A measurement port (Pfeil)(1) is in-
stalled in the exhaust pipe for this purpose (the
illustration shows a CWTA 3.6 l engine as an ex-
ample). An optimum mixture ratio guarantees a
low CO value and low fuel consumption.
ieved
checked via the measurement


nition map shifted)
If the measurement needs to be performed up-
stream of the catalytic converter, please note
the following:
The closed-loop control valve can only bring
about reductions in the air / gas combustion mix-
ture; it cannot supplement the mixture. For this
reason, the following values are expected when
measuring the CO content upstream of the cata-
lytic converter:
Lambda control active: CO 0.5 - 1.0 vol. %
Lambda control inactive, adaption mode: CO 1.5
- 2.0 vol. %

CNG system
Checks
Leak test 
NOTE
In accordance with the statutory inner and outer

inspection, leak tests must be carried out by a
specialist in gas high-pressure systems.
Refuelling the pre-assembled tank, which is

disconnected from the truck, and leak test
 Tightly seal the low-pressure side (9) of the
high-pressure regulator using union nut
1 Pipe
0009520105 and stopper 0009527001. 2 Non-return valve
3 Pressure sensor, 0.5 V at 0 bar, 3.7 V at 200
 Turn the manual shut-off valve to "O", "open". bar
 Secure the tank to prevent it rolling away. 4 High-pressure side, refuelling pressure up to
200 bar at 15°C (250 bar at 25°C)
Keep it away from sources of ignition. 5 Electromagnetic shut-off valve
 Fit the tank hose on the fill valve and refuel up 6 Cooling water connection
7 High-pressure relief valve
to about 5 to 40 bar. Remove the tank hose 8 Pressure reducing valve
from the fill valve. 9 Low-pressure side, constant 10 bar
10 Manual shut-off valve
 Carry out a leak test at low pressure using a 11 Fill valve with integrated non-return valve
bubble-forming leak detection spray and a 12 Pressure gauge
gas detector.
 Fit the tank hose on the fill valve and refuel up
to about 100 to 200 bar. Remove the tank
hose from the fill valve.
 Carry out a leak test at high pressure using a 
bubble-forming leak detection spray and a
gas detector.
 Turn the manual shut-off valve to "C", "close".
 Put protective cap on fill valve.
 Carefully open union nut 0009520105 and re-
lease the pressure via the low-pressure side.
Draining CNG out of the lines can only be
done out in the open. Maintain a safety zone
of at least 5 m.
 After completing the CNG system, repeat the
leak test in the truck on the high-pressure
side at 100 to 200 bar.
 Check on the low-pressure side for leaks.
 Log the leak test.

CNG system
Test log after testing the natural gas system for leaks
Undercarriage number
Bottles number 1
Bottles number 2
Natural gas equipment fully assembled on the

truck and successfully tested with test pressure
of 5-40 bar in accordance with instructions:
Current test pressure

Date
Name of the inspector
Natural gas equipment fully assembled on the

truck and successfully tested with test pressure
of 100 - 200 bar in accordance with instructions:
Current test pressure

Date
Name of the inspector

CNG system
Engine electrics
Electronic ignition system − overview
1 "E-Control" ignition control unit 9 Spark plugs

2 Error light 10 Coolant temperature sensor
3 Battery 11 Engine speed sensor
4 Fuse 12 Camshaft phase sensor, 2 pieces
5 Ignition and starting switch 13 Suction pipe temperature sensor
6 Shut-off valve 14 Servo motor for butterfly valves, with potenti-
7 Diagnostic connector ometer
8 Ignition coils

CNG system
Properties of the E-Controls ignition control
unit
● A sensor for measuring the suction pipe tem-
perature is mounted in the intake connection
● Gas shortage shut-down device
● The gas shut-off valve (6) is activated by the
ignition control unit, not by the LHC controller
● The speed signal is sent from the LHC con-
troller to the ignition control unit via the CAN
bus The speed controller in the ignition con-
trol unit adjusts the butterfly valve via the ser-
vo motor for the butterfly valve in combination
with a monitoring potentiometer
● Error display in the display unit
If an engine fault occurs, the "engine malfunc- 
tion" error light (2) illuminates in the display unit
instead of the "preheating indicator" error light
(1).
Diagnostics for ignition control unit and wir- 

ing harnesses
The "E-Control" ignition control unit and the wir-
ing harnesses can be checked using measuring
adaptor 0009734313 in connection with adaptor
7917299010.
The diagnostic program (servicebase "IMPCO"
with diagnostics cable 3003652504) offers the
● Ability to change parameters
Ability to display sensors and actuators, e.g.

temperature sensor and camshaft phase ad-
juster
● Ability to switch off individual ignition coils
while the engine is running for diagnostics

purposes
● Ability to change the ignition timing (ignition
map)
This may be necessary depending on wheth-
er CNG with a higher calorific value (H gas) or
a lower calorific value (L gas) is used.
● Ability to calibrate components
● Ability to display errors
Current errors are also indicated by an error

light in the driver's cab.
The error history can be read out.

CNG system
NOTE
Error "359 - engine run-on too long" is only

shown in the error history and is indicated by a
flashing error light.
Gas shortage shut-down device
1 Signal lights in the display unit (error light for 3 Traction controller and lift control LHC (N1)
engine control unit and warning light for gas 4 Gas shut-off valve (1Y6)
system) 5 Ignition coils (0T1) to (0T6)
2 Ignition and starting switch (S1) 6 Ignition control unit E-Control (0N1)
Function
If the ignition and starting switch (2) is used to
switch off the gas engine, the LHC (3) shuts
down all lifting and traction functions. The igni-
tion control unit (6) can, however, take up to a
maximum of 65 seconds to switch off power to
the ignition coils (5). The gas shut-off valve (4) is
immediately closed by the ignition control unit
(6) when the ignition and starting switch (2) is
switched off.
Depending on the temperature of the gas, the
engine can run on for 2 seconds up to a maxi-
mum of 20 seconds after being switched off.
If the engine runs on for longer than 20 seconds,
the gas shortage shut-down device is defective.

CNG system
A possible cause is leakage at the gas shut-off
valve. The signal lights (1) illuminate. In such in-
stances, the shut-off cock on the gas cylinder
must be closed immediately.
The diagnostics program shows the error "359 -
engine run-on too long".
Signal light in the display unit 
 Rectify the error.

 Switch the ignition off and on.
 Delete the error memory in the diagnostic pro-
gram.
After the engine has run on for 65 seconds, the
ignition control unit switches off the power to the
10:30
ignition coils. In this case, the engine is shut 01.01.2018
down even if there is a leakage at the gas shut-
12345,6 h
off valve.
EFF
393-02_01-047

Linde Engine Protection System (LEPS)

The Linde Engine Protection System (LEPS) is
designed to protect the internal combustion en-
gine from damage, for example due to operating
fluids shortage (e.g. engine oil).
LEPS is installed in series and must be activated
in the diagnostic program (factory setting: activa-
ted).
The display unit monitors specific truck data. If
the relevant values are exceeded or undercut,
the driving speed is reduced to creep speed.
Each LEPS function can be activated and deac-
tivated individually in the diagnostic program
(factory setting: activated).
Function Designation Default setting Associated error code

Engine oil level. 0B16 Activated D201
Engine oil pressure 0B7 Activated D202
Coolant level 0B19 Activated D203
Coolant temperature 0B1 Activated D204
Hydraulic oil temperature 1B4 Activated D205
Water in the fuel filter 0S3 Activated D206
Air filter vacuum S3 Activated D207
The cause of the driving speed reduction is indi-

cated to the operating company via an error
code on the display unit. This is indicated only if
the LEPS function is activated. If CAN communi-
cation is interrupted or if the sensors have failed,
the driving speed reduction is not activated. If an
LEPS function is deactivated via the diagnostic
program, the escalation level 3 "creeping" be-
comes inactive.
Overview of escalation levels:


(1) Escalation level 1: warning light and function
number briefly, if necessary.
(2) Escalation level 2: warning light, warning
buzzer and entry in the operating data memory.
(3) Escalation level 3: warning light, creeping
and entry in the operating data memory.

Escalation levels of the indicator lights in
the IC truck
Engine oil level below the minimum: 
(1) Minimum: warning light and function buzzer

briefly ON.
(2) Minimum -2 mm: warning light, warning buz-
zer and error 1.
(3) Minimum -3 mm: warning light, creeping and
error 2.
Engine coolant temperature: 
(1) T1 = 113°C: warning light, function buzzer

briefly ON and X1 initialised.
(2) T2 = T1 + 5°C warning light, warning buzzer
and error 1.
(3) T2 + 3°C warning light, creeping and error 2.
Hydraulic oil temperature: 
(1) T1 = 115°C warning light, function buzzer

briefly ON and X2 initialised.
(2) T2 = T1 + 7°C warning light, warning buzzer
and error 1.
(3) T2 + 3°C warning light, creeping and error 2.
Escalation levels of the indicator lights in

the IC truck (if signal transmitter is a switch)
Engine oil pressure: 
(1) Warning light without delay and function

number briefly ON.
(2) Warning light, warning buzzer and error 1;
t > 1 s + starting procedure completed ("engine
start bit") "without lock".
(3) Warning light, creeping and error 2; t > 8 s +
revolution speed > idling.
Water trap in the diesel filter: 
(1) Warning light with large hysteresis, "delay

time" min. 10 s; function buzzer briefly ON.
delay 60 min.
(3) Warning light, creeping and error 2 after 2
operating hours.
Air filter vacuum: 
(1) Warning light t > 500 ms + mechanical hyste-

resis; function buzzer briefly ON.
(2) Warning light, warning buzzer and error 1 af-
ter 8 operating hours.

operating hours.
Coolant level: 
(1) Warning light with large hysteresis, "delay

time" min. 10 s; function buzzer briefly ON.
delay min. 10 min.
operating hours.
Activation threshold in the oil level sensor 
The system is designed such that when the

truck is on a horizontal surface the activation
threshold lies at the lower end of the dotted area
on the oil dipstick. The oil level sensor has a
possible measurement error of ± 3 mm.
1 Engine
2 Oil pan

If the truck is tilted to the rear, the oil level on the
dipstick is lower at the same activation threshold
(on the sensor). Reasons could be the ground or
severely damaged tyres in the rear.
If the activation threshold in the oil level sensor
is selected as the reference point, the following
applies:
If the truck is tilted 1 degree to the rear, the oil
level on the dipstick is reduced by 1.3 mm.
1 Engine
2 Oil pan


If the truck is tilted forwards, the oil level on the
dipstick is higher at the same activation thresh-
old (on the sensor). Reasons could be the
ground or severely damaged tyres in the front.
If the activation threshold in the oil level sensor
is selected as the reference point, the following
applies:
If the truck is tilted 1 degree to the front, the oil
level on the dipstick rises by 1.3 mm.
1 Engine
2 Oil pan

Running gear and drive train 20
Drive components
Technical data for drive unit
Travel drive - introduction

Driving speed controller portion to the pedal travel and the drive motor
speed is increased. The driving speed reaches
The driving speed of a hydrostatic-powered the setpoint value specified by the accelerator
truck results from the speed of the internal com- pedal.
bustion engine and the hydraulic transmission
ratio (variable displacement pump delivery vol- If the accelerator pedal is depressed further and
ume to the intake volume of the hydraulic mo- a higher driving speed is thus specified, this re-
tors). The delivery volume of the variable dis- sults in an increase in the engine speed propor-
placement pump in turn results from the pump tional to the pedal travel and in an increase in
speed, the pump swivel angle and the specific the pump swivel angle. If the maximum engine
pump delivery volume. speed is reached, the maximum driving speed
and the maximum pump swivel angle are
To maintain a speed specified by the actuation reached. The power control prevents the maxi-
of the accelerator pedal, the electronic control mum available engine power rating from being
unit regulates the speed of the internal combus- exceeded.
tion engine and the swivel angle of the pump.
At a speed specified by the accelerator pedal Power control — drive unit
(setpoint value), any change in the engine speed
is compensated by changing the swivel angle of The swivel angle of the variable displacement
the pump. This is only possible as far as the pump and the speed of the internal combustion
power limit of the internal combustion engine, engine are regulated by the electronic control
beyond which point the speed decreases. Vari- unit in accordance with the pedal travel.
ous regulation situations with different pedal po- An impulse transmitter reports the engine speed
sitions are explained below. to the control unit. A comparison of the setpoint
value with the actual value is performed in the
Starting on a slope control unit; in the event of a deviation, this re-
sults in the variable displacement pump swivel-
The brake pedal actuates the parking brake me- ling out or back.
chanically/hydraulically by means of a valve.
The brake pedal also actuates 2 microswitches If the engine power rating is exceeded (engine
(1 and 2). pressure too high), the electronic control unit ini-
tiates a reduction in the pump swivel angle and
If the brake pedal is semi-released, micro- therefore a reduced power request until the en-
switch 1 switches while the brake is still closed. gine speed (actual value) corresponds to the
If the accelerator pedal is depressed at the setpoint value specified by the accelerator pedal
same time, the electronic control unit only appro- again. As a result of the setpoint/actual value
ves a small swivel angle of the pump and the comparison of the speed of the internal combus-
truck drives against the activated brake. tion engine, the power consumption of the work-
If the brake pedal is fully released, microswitch 1 ing hydraulics is also included in the regulation.
switches (microswitch 2 remains in its original
position), the limitation of the pump angle is can- Speed control — working hydraulics
celled, the brake is released and the truck starts
without rolling backwards. The central control lever for the working hydraul-
ics (joystick) transmits a signal to the electronic
controller for the tilting or auxiliary hydraulics
Driving functions via a potentiometer, and the controller
When the accelerator pedal is depressed, the increases the speed of the internal combustion
variable displacement pump swivels out in pro- engine.

Drive components
A signal is transmitted with the lifting function to crease. Because the actual speed is now great-
the electronic controller, which increases the er than the setpoint value from the accelerator
speed of the internal combustion engine to the pedal, the electronics immediately reduces the
maximum value. pump swivel angle to prevent the driving speed
from increasing.
Working hydraulics speed control: MPR This reduction is performed so quickly that the
driver does not register a change in the driving
The central lever for the working hydraulics speed.
transmits a signal to the electronic controller
LHC 20 for all functions via the potentiometer.
Braking
The LHC 20 transmits a signal to the proportion-
al solenoid valve 1Y15 and swivels the working The minimum and maximum swivel time of the
pump MPR to a greater delivery volume. The variable displacement pump from Qmin to QMax
number of revolutions is increased to approx. or from QMax to Qmin is specified by the elec-
1600 rpm. This is dependent on the load, how- tronic control unit. The control unit regulates the
ever. The load of the motor is assessed by the swivel speed of the variable displacement pump
rev sensor on the sprocket. A large load means within these threshold values, depending on the
an increase in the engine speed and reduction in engine speed. As a result, a brake retardation is
the pump swivel angle. obtained that is (almost) unaffected by the load
status of the truck.
Regulating the driving speed
Changing the drive direction
The swivel angle of the variable displacement
pump and the speed of the internal combustion When reversing, the signals for the new drive di-
engine are regulated by the electronic controller rection and the engine speed are only released
by means of a setpoint/actual value comparison once the electronic control unit has detected that
with the accelerator pedal. If a higher internal the variable displacement pump is in the zero
combustion engine speed is requested by position. This ensures that the engine speed
means of a signal from the working hydraulics to drops to a lower idling speed and only increases
the controller, the controller responds to the again when the new drive direction has been se-
higher value and allows the engine speed to in- lected.
Working hydraulics pump MPR50

Description 
The working hydraulics pump comprises an ad-

justable medium-pressure piston pump (MPR)
and an internal-gear pump with a volume of
16 cm3, which is used as the feed pump.
MPR50
M: ► Series medium pressure

P: ► Linde piston pump
R: ► Regulation, adjustable
50: ► Delivery volume: 50 cm³/rev

Drive components
Sectional view
1 Sliding shoe 5 Port plate

2 Piston (7 x) 6 Actuator piston
3 Feed pump 16 cm3/rev 7 Cradle
4 Cylinder block

Drive components
Pump displacement
1 MPR50 4 Pilot valve

2 Feed pump 16 cm3/rev 5 Pressure regulating valve and solenoid valve
3 Actuator piston for cradle 1Y15

Drive components
Schematic view of the traction hydraulics and working hydraulics
1 Internal combustion engine 8 Priority valve

2 Engine control unit 9 Working hydraulics control valve
3 LHC20 Tricor controller 10 Load lift system (lift mast, sideshift, attach-
4a Joysticks ments etc. )
4b Pedal group 11 Steering
5 Traction pump (HPV 125 V+) 12 Control cable
6 MPR 50 13 Hydraulic line
7 Feed pump 16 cm3/rev
Introduction
In most hydraulic systems on mobile machines,
fixed displacement pumps are used for working
functions such as lifting, steering, pilot-control
hydraulic oil and other functions. This section
describes an extremely efficient and dynamic
design for the working hydraulics circuit. The de-
sign includes two hydraulic components, an
electrically switched medium pressure pump and
an electro-hydraulic directional control valve de-
livering high response dynamics, a high level of
precision, minimal space requirements, a low
noise level and high numbers of revolutions.
Open working hydraulics circuits in forklift trucks
frequently use a combination of fixed displace-
ment hydraulic pumps and an "LS load-sensitive
valve (load-detection valve)". There are two con-
siderable disadvantages to this design. The first
disadvantage is the linear relationship between
the volume flow rate and the speed of the inter-
nal combustion engine, and the resulting energy

Drive components
losses due to large volume flow rates, especially
in the partial-load range. The second disadvant-
age is the limitation of the pump displacement
(size) by the torque of the internal combustion
engine. To move the consumer, e.g. a lift cylin-
der, quickly, the relatively small hydraulic pump
must force the entire drive train to move at high
speeds, which results in energy loss and a high
noise level. A more modern and efficient ap-
proach is depicted here. This approach presents
a simplified hydraulic and electric circuit diagram
for the drive hydraulics and working hydraulics
of a forklift truck. The main goal is to save ener-
gy by adopting modern working hydraulics sys-
tems.
The system is made up of the internal combus-
tion engine (1), the closed hydraulic drive
(5, 6, 7), the open working hydraulics and the
electronic control unit (3). The working hydraul-
ics pump (6) is a variable displacement pump
that can adapt the volume flow rate independ-
ently of the speed. The drive command transmit-
ted by means of the joystick (4a) corresponds to
an operating speed at the consumer, and thus to
the volume of oil delivered from the working hy-
draulics pump (6) and the directional control
valve (9). The control unit receives the meas-
ured engine speed and continuously calculates
the required pump stroke and opening ranges at
the valve. When multiple consumers are being
moved simultaneously, the control unit merges
the required volume flow rates, increases the
pump signal in line with this and, where neces-
sary, adapts the speed. One possible control
unit is the Linde LHC20, an electronic controller
for the entire hydrostatic drive system featuring
optional switches and a proportional output for
auxiliary functions such as working hydraulics
components.
The working hydraulics pump

The MPR50 is an open axial piston variable dis-
placement pump.
Variable displacement pump

Manufacturer Linde
Model MPR50
Number of pistons 7
Maximum nominal pressure pmax 320 bar
Maximum lift swivel angle 13° Vg max 50 cm³/rev
Minimal stroke swash angle 2.2° Vg min 8.5 cm³/rev
Maximum speed n 1000-3100
Pilot pressure pF 21 bar
Electrical proportional flow regulation E2
Start of regulation 5.7 bar 580 ±35 mA

Drive components
Variable displacement pump
End of regulation 15.46 bar 1135 ±35 mA
Regulation measurement point 9.45 bar 810 mA at 25 cm³/rev
Internal gear pump feed pump 16 cm³/rev, pmax = 100 bar
Start of regulation and end of regulation
1 Mechanical Vmin stop

Start of regulation 580 ±35 mA
2 Setting point 810 ±1 mA at 25 ±0.5 cm³/rev
3 Mechanical Vmax stop
End of regulation 1135 ±35 mA
Setting the start of regulation

The setting point for the start of regulation of the
MPR has no bearing on the actual delivery rate
(swivel angle). The characteristic curve depicts
the relationship between the current to the ad-
justment magnet at plug 1Y15 and the actual de-
livery rate of the MPR. It is not possible to meas-
ure the delivery rate in the truck. For this reason,
the setting point (9.25 bar at 810 mA) is set on
the test bench and secured with sealing varnish.
If the setting for the start of regulation is never-
theless disturbed, the initial state can be re-
stored by approximation.
Basic setting of the adjustment screw:

Drive components
Fully screw in the adjusting screw. Then un-
screw it by three turns.
Fine adjustment
Error Course of action Potential result

The MPR delivers insufficient
medium (measurement of the Unscrew the adjustment by The engine may possibly now be
stroke speed without a load: 0.57 0.25-0.5 turns overloaded.
m/sec)
Screw in the adjustment screw The MPR now delivers insuffi-
Engine overloaded or cuts out
by 0.25-0.5 turns cient medium
The optimum operating point is between the

minimum level of engine overloading and the
maximum stroke speed.
Internal combustion engine performance

test
Lift joystick to mast stop
● Check 1Y15 > 810 mA ≙ 9.65 bar of control
pressure
● Setpoint value n > 2150 rpm
● In this case, the pump adjusts itself to
25 cm³/rev
The theoretical static characteristic curve of the
pump controller is shown here. The stroke is al-
ways directly proportional to the current at the
magnet. The behaviour of the pump controller is
not dependent on external parameters, thanks to
the constant oil supply at 20 bar via the integra-
ted feed pump. These controller characteristics
offer advantages in the system. The controller
enables extremely dynamic and precise regula-
tion of the volume flow rate on the basis of the
current requirement, thus reducing system los-
ses. The LHC controller transmits the signals to
the pump controller (A) and to the directional
control valve (B) simultaneously, which provides
the driver with a particularly fast response.
Regulated LS high-pressure pumps frequently
respond with a delay if the directional control
valve is opened suddenly. This is because the
LS controller increases the stroke only when
there is already a deficit of supply. In the event
of low system pressure, the pump controller re-
sponds correspondingly slowly.
The fail-safe position, i.e. in the event of loss of
the electrical signal, is at Vg min and therefore at
a lower level of performance. For safety rea-
sons, the minimum stroke is set at a swash an-
gle of 2.2° in the event of a fault. This provides
an adequate oil volume for the steering via the
priority valve and general operating functions at
low speed; see Fig. 1. This important safety and
availability function Vg, min > 0 cannot be

Drive components
achieved by a combination of a load-detection
pump and a closed-centre LS valve. A further
advantage compared to conventional open
pumps is the switch-off position at minimum
stroke, which relieves the load on the starter mo-
tor of the internal combustion engine, particularly
where outside temperatures are low.
Schematic view of the displacement
The schematic view shows how this behaviour is

achieved. The pump controller is primarily made
up of the control piston with two seals (I), the in-
ternal slider (II), a parallel pin (III), a spring with
spring cap (IV), a sealed connection line (V), the
adjustable electrical pressure reduction valve
(VI) and the cover (VII). The pressure reduction
valve and the space between the two control
piston seals (A) are charged with a boost pres-
sure of pF = 20 bar. The current at the
magnet /mag acts as the input signal; in doing
so it is assumed that the position of the control
piston or the angle at the pan is proportional to
it. The internal slider (II) is charged with the con-
trol pressure pctr at one end (space B) via the
connecting pipe (V) and is supported at the oth-
er end by the spring (IV) via the parallel pin (III).
If the electrical current at the solenoid /mag
changes, the control pressure pCTR at the slider
surface changes proportionately and moves the
slider against the spring force or with it to the
new position 1 or 2. The relative movement

Drive components
between the slider and the control piston con-
nects piston chamber C either to the feed pres-
sure chamber A or to the housing D, with the re-
sult that the control piston follows the movement
of the slider into its position. In the setpoint value
position, the slider closes the piston chamber
and stabilises the system.
● Highly dynamic, as the slider lift is not restric-
ted by the magnet lift as in other designs.
● Highly accurate, as the current position of the
pan is reproduced directly and not via a
spring force as in other designs.
● Small number of components, as many com-
ponents have dual functions, e.g. the slider
acts as a valve and specifies the setpoint val-
ue position. The control piston generates the
movement force for the cradle and simultane-
ously acts as an element for position feed-
back. The spring is used to define the setpoint
value position and reposition the cradle
● The pump controller operates using feed
pressure and as a result is not dependent on
external operating parameters.
The figure illustrates the high level of accuracy
of the new pump controller based on the signal
behaviour at the critical operating point with a
low speed, low pressure and close to αmax. The
cradle position is increasingly critical as it ap-
proaches αmax because the spring force (IV) is
high and exerts a lateral force. This can lead to
friction and can have a negative impact on the
hysteresis and weak signal behaviour. This is
not the case here, however. The figure shows
the response of the swash plate angle to minor
changes in the current. Every step in the figure
corresponds to a change in the working volume
of 0.14 cm³/rev/step.

Drive components
Hydraulic adjustment with electronic activation
1 Rev sensor 1B1 17 2/2 directional control valve

2 Hydraulic variable displacement pump 18 Integrated brake valves
HPV 125 V+ 19 Output valve p = 15 bar, output quantity
3 Proportional solenoid Q = 19 l/min
4 Release valve 20 3/3 directional control valve (priority valve)
5 Proportional valve 21 Pressure filter for working hydraulics / micro-
6 2/2 directional control valve filter
7 Actuator piston (cradle) 22 Pressure regulating valve and solenoid valve
8 Non-return valve, 1 bar 23 Pilot valve
9 4/2 directional control valve 24 Actuator piston for cradle
10 Pilot valve 25 Adjustable medium pressure piston pump
11 Pressure filter (boost pressure) / microfilter MPR
12 Servo piston 26 16 cm3 gear pump (feed pump)
13 Feed pressure valve, 21+0.5 bar G Hydraulic variable pump
14 Choke plunger (towing unit) H Working hydraulics pumps
15 Combined feed maximum valve, 420+20 bar N Pressure filter (boost pressure) / microfilter
16 Shuttle valve

Drive components
Function characteristics - displacement
When the engine is running and the brake pedal
is actuated, the magnet of the release valve (4)
is de-energised. The boost pressure is present
between connection F and the release valve (4).
The pilot valve (23), the 4/2 directional control
valve (9) and the actuator circuit nozzles con-
nect both sides of the actuator piston (7) to con-
nection F and keep the hydraulic variable dis-
placement pump (G) in the hydraulic zero posi-
tion.
Following a switching signal from the electronic
control, the release valve (4) opens. Both of the
2/2 directional control valves (6) are switched to
the feed-through position so that the supply
pressure is applied to the unactuated proportion-
al valves (5) by pressure channel F. At the same
time, the 4/2 directional control valve (9) is push-
ed from the throttled position to the unthrottled
position.
When an accelerator pedal is actuated, the pro-
portional solenoid (3) assigned to that pedal is
activated with a signal based on the pedal travel.
The downstream proportional valve (5) causes a
correspondingly regulated pressure to build up
at the servo piston (12). The servo piston (12)
moves and forces the oil flowing from the oppo-
site side through the respective proportional
valve (5) and into the oil tank. The movement of
the servo piston (12) causes the pilot valve (23)
to be displaced, so that the actuator piston (7) is
supplied with control pressure and the pump
swivels outwards.
When the accelerator pedal is completely re-
leased so that it moves towards the zero posi-
tion, the signal at the proportional solenoid (3)
reduces, the proportional valve (5) lowers the
pressure at the servo piston (12), the pump
swivel angle decreases and the truck brakes.
If the electronic control detects an error in the
speed regulation, the truck is brought to a stand-
still irrespective of the accelerator pedal position.
This is done by de-energising the release valve
(4), causing the pressure to fall to 0 bar. The 2/2
directional control valves (6) switch to the
blocked position and remove the supply pres-
sure to the proportional valves (5). The propor-
tional valve (5) actuated by the proportional sol-
enoids (3) is then mechanically pushed back into
the initial position. The pressure at the servo pis-
ton (12) drops. The piston is mechanically push-
ed to the zero position, taking the pilot valve (23)
to the zero position as well. As a result of the ex-
haust valve (4) closing and the associated pres-
sure drop to 0 bar, the 4/2 directional control

Drive components
valve (9) is also switched from the unthrottled
position to the throttled position.
The retraction time of the actuator piston (7) is
extended by the actuator circuit nozzles and
throttling via the 4/2 directional control valve (9).
This prevents abrupt braking and initiates a con-
trolled brake retardation.
Emergency stop with the brake pedal

If the truck can no longer be braked using the
accelerator pedals as a result of a malfunction,
the brake pedal can be used to achieve an
emergency stop.
When the brake pedal is applied, the two micro-
switches in the pedal box are switched. The re-
lease valve (4) is de-energised and the truck
brakes in the same way as when a fault occurs
in the control system. The air pressure at the
multi-disc brakes is simultaneously reduced and
the truck is also mechanically braked.
Dirt in the actuator circuit nozzles

Dirt in the actuator circuit nozzles changes the
braking distance (causes an increase, for exam-
ple).
When the braking distance changes, the actua-
tor circuit nozzles must be cleaned. To do this,
loosen the screw plugs, remove the actuator cir-
cuit nozzles and clean them.
NOTE
The screw plugs are installed using Loctite.

When replacing a screw plug, it must first be
heated before being unscrewed. The thread
area must then be thoroughly cleaned and the
screw plug inserted with Loctite© 270TM.

Drive components
HPV 125 V+
1 Short-circuit valve (towing procedure) 3 Integrated brake valves

2 Pressure relief valve, reverse

Drive components
1 Flushing valve 3 Feed pressure valve (setting: 21+0.5 bar)

2 Switch valve 4 Pressure relief valve, forwards

Drive components
Start of regulation of variable displacement pump
Start of regulation and reverse swivel angle adjustment 7 Pilot housing

1 Adjustment pin (swivel angle) 8 Slotted nut
2 Adjusting ring (start of regulation) F Servo pressure upstream of exhaust valve (meas-
3 Slotted nut (start of regulation) urement port)
Y Forwards control pressure
Adjusting the start of regulation and forwards swivel angle 1Y2 Forwards control solenoid
4 Slotted nut (start of regulation) 1Y3 Reverse control solenoid
5 Adjusting ring (start of regulation) 1Y4 Exhaust valve
6 Adjustment pin (swivel angle) Z Reverse control pressure
Adjusting the hydraulic zero position
Checking the start of regulation of the varia-

ble displacement pump
Requirement: Truck is jacked up and one wheel
is blocked
 Start the engine and release the brake pedal.
 Connect laptop and select "Inputs + Outputs/
Traction/Currents".
 Actuate the forwards or reverse pedal until
iY2 or iY3 = 440-460 mA.
 Hold the accelerator pedal in this position.
When iY2 = 440-460 mA, loosen the slotted
nut (4) and rotate the adjusting ring (5) until
the wheel just begins to rotate.
 Then block the slotted nut (4) again.

Drive components
 When iY3 = 440 - 460 mA, carry out the same
adjustment at the adjusting ring (2).
 Release the blocked wheel.
 Push the accelerator pedal all the way down;
"Currents" tab must show 1220 mA (deter-
mined by controller).
 Measure the maximum wheel speed.
The maximum speed is averaged from the
speed of both drive wheels.
Setpoint value n = 155±7 rpm.
Start of regulation - Diagram 
NOTE
If the electrical values are correct, but the maxi-

mum wheel speed is not reached, the position-
ing travel of the servo piston (pump swivel an-
gle) must be checked and adjusted.
Q Volume flow rate

Adjusting the swivel angle s Accelerator pedal travel
I The exhaust valve switches
 Jack up the truck and block one wheel. II Start of rotation of drive wheels
II Maximum speed of drive wheels
 Release the lock nut of the adjustment pin (1)
on the Y side of the adjustment and screw in
the adjustment pin (1) until the free wheel just
begins to rotate.
 Unscrew the adjustment pin (1) by 12 turns
and retighten the lock nut.
 Repeat the same procedure on the Z side.
Adjusting the hydraulic zero position

 Jack up the truck and block one wheel.
 Start the engine and release the brake.
 Determine the position of the pilot housing
(7). Do this by releasing the slotted nut (8)
and turning the pilot housing (7) to one side
until the free wheel begins to rotate.
 Repeat the process in the opposite direction.
 Measure the distance between the two posi-
tions, half it and turn the pilot housing (7) to
the centre by the precise resulting value.
 Block the pilot housing (7) with the slotted nut
(8).
 Release the blocked wheel.
If a drive wheel still rotates, repeat the adjust-
ment.

Drive components
Adjustment - Cross-sectional diagram
1 Lock nut 9 Return spring (p >12 bar)

2 Swivel angle adjustment screw 10 4/2 directional control valve (proportional
3 Start of regulation adjusting sleeve valve)
4 Lock nut 11 Exhaust valve
5 Control springs 12 Nozzles
6 Servo piston 13 Directional control valve
7 Control pilot x Maximum servo piston travel 15.1 mm
8 2/2 directional control valve

Drive components
Auxiliary brake valve
1 Pressure relief valve p = 10 bar 8 Brake valve including backward pilot control,
2 Panel p = 90 ±7 bar for H 40, p = 190 ±10 bar for
3 Switch valve H 45/50
4 HPV 125 V+ 8a Brake valve including forward pilot control,
5 Feed pump V2, q2 = 16 cm3/rev p = 90 ±7 bar for H 40, p = 190 ±10 bar for
6 Feed pressure valve p = 21+0.5 bar H 45/50
7 Pressure relief valve, backwards, 10 Choke plunger
p = 420+20 bar 11 HMF 135-02
7a Pressure relief valve, forwards,
p = 420+20 bar

Drive components
Brake valves - functional description
7 Pressure relief valve, forwards, 8a Brake valve including forward pilot control,
p = 420+20 bar p = 90 ±7 bar for H 40, p = 190 ±10 bar for
7a Pressure relief valve, backwards, H 45/50
p = 420+20 bar 10 Choke plunger
8 Brake valve including backwards pilot con-
trol, p = 90 ±7 bar for H 40, p = 190 ±10 bar
for H 45/50
To achieve maximum braking action in both

drive directions without over-revving the internal
combustion engine (i.e. increasing the engine
speed), the closed circuit for each drive direction
incorporates a brake valve with integrated servo
valve that is activated if the support pressure
pHD1 is greater than 90 ±7 bar (H40) or
190 ±10 bar (H45/50).
In addition, the combined feed/pressure relief
valves have been modified to ensure a pressure
limit of 420+20 bar.

Drive components
Driving − forwards
When driving, the volume flow rate passes
through the brake valves, which are not activa-
ted. If the high pressure is less than 90 bar
(H 40) or less than 190 bar (H 45/50), the servo
valves are set to neutral.
The high pressure is limited to a maximum of
420+20 bar by the pressure relief valve. This
functionality is identical whether driving forwards
or backwards.
Braking (retardation) − forwards

Due to the momentum of the truck and the re-
sulting reversal of forces on braking (traction
forces exchanged for overrun forces), the oil mo-
tors now drive the variable displacement pump.
The pressures are inverted: LP becomes HP
and HP becomes LP. As the pump is connected
to the internal combustion engine, the speed of
the engine is driven up. To counteract uncontrol-
led over-revving of the engine and any resulting
reduction in brake retardation or increased noise
level, a brake valve is actuated at pHD1 more
than 90 ±7 bar (H40) or more than 190 ±10 bar
(H45/50).
This ensures that the support pressure pHD1 at
the HPV 125 V+ variable displacement pump
cannot exceed 90 ±7 bar (H40) or 190 ±10 bar
(H45/50) and the internal combustion engine's
revolution speed is therefore limited.
Switching function
If, during braking, the high pressure pHD1 ex-
ceeds 90 ±7 bar (H40) or 190 ±10 bar (H45/50),
the pilot control is tripped and the brake valve
limits the support pressure in the closed circuit
to the HPV 125 V+ variable displacement pump
to a maximum of 90 ±7 bar (H40) or 190 ±10 bar
(H45/50). The high pressure pHD2 at the wheel
motors can rise to a maximum of 420 bar.
This functionality is identical whether driving for-
wards or backwards.

Drive components
Start of rotation of drive wheels
The adjusting screw sets the start of rotation of
the wheels so that this occurs directly as the en-
gine increases in speed, or shortly afterwards.
Under no circumstances should the wheels start
to turn before the engine speed increases.
Setting requirements
● Pedal adjustment correct
● Truck jacked up so that both drive wheels can
freely rotate
● Engine and traction drive at operating temper-
ature
Testing
 Actuate the forwards accelerator pedal care-
fully, until the engine speed increases and the
wheels start to turn.
If the wheels start to turn immediately after or at
the same time as the engine increases in speed,
the setting is correct. If the wheels turn before
the engine jumps in speed, correct the setting as
follows:
Adjust the swivel angle

 Release the hexagon head screw (1) 
 Remove the locking plate (2)

 Turn the adjusting screw (3) until the start of
rotation of the wheels is set such that this oc-
curs directly as the engine increases in
speed, or shortly afterwards.
NOTE
● Setting for forwards: opposite connection (Y)
● Setting for backwards: opposite connection
(Z)
 Fit locking plate (2) with hexagon head screw
(1)
Output unit
It is necessary to replace the oil in the closed cir-
cuit in order to ensure a certain level of cooling.
A switch valve ensures that a specific volume
flow rate is always diverted from the low-pres-
sure side.

Drive components
Switch valve − function
If both high-pressure lines are depressurised or

supplied with feed pressure (when the pump is
at zero setting), both switching pistons (A1) and
(B1) are in the spring-centred middle position.
Hydraulic oil cannot flow to the output valve ei-
ther from the high-pressure connection (A) or
from (B).
If, for instance, high pressure nonetheless builds
up on the A side, this pushes piston (A1), to-
gether with piston (B1), towards connection (B).
The taper seat on piston (A1) acts as a stop,
while at the same time preventing an overflow of
high pressure from being transferred from spring
chamber (A1) to the output valve. Oil can never-
theless flow from connection (B) to the output
valve.
Output valve − function

A volume flow rate flows from the low-pressure
side of the closed circuit to the oil tank via the
output valve (1) p = 15 bar.
The small diameter of the bore (D) creates a ∆p,
which maintains the feed pressure at p = 21 bar.
Removing and installing a switch valve

Drive components
Special tool required 
● Wrench for switch valve 294 880 00 72

Sectional drawing of the output unit
1 Output valve p = 15 bar, Md = 30+5 Nm

2 Removing
Hydraulic fan drive
1 Gear pump q2 = 16 cm3/rev 2 Bypass valve

Drive components
3 Proportional solenoid Y5 S Suction line
4 Hydraulic motor q = 12 cm3/rev P1 Pressure connection
5 Fan impeller F Feed pressure connection
6 Radiator T6 Return connection to tank
7 Feed pressure valve p = 21+0.5 bar
Fan drive - function

The hydraulic fan drive comprises a hydraulic
motor (4) with an intake volume of q = 12 cm3
that is supplied by the feed pump V3 (1). Attach-
ed to the hydraulic motor (4) is a fan impeller (5)
that draws the cooling air from the engine com-
partment and discharges it to the outside. The
fan speed depends on the speed of the engine
and the temperatures of the coolant and hy-
draulic oil.
Temperature sensors detect the temperatures of
the coolant and hydraulic oil and transmit them
to the LTC control unit. This activates the pro-
portional valve Y5 (3), which regulates a bypass
valve (2) fitted to the fan motor (4). The number
of revolutions of the fan motor (4) is regulated by
the volume flow rate. If the coolant temperature
is < approx. 95°C and the hydraulic oil tempera-
ture is lower than approx. 68°C, the bypass
valve (2) opens and the fan motor (4) stops run-
ning. Only when the temperature exceeds these
limits does the fan start at approx. 1000 rpm. Af-
ter this the number of revolutions increases in
proportion to the temperature.
This cooling design achieves the optimum oper-
ating temperature more quickly, reduces fan
noise and is more effective at recovering from
temperature peaks.
WARNING
During maintenance work with the bonnet open, the
temperature control can cause the stationary fan mo-
tor to suddenly start up at a relatively high speed.
Do not reach into the fan.
Keep your distance.

Drive components
Fan control 
1 Temperature [°C]
2 Fan current [mA]
3 Coolant
4 Hydraulic oil
Removing and installing the HPV

variable displacement pump cou-
pling flange
● Claw extractor with three long claws

(e.g. by Nexus, type 113-20 with three hooks
3-200)
● Spacer
● Gas-oxygen burner
● Protective gloves

Drive components
Removing the coupling flange
 Position the claw extractor with spacer. 
NOTE
It is not possible to remove it without using an

impact wrench because the claws will slip.
 Position the impact wrench on the claw ex- 

tractor.
Remove the coupling flange using the impact
wrench. Hold the claw extractor securely while
doing so.
 If it cannot be removed, heat the coupling
flange first to approx. 380 °C.
CAUTION
Damage to the rotary shaft seal caused by heat.
Remove the hot coupling flange immediately. Use wa-
ter to cool the shaft down.
Installing the coupling flange

 Heat the coupling flange with a gas-oxygen 
burner to approx. 380 °C.

Drive components
 Use protective gloves to fit the coupling flange 
and push it in to the stop.
CAUTION
Damage to the rotary shaft seal caused by heat.
Cool the coupling flange immediately after fitting.
 Use water to cool the coupling flange down. 

Drive components
Hydraulic truck diagnostics
Overview and explanations of diagnostics
Pressure measurement points - Overview
1 HP forwards pressure measurement point a MPR 50

2 HP backwards pressure measurement point b Fan motor
3 Y (forwards) pressure measurement point c Low-pressure filter
4 Z (backwards) pressure measurement point d Working hydraulics control valve
5 F″/F2 (boost pressure) pressure measure- e Brake release valve
ment point f Drive axle AH 40-04 / AH 50-04 up to
6 F (boost pressure) pressure measurement 07/2018
point Drive axle AH 45–05 / AH 50-05 from
7 MP (working hydraulics) pressure measure- 08/2018
ment point
8 BR (brake pressure) pressure measurement
point
Pressure data - Overview
Position of accelerator pedal Position of brake pedal Measurement point Pressure (bar)
0 position Released F 21.0+0.5
0 position Released F″/F2 0
Actuated by approx. 4 mm Released F″/F2 21.0+0.5
Forwards pedal fully applied Released Y 21.0+0.5
Backwards pedal fully applied Released Z 21.0+0.5
0 position Released BR 21.0+0.5
0 position Applied BR 0

Drive components
Troubleshooting - Explanations
Function checking and, where necessary, trou-
bleshooting are carried out separately for the in-
dividual main groups and cover the following
components and functions:
● Hydraulic brake system
● Hydraulic steering system
● Start of regulation for the adjustable high-
pressure pump (HPV)
● Hydrostatic drive unit
Before starting the work described below, check
the oil level and top up if necessary.
If, during a test procedure, it is necessary to fit a
pressure gauge or a screw plug, the hydraulic oil
tank breather valve must be unscrewed. This re-
leases any pre-load in the oil tank.
The points at which the pressure gauge or seal-
ing plugs should be fitted are shown in the circuit
diagram.
Perform all pressure measurements with the
brake pedal released, unless explicitly instructed
otherwise.
Some test procedures require the drive axle to
be disconnected. To do this, proceed as follows:
● Unscrew the union nuts of the high-pressure
hoses from the threaded plugs of the drive

axle.
● Seal the threaded connections using sealing
plugs (4 x 0009620003).
● Reconnect the hoses.

Drive components
Special tools required for the measurements
1 Screw coupling M14x1.5, spare part number 34 Screw coupling M12x1.5, spare part number
0009516400 0009516410
2 Screw coupling M10x1, spare part number 35 Sealing plug, spare part number 0009513900
0009516407 38 MultiHandy 2020 measuring device, spare
5 Screw coupling M8x1, spare part number part number 0009418736
0009516402
NOTE NOTE
Measurement tool case 0009416000 was re- The following pressure gauges can be used in-
placed in 04/2013 by measurement tool case stead of the "MultiHandy 2020" measuring de-
0009416006 and 0009416007. Measurement vice:
tool case 0009416006 was replaced in 05/2016
by measurement tool case 0009416020. ● 0-40 bar low-pressure gauge, spare part num-
ber 0009430106
● 0-600 bar high-pressure gauge, spare part
number 0009430107
HPV 125 V+ pressures - measurements

Boost pressure at the filter
Measurement port: position 6
 Unscrew the plug on the filter (c).
 Connect the screw coupling (34).

Drive components
 Connect the low-pressure gauge.
 Start the internal combustion engine.
Setpoint value p = 21 bar
Boost pressure at HPV 125 V+

Measurement port: position 5
 Unscrew the plug at servo cover F″ / F2.
 Connect the screw coupling (2).
Accelerator pedal in
0 bar
neutral
Accelerator pedal actu-
21 bar
ated
Measuring at start of regulation for HPV 125

V+
Measurement ports: positions 3 and 4
 Unscrew plugs Y (3) and Z on the servo cov-
er.
 Screw in the screw couplings (1).
 Actuate the forwards pedal or the reverse
pedal until the wheels start to turn.
Setpoint value ∆p at Y and Z when the wheels
start to turn:
Forwards and backwards: ∆p = 4 bar
Measuring high pressure for the HPV 125 V

+
Measurement ports: positions 1 and 2
 Unscrew the plugs on the HPV 125 V+.
 Screw in the screw coupling (5).
 Connect the high-pressure gauge.
 Release the brake pedal.
 Using a long screwdriver, push in the brake
piston on the valve (e) as far as it will go.
 Actuate the forwards pedal or the reverse
pedal.
Setpoint value: pHD = 420+20 bar

Drive components
Determining the average wheel speed
 Start the internal combustion engine. Setpoint value for wheel speed:
 Release the brake pedal. Forwards 155±7 rpm
 Press the forwards pedal as far as it will go. Reverse 155±7 rpm
 Measure the left-hand and right-hand wheel
Example: Calculating the average wheel speed.
speeds.
 Press the reverse pedal as far as it will go. Left-hand side 170 rpm
 Measure the left-hand and right-hand wheel Right-hand side 140 rpm
speeds. Total 310 rpm
Divided by 2
Result 155 rpm
NOTE
When measuring wheel speeds, keep the re-

spective accelerator pedal pushed down as far
as it will go.
Checking the hydrostatic drive unit

Test conditions - Troubleshooting
● Truck jacked up so that both drive wheels can
freely rotate
● Hydraulic steering system in working order
● Parking brake applied
● Display unit displays no error message (warn-
ing light not flashing)
● Drive engine starts
● Pedal position correct
● Test values and set values are OK
Connect the screw coupling (5) with a high-pres-
sure gauge from measurement port (1) to high-
pressure measurement port (2) (low-pressure
gauge remains at connection F″/F2) and then
carry out the test using the reverse pedal.
The test values refer to the other drive direction
or components.
Troubleshooting the drive unit
Step Yes No
Procedure
Type (Test) (Test)
Connect the screw cou-
pling (34) and the low-
1 pressure gauge to connec-
Action tion F on the filter (C), with
the engine idling and the
brake applied.
2 Low pressure approx.
Go to steps 9–12. Go to step 3.
Test 21 bar?

Drive components
Step Yes No
Procedure
Type (Test) (Test)
Use a blind plug to close
3 off line connector E at the
Action brake release valve (e)
and repeat the test.
Errors in the brake system. Go to step 5.
Test 21 bar?
Check or replace the feed
5
pressure valve; repeat
Action
measurement.
Go to steps 9–12. Go to step 7.
Test 21 bar?
Disconnect axle
7 AH 40/45/50 using the
Action sealing plug (35); repeat
measurement.
Repair the fault in the Repair the fault in the
AH 40/45/50 or replace the HPV 105 -02 or replace
Test 21 bar?
AH 40/45/50. the HPV 105 -02.
Connect diagnostics. Con-
9 nect the screw coupling (2)
Action and a low-pressure gauge
to connection F″/F2 (5).
10 Start the engine and open
Action the diagnostic program.
Access "Inputs + Outputs/
11
Traction/Outputs" and re-
Action
lease brake.
Actuate forwards or re-
12
verse pedal until 1Y4 is
Action
switched.
Check the function of the
When 1Y4 is switched, the
switching magnet and the
13 pressure at pressure
Go to steps 14 - 16. hydraulic part of the ex-
Test measurement port 5 in-
haust valve, or replace the
creases to approx. 21 bar.
valve.
14 pling (1) with the low-pres-
Action sure gauge to connection
Y.
Start the engine; release
the brake. Access "Inputs
+ Outputs/Traction/
Currents/Hydraulic pump
15
forward (1Y2)" and apply
Action
the forwards pedal careful-
ly, reading the current in-
crease at 1Y2 (forwards
control solenoid).
Observe the pressure in-
16 crease at connection Y
Action and the start of rotation of
the wheels.

Drive components
Step Yes No
Procedure
Type (Test) (Test)
Current to 1Y2 increases,
Check or replace propor-
pressure remains 0 bar,
tional valve 1Y2.
wheels do not turn.
The current and the pres- Check the servo control or
17
sure increase, the wheels the actuator piston of the
Test
do not turn. cradle.
The current and the pres-
sure increase, the wheels Go to step 18.
turn.
Actuate the forwards pedal
18 once more and read off the
Action current increase at 1Y2 as
the wheels begin to turn.
19 Wheels begin to turn when
Go to step 22. Go to step 20.
Test I = 440-460 mA.
20 Adjust the start of regula-
Action tion.
21 The start of regulation can Check the hydraulic servo
Go to step 22.
Test be adjusted. control.
22 Actuate the forwards pedal
Action as far as it will go.
23 Current to 1Y2 ap- Carry out electrical diag-
Go to step 24.
Test prox. 1220 mA. nostics.
Actuate the forwards pedal
24 once more as far as it will
Action go and read off the pres-
sure.
Check or replace the pro-
25 Pressure at the stop at
Go to step 26. portional valve and the ser-
Test least 16 bar.
vo control.
Determine the average
wheel speed while the for-
wards pedal is pushed
26
down as far as it will go;
Action
refer to the section entitled
"Determining the average
wheel speed".
Check the swivel angle of
27 The average wheel speed
Go to steps 28–31. the variable displacement
Test is OK.
pump.
28 pling (2) and a low-pres-
Action sure gauge to connection
F″/F2 (5).
pling (5) with a high-pres-
29
sure gauge to high-pres-
Action
sure measurement port
(1).
Block the brake (push in
30 the brake piston as far as it
Action will go using a screwdriv-
er).

Drive components
Step Yes No
Procedure
Type (Test) (Test)
Actuate the forwards ped-
31 al; determine the high
Action pressure and the low pres-
sure.
High pressure approx.
Pressure relief valve for
32 425 bar
forwards drive direction
Test Low pressure approx.
OK.
21 bar
High pressure far below Internal leakage.
425 bar Possible causes: Feed/
Low pressure approx. pressure relief valves or
21 bar short-circuit valve leaking.
Leaks in forwards high-
pressure section.
As the high pressure in-
Disconnect AH 40/45/50 to
creases, the low pressure
locate faults in the
falls to nearly 0 bar.
HPV 105 -02 or
AH 40/45/50.

Drive axle
Wheel motor HMF 135-2, replacing the tapered roller bearing
1 Gearbox GR6H-03 12 Drive shaft

2 Sun gear shaft 13 Swash plate
3 Washer 14 O-ring
4 Disc spring 15 Sliding disc
5 Brake piston 16 Piston
6 Quad rings 17 Pull-back plate
7 O-ring 18 Spacer plate
8 Brake discs, inner, 5 x 19 Holding plate
9 Brake discs, outer, 6 x 20 Transmitter (LSP)
10 Locking ring 21 Cylinder block
11 Tapered roller bearing 22 Compression spring

Drive axle
23 Washer 26 Washer
24 Locking ring 27 O-ring
25 Port plate
Tools required
Extractor strip 0009419424 
Extractor hook 0009419113 
Assembly device for fixed displacement motor 

3008802633
Adaptor for device 3008802698 

Drive axle
Rod 3008802734 
Clamping holder for spring element 3008802635 
Pressing tool 0009419850 
Handle 0009419767 

Drive axle
Removing the wheel motor HMF 135-02
 Remove the drain plug on the gearbox. Care- 
fully collect the hydraulic oil in a collection
vessel.
 Remove the drain plug on the axle housing. 

Carefully collect the hydraulic oil in a collec-
tion vessel.
 Dismantle the wheel gear. To do this, remove 

the socket head screws and remove the
wheel gear using the guide rods 3008802633.
 Remove the disc spring (1) and the sun gear 

shaft (2).

Drive axle
 Remove the brake piston. To prevent damage 
to the brake discs, use a suitable extraction
tool.
For example, use the Kukko internal extractor
no. 21–8, 56–70 mm with 22-3 counter support.
 Remove the six outer brake discs (3). 
 Remove the five inner brake discs (4).

 Replace the quad rings (5, 6) and the O-ring
(7). Coat with hydraulic oil.
 Dismantle the rev sensor (9). The rev sensor 

is installed only with the LSP variant and can
be damaged while dismantling the wheel mo-
tor. Remove the socket head screw (8) and
remove the rev sensor.
 Unscrew all of the socket head screws (10). 
NOTE
Note the positions of the different socket head

screws.

Drive axle
 Dismantle the wheel motor. To do this, as- 
semble the clamping holder 3008802635 (11),
the adaptor (12) and the extractor strip
0009419424 (13) on the swash plate.
 To prevent the swash plate from tilting while
removing, fit the guide rods 3008802633 (14)
and the assembly devices (15).
 Pull the swash plate out of the spring ele-
ment. To do this, tighten the hexagon nuts al-
ternately.
 Screw the centring device (16) into the drive 

shaft and remove the wheel motor.
The centring device (16) prevents the wheel mo-
tor from tipping.
 Replace the O-rings (17, 18). 
 Coat with lithium-saponified grease (e.g. KPF

2 K).
 Remove the port plate. 

Drive axle
 Remove the outer ring of the tapered roller 
bearing using a suitable extraction tool.
For example, use the Kukko internal extractor
no. 21–8, 56–70 mm with 18-2/22-4 counter sup-
port.
 Remove the tapered roller bearing using a 

suitable extraction tool (e.g. Kukko extractor
20-10).
 Dismantle the two holding plates with the 

spacer plates. To do this, remove the four
socket head screws.
 Remove the cylinder block with the piston. 

Drive axle
 Remove the sliding disc. 
 Remove the locking ring. 
 Knock out the drive shaft and the tapered roll- 

er bearing using a rubber mallet.
 Remove the tapered roller bearing using a 

suitable extraction tool (e.g. Kukko extractor
20-10).

Drive axle
Assembling the wheel motor
 Clean any oil and dirt off all parts. 
 Press in the tapered roller bearing as far as it

will go using a suitable tool.
 Insert the drive shaft. 
 Press in the outer ring of the tapered roller 

bearing as far as it will go using a suitable
tool.
 Insert the locking ring. 
If new tapered roller bearings have been assem-

bled, the bearing clearance must be determined.
The following table shows the increments and
spare part numbers for the locking rings.
Spare part Spare part number

Locking ring 95x2.72 0009070887
Locking ring 95x2.8 0009070888
Locking ring 95x2.85 0009070889
Locking ring 95x2.95 0009070890
Locking ring 95x3.05 0009071297
Locking ring 95x3.15 0009071289

Drive axle
Locking ring 95x3.25 0009070894
Locking ring 95x3.35 0009070895
Locking ring 95x3.45 0009071287
Locking ring 95x3.55 0009071286
Locking ring 95x3.65 0009070899
Locking ring 95x3.75 0009071231
Locking ring 95x3.85 0009071279
Locking ring 95x3.95 0009071278
Locking ring 95x4.05 0009071277
Locking ring 95x4.15 0009071275
 To perform the bearing clearance measure-

ment, a locking ring with the dimensions
95x2.7 must be used initially.
NOTE
The bearing clearance of the drive shaft is

measured once the wheel motor is place.
 Fit the sliding disc. Coat the sliding surface 
with a film of oil.

Drive axle
 Fit the cylinder block with the piston inserted. 
Checking the play of the holding plates

 Fit the two holding plates with the spacer 
plates. To do this, insert the four socket head
screws with pourable plastics (FK3-12612)
and tighten to a torque of 14 Nm torque.
NOTE
The play of the holding plates in relation to the

sliding shoes is 0.01 mm to 0.06 mm.
 Support the drive shaft using a suitable tool. 
 Press in the tapered roller bearing. To do this, 

use the pressing tool 0009419767 and press
in the tapered roller bearing as far as it will
go.

Drive axle
 Press in the outer ring of the tapered roller 
bearing using a suitable pressing tool.
 Fit the port plate. 
 Coat the port plate with hydraulic oil.
NOTE
The port plate must lie flat on the seating.
 Install the wheel motor using the centring de- 

vice 3008802632 (16), the guide rods
3008802633 and the assembly devices.
The centring device (16) prevents the cylinder
block from tipping while inserting.
Checking the bearing clearance of the drive

shaft
 Avoid tilting the swash plate when inserting it. 
For this purpose, hand-tighten the socket
head screws (10) continuously one after the
other in a round robin sequence. Then tighten
the socket head screws to a torque of
110 Nm.
The bearing clearance of the drive shaft must be
between -0.02 mm to +0.07 mm.

Drive axle
 Check the O-ring on the rev sensor for dam- 
age and add a coat of hydraulic oil.
 Install the rev sensor (9). To do this, insert the 

rev sensor and tighten the socket head screw
(8).
Determining the brake play

If new brake discs have been installed, the
brake play must be determined. Follow this se-
quence:
 Check the housing depth using a depth 

gauge.
A: Housing depth = 70.5-0.3 mm
 Place the outer brake discs, inner brake discs 

and brake piston on top of each other on a flat
surface.
 B: Measure the thickness of the brake pack-
age (e.g. 70.1 mm).
C: If the brake package is not measured in the
compressed state, as in this manual, a setting of
0.3 mm should be assumed when determining
the spacer washer.

Drive axle
 D: Measure the distance from the housing to 
the flange (e.g. 11.7 mm).
 E: Measure the distance from the flange to 

the sprocket (e.g. 17.5 mm).
Identify the adjusting washer for brake play.
● F: Difference between the flange and the pis-
ton
● G: Difference between the sprocket and the
housing
● H: Adjusting washer thickness
● I: Brake play
Example calculation:
A= 70.2 mm
B= 70.1 mm
C= 0.3 mm
D= 11.7 mm
E= 17.5 mm
Example calculation:
F=A-B-C= 70.2 - 70.1 -0.3 = –0.02 mm
G=E-D= 17.5 mm - 11.7 mm = 5.8 mm
I=G-H-F= 5.8 mm - 4.8 mm - (-0.02 mm) = 1.2 mm
Result:
Brake play ≙ 1.2 mm
 There are two adjusting washers: 
Dimension Spare part number

4.8 mm 4173112001
5.9 mm 4173112002
NOTE
The adjusting washers must be fitted with the

groove (arrow) facing the gears.

Drive axle
The brake play on the assembled, flattened mul- 
ti-disc brake pack is now set.
NOTE
Setpoint value (1) for brake play 1.1 to 2.2 mm
Assembling the wheel gear

 Position the six outer brake discs (3). 
 Position the five inner brake discs (4).
 Fit the brake piston. 
NOTE
If the brake piston is difficult to assemble, the

assembly sequence must be changed:
● First insert the brake piston into the swash

plate.
● Then guide the swash plate into the axle
housing and pull it in with the socket head
screws.
 Fit the disc spring (1) and the sun gear shaft 
(2).
NOTE
The four holes of the inner brake discs must be

positioned one above the other.

Drive axle
 Install the wheel gear. To do this, position the 
wheel gear using the guide rods 3008802633.
Then tighten the socket head screws to a tor-
que of 275 Nm.
 Fit the drain plug on the axle housing and 

tighten to 25 Nm.
 Fit the drain plug on the gearbox and tighten 

to 70 Nm.
 Before commissioning, top up the gearbox 

with hydraulic oil. Follow this assembly se-
quence:
 Clean the area around the filler plug.
 Remove the filler plug.
 Top up the wheel gear with hydraulic oil.
 Tighten the filler plug to 70 Nm.

Chassis frame components

Gearbox GR6H − changing the
shaft seal
1 Wheel shaft 7 Planet gear carrier

2 Tapered roller bearing 8 Magnetic plug
3 Shaft seal 9 Gearbox housing
4 Spacer ring 10 Sun gear
5 Tapered roller bearing
6 Slotted nut Md =2200 +100 Nm, with Loctite
type 270

Tools required
Extractor strip, 0009419424 
Threaded rod with thrust piece, 0009419429 
Tensioning screw M12 x 320, 2 x 0009419104 
Ejector rod for removing shaft seal, 0009419469 
Fastening bolt, 4 x 0009011575 
Fastening plates, 4 x 0009186614 
Slotted nut spanner, 0009417002 

Torque multiplier 200-3000 Nm, e.g. Stahlwille 
Torque wrench 60-300 Nm, commercially availa- 

ble
Pressing tool for pressing in shaft seal, 

0009418005
Sealing the wheel shaft

 Screw 4 fastening bolts into the wheel hub. 
Note hole spacing of the retaining plates.
 Use the retaining plates to secure the drive
unit to the fork arms.

 Loosen the socket head screws (M10 x 20) by 
64 Nm and unscrew them.
 Remove plug from cover. 
 Screw in an eye bolt.

 Separate the fixed displacement motor from
the gearbox.

 Take out the sun gear shaft. 
 Loosen the socket head screw and unscrew 

it.

 Remove the planet gear carrier from the gear- 
box.
 Heat up the slotted nut (1) (to release the 

Loctite).
 Apply slotted nut spanner 0009417002 (at- 

tach it with a countersunk screw)
 Fit a torque multiplier, support it on the fork
arms.
 Loosen slotted nut and remove.

 Secure threaded rod with thrust piece 
0009419429 and extractor strip 0009419424
with two tensioning screws 0009419104
 Pull the transmission housing off the wheel
shaft.
 Take off the transmission housing. Take out 

the tapered roller bearing.
 Remove the retaining ring. 

 Remove the rotary shaft seal (extractor with 
ejector rod 0009419469)
 Clean wheel shaft.
 Insert the shaft seal into the pressing-in tool. 
CAUTION
There is a risk of damage to the sealing lips.
Check that the sealing lips are correctly positioned
(see sectional drawing).
 Position the pressing-in tool.

 Pull down evenly with two wheel screws.
 Fit lock ring.
 Oil sealing lip on shaft seal.

 Slide the transmission housing onto the wheel 
shaft.
 Centre the transmission housing to the shaft
seal and push it home.
 Heat up the tapered roller bearing. 
 Guide the tapered roller bearing onto the 

wheel shaft and strike it home onto the bear-
ing shell.

 Coat slotted nut with Loctite FK2, spare part 
number 7379200108. Insert and screw in slot-
ted nut
 Tighten the slotted nut to 2200 +100 Nm. 

 Insert the planet gear carrier into the gearbox. 
 Coat hexagon socket screw with Loctite FK2 

and screw in using a tightening torque of
25 Nm

 Insert the sun gear shaft. 
 Join the wheel motor to the gearbox. 

 Screw in the socket head screw and tighten it 
to a setpoint value of 64 Nm

Steering system
Steering system - functional description
1 Steering control valve LS Load-sensing pressure connection

2 Gear pump (feed pump) P Pressure connection, steering control valve
3 Steering cylinder R Pressure connection, right steering cylinder
CF Priority valve T Tank return flow connection
L Pressure connection, left steering cylinder

Steering system
Hydraulic circuit diagram
1 MPR50 for working hydraulics and steering, 11 Suction valves

q2= 50 cm3/rev 12 Hose safety valve 220+10 bar
2 Gear pump (feed pump) for feed, servo con- 13 Steering cylinder
trol and hydraulic fan drive; q3 = 16 cm3/rev P Pressure connection, steering control valve
3 Actuator piston for cradle EF Working hydraulics pressure connection
4 Pilot valve CF Steering pressure connection
5 Pressure regulating valve and solenoid valve P1 Pressure connection for hydraulic fan motor
1Y15 and feed
6 Priority valve LS Load-sensing pressure connection
7 Retarder valve 1Y1 (only H 45/50) S Suction connection.
8 Maximum valve 120+5 bar T Tank return flow connection
9 Non-return valve L Pressure connection, left steering cylinder
10 Steering control valve R Pressure connection, right steering cylinder
Steering system function This increase in pressure causes the priority

valve (6) to make the entire volume flow rate
The oil supplied by pump V2 enters the priority from the MPR50 available to the steering. De-
valve (6), which is in the centre position. pending on the movement of the steering control
As long as the steering control valve (10) is not valve (10), the steering cylinder (13) is supplied
actuated, a volume flow rate of Q ~ 1 l/min flows with a volume flow rate via connections (R) or
through the steering control valve (10) via (CF) (L). The oil that is displaced from the steering
and (P) and exits at (T). The vast majority of the cylinder (13) during steering movement flows
volume flow rate supplied by pump V2 is availa- through the steering control valve (10) and the
ble at the working hydraulics connection (EF). connection (T) back to the oil tank.
The load-sensing pressure connection (LS) is If retraction forces create pressure peaks in the
connected to the oil tank (T) via the steering steering circuit, e.g. when driving over obstacles,
control valve. these peaks are limited by the hose safety
The steering is protected by the maximum valve valves (12).
(8).
Steering up to end stop
Steering When steering the steering cylinder (13) up to
When the steering is actuated, the oil tank con- the end stop, the pressure increases at connec-
nection of the load sensing pressure connection tion (P) of the steering control valve, on the
is blocked by the steering control valve (10). pressure side of the steering cylinder and in the
This causes the pressure in the LS line to rise. load sensing line (LS) to the value specified by
the maximum valve (8) (pmax = 120+5 bar). The

Steering system
maximum valve opens and decreases the load trol valve (10) that draws oil from one chamber
sensing pressure for the oil tank. This induces of the steering cylinder and pumps it into the
the priority valve to switch to a position in which other chamber, depending on the direction of ro-
only the volume flow rate required to maintain tation. If oil is lost from the cycle because of
the maximum pressure is sent to the steering leakages, the corresponding suction valves (11)
cylinder. The vast majority of the remainder of draw oil from the oil tank line (T).
the volume flow supplied by MPR50 is diverted
via the working hydraulics pressure connection
(EF) to the oil tank.
Emergency steering when drive engine is

switched off
During emergency steering, the steering wheel
actuates a rotor-type pump in the steering con-
Linde Curve Assistant (LCA)

The Linde Curve Assistant (LCA) automatically
reduces the speed when cornering depending
on the steering angle. This function represents a
comfort feature.
Operation 
A steering angle sensor is installed on the steer-

ing pivot pin of the steering axle (arrow). If the
steering wheel is actuated, the steering axle
swivels out and the sensor records the steering
angle. The sensor sends this value to the
LHC 20 as a signal. Based on the steering an-
gle, the speed is reduced when cornering and
the risk of the truck tipping over is minimised.
Errors
If the LHC 20 identifies a defective function, an
error is displayed in the display unit and is repor-
ted acoustically by a buzzer. The driving speed
is reduced to a non-critical value. The curve ac-
celeration and delay are also reduced. The error
is stored in the display unit.
Diagnostics
The LCA is always active and cannot be switch-
ed off in the diagnostic program. To monitor the
steering angle sensor, the internal combustion
engine must be running. The battery voltage
must not drop below a value of 7.8 V.

Steering system
The mechanical end stops must be set and cali- 
brated correctly. (The arrow indicates the drive
direction.)
1602 1603 1604

α 82° 82° 82°
β 61° 56.5° 57°
Replacing the LHC 20

If the steering angle sensor is not calibrated af-
ter replacing the LHC 20, an error is displayed in
the display unit (fault warning lamp H4). The
steering angle is displayed in the diagnostic pro-
gram.

Steering system
Functional description
The rear wheels are steered by a double-acting, counter-balanced hydraulic cylinder (1) that is con-
nected to the steering cylinder (1) via two track rods (fixed length) (2) and to both axle stubs (3). The
movement of the steering wheel activates the servostat, which regulates the oil flow to the steering
cylinder. The oil is fed in by a gear pump that is powered by the diesel engine. The axle casing is
connected to the chassis by elastic bearings (4) that enable a swinging movement by the axle on un-
even ground. The steering cylinder is connected to the axle casing with dowel pins and four screws.
The track rods (2) have sealed spherical bearings on each end and are connected to the piston rod
and the axle stubs with press-in bolts and slotted spring pins.
These tie rods have a fixed length, making axle alignment unnecessary.
Structural design 
(3) The axle stub bearings are fitted in the

axle beam casing and each have a
separate grease supply
● The outer rings for the axle stub bear-
ings are fitted with slack in the axle
beam casing, and are held tightly in
place as a result of the bearing pre-ten-
sion
● The inner rings for the axle stub bear-
ings are held tightly in place in relation
to the steering pivot pin
● The steering pivot pin is held tightly in
place in the axle stub
● Pre-load of the axle stub bearings is
produced by screwing the flange cover
onto the block
● Upper and lower wipers, each with two
radial sealing lips and upstream me-
chanical labyrinth seal
(2) Track rod
● Polyurethane track rod seals to in-
crease wear resistance
● Wheel hub bearing
● Wheel hub with optimised protection
against the entry of fibres
(1) Steering cylinder
Arrow Identification plate

Steering system
Adjusting the steering stop 
To prevent damage to the steering cylinder, both

the left-hand and right-hand steering stops must
be checked and, if necessary, adjusted after re-
pairs have been carried out to an axle stub,
track rod or steering cylinder.
 Loosen the lock nut (2) and turn back the stop
screw (1) approx. 10 turns.
 Start the engine and steer until the steering
cylinder is completely extended.
 Screw in the stop screw up to the mounting
face on the axle casing (3). 1 Stop screw
2 Lock nut
 Bring the steering cylinder to the centre posi- 3 Axle casing
tion.
 Screw in the stop screw (1) 2-3 turns and lock
it with the hexagon nut (2).
Removing and installing the steer-

ing axle
Removing
1 Steering axle 3 Joining plates

2 Rubber buffer 4 Mounting screws

Steering system
 Loosen the spherical collar bolts on both
wheels.
 Jack up the truck at the rear and support it se-
curely.
 Remove the rear wheels.
 Position an oil pan underneath.
 Unscrew the oil lines on both sides of the
steering cylinder.
 Support the steering axle (1).
 Unscrew the mounting screws (4).
 Remove the joining plates (3).
 Slowly lower the steering axle (1) using the
rubber buffer (2).
Installing
 Fit two rubber buffers (2) to the axle beam.
NOTE
If the rubber buffers are not symmetrical, use a

wider crosspiece at the top.
 Insert the steering axle (1) into the counter-
weight from below; raise slightly until the rub-
ber buffer (2) is resting on the counterweight
and support it.
NOTE
For trucks up to 02/2017: Apply Loctite FK5 to

mounting screws (4).
 Screw on the joining plates (3) and rubber
buffers (2) using the screws (4).
 Tighten the screws (4) to 195 Nm.
 Screw the oil lines onto both sides of the
steering cylinder.
 Bleed the steering by turning the steering
wheel about ten times from stop to stop.
 Mount the wheels.
 Lower the truck.
 Tighten the spherical collar bolts of the
wheels crosswise to 640 Nm.

Steering system
Replacing the steering cylinder seals
1 Piston rod 6 Guide strip

2 Sealing ring 7 Grooved ring
3 Bore 8 Shaft gasket
4 O-ring 9 Snap ring
5 Guide bush
 Remove the steering cylinder and clamp it in  Pull the piston rod out of the cylinder and re-
a vice. move the guide bush (5) from the piston rod.
 Pull out the piston rod to the stop (1) on one  Remove the O-ring (4), grooved ring (7) shaft
side. gasket (8) and guide strip (6) from the guide
bush.
 Knock in the guide bush (5) approx. 1–2 mm.
 Insert the new O-ring, grooved ring, shaft gas-
 Loosen the snap ring (9) using a 2.5-mm drift
ket and guide strip, ensuring that the individu-
punch through the bore (3) and remove using
al seal elements are correctly positioned (see
a screwdriver.
detail A).
 Push the piston rod towards the removed
 Remove the sealing ring (2) from the piston
snap ring, and with light blows (plastic mallet)
rod and replace the sealing ring with a new
on the opposite end of the piston rod drive out
one.
the guide bush (5).
 Remove second snap ring (9).
NOTE  Remove the guide bush (5) and replace the

seal elements.
The piston rod can only be removed if the pipe
connections of the hydraulic hoses have been  Lightly grease or oil the guide bush (5) and
unscrewed. cylinder pipe and insert into the cylinder, mak-
ing sure to place them in the correct positions:

Steering system
the chamfer on the outside diameter should careful not to damage the sealing lips on seal-
face outwards. ing elements.
 Insert the snap ring (9).  Insert the second greased guide bush (5),
push it all the way to the stop and secure it
 Carefully insert the piston rod (1) into the cyl-
with a snap ring (9).
inder from the opposite side, and slide it
through the guide bush (5) to the stop. Be
Assembling the steering angle

sensor/cover
Assembling the steering angle sensor 
NOTE
The steering angle sensor is always installed in

the left drive direction (see arrow).

 Insert the steering angle sensor transmitter
and the retaining ring (see arrow) into the
steering pivot pin

 Attach the steering angle sensor using four
"M4" hexagon head screws (see arrows)
 Tightening torque 2,7 Nm

Steering system

 Fit holder (1) on the steering angle sensor ca-
ble and attach to the axle beam
Assembling the cover 
NOTE
The cover is always fitted in the right drive direc-

tion (see arrow).

 Lightly coat the sealing ring on the cover with
oil

 Insert the cover into the axle beam
 Secure the cover using four "M4" hexagon
head screws and washers (see arrows)
 Tightening torque approx. 2.7 Nm

Steering system
Removing and installing the axle stub
Special tools for manual assembly
NOTE
An extraction tool is required for pressing the

track rod pins in and out.
Tool kit for steering pivot pin 
 Spare part number: 0009409101

The tool kit includes:
1 Pipe: 0009419817
2 Pressing tool: 0009419818
3 Pressing tool: 0009419819
4 Centring support device: 0009419820
5 Centring pin: 0009419821
6 Bolt: 0009419823
Pipe for supporting the axle beam 

 Dimensions: ∅ 94 mm x ∅ 80 mm x 115 mm
Stamp for pressing in the wiper (upper axle stub 

bearing)
 Dimensions: ∅ 85 mm x ∅ 75.5 mm x 15 mm

Steering system
Stamp for pressing in the wiper (lower axle stub 
bearing)
 Dimensions: ∅ 90 mm x ∅ 72.9 mm x 31 mm
Centring support device, lower guide 

 Dimensions: ∅ 101 mm x ∅ 73 mm x 30 mm
Centring pin for steering pivot pin 

 Dimensions: ∅ 33.15 mm x 57 mm with M12
thread
Bolt 

 Dimensions: ∅ 44 mm x 150 mm

Steering system
Wheel hub press-in stamp for assembling the 
shaft gasket
 Dimensions: ∅ 65 mm x ∅ 85 mm

Steering system
Process for manual removal

Preparation:
− Press out the tie rod bolts on the side of the
axle stub
− Remove the wheel hub
Removal position 1 = zero position

1 Remove the steering angle sensor and cov-
er
2 Unscrew the flange covers
Unscrew the "M12" locking screw
Remove lubricating grease from the grease
reservoirs (manually and using a cloth)

Removal position 2 = axle turned 180°
3 Press out the steering pivot pin
4 Remove the retaining ring on the wiper for
the upper axle stub bearing
Remove the axle stub
5 Remove the wiper

Steering system
Removing the steering pivot pin (press- 
ing out using a fixed press)
Steering axle is in removal position 1 (= zero po-
sition)
 Remove the steering angle sensor and cover

(1)
 Remove the wheel hubs (2)
 Remove the steering cylinder and tie rods (3)
 Screw off the flange cover on the lower axle 

stub bearing.
 Remove the outer ring on the lower axle stub 

bearing
 Remove the retaining ring on the upper wiper 
 Gently knock the axle stub towards the upper

axle stub bearing using a mandril.
NOTE
Place the mandril solely on the inner ring of the

upper axle stub bearing.
 Support the axle beam

 Press out the steering pivot pin

Steering system
Removing the axle stubs from the axle
beam
 Press out the tie rod bolts on the side of the 
axle stub
 Remove the wheel hub.
 Unscrew the steering angle sensor and cover
 Unscrew the lower flange cover
 Remove the steering pivot pin 
 Move the steering axle into removal position 2

(= axle turned 180°)
 Remove the lower axle stub bearing
 Knock the axle stub towards the lower axle
stub bearing using a mandril until the wiper
and the spacer bushing fall out of the bottom.
 Place the mandril on the inner ring of the low-
er axle stub bearing.
 Remove the axle stubs from the axle beam to 

the side (arrows).

Steering system
Assembly process

Assembly position 2 = axle turned 180°
1 Insert the upper axle stub bearing and upper
wiper
2 Insert the axle stub
3 Pre-assemble the lower wiper and spacer
bush; insert the wiper/spacer bush assembly
4 Pre-assemble the steering pivot pin

Assembly position 1 = zero position
5 Align the steering pivot pin (only if steering
angle sensor fitted)
6 Press in the steering pivot pin
7 Insert the outer ring into the lower axle stub
bearing
Screw M12 screw into the steering pivot pin
Screw on the flange cover
Screw in the lubricating nipple
8 Insert the steering angle sensor/sensor
transmitter and cover
9 Insert the wheel hub assembly
1 Lubricate the axle stub bearing with heavy-
0 duty grease e.g. Aralub 4320 (7337475140)

Steering system
Assembling the upper axle stub bearing
and wiper
Steering axle in assembly position 2 (= axle
turned 180°)
Axle stub bearing
● Wiper with two radial lips and upstream me-
chanical labyrinth seal
● Can also be held in position with a locking
ring (prevents being pressed out by pressure
exerted by lubricant)
 Support the axle beam using a pipe (see ar- 
row)
 Insert the axle stub bearing 
NOTE
Outer ring to axle beam = transition fit
 Insert the wiper and align to guide chamfer (1) 

Steering system
 Drive in the wiper 
 Insert the retaining ring 
 Position the retaining ring in the groove 

Steering system
Assembly — axle stub
 Lightly oil the inner ring of the axle stub bear- 
ing and the sealing lips of the wiper.
 Lightly oil the inner axle stubs on both contact 

surfaces

Steering system
 Insert the axle stub 
Assembly — lower axle stub bearing

wiper
 Attach the lower wiper to the spacer bush. 
 Spray the wiper sealing lips with a little oil
 Insert the spacer bush with the wiper into the 

bearing lug

Steering system
 Fit the stamp. 
 Knock in the stamp up to the block. 
Assembling (pre-assembling) the steer-

ing pivot pin (pressing in using a fixed
press)
Pre-assemble the lower axle stub bearing 
 Screw the guide bolt onto the steering pivot

pin

Steering system

 Lightly grease the fitting points (see arrows)
on the steering pivot pin

 Insert the steering pivot pin and

 the inner ring of the axle stub bearing

Steering system

 Insert the steering pivot pin
 Fix the steering pivot pin in a longitudinal po-
sition under slight pressure using a plastic
hammer

 Insert the inner ring of the axle stub bearing

Steering system

 Screw on the centring support device
NOTE
Centring (1) is required to ensure that the axle

stub and the axle stub bearing are centred and
guided in when the steering pivot pin is pressed
in.
NOTE
The inner ring of the lower axle stub bearing

must be supported (2)to ensure that the press-in
force is supported when the steering pivot pin is
pressed in.

 Tighten the "M8" Allen screws (see arrows)
by hand
NOTE
Centring (1) is required to ensure that the axle

stub and the axle stub bearing are centred and
guided in when the steering pivot pin is pressed
in.
Aligning the steering pivot pin 
NOTE
The alignment of the steering pivot pin is re-

quired for the subsequent positioning of the
steering angle sensor transmitter.
NOTE
In the event of a repair, the steering pivot pin

must be aligned. When doing so, the bore (see
arrow) is within the range of ±20°.
Assembling the steering pivot pin

(pressing in using a fixed press)
 Move the steering axle into assembly position
1 (= zero position)

Steering system
 Position the steering axle under the pressing 
tool.
 Press in the steering pivot pin with a press-in 

force of > 80 kN (press-in path approx.
32 mm)

Steering system
Assembling the lower axle stub bearing/
flange cover
 Insert the outer ring of the axle stub bearing. 
NOTE
For the assembly of the flange, use grease to at-

tach the O-ring
 Insert the O-ring into the flange (arrow). 
 Position the flange 
 Tighten the hexagon head screws to 42 Nm. 
NOTE
Observe the tightening sequence.

Steering system
 Check the bearing pre-load using a 0.04-mm 
feeler gauge (1).
NOTE
When the cover is tightened, it must no longer

be possible to insert the feeler gauge.
Removal/assembly of the wheel hub/wheel bearing
1 Axle casing 7 Slotted spring pin

2 Axle stub 8 Hubcap
3 Shaft seal 9 Hexagon nut
4 Tapered roller bearing 10 Washer
5 Wheel hub assembly 11 Wheel nut
6 Tapered roller bearing 12 Wheel bolt
Dismantling the wheel hub

 Apply the parking brake

Steering system
 Prevent the truck from rolling away using
chocks at the front wheels.
 Loosen the wheel nuts (11)
 Jack up the truck at the counterweight.
 Remove the wheel
 Remove the hubcap (8)
 Unscrew the hexagon nut (9) and remove
along with washer (10), making sure that the
slotted spring pin (7) is properly seated while
doing so
 Remove the wheel hub (5)
 Remove the shaft seal (3)
 Remove the tapered roller bearings (4, 6)
from the wheel hub
 If necessary, drive out the outer rings of the
tapered roller bearings
Reassembling the wheel hub
NOTE
● Check the quality of the screws and lubricant,
as well as the correct tightening torques
● Use lithium soap grease KPF 2 K
(7337400160)
 Carefully grease the sealing lips of the radial
seal ring.
 Fill the tapered roller bearings between the in-
ner ring and the cage with grease
 Fill the bearing chambers with grease at the 
points indicated (x)
 Press in the outer rings of the tapered roller
bearings
 Insert the tapered roller bearings (4, 6) into
the wheel hub

Steering system
 Fit the shaft seal (3) 
NOTE
● Use a pressing tool with a diameter of
67.5 mm.
● Press-in depth of the rotary shaft seal: 5 mm.
 Press in the wheel hub (5)
 Insert the washer (10) into the slotted spring
pin (7) and attach the hexagon nut (9)
CAUTION
Inserting the washer in an incorrect position or reus-
ing the hexagon nut will damage the steering axle.
 Use a new self-securing hexagon nut
 Install the washer with the chamfered edge facing
the axle
 Tighten the hexagon nut (9) to 470 Nm by

continuously turning the wheel hub.
 Fill the hubcap (8) half way up with lithium
soap grease KPF 2 K (7337400160), fit to the
wheel hub and knock in securely using a plas-
tic mallet.
 Mount the wheel
 Lower the truck.
 Tighten the wheel nuts (11)

Steering system
Removing and installing the track rod
Press tool - Overview of parts
Spare part
Description
number
Tool kit - fully equipped

Service case for press tool used for track-rod pin, fully equipped with
1 0009416019
basic device and two replacement kits
2 0009418807 Foam insert for service case
Tool kit - basic device
3 0009409103 Basic device (including insert pin)
4 0009419856 Replacement insert pin for basic device
Tool kit - replacement kit for steering axle 301 and steering axle 1601 with self-steering mudflaps
Centring pin with latch recess for "track-rod pin for mud flap on axle
5 0009419218
stub"
6 0009419857 Press-out pin
7 0009419220 Press-in bolt
Press-out pin and shortened ""track-rod pin" changing part for the mud
8 0009419219
flap on the axle stub"
9 0009419860 Replacement kit for axle stub
10 0009419859 Replacement kit for steering cylinder
Tool kit - replacement kit for steering axle 302, 303 and 1602, 1603 with self-steering mudflaps
11 0009419863 Replacement kit for steering cylinder
12 0009419864 Replacement kit for axle stub
Press-out pin and shortened ""track-rod pin" changing part for the mud
13 0009419865
flap on the axle stub"

Steering system
Spare part
Description
number
14 0009419861 Press-out pin
Centring pin with latch recess for "track-rod pin for mud flap on axle
15 0009419862
stub"

Steering system
Basic device 
(1) Basic device

(2) Bridge
(3) Insert pin
Hydraulic cylinder with hand pump 0009416009 

Steering system
Basic design
 Screw the insert pin onto the hydraulic cylin- 
der.
 Tighten the insert pin using an open-ended 

spanner.
 Place the basic device on the hydraulic cylin- 

der.

Steering system
Steering axle 302/303/1602/1603 
(1) Press-out pin

(2) Centring pin
(3) "Steering cylinder" changing part
(4) "Axle stub" changing part
(5) Centring pin with centring tip
(6) "Track-rod pin" changing part for the mud
flap on the axle stub
Pressing the track rod pin on the steering cylinder in and out
Track-rod pin on the steering cylinder - Preparing the press tool
 Insert the press-out pin into the basic device. 
 Fit the "steering cylinder" changing part on 

the basic device.

Steering system
 Fit the "steering cylinder" changing part in the 
changing bridge.

Steering system
Pressing out the track-rod pin on the
steering cylinder
 Remove the pin retainer.
 Position the prepared press tool. 
 Position the prepared changing bridge. 
 Mount the changing bridge using an open- 

ended spanner.
 Press out the track-rod pin by actuating the
hand pump as far as it will go.

Steering system
 Remove the track-rod pin. 
 Remove the press tool.

Steering system
Pressing in the track-rod pin on the
steering cylinder
 Prepare the press tool (see "Track-rod pin on
the steering cylinder - Preparing the press
tool").
NOTE
Make sure that the press-out pin is no longer in

the basic device.
 Insert the track-rod pin into the press tool.
 Position the prepared press tool. 
NOTE
Note the position of the bore for the retaining

pin:
● Upper bore, lengthwise to the steering cylin-

der
● Lower bore, crosswise to the steering cylinder
 Position the prepared changing bridge. 
 Insert the centring pin and align the fixture. 

Steering system
ended spanner.
 Press in the track-rod pin by actuating the
Doing so pushes the centring pin out at the top. 

 Install the pin retainer.

Steering system
Pressing the track rod pin on the axle stub in and out
Track-rod pin for the mud flap on the axle stub - Preparing the press tool
 Fit the "track-rod pin" changing part for the 
mud flap on the axle stub.
 Insert the centring pin along with the centring 

tip in the changing bridge.
 Fit the "axle stub" changing part in the chang- 

ing bridge.

Steering system
Pressing out the track-rod pin for the
mud flap on the axle stub
 Loosen the hexagon head screws. 
 Remove the washers. 
 Reinsert the upper hexagon head screw with- 

out a washer.
 Position the tool with the centring pin at the 

top and position the press-out pin with the
centring tip at the bottom.

Steering system
ended spanner.
 Press out the track-rod pin by actuating the
Doing so pushes the centring pin out at the top.
 Remove the centring pin. 
 Remove the press tool. 
 Remove the track-rod pin.

Steering system
Pressing in the track-rod pin for the mud
flap on the axle stub
 Remove the press-out pin along with the cen- 
tring pin from the basic device.
 Insert the track-rod pin into the press tool. 
 Position the prepared press tool with the cen- 

tring pin.

ended spanner.
 Press in the track-rod pin by actuating the

Steering system
Doing so pushes the centring pin out at the top. 

 Fit the hexagon head screws and washers.

Wheels and mounting

Electrostatic charging 
Under certain circumstances the truck may be-

come electrostatically charged. The charging
level depends on a number of factors such as
tyre type, air humidity, floor covering etc..
Excessive electrostatic charging is noticed by
the electrostatic charge being discharged to the
ground via a person's body when the truck is
touched (electric shock) or a spark passing from
the truck to an earthed part (e.g. metal shelf).
With standard tyre types (black pneumatic or
solid rubber tyres) with a high level of graphite
electrostatic charging is relatively rare. However,
if non-grind tyres (light-coloured tyres) are used
and the truck is driven in an area with a sealed
floor, the electrostatic charging effect is very fre-
quent.
Non-grind tyres are marked with a safety notice
on the tyre .
DANGER
Safety warning: Tyres are not electrically conductive.
Risk of fire and explosion possible with electrostatic
discharging.
The truck must always be earthed with an antistatic
belt.
To prevent electrostatic charging use is made of

an antistatic belt, which is attached to the frame
under trucks with light-coloured tyres and trails
on the ground with the other end. The antistatic
belt is made of a conductive synthetic material. It
is fitted to trucks with light-coloured tyres as
standard.

Brake system
Brake release valve
Switch cabinet
54 Towing unit 59 Non-return valve

55 Pedal group 60 2/2 directional control valve
56 3/2 directional control valve BR Brake connection
57 Pump for venting the brake T Connection to oil tank
58 Pressure relief valve

Brake system
Brake release valve − sectional drawing: brakes in tow-away mode
A Piston H Emergency operation valve

B Pump chamber I Brake pedal
C Emergency pump non-return valve J Ball ∅ 14 mm
D Control edge BR Brake connection
E Control pressure connection K Brake pressure relief valve
F Non-return valve (suction connection) L Valve cone (not shown in the circuit diagram)
G Ball ∅ 9 mm T Connection to oil tank
Brake release valve — functional descrip-

tion
Brake released (brake chamber BR pressur-
ised):
● Piston is in the deactivated position (piston
travel s = 0 mm).
● Oil flows from the connection (E) via the
bores (15), (16), (7), (21) to the brake connec-

tion (BR).
● That means there is pressure in the brake
chamber (BR); the brake is released and

does not brake

Brake system
Brake applied (brake chamber BR depressur-

ised):
● Piston is in the activated position (piston trav-
el s = 11 mm).
● Oil flows from connection (BR) via the holes
(21), (7), (16) and (15) to the oil tank connec-

tion (T).
● That means there is no pressure in the brake
chamber (BR); the brake is applied and the

truck brakes.
Towing mode (pressure build-up in brake cham-

ber BR):
● The screw for the emergency operation valve
(H) is unscrewed and, along with the ball

(∅ 14 mm), closes the connection between
bore 21 (connection to brake) and bore 7
(brake piston control edge).
● At the same time, the ball with ∅ 9 mm closes
the connection between the pump chamber

(bore 18) and the oil tank (bore 6).
● The non-return valve for the emergency pump
(C) and the valve cone block the connection

to the pump chamber.
● A movement of the piston drives oil out of the
pump chamber (B) through the non-return

valve for the emergency pump (C) into the
brake chamber, and sucks oil into the non-re-
turn valve from the oil tank pipe.
● Pressure is created in the brake chamber
(BR).
● The pressure in the brake chamber (BR) is
limited by the pressure relief valve (K).
Bleed brake release valve (e.g. after rein-

stallation)
 Remove the rubber cap (2). 
 Attach ∅ 6-mm hose to the bleeder valve and

route back to the oil tank or tank.
 Start the engine and open the bleeder screw
(1).
 Pump the brake lever until the oil flowing out
has no bubbles in it.
 Close the bleeder valve (1), remove the hose
and refit the rubber cap.

Brake system
Microswitches 1S1 and S2 — adjusting the switch-on point
1 Adjusting screw for microswitch S2 5 Piston

2 Adjusting screw for microswitch 1S1 T Connection to oil tank
3 Prevailing torque nuts E Control pressure connection
4 Actuating lever BR Brake connection
 Loosen both prevailing torque nuts (3) and

unscrew the screws by approx. 10 mm.
 Screw in the screw (1) as far as it will go.
 Hold the lever (4) against the inactivated pis-
ton (5), piston stroke S = 0 mm.
 Push the lever (4) 9.0 mm inwards.
 Screw in screw (1) until microswitch S2
switches. Tighten the prevailing torque nut;
tightening torque 5 Nm.
 Screw out the screw (2) about 4 mm.
 Hold the lever (4) against the inactivated pis-
ton (5), piston stroke S = 0 mm.
 Move lever (4) 3.8 mm inwards.
 Screw in screw (2) until microswitch 1S1
switches. Tighten the prevailing torque nut;
tightening torque 5 Nm.

Brake system
Microswitch activation
h Piston stroke in mm 3 Brake released

4 Brake applied
OFF Microswitch switches off 5 Pump enabled
ON Microswitch switches on 6 Pump with reduced volumetric flow
1 Microswitch 1S1 setting point 7 Signal for pump set to "0", start condition sat-
2 Microswitch S2 setting point isfied.
Brake cable pulls - Adjusting

Two differently set brake cables affect the brake
release valve's tappets.
● The cable pull for the parking brake is set to
an actuating travel of 16 mm. After the 16 mm
of travel, there should be noticeable resist-
ance.
● The cable pull for the service brake is set to
an actuating travel of 19 mm.

Brake system
Brake cable pulls - Installation positions 
Parking brake cable pull: left

Service brake cable pull: right
Before the cable pulls are attached to the brake
release valve rocker, the nuts must be turned
fully to the front (1) or to the back (2) respective-
ly.
Parking brake cable pull - Adjusting

 Bring the hand brake lever into the "Release
brake" position.
 Loosely attach the cable pull (4) to the brake 
release valve support.
 Tighten the front nut, until the rocker (6) lies
with no play on unactuated piston rod (5).
 Lock with nut (1). 
Service brake cable pull - Adjusting

 Loosely attach the cable pull to the brake re-
lease valve support.
 Tighten the front nut (1), until the cable pull's 

nipple has approx. 2 mm play (s) to the rocker
(6) in 0 position.

Brake system
 Actuate brake pedal. 
If the pedal is approx. 5 mm before the stop

screw (8), there should be clearly noticeable re-
sistance.
At the pedal stop, the rocker must still have ap-
prox. 0.5 mm play up to the stop of the tappet. If
necessary, correct the setting.
 Lock with nut (2).
Brake cable pulls - Function test

DANGER
If cable pulls have been set incorrectly, it is possible
that the forklift truck may no longer be braked using
the brake.
To avoid fatal accidents, a functional check of the
brakes must be carried out on the jacked-up forklift
truck.
When all adjustments have been carried out,

perform a functional test:
● Check for smooth action of the cable pulls.
● Check brake function by actuating the parking
brake.
● Check brake function by actuating the service
brake.

Brake system
Checking the brake system
Pressure measurement points - Overview
1 HP forwards pressure measurement point 8 BR (brake pressure) pressure measurement

2 HP backwards pressure measurement point point
3 Y (forwards) pressure measurement point a MPR 50
4 Z (backwards) pressure measurement point b Fan motor
5 F″/F2 (feed pressure) pressure measurement c Low-pressure filter
point d Control valve working hydraulics
6 F (feed pressure) pressure measurement e Brake release valve
point f Drive axle AH 40-04/AH 50-04
7 MP (working hydraulics) pressure measure-
ment point

Brake system
Tools for the measurements
1 Screw coupling M14x1.5, spare part number: 17 Banjo bolt M18x1.5, spare part number
0009516400 0009031129
2 Screw coupling M10x1, spare part number 18 Banjo bolt M18x1.5, internal thread M14x1.5,
0009516407 spare part number 0009031130
3 Threaded plug M14x1.5 - M18x1.5, spare 34 Screw coupling M12x1.5, spare part number:
part number 0009512115 0009516410
5 Screw coupling M8x1, spare part number 35 Sealing plug, spare part number 0009513900
0009516402 38 MultiHandy 2020 measuring device, spare
7c Banjo bolt M14x1.5, spare part number part number 0009418736
0009031126
Function test
● Forklift truck jacked up so that both drive
wheels can freely rotate.
● Pedal adjustment correct.
● Brake pedal in the "released" position.
 Start the engine and fully push in the brake
valve brake piston with a long screwdriver.
 Press the forwards and reverse accelerator
pedals.
If this test yields pHP > 420 bar and the wheels
do not rotate, the brake system is OK.
If during this test the wheels rotate, the brake
system must be checked.

Brake system
NOTE
Measurement tool case 0009416000 was re-

placed in 04/2013 by measurement tool case
0009416006 and 0009416007. Measurement
tool case 0009416006 was replaced in 05/2016
by measurement tool case 0009416020.
NOTE
The following pressure gauges can be used in-

stead of the "MultiHandy 2020" measuring de-
vice:
● 0-40 bar low-pressure gauge, spare part num-

ber 0009430106
● 0-600 bar high-pressure gauge, spare part
number 0009430107
Troubleshooting
 Forklift truck jacked up so that both drive
wheels can freely rotate.
 Bonnet lifted.
 Floorplate lifted.
 Pedal adjustment correct.
 Engine and traction drive at operating temper-
ature.
 Brake pedal secured in "Brake blocked" posi-
tion.
Troubleshooting - brake system
Step Yes No
Procedure
Type (Test) (Test)
Connect the M12x1.5
screw coupling and the
1
low-pressure gauge to
Action
measurement connection 6
of the LP filter (C).
2 Start the engine and read
Action the pressure gauge display
3
Pressure at least 21.0 bar? Go to steps 6–8 Go to step 4
Test
Use blind plug
0009031129 to seal line
4
connector E at the brake
Action
release valve (e) and re-
peat the test.
5 Brake release valve defec- Check the hydrostatic drive
Pressure at least 21.0 bar?
Test tive unit
Connect the low-pressure
6 gauge to connection 11 us-
Action ing the banjo bolt and the
M18x1 screw coupling.

Brake system
Step Yes No
Procedure
Type (Test) (Test)
Release the brakes and
7
check the pressure with
Action
the engine running.
8 Pressure at least
Go to step 9 Go to steps 11–12
Test 16 - 21.0 bar?
With the engine running
9 fully depress the brake
Action pedal and monitor the
pressure gauge
Brake release valve failing
10 Does the pressure drop to
Go to steps 11–12 to trip. Repair or change
Test approx. 0 bar?
the valve
Use blind plug
11 0009031129 to seal con-
Action nection BR at the brake re-
lease valve.
12 Start the engine and re-
Action lease the brake.
Fully depress the forwards
13
pedal or reverse pedal to
Action
the stop.
The multi-disc brake on the
14 Are the drive wheels rotat- wheel that is rotating is de-
Brake system OK.
Test ing? fective. Remove it and rec-
tify the fault.
Connect the low-pressure
gauge with the adaptor and
15 the screw coupling to
Action measurement connection 8
of the brake release valve
(without brake pipe).
Check the pressure with
16
the engine running and the
Action
brakes released.
17 Brake release valve defec-
Pressure at least 21.0 bar? Go to steps 18–20
Test tive, repair or change it.
Remove the measurement
18
connection and reconnect
Action
the brake pipe.
Use the banjo bolt to seal
19
connection 9 on the right-
Action
hand brake.
With the engine running
and the brakes released,
20
check the pressure at
Action
the measurement connec-
tion 8.
21 Pressure at least Right brake piston seal de- Left brake piston seal de-
Test 16 - 21.0 bar? fective fective

Brake system
Towing
DANGER
Risk of fatal injury for people between the truck and
the towing vehicle.
Only attach the tow bar and manoeuvre the towing
vehicle with an additional guide.
The guide must alert the driver to possible dangers.
DANGER
Risk of accident.
The truck could drive into the towing vehicle when the
towing vehicle brakes.
For safety reasons, only use a tested tow bar.
CAUTION
Overloading the towing vehicle.
The towing vehicle must be able to absorb the re-
quired tractive and braking forces from the unbraked
towed load.
 Check the tractive and braking forces of the towing
vehicle.
If the truck needs to be towed away, the towing

unit can
● Short-circuit the hydraulic oil circuit
● Release the multi-disc brakes in the drive axle
via the brake valve and stop pedal
CAUTION
There is no power steering if the hydraulics fail.
If the truck is not steered while it is being towed, the
truck may veer out in an uncontrolled manner.
Always tow at a low speed, so that the truck and the
towing vehicle remain controllable at all times.
Prerequisites for the towing procedure

 Lower the load to a height at which the fork
arms will not scrape along the ground during
towing.
 Remove the load.
 Attach the tow bar on the towing vehicle to
the towing pin on the truck.
 Release the parking brake.
Opening the choke plunger of the hydraul-

ics

Brake system
WARNING
ponents.
WARNING
 Use a socket to release the self-locking nut 

(1) (19 mm AF) on the left-hand side of the
variable displacement pump housing.
 Unscrew the threaded stud (2) (8 mm AF) by
two rotations using the socket.
 Lock the threaded stud with the self-locking
nut (1) and tighten.
Loosening the multi-disc brake

The brake valve is located under the bottom
plate on the left-hand side of the truck chassis.
 Remove the floormat.
 Insert a hexagon socket wrench (5 mm AF) 
through the bore in the bottom plate and un-
screw the socket head screw (3) by ap-
prox. 8 rotations.
 Sit on the driver's seat.
 Move the parking brake lever downwards.
The symbol on the display unit goes out.
 Move the stop pedal back and forth several
times in the easy-movement range until re-
sistance is felt (approximately 10 strokes) and
the brake is released.

Brake system
After towing
 Secure the truck using wheel chocks.
WARNING
ponents.
WARNING
 Loosen the self-locking nut (1) on the variable

displacement pump.
 Screw in the threaded stud (2) (8 mm AF) and
tighten.
Tightening torque: 20+5 Nm.
 Lock the threaded stud with the self-locking
nut (1).
 Tighten the self-locking nut.
Establishing braking readiness

 Screw the socket head screw (3) into the
valve block as far as the stop.
 Replace the floormat and close the bonnet.
DANGER
The truck must not be driven if the brake system is
faulty.
After repairs have been made to the brake system,
check that the brakes function correctly. If there are
any faults in the brake system, contact your service
partner.

Brake system

Chassis and bodywork 30
Mounting the drive axle

Affixing the axle bearing
To replace the drive axle or the axle bearings,
the following service instructions must be ob-
served.
The surfaces (sleeve bearing (4), bearing shells
(3), axle bearings) must be free of dirt, rust and
adhesive residue.
 Clean the surfaces of the sleeve bearing (4) 
and the adhesive surface in the bearing shells
(3) with a clean paper towel and isopropyl al-
cohol or a similar cleaning agent. The clean-
ing agent must not contain refatting agents.
 Once surfaces are clean, do not touch them
again.
 Mount the static mixing tube on the double 

cartridge of the 3M DP8805 NS adhesive. In-
sert the cartridge into the cartridge pistol.
 Observe the datasheet for the adhesive.
CAUTION
Observe the adhesive processing time of approx. 3 to
5 minutes!
After this time, the mixed adhesive must not be used
again. It is not permitted to move the components af-
ter this time.
 Apply the adhesive evenly on the bearing 

shells in a "sinuous line".
NOTE
Mount the drive axle so that it is tilted 2° to the

rear. To do this, observe the following instruc-
tions:

 Insert a sufficiently long bolt, pin or screw (5) 
through the guide (6) of the drive axle (on the
right-hand side when viewed in the drive di-
rection) and into the slotted hole (7) in the
chassis.
Depending on the type of drive axle mounted,
the position of the bolt (5) inside the slotted hole
(7) may vary.
 Remove the guide bolt (5).
NOTE
Alternatively, a set of scales can also be placed

on the holding fixture for the lift mast in order to
align the drive axle.
 Position the bearing shells (3) with the socket
head screws (1) and washers (2) and screw
the components into place.
Tightening torque for M20 socket head screws 
(1): 540 Nm
 Wipe off any excess adhesive.
 Loosen the lock nuts (8) on the spring ele- 

ments (9).
 Adjust the spring elements (9) on both sides
to a distance of 1 mm from the chassis.
 Tighten the lock nuts (8).
CAUTION
It is only possible to rotate the drive axle by tilting the
lift mast after 140 minutes at the earliest. Applying the
full load (interaction of forces, torsion when tilting,
load applied by load-bearing capacity, driving over un-
even surfaces and cornering) is permitted only after
24 hours.
Allow the 3M DP8805 NS adhesive sufficient time to
cure.

NOTE
It is only possible to rotate the drive axle by tilt-

ing the lift mast after 140 minutes at the earliest.
Applying the full load (interaction of forces, tor-
sion when tilting, load applied by load-bearing
capacity, driving over uneven surfaces and cor-
nering) is permitted only after 24 hours.

Gas springs
Instructions for working with gas
springs
Description
Gas compression springs and gas tension
springs are used in Linde trucks for a range of
applications, for example opening doors and the
bonnet, or swivelling the LPG console.
The gas springs are pressurised up to 300 bar. If
gas springs are damaged, pressure can be re-
leased uncontrollably under unfavourable condi-
tions.
Therefore, please adhere to the following when
handling gas springs:
● Only open gas springs in accordance with the
operating instructions.
● Mount gas springs securely and protect from
damage.
● Do not allow gas springs to fall.
● Avoid lateral forces, buckling and heavy soil-
ing.
● Do not expose gas springs to temperatures
above 80°C.
● Remove gas and, if necessary, any damping
oil present in the gas springs and dispose of

in an environmentally friendly manner.
● Damaged or defective gas springs must be
changed immediately. Take great care when

handling deformed or blocked gas springs.
● Wear industrial goggles and protective
gloves. Always hold gas springs away from

the body.
Procedure for removing a gas spring

Check gas spring for damage, for example:
● Damaged connecting parts
● Deformed cylinder pipe
● Deformed piston rod
Remove damaged gas springs and do not use

again, reshape or repair.
Depending on the version, gas springs can only

be removed and fitted in one position without be-
ing under tension and thus without presenting a
hazard:
● Gas compression springs: piston rod exten-
ded
● Gas tension springs: piston rod retracted
Considerable forces can occur in other positions

due to the gas pressure. In these cases, the gas
must be removed from the gas springs by drilling

Gas springs
into or sawing open the cylinder tube before dis-
assembly.
WARNING
Gas will escape when drilling or sawing.
Wear industrial goggles and protective gloves.
Example procedure for removing the gas filling and the damping oil
1 Gas 2 Oil

NOTE
Description using the example of a gas com-

pression spring (spare part number:
000 965 5592) fitted in a 392/393 series truck
(LPG tank version, maximum console).
WARNING
The damping oil is pretensioned by the gas filling and
can escape under pressure.
To remove the pressure, adhere to the sequence indi-
cated. Wear industrial goggles and protective gloves.
 To remove the gas pressure, first drill a hole

(∅ 2–3 mm) at position "X1" or saw open at
position "X1".
 To remove the damping oil, then drill a hole
(∅ 2–3 mm) at position "X2" or saw open at
position "X2".
WARNING
The positions of the gas and oil chambers vary de-
pending on the type of gas springs used.
Adhere to the measurements applicable to the gas
springs in question.

Gas springs

Driver's compartment 40
Driver's seat
Seat switch bypass 
Working safely with the seat switch bridge

The seat switch bridge may only be used by
trained service personnel working on behalf of
the service partner, and only on Linde industrial
trucks.
The seat switch bridge is designed only for re-
pairs and maintenance work where it is essential
to bridge the seat switch. It must not be used for
any other purpose.
It is prohibited to hand the seat switch bridge 0009409102 (for 38x, 39x)
over to unauthorised persons.
Once servicing is complete, the seat switch
bridge must be removed again and the seat
switch must be checked to ensure that it is work-
ing correctly.
12023810390 (for 12xx)
If the seat switch is bridged, observe the follow- 

ing points:
NOTE
Enter the name and telephone number of the

relevant service engineer responsible on the
warning sign.
DANGER
The driving function is operational.
Secure the industrial truck from rolling away by jack-
ing it up correctly.
DANGER
All functions of the lift mast are operational.
Working on the lift mast is prohibited.

Driver's seat
Replacing the seat switch
Removing the seat switch
 Push the seat all the way to the front.
 Remove two Torx screws (T25) on the under- 
side of the seat.
 Lift the front seat upholstery and pull it out in 

a forward motion.
 Drill out the mounting rivets on the seat 

switch.
 Remove the cable tie for the seat switch ca-
ble.
 Remove the seat switch.
Installing the seat switch

 Rivet the new seat switch with blind rivets to
the seat support and the rocker.

Driver's seat

NOTE
Observe the installation direction (the arrows

must be pointing towards each other).
 Use the diagnostic program to check the seat
switch is working
 Route the seat switch cable and secure with
cable ties.
 Insert the seat upholstery at an angle. 
NOTE
Note the mounting holes at the back of the seat

upholstery and the lugs on the seat support.
 Secure the seat using two Torx screws (T25). 

Air conditioning
Basic principles
Physical principles
Definition of cold and heat
In physical terms, there is no such thing as cold.
Starting from absolute zero (-273°C), objects or
bodies are all varying degrees of warm. In order
to lower a body's temperature, heat must be ex-
tracted from it.
Heat transfer
Heat transfer takes place whenever two materi-
als with different temperatures touch each other,
thereby transferring heat from the hotter material
to the cooler one. Heat continues being transfer-
red in this way until both materials have reached
the same temperature.
Heat can be transferred in different ways:
Heat conduction: heat is transferred from atom
to atom in a material.
Heat transmission: Heat remains bound to a ma-
terial and is transferred in this way.
Heat radiation: heat is radiated in the form of in-
visible light.
Physical states 
Any material can adopt different physical condi-

tions depending on the ambient pressure and
temperature.
Example: water
1 Solid, <0°C
2 Liquid, >0°C
3 Gas, >100°C

Air conditioning
Evaporation heat and condensation heat 
During evaporation, the heat supply is used to

change a liquid material into a gaseous material.
Example:
At a temperature of 100°C, water starts boiling
and steam forms. If more heat is added at this
stage, the water temperature will remain at
100°C. If more heat is added, the hot water
changes completely into steam.
1 Ice
2 Water
Vapour pressure 3 Water / water vapour
At atmospheric pressure (1013 mbar), water
evaporates and condenses at 100°C. This tem-
perature depends on the pressure above the liq-
uid, otherwise known as the vapour pressure.
For example, at a pressure of 5 bar, water will
not boil until 152°C.
Air humidity
Air humidity is very important for people's well-
being. Air humidity below 60% is perceived as
dry and pleasant because the air has no difficul-
ty absorbing the humidity given off by the body.
If air humidity rises above 75%, the air is per-
ceived as unpleasant in hot weather because
the air can no longer absorb almost any addi-
tional humidity. This phenomenon is exhibited by
glasses containing cold drinks on hot days. The
hot, humid air cools on the outside of the cold
glass and water condenses. This means that air
conditioning systems affect the air humidity, as
well as the temperature.
Compression heat 
If a material is compressed, the constant heat

content will also be compressed. This causes
the temperature to increase, for example in com-
pression strokes of internal combustion engines.
Saturated steam and superheated steam

If water is brought to the boil in a closed contain-
er, a steam cloud forms above the liquid. This
cloud continues growing until the vapour pres-
sure and ambient pressure are equal. It is not
possible for more steam to form because part of
the steam will condense again due to the in-
creasing pressure. A state of equilibrium exists
between the steam-forming liquid and the steam
(saturated steam) that is created. If the tempera-
ture continues to increase once all the liquid has
evaporated, the steam is known as "superhea-
ted steam".

Air conditioning
Oxygen and carbon dioxide are superheated
steams. They are no longer connected to the liq-
uid that created them.
Refrigerant is a saturated steam. It is directly
connected to the liquid that created it.
How pressure reacts to changes in volume

Superheated steam, e.g. air 
Cylinder filled with air

If the piston is slowly pushed half-way down, the
pressure will double.
Saturated steam, e.g. refrigerant R 134a 
Cylinder filled with refrigerant gas

If the piston is pushed half-way down, the pres-
sure will not rise. Instead, the gas will condense
into liquid form. If the piston is pulled back to its
original position, the liquid will evaporate. The
pressure depends only on the temperature.
NOTE
Refrigerant R 134a is used as a refrigerant be-

cause it has a low boiling temperature (approx.
-26°C at normal pressure).

Air conditioning
Refrigerant circuit
Basic principles 
Cold cannot be generated. To cool a location

down, heat must be transferred from the area to
be cooled to a different location.
The fact that a material's heat content rises con-
siderably during melting and evaporation while
the temperature remains constant is used in the
cooling device. The easiest method to extract
heat from a space is to use an ice block (2).
While it is melting, the ice absorbs the heat flow
from the environment (3) and the foodstuffs (1),
and releases it into the environment with the
melt water (4).
As the evaporation enthalpy is many times
greater than the melt enthalpy, a higher heat
flow can be absorbed during the vaporisation
procedure than during melting as long as the
temperature remains constant.
It is therefore advisable to bring a material to
boiling point for the purposes of heat transmis-
sion. The compression cooling device makes
use of this advantage.
Simple refrigerant circuit 
The function of the compression cooling device

with its four basic components (compressor,
condenser, evaporator and throttle) is explained
in this section taking a fridge as an example.
The fridge contains a heat exchanger (evapora-
tor) (1) into which wet steam is injected. At a
temperature of +5 °C in the fridge, the vaporisa-
tion temperature of the refrigerant in the evapo-
rator is approx. -15 °C. For the R 134a refriger-
ant, this corresponds an absolute pressure of
1.7 bar. Heat from the fridge is absorbed by the
much colder evaporator, and this causes the liq-
uid portion of the refrigerant to evaporate. The
inside of the fridge cools down.
The compressor (4) extracts the refrigerant va-
pour out of the evaporator and carries the va-
pour into a second heat exchanger, the con-
denser, which is located outside the fridge.
In the condenser (3), the refrigerant undergoes
a phase change and changes from steam into a
liquid. The room temperature around the con-
denser is generally 20-25 °C. To maintain a suf-
ficient heat flow from the condenser to the sur-
rounding air, the liquefaction temperature must
be 20-30 K above the ambient temperature.
When R 134a is used as the refrigerant and the

Air conditioning
assumed liquefaction temperature is 50 °C, the
absolute pressure in the condenser is 13.2 bar.
Therefore, not only must the compressor extract
evaporated refrigerant from the evaporator, it
must also compress it until it has reached a
higher pressure.
There is a throttle (2) between the condenser
and the evaporator. The throttle is used to ex-
pand the refrigerant until its pressure has fallen
from the liquefaction pressure to the evaporation
pressure. This step completes the refrigerant cir-
cuit.
Basic schematic of a compression cooling 

device
(1) Condenser
(2) Expansion valve
(3) Evaporator
(4) Compressor
(5) Gas
(6) Liquid
(7) High-pressure side
(8) Low-pressure side
(9) Warm
(10) Cold

Air conditioning
Schematic view of a refrigerant circuit
1 Compressor with magnetic coupling 7 Evaporator

2 Condenser 8 Low pressure service connection.
3 Fluid container with dryer 9 Damper (truck-specific)
4 High-pressure switch 10 High pressure
5 High-pressure service connection. 11 Low pressure
6 Expansion valve

Air conditioning
Change in physical state
1 Injection line (wet vapour) 8 Hot gas line (superheated vapour)

2 Expansion valve 9 Compressor
3 Line (undercooled liquid) 10 Suction vapour line (superheated vapour)
4 Undercooling (liquid) 11 Overheating (superheated vapour)
5 Condensation (wet vapour) 12 Evaporator
6 Condenser 13 Evaporation (wet vapour)
7 Cooling (superheated vapour)
Refrigerant
Chemical-thermal stability
The conditions in the refrigerant circuit must
cause no changes, or only non-critical changes,
to the characteristics of the refrigerant.
Material compatibility
If a refrigerant is used in existing systems, the
materials in the system must either be compati-
ble or it must be possible to make them compati-
ble by replacing some components (seals, dry-
ers).
Safety, environmental compatibility

Properties of the refrigerant:

Air conditioning
● odourless
● Non-toxic in low concentrations
● non-flammable
● Mixable only with synthetic PAG lubricants
(polyalkylene glycol)
● Not mixable with mineral oils
● Heavier than air when gaseous, hence risk of
suffocation close to the ground
● non-explosive.
● Absorbs humidity easily
● Does not attack any metals
NOTE
Refrigerants must not be mixed with each other.

Only the refrigerant prescribed for the air condi-
tioning system in question must be used.
Vapour pressure curve 
The change in physical state from liquid to gas

and vice versa is the basis on which the air con-
ditioning system works in the truck.
All refrigerant types exhibit a liquid phase and a
steam phase in pressure tanks within the selec-
ted pressure ranges, i.e. there is a steam cush-
ion above the liquid. As long as there is still
steam in the tank along with the liquid, the pres-
sure in the tank depends on the ambient temper-
ature (see Vapour pressure table).
The R 134a refrigerant used is tetrafluoroethane
(CH2FCF3). The boiling point is -26.5 °C at nor-
mal atmospheric pressure (1013.25 mbar).
Vapour pressure table (extract)
The vapour pressure table follows the vapour A Liquid
pressure curve depending on the temperature B Gas
for R 134a.
Pressure in bar for R

Temperature in °C
134a
26.5 1.01
16 1.57
10 2.01
6 2.34
0 2.93
6 3.62
10 4.15
16 5.05
20 5.72
26 6.86
30 7.71
36 9.13
40 10.18

Air conditioning
Pressure in bar for R
Temperature in °C
134a
46 11.91
50 13.19
54 14.57
60 16.83
Compressor oil
The mixture of refrigerant and oil contains ap-
prox. 20-40% of oil, depending on the type of
compressor and the refrigerant quantity. The
compressor oil circulates constantly in the circuit
and lubricates the moving parts.
Special synthetic oils such as PAG oil (polyalky-
lene glycol) or POE oils (polyolester oils) are
used in conjunction with R 134a air conditioning
systems.
NOTE
IC trucks and electric trucks require different

compressor oils that must not be mixed with oth-
er compressor oils!
● IC trucks → PAG oil (electrically conductive)

● Electric trucks → POE oil (electrically non-con-
ductive)
CAUTION
Using the incorrect oil can damage the air condition-
ing system.
Use the oils specified for the truck type (IC or electric
truck)!
To avoid contamination and to prevent damage from
using the incorrect oil, it is mandatory to use air condi-
tioning units for only one specific oil. PAG oils and
POE oils must not be mixed together or used one af-
ter the other in the same air conditioning unit.
CAUTION
Other oils can lead to copper plating, coking and the
formation of residues. This can result in premature
wear and destruction of the moving parts in the sys-
tem.
Use only oils approved for the compressors.
Properties
● Fully synthetic
● Mixable/soluble with R 134a
● Hygroscopic = attracts water

Air conditioning
● Dehydrated
● Good viscosity/temperature characteristics
(high viscosity index)
● Good load-carrying capacity
● High level of wear
● High thermal stability
● Not compatible with mineral oil
● In addition, for POE oils only: electrically non-
conductive
1 2 3 4 5 6
● ● Hydrodynamic power transmission
● ● ● Heat dissipation
● ● ● ● Reduction in friction (drive energy)
● ● ● ● Reduction in wear
● ● ● ● Increased leak tightness
● ● ● ● Reduction in noise
● ● ● Transportation of wear particles
● Hydrostatic power transmission
1 Hydraulic power control

2 Static seals
3 Travelling valves
4 Shaft gasket
5 Piston cylinder
6 Drive bearing
Distribution of the oil volume in the refrigerant

circuit:
Component Distribution in %
Compressor 50
Evaporator 20
Condenser 10
Liquid container 10
Suction hose 10
Please note the following:

Compressor oil can absorb large quantities of
humidity from the air. Therefore, it must not be
stored in the open.
Do not use compressor oil that has already been
used. Instead, dispose of it as hazardous waste.
Remove compressor oil from new compressors,
as the filling quantity could be too high or the
compressor may have been filled only with cor-
rosion protection oil.
An oil level check cannot be performed for com-
pressor oil. Too much oil may damage compres-
sors and impair system performance.
The oil filling capacity of a new compressor de-
pends on the manufacturers' specifications or on

Air conditioning
the oil volume that runs out of the old compres-
sor.
In winter operation, the compressor must oper-
ate for at least 10 minutes per month in order to
maintain the oil film on the moving parts and to
ensure the leak tightness of the compressor
shaft gasket or the compressor spiral gasket.
When replacing compressors that have been
damaged mechanically, the system must be
checked for chip deposits and must be flushed
out if necessary (nitrogen flushing, flushing de-
vice for automatic gearboxes).
Design and function

Function of the air conditioner
The air conditioning system purifies the air to
create a pleasant atmosphere in the driver's
cab. Depending on the outside temperature,
conditioning the air will mean either heating or
cooling it.
The air conditioning system performs the follow-
ing tasks:
● It extracts heat from the air in order to lower
the temperature
● It extracts humidity from the air. The humidity
is conducted to the floor of the vehicle and

drips off there
● It carries the air that has been cooled and de-
humidified into the truck interior
How the air conditioner operates

When the air conditioning system is switched on The blower sucks in the hot circulating air inside
using the push-button, the compressor is engag- the driver's cab. The circulating air is cooled in
ed via the magnetic coupling and is activated by the evaporator, dried and fed back into the driv-
the drive belt in the truck engine. The compres- er's cab via the air distribution system. The con-
sor compresses the refrigerant gas and carries it densed water which forms in the process is sep-
into the condenser. In the condenser, the refrig- arated and released into the outside air via the
erant gas dissipates heat, causing it to con- drain opening.
dense.
The anti-icing protection switch and the pressure
As a result, condensation heat is generated. The switch monitor the cooling circuit during opera-
condenser moves this heat into the surrounding tion. These two switches switch the magnetic
air flowing through the condenser. Throughout coupling off and on, thereby engaging and dis-
this process, the fans ensure sufficient ventila- engaging the compressor.
tion, even if the truck is at a standstill.
If the air conditioning system is switched off via
The liquid refrigerant flows through the dryer to the push-button, the power supply to the mag-
the expansion valve. A controlled pressure drop netic coupling and the fan motors is disconnec-
causes the refrigerant to expand and it absorbs ted. The cooling circuit and the recirculated air
a large quantity of heat in the evaporator. As a circuit are also switched off.
result, the refrigerant reverts to a gaseous state.

Air conditioning
Schematic diagram
1 Compressor 8 Evaporator
2 Magnetic coupling 9 Blower
3 Condenser 10 Expansion valve
4 Fan A High pressure, gaseous
5 Pressure switch B High pressure, liquid
6 Filter dryer C Low pressure, liquid
7 High-pressure service connection D Low pressure, gaseous
Compressor
The compressor is an oil-lubricated volumetric
displacement compressor. The compressor
power is designed so that sufficient cooling out-
put is achieved even at idle speed. The output is
adapted to suit the selected temperature inside
the truck, the various engine speeds and the
ambient temperatures by switching the magnetic
coupling on and off.
The compressor is powered directly by the
crankshaft in the internal combustion engine by
means of a belt drive and a magnetic coupling.
The power requirement of the compressor is ap-
prox. 4-8 kW.

Air conditioning
Function 
The compressor is built into the line between the

evaporator and the condenser, and draws cool
refrigerant gas from the evaporator. The com-
pressor compresses the refrigerant from
1.2-3 bar to 6-16 bar and heats it up from 10°C
to 70-120°C at the same time. The hot refriger-
ant gas is pumped at high pressure to the con-
denser via the pressure connection. The com-
pressor is cooled by the cold, gaseous refriger-
ant intake.
CAUTION
The compressor may only take in gaseous refrigerant.
If liquid refrigerant or large quantities of oil are drawn
in, this will destroy the compressor.
Ensure that the filling quantity of refrigerant is correct.
1 Pressure connection
2 Intake connection
3 Belt pulley with magnetic coupling
Sectional view of an axial piston compres- 

sor
(1) Connection
(2) Valve plate
(3) Piston with piston ring
(4) Swash plate
(5) Shaft
(6) Front cover with the guide hub of the
magnetic coupling
(7) Bearing
(8) Connecting rod
(9) Cylinder head
(10) Combined suction/pressure valve

Air conditioning
Axial piston compressor with variable deliv- 
ery rate
The axial piston compressor with variable stroke
contains a swash plate drive that can change its
operating angle, and a single-action main piston
(1). When the swash plate (2) changes its angle
(position), the piston travel becomes longer or
shorter, thereby allowing the compressor's deliv-
ery volume to be adapted to the operating condi-
tions.
The angle (position) of the swash plate is
changed solely by the gas forces working on the
pistons. The total of all gas forces, both above
the piston (suction/delivery pressure) and below
the piston (gas pressure in the swash plate
chamber), and the design-related effective lever
lengths of the relevant gas forces in relation to
the pivot point (3) determine the current position
of the swash plate drive.
Delivery
Low suction pressure = short
A rate 5% -
piston stroke
8.1 cm3
Delivery
rate
High suction pressure = long pis-
B 100% -
ton stroke
161.3 cm
3
Advantages of variable delivery rate

● Reduction in the switch-on/switch-off frequen-
cy of the compressor coupling
● Less operating noise from the compressor
● Very good anti-icing protection for the evapo-
rator
Identification plate for diesel trucks 
Sanden piston compressor with swash

SD
plate
6 Number of pistons
V Variable
12 Piston stroke (approx. 125 cm3)

Air conditioning
Identification plate for LPG trucks 
Sanden piston compressor with swash

SD
plate
7 Number of pistons
V Variable
16 Piston stroke (approx. 160 cm3)
Condenser with fan 
Design and function

The condenser is located on the high-pressure
side between the compressor and the dryer, and
liquefies the gaseous refrigerant by cooling it.
The condenser consists of a pipe coil that is se-
curely attached to numerous fins. Hot refrigerant 1 Fan
gas at a temperature of 70-120°C is pumped 2 Housing
from the compressor into the input line on the 3 Condenser
condenser at high pressure. As the hot gas
flows through the pipe coil, the gas cools down
until it condenses. The heat that is extracted
from the gas at this stage is discharged into the
surrounding air.
Fans
The fans ensure that the heat discharged from
the condenser is dissipated rapidly, meaning
that the refrigerant cools more quickly. The pres-
sure switch in the refrigerant line and the tem-
perature-dependent radiator fan switch in the re-
frigerant circuit are used to control the fans.
New condenser 3005804900 from 06/2018

Air conditioning
A new condenser has been introduced to re- 
place the previous version in the 391-01 evo /
392-02 / 393-02 / 394-02 series. The introduc-
tion of the new condenser will also change the
filling quantities of the air conditioning system.
The new condenser can also be installed on old-
er trucks. In this case, the different filling quanti-
ties for the air conditioning systems must be ob-
served, depending on which condenser is instal-
led.
Check which condenser is installed before filling
the system. The part number can be found on
the identification plate on the condenser.
1 Old condenser 3915804903 and 3945804905

2 New condenser 3005804900
Amended filling quantities

Spare part number Filling quantity
391 392 / 393 394
3915804903 (old) 1500 g 1500 g 1600 g
3945804905 (old) - 1300 g 1370 g
3005804900 (new) 1130 g 1130 g 1130 g
Implementation at the factory

From serial number: H2X391J01624
H2X392J01316
H2X393J02975
H2X394J01779
Pressure switch
The pressure switch 9S6 (1) monitors the pres- 
sure in the high-pressure part of the air condi-
tioning and protects the cooling circuit against
damage from:
1
● Overpressure: cooling circuit components
break or the high-pressure relief valve is trig-
gered
● Underpressure: the compressor is insufficient-
ly lubricated
The pressure switch also has two other func-
tions:
● Switching the magnetic coupling of the com-
pressor on and off (contacts 1 and 2) 391_03-033
● Switching the third fan 9M9 on and off (con-
tacts 3 and 4)

Air conditioning
Function Off [bar] On [bar]
< 3.5 bar
Magnetic coupling > 3.5 bar
> 25 bar (protective shut-off)
Fan 9M9 < 15 bar > 15 bar
Switch-on and shut-off function of the mag-

netic coupling
If the pressure in the system is less than 3.5 bar,
the magnetic coupling does not switch on. The
compressor remains inactive (contacts 1 and 2
open).
If the pressure in the system is greater than
3.5 bar, the magnetic coupling switches on. The
compressor is switched on (contacts 1 and 2
closed).
If the pressure in the system exceeds 25 bar,
the magnetic coupling shuts off. The compressor
is shut off to protect the air conditioning (con-
tacts 1 and 2 open).
Third fan switch-on and shut-off function

If the pressure in the system exceeds 15 bar,
the pressure switch 9S6 switches on the third
fan 9M9 (contacts 3 and 4 closed).
NOTE
The two fans 9M7 and 9M8 are permanently in

operation when the air conditioning is on.
Dryer 
The dryer is located on the high-pressure side

between the condenser and the expansion
valve.
The dryer is a reservoir for liquid refrigerant and
is used to filter and dry the refrigerant.
The high-pressure liquid refrigerant passes from
the condenser into the dryer through the input
line. In the dryer, a drying element removes hu-
midity from the refrigerant (max. 12 g) and filters
out foreign matter. The refrigerant passes
through a riser into the output line and then on to 391_03-030
the expansion valve.

Dryers are cleaned, dried and sealed air-tight.
NOTE
As the compressor oil in the compressors has a

strong tendency to absorb humidity, the individu-
al components must be kept closed for as long
as possible during installation.

Air conditioning
NOTE
If the air conditioning unit was opened or had

been leaking for a long period of time, thus al-
lowing moisture to penetrate it, the dryer must
be replaced.
Inspection glass
Function 
The expansion valve only works properly when

liquid refrigerant is present for expansion purpo-
ses. In the absence of a liquid collector, liquid
refrigerant will only be present if the refrigerant
is undercooled. The purpose of the inspection
glass is to check the state of the refrigerant. The
inspection glass is integrated into the dryer bot-
tle.
The refrigerant is colourless. When the refriger-
ant is sufficiently undercooled, nothing is visible
in the inspection glass. Likewise, nothing will be
visible in the inspection glass when the cooling
Bubbles in the inspection glass due to a lack of refrigerant
device has been completely emptied. The only
way to check the refrigerant quantity present is
to measure the pressure.
If no undercooling is effected upstream of the
expansion valve, the refrigerant will contain va-
pour pockets and bubbles will be visible in the
inspection glass.
The refrigerant flow and the filling quantity can
be checked using the inspection glass.
State Refrigerant quantity Action

Check refrigerant pressure and
Bubbles in the inspection glass Insufficient refrigerant
quantity
No bubbles in the inspection Refrigerant quantity too high or Switch off the air conditioner and
glass correct watch the inspection glass
As soon as the air conditioning
system is switched off, refriger- Check refrigerant pressure and
Refrigerant quantity too high
ant is visible in the inspection quantity
glass
After the air conditioning system
is switched off, refrigerant froths
Refrigerant quantity correct Normal refrigerant quantity\
up. The inspection glass be-
comes transparent

Air conditioning
Evaporator
Design and function 
The evaporator is located on the low-pressure

side between the expansion valve and the com-
pressor. It cools, dries and cleans the air.
The evaporator is located in the blower unit be-
hind the blower and works in the same way as a
heat exchanger. It consists of numerous cooling
coils connected by cooling fins. The refrigerant
metered by the expansion valve is sprayed as
low-pressure liquid into the evaporator. As soon
as the refrigerant contacts the inner surface of
the cooling coils, it evaporates and so extracts
heat from them. The cooling coils and the entire
evaporator cool down dramatically. The com-
pressor extracts the refrigerant gas.
The air flowing through the evaporator is cooled
down and dried. The air humidity released in the
process is deposited on the fins and condenses.
The condensation water that is generated is re-
leased via a drainage line, taking dust particles
and pollen that has stuck to the evaporator with
it. This cleans and dries the air. During opera-
tion, the temperature mixing valve can be used
to conduct some of the air that has been cooled
down and dehumidified through the heat ex-
changer and heat it up. Therefore, an individual
temperature can be set inside the driver's cab
despite the almost constant air conditioning out-
put of the system.

Air conditioning
Expansion valve
Design
The expansion valve is located on the high-pres-
sure side upstream of the evaporator inlet, be-
tween the dryer and the evaporator. Its function
is to regulate the refrigerant flow into the evapo-
rator. The expansion valve consists of the valve
body and membrane head.
Function 
The thermostatic expansion valve works through

the interaction of three forces:
1 The pressure in the sensor line is depend-
ent on the temperature of the refrigerant,
which is heated up considerably. This pres-
sure acts as an opening force (PFü) on the
membrane
2 The evaporator pressure (PSa) acts in the
opposite direction on the membrane
3 The pressure of the regulator spring (PFe)
acts in the same direction as the evaporator
pressure
Liquid refrigerant flows from the dryer and
through the valve inlet. The refrigerant passes
by the spring-loaded valve seat, towards the
valve outlet, and continues on into the evapora-
tor. The opening of the valve seat is regulated
by the temperature and the pressure of the re-
frigerant gas that flows out of the evaporator.
The spring ensures that only gaseous refrigerant
can flow back. If, for example, the temperature
of the refrigerant gas coming from the evapora-
tor rises in the top valve bore, the liquid refriger-
ant enclosed in the membrane head is also
heated up by way of the temperature sensor.
The refrigerant expands and pushes a mem-
brane and a valve spool, which in turn press the
ball in the valve seat downwards. The valve seat
opens and as a result, the refrigerant supply to
the evaporator increases, the evaporator cools
down and the temperature of the refrigerant gas
that flows out drops further.
Tubing and hoses

The individual components in the air condition-
ing system are connected to each other by alu-
minium pipes and reinforced rubber hoses. The
lines differ from each other in their diameters.
Suction lines (low pressure) have a larger diam-
eter than pressure lines.

Air conditioning
Electrics
Electrical activation of the magnetic cou-
pling
To guarantee anti-icing protection for the evapo-
rator, the air conditioning output must be control-
led depending on the outside temperature and
the engine speed. The only way to control the
output is to switch the compressor coupling on
and off. For this purpose, the system switches at
a pressure above 28 bar and below 0.5 bar.
The anti-icing protection switch prevents the
evaporator fins from icing over. Fins that have
iced over reduce the air flow through the evapo-
rator and also reduce the heat transfer.
Switches and sensors

Pressure switches are used as a safety system
for protection against pressures that are too high
or too low. They act directly on the compressor's
magnetic coupling.
If the system pressure increases too much, the
high-pressure switch cuts the power supply to
the magnetic coupling when the set pressure
(approx. 26 bar) is reached. Possible causes in-
clude a heavily contaminated condenser, a
failed fan or a faulty expansion valve. As soon
as the system pressure has fallen by the preset
differential pressure (approx. 5-6 bar) below the
cut-out pressure, the compressor is switched
back on (20-21 bar).
If the system pressure falls below the set pres-
sure, the low-pressure switch cuts the power
supply to the magnetic coupling. Possible cau-
ses include insufficient refrigerant, a faulty ex-
pansion valve, an insufficient thermal load or a
faulty evaporator fan. As the R 134a refrigerant
has a vaporisation temperature of 0°C at an over
pressure of 2 bar, the low-pressure switch is set
to a value of approx. 2 bar in order to prevent
icing. The cut-in pressure is 0.5 bar above the
cut-out pressure. Therefore, if the cut-out pres-
sure is 2 bar, the compressor would start up
again at 2.5 bar. If the compressors are not pow-
er-controlled, this principle is also used for the
purposes of power control.
An anti-icing protection thermostat is equipped
in order to protect the evaporator from icing. Just
like the pressure regulator, the anti-icing protec-
tion thermostat switches the magnetic coupling
of the compressor on and off. Depending on the
system design, the gauge of the temperature
regulator is either located between the evapora-
tor fins or attached to the evaporator outlet (suc-
tion side). If a non-adjustable setting has been

Air conditioning
made for the temperature regulator, the com-
pressor switches off at approx. 0°C and back on
at approx. +4°C. If the temperature regulator can
be adjusted, the switching point can be changed
in such a way that the compressor switches off
at higher temperatures. In doing so, the air tem-
perature can be controlled.
Connection diagram for electrical safety 

components (example)
(1) On/Off switch

(2) Fuse
(3) Anti-icing protection
(4) High-pressure switch
(5) Low-pressure switch
(6) Magnetic coupling
(7) Coupling relay
Anti-icing protection thermostat 
Switching temperatures:
● Switch off: 1.5±1°C
● Switch on: 4.1±1°C
Pressure switch 
Connec-
ted com- Off On
ponent
Low pres- max. 3.5 b
2±0.5 bar
Magnetic sure ar
coupling High pres-
25±2 bar 18±1.5 bar
sure
Mean pres-
Fan 11±1 bar 15±1 bar
sure

Air conditioning
Performing work on air conditioning systems
Safety precautions
WARNING ● If you notice a pungent smell during soldering,
these poisonous decomposition products
Refrigerant is a hazardous material. Working on air have been formed. Inhaling these decomposi-
conditioning systems can pose health risks. tion products can damage airways and other
The following regulations must be observed. organs
● Even if refrigerants are non-combustible, they
still represent a fire hazard if oil residues in
ENVIRONMENT NOTE them or insulating material ignite, or if oil mist
is created due to heavy leakage
Refrigerant and compressor oil must not be re-
leased into the environment. Work with care and Working with pressure vessels
observe the following guidelines.
● Secure vessels to prevent them falling over or
rolling away.
Working with refrigerants
● Do not throw vessels. If they fall, vessels can
When working on refrigeration systems, comply be so heavily deformed that they rip open. If
with EN 378. Every refrigerant has safety data the refrigerant evaporates and leaks out all of
sheets or material data sheets (available from a sudden, significant energies will be re-
the manufacturer) as well as the general instruc- leased. This will also happen if bottle valves
tions from the employers' liability insurance as- are broken off. Therefore, the bottles must on-
ly be handled with the protective cap screwed
sociation for the chemical industry.
on
Specific regulations must be complied with in or- ● Do not place refrigerant bottles near heating
der to ensure safe, appropriate use of refriger- devices. The higher the temperature, the
ants: higher the pressure, and this may cause the
vessel pressure to rise above permissible lev-
● Wear industrial goggles. If refrigerant gets in
els. The German Pressure Vessel Code
the eyes, it can cause serious frostbite dam-
specifies that vessels must not be heated to
age. Immediately rinse eyes with plenty of
temperatures above 50°C
water and consult a doctor
● Never heat refrigerant bottles with an open
● Wear protective gloves. Refrigerant must not
flame. Excessive temperatures can damage
come into contact with skin. Hands must be
the material and cause the refrigerant to de-
protected from frostbite (R 134a evaporates
compose
at -26.5°C) and from erosion of the skin's pro-
tective layer (refrigerants dissolve fats). If re- ● Seal empty vessels in order to prevent humid-
frigerant does come into contact with skin, ity from penetrating into them
wash with plenty of water and consult a doc- ● Never overfill refrigerant bottles, as a rise in
tor. Leather gloves and fabric gloves are un- temperature can cause enormous pressures
suitable; fluoroelastomer gloves are better to arise
● There is a possible risk of suffocation if refrig-
erant escapes into the atmosphere. Refriger- Disposing of refrigerants and compressor
ants are heavier than air. At refrigerant levels
of approx. 12%, the air will lack the oxygen oil
required for breathing. This can lead to un- They must be stored and disposed of correctly in
consciousness and increased heart circulato-
accordance with national regulations.
ry problems due to stress and lack of oxygen
● Never smoke when working with refrigerants. The refrigerants that are earmarked for disposal
The cigarette embers can cause the refriger- must be placed in labelled recycling tanks.
ant to decompose, resulting in formation of
toxic substances Used compressor oils from systems with halo-
genated hydrocarbons must be disposed of as
● Before welding or soldering cooling devices,
hazardous waste. They must not be mixed with
remove the refrigerant by suction and remove
the residues by blowing out with nitrogen other oils or materials.
● Heat can cause the refrigerant to create de-
composition products that are hazardous to
health and can cause corrosion.

Air conditioning
First aid person oxygen. If the person can no longer
breathe or can only breathe with difficulty,
● If refrigerant or refrigerator oil comes into con- bend the head back towards the neck and
tact with eyes or mucous membranes, rinse give mouth-to-mouth resuscitation
them off with plenty of flowing water and con- ● Notes for the doctor: high concentrations of
sult an optician refrigerants can cause limited consciousness
● If they come into contact with skin, remove or even unconsciousness. As the refrigerants
the wet clothing and rinse the affected areas sensitise the heart to catecholamines, no
with plenty of water adrenomimetics may be administered. Inhala-
● If large concentrations of refrigerant vapours tion of decomposition products can cause the
are inhaled, bring the person in question out development of lung nodes after a period of
into fresh air immediately. Consult a doctor. In latency
case of difficulty breathing, give the affected
Instructions for working on air conditioners

When working on cooling devices, observe the ● Only install components at room temperature
following points: ● Do not remove the sealing plug from the
● Ensure that the system is kept clean: foreign mounting parts until just before installation
matter such as air, humidity or dirt in the re- ● After removing parts, seal them with the seal-
frigerant circuit impair the function of the air ing plug immediately.
conditioning system ● Seal the refrigerant circuit as quickly as possi-
● In order to prevent contamination of the air ble
conditioning system, refrigerant hoses, con- ● Do not perform maintenance work in the open
nections and connection pieces must be air (moisture).
cleaned before being removed ● Observe the change intervals for filters and
● The refrigerant oil has a very low humidity dryers of the servicing device
content and therefore easily absorbs humidity ● After all servicing or repair work, add contrast
from the air. For this reason, the vessel must
be kept closed medium to the air conditioning system to
make it easier to find leaks later on
● Store installation kits, tools and spare parts in ● O-rings must be replaced after connections
an appropriate manner in a dry place.
have been loosened and must be moistened
● Ensure adequate evacuation of the system with refrigerant oil prior to use
prior to filling
Emptying an air conditioner

A servicing device is required in order to empty
an air conditioning system. The servicing device
enables the refrigerant to be suctioned out of the
air conditioning system.
NOTE
Read the operating instructions for the servicing

device.

Air conditioning
Connecting the servicing device on the low- 
pressure side
Suction out the gaseous refrigerant. Little or no
compressor oil is removed in the process.
1 Compressor
2 Condenser
3 Dryer
4 Expansion valve
5 Evaporator
Connecting the servicing device on the 

high-pressure side
Suction out the liquid refrigerant. A low to high
quantity of compressor oil is removed in the
process.
Connecting the servicing device on the low- 

pressure side and the high-pressure side
Suction out the gaseous and liquid refrigerant. A
low to high quantity of compressor oil can be re-
moved in the process.

Air conditioning
Service units 
Depending on its make, a servicing device con-

tains the following components:
● Vacuum pump
● High-pressure gauge
● Low-pressure gauge
● Vacuum meter
● Suction device
● Oil tank
● Filter dryer
Connecting the servicing device

 Connect the low-pressure hose (blue) to the
low-pressure valve (small diameter) on the air
conditioning system.
Sample service unit
 Connect the high-pressure hose to the high-
pressure valve (large diameter) on the air
conditioning system.
 Open the appropriate valves on the servicing
device. If a refrigerant bottle is directly con-
nected to the servicing device, the bottle
valves must be opened.
 Screw in the service connection spindles.
Removing the refrigerant by suction

 Switch the servicing device to the "Suction"
mode of operation.
Some models are emptied automatically. The
servicing device switches itself off after the air
conditioning system has reached approx.
-500 mbar.
Some servicing devices must be switched off
manually.
NOTE
It may be necessary to repeat the suction

process. This is the case if the vacuum display
on the servicing device returns to the positive
range.
The servicing device automatically filters out dirt
and humidity during the suction process. The re-
frigerant oil is collected in an oil separator.
When the suction process is complete, the ex-
tracted oil volume must be measured and the
quantity recorded.
The air conditioner can now be opened for work.

Air conditioning
Evacuating an air conditioning system
(building up a vacuum)
Evacuating an air conditioning system means
completely removing refrigerant residue and air
by suction. An air conditioning system must al-
ways be evacuated before being refilled or if it
has been opened to allow service work to be
performed on it. If air penetrates the air condi-
tioning system, the humidity and dirt particles
contained in the air will damage the air condi-
tioning system, as will the air itself.
Filling the air conditioning system

The air conditioning system can be filled using
the "Robinair AC500-PRO" servicing device.
 Switch on the main switch (on the rear of the
device).
 Check the refrigerant quantity. At least 2 kg.
 Remove the protective caps and connect the
filling hoses to the truck connections.
The connections are located underneath the 
heating console.
(1) Red connection: HP ≙ high pressure
(2) Blue connection: LP ≙ low pressure
 Press the F button until Pr NA appears on 

the display.
 Press the Start button (bottom right).
 Press the F button until the white light flash-
es (V) → vacuum.
 Enter the time on the keypad: 60 minutes.
 Open both valves (LP and HP) by moving the
levers beneath the pressure gauges to the O
position (open).
 Use the Start button (bottom right) to start the
vacuum process.
The servicing device starts the vacuum process.
The time is counted down on the display. A leak
test is then performed. At the end, 999 must
flash on the display. The servicing device emits
a beep when the process has been completed.

Air conditioning
Once the vacuum process is complete:
 Close the blue valve beneath the LP pressure
gauge by moving the lever to the C position
(closed).
 Press the Start button.
 Press the F button until Pr NA appears on
the display.
 Press the F button until the red light flashes
(filling).
IN OIL appears on the display.
NOTE
If the air conditioning system was evacuated be-

fore being filled, the refrigerant oil that was re-
moved must be refilled using the servicing de-
vice (see operating instructions for the servicing
device).
 Enter the filling quantity (see "Filling quanti-
ty").
 Start the filling process with the Start button.
The servicing device starts to fill the air condi-
tioning system. The display shows the quantity
that has been poured in. The servicing device
emits a beep when the process has been com-
pleted.
Once the filling process is complete:
 Switch the air conditioning system on (2). 
1 2 3
Charging indicator (H2) in the display unit must
be off, the cryostat (1) and blower switch (3)
must be set to the maximum level, and the com-
pressor must switch on (clicking sound or visual
inspection). 0 1
2
3
 Remove the red filling hose from the truck. AC
 Repeatedly open the blue valve (LP) slightly

(the pressure gauge readout must not exceed
3 bar).
When the blue valve is fully open, the process is 394-02_03-011
complete.
 Remove the blue filling hose from the truck.
 Screw on the protective caps.

Air conditioning
NOTE
The process for filling the air conditioning sys-

tem may vary if different servicing devices are
used.
Filling quantity
Refrigerant R 134a
The filling quantity for refrigerant differs depend- 
ing on the manufacturer. The spare part number
on the identification plate of the air conditioning
system can be used to identify the manufacturer
of the air conditioning system.
Spare part number

Manufacturer Filling quantity
Air conditioning Condenser
3945803430
3945803431
3945803432
3945803433
Wölfle 3915804903 1600 g
3945803435
3945803436
3945803441
3945803442
3945803445
3945803446
MBI 3945804905 1370 g
3945803447
3945803448
NOTE
In the event of a replacement, the air condition-

ing system and the condenser from Wölfle must
be replaced with components from MBI.
Compressor oil (PAG)

Filling quantity: 150 cm3
Troubleshooting
Technical equipment
Refrigerant states such as overheating and un- when performing this task. Bubbles in the in-
dercooling provide important clues when trouble- spection glass, dirt and rime are all visible. If the
shooting. Even your own senses are important compressor is drawing in wet steam, this is

Air conditioning
visible in the suction line and may even be audi- ● Refrigerant bottles for new refrigerant
ble. An overloaded compressor will produce a ● Refrigerant bottles for used refrigerant
smell. ● Collecting tank for old oil
Tools and devices required for troubleshooting: ● Leak detector
● Pressure gauge
● Thermometer
Procedure for troubleshooting

Refrigerant
Determine which refrigerant is in the system.
The refrigerant and the filling quantity are speci-
fied in the operating instructions for the air con-
ditioning system and on the identification plate.
Knowledge
Without knowledge of the design of the air con-
ditioning system, the components it contains and
how these components work, you will not be
able to perform troubleshooting.
Visual inspection
Some faults can be detected visually or can be
determined by someone with the necessary ex-
perience. The inspection glass allows contami-
nation of the condenser or the formation of va-
pour pockets to be easily determined.
Factors influencing operating pressures

The pressures that arise in a cooling device vary
considerably depending on the ambient condi-
tions. The table below lists some of these de-
pendences.
Suction pressure High pressure

Measurement
rising falling rising falling
Compressor rising X X
speed falling X X
Temperature in rising X X
the driver's cab falling X X
Outside tem- rising X X
perature falling X X
rising X X
Air humidity
falling X X
Typical faults
System does not cool down sufficiently:

Air conditioning
Cause Error detection Remedy
Check the recirculated air
filter and the fresh air filter Clean filter, replace it if necessary
Insufficient air flow in the
Leaks in the air flow system Seal leaks
cab
Thermostat faulty (evapora- Replace the gauge
tor iced up)
Bubbles in the inspection
glass
Small difference in tempera-
ture between the suction Check the system for leaks
Insufficient refrigerant in the line and the pressure line, Repair leaks
system as well as between the high- Fill the system until there are no bubbles
pressure side and the low- in the inspection glass
pressure side
Temperature of suction line
falls very slightly
Filter dryer noticeably colder
than line (dryer may even
Filter dryer dirty have iced up) Change the filter dryer
glass
glass
Replace the refrigerant (evacuate the sys-
High pressure and low pres-
Foreign gases in the system tem thoroughly)
sure too high
If necessary, replace the dryer
Temperature of suction line
falls very slightly
V-belt loose or worn out Whistling noise Tension the V-belt, replace it if necessary
Clean the fins (be gentle, do not apply any
Condenser contaminated Visual inspection
pressure and do not bend the fins)
Visual inspection (while the Check electrical connections, lines and
air conditioning system is in fuses
Condenser blower faulty
operation, the condenser Replace the condenser blower if necessa-
blower is running) ry
sure too high
Insufficient cooling on the
condenser
Compressor switches on
Too much refrigerant in the briefly, high pressure increa- Remove refrigerant from the system by
system ses extremely quickly to suction
reach over pressure. Com-
pressor switches off briefly
until normal pressure has
been reached; compressor
switches on briefly
Check all possible faults
Expansion valve faulty sure too high
Replace the expansion valve
Pressure balancing
Abnormal sounds
Increased compressor tem-
Change the compressor
Damage to compressor perature
Clean
Oil or similar lubricants on
the belt pulley

Air conditioning
Dependent temperatures and pressures
Outside temperature [°C] 21 27 32 38

Temperature at right-hand
2-7 3-9 5 - 12 7 - 13
vent [°C]
Low pressure [bar] 1.7 - 2.5 1.7 - 2.5 1.8 - 2.8 1.9 - 3.0
High pressure [bar] 6 - 16 9 - 17 10 - 18 19 - 20
Troubleshooting using a pressure gauge 

unit
In addition to the servicing device, a pressure
gauge unit is used to measure the working pres-
sures and for service purposes. Both the high-
pressure side and the low-pressure side of the
system can be connected to the pressure gauge
unit, as can the vacuum pump, suction station or
refrigerant bottles. The pressure gauge unit is
equipped with a high-pressure gauge and a low-
pressure gauge. Some models also have an ad-
ditional vacuum meter.

Air conditioning
Connection diagram for troubleshooting with a pressure gauge unit

Air conditioning
Suction pressure too low, high pressure low to normal
A Suction pressure too low B High pressure too low to normal
Cause Possible effects Remedy

Bubbles in the inspection glass,
extreme overheating, condensa- Look for leaks, add more refrig-
Insufficient refrigerant
tion on evaporator, no under- erant
cooling
Evaporator fins or air filter dirty Insufficient cooling output Cleaning
Evaporator fan has broken down Deactivation of low pressure Repair fan
Expansion valve faulty (leaks in Suction gauge shows vacuum
Replace valve
gauge system) because the valve has closed
The strainer or nozzle of the ex-
Extreme overheating Cleaning
pansion valve is clogged
Bubbles in the inspection glass,
Filter dryer clogged extreme overheating, filter dryer Change the filter dryer
cold
The shut-off valve on the collec- Bubbles in the inspection glass,
tor is throttling; pressure drop in major overheating, section of line Open valve, check line
the line cold
Frequent deactivation of low
Insufficient thermal load pressure, anti-icing thermostat Check power control
frequently activates

Air conditioning
Suction pressure normal, high pressure too high
A Suction pressure normal B High pressure too high

High hot-gas temperature, low
Condenser contaminated Cleaning
cooling output
High hot-gas temperature, high
Condenser fan has failed Repair
pressure cut off
High hot-gas temperature, ex-
Congestion treme undercooling, low cooling Optimise filling quantity
output
High hot-gas temperature, ex-
Carrier gas (air) treme undercooling, low cooling Refill
output
Throttling between compressor High hot-gas temperature, low
Check lines and valves
and condenser cooling output

Air conditioning
Suction pressure too high, high pressure too low to normal
A Suction pressure too high B High pressure too low to normal

Compressor (valve plate, piston Replace compressor or faulty
Insufficient cooling output
rings) faulty parts
Insufficient cooling output, ex-
Power control faulty cessively high hot-gas tempera- Repair the power control
ture when bypass is open
Suction pressure too high, high pressure too high

Air conditioning
A Suction pressure too high B High pressure too high

Gauge on the thermostatic ex-
pansion valve is loose, has a Insufficient overheating, com-
Attach gauge correctly
faulty contact or is not thermally pressor is operating with liquid
insulated
Other faults
Symptom Cause Possible effects Remedy

Hot-gas temperature too Increased compressor
Insufficient oil Filling with oil
high wear
Pressure switch or
some other safety Check the switching de-
Compressor does not switching device has System comes to a vices, find the cause of
start triggered, electrical fault, standstill the trigger and eliminate
cylinder has been filled it
with liquid refrigerant
Switching difference too
small, a shifting device
Compressor cycling, in-
(over-pressure switch, Check the shifting devi-
Compressor activates creased wear and tear,
low-pressure switch) ces, eliminate the cause
repeatedly insufficient cooling out-
triggers, insufficient re- of the triggering
put
frigerant, faulty fan, con-
gestion
Valve misaligned, valve
Lower cooling output, Adjust valve, change
nozzle too small, valve
Excessive overheating high hot-gas tempera- nozzle, clean, refill, per-
strainer clogged, insuffi-
tures form leak detection
cient refrigerant
Valve misaligned, valve
nozzle too large, con- Operating the compres- Adjust valve, optimise
Insufficient overheating gestion (capillary), sor with liquid, damage filling quantity, attach
gauge attached incor- to compressor gauge correctly
rectly
Checking for leaks in refrigerant circuits

Description
One of the most common causes of malfunc-
tions in the air conditioning system are leaks in
the refrigerant circuit. These leaks lead imper-
ceptibly to a reduction in the level of refrigerant
and thus to reduced performance and eventually
to total failure. It is known that the R134a refrig-
erant in particular diffuses from rubber hoses
and connections.
Since it is not immediately apparent whether the
refrigerant loss is due to a leak or to normal dif-
fusion over time, it is essential to perform a thor-
ough leakage test.

Air conditioning
NOTE
When performing a leakage test, the air condi-

tioning system must be empty of refrigerant. Re-
move the remaining refrigerant from the air con-
ditioning system by suction. The air conditioning
system must not be filled with refrigerant again
until it has been successfully repaired.
Components to be tested:
● All connections and lines
● Air-conditioning compressor
● Condenser and evaporator
● Filter dryer
● Pressure switch
● Service connection.
● Expansion valve
The three most common leakage tests are ex-

plained below. These are:
1. Contrast medium and UV lamp
2. Electronic leakage test
3. Leakage test with forming gas
Leakage test using contrast medium and

UV lamp
If the leakage rate is below 50 g/year, all system 
components must be examined very carefully to
see if compressor oil is adhering to them. When
the air conditioning system is being serviced or
after it has been repaired, the contrast medium
is either added via a service connection once
the system has already been filled, or it is added
with the compressor oil before the system is fil-
led. This contrast medium behaves like com-
pressor oil but is clearly visible when UV light is
shone on it. This detection method will find leaks
in the evaporator based on the condensation
water that escapes from the underbody after the
system has been in operation for only a short
time.
CAUTION
Too much contrast medium can cause damage to the
air conditioning system.
The amount of contrast medium must not exceed 5%
of the total amount of oil in the air conditioning sys-
tem.
NOTE
If there is leakage near the air conditioning sys-

tem, contrast medium must not be added retro-
spectively for leak detection purposes!

Air conditioning
Leakage test with an electronic leak detec- 
tor
If the leakage rate exceeds 50 g/year, an elec-
tronic leak detector will prove effective. The best
leak detectors are fitted with a "swan-neck
gauge" and an optical/acoustic display. There
should be as little air flow as possible at the
place of use (engine off). Refrigerant is heavier
than air. When searching for leaks, the sensor is
therefore slowly guided along the underside of
the components. For a systematic search, begin
at the shaft seal on the compressor and move
slowly in the system flow direction. The evapora-
tor can be tested accurately at a low blower po-
sition via the centre air vent. The search ends
back at the compressor.
Leakage test with nitrogen 
This tool can also be used - in addition to drying

the system - to perform a leak test. A filling
adapter for the service connection and a hose
adapter are required for this purpose. The emp-
tied air conditioning system is filled with nitrogen
(max. 12 bar). Over an extended period of time
(e. g. 5-10 min.) it is then monitored whether the
pressure remains constant (pressure loss test-
ing). The leakage can be detected by a "hissing"
noise. Otherwise, it is a good idea to render
those places where there are leaks visible using
a leak-detecting agent. The leak-detecting agent
is sprayed on from the outside. The foam ap- 1 Leak detection spray
pears in places where there are leaks. This 2 Nitrogen
method is only suitable for finding large leaks in
easily accessible places.
Leakage test with forming gas and a suita-

ble leak detector
NOTE
A leakage test with forming gas may be per-

formed only if a leakage test with nitrogen has
previously been carried out.

Air conditioning
To locate leaks, the empty air conditioning sys- 
tem is filled with forming gas (4), a mixture of
95% nitrogen and 5% hydrogen. The compo-
nents are checked for leaks using a special elec-
tronic leak detector (3). Because hydrogen is
lighter than air, the sensor should be slowly
passed across above the suspected leakage
(line connections/components). Once the leak-
age test has been completed, the forming gas
can be dispersed into the ambient air. This leak-
age test complies article 6, §3 of EU Directive
2006/40/EC.
Service and maintenance

System component Maintenance work
Refrigerant circuit
Hose lines Check for abrasion and check general condition
Connections Perform a leak test with a leak detector
Refrigerant filling Check the refrigerant quantity on the inspection glass
Condenser Check the condition of the fins and clean them if they are dirty
Dryer Visual inspection
Condensation water drain Check the opening for passage, clean it if necessary
Check its overall condition, and check that connection points are
Air conditioning unit
secure
Compressor
Magnetic coupling Check that the compressor engages/starts without slippage
Compressor Check that it is running silently
V-belt Check the condition and tension
Mounting element Check its condition, check that it is attached securely
Electrical connections Visual inspection
Connection lines Check the condition
Connection assemblies Check its condition, check that it is attached securely
Repair instructions for the compressor

Correct fill quantity
Every compressor is delivered with a sufficient
quantity of compressor oil for the air conditioning
system. The oil type and oil volume are specified
on the identification plate.

Air conditioning
Checking the compressor oil 
 Remove the compressor.

 Remove the drain plug and let the compres-
sor oil flow out through the outlet line.
 Measure the compressor oil that is dis-
charged using a graduated cylinder.
NOTE
Drain the remaining compressor oil by turning

the outlet connection several times by hand.
 Check the compressor oil for contamination.
 Using a new O-ring, tighten the drain plug.
Lightly lubricate the O-ring with compressor
oil.
Tightening torque: 13-15 Nm.
 Fill with new compressor oil in accordance
with the quantity of discharged compressor
oil.
Fitting tips
There are 150 cm3 of PAG oil and nitrogen (N2)
in the compressor.
 Remove the plastic covering from the low-
pressure side of the compressor in order to
carefully drain the nitrogen.
CAUTION
Do not allow the compressor oil to escape.
Pay attention to the system's orientation during instal-
lation. Do not tilt the system.
 To better distribute the oil, turn the compres-

sor a few times by hand.
Checking the oil level

Check the condition of the compressor oil in the
following cases:
● If the compressor, evaporator, condenser or
dryer are being replaced.
● If refrigerant has leaked out of the cooling cir-
cuit
Magnetic coupling faulty

 Fit a new magnetic coupling on the compres-
sor.
 Mount the compressor and set it in operation,
i.e. switch on the air conditioner.

Air conditioning
 Operate the compressor at idling speed.
Switch on the air conditioning system for ten
seconds at least ten times.
Assembly instructions
Assembling the O-ring connections
 Lubricate the O-ring fitting and flange area 
with refrigerant oil (3). Ensure correct assem-
bly. The O-ring (1) and flanging (2) must be
parallel to each other.
CAUTION
No humidity or dirt must penetrate into the system.
Do not remove the locking caps on the various com-
ponents until immediately prior to assembly.
 Fittings and their counterparts must fit into 

each other smoothly. Press the parts together
firmly and tighten the nut by hand.
 When tightening the connections as a final 

step, use a wrench to hold on to the fixed
side.
NOTE
Lubricating the O-rings with compressor oil

makes assembly easier and prevents damage to
the sealing rings.
CAUTION
When the pressure switch and the pressure sensors
are unscrewed, refrigerant will flow out.
Suction out the refrigerant beforehand.

Air conditioning
Assembling conical nipple connections
 The sealing cone (1), copper seal (2) and fit- 
ting (3) must fit into each other smoothly.
Press the parts together firmly and tighten the
nut by hand.

Air conditioning
Air conditioning system in the truck
Components
3
1
3
1
394-02_03-013
1 Evaporator 3 Condenser with dryer

2 Compressor 4 Support
Design 
(1) Operating cables

(2) Recirculated air filter
(3) Evaporator
(4) Expansion valve
(5) Moulded tubes for water
(6) Bottom plate
(7) Blower
(8) Condenser
(9) Air flap

Air conditioning
Electric circuit diagram

Air conditioning
a Wire to the generator 9V1 Free-wheeling diode (electric clutch)
1 Indicator light in on/off switch 9X9 2-pin plug connector (heating system, air
2 Rotary switch for blower setting conditioning)
3 Blower motor, cab 9X10 1-pin plug connector (air conditioning)
4 On/off switch 9X11 6-pin plug connector (air conditioning)
5 Anti-icing protection switch 9X12 2-pin plug connector (heating system)
6 Controller 9X13 4-pin plug connector (pressure switch for air
7 Relay K1 for fan motors 1 and 2 conditioning)
8 Relay K2 for fan motor 3 9X32 2-pin plug connector (transfer to air condi-
9E2 Heating system with air conditioning tioning)
9F9 Fuse (heating system) 9X33 4-pin plug connector (transfer to air condi-
9M7 Fan motor 1 for air conditioning tioning)
9M8 Fan motor 2 for air conditioning 9Y1 Electric clutch for air conditioning
9M9 Fan motor 3 for air conditioning F25 Fuse (air conditioning)
9S6 Pressure switch for air conditioning
Electrical components 
(6) Control unit

(7) Relay K1 for fan motors 1 and 2
(8) Relay K2 for fan motor 3
Wiring harness 
(5) Anti-icing protection switch

(6) Control unit
(7) Relay K1 for fan motors 1 and 2
(8) Relay K2 for fan motor 3
Connection assembly for operating con-
(9)
sole
9X1
1-pin plug connector
0
9X1
1
9X1
2

Operating units
Accelerator
Function 
The accelerator (3) is located under the bottom

plate and is secured to the step-down gearing of
the pedals with two socket head screws (4). The
spring preload of the step-down gearing of the
pedals is adjusted with four nuts (2). The nuts
must be screwed down until the thread projects
3 mm beyond the nuts.
The bearing block used to secure the pedals is
fixed in place with a hexagon head screw (1).
NOTE
When dismantling the bearing block, the screw

(1) must be inserted with Loctite© 243TM and se-
cured against working loose with thread retain-
ing compound.
The accelerator includes a guide potentiometer
and a monitoring potentiometer, which are con-
nected to the truck control unit via the 4-pole
plug 1X10 .The guide potentiometer controls the
direction of rotation and speed of the drive mo-
tors while the monitoring potentiometer is used
for electrical control of the guide potentiometer.
The accelerator is supplied with +5 V at 1X10:4 
and battery negative at 1X10:1. The output sig-
nal of slider C1 at the guide potentiometer is
connected to the truck control unit via 1X10:2,
and the output signal of slider C2 at the monitor-
ing potentiometer via 1X10:3. Both output sig-
nals can be tested using the diagnostic program.

Operating units
The sliders of the two potentiometers connected 
to each other mechanically. The slideways of
both potentiometers are supplied with a voltage
of 5 V, but the polarity of the two slideways is
opposite.
Output signals 
This means that the output signal added togeth-

er by the truck control unit between the two slid-
ers C1 and C2 must always be 5 V. If there is a
fault in the accelerator potentiometers or in the
supply voltage (e.g. line breakage), the voltage
between the two slider points will change, and
an error is detected by the truck control unit.
NOTE
Over time, wear to mechanical parts may alter

the value of the accelerator when the pedals are
in the zero position. For this reason the acceler-
ator must always be adjusted during every serv-
ice.
NOTE
When installing a new accelerator, the zero posi-

tion must be adjusted.
Calibration 

Operating units
Replacement 
 Turn off the ignition.

 Remove or lift up floorplate.
 Disconnect plug from accelerator.
 Unscrew two socket head screws M4x25 with
washer at accelerator and pull out accelera-
tor.
 Insert a new accelerator in the drive dog and
ensure that the bracket of the accelerator en-
gages with the recess at the drive dog.
 Turn accelerator against the spring and se-
cure with the two socket head screws M4x25
and washers.
 Fit plug and adjust zero position of accelera-
tor via diagnostic program.
Stop screws 
The stop screws of both pedal levers are used to

adjust the maximum output voltage of the accel-
erator. If the accelerator is deflected beyond the
maximum permissible value, the truck control
unit reports an error.
NOTE
After the pedals or the stop screws have been

disassembled, the stop screws must be readjus-
ted.
To adjust the stop screws, start the diagnostic ► Inputs + outputs

program: ▼
Driving
▼
Accelerator
Adjust the stop screws such that the following

voltage values are produced for the "end stops"
parameter:
● Maximum pedal travel in forwards direction:
4.1 V
● Maximum pedal travel in reverse direction:
0.9 V
Once the stop screws have been adjusted, they
must be secured using a lock nut.

Operating units
Joysticks
Joystick variants 
The joysticks are available as central lever,

cross lever (1) or single lever (2) designs.
Central lever/cross lever joystick 

● Central lever (lifting/lowering/tilting)
● Cross lever (auxiliary hydraulics 1 + 2)
Single lever 
Lifting + lowering
Tilting forwards + tilting backwards
Auxiliary hydraulics 1

Operating units
Joystick interlock

Operating units
CAUTION
For attachments that hold a load by exerting pressure
on it, e.g. bulldog clips, the mechanical engineering
directive DIN EN ISO 3691-1 requires a second de-
vice to be actuated in order to prevent the load from
unintentionally being released.
This is achieved as a result of an operating direction
of a joystick on the auxiliary hydraulics (used to open
a bulldog clip, for example) being capable of being
locked via the diagnostic program in the truck control
unit.
NOTE
An electrical switch valve for a third auxiliary hy-

draulic system must not be used for attachments
that have a clamping function (e.g. bale clamps).
NOTE
In the case of trucks which have been retrofitted

with an attachment that is affected by the stand-
ard, the retrofitter is responsible for ensuring
compliance with regulations. Correct functioning
of the lockable joystick must be checked as part
of the periodic testing of the industrial truck in
accordance with FEM 4.004 (formerly UVV acci-
dent prevention regulation check).
An operating direction is one of the axle direc-
tions 1, 2 or 3.
The diagnostic program in the truck control unit 
can be used to set which operating direction of
an auxiliary hydraulics system should be locked
(1, 2 or 3). In each case, only one operating di-
rection of the respective axle can be locked.
However, several auxiliary hydraulic functions
may be locked in the truck.
Operation:
 Briefly move the joystick approx. 50% in the
locked operating direction (auxiliary hydraul-
ics not active).
 Move the joystick into the neutral position.
 In the display unit, the green lamp illuminates 
for the lift mast special functions.
 Move the joystick in the locked operating di-
rection (auxiliary hydraulics active).
NOTE
As soon as the joystick with locked operation is

brought into the neutral position for longer than
1 second, the joystick is locked once more and
the operation of the working hydraulics can only
be activated again once the joystick has been
moved twice.

Operating units
Functional description 
The joysticks control the working hydraulics

functions. The joystick delivers an electric signal
to the truck control unit, which controls the num-
ber of revolutions of the pump motor and acti-
vates the corresponding valve at the valve block.
The joysticks are integrated in the armrest and
connected to the truck control unit via a plug.
The joystick has two output signals for each
function. The guide signal and the monitoring
signal work in opposing directions. The power
supply to the joysticks is 5 V.
The joysticks work with Hall generators, which
detect a magnetic field from a permanent mag-
net. The magnetic field changes when the joy-
stick is actuated.
When the joystick is moved in the + direction, 
guide signal C1 becomes positive and monitor-
ing signal C2 becomes negative.
These two signals are added together in the
controller and must return a value of zero. If
there is an error in the joysticks or in the supply
voltage (e.g. cable break), the signal changes
between the two output signals and an error is
detected by the truck control unit. The output
voltage of the guide signal controls the speed of
the pump motor and the function at the valve
block. The monitoring signal output voltage is
used as a control signal to ensure that the guide
signal functions without any problems.
Joystick 2B1 

Operating units
Joystick 2B2 
NOTE
Over time, wear to mechanical parts may alter

the joystick value when in the neutral position.
For this reason, it is advisable to always align
the joysticks during each maintenance opera-
tion.
NOTE
When installing a new joystick, the neutral posi-

tion must be aligned.
Alignment of joysticks 
Exchange
 Remove the cutting screws (Torx T20) on the 
lower cover of the armrest.
 Remove the lower cover.

Operating units
 Disconnect the plug for the joysticks. 
 Remove the hexagon head screws on the joy- 

sticks.
 Remove the joysticks with the panel facing
upwards.
 Remove the panel. 
 Replace the joystick and calibrate using the

diagnostic program.

Display elements
Display unit
1 2 3 4 5 6 7
8
40
39 9
38
10
37
11
36 12
35
34 13
33 14
10:30
32 03.03.2015
15
31
12345,6 h 16
30
EFF
17
29 18
28 19
27 20
26 21
25 24 23 22
Display_t0001

Display elements
1 Display unit 22 "Confirm" button
2 Hydraulic oil temperature indicator (red) 23 "Down" button
3 Charging indicator (red) 24 "Up" button
4 Engine oil pressure indicator / engine oil fill- 25 "Back" button
ing level indicator (red) 26 "Service interval exceeded" symbol
5 Electronic control error (red) 27 "Mast positioning active" symbol (special
6 Engine coolant temperature indicator (red) equipment)
7 Forwards drive direction (single-pedal opera- 28 "Lift height restriction active" symbol (special
tion) (green) equipment)
8 Warning light for assistance system (special 29 "Creep mode active" symbol
equipment) (yellow/red) 30 Malfunctions menu
9 Particle filter warning (red) (diesel) 31 Settings menu
9 Display not operational (gas) 32 Favourites display menu
10 Display not operational 33 Status display menu
11 Water in the fuel filter (yellow) (diesel) 34 Level display for diesel tank (green/red) (die-
11 Display not operational (gas) sel)
12 Reverse drive direction (single-pedal opera- 34 Level display for LPG tank / replacement cyl-
tion) (green) inders or CNG tank (green/red) (gas)
13 Hydraulic oil microfilter indicator (special 35 Air filter vacuum indicator (yellow)
equipment) (yellow) 36 Coolant level indicator (yellow)
14 Brightness sensor 37 Indicator light: preheating or malfunction (yel-
15 "Time/date" display low) (diesel)
16 "Operating hours" display with the "Operating 37 Display not operational (gas)
hours active" symbol flashes (only if the inter- 38 Display not operational (diesel)
nal combustion engine is running) 38 Warning light for gas system (gas)
17 Function display 39 Display not operational (diesel)
18 Symbol for "Driving dynamics mode" 39 Error light for engine control unit (gas)
19 "Parking brake applied" symbol 40 Electronic joystick unlocked display (green)
20 "Safety belt not fastened" symbol (special or lift height restriction (green when function-
equipment) ing/red for warning) (special equipment)
21 "Cannot start engine" symbol
The display unit performs a self-test after the key switch has been switched on. During the self-test,
all indicator lights and the displays are activated.
NOTE
When replacing a faulty display unit, the operat-

ing hours that have accumulated up to that point
must be recorded. Add the information to an em-
bossed strip and attach near the display unit. It
is also possible to update new display units dur-
ing the first 10 operating hours.

Electrics / electronics 60
General
Safety information for the electrical system
CAUTION CAUTION
Damage to electrical components due to working on Control units can be damaged by electrostatic dis-
live parts. charges.
Before any work on electrical equipment, always first: Do not touch the connections on the plug. Some re-
 Switch off the ignition placement control units are supplied with a protective
cover over the plug to protect against electrostatic dis-
 Disconnect the battery male connector charges. When transporting the control unit, this cover
must be put back in place.
Only when the battery male connector has been
disassembled may plug connections be discon-
nected and electrical components removed.
CAUTION
On opening the control unit, the sealing elements may
be found to be damaged.
The truck control unit must not be opened under any
circumstances. In addition, check that the membrane
on the front of the control unit is not damaged. Open-
ing this renders guarantee and warranty claims void.
Cleaning the electrical system

The components of the electrical system can be blower, heating system) to prevent corrosion
cleaned thoroughly on the outside. The best me- damage.
dium for cleaning is oil-free compressed air. If
the components are very strongly contaminated CAUTION
on the outside, a high-pressure cleaner can be
used for cleaning. Only water may be used for Electrical components can be destroyed by overtem-
this. Under no circumstances should chemical perature.
cleaning additives be added when using a high- Observe the maximum temperature when using a hot
pressure cleaner. Chemical cleaning additives air blower.
may attack the plastic parts of the electrical
components. Electrical components can also be cleaned us-
ing an electric cleaner (e.g. S. L. X. electric
CAUTION cleaner – www.rivolta.de). These electric clean-
ing materials have a dielectric strength of up to
Moisture must not enter the electrical components. 100,000 V/cm and are free from hydrocarbons
When cleaning with a high-pressure cleaner, a suffi- such as CHCs, CFCs, aromatics, PCB/PCTs
cient distance must be observed between the jet and other pollutants.
lance and the component, particularly the connector
plug. ● PCB – polychlorinated biphenyls
● PCT – polychlorinated terphenyls
However, if moisture does enter the compo- ● CHCs – chlorinated hydrocarbons
nents, they must be dried by heating (hot air ● CFCs – chlorofluorocarbons

General
EMC – Electromagnetic compatibility
Electromagnetic compatibility (EMC) is a key secondly checks it for sufficient resistance to
quality feature of the truck. electromagnetic interference with reference to
the planned usage location . A number of electri-
EMC involves cal measures are taken to ensure the electro-
● limiting the emission of electromagnetic inter- magnetic compatibility of the truck .
ference to a level that ensures the troublefree
operation of other equipment in the environ-
ment. CAUTION
● ensuring sufficient resistance to external elec- The EMC regulations for the truck must be observed.
tromagnetic interference so as to guarantee When replacing truck components the protective EMC
proper operation at the planned usage loca- components must be installed and connected again.
tion under the electromagnetic interference
conditions to be expected there .
An EMC test thus firstly measures the electro-
magnetic interference emitted by the truck and
Line routing
In order to prevent wires in the wiring harness
from bending, shearing, rubbing or breaking,
please observe the following instructions:
 Secure the wiring harness to the yellow mark- 
ings at the designated points.
 Do not route wires over edges.
 Do not bend wires.
 Do not route wires along moving parts.
 Do not route wires in a way that means they
are under strain.

General
Identifying components in electrical circuit diagrams
Example: 1 x 1 : 4
1 (function group) X (type of operating material) 1 (sequential number) : 1(pin number)
Examples of the operating materials assigned to the

Code Type of function group
functional groups
Battery, main switch, battery male connector, battery
Nil General
charger
0 Combustion engine Including attached components
Traction motor, drive contactor impulse control system -
1 Drive unit
driving
2 Working hydraulics Lift motor, valve switch
3 Power take-offs Power-assisted steering motor, compressor drive
4 Signalling devices Horn, signal horn, rotating beacon, buzzer
5 Lighting Truck lighting, workplace lighting
6 Measuring and display devices Display unit, battery discharge indicator, hour meter
Special functions (safety func-
7 Dead man switch, emergency off switch, door lock
tions)
8 Automated functions Height preselection, position control
9 Other Heating system, windscreen wipers, fan
Code let-
Type of operating material
ters
A Units
B Sensors, thermoelectric gauges, potentiometers, strain gauges etc.
C Capacitors
D Binary elements, delay devices, storage and memory functions
E Lighting devices, heating devices, fans
F Fuses
G Generators, power supplies
h Visual and audible signalling devices such as signal lights, indicator lights and buzzers
K Contactors, relays
L Coils, inductors
M Motors
N Controllers, amplifiers, regulators
P Display units
R Resistors
S Switches, push buttons
U Voltage transformers
V Semi-conductors
X Terminals, plug connectors
Y Solenoid valves
Z Suppressor circuits
Examples:
1A1 Traction controller N1 Electronic traction control LHC
2B1 Rev sensor 6P2 Instrument panel
4C1 Horn capacitor 1R1 Charging resistor
5E1 Working spotlight S1 Key switch
1F1 Main current fuse U1 Voltage transformer

General
Examples:
G1 Truck battery 1V1 MOSFET power module
H1 Indicator lamps 1X1 Plug connector
1K1 Main contactor 1Y4 Exhaust valve
1M
Traction motor 1Z11 Contactor suppressor circuits
1

General
CAN bus
Function Signal level
Interfaces are used to transmit information be- The physical specifications for CAN are defined
tween the individual components of a system. All in ISO 11898. Resistance against electrical in-
components are connected to a common data terference is achieved by representing each bit
line in a bus system. This reduces the outlay re- via two lines at the same time (CAN high and
quired for line connections, and additional com- CAN low) with an inverse change in potential.
ponents can easily be connected. This is known as a differential signal. Redundant
inverted transmission of the logical signal is
The CAN bus (Controller Area Network) links to-
therefore carried out on a second line. Any inter-
gether several equally entitled components (no-
ference occurring on the line acts on both lines
des) via a 2-wire bus. The flow of data is control-
in the same direction. However, as the two dif-
led via an access procedure (protocol). This sig-
ferential lines always have inverse levels, the
nificantly reduces the outlay required for con-
difference in levels is largely maintained, even in
tacts and lines. In addition, it allows extensive
the case of interference. This is known as com-
monitoring and control of truck functions.
mon-mode rejection.
The CAN protocol was developed by Bosch in
The CAN high and CAN low lines contain the in-
1983 for use in motor vehicles. CAN can also be
verted and non-inverted serial data signal. The
used in Linde trucks thanks to the high level of
state in which there are two different levels on
interference resistance, low costs and real-time
CAN high and CAN low is known as the domi-
capabilities.
nant state (level difference > 3.5 V), while the
The bus concept allows the components of the state in which the two levels are identical is
truck electronics to be connected in series. known as the recessive state (level difference
These components can either be integrated into < 1.5 V).
an overall system, or subsystems can be cre-
ated that only encompass critical areas. When the bus is not active, i.e. no signals are
being transmitted or received, the recessive
Two CAN bus systems are integrated in trucks state is present. As the bus load is below 50%
of the 393-02 family: when active, a good multimeter is triggered on
● CAN bus 1 − truck control unit ◄► engine con-
the recessive CAN bus level. This allows the
voltage to be measured between CAN high/low
trol unit VW/Impco power modules and battery negative. The following results are
● CAN bus 2 − truck control unit ◄► display ◄►
possible depending on the system:
diagnostics ◄► other controllers ● between earth and CAN high: 2.6 V
CAN bus systems can be designed to offer ex- ● between earth and CAN low: 2.4 V
cellent performance and flexibility in terms of da-
ta exchange. The benefits of CAN bus systems
at a glance: Terminal resistance
● Greater reliability To avoid signal reflections and interference on
● Smaller wiring harness the twisted 2-wire bus line, the CAN bus re-
● Multiple use of sensors quires a terminating resistor of approx. 120 Ohm
● New functions possible at either end.
● More flexible system configuration This allows the resistance to be measured on
● Excellent operational reliability the de-energised bus between CAN high and
CAN low:
In a bus system, data transfer functions in a ● Both resistances OK: 60 ohm
manner similar to that of a conference call sys-
● One resistance not OK: 120 ohm
tem. In the truck, the individual controllers are
networked together. As in a conference call, one Terminating resistors CAN bus
participant (controller) "speaks" his or her infor-
mation (data) into the wiring system while the Terminal resistance Incorporated in:
other participants (controllers) "listen in" to this CAN bus 1Mot Engine control unit
information. This information is of interest to cer-
Truck control unit LHC
tain participants, who will make use of it, while CAN bus 1
20
other participants will not.

General
Truck control unit LHC During the subsequent acceptance check, all
CAN bus 2 components use the identifier after the message
20
CAN bus 2 Display 6P1 has been correctly received to determine wheth-
er the data received is relevant in their case.
Such content-specific addressing results in a
Data transfer high level of flexibility. A message can be simul-
taneously received and analysed by several par-
When data is transferred via the bus, no specific
ticipants.
truck components are addressed; the content of
a message (e.g. engine speed or temperature) Measured variables required as information by
is indicated by a unique identifier. The identifier several components can thus be distributed via
not only characterises the content but also the CAN bus so that each component does not
specifies the priority for the message. need its own sensor.
CAN bus connection assembly

X15
For specific assignment of the CAN bus connec-
tion assembly X15, these connection assemblies
have been given designations.
If the connection assembly is assigned without
this designation, the wiring diagram must be
used to identify the connection assembly.
The CAN bus component assignment must be
observed; failure to do so may lead to errors
(e.g. "D160" or "F297").
Illustration of the sheet metal plug holder in

the central electrical system
The designation "X15" is printed on all CAN bus 
connection assemblies (1).
● CAN bus connection main harness
● LFM / connect:

General
LIN bus
Introduction History and prospects
The LIN bus has been designed as an inexpen- Due to its characteristics, the CAN data bus has
sive addition to hierarchical vehicle networks in shown since the early 1990s that it is not suita-
the low-end market. Typical fields of application ble, or is less suitable, for special applications in
include modules for doors, steering wheels, trucks. These applications include safety-related
seats, climate control, lighting systems, rain sen- applications such as driver assistance and x-by-
sors, alternators and fans. Intelligent sensors wire systems, as well as transmission of multi-
and actuators can be easily connected to these media data and networking of intelligent sensors
units via the LIN bus. and actuators. This has led to an increased use
of other bus systems in recent years. The LIN
With the LIN bus, the automotive industry has
bus is ideally suited for use with "sensors and
agreed on a communication standard below the
actuators", and is characterised by its simple
CAN bus. The LIN bus has now replaced virtual-
communication protocol, low cost, easy integra-
ly all proprietary low-end protocols worldwide.
tion and reliability.
It has been specially designed for simple com-
munication tasks in mechatronic applications. In
a similar way to the CAN bus, the LIN bus has
the potential for wider use outside automotive
applications.
Application models
1 ECU 5 Subbus
2 Sensors 6 Sensor
3 Actuators 7 Actuators
4 Bus
In classic architectures, the sensor and actuator tronics to be adapted flexibly to the correspond-
systems required for the control unit (ECU) were ing platform and equipment variant.
connected directly to the control unit, which was
Instead of now constructing a large control unit
connected to a CAN bus, for example. This re-
that incorporates all the functions and is coupled
sulted in a large number of sensors being instal-
via the CAN bus to the other truck functions, in-
led in the truck, and meant that in some cases,
dividual function groups can be easily linked to-
the measured values needed by more than one
gether using the LIN bus, meaning new func-
control unit were obtained from two or more sen-
tions can be added as required.
sors.
Today, the industry is increasingly relying on hi- Bit transmission layer (physical layer)
erarchical architectures. The sensor and actua-
tor systems are connected via a subbus (the LIN LIN is a 12-V single-wire bus that conforms to
bus) to the control units. This enables sensor ISO standard 9141, but is limited to a maximum
signals to be used multiple times and the elec- data transfer rate of 20 kbit/s (gross). For EMC
reasons, the gradient of the signal slopes is also

General
defined within narrow limits. The "wired AND" resistance protects the control unit against para-
connection enables unambiguous error detec- sitic currents from the LIN bus in the event that
tion if two nodes send data to the bus simultane- there is no power supply to the local node.
ously. A diode switched in series to the "pull-up"

General
Pin assignment for the LHC 20 Tricor controller with 154 contacts
in the mating direction ↑front
154-pin measurement adaptor 
The measurement adaptor with the part number

000 973 43 14 must be used for checking all in-
puts and outputs of the LHC 20.
NOTE
Examining the cables, signals and power sup-

plies by penetrating the cable insulation is not
permitted. The resulting contact resistances
cause truck malfunctions.
Pin Signal Function

A01 Output Retarder valve (only in H45/H50)
A02 Output Drive pump, reverse
A03 Output Fan control
A04 Output Drive pump, forwards
A05 Terminal 15 (ignition)
A06 Sensor earth for lifting 1
A09 Sensor earth for driving 1
A12 Sensor power supply for driving 1 (5 V)
A15 Output Working hydraulics safety valve
A16 Output
A17 Output Working hydraulics pump adjustment
A18 Output Reversing signal for the wiper controller
A19 Output Engine stop

General
Pin Signal Function
A20 Output
A21 Output
A22 Input Tilting the joystick forwards/backwards
A23 Input Lifting/lowering the joystick
A24 Input Ref. drive potentiometer
A25 Input Joystick for auxiliary 1
A26 Input Ref. brake switch 1 (M:=brake actuated)
A27 Input Joystick for auxiliary S
A28 Input Reserve
A30 Earth for auxiliary valves S
A31 Output
A32 Output Auxiliary valve 1B
A33 Output Auxiliary valve 1A
A34 Output Forwards tilting valve
A35 Output Backwards tilting valve
A36 Output Lowering valve
A37 Input
A38 Input Joystick for auxiliary 2
A39 Input Ref. seat switch (M:= seat unoccupied)
A40 Input
A41 Input
A42 Input Reserve
A43 Input
A44 Output Auxiliary valve SB
A45 Earth for auxiliary valves 2
A46 Output
A47 Output
A48 Drive pump earth (forwards/backwards)
A49 Earth for fan, retarder valve
A50 Earth for working hydraulics pump adjustment
A51 Output Lifting valve
A52 Earth for lifting/lowering valves
A53 Earth for forwards/backwards tilting valves
A54 Output Mast-positioning lamp
A55 Output
A56 Output
A57 Output Auxiliary valve SA
A58 Output Auxiliary valve 2B
A59 Output Auxiliary valve 2A
A60 Earth for auxiliary valves 1
K01 Terminal 30 (supply voltage)
K02 Terminal 31 (earth)
K07 Output Forwards/backwards driving signal

General
Pin Signal Function
K08 Output
K09 Output
K10 Output
K11 Output Rev sensor
Lift height switch 1 (reduction in speed) (Namur: low 1.25k = below/high 7.5k
K12 Input
= reached/overrun)
K13 Input Activating the lift-height restriction (M: = no lift height restriction)
K14 Input
K15 Input
K16 Input Coding for direction selection lever (M: = direction selection lever connected)
K17 Input
K18 Input Direction selection lever, middle (M:=direction selection lever middle)
K19 Input
K20 Input Brake switch 2 (M:=brake open)
K21 Input Tilting the ref. joystick forwards/backwards
K22 Input
K23 Input Seat switch (M:=seat occupied)
K24 Input Auxiliary ref. joystick S
K25 Input Speed limitation switch 1 (Namur: low 1.25k = ON/high 7.5k = OFF)
K26 Input Ref. joystick for auxiliary 2
K27 Input Hydraulic oil temperature sensor
K28 Output Reversing signal flashing from 0.3 km/h
K29 Output Reversing signal constantly lit from 0.3 km/h
K30 Output
K31 Output
K32 Output
K33 Output
K34 Input
Lift height limit switch 2 (retaining point) (Namur: low 1.25k = below/high 7.5k
K35 Input
= reached/overrun)
K36 Input Mast-positioning button (M = function activated once)
K37 Input
K38 Input Auxiliary limit switch SA (M: = SA active)
K39 Input Direction selection lever forwards (M:=direction selection lever forwards)
K40 Input Direction selection lever backwards (M:=direction selection lever backwards)
K41 Input Drive potentiometer
K42 Input Lifting/lowering the ref. joystick
K43 Input Brake switch 1 (M:=brake open)
K44 Input Auxiliary ref. joystick 1
K45 Data line
K46 Data line CAN1 High/LMH bus
K47 Data line CAN1 Low/LMH bus
K48 Data line CAN2 High/LMH bus
K49 Data line CAN2 Low/LMH bus
K50 Output
K51 Output Brake light signal
K52 Output
K53 Output

General
Pin Signal Function
K54 Output
K55 Input
K56 Input Sweeper operation button (M = function selected)
K57 Input
K58 Input
K59 Input
K60 Input Coding 1
K61 Input
K62 Input Coding 2
K63 Input Speed limitation switch 2 (Namur: low 1.25k = ON/high 7.5k = OFF)
K64 Input Limit switch for auxiliary SB (M: = SB active)
K65 Input
K66 Input Suction filter vacuum (M = "1" = warning light ON)
K67 Data line
K68 Data line CAN1 High/internal combustion engine
K69 Data line CAN1 Low/internal combustion engine
K70 Data line
K71 Data line
K72 Output Sweeper operation lamp
K73
K74 Output Drive pump safety valve (directly connected to earth)
K75 Earth impulse transmitter
K76 Input Tilt angle potentiometer
K77 Input Monitoring-system hydraulic oil filter (M = "1" = warning light ON)
K78 Input
K79 Input
K80 Input Shovel insert switch (M = function activated)
K81 Input Ref. tilt angle potentiometer
K82 Input Diesel filter water trap (M: = "1" = warning light ON)
K83 Input Coding 3
K84 Input Door switch/buckle (M = driving prevented)
K85 Input
K86 Input Coding 4
K87 Input
K88 Input
K89 Input
K90 Input Terminal 50
K91 Sensor power supply for lifting 2 (5 V)

General

General
Working spotlight position

General
BlueSpotTM 
The BlueSpotTM is used to alert passers-by to

oncoming trucks in good time by means of a
light spot projected onto the ground.
1 BlueSpotTM up to 01/2017
2 BlueSpotTM from 02/2017
The BlueSpotTM is fitted on the truck in place of 

a working spotlight.
Terminal Potential
1 +12 to 48 V
2 Minus potential
Technical data:
● Voltage range: 12 to 48 V
● Power: 9 W
● Protection class: IP67
WARNING
The two LEDs emit a bright light beam that can irritate
the eyes. The BlueSpotTM is assigned to risk group 2
in accordance with DIN EN 62471.
The projected light spot must always be directed at
the ground! Do not look into the light beam.

General
TruckSpotTM
The TruckSpotTM is used to alert passers-by to 
oncoming trucks in good time by means of a
warning signal projected onto the ground. The
"TruckSpotTM" is mounted on top of the truck
with a support.
d3931429
Electrical connections: 
Terminal Potential
1 +12 to 48 V
2 Minus potential
Technical data:
● Voltage range: 12 to 48 V
● Power rating: approx. 27 W
● Protection class: IP6k9k
WARNING
Both LEDs emit a bright warning signal that can irri-
tate the eyes. The TruckSpotTM is assigned to risk
group 1 in accordance with DIN EN 62471.
The projected warning signal must always be directed
at the ground! Do not look into the light beam.

General
Sensor system
LHC 20 functional overview

General
1B1 Speed actual value sensor S4 Seat switch
1B2 Accelerator potentiometer 2B1 Joystick
1B4 Hydraulic oil temperature sensor 2B2 Joystick
1B11 Steering angle sensor 2B3 Tilt angle sensor
1B13 Water trap sensor 2Y1-2Y9 Solenoid valves for working hydraulic
1S1 Brake switch 1Y2 Solenoid valve: forwards
1S2 Drive direction switch 1Y3 Solenoid valve: backwards
S2 Brake switch 1Y4 Solenoid valve: release
S3 Suction filter vacuum-operated switch 1Y15 Working pump adjustment
Actual-value transmitter for speed 1B1 
The actual-value transmitter for speed 1B1

sends the controller data concerning the actual
speed. The setpoint speed is determined by the
joystick or accelerator pedal. If the setpoint
speed and actual speed do not correspond, this
is corrected. The deviation from the LHC 20 is
communicated to the VW controller via the CAN
bus. The VW controller corrects the deviation
(changing of the fuel injection quantity). When
braking, the number of revolutions may be driv-
en up. If this is detected by speed sensor 1B1,
the working pump is swivelled to a larger swivel
angle and brake valves may be actuated. 1 Actual-value transmitter for speed in installa-
tion position on the flywheel
Basic setting: Distance measurement between
flywheel and actual-value transmitter: 0.5 mm +
0.3
Function: Sprocket 132 teeth/1 rotation
Diagnostics: In the engine data window, two ac-
tual rev sensors are displayed (crankshaft VW
and flywheel 1B1). The values must be identical.
Error: T248; effect on the truck = stop
Peculiarity: Basic setting incorrect or defective
sensor:
1. This starts when starting the truck. The
truck cannot perform any function (lifting, driv-
ing). However, no error is detected.
2. The sensor communicates the speed signal
via the LHC. The display indicates the excitation
voltage of the three-phase alternator. No signal
means no charging current for the battery. The
engine starts and runs, but the battery is not
charged.

General
Accelerator potentiometer 1B2

The accelerator potentiometer is located in the
pedal unit (arrow). It communicates the driver's
intention with respect to motion, drive direction
and speed to the LCH 20. The function, configu-
ration, position in the truck and diagnostics infor-
mation including settings are described in Chap-
ter 5 Operating Devices.
The basic setting is calibrated. No adjustment
necessary.
Peculiarity: Wear on the teeth of the gear and
gear segment are a frequent cause of fault oc-
currence.
The potentiometer can be calibrated. With firm
pressure on the gas pedal, the potentiometer
leaves the permitted voltage range (tolerance).
The potentiometer with gearing must be
changed.
The truck control unit supplies the accelerator 
potentiometer with voltage of 5 V via :A13. The
output signal of the accelerator controls the
number of revolutions and the swivelling of the
drive pump. For safety reasons, the accelerator
includes two sensors which operate in opposite
directions. Both output signals are connected to
the truck control unit via connections :K41
and :A24.
The accelerator does not include any facility for 

mechanical adjustment. Once the accelerator
has been replaced, it must be adjusted using the
Pathfinder diagnostics. As the pedals are sub-
ject to mechanical wear, adjustment must also
be repeated whenever maintenance is carried
out.

General
1B4 hydraulic oil temperature sensor 
The hydraulic oil temperature sensor 1B4 sends

the LHC 20 the actual temperature of the hy-
draulic oil. This is measured on the servo adjust-
ment E2 of the drive pump HPV. The hydraulic
oil temperature is required for temperature man-
agement in the truck. At a hydraulic oil tempera-
ture of 68°C, the fan is switched on and runs
faster in proportion to the rise in temperature.
The temperature is communicated to the engine
control unit via the CAN bus connection. The en-
gine control unit requires this to calculate the
fuel injection quantity.
The basic setting is calibrated. No adjustment is
necessary.
Function: NTC measurement range: -48°C to
150°C
Diagnostics: Inputs and outputs/error code?
Error: Effect on the truck (tolerance – of E)
R-T characteristic curve NTC type Z-S 088 
1 Resistance R in [Ω]
2 Temperature T in [°C]
Steering angle sensor 1B11

Position in the truck (arrow) 
The steering angle sensor 1B11 is mounted on

the steering axle. It records the steering axle's
current steering angle and communicates this to
the LHC 20. This reduces the engine speed of
the internal combustion engine depending on
the steering angle, thus controlling the driving
speed reduction during cornering. In the event of
an error, the driving speed is corrected to a non-
critical value and the vehicle is decelerated in

General
the curve. The sensor is always active and can-
not be deactivated via the Pathfinder diagnos-
tics. The sensor cannot be monitored at a bat-
tery voltage <7.8 V. The engine must be running
for sensor monitoring.
The steering angle can be read out via diagnos- 
tics. Maximum impact:
1602 1603
α 82° 82°
β 61° 56.5°
The arrow indicates the drive direction.

Basic setting: The mechanical stops must be ad-
justed correctly and the steering angle signal
must be calibrated.
Function: Two-channel PWM signal
Error: Error code is indicated in the display as D
xxx.
Effect on the truck: Reduces speed and initiates
safe braking when cornering.
Modulation process of the signals (1) and (2) 
from -128° to 128°
Supply:
Supply voltage UB: 5V ±100mV
Current draw: < 70mA
The steering angle sensor is supplied by the
truck control unit with 5 V via connection :A12.
The negative supply is at :A09.
The two output signals from the steering angle
sensor operate in opposite directions. They have
a constant frequency of:
● Guide signal 200 Hz (signal A) :K53
● Reference signal 280 Hz (signal B) :K31
Depending on the position of the steering axle,

the time that the output signals are on varies
from 10% to 90%.
NOTE
Following replacement of the truck control unit or

steering angle sensor, the steering angle sensor
must be realigned using the truck diagnostics.
The mechanical basic setting (stop screws on
the steering angle) must be made correctly.

General
Suction filter vacuum-operated switch S3
Installation position in the truck (arrow) and ex- of the air filter is found. From approx. 50 mbar
tract from the wiring diagram this is indicated in the display unit.
Suction filter vacuum-operated switch S3 com- Basic setting: None
municates the vacuum prevailing in the intake
Function: Negative signal at LHC 20; pin: K66
tract to the LHC 20. In this way a contamination

General
Brake pedal switches 1S1 and S2
Function: 2. Starting on a slope. Ratio of the speed

reduction to the engine speed.
When not activated, switch 1S1 conveys a nega-
When starting on a slope, a small pump
tive signal to :K43. If the brake pedal is com-
swivel angle (speed reduction) and possibly
pletely applied or in the case of manual actua-
a high engine speed are required.
tion, a negative signal is conveyed to :A26.
When the accelerator pedal is depressed,
If the brake pedal is not applied or the parking the pump swivel angle and the engine
brake is released, a negative signal is transmit- speed are changed according to a curve
ted to :K20 via the switch S2. that is programmed in the LHC 20.
This must not be used when starting on a
If the brake pedal is semi-applied, a negative
slope → The truck may stall. Therefore, the
signal is transmitted to :K20.
"half depressed" status is monitored. This
If the brake pedal is fully applied or the parking means that the multi-disc brake is still
brake is applied, no signal is transmitted to :K20. closed and the truck cannot roll away on the
slope.
The two brake switches monitor two statuses of
If the accelerator pedal is actuated simulta-
the truck:
neously, a second curve is called up in the
1. The internal combustion engine can only LHC 20. With this curve, the pump swivel
be started with the brake applied. angle remains unchanged at 2°. The engine
Reason: Due to air or faults in the hydraulic speed is increased by depressing the pedal
activation, the truck could start rolling unin- further.
tentionally. This is prevented by the multi- This prevents the truck rolling away on
disc brake (stronger than the truck's maxi- slopes and ensures smooth starting on in-
mum tractive force). This is therefore moni- clines.
tored by switch 1S1. The applied parking brake is monitored by
switch S2.

General
Diagnostics:
The mechanical setting of the brake
switches is not monitored. Cable break, il-
logical signals (plug from 1S1 and S2 re-
versed) are monitored and are displayed as
"driving error T238". Effect on the truck:
truck no longer moves.
Water trap sensor 1B13
Installation position in the truck (arrow) Basic setting: None

Water trap sensor 1B13 communicates the wa- Function: Minus signal on LHC 20; pin: K82
ter percentage in the fuel (diesel) to the LHC 20.

General
Single-pedal drive direction switch 1S2
Installation position in the truck (arrow) plug 1X3 is connected to a jumper plug, with the
battery negative at connections :K40, :K18
The drive direction switch is only installed in sin-
and :K39.
gle-pedal trucks. The reverse accelerator pedal
is not installed in single-pedal trucks. The drive
direction switch communicates the desired drive
direction to the LHC 20: forwards, backwards
and neutral. The cables for the switch are al-
ready installed in the armrest and are equipped
with a coded plug in dual-pedal trucks. In single-
pedal trucks, connection :K16 is connected to
battery negative via the drive direction switch. In
dual-pedal trucks, there is no battery negative
signal at :K16. This provides the truck with the
information that a dual-pedal truck is involved.
Function: on plug 1X3 on LHC 20: pin K:40
backwards; K:39 forwards; :K16 code, :K18 cen-
tre With single-pedal trucks, the single-pedal switch
transmits a negative signal to the following con-
Error: T 236 nections according to the drive direction selec-
Effect on the truck: Stop ted:
In single-pedal trucks, a 1S2 selector switch is Neutral position :K18

located in the area of the joysticks. This switch is Forward drive direction :K39
used to preselect the desired drive direction and
is connected to plug 1X3. In dual-pedal trucks, Reverse drive direction :K40

General
Tilt angle sensor 2B3 
The tilt angle sensor 2B3 records the current tilt

position of the lift mast. When tilting forwards
and backwards, the lift mast moves between the
two adjusted predefined limit values. This means
that when tilting backwards or forwards, the stop
is preset electronically, not mechanically.
The tilt angle sensor consists of the potentiome-
ter (2), which is secured in a potentiometer hold-
ing fixture (3). The potentiometer is secured to
the drive axle via the support (1). Potentiometer
linkage is triggered by a lever (7), which is con-
nected to an angle joint (6) and the support (5)
on the lift mast.
1 Drive axle support

2 Potentiometer
3 Potentiometer holding fixture
4 Plug
5 Lift mast holder
6 Angle joint
7 Lever
The tilt angle sensor contains a guide potentiom- 

eter and a monitoring potentiometer, the sliders
of which are mechanically connected to each
other. The slideways of the two potentiometers
are supplied with a voltage of 5 V. The output
voltage at slider C2 of the guide potentiometer
detects the tilt angle position. The output voltage
at slider C1 of the monitoring potentiometer is
used as a control signal for the electrical moni-
toring of the guide potentiometer.
The resistance of the guide potentiometer (4 kΩ) 

is half that of the monitoring potentiometer
(8 kΩ). This means that the output signal from
slider C2 is twice that of slider C1. If there is a
fault in either of the potentiometers or in the sup-
ply voltage (e.g. a line breakage), the ratio be-
tween the signals from the two sliders changes
and the truck control unit detects a fault.
Pin assignment
The 4-pin plug 2X8 connects the tilt angle sen-
sor to the truck control unit.

General
Plug 2X8
Pin Function
Output signal C2
1
(guide potentiometer)
Output signal C1
2
(monitoring potentiometer)
3 5 V power supply
4 Battery negative
The two output voltages can be checked using

the diagnostics program.
NOTE
When installing a new tilt angle sensor, the tilt

angle sensor must be calibrated
Seat switch S4
Installation position (arrow) and extract from the Basic setting: None
wiring diagram
Position in the truck: In the seat cushion
The seat switch signals to the LHC 20 whether
Function: Minus signal when there is a change
the driver is in the driver's seat.
to pin :A39 or :K23

General
Plug positions
Plug positions in the overhead guard
1X3 5-pin plug connector, coded plug for dual- X11 9-pin plug connector, adaptor connector,
pedal identification special equipment for central electrical sys-
6X1 10-pin plug connector, display unit tem
6X2 7-pin plug connector, diagnostic connector X15 2-pin plug connector, CAN transfer
9X33 4-pin plug connector, air conditioning
X4 5-pin plug connector, seat switch
X10 21-pin plug connector, adaptor connector,
special equipment for central electrical sys-
tem

General
Plug positions under the seat cover
0B1 Boost pressure sensor 1X1 on 3-pin rev sensor 1B1

0B6 Air volumeter 1X11 8-pin plug connector (steering angle sensor,
0B12 Fuel temperature sensor axle load sensor)
0B14 Position transmitter for boost pressure regu- 2X1 Plug connector, 2-pin (microfilter)
lator 0Y2 2nd cylinder injection valve
1B4 Hydraulic oil temperature sensor 0Y7 Boost pressure regulator valve
0S1 Switch for engine oil pressure 1Y2 Forwards solenoid valve "y"
0X1 5-pin plug connector (lambda probe) 1Y3 Backwards solenoid valve "z"
0X2 2-pin plug connector (exhaust gas tempera- 1Y4 Exhaust valve
ture sensor) 1Y15 Working pump adjustment (on bottom of
0X4 2-pin plug connector (exhaust gas tempera- pump)
ture sensor) S3 Vacuum-operated switch for suction filter
0X5 3-pin plug connector (camshaft transmitter)
0X7 2-pin plug connector (exhaust gas tempera-
ture sensor)

General
Plug positions under the seat cover for
the CWTA engine
Sensors
0B1 Coolant temperature sensor 0B13 Phase sensor for the outlet camshaft (on the
0B2 Engine speed sensor control housing facing the right, below the
0B6 Sensor for intake air pressure/temperature flexible formed hose for the engine air sup-
0B10 Phase sensor for the intake camshaft (on the ply)
control housing facing the left, below the flex- 0B16 Engine oil level sensor (below the engine on
ible formed hose for the engine air supply) the oil sump)
0B11 Lambda probe (between the counterweight 0B19 Coolant level sensor
and the engine, below the flexible formed
hose for the engine air supply)

General
Plug
X6 6-pin plug connector for the gas tank 5X2 6-pin plug connector for rear lighting
0X7 3-pin plug connector for the engine speed 9X32 2-pin plug connector for the adapter for air
(on the left next to the electric coolant pump) conditioning (on the oil tank below the fuse
1X1 3-pin plug connector for speed actual value box)
sensor 1B1 (below the flexible formed hose 9X33 4-pin plug connector for the adapter for air
for the engine air supply) conditioning (on the oil tank below the fuse
1X11 8-pin plug connector for steering angle sen- box)
sor/axle load sensor
2X5 10-pin plug connector for the valve block (on
the oil tank below the fuse box)

General
Valves
0Y3 Pulse valve (only with a closed-loop evapora- 1Y3 Solenoid valve "z", reverse (below the air fil-
tor) ter)
0Y7 Valve in the intake for camshaft phasing (on 1Y4 Exhaust valve (below the air filter)
the control housing below the flexible formed 1Y5 Fan valve
hose for the engine air supply) 1Y6 Gas shut-off valve
0Y8 Valve in the outlet for camshaft phasing (on 9Y1 Electric coupling for the air conditioning (be-
the control housing below the flexible formed low the generator)
hose for the engine air supply)
1Y2 Solenoid valve "y", forwards (below the air fil-
ter)

General
Generator, motors, switches, ignition coils
G1 Three-phase generator with regulator S3 Suction filter vacuum-operated switch

M1 Starter motor (flange-mounted in front of the 0S1 Engine oil pressure switch (next to the regu-
counterweight on the engine) lator housing for coolant)
0M1 Electric coolant pump 0T1-0T6 Ignition coils for cylinders 1-6
0M2 Servo motor for butterfly valves with potenti-
ometer (below the mixer)

General
Plug positions under the bottom plate
1B2 Dual potentiometer accelerator X1.1 Engine switch-off via seat switch (special
1X2 3-pin plug connector on the 1S1 brake pedal equipment)
switch X2 on the S2 brake pedal switch
2X5 Plug connector, 10-pin (valve block)

Central electrical system

Arrangement of relays and fuses for basic equipment and special equip-
ment
Fuses
Position Designation Name Value
1.1 6F3 Terminal connection 10 A
1.2 9F103 I.D. Systems 5A
Circumferential view system (terminal
5A
1.3 9F101 15)
5A
Camera system (terminal 15)
5F46 Front LED light strip, white
1.4 10 A
5F47 Front/rear LED light strip, white-red
7.5 A
6.1 5F2 Working spotlight, positions 3, 4
15 A for two working spotlights
7.5 A
7.5 A
6.4 9F5 Rear window heating 20 A
9.1 F5 Display unit (terminal 30) 5A
9.2 F6 Display unit (terminal 15) 5A
9.3 F7 Signal horn 15 A
Traction control/lift control (terminal
9.4 F8 5A
15)
14.1 9F10 12-V socket 15 A
14.2 9F9 Heating system/air conditioning 20 A
14.3 9F6 Seat heater 20 A
Flashing beacon/rotating beacon/
14.4 4F3 7.5 A
BlueSpot
Traction control/lift control (terminal
17.1 F9 15 A
30)
17.2 F10 Terminal 50 5A
20 A, diesel
17.3 F11 Engine control unit
5 A, LPG
7.5 A, diesel
17.4 F12 Engine control unit
10 A, LPG
18.1 5F8 Left-hand headlight 7.5 A
18.2 5F9 Right-hand headlight 7.5 A

Fuses
Position Designation Name Value
18.3 5F10 Left-hand sidelights 5A
18.4 5F11 Right-hand sidelights 5A
Lighting/working spotlight, positions
19.1 5F5/5F1 15 A
1, 2
19.2 5F6/5F13 Warning light 10 A
19.3 5F7 Brake light 5A
19.4 5F12 Interior light 5A
20.1 9F1 Windscreen wiper 5A
20.2 9F2 Front windscreen wiper 10 A
Rear windscreen wiper and roof pan-
20.3 9F3 10 A
el wiper
20.4 9F4 Wash pumps 10 A
21.1 9F7 Radio, terminal 30 5A
21.2 9F8 Radio, terminal 58 10 A
21.3 4F1 Reverse travel 10 A
21.4 6F1 Truck data management 5A
23.1
23.2
23.3
0F1 Blower, toothed belt sealing 10 A
23.4
F17 Time-delayed lighting off 5A
Linde Safety Pilot (LSP) assistance
24.1 F13 5A
system
24.2 F14 Terminal 58 5A
24.3 F15 Terminal 15 10 A
LPG: coolant return-flow pump 5A
24.4 F16
Diesel: 3rd auxiliary hydraulics 5A
Fuse Spare part number

2A 7919086800
5A 7919086803
7.5 A 7919086804
10 A 7919086805
15 A 7919086806
20 A 7919086807
30 A 7919086809
Relays
Position Designation Name
9K9 Speed limitation via indoor/outdoor sensor
2
9K118 I.D. Systems relay (D+)
3 9K101 Relay for buckle monitoring
4 4K1 Relay for reversing signal
5 K1 Relay for terminal 58 (70 A)
0K2 Diesel: Relay for VW controller
7
0K3 LPG: relay for supply
0K3 Diesel: relay for fuel delivery pump
8
0K4 LPG: relay for coolant return-flow pump

Relays
Position Designation Name
10 5K2 Relay for stop lights
5N1 Flasher unit
11
5K5 Warning light for reverse travel
12 5K3 Relay for warning light for reverse travel
13 5K4 Relay for working spotlight, positions 7, 8
15 K3 Relay for truck deactivation
16 K2 Starter relay
22 5K6 Relay for switching LED light strip
22.1 9K103 I.D. Systems micro-relay (driving signal)
22.2 9K104 I.D. Systems micro-relay (speed limitation)
23 9N1 Controller for wiper and screen heating
X K4 Time delay relay, 60 s

Arrangement of the adaptor connectors from the console to the truck
Plug desig- Plug connec-

Number Usage Marking
nation tor
1 5X1/5X4 12-pin Lighting/higher lighting/working spotlights
2
3 9X5 6-pin Wash pumps White
4 4X2 6-pin Reversing signal
5 5X9 3-pin Warning light for reverse travel Green
9X15 3-pin 12-V socket Red
6
5X14 3-pin Working spotlight, positions 5, 6 Blue
Transfer from basic equipment to special
7 X10 21-pin
equipment
8 6X1 10-pin Display unit
9 9X1 9-pin Windscreen wiper
10 0X16 6-pin Blower for toothed belt sealing Green
11 5X60 3-pin Front LED light strip Brown
12 9X9 2-pin Heating system
6X5 3-pin Truck data management White
13
7X16 3-pin Door contact monitoring Grey
9X7 3-pin Seat heater
14
9X29 3-pin Camera system Orange
15 9X8 3-pin Radio Yellow
16 X15 2-pin CAN bus
17
Transfer from basic equipment to special
18 X11 9-pin
equipment
19

Plug housing X10
Spare part
Chamber Name Wire colour Wiring harness
number
Supply to special equipment 3923810333
Monitoring system of blower for tooth-
1 Terminal 58 Red/green 3923810452
ed belt housing
Lighting switched off after a delay 3923810487
Speed limitation via indoor/outdoor
3943812552
sensor
Speed limitation, switchable 3943810460
Central electrical system for camera
3943810393
system
2 Terminal 15 Red/blue Power cable to monitor (IP65) for cen-
tral electrical system/overhead con- 3943812548
sole
Shovel insert 3923810402
Intelligent buckle monitoring 3943812528
Reverse proximity warning unit 3943810486
Central electrical system for truck data
3923810390
management
Lighting switched off after a delay 3923810487
Sweeper 3943810488
3 Terminal 15 Red/blue connect:hr / tc Attachment position,
3913810415
left
connect:hr / tc Attachment position,
3923812693
right
Terminal connection 3923812654
Speed limitation via indoor/outdoor
3943812552
sensor
Speed limita- Speed limitation, switchable 3943810460
4 White
tion 1 Central electrical system for door mon-
3943812544
itoring
5 Buckle Green Buckle monitoring 3943810493

Spare part
number
Lighting for console and light for clip-
3943810456
board
Higher lighting for console and light for
3943810458
clipboard
Higher lighting and BlueSpot front con-
3943812564
sole and clipboard
Standard front lighting/higher rear
6 Brake light Grey/blue lighting for console and light for clip- 3943812560
board
Hazard warning system when revers-
3923810352
ing without lighting
Top centre tail light/brake light switch-
3943812545
ed via working spotlight
Top centre tail light/brake light switch-
3943812546
ed via ignition
Working spotlight, positions 3/4/7/8
3923810317
Reversing sig- console
7 Grey/red
nal Working spotlight, positions 3/4/5/6/7/8
3923810405
console
3943810458
clipboard
3943812564
sole and clipboard
Central electrical system for reversing
3923810327
Reversing sig- signal
8 Grey/red
nal Central electrical system for camera
3943810393
system
Monitor (IP65) power cable for central
electrical system/overhead console/ 3943812548
variant 1
Circumferential view system 3943812584
Reversing sig- Hazard warning system when revers-
9 Grey/red 3923812587
nal ing with lighting
Flashing re- Hazard warning system when revers-
10 Yellow/blue 3923810352
versing signal ing without lighting
Shovel opera-
11 Green/orange Shovel insert 3923810402
tion
Reversing sig- Windscreen wiper 3923812576
12 Green/grey
nal Front/rear LED light strip, white-red 3913810440
Monitor (IP65) power cable for central
electrical system/overhead console/ 3943812548
13 Driving signal Yellow/red variant 2
14 Sweeper Yellow/green Sweeper 3943810488
15 Terminal D+ Blue
Indicator light
16 Grey/white Sweeper 3943810488
for sweeper
Buckle monitoring 3943810493
17 Door lock Orange/green

Spare part
number
Reference for
18 Grey/black Sweeper 3943810488
sweeper
19 Seat switch Brown/yellow Intelligent buckle monitoring 3943812528
20 Terminal 30 Red/white Intelligent buckle monitoring 3943812528
21
NOTE
After connecting the wiring harnesses to plug

7912503408 (1), secondary interlock
7912503312 (2) must be snapped into place.
NOTE
If a chamber is occupied twice, wiring harness

3923810366 must be used.
Plug housing X11 
Spare part
number
Earth for elec-
1 Brown/blue
tronics
2
3
connect:hr / tc Attachment position,
3913810415
Earth for elec- left
4 Brown/blue
tronics connect:hr / tc Attachment position,
3923812693
right
5
Engine switch-
6 Blue/green Truck cut-out 3943810313
off
Lighting for console and light for clip-
board
3943812558
Earth for elec- 3943812559
7 Brown/blue clipboard
tronics 3943812560
Standard front lighting/higher rear
3943812564
lighting for console and light for clip-
board

Spare part
number
sole and clipboard
8
9
NOTE
After the wiring harnesses have been plugged

in, the secondary locking device must be snap-
ped into place. The plug housing and secondary
locking device are included in the scope of deliv-
ery of the wiring harness.

Truck control unit

Truck control unit overview
● Supply voltage 7.8 - 16.5 V cessor for the traction function. Should an inter-
● Minimum voltage 6 V nal control unit fault be detected, the control unit
● Reverse polarity protection will immediately initiate measures to ensure that
the truck operates safely. These measures may,
● Maximum excess voltage 24 V for 5 minutes
for example, involve reducing the speed of a
specific function or switching off the truck com-
CAUTION pletely.
Electrostatic charge can destroy electronic compo- The controller is equipped with a 154-pin (1)plug
nents. Sealing elements will be damaged if the con- that is attached to the truck's main harness.
troller is opened.
Communication with the VW/Impco engine con-
Do not touch connections at the plug, as internal com-
trol units takes place via the internal CAN bus
ponents may be damaged due to electrostatic dis-
charge. The truck control unit must not be opened un- (CAN bus 1)..
der any circumstances. It should also be ensured that
the membrane on the front of the controller is not
The spare part number, software version, serial
damaged. number and operating hours of the controller
can be read using the truck diagnostics.
The truck central control includes two micro-con-
trollers to control the traction drive, working hy- NOTE
draulics and steering function. The first micro-
controller controls the traction function and
If a new control unit is fitted to the truck, the di-
serves as a safety processor for the working hy-
agnostics program must be used to enter a num-
draulics. The second processor controls the
ber of settings.
working hydraulics and serves as a safety pro-

Truck control unit
If these settings are only partially entered on a ● Steering angle sensor
new controller, the speeds for driving and the ● Tilt angle sensor
working hydraulics will be greatly reduced and a
status message to this effect will be displayed in Programming
the truck diagnostics. ● Truck serial number
● Special functions (speed reduction, warning

When the truck control unit has been replaced,
signals etc.)
the following settings must be entered using the
diagnostics program. Once the settings have been entered, switch the
truck off and on again to save the values in the
Alignment truck control unit.
● Accelerator
● Joysticks

Truck control unit
Overview - Sensors
0B1 Boost pressure sensor 0M2 EGR valve (with potentiometer)

0B2 Particle difference pressure sensor 0M4 Diesel supply pump
0B3 Common rail distributor strip pressure sensor 0N1 Control unit for diesel direct fuel injection
0B4 Lambda probe before catalytic converter 0R1 1st cylinder glow plug
0B6 Air volumeter 0R2 2nd cylinder glow plug
0B7 Exhaust gas temperature sensor 0R3 3rd cylinder glow plug
0B8 Exhaust gas temperature sensor after oxida- 0R4 4th cylinder glow plug
tion catalytic converter 0Y1 1st cylinder injection valve
0B9 Exhaust gas temperature sensor after diesel 0Y2 2nd cylinder injection valve
particle filter 0Y3 3rd cylinder injection valve
0B10 Coolant temperature sensor 0Y4 4th cylinder injection valve
0B11 Camshaft sensor 0Y5 High-pressure control valve
0B12 Fuel temperature sensor 0Y7 Boost pressure regulator valve
0B13 Crankshaft sensor 0Y8 High-pressure pump fuel metering valve
0B14 Position transmitter for boost pressure regu- 6B1 Display unit
lator H8 Glow plug indicator
0B16 Engine oil level sensor H13 Particle filter warning
0K3 Diesel supply pump relay N1 LHC electronic controller
0M1 Butterfly valve (with potentiometer)

Truck control unit
Heating - sensor overview
0B10 Coolant temperature sensor 0R2 Glow plug for 2nd cylinder
0B13 Crankshaft sensor 0R3 Glow plug for 3rd cylinder
0N1 Control unit for diesel direct fuel injection sys- 0R4 Glow plug for 4th cylinder
tem 6B1 Display unit
0N3 Automatic preheating time control unit H8 Preheating indicator
0R1 Glow plug for 1st cylinder

Truck control unit
Linde Hydraulic Control (LHC)
Digital electro-hydraulic controller ● The truck brakes via the emergency function;
the internal combustion engine switches off
Vehicles in series 39X are industrial trucks and ● An error code appears on display
feature the latest control technology. Instead of
a hydraulic accelerator, a compact electronic These measures can be overridden by switching
controller equipped with a very powerful micro- off the combustion engine with the key switch.
controller performs all control functions for the During a restart, the control unit checks whether
drive unit and the working hydraulics (1). the error is still present. If the error is no longer
present, the truck resumes normal operation. If
the error persists, the error code reappears on
Adaptation to various trucks the display and one of the measures listed
The electronic control unit is capable of control- above is activated.
ling trucks from a variety of series and with dif-
ferent drive motors. To take differing truck pa- Changing the controller
rameters into account, each truck cable harness
has a coding that uniquely identifies the truck. CAUTION
Possible irreparable component damage due to elec-
Troubleshooting trostatic discharge. Irreparable damage to sealing ele-
ments will occur if the controller is opened.
The processor of the electronic control unit Do not touch connections at the plug, as internal com-
analyses analogue and digital signals. The pro- ponents may be damaged due to electrostatic dis-
cessor recognises illogical statuses and system charge. The truck control unit must not be opened un-
errors, and displays an error message on the der any circumstances. It should also be ensured that
testing instrument via the serial interface. In ad- the membrane on the front of the controller is not
dition, the control unit activates a variety of damaged.
measures according to the error's hazard poten-
tial: The controller is equipped with a 154-pin plug,
● Warning light flashes
which is attached to the truck's main wiring har-
● Revolution limitation of the internal combus- ness. Communication takes place via CAN bus.
tion engine
● The truck brakes with normal brake retarda-
The spare part number and the software version
of the controller can be read out via the truck di-
tion and will no longer move
agnostics.

Truck control unit
NOTE
If the controller is replaced, the permitted spare

part controllers must be identified and also
adapted to the cable harness. All necessary in-
formation is available on the Linde Extranet.
Power supply
The truck control unit is supplied with voltage via 
various connections.
● Permanent battery :K01; :K03; : K05
● Ignition on :A05
Power supply for external compo-

nents
The following external sensors are supplied with 
a voltage of 5 V by the truck control module:
● Accelerator :A13; :A10
● Steering angle sensor :A12; :A09
● Joysticks 2B1, 2B2
● Tilt angle sensor 2B3; :K97; :A07

Truck control unit
Enable signal
The traction and working hydraulics functions 
can only be activated if a battery negative signal
is present at connection K23. This negative sig-
nal is controlled via the seat switch S4.
The seat switch S4 has an alternating contact
which is connected to connections :K23
and :A39. The two controller inputs alternately
receive a battery negative signal according to
the switch status of the seat switch. This ena-
bles the correct function of the seat switch to be
monitored.
Truck coding
The truck control unit has four input signals for
truck coding.
Connections :k60, :K62, :K83, :K86 are connec-
ted to the battery negative pole via the main har-
ness.
The LHC 20 can be installed in every truck of
the 39x-02 series. Because the encoding is per-
formed via the main wiring harness, the LHC 20
recognises the truck where it is installed.
Pin: K60 Pin: K62 Pin: K83 Pin: K86

Code 1 Code 2 Code 3 Code 4
393-02-series D
Open Open Earth Open
CR
393-02-series T Open Open Earth Earth

Truck control unit
LHC controller with ECO mode
Since the beginning of 2010, a modified LHC
controller has been fitted. This is also equipped
with an ECO mode, which is activated at the fac-
tory.
Effects of ECO mode:
● Power reduction of up to 10% in drive mode
● Decrease of revolutions (both static and dy-
namic) in drive mode

● Modified fan characteristic curve
● Reduction in operational noise levels
● Longer tyre service life
● Reduction in fuel consumption: according to
VDI cycle — up to approx. 9%; in dynamic lor-

ry cycle — up to approx. 20%
● Working hydraulics (speed of lifting and auxili-
ary hydraulics) remain unchanged

Following the introduction of the ECO mode, the
following functions can be adjusted via the diag-
nostics software:
● "ECO consumption optimisation"
● "Monitoring for number of engine starts"
● "Handbrake monitoring"
ECO consumption optimisation

ECO mode in 2 levels: "ECO" and "ECO light"
These settings initiate a speed/Vmax reduction
as follows:
Mode Nominal speed vmax Acceleration

393-02
Series Performance 2700 rpm 23 km/h
Efficiency (fac- Forwards -3%/backwards
ECO light 2500 rpm 21 km/h
tory setting) -10%
Forwards -10% / backwards
ECO Economy 2500 rpm 21 km/h
-10%
When resetting the mode from "ECO" or "ECO

Light" to "Standard", the engine speed must be
manually reset to 2700rpm. As shown above,
this change in speed can be carried out on the
same screen.

Checks
Testing the LHC
Step
Yes No
Type of Procedure
(Test) (Test)
step
To start the test:
1
Switch on the ignition; read
Action
out the error memory
2
Error logged - driving Go to step 3 Go to step 8
Test
3 Perform troubleshooting with
Action guided diagnostics
4 "Testing of wiring harness"
Error found Go to step 5
Test and "Testing of sensors"
5 Perform repair and remedy
Action the fault
Perform function checking
6
and clear the error memory,
Action
continue to step 11
7 To repeat the troubleshooting
Function OK End
Test process, go to step 1
8 Error logged - working hy- Perform a test drive. Go to
Go to step 3
Test draulics step 9
"Testing of wiring harness"
9 Error detected or error stored
Go to step 3 and "Testing of sensors";
Test in error memory
continue to step 10
10 Error detected - wiring har-
Go to step 5 Go to step 11
Test ness
11 Error detected - sensors/
Go to step 6 Replace the controller
Test actuators
NOTE
For step 11 (No): Use the diagnostic program to

save a log file. Make a note of the voltage val-
ues and resistance values from the "Testing of
wiring harness" and "Testing of sensors" steps.
In the event of a warranty claim, the data from
the log file (error types and frequency of errors)
plus the voltage and resistance values must be
specified in the claim text. A print-out of the log
file must be included with the defective part
when it is sent back.
Testing the VW controller and the immobiliser

Step YES no
Procedure
Type (Test) (Test)
1
Start the test
Action
2
Connection possible Go to step 3. Go to step 11.
Test

Checks
Step YES no
Procedure
Type (Test) (Test)
Test the supply voltage ter-
3
Read the error log. Go to step 4. minal and earth; continue to
Action
step 11
4
Identify the error Go to step 5. Go to step 10.
Test
Perform troubleshooting with
5 guided diagnostics; "Testing
Action of wiring harness" and "Test-
ing of sensors"
6 Perform repairs and remedy
Action the error
7 Perform function checking
Action and clear the error memory
8 Replace the VW controller
Operation OK End
Test and the immobiliser
9
Identify the error Go to step 1. Go to step 7.
Test
10
Perform test run.
Action
Disconnect the connection Test the supply voltage ter-
11 assembly for the immobiliser; minal 15/30 and earth on the
Supply voltage OK
Test bridge pin 2 and pin 3 in plug immobiliser and controller.
0N2. Go to step 12 Go to step 5
12
Connection possible Go to step 13 Go to step 5.
Test
13
Read the error log.
Action
14 Check plug 0N2; connect the
Action immobiliser
15
Connection possible Go to step 5. Replace the immobiliser
Test
NOTE
For step 8 (No) and step 15 (No): Use the diag-

nostic program to save a log file. Make a note of
the voltage values and resistance values from
the "Testing of wiring harness" and "Testing of
sensors" steps. In the event of a warranty claim,
the data from the log file (error types and fre-
quency of errors) plus the voltage and resist-
ance values must be specified in the claim text.
A print-out of the log file must be included with
the defective part when it is sent back.
Testing the wiring harness

1. Mechanical testing
 Check wiring harnesses for external damage
to the insulation, pinch points, heavy contami-
nation with oil, grease, water etc.

Checks
 Starting from the battery through to the cen-
tral electrical system and the components,
check that all screw connections are securely
attached.
Examples:
 Check attachment of the main harness to the 
battery terminal.
 Check all connection assemblies for corrosion 

and check that they are securely attached.
Never use contact spray.
 Check the insertion force of the contacts on 

the main fuse: maximum contact distance
0.4 mm (check this using a feeler gauge).
Tighten the nut for the cable connection to
max. 5 Nm.

Checks
 Check that crimped joints are secure. Perform 
a pull test on each individual wire.
2. Electrical testing
 Check that the wiring is correct according to
the configuration and wiring diagram for the
truck.
 Measure the battery voltage. 

:
Perform a voltage measurement (1) at terminal
15/58 (switched positive) with a current load on
the wiring harness, e.g. 55-W headlight bulb (2),
against the truck earth.
9
 Use a suitable measurement box; for LPG, al-
so use the measurement adaptor. B
LHC20
Series Measurement box designation Measurement adaptor designation
391 evo, 392-02, 393-02,
154 pin (0009734314)
394-02, 396-02, 396-03
Diesel engine control unit

391 evo, 392-02 121 pin (7917299010)
393-02, 394-02 154 pin (0009734314)
396-02, 396-03 196 pin (0009734335)
LPG engine control unit

391 evo, 392-02,
121 pin (7917299010) + adaptor (0009734313)
393-02, 394-02
396-02, 396-03 154 pin (0009734314) + adaptor (0009734324)
 Check the CAN bus connections: Ensure that

the CAN high and CAN low are connected
with the correct polarity; check the line resist-
ance.
NOTE
Resistance measurements and voltage meas-

urements under load are measurements purely
on the wiring harness. No controllers or compo-
nents may be connected.

Checks
Testing sensors
1. Mechanical checking:  Visually check plug connector seals
 Visual checking for mechanical damage  Check the actuator mechanisms for free
movement
 Positioning and installing the sensors.
 Check the connection assemblies for corro- 2. Electrical testing:
sion
 Perform resistance measurements and volt-
age measurements directly on the component
2. Electrical testing:
 Perform current measurements
 Check the supply voltage
 Perform resistance tests on each of the sen- 3. Diagnostics:
sors
 Actuator test (VW controller)
 Check the signal output from the sensors
Test actuators (control solenoid, valve sole-

noids)
1. Mechanical checking:
 Check that the cable connections and con-
nection assemblies are securely attached

Assistance systems
Assistance systems overview
There are currently six different "assistance sys- Linde Safety Pilot select (LSP select)
tems" available.
The LSP select assistance system supports the
● Load weight indicator "+ function" driver with a number of functions available for
● Linde Safety Pilot select (LSP select) selection. However, LSP select is a "passive"
● Linde Safety Pilot active (LSP active) system that does not interfere with the drive
● Reverse proximity alarm function and other operational functions.
● Linde Curve Assist (LCA) Linde Safety Pilot active (LSP active)
● Linde Speed Assist (LSA) The LSP active assistance system supports the
These systems differ both in terms of functionali- driver by offering a range of advanced functions
ty and in terms of technical design. compared to the LSP select. LSP active reduces
the risk of tipping and increases the stability of
the truck. The system is identical to the LSP se-
NOTE lect in terms of the design and sensor system,
but also features an axle load sensor on the
Assistance systems are only designed to offer a
steering axle and two rev sensors on the wheel
supporting function and do not guarantee safety.
The responsibility for operating the industrial motors. This enables LSP active to "actively" in-
truck in a safe manner always lies with the driv- tervene in the truck's drive function and other
er. Even in the event of a potential malfunction, operational functions. One example of such an
the driver must have full control of the truck at all intervention is initiating creep speed when the
times. escalation level kicks in.
Reverse proximity alarm
Brief description
Supports the driver with the aid of ultrasonic
Load weight indicator "+ function" sensors that are attached at the rear of the
truck. If the distance to an obstacle drops below
Load weight indicator "+ function" is a load-de-
a certain level, the system reduces the reverse
pendant assistance system that reduces the risk
driving speed to 1 km/h. Full braking to a stand-
of tipping and enhances the stability of the truck.
still is not initiated automatically and must be
The "lifting and tilting limitation" assistance func- performed by the driver. This system offers sig-
tion actively intervenes in the lifting movement nificant support during reverse travel if the driver
and tilting movement and reduces these move- needs to keep the load (e.g. liquid steel) in view
ments to a complete stop if necessary. in addition to the roadway.
The "overload protection" assistance function re- A detailed description of the reverse proximity
duces the risk of tipping by stopping the lifting alarm and its components can be found in chap-
movement when the load exceeds 30% of the ter "90 Special equipment".
rated capacity of the truck. Linde Curve Assist (LCA)
The "load-dependent reduction of driving speed"
Supports the driver when cornering by automati-
assistance function can be optionally activated
cally adapting the speed. To prevent the truck
via the diagnostic software.
from tipping over due to excessive speeds when
To collect the data, the system is equipped with cornering, the LCA reduces the cornering speed
three sensors: and rate of acceleration out of corners depend-
● Lift height switch ing on the steering angle.
● Tilt angle sensor Linde Speed Assist (LSA) "radar sensor"
● Load pressure sensor Supports the driver by adapting the speed in line
For the load-dependent assistance system load with the surroundings. To enable the system to
weight indicator "+ function", no additional con- differentiate between various surroundings (e.g.
troller or display unit is fitted. The functionality a hall or outdoors), a radar sensor fitted on the
for the load weight indicator "+ function" is inte- roof of the truck measures the distance to poten-
grated in the LHC 20. tial obstacles or ceilings. When entering halls,
the speed is automatically reduced and limited.

Assistance systems
When driving outdoors, the truck can travel at
maximum speed again.
Instructions for adjusting the sur-

round view (Surround View) sys-
tem
Functional description and notes
The surround view system is used to detect oth-
er trucks, people and objects.
The cameras are set to a 360° circumferential
view at the factory.
NOTE
The surround view system supports the driver in

handling the truck. The responsibility and control
for operating the truck in a safe manner always
lies with the driver.
NOTE
The national regulations must be observed with-

out fail.
DANGER
Risk of accident!
If a camera position is changed or if a camera is dam-
aged, the circumferential view is no longer guaran-
teed.
The driver must always be able to verify the area
shown on the monitor by making direct visual contact.
WARNING
Operating error!
The monitor cover protects the system against operat-
ing errors. The components of the surround view sys-
tem must not be opened by the driver or the operating
company.
After the surround view system has been adjusted, it
is essential that the monitor cover is refitted!

Assistance systems
Factory setting of cameras
6 4 9
1
3
d3961270
1 Front camera 6 Front field of vision

2 Right-hand camera 7 Right-hand field of vision
3 Left-hand camera 8 Left-hand field of vision
4 Rear camera 9 Rear field of vision
The camera is adjusted at 0° (neutral position) to 

the plastic housing at the factory.
All camera mounting supports are designed
such that no readjustment of the camera is nec-
essary after installation. All four views are dis-
played accordingly on the monitor in an "H" ar-
rangement. For this to happen, the lift mast must
be in the vertical position (0° forwards/back-
wards tilt).

Assistance systems
Adjustment options (camera angle)
If attachments or structures on the lift mast cov- 
er the right-hand side of the lift mast, the camera
angle can be readjusted.
 Loosen the four Torx screws in the plastic
housing using a suitable tool (TX15).
 To show the desired field of vision on the
monitor, adjust the camera angle within a
range of ±15° from the neutral position.
 Afterwards, tighten the four Torx screws to a
tightening torque of 4 Nm.
The same procedure must be followed if attach-
ments on the overhead guard or on the counter-
weight obstruct the circumferential view.
Monitor display
The monitor is configured in the "H" arrange- 
ment for forwards travel at the factory.
6
8 7
9
d3961272
6 Front field of vision

7 Right-hand field of vision
8 Left-hand field of vision
9 Rear field of vision

Assistance systems
The factory setting for reverse travel is represen- 
ted by a three-way display on the monitor.
When the drive direction indicator is actuated,
the front and rear camera and the corresponding
side camera is always shown.
8 9 7
d3961275

Display during forwards travel with the left-hand 

turn indicator activated
6
8
9
d3961273


Assistance systems
Display during forwards travel with the right- 
hand turn indicator activated
6
7
9
d3961274

On the 394 and 388 series, the position of the 

front camera is rotated by 180° compared to the
396 and 1279 series. As a result, the front view
in the "H" arrangement on the monitor is rotated
by 90° (image 5). For this reason, the view of the
front camera for the 394 and 388 series must be
rotated as follows:
 Remove the two socket head screws (1) on 

the monitor and remove the cover (2). It is es-
sential that the cover (2) is refitted after the
adjustment procedure.

Assistance systems
 To access the (Main Menu), press the middle 
button on the monitor.
 Use the right or left arrow keys to select the
"(Cameras)" menu item in the main menu and
confirm using the middle button.
 The monitor display switches to the "Cam-
eras" menu item. Now select the "front cam-
era" (Cam1) and confirm using the middle
button.
 Press the right arrow button until the "(Ro-
tate)" menu item is selected and confirm. Now
use the right arrow button to change the num-
ber of degrees.
 Press the right arrow button until "270°" (270
DEG) is set and confirm.
 Now use the right or left arrow keys to select
(Back) and press the middle button to switch
to the forwards field of vision.
 Return to the (Main Menu) and use the right
or left arrow keys right to select (Exit) and
confirm using the middle button. The monitor
display changes to show the "H" arrange-
ment.
Checking the camera angle
NOTE
The minimum truck contour must be visible in

the "H" arrangement view. In other words, as lit-
tle as possible of the truck outer contour should
be visible.
The views of the truck contour can be checked 
against this plan.
3 "H" arrangement of the monitor

4 Truck contour
5 Monitor
10 Lift mast
11 Counterweight

Assistance systems
To test the surround view system, cones can be 
placed at the corners of the truck.
The cones must be visible in the sections for the
front and side view and for the rear and side
view. Performing this test ensures that there are
no blind spots around the truck.

Assistance systems
Load weight indicator "plus"
Safety guidelines for the load-dependant assistance system (load weight indicator
"plus")
The load-dependant assistance system reduces Application conditions
the risk of tipping and increases the stability of
the truck. The load-dependant assistance system is not
● This is achieved by actively intervening in the suitable for applications in which the system
lifting and tilting movements. In addition, there components may be damaged by exposure to
is the option to intervene in the driving speed. dirt, chemicals or bulky loads. This applies to the
● The load centre of gravity is not taken into ac- sensors of the assistance system in particular.
count. Consult the load capacity diagram. If a limit value is approached or reached, a visu-
To ensure that the system functions reliably, the al and audible signal is provided via the display
following safety guidelines must be observed. unit. At the same time, the assistance system in-
tervenes in the movements of the truck. In this
case, the driver must leave the critical area.
Assistance system
The load-dependant assistance system (load Error messages in the display unit
weight indicator "plus") provides information to
help the driver and reduces the risk of tipping in ● If the display unit fails, the driver does not re-
line with defined limit values. To reduce the risk ceive any warnings. Should this occur, the
caused by certain impermissible load states, the truck must not be operated
load-dependant assistance system actively inter- ● If the display fails or if the legibility of the dis-
venes in the controller. This only applies where play is impaired, the display unit must be re-
the truck is being used for its intended purpose. placed
● If an assistance function fails, the red warning
light for the assistance system flashes in the
NOTE display unit and an intermittent tone sounds
● An error code makes it possible to determine
Assistance systems are only designed to offer a which system component has failed
The responsibility for operating the truck in a
● Following a failure, the assistance functions
safe manner always lies with the driver. Even in are available only to a limited extent
the event of a potential malfunction, the driver
must have full control of the truck at all times. Maintenance
● The functions of the load weight indicator
Hazard assessment "plus" assistance system must be checked
The load-dependant assistance system changes within the maintenance intervals.
the driving characteristics and operation of the ● The lift mast must be checked and maintained
truck, and therefore influences the hazard as- within the maintenance intervals.
sessment. It is therefore necessary to adapt the ● Cleaning work must be carried out in accord-
hazard assessment in line with national health ance with the truck operating instructions.
and safety directives, and to train the driver on ● If sensors or the lift mast have been replaced,
how to operate the truck with the load-depend- the sensors must be recalibrated.
ant assistance system. It is imperative that driv- ● In the event of a tyre change, the tilt angle po-
ers familiarise themselves with how to operate tentiometer must be calibrated.
the truck with the load-dependant assistance
system.

Assistance systems
Load-dependant assistance system load weight indicator "plus"
The load weight indicator "plus" special equip- To collect the data, the truck is equipped with
ment is an assistance system that, in addition to the following sensors:
displaying the load weight in the display unit, al- ● Push button in the armrest (load weight dis-
so reduces the risk of tipping and increases the play)
stability of the truck. This is achieved by actively ● Lift height switch
intervening in the lifting and tilting movements. ● Tilt angle sensor
● Two load pressure sensors

Variants of the assistance functions
Push button (1) in the armrest
● "Load weight indicator" assistance function
The weight of the load being carried is shown
on the display unit.
● "Overload protection" assistance function
If the truck is overloaded by lifting too heavy a
load, the assistance system reduces the lifting
speed to the extent of stopping the movement
if necessary. In addition, the driver receives a
visual and audible warning via the warning
light of the assistance system (3).
● "Lifting and tilting limitation" assistance func-
tion
At significant lift heights and depending on the
load in question, the lifting and tilting speed is
reduced to the extent of stopping the move- 1
ment if necessary. At the same time, the for-
wards tilt angle is restricted at significant lift
heights, depending on the load. In addition, d3941490
the driver receives a visual and audible warn-
ing via the warning light of the assistance sys-
Settings
tem (3). At higher lift heights and depending
on the load in question, the lifting speed is re- For the assistance system to function correctly,
duced to 25% of the maximum lifting speed. it is necessary for various truck parameters to be
● "Load-dependant reduction of driving speed" set using the diagnostic program.
assistance function
The driving speed is limited depending on the Adjustable parameters: lift mast (required)
load. In addition, the driver receives a visual ● Lift mast series (e.g. 1523)
and audible warning via the warning light of ● Lift mast type (standard, duplex, triplex)
the assistance system (3). This assistance
● Load capacity (tonnage)
function can be activated using the diagnostic
program. Adjustable parameter: Safety offset (optional)
● 0° to 2° safety offset
Function monitoring
The load weight indicator "plus" assistance sys- NOTE
tem is ready for operation when the truck is
switched on and the subsequent self-test of the
The safety offset can be used to configure the
display unit is completed. After the truck is
assistance system to also intervene when tilting
switched on, the assistance functions are moni-
backwards.
tored and shown in the display unit.
Adjustable parameter: Speed reduction (option-
System components al)
● Load threshold for reduction
The load weight indicator "plus" assistance sys- ● Minimum speed
tem evaluates the lift height, the mast position
and the carried load. The driving speed can also
be evaluated in conjunction with the load.

Assistance systems
Load pressure sensors 
The load-dependant assistance system (load

weight indicator plus) uses two pressure sensors
to detect the load weight on the fork arms.
These sensors measure the pressure at connec-
tion A1 of the control valve (pressure connection
for the lift cylinder).
Both pressure sensors measure the same pres-
sure (redundancy) and are connected to the
truck control unit via the plug (1) and the main
harness. The truck control unit calculates the
load weight based on the load pressure and
transmits the values via the CAN bus to the dis-
play unit variant 2 (EVO).
NOTE
Prior to installing a new pressure sensor, the

protective cap on the pressure sensor must be
removed. The internal thread must be clean and
the load pressure sensors must be calibrated
following installation of the new pressure sensor.
The pressure sensor is supplied with a voltage 
of 5 V from the truck control unit and delivers an
analogue output voltage that increases as the
pressure increases.
Connector plug for pressure sensor 
Pin
1 Negative supply voltage
2 Output voltage
3 5-V supply voltage

Assistance systems

Lift height switch 
The lift height switch records the extension of

the second lifting stage (above the free lift) for
duplex and triplex lift masts. For standard lift
masts, the lift height switch records a lift height
of approx. 2 m.
Upon detection of these lift heights, the load-de-
pendant assistance system is activated to re-
duce the tilting speed and lifting speed.
The lift height switch has two integrated induc-
tive proximity sensors: sensor 1 (S1) and sensor
2 (S2). The lift height switch is attached to the lift
mast and is activated via a metal plate.
The lift height switch provides the two output sig-
nals S1 and S2, which are connected to the
truck control unit. The output signal S1 is con-
nected to K57 and the output signal S2 is con-
nected to K15 of the truck control unit.
Lift mast retracted (S1 and S2 activated) Signal 1 approx. 4 V/signal 2 approx. 4 V
Lift mast extended (S1 and S2 not activated) Signal 1 approx. 10 V/signal 2 approx. 10 V
Only S1 activated Signal 1 approx. 6 V
Only S2 activated Signal 2 approx. 8 V

Assistance systems

LSP overview
Safety information
The LSP system is a driver assistance system.
To ensure that the system functions reliably, the NOTE
following safety information must be observed.
Assistance systems are only designed to offer a
Assistance system The responsibility for operating the truck in a
safe manner always lies with the driver. Even in
The assistance system supports the driver in the event of a potential malfunction, the driver
handling the truck by providing information and must have full control of the truck at all times.
pre-selectable limit values. In addition, the
"Load rating assistant" function ("ac- Hazard assessment
tive" variants) makes direct interventions in the
controller to reduce the risks caused by inadmis- The LSP system changes the driving character-
sible load states. This only applies where the in- istics and operation of the industrial truck and
dustrial truck is being used for its intended pur- therefore influences the hazard assessment. It is
pose. therefore necessary to adapt the hazard assess-
ment in line with national health and safety di-
The aim is to achieve an improved, ergonomic
rectives, and to train the driver on how to oper-
and more efficient method of operating the in-
ate industrial trucks with LSP. It is imperative
dustrial truck.
that drivers familiarise themselves with the oper-
If changes are made to the industrial truck in ation of industrial trucks fitted with LSP.
terms of its equipment and attachments, and
these changes have a significant impact on the Application conditions
axle loads, the sensors must be recalibrated. In
addition, a new data record must be loaded and The LSP system is not suitable for applications
reselected for the load rating assistant; see the in which the system components, particularly the
section entitled "Selecting the attachment" in the lift height measurement system, may be dam-
operating instructions. aged by exposure to dirt, chemicals or bulky
loads.
NOTE
Applications with oscillating loads (e.g. stone

clamp) are not permitted for LSP active.

Assistance systems
Climatic conditions: whether the truck configuration shown in the
● See the operating instructions for the industri- LSP display is identical to the actual truck
al truck configuration. This affects attachments in par-
ticular
● Not for use in cold stores and foundries
● The load rating assistant only operates cor-
● Do not subject to rapid temperature changes
rectly if the industrial truck is used in line with
The information about positioning the load provi- its intended purpose. Refer to the section en-
ded in the operating instructions for the industrial titled "Intended use" in the operating instruc-
truck must be observed. tions for the industrial truck, especially the in-
formation about the required form of road-
When the LSP active restricts the driving, tilting ways
or lifting function, information is shown in the dis- ● If an industrial truck equipped with an "active"
play. In such cases, immediately ease off the ac- variant of LSP is used to tow trailers, the sen-
celerator pedal and/or stop operating the joystick sor system can be affected. As a result, mal-
until the warning disappears. functions are possible when the load rating
assistant intervenes in the driving, tilting and
lifting functions. When towing trailers, loads
NOTE must not be stacked using the lift mast.
● Solid rubber tyres must not be used on the
For lift heights below 0.5 m, LSP does not inter- steering axle. The stops on the combined axle
vene in driving, tilting and lifting functions. on the counterweight must be kept free from
"Lift limits" function: dirt
● Following a strong impact load on the steering
● When the hydraulic oil is cold, setting a lift
axle or its wheels in a horizontal or vertical di-
limit does not reliably limit the maximum vehi-
rection, e.g. after a forceful dropping of the
cle height
rear during crane loading or in the event of a
● If the "lift height zero point" has been reset, collision with an obstacle, the "Check axle
the lift limit must be checked and saved again load" function must be performed. If the axle
as required. load sensor is out of tune, it must be recali-
● It may be necessary to save the lift limits brated; defective axle load sensors must be
again after fitting or changing an attachment. replaced
● After every tyre change, the "Lift height zero ● Electronic components are integrated into
point" must be reset. Existing lift limits must steering axles with axle load sensors. These
be checked and, if necessary, reset electronic components must not be sprayed
with a water jet, e.g. high-pressure cleaners
or steam cleaners. Electronic components are
NOTE particularly at risk on industrial trucks with
turntable steering axles.
The selected positions must not exceed the ● After changing an attachment, the attachment
maximum permissible lift height as set out in the must be reselected for the load rating assis-
load capacity diagram. tant; see the section entitled "Selecting the at-
"Load weighing" function: tachment" in the operating instructions. Have
adjustments carried out by your service part-
● The accuracy of the load weight determined ner where necessary. Check existing equip-
on an on-going basis and of the more precise ment to make sure that it matches the LSP
load scale may vary. The level of accuracy is display screen. Then execute the "Check axle
also influenced by temperature and load load" function
movement.
● The load rating assistant does not intervene
● If a line breakage safety device activates in the actuation of the stop pedal. The driver
while lowering the load, an incorrect weight is alone is responsible for the stability of the in-
displayed during lowering. As soon as the dustrial truck
lowering procedure has ended, the weight of
the load is displayed correctly again.
Error signals on the LSP display
"Load rating assistant" function ("ac-
tive" variant): ● A dot that alternately flashes blue and light
● The load rating assistant intervenes in the grey signals that the LSP display is function-
controller to limit the driving, lifting and tilting ing
functions, but does not intervene in auxiliary ● A non-flashing blue or light grey dot signals a
hydraulics functions malfunction. In this case, the values and sta-
● When the industrial truck is switched on, tuses displayed may be incorrect. The indus-
checks must be carried out to determine trial truck must be checked.

Assistance systems
● If the LSP display fails, operation via the rota- Maintenance
ry/push buttons or buttons is not permitted
● If the display fails or can only be read to a
● The functions of the LSP must be checked in
limited extent, the LSP display screen must line with the maintenance intervals
be replaced. ● The lift mast must be checked and maintained
● For the LSP "active" variant only: in line with the maintenance intervals.
In the event of an error, the red Assist warn-
● Cleaning work must be performed as descri-
ing light flashes on the display unit of the in- bed in the operating instructions for the indus-
dustrial truck. In addition, depending on the trial truck
cause of the error, the red warning light with ● Sensors must be recalibrated following re-
the lightning symbol may light up permanent- placement.
ly. A continuous warning sound is emitted at ● After replacing the truck control unit, new data
the same time. After acknowledging the error, records must be read in to the LSP and all
the warning sound stops and two short signal sensors must be recalibrated.
tones are emitted in succession. The colour of ● Following replacement of the LSP display in
the Assist warning light changes from red to
"active" variants, new data records must be
yellow. The red warning light with the lightning
read in to the LSP. Not necessary for the "se-
symbol goes out.
lect" variant
The "Load rating assistant" is not available for ● The first time you fit an attachment, the truck
the continued operation of the industrial truck.
control unit must be adjusted; new data re-
No interventions are made in the driving, tilt-
cords must be read in to the LSP
ing and lifting functions.
NOTE
For more information, see the section entitled

"Error messages".

Assistance systems
LSP system description

Assistance systems
N1 Electronic control LHC 20 2B14 Load pressure sensor
1B11 Steering angle sensor 2B15 Reference for the load pressure sensor
1B12 Axle load sensor 6S1 Rotary dial/push button
1B14 Speed sensor for left-hand traction motor 6P5 LSP display
1B15 Speed sensor for right-hand traction motor 8B1 Lift height sensor
2B3 Tilt angle sensor
The Linde Safety Pilot system (LSP) is a driver

assistance system that supports the driver's
work by providing driver information and warning
signals, and/or intervening in the operation of
the truck.
NOTE
When working on the LSP system, "competent

persons" are expected to have specific system
knowledge about LSP, e.g. having attended a
special LSP service seminar. In the event of re-
pairs, it is important to check whether the LSP
settings match the configuration of the truck.
The zero point for the lift height must be
checked.
CAUTION
To ensure that LSP detects errors correctly, the sys-
tem requires the serial number entered in the truck
control unit.
When replacing the truck control unit, the correct seri-
al number must be entered in the truck control unit via
Pathfinder diagnostics.
The main components of the LSP system in-

clude:
● LSP display 6P5
● Rotary dial/push button 6S1 in the armrest
These two components form the user interface
to the LSP system.
A number of sensors are required for the LSP
system to function:
● Axle load sensor 1B12 (only for LSPactive)
● Speed sensors 1B14/1B15
● Load pressure sensors 2B14/2B15
● Lift height sensor 8B1
In addition, the signals from the following sen-
sors are incorporated in the function of the LSP
system.
● Steering angle sensor 1B11
● Tilt angle sensor 2B3
The rotary/push button, the LSP display and the
truck control unit communicate with each other
via the CAN bus in the truck. The lift height sen-
sor sends a signal to the truck control unit via

Assistance systems
the CAN bus; this signal is used to calculate the
current lift height.
The two load pressure sensors send a signal to
the truck control unit. The truck control unit cal-
culates the load weight and sends this informa-
tion via the CAN bus to the LSP display.
The axle load sensor on the steering axle also
sends a signal to the truck control unit. This sig-
nal is used in the load capacity assistant calcula-
tion and for the load capacity display.
For subsequent operations, settings and/or cali-
bration processes will need to be checked or
carried out.
Replacing the front and/or rear tyre
● Changing the tyre type (pneumatic, supere-
lastic) or size affects the load capacity of the

truck. The residual load capacity must there-
fore be calculated again (new load capacity
sign) and new data files must be loaded into
the truck control unit and LSP display.
● After every tyre change (even when replacing
worn tyres with new tyres of the same size

and type), the zero point of the lift height (LSP
display, Main menu, Settings) must be recali-
brated. Check whether lift limits have been
activated and reset the limits if necessary.
Replacing the lift mast and/or attachment
● This will affect the load capacity of the truck.
The residual load capacity must therefore be

calculated again (new / additional load ca-
pacity sign) and new data files must be loa-
ded into the truck control unit and LSP dis-
play. The axle load sensor and load pressure
sensors must be calibrated again. The lift
height sensor must also be recalibrated.
LSP variants
The LSP system is available in two different var-
iants.
● LSP select
● LSP active
The two variants differ in terms of the truck's
range of functions and equipment.
Variant Variant
Range of functions
"LSP select" "LSP active"
Display of current lift height ■ ■

Display of current tilt angle ■ ■

Assistance systems
Lift height preselector (10 heights) ■ ■
Tilt angle preselector (4 angles) ■ ■
Lift height restriction ■ ■
Lowering limit ■ ■
Lift height display/load rating display - lift height ■ ■
Tilt angle display/load rating display - tilt angle ■ ■
Load weight display/load rating display - load weight ■ ■
Load rating display - load centre of gravity distance ■
Load rating display - maximum permissible lift height ■
Load rating display - maximum permissible tilt angle ■
Load rating display - current utilisation ■
Load rating assistant on/off ■
Weighing function ■ ■
Display of total weighed loads ■ ■
Display of number of positions in total ■ ■
Shovel operation (only for IC trucks) ■ ■
Restriction on functions and display using PIN code ■ ■
Adjustable speed limit ■ ■
Adjustable power level ■ ■
Display of driving speed and drive direction ■ ■
Display of steering angle ■ ■
Display of coolant temperature (only for IC trucks) ■ ■
Display of hydraulic oil temperature (only for IC trucks) ■ ■
Display of traction motors temperature (only for electric trucks) ■ ■
Display of pump motor temperature (only for electric trucks) ■ ■
Display of fuel consumption in l/h (only for diesel IC trucks) ■ ■
Display of energy consumption in kWh/h (only for electric trucks) ■ ■
Display of error messages for the LSP system ■ ■
Display of system information for the LSP system ■ ■
Variant Variant
Equipment
"LSP select" "LSP active"
LSP display ■ ■
Rotary/push button ■ ■
Lift height sensor ■ ■
Load pressure sensor ■ ■
Axle load sensor ■
Speed sensors1) ■
1) Speed sensors are fitted as standard for all

electric trucks as well as the 396-03. However,
these sensors are only used for the LSP system
if "LSP active" is present.
The "LSP active" variant is equipped with an
axle load sensor on the steering axle, supple-
mented by the existing 1) or additional speed

Assistance systems
sensors. Additional functions can be performed
using these sensors; functions that are not avail-
able in the "LSP select" basic version.
The variant is displayed on the LSP display once
the key switch is switched on.
NOTE
If the LSP display or the truck control unit is re-

placed, the component in question must be con-
figured via the truck diagnostics.
LSP display 
The LSP display is fitted beneath the display unit

on the right-hand A-column. It has a 4.3-inch
colour display (1).
The display features a light sensor (2) that is
used to automatically regulate the brightness of
the display.
The display is controlled via the truck CAN bus.
Servicebase 
Using the diagnostic program, a service address

(dealer address) can be entered in the LSP dis-
play; this service address will appear in the LSP
display. The display brightness and the unit of
measurement can also be configured. When at-
tachments are fitted, the unique designation of
the attachments must be entered; the designa-
tions will appear in the selection menu of the
LSP display.
The display is connected to the truck electronics 

via a 26-pin plug.

Assistance systems
Pin assignment 
PIN
1 12-V power supply, continuous
2 12-V power supply, switched
3 Negative power supply
4 Truck earth GND
5 No function
6 No function
7 No function
8 CAN High
9 CAN Low
10-2
No function
6

Assistance systems
Rotary push button 
The rotary push button is fitted in the armrest of

the truck and is used to operate the LSP system.
The rotary push button communicates with the
LSP display via the CAN bus of the truck.
The LSP system is operated using a turning 

knob (2) which can be rotated in both directions
and pressed to select a function. The "Back"(1)
and "Switch"(3) buttons are also integrated into
the rotary push button for controlling the LSP
system.
The rotary push button is connected to the main 

wiring harness of the truck via a 4-pin plug. The
rotary push button is supplied with a voltage of
12 V and communicates with the CAN bus of the
truck via this plug.
Pin
1 12-V power supply
3 CAN High
4 CAN Low
LSP servicebase 

Assistance systems
Turning the rotary push button 
Turning the rotary push button to the left or right

allows the following actions to be executed:
● Scroll between menu items
● Change values continuously or in increments
(brightness, digit value or numerical value)
Pressing the rotary push button 
Briefly pressing the rotary push button allows the

following actions to be performed:
● Select menu item
● Activate or deactivate a function
● Go back one menu level from the display
function
● Acknowledge a message
Pressing the rotary push button for longer than

two seconds activates the following functions:
● Program the position (tilt angle, lift height, lift
limits)
● Assign or overwrite the favourite position
● Select a function or display after entering the
PIN code
● Delete programmed values
● Delete favourite
● Set a new time/date or PIN code
● Reset consumption
"Back" button 
Briefly pressing the "Back" button allows the fol-

lowing actions to be performed:
● Go back one menu level
● Acknowledge a message
Pressing the "Back" button for longer than two

seconds switches to the first position in the main
menu.

Assistance systems
"Switch" button 
Briefly pressing the "Switch" button allows the

following actions to be performed:
● Switch between favourites
● Jump from the menu item to the favourite last
used
By pressing the "Switch" button for longer than
two seconds, the function or display currently
shown on the display is saved as a favourite.

Assistance systems
Lift height sensor

Assistance systems
1 Housing for upper part 6 Housing for bottom part
2 Sensor 7 Guide pulley
3 Bellows 8 Cleaning brush
4 Nozzle 9 Steel cable drum with spring accumulator
5 Steel cable
The lift height is recorded using a lift height sen-

sor. The lift height sensor is secured to the lift
mast and, depending on the design of the lift
mast, is connected by means of a steel cable to
the fork carriage or the inner mast. The lift height
sensor measures the extended cable length and
transmits this absolute value to the truck control
unit via the CAN bus on the truck. The measur-
ing system has an accuracy of ± 5 mm.
The lift height sensor consists of a cable-exten-
sion transducer and a sensor.
WARNING
Risk of injury during disassembly of the cable-exten-
sion transducer due to the pre-load on the steel spring
in the spring accumulator.
The cable-extension transducer must not be opened
because the steel cable drum, along with the spring
accumulator, can jump out. Note the service instruc-
tions when performing maintenance work.
NOTE
The lift height sensor must not be cleaned using

a high-pressure cleaner; otherwise, dirt particles
may be pressed into the inside of the cable-ex-
tension transducer and the polyamide coating of
the steel cable may be damaged.
NOTE
For the lift height measurement to be accurate,

the zero points of the measuring system must be
correctly calibrated. If components in the lift
height sensor are replaced, the zero points must
be re-calibrated.
Cable-extension transducer
The cable-extension transducer is identical for
all mast variants (standard lift mast, duplex lift
mast and triplex lift mast). The cable-extension
transducer includes a steel cable drum (9) which
is pre-loaded by means of a spring accumulator.
This pre-loading ensures that there is always a
pre-load on the steel cable (5) between the lift
mast and the moving fork carriage.
The steel cable (5) is attached to the fork car-
riage (on the duplex lift mast and triplex lift mast)
or the inner mast (on the standard lift mast). The
steel cable (5) is fed into the cable-extension
transducer through a nozzle (4) and bellows (3).

Assistance systems
The steel cable loops around a roller (7) and
passes through a cleaning brush (8) before be-
ing wound onto the steel cable drum (9) with the
spring accumulator. The steel cable has a plas-
tic sheath; this sheath must be checked for dam-
age. The steel cable drum (9) is connected to
the sensor (2) which records the extended cable
length.
The steel cable must be replaced if the plastic
sheath is torn or damaged.
Connection to standard lift masts
On trucks with a standard lift mast, the lift height
sensor is secured to the left-hand lift cylinder by
means of a bracket. The steel cable is attached
to the inner mast. On trucks with a standard lift
mast, the lift height sensor measures the lift
height indirectly. It records the movement of the
inner mast. Based on this movement, the fork
carriage and steel cable move at a ratio of 2:1.
Connection to duplex lift masts and triplex lift
masts
On trucks with a duplex lift mast or a triplex lift
mast, the lift height sensor is secured to the
right-hand outer profile by means of a bracket.
The steel cable is attached to the fork carriage.
The lift height sensor measures the lift height di-
rectly. The fork carriage and the steel cable
move at a ratio of 1:1.
Sensor
The sensor (2) is different for standard lift masts
and for duplex lift masts and triplex lift masts be-
cause the ratio of the cable movement to the
fork carriage movement varies depending on the
type of lift mast. There are two different sensors:
● Sensor for standard lift masts (connector plug
pointing downwards)
● Sensor for duplex and triplex masts (connec-
tor plug facing backwards/facing the direction
opposite to the drive direction)
NOTE
It is impossible to confuse the two sensors; the

position of the plug differs, meaning that the
wrong sensor cannot be fitted.
The sensor (2) is screwed onto the cover (1) of
the cable-extension transducer using four
mounting screws. The steel cable drum (9) is
connected to the sensor (2) via a rod.
The extended cable length is measured by re-
cording the number of steel cable drum revolu-
tions. The lift height sensor electronics are re-
dundant in design for safety reasons. This

Assistance systems
means that the absolute value of the extended
cable length is recorded and transmitted to the
truck control unit via two measuring systems that
are independent of one another. Each measur-
ing system consists of a transmission gear and
two Hall generators. The Hall generators are ac-
tivated via permanent magnets on the shafts of
the gears for the transmission gear.
The Hall generator signals are recorded by two
microcontrollers. The signals are sent as abso-
lute values of the extended cable length to the
truck control unit via two separate CAN bus con-
nections.
NOTE
If the lift height sensor is disconnected from the

main harness, a jumper plug must be attached
to 8X1 of the main harness; otherwise the truck
CAN bus is cut off from the truck and the truck
will not work.
The power supply of the sensor is 12 V and is
supplied via the 12-V on-board power supply.
Connector plug
Pin
1 12-V power supply
3 CAN A High
4 CAN A Low
5 CAN B High
6 CAN B Low

Assistance systems
Load pressure sensors 
The LSP system uses two pressure sensors to

detect the load weight on the fork arms. These
sensors measure the pressure at connection A1
of the control valve (pressure connection for the
lift cylinder).
Both pressure sensors measure the same pres-
sure (redundancy) and are connected to the
truck control unit via the plug (1) and the main
wiring harness. The truck control unit calculates
the load weight based on the load pressure and
transmits this value to the LSP display via the
CAN bus.
NOTE
Prior to installing a new pressure sensor, the

protective cap on the pressure sensor must be
removed. The internal thread must be clean and
following installation of the new pressure sensor,
the load pressure sensors must be calibrated.
The pressure sensor is supplied with a voltage 
of 5 V from the truck control unit and delivers an
analogue output voltage which increases as the
pressure increases.
Connector plug for the pressure sensor 
Pin
1 Negative supply voltage
2 Output voltage
3 5-V supply voltage

Assistance systems

Axle load sensor for the 1603 steering

axle (LSP active only)
Bridge piece for the series 1603 steering axle 
with axle load sensor
On series 1603 steering axles, the axle load
sensor is pressed into the axle central body. The
axle load sensor has two measuring cells that
are equipped with strain gauges. These strain
gauges are analysed using electronic measuring
equipment that is integrated into the axle load
sensor.
The output signals are sent to the truck control
unit via the plug and the main harness.
The electronic measuring equipment is supplied 

with a voltage of 12 V at terminal 15 by the truck
electrics and generates two opposing PWM sig-
nals (1) and (2) with a frequency of 254 Hz (tol-
erance range of +30%) which change according
to the load on the axle. A negative load (wheels
lifting off the ground) can also be recorded.

Assistance systems
Axle load sensor for series 1603 steering axles 
The PWM signals can be read out in the diag-

nostic software. If the total is not 254 Hz, the
sensor may be defective.
Inputs + outputs
▼
Driving
▼
Axle load
The correct function of the axle load sensor can 

be checked in the LSP display under the "Set-
tings" → "Check axle load" menu item.
NOTE

be checked via the "Check axle load" menu item
in the LSP"Settings" menu to ensure that the
axle load sensor is functioning correctly.
The following examples of load cases illustrate
the fact that the signals must change when the
sensor is functioning correctly. The sum of both
signal values must always be 100%. Tolerance:
2 percentage points
The assumed values are examples and may dif-
fer for different truck models.
1 Check
Examples of load cases: 2 Back
3 Check axle load
Output signals at 3250 kg 

Assistance systems
Output signals at 1500 kg 
Output signals at -250 kg 
Connector plug
Pin
1 12-V power supply
2 Signal 1
3 Signal 2

Assistance systems
Speed sensors at the wheel motors
(LSP active only)
Description
The speed sensor is an external component and

records the number of revolutions and the direc-
tion of rotation of the respective wheel motor.
The sensor is dust-proof and splash-proof. The
speed sensors allow the driving speed to be
shown on the LSP display.
(With the LSP select, the driving speed is calcu-
lated from the engine speed and the swivel an-
gle of the hydraulic variable displacement pump
(HPV).)
With the LSP active, the speed sensors are
used primarily to calibrate the pump swivel end
when components of the HPV have to be re-
placed in the field.

Assistance systems
Installation position
Speed sensors (1B14) and (1B15) are fitted to

the wheel motors.
The speed sensors (here: 1B15) are enclosed 
by the port plate of the wheel motors.
Function
The speed sensors 1B14 and 1B15 each have 
two integrated inductive sensors (1). The sen-
sors measure the revolution speed and direction
of rotation of the relevant wheel motor via a trig-
ger wheel (2) on the wheel shaft.
The revolution speed is determined from the fre-
quency of the output signal, and the direction of
rotation via the sequence of the output signals.
The direction of rotation is only analysed for both
wheel motors. The speed sensors are connec-
ted to the controller N1 via a 4-pin connector
plug.
Speed sensor connector plug

Assistance systems
Pi
Function
n
1 12-V power supply
2 Output signal A
3 Battery negative
4 Output signal B
Output signals

The sensor operates using PWM signals. The
revolution speed of the motor is determined from
the frequency of the output signals A and B. The
sequence of signals from the two outputs A and
B is different depending on the direction of rota-
tion of the motor.
When the motor rotates anti-clockwise, output B
is switched on first and then output A. Output B
is then switched off, followed by output A.
Speed sensor signal for traction motors
The speed sensors can be tested via the diag- Inputs + outputs
nostic program. In the event of incorrect sig- ▼
nals, the power supply, the connector plug and Driving
the line connection must be checked.
▼
Wheel motors
Replacement
NOTE
When replacing the speed sensors, check that

the spare part number is correct. Speed sensors
from other trucks must not be used.
 Disconnect the connecting plug (3) from the 
speed sensor.
 Unscrew the socket head screw M6x16 (4)
with a washer.
 Pull out the speed sensor (1) from the hous-
ing. Note the required connection line and O-
ring.
 Insert and align the new speed sensor (1)
with the new O-ring.
 Screw in the M6x16 socket head screw (4)
with a washer.
Tightening torque: 9.5 Nm

Assistance systems
NOTE
The speed sensor does not have to be adjusted

on installation.
LSP wiring harness
Wiring harness (1) Lift height sensor

8B1 Plug, lift height sensor
8X1 Plug, main wiring harness
NOTE
Plugs 8B1 and 8X1 are identical in type and may

cause malfunctions if mixed up. Pay attention to
the labelling!
Wiring harness for (2)LSP display

6P1 Truck display unit
6P5 LSP display
Wiring harness (3) Axle load sensor

1B12 Plug, axle load sensor

Assistance systems
LSP diagnostics
LSP calibration process
Overview of the calibration process:
1. Mast vertical
2. Lift height sensor
3. Load pressure sensor
Additional points for LSP active only:
4. Axle-load sensor, zero point
5. Axle-load sensor, reference
6. Check axle load
(NOT via Pathfinder! Test is performed via the
LSP display: (Settings / Check axle load /
Check?)
Additional points for IC trucks only:
7. Pump swivel end
Calibrating the vertical mast position

Before calibrating the lift height sensor, the verti-
cal position of the lift mast must be calibrated.
The lifting chains must be set up correctly in or-
der to accurately perform the calibration. In addi-
tion, there must be a valid data file in the LSP
display and in the truck control unit.
In order to carry out the calibration, the following
equipment)
● Parking brake applied
● Truck at a standstill
tion
 Start the diagnostic software and select the

"Mast vertical"LSP calibration
NOTE
Inaccurate calibration of the "Mast vertical" pa-

rameter leads to the tilt angle being displayed in-
accurately on the LSP display.

Assistance systems
CAUTION
The tilt angle information is obtained using the truck
tilt angle sensor.
The "Mast vertical" parameter must always be calibra-
ted after the tilt angle sensor, lift mast or LHC 20 has
been assembled or replaced.
NOTE
Alternatively, the tilt angle can be ascertained by

measuring the distance between a reference
point on the truck chassis and on the lift mast.
For more information, please refer to the docu-
mentation for the truck in question.
 Raise the fork carriage by approx. 300 mm.
 Move the joystick until the lift mast is exactly
vertical (tilt 0°).
 Perform the "Mast vertical" calibration via the
Calibrating the lift height sensor

To calibrate the lift height sensor, the nominal lift
height (h3) of the lift mast must be determined.
This value is read out from the truck control unit
during the calibration process.
NOTE
The nominal lift height (h3) is the maximum lift

height measured from the ground up to the top
edge of the fork arms. The nominal lift height
(h3) can be read out from the operating instruc-
tions of the respective truck in the technical data
section.
Entering the nominal lift height (h3) of the lift
mast is required only if the calibration process
cannot be performed when the lift height is
0 mm. For example, this is the case if the attach-
ment prevents the lift cylinders from being fully
retracted. In this case, the calibration is per-
formed at the upper stop when the lift mast is at
the maximum lift height.
 Tilt the lift mast back completely.
(seat switch actuated)

Assistance systems
equipment)
tion
 Start the diagnostic software.In the LSPcali-
bration section, select "Lifting height sensor".
 Perform the "Lifting height sensor" calibration
using the diagnostic software.
If the lift cylinders cannot be fully retracted, the
upper stop must be calibrated when the lift mast
is at the maximum lift height.
 Refer to the maximum lift height (h3) on the 
identification plate on the lift mast, e.g. 0551 =
5510 mm.
 Actuate the joystick for lifting. Move the lift
mast all the way to the top until it reaches the
stop.
CAUTION
Note the maximum ceiling height when lifting the lift
mast.
Extend the lift mast only when the ceiling is of a suffi-
cient height.
 Enter the maximum lift height (h3) via the di-

agnostic program.
Calibrating the load pressure sensor

The load pressure sensor is calibrated via the di-
agnostic program. An automatic process for cali-
brating the load pressure sensor is stored in the
truck control unit.
NOTE
The load pressure sensor is calibrated when the

truck is not carrying a load. The lowering limit
must be permanently deactivated during the cali-
bration process.

Assistance systems
The "Lowering limit" sub-menu can be found un- 
der the "Mast positioning" main menu on the
LSP display.
1 Lift height
2 Tilt angle
3 Lift limits
4 Lowering limit
5 Mast positioning
 Deactivate the lowering limit in the "Lowering 

limit" sub-menu (5) ("Off").
NOTE

the attachment being used must be selected
correctly in the LSP display under "Settings -
Load rating assistant".
 Bring the hydraulic oil to operating tempera-
ture (restrict the pressure via the pressure re-
lief valve for approximately two minutes).
 Move the mast to a vertical position (tilt ap-
prox. 0°).
 Raise the mast to approx. 500 mm below the
upper mechanical stop (without a load).
equipment)
tion

Assistance systems
 Start the"Load pressure sensor calibration"
process via the diagnostic program.
 Actuate the joystick for lifting and extend the
lift mast to the maximum lift height until the
pressure relief valve responds audibly for ap-
prox. two to three seconds.
NOTE
The maximum lift height, the number of lifting

stages and the position of the lifting stage transi-
tions are stored automatically in the truck control
unit.
 Move the joystick for lifting into the neutral po-
sition.
 Actuate the joystick for lowering. Lower the lift
mast.
NOTE
When the lift mast is lowered, the speed of the

lowering procedure is automatically reduced dur-
ing the lifting stages and between the individual
lifting stages.
 Move the joystick for lowering back into the
neutral position only when the lift mast is fully
lowered.
The truck control unit calculates and records the
heights of the lifting stage transitions and the
maximum lift height. These values are stored in
NOTE
If the joystick is moved into the neutral position

during the lifting operation or lowering proce-
dure, the calibration process is interrupted and
must be restarted.

Assistance systems
Calibrating the axle load sensor
 Lower the truck until the wheels on the steer-
NOTE ing axle are back on the ground.
Calibrate the axle load sensor when the truck is
not carrying a load. Calibrating the reference for the axle load
sensor
NOTE
NOTE
the attachment being used must be selected To calibrate the "reference point for the axle
correctly in the LSP display under "Settings - load sensor", somebody has to sit on the driver's
Load rating assistant". seat. This allows the driver's weight to be recor-
ded. If a seat switch bridge has been fitted, this
must be removed. The seat switch must be func-
Calibrating the zero point for the axle load tional.
sensor
 Switch off the truck. requirements must be met:
 Lift the truck at the rear using a hydraulic jack
until the wheels on the steering axle are off (seat switch actuated)
the ground.
equipment)
 Prop up the chassis of the truck. ● The parking brake must be applied
 Lower the truck using a hydraulic jack. ● The truck must be at a standstill
tion
NOTE
Alternatively, the truck can be raised at the rear  Start the diagnostic program.
using a crane with sufficient load capacity until
the wheels on the steering axle are lifted off the  Raise the fork arms without a load until the
ground. fork arms are no longer touching the ground
 Switch on the truck. (maximum 300 mm).
 Actuate the joystick until the lift mast is exact-
requirements must be met: ly vertical (tilt of 0°).
● The parking brake must be applied  Start the "Axle load sensor reference" calibra-
● The truck must be at a standstill tion process via the diagnostic program.
● The accelerator must be in the neutral posi-  Perform the "Axle load sensor reference" cali-
tion bration via the diagnostic program.
 Start the diagnostic program. NOTE

 "Calibrate the zero point for the axle load sen-
sor" via the diagnostic program. be checked via the "Check axle load" menu item
 Switch off the truck. in the LSP menu to ensure that the axle load
sensor is functioning correctly.

Assistance systems
Checking the axle load sensor
Description
After calibrating the reference point for the axle Settings
load sensor, you have to check the axle load ▼
via the rotary push button in the "Settings" → Check axle load
"Check axle load" menu item on the LSP dis-
▼
play.
Perform the Check axle load
operation
If this test is not performed, error T679 appears

on the display unit and the driving speed is limi-
ted to 6 km/h.
Prerequisites
● The truck is in a horizontal position on a level
surface
● There is no load on the truck
● The fork carriage must be raised at least
10 cm and a maximum of 2.0 m above the
ground
● The mast must be vertical
● The seat switch must be actuated
● If an attachment is fitted, it must be activated
on the LSP display. To do this, check the acti-
vated attachment in the "Select attachment"
action menu. If necessary, correct the setting
Menu navigation 
 To perform the test, select the "Check" menu

item (1) using the rotary push button.
1 Check
2 Back
3 Check the axle load.

Assistance systems
The following user notification appears: "Park 
the truck on level, even ground without a load,
lift the load support and move the mast into a
vertical position" (1).
 Follow the instructions.
 After following the instructions, select the
"Yes" menu item (2) using the rotary push
button.
The axle load sensor is tested automatically.
The test can still be cancelled at this point by us-
ing the "Back" button or selecting the "No" menu
item (3).
If the test is successful, the following user notifi- 

cation is displayed: "Axle load testing was suc-
cessful." (1).
 Acknowledge the user notification by pressing
If the automatic test procedure finds that a test 

condition has been violated, the following error
message appears: "Axle load testing value" (1).
 Acknowledge the error message by pressing

Assistance systems
A user notification (1) appears. The user notifi- 
cation provides information about why the test
failed.
 Establish the correct testing conditions. Re-
peat the test on the axle load sensor.
If the automatic test procedure finds a deviation
that is too far from the preset values, the follow-
ing user notification appears: "Implausible axle
load value. Please notify service."
The "Load rating assistant" function is automati-
cally deactivated.
Calibrating the pump swivel end

Description ● The brake must not be actuated
● The seat switch must not be actuated
NOTE ● The joystick must be in the neutral position
● The truck must be jacked up so that both front
The pump swivel end must always be calibrated wheels can turn freely
if the LHC controller, high-pressure variable dis-
placement pump or parts of the adjustment
mechanism are replaced. Ramifications if the truck is not calibrated
The dynamic stability of a truck depends on the With the LSP active equipment variant, the red
driving speed and the rate of deceleration and lightning symbol in the display unit lights up if
acceleration. The effect these factors have is de- trucks are not calibrated. The maximum driving
termined by the extent to which the pump can speed is limited to 6 km/h.
swivel out.
In this way, the actual pump swivel end has a di- NOTE
rect impact on the stability of the truck. The
pump swivel end is configured within a tolerance No error message is produced if the "Pump
band. In order to determine the actual pump swivel end" calibration is not performed or is un-
swivel end, the pump swivel end must be cali- successful! With all other sensors, error mes-
brated. sages are generated if calibration is unsuccess-
ful.
Prerequisites
Calibration process
● All sensors on the basic vehicle must be cali-
brated: tilt angle, accelerator, joystick and  Ensure that all prerequisites have been fulfil-
steering angle sensor. led.
● There must be no current errors relating to  Follow the instructions given in the diagnostic
the LHC 20 program.
● Servicebase "E: LLA/LSP" version 1.6.0 or
later must be selected First, the controller increases the speed to a
constant value. The pump then starts to swivel
● There must be no warnings (T102, T103) ac-
slowly out. At the end of the process, the pump
tive
swivels back. The revolution speed falls back to
● The engine must be running the idle speed. Premature releasing of the pedal
● The hydraulic oil temperature must be in ex- is deemed a cancellation condition.
cess of 60°C

Assistance systems
Checking the lift height sensor
 Check the condition of the lift height sensor,
electrical supply line, steel cable, bellows, ca-
ble holder and cable protection device and
check for damage.
 Check that the steel cable for the lift height
sensor can move freely.
 Replace any damaged parts.

Assistance systems
Replacing the bowden cable
The bowden cable can be replaced separately. 
The repair kit with spare part number

0009909003 contains the following components:
● Cleaning spiral (1)
● Bowden cable on plastic reel (2)
● 2x crimping sleeves (3)
● Bellows (4)
● Cable nozzle (5)
A special tool with spare part number

0009419833 is required for the replacement, as
well as a special crimping tool 3505082010 with
insert 0009419914.
WARNING
The bowden cable is pre-loaded by means of a flat
spiral spring. The flat spiral spring may spring out dur-
ing the disassembly process and injure the service
engineer.
Wear protection goggles when replacing the bowden
cable. Observe the following steps.
The entire cable-extension transducer and sen-

sor must be removed from the lift mast in order
to replace a faulty bowden cable.
Special tool with spare part number 0009419833 
comprising a holding plate (6) and turning han-
dle (7).
Crimping tool
 Unscrew the four mounting screws (Torx T20) 

on the sensor.

Assistance systems
 Remove the sensor by pulling it upwards. 
 Remove the warranty seal (if present). 
 Unscrew the eight mounting screws (Torx 

T20) on the upper part of the housing for the
cable-extension transducer.
NOTE
Re-use the original mounting screw in the same

location during assembly. Otherwise, cracks
may form in the plastic housing.
 Carefully remove the upper part of the hous- 

ing by pulling it upwards. At the same time,
push the shaft of the bowden cable drum
downwards.
WARNING
Take care when separating the two halves of the
housing. The bowden cable drum may still be pre-loa-
ded if the bowden cable is tangled. The flat spiral
spring may spring out and cause injury.
The bowden cable drum must not be removed from
the lower part of the housing.

Assistance systems
 Expose the faulty bowden cable and unwind it 
completely from the bowden cable drum.
CAUTION
Releasing the tension of the flat spiral spring in the
neutral position will destroy the flat spiral spring. In
this case, the entire cable-extension transducer must
be replaced.
If the flat spiral spring is pre-loaded, make sure that it
is possible to release the tension of the flat spiral
spring in a controlled manner.
 Remove the cable sleeve. Remove the faulty 

bowden cable.
 Rotate the Bowden cable drum anti-clockwise 

(Pfeilrichtung) to check that the flat spiral
spring in the Bowden cable drum is not bro-
ken and is connected.
CAUTION
Rotating the bowden cable drum clockwise when
checking the pre-load will destroy the flat spiral
spring.
NOTE
If it is possible to determine that the bowden ca-

ble drum is pre-loaded, the flat spiral spring is in
good condition and the bowden cable can be re-
placed. If it is not possible to determine that the
bowden cable drum is pre-loaded, the entire ca-
ble-extension transducer must be replaced.

Assistance systems
 Screw the holding plate onto the lower part of 
the housing using two Torx screws from the
upper part of the housing.
 Fit the turning handle onto the shaft of the 

bowden cable drum.
 Insert the cable nozzle into the bellows. 
 Remove the old bellows. 

Assistance systems
 Pre-load the flat spiral spring in the bowden 
cable drum by turning the bowden cable drum
anti-clockwise.
NOTE
There are markings on the holding plate and on

the turning handle that are used to monitor the
number of revolutions.
CAUTION
The measuring system only works properly if the bow-
den cable drum is pre-loaded correctly.
The bowden cable drum must be pre-loaded with ex-
actly 34 revolutions (observe the marking on the bow-
den cable drum and on the lower part of the housing).
Observe the correct number of revolutions.
 After 34 revolutions, fix the turning handle in 

place on the holding plate using an M5x10
hexagon head screw (8).
 Feed in the end of the new bowden cable 

through the new cable nozzle and new bel-
lows.

Assistance systems
 Guide the bowden cable into the lower part of 
the housing.
 Route the bowden cable via the guide pulley. 
 Remove the old cleaning spiral.
 Wind the bowden cable into the spring coils of 

the new cleaning spiral.
 Check the Bowden cable for freedom of 

movement (in Pfeilrichtungen).

Assistance systems
 Insert the cleaning spirals into the lower part 
of the housing.
 Mount the bellows on the lower part of the 

housing.
 Insert the end of the Bowden cable through 

the hole (Pfeil) in the Bowden cable drum.
 Thread the bowden cable into the crimping 

sleeve.

Assistance systems
 Use the crimping tool (3505082010 / insert 
0009419914) to crimp the crimp barrel at the
end of the steel cable. (Crimp diameter 1.25
to 2.0 mm)
 Check that the crimping is correct. 
 Cut off the excess bowden cable using side

cutters.
NOTE
The bowden cable must not protrude beyond the

crimping, otherwise the cable will grind against
the lower part of the housing. The resulting chips
may destroy the sensor.
 Check for any excess cable protruding be- 

yond the crimping (for example, with a knife
edge).
 Check that the bowden cable is routed cor- 

rectly, particularly around the guide pulley and
the cleaning spiral.

Assistance systems
 Hold the turning handle in place. Remove the 
hexagon head screw (8) on the turning handle
from the holding plate.
 Fully unwind the bowden cable from the plas- 

tic reel, slowly and in a controlled manner,
and allow it to wind onto the bowden cable
drum.
 Wind the Bowden cable onto the Bowden ca- 

ble drum, starting from the top and moving to
the bottom (Pfeilrichtung).
 At the same time, ensure that the bowden ca-
ble is wound correctly onto the bowden cable
drum (coil after coil).
 Check again that the cleaning spiral is posi- 

tioned correctly (Pfeil).
NOTE
The bowden cable must always be pre-loaded if

the bowden cable is unwound from the plastic
reel.

Assistance systems
 Remove the turning handle (7). 
 Remove the holding plate (6) from the lower 

part of the housing.
WARNING
Risk of injury due to pre-loaded flat spiral spring in the
bowden cable drum.
Until the upper part of the housing is secured using
the eight screws, the bowden cable drum must be
constantly held against the lower part of the housing.
 Press the Bowden cable drum against the 

lower part of the housing (Pfeil).
 Fit the upper part of the housing. 

Assistance systems
 Screw the eight long mounting screws into the 
upper part of the housing.
NOTE
Only screw the mounting screws into the hous-

ing a maximum of three times.
 Position the sensor on the upper part of the 

housing. Ensure the plastic tab is in the cor-
rect position when positioning the sensor.
NOTE
There are two variants of the sensor. The cable-

extension transducer is always the same.
Sensor for the standard lift mast: sensor plug
facing downwards (in the direction of the bel-
lows)
Duplex/triplex lift mast: sensor plug facing back-
wards (in the opposite direction to the drive di-
rection)
 Screw in the four short mounting screws for 
the sensor.
Tightening torque: 1.5 Nm
NOTE
Only screw the mounting screws into the hous-

ing a maximum of three times.
CAUTION
If the bowden cable is wound up too fast, this can
cause damage to the winding mechanism.
Do not pull out and release the bowden cable from
the lift height sensor.
 Screw the lift height sensor onto the lift mast.

Re-align the sensor.

NOTE
 Lift the fork carriage.
Check the load pressure sensor when the truck
is not carrying a load.  Read off the weight indicator in the LSP dis-
play.

Assistance systems
The weight indicator in the LSP display must If the value displayed deviates from this value,
show approx. 0 kg (±50 kg). the load pressure sensor must be calibrated.
Warning messages and error messages

Warning messages for the LSP display
1001 The lowering limit is active. Please deactivate.
1003 Target lift height has already been exceeded.
1004 Target tilt angle has already been exceeded.
1005 Lift limit has been reached. Deactivate temporarily?
1007 Current lift height is above the lift limit.
Lower the load support, tilt the lift mast forwards slightly, apply the parking brake, switch off
1008
the truck.
1012 Load rating assistant not available!
1013 Access denied. Please enter the correct PIN code.
1014 Incorrect PIN. Please enter the PIN again.
1015 Axle load testing was successful.
1016 Implausible axle load value. Please notify service.
1017 Display not operational: Passive Mode.
1018 Lift height zero point reset. Please check the lift limits and reset if necessary.
1019 All lift height values assigned. Delete any values that are no longer required.
Park the truck on level, even ground without a load, lift the load support and move the lift mast
1020
into a vertical position
1021 Check the lift limits and reset if necessary
1023 Load capacity display with warnings is not available
1024 All tilt angle values assigned. Delete any values that are no longer required.
1025 Check the axle load: no load!
1026 Check the axle load: lift the load support!
1027 Check the axle load: lower the load support!
1028 Check the axle load: move the lift mast into a vertical position!
1029 Check the axle load: do not actuate the accelerator pedal!
1030 Check the axle load: move the joysticks into a neutral position!
1031 Check the axle load: sit on the driver's seat!
1032 Lift height signal is poor; please clean the sensor.
1033 Error with lift height signal. Clean the sensor, remove foreign objects, check the alignment.
NOTE
The warning messages >1000 are pop-up mes-

sages that are shown on the LSP display de-
pending on the situation.
Error messages for the LSP display

100 -
CAN bus error
159
160 Internal display temperature too high

Assistance systems
NOTE
The display's internal error messages 100 to

199 are shown in the "Cockpit diagnostics" sec-
tion when an error occurs and can be read out
via the diagnostic software. Some of these error
messages also lead to pop-up error messages.
LSP configuration
LSP data file
LSP select data file H2X189A00000_TC_189_02_3200_230_
The dimensions and weights of the truck and lift Variant code
mast are specified in a data file saved in the 0000010367.lsp
truck control unit. This data file is created specif-
ically for the lift mast when the truck is produced, Creation date_creation time.lsp
and is loaded into the truck control unit. This da- Options for transferring data via the diagnostic
ta file includes the following information: program:
● Lift mast type and lift cylinder data ● Parameterising LSP select
● Lift height ● Reading out and saving LSP select
● Tonnage ● Viewing a LSP select data file
● Load centre of gravity
● Truck model
NOTE
If the change listed below is made to the truck, a
new data file must be created and loaded into A data file that has been read out and saved can
the truck control unit: be transferred back to the truck.
Conversion to a different lift mast (type, lift
height, etc.) NOTE
Source of the data file: After transferring a new data file, the truck must
Prerequisites: Internet and Extranet access be switched off (via the key switch or truck ac-
cess system). All components and functions of
Extranet: https://extranet.linde-mh.com/ → After the LSP system must then be calibrated.
Sales \ Service Fork Lifts → Software \ Download
of Service Software → Pathfinder → ServiceBa- LSP active data file
ses → LSP select Datensätze.zip
The dimensions and weights of the truck and the
lift mast, and the data relating to the attachment
NOTE are stored in a data file in the truck control unit
and in the LSP display. This data file is created
The valid data file for the truck can be obtained
from Linde Customer Service via your local serv- specifically for the truck when the truck is pro-
ice partner. The data file is saved onto a data duced, and is loaded into the truck control unit.
carrier and needs to be copied into the C:\LSP This data file includes the following information,
directory. The new data file can then be transfer- among other data:
red to the truck using the diagnostic program. ● Weight of the truck
Example of the structure used for the file name ● Battery type and weight
of the data file: ● Wheelbase
M189-040D01- ● Width of the truck
● Lift mast type and lift cylinder data
Lift mast, family - tonnage, type, version-
● Lift height
0303-05_394_ ● Tonnage
Lift height-load centre point_Truck series_ ● Weight of the attachment

Assistance systems
● Dimensions of the attachment item number. This can be read from the file
● Weight and length of the fork arms name for the data file.
The data file is created on the basis of truck- Example of the structure used for the file name
specific data from a program used to calculate of the data file:
the load capacity. If modifications are made to
H2X392C01201_
the truck, a new data file must be created and
loaded into the truck control unit. Chassis number_
00112965620010_0000000036_
NOTE Order number_item number_
Only one data file can be imported. This data file 2013-11-19_12-00-00.lsp
can cover up to four attachments.
Creation date_creation time.lsp
If any of the changes listed below are made to
the truck, a new data file must be created and Example:
loaded into the truck control unit: Serial number: H2X392C01201
● Fitting of an attachment or modification to an
Order number + item number:
attachment
00112965620010_0000000036 (the separator _
● Change to the length of the fork arms
must be entered).
● Change of tyres
● Conversion to a different lift mast (type, lift Options for transferring data via the diagnostic
height, etc.) program:
● Parameterising LSP active
● Change to the forwards tilt angle and back-
wards tilt angle ● Truck control unit -> Display data file
● Modifications to the truck that affect the over- ● Display -> Truck control unit data file
all weight or the outer dimensions of the truck ● Reading out and saving LSP active
Source of the data file: ● Viewing a LSP active data file
In TRALA Online via Linde World Online.

NOTE
NOTE A data file that has been read out and saved can
be transferred back to the truck.
A new data file is created using the program for
calculating the load capacity in the "Linde World
Online" application. Special training is required NOTE
to carry out this task. The data file is saved onto
a data carrier and needs to be copied into the After transferring a new data file, the truck must
C:\LSP directory. The new data file can then be be switched off (via the key switch or truck ac-
transferred to the truck using the diagnostic process system). The transferred configuration will
gram. only be shown in the LSP display once the oper-
ating system for the LSP display has been re-
booted. All components and functions of the
NOTE LSP system must then be calibrated.
If the truck control unit or LSP display is re-
placed on the truck, the data file can be transfer- NOTE
red to the newly installed components using the
diagnostic program. If both components are re- When installing in control units that have already
placed at the same time, a new data file must be been used in other trucks, it is essential to check
created and saved using the program for calcu- that the serial number matches the number of
lating the load capacity (parameterising func- the data file.
tion).
After installing the data file, you will be asked to
enter the serial number, plus the order number +

Assistance systems
LSP select configuration
After replacing the truck control unit
NOTE
After transferring a new data file, the truck must NOTE

be switched off (via the key switch or truck ac-
cess system). For the LSP select, no data file is stored in the
LSP display. If the truck control unit fitted before
the replacement is still functional, the data file
NOTE must be read out before replacing the truck con-
trol unit. If the truck control unit is no longer
To transfer the data file, the CAN box must have functional, the valid data file for the truck must
the current firmware version installed (CAN box I be obtained from Linde Customer Service via
version 2.45 or CAN box II version 2.46). The the local service partner.
LSP servicebase must be version 1.4.0 or high-
er. Reading out the data file (LSP servicebase):
 "Guided diagnostics" ► "LSP select (Linde
Transferring a data file Safety Pilot)" ► "Start"
Fulfilling the preconditions (truck servicebase):  "1. Data set/activation" ► "OK"

● Select the lift mast type  "Read out data set and save" ► "OK"
● Register the optional components on the truck
 Replace the truck control unit.
control unit (current sensor, battery charger
etc.) Transferring the data file (LSP) servicebase):
● Activate the optional functions for the truck
control unit (optional outputs, speed reduc-
tions etc.) Safety Pilot)" ► "Start"
● Adjust the accelerator  "1. Data set/activation" ► "OK"
● Adjust the joysticks
 "Activate" ► "OK"
● Adjust the steering-angle sensor
● Adjust the tilt angle sensor

Fulfilling the preconditions (truck servicebase):
● Select the lift mast type
Transferring the data file (LSP servicebase): ● Register the optional components on the truck
 Create the directory C:\LSP control unit (current sensor, battery charger
etc.)
 Save the data file in C:\LSP ● Activate the optional functions for the truck
 "Guided diagnostics" ► "LSP select (Linde control unit (optional outputs, speed reduc-
Safety Pilot)" ► "Start" tions etc.)
● Adjust the accelerator
 "1. Data set/activation" ► "OK"
● Adjust the joysticks
 "Activate" ► "OK" ● Adjust the steering-angle sensor
Calibrating the LSP components (LSP service- ● Adjust the tilt angle sensor
base):
Calibrating the LSP components (LSP service-
 "Guided diagnostics" ► "LSP select (Linde base):
Safety Pilot)" ► "Start"
 "3. Calibration" ► "OK" Safety Pilot)" ► "Start"
● 1. The mast must be vertical  "3. Calibration" ► "OK"
● 2. Lift height sensor ● 1. The mast must be vertical
● 3. Load pressure sensor ● 2. Lift height sensor
 Using the key switch or the truck access sys- ● 3. Load pressure sensor
tem, switch the truck off and then on again.
 Using the key switch or the truck access sys-

Assistance systems
After resetting the truck control unit to the Activating/deactivating LSP select
factory setting
If there is a problem with a LSP component, the
LSP system can be temporarily deactivated. The
NOTE truck can still be used until the appropriate com-
ponent is available and can be replaced. Deacti-
If either the driving or working hydraulics param- vating the system in no way restricts the function
eters of the truck control unit is reset to the fac-
tory parameters, both the driving and working of the truck. Before the system is deactivated,
hydraulics parameters must always be reset to the data file must be read out from the truck con-
the factory parameters. trol unit.
Reading out the data file (LSP servicebase): Reading out the data file (LSP servicebase):
 "Guided diagnostics" ► "LSP select (Linde  "Guided diagnostics" ► "LSP select (Linde
Safety Pilot)" ► "Start" Safety Pilot)" ► "Start"
 "1. Data set/activation" ► "OK"  "1. Data set/activation" ► "OK"
 "Read out data set and save" ► "OK"  "Read out LSP select and save" ► "OK"
Truck servicebase: Deactivating LSP select functionality (LSP serv-

icebase):
 Reset the driving parameter to the factory pa-
rameter.  "Guided diagnostics" ► "Deactivate LSP /
LLA" ► "Start"
 Reset the working hydraulics parameter to the
factory parameter.  "Deactivate"
 Register optional components with the truck Activating LSP select functionality (LSP service-
control unit (driving and working hydraulics), base):
e.g. current sensor, battery charger.  "Guided diagnostics" ► "LSP select (Linde
 Activate optional functions on the truck control Safety Pilot)" ► "Start"
unit (driving and working hydraulics), e.g. op-  "1. Data set/activation" ► "OK"
tional outputs, speed reductions etc.
Transferring the data file (LSP servicebase):
 "OK"
Safety Pilot)" ► "Start"  Using the key switch or the truck access sys-
 "1. Data set/activation" ► "OK"
After replacing the LSP display
NOTE
If only the LSP display is changed, the data for

the new LSP display is taken automatically from

Assistance systems
LSP active configuration
● 3. Load pressure sensor
NOTE ● 4. Axle-load sensor, zero point
After transferring a new data file, the truck must ● 5. Axle-load sensor, reference
be switched off (via the key switch or truck ac- ● 6. "Check the axle load!" (testing the axle load
cess system). The transferred truck configura- sensor/not in Pathfinder)
tion is only shown in the LSP display once the ● 7. Pump swivel end
operating system for the LSP display has been
rebooted. Selecting the attachment (menu on the LSP dis-
play):
NOTE  Select the relevant attachment via the "Set-

tings" ► "Attachment" LSP menu item using
To transfer the data file, the CAN box must have the rotary push button and confirm by press-
the current firmware version installed (CAN box I ing the rotary push button.
version 2.45 or CAN box II version 2.46). The
LSP servicebase must be version 1.4.0 or high-  Using the key switch or the truck access sys-
er. tem, switch the truck off and then on again.
Transferring a data file After replacing the truck control unit

Fulfilling the preconditions (truck servicebase): Fulfilling the preconditions (truck servicebase):
● Enter the serial number in the truck control ● Enter the serial number in the truck control
unit unit
● Select the lift mast type ● Select the lift mast type
● Register the optional components on the truck ● Register the optional components on the truck
control unit (current sensor, battery charger control unit (current sensor, battery charger
etc.) etc.)
● Activate the optional functions for the truck ● Activate the optional functions for the truck
control unit (optional outputs, speed reduc- control unit (optional outputs, speed reduc-
tions etc.) tions etc.)
● Adjust the accelerator ● Adjust the accelerator
● Adjust the joysticks ● Adjust the joysticks
● Adjust the steering-angle sensor ● Adjust the steering-angle sensor
● Adjust the tilt angle sensor ● Adjust the tilt angle sensor
Transferring the data file (LSP servicebase): Installing the data file ( LSP servicebase):
 Create the directory C:\LSP  Apply the data file from the LSP display.
 Save the data file in C:\LSP  "Guided diagnostics" ► "LSP active (Linde
 "Guided diagnostics" ► "LSP active (Linde
Safety Pilot)" ► "Start"  "1. Data set/activation" ► "OK"
 "1. Data set/activation" ► "OK"  "Data file display -> Controller" ► "OK"
 "Activate"► "OK"
 Enter the serial number. ► "OK" NOTE
 Enter the order number and the item number. Alternatively, the data file from the hard drive of
► "OK" the notebook can be saved in the truck control
Calibrating the LSP components (LSP service- unit (see "Transferring a data file").
base):
 "Guided diagnostics" ► "LSP active (Linde NOTE
The data file number (UUID) entered must al-
 "3. Calibration" ► "OK" ways be identical in the control unit (under "Error
● 1. The mast must be vertical codes + parameters" in the tabs "Driving", "Lift-
● 2. Lift height sensor ing" and "LSP") to the data file end number.

Assistance systems
Calibrating the LSP components (LSP service-  "1. Data set/activation" ► "OK"
base):
 "Data file display -> Controller" ► "OK"
 "Guided diagnostics" ► "LSP active (Linde
Selecting the attachment (menu on the LSP dis-
play):
 "3. Calibration" ► "OK"
 Select the relevant attachment via the "Set-
● 1. The mast must be vertical tings" ► "Attachment" LSP menu item using
● 2. Lift height sensor the rotary push button and confirm by press-
● 3. Load pressure sensor ing the rotary push button.
● 4. Axle-load sensor, zero point  Using the key switch or the truck access sys-
● 5. Axle-load sensor, reference tem, switch the truck off and then on again.
● 6. "Check the axle load!" (testing the axle load
sensor/not in Pathfinder) Activating/deactivating LSP active
● 7. Pump swivel end
If there is a problem with a LSP component, the
Selecting the attachment (menu on the LSP dis-
LSP system can be temporarily deactivated. The
play):
truck can still be used until the appropriate com-
 Select the relevant attachment via the "Set- ponent is available and can be replaced. Deacti-
tings" ► "Attachment" LSP menu item using vating the system in no way restricts the function
the rotary push button and confirm by press- of the truck. Before the system is deactivated,
ing the rotary push button. the data file must be read out from the truck con-
trol unit.
tem, switch the truck off and then on again. Deactivating LSP active functionality (LSP serv-
icebase):
After resetting the truck control unit to the  "Guided diagnostics" ► "Deactivate LSP /
factory setting LLA" ► "Start"
 "Deactivate"
NOTE
Activating LSP active functionality (LSP service-
If either the driving or working hydraulics param- base):
eters of the truck control unit is reset to the fac-  "Guided diagnostics" ► "LSP active (Linde
tory parameters, both the driving and working
hydraulics parameters must always be reset to
the factory parameters.  "1. Data set/activation" ► "OK"
Truck servicebase:  "Data file display -> Controller" ► "OK"
 Reset the driving parameter to the factory pa- Alternatively, if the data file is in the folder
rameter. C:\LSP:
 Reset the working hydraulics parameter to the  "Parameterising as LSP active" ► "OK"
factory parameter.
 Enter serial number ► "OK"
 Register the optional components on the truck
control unit (current sensor, battery charger Selecting the attachment (menu on the LSP dis-
etc.). play):
 Activate the optional functions for the truck  Select the relevant attachment via the "Set-
control unit (optional outputs, speed reduc- tings" ► "Attachment" LSP menu item using
tions etc.). the rotary push button and confirm by press-
ing the rotary push button.
LSP servicebase:
 "Guided diagnostics" ► "LSP active (Linde tem, switch the truck off and then on again.

Assistance systems
Setting the zero point for the lift height 
The ground zero point can be set using the "Lift

height zero point" action menu. The ground zero
point is required as a reference value to analyse
and display the current lift height and the lower-
ing limit. It may be necessary to calibrate a new
ground zero point as a result of tyre wear, fol-
lowing a tyre change or after changing the fork
arms or an attachment.
CAUTION
Risk of damage to property due to the lift mast collid-
ing with racks or other objects!
The current lift height display is always based on the
saved ground zero point. If the ground zero point is
set above ground level, the incorrect lift height will be
displayed.
 The lift height zero point must only be set at the
ground level of the fork arms or the attachment.
 Using the rotary push button, select the "Set-

tings" menu item (3).
 Push the turning/push knob to select the
menu item.
The display changes to show the submenu se-
lection options.
 Position the mast so that it is vertical.
 Lower the fork arms until the lower edge of
the fork arms or the attachment just touch the
ground.
 Using the rotary push button, select the "Lift 
height zero point" menu item (1).
 Push the turning/push knob to select the
menu item.

Assistance systems
 Menu item "Set now?"Select (3) using the 
turning/push knob.
 Push the turning/push knob to save the zero
point.
The zero point is saved. An acoustic signal
sounds at the same time as confirmation.
When exiting the menu, the Zero point of lift 

height reset note is displayed." Please check the
lift height restrictions and reset" (1) as required
in the display.
 Switch to the "Lift limits" submenu and check
the saved lift limits.

Assistance systems
Configuring the lowering limit
The lowering limit prevents the fork arms or an
attachment from unintentionally being lowered
onto the ground. During the lowering process,
the lift mast movement is stopped at an adjusta-
ble value. The lowering limit is activated and
configured via the diagnostic program.
The lowering limit can be deactivated temporari-
ly via the LSP menu. Permanent deactivation of
the lowering limit is not possible via the LSP
menu.
NOTE
When calibrating the load pressure sensors, the

lowering limit must be deactivated via the diag-
nostic program.

Hydraulics 70
Clean working in the hydraulic system

Dirt in the hydraulic system
Causes Prior to connecting attachments, check the
hose couplings for contamination.
An increased contamination in the vicinity of the When checking the hydraulics for the lift mast,
regulating pistons frequently leads to the hy- the attachments must also be checked.
draulic control valves not functioning. Clean hose couplings before releasing them.
If a truck suffers from repeat malfunctions in the After releasing the hose couplings, clean
hydraulic system, it is frequently the case that them once more and seal with caps.
particles are entering the hydraulic oil.
Response in the event of malfunctions
Dirt penetration caused by: ● If a control valve is replaced due to contami-
● Unclean auxiliary hydraulic hose couplings on nation, the pressure and feed filter must also
detachable attachments be replaced.
● Carelessness during servicing ● Usually, simply changing the component af-
● Worn seals
fected by the malfunction is not sufficient. The
hydraulic system must be flushed and the oil
● Movement of the piston rods
replaced (see section "Cleaning the hydraulic
● Mechanical damage to the hydraulic compo- system").
nents ● If a faulty line break safety device is suspec-
● Fork lifters, because the cylinders are always ted, it should be checked and replaced if nec-
operated in areas with high levels of dirt. essary. In the event of a damaged or de-
stroyed line break safety device, flush the en-
tire hydraulic circuit.
NOTE Note: Particles in the faulty line break safety
device can be spread to all lift cylinders and
The largest area for dirt entering the hydraulic deposit themselves at the cylinder bottom. Af-
system is the auxiliary hydraulics. ter a few hours, they can be released and
cause further problems. Because the particles
Course of action cannot usually be detected on the piston base
by the naked eye, the entire lift cylinder must
Prevention be replaced.
● When working on the hydraulic system, en- ● Determine the causes of the dirt in order to
sure that it is clean. protect the system in the long term. Clean the
● Seal the open or disconnected hydraulics as- affected components before rinsing and re-
semblies with plugs or cover if necessary. seal; replace where necessary.
● Use lint-free cleaning cloths. ● If the oil purity as per ISO 4406 (determined
● Observe the prescribed change intervals of

by means of an oil analysis) is worse than
20/17/13, it is recommended to install a mi-
the filter units.
crofilter as well as rinsing twice (see section
● The microfilter special equipment option is
"Cleaning the hydraulic system").
recommended for deployment in very dust-in-
tensive operations, such as the building mate-
rial and cement industry, with very fine dust
(particle size 0.5 – 5 μm). Standard filter sys-
tems are inadequate in such cases.
● Check sealing rings and wipers of the piston
rods. The seals can be changed after 2 to 3

years of service life as a preventative meas-
ure.
● Prevent dirt from entering via the hose cou-
plings on attachments:

70 Hydraulics
Cleaning the hydraulic system
Rinse process for the complete hydraulic sys-
tem:
• Drain the hydraulic oil

• Remove the suction filter
Warm up the truck for ap- • Replace the suction filter,
• Wipe the tank with a lint-
prox. 15 min: feed filter and pressure filter
free cloth
► Continuously actuate the lift- ► • Fill the hydraulic oil tank
• Re-install the old suction
ing/lowering, tilting, steering according to the operating
filter
and auxiliary hydraulics instructions
• Fill the hydraulic tank ap-
prox. half full
▲
Repeat twice
In order to document the completion of the

measure, take and analyse an oil sample after
the rinse process (see section "Taking hydraulic
oil samples and oil analysis").
Even higher oil purity is achieved by replacing
the standard filter cartridges with microfilter car-
tridges (in the feed and pressure filter housing)
before the first rinse process.
After rinsing, the hydraulic oil should correspond
to contamination level 18/15/12 in accordance
with ISO 4406.
Taking hydraulic oil samples and oil analysis

It is possible to take and analyse hydraulic oil The following can be identified by means of the
samples as a precautionary measure to prevent laboratory oil analysis:
damage to hydraulic components. By doing so, it ● Indicators of possible faulty components or
is possible to pre-emptively detect a potential impending damage
breakdown. ● Quality/viscosity of the oil currently in the
In addition, an oil sample must be taken in the truck

● Proof of mixtures
event of damage. The cases where this is nec-
essary are listed in the warranty directives. ● Indicator of required maintenance
The collaboration with the "Firma OELCHECK For an meaningful analysis, the following investi-
GmbH" laboratory (www.oelcheck.de) is very ef- gations are usually required (similar to "OEL-
fective. The analysis set no. 2 provides all nec- CHECK" analysis set no. 2)
essary conclusions. The samples must be ● Wear metals: iron, chrome, tin, aluminium,
placed directly into the "OELCHECK" sample nickel, copper, lead, molybdenum, PQ index
bottles in compliance with the necessary cleanli- (magnetisable iron particles)
ness rules. ● Additives: calcium, magnesium, zinc, phos-
phorus, barium, boron

● Contaminants: silicon, potassium, sodium,
water in %

Hydraulics 70
● Oil condition: viscosity at 40°C and 100°C, 7 Allow approx. 0.5-1 litres of oil to flow out
viscosity index, oxidation, appearance (approx. 30 seconds) or allow the oil to flush
● Particle counting in accordance with ISO into the hydraulic tank
4406 and SAE 4059 8 Without interrupting the flow of oil, allow ap-
prox. 250 ml of oil to drain into the sample
bottle via the mini measuring line This
NOTE process must always be completed outside
of the truck so that the sample is not distor-
Complete cleanliness is required for a realistic ted by the air flow inside the truck
analysis. An incorrectly taken oil sample leads to 9 Seal glass immediately after sample remov-
incorrect results. al.
The correct method to take a hydraulic oil sam- 10 Provide the following information on the
ple is as follows: sample certificate accompanying the oil
1 Before taking the sample, the measurement sample:
port and the surrounding parts must be - Machine type/manufacturer (e.g. forklift
cleaned of any loose dirt. Use Linde clean- truck/Linde)
ing spray for this purpose. - Chassis number
2 Screw the mini test socket (0009452214/ - Operating hours, operating hours since the
content of measurement box 0009416007) last oil change/top-up quantity since the last
into the output of the feed filter oil change
3 Warm up the truck (the oil temperature in - Name of the person who took the sample
the tank should be between 60°C and 80°C) - Date of the sample removal
and park it in an environment that is as
clean and as protected from the wind as - Type of fluid (e.g. hydraulic oil HLP 68)/
possible. viscosity/volume of oil in the system
4 Loosen the cap on a sample bottle but do - Oil manufacturer and oil designation
not remove the cap Place the sample bottle - Type of sample removal: dynamically, with
within reach Use only the sample bottles the engine running
provided by the laboratory - Removal place: downstream of the feed fil-
5 Connect the mini measuring line ter
(0009579074) to the test socket of the feed - Notes on possible contamination, e.g. con-
filter taminants in the vicinity of the truck that
6 Start the engine could have entered the oil

70 Hydraulics
Cleaning work on the Linde con-
trol valve - cast valve
Malfunctions in the working hydraulics can be
caused by contamination in the control valve,
amongst other things.
Before starting cleaning work, exclude all other
possible causes of the malfunctions. To do so,
check the following:
● The feed pressure must match the specifica-
tions in the training manual.

● Exclude leakage or malfunctions at the lift and
tilt cylinders by disconnecting them.

Before removing individual parts of the control
valve, it is necessary to perform a thorough ex-
ternal cleaning of the control valve. If compo-
nents are difficult to access for this external
cleaning, the control valve must be removed.
Comply with notes on the use of special tools,
tightening torque data and test instructions.
Tests with the note "Safety risk!" must always be
performed in accordance with "UVV regula-
tions".
When performing cleaning work, use only clean,
lint-free cloths. The use of oil-based cleaning
materials on components with sealing elements
is not permitted. Check the freedom of move-
ment of components by moving them back and
forth with a turning movement. When assem-
bling the valve, always fit new closure and seal-
ing elements.
Fault table
see "Emergency lowering screw"

Load lowers too quickly without the joystick being see "Load holding valve cone with throttle non-re-
actuated. turn valve"
see "Unblocking valve with push-open piston"
Load lowers too quickly without the joystick being
actuated. Leak tightness is established only after see "Unblocking valve with push-open piston"
an excessive period of time.
see "Pressure relief valve 1"
Maximum lifting speed no longer achieved with full see "Nozzle D1"
load. see "Flow pressure governor"
see "Release valve"
Maximum speed/force of the attachment is not
see "Release valve"
achieved.
see "Flow pressure governor"
see "Nozzle D1"
Cylinder movement does not correspond with the see "Pilot control"
joystick. see "Spring plate"
Mast tilts forwards without actuation. see "Over-centre valve"

Hydraulics 70
see "Non-return valve" (tilt recharge valve)
see "Release valve"
Valve has no function.
see "Nozzle D1"
see "Flow pressure governor"
see "Directional control valve piston"
Jerky movement during lifting.
see "Spring plate"
Jerky movement during lowering. see "Spring plate"
see "Nozzles at the over-centre valve"
Vibrates so much during lowering that the line see "Directional control valve piston"
break safety valve in the lift mast trips. see "Spring plate"
Tilt speed too high in parallel operation.
see "Spring plate"
Mast tilts forwards too quickly. see "Non-return valves"
Mast does not tilt when actuated. see "Nozzles at the over-centre valve"
Emergency lowering screw
1 Emergency lowering screw 2 Lock nut
Component Possible fault Possible cause Course of action Testing

Release the lock
Load lowers too Emergency lower-
nut and screw the
Emergency low- quickly without the ing screw not
emergency lower-
ering screw joystick being actu- screwed in fully and
ing screw in as far
ated. secured.
as the stop

70 Hydraulics
(housing) and tight-
en (MA = 10 Nm).
Tighten the self-
locking nut
(MA = 9.5 Nm).
Load holding valve cone with throttle non-return valve
1 Position in the control valve 3 Throttle non-return valve

2 Load holding valve cone
To remove the load holding valve cone (1), the 

following steps must be performed:
 Remove the lid (2) of the solenoid coil (3) (AF
26).

Hydraulics 70
 Remove the solenoid coil (3). 

Clean the valve
cone and valve
Dirt on the valve seat. Safety risk!
seat. When refitting, Always perform a
check for ease of leakage test in ac-
movement. cordance with UVV
accident prevention
Visual inspection regulations.
for contamination or If necessary, repeat
Load holding Load lowers too damage to the the test several
valve cone with quickly without the bore. times.
throttle non-re- joystick being actu- If contamination is Note: when the
turn valve ated. present, clean the truck is at operating
bore. When refit- temperature, the
Valve cone sticking.
ting, check for ease mast is always ini-
of movement. tially lowered due to
If there are any contraction of the
bulges in the bore oil during cooling
or the valve cone, down.
replace the control
valve.
 Remove the screw plug (1) with an angle 

screwdriver (4) (AF 10).

70 Hydraulics
Installation position of the load holding valve 
cone and spring
Load holding valve cone 
Tightening torque of the screw plug (1): 95 Nm 

Hydraulics 70
Unblocking valve with push-open piston
1 Position in the control valve 3 Unblocking valve

2 Push-open piston 4 Push-open pin

Clean the ball and
the valve seat. Re- Safety risk!
place all support Always perform a
rings and O-rings. leakage test in ac-
Dirt on the valve
When refitting, cordance with UVV
seat.
check for ease of accident prevention
movement. regulations.
Caution: max. tor- If necessary, repeat
Load lowers too que: 50 Nm the test several
quickly without the
Unblocking valve Visual inspection times.
joystick being actu-
for contamination in Note: when the
ated.
the bore. truck is at operating
If contamination is temperature, the
Push-open pin present, clean the mast is always ini-
sticking. bore. When refit- tially lowered due to
ting, check for ease contraction of the
of movement. oil during cooling
Caution: max. tor- down.
que: 50 Nm
Load lowers too Visual inspection Safety risk!
Push-open pis- Unblocking valve
quickly without the for contamination or Always perform a
ton fails to open.
joystick being damage to the leakage test in

70 Hydraulics
Load holding valve accordance with
fails to open. UVV accident pre-
push-open piston
vention regulations.
and the bore.
If necessary, repeat
If no serious dam-
the test several
actuated. Leak age is visible, clean
times.
tightness is estab- Push-open piston is the components.
Note: when the
lished only after an contaminated and When refitting,
truck is at operating
excessive period of is holding the un- check for ease of
temperature, the
time. blocking valve movement.
mast is always ini-
open. Caution: max. tor-
tially lowered due to
que of unblocking
contraction of the
valve: 50 Nm.
oil during cooling
down.
 Unscrew the unblocking valve with AF 21 and 

T30.
Push-open piston and unblocking valve disas- 

sembled.
(1) Push-open piston

(2) Push-open pin
(3) Unblocking valve
NOTE
When reassembling, take care that the pin is in

the correct location. The point must face in the
direction of the unblocking valve housing.
Tightening torque of the unblocking valve:
50 Nm
Tightening torque of the screw plug: 15 Nm

Hydraulics 70
Pressure relief valve 1
Pressure relief valve on the 3-way block: 
(1) Pressure relief valve for lifting and tilting

(2) Pressure relief valve for auxiliary hydraul-
ics
Pressure relief valve on the 4-way block: 
(1) Pressure relief valve for lifting and tilting

(2) Pressure relief valve for auxiliary hydraul-
ics

Maximum lifting Pressure relief
speed no longer valve does not ach-
Pressure relief Check components
achieved with full ieve the set pres-
valve for for contamination or
load. sure.
lifting, tilting, damage.
Pressure relief
auxiliary hydraul- Clean the compo- Set and test the
Valve has no func- valve does not
ics nents. pressure.
tion. close due to con-
tamination. Tighten the self-
locking nut to
Check that the seal- 60 Nm and seal to
ing varnish is intact. the threaded pin
Additional pres- (settling phenom- with sealing var-
Maximum speed/
sure relief valve The set value for ena are fairly un- nish.
force of the attach-
for the pressure has likely)
ment is not ach-
auxiliary hydraul- changed. Set the pressure
ieved.
ics according to the
training manual,
seal the thread.

70 Hydraulics
Pressure relief valve disassembled. 
Visual inspection and cleaning of the pres-

sure relief valve (on the example of the mul-
ti-layer valve)
 Open the fuel tank cap.
 Release the self-locking nut M12x1 - the re- 

taining compound between the adjustment
screw and the self-locking nut should not be
damaged.
 Remove the compression spring and valve 

cone with magnet.
 Remove contamination from the valve cone. 

Hydraulics 70
 Remove contamination from the valve seat 
using a lint-free cloth or a magnet.
Rinsing the valve
 Fit the adjustment screw and self-locking nut
without the valve cone.
 Start the truck and actuate the lift joystick
(rinse valve).
 Undo the adjustment screw (AF 19) and as- 

semble the valve cone together with the
spring.
 Make sure that the tip of the cone lies in the 

valve seat.
The spring lies about 5 mm deep in the threaded 

hole.
 Refit the self-locking nut along with the adjust-
ment screw. Tighten the self-locking nut.
Tightening torque of the self-locking nut: 60 Nm
 Close the fuel tank cap.
 Measure the maximum pressure and correct if
necessary.

70 Hydraulics
Flow balance valve
1 Position of the pressure governor 2 Pressure governor complete with screw

plugs

Maximum lifting
speed no longer
achieved with full
load.
Flow pressure Maximum speed/ Pressure governor
Unscrew and clean.
governor force of the attach- is contaminated.
ment is not ach-
ieved.
Valve has no func-
tion.
Removing the flow pressure governor

 Open the screw plug (5) on the spring side 
(AF 8).
 Remove the (4) spring.

Hydraulics 70
 Open the screw plug (2) on the piston side 
(AF 8).
 From the spring side, push out the piston (3) 

using a screwdriver.
Installing the flow pressure governor
NOTE
To remove and clean nozzle D1 0.8 mm with

disc filter, the spring side of the flow pressure
governor must remain open and the spring must
be removed. Otherwise, removal is not possible.
 Install the piston (3) from the piston side (note
the installation direction).
 Install the screw plug (2) on the piston side 

(AF 8).
Tightening torque of the screw plug on the pis-
ton side: 70 Nm
 Insert the spring (4). 
 Install the screw plug (5) on the spring side

(AF 8).
Tightening torque of the screw plug on the
spring side: 70 Nm

70 Hydraulics
Exhaust valve
1 Attachment position on the control valve

Valve has no func- Switching magnet Replace the switch-
Function checking
tion. defective. ing magnet.
Maximum lifting
Release valve speed no longer Remove and clean
for the achieved with full the safety valve pis-
Safety risk!
safety valve pis- load. ton.
Valve piston jams Check the valve
ton When refitting,
Maximum speed/ or is stiff due to dirt. functions several
check for complete
force of the attach- times.
freedom of move-
ment is not ach- ment.
ieved.
Removing the release valve

Hydraulics 70
 Remove the lid (2) of the release valve (1) 
(AF 26).
 Remove the solenoid coil (1).
 Remove the magnetic tube (3) (AF 17). 
 Remove the valve piston (5) and the valve 

spring (4) using a magnet.
Release valve removed 
(1) Solenoid coil

(2) Lid
(3) Magnetic tube
(4) Spring
(5) Valve piston
(6) Complete release valve
Installing the release valve

Installation is performed in the reverse order.
Tightening torque of the solenoid valve: 9 Nm
Tightening torque of the lid: 5 Nm

70 Hydraulics
Nozzle D1 0.8 mm with disc filter
Removing nozzle D1
NOTE
To remove and clean nozzle D1 0.8 mm with

disc filter, the spring side of the filter pressure
governor (see Removing the flow pressure gov-
ernor) must remain open and the spring must be
removed. Otherwise, removal is not possible. A
damper nozzle is installed before nozzle D1.
Position on the control valve (1) 
 Remove the screw plug (1).
 Unscrew the damping nozzle (2) (AF 5) and 

remove using a magnet.
 Unscrew nozzle D1 0.8 mm with disc filter (3) 

(AF 3) and remove using a magnet.

Hydraulics 70
Nozzle D1 0.8 mm with disc filter and damping 
nozzle removed
(1) Screw plug (AF 6)

(2) Damping nozzle (AF 5)
(3) Nozzle D1 0.8 mm with disc filter (AF 3)

Maximum lifting
speed no longer Open sealing
achieved with full plug (1).
load. Unscrew the damp-
ing nozzle.
Maximum speed/ Nozzle D1 is conta-
Nozzle D1 Unscrew nozzle D1.
force of the attach- minated.
Clean the oil chan-
ment is not ach-
nel.
ieved.
Thoroughly clean
Valve has no func- nozzle D1.
tion.
Pressure relief valve 2
1 Position on the 3-way block 2 Position on the 4-way block
See Pressure relief valve 1
NOTE
The pressure for pressure relief valve 2 is al-

ways lower than that for pressure relief valve 1.
There must be a difference of at least 20 bar.
Exception: Pressure relief valve 1 is lower than
or equal to 190 bar. Then pressure relief valve 2
is blocked.

70 Hydraulics
Pilot
1 Control pressure cover
DANGER
Injuries may occur in the event of a malfunction, e.g.
due to unintended lowering of the lift mast.
During disassembly, take great care to ensure that
the magnets, spring plates, compression springs and
shim rings for the individual sections are not mixed
up.
Pilot 
(1) Valve sleeve

Hydraulics 70
Pilot 
(1) Magnetic tube

(2) Pressure reduction valve pilot
(3) Compression spring
Pilot 
(1) Tightening torque: 5 Nm with spline

(2) Tightening torque: 9 Nm
Component Possible fault Possible causeCourse of action Testing

Unscrew the control
pressure cover.
Caution: During dis-
assembly, take
great care to en-
sure that the mag-
nets, spring plates,
compression
Cylinder movement
Valve sleeve and springs and shim
does not corre- Pilot control is con-
pressure reduc- rings for the individ- Function checking
spond with the joy- taminated.
tion valve pilot ual sections are not
stick.
interchanged.
The cover must be
completely free of
oil.
Clean the compo-
nents. In so doing,
do not unscrew the
valve sleeve from

70 Hydraulics
the control pressure
cover.
Caution: Watch out
for the compression
spring underneath
the pilot.
Spring plate
1 Spring plate

Cylinder movement
does not corre-
spond with the joy-
stick.
Jerky movement Remove the pilot.
during lifting. Check the spring
Check the direc-
plate and slider for
Jerky movement tional control valve
pressure marks
during lowering. The slider jams at piston for ease of
Spring plate (grooves).
Vibrates so much the spring plate. movement by slid-
If there are grooves
during lowering that ing and rotating in
on the slider in area
the line break safety the housing.
(a), sand down the
valve in the lift mast pressure marks.
trips.
Tilt speed too high
in parallel opera-
tion.

Hydraulics 70
Over-centre valve
1 Position on the valve block

Clean the compo-
nents.
Dirt on the valve
When refitting,
seat.
check for ease of
movement. Safety risk!
Always perform a
Clean the valve.
leakage test in ac-
Dirt between the When refitting,
cordance with UVV
Over-centre Mast tilts forwards ball and the seat. check for ease of
accident prevention
valve without actuation. movement.
regulations.
Clean the valve. If necessary, repeat
The sealing ring the test several
must be undam- times.
Valve is stiff in the
aged.
bore.
When refitting,
check for ease of
movement.

70 Hydraulics
Disassembly of the over-centre valve with non- 
return valve.
Over-centre valve with non-return valve. Ball (1) 

must move freely.
Nozzles at the over-centre valve

Hydraulics 70
1 2x M10 screw plug (MA = 20 Nm) 3 2x M6 nozzles (MA = 5.9 Nm)
2 1x M8 threaded plug (left), 1x M8 nozzle
(right) (MA = 14 Nm)

Jerky movement
Nozzles on the during tilting. Nozzles are conta- Remove and re-
over-centre
Mast does not tilt minated. place the nozzles.
valve
when actuated.
Directional control valve piston

NOTE
During disassembly, take great care to ensure

that magnets, spring plates, compression
springs and shim rings for the individual sections
are not mixed up.
NOTE
The pistons are not mutually interchangeable.

They must be fitted in the respective position
and location from which they were removed.

70 Hydraulics
DANGER
Malfunctions leading to injuries may occur in the
event of damage to the pistons, e.g. due to uninten-
ded lowering of the lift mast.
During disassembly of the lift and tilt pistons, the pis-
tons must be clamped in special wooden jaws.

Jerky movement Check the compo-
during lifting, tilting Dirt between the nents for damage.
or an auxiliary func- piston and the bore. Clean the compo-
tion. nents.
When refitting,
Lift piston check for ease of
Tilt piston movement. Function checking
Auxiliary piston If there are any
Jerky movement Dirt between the deep scratches or
during lowering. piston and the bore. bulges in the bore
or on the piston, re-
place the control
valve.
Remove the lift pis-
ton and clamp it in
wooden jaws. Open
the screw plug and
clean the discharge
flow controller.
Vibrates so much Apply Loctite FK5
during lowering that Contaminated dis- to the screw plug
Lift piston the line break safe- charge flow control- (keep the piston Function checking
ty valve in the lift ler in the lift piston. free of oil) and
mast trips. screw in using a
tightening torque of
30 Nm. Allow the
adhesive to cure.
When refitting,
check for ease of
movement.
Remove the tilt pis-
ton and clamp it in
wooden jaws. Open
the screw plug and
clean the pressure
governors.
Apply Loctite FK5
Tilt speed too high Contaminated tilt to the screw plugs
Tilt piston in parallel opera- pressure governors (keep the piston Function checking
tion. in the piston free of oil) and
screw in using a
tightening torque of
20 Nm. Allow the
adhesive to cure.
When refitting,
check for ease of
movement.

Hydraulics 70
Directional control valve piston disassembled. 
(1) Lifting/lowering - piston is not symmetrical

(2) Tilting - piston is not symmetrical
(3) Auxiliary hydraulics 1
(4) Auxiliary hydraulics 2
NOTE
The pistons are not mutually interchangeable.

They must be fitted in the respective position
and location from which they were removed.
Lift/lower directional control valve piston disman- 

tled.
Directional control valve piston for

(1)
lifting/lowering
(2) Discharge flow regulator
Screw plug (tightening torque
(3)
20 Nm)
Non-return valves
Tilt recharge valve (1) for 3-way and 4-way valve 
block. Load-sensing non-return valve (2) for 4-
way valve block.
Load-sensing non-return valve (1) for 3-way 

valve block.

70 Hydraulics
Contaminated or
Maximum pressure
damaged valve seat
Non-return valve is no longer ach-
in the non-return Clean the valve. Function checking
for load sensing ieved; on-
valve for load sens-
ly 170+10 bar.
ing.
Safety risk!
Always perform a
leakage test in ac-
Contaminated or Clean the valve.
cordance with UVV
Tilt recharge Mast tilts forwards damaged valve seat If the valve seat is
accident prevention
valve too quickly. in the tilt recharge damaged, replace
regulations.
valve. the control valve.
the test several
times.
Tilt recharge valve
1 Tilt recharge valve 2 Sealing plug
 Open and close using a T30.

Tightening torque of the screw plug: 20 Nm

Safety risk!
Always perform a
leakage test in ac-
Contaminated or Clean the valve.
cordance with UVV
Tilt recharge Mast tilts forwards damaged valve seat If the valve seat is
accident prevention
valve without actuation. in the tilt recharge damaged, replace
regulations.
valve. the control valve.
the test several
times.

Hydraulics 70
Cleaning instructions
No function or malfunction following actuation of
the joystick
Position of the sealing plug (1) and the 1.5-mm 
nozzle with disc filter on the control valve
Position of the 1.5-mm nozzle with disc filter (2) 

as seen from connection X
Control pressure nozzle removed 
(1) Sealing plug T25,

(2) 1.5-mm nozzle with disc filter
Component possible error Action

Control pressure nozzle, connec- No function or malfunction fol- Clean the 1.5-mm nozzle with
tion "X" lowing actuation of the joystick disc filter (2)

70 Hydraulics
Control valve
Overview
8 Measurement point "P" 2Y3 Tilt forwards solenoid

11 Lifting and tilting pressure relief valve 2Y4 Tilt backwards solenoid
13 Release valve 2Y5 / 2Y6 Auxiliary hydraulics 1 solenoid
16 Auxiliary hydraulics pressure relief valve 2Y7 / 2Y8 Auxiliary hydraulics 2 solenoid
2Y1 Lowering solenoid NA Emergency lowering
2Y2 Lifting solenoid
Oil volume for the auxiliary hydraulics

The maximum available oil volume at the auxili-
ary hydraulics of the control valve for attach- NOTE
ments is 48 l/min. This value applies if no by- ● Long oil lines influence the pressure and pos-
pass pipe is fitted and the volume has not been sibly the oil volume.
increased in the "Pathfinder" diagnostics. With a
● The specified oil volume is subject to a toler-
bypass pipe and a volume increase in "Pathfind-
ance band and may therefore deviate.
er", the oil volume can be increased to 55 l/min.
Both values apply at an oil temperature of 60°C.
● The specified oil volume always applies to the
output at the control valve.

Hydraulics 70
Control valve

70 Hydraulics
Control valve
Operating hydraulics circuit diagram

Hydraulics 70
Control valve
1 Tilt cylinders A2 Tilt forwards
2 Tilt distributor B2 Tilt backwards
3 Raise/lower distributor A3/B3 Additional hydraulics 1
4 Forwards tilt brake valve A4/B4 Additional hydraulics 2
5 Solenoid valve MP/P2 Measurement point for circulation and maximum
6 Unblocking valve for the load holding valve pressure
7 Load holding valve P Pump V1
8 Emergency lowering screw X Pilot pressure
9 Pressure relief valve for lifting, tilting forwards and T Return/tank
tilting backwards
10 2/2-way valve (pressure balance) Valves
11 Release valve (safety valve) 2Y1 Lowering valve
12 Raise/lower solenoid valve 2Y2 Lifting valve
13 Tilt solenoid valve 2Y3 Tilt forwards valve
14 Braking valve for tilting backwards 2Y4 Tilt backwards valve
15 Auxiliary hydraulics pressure relief valve 2Y5 Auxiliary hydraulics valve B3
16 Solenoid valve for auxiliary hydraulics 1 2Y6 Auxiliary hydraulics valve A3
17 Solenoid valve for auxiliary hydraulics 2 2Y7 Auxiliary hydraulics valve B4
2Y8 Auxiliary hydraulics valve A4
Connections 2Y9 Release valve (safety valve)
A1 Lift cylinders

70 Hydraulics
Control valve
Function characteristics
Introduction ● The LS path is closed. This allows the great-
est consumer pressure present to act togeth-
The valve mentioned below is an LS control er with the spring force in the closing direction
valve with electro-hydraulic activation in a mono- of the flow pressure governor. The pump
block design. The control valve is available op- pressure increases to the pressure level at
tionally as a three-way monoblock (single auxili- which a balance of forces is restored at the
ary hydraulic section) or a four-way monoblock flow pressure governor.
(double auxiliary hydraulic sections). ● The control pressure supply X is connected to
the supply of the pressure reduction valves.
Section 1 Lifting/lowering Only in this way is it possible to actuate the
respective directional control valve axis via an
Section 2 Tilting forwards and backwards
activation signal 2Y1 to 2Y8.
Section 3 Auxiliary hydraulics 1
If the signalled consumer pressure exceeds the
Section 4 Auxiliary hydraulics 2
maximum permissible pressure value of the
pressure relief valve (1), the pressure relief
The control valve housing contains directional
valve opens a connection to the oil tank. A pres-
control valves, a flow pressure governor, pres-
sure gradient is then reduced at the flow limita-
sure relief valves, a safety valve and various
tion nozzle in the LS path. The flow pressure
non-return valves.
governor is now only subject to the pressure set
at the pressure relief valve (2) and the spring
Safety valve, flow pressure governor, pres- force. This limits the maximum pump pressure. If
sure relief valve the consumer pressure that is present is greater,
no positive control ∆p can result at the measur-
The safety valve is a piston valve, which influen- ing orifice of the directional control valve axis,
ces both the LS signalling path and also the con- which means that there is no flow to the con-
trol pressure supply. When the joystick is not ac- sumer. The pump surplus flow is discharged to
tivated, the 2Y9 connection at the safety valve is the oil tank at the flow pressure governor.
in a de-energised state. Spring force therefore
pushes the safety valve into the following posi-
tion: Functional description - lifting, lowering and
emergency lowering
● The LS signalling path is connected to the oil
tank. When the joystick for lifting is actuated, the con-
● The control pressure supply X is blocked off trol signal 2Y2 is increased in proportion to the
from the supply of the pressure reduction movement of the lever. At the same time, the
valves. safety valve mentioned above is switched by the
● The pressure reduction valve supply is direc- movement of the joystick. The control signal acts
ted to the oil tank via the switching solenoid on the proportional solenoid of the pressure re-
tappet. duction valve and regulates the existing supply
A flow limitation nozzle in the LS path ensures pressure X.
that only the oil tank pressure is signalled to the Dependent on the control signal, the pressure
flow pressure governor in the spring chamber. reduction valve then generates a control pres-
When the motor is running, the flow pressure sure that pushes the directional control valve
governor adopts the control position which al- piston (4) against a return spring.
lows the available pump volume to flow to the oil
tank with a ∆p of approx. 8 bar (depending on The measuring orifice fitted in the directional
the spring force at the pressure governor). When control valve enlarges as the piston stroke in-
a joystick is actuated, the switching magnet on creases. At the same time, the movement of the
the safety valve is activated, and the valve piston signals the consumer pressure in the LS
switches the following functions: path, and the flow pressure governor then regu-
lates the pump pressure to a pressure level that
ensures that there is always a constant control
∆p at the measuring orifice. This switching logic
means that the volume flow rate to the consum-
er is a function of the surface of the measuring
orifice.

Hydraulics 70
Control valve
During lifting, the flow merely passes through ● signalling of load pressure in LS path
the load holding valve (6). The surplus volume ● opening the discharge to the oil tank
flow is discharged to the oil tank via the flow ● opening of measuring orifice between pump
pressure governor. and consumer.
When the lowering function is actuated, the con- As long as the tilt forwards/backwards load pres-
trol signal 2Y1 is transmitted to the pressure re- sure is the highest pressure in the LS path, it is
duction valve. The resulting reduction in control signalled to the flow pressure governor and the
pressure acts on the directional control valve pump moves to a value that is higher than the
piston (4) and simultaneously on the unblocking control ∆p. The volume flow rate to the consum-
valve (7). er is therefore proportional to the movement of
The unblocking valve has a switching point that the measuring orifice. In this situation, the pres-
lies below the function start of the lowering func- sure governors (12) and (13) incorporated in the
tion. In the switched position, the spring cham- piston are fully opened. As soon as another con-
ber of the load holding valve (6) is connected to sumer signals a higher load pressure, the higher
the main volume flow path upstream of the low- load pressure is applied to the pressure gover-
ering measuring orifice. Such switching has the nor in the inlet, causing it to close. The pressure
advantage that the load holding valve only governor now adjusts to a position at which the
opens when the lowering measuring orifice control ∆p is still present at the measuring ori-
opens to the oil tank. This means that very pre- fice, and the load ∆p (differential pressure be-
cise lowering is possible even under high load. tween the highest load pressure and the tilt
pressure) is regulated at the control orifice of the
The function "Stop lowering" is initiated every pressure governor.
time the flow signal 2Y1 or 2Y9 is interrupted. As
soon as the unblocking valve (7) no longer has a Such switching ensures that the volume flow
control pressure supply, the above-mentioned rate for the tilt function is not affected, even in
connection is closed again, and the load pres- parallel operation with other consumers.
sure in A1 falls in the spring chamber of the load
holding valve. This causes the valve to be tightly Functional description — brake valves
sealed.
In the directional control valve block, down-
There is a flow control valve (5) integrated in the stream from the directional control valve (9), two
directional control valve piston (4). This controls brake valves (10) and (11) are fitted. These
a ∆p at the measuring orifice for lowering, which valves are designed so that they form a tight
is designed to limit the lowering speed so that seal, and each includes a bypass non-return
even when loaded it does not exceed a maxi- valve. The operation of these valves is explained
mum of 0.6 m/s. To lower a raised mast follow- with the forwards tilt function.
ing a malfunction of the control valve, it is possi-
ble to manually open a connection between con- The directional control valve piston (9) is moved
sumer A1 and the oil tank using the emergency by means of the control signal 2Y3 and the pres-
lowering function. The emergency lowering sure reduction valve so that a volume flow rate
screw can be opened by inserting an SW 10 flows from the pump to the consumer A2 via the
socket wrench through a hole in the bottom bypass non-return valve in the brake valve (10).
plate. The consumer pressure in A2 is signalled to the
brake valve (11) and moves it in the opening di-
After doing so, and before starting up the device rection.
again, be sure to retighten the emergency lower-
ing screw to the correct torque in accordance The oil forced out of the cylinders (17) can flow
with the installation drawing. from connection B2 to the oil tank via the brake
valve (11) and the directional control valve pis-
ton (9).
Functional description — tilting and pres-
sure governors If a dragging load causes the lift mast to adopt a
speed that is greater than that specified by the
When the joystick is actuated, either the control volume flow rate in A2, the pressure in A2 drops
signal 2Y3 (tilt forwards) or 2Y4 (tilt backwards) and the brake valve (11) is forced back into the
is signalled to the relevant pressure reduction closed position by a spring. The discharged vol-
valve (tilt forwards or tilt backwards). As in the ume flow rate in B2 then accumulates, and in
case of lifting, this results in movement of the di- conjunction with the cylinder area represents a
rectional control valve piston (9). The following force that opposes the dragging load.
switching positions are run through here:

70 Hydraulics
Control valve
The pressure in A2 therefore increases again pressure reduction valve and generates a con-
and is able to re-open the brake valve (11). trol pressure that acts on the valve piston (15).
Since the brake valve is a closed loop control The control pressure increases along with the
valve, this results in a situation where the brake control signal, and the valve piston moves
valve regulates precisely to ensure that the against a return spring in the opening direction.
speed of the mast corresponds to the specified The load pressure in A3 is signalled by the pis-
volume flow rate in A2. ton (15) moving to the flow pressure governor
(3) via the LS path. The measuring orifice at the
The brake valve is designed so that it forms a
valve piston connects the pump path to the con-
tight seal, thus preventing movement of the mast
sumer connection A3.
when the control valve is not activated.
The consumer B3 is connected to the oil tank. A
Functional description — auxiliary hydraul- volume flow rate is brought about by the control
∆p generated at the flow pressure governor, and
ics
flows in proportion to the deflected measuring
The additional consumers (1) and (2) work in ex- orifice. The surplus volume flow of the pump is
actly the same way for both the A and the B discharged to the oil tank via the flow pressure
side. Their maximum volume flow rate depends governor.
on the respective maximum control signal 2Y5 to If the load pressure of the additional consumer
2Y8. This can be between 3 and 48 l/min. exceeds the maximum permissible value set at
The maximum permissible consumer pressure the pressure relief valve (14), the control ∆p is
of the auxiliary function is limited by the pressure reduced at a flow limitation nozzle in the LS
relief valve (14) to a value between 160 and path. This means there is no pressure gradient
180 bar. The function is explained as an exam- between the pump pressure and consumer pres-
ple with auxiliary A3. sure A3, and no volume flow rate can pass to
the consumer.
When the joystick is actuated, the control sig-
nals 2Y6 and 2Y9 are enabled at the same time. The additional consumers have no device to
The safety valve is switched by the control sig- keep the volume flow rate to the consumer con-
nal 2Y9 before the function start of the auxiliary stant during parallel operation with other func-
function. The control signal 2Y5 acts on the tions.
Checking the function and safety system of the third auxiliary hydraulics
(special equipment)
The following description applies only when fit- If the electrical system is switched on using the
ting a third auxiliary hydraulics system. The aux- switch key, one of the two toggle switch illumina-
iliary hydraulics system is controlled via a toggle tions must light up. If neither or both of the
switch. A function test and safety check always switch illuminations light up, there is an error.
need to be performed on the third auxiliary hy- There is a risk of malfunction. The auxiliary hy-
draulics system following commissioning and re- draulics may not be used.
pair.
Safety check:
DANGER  Switch on the ignition
Increased risk of accident from a falling load.  Remove one cable connector from the sole-
For attachments that perform a clamping function
noid valve on the fork carriage
(e.g. a bale clamp), a lockable joystick must be used.  Actuate joystick for the third auxiliary hydraul-
ics system
Functional test:
The following safety precautions and warning
Activate all three additional functions one after messages are activated:
the other. The functions performed at the attach- ● Switchable auxiliary hydraulics function
ment must comply with the labelling on the oper- blocked
ating console. ● Truck switched to crawler mode
Possible malfunction via toggle switch:

Hydraulics 70
Control valve
● Error code displayed in text field of display ● Buzzer sounds
unit

70 Hydraulics
Valves
Pressure relief valve
Pressure relief valve adjustment instruc- WARNING
tions
Pressure increases very rapidly when screwing in the
Pressure settings: adjusting screw and may reach impermissible levels.
● H 40, standard, duplex and triplex mast:
The setting is highly sensitive.
p = 250+5 bar Setting must always be conducted very carefully in in-
crements of a maximum turn angle of 90° of the ad-
● H 45/50, standard, duplex and triplex mast:
justing screw.
p = 275+5 bar
 Loosen locknut.  Screw in the adjusting screw (increase pres-
sure).
 Screw out the adjusting screw (reduce pres-
sure).
Depressurisation
Auxiliary hydraulics 1 and 2
For special equipment with quick hitch connec-
tions for attachments the hose connections must
be depressurised when the attachment is being
unhitched. For the Linde control valve this can
be performed only by using the "depressurisa-
tion" special equipment.
The "depressurisation" system comprises an ac- 
cumulator (1) which is connected via a hose (2)
and a pipe (5) to the control valve at (X). During
operation the brake valve (4) acts to charge the
accumulator (1).
After the engine is switched off the feed pipe is 

depressurised, but the non-return valve (3) pre-
vents loss of pressure. The accumulator main-
tains pressure at the control valve that is used to
depressurise the auxiliary hydraulics.
Procedure
 Switch off the fork lift truck at the ignition.
 Switch on the ignition again.
 Sit on the driver's seat so that the seat switch
is activated.
 Move the auxiliary hydraulics joystick several
times. This causes the auxiliary hydraulics to
be depressurised.

Hydraulics 70
Valves
Hose layout for pump — control valve
D
EF
P1
LS
B
CF
393-02_07-002a
B Working control valve F Feed pressure

D Working hydraulics pump MPR LS Steering control valve pressure connection
E Pressure filter for working hydraulics (Load Sensing)
CF Volume flow rate for steering control valve P Control valve pressure connection
EF Volume flow rate for working hydraulics P1 Feed pump pressure connection
pump

70 Hydraulics
Valves
Hose layout of control pressure supply
D
EF
P1
O
F
LS
CF
393-02_07-001a
B Working control valve F Feed pressure

D Working hydraulics pump MPR LS Steering control valve pressure connection
O Feed filter (Load Sensing)
CF Volume flow rate for steering control valve P1 Feed pump pressure connection
EF Volume flow rate for working hydraulics X Working hydraulics pressure connection
pump
Increasing the volume flow rate

To increase the operating speed of various at-
tachments, the following measures must be tak-
en:
In the diagnostic program (servicebase Error Codes + Parameters

394-02), open the following window: ▼
Working hydraulics
▼
Speeds Aux. Hydraulics
 In the "Oil mass flow aux. hydraulics" window,

set the parameter to "increased".
 Install bypass pipe (3).
The volume flow rate is then approx. 55 l/min.

Hydraulics 70
Valves
Assembling the pipe line for increased volu-
metric flow
Parts list for customised options: 
Single auxiliary hydraulics 3930173066

Double auxiliary hydraulics 3930173065
Pipe-line parts: 
(1) Pipe connection 0009511942

(2) Pipe union 9714010682
Pipe for single auxiliary hydraulics
3934414004
(3)
Pipe for double auxiliary hydraulics
39344140 05
(4) Pipe union 9721002010

70 Hydraulics
Tilt cylinder
Tilt cylinders
Screw-in depths for mechanically adjusting

the tilt cylinders
CAUTION
Incorrect adjustment of the tilt angle limitation can sig-
nificantly impair the guaranteed stability when carry-
ing a load with the mast extended, and the forklift
truck may tip over as a consequence.
When making repairs, always check that the piston
rod is screwed into the eye bolt to the correct depth.
The screw-in depth depends on the forklift truck mod-
el, the lift height and the mast type.
Thread on the piston rod: M20 x 1.5 mm
H40 - Standard lift mast
Lift Tilt cylinder (1) Eye bolt (3) Threaded rod (2) Screw-in
height L = 828 L = 869 L = 130 L = 158 L = 182 L = 77 L = 159 L = 200 depth (4)
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
3000 1 — — — 2 — — — 33
3000(1) 1 — — 2 — 2 — — 48
3100 1 — — — 2 — — — 33
3100(1) 1 — 2 — — 2 — — 48
3200 1 — — — — — — — 43
3200(1) 1 — — — — — — — 33
3300 1 — — 2 — — — — 33
3300(1) 1 — — — — — — — 38
3400 1 — 2 2 — — — — 33
3400(1) 1 — 2 — — — — — 38
3500 1 — — 2 — — — — 33
3500(1) 1 — — — — — — — 43
3600 1 — — 2 — — — — 33
3700 1 — — 2 — — — — 33
3800 1 — — 2 — 2 — — 33
3900 1 — — 2 — 2 — — 38
4000 1 — — 2 — 2 — — 43
4100 1 — — 2 — 2 — — 43

Hydraulics 70
Tilt cylinder
4200 1 — — 2 — 2 — 2 43
4300 1 — — 2 — 2 — 2 38
4400 1 — — 2 — 2 — — 33
4500 1 — — — 2 2 — — 48
4600 1 — — — 2 2 — — 38
4700 1 — — — 2 2 — — 33
4800 1 — 2 — — — 2 — 38
4900 1 — — 2 — — 2 — 48
5000 1 — — 2 — — 2 33
5100 1 — — — 2 — 2 33
5200 1 — — 2 — 2 — 33
5300 1 — — — 2 2 — 38
5400 1 — — — 2 2 — 33
5900 1 — 2 — — — 2 33
6300 1 — 2 — — — 2 33
6500 1 — 2 — — — 2 33
(1) with overhead guard 3 to 6
H40 - Duplex/triplex lift mast
2730/
1 — — — 2 2 — — 48
4075
3030/
1 — — — 2 — — — 33
4525
3130/
1 — — — 2 — — — 33
4675
3230/
1 — — — 2 — — — 38
4765
3330/
1 — — — 2 — — — 48
4915
3430/
1 — — 2 — — — — 33
5065
3530/
1 — 2 — — 2 — — 33
5215
3630/
1 — 2 — — 2 — — 33
5365
3730/
1 — 2 — — 2 — — 38
5515
3830 1 — 2 — — 2 — — 43
3930/
1 — 2 — — 2 — — 43
5715
4030/
1 — 2 — — 2 — — 43
5865
4130/
1 — 2 — — 2 — — 33
6015

70 Hydraulics
Tilt cylinder
4230/
1 — 2 — — 2 — — 33
6165
4330/
1 — 2 — — 2 — — 33
6315
H45/H50 - Standard lift mast
3000 1 — — 2 2 2 — — 33
3100 1 — — 2 2 2 — — 33
3200 1 — 2 — — 2 — — 48
3300 1 — 2 — — 2 — — 48
3400 1 — 2 — — 2 — — 33
3500 1 — 2 — — 2 — — 33
3600 1 — 2 — — 2 — — 38
3700 1 — 2 — — 2 — — 38
3800 1 — 2 — — — 2 — 38
3900 1 — — — 2 2 — — 38
4000 1 — — — 2 2 — — 33
4100 1 — — — 2 2 — — 38
4200 1 — — — 2 2 — — 33
4300 1 — — — 2 2 — — 33
4400 1 — 2 — — — 2 — 33
4500 1 — 2 — — — 2 — 33
4600 1 — — 2 — — 2 — 33
4700 1 — — 2 — — 2 — 38
4800 1 — — — 2 — 2 — 33
4900 1 — — — 2 — 2 — 33
5000 1 — — — 2 — — 2 33
5100 1 — — — 2 — — 2 38
5200 1 — 2 — — — 2 — 38
5300 1 — 2 — — — 2 — 33
5400 1 — — 2 — — 2 — 43
5900 1 — — — 2 — — 2 38
6300 1 — — — 2 — — 2 38
H45/H50 - Duplex/triplex lift mast
2700/
1 — — — 2 2 — — 48
4045
3030/ 1 — — 2 — 2 — — 33

Hydraulics 70
Tilt cylinder
4525
3130/
1 — — 2 — 2 — — 43
4675
3230/
1 — 2 — — 2 — — 33
4765
3330/
1 — 2 — — 2 — — 33
4915
3430/
1 — 2 — — 2 — — 33
5065
3530/
1 — — — 2 2 — — 33
5215
3630/
1 — — — 2 2 — — 43
5365
3730/
1 — — — 2 2 — — 48
5515
3830 1 — — 2 — 2 — — 33
3930/
1 — — 2 — 2 — — 33
5715
4030/
1 — — 2 — 2 — — 33
5865
4130/
1 — — — 2 2 — — 48
6015
4230/
1 — — — 2 2 — — 43
6165
4330/
1 — — — 2 2 — — 33
6315
H50-600 - Standard lift mast
2800 — 1 — 2 2 2 — — 33
2900 — 1 — 2 2 2 — — 48
3200 — 1 2 — — 2 — — 38
3700 — 1 — — 2 2 — — 33
4100 — 1 — — 2 2 — — 33
4400 — 1 — 2 — — 2 — 33
5000 — 1 — 2 — — 2 — 38
H50-600 - Duplex/triplex lift mast
3745 — 1 — — 2 2 — — 48
4225 — 1 — 2 — 2 — — 33
4375 — 1 — 2 — 2 — — 43

70 Hydraulics
Tilt cylinder
4615 — 1 2 — — 2 — — 33
5065 — 1 — — 2 2 — — 43
5565 — 1 — 2 — 2 — — 33
6015 — 1 — — 2 2 — — 33
H40 - Standard lift mast, elevated driver's compartment
3800 1 — 2 — — 2 — — 38
3900 1 — 2 — — 2 — — 48
4000 1 — — — 2 — — — 48
4100 1 — — 2 — 2 — — 43
4400 1 — — — 2 2 — — 38
5000 1 — — — 2 2 — — 33
5400 1 — — — 2 2 — — 33
5900 1 — — — 2 2 — — 33
H40 - Duplex/triplex lift mast, elevated driver's compartment
5715 1 — — 2 — 2 — — 43
4030 1 — — 2 — 2 — — 48
4130 1 — 2 — — 2 — — 33
4230/
1 — — 2 — 2 — — 33
6165
4330/
1 — — 2 — 2 — — 48
6315
H45/H50 - Standard lift mast, elevated driver's compartment
3800 1 — — 2 — 2 — — 33
3900 1 — — 2 — 2 — — 38
4000 1 — — 2 — 2 — — 48
4100 1 — 2 — — — 2 — 38
4400 1 — 2 — — — — 2 33
5000 1 — — 2 — — — 2 33
5400 1 — — 2 — — 2 — 48
5900 1 — — 2 — — 2 — 48

Hydraulics 70
Tilt cylinder
H45/H50 = Duplex/triplex lift mast, elevated driver's compartment
5715 1 — 2 — — — 2 — 48
5865 1 — — 2 — 2 — 33
4130 1 — — 2 — 2 — 43
4230/
1 — 2 — — — 2 — 48
6165
4330/
1 — 2 — — — 2 — 48
6315
Removing the tilt cylinders
1 Hexagon head screw 11 Cylinder head

2 Spring element 12 O-ring 40x3-P90
3 Adaptor 13 Snap ring
4 Cylinder pipe 14 Wiper
5 Hexagon nut M18x1.5-10 15 Threaded rod (extension)
6 Guide strip 16 Hexagon head screw
7 Piston seal 17 Clamping piece
8 Piston 18 Eye bolt
9 Piston rod 19 Spring element
10 Grooved ring 20 Clamping piece

70 Hydraulics
Tilt cylinder
CAUTION
The tilt cylinders are mounted on top of the overhead
guard and are not accessible without the use of an
aid.
Work on the installed tilt cylinders must only be per-
formed using a suitable ladder.
CAUTION
When working beneath leaking tilt cylinders, the serv-
ice technician may come into contact with hydraulic
oil.
Wear a personal protection suit.
 Lower the fork carriage and tilt the mast ap-

prox. 2° backwards.
 Attach it to a crane to prevent the lift mast tilt-
ing forwards.
 Unscrew the hydraulic connections at the
front and rear of the tilt cylinder; remove the
banjo bolts.
 Unscrew the hexagon head screw from the
front tilt cylinder support.
 Remove the inner and outer clamping pieces.
rear tilt cylinder support and remove the
adaptor.
 Lift the tilt cylinder from the truck.
NOTE
Tilting back the mast by approx. 2° relieves the

tension on the spring elements of the tilt cylinder
supports.
Sealing the tilt cylinders

Requirement:
The tilt cylinder has been removed. A set of
seals is available.
NOTE
The set of seals assy. consists of a guide strip,

piston seal, grooved ring, O-ring and wiper.
 Clamp tilt cylinder in vice with suitable jaws.
 Use a screwdriver to free the wiper; remove it.
 Push the cylinder head back about 10 mm to
release the load on the snap ring.
 Extract the lock ring from its groove and re-
move it.

Hydraulics 70
Tilt cylinder
 If necessary, use a triangular scraper to re-
move the burr produced by the locking ring.
 Remove the piston rod with cylinder head.
When doing so, the hydraulic oil left in the cyl-
inder will escape via the front connection.
Place a suitable container underneath.
 Loosen the clamping screw on the eye bolt
and unscrew the eye bolt from the threaded
rod.
 Lightly grease the seal elements and change
them.
 Slide the piston rod into the cylinder pipe.
 Position the cylinder head. When doing so,
make sure that the groove of the cylinder
head is aligned with the front connecting
thread, but that the cylinder head is not inser-
ted too far.
 Fit the snap ring.
NOTE
When connecting the hydraulic line, the cylinder

head is held in position using the banjo bolt.
 Fit the wiper using Loctite No. 270.
 Screw the eye bolt onto the threaded rod. En-
sure that the installation dimensions are cor-
rect when doing so.
 Tighten the safety bolt to Ma = 80 Nm.
Installing the tilt cylinders

 Attach the tilt cylinder to the rear tilt cylinder
support using the adaptor and hexagon head
screw.
Tightening torque for the rear hexagon head
screw: Ma = 275 Nm
 Attach the inner and outer clamping piece to
the front spring element.
NOTE
The oval opening of the spring element must be

vertical.
 Bolt it to the front tilt cylinder support / lift
mast with a hexagon head screw.
Tightening torque for the front hexagon head
screw: Ma = 275 Nm
 Attach the hydraulic hoses using banjo bolts.
 Perform a functional test.

70 Hydraulics
Accumulator
Accumulators 
Hydraulic accumulators can store a certain

amount of energy and transfer this energy to the
hydraulic system as required. Fluids are only
very slightly compressible. In contrast, gases
have a high level of compressibility. The operat-
ing principle of gas-charged hydraulic accumula-
tors is based on this difference. A distinction is
made between bladder accumulators and dia-
phragm accumulators, depending on the design
of the separating element. Hydraulic accumula-
tors consist of a fluid section and a gas section
with a gas-tight separating element. The fluid
section is connected to the hydraulic circuit.
When a certain amount of pressurised gas is
subjected to a higher level of fluid pressure, the
volume of gas decreases as the fluid pressure
increases. The gas pressure rises with the fluid
pressure. When the pressure of the fluid drops,
the expansion of the gas pushes the fluid back
into the hydraulic system until the pressures are
equal again.
Accumulators in the working hydraulics

Accumulators fitted in the working hydraulics are
filled with nitrogen to facilitate damping. This in-
volves a special equipment variant that enables
easier transportation of fragile and liquid goods.
These accumulators are filled with nitrogen and
pre-loaded with 2/3 of the maximum working hy-
draulic pressure at the factory. The customer
may need to adjust the filling pressure during
use. The minimum pressure must not be less
than half of the maximum working pressure.
Example:
Maximum working pressure 240 bar

Factory setting 160 bar
Minimum pressure after any adjust- 120 bar
ments
If the damping properties can no longer be guar-

anteed, the filling pressure must be maintained
and tested. If the filling pressure is too low, this
will damage the integrated bladder. The accu-
mulator must be replaced. The accumulator
must be checked and filled using a testing and
filling device, which is available from numerous
manufacturers. Accumulators from the Linde
spare parts warehouse must be adjusted to
meet the requirements of their particular use.

Hydraulics 70
Accumulator
NOTE
In accordance with Pressure Equipment Direc-

tive 2014/68/EU, regular testing of the accumu-
lators is not essential. This regulation applies in
Germany. Other directives may be in place in
other countries.
Bladder accumulators 
Bladder accumulators consist of a smooth, cylin-

drical pressure tank (1) manufactured from high-
strength steel. The elastic bladder (2) fitted in
the tank interior divides the accumulator into a
gas section and a fluid section. The bladder is
filled with nitrogen via the gas valve (4) at the
specified gas filling pressure of p0. The oil con-
nection of the bladder accumulator contains the
oil valve (3), which closes if the pressure in the
gas section is higher than in the fluid section.
This stops the bladder escaping into the oil
channel and thus prevents damage to the blad-
der. When the minimum operating pressure is
reached, a small amount of fluid (approx. 10% of
the nominal volume of the hydraulic accumula-
tor) must remain between the bladder and the oil
valve, so that the bladder does not hit the valve
during every expansion process. The gas valve
(4) consists of a sealing cap (4.1), a gas valve
insert (4.2) and a gas filling valve body (4.3).
These parts can be replaced individually. The
type cap (7) contains the technical data and
properties of the hydraulic accumulator.

70 Hydraulics
Accumulator
Filling, checking and correcting the pressure
1 Transition piece 6 Adaptor

2 Pressure reduction valve 7 Nitrogen tank
3 G1 8 Hydraulic accumulator
4 Filling hose 9 Fluid connection
5 Filling and testing device
A standard filling and testing device (5) is re-

quired to fill empty accumulators with nitrogen or
to correct the pressure.
The filling and testing device is used to fill hy-
draulic accumulators (8) with nitrogen or to
check and modify the current pre-charge pres-
sure. The filling and testing device is screwed
onto the gas valve of the hydraulic accumulator
and connected to a nitrogen tank (7) via a flexi-
ble filling hose (4). If the pre-charge pressure of
the nitrogen only needs to be checked or re-
duced, the filling hose does not have to be con-
nected. The filling and testing device (5) is a
screw joint fitting with a pressure gauge attach-
ed to it, and with a non-return valve and a spin-
dle. The gas valve on the accumulator is opened
via the spindle to check the pressure.
To enable the filling and testing device to be
connected, the thread of the accumulator and
the thread of the filling unit must fit each other.
An adaptor may be required.

Hydraulics 70
Accumulator
NOTE
Hydraulic accumulators must only be filled with

nitrogen. Do not use other gases.
The accumulator from the Linde spare parts
warehouse is filled at a low pressure (2 to 3 bar)
so that the bladder is inflated and is not dam-
aged if it moves during transportation.
The pressure relief valve is intended to protect
the accumulator rather than to control the maxi-
mum pressure of the lifting hydraulics.

70 Hydraulics
Accumulator

Lifting system 80
Lift mast
Safety information for working on
the lift mast
DANGER
Risk of crushing when the lift mast or fork carriage is
raised.
No work may be carried out on the lift mast or at the
front of the truck unless the following protection meas-
ures are observed.
Use a safety chain with a sufficient load capacity for
the lift mast in question.
NOTE
A special tool may be necessary for the follow-

ing protection measures.
Securing the lift mast against tilting back- 

wards
The lift mast must be secured against acciden-
tally tilting backwards.
 Tilt the mast fully forwards.
tric trucks only).
 Insert a hardwood block.
Securing the lift mast against tilting for- 

wards
When working on the tilt cylinders, the lift mast
must be secured against unintentionally tilting
forwards.
 Set the lift mast to vertical.
tric trucks only).
 Attach a round sling to the crane hook. Adjust
the tension of the round sling using the crane.

80 Lifting system
Lift mast
NOTE
Use a suitable mounting aid.
Standard lift mast

Function:: When raising the inner mast, the
chain rollers are moved upwards with the chains
so that the fork carriage is lifted with a transmis-
sion ratio of 2:1 due to the chain deflection.
Securing the 
raised standard lift mast 1
of the outer mast.
 Lower the inner mast to the end of the chain.
Duplex lift mast

2
cial free lift height via the chain guide pulley of d3921482
Here, it moves twice as fast as the centre cylin-
der.
The inner mast is then lifted by the two outer cyl-
inders, taking the fork carriage with it.
ble inner mast.
Securing the 
raised duplex lift mast 1
of the outer mast.
2 d3921483

Lifting system 80
Lift mast
Triplex lift mast
cial free lift height via the chain guide pulley of
Two lift cylinders then raise the inner mast.
Once the inner mast is fully extended, two addi-
tional lift cylinders lift the middle mast, which is
lifted together with the inner mast and the fork
carriage.
ble inner mast.
Securing the raised triplex lift mast 
 Extend the lift mast (lift 1 and lift 2).

middle mast (1) and over the cross beams of
the inner mast (2), and connect them to one
another.
of the outer mast.

 Extend the lift mast further (lift 3). 1
outer mast (1) and over the cross beams of
the middle mast (2) and connect them to one
another.
of the outer mast.
2
d3921484

80 Lifting system
Lift mast
Lift mast - Identification
A 12-digit serial number and a type description 45 Load bearing capacity 4.5 t
are stuck onto the mast profile to identify the lift T S = Standard, D = Duplex, T = Triplex
mast.
01 Variant 01
Example for truck family 394 and lift mast model 46 Lift height 4600 mm
189 in standard, duplex and triplex versions: 5 Load centre of gravity 500 mm
Serial number: ME 45T 01-46-5/394 394 Truck family 394
M Mast
E Mast profile code E = 4 to 5 t
Measuring the lifting speed

In order to determine whether the truck reaches  Using a stop clock, measure the time required
the necessary lifting speed, proceed as follows: for the lift mast to reach the marking.
 Lower the lift mast completely.
 Mark the outside of the lift mast at a minimum NOTE
height of 2 m.
The different lifting speeds and lowering speeds
 Start the truck. are dependent on the tonnage and the lift mast
(standard, duplex, triplex). The setpoint values
 Actuate the joystick fully and raise the lift must be taken from the "technical datasheet".
mast.
Removing and installing lift mast

model 189
WARNING
There is a risk of becoming trapped be-
tween parts due to the moving lift mast
or attachment.
For this reason, never reach into or enter
the lift mast or the area between the lift
mast and the truck.
If necessary, secure the lift mast in
place.
Removal
 Remove the fork arms or attachment.
 Lower fork carriage.
 Tilt the lift mast backwards by approx. 2°.
NOTE
Tilting the lift mast backwards by approx. 2° re-

leases the tension on the spring elements of the
drive axle.

Lifting system 80
Lift mast
 Attach the round sling to the crane hook. Ad- 
just the tension of the round sling using the
crane.
 Remove the panelling.
 Extend the lift mast far enough to allow ac-
cess to the hexagon head screws with spring
elements and the bearing halves.
 Loosen the 2 M20x100 hexagon head screws
at the bottom on the crossmember of the lift
mast and remove the screws.
 Loosen 4 M16x70 hexagon head screws on
the bearing halves.
 Lower the lift mast.
 Disconnect the articulated lever of the tilt an-
gle sensor from the lift mast.
 Disconnect the pressure lines and any auxili-
ary hydraulic lines between the truck and the
lift mast.
 Remove 4 M16x70 hexagon head screws
from the bearing halves.
upper eye bolt on each of the two tilt cylin-
ders.
 Remove inner and outer clamping piece.
 Lift out the lift mast.
 Lock the tilt angle sensor with the two slotted 
spring pins 5 x 40 mm (1).
NOTE
Assembling the slotted spring pins acts as a

transportation safety device. If the tilt angle sen-
sor is not fixed and locked, an error message
may be generated. As a result of the error mes-
sage, the speed of the truck is significantly re-
duced.
Installation
 Attach the round sling to the crane hook. Lift
the lift mast using the crane.
 Fit the lift mast with bottom crossmember into
the holding fixtures on the axle pipe and align
centrally.
 Secure the bearing halves in position using 4
M16x70 hexagon head screws.
 To assemble the tilt cylinders, insert the inner
clamping pieces into the hole on the lift mast.
 Position the connection for the tilt cylinder.

80 Lifting system
Lift mast
 Fit the clamping piece from the outside.
 Insert an M16x130 hexagon head screw with
a washer and tighten the screw.
 Connect the pressure lines and any auxiliary
hydraulic lines between the truck and the lift
mast.
 Extend the lift mast far enough to allow ac-
cess to the hexagon head screws with spring
elements and the bearing halves.
 Screw in the 2 M20x100 hexagon head
screws complete with bushes and spring ele-
ments through the bottom crossmember of
the lift mast and into the drive axle.
 Tighten the 4 hexagon head screws on the
bearing halves.
 Lower the lift mast.
 Remove the slotted spring pins 5 x 40 mm (1) 
from the housing of the tilt angle sensor.
NOTE
After removing the slotted spring pins, the lift

mast can be tilted again. While the slotted spring
pins remain in the tilt angle sensor, the "tilting"
function is locked.
 Check that the movement of the tilt angle sen-
sor is not restricted.
 Screw the articulated lever of the tilt angle
sensor onto the lift mast.
 Lower the crane.
 Detach the round sling from the crane hook
and release the round sling from the cross-
member.
 Switch on the truck and bleed the hydraulic
system.
 Set the tilt angle sensor (see "Setting the tilt
angle sensor").

Lifting system 80
Lift mast
Driving without the lift mast
CAUTION
When driving without the lift mast, the speed of the
truck must be reduced for safety reasons.
Therefore, before removing the lift mast, an additional
stop screw must be fitted under the reverse travel ac-
celerator pedal (dual-pedal operation) or accelerator
pedal (single-pedal operation) to restrict the speed.

 Screw the hexagon head screw M8 x 20 (3) 
half-way into hexagon nut M8 (2) (DIN 6330,
6331, 6334).
 Screw the hexagon nut (2) onto the existing
hexagon head screw M8 (1) until one hexa-
gon head screw (3) hits the other hexagon
head screw (1). 3
 Lock them into the hexagonal nut (2).
 Remove the lift mast. 2
After reattaching the lift mast, the additional stop
must be removed.
1
d3921520
Setting the tilt angle sensor

DANGER
Attachments and/or special tyres may make it neces-
sary to restrict the backwards tilt.
When using an attachment, the actual load capacity
and the restricted backwards tilt required to achieve
this must be calculated using the "TRALA" software.
DANGER
Failure to apply the tilt angle restriction may cause
the truck to overturn.
The truck must be unloaded when setting the tilt angle
transmitter.
Comply with any tilt angle restrictions.
Restrictions apply to the backwards tilt depending on
the tonnage, the lift mast type, the lift height, attach-
ments and tyres.
Requirements
A laptop with the diagnostic program is required
for adjusting (configuring) the tilt angle transmit-
ter.

80 Lifting system
Lift mast
Marking out the reference points
 Draw a line on the front plate parallel to the A-
column at a distance of 87 ±2 mm from the
centre of the M8 screw.
 Draw a further line horizontally on the front
plate at a distance of 314 ±2 mm from the
mudguard.
The intersection of the two lines forms the vehi-
cle-side reference point.
 Mark the lift-mast-side reference point at a 
distance of 939 ±2 mm from the lower end
and at a distance of 100 ±2 mm from the side
of the outer mast profile.
Calibrating the tilt angle sensor
CAUTION
On trucks with windscreens and wipers, contact be-
tween the lift mast and the wiper arm is possible when
tilting back against mechanical stop.
Remove wiper arm.

 Select the "Adjustment work (Configuring the
tilt angle transmitter)" window.
 Tilt the lift mast back to mechanical stop.
 Measure and make a note of the distance X0
(standard dimension) between the truck-side
and lift-mast-side reference points.
 Tilt the lift mast forwards from the mechanical
end stop by the distance value XR (backwards
tilt dimension).
Select numerical value XR from the "Nominal
backwards tilt" table shown below.
H 40
Nominal H 40
All other lift standard
backwards standard
masts Lift height
tilt1 Lift height
Model 189 3100 to
In degrees 3000
3500
XR in (mm) XR in (mm) XR in (mm)
0.0° 143 137 130
0.5° 136 130 123
1.0° 129 123 116
1.5° 122 116 109
2.0° 115 109 102
2.5° 108 102 95
3.0° 101 95 88
3.5° 94 88 82
1 Restrictions apply to the backwards tilt depending on the tonnage, the lift mast type, the lift height, attachments and tyres.

Lifting system 80
Lift mast
H 40
Nominal H 40
backwards standard
masts Lift height
tilt1 Lift height
Model 189 3100 to
In degrees 3000
3500
4.0° 87 82 75
4.5° 80 75 68
5.0° 73 68 61
5.5° 66 61 54
6.0° 59 54 46
6.5° 52 46 39
7.0° 45 39 32
7.5° 38 32 25
8.0° 31 25 18
8.5° 24 18 172
9.0° 23 172 -
 Measure the distance between the truck-side

The distance must equal X0 + XR. Interrogate
the value XR in the diagnostics program.
 Input the value.
 Adjust the rear electronic stop.
 Press the "Done" button within the diagnos-
tics window.
 Tilt the lift mast forwards from the mechanical 
end stop by the distance value XV (forwards
tilt dimension).
Take XV from the following table.
 Measure the distance between the truck-side
The distance must equal X0 + XV.
 Enter the XV value in the diagnostic program.
 Adjust the front electronic stop.
 Press the "Done" button within the diagnos-
tics window.
H 40
Nominal H 40
forwards standard
masts Lift height
tilt1 Lift height
Model 189 3100 to
In degrees 3000
3500
XV in (mm) XV in (mm) XV in (mm)
0.0° 126 120 113
0.5° 133 127 120
1.0° 140 134 127
1.5° 147 141 134
2 Standard factory setting if no restriction of backwards tilt is stipulated.

80 Lifting system
Lift mast
H 40
Nominal H 40
forwards standard
masts Lift height
tilt1 Lift height
Model 189 3100 to
In degrees 3000
3500
2.0° 154 148 141
2.5° 161 155 148
3.0° 168 162 155
3.5° 175 169 162
4.0° 181 176 169
4.5° 188 183 176
5.0° 2 195 189 182
Removing and installing the outer lift cylinder
394-02_08-003
1 Inner mast 4 Holding fixture

2 Locking ring 5 Connecting line
3 Outer lift cylinder
2 Standard ex works forwards tilt setting

Lifting system 80
Lift mast
CAUTION  Secure the inner mast to prevent it from low-
ering.
When opening the pressure lines, the inner mast may
lower independently and cause serious injury.  Remove the mounting clip and remove the
Secure the inner mast to prevent it from lowering! hose clips if necessary.
 Lift out the faulty outer lift cylinder.
 Lower the mast completely and tilt it forwards  Insert a new outer lift cylinder.
to ensure that no pressure builds up in the
system and good accessibility is assured.  Remove the inner-mast locking device and
lower the inner mast.
 Remove the locking ring (2) at the head of the
piston rod on the outer lift cylinder (3).  Insert the locking ring (2).
 Detach the connecting line (5) from the base  Connect the connecting line (5).
of the outer lift cylinder and seal the hose  Bleed the hydraulic circuit.
opening with a plug.
 Using the fully operational lift cylinder, fully
extend the inner mast (1).
Standard lift mast

Sealing the outer lift cylinder 
1
 Remove the connection piece to the centre lift
cylinder.
2
 Clamp the bottom of the outer lift cylinder in a
vice.
 Heat the cylinder head (3) (which will have
3
been secured with Loctite) and unscrew the
cylinder head from the cylinder pipe using a
pin wrench.
 Remove the wiper (1), grooved ring (2) and 4
O-ring (4) from the cylinder head (3).
 Clean the cylinder head (3), particularly 5
around the thread.
 Fit a new wiper (1), grooved ring (2) and O-
ring (4) to the cylinder head (3).
6
 Remove the piston rod (7) from the cylinder

pipe. 7
 Check the piston rod for damage and scratch- 393-02_08-012
es, and replace if necessary.
1 Wiper
 Replace all seals (note the spare parts cata- 2 Grooved ring
logue). 3 Cylinder head
4 O-ring
 Insert the piston rod into the cylinder pipe. 5 Bolt
6 Snap ring
 Clean the cylinder pipe around the thread. 7 Piston rod
 Fit the cylinder head (3) to the cylinder pipe
using Loctite 243.

80 Lifting system
Lift mast
Duplex/triplex lift mast
Sealing the outer lift cylinder 
1
 Remove the connection piece to the centre lift
cylinder. 2
 Clamp the bottom of the outer lift cylinder in a
vice.
been secured with Loctite) and unscrew the 3
cylinder head from the cylinder pipe using a
pin wrench.
 Remove the wiper (1), grooved ring (2) and
O-ring (4) from the cylinder head (3). 4
 Clean the cylinder head (3), particularly
around the thread.
 Fit a new wiper (1), grooved ring (2) and O-
5
 Remove the piston rod (5) from the cylinder
pipe.
 Check the piston rod for damage and scratch- 393-02_08-006
1 Wiper
 Replace all seals (note the spare parts cata- 2 Grooved ring
logue). 3 Cylinder head
4 O-ring
 Insert the piston rod into the cylinder pipe. 5 Piston rod
 Clean the cylinder pipe around the thread.
using Loctite 243.

Lifting system 80
Lift mast
Removing and installing the centre lift 
cylinder
 Raise the fork carriage approx. 10 cm with the
working hydraulic system.
 Secure the fork carriage in this position to
prevent it from lowering.
 Operate the working hydraulics so that the
centre lift cylinder is retracted again and the
chains are loose.
 Remove the clamps on the guide pulleys of
the chains.
 Remove the chains from the guide pulleys.
 Remove the connection line on the underside
of the centre lift cylinder.
 Remove the retaining clamp of the cylinder.
 Remove the centre lift cylinder.
 Insert a new centre lift cylinder.
393-02_08-005
 Fit the retaining clip on the cylinder.
 Attach the connection line on the underside of
the centre lift cylinder.
 Secure the chains to the guide pulleys.
 Secure the bracket on the guide pulleys for
the chains.
 Lift the fork carriage.
Sealing the centre lift cylinder 

1
 Remove the support and guide pulley.
 Clamp the bottom of the centre lift cylinder in
a vice. 2
been secured with Loctite) and unscrew the
cylinder head from the cylinder pipe (6) using 3
a pin wrench.
 Remove the wiper (1), grooved ring (2) and
O-ring (4) from the cylinder head (3). 4
 Clean the cylinder head (3), particularly
around the thread.
 Fit a new wiper (1), grooved ring (2) and O- 5
6
393_08-002

80 Lifting system
Lift mast
 Remove the piston rod (6) from the cylinder 
pipe (12).
6
 Check the piston rod for damage and scratch-
 Remove the piston seal (9) and guide ring 7
(10) from the piston cover (8).
 Insert a new piston seal (9) and guide ring
(10) into the piston cover (8). 8
 Insert the piston rod (6) into the cylinder pipe
(12). 9
 Clean the cylinder pipe (12) around the
thread. 10
(12) using Loctite 243. 11
12
393-02_08-011

Lifting system 80
Assembly parts
Support rollers / wear strips
Setting the roller play
The settings described here refer to the reas- hardly perceptible. The operational safety of the
sembly of parts. On no account do they repre- lift mast is not impaired by this.
sent maximum permissible wear values or play
It is necessary to critically inspect whether the lift
for lift masts in service.
mast continues to function correctly only when a
Wear in mast profiles does not occur uniformly wear dimension of approx. 3% of the roller diam-
along the entire length. Instead, wear occurs in eter is detected. This inspection must be per-
the main working area, e.g. where the support formed slightly earlier for longer triplex lift masts,
rollers are normally positioned while the truck is and only when a wear dimension of 4% is detec-
transporting a load. Often, the rails at the top are ted for short standard lift masts.
used so infrequently that they are almost like
The operational safety of the lift mast is main-
new. As a result, larger rollers or additional shim
tained for a significantly longer period of time be-
rings cannot be fitted to compensate for play
cause the individual lift mast components remain
without having the effect of jamming the rollers.
securely locked into each other even in the case
The limit values for local wear of this type cannot of extreme wear. If a support roller fails or
generally be defined because several factors in- breaks, the lift mast must be taken out of opera-
fluence whether the given play is damaging or tion immediately.

80 Lifting system
Assembly parts
Roller play - fork carriage in the inner
mast, family 189
Axial play (AS) 
Play is adjusted using adjusting washers which

are slid over the locating studs.
● Support roller A, B: min. 0 mm, max. 0.2 mm
at the tightest spot Otherwise maximum
1.0 mm
● Support roller C: thickness of adjusting wash-
ers equal to A + X.
Dimension "X" is stamped into the fork carriage
bar (see sketch). To enable tolerance compen-
sation the contact face of stud C is slightly offset
in relation to A and B.
The following always applies for 6-roller fork car-
riages:
● The third pair of rollers C should bear the full
load only when the upper rollers A are exten-
ded beyond the mast profile.
● When rollers A and B are running on their
tracks, roller C may exhibit some minor play
(0–0.2 mm).
● Depending on the stud position, roller C may
be one stage smaller than A and B.
Radial play - adjustment
Dimension "RS" Support rollers

Positions A, B,
C
Spare part no.
over up to See Spare
Parts Cata-
logue
Support roller
- 105.8
size 1
Support roller
105.81 106.1
size 2
Support roller
106.11
size 3

Lifting system 80
Assembly parts
Roller play - middle and inside mast pro- 
file, Series 189
Illustration: centre mast support roller on the in-
ner mast
Radial play - setting (RS)
Dimension "RS" Supporting

rollers
Spare part no.
over to See Spare
Parts Cata-
logue
Support roller
- 105.8
size 1
Support roller
105.81 106.1
size 2
Support roller
106.11 -
size 3
Axial play (AS)

Play is adjusted using shim washers which are
slid over the locating studs.
Axial play at the tightest spot 0+0.2 mm. Other-
wise, maximum 1.0 mm at the slackest spot.
Play is adjusted using shim washers.
Outer Mast Roller Clearance, Type 189 
Illustrated: Support roller on inner mast to middle

mast
Dimension "RS" Support rollers

Part No.
from to see Parts
Catalogue
Support roller
- 160.8
size 1
Support roller
160.81 161.1
size 2
Support roller
161.11 -
size 3
PERMISSIBLE LATERAL CLEARANCE

(AS)
The clearance dimension is adjusted with adjust-
ing shims which are slipped over the centring
pivot. 1 Guide
Adjusting clearance at narrowest point

0+0.2 mm. Otherwise, it reaches a maximum of
1.0 mm at the widest point.

80 Lifting system
Assembly parts
Removing wear strips - Standard lift
mast
 Remove the locking ring from the lift cylin- 
ders.
 If auxiliary hydraulics are fitted, remove the
upper hose guide to prevent the hose from
bending later in the process.
 Support the fork carriage or secure the outer
mast and fork carriage by connecting a chain
between them. Lower the inner mast to ap-
prox. 100 mm. At the same time, support the
cross beam at the bottom using a hydraulic
jack. The hydraulic jack is extended ap-
prox. 200 mm.
 Remove mast supply lines and seal cylinders
with sealing plugs.
 Attach a chain hoist to the outer mast cross
beam. Using suitable equipment, lift the cylin-
ders out of the lower holding fixture and set
them down towards the middle of the truck.
 Lower the hydraulic jack until the inner mast
is resting on the outer mast cross beam.
 Replace the wear strips and support rollers.
Removing wear strips - Duplex lift mast

 Remove the locking ring from the outer cylin-
ders.
 Extend the lift mast and secure the fork car- 
riage to the central transverse strut using a
chain.
 Lower the lift mast. At the same time, support
the transverse strut on the inner mast using a
hydraulic jack. The hydraulic jack is extended
approx. 200 mm.
 Remove the pipe lines from the lift cylinder
and seal the connections at the top of the out-
er cylinders.
 Fully retract the cylinders and remove the
buckling protection devices.
 Tilt the lift cylinder backwards and hold it in
position with a wooden chock if necessary.
Removing wear strips - Triplex lift mast

 If auxiliary hydraulics are fitted, remove the
outer guide (hoses can remain in the guide).

Lifting system 80
Assembly parts
 Secure the guide to the transverse strut of the 
outer mast.
 Remove the right-hand guide and attach it to 

the upper transverse strut of the middle mast.

80 Lifting system
Assembly parts
 Extend the lift mast until the central strut of 
the inner mast is at the same height as the
upper transverse strut of the middle mast. Se-
cure the two struts at this height using a chain
and lower the fork carriage again.
 Remove the locking rings from the outer cylin-
ders and remove the pipe lines from the up-
per connection pieces.
 Seal the cylinders with the correct screw 

joints so that they are pressure-tight. This is
because the cylinders will be pressurised
again.
 Using the truck hydraulics, extend the lift mast
until the bottom connections of the middle
mast cylinders can be accessed.
 After removing the pipes, seal the cylinders 

with suitable sealing plugs.
 Using the rope device, fully lower the lift mast.
At the same time, support the middle mast us-
ing a hydraulic jack. The hydraulic jack is ex-
tended approx. 200 mm.

Lifting system 80
Assembly parts
 Remove the buckling protection devices from 
the outer cylinders. Carefully pull the cylinders
back and hold them in position with a wooden
chock if necessary. The mast lines at the bot-
tom can remain fitted.
 Lower the middle mast fully using the hydraul-
ic jack. When doing so, make sure that the
outer cylinders have enough space.
 The support roller and wear strip can now be
removed.

80 Lifting system
Assembly parts
Protection elements
Line break safety valve in the lift mast 
(throttle valve)
The line break safety valve prevents the load

from being abruptly lowered in an uncontrolled
manner in the event of a line breakage.
The line break safety valve consists of a valve
disc, which is lifted from the valve seat by spring
force when in the quiescent state, thus keeping
a flow cross-section free.
Under normal operation, the spring keeps the
valve open. In the event of a line breakage, the
flow rate increases, the flow forces exceed the
spring force and the valve closes immediately.
A small bore in the valve disc enables the load
to be lowered slowly when the valve is closed
(max. 0.1 m/s).
NOTE
In the event of damage, move the lift mast re-

peatedly up and down in order to detect which
line break safety valve is faulty. Due to the re-
duced passage, the faulty line break safety valve
heats up significantly. It is possible to feel this
heat and measure it using an infra-red thermom-
eter.
The flow rate (1) is marked on the valve (exam- 
ple diagram).
NOTE
The line break safety valves are installed using

Loctite. When replacing the old line break safety
valve, it must first be heated before being un-
screwed. Then the thread areas must be thor-
oughly cleaned and the new line break safety
valve inserted with Loctite© 270TM.

Lifting system 80
Assembly parts
Installation position of the line break safety 
valves
● Line break safety valves in a standard lift 2
mast (1) 3
● Additional line break safety valves in a duplex
lift mast (2)
● Additional line break safety valves in a triplex
lift mast (3) 3 2
1
3
3
3
3 1
394-02_08-002
Installation direction of the line break safety 

valves in a duplex lift mast and a triplex lift 2
mast 1
2
NOTE 1
Observe the installation direction of the line
break safety valves (1) at the top of the connec- 2
tion piece (2). 2 1
1
393-02_08-010
The hexagon hole of the line break safety valves 

must be pointing towards the connection piece.

80 Lifting system
Assembly parts
Hose reservoir − removal, ex-
changing hose, sealing, fitting
WARNING
The hose reservoir is pre-loaded by spring force.
Take care to follow the operation sequences exactly.
NOTE
The hose reservoir is located underneath the

floor plate in the front part of the frame. The de-
scription refers to a hose reservoir for single
auxiliary hydraulics. For industrial trucks with
two hose reservoirs (double auxiliary hydraulics)
the instructions must be complied with in the
same way for both hose reservoirs.
Hose reservoir - removal
NOTE
Before taking out the floor plate, unplug the drive

potentiometer and disconnect the brake cable
from the brake valve.
 Opening the hood
 Take out the floor mat
 Removing the floor plate. 
WARNING
The hose reservoir is pre-loaded by spring force. If
the hose reservoir is removed without restraint, the
hose reservoir spring will release spontaneously,
which can lead to serious injuries.
The locking wedge must engage in the cam provided
at the circumference of the hose reservoir, so that the
hose reservoir is restrained against unintended unroll-
ing of the hose.

Lifting system 80
Assembly parts
 Lock the hose reservoir in the pre-loaded 
state. To do this, turn the locking wedge in the
direction of the hose reservoir. And at the
same time unroll the hose slightly. This leaves
the reservoir locked and the double hose un-
tensioned.
 Disconnect the double hose at its connection 

with the lift mast.
 Disconnect the line from the control valve to
the hose reservoir.
 Undo the front hexagon-headed screws (two
pieces) at the hose reservoir support.
The hexagon-headed screws are located at the
front on the support above the deflection pulleys.
 Undo two hexagon-headed screws on the
side of the hose reservoir support.
 Undo the rear hexagon-headed screws (two
pieces) at the hose reservoir support.
 Release the hose reservoir from the support. 
 Do this by unscrewing the two Allen screws

(2) on the side of the hose reservoir support.
 Take out the hose reservoir support.
 Take out the hose reservoir.

80 Lifting system
Assembly parts
Exchanging a hose
 Clamp the hose reservoir in a vice and undo 
four Allen screws.
 Remove the hose reservoir cover.
 Unroll the double hose and exchange it for a
new double hose.
 Roll up the double hose and secure the hose
reservoir cover with four Allen screws.
 Install the hose reservoir with its support into
the industrial truck.
Hose reservoir − sealing

 Clamp the hose reservoir in a vice.
 Pull out the double hose until the locking
wedge is no longer holding back against the
spring force.
 Turn the locking wedge out of the cam. Hold
the double hose securely whilst you do this.
The hose reservoir is still pre-loaded.
 Holding the double hose securely, carefully
release the hose reservoir against the spring
force. The double hose will be drawn further
back into the hose reservoir.
 Unscrew a hexagon-headed screw (5). 
 Remove the cover with the O-ring.

 Unscrew two Allen screws (2) and take out
the support with the locking wedge.
 Pull out the hose reservoir shaft.
 Exchange a shaft seal (3) on the shaft.
 Pull out three O-rings with the support ring (6)
and exchange them.
 Exchange two O-rings (1) on the support with
the locking wedge.

Lifting system 80
Assembly parts
Hose reservoir − fitting
 Lightly grease the O-rings, support rings and 
shaft seal.
 During assembly, check that the hose reser-
voir load spring engages in the slot in the
shaft.
 Assemble the support with the locking wedge.
 Clamp the hose reservoir in a vice.
 Fit the cover, with a new O-ring (4).
WARNING
The hose reservoir is pre-loaded by spring force.
Spontaneous release of the hose reservoir spring can
lead to serious injuries.
The following work must be carried out with the ut-
most care.
 Pre-loading the hose reservoir.

 To do this, rotate the hose reservoir by hand
against the force of the spring.
 Lock the locking wedge at the circumference
of the hose reservoir and pre-load the hose
reservoir by 8 rotations; see hose reservoir
identification plate.
 Install the hose reservoir with its support in
the industrial truck.

80 Lifting system
Load support
Sideshift
Safety information for working on the sideshift
WARNING
Switch off the truck and release the pressure from the
hydraulic system.
NOTE
During repairs, do not switch on the truck and do

not actuate the joysticks.
Removing the moveable frame

WARNING
Observe the "Safety information for working on the
sideshift".
 Support the moveable frame using a lifting 

sling (arrows).
 Remove the lower adjustable hooks using a
spanner (1).
CAUTION
The cylinder shafts can move freely and can slide out
from the guides.
Ensure that the hydraulic circuit is depressurised.
 Rotate the lower part of the moveable frame 

forward and then unhook the frame.
To reinstall the moveable frame, the work must
be carried out in the reverse order.
When reinstalling the hooks, tighten them to a
tightening torque of 145 Nm.

Lifting system 80
Load support
Replacing the upper wear strips
WARNING
sideshift".
 To remove the wear strips, carefully push the 

outer pins of each wear strip (1) alternately
until every wear strip emerges from its seat.
 When installing the wear strips, the pins must
be inserted into the relevant seats as they
were originally.
Removing the lower slide rollers

WARNING
sideshift".
 Eject the slotted spring pin (1) using a drift 

punch of ∅ 4 mm.
 Pull out the trunnion (2) that acts as a support
for the slide roller.
 Remove the slide roller (3).
Replacing the cylinder seals, the shafts

or the shaft guides
WARNING
sideshift".

80 Lifting system
Load support
NOTE
Replace the seals in a clean, dust-free environ-

ment and observe the correct installation direc-
tion.
 Pull out the shaft (1). 
 Pull out the wiper (2).

 Pull out the first shaft guide (3). To do this,
exert slight leverage along the guide slot us-
ing a screwdriver.
 Remove the seal (4).
 Pull out the second shaft guide (5). To do this,
exert slight leverage along the guide slot us-
ing a screwdriver.
Installation direction of the seals

The shaft has a curved end and a flat end. 
When the shaft is installed, the curved end must
remain outside the cylinder.
NOTE
To check the leak tightness of the hydraulics fol-

lowing a replacement, perform a number of
movements without a load.
Releasing air out of the hydraulic circuit

WARNING
sideshift".
CAUTION
Hydraulic oil can spurt out at a high pressure.
Use personal protective equipment, especially to pro-
tect the eyes.

Lifting system 80
Load support
 To release the air out of the hydraulic circuit, 
slowly loosen the cover using a 5-mm span-
ner. As soon as hydraulic oil runs out, tighten
the cover and restore the leak tightness.
 Move the entire sideshift to the left. The cylin-
der must remain under pressure when the
lever for the distributor is in the neutral posi-
tion.
Repeat the procedure:
 To release the air in the opposite cylinder,
move the moveable frame to the right.
NOTE
To check the leak tightness of the hydraulics af-

ter releasing the air, perform a number of move-
ments without a load.
Malfunctions and remedies

Error Causes Remedies
Replace the moveable frame. If
the wear strips are still in good
Deformed moveable frame
condition, retain them as re-
quired.
Deformed rigid frame Replace the rigid frame.
Clean the track. Lubricate the
Mud or other blockage on the
slide rollers and the sliding
track for the lower slide rollers
Sideshift is not functional. shoes.
Worn hoses Replace the hoses.
Blockage in the hydraulic circuit Remove any blockages.
Insufficient pressure Increase the pressure.
Worn pump Repair or replace the pump.
Replace the seals or guides and
Defective cylinder if necessary replace the cylinder
shaft.
Replace the seals and if neces-
Worn cylinder seals
sary replace the shaft guide.
The sideshift movement is per- Wear strips worn Replace the wear strips.
formed too slowly. Emulsified oil; the pump draws in Check the oil level in the truck
air tank.
Worn pump Repair or replace the pump.
Insufficient pressure Increase the pressure.
Bleed the hydraulic system of
Air in the hydraulic system the truck and check the oil level.
Sideshift movement is jolty or er- Release air from the sideshift.
ratic.
Debris or similar on the track for Clean the track and lubricate the
the lower slide rollers slide rollers.
Wear strips worn Replace the wear strips.

80 Lifting system
Load support
Bleed the hydraulic system of
Air in the hydraulic system the truck. Release air from the
sideshift.
Sideshift functions on one side
only. If damaged, replace the seals or
the cover along with the corre-
Defective cylinder
sponding guides and cylinder
shafts.
NOTE
If you encounter any difficulties when performing

repairs or in the event of errors that are not
specified in the list, please contact the "Bolzoni"
customer service team.
Kaup fork prong positioner

Description and mode of operation
The fork prong positioner is an attachment for 
positioning the fork arms with two main move-
ments. The fork arms can be moved in parallel
to increase or decrease the width. The entire
fork carriage can be adjusted as a unit (side-
shift).
The moveable fork carriage (4) is moved within
the slide guides in the lift truck (2) by means of
the sideshift reach cylinder (1). The fork
guides (6) are moved by the reach cylinders of
the fork arm positioner (5). The fork guides are
equipped with wear strips. The slide guides and
wear strips are lubricated via lubricating nipples
on the fork carriage and on the fork guides.
The fork arms are inserted into the fork guides
and held in position with a locking lever. Fork
locking devices prevent loads from slipping side-
ways off the fork arms.
The reach cylinders are activated via the truck
hydraulics. The flow divider (3) (junction) en-
sures virtually synchronous movement (synchro-
nisation) of the fork arm positioner reach cylin-
ders. Flow dividers can have a flow division error
of up to 5% of the cylinder stroke.
NOTE
The fork prong positioner is fitted in a variety of

versions. The descriptions and diagrams of the
repairs may therefore differ slightly. The repairs
must be carried out in the same way.

Lifting system 80
Load support
NOTE
The fork prong positioner must be used only to

position the fork arms. Clamping loads or lateral
shifting of loads can impair synchronisation of
the fork arms.

80 Lifting system
Load support
Integrated fork prong positioner
 Install the fork prong positioner in the lift mast
of the truck
NOTE
Observe the assembly instructions for the lift

mast.
 Connect the attachment to the lifting chain
NOTE
Adjust the lifting chains in accordance with the

instructions for the lift mast/truck
 Connect the hydraulic system on the lift mast
to the connection pieces of the reach cylin-
ders on the attachment. When performing this
step, tighten the connection pieces used in
accordance with the applicable regulations
NOTE
Prior to commissioning, check the functions of

the fork prong positioner and their identification
with the directions of movement on the operating
devices.
Installing the hydraulic system

 Connect the connection lines of the hydraulic 
system of the truck to the connections (1)
and (2)
 Connect the connection lines of the hydraulic
system of the truck to the connections "A" (3)
and "D" (4) at the flow divider (junction)
NOTE
Observe the tightening torque for the connec-

tions.
 Put the truck into operation
 Extend and retract the sideshift to the stop
several times and check the speed of the
movements

Lifting system 80
Load support
 Check the hydraulic connections at the con- 
nections (2) for leak tightness
If necessary, release the pressure from the hy-
draulic system and rectify leakages.
 Open and close the fork arms to the stops
several times, and check the speed of the
movements
NOTE
The position of the fork arms is synchronised

through repeated movements to the stops.
 Check the hydraulic connections at the flow
divider (1) for leak tightness
 Move the fork arms to the end positions sev-
eral times until the symmetrical position (syn-
chronisation) is reached
Removing and installing the fork arms

Removing the fork arms 
 Remove the two bolts (2) and stops (1) from

the fork guide (3)
 Lift the locking lever (4) on the fork arms 

80 Lifting system
Load support
 Remove the fork arm (5) to the side 
The second fork arm is removed in the same

way.
Installing the fork arms

 Tighten the four bolts (2) to a tightening tor-
que of 190 Nm
Mounting the load backrest

 Lift the load backrest (1) and position the fork 
prong positioner (3).
 Fit the load backrest(1) to the fork prong posi-
tioner (3) with four socket head screws
M16x30-8.8-ZNS (2).
Tightening torque of the socket head screws:
190 Nm
Course of action after assembly

Bleeding the hydraulic system
 Put the truck into operation
 Move the sideshift to the stop in both direc-
tions several times, maintaining the maximum
pressure for a few seconds in each case
eral times, maintaining the maximum pres-
sure for a few seconds in each case
Checking the hydraulic system for leak

tightness
 Check the hydraulic connections for leak
tightness

Lifting system 80
Load support
Adjusting the symmetrical position of the
fork arms (synchronisation)
NOTE
The fork prong positioner is equipped with a flow

divider. The flow divider can balance out any in-
accuracy in the cylinder stroke up to 5%.
eral times until the symmetrical position is
reached

80 Lifting system
Load support
Safety information for working on the
fork prong positioner
WARNING
Risk of injury due to hydraulic oil spraying out.
Before working on the hydraulic system, switch off the
truck and release the pressure from the hydraulic sys-
tem.
WARNING
Risk of scalding due to hot hydraulic oil when opening
hydraulic lines.
When opening hydraulic lines, cover them with a
cloth.
ENVIRONMENT NOTE
Collect any hydraulic oil that escapes and dis-

pose of it in an environmentally friendly manner.
NOTE
During repairs, do not switch on the truck and do

not actuate the joysticks.
Checking the wear strips for wear 
 Move the fork arms fully outwards

 Check the top, button, left and right wear
strips for wear
NOTE
The wear strips must be replaced if at least one

of the specified dimensions (wear limit values in
mm) is exceeded.

Lifting system 80
Load support
Removing and installing fork guides
Removing fork guides 
 Remove the fork arms

 Remove the nut (1) (30 AF) on the right-hand
fork guide (4), locking the cylinder rod (22 AF)
 Remove the nut (2) (30 AF) on the left-hand
fork guide (3), locking the cylinder rod (22 AF)
 Pull the fork guides out of the fork carriage
Installing the fork guides

 After tightening the nuts (1) and (2), turn them 
back by approximately a quarter turn (90°)
NOTE
The reach cylinders are installed with an axial

play of 1.5 mm to 2 mm.
 Lubricate the fork guides

80 Lifting system
Load support
Replacing the wear strips
Removing the wear strips 
 Remove the fork arms

 Remove the fork guides
 Remove worn wear strips (1) from the respec-
tive fork guide
NOTE
Each fork guide has four wear strips.
Installing wear strips

 Before inserting new wear strips, clean the
fork guide
Checking the slide guides for wear 
 Using a feeler gauge at the designated posi-

tion, check the upper and lower slide guides
for wear
NOTE
The slide guides must be replaced when the

play between the fork carriage and the locking
plate of the slide guides is less than 0.5 mm.
Removing and installing the fork car-

riage
WARNING
fork prong positioner".

Lifting system 80
Load support
Removing the fork carriage 
 Remove the M6 screw and the clip
 Disconnect two hose lines (17 AF) from the 

pipe lines to the flow divider (14 AF)
 Fit plugs to close off the open connections of
the hose lines and pipe lines
 Disconnect two pipe lines (17 AF) from the 

hose lines (22 AF)
the pipe lines
 Remove the nut (30 AF) at the cylinder rod 

end of the reach cylinder, locking the cylinder
rod (22 AF)

80 Lifting system
Load support
 Remove two M8 bolts (1) and the stop (2) 
 Loosen the two bolts (3) holding the fork car- 

riage in position
 Carefully support the fork arms with a lift truck
NOTE
Do not tilt the fork carriage with the lift truck.
 Move the fork carriage in the direction of the 

arrow and remove it
Installing the fork carriage

 Do not screw in the two bolts (3) holding the
fork carriage in position all the way to the
stop. The fork carriage must be able to move
freely
 When fitting the two M8 bolts (1), apply Loc-
tite FK5

Lifting system 80
Load support
 Put the truck into operation and check the fork
prong positioner for correct operation and
leak tightness
 Adjust the synchronisation
Replacing the slide guides

Removing the slide guides
 Remove the fork carriage
 Remove two M8 bolts (2) and the locking 
plate (1) at the top and bottom of the cross-
member
 Remove the two slide guides (3) at the top 

and bottom
Installing the slide guides

 Lubricate the slide guides (3)
 When fitting the M8 bolts (2), apply Loc-
tite FK5
 Install the fork carriage
 Put the truck into operation and check the fork
positioner for correct operation and leak tight-
ness

80 Lifting system
Load support
Replacing the sideshift reach cylinder
WARNING
Removing the sideshift reach cylinder 
 Remove the M8 bolt (2) and the clip (1)
 Disconnect the two pipe lines (17 AF) (3) on 

the reach cylinder
the pipe lines and on the reach cylinder
 Remove the nut (4) (30 AF) at the cylinder rod 

end, locking the cylinder rod (22 AF)
 Move the fork carriage (7) with the fork arms
far enough to the outside so that the cylinder
rod is free
 Remove the nut (6) (30 AF) at the cylinder
bottom end and remove the reach cylinder (5)

Lifting system 80
Load support
 If necessary, remove two M12 elbow un- 
ions (8) (14 AF)
 Drain the reach cylinder and close off the
open connections with plugs
Installing the sideshift reach cylinder

 Apply Loctite 5331 to the M12 elbow un-
ions (8) before installing them
 After tightening the nuts (4) and (6) (30 AF), 
turn them back by approximately a quarter
turn (90°)
NOTE

 When installing the pipe lines, check the O-
rings and replace them if necessary
 Put the truck into operation and check the
reach cylinder for correct operation and leak
tightness
Replacing the fork arm positioning reach

cylinders
WARNING

80 Lifting system
Load support
Removing the left-hand reach cylinder 
 Disconnect the pipe line (17 AF) from the

reach cylinder
the pipe line and on the reach cylinder
 Disconnect the pipe line (17 AF) from the 

reach cylinder
 Remove the nut (1) (30 AF) at the cylinder rod 

end, locking the cylinder rod (22 AF)
 Remove the nut (2) (30 AF) at the cylinder
bottom end and remove the reach cylinder
 If necessary, remove two M12 elbow un- 

ions (3) (14 AF)
 Drain the reach cylinder and close off the
open connections with plugs

Lifting system 80
Load support
Installing the left-hand reach cylinder
 Apply Loctite 5331 to the M12 elbow un-
ions (3) before installing them
 After tightening the nuts (1) and (2), turn them 
back by approximately a quarter turn (90°)
NOTE

reach cylinder for correct operation and leak
tightness
Removing the right-hand reach cylinder

 Disconnect the pipe line (17 AF) from the 
reach cylinder
 Disconnect the two pipe lines (17 AF) on the 

reach cylinder (T-piece)
the pipe lines and on the reach cylinder (T-
piece)
Further disassembly is performed as for the left-
hand reach cylinder.
quence. Follow the instructions for the left-hand
reach cylinder.

80 Lifting system
Load support
Replacing the reach cylinder seal sets
WARNING
Removing the sets of seals

 Remove the reach cylinder and carefully
clamp it in a vice
 Remove the M4 bolt 
 Using a pin wrench, remove the cover 

Lifting system 80
Load support
 Pull off the cover from the piston rod and re- 
move the O-ring
 Remove the back-up rings from the cover 
 Pull out the piston rod from the reach cylinder
 Remove the sealing ring (3) and back-up 

rings (1) and (2) from the piston
Installing the sets of seals

 Clean the piston, piston rod and cover
 Oil the new set of seals

80 Lifting system
Load support
NOTE
Observe the sequence and alignment of the

back-up rings (1) and (2) on the piston! Arrange
the slotted back-up rings at intervals.
Removing and installing the flow divider

(junction)
Removing the flow divider 
 Remove the pipe lines (3), (4) and (5)

 Remove the two M6 bolts (1)
 Remove the flow divider (2)
 If necessary, remove the elbow union (6) and 

pipe union (7)
Installing the flow divider

 Apply Loctite 5331 to the pipe union (7) and
elbow union (6) before installing them
flow divider for correct operation and leak
tightness

Lifting system 80
Load support
Errors and remedies
Obstacles or dirt on the slide Remove any obstacles. Clean
guides. and lubricate the slide guides.
Check and adjust the pressure
Insufficient pressure. generated by the hydraulic
Failure to perform fork arm posi- pump.
tioning.
Blockages or failures in the hy- Remove any blockages or re-
draulic circuit. place the hose if damaged.
Internal leakage in the cylinder Check the seals and replace if
(worn seals). necessary.
Check and adjust the oil flow
rate generated by the hydraulic
Oil flow rate insufficient.
circuit. Adjust the oil flow rate of
Fork arm positioning is per- the truck.
formed too slowly. Blockages in the hydraulic cir- Remove any blockages or re-
cuit. place the hose if damaged.
Internal leakage in the cylinder Check the seals and replace if
(worn seals). necessary.
Check and adjust the oil flow
Fork arm positioning is per-
The oil flow rate is too high. rate generated by the hydraulic
formed too quickly.
pump.
Obstacles or dirt on the slide Remove any obstacles. Clean
The fork arm positioning is not guides. and lubricate the slide guides.
synchronised. No synchronisa- Adjust the synchronisation: Move
tion when opening and closing. Flow divider tolerance. the fork arms to the end posi-
tions several times.
Fork guides have excessive
Wear strips worn out. Replace the wear strips.
play.
The fork guides tilt outwards. Wear strips worn out. Replace the wear strips.
Fork guides scrape in the profile. Wear strips worn out. Replace the wear strips.
Screw joint leaking. Tighten the screw joint or seal it.
Loss of oil at the fork arm posi- Set of seals defective. Replace the set of seals.
tioning reach cylinders. Replace the piston rod and set of
Piston rod is scratched.
seals.
Fork arm positioning reach cylin-
Fork arms move spontaneously
ders are exchanging oil internal- Replace the set of seals.
when the truck is cornering.
ly.
Bent frame. Replace the frame.
Bent fork carriage. Replace the fork carriage.
Mud or blockage on the slide Clean and lubricate the slide
guides. guides.
Worn hoses. Replace the hoses.
The sideshift movement is not Blockage in the hydraulic circuit. Remove the blockage.
performed. Insufficient oil pressure. Increase the pressure.
Repair or replace the pump on
Worn pump.
the truck.
Replace the piston rod set of
Defective sideshift reach cylin-
seals, replace the piston rod if
der.
necessary.

80 Lifting system
Load support
Replace the piston rod set of
Worn seals in the reach cylinder. seals, replace the piston rod if
necessary.
Worn slide guides. Replace the slide guides.
Replace the throttle orifice with a
The sideshift movement is per- Throttle orifice bore too small. larger one or enlarge the bore.
formed too slowly.
Oil emulsion; the pump is draw- Check the oil level in the oil tank
ing in air. on the truck.
Repair or replace the pump on
Worn pump.
the truck.
Insufficient oil pressure. Increase the pressure.
Drain the hydraulic circuit on the
Air in the hydraulic circuit.
The sideshift movement is per- truck and check the oil level.
formed in a jerky or irregular mo- Mud or other dirt on the slide Clean and lubricate the slide
tion. guides. guides.
Worn slide guides. Replace the slide guides.
Air in the hydraulic circuit. Bleed the hydraulic circuit.
The sideshift movement is per- Replace the piston rod set of
formed only on one side. Defective reach cylinder. seals, replace the piston rod if
necessary.
Screw joint leaking. Tighten the screw joint or seal it.
Loss of oil at the sideshift reach Set of seals defective. Replace the set of seals.
cylinder. Replace the piston rod and set of
Piston rod is scratched.
seals.

Lifting system 80
Load support
Hydraulic diagram
1 Reach cylinder for fork arms 3 Reach cylinder for sideshift

2 Reach cylinder for fork arms 4 Flow divider (junction)
Positioning the fork arms

 The reach cylinders for the fork arms (1)
and (2) are opened via the connection "A"
 The reach cylinders for the fork arms are
closed via the connection "D"
Positioning the sideshift

 The sideshift is extended via the connections
on the sideshift cylinder (3)
Oil flow rates, speeds and operating pressures

Oil flow rates:

80 Lifting system
Load support
Minimum Recommended Maximum
Fork arm positioning
15 l/min 25 l/min 30 l/min
and sideshift
Speeds:
Fork arm opening/clos-

Sideshift speed
Manufac- ing speed
Truck Tolerance Tolerance
turer Without Without
With load With load
load load
+ 10 mm/s Not permit- + 25 mm/s
392, 393 Kaup 80 mm/s 70 mm/s 205 mm/s
- 15 mm/s ted - 40 mm/s
Operating pressures:
Minimum Maximum
Fork arm positioning 200 bar 250 bar
Sideshift 120 bar 220 bar

Lifting system 80
Suspension element
Adjusting the lift mast chain
Standard lift mast
NOTE

operation and therefore has to be readjusted on
the right and left sides.
 Lower lift mast completely.
 Loosen locknut (1). 
 Adjust chain at adjustment nut (2) of chain an-

chor. 2
only protrude max. 30 mm from the inner lift 1
mast guide rail.
 Also adjust second chain.
CAUTION
end stops.
stops.
d3941365
Apply chain spray.
NOTE

and chain.
Duplex lift mast or triplex lift mast
NOTE

operation and therefore has to be readjusted.
 Lower the lift mast and fork carriage com-
pletely.

80 Lifting system
Suspension element
 Loosen lock nut (4). Adjust chain at adjust- 
ment nut (3) of chain anchor.
only protrude max. 30 mm from the inner lift
mast guide rail.
CAUTION
end stops.
stops. 3
Apply chain spray.

4 d3921486
NOTE

and chain.
Assembly sequence of the lock nuts on the chain anchor

Lifting system 80
Suspension element
1 System crossmember 4 Chain anchor
2 Hexagon nut (flat) 5 Pulling direction of chain anchor
3 Hexagon nut (high) 6 Flanks engaged
By locking the two hexagon nuts, their flanks are

pressed onto the flanks of the bolt (6).
If the chain anchor (4) is pulled, only the flanks
on the lower hexagon nut (3) come into contact
with the bolt.
As the higher hexagon nut (3) has more flanks
engaged, it must move downwards.

80 Lifting system
Suspension element

Special equipment 90
Reverse proximity warning unit

Function
Functional description 
The reverse proximity alarm is a simple and ef-

fective device that is used to increase safety
when reversing industrial trucks in situations
where visibility is obstructed.
Two sensor units at the rear of the truck detect
the area behind the truck using ultrasound. This
area is divided into three zones. The dimensions
of the zones (1, 2, 3) can be adjusted via the
programming interface of the control unit by
"service engineers who must have completed
training in this area".
NOTE
The reverse proximity alarm detects objects be-

hind the truck and uses visual and acoustic sig-
nals to warn the driver during reverse travel.
However, the system does not release the driver
from the duty to drive in a responsible manner or
from the necessary duty of care and attention
when reversing. The system is solely a comfort
feature.
Product overview
The "RRW-107" reverse proximity alarm con-
sists of:
● Two ultrasonic units, each with six integrated
ultrasonic sensors
● Two ultrasonic units attached to the side
● A visual and acoustic signal transmitter
● A central control unit

Functionality of ultrasonic sensor 
The ultrasonic sensor contains a special trans-

ducer that enables optional transmission and re-
ception of sound waves.
The converter transmits a certain number of
sound waves that are reflected by the object that
is being detected. After the pulses are emitted,
the ultrasonic sensor is switched to reception
mode.
The time taken until any echo is received is pro-
portional to the distance of the object from the
ultrasonic sensor.
S = t·c/2
S : Distance from object
t : Time difference
c = 344 m/s at room temperature (20°C)
How do ultrasonic sensors collect informa- 

tion?
The highly sophisticated ultrasound technology
inside the sensors makes the diversity possible.
The underlying principle is to detect objects us-
ing a non-contact method and measure their dis-
tance from the sensor. Depending on the type of
ultrasonic sensor, this process can be per-
formed over distances ranging from a few centi-
metres to ten metres. The sensor transmits ul-
trasonic pulses that are reflected by an object.
The sensor receives the echo that is generated
and converts it into an electrical signal via a pie-
zoelectric transducer. This procedure is called
the echo transmit time method. The ultrasonic
sensor measures the time difference(t) between
the transmitted ultrasonic pulse and the received
echo, and uses the speed of sound to calculate
the distance from the object(S). At room temper-
ature (20°C), the speed of sound in the air is ap-
proximately 344 m/s(c).

Factors influencing measurement accuracy 
(ultrasonic field)
● Air temperature (speed of sound ~ proportion-
al to temperature)
● Humidity (relative air humidity)
● Air pressure
● Air flow
● Air turbulence (see air outlet, rear guide/floor
surface)

Display
Display 
(1) One green LED

(2) Two yellow LEDs
(3) Two red LEDs
(4) Two digits/error code display
(5) Beeper
Commissioning, switching on the ignition
Signalling during self-testing

Light signal Error code display Acoustic signal
Chase light:
Chase light:
Both seven-segment
All LEDs illuminate in Continuous sound:
During switch-on displays show 8 (4) one
sequence for 0.7 sec- Approx. 1 second
after another for
onds
0.3 seconds
Green LED illuminates
After 1 second No signal No signal
with a steady light
NOTE
If the green LED does not illuminate or the buz-

zer sounds, there is a system error.
Self-testing - Signalling in the event of a fault
Signalling after self-testing in the event of a fault

Error code display Light signal Acoustic signal Meaning
Red and yellow LEDs Continuous sound: Malfunction:
F1 - F3
flash Approx. 3 seconds Left-hand bottom sensor
Malfunction:
Red and yellow LEDs Continuous sound:
F4 - F6 Right-hand bottom sen-
flash Approx. 3 seconds
sor
Malfunction:
Red and yellow LEDs Continuous sound:
F7 Bottom sensor or sensor
flash Approx. 3 seconds
cable
E1
flash Approx. 3 seconds Left-hand side sensor
E2
flash Approx. 3 seconds Right-hand side sensor
Red and yellow LEDs Continuous sound: Problem:
F10
flash Approx. 3 seconds Power supply
Red and yellow LEDs Continuous sound: Error:
F11
flash Approx. 3 seconds Memory (control unit)

Signalling after self-testing in the event of a fault
Red and yellow LEDs Continuous sound: Error:
FF
flash Approx. 3 seconds Communication
Red and yellow LEDs Continuous sound: Problem:
HF
flash Approx. 3 seconds Hardware

Operation
392/393/394 series: Operation
General
NOTE
The truck is equipped with a reverse proximity

alarm. The alarm is active when the truck is at a
standstill and during reverse travel.
● The maximum reverse driving speed is limited
(e.g. to 5 km/h with a monitoring area of

4 metres).
● If an obstacle is detected within the monitor-
ing area during reverse travel, the truck

brakes to a preset speed (e.g. 1 km/h).
DANGER
The reverse proximity alarm with speed reduction is
not a safety function as referred to in DIN EN ISO
13849. It is purely a comfort feature! It is there simply
to support the driver.
During reverse travel, the driver must still turn round
to see the route behind him in order to avoid the risk
of colliding with a person or an object. Road traffic
regulations or rules for driving on factory premises
must be followed even when the truck is not being
driven in a public traffic area. Before setting off, the
functionality of the rear-area monitoring system must
be checked.
NOTE
The condition of the floor covering or the effect

of strong winds on the sensors can have a nega-
tive effect on the system and correct function
can no longer be guaranteed.
NOTE
When replacing the controller (LHC), the same

parameters and values must be set in the new
controller as those programmed in the removed
controller. Contact your service partner regard-
ing this matter.

Signal transmitter
The signal transmitter (1) consists of: 
(2) One green LED

(3) Two yellow LEDs
(4) Two red LEDs
(5), (6) A two-digit error code display
(7) A buzzer
Different signal statuses are issued in the signal

transmitter depending on the distance to a per-
son or object present in the monitored area be-
hind the truck.
NOTE
The individual distances can be changed. Con-

tact your service partner.
Example
Distance to the rear

Light signal
of the truck
>4m Green (2) steady light
Yellow (3) flashing, buzzer
< 4 m to 3 m sounding, truck is braked
to a preset speed
Red (4) flashing, buzzer
< 3 m to 2 m sounding at double fre-
quency
Red (4) steady light, buz-
< 2 m to 0 m
zer sounding continuously
Commissioning
 Start the engine. 
 Actuate the toggle switch (8) with the tortoise

symbol in the switch panel.
Green indicator light (9) in the toggle switch (8)
illuminates.
NOTE
From 06/2010, the toggle switch (8) is available

only as an option. Linde recommends that you
do not switch off the alarm.
8 9
t3941126b

The system carries out self-testing within the 
next few seconds, as indicated at the signal
transmitter in the driver's cab:
● All LEDs (2), (3) and (4) illuminate one after
another
● Both error code displays (5) and (6) illuminate
one after another
● The buzzer (7) sounds for approximately 1
second
● The green LED (2) illuminates; the truck is
ready for operation
NOTE
If the green LED does not illuminate or the buz-

zer sounds, there is a system error. Contact
your service partner.
Function-limiting effects
Adjusting the sensors will change the detection
area and increase the probability of creating
zones in which persons/objects can no longer be
reliably detected.
The sensors function correctly only when they
are free of dirt, snow and ice. Otherwise, it is
possible that no objects will be detected.
Dirty sensors must be cleaned. When washing
by hand, commercially available cleaning agents
and sponges can be used, for example.
CAUTION
If a high-pressure cleaner is used, a minimum dis-
tance of 1 m to the round metal sensors on the ultra-
sonic units must be maintained!
Recommendation: Avoid the use of high-pressure
cleaners.
Below -25°C, the reverse proximity alarm will no

longer work. This lack of functionality is indica-
ted by a red light signal or an alternating red and
yellow flashing signal.

Functional test - Specification test
General information
► Reverse proximity alarm must not be used as personal protective equipment!
► The driver must always check the surrounding area when reversing!
► Procedure for changing the Linde settings:
Changes only within the functional area
-
(truck stops before the obstacle; response time)
Perform a functional test on a test track in accordance with Linde guidelines
-
(load, truck condition, tyres and ground conditions on the test track)
- New, changed setting documented by service engineer
Functional test 
Final acceptance of the rear-area monitoring

system
The functional test for the rear-area monitoring
system requires a space (approx.
10.0 m x 4.0 m) that is blocked off and unob-
structed, and which has an obstacle (e.g. a wall
or another truck) at the end.
Specification test
The following functions must be tested:
1. Truck reverses only at reduced speed (e.g. 5 km/h)
2. Function of the system
Self-testing
 After the ignition is switched on, all LEDs illu-
minate in sequence, the individual segments
of the error code display illuminate and the
buzzer sounds for approx. 1 second.
 The green LED then illuminates with a steady
light, the error code display transmits no sig-
nal and the buzzer is switched off (if no obsta-
cle has been detected).
 The system is inactive in forward travel. If the
truck switches to a standstill or to reverse
travel, the system performs self-testing again.
Function of the rear sensors

 Reverse to the obstacle.
 If there is an obstacle outside zone 1 (dis- 
tance from truck is predefined), the green
LED illuminates and the buzzer is switched
off.
 If the obstacle enters zone 1 (distance from
truck as previously set), the truck brakes (as
previously set, e.g. to 1 km/h). In addition, the
yellow LEDs flash on the display and the buz-
zer sounds at a frequency of 1 Hz.
truck as previously set), the red LEDs flash
and the buzzer sounds at double frequency.
The speed reduction remains active.
truck as previously set), the red LEDs illumi-
nate with a steady light and the buzzer
sounds continuously. The speed reduction re-
mains active.
 The obstacle must also be detected at a
standstill and signalled by the display and
buzzer.
 Obstacles must not be detected in forward
travel.
Function of the side sensors

 Park the truck parallel to the obstacle. The
distance between the truck and the obstacle
must be approximately 0.5 m.
 The obstacle must be detected at a standstill
and in reverse travel (parallel to the obstacle).
As in zone 3 for the rear sensors, the signal is
provided by the red LEDs illuminating with a
steady light and the buzzer sounding continu-
ously.
 In forward travel, the side sensors are also
deactivated and must not provide an alarm.

Setting the zones
Monitoring zones 
Zone (1) (yellow) Warning area, can be adjusted between 0.9 and 9.0 m
- Yellow LEDs flash
- Warning sound (interrupted signal, twice a second)
Truck is braked to 1 / (2) km/h
- Requirement: Truck is permanently limited to max. 5 / (9) km/h in reverse
travel.
Zone (2) (orange) Danger area, can be adjusted between 0.6 and 6.0 m
- Red LEDs flash
- Warning sound (interrupted signal, four times a second)

travel.
Zone (3) (red) Collision area, can be adjusted between 0.3 and 3.0 m
- Red LEDs illuminate with a steady light
- Warning sound (continuous sound)

travel.

LHC function (IC trucks)
LHC20 (154-pin connection assembly) ► 394-02 (MPR): Speed reduction ON
Speed reduction: ON (object in the area) 
Reverse travel and stop, 2 yellow LEDs (2)

● N1:K07 = low (0 V), LHC20
● Monitoring of rear area active

Software
Diagnostics and parameterising: Ultrasonic ECU 9A7
Accessories required:
● Software: installation and driver CD
● Signal converter (USB ◄► CAN)
● Wiring harness
● Plug for diagnostics 9A7 (2-pin VW plug)
● Plug connector for diagnostics 9X41 (2-pin)
NOTE
The software (current version 7.8) for the

9A7 controller can be downloaded from the Ex-
tranet:
● https://extranet.linde-mh.com/web031/down-
loads/ServiceSoftware/Install_Projects/
RRW_RPA_(only_for_author-
ized_and_trained_users)/

Setting: Ultrasonic sensor ECU
(Windows XP)

Setting the zones: Reversing sensors: Ultrasonic sensor ECU
Example:
Distance from the sensor Signal on the display

>5m Green LED, illuminates continuously
Yellow LEDs, flashing and beeper ON
5m<x<2m
Truck brakes to set speed
2m<x<1m Red LEDs, flashing and beeper ON
1m<x<0m Red LEDs, illuminates continuously and beeper ON (double frequency)
NOTE
You are strongly recommended to retain the

Linde settings!
● Changes must be tested and documented!

● Caution: Never disconnect the connection
during the GS application!

Setting the sensors: Ultrasonic sensor ECU, side sensor and reversing sensor

Setting the sensors: Ultrasonic sensor ECU and reversing sensor
Definition of the channels 
CH Channel
T Transmitter
R Receiver

Object detection: Ultrasonic sensor ECU
Objects (1) in obstacle area

Setting the ultrasonic sensor ECU
(Windows 7)
NOTE

Linde settings!


1 Error list and description

1 Width of bottom sensors 3 Settings for bottom sensors

2 Settings for side sensors 4 Zones for bottom sensors (5 → 1 km/h)

Software and hardware version

392/393/394-02/396-03 series: LHC20 software settings: Pathfinder
Setting for optional output (:K7): 0.1 km/h
NOTE

Linde settings!


Setting for max. reverse driving speed: 5 km/h or

9 km/h

Setting for speed reduction in reverse: 1 km/h or
2 km/h

Parts lists
394 series: Truck parts list
Series: 394
System overview (MZ) 3948085155
Display unit (MZ) 3928081207
Wiring diagram 3948026038
Wiring harness 3943810486
Wiring harness with „Tucher“ functionality 3943812505
Accessories parts list
Series: 394
Ultrasonic ECU with housing (392/393/394 series) 0009701505
Ultrasonic ECU 0009737062
Display with beeper 7917292546
Display without beeper 7917292549
Rear sensor 7917415412
Side sensor 7917415413
Signal transmitter for display without beeper 0009731538
Datasheet for ultrasonic ECU 0009737062
Ultrasonic ECU assy. 0009701505
Set for ultrasonic ECU diagnostics 3903605406
Diagnostic line between truck and CAN converter 3003810355
Datasheet for setting parameter values 3938041118

Adjustment instructions for sensors 3938040502
Specification test 3938041728
Wiring harness for sensor, rear left

3943810443
(392/393/394/396 series)
Wiring harness for sensor, rear right (392/393/394 series) 3943810444
Wiring harness for sensor, left side (394 series) 3943810445
Wiring harness for sensor, right side (394 series) 3943810446
Wiring harness for display (392/393/394 series) 0009779544

Wiring harness for buzzer, cab (392/393/394 series) 3933810329
Wiring harness for signal transmitter for display without
3943812506
beeper

Assembly
392 series: Assembly of ultrasonic 
ECU 9A7 and display
(1) One green LED

(2) Two yellow LEDs
(3) Two red LEDs
(4) Two digits/error code display
(5) Beeper
NOTE
Option to install an additional beeper (9B5:

beeper for reverse proximity alarm, cab) (see
392 802 60 05).
1 9X37: 8-pin plug connector (sensor, left side)

2 9X38: 14-pin plug connector (sensor, rear
left)
3 9X39: 8-pin plug connector (sensor, right
side)
4 9X40: 14-pin plug connector (sensor, rear
right)
5 9X42: 10-pin plug connector (power supply,
CAN, signals)
6 9X43: 6-pin plug connector (controller dis-
play)
7 9X49: 2-pin plug connector (beeper)

392/393/394 series: Assembly of relays 
and fuses
1 9K9
2 9X41
3 9K10
4 9F17

394 series: Position of the ultrasonic 
sensors
The bottom sensors (1) must be able to commu- 

nicate with each other!
1 Bottom sensors
2 Side sensors

392/393/394 series: Setting: Sensors
1 Series 394 2 Series 392

 Support parallel to clamping piece


Wiring diagram
394 series: Reverse proximity alarm

Legend 9X46 14-pin plug connector (sensor 9B2, rear left),
1R2 Resistor, 7.5 kOhm, 165 201-215
1R3 Resistor, 1.5 kOhm, 166 9X47 8-pin plug connector (sensor 9B3, right side),
1S6 Switch for speed limitation, 165-171 216-222
9A7 Control unit, 177-237 9X48 14-pin plug connector (sensor 9B4, rear right),
9B1 Ultrasound unit, left side, 194-200 224-237
9B2 Ultrasound unit, rear left, 201-215 9X49 2-pin plug connector (buzzer), 185-191
9B3 Ultrasound unit, right side, 216-223 :1 - Buzzer +
9B4 Ultrasound unit, rear right, 224-237 :2 - Buzzer -
9B5 Buzzer for reverse proximity alarm, cab, 192 9X51 8-pin plug connector (buzzer), 190-218
9B6 Buzzer for reverse proximity alarm (3x volume, 3x 9X52 9-pin plug connector (buzzer), 187-218
tone type), 170 F15 Fuse, terminal 15, 170
9F17 10-A fuse (reversing signal), 180 N1 LHC electronic traction controller, 165
9K9 Relay (speed reduction), 166-169 X10 18-pin plug connector (for basic equipment), 165,
9K10 Relay for reversing signal, 175, 180 175, 178
9K12 Relay for reversing signal, 175-181
9P1 Display for reverse proximity alarm, 187-191 Wire colours
9S11 Switch for volume (buzzer), 199-202 BK Black
9S12 Switch for tone type (buzzer), 212-215 BN Brown
9X34 6-pin plug connector (disconnection point for dis- BU Blue
play, roof), 187-192 GN Green
9X37 8-pin plug connector (sensor, left side), 194-200 GY Grey
9X38 14-pin plug connector (sensor, rear left), 202-215 OG Orange
9X39 8-pin plug connector (sensor, right side), 217-223 PK Pink
9X40 14-pin plug connector (sensor, rear right), 224-237 RD Red
9X41 2-pin plug connector (diagnostics), 183-185 VT Violet
9X42 10-pin plug connector (power supply, CAN, sig- WH White
nals), 177-185 YE Yellow
:1 - Terminal 15 (12 V) The number in front of the wire colour corresponds
:2 - Terminal 31 (0 V) to the wire cross-sectional area.
:3 - Reversing signal (+) Wires with an unspecified cross-section =
:4 - Speed signal 0.75 mm2
:5 - Signal provision + Notes
:6 - Signal provision - (I) Speed limitation via reverse proximity alarm
:7 - CAN-L (switchable) - with ultrasonic sensors
:8 - CAN-H (a) Twisted pair cables
:10 - Shielding (b) Shielded cable
9X43 6-pin plug connector (display for controller), (c) Switch shown in the speed limitation OFF position
187-192 (d) Note: plug 9X51/52, buzzer 9B6, toggle switch
:1 - 12 V 9S11, 9S12, relay 9K12
:2 - 0 V (e) To electronic control (N1:K29/continuous reversing
:3 - CAN-L signal)
:4 - CAN-H (f) Note: plug 9X44 connected, optional toggle switch
:5 - Shielding 1S8 in overhead console
:6 - Shielding (g) To electronic control (N1:K07/driving signal)
9X44 5-pin plug connector (disconnection point for
switch), 160-173, 201-204
9X45 8-pin plug connector (sensor 9B1, left side),
194-200

Intelligent buckle monitoring

Components
OrangeBelt kit consisting of a web belt (1) and 
buckle (2)
Spare part number

Truck model
OrangeBelt kit
Series 394-01/02 con-
3874338500
tainer
Series 391-01
Series 392-01
Series 393-01
Series 394-01 to medi-
3004338501
um-pressure piston
pump (→
H2X394B01709)
Series 396-01
Series 392-02
Series 393-02
Series 394-01 from
medium-pressure pis-
3004338504
ton pump
(H2X394B01710 →)
Series 394-02
Series 396-02
Cover (10) 
Spare part number

Truck model
Cover
Series 391-01
Series 392-01
Series 393-01
Series 394-01 contain-
er
3924335609
um-pressure piston
pump (→
H2X394B01709)
Series 396-01
Series 392-02
Series 393-02
Series 394-01 from
medium-pressure pis-
3004335608
ton pump
(H2X394B01710 →)
Series 394-02
Series 396-02


3864335600
er
NOTE
Sequence monitoring is not possible for trucks

39x-01 and 396-02.
Installation
DANGER
Incorrect assembly can cause serious injury or dam-
age to property.
Perform all assembly work correctly; otherwise the
functionality of the driver's seat and the attached parts
cannot be guaranteed.
 Check for correct function.
WARNING
There is a risk of injury due to the back plate moving
suddenly.
If the mechanism for adjusting the seat backrest is ac-
tuated when the seat backrest upholstery is removed,
the back plate must be supported manually.
NOTE
Before any repairs to the driver's seat, discon-

nect the electrical system of the truck.
Preparations
 Remove the seat backrest.
 Remove the seat upholstery.
 Remove the cover (10). 
Replacement
NOTE
Replace all existing old parts with the new parts

provided. If no corresponding new part is inclu-
ded in the scope of delivery for an existing old
part, clean the old part and check whether it can
be recycled. Always replace defective parts and
wear parts.
NOTE
If the removal and installation are made difficult

by the armrest, the armrest can also be re-
moved.

 Lever off the lid (5) on the hexagon head 
screw (3) of the buckle (6).
 Remove the hexagon head screw (3) of the
buckle (6).
 Remove the old buckle (6).
 Remove the hexagon head screw (8) from the 

seat plate (4).
 Remove the old winder (1).
The seat belt with intelligent buckle monitoring is
installed in the reverse sequence.
Note the following:
 The joining plate (9) of the winder (1) must be 

inserted into the bore (7) in the seat plate (4)
in order to secure the winder in position.
 Tighten the hexagon head screw (8).
Tightening torque: 50 Nm secured with Loctite
FK2
 Align the buckle (6) at an angle of approx. 

60°.

 Fit the buckle (6) with the hexagon head 
screw (3) onto the seat plate (4).
Tightening torque: 50 Nm secured with Loctite
FK2
 Put the lid (5) back in place.
 Insert the plug (11) into the transition point 

(10) of the main harness and connect it to the
main harness (to do this, remove the dummy
plug from the main harness).
 Install the new cover (2). 
 Install the seat upholstery.

 Install the seat backrest.
NOTE
If the armrest was removed, re-install the arm-

rest in accordance with the default configuration
from the factory.
Assembling the wiring harness
Spare part number

Truck model
Wiring harnesses
Series 391-01
Series 392-01
Series 393-01
3923810447 um-pressure piston
pump (→
H2X394B01709)
er
Series 392-02
3943812528 Series 393-02
Series 394-02

er
3963810365 Series 396-01
NOTE
In addition, the relevant maximum main har-

nesses must be available for the following truck
types:
● Series 392-02
● Series 393-02
● Series 394-01 medium-pressure piston pump
● Series 394-01 medium-pressure piston pump
container
● Series 394-02
● Series 394-02 container
● Series 396-02
Installation for the 39x-02 series (except
396-02):
Wiring harness 3943812528
 Connect the brown wire to the earth distribu- 
tor (12).
 Insert the following wires into plug X10 (13):
● Red-blue wire in chamber 2
● Green wire in chamber 5
● Orange-green wire in chamber 17
● Brown-yellow wire in chamber 19
● Red-white wire in chamber 20
 Insert relay 7916291004 (9K101) in slot 3.

Setting up the software
Depending on the truck model and the version of
the diagnostic software, you can select either a
block on driving mode or a speed limitation of 2
km/h.
NOTE
If the door switch function is deactivated, other

functions connected to this input may also be af-
fected.
Series 392-02 / 393-02 / 394-01 / 394-02: In-
put :K84 on the LHC20 must be activated in the

▼
Driving
▼
Door switch
Series 396-02 / 396-03: Input :K84 on the

LHC20 must be activated in the diagnostic soft-
ware.
For series 396: TC_396_02_6140_040 "Buckle
lock monitoring with I.D.-Systems": Insert bridge
3963812571 into plug X10, chamber 5 and plug
9X73, chamber 3.
Function checking
Truck function enabled: 
 Actuate the seat switch.

 Lock the buckle (must be unlocked for at least
1 second after the seat switch is activated).
The truck function is enabled (the belt icon is
NOT ILLUMINATED on the display unit; no influ-
ence on driving behaviour).

Truck function restricted: 
 Lock the buckle.

 Actuate the seat switch.
The truck function is limited (the belt icon is IL-
LUMINATED on the display unit; a speed limita-
tion or block on the truck function is active in line
with the setting in the diagnostic software).

Reducing the driving speed using the toggle switch

● Wiring harness 3943810460
● Toggle switch 7915490606
● Circuit diagram
The Namur switch switches between two differ- 
ent resistance values. This enables the switch
status to be distinguished from a short circuit or
a line breakage in the supply lines. With an open
Namur switch there is a resistance of 7.5 kΩ
(1R2), and with a closed Namur switch a resist-
ance of 1.5 kΩ (1R3) at the input of the truck
control unit. At the controller input, the two differ-
ent resistance values are recorded as two differ-
ent input voltages.
To activate the driving speed reduction, a Namur 

switch designed as a toggle switch (1) (tortoise
symbol) is installed in the overhead console.
When the toggle switch is actuated, the green
lamp (2) in the switch illuminates and the re-
duced driving speed is activated. The resistors
are connected to the toggle switch externally via
a wiring harness.
CAUTION
When speed reduction is activated, the handling and
operation of the truck is altered. This may prompt the
operating company to adapt its risk assessment in ac-
cordance with the German labour protection law
(ArbSchG) and the Ordinance on Industrial Safety
and Health (BetrSichV). 1 2
After activating speed reduction, the operating com- d3911407
pany must be provided with information on the func-
tion and referred to the explanation of this function in
the operating instructions.

NOTE
The labour protection law (ArbSchG) and the Or-

dinance on Industrial Safety and Health (Betr-
SichV) are German legislative decrees. Outside
of Germany, the corresponding national legisla-
tion applies.
If there is no cable harness, the maximum ► Error codes + parameters

speed must be set in the diagnostic program ▼
via the following path: Traction
▼
Switch-controlled speed reduction
If the speed is changed in the "Traction parame-

ters" window, the "Switch-controlled speed" au-
tomatically changes.

Reducing the driving speed via the lift height

Reducing the driving speed via the
lift height

The reduction in the driving speed is linked to a
defined lift height.
A reed contact switch (1) is activated via a mag-
net on the fork carriage, thus reducing the driv-
ing speed at a specified lift height.
In such instances, the green indicator light with
the tortoise symbol illuminates in the display
unit.
1 394-02_09-006

Reducing the driving speed via the lift height

Connection: plug X24
Contacts :K63 input / :K15 On/Off switch
Function: A negative signal is received at in-
put :K63. The signal is changed from 7.5 kΩ to
1.5 kΩ by a switch. This means that the control-
ler detects the request for speed reduction. The
speed reduction must first be entered in the di-
agnostic program. This function is switched on
or off at :K15.
Basic setting: Without the "special equipment"
cable harness, the speed must be set to "maxi-
mum" in the diagnostic program.

Engine switch-off via seat switch

The "engine switch-off via seat switch" function
automatically switches off the engine when the
driver's seat is vacated. The engine switch-off
function is activated by operating the seat
switch.
The LHC 20 receives the "driver's compartment Parameter

occupied" signal or the "driver's compartment ▼
not occupied" signal via the seat switch S4. In Engine switch-off
the diagnostic program, the engine switch-off
▼
can be activated after a period of between 10
seconds and 600 seconds. Engine switch-off time
In the basic setting, the engine switch-off is set

to 0 seconds.
The engine switch-off requires an additional wir- 
ing harness (1) (3923810389) and an additional
relay (2)(7916291264).

Connection
Plug X11: The output signal :A19 switches the

additional relay K3 and disconnects the

terminal :15 at the ignition. The engine is switch-
ed off.
Installing
 Insert relay socket and relay TNR K3 (2) 

(7916291264) into slot 15. Connect the plug
connector X11 (3).
If the plug connector X11 is already being used
for a different item of special equipment, switch
to Pin :6.
 Route the wiring harness (1) (3923810389) 

along the left-hand side of the chassis to the
brake valve.

 Insert the plug connector X1.1 (4) into the slot 
(near the brake valve) next to the plug con-
nector 2X5 (5). Connect the plug connector
X1.1.

Service work on the trailer coupling

Service work on the trailer cou-
pling
WARNING
Risk of injury due to components moving suddenly!
Do not reach into the open coupling.
Maintenance 
To reduce wear of the coupling and the tow bar

eye, lubricate the components with multi-pur-
pose grease at regular intervals depending on
the application conditions and after cleaning with
a high-pressure and/or steam cleaner:
● Via the lubricating nipple (N)
● Supporting surface (A)
Testing 
Storage (pivot)
Gap at pivot between towing jaws and flange
collar with light loading of the lower lug in driving
position: a maximum of 3 mm.
Diameter of the coupling pin 
Nominal di-
Type Lower wear limit
mension
245A 30.6± 0.1 mm 28.6 mm
841B 38.0± 0.1 mm 36.5 mm
850B 30.6± 0.1 mm 28.6 mm

Service work on the trailer coupling
Vertical play on the coupling pin 
Type Vertical play

245A Maximum 2.5 mm
841B Maximum 2.0 mm
850B Maximum 2.5 mm
Body bore on the coupling pin 
Play in the lower pin guide a maximum of

2.5 mm: wear of the coupling pin or the bore: a
maximum of 1.5 mm
Bearing ring only for model 841B 
The lower bush must not be damaged under any

circumstances, as otherwise the closing function
of the coupling may be impaired!
The bearing ring for the tow bar eye must be re-
placed if the tow bar eye may come into contact
with the lower bush due to wear or damage or if
(H) is at least 14 mm.
NOTE
Always grease the bearing ring to reduce wear!

Linde Material Handling GmbH
3948012101 EN - 04/2020

394-02 EU5 Series Service Manual 3948012101EN 04-2020 Motor Doosan

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394-02 EU5 Series Service Manual 3948012101EN 04-2020 Motor Doosan

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Service Training

394-02 EU5 series

H40D-02, H45D-02, H50D-02,

Edition 02/2020 ● New: Traction hydraulics pump HPV 125 V+

Service Training - 3948012101 EN - 04/2020 I

Linde − Your Partner

Format of the training manual

Service Training - 3948012101 EN - 04/2020 III

suitable for self-study without an accompanying

The introduction is followed by a complete table

IV Service Training - 3948012101 EN - 04/2020

For your safety other symbols are also used.

Service Training - 3948012101 EN - 04/2020 V

Identifying components in electrical circuit diagrams

Examples of the operating materials assigned to the

VI Service Training - 3948012101 EN - 04/2020

Service Training - 3948012101 EN - 04/2020 VII

Internal test specifications / diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6

Servicing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-6

Service Training - 3948012101 EN - 04/2020 IX

Changing the air filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-27

X Service Training - 3948012101 EN - 04/2020

Checking the swivel bearing of the tilt angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 02-76

10 Internal combustion engine

Service Training - 3948012101 EN - 04/2020 XI

XII Service Training - 3948012101 EN - 04/2020

Behaviour during incorrect refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84

Service Training - 3948012101 EN - 04/2020 XIII

Radiator for exhaust gas recirculation - assembly overview . . . . . . . . . . . . . . . . . . . . 10-150

VW CWTA LPG engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188

XIV Service Training - 3948012101 EN - 04/2020

Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-214

LPG system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-259

Service Training - 3948012101 EN - 04/2020 XV

LPG cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-320

LPG tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-332

CNG system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-340

XVI Service Training - 3948012101 EN - 04/2020

Linde Engine Protection System (LEPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-389

20 Running gear and drive train

Drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37

Chassis frame components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-53

Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66

Service Training - 3948012101 EN - 04/2020 XVII

Removing and installing the axle stub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-76

Wheels and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111

Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112

30 Chassis and bodywork

Gas springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4

XVIII Service Training - 3948012101 EN - 04/2020

Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4

Service Training - 3948012101 EN - 04/2020 XIX

Operating units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50

Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-59

XX Service Training - 3948012101 EN - 04/2020

Central electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-35

Truck control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-43

Assistance systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-56

Service Training - 3948012101 EN - 04/2020 XXI

Speed sensors at the wheel motors (LSP active only) . . . . . . . . . . . . . . . . . . . . . . . . 60-88

Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30

XXII Service Training - 3948012101 EN - 04/2020

Tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-42

Assembly parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-15