WL 318

Service Training
Series 318
C90-5, C90-6, C90-7,

C90-8
This service document is provided for use only and remains
the exclusive property of Linde Material Handling.
EN 2010/02 Revision 1
Header
g
Linde − Your Partner
Selling over 100,000 forklift and warehouse start. But it is only under the toughest condi-
trucks per year, Linde ranks as one of the world’s tions that a machine can show its true worth.
leading manufacturers. And there are good Carefully thought-out functionality combined with
grounds for its success. Linde products not only maximum economic efficiency. Linde trucks are
win over customers with their innovative technol- bursting with ideas. For the benefit of the cus-
ogy with a reputation for excellent performance, tomer. And to protect the environment.
but in particular with reduced energy and operat-
Linde Heavy Truck Division Ltd
ing costs, which are up to 40% lower than those
Linde Industrial Park
of the competition.
Merthyr Tydfil
High production quality is also the benchmark for Telephone: +44 (0) 01443 624200
the quality of our services. With ten production Fax: +44 (0) 01443 624300
plants and a dense network of distribution part- E-mail: info.forklifts@linde-htd.com
ners, we are at your disposal both round the clock Website: http://www.linde-htd.com
and round the world.
Be it leasing, hire or hire purchase — the
cost-benefit ratio is right on target from the very
Service Training – 359 807 50 01 EN – 03/2009 III

Header
g
Structure of training document
This training document is based on the relevant Section Content
seminar held at our Linde training centres or at 7 Hydraulics
the authorised dealer’s premises and is designed 8 Load lift system
to supplement it. The training document taken
by itself without an accompanying seminar is not 9 Special equipment and accessories
suitable for self-study. 10 Circuit diagrams
This training document is divided into numbered The training document is not organised so that it
sections from 0 to 10, with the content being successively describes the structure of the truck
identical in all training documents. The sections but is based on a modular concept. This means
are only guided by the organisation of the spare that in the different sections the individual vehicle
parts list and may differ from the content . The components are described as independent units
circuit diagrams for the truck can be found in one after the other. This is another reason why a
section 10 in the Appendix. course at one of our training centres is essential.
Section Content The introduction is followed by a complete con-
0 Product information tents list for the training document. This is sup-
plemented by an index at the end of the training
1 Motor
document.
2 Gearbox
Here we should like to inform you that a list of all
3 Chassis
special tools and measuring instruments used
4 Undercarriage for this truck can be called up referred to type,
5 Controls including spare part number, usage and graphics,
6 Electrics / Electronics in the documentation software "Truck Expert".
Symbols used
The precautions Danger, Warning, Caution,
Note und Environment Note in this manual are NOTE
provided to indicate special hazards or unusual
information requiring special identification:
Identifies technical information requiring special
attention because the connection may not even
DANGER be obvious to skilled personnel.
indicates hazards that may result in personal injury or
death and/or substantial damage to the product. ENVIRONMENT NOTE
The information contained herein must be ob-

WARNING served, otherwise environmental damage may
occur.
indicates hazards that may result in personal injury
and/or substantial damage to the product. For your safety other symbols are also used.
Please note the different symbols.
CAUTION
indicates hazards that may result in damage to or
destruction of the product.
IV Service Training – 359 807 50 01 EN – 03/2009

Table of contents
g
0 Product information
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The BR 318 truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VDI datasheet
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LTC basic structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAN bus communication — overview and installation position . . . . . . . . . . . . . . . . . . .
Error code lists .....................................................
Indicator unit — error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LTC traction control codes, version1.X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LTC lift control codes, 0.040 version, LTC module N1 . . . . . . . . . . . . . . . . . . . . . . . . .
LTC lift control codes, Version 0.040, LTC module N2 . . . . . . . . . . . . . . . . . . . . . . . . .
Cummins diesel engine fault codes ......................................
1 Engine
Diesel engine ...............................................
Description of the drive ................................................
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
View of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine identification ..................................................
Engine data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection pump plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine control unit data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing, removing and checking the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker levers and pushrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing, removing and checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front crankshaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing the oil sump seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and refitting the injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing, installing and checking the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing, removing and checking the exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . .
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Diesel engine ..............................................
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the EFC actuator .................................
Removing and installing the high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and fitting the V-ribbed belt ....................................
Removing and installing the exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing, installing and checking the exhaust manifold . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking rocker levers and pushrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing, installing and checking the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing, installing and checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the oil sump seal ............................................
2 Drive axle
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Technical data for traction drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Schematic view of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Linde Truck Control (LTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Traction drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Travel drive − introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Variable displacement pump controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Motor variables controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Pedal group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
HPV 210-02 variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Electro-hydraulic remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Variable pump advance start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Variable motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Variable motord HMV 280-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Output unit function characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Reduction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Reduction gearbox GR 26-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Braking process - function characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Retarder valve block components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Retarder valve block function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Brake release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
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Towing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Checking the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Hydraulic fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

Function characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Checking the hydraulic fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
4 Chassis, bodywork and fittings

Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Function characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
stub axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Wheel hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Adjusting the inner steering stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Adjusting the outer steering stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Removing and installing the steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Sealing the steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
5 Controls
Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Indicator unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6 Electrics / Electronics
Central electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Arrangement of relays and fuses for basic equipment and special equipment . . . . . . . . . 6-1
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Testing the electronic controllers and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Testing the LTC (vehicle and lift controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Checking wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Testing sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Checking actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Testing the indicator unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
7 Hydraulics
Regulating pump HPR 210-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Technical data for regulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
HPR 210-02 regulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Load sensing regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
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Working hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Working hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Hose layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Hose layout, supply, valve block, working hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Hose layout — lifting/lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Tilting hose layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Hose layout for sideshift and fork positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Measurements and settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Checking the maximum working pressure and LS pressure . . . . . . . . . . . . . . . . . . . . . 7-14
Checking and adjusting delta pressure P to LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
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Annex
10 Circuit diagrams
Hydraulic circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring diagrams QSB 6.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring diagram, sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring diagram, sheet 4 - dipped beam, sidelight, direction indicator and hazard warning
light, reverse light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring diagram, sheet 5 - work lights, horn, interior light, cigarette lighter, radio .....
Wiring diagram, sheet 6 - windscreen wiper motors . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring diagram, sheet 7 − seat heater, flashing beacon, brake light, programmable roof
light/ beacon, mast speed limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring diagram, sheet 8 − cabin tilting mechanism, door release, spare fuses ......
Wiring diagram, sheet 9 - air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring diagram, sheet 10 − twistlocks, extend/retract, sideshift, work lights, safety over-
ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Training – 359 807 50 01 EN – 03/2009 IX

Product information 0
a
Preface
The BR 318 Truck
For the first time in forklift history, the new heavy- functions. Along with the considerably improved
duty forklift models come with Linde hydrostatic lifting and lowering speeds of the lift mast, this
drive. This tried-and-tested, leading technology ensures savings in terms of both time and money
is now being used universally in all Linde ECH’s and results in increased economic efficiency.
with an internal combustion engine .
The dimensions of the new Linde ECH’s range
set new standards in the heavy-duty ECH
The functionality of the Linde hydrostatic system class. In comparison with the previous model,
is as simple as it is impressive. Instead of energy this compact truck requires a reduced aisle width
and effort-wasting shifting, the system has dual- and is significantly easier to manoeuvre. The lift
pedal control. This is basically one accelerator mast, carriage and spreader have been
pedal for forward travel and one for reverse travel, completely redeveloped. The latest design has
which the operator can use to continually adjust resulted in increased strength, improved visibility
the speed and deceleration. This enables swift and an optimised hose guide.
reversing and sensitive, precise control.
As there is no need for a clutch, gearbox and
Safety
differential, there is also no further need for
costly, mechanical wearing parts. That means Perfect load control and manoeuvrability, even
low maintenance costs. when space is restricted. The driver’s cab is
located on a pedestal and in the centre to provide
Another clear advantage over the previous
an optimum view through the mast and under the
converter transmission is the decoupling of
lifted load. The generously-sized glass
driving and lifting functions. This means no
surfaces plus the curved windscreen ensure that
more change in vehicle speed during a lifting
your entire surroundings remain in view at all
or tilting function. It also removes the need for the
times.
previously essential ""inching" of the truck due
to simultaneous control of the driving and lifting
Preface
Performance reduced via rubber-cushioned drive axle to
improve driver comfort.
Linde container handlers enable you to work with
precision and considerable speed, even in the • Extremely low noise level improves comfort for
higher load-bearing class. The continuously the driver and those in the surrounding area.
variable Linde hydrostatic drive system enables • The overhead guard provides a high level of
the truck to accelerate up to full speed without the protection from falling loads.
need of coupling or shifting. You can also save • Non-dazzling indicator unit and switches are
time when handling loads as the Linde dual-pedal well positioned and enable the steering wheel
control and the "Linde Load Control" hydraulic panelling to be thin, thus providing an optimal
control lever allow the truck to be operated with forward view.
minimal movement.
• Excellent all-round view due to curved cab
windscreen.
Comfort
Comfort in motion. The double-sealed driver’s Engine
cab is separated from the engine and drivetrain
by rubber bearings. This means that most move- Diesel engine with the latest engine technology
ments and vibrations are absorbed. The driver’s for:
seat is fitted with hydraulic suspension for addi- • High torque
tional damping. • Low fuel consumption
• Low exhaust emissions (NO x, CO, HC)
Reliability • Low particulate emissions
A superior hydrostatic drive design with a mini- • Low noise levels
mum of wearing parts, a low-maintenance engine
and ultimate durability for the lift mast and lifting
Drive
system. The best conditions for high availability
and a long service life. Linde hydrostatic drive, in-house development
and production resulting in quality for:
Economic efficiency • Sensitive and smooth traction
Efficiency during use, efficiency during a service. • Smooth reversing with no time lag
The genuine Linde hydrostatic system operates • Robust drive, tried and tested in extreme
without a gearbox, clutch, differential and drum operations
brakes. This means low service costs and in- • Hydrostatic drive: the hydraulic motor powers
creased handling performance. A significant the drive wheel via a two-stage planetary
competitive edge, particularly in terms of heavy, transmission
continuous use. • No clutch, differential or drum brakes required.
Driver’s compartment design Electronics/electrics

Driver’s compartment designed according to the Linde Truck Control (LTC), the electronic system
latest ergonomic findings: controlling the forklift’s drive and lifting hydraulics
• Large cab volume to give the impression of for:
space, internal design meeting automobile • Sensitive, smooth driving and reversing
standards.
• Automatic engine speed control depending
• Large, comfortable footwell. on the power required by the hydraulics, i.e.
• Linde Load Control: Precise and simple engine speed is always set to the lowest pos-
operation of all lift mast functions via the sible value. This minimises fuel consumption,
operating lever integrated into the armrest, noise and exhaust emissions, thus increasing
individually adjustable to suit the height of the comfort for the driver and the environment.
driver. • Truck adjustment to the relevant use by the
• Linde dual-pedal control for effortless oper- service engineer.
ation and increased handling performance: • Fast service thanks to self-diagnostics.
enables swift reversing, feet can rest com-
fortably on the pedals with no movement re- • All safety-related components such as mi-
quired, short pedal travel, impact during travel croprocessors are in pairs and monitor each
Preface
other. This ensures maximum operational reli- • Linde dual-pedal control for all truck movement
ability and Linde Load Control for simple and precise
• The controller is protected from splashes and operation of all mast functions
dust by a sealed housing. • Hydrostatic power steering as needed; fuel-
• All electronic/electrical components in central efficient, with quick and accurate response
layout, protected and easily accessible behind • High-performance hydraulic filter design for
the driver’s seat. All electrical connections are highest oil purity and thus an optimum service
sealed and insulated individually, protecting life for all hydraulic components
them from dirt and humidity. • Central lever actuation for lifting/lowering and
tilting, moves freely
Steering
• Non-dazzling display with indicators such as
The hydrostatic steering reacts with virtually no fuel tank level, time, operating hours, service
play. This means that the ergonomically shaped information etc., and indicator lights for all
steering wheel with adjustable tilt angle fits in the important truck functions
driver’s hand with ease and precision.
• Diverse storage areas for stationary, drinks
Brake containers etc.
• Pneumatic tyres
Three independent brake systems ensure opti-
mum safety: • Standard lift mast, stroke h 3 = 12,678-18,926mm
• Spreader carriage width b3 = 6050mm
• Gentle hydrostatic braking as soon as the
accelerator pedal is released, i.e. non-wearing
retardation for everyday use. Special equipment
• Braking requiring increased retardation by • Single-pedal version with two-way switch for
operating the hydrostatic brake pedal and direction of travel in armrest
additional retardation from the maintenance-
• Standard lift masts with 2430 to 9500 mm
free multi-disc brake.
stroke
• Parking brake applied automatically when the • Load backrest
truck’s engine is switched off.
• Single and double auxiliary hydraulics for all lift
Container spreader mast versions
• Overhead guard extendable to driver’s cab
The spreader is used to pick up empty containers. with roof window, front and rear windows plus
It is mounted directly on the outer upright and it doors (also with tinted windows)
can handle ISO containers with a length of 20 • Windscreen wiper/washer system for front,
to 40 feet (6100 to 12200 mm) and a height of rear and roof windows
8 feet to 9 feet 6 inches (2438 to 2896 mm). • Seat with increased comfort (lumbar support,
The maximum container width can be 8 feet seat heater), adjustable
(2438 mm). The spreader is equipped with two
hydraulic cylinders for extending it to the correct • Warm water heating system with integrated
container length. When transporting empty pollen filter
containers two hydraulically operated twistlocks • Air-sprung seat with compressor
are engaged into the carrying corner castings on • Single-lever actuation for raising/lowering and
the container and locked. When the container is tilting
lifted, it hangs on these twistlocks. With a hydraulic • Single-lever actuation for fork positioning and
cylinder as integrated sideshift, the spreader can sideshift
be adjusted laterally 12 in (300 mm) to the left and
right side. • Cross lever actuation for auxiliary hydraulics
The functions of the twistlocks are indicated by • Single-lever actuation for auxiliary hydraulics
indicator lights on the spreader and in the cabin. • Air filter with integrated cyclone separator
Orange-coloured flags on the twistlocks also • Electrical tipping cab, with manual emergency
indicate the position of the twistlocks. mode for service access
Standard equipment • Klimatronic air conditioning with integrated
pollen filter
• Overhead guard height: 4179 mm
• Radio with CD player and loudspeakers
• Comfortable, hydraulically damped seat with
• Truck lighting, working headlights
full adjustment
• Mirror
• Lockable storage box under the driver’s seat
Preface
• Integrated particle filter with build-up display

• Dust pre-cleaner
• Warning sound when reversing, flashing
beacon and direction indicators
• Adjustable steering column
• Sun visor for roof window and windscreen
• Lifting hydraulics accumulator
• Built-in battery charger
• Elevated air inlet for cab heating
• Induction air filter with dust separator
• Special paint options
Technical data
Dimensions
Technical data
Datasheet BR318 - C90/5

1.1 Manufacturer Linde
1.2 Model designation C90/5
1.3 Power unit: battery, diesel, LP gas, mains power Diesel
Weights Caracteristics
1.4 Operation: manual,pedestrian,stand-on,seated,order picker Rider seated

1.5 Load capacity Q (t) 9
1.6 Load centre c (mm) 1,295
1.8 Load centre distance x (mm) 1,127
1.9 Wheelbase y (mm) 4,000
2.1 Service weight kg 32,285
2.2 Axle load with load, front/rear kg 33,092/8,196
2.3 Axle load without load, front/rear kg 18,588/13,697
3.1 Tyres, front/rear. SE = (superelastic), P = (pneumatic) P/P
3.2 Tyre size, front 12.00 x 24 20pr
3.3 Tyre size, rear 12.00 x 24 20pr
Wheels &
3.5 Wheels, number, front/rear (x = driven) 4x - 2

Tyres
3.6 Track width, front b10 (mm) 2,900

3.7 Track width, rear b11 (mm) 2067
4.1 Mast/fork carriage/truck tilt, forward/backward Grad 3/3.5
4.2 Height of mast lowered h1 (mm) 8,983
4.4 Lift h3 (mm) 12,678
4.5 Height of mast extended h4 (mm) 15,488
4.7 Height of overhead guard (cabin) h6 (mm) 4,179
4.8 Height, operators seat/stand-on platform h7 (mm) 2,999
4.12 Towing coupling height h10 (mm) 600
4.15 Twistlock height lowered h13(mm) 2,290
4.19 Overall length l1 (mm) 6,177
4.20 Length to fork face l2 (mm) 6,009
4.21 Overall width b1/b2 (mm) 3600/2545
4.24 Width of attachment 20'/40' s/e/l (mm) 6050/12150
4.31 Ground clearance, mast m1 (mm) -
4.32 Ground clearance, centre of wheelbase m2 (mm) 342
Dimensions
4.33 Stacking aisle, 20' containers Ast (mm) 9702

Stacking aisle, 40' containers Ast (mm) 14232
4.35 Turning radius Wa (mm) 5,292
4.36 Minimum pivoting point distance b13 (mm) 928
5.1 Travel speed, with/without load km/h 29.7/31
5.2 Lift speed, with/without load m/s 0.60/0.60
Performance
5.3 Lowering speed, with/without load m/s 0.54/0.54

5.5 Tractive force, with/without load kN 86.7
5.7 Climbing ability, with/without load % 17.6/-
5.9 Acceleration time, with/without load s 5
5.10 Service brake wet disc
6.4 Battery voltage, rated capacity V/Ah 2x12/200
7.1 Engine manufacturer/type Cummins
7.2 Engine performance according to ISO 1585 kW 129
7.3 Rated speed 1/min 2,000
Drive
7.4 Number of cylinders/displacement / cm³ 6/5900

7.5 Fuel consumption - average l/h -
8.1 Type of drive control Hydrostatic
8.2 Working pressure for attachments bar 250
Other
8.4 Noise level, at operator's ear, Overhead guard/Cab dB(A) /

8.5 Trailer coupling, design/type DIN Ø (mm) 50
Technical data


Wheels &

Tyres

4.4 Lift h3 (mm) 15,574
Dimensions

Performance

Drive

Other

0
Technical data


Wheels &

Tyres

4.4 Lift h3 (mm) 16,352
Dimensions

Performance

Drive

Other

Technical data


Wheels &

Tyres

4.4 Lift h3 (mm) 18,926
Dimensions

5.1 Travel speed, with/without load km/h 25/26
Performance

Drive

Other

0
Diagnostics
LTC basic structure
1 Integrated drive/lift control — LTC module N1 6 Indicator unit

2 Travel direction switch 7 Directional control valve block/lift mast
3 Pedal group 8 Motor variables
4 Joysticks 9 Combustion engine
5 Integrated drive/lift control — LTC module N2 10 Variable pump
Service Training – 359 807 50 01 EN – 03/2009 0-15

Diagnostics
CAN bus communication — overview and installation position
1 LTC module N1 4 Display

2 LTC module N2 5 LTC diagnostic connector
3 Cummins module 6 Cummins module diagnostic connector
LTC modules N1 (1) and N2 (2) and the diag-

nostic connectors for LTC diagnostics (5) and
Cummins diagnostics (6) are located in the cabin
behind a covering next to the cabin door.
The Cummins module (3) is mounted directly on
the engine.
0-16 Service Training – 359 807 50 01 EN – 03/2009

Diagnostics
Error code lists
Indicator unit — error codes
Residual capacity for "particle filter special equip-
ment" and error codes are displayed in the text
field (1) (2 x 11 characters).
The error code display sequence is determined
by the code letter (T before L before D ... error)
and by the sequence of transmission of the error
numbers via the CAN. If more errors have oc-
curred 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 button is used for scrolling to the left and
when the ">" symbol is displayed, the right 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.
1 Text field
T Traction
L Lift
D Display
F Particle filter
R Recorder (data logger)
X Diesel engine
Y, Z UPA 2 to 3
NOTE
Error codes and possible error correction is outli-

ned and analysed by the "Pathfinder" diagnostic
program.

Diagnostics
LTC traction control codes, version1.X
Statuses
Error in accelerator potentiometer zero position or 5 V potentiometer power supply after
1
ignition ON
2 Accelerator potentiometer in zero position
3 Brake pedal not yet actuated after ignition ON
4 Driver seat not occupied
5 Speed limitation active or incorrectly reset
Travel direction switch signals not plausible or travel direction switch in zero position
6
(single-pedal trucks)
8 Brake pedal half actuated
9 Brake pedal fully actuated
10 Speed limitation requested by operating hydraulic or reset faulty
11 Control unit in programming mode
13 Safety relay: voltage lower than 8 V
14 Terminal 15: voltage lower than 8 V
16 Speed limitation requested by data logger
17 Speed limitation requested by soot filter
19 Accelerator potentiometer not yet taught
48 Sensed engine speed does not match the diesel engine control unit speed
Warnings
Seat switch and accelerator potentiometer signals not plausible for longer than 2 sec-
104
onds
124 Seat switch: signal missing for more than 5 seconds
134 Hydraulic oil temperature sensor: signal outside the valid range
180 Safety processor data missing for more than 1 second
Error
220 Invalid vehicle type
221 Production test not OK
222 EEPROM error
Travel direction switch: direction signal and zero position signal concurrent for more
225
than 10 seconds
Switch-controlled speed limitation function was activated, but the corresponding switch
226
(changeover contact) signals do not match.
227 LS pressure sensor: signal outside the valid range
228 Load pressure sensor and reference load pressure sensor: signals not plausible
229 Load pressure sensor: signal outside the valid range
230 Reference load pressure sensor: signal outside the valid range
Accelerator pedal: signals from the actuating potentiometer and monitoring potentiome-
231
ter are not plausible
232 Accelerator pedal: signal from the actuating potentiometer is outside the valid range
233 Accelerator pedal: signal from the monitoring potentiometer is outside the valid range
235 Travel direction switch: signals not plausible
236 Travel direction switch: all inputs open (e.g. coding plug missing)
239 Seat switch: signals not plausible

Diagnostics
240 Error in motor variable Vmin ON/OFF solenoid valve 1Y11 circuit
241 5 V power supply voltage for transmitter too low
243 Safety relay fails to close
244 Safety relay fails to open
246 Release valve output stage never activated
247 Release valve: current too low
248 Sensed engine speed does not match the diesel engine control unit speed
249 Motor variable Vmin ON/OFF solenoid valve 1Y11: current too low
250 Motor variables: current too low
251 Retarder brake oil volume: current too high
252 Retarder brake oil volume: current too low
253 Pump, forwards: current too high
254 Pump, forwards: current too low
255 Pump, backwards: current too high
256 Pump, backwards: current too low
257 Retarder brake oil pressure: current too high
258 Retarder brake oil pressure: current too low
259 Motor variables: current too high
260 Motor variables: no voltage whilst transistor is activated
261 Retarder brake oil volume: voltage present whilst transistor not activated
262 Retarder brake oil volume: no voltage whilst transistor is activated
263 Pump, forwards: voltage present whilst transistor not activated
264 Pump, forwards: no voltage whilst transistor is activated
265 Pump, backwards: voltage present whilst transistor not activated
266 Pump, backwards: no voltage whilst transistor is activated
267 Retarder brake oil pressure: voltage present whilst transistor not activated
268 Retarder brake oil pressure: no voltage whilst transistor is activated
269 Motor variables: voltage present whilst transistor not activated
270 Safety processor detecting deviating signal from impulse transmitter
271 Safety processor detecting deviating value for 5 V supply voltage
272 Safety processor detecting deviating signal from accelerator potentiometer
273 Safety processor detecting deviating signal for pump, forwards, current
274 Safety processor detecting deviating signal from travel direction switch
275 Motor variables: current reduction too fast whilst transistor not activated
276 Retarder brake oil volume: current reduction too fast whilst transistor not activated
277 Pump, forwards: current reduction too fast whilst transistor not activated
278 Pump, backwards: current reduction too fast whilst transistor not activated
279 Retarder brake oil pressure: current reduction too fast whilst transistor not activated
Brake pedal: signals from the actuating potentiometer and monitoring potentiometer are
331
not plausible
332 Brake pedal: signal from the actuating potentiometer is outside the valid range
333 Brake variable
Motor pedal: signal
Vminfrom the monitoring
ON/OFF potentiometer
solenoid valve is outside
1Y11: voltage thewhilst
present valid range
transistor not
340
activated
345 Release valve: maximum current exceeded
346 Release valve: voltage present whilst transistor not activated
347 Release valve: current too high whilst transistor not activated

Diagnostics
348 Motor variable Vmin ON/OFF solenoid valve 1Y11: maximum
current toocurrent exceeded
high whilst transistor not
activated
349
350 Motor variables: current increase too slow
352 Retarder brake oil volume: current increase too slow
354 Pump, forwards: current increase too slow
356 Pump, backwards: current increase too slow
358 Retarder brake oil pressure: current increase too slow
Safety processor detecting deviating feedback signal at PWM output stage of V-engine
370
actuators
Safety processor detecting deviating feedback signal at PWM output stage of hydrostatic
371
actuators
372 Safety processor detecting deviating signal at operator inputs
373 Safety processor detecting deviating signal for pump, backwards, current
374 Safety processor detecting deviating signal for pedal coding
375 Safety processor detecting deviating signal from brake pedal potentiometer
376 Safety processor detecting deviating signal from load pressure sensor
380 No data from safety processor for 5 seconds
481 Safety processor: vehicle speed too high
482 Safety processor: vehicle speed too low
Safety processor: pump, forwards, activation not plausible to accelerator pedal poten-
483
tiometer
Safety processor: pump, backwards, activation not plausible to accelerator pedal poten-
484
tiometer
490 Safety processor: switch-off test error

Diagnostics
LTC lift control codes, 0.040 version, LTC module N1
Statuses
1 Power On, procedure not completed.
2 Joystick neutral
3 Tilting at stop, end cushioning active or programmed position reached
4 Programmed end position exceeded (over 1 degree)
12 Safety processor inactive
14 Terminal 15: Voltage below 8 V
15 EEPROM error, current adjustment values missing or defective
16 Mast positioning active
17 Seat switch not actuated
18 Tilt stops not taught
19 Joysticks not taught
Warnings
141 Incompatibility between seat switch signal/reference signal
146 Seat switch: Seat not occupied for over 2 seconds and joystick actuated
180 No data from safety processor (for over 1 second)
Error
220 Tilt transmitter cable break
221 Tilt angle transmitter reference potentiometer incompatible
222 Joystick not in neutral for over 2 seconds after Power On
230 Lift/lower joystick cable break
231 Tilt joystick cable break
235 Incompatibility between lift/lower signal/reference potentiometer
236 Incompatibility between tilt signal/reference potentiometer
Switching from 2nd to 3rd auxiliary hydraulic spool valve producing persistent implausi-
247
ble signals
254 Lift/lower magnetic current too low
255 Tilt magnetic current too low
257 Variable pump magnetic current too low
258 Lift/lower magnetic current too high
259 Tilt magnetic current too high
261 Variable pump magnetic current too high
262 Lift magnet voltage permanently high
263 Lower magnet voltage permanently high
264 Tilt forwards magnet voltage permanently high
265 Tilt backwards magnet voltage permanently high
266 Retarder switch magnet voltage permanently high
268 Variable pump magnet voltage permanently high
270 Lift magnet voltage permanently low

Diagnostics
271 Lower magnet voltage permanently low
272 Tilt forwards magnet voltage permanently low
273 Tilt backwards magnet voltage permanently low
274 Retarder switch magnet voltage permanently low
276 Variable pump magnet voltage permanently low
280 Safety relay permanently off
282 Safety relay permanently on
284 Lowering release valve current low although activated
285 Lowering release valve current high although not activated
286 Lowering release valve current extremely high
287 Lowering release valve permanently OFF
288 Lowering release valve permanently ON
289 Safety valve current low although activated
290 Safety valve current high although not activated
291 Safety valve current extremely high
292 Safety valve permanently OFF
293 Safety valve permanently ON
294 5 V supply too low
296 Retarder switch magnet current low although activated
297 Retarder switch magnet current high although not activated
298 Retarder switch magnet current extremely high
299 Retarder switch magnet permanently OFF
300 Retarder switch magnet permanently ON
306 Short circuit via lift magnet
307 Short circuit via lower magnet
308 Short circuit via tilt forwards magnet
309 Short circuit via tilt backwards magnet
310 Short circuit via retarder switch magnet
312 Short circuit via variable pump magnet
314 Communication of process data interrupted for over 200 ms
350 Safety processor detecting deviating signal from lift/lower joystick
351 Safety processor detecting deviating signal from tilt joystick
Safety processor detecting deviating PWM (pulse width modulation) from lift/lower joy-
354
stick
355 Safety processor detecting deviating PWM from tilt joystick
357 Safety processor detecting deviating PWM from variable pump magnet
358 Tilt angle stops not taught in safety processor
359 Incompatibility between tilt angle measurement in function and safety processor
380 No data from safety processor (for over 5 seconds)
410 Safety processor: Lift, PWM high although joystick signal low
411 Safety processor: Lower, PWM high although joystick signal low
412 Safety processor: Tilt forwards, PWM high although joystick signal low
413 Safety processor: Tilt backwards, PWM high although joystick signal low
418 Safety processor: Safety valve switch-off test failed
420 Safety processor: Lowering release valve switch-off test failed

Diagnostics
425 Safety processor: Internal PWM signal error
426 Safety processor: Mast tilted forwards beyond stop
427 Safety processor: Mast tilted backwards beyond stop

Diagnostics
LTC lift control codes, Version 0.040, LTC module N2
Statuses
1 Power On, procedure not completed.
2 Joystick neutral
12 Safety processor inactive
14 Terminal 15: Voltage below 8 V
15 EEPROM error, current adjustment values missing or defective
17 Seat switch not actuated
19 Joysticks not taught
Warnings
146 Seat switch: Seat not occupied for over 2 seconds and joystick actuated
180 No data from safety processor (for over 1 second)
Error
222 Joystick not in neutral for over 2 seconds after Power On
230 Additive 3 joystick cable break
235 Incompatibility between additive 3 signal/reference potentiometer
254 Additive 3 magnetic current too low
258 Additive 3 magnetic current too high
262 Additive 3+ constant high magnetic voltage
263 Additive 3- constant high magnetic voltage
264 Additive 4+ constant high magnetic voltage
265 Additive 4- constant high magnetic voltage
266 Additive 1A constant high magnetic voltage
267 Additive 1B constant high magnetic voltage
268 Additive 2A constant high magnetic voltage
269 Additive 2B constant high magnetic voltage
270 Additive 3+ constant low magnetic voltage

Diagnostics
271 Additive 3- constant low magnetic voltage
272 Additive 4+ constant low magnetic voltage
273 Additive 4- constant low magnetic voltage
274 Additive 1A constant low magnetic voltage
275 Additive 1B constant low magnetic voltage
276 Additive 2A constant low magnetic voltage
277 Additive 2B constant low magnetic voltage
280 Safety relay permanently off
282 Safety relay permanently on
294 5 V supply too low
306 Short circuit to additive 3+ magnet
307 Short circuit to additive 3- magnet
308 Short circuit to additive 4+ magnet
309 Short circuit to additive 4- magnet
310 Short circuit to additive 1A
311 Short circuit to additive 1B
312 Short circuit to additive 2A
313 Short circuit to additive 2B
314 Communication of process data interrupted for over 200 ms
350 Safety processor detecting deviating additive 3 joystick signal
354 Safety processor detecting deviating additive 3 joystick PWM (pulse width modulation)
355 Safety processor detecting deviating additive 4 joystick PWM
380 No data from safety processor (for over 5 seconds)
410 Safety processor: Additive 3+ PWM high although joystick signal low
411 Safety processor: Additive 3- PWM high although joystick signal low
418 Safety processor: Safety valve switch-off test failed
420 Safety processor: Lowering release valve switch-off test failed
425 Safety processor: Internal PWM signal error

Diagnostics
Cummins diesel engine fault codes
Error
X111 Engine control unit: internal faults
X115 Engine speed transmitter: both signals absent
X122 Suction pipe pressure transmitter: short circuit to positive
X123 Suction pipe pressure transmitter: short circuit to negative
X135 Engine oil pressure transmitter: short circuit to positive
X141 Engine oil pressure transmitter: short circuit to negative
X143 Engine oil pressure warning signal
X144 Coolant temperature transmitter: short circuit to positive
X145 Coolant temperature transmitter: short circuit to negative
X146 Coolant temperature too high warning signal
X151 Coolant temperature too high warning signal — critical
X153 Induction air temperature transmitter: short circuit to positive
X154 Induction air temperature transmitter: short circuit to negative
X155 Induction air temperature too high warning signal — critical
X184 Engine control unit identification — input error
X234 Engine speed too high warning signal — critical
X235 Coolant level too low warning signal — critical
X241 Vehicle speed transmitter — false data
X242 Vehicle speed transmitter — corrupt value detected
X261 Fuel temperature too high warning signal
X264 Fuel temperature transmitter: signal outside the valid range
X278 Pre-injection fuel pump control circuit — short circuit
X283 Engine speed transmitter voltage supply: short circuit to positive
X284 Engine speed transmitter voltage supply: short circuit to negative
X285 Timeout during CAN bus data transmission
X286 Configuration error in CAN bus data transmission
X287 Accelerator pedal system error in CAN bus data transmission
X319 Voltage supply to real time clock interrupted
X352 Transmitter #1 voltage supply: short circuit to negative
X361 Fuel pump control unit, fuel control valve circuit: short circuit to positive
X362 Fuel pump control unit, fuel control valve circuit: short circuit to negative
X363 Fuel pump control unit, fuel control valve: mechanically jammed
X364 Fuel pump control unit, CAN bus communication error — abnormal update rate
X365 Fuel pump control unit voltage supply: short circuit to negative
X366 Fuel pump control unit voltage supply: false value
X367 Fuel pump control unit, fault in incremental angle/time transmitter
X368 Fuel pump control unit, timing error
X369 Fuel pump control unit, engine synchronisation fault
X372 Fuel pump control unit, idling comparison error
X373 Fuel pump control unit, fuel cutoff fault
X374 Fuel pump control unit, self-test fault
X375 Fuel pump control unit, electronic calibration code error
X376 Fuel pump control unit, fuel supply and engine speed not plausible

Diagnostics
X377 Fuel pump control unit, relay hanging

X381 Induction air pre-heating relay release #1, false data
X382 Induction air pre-heating relay release #2, false data
X386 Transmitter #1 voltage supply: short circuit to positive
X391 Fuel cutoff valve voltage supply incorrect
X415 Engine oil pressure too low warning signal — critical
X418 Water in fuel warning signal
X422 Coolant temperature transmitter circuit: false data
X429 Water in fuel transmitter: short circuit to negative
X434 Voltage supply switched off but ignition still on
X441 Battery voltage too low warning signal
X442 Battery voltage too high warning signal
X488 Induction air temperature too high warning signal — critical
X497 Synchronisation circuit, false data
X517 Fuel metering valve: misaligned
X611 Engine stalled

Diagnostics
X701 Cylinder power imbalance between cylinders.

X702 Power lost with ignition on.
X703 Injector #1 cylinder not responding correctly.
X709 Control module identification input state error.
X710 Control module identification input state error.
X711 Injector metering rail 1 pressure – data valid but above normal operational range.
X712 Coolant temperature 2 sensor circuit – voltage above normal or shorted to high
source.
X713 Coolant temperature 2 sensor circuit – voltage above normal or shorted to high
source.
X714 Coolant temperature 2 sensor circuit – data above normal or shorted to high source.
X715 Coolant temperature 2 sensor circuit – data above normal or shorted to high source.
X716 Coolant pressure 2 sensor circuit – voltage above normal or shorted to high source.
X719 Sensor supply voltage #4 circuit – voltage above normal or shorted to high source.
X720 Sensor supply voltage #4 circuit – voltage above normal or shorted to high source.
X721 Auxiliary equipment sensor input 3 engine protection critical.
X722 Fuel pump delivery pressure – date valid but below normal operational range.
X723 Fuel pump delivery pressure – date valid but above normal operational range
X724 ECM program memory (RAM) corruption – condition exists.
X725 Injector metering rail 1 pressure – data valid but below normal operational range.
X726 Fuel priming pump control signal circuit – voltage above normal or shorted to high
source.
X727 Fuel priming pump control signal circuit – voltage below normal or shorted to low
source.
X728 Fuel inlet meter device – data valid but above normal operational range.
X729 Fuel inlet meter device flow demand lower than expected.
X730 Fuelling actuator #1 circuit error
X731 Engine speed/position sensor #1 – data erratic or incorrect.
X732 Engine speed/position sensor #2 - data erratic or incorrect.
X733 Turbocharger speed invalid rate of change detected
X734 Turbocharger turbine inlet temperature (calculated) – data valid but above normal
operational range.
X735 Turbocharger compressor outlet temperature (calculated) – valid but above normal
operational range.
X736 Intake air heater #1 circuit – voltage above normal or shorted to high source.
X737 Intake air heater #1 circuit – voltage below normal or shorted to low source.
X738 Engine coolant temperature high – data valid but above normal operational range.
X739 Intake manifold temperature high – data valid but above normal operational range.
X740 Intake manifold pressure sensor circuit – data erratic or incorrect
Diagnostics

Engine 1
a
Diesel engine QSB 6.7

Description of the drive
Technical data
Manufacturer Cummins
Engine type QSB 6.7
Number of cylinders 6
Displacement 6700 cm3 (409 cubic inches)
Power 142 kW
Maximum torque 800 Nm
Fuel Rail pressure 250-1600 bar (3626-23206 psi)
Compression
Compression pressure
Maximum permissible pressure difference
Lower idling speed 750 rpm
Upper idling speed 2000 rpm
Valve clearances In = 0.254mm (0.010”) Ex = 0.508mm (0.020”)
Firing order 1-5-3-6-2-4
Position of cylinder 1 Fan end
Thermostat
Fuel Diesel
Flywheel teeth count
Oil pressure at 2000 rpm and oil temperature of
207 kPa (30 psi)
80 °C
-1
1 Engine
View of engine
1
2
8
4
6
5
1 Oil filler cover

2 Intake air heater
3 Engine data plate
4 Vibration damper
5 Oil drain plug
6 Automatic belt tensioner
7 Fuel filter
8 Starter motor
9 Exhaust manifold
1 Engine
Engine control unit data plate
The engine control unit data plate is located
above the connection plug on the control unit.
The following data is shown on the data plate:

• PN: part number
• SN: serial number
• DC: data code
• ESN: engine serial number
• ECM CODE: software identification code

Engine 1
Fuel supply
Removing and installing injectors
DANGER
The high operating pressure of up to 1600 bar can
cause serious injury.
Once the engine has been switched off, wait 30 se-
conds before carrying out any work on the fuel system.
ENVIRONMENT NOTE
Collect escaping consumables in suitable con-

tainers and dispose of them in accordance with
applicable regulations.
Special tools required

• High-pressure connection removal tool,
Cummins part number 3164025
• Injector extractor,
Cummins part number 3823024
Removing injectors
¾ Remove the high-pressure fuel lines from the
rail and the high-pressure connection. Re-
move the mounting screws from the support
mountings and release the fastening nut on
the line.
¾ Do not remove support mountings and insula-
tors from the fuel line.
¾ Remove high-pressure fuel lines.
¾ Remove high-pressure connections from the

cylinder head. Install the fuel line connector
removal tool (3164025).
NOTE
When removing a high-pressure connection, be

careful not to damage the O-ring.

¾ Remove valve covers, and also remove the
clips from the breather hose between the valve
cover and the transmission housing.
¾ Clean the attachment points of the valve cover
and remove mounting screws.
¾ Remove the valve cover.
¾ Remove the exhaust rocker levers.

⇒ Chapter "Checking rocker levers and
pushrods", P. 1-52
¾ Remove the electrical connection from the

solenoid valve.
¾ Undo the two mounting screws of the injector
support and remove the support.
¾ Remove the injector, either with the injector
extractor (3823024) or prise it out at the at-
tachment flange directly above the cylinder
head.
¾ Clean injector tip and housing with a soft clean

rag.
NOTE
To avoid damage, do not use a steel brush or

similar.

1 Engine
¾ Fit exhaust manifold and new seals.

¾ Tighten fixing screws in the correct tightening
sequence, tightening torque: 43 Nm.
¾ Fit the turbocharger, see ⇒ Chapter "Re-
moving, installing and checking the tur-
bocharger", P. 1-30.

1 Engine
¾ First tighten by hand to ensure that the mount-
ing screws are tightened evenly. Then tighten
alternately by 90° up to a torque of 8 Nm.
The distance between the support and the in-
jector must then be the same over the entire
housing.
¾ Fully tighten the fastening nut of the high-pres-
sure connection, tightening torque of 50 Nm.
¾ Tighten the electrical connection on the sole-

noid valve, tightening torque of 1.5 Nm.
NOTE
Check the position of the connection cables.

When installed, they must not touch the rocker
levers.
¾ Install exhaust rocker levers and adjust the
valve clearance.
¾ Install the valve cover. If the valve cover seal
has been removed, a new one must be used.
Tightening torque 10 Nm.
¾ Reattach the breather hose.
¾ Attach the high-pressure fuel line to the rail and
the high-pressure connection. First slacken
the rail mounting screws. Do not remove the
rail. After the new fuel line has been con-
nected, the rail can be correctly aligned by
slackening the mounting screws.
¾ Connect the high-pressure fuel line and tighten
by hand.
¾ Tighten the high-pressure fuel line mounting
screws, tightening torque 35 Nm.
¾ Tighten the mounting screws of the support
mountings on the high-pressure fuel line, tight-
ening torque 24 Nm.
¾ Tighten the rail mounting screws, tightening
torque 24 Nm.
¾ Allow the engine to idle and check for leaks.
Checking the fuel supply

If the fuel supply is inadequate, perform the fol-
lowing check.
¾ Carefully clean the high-pressure pump and
the area around it.

Engine 1
The electronic EFC actuator (1) for fuel metering
is located on the high-pressure pump.
¾ Remove the cable connector from the EFC
actuator.
¾ Measure the resistance of the EFC actuator:

the maximum resistance is 5 .
¾ After measuring, reattach the cable connector.
Measure the flow volume of the high-pressure
pump as follows:
¾ Remove the high-pressure line that runs to the
rail from the high-pressure injection pump.
¾ Connect a transparent hose to the outlet of the

high-pressure injection pump and feed into an
empty bucket.
¾ Switch on the ignition.
¾ Actuate the engine starter motor for 30 sec-
onds and measure the flow volume of the
high-pressure pump.
The minimum flow rate is:

• 75 ml in 30 seconds at 125 rpm,or
• 90 ml in 30 seconds at 150 rpm.
If the minimum throughput is not reached, the
high-pressure pump is defective and must be
changed.
If the minimum throughput is reached, the EFC
actuator is defective.
Removing and installing the EFC actua-

tor
Removing the EFC actuator
actuator.

1 Engine
¾ Release and remove the three mounting
screws of the EFC actuator.
¾ Pull the EFC actuator out with an upward turn-
ing movement.
Installing the EFC actuator
NOTE
When installing a new EFC actuator, always fit a

new O-ring.
¾ Lubricate the new O-ring with clean oil before
inserting.
¾ Push home the EFC actuator with a turning
movement until it is flush with the mounting
surface.
¾ Insert mounting screws and tighten in two
steps. The EFC actuator must be flush with
the mounting surface.
CAUTION
Insufficient tightening torque could result in leaks or
engine damage.
No more than 2 minutes may elapse between tighte-
ning steps 1 and 2, otherwise the mounting screws
cannot hold their tightening torque.
¾ Step 1: Tightening torque 3 Nm.

¾ Step 2: Tightening torque 7 Nm.
¾ Attach the cable connector to the EFC actua-
tor. Ensure proper connection.
¾ Allow the engine to idle and check for any leaks
or error codes.
Removing and installing the high-pres-

sure pump
Removing the high-pressure pump
ENVIRONMENT NOTE
Collect any escaping fuel and dispose of it in

accordance with applicable regulations.

Engine 1
¾ Remove the high-pressure line between the
high-pressure pump and the rail, and release
the fastening clips while restraining the high-
pressure pump connection. This prevents the
connection from being released and causing a
leak.
actuator on the high-pressure pump.
¾ Remove the three high-pressure pump fasten-

ing nuts.
¾ Remove the high-pressure pump from the
transmission housing.
¾ Visually inspect the drive shaft and gear for

damage. Change if there is any damage.
¾ Check the O-ring for damage. Change if there
is any damage.
¾ Check the area around the O-ring for damage.
Clean, and remove any burrs.
¾ Check the gear housing, the high-pressure-
pump mounting bore and the fastening bolts
for cracks.
Installing the high-pressure pump

¾ Mount the high-pressure pump on the guide
bolts at the transmission housing and tighten
the fastening nuts. Tightening torque: 25 Nm.
NOTE
Adjustment of the high-pressure pump on the

crankshaft is not required.

1 Engine
¾ Fit the high-pressure line between the high-
pressure pump and the rail, and tighten the
fastening clips while restraining the high-pres-
sure pump connection to avoid overtightening.
Tightening torque: 30 Nm.
NOTE
It is not necessary to bleed the high-pressure part

of the fuel system before the engine starts. The
fuel system is filled when the engine starts.
¾ Attach the cable connector to the EFC actua-
tor. Check that the connection is perfect.
Removing and installing the rail
DANGER
The high operating pressure of up to 1600 bar can
cause serious injury.
Once the engine has been switched off, wait 30 se-
conds before carrying out any work on the fuel system.
CAUTION
Even tiny amounts of dirt can cause the fuel system to
fail.
When working on the fuel system, ensure that it is
completely clean. Carefully clean the area around
the relevant components. Blow dry damp areas with
compressed air. Observe safety regulations and coun-
try-specific regulations when handling fuels. All con-
nections should be sealed immediately with new, clean
sealing plugs / locking caps after they have been ope-
ned. Do not remove these again until immediately
before assembly.
ENVIRONMENT NOTE
Collect escaping consumables in suitable con-

tainers and dispose of them in accordance with
applicable regulations.
Removing the rail
NOTE
Note the position of the high-pressure fuel lines.

They must be reinstalled later at the same place.

Engine 1
¾ Remove the high-pressure fuel lines from the
rail and from the high-pressure connection.
Remove the mounting screws on the support
mountings and slacken the fastening nut on
the line.
¾ Do not remove support mountings and insula-
tors from the fuel line.
¾ Remove the high-pressure fuel lines.
¾ Remove the fuel pressure sensor plug.
¾ If necessary, remove the fuel pressure sensor.
NOTE
A fuel pressure sensor that has been removed

must not be reinstalled. It should therefore only
be removed if it is to be changed.
¾ Remove the fuel return line (1) of the pressure

relief valve from the rail. Release the quick-
release coupling by pressing the white latch
down.

1 Engine
¾ If necessary, remove the pressure relief valve.
¾ Remove the high-pressure line between the

rail and the high-pressure pump from the rail.
The line does not have to be removed com-
pletely.
¾ Slacken the mounting screws and remove the

rail.
¾ Visually check the fuel line connectors on the
rail for cracks and scratches.
¾ Visually check the high-pressure lines for dam-
aged sealing faces.
Installing the rail

¾ Fit the rail and tighten the mounting screws by
hand.
¾ Connect the high-pressure fuel lines and
tighten by hand.
¾ Tighten the high-pressure fuel line mounting

screws, tightening torque 35 Nm.
¾ Tighten the mounting screws of the support
mountings on the high-pressure fuel line, tight-
ening torque 24 Nm.
¾ Tighten the rail mounting screws, tightening
torque 24 Nm.
¾ Insert and tighten a new fuel pressure sensor,
tightening torque 70 Nm.
¾ Attach the fuel pressure sensor plug, making
sure that the connection is perfect.
¾ Check and clean the sealing face between the
rail and the pressure relief valve.

Engine 1
¾ Screw on the pressure relief valve and tighten,
tightening torque 100 Nm.
CAUTION
Overtightening of the pressure relief valve can cause
leaks.
Apply correct tightening torque.
¾ Allow the engine to idle and check for leaks.
Engine block
Removing and fitting the V-ribbed belt
1 Air inlet 8 Water pump

2 Fan drive 9 Starter motor
3 Electronic control module 10 Tensioner for V-ribbed belt
4 Engine speed sensor 11 Three-phase alternator
5 Camshaft sensor 12 Coolant outlet
6 Fuel filter 13 Coolant temperature sensor
7 Vibration damper 14 Turbocharger air outlet

1 Engine
Removing the V-ribbed belt
¾ Swivel the tensioning pulley away from the
V-ribbed belt using a compass wrench.
CAUTION
The tension lever may crack or break if too much pres-
sure is applied.
Swivel the tensioning pulley only as far as the stop
position.
¾ Remove the V-ribbed belt.

¾ Clean the tensioning pulley and check for dam-
age.
Fitting the V-ribbed belt

CAUTION
The tensioner can be damaged if turned in the wrong
direction.
The tensioner is under spring tension and must be
turned away from the V-ribbed belt.
¾ Guide the V-ribbed belt along the engine while

releasing the water pump belt pulley.
¾ Turn the tensioner and raise the V-ribbed belt;
finally push the belt onto the belt pulley of the
water pump.
¾ Release the tensioner to apply tension to the
V-ribbed belt.
¾ Check that the V-ribbed belt is seated cor-
rectly.
¾ Start the engine and check that the belt runs
correctly. Loud squeaking indicates belt slip-
page.
Removing and installing the exhaust

turbocharger
Removing the exhaust turbocharger
¾ Remove the oil supply line from the oil filter
(1). Restrain the oil filter connection so that the
connection does not become released from
the oil filter.
¾ Remove the oil supply line from the exhaust
turbocharger housing (2).

Engine 1
¾ Remove the oil return line mounting screws of
the exhaust turbocharger.
¾ Pull the oil return line out of the pipe connection
at the cylinder block.
¾ Remove the exhaust pipe from the tur-

bocharger.
¾ Remove the air inlet from the turbocharger.
¾ Remove the outlet manifold, V-band clamp

and O-ring at the compressor outlet of the ex-
haust turbocharger.
WARNING
The exhaust turbocharger weighs more than 23 kg.
Use a hoist.
¾ Remove the four exhaust turbocharger fasten-

ing nuts.
¾ Remove the exhaust turbocharger and seal.
Installing the exhaust turbocharger

¾ Apply a thin film of high-temperature parting
compound to the fastening bolts of the exhaust
turbocharger.
¾ Fit a new seal to the exhaust turbocharger.
CAUTION
Use of the wrong seal can result in damage to the ex-
haust turbocharger.
Ensure that the new seal is identical to the one that was
removed.
¾ Mount and tighten the four fastening nuts.

Tightening torque 43 Nm, measured with part-
ing compound.

1 Engine
¾ Install the outlet manifold, V-band clamp and
new O-ring at the compressor outlet of the
exhaust turbocharger.
¾ If necessary, turn the exhaust turbocharger
housing to mount the inlet pipes.
NOTE
Use a locking ring or release the clamp to make

the required settings.
¾ Mount the exhaust pipe and tighten the clamp.
¾ Tightening torque of all clamps: 8 Nm.
¾ Fit the oil return line. Lightly oil the oil return
line O-rings.
¾ Clean all sealing faces and ensure that they
are free from contamination and foreign mat-
ter.
¾ Press the oil return line into the pipe connec-
tion on the cylinder block. Both O-rings must
sit right inside the bore.
¾ Insert the mounting screws for the oil return
line at the exhaust turbocharger with a new
seal and tighten, tightening torque 23 Nm.
¾ To lubricate the exhaust turbocharger bear-
ings, pour 60 to 90 cm3 of clean engine oil
(15W-40) into the exhaust turbocharger oil in-
let.
¾ Turn the turbine wheel so that the oil can flow
into the bearing housing.
¾ Attach the air inlet and tighten the clamp.
When installing the oil supply line, only use new
copper sealing washers.
¾ Install the oil supply line at the oil filter (1) and
the exhaust turbocharger housing (2), tighten-
ing torque 28 Nm.

Engine 1
Removing, installing and checking the
exhaust manifold
• Flat scraper
• Feeler gauge
• Knife edge
Removing the exhaust manifold

¾ Remove the turbocharger, see ⇒ Chap-
ter "Removing and installing the exhaust
turbocharger", P. 1-46.
¾ Undo the mounting screws.
¾ Remove the exhaust manifold and seal.
Checking the exhaust manifold

¾ Clean the sealing surfaces on the cylinder
head and exhaust manifold.
NOTE
With two-part exhaust manifolds, the sealing con-

nection must be separable. Change the exhaust
manifold if the connection cannot be separated.
¾ Clean the two-part manifold connection.
¾ Check exhaust manifold for cracks and dam-
age.
¾ Check the exhaust manifold for distortion.
The maximum permitted distortion of 0.2 mm
must not be exceeded.

1 Engine
Installation
¾ Fit exhaust manifold and new seals.
¾ Tighten the mounting screws in the correct
tightening sequence, tightening torque:
43 Nm.
NOTE
To facilitate alignment of the exhaust manifold,

two screw bores have a smaller diameter than
the other bores. The screws in the smaller bo-
res must be tightened first; the remaining screws
should then be tightened in the specified se-
quence.
¾ Fit the turbocharger, see ⇒ Chapter "Re-
moving and installing the exhaust tur-
bocharger", P. 1-46.
Removing and installing the valve cover

Removing the valve cover
¾ Release the breather pipe for crankcase
breathing at the valve cover. Remove the
mounting screws from the valve cover.
NOTE
The oil return line (1) is integrated in the breather

pipe.
¾ Pull the breather pipe straight up out of the
gear housing.
¾ Dismantle the valve cover. To do so, clean the

valve cover attachment points and remove the
mounting screws.
¾ Remove the valve cover.
Installing the valve cover

¾ Tighten the mounting screws, tightening
torque 10 Nm.

Engine 1
¾ Check the breather pipe O-rings and change if
damaged.
¾ Lightly oil the O-rings.
¾ Guide the breather pipe into the gear housing
until it engages.
¾ Secure the breather pipe to the valve cover
with mounting screws, tightening torque
10 Nm.
Adjusting the valve clearance
NOTE
Adjustment of the valve clearance is only neces-

sary as part of regular maintenance or after work
has been carried out on the rocker levers.

• Feeler gauge
• Cummins turning tool, part number 3824591
Prerequisites
• Coolant temperature below 60°C
• Valve cover removed
Adjusting the valve clearance

¾ Using turning tool 3824591, position the en-
gine with cylinder 1 at top dead centre.
¾ To do this, turn the TDC mark on the flywheel

to the 12 o’clock position while ensuring that
there is adequate clearance for the intake and
outlet valves on cylinder 1.
¾ If there is no clearance, turn the crankshaft
360° and continue.

1 Engine
With the engine in this position, check the valve
lash for the following valves and adjust
as necessary:
Lash values: E = 0.508 mm, 0.020”
Lash values: I = 0.254 mm, 0.010”
(E = Exhaust, I = Intake)
1I, 1E, 2I, 3E, 4I and 5E.
Using turning tool 3824591, turn the crank-

shaft 360° and check the valve clearance for
the following valves and adjust as necessary:
(E = Exhaust, I = Intake)
2E, 3I, 4E, 5I, 6I and 6E.
NOTE
After adjusting, tighten the lock nut with a tighte-

ning torque of 24 Nm.
Checking rocker levers and pushrods

• Inside dial gauge
• Outside dial gauge
Removal
Slacken the lock nut and undo the adjustment
screw as far as the stop.
Slacken mounting screws, remove rocker

lever and mark for correct installation.

Engine 1
¾ Remove valve crossheads. Mark position and
alignment for correct installation.
¾ Remove tappet rod and mark for correct instal-

lation.
Checking the rocker lever

¾ Disassemble the rocker lever into its compo-
nent parts and clean with cleaning agent and a
brass brush.
NOTE
The bush at the rocker lever tip must not be remo-

ved. If there is any damage, the complete rocker
lever must be changed.
¾ Check the rocker lever components for cracks
and wear.
¾ Measure the inside diameter of the bore in the

rocker lever.
Maximum bore diameter: 22.03 mm

1 Engine
¾ Measure the outside diameter of the rocker
lever shaft.
Minimum outside diameter: 21.96 mm
Checking the pushrods

¾ Clean the pushrods with cleaning agent.
¾ Check both ends of the pushrods for excessive
wear.
¾ Check pushrods by rolling them on a level

surface. They must not be bent.
CAUTION
Bent pushrods cause engine damage.
¾ Do not straighten bent pushrods; change them.
Assembling rocker levers

¾ Lightly oil and reassemble the rocker lever
components.
CAUTION
Incorrectly assembled rocker levers cause engine da-
mage.
¾ Make sure that the intake (2) and exhaust rocker
levers (1) are installed at the correct position.
Installation
¾ Oil the pushrods and place them at the correct
locations.
¾ Insert the valve crossheads so that they are
correctly allocated and aligned.

Engine 1
¾ Place the rocker levers at the correct locations
and tighten the mounting screws; tightening
torque: 36 Nm.
¾ Adjust the valve clearance.
Removing, installing and checking the

cylinder head
Removing the cylinder head

¾ Disconnect the battery.
¾ Drain coolant and disconnect all hose connec-
tions to the cylinder head.
¾ Remove exhaust turbocharger.
¾ Remove exhaust manifold.
¾ Remove valve cover.
¾ Remove rocker levers and pushrods.
¾ Disconnect the fuel return line (1) from the
pressure relief valve on the rail. Release the
quick-release coupling by pressing the white
latch down.
¾ Disconnect the fuel return line (2) on the back
of the cylinder head from the connection piece
(3). Release the quick-release coupling by
pressing the white latch down.
NOTE
The connection piece (3) contains a non-return

valve to retain the prescribed counterpressure.
¾ Remove the rail with high-pressure fuel lines,
⇒ Chapter "Removing and installing the
rail", P. 1-42

1 Engine
¾ Remove high-pressure connections from the
cylinder head. To do so, install the fuel line
connector removal tool (3164025).
NOTE
When removing a high-pressure connection, be

careful not to damage the O-ring.
¾
CAUTION
When removing the cylinder head with fitted injectors,
the tips of the injectors could be damaged.
When setting down a cylinder head fitted with injectors,
ensure that the side of the combustion chamber is not
facing downwards.
¾ Slacken the cylinder head screws in the speci-

fied sequence.
¾ Remove cylinder head.
WARNING
The cylinder head weighs more than 23 kg.
Use a hoist.
¾ Remove cylinder head seal.
¾ Clean the sealing surfaces on the cylinder

head and cylinder block.

Engine 1
Checking the cylinder block
¾ Check that the cylinder block is flat.
The maximum permitted distortion of 0.075 mm
must not be exceeded.
Checking the cylinder head

¾ Check the cylinder head for cracks.
The cylinder head can continue to be used pro-
vided that any cracks between the injector and
the valve seat do not extend into the valve seat
itself.
¾ Check that the cylinder head is flat.

The maximum permitted longitudinal distortion of
0.305 mm must not be exceeded.
The maximum permitted lateral distortion of
0.076 mm must not be exceeded.
¾ Measure the projection of the injectors.

¾ To do this, attach a depth gauge and turn so
that it measures the projection of the injectors
at their highest point.
Permissible range: 2.45 to 3.15 mm
¾ If the projection is not within the prescribed
range, check the thickness of the injector seal-
ing washer.
NOTE
The projection of the injectors must not be cor-

rected using thicker or double sealing washers

1 Engine
as this would result in incorrect alignment of the
high-pressure fuel connector.
Installing the cylinder head

¾ Fit a new cylinder head seal.
¾ Carefully position the cylinder head.
WARNING
The cylinder head weighs more than 23 kg.
Use a hoist.
¾ Oil the cylinder head bolts then insert and

hand-tighten them.
¾ Tighten the cylinder head bolts in the correct

tightening sequence.
Tightening sequence:
• Step 1: 90 Nm
• Step 2: 90 Nm (monitor)
• Step 3: + 90°

Engine 1
¾ Attach the high-pressure connections to the
cylinder head. Lightly oil the O-ring of the
high-pressure connection and thread of the
prevailing torque nut.
NOTE
Only attach the high-pressure connections if the

injectors have been installed and tightened to the
prescribed torque.
¾ Carefully insert the high-pressure connection.
The guide ball must be aligned with the slot in
the cylinder head at the 12 o’clock position.
NOTE
When fitting, apply equal axial pressure to avoid

damage. Do not pull on the O-ring.
¾ Tighten the prevailing torque nut of the high-
pressure connection, tightening torque 50 Nm.
¾ Install the rail with high-pressure fuel lines.
⇒ Chapter "Removing and installing the
rail", P. 1-42
¾ Screw in connection piece (3) with non-return
valve and tighten, tightening torque 24 Nm.
¾ Secure the fuel return line (2) to the connec-
tion piece and secure fuel return line (1) to the
pressure relief valve. Lock the line in position
by pulling out the white latch.
¾ Fit the rocker levers and pushrods.
¾ Adjust the valves.
Tightening torque 10 Nm.
¾ Reattach the breather hose.
¾ Fit the exhaust manifold.
¾ Install the exhaust turbocharger.
Removing, installing and checking

valves
• Inside dial gauge
• Outside dial gauge
• Compressor for valve spring, Cummins part
number 3164329
Removing valves
¾ Remove the cylinder head.

1 Engine
¾ Remove the injectors.
¾ Before removing the valves, mark them to
ensure that they are reinstalled correctly.
¾ Position the bottom part of the valve compres-

sor 3164329 over the injector opening and
tighten the mounting screws in the bores for
the injector support, tightening torque 5 Nm.
¾ Mount the plate (1) of the valve compressor

on the bolt (4) and align the openings with the
valve springs.
NOTE
The valves are not arranged at an equal distance

from the injector bore. Carefully align the plate
with the openings.
¾ Fit the flat washer (3) and nut (2).
DANGER
Eye injuries can be caused by valve springs which can
fly through the room like projectiles.
Wear industrial goggles with side protection.
¾ Compress the valve springs by turning the nut

(2) clockwise .
¾ Turn the nut (2) until the valve collets can be
removed with a magnetic tool.
¾ Remove the valve collets and release and
remove the valve spring compressor.

Engine 1
¾ Release the valve springs and remove parts.
¾ Remove the valve stem seals. While doing so,

note the version and colour of the valve stem
seals to ensure that they are installed correctly.
¾ Remove the valves. To ensure that they are
installed correctly, store the valves together
with the accompanying valve collets, spring
plates and springs.
Checks
¾ Check the valve stem guide for wear and mea-
sure the inside diameter.
Setpoint value: 7.027 mm to 7.077 mm
Change the cylinder head if the inside diameter is
too large.
¾ Check valve seats for damage.

1 Engine
¾ Check valves for damage.
¾ Check the valve stem for damage and mea-

sure the diameter at the specified intervals.
Setpoint value: 6.96 mm to 7.01 mm
¾ Measure and note the installation depth (1) for

each valve.
Intake valve setpoint value: 0.584 to 1.092 mm
Outlet valve setpoint value: 0.965 to 1.473 mm
¾ Check valve is not bent.
¾ Measure the valve seat height to determine

whether regrinding is possible.
Min. valve seat height: 0.79 mm
¾ Grind in the valves if necessary.

Engine 1
¾ Check the valve springs for damage and mea-
sure them.
Length, untensioned: about 47.75 mm
Maximum tilt at upper spring coil: 1.5 mm
Installing valves
¾ Oil the valve stem and install valves in the cor-
rect position.
¾ Insert new valve stem seals while restraining

the valves by hand.
CAUTION
Incorrectly fitted valve stem seals may cause engine
damage.
Note the original installation position.
The following versions and colours are used:
(1): "Drive-On" seal

• Green for outlet valves
• Yellow for intake valves
(2): "Top-Hat" seal

• Green for outlet valves
• Yellow for intake and outlet valves

1 Engine
¾ Install the valve springs and compress with
valve compressor 3164329.
DANGER
Eye injuries can be caused by valve springs which can
fly through the room like projectiles.
Wear industrial goggles with side protection.
¾ Insert valve keepers.

¾ Release the valve springs and remove the
valve compressor.
¾ Strike the valves with a soft-faced hammer
to ensure that the valve keepers are seated
correctly.
Changing the oil sump seal

• Flat scraper
• Torque wrench 5–50 Nm
• Torque wrench 40 – 200 Nm
• Three-Bond
Removal
¾ Allow the engine to run at operating tempera-
ture until the coolant has reached a tempera-
ture of ≥ 60 °C.
¾ Place a suitable collection container (at least
20 l) under the oil drain plug.
WARNING
Risk of scalding when draining hot engine oil.
¾ Wear a protection suit!
¾ Unscrew the oil drain plug and drain the oil.

¾ Remove the oil sump.

Engine 1
¾ Check the oil sump, oil intake pipe and support
for damage; change if necessary.
Installation
¾ Seal connection points between the oil sump
and control housing and between the oil sump
and the shaft seal housing with sealant.
¾ Fit the oil sump with seal.
¾ Tighten all mounting screws in the specified

sequence, tightening torque 28 Nm.
¾ Screw in the oil drain plug, tightening torque:
60 Nm.
¾ Add new oil.

Drive axle 2
a
Description
Technical data for traction drive
Variable displacement pump

Manufacturer Linde
Model HPV 210 -02
Maximum delivery volume 210 cm3/U
Number of pistons 9
Piston diameter 27 mm
Maximum working pressure 420 bar
Feed and control pressure 27+ 1 bar
Swivel angle 0 - 20°
Pump speed 2100 rpm
Type of pump adjustment Electrohydraulic
Control of pump adjustment by Linde Truck Control (LTC)
Power transmission from internal combustion
Flexible coupling
engine
Variable motors
Manufacturer Linde
Model
HMV 280-02
Number of pistons 11 (HMV 280-02)
Swivel angle
5 - 19° (HMV 280-02)
Planetary transmission, ratio 14:1
Type of engine adjustment Electrohydraulic
Control of engine adjustment by Linde Truck Control (LTC)
Brake
Oil pressure multi-disc brake between the first and second gear range, enclosed
Tandem gear pump

Pumps V1 and V2 for feed, servo adjustment and
each q3 = 31 cm3/U
hydraulic fan drive

2 Drive axle
Description
Schematic view of the drive
1
A
2 B
4 C
10 9 8 7 7 8 9 10
11 11
359_02-005
1 Gear pumps (2 x 31 cm3) 8 Planetary transmission 1st stage (i = 2.959)

2 Internal combustion engine 9 Multi-disc brake
3 HPV 210-02 variable displacement pump 10 Planetary transmission 2nd stage (i = 4.738)
4 HPR 210-02 regulating pump 11 Drive wheels
5 Distributor plate A Feed
6 Hydraulic oil tank B Fan motor feed
7 HMV 280-02 variable motor C Working hydraulics

Drive axle 2
Description
Linde Truck Control (LTC)
Digital electro-hydraulic controller • Vehicle brakes via emergency function,
combustion engine switches off.
Trucks in the 318 range are industrial trucks
equipped with the latest control technology. In- • Error code appears on display.
stead of a hydraulic accelerator, all control func- These measures can be overridden by switching
tions for traction drive and operating hydraulic are off the combustion engine with the key switch.
assumed by a compact electronic controller with During restart, the control unit checks whether
two powerful micro controllers. the error is still present. If an error is no longer
present, the vehicle resumes normal operation.
Adaptation to various vehicles If the error persists, the error code re-appears on
the display and one of the above-listed measures
The electronic control units are able to control is initiated.
vehicles from various series and with different
traction engines. To take differing vehicle param-
eters into account, each vehicle cable harness Mechanical/hydraulic multi-disc brake
has a coding that uniquely identifies the vehicle. The brake is designed as a proportionally actu-
ated service brake and as a parking brake. It is
Troubleshooting mechanically/hydraulically actuated via a propor-
tional pressure regulation valve.
Each electronic control unit’s processor analyses
analogue and digital signals. It recognizes
illogical statuses and system errors and displays Exhaust valve
error messages on the testing instrument via The exhaust valve is a safety valve which ensures
the serial interface. In addition, the control unit that when a fault is detected, the variable pump
activates a variety of measures according to the pivots to zero (no more drive) and prevents the
potential error hazard: truck from starting at all. The valve closes when
• Warning light flashes. a travel direction pedal is pressed; it opens again
when the truck comes to a standstill.
• Combustion engine speed limitation.
• Vehicle brakes with normal braking retardation
and will no longer move.

2 Drive axle
Traction drive
Travel drive − introduction
Introduction
Driving speed controller The maximum variable displacement pump
delivery volume is 210 cm3.
The driving speed of a hydrostatic-powered vehi-
cle results from the speed of the internal combus- The minimum intake volume for the large variable
tion engine and the hydraulic transmission ratio motors (HMV 280-02) is 95 cm3.
(variable displacement pump delivery volume to
The difference in minimum intake volume is due
the intake volume of the variable motors).
to the combination of smaller variable motors with
The delivery volume of the variable displacement smaller wheel sizes. In order to achieve the same
pump results from the pump speed, the swivel maximum speed, the wheels have to rotate at
angle and the pump’s specific delivery volume. higher speed.
The intake volume in variable motors is deter- The power limiting controller permits only a
mined by the wheel speed, the swivel angle and limited level of combustion engine suppression.
the specific intake volume of the variable motors. If this level is exceeded, vehicle acceleration is
reduced.
The driver generates the signal for the required
driving speed by actuating the accelerator pedal. The reduction of vehicle acceleration during
small or slow combustion engine overload is
The control unit uses the signal to calculate a
achieved by modification of the variable motor
reference value for the combustion engine speed
intake volume.
required for achieving the driving speed.
If quick countermeasures are necessary, the
To select the required driving speed, the control
delivery volume of the variable displacement
unit applies an electric current to adjust the
pump is first reduced, while the intake volume
variable displacement pump and the variable
of the variable motors is set to the appropriate
motors. This current depends on the speed signal
value.
from the combustion engine.
Subsequently, the variable displacement pump
Different control situations with different pedal
delivery volume is reset to the maximum value.
positions are explained in the following.
The transmission ratio of variable displacement
pump to variable motors is kept constant during
Maximum acceleration from standstill to full
load adjustment.
speed
Combustion engine speed is increased and the Retardation and braking
variable displacement pump begins to alter its
swivel angle to maximum delivery volume. By lifting the accelerator pedal and/or pressing
the brake pedal, a desire to decelerate is trans-
As soon as the variable displacement pump has mitted to the controller.
reached the maximum swivel angle, the variable
motors start to reduce their swivel angle in order The braking torque on the wheel, i.e. the level of
to further increase the gear wheel speed, and retardation, results from differential pressure on
thus the driving speed. the variable motors and the variable motor intake
volume set by the controller.
To ensure maximum efficiency and thus an
acceptable level of noise from the complete drive For the controller to be able to set the desired
system, the combustion engine is not allowed level of retardation and/or the correct swivel angle
to reach its maximum speed of 2100 rpm, but on the variable motors, it is necessary to know the
remains for a long time at 1600 rpm. Maximum exact vehicle mass (including load).
torque is already available at this speed.
Total vehicle weight comprises the following:
Once the hydraulic units have reached their max- • The tare weight of the truck without the mast
imum adjustment values, any further increase in (defined in the traction control software and
driving speed is achieved by an increase in com-
bustion engine speed.

Drive axle 2
Traction drive
depends on the truck detected via the coding With the regulating pump, this secondary hy-
plug) draulic system produces a braking torque on the
• The weight of non-moving lift mast compo- internal combustion engine that protects the en-
nents (programmable in the traction control gine from over-revving.
software) The braking energy is converted to heat energy
• The recognised load weight. The controller by heating the hydraulic oil in the retarder valve
recognises this via the two load pressure (pressure relief valve) and transferring it to the
sensors. (The second load pressure sensor radiator, where the heat is discharged into the
prevents incorrect measurements from the environment.
first load pressure sensor.) However, it is
The excess volume flow (approx. 750 l/min)
necessary to define the correct lift cylinder
that is generated by the variable motors and not
diameter in the software first. (The adjustment
absorbed by the variable displacement pump
is made via the diagnostic software.)
must be released via the pressure relief valve of
The moving vehicle’s total weight is calculated the traction hydraulic circuit. In the course of this
from these three items of information. process the hydraulic traction circuit is heated up.
The energy (the hot oil) is transported out of the
DANGER traction circuit via an outfeed. The hydraulic oil
Risk of accident! can then discharge its energy to the environment
An incorrect total weight value leads to an unexpected
in the radiator.
retardation curve. At the later retardation stage, the variable motor
volume flow is reduced, so that the variable
Reduction of the current accelerator pedal po- displacement pump remaining in maximum
sition, which is intended to result in a slower volume flow setting is able to absorb the entire
required driving speed, is sensed by the trac- volume flow.
tion controller. A specific level of retardation is
calculated from an actual value/reference value The variable motors deliver less than 400 l/min.
comparison between current and required driving The remainder of the braking process to vehicle
speeds. standstill can be achieved by reducing the vari-
able displacement pump advance angle.
In order to achieve the required level of driving
speed retardation, the required swivel angle of This phase, during which the switchover from
the variable motors is set. torque-controlled to transmission-controlled
retardation takes place, is critical for the driving
In order to ensure a precisely matched level of process and the braking distance.
retardation that is neither too high nor too low,
it is necessary to achieve the requested swivel To prevent a "drop" in the retardation curve, it
angle quickly and correctly, based on the fact that is essential that the transition point, at which
the maximum possible pressure in the system is the volume flow is no longer released via the
always 420+30 bar. pressure relief valve, exactly matches the point
at which the pump starts changing its advance
Due to the adjustment of the variable motor swivel angle.
angle, an increase in volume flow via the variable
motors occurs during braking. Retardation must take place as accurately as
calculated, which can only be achieved by exact
To enable a maximum level of oil volume flow to adjustment of the variable motor stroke volume.
be absorbed by the variable displacement pump,
the pump is set to an almost maximum swivel The remaining retardation is carried out exclu-
angle, which causes the internal combustion sively by reducing the volume flow on the variable
engine to accelerate. displacement pump.
This is necessary to extract as much brake The retarder function of the regulating pump de-
energy out of the drive system as possible. scribed above is not a direct part of the intended
braking process, but acts as a safety feature that
Due to the internal combustion engine’s reduced protects the internal combustion engine from
capacity to absorb only a maximum of 40 kW of over-revving.
the total required braking power of 500 kW, the
regulating pump and the retarder valve must be Retardation itself is exclusively defined by the
used as a retarder (hydraulic brake). current speed of the internal combustion engine,
the variable displacement pump volume flow and
the intake volume of the variable motors.

2 Drive axle
Traction drive
It is an independent control system that reacts The retarder function pressure always exceeds
to excessive engine speed that is determined by the working hydraulic pressure, so that the
actual value/reference value comparison of the working hydraulic always remains the first user of
combustion engine speed, a pre-calculated value the working hydraulic system.
for total vehicle weight, and the required level of
The volume flow via the retarder valve is only
retardation.
increased if an additional load is required on the
If excessive combustion engine speed is de- pump shaft.
termined, the retarder valve is actuated by the
The pressure regulation valve for the retarder
activation of a required volume flow at a minimal
function operates independently of the required
pressure of 100 bar.
retarder power in a pressure range of between
The volume flow and pressure can be increased, 80 and 367 bar.
if necessary.
Pressure in the retarder valve can exceed operat-
The retarder function pressure must always ing hydraulic pressure, as all operating hydraulic
exceed the current working hydraulic pressure. and steering control valves have pressure equal-
ization functions.
The working hydraulic pressure signal is sensed
by a pressure sensor that is located in the LS On the other hand, the retarder valve has no
line between the working hydraulic valve and the retarder flow pressure equalization function.
retarder valve.

Drive axle 2
Traction drive
Variable displacement pump controller
The variable displacement pump is fitted with an pump in one or the other direction, in proportion
"E2 controller" consisting of two proportional to the applied current.
pressure regulating valves and an ON/OFF
The working range of the variable displacement
solenoid valve.
pump lies between 435 mA at the start of variation
The ON/OFF solenoid valve is a safety valve and 1200 mA at maximum advance angle.
(release valve) that, if not activated, completely
If the current at the proportional pressure regu-
disables activation of the variable displacement
lating valves or at the ON/OFF solenoid valve is
pump. The proportional pressure regulating
switched off, the working pump returns to zero
valves are switched off and the variable displace-
delivery as quickly as possible in order to prevent
ment pump is set to zero delivery. This brings the
torque being applied back to the diesel engine
truck to a standstill.
and the engine overspeeding.
Either of the two proportional pressure regulating
valves can activate the variable displacement
Motor variables controller

The HMV 280-02 motor variables are fitted The minimum intake volume for the
with an "H3 controller" that is hydraulically HMV 280-02 motor variables:
activated.
• HMV 280-02 motor variable it is 95 cm3
The control pressure is directly proportional to at approx. 15.3 bar.
the motor variables advance angle. The motor
The hydraulic signal used to reduce the pump
variables start with a zero signal at maximum
advance angle is generated as a subfunction
advance angle.
in the brake release valve by a proportional
The controller starts to adjust the motor variables pressure regulation valve.
towards Vmin at approx. 4 bar p (control
The valve setting is 4.0 bar p at a current of
pressure to tank pressure).
690 mA.
The minimum intake volume is achieved at a
control pressure of approx. 15 bar.
In emergencies, the driver can push the pedal

Pedal group
further (2nd segment of pedal travel) and activate
The pedal group comprises a central brake pedal a brake cable that actuates a mechanical pro-
and either one or two accelerator pedals. portional pressure regulating valve in the brake
release valve.
The brake pedal is designed to provide increased
braking action with increasing brake pedal travel. The brake release valve proportionally actuates
the spring-loaded multi-disc brakes in both wheel
The pedal travel is divided into two segments
drives.
(75 %/25 %). The first section merely generates
an electric signal that influences the electronic By reducing the release pressure, a mechanical
brake controller. The signal is used for remote brake is actuated that produces braking torque.
control of the hydraulic components and acts as This function is proportional to the second seg-
a service brake. ment of brake pedal travel and can be controlled
by the driver as necessary.
NOTE Since the force needed to actuate the brake pedal
is relatively high, there is a second, independent
The braking effect of the first pedal travel section control valve in the brake release valve that is
is equivalent to the reverse braking effect. used for the parking brake. Actuation of this valve
Once the end of the first pedal travel section has is based on an on/off function.
been reached, the driver notices an increase in
pedal counterforce.
2 Drive axle
Traction drive
To enable emergency use, it is possible to re- In order to fully achieve the towing condition,
lease the parking brake without having to start a hydraulic short circuit between forwards and
the diesel engine. For emergency use, a valve reverse is required.
inside the brake release valve must be rotated
This is achieved by opening the choke plunger in
by 90° and the steering wheel must be turned by
the HPV 210-02 variable displacement pump.
approx. two rotations in one direction.
The truck can then be towed.
Use of the steering as a hand pump generates
the necessary release pressure and flow for
releasing the parking brake.

Drive axle 2
Traction drive
Variable displacement pump
HPV 210-02 variable displacement pump
Mp 1
1
2 3 4 5
210
1Y3 A B
1Y2 1Y4 vorwärts rückwärts
L1
Z 7
6 6
T1
Y T3
vorwärts rückwärts
U1 Y Z
Ms
23+0.5 bar
1 420 bar 8
12 11 9
11 10 10 d=1,5
F
S1 P1
13
359_02-027
1 HPV 210 -02 variable displacement pump 10 Feed valves

2 Proportional pressure regulation valve for- 11 Pressure relief valve 420 bar
wards 1Y2 12 Servo piston Y = forwards, Z = backwards
3 1Y4 release valve 13 Shorting plunger
4 Proportional pressure regulation valve back- Mp1/Ms1 Test connectors
wards 1Y3 T1/U1/L1 Leak oil connection
5 Set piston, A = forwards, B = backwards T3 Brake cooling connection
6 2/2 solenoid valve F Feed pressure
7 2/2 solenoid valve, stuck open P1/S1 High pressure/low pressure connection
8 Feed pressure valve, p = 23+0.5 bar Y Forward control pressure test connector
9 Pilot valve Z Backwards control pressure test connector

2 Drive axle
Traction drive
T1 14
13
T3
11
U1 Mp 1 359_02-016
8 Feed pressure valve, p = 23+0.5 bar T1/U1 Leak oil connection

11 Pressure relief valve 420 bar T3 Brake cooling connection
13 Shorting plunger F Feed pressure
14 Servo cover Mp1 Test connector

Drive axle 2
Traction drive
10
11
L1
P1
S1
359_02-034
10 Feed valves P1/S1 High pressure/low pressure connection

11 Pressure relief valve 420 bar L1 Leak oil connection

2 Drive axle
Traction drive
24 17
18
23
22 21 20 19 359_02-035
17 Main piston 21 Holding plate

18 Port plate 22 Pull-back plate
19 Cylinder block 23 Shaft
20 Plain coupler 24 Cradle

Drive axle 2
Traction drive
21 20 25 5
26
U1 359_02-036
5 Actuator piston 25 Compression spring

20 Plain coupler 26 Sealing ring
21 Holding plate U1 Leak oil connection

2 Drive axle
Traction drive
Electro-hydraulic remote control
1 2
A
4 4
T1
1 Proportional pressure regulation valve for- 7 Servo piston Y = forwards, Z = reverse

wards 1Y2 A Cradle variation pressure forwards
2 1Y4 release valve B Cradle variation pressure reverse
3 Proportional pressure regulation valve T1 Leak oil connection
reverse1Y3 F Feed pressure
4 2/2 solenoid valve Y Forward control pressure test connector
5 2/2 solenoid valve, stuck open Z Reverse control pressure test connector
6 Pilot valve
Drive axle 2
Traction drive
11 12 7 6
10
9
1
2
359_02-013
1 Proportional pressure regulation valve for- 7 Servo piston

wards 1Y2 8 Locknut
2 1Y4 release valve 9 Swivel angle adjusting screw
3 Proportional pressure regulation valve back- 10 Start of regulation adjusting sleeve
wards 1Y3 11 Locking plate
5 2/2 solenoid valve, stuck open 12 Control springs
6 Pilot valve

2 Drive axle
Traction drive
Function characteristics Returning the accelerator pedal towards its zero
position has the effect of reducing the signal on
When the engine is running and the brake pedal
the corresponding proportional pressure regu-
is actuated, the release valve magnet (2) is
lation valve (1), (3) and reducing the pressure
de-energised.
on the servo piston (7). The swivel angle of the
The channel behind the release valve (2) is con- pump is reduced and the truck brakes.
nected to the oil tank, and is therefore depres-
If the electronic controller detects an error in
surised.
the speed regulation, the truck will be brought
In the same way as when an accelerator pedal is to a standstill irrespective of the position of the
pressed, the release valve(2) is first energised. accelerator pedal.
The feed pressure is transferred to the 2/2 sole-
This is done by de-energising the release valve
noid valves (4).
(2), causing the pressure to fall to 0 bar.
Depending on the direction of travel selected,
The 2/2 solenoid valves (4) switch to the blocked
the proportional pressure regulation valve for-
position and remove the supply pressure from the
wards 1Y2(1) or the proportional pressure regu-
proportional pressure regulation valves (1, 3).
lation valve reverse 1Y3 (3) is energised, and
as a result the corresponding channel from the This causes the actuated proportional pressure
2/2 solenoid valve (4) to the servo piston (7) is regulation valve (1), (3) to be mechanically
opened and the servo piston (7) is diverted to the pushed back to its initial position.
selected direction of travel.
The pressure on the servo piston (7) collapses.
Since the servo piston (7) is mechanically con- The piston is mechanically pushed to the zero
nected to the pilot valve(6), the latter is diverted position, taking the pilot valve (6) to the zero
accordingly. The feed pressure now applies a position as well.
control pressure to the actuator pistons of the
variable displacement pump and diverts the cra-
dle.

Drive axle 2
Traction drive
Variable pump advance start
Y
T1
13
11
1 10
2
9
3
14
15
359_02-014
1 Proportional pressure regulation valve for- Control start and swivel angle adjustment
wards 1Y2 9 Swivel angle adjusting screw
2 1Y4 release valve 10 Start of regulation adjusting sleeve
3 Proportional pressure regulation valve reverse 11 Lock plate
1Y3 13 Safety bolt
Y Forward control pressure test connector
Adjustment o f hydraulic z ro position
T1 Leak oil connection
14 Pilot housing
Z Backwards control pressure test connector
15 Safety bolt
Checking the variable pump control start

Test prerequisites:
• Truck jacked up
• 1 wheel blocked
• Lift mast limit switch has not tripped
CAUTION
The variable motor can be damaged!
Never press the accelerator pedal down fully if 1 wheel
is blocked, as over-revving may damage the variable
motor.
Start the engine and release the brake pedal.

Connect laptop and select "Inputs + out-
puts/Power module Traction/Voltages".
Press forward or reverse accelerator pedal
until 1Y2 or 1Y3 = 435+10 mA.
2 Drive axle
Traction drive
¾ Hold the accelerator pedal in this position with
1Y2 = 435+10 mA and release the safety bolt
(13). Then rotate the adjusting sleeve (10) until
the wheel just begins to rotate.
¾ Re-tighten the safety bolt (13).
¾ Perform the same adjustment at
1Y3 = 435+10 mA.
¾ Release the blocked wheel.
¾ Push the accelerator pedal all the way down,
"Currents" tab must show 1095 mA (deter-
mined by controller).
¾ Measure maximum wheel speed.
NOTE
The maximum wheel speed can only be reached

if the lift mast limit switch has not tripped.
The maximum speed is averaged from the speed
of both drive wheels.
Reference value n = 160-20 min-1.
Start of variation — diagram

1095
NOTE
If the electric values are correct, but the maximum

wheel speed is not reached, the servo piston’s
positioning travel (pump swivel angle) must be 359_02-028
checked and adjusted.
Q Volume flow
s Accelerator pedal travel
Adjusting the swivel angle of the pump I The release valve switches
II Start of rotation of drive wheels
Test prerequisites: II Maximum speed of drive wheels
• Truck jacked up
• 1 wheel blocked
¾ Start the engine and release the brake pedal.
¾ Release the safety bolt (13) on the Y side of the
remote control and screw in the adjustment pin
(9) until the free wheel just begins to rotate.
¾ Unscrew the adjustment pin (9) by 12 turns
and retighten the safety bolt (13).
¾ Repeat the same procedure on the Z side.
Adjusting the hydraulic zero position

Test prerequisites:
• Truck jacked up
• 1 wheel blocked
¾ Start the engine and release the brake.

Drive axle 2
Traction drive
¾ Determine the position of the pilot housing
(14). Do this by releasing the safety bolt (15)
and slightly turning the pilot housing (14) to
one side, until the free wheel begins to rotate.
¾ Repeat the process in the opposite direction.
¾ Measure the distance between the two posi-
tions, half it and turn the pilot housing (14) by
the precise resulting value to the middle.
¾ Block the pilot housing (14) with the safety bolt
(15).
¾ Release the blocked wheel.
If a drive wheel still rotates, repeat the adjust-
ment.
Variable pump delivery rate characteristics
100
50
2 0 2 4 6 8 10 12 14 16 18
3 435 ± 10 1095
359_02-015
1 Delivery volume (%)

2 Control pressure (bar)
3 Control current (mA)

2 Drive axle
Traction drive
Variable motor
Variable motor HMV 280-02
Basic design
2 3
E F
1
B
14 bar
U
X1 4
i=14
5
M1 280
95
min. max.
A p Bl 6
L
10 9 8 7
TL
359_02-023
9 Swivel angle locking mechanism, stuck open

1 Pilot valve 10 Control piston
2 3/3-way switch valve A High pressure
3 Output valve, p = 14 bar B Low pressure
4 Multi-disc brake X1 Control pressure
5 Wheel E Feed pressure
6 Reduction gear 1:14 L Leak oil connection
7 Brake piston U Outlet from cooling system
8 Variable motor HMV 280-02 TL Feed to cooling system

Drive axle 2
Traction drive
3 2
X1
L B 359_02-022
2 3/3-way switch valve B Low pressure

3 Output valve, p = 14 bar X1 Control pressure
A High pressure L Leak oil connection

2 Drive axle
Traction drive
11 12
15
14 13
359_02-030
11 Control piston
12 Cylinder block
13 Port plate
14 Cradle
15 Shaft

Drive axle 2
Traction drive
14
16
11
17
11 359_02-031
11 Control piston 16 Stop screw Vmax

14 Cradle 17 Stop screw Vmax

2 Drive axle
Traction drive
19
18
ZP
29 20
24
28 23
21 22
25
3
HM V 0 2
2
HP V 0 2
p-Vmax
p-Vmin
1
27
11
11
26 14
14
359_02-033
1 Pilot valve 21 Feed pressure valve p = 23+0.5 bar

2 3/3-way switch valve 22 Non-return valve
3 Output valve, p = 14 bar 23 Filter
11 Control piston 24 Feed pressure
14 Cradle 25 To tank
18 Proportional pressure regulation valve HMV 26 Feedback bar
remote control 1Y7 27 Feedback spring
19 Feed pump 31 cm3/U 28 Start of regulation adjusting screw
20 Feed pump 31 cm3/U 29 Control pressure

Drive axle 2
Traction drive
The variable motor is a swash plate design The pilot valve (1) is at this point in the adjustment
axial-piston motor for closed circuits. position.
The engine is equipped with a continuously- In this position, the motor stops until the control
adjustable hydraulic remote control H3 and an pressure (X) is changed.
output unit.
This feedback system enables all the interim po-
sitions to be achieved with precision depending
Function characteristics of continuously- on the control pressure.
adjustable hydraulic remote control H3
Remote control takes place in proportion to the
The motor’s swivel angle can be hydraulically ad- control pressure (usually 8 to 14 bar).
justed continuously variable between maximum
and minimum volume intake.
The feed pressure at the pilot valve (1) is > 16 bar.
The pilot valve (1), which is in its home position,
transfers the feed pressure to the control piston,
which in turn causes an adjustment in the direc-
tion of "maximum intake volume".
The second control piston is connected via the
pilot valve (1) to the leak oil connection.
If there is control pressure via the connection
(X), then the pilot valve (1) moves towards the
feedback spring (27) in such a way that the control
edges connect the channel of the control piston,
which is causing an adjustment in the direction of
"maximum intake volume, " to the tank.
The pressure is increased until the cradle’s re-
verse movement produces an equilibrium be-
tween the control pressure (X) and the feedback
spring(27).

2 Drive axle
Traction drive
Output unit function characteristics
I ND ND L
A 2 B
B
A1 B1
A
3
II HD ND L
A 2 B
B
A1 B1
U
Ablauf
30
A
3
359_02-017
2 3/3-way switch valve B Low pressure

3 Output valve, p = 14 bar L Leak oil connection
30 Conical seat U Leak oil connection
A High pressure
The hydraulic motor is fitted with an output unit. Housing flushing

It combines two flushing systems, one for the The heat generated in the drive parts of the
circuit and one for the housing. hydraulic motor (bearings, joints, sliding faces)
can be dissipated from the motor housing only by
leakage flows.
Circuit flushing
Under certain unfavourable operating conditions,
If thermal problems arise (e.g. when the ambient
e.g. high speed and low operating pressure,
temperature is too high) the temperature in the
the leakage rate is insufficient to dissipate the
closed circuit can be significantly lowered by
frictional heat.
flushing.
The output unit allows an oil quantity of approx.
The 3/3-way switch valve (2) connects the low-
15 I/min to flow from the output valve (23) as
pressure side to the output valve (3).
flushing oil for cooling the hydraulic motor hous-
After intensive mixing between the cooled oil ing; after the flushing oil has flushed the housing,
that was fed in and the circulating fluid, and it is discharged with the leakage.
replacement of the escaped leakage, a limited
quantity is released from the output valve (3).
Method of operation
If both high pressure lines are unloaded and
subjected only to feed pressure (e.g. when the

Drive axle 2
Traction drive
pump is in zero position), both the change-over together with piston B1, towards the low pressure
pistons in the 3/3-way switch valve (2) (Figure (I)) (ND) connection "B" (illustrated(II)).
are spring-loaded to take up central positions.
The conical seat (30) on piston A1 acts as a stop,
Fluid cannot flow to the output valve (3) from at the same time preventing an overflow of high
either high pressure connection (A) or high pressure fluid from spring chamber A1 to the
pressure connection (B). output valve (3).
If, for instance, high pressure (HD) nonetheless
builds up on the A side, this pushes piston A1,

2 Drive axle
Traction drive
Reduction gearbox
Reduction gearbox GR 26-01
Planetary transmission, i = 14.02 (1st stage:
2.959; 2nd stage: 4.738)
PBL U
TL
359_02-025
PBL Brake ventilation pressure

U Outlet from cooling system
TL Feed to cooling system

Drive axle 2
Traction drive
3 4 5 6 7 8 9 10 11
2
1
12
21
20
19 18 17 16 15 14 13 359_02-026
1 Level 1 planetary gears 12 Wheel hub

2 Level 1 annular gear 13 Tapered roller bearing
3 Level 1 planetary gear carrier 14 Slotted nut (M = 9000 Nm, secured with FK2)
4 Brake springs 15 Drain plug
5 Brake piston 16 Axle pipe plug
6 Pre-load plate 17 Drain plug
7 Level 2 annular gear 18 Cooling jacket
8 Level 2 planetary gears 19 Axle pipe
9 Level 2 planetary gear carrier 20 Brake discs
10 Level 2 sun gear 21 Level 1 sun gear
11 Shaft seal

2 Drive axle
Traction drive
Brake
Braking process - function characteris-
tics
Braking can be performed in different stages as
necessary:
• Hydrostatic braking
• Hydrostatic braking + retarder
• Hydrostatic braking + retarder + multi-disc
brake
Hydrostatic braking
If the controller calls for hydrostatic braking as a
result of lifting the accelerator pedal, the variable 1
motors (1) are initially adjusted towards the max- A
imum swivel angle (Qmax). As soon as the vari-
able motors (1) reach the maximum swivel angle, max
the variable displacement pump (2) is swivelled
back to the minimum swivel angle (Qmin).
The speed of the truck reduces until the truck
comes to a stop.
If the accelerator pedal is returned abruptly to 2
neutral, the maximum hydrostatic braking torque
set in the controller is requested (can be set using B
Vmax
Pathfinder to between 0.09 and 0.3 g).
This maximum value is only achievable by a very
abrupt release of the accelerator pedal. In nor- 359_02-038
mal driving mode, continuously variable brake A Swivel angle

retardation can be activated by the driver. B Driving speed
The maximum hydrostatic braking torque (0.3 g) 1 Variable motor
2 Variable displacement pump
is requested when reversing and when the brake
pedal is pressed (up to 75 % of the pedal travel).
Hydrostatic braking + retarder

The maximum hydrostatic braking torque is
requested if the accelerator pedal is returned
abruptly to neutral, when reversing and when the
brake pedal is pressed (75 % of the pedal travel).
A retarder is required to prevent over-revving of
the internal combustion engine.
The retarder valve requests a volumetric flow
from the HPV 210-02 variable displacement
pump and generates a dynamic pressure of up to
367 bar.
This additional reduction in power prevents over-
revving of the internal combustion engine.

Drive axle 2
Traction drive
Hydrostatic braking + retarder + multi-disc
brake
If the maximum hydrostatic braking power is not
sufficient (e.g. emergency braking with full load),
the multi-disc brake can be activated by pressing
the brake pedal again (76 - 100 % of pedal travel).
Pressing the brake pedal (76 - 100 % of pedal
travel) causes the pressure regulation valve to
reduce the release pressure of the multi-disc
brake in proportion to the brake pedal travel (foot
brake).
This enables a braking force of up to 0.45 g to be
achieved.
Calculation of the required braking torque

Various parameters are required for calculation
of the required braking torque; these are either
fixed programmed values or variables that are
collected by the controller.
Fixed programmed values:

• Vehicle weight
• Mast weight
Variable values:
• Current load (sensed by pressure sensors in
the lift cylinders)
• Changes in the acceleration pedal position for
the direction of travel
• Reversing speed (pedal change-over)
• Brake pedal position
The controller applies the necessary braking
torque according to the current pedal application
position and the calculated load values.
WARNING
Should the controller fail completely, the minimum
hydrostatic braking torque is provided automatically.
If more braking force is required, the multi-disc brake
must be applied using the brake pedal (second stage).

2 Drive axle
Traction drive
Retarder valve block components
2 3 4 5
6
LS 1 LS F P3
T1
LS 0
T2
1 2Y9 Msa 1Y8 1Y1
7
80
340 bar
bis
Mp 340
bar
2 45+5 bar
P2
9 8
359_02-008
1 LS pressure relief valve, p = 340 bar 6 Diaphragm

2 Release valve 2Y9 (LS pressure) 7 Pressure regulator VD 20-07
3 Non-return valve 8 Quantity regulator
4 Proportional pressure regulation valve (quan- 9 Pressure relief valve, p = 45+5 bar (pump
tity of retarder) 1Y8 protection valve)
5 Proportional pressure regulation valve (re-
tarder pressure) 1Y1

Drive axle 2
Traction drive
8 P2
5
4
F
P3
1
T1 6
3
LS o 2 359_02-021
1 LS pressure relief valve, p = 340 bar 7 Pressure regulator VD 20-07

2 Release valve 2Y9 (LS pressure) 8 Quantity regulator
3 Non-return valve F Feed pressure
4 Proportional pressure regulation valve (quan- P2 Pressure input
tity of retarder) 1Y8 P3 Pressure output towards working hydraulic
5 Proportional pressure regulation valve (re- valve block
tarder pressure) 1Y1 T1 Tank pressure
6 Diaphragm LS0 LS pressure towards pump controller

2 Drive axle
Traction drive
5 4 8
3 2
359_02-037
2 Release valve 2Y9 (LS pressure) 5 Proportional pressure regulation valve (re-
3 Non-return valve tarder pressure) 1Y1
4 Proportional pressure regulation valve (quan- 6 Diaphragm
tity of retarder) 1Y8 8 Quantity regulator

Drive axle 2
Traction drive
The brake system consists of the following main • Quantity regulator (8) for proportional pressure
sub-assemblies: regulation valve (quantity of retarder) 1Y8
• HPV 210-02 variable displacement pump (4); activates the retarder function (issues
an S signal to start the volume flow of the
• Variable motors HMV 280-02
regulating pump, regulates the volume flow
• Brake release valve with respect to the proportional pressure
• Multi-disc brake packs within the planetary regulation valve (retarder pressure) 1Y1 (5))
gearboxes • Proportional pressure regulation valve (re-
• Retarder valve block tarder pressure) 1Y1 (5)
• Pressure regulator VD 20-07 (7) for propor-
The retarder valve block contains the following
tional pressure regulation valve (retarder pres-
components:
sure) 1Y1 (5) (regulates the retarder pressure
• LS pressure relief valve p = 340 bar (1) (also between 80 and 340 bar)
limits the maximum working pressure)
• Pressure relief valve, p = 45+5 bar (pump
• Release valve 2Y9 (LS pressure) (2) (activated protection valve) (9)
if the line is interrupted, no operating function
possible)
• Proportional pressure regulation valve (quan-
tity of retarder) 1Y8 (4)

2 Drive axle
Traction drive
Retarder valve block function
Retarder in standby
LS 1 LS F P3
T1
LS 0
T2
2Y9 Msa 1Y8 1Y1
80
340 bar
bis
Mp 340
bar
2 45+5 bar
P2
A
B
359_02-009
A Feed pressure
B HPR 210-02 regulating pump pressure
• Standby situation
• No retarder power requested by the LTC
controller

Drive axle 2
Traction drive
Retarder power requested
LS 1 LS F P3
T1
LS 0
2Y9 Msa 1Y8 1Y1
T2
80
340 bar
bis
Mp 340
bar
2 45+5 bar
P2
A
8 7
B
C
359_02-010
4 Proportional pressure regulating valve (re- A Feed pressure

tarder flow) 1Y8 B HPR 210-02 regulating pump pressure
7 VD 20-07 pressure regulator C Electrical control signal from the LTC con-
8 Flow regulator troller
• Request for retarder power by the LTC con- signal (0 to max. feed pressure) to be sent to the
troller flow regulator (8).
• The proportional pressure regulating valve The flow regulator (8) now opens in proportion
(retarder flow) 1Y8 (4) supplies a defined to the pressure signal from the 1Y8 proportional
control pressure to the flow regulator (8) pressure regulating valve (retarder flow) (3).
• The flow regulator (8) adjusts in proportion
• A defined LS pressure signal (derived from the
to the signal from the proportional pressure
standby pressure or the current P-pressure)
regulating valve (retarder flow) 1Y8 (4). An
is returned to the E1L pump regulator. This
LS signal is sent to the E1L pump regulator.
causes the HPR 210-02 regulating pump to be
Since all acceleration or braking requests are advanced towards maximum delivery volume.
routed to the LTC controller, from a certain level • A connection opens between the flow regulator
of requested braking torque the LTC controller is (8) and the pressure regulator VD 20-07 (7).
able to send an electrical control signal (C) to the The volumetric flow through this connection
1Y8 pressure regulating valve (retarder flow) (4). depends on the braking torque requested by
This signal causes a defined control pressure (A) the LTC controller.
that depends on activation by the LTC controller

2 Drive axle
Traction drive
Minimum retarder power
LS 1 LS F P3
T1
LS 0
2Y9 Msa 1Y8 1Y1
T2
80
340 bar
bis
Mp 340
bar
7
2 45+5 bar
P2
A
8 B
C
D
359_02-011
4 Proportional pressure regulating valve (re- B HPR 210 pump pressure

tarder flow) 1Y8 C Electrical control signal from the LTC con-
7 VD 20-07 pressure regulator troller
8 Flow regulator D Unpressurised return flow to the tank
A Feed pressure
• Request for retarder power by the LTC con- (regulated by the VD 20-07 pressure regulator
troller (7)). The increased volumetric flow is diverted
• The proportional pressure regulating valve to the tank by the VD 20-07 pressure regulator
(retarder flow) 1Y8 (4) supplies a defined (7).
control pressure to the flow regulator (8). • Minimum retarder power
• The pump increases the delivery rate and
the pressure increases to at least 100 bar

Drive axle 2
Traction drive
Maximum retarder power
4 5
LS 1 LS F P3
T1
LS 0
2Y9 Msa 1Y8 1Y1

T2
80
340 bar
bis
Mp 340
2 45+5 bar
bar 7
P2
A
B
8 C
D
359_02-012
4 Proportional pressure regulating valve (re- A Feed pressure

tarder flow) 1Y8 B HPR 210 pump pressure
5 Proportional pressure regulating valve (re- C Electrical control signal from the LTC con-
tarder pressure) 1Y1 troller
7 VD 20-07 pressure regulator D Unpressurised return flow to the tank
8 Flow regulator
• Request for maximum retarder power by the Since the delivered oil can only flow back to the
LTC controller tank via the flow regulator (8) and the VD 20-07
• Control pressure is supplied by the propor- pressure regulator (7), overspeeding of the inter-
tional pressure regulating valve (retarder flow) nal combustion engine is avoided in response the
1Y8 (4) to the flow regulator (8) and by pro- requested retarder power, which is regulated by
portional pressure regulating valve (retarder the LTC controller at the 1Y8 proportional pres-
pressure) 1Y1 (5) to the VD 20-07 pressure sure regulating valve (retarder flow) (4) and at
regulator (7). the 1Y1 proportional pressure regulating valve
(retarder pressure) (5).
• The increased flow pressure on the VD 20-07
pressure regulator (7) further increases the At maximum retarder power, the HPR 210-02
LS signal to the HPR 210-02 regulating pump. variable displacement pump delivers a maximum
The volumetric flow is thus further increased. of 170 cm3/rev, corresponding to a volumetric
P-pressure = approx. 367 bar; volumetric flow flow of 357 l/min at a maximum internal combus-
= Qmax. tion engine speed of 2100 rpm.
• Maximum retarder power The pressure at the HPR 210-02 variable dis-
If the working hydraulics or steering function are placement pump can reach up to 340 bar + 27 bar
already activated, the volumetric flow increases standby pressure = 367 bar.
sharply (potentially up to Qmax).

2 Drive axle
Traction drive
This exploitation of the maximum HPR 210-02 proportion to the pedal travel and thus the friction
variable displacement pump power reliably torque of the multi-disc brakes is used for rein-
avoids overspeeding of the internal combustion forcement of the braking torque.
engine.
Since at maximum braking power the kinetic NOTE
energy is converted into heat, the hydraulic
cooling system is an integral part of the braking The braking power during hydrostatic braking
system. can be adjusted with the aid of Pathfinder.
If the maximum available hydrostatic braking Braking power

torque is insufficient, applying the brake pedal Hydrostatic braking (releasing the
(pedal travel greater than 75 %) will reduce the 0.09 to 0.3 g
travel direction pedal)
multi-disc brake release pressure in proportion to
Hydrostatic braking — reversing
the brake pedal travel.
or applying the brake pedal to 0.3 g
75 % of the pedal travel
Braking power Hydrostatic braking + exploitation
0.45 g
• 0–75 % pedal travel: hydrostatic brake of the full brake pedal travel
• 75–100 % pedal travel: multi-disc brake
Up to 75 % pedal travel, maximum release NOTE
pressure is present at the brakes.
g = 9.81 m/s2 (acceleration due to gravity)
Starting at 76 % pedal travel, the release pres-
sure is diverted to the tank via the brake valve in

Drive axle 2
Traction drive
Brake release valve
3
4 4
2 1
1 Switch setting 1: normal mode 6 3/3-way proportional valve (parking brake)

2 Switch setting 2: towing mode P Feed pressure
3 5/2-way solenoid valve (towing valve) PL Emergency release pressure from the steer-
4 Non-return valve ing system
5 Pressure regulating valve (foot brake) BR Release pressure 0–24 bar
T Tank connection
2 Drive axle
Traction drive
1 Switch setting 1: normal mode 6. 3/3-way proportional valve (parking brake)

2 Switch setting 2: towing mode PL Emergency release pressure from the steer-
3 Non-return valve ing system
4 5/2 way sol BR Release pressure 0–24 bar
5 Non return valve T Tank connection
In normal mode, the 5/2-way solenoid valve the multi-disc brake (BR) is reduced, and the
(towing valve) (4) is in position (1). brake engages.
The connection (P) exists through the 5/2-way In towing mode, the connection (P) to the control
solenoid valve (towing valve) (4) to the control piston of the pressure regulating valve (foot
piston of the pressure regulating valve (foot brake) (6) is closed off.
brake) (6).
The connection (PL) exists through the 5/2-way
Upon actuating the tappet rod in the pressure solenoid valve (towing valve) (4) to the brake
regulating valve (foot brake) (6) the pressure at valve control piston.

Drive axle 2
Traction drive
Towing unit
Towing
Before the vehicle can be towed, two conditions
must be satisfied:
• The short-circuit valve must be in towing posi-
tion.
• The multi-disc brake must be opened.
DANGER
Risk to life! When the multi-disc brake is open, the fork
lift truck cannot brake.
To tow the fork lift truck, a towing vehicle with sufficient
tractive power and braking force for the unbraked to-
wed load is required.
The fork lift truck may only be towed with a rigid con-
nection (tow bar).
Before opening the short circuit-valve, ensure that
the truck cannot roll by either chocking the wheels or
connecting it to the braked towing vehicle using a rigid
tow bar.
Opening the short-circuit hydraulic valve

¾ Tilt the cabin.
¾ Undo the self-locking nut (1) at the top left
of the variable pump housing using a socket
driver.
¾ Use the socket driver to unscrew the threaded
stud (2) by 2 turns.
¾ Lock the threaded stud with the self-locking
nut (1), tighten to 60 Nm.
359_02-019

2 Drive axle
Traction drive
Releasing the multi-disc brake
NOTE
The brake release valve is located underneath

the driver cabin on the left side of the vehicle
chassis.
¾ Turn the 5/2-way solenoid valve (towing valve)
from position 1 to position 2.
¾ Lower the cabin back into position.
¾ Turn the steering wheel to the right until it en-
counters tangible resistance (pressure is being
generated at the multi-disc brake).
¾ Turn the wheel further until the brake is fully
released.

Drive axle 2
Traction drive
Checking the brake system
Test prerequisites:
• Hydraulic oil min. temperature 60 °C
• Towing valve in position 1
• Truck jacked up
Special tool required:

• Lifting iron/tyre lever or rigid pipe, approx.
1.5 m long
• Linde hydraulic measurement tool case, digital
pressure gauge if available
• Jack 40 t
• Wooden blocks or any other suitable material
that will allow the truck to be jacked up safely
Procedure
Step Yes No
Procedure
Type (Test) (Test)
Carefully jack up the drive
1
axle of the truck so that the
Action
wheels can rotate freely.
Start the internal
2
combustion engine,
Action
release the parking brake
Turn both wheels using the
lifting iron or pipe (brace
the pipe/lifting iron against
3 the tyre tread block at an Turn off the motor, go to
Go to step 4.
Test angle to the ground and step 6
pull on the pipe/lifting iron
to turn the wheels).
Do the wheels turn?
4
Apply the parking brake.
Action
Turn both wheels using the
If the wheels on one or
lifting iron or pipe (brace
both sides do not turn, one
the pipe/lifting iron against
or both brake pistons may
the tyre tread block at an
5 be jammed.
angle to the ground and Go to step 6.
Test Switch off the engine.
pull on the pipe/lifting iron
Repair the planetary
to turn the wheels).
transmission/multi-disc
The wheels must not turn!
brake.
Are the wheels blocked?
2 Drive axle
Traction drive
Step Yes No
Procedure
Type (Test) (Test)
Fit 2 pressure measuring
connectors:
- brake valve connection
MP (nipple M … straight)
- brake valve connection
BR (T-piece)
6
Connect 2 low-pressure
Action
gauges (min. 40 bar) or
0 - 60 bar pressure sensor
and digital measuring
device.
Start the engine, apply the
parking brake.
Check the towing valve,
7 Pressure on connection see "Checking the traction
Go to step 9
Test MP: 27 +5 bar? drive, checking the feed
pressure"
Check the settings of
the Bowden cables on
the brake release valve,
parking brake, service
brake.
8 Pressure on connection
Go to step 9 Check the pressure
Test BR: 0 bar?
regulation valve
(footbrake) and the
3/3-way proportional valve
(parking brake) (jamming,
stiffness, internal leaks)
9
Release parking brake
Action
Pressure regulation valve
(foot brake) defective,
Go to step 12 exchange
Test MP 27 +5 bar?
3/3-way proportional valve
defective, exchange
Required pressure not
reached. There may be an
Go to step 12 internal leak in one or both
Test BR 24 bar?
brakes.
Go to step 16
Check the operation of the
service brake.
Engine running, parking
brake applied.
12
Pressure on connection
Action
MP: 27 +5 bar?
BR: 0 bar?
Release parking brake.

Drive axle 2
Traction drive
Step Yes No
Procedure
Type (Test) (Test)
Press brake pedal.
BR: constant 24 bar up to
75 % of pedal travel. Check the setting of the
Pressure drops in service brake cable pull.
13
proportion to 75 - 100 % Go to step 14 Check the pressure
Test
pedal travel to less than regulation valve (foot
3 bar. brake).
Release brake pedal.
BR: 24 bar?
14
Apply the parking brake.
Action
Check the setting of the
15 Pressure on connection parking brake cable pull.
Brake system OK
Test BR less than 3 bar? Check the 3/3-way
proportional valve.
Check for internal leaks.
16 Shut off each side in turn to
Action determine which brake is
leaking.
The left brake is defective.
Does the pressure remain An excessively high oil
17
constant when the right level in the planetary
Test
brake is connected? transmission may also be
a sign of a defective brake.
The right brake is
defective.
Does the pressure remain
18 An excessively high oil
constant when the left
Test level in the planetary
brake is connected?
transmission may also be
a sign of a defective brake.

2 Drive axle
Hydraulic fan drive

Function characteristics
1 2 3
4
P4
1Y5
65 l/min P4 F
31 31
L
S 5
3 bar
T3
7
23+0.5 bar
d=1,5
F
359_02-001
1 Gear pump, Vg = 31 cm3 8 Feed pressure valve p = 23+0.5 bar

2 By-pass valve S Suction line
3 Proportional pressure regulation valve 1Y5 P4 Pressure connection
4 Hydraulic motor Vg = 31 cm3 F Feed pressure connection
5 Fan L Return connection to hydraulic oil tank
6 Radiator T3 Return connection to hydraulic oil tank
7 3 bar safety valve (housing pressure)
The hydraulic fan drive consists of a hydraulic which regulates a bypass valve (2) fitted to the
motor (4) with an intake volume of Vg = 31 cm3, fan motor (4). The speed of the fan motor (4) is
supplied by the gear pump (1). regulated by the volumetric flow.
A fan wheel rotor (5) that draws cooling air from If the coolant temperature is below approx. 85 °C
the engine compartment and blows it outwards is and the hydraulic oil temperature is below approx.
mounted on the hydraulic motor (4). xx °C, the bypass valve (2) opens and the fan
motor (4) remains stationary. Only when the
The fan speed depends on the speed of the diesel
temperature exceeds these limits does the fan
engine and the temperatures of the coolant and
start up at approx. 800 rpm. After this the speed
hydraulic oil.
increases in proportion to the temperature.
Temperature transmitters sense the tempera-
This cooling design achieves the optimum op-
tures of the coolant and hydraulic oil and trans-
erating temperature more quickly, reduces fan
mit them to the LTC module. This activates the
noise and is more effective at recovering from
proportional pressure regulation valve 1Y5 (3),
temperature peaks.

Drive axle 2
Hydraulic fan drive
WARNING
During maintenance work the temperature controller
can cause the stationary fan motor to suddenly start up
at a relatively high speed.
Do not reach into the fan.
Keep your distance.
Checking the hydraulic fan drive

¾ Tilt the cabin.
¾ Disconnect the connector plug (1) at the fan
motor.
¾ Fit adhesive strips (2) to the fan wheel rotor.

¾ Start the diesel engine.
WARNING
The fan motor will start.
Do not reach into the fan.
Keep your distance.
¾ Fully open the throttle.
¾ Measure the fan speed with a speed meter (3)

and compare it with the reference value.

2 Drive axle
Hydraulic fan drive
Engine speed Water temperature Fan speed
600 rpm (with electrical fan motor
800 rpm 0 — 85 °C
activation)
700 rpm (without electrical fan
800 rpm 0 — 85 °C
motor activation)
800 rpm 85 — 92 °C 600 — 700 rpm (proportional)
730 rpm (with electrical fan motor
2100 rpm 0 — 85 °C
activation)
1800 rpm (without electrical fan
2100 rpm 0 — 85 °C
motor activation)
2100 rpm 85 — 92 °C 730 — 1800 rpm (proportional)

Chassis, bodywork and fittings 4
a
Steering system
1 2 3
4
LS L
LS
L
P
250+20 bar
S 5
190+5 bar
17 bar
T T
R
370+5
LS P
7 6
HPR210
170
20
8 359_04-002
1 Priority valve LSL LS steering connection

2 Non-return valve S Pressure output towards steering control
3 Steering control valve valve
4 Suction valves T Tank return connection
5 Steering cylinder LS LS connection
6 Secondary valve p = 250+20 bar P Pressure input
7 LS pressure relief valve, p = 190+5 bar L Left steering cylinder connection
8 Variable displacement pump R Right steering cylinder connection

Steering system
L
R
LS T
P
PL
LS L
10
359_04-011
3 Steering control valve R Right steering cylinder connection

5 Steering cylinder PL Emergency release pressure from the steer-
9 Brake release valve ing
10 Working hydraulics valve block LSL LS steering connection
LS LS connection S Pressure output towards steering control
T Tank return connection valve
L Left steering cylinder connection P Pressure input
Steering system function Steering

The oil delivered by the HPR 210-02 variable When the steering is actuated, the load sensing
displacement pump (8) passes to the priority pressure connection’s oil tank connection is
valve (1). blocked by the steering control valve (3).
As long as the steering control valve(3) is not This causes the pressure in the LS line to rise.
actuated, a volume flow Q ~ 1 l/min flows via (S) This increase in pressure causes the priority
and (P) through the steering control valve (3) and valve (1) to make the entire volume flow from the
exits at (T). variable displacement pump (8) available to the
steering.
The vast majority of the volume flow delivered by
the variable displacement pump (3) is available Depending on the deflection of the steering
to the working hydraulics. The load sensing control valve (3), the steering cylinder (5) is
pressure connection (LS) is connected to the oil supplied via the connections (R) or (L) with a
tank (T) via the steering control valve. volume flow.
The steering is protected by the primary valve (7) The oil that is displaced from the steering cylinder
at pmax = 190+5 bar. (5) during steering movement flows through the

Steering system
steering control valve (3) and the connection (T) required to maintain maximum pressure is sent
back to the oil tank. to the steering cylinder.
If retraction forces create pressure peaks in the The vast majority of the remainder of the volume
steering circuit, e.g. when driving over obstacles, flow delivered by the variable displacement pump
these peaks are limited by the secondary valves (8) is diverted to the oil tank.
(6) to pmax = 250+20 bar.
Emergency steering when drive engine is
Steering up to end stop switched off
When steering the steering cylinder (5) up to During emergency steering, the steering wheel
the end stop, the pressure increases at the actuates a rotor-type pump in the steering control
connection (P) of the steering control valve, on valve (3) that draws oil from one chamber of
the pressure side of the steering cylinder and in the steering cylinder and pumps it into the other
the load sensing line (LS) to the value specified chamber, depending on the direction of rotation.
by the primary valve (7) (pmax = 190+5 bar). If oil is lost from the circuit because of leaks, the
The primary valve opens and decreases the load corresponding suction valves (4) draw oil from
sensing pressure to the oil tank. the oil tank line (T).
This induces the priority valve (1) to switch to a

position in which only as much volume flow as is

Steering system
Steering axle
1 3
4
5
2
3 5
359_04-001
1 Hydraulic cylinder
2 Cover
3 Axle stub
4 Tie rod
5 Elastic bearings
The rear wheels are steered by a double-action, The steering cylinder is mounted on the axle
counter-balanced hydraulic cylinder (1) that is casing with four bolts.
connected to the steering cylinder and both axle
The tie rods have sealed spherical bearings on
stubs (3) via two fixed-length tie rods (4).
each end and are connected to the piston rod and
The steering control valve is activated by move- axle stubs with press-in bolts and slotted spring
ments of the steering wheel and controls the oil pins. These tie rods have a fixed length, so that
flow to the steering cylinder. axle alignment is unnecessary.
The oil is fed in by the variable displacement The covers (2) over the two steering pivot pins
pump, which is powered by the internal combus- are each attached with four screws and spring
tion engine. washers. The cover under each steering pivot
pin is attached with four screws and spring wash-
The axle casing is connected to the chassis
ers. Each cover and tie rod end has lubricating
by elastic bearings (5) that enable a swinging
nipples.
movement by the axle on uneven ground.

Steering system
stub axle
359_04-003
1 Bush 6 Spacer ring

2 Felt washer with back-up ring 7 Adjustment washers
3 stub axle 8 Tapered roller bearing
4 Steering pivot pin 9 Pressure plate
5 Bush with O-ring 10 Nut
Removing the steering pivot pin

¾ Jack up the truck and place wooden blocks
underneath the steering axle.
¾ Remove wheel.
¾ Press out the tie rod bolt and remove the tie
rod.
¾ Remove top and bottom covers and degrease.
¾ Unlock nut (10), undo and screw out
¾ Remove washer (9).
¾ Place the jack on the steering pivot pin (4) and
tension the bolt.
¾ Using a large burner, heat up the stub axle until
the steering pivot pin detaches itself from the
stub axle.

Steering system
¾ Lift the bolt clear.
¾ Take the stub axle out to the side.
Inserting and adjusting the steering pivot pin
359_04-004
1 Bush 6 Spacer ring

2 Felt washer with back-up ring 7 Adjustment washers
3 stub axle 8 Tapered roller bearing
4 Steering pivot pin 9 Pressure plate
5 Bush with O-ring 10 Nut
¾ Soak the felt washer (2) in oil and insert with

the back-up ring into the axle casing, pulling it
firmly upwards with plastic film. Insert the stub
axle (3) and pull out the plastic film.
¾ Insert the steering pivot pin (4) without ta-
pered roller bearing (8), adjusting washers (7),
spacer ring (6) and bush (5).
¾ Insert dummy bearing and pressure plate,
screw nut (10) onto steering pivot pin and
torque to 1000 Nm.
¾ Undo nut (10) and take off, remove pressure
plate and dummy bearing.
¾ Insert bush with O-ring (5) into axle.
NOTE
The short side of the bush (5) must point towards

the thread side of the steering pivot pin.
¾ Place spacer ring (6) in axle then drive in outer
race of tapered roller bearing (8).

Steering system
¾ Put adjusting washers (7) with a total thickness
of 0.7 mm onto the steering pivot pin (4).
¾ Insert bearing (8) and pressure plate (9) and
torque nut (10) to 815 Nm.
¾ Place dial gauge with magnetic holder on
steering pivot pin, set dial gauge to zero.
¾ Using a tyre lever, raise the stub axle and mea-
sure the axial play of the steering pivot pin.
Axial play: 0.00 mm
NOTE
Maximum axial play: 0.12 mm

Example:
Thickness of fitted
0.7 mm
washers:
Measured axial play: 0.5 mm
Final washer
0.2 mm
thickness:

Steering system
Wheel hub
1 Wheel hub 8 Locking screw

2 External tapered roller bearing 9 Split pin
3 Internal tapered roller bearing 10 Adjusting nut
4 Sealing ring 11 O-ring
5 Wheel bolt 12 Face cover
6 Race 13 Lock ring
7 Pressure plate

Steering system
Adjusting the wheel bearing
¾ Remove lock ring.
¾ Remove lock ring (13) and take off cover (12).
¾ Degrease.
¾ Undo locking screw (8).
¾ Pull out split pin (9)

¾ Tighten adjusting nut (10) until no more axial
play can be felt.
¾ Using a hammer, hit the wheel hub towards
the adjusting nut to relieve the tension on the
wheel bearings.

Steering system
¾ Place dial gauge (14) with magnetic holder
on wheel hub. Set the dial gauge to zero and
measure the axial play.
Max. axial play 0.10 - 0.15 mm
¾ Adjust the adjusting nut (10) so that the split
pin (9) can be inserted through the hole.
¾ Secure the split pin (9).
¾ Tighten the locking screw (8).
¾ Fill with grease.
¾ Fit cover (12) and insert lock ring (13).

Steering system
Adjusting the inner steering stop
X
3
501_10-001
359_04-007
1 Pin (steering cylinder) 4 Adjustment washers

2 Steering cylinder X Setting dimension: 75 mm
3 Inner steering stop
To prevent damage to the hydraulic steering

cylinder, the inner and outer steering stops must
be checked and adjusted as necessary after re-
pair of axle stubs, tie rods or steering cylinders.
Checking the steering stop

Turn the wheels to the right or the left until the
inner steering stop screw (3) strikes the stub
axle.
Check the dimension (X) at the steering cylin-
der, setting dimension: 75 mm.
If the dimension (X) is too large or too small, ad-
just the inner stops as follows:
Raise the fork lift truck so that the steering axle
wheels are clear of the ground.
Activate the steering cylinder until the setting
dimension X = 75 mm is achieved.
Adjust the stop screw (3) with washers (4), so
that when the steering is applied (maximum
Steering system
pressure is achieved) and the stop screw is
correctly adjusted, a setting dimension X =
75 ± 0.5 mm is maintained.
NOTE
Always check and adjust both inner steering

stops.
Stop screw tightening torque (3): 180 Nm.
Steering system
Adjusting the outer steering stop
2 3 4
1
501_10-002
359_04-008
1 Outer steering stop 3 Adjustment washers

2 Stop screw 4 Fastening nut
Checking the steering stop

Turn the wheels to right or left until they reach
the stop and achieve the maximum pressure
in the steering system.
There must be a clearance of 1 mm between
the stop screw (2) and the outer steering
stop(1).
If the clearance is absent or too large, unscrew
the fastening nut (4), remove the stop screw
(2) and insert washers (3) to adjust the outer
steering stop.
NOTE
Always check and adjust both outer steering

stops.
Stop screw tightening torque (2): 180 Nm.

Steering system
Removing and installing the steering cylinder
1 2 3
9 7 6
8
3
5 4
359_04-009
501_10-003
1 Pin. 6 Split locking pin (4 off).

2 Piston rod. 7 Hole.
3 Split location dowel (2 off). 8 Knock-out pin.
4 Washer (4 off). 9 Tie rod.
5 Cap-head bolt (4 off).
Removing the steering cylinder

Jack up the rear of the truck onto stands so
that the wheels can rotate freely, and securely
support the truck.
Move the steering cylinder piston rod (2) until
the pin (1) is in line with the hole (6) in the
steering axle housing.
Remove split locking pin (7) from the pin
(1).
Using a suitable jack and knock-out pin (8)
(∅ 29 mm, length 150 mm), drive the pin (1)
far enough out so that the tie rod (9) can be
swung out of the piston rod (2).
Push out the second pin (1).
Disconnect the two hose lines from the
steering cylinder extension tubes.
Remove the two service extension tubes which
pass through the axle casting.
Undo fixing screws (4) (4 off) from the steer-

ing cylinder.
Remove the steering cylinder. Pay attention to
the split location dowels (3) (2 off).
Fully drive the pin (1) out of the piston rod.
Steering system
Installing the steering cylinder
Lift the steering cylinder into the steering axle,
watching out for the split location dowels.
Insert four screws M20 x 130 10.9 (5) with
washer (4) and secure with Loctite 270 and
tighten to 580 Nm.
Adjust the steering cylinder piston rod (2) until
the hole (7) in the steering axle housing is in
line with the hole for pin(1) in the piston
rod.
Slide the tie rod (9) into the piston rod fork.
Insert pin (1) from below through the hole

(7) in the steering axle housing and push it
into the piston rod (2) using a suitable jack and
insertion pin (∅ 29 mm).
Drive in the split locking pins (6) centrally into
pin (1).
NOTE
Insert the pin (1) so that the holes for the split
locking pins (6) are 90° offset from the piston rod
(2).
Push in the second pin and secure with split
locking pins (6).
Re-install service extention tubes through axle

body and into steer cylinder. Tighten to 180 Nm
132 lbs-ft.
Reconect hydraulic hose lines and tighten to 90 Nm
66 lbs-ft.
Start the engine and bleed the steering system

by turning the steering wheel from stop to stop
about ten times.
Check the steering cylinder for leaks.
Lower the truck down from the stands.
Steering system
Sealing the steering cylinder
359_04-010
1 Piston rod 6 Cylinder pipe

2 Wiper 7 Sealing sleeve
3 Lock ring 8 Guide bush
4 Seal 9 Sealing ring
5 Guide ring 10 Hole
¾ Remove the steering cylinder and clamp it in a

vice.
¾ Pull out the piston rod to the stop (1) on one
side.
¾ Drive back the guide bush (8) a little with a few
blows; release the lock ring (3) using a 2 mm
drift punch through the hole (10) and lift it out
using a screwdriver.
¾ Push the piston rod towards the removed lock
ring and with light blows (plastic hammer) on
the opposite end of the piston rod drive out the
piston rod and guide bush.
¾ Pull the piston rod out of the cylinder pipe and
remove the guide bush from the piston rod.
¾ Remove the wiper (2), seals (4)(9) and guide
rings (5) from the guide bush (8).
¾ Insert new seals, guide rings and wipers into
the guide bush, taking care to place the indi-
vidual seal elements in the right positions.
¾ Remove the sealing sleeve (7) from the piston
rod and replace it with a new one.
¾ Remove the second lock ring.
¾ Remove the second guide bush (8) and renew
the seal elements.
¾ Lightly grease the guide bush and insert it into
the cylinder pipe, making sure to place it in the
correct position.
¾ Insert the lock ring.
¾ Carefully insert the piston rod into the cylinder
pipe from the opposite side, and slide it through

Steering system
the guide bush (8) to the stop. Be careful not to
damage the sealing lips on sealing elements.
¾ Insert the second greased guide bush, push it
home to the stop and secure it with a lock ring.

Controls 5
a
Display elements
Indicator unit
1 Indicator unit 16 Clock

2 Hydraulic oil temperature warning light 17 Symbol for "Service interval exceeded"
3 Battery charge warning light 18 Function button
4 Engine oil pressure warning light 19 Reset button
5 Electrical controller malfunction warning light 20 Symbol for "Parking brake applied"
6 Coolant temperature warning light 21 Symbol "do not start the engine"
7 Load/overload indicator (special equipment) 22 Symbol for "Operating hours until the next
8 Soot filter warning light (special equipment) service" (shown for only 4 sec on display field
9 Coolant level warning light (14))
10 Hydraulic oil filter indicator light 23 Symbol for "Lift mast position sensing"
11 Fuel level indicator 24 Text field
12 Display 25 Preheating indicator light
13 Symbol for "Soot filter" (special equipment) 26 Air filter blocked warning light
14 Operating hours meter 27 Engine stop warning light (red)
15 Symbol for "Operating hours meter running" 28 Engine warning light (yellow)

5 Controls
Display elements
Indicator unit installation position
The indicator unit (1) can be positioned to the
right of the steering wheel, where it will be easy
to see. The indicator unit displays warnings and
information (12).
Display
DANGER
The load/overload indicator (7) lights up red in the
event of an overload. If the fork lift truck is overloaded
it can tip over, leading to very serious injuries.
set down load immediately.
Consult load diagram.
Possible faults
Indicator element Purpose
Remedy
Oil level in the hydraulic circuit
too low.
Illuminates if the specified
temperature limit is reached. Wrong type of oil.
(2) Hydraulic oil temperature
Once the permitted temperature Oil filter clogged
warning light (red)
has been reached, a warning Oil cooler clogged
tone will also sound. Press Reset button(19) to switch
off warning tone.
Ribbed V-belt torn or slack; belt
tensioner faulty.
(3) Battery charge indicator lamp Lights up if the charging system Cable defective.
(red) is not working correctly. Alternator defective
Charge controller or cut-out relay
defective.
Engine oil level too low.
Engine overheating
Lights up if the engine oil Wrong type of oil.
(4) Engine oil pressure warning
pressure is too low. A warning Leak within the lubricating oil
light (red)
tone will also sound. circuit.
Press Reset button(19) to switch
off warning tone.
Lights up when the connection CAN bus cable faulty.
(5) Electrical controller malfunc-
to a CAN bus node is down. An
tion warning light (red)
error code will also be displayed. CAN bus node (controller) faulty.
Fan motor defective
Lights up when the specified Thermostatic switch defective
temperature limit is reached. Water cooler clogged
(6) Coolant temperature warning
When the permitted temperature Leakage in the coolant circuit
light (red)
limit is reached, a warning tone Coolant level too low
will also sound.
Press Reset button(19) to switch
off warning tone.

Controls 5
Display elements
Possible faults
Remedy
Symbol lights up orange when
(7) Load/overload indicator load is normal.
(special equipment) (orange DANGER
or red) Symbol lights up red in the event
Set load down immediately
of an overload.
Consult load diagram.
Illuminates if the soot filter must
(8)Soot filter warning light (red) Regenerate soot filter.
be regenerated.
(9) Coolant level warning light Lights up if coolant level is below
Coolant level too low, top up.
(orange) the minimum level.
(10)Hydraulic oil filter indicator Lights up if the hydraulic oil filter Hydraulic oil filter clogged,
light (orange) needs changing. change it.
(11) Fuel level indicator (green
Shows the current fuel level.
or red depending on fill level)
Lights up or flashes and
indicates the remaining capacity Soot filter clogged, regenerate
(13) Symbol for "soot filter"
with four symbols in a text field filter
(24).
If a defective indicator unit is
Shows the operating hours of
exchanged, the operating hours
the forklift truck. This indicator
up to that point must be recorded.
shows the fork lift truck’s
Affix the data on an embossed
(14)Operating hours meter operating hours up to this point,
strip near the indicator unit. It is
and gives an indication of when
also possible to retrospectively
inspection and maintenance
update a new indicator unit using
work will have to be performed.
a diagnostic device.
Flashes when the operating
(15)Symbol for "Operating hours hours meter is running (only
meter running" when the ignition is on and the
engine speed is above 500 rpm))
The time is displayed in 24-hour
format It can be set using the Change to 12 hour format with
(16) Clock
function key (18) and the Reset diagnostic device.
button(19).
If the number of operating hours
until the next scheduled service
The interval can only be reset
(17) Symbol for "Service Interval is ≤ 0, this symbol will flash
or adjusted using the diagnostic
Exceeded" initially for 10 seconds each time
device.
the truck is restarted, before
staying on all the time.
(18)Function button Function depending on model.
For setting the time, switching
off the warning tone and other
(19) Reset button
functions (depending on the
version).
Lights up when the parking brake
(20) Symbol for "Parking brake"
is applied.
Leave the ignition switched
Lights up if the engine stalls
on until the symbol goes out
or when the glow plugs are
(21) Symbol for "Do not start (this takes between 15 and
warming up. You will have to
engine" 20 seconds depending on the
wait a few moments before you
oil temperature Try to start the
can restart the engine.
engine again.

5 Controls
Display elements
Possible faults
Remedy
After the ignition has been
switched on, display field (14)
shows the operating hours
until the next service (counting
(22) Symbol for "Operating hours backwards). Symbol (22) lights
until the next service" up. After 4 seconds, the display
(14) switches automatically to
the truck’s operating hours, and
the operating hours symbol (15)
starts to flash.
(23) Symbol for "Lift mast Lights up when permissible tilt
position sensing" angle is exceeded.
(24) Text field Serves as display field.
Lights up while the glow plugs
(25) Glow plug indicator (orange)
are warming up, then goes out.
(26) Air filter clogged warning Lights up when the air filter is Air filter clogged; clean or
light (orange) excessively clogged. change it.
Lights up if the engine malfunc-
(27)Stop engine warning light
tions. Switched off or remains Perform engine diagnostics.
(red)
activated at slow engine speeds.
(28)Engine warning light (yellow) Reduced engine power. Perform engine diagnostics.

Electrics / Electronics 6
a
Central electrical system

Arrangement of relays and fuses for basic equipment and special equip-
ment
1 2 3 4 5 6
8.1
8.2
8.4
8.3
7
9 10 11 13
16.1
16.2
16.4
16.3
12.2
14.3
15.3
12.1
12.3
12.4
14.1
14.2
14.4
15.1
15.2
15.4
24.3
24.4
24.2
24.1
21
17.2
23.4
22.3
23.2
23.3
17.1
17.3
18.1
18.2
18.3
18.4
19.2
19.4
20.2
20.3
20.4
22.1
22.2
22.4
23.1
19.1
19.3
20.1
17.4
359_06-011
Fuses
Position Designation Name Displayed
Power supply for radio, ignition on
8.1 F45 10 A
(24 V)
8.2 F46 Not assigned
8.3 F47 Not assigned
8.4 F48 Radio battery voltage (24 V) 5A
Power supply for air conditioning
12.1 F21 10 A
system
12.2 F22 Air conditioning system fan 20 A
12.3 F23 Air conditioning system condenser 20 A
12.4 F24 Seat heater 15 A
14.1 F25 24/12 V-converter 20 A
14.2 F26 Spreader 15 A
14.3 F27 Spreader lighting 20 A
14.4 F28 Lighting toggle switch 15 A
15.1 F33 Ignition switch 5A
15.2 F34 Door opener 15 A
15.3 F35 Cab tilt mechanism safety switch 7.5 A
15.4 F36 Horn 15 A
16.1 F41 Left headlight 10 A
16.2 F42 Right headlight 10 A
16.3 F43 Left sidelights 15 A
16.4 F44 Right sidelights 15 A
17.1 F1 Roof working headlights 20 A
17.2 F2 Mast working headlights 20 A
Programmable roof-mounted
17.3 F3 20 A
flashing light
17.4 F4 Reverse lights 10 A
18.1 F5 Brake light 15 A

Fuses
Position Designation Name Displayed
18.2 F6 Work light switch 10 A
18.3 F7 Rotating signal beacon 7.5 A
18.4 F8 Spare ignition 5A
19.1 F9 Spare ignition 10 A
19.2 F10 Power supply for turn indicators 10 A
19.3 F11 Engine control unit 5A
19.4 F12 Not assigned -
20.1 F13 Rear wiper motor 10 A
20.2 F14 Top wiper motor 10 A
20.3 F15 Front wiper motor 15 A
20.4 F16 Constant positive terminal 15 A
22.1 F17 Indicator unit (terminal 30) 2A
22.2 F18 LTC module N1 (terminal 30) 15 A
22.3 F19 LTC module N2 (terminal 30) 15 A
22.4 F20 Terminal 15 10 A
23.1 F29 Indicator unit (terminal 15) 2A
23.2 F30 LTC module N1 (terminal 15) 2A
23.3 F31 LTC module N2 (terminal 15) 2A
23.4 F32 Terminal 30 10 A
24.1 F37 Side lights 15 A
24.2 F38 Spare battery + 5A
24.3 F39 Interior light 5A
24.4 F40 Battery + indicator 15 A
Fuse LMH spare part no.

2A 7 919 086 800
3A 7 919 086 801
5A 7 919 086 803
7.5 A 7 919 086 804
10 A 7 919 086 805
15 A 7 919 086 806
20 A 7 919 086 807
30 A 7 919 086 809
Relays
Position Designation Name
1 AC K1 Power supply for air conditioning system (12 V)
2 AC K2 Air conditioning system fan level 1 (12 V)
5 3K10 Cab tilt mechanism (24 V)
6 3K8 Power supply (24 V)
7 3K9 Brake light (12 V)
9 3K5 Reversing lights (12 V)
10 3K6 Programmable roof-mounted flashing light (12 V)

Relays
Position Designation Name
11 3K4 Flashing lights (24 V)
13 3K1 Top windscreen wiper (24 V)
21 3K2 Rear windscreen wiper (24 V)

Checks
Testing the electronic controllers and components
The following instructions assist fault-finding Tools required:
with a view to avoiding unnecessary exchange • Measurement box: spare part no.
of electrical and electronic components. The 791 729 90 10
testing of wiring harnesses also described is
• Ejection tool box: spare part no. 000 941 81 00
based on experience in the field. If, after the lamp
test (approx. 30 s), the indicator unit indicates • Multimeter: e.g. spare part no. 000 941 94 19
an error in the traction function (T xxx), the lifting • PC with "Pathfinder" diagnostics program
function (L xxx), the indicator unit itself (D xxx) • CAN box with connection cables
or the engine (X xxx), troubleshooting should be
• Training documents
performed as described in the manuals for the
relevant controllers.
Creating a parameter file:
NOTE The parameter file is very useful for fault-finding.
It is produced using the "Pathfinder" diagnostic
The status displays 1 - 99 and the warning dis- program by the actions Menu "Save" ► "Text file"
plays 100 - 199 do not indicate an error in the ► "Save as" ► "+all" ► "File name". The file name
controllers or the indicator unit; their function is should contain the chassis number and the date.
to assist troubleshooting and analysis on the ve-
hicle. (e.g. "18" Tilt stops teach-in procedure not
performed or cancelled, or "104" Seat switch and Producing a log file:
accelerator potentiometer signals implausible for On closing the "Pathfinder" diagnostic program
more than 2 seconds). a dialogue box "Save log?" appears. Clicking
Requirements: on Yes calls up the Save dialogue box. Expand
the suggested file name to include the chassis
The electrical testing assumes that the hydraulic number, and save the file.
and mechanical components of the vehicle are in
good working order.
Testing the LTC (vehicle and lift controller)
Step Yes no
Procedure
Type (Test) (Test)
1 Start LTC test of traction/lift:
Action ignition ON - read error log
2
Error logged for traction Go to step 3. Go to step 8.
Test
Troubleshooting with
3
prompted diagnostics,
Action
training documents.
4 General testing of wiring
Error found Go to step 5.
Test harness and sensors.
5 Perform repair and remedy
Action the fault.
Clear down the operating
6
test and error log, go on to
Action
step 11
7 For further troubleshooting,
Operation OK End
Test go to step 1

Checks
Step Yes no
Procedure
Type (Test) (Test)
8 Error logged for operating Perform test run. Go to step
Go to step 3.
Test hydraulics 9.
General testing of wiring
9 Error found or recorded in the
Go to step 3. harness and sensors. Go on
Test log
to step 10.
10
Error found in wiring harness Go to step 5. Go to step 11.
Test
11 Error found in sensors /
Go to step 6. Exchange the controller.
Test actuators
NOTE
For step 11 (No): Use the diagnostics program to

save a log file. Make a note of the voltage and re-
sistance values found during the general testing
of wiring harness and sensor. In warranty cases
the data from the log file (types and frequency
of errors) together with voltage and resistance
values found during the general testing of wiring
harness and sensor should be stated in the claim
text. A print-out of the log file must be included
with the defective part when it is sent back.

Checks
Checking wiring harness
1. Mechanical checking
¾ Check wiring harnesses for external damage
to the insulation, pinch points, heavy contami-
nation with oil, grease, water etc.
¾ Check all screw connections, positive and neg-
ative side, starting from the battery through to
the central electrical system and the compo-
nents, for secure seating.
Examples:
¾ Check attachment of the main harness to the
battery terminal.
¾ Check all plug connectors for corrosion and

secure seating. Never use contact spray!
¾ Check the insertion force of the contacts on

the main fuse: maximum contact clearance
0.4 mm (check with a feeler gauge). Tighten
cable connection nut to max. 5 Nm.

Checks
¾ Check that crimped joints are secure. Perform
a pull test on each individual wire.
2. Electrical testing
¾ Check for correct wiring according to the con-
figuration and wiring diagram for the truck.
¾ Measure the battery voltage.

Perform a voltage measurement (1) at terminal
:
15/58 (switched positive) with power being drawn
on the wiring harness, e.g. headlight bulb 55 W :
(2), to the truck earth (supply voltage PIN 120 to
earth PIN 114). 9

B
Use a 121-pin test adapter 7 917 299 010 or 154-

pin test adapter 000 973 4314 for this.
¾ Check the CAN bus connections: correct po-
larity of connections to CAN-high and CAN-
low, check the cable resistance.
NOTE
Resistance and voltage measurement under load

are pure measurements of the wiring harness, i.e.
with no controllers or components connected.
Testing sensors
1. Mechanical checking:
¾ Visual checking for mechanical damage
¾ Positioning and installing the sensors
¾ Check plug contacts for corrosion
2. Electrical testing:
¾ Check supply voltage to circuit diagram.
¾ Perform resistance tests for each sensor as
described in the training documents.
¾ Test signal outputs of sensors to circuit dia-
gram and training documents (voltage, cur-
rent).

Checks
Checking actuators
Test actuators (control solenoid, valve
solenoids)
1. Mechanical checking:
¾ Check that the cable connections and plug
connectors are securely seated
¾ Visually check plug connector seals
¾ Check the actuator mechanisms for free move-
ment
2. Electrical testing:
¾ Perform resistance and voltage measure-
ments directly at the component
¾ Perform current measurements (measure-
ment values to training documents)
Testing the indicator unit
Step Yes no
Procedure
Type (Test) (Test)
1 Ignition: perform lamp test.
Action Test background lighting.
Test supply voltage at
2
Lamp test OK Go to step 3. terminal and earth. Go to
Test
step 11.
Test supply voltage at
3
Background lighting OK Go to step 4. terminal and earth. Go to
Test
step 11.
4
Read the error log.
Action
5 Read the operating data log.
Error found. Go to step 6.
Test Go to step 12.
Troubleshooting with
6 prompted diagnostics.
Action General testing of wiring
harness and sensors.
7 Read the operating data log.
Error found. Go to step 8.
Test Go to step 12.
8 Perform repair and remedy
Action the fault.
9 Test operation and clear
Action down the error log.
10 Repaint the display.
Operation OK End of test
Test (See note below.)
11 Repaint the display.
Supply voltage OK
Test (See note below.)
12
Warning present. Go to steps 13 - 14. Go to step 6.
Test

Checks
Step Yes no
Procedure
Type (Test) (Test)
Test parameter settings,
adjust them if necessary.
13
Test the UPA inputs, adjust
Action
them if necessary. Go to step
14.
Clear down the operation
14 Operating data log cleared
testing log and operating data Go to step 6.
Test down.
log. Go to step 9.
NOTE
For step 10 (No) and step 11 (Yes): Use the dia-

gnostics program to save a log file. Make a note
of the voltage and resistance values found during
the general testing of wiring harness and sensor.
In warranty cases the data from the log file (types
and frequency of errors) together with voltage
and resistance values found during the general
testing of wiring harness and sensor should be
stated in the claim text. A print-out of the log file
must be included with the defective part when it is
sent back.

Hydraulics 7
a
Regulating pump HPR 210-02

Technical data for regulating pump
Manufacturer Linde
Model HPR 210 -02
Maximum delivery volume 210 cm3/U
Number of pistons 9
Maximum working pressure 367 bar
Feed pressure 27+1 bar
Swivel angle 3 - 20°
Pump speed 0 - 2100 min
Type of pump adjustment electrohydraulic
Pump adjustment controller Linde LS and LHC

7 Hydraulics
HPR 210-02 regulating pump
359_07-008
1 SPU cap (part of the reservoir change-over)

2 Stop screw Qmax
3 Stop screw Qmin (standby)
P High-pressure connection
T Suction connection

Hydraulics 7
5 LS 1
X
LS 2
6 1
4
3
2
T
359_07-009
1 SPU cap (part of the reservoir change-over) 7 PTO

2 Stop screw Qmax X Setting pressure test connector
3 Stop screw Qmin (standby) LS1 Load sensing connection
4 Proportional pressure regulation valve maxi- LS2 Load sensing connection
mum load regulation 1Y10 P High-pressure connection
5 Load-sensing regulator E1L T Suction connection
6 LS regulator adjusting screw ( Pp — LSp)

7 Hydraulics
4 5
9 10
15
7
14
13 11
12
359_07-010
4 Proportional pressure regulation valve maxi- 12 EL1 regulator

mum load regulation 1Y10 11 Port plate
5 Load-sensing regulator E1L 12 Main piston
7 PTO 13 Swash plate
8 Pipe 14 Shaft seal
9 Cylinder block 15 Shaft
10 Sleeve
Name The regulator for the HPR 210-02 regulating

pump incorporates two sorts of regulators:
HPR 210-02 R E1L with load sensing regulator
and electrical proportional pressure regulation • Load sensing regulator L
valve. • Electrical proportional pressure regulation
valve E1
Load sensing regulator
The HPR 210-02 R E1L regulating pump is a
self-priming axial piston swash plate pump with The HPR 210-02 pump load sensing regulator
a variable stroke volume for the open circuit. regulates the volumetric flow starting from a zero
The regulating pump is also fitted with an "SPU" pump delivery flow.
reservoir change-over.
If no volumetric flow is taken when the pump is
running, only the "stand-by pressure" for system
requirements is maintained.

Hydraulics 7
If any consumer control valves are actuated, Depending on the flow consumption the pressure
the load sensing regulator on the HPR unit regulation valve reduces the internally applied
automatically adjusts the stroke volume, and pump pressure.
with it the volumetric flow, to match the "required
This signal changes the pressure differential
flow rate" demanded by the control valves, up to
( p) setting (which reduces the stroke volume)
the maximum available pump capacity.
with the help of an additional measuring surface
In these circumstances the pump pressure is on the LS regulator.
only about 27 bar above the respective (highest)
pressure of the active consumers. The load
SPU reservoir change-over
sensing regulator is thus a required flow rate
system that adjusts the pump delivery flow rate of Noise optimisation by definite reduction of the
the variable measuring orifice size by keeping the body and liquid noise using the SPU reservoir
pressure gradient at the spool valve measuring change-over.
orifice constant.
This greatly reduces the noises generated by
pressure changes and pressure pulses.
Electrical pressure regulation valve
The pressure regulation valve is actuated via a
proportional pressure regulation valve.

7 Hydraulics
Load sensing regulation
LS T
LS 1
P
2
359_07-016
1 Control piston T Suction connection

2 HPR 210-02 regulating pump X1 Control pressure for emergency actuation
3 Pump line (max. 30 bar)
4 LS regulation control pilot A Control pressure test connector
5 LS line LS Load sensing connection
6 1Y10 regulating solenoid X Setting pressure test connector
7 Pressure regulation valve L Leak oil connection
8 Channel U Leak oil connection
P High-pressure connection
Operating procedure of the load sensing Actuating the control piston (1) causes the con-
regulator nection from the pump (2) to the consumer to be
opened.
Assuming no consumer is actuated and the
control piston (1) is in the neutral position, the The cross-section that is opened up is thus
pump (2) will only pump enough oil to ensure essentially nothing but a metering throttle.
that the pressure in the pump line (3), which acts If a constant flow of oil must pass through this me-
on the LS regulation control pilot(4), is sufficient tering throttle, the pressure gradient at this point
to maintain a state of equilibrium between the must remain constant irrespective of consumer
spring on the opposite side of the regulator and pressure.
the swivel spring (on the control piston qmin).
If the control piston (1) is opened, the pump
Any change in pressure (P or LS) changes the pressure is extended to this consumer.
position of the LS regulation control pilot (4), the
immediate effect of which is to adapt the feed rate At the same time the consumer pressure acts
accordingly. via the LS line (5) on the spring side of the LS
regulation control pilot (4), causing the pump (2)

Hydraulics 7
to receive a signal to increase the swivel angle, positioned so it blocks the connection channel (3)
which increases the pressure in the P-line (3). (pump pressure) to the channel (8) (leading to the
measuring surface on the LS regulation control
If the pump pressure exceeds the load pressure,
pilot (4)).
the consumer starts to move and the oil flowing
through it creates a pressure loss at the control The channel (8) to the tank (within the HPR pump
edge (metering throttle). casing) is depressurised.
Equilibrium is restored when this pressure loss If a pre-determined current flows in the regulating
equals the initial spring tension of the LS regula- solenoid (6), the solenoid tappet moves the
tion control pilot (4). pressure regulation valve pilot piston (7) into
the position in which the channels (3) and (8) are
The pump (2) responds to every movement of the
connected.
control piston because it endeavours to balance
out every change in the metering throttle aperture The magnetic force is converted into a hydraulic
and to maintain a constant pressure gradient at force in proportion to the level of the connected
all times. current.
This signal (control pressure) uses an additional
Operating procedure of the electrical pres- measuring surface in the LS regulation control
sure regulation valve pilot (4) to reduce the pressure differential ( p)
setting. The result is a reduction in the stroke
When the regulating solenoid (6) is deenergised,
volume of the HPR 210-02 regulating pump.
the pressure regulation valve pilot piston (7) is

7 Hydraulics
Working hydraulic
Working hydraulic circuit diagram
6
5
22
3
2
21
20
3
19
10
2
8
8
18
17
10
1
8
8
16
15
10
1
8
8
14
13
12
10
8
8
11
9
Hydraulics 7
Working hydraulic
Components
1. Tilt cylinder.
2. Lift cylinders.
3. Line breakage protection.
4. Tilt pre-load valve.
5. 1B10 reference load pressure sensor.
6. 1B9 load pressure sensor.
7. 2Y10 lowering stop valve.
8. Proportional pressure regulation valve.
9. Filter.
10. LS change over valve.
11. Auxiliary pressure relief.
12. Auxiliary function spool.
13. Auxiliary compensation spool.
14. Spreader pressure relief.
15. Spreader function spool.
16. Spreader compensation spool.
17. Tilt function spool.
18. Tilt compensation spool.
19. Lift/lower function spool.
20. Raise/lower feed pressure balance.
21. Priority valve.
22. Pressure relief valve.
P. Pressure connection, main pump.
T. Tank return flow.
LS. Pressure connection, load sensing.
LS1 Pressure connection, load sensing.
LSL. Pressure connection, load sensing, steering.
S. Pressure connection, steering.
MP. Measurement point for circulation and maximum pressure.
MLS. Load sensing measuring point.
X. Pilot pressure supply.
T. Return / oil tank.

7 Hydraulics
Working hydraulic
Hose layout
Hose layout, supply, valve block, working hydraulics
LS T
LS 1
P
2
359_07-016
1 Retarder valve block T Tank return flow

2 Valve block, working hydraulics LS Pressure connection, load sensing
P Pressure connection, working hydraulics LS1 Pressure connection, load sensing

Hydraulics 7
Working hydraulic
Hose layout — lifting/lowering
2Y1 2Y2
A1
1
2 359_07-013
1 Lift/lower hydraulic cylinder 2Y1 Proportional pressure regulating valve for

2 Line breakage protection lowering
3 Lowering stop valve 2Y10 2Y2 Proportional pressure regulating valve for
A1 Connection for lifting lifting

7 Hydraulics
Working hydraulic
Tilting hose layout
2Y3
2Y4
A2
B2
2
359_07-014
1 Tilt cylinder 2Y3 Tilt proportional pressure regulation valve

2 Tilt pre-load valve forwards
A2 Tilt back connection 2Y4 Tilt proportional pressure regulation valve
B2 Tilt forward connection backwards

Hydraulics 7
Working hydraulic
Hose layout for spreader supply
5
3
2Y15
1 4
1. Spreader hose. 2. Hose union. 3. Mast hose.

4. Pipe union. 5. Spreader valve block. 2Y15. Spreader function spool.

7 Hydraulics
Working hydraulic
Measurements and settings
Checking the maximum working pres-
sure and LS pressure
Checking requirements:

• PC with "Pathfinder" diagnostic program
• Linde hydraulics measurement tool case
• Digital pressure gauge
• Minimum test weight 5 t
NOTE
Since the pressure settings may have an enor-

mous effect on the truck’s handling, it is not ad-
visable to use conventional pressure gauges.
Checking and adjustment procedure

The maximum working pressure (P) and the load
sensing pressure (LS) can be determined very
easily using the "Pathfinder" diagnostic software.
¾ Connect a PC with the "Pathfinder" diagnostic
program to the truck.
¾ Start diagnostic 359.
¾ Select working hydraulic, inputs/outputs, pres-
sure sensors.
At present, the displayed voltage value (mV) still

has to be converted into pressure (bar):
• 500 mV = 0 bar
• 4500 mV = 600 bar
• 1 bar ≈ 6.6666 mV
• 0.15 bar ≈ 1 mV
Example: a value of 1500 mV
= 1500 mV x 0.15 ≈ 225 bar
If conventional measuring methods are being
used (pressure gauge/digital pressure gauge),
pressure test connectors must be fitted to carry
out the various measurements.

Hydraulics 7
Working hydraulic
The pressure test connection P on the working
hydraulic valve block must be used to measure
the maximum working pressure (P).
The load sensing pressure (LS) must be read

off using a T-piece located upstream of the LS
pressure sensor.
¾ Start the truck.
¾ Read off the pressure (idling, no function actu-
ated)
Setpoint values:
• P: approx. 50 bar
• LS approx. 10 bar
¾ To check the primary protection system (pres-

sure relief valve in working hydraulic valve
block), first increase the tension on the LS
pressure relief valve (1) on the retarder valve
block by two more turns.
¾ Now actuate the Lift function and raise the
mast as far as the stop.
¾ Read off the pressure
Setpoint values:
• P: approx. 370+5 bar
NOTE 1
You should be able to hear loud flow noises 359_07-020
coming from the working hydraulic valve block
(pressure relief valve opens).
¾ If necessary, adjust the maximum P pressure
by undoing the locknut on the pressure relief
valve cartridge (2) and slowly increase the
pressure by turning the adjusting screw in a
clockwise direction until the maximum pres-
sure of 370+5 bar is reached. Lock the adjust-
ing screw again.

7 Hydraulics
Working hydraulic
¾ If the correct pressure cannot be set, check the
pressure relief valve cartridge (2) and change
it if necessary. Check the retarder valve as
well if necessary.
¾ If the setpoint values are obtained, turn the LS
pressure relief valve (1) on the retarder valve
block back two turns into its original position.
¾ Then raise the mast again as far as the stop
and read off the pressure.
Setpoint values:
• P: approx. 367 - 370 bar
¾ If necessary, adjust the LS pressure by turn-
ing the adjusting screw to the desired value.
Retighten the locknut.

Hydraulics 7
Working hydraulic
Checking and adjusting delta pressure P
to LS
Checking requirements:

• PC with "Pathfinder" diagnostic program
• Linde hydraulics measurement tool case
• Digital pressure gauge
• Minimum test weight 5 t
NOTE
Since the pressure settings may have an enor-

mous effect on the vehicle’s handling, it is not
advisable to use conventional manometers.
Checking and adjustment procedure

The delta pressure is adjusted using pump con-
troller E1L. Normally all the pump controllers are
adjusted on a test bench and the adjusting screw
is sealed using what is known as a Gardena cap.
If the setting needs to be altered, the sealing cap
must first be removed.
¾ Pick up the test weight.
¾ Slowly raise the mast in a controlled manner
and at the same time read the maximum delta
pressure.
NOTE
It may be necessary to raise and lower the mast

several times before experience permits a stable
pressure value to be read.
¾ If necessary move the mast towards the stop.
Setpoint value:
• P: approx. 27 bar

7 Hydraulics
Working hydraulic
¾ To increase the delta pressure ( P), carefully
turn the adjusting screw in a clockwise direc-
tion.
¾ To reduce the delta pressure ( P), carefully
turn the adjusting screw in an anti-clockwise
direction.
One revolution corresponds to approx. 27 bar.
¾ If the delta pressure cannot be set to 27 bar,

then the LS pressure relief valve (1) and the
release valve 2Y9 (2) on the retarder valve
block must be checked. 1
¾ Remove LS pressure relief valve (1).
NOTE
Before it is dismantled, the length of the adjus-

ting screw must be measured so that the basic
adjustment can be performed again after the in-
spection.
¾ Dismantle and clean the valve, check it for
damage and change it if necessary. 2 359_07-023
¾ To check the 2Y9 release valve (2), remove the

entire valve, including the insert, and check it
for dirt and freedom of movement, change it if
necessary.
¾ Repeat pressure test, re-adjusting the max. LS
pressure if necessary; see ⇒ Chapter "Check-
ing the maximum working pressure and LS
pressure", P. 7-14
¾ If the delta pressure is not the same as the
setpoint value, there could be a leak in the LS
shuttle valve in the operating hydraulics valve
block.
¾ Block the LSL connection.
¾ Measure the delta pressure again.
If the value is now OK, this means that the LS
shuttle valve is faulty.
¾ Change the LS shuttle valve in the operating
hydraulics valve block.
¾ Measure the delta pressure again and adjust it
if necessary.

Load lift system lubrication
Check and adjust mast chains, lubricate with chain spray
Check and adjust mast chains,

lubricate with chain spray
NOTE
After some time in service the lifting chains
stretch and therefore must be checked and 3
adjusted as necessary on the left and right
sides of the mast.
2
¾ Clean the mast chains.
¾ Put the mast vertical.
¾ Remove split pin (1).
¾ Release locknuts (2). 1
d3591115
¾ Using nuts (3), adjust the chains to allow a
clearance of 12 mm (1/2 inch) between the
fork heels and the ﬂoor.
¾ Tighten locknuts (2).
¾ Fit new split pin (1).
NOTE
Ensure both chains are adjusted equally.
¾ Spray channel surfaces, pulleys and chains
with Linde chain spray.
NOTE
Trucks in service in the food industry must be
lubricated with an oil approved for the food
industry instead of chain spray.
Lubricate the spreader
1
1
5 5
2 2
3 4 3
d3181045
5 5
NOTE
Use Linde heavy duty lubricating grease with
additives EP and MOS2.
Position 1 - Twistlocks
¾ Apply grease at points (A) & (B).
B A
d3181046
¾ Check for wear and general condition of

twistlock. If in doubt replace the twistlock.
NOTE
Replace twistlock if dimension (C) is less than
25 mm and after 5000 hours service.
d3181052
Position 2 - End beam slider pads
NOTE
No greasing is necessary.
¾ Check the condition of slider pads.
CAUTION
Do not allow metal to metal contact.
d3181047
Position 3 - Main frame and extension

beam wear pads
¾ Apply grease on the inside of the end rings
of each main frame beam.
d3181048
Position 4 - Side shift cylinder bearings

¾ Apply grease to grease nipples on the
cylinder tube bearing.
d3181049
Position 5 - Side shift slider pads
NOTE
No greasing is necessary.
¾ Check the condition of slider pads.
CAUTION
Do not allow metal to metal contact.
5
d3181050
Load lift device lubrication information
1 2
(ii)
(i)
3
4
(i) (i)
(i)
d3180001
The scheduled maintenance intervals detailed

below should be reviewed according to the
application of the truck, the usage of the truck
and the environmental conditions in which the
truck is operated.
Refer to illu d31800001.
¾ Mast guide rollers (top and bottom) (Illustra-
tions 1,2,3 & 4) and spreader guide rollers
(Illustration 5) are sealed for life rollers, but
must be checked for damage every 500
hours.
NOTE
Please see the wear limit table which identiﬁes
individual wear limits on wear pads.
Table 1
Original
Illustration Service limit Quantity
Part number Description dimension
reference (mm) required
(mm)
Illu 3 (i) 1754465600 Wear strip 20 x 15 x 15 17 x 10 x 10 2
Illu 1 (i), Illu 4
1794465600 Wear strip 25 19 8
(i), Illu 5 (i)
Wear strip
Illu 1 (ii) 1794465602 33.5 27 2
outer mast top
NOTE
If service limits are reached on any face of
wear pad 1754465600, it must be replaced.
Mast (Nylube) wear pad - Wear limits
Refer to illustration d3180001, 3(i) and 

Table 1 above.
Refer to illustration d3180001, 1(i) and 4(i) and 

Table 1 above.
Refer to illustration d3180001, 1(ii) and 

Table 1above.
Circuit diagrams 10
g
a

10 Circuit diagrams
Wiring diagrams QSB 6.7

Wiring diagram, sheet 1

Circuit diagrams 10
Legend F61 Heating system fuse, 4-5 S22 Coolant level switch, 66-70 :32 − Coolant level return line
B21 Heating system, 53 F62 Cab opening fuse, 4-5 S23 Footbrake switch, 12-14 :37 − CAN bus screen
3B1 12/24 V converter, 39 F63 Cab main supply fuse, 15-16 X1 Plug connector for wiring harness between cab and :39 − E-switch
6B2 Linde Forklift Data Management load sensor plug, F64 Starter motor fuse, 4-5 chassis :40 − Heating system output
49-51 G1 Alternator, 9-10 X12 Plug connector for wiring harness between chassis :42 − Heating return line
6X4 Linde Forklift Data Management plug, 41-50 G2 24 V battery, 1-2 and engine :46 − CAN_HIGH
6X4a Linde Forklift Data Management dummy plug, 41-43 K1 24 V ignition relay, 18-26 X2 Plug connector for wiring harness between cab and :47 − CAN_LOW
F11 Engine ignition fuse, 55 K15 Starter motor relay, 5-13 chassis J3 QSB engine output module, 74-80
F20 12 V fuse, 36 K44 Heating system relay, 52-57 X3 Electronic control module (ECM) plug connector X5:1/2 battery -
F25 12/24 V converter fuse, 39 3K8 12 V ignition relay, 21-22 (angular) X5:3/4 battery +
F32 Fuse for 12 V battery +, 30-31 M1 Starter motor, 6 X4 CAN bus plug connector
Notes
F33 Ignition switch fuse, 21 N3 QSB engine, engine control unit X5 QSB engine plug connector (round)
(a) Main fuse
F54 Chassis cable harness fuse, 76 S1 Ignition switch, 19-23 X50 Plug connector for cab steering column main harness
(b) 12 V supply controller
F55 12/24 V converter fuse, 4 S2 Battery switch, 1-2 J2 QSB engine control module, 55-74
(c) QSB engine, engine management
F60 Heating system fuse, 4-5 S21 Handbrake switch, 11-14 :28 − Coolant level input

10 Circuit diagrams

Circuit diagrams 10
Legend :26 − Lift height switch reference :78 − CAN bus + engine 1X1 3-pin plug connector (speed actual-value transmitter),
1B1 Speed actual-value transmitter, 85–86 :27 − Seat rotation, middle :79 − CAN bus - engine 84
1B2 Accelerator dual potentiometer, front, 90-94 :28 − Truck type coding 4 :80 − GND sensors, drive 1X3 6-pin plug connector (single pedal), 144
1B4 Hydraulic oil temperature sensor, 88-89 :29 − Load sensor reference :81 − GND sensors, drive 1Y1 Retarder valve, 103
1B5 LS pressure sensor, 108-109 :30 − Tilt angle sensor :83 − Lift height switch 1Y2 Forwards solenoid valve, 96
1B6 Accelerator dual potentiometer, rear, 85-90 :31 − Lift height sensor :84 − Backwards seat rotation 1Y3 Backwards solenoid valve, 99
1B7 Braking potentiometer, front, 92-96 :32 − Drive potentiometer 1 reference (front) :86 − CAN bus - 1Y4 Exhaust valve, 101
1B8 Braking potentiometer, rear, 97-102 :33 − Seat switch reference :88 − GND sensors, lift 1Y7 Hydraulic motor solenoid valve, 107
1B9 Boost pressure sensor, 106-107 :34 − Drive potentiometer 2 reference (rear) :90 − Lift height display 1Y8 Injector proportional valve, 113
1B10 Boost pressure sensor reference, 104-105 :35 − Handbrake switch :91 − Tilt forwards (A2) 1Y10 Hydraulics main pump valve, 158
2B1 Basic joystick functions, 132-137 :36 − Middle :92 − Tilt backwards (B2) 1Y11 Cold start valve, 111
:1 − 5 V :37 − Forwards :93 − Lift 2Y1 Lower valve, 139
:2 − Lift/lower :38 − Seat switch :95 − CAN bus + 2Y2 Lift valve, 141
:3 − Tilt forwards/back :40 − Seat rotation release :96 − 0 V lift 2Y3 Tilt forwards valve, 145
:4 − Lift/lower reference :41 − Brake light :98 − Lower 2Y4 Tilt backwards valve , 147
:5 − Tilt forwards/back reference :42 − Engine switch-off :99 − Forwards seat rotation 2Y9 Exhaust valve, 151
:6 − 0 V :43 − Retarder 1Y1 :103 − Tilt angle sensor reference 2Y10 Lower safety valve, 154
2B3 Tilt angle potentiometer, 131-136 :44 − Mast vertical display :104 − Lift height display reference
Wire colours
F18 15 A fuse, 82-83 :45 − Main pump valve 1Y10 :105 − Mast vertical
SW Black
F30 2 A fuse, 81 :46 − Exhaust valve 1Y4, WDO drive :106 − 0 V lift/lower
BR Brown
N1 LHC electronic traction controller, 81-159 :47 − Truck type coding 2 :107 − 0 V tilt forwards/backwards
BL Blue
:1 − 5 V drive :49 − Drive potentiometer 1 (front) :108 − 0 V lower safety valve
GN Green
:2 − 5 V drive :50 − Speed limitation :109 − 0 V exhaust valve
GR Grey
:3 − 5 V drive :51 − Backwards seat rotation SW :110 − Lower safety valve 2Y10
OR Orange
:6 − Forwards hydraulic pump 1Y2 :52 − Truck type coding 3 :111 − Exhaust valve 2Y9
RT Red
:7 − Reverse hydraulic pump 1Y3 :54 − Backwards seat rotation :113 − 0 V main pump valve
VI Violet
:8 − Forwards seat rotation SW :55 − Load sensor :114 − GND
WS White
:9 − LS pressure sensor :56 − Code :116 − 5 V lift
GE Yellow
:10 − Truck type coding 1 :58 − Braking potentiometer reference, front :118 − 5 V lift sensor
The number in front of the wire colour refers to the wire
:11 − Braking potentiometer, front :59 − Forwards seat rotation S4 Single-pedal drive direction switch, 140-146
cross-section.
:13 − Hydraulic oil temperature sensor :60 − Drive potentiometer 2 (rear) S5 Seat switch, 138-139
Wires with unspecified cross-section = 0.75 mm2
:14 − 0 V proportional valve injector :61 − GND, drive X1 Plug connector for wiring harness between cab and
:15 − 0 V forwards hydraulic pump :62 − Retarder valve 1Y1 chassis Notes
:16 − 0 V reverse hydraulic pump :63 − Speed actual-value transmitter X2 Plug connector for wiring harness between cab and (a) 12 V from converter
:17 − 0 V retarder valve :64 − Braking potentiometer, rear chassis (b) Supply from the display unit, pin 2 at 6P1 (sheet 3)
:18 − 0 V cold start valve :65 − Mast vertical reference X12 Plug connector for wiring harness between chassis (c) Wires twisted together
:19 − 0 V exhaust valve, WDO drive :72 − Reverse and engine (d) to the engine control unit
:22 − Reverse light :73 − Braking potentiometer reference, rear X16 LHCM / chassis plug connector (e) for production purposes
:23 − Programmable reverse light :75 − Speed limitation reference X17 Truck types coded plugs, 154-157 (f) Detection for dual-pedal operation
:24 − Injector proportional valve 1Y8 :76 − CAN bus + X19 LHCM / chassis plug connector (g) Drive direction switch
:25 − Cold start valve 1Y11 :77 − CAN bus -

10 Circuit diagrams

Circuit diagrams 10
Legend :24 - Fork prong positioner oil supply 2Y15 :112 - 0 V fork prong positioner 2Y14 Additional proportional solenoid valve A6, 237
B1 Fuel quantity sensor, 170-171 :27 − Oil supply 1 :113 − 0 V 2Y15 Fork prong positioner oil supply solenoid valve
2B2 Sideshift / fork prong positioner joystick, 203-209 :28 − Truck type coding 4 :114 − Earth spreader, 240
:1 − 5 V :33 − Coding 2 :116 − 5 V lift
Wire colours
:2 − Shift fork :35 − Lift release 1 :119 − Earth
SW Black
:3 − Adjust fork arms :38 − Coding 1 6P1 Display unit, 162-177
BR Brown
:4 − Shift fork reference :44 − Sideshift, left (B4) 2Y7 OS1 Engine oil pressure switch, 164-166
BL Blue
:5 − Adjust fork arms reference :45 − Sideshift, right (A4) 2Y8 S3 Vacuum-operated switch suction filter, 167-168
GN Green
:6 − 0 V :47 − Truck type coding 2 S6 Return line filter switch contaminated, 209-211
GR Grey
2B4 Additional joystick functions, 211-217 :50 − Lift release 2 X1 Plug connector for wiring harness between cab and
OR Orange
:1 − 5 V :52 − Truck type coding 3 chassis
RT Red
:2 − Additional function 5 :56 − Oil supply 2 X2 Plug connector for wiring harness between cab and
VI Violet
:3 − Additional function 6 :62 − 0 V fan chassis
WS White
:4 − Additional function reference 5 :75 − Return line filter switch contaminated X15 2-pin plug connector (CAN bus)
GE Yellow
:5 − Additional function reference 6 :76 − CAN bus + X18 Container functions plug connector, 218-228
The number in front of the wire colour refers to the wire
:6 − 0 V :77 − CAN bus - 6X2 7-pin plug connector (diagnostics controller), 184-185
cross-section.
F17 Display unit fuse, 163 :82 - Fork prong positioner together (A3) 2Y6 6X3 7-pin plug connector (diagnostics engine), 184-185
Wires with unspecified cross-section = 0.75 mm2
F19 LHCS fuse, 197 :86 − CAN bus - 1Y5 Fan proportional solenoid valve, 207
F29 Display unit fuse, 165 :88 − 2Y5 Fork prong positioner apart proportional solenoid Notes
F31 LHCS fuse, 194 :90 - Fork prong positioner apart (B3) 2Y5 valve, 219 (a) from the converter
2B3 Tilt angle potentiometer, 131-136 :91 − Additional function (B6) 2Y13 2Y6 Fork prong positioner together proportional solenoid (b) Controller diagnostic connector
F18 15 A fuse, 82-83 :92 − Additional function (A6) 2Y14 valve, 220-221 (c) Engine diagnostic connector
F30 2 A fuse, 81 :93 − Additional function (A5) 2Y12 2Y7 Left sideshift proportional solenoid valve, 224 (d) Container functions
N1 LHCS electronic traction controller, 193-240 :95 − CAN bus + 2Y8 Right sideshift proportional solenoid valve, 226 (e) No container functions
:8 − Lower shut-off :96 − Lift earth 2Y11 Additional proportional solenoid valve B5, 230 (f) No fork prong positioner
:10 − Truck type coding 1 :98 − Additional function (B5) 2Y11 2Y12 Additional proportional solenoid valve A5, 232 (g) Fork prong positioner available
:14 - 0 V fork prong positioner oil supply :106 − 0 V additional function 2Y13 Additional proportional solenoid valve B6, 235
:17 − Fan 1Y5 :107 − 0 V additional function

10 Circuit diagrams
Wiring diagram, sheet 4 - dipped beam, sidelight, direction indicator and hazard warning light, reverse light

Circuit diagrams 10
Legend H17 Front left sidelight, 245 8S2 Steering column multifunction switch, 263-265 OR Orange
B20 Reverse light buzzer, 281 H18 Rear left sidelight, 247 X1 Plug connector for wiring harness between cab and RT Red
F4 Reverse light fuse, 277 H19 Front right sidelight, 249 chassis VI Violet
F6 Dipped beam fuse, 242-243 H20 Rear right sidelight, 251 X2 Plug connector for wiring harness between cab and WS White
F10 Direction indicator fuse, 266-267 H21 Front left direction indicator, 260-261 chassis GE Yellow
F37 Sidelights main fuse, 244-245 H22 Rear left direction indicator, 263 X50 Plug connector for steering column main harness The number in front of the wire colour refers to the wire
F40 Direction indicator fuse (battery +), 264-265 H23 Front right direction indicator, 265-266 X52 Cab / cab roof plug connector cross-section.
F41 Left dipped beam fuse, 241 H24 Rear right direction indicator, 268 Wires with unspecified cross-section = 0.75 mm2
Wire colours
F42 Right dipped beam fuse, 243 H25 Left reverse light, 277
SW Black Notes
F43 Left sidelight fuse, 245 H26 Right reverse light, 279
BR Brown (I) Dipped beam, sidelight
F44 Right sidelight fuse, 249 3K4 Flasher relay, 262-265
BL Blue (II) Direction indicator / hazard warning light
H14 Direction indicator light, 263-266 3K5 Reverse light relay, 273-277
GN Green (III) Reverse light
H15 Left dipped beam, 241 1S9 Dipped beam switch, 214-247
GR Grey
H16 Right dipped beam, 243 1S11 Hazard warning switch, 258-269

10 Circuit diagrams
Wiring diagram, sheet 5 - work lights, horn, interior light, cigarette lighter, radio

Circuit diagrams 10
Legend H45 Lift mast work light 6, 302 X50 Plug connector for steering column main harness The number in front of the wire colour refers to the wire
D13A 12/24 V converter, 327-329 4H1 Horn 1, 317 X51 Cigarette lighter, 330 cross-section.
F1 Cab roof work lights fuse, 312 4H2 Horn 2, 320 X52 Cab / cab roof plug connector Wires with unspecified cross-section = 0.75 mm2
F2 Lift mast work lights fuse, 304 H46 Cab roof work light 1, 308-309
Wire colours Notes
F48 Fuse for radio 24 V battery +, 333 H47 Cab roof work light 2, 309-310
SW Black (I) Lift mast work lights, positions 1 and 2
F45 24 V radio fuse, 335 H48 Cab roof work light 3, 311
BR Brown (II) Lift mast work lights, positions 3 and 4
F36 Horn fuse, 317 H49 Cab roof work light 4, 312-313
BL Blue (III) Cab roof work lights
F39 Interior light fuse, 323-324 H50 Interior light, 323-324
GN Green (IV) Horn
F16 Free fuse for battery +, 331-332 1S8 Cab roof work lights switch, 310-315
GR Grey (V) Interior light
H40 Lift mast work light 1, 291 1S10 Mast work lights switch, 300-307
OR Orange (VI) 12 V cigarette lighter
H41 Lift mast work light 2, 293 4S1 Horn switch, 316-317
RT Red (VII) 24 V radio
H42 Lift mast work light 3, 295 X2 Plug connector for wiring harness between cab and
VI Violet (a) Supply for battery +
H43 Lift mast work light 4, 297 chassis
WS White (b) 24 V radio
H44 Lift mast work light 5, 299-300 X14 Lift mast work lights plug
GE Yellow (c) Loudspeaker

10 Circuit diagrams
Wiring diagram, sheet 6 - windscreen wiper motors

Circuit diagrams 10
Legend F14 Roof panel wiper fuse, 380 1S7 Front windscreen wiper switch, 347-353 GR Grey
28BI/II Windscreen wiper synchronisation, 345-357 F15 Front windscreen wiper fuse, 347 8S2 Steering column multifunction switch, 347-351 OR Orange
I:1 − Left motor 3K1 Roof panel wiper relay, 382-385 X1 Plug connector for wiring harness between cab and RT Red
I:2 − Earth 3K2 Rear window wiper relay, 368-371 chassis VI Violet
I:3 − Left inactive position 1M7 Right wiper motor, 353-357 X2 Plug connector for wiring harness between cab and WS White
I:4 − Continuous wiping 1M7A Left wiper motor, 345-349 chassis GE Yellow
II:1 − Right windscreen wiper earth 2M1 Roof windscreen washer motor, 381-383 X50 Plug connector for steering column main harness The number in front of the wire colour refers to the wire
II:2 − 24 V 2M2 Rear windscreen washer motor, 367-369 X52 Cab / cab roof plug connector cross-section.
II:3 − Right motor 2M3 Front windscreen washer motor, 359-361 Wires with unspecified cross-section = 0.75 mm2
Wire colours
II:4 − Washing signal 3M1 Roof wiper motor, 385-388
SW Black Notes
II:5 − Interval 3M2 Rear wiper motor, 371-374
BR Brown (I) Front windscreen wiper
II:6 − Right inactive position 1S5 Roof panel wiper switch, 377-386
BL Blue (II) Rear window wiper
F13 Rear window wiper fuse, 366-367 1S6 Rear window wiper switch, 363-372
GN Green (III) Roof panel wiper

10 Circuit diagrams
Wiring diagram, sheet 7 − seat heater, flashing beacon, brake light, programmable roof light/ beacon, mast speed limit

Circuit diagrams 10
Legend H32 Brake light right X10 Plug connector rear lights WS White
B24 Buzzer programmable roof light/ beacon H33 Programmable roof light 1 X52 Cab / cab roof plug connector GE Yellow
6B1 Seat heater H34 Programmable roof light 2 The number in front of the wire colour refers to the wire
Wire colours
F3 Fuse programmable roof light/ beacon H35 Programmable beacon cross-section.
SW Black
F5 Fuse brake light 1S4 Seat heater switch Wires with unspecified cross-section = 0.75 mm2
BR Brown
F7 Fuse flashing beacon 1S13 Programmable roof light/ beacon switch
BL Blue Notes
F24 FuseSeat heater S20 Mast speed limit switch
GN Green (I) Seat heater
3K6 Relay programmable roof light/ beacon X1 Plug connector for wiring harness between cab and
GR Grey (II) Flashing beacon
3K9 Relay Brake light chassis
OR Orange (III) Brake lights
H30 Flashing beacon X2 Plug connector for wiring harness between cab and
RT Red (IV) Programmable roof light/ beacon
H31 Brake light left chassis
VI Violet (V) Mast speed limit

10 Circuit diagrams
Wiring diagram, sheet 8 − cabin tilting mechanism, door release, spare fuses

Circuit diagrams 10
Legend X1 Plug connector for wiring harness between cab and Wire colours GE Yellow
F34 Fuse door release motor, 459 chassis SW Black The number in front of the wire colour refers to the wire
F35 Fuse cabin tilting mechanism, 455-456 X2 Plug connector for wiring harness between cab and BR Brown cross-section.
3K10 Relay cabin tilting mechanism, 449-455 chassis BL Blue Wires with unspecified cross-section = 0.75 mm2
M4 Door release motor, 463-466 X12 Plug connector for wiring harness between chassis GN Green
Notes
3S5 Cabin tilting mechanism rocker switch, 448-454 and engine GR Grey
(I) Cabin tilting mechanism
23S1 Window switch, 455-456 X52 Cab / cab roof plug connector OR Orange
(II) Door release
S7 Door switch, 450-454 3Y1 Cabin down valve, 451-452 RT Red
(III) Spare fuses
S8 Door release switch, 463-466 3Y2 Cabin up valve, 453-454 VI Violet
(a) Main fuse box, from F62
WS White

10 Circuit diagrams
Wiring diagram, sheet 9 - air conditioning

Circuit diagrams 10
Legend F23 Air conditioning fuse, 532 Wire colours WS White
AC-K1 Air conditioning compressor coupling relay, 493/513 K10 Capacitor relay, 530-532 SW Black GE Yellow
AC-K2 Relay for low fan speed, 495/515 M2 Capacitor motor, 535-536 BR Brown The number in front of the wire colour refers to the wire
AC-K3 Relay for medium fan speed, 497/517 M3 Capacitor motor, 535-536 BL Blue cross-section.
AC-K4 Relay for high fan speed, 500/519 N4 Air conditioning controller, 502-509 GN Green Wires with unspecified cross-section = 0.75 mm2
B30 Low pressure sensor, 523 Y1 Air conditioning compressor coupling, 493 GR Grey
Notes
B31 High pressure sensor, 525 X1 Plug connector for wiring harness between cab and OR Orange
(a) Air conditioning controller
F21 Air conditioning fuse, 497-498 chassis RT Red
(b) Capacitor unit
F22 Air conditioning fuse, 495 X12 Chassis / engine plug connector VI Violet

10 Circuit diagrams
Wiring diagram, sheet 10 − twistlocks, extend/retract, sideshift, work lights, safety override

Circuit diagrams 10
Legend H37 Unlocking indicator light VI Violet (IV) Spreader work lights
4K1 Lift enable relay H38 Seated indicator light WS White (V) Safety override
4K2 Reference lift enable relay GE Yellow (VI) Extend/retract adjust
Wire colours
4K3 Lowering allowed relay The number in front of the wire colour refers to the wire (a) 24 pin spreader connection
SW Black
4K4 Oil supply relay cross-section. (b) Spreader type code pins
BR Brown
4S1 Twistlock switch Wires with unspecified cross-section = 0.75 mm2
BL Blue
4S2 Extend/retract switch
GN Green Notes
4S3 Sideshift switch
GR Grey (I) Twistlocks
4S4 Spreader work lights
OR Orange (II) Extend/retract
4S5 Safety override key switch
RT Red (III) Sideshift
H36 Locking indicator light

7 Circuit diagrams
3 3
K 1 I 1
Hydraulic Circuit
4 4
2 J 5
6
H
8 11 11 11
8 8 8 11
7
K 11 24 L 25 26
9 23
[ 51 10 22
M
52
21
20 25
26
10 8 12 13 14 8 15 16 8 17 18 8 19 27
29
28 30
W
Q 31 32
47
33 47
34
38
37
39 S
49 48 48
45
T
35 36
43 44 U X
57 40
O 54 55 56
42 41 46
65
53
R 58 59 V 50
58
60 79
63 65
61
60
64 62 62
60 73 72
72 73
74 74 80 81
71
71
Y 75 75
78
70 Z
78 77 76 77
70
76
Circuit diagrams 7
Hydraulic Circuit
Hydraulic Circuit
a
H. Auxiliary hydraulics h. Internal combustion engine
b. Tilt n. Pressure filter (feed pressure filter)

1. Tilt cylinder.
2. Tilt pre-load valve. j. Retarder valve block
28. LS safety valve operated by LHC.
29. Check valve. o. Radiator
c. Raise 30. Proportional pressure regulation valve.
3. Lift/lower hydraulic cylinder. 31. Proportional pressure regulation valve.
4. Line rupture protection. 32. Restrictor.
5. 1B9 load pressure sensor. 33. LS pressure relief valve. p. Brake ventilation valve
6. 1B10 reference load pressure sensor. 34. Pump protection pressure relief valve. 47. 5/2 – way solenoid valve (towing valve).
7. 2Y10 lowering stop valve. 35. Flow regulator. 48. Check valve.
36. Pressure regulator. 49. Pressure regulation valve (foot-brake).
50. 3 – way proportional valve (parking brake)
d*.3 spool valve block working hydraulics,
post Nov 2009
k. Variable displacement pump
53. HPV 210-02 variable displacement pump. q. Pedal box
54. Proportion pressure regulation valve forward 1Y2.
55. 1Y4 release valve.
d. Valve block working hydraulics 56. Proportion pressure regulation valve reverse 1Y3.
8. Proportional pressure regulating valve.
57. Set piston A=forward B=reverse. r. Drive unit
58. 2/2 spool valve.
9. Filter. 70. Wheels.
59. 2/2 spool valve.
10. Pressure relief valve, auxiliary. 71. Multi wet disc brake.
11. Chang-over vale. 72. Output valve.
61. Servo piston Y=forward Z=reverse.
12. Auxiliary function spool. 73. 3/3 – way spool valve.
62. Check valve.
13. Auxiliary compensation spool. 74. Pilot spool valve.
63. Pilot valve.
14. Spreader pressure relief. 75. Regulating control piston.
64. Sorting valve (towing).
15. Spreader function spool. 76. HMV 280-02 variable motor.
65. Feed pressure valve.
16. Spreader compensation spool. 77. Brake actuation cylinder.
66. 1B4 oil temperature sensor.
17. Tilt function spool. 78. Duel stage reduction gear.
18. Tilt compensation spool. 79. Protection valve (brake cooling).
19. Lift/lower function spool.
20.
21.
Raise/lower feed pressure balance.
Priority valve.
l. Regulating and gear pumps s. Oil tank
22. Pressure relief valve. 37. Restrictor 1 mm. 80. Breather
23. Pilot bleed. 38. Proportional pressure regulation valve, maximum 81. Return flow filter with by-pass valve.
load 1Y10.
39. Check valve.
40. LS regulation control pilot. t. Cab tilt cylinder circuit
e. Steering control valve 41. Pump swash control.
51. Cab lift spool.
42. HPR210 pump.
24. Steering column. 52. Cab lower spool.
43. Gear pump (fan drive).
25. Check valve.
44. Gear pump.
26. Cross line relief valve.
m. Fan motor
45. Proportional pressure regulation valve (by-pass)
f. Steering cylinder 1Y5.
46. Hydraulic fan motor.
Circuit diagrams 7
Elme electrical circuit

Page 1
7 Circuit diagrams
Page 2
Circuit diagrams 7
Elme hydraulic circuit
Elme hydraulic circuit

Page 1
Linde Material Handling GmbH
2010/02 Revision 1

WL 318

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Service Training

C90-5, C90-6, C90-7,

Service Training – 359 807 50 01 EN – 03/2009 III

The information contained herein must be ob-

IV Service Training – 359 807 50 01 EN – 03/2009

Service Training – 359 807 50 01 EN – 03/2009 V

Traction drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

VI Service Training – 359 807 50 01 EN – 03/2009

Hydraulic fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

4 Chassis, bodywork and fittings

Service Training – 359 807 50 01 EN – 03/2009 VII

VIII Service Training – 359 807 50 01 EN – 03/2009

Wiring diagrams QSB 6.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Training – 359 807 50 01 EN – 03/2009 IX

Driver’s compartment design Electronics/electrics

• Integrated particle filter with build-up display

Datasheet BR318 - C90/5

1.4 Operation: manual,pedestrian,stand-on,seated,order picker Rider seated

3.5 Wheels, number, front/rear (x = driven) 4x - 2

3.6 Track width, front b10 (mm) 2,900

4.33 Stacking aisle, 20' containers Ast (mm) 9702

5.3 Lowering speed, with/without load m/s 0.54/0.54

7.4 Number of cylinders/displacement / cm³ 6/5900

8.4 Noise level, at operator's ear, Overhead guard/Cab dB(A) /

Datasheet BR318 - C90/6

1.4 Operation: manual,pedestrian,stand-on,seated,order picker Rider seated

3.5 Wheels, number, front/rear (x = driven) 4x - 2

3.6 Track width, front b10 (mm) 2,900

4.33 Stacking aisle, 20' containers Ast (mm) 9702

5.3 Lowering speed, with/without load m/s 0.54/0.54

7.4 Number of cylinders/displacement / cm³ 6/5900

8.4 Noise level, at operator's ear, Overhead guard/Cab dB(A) /

Datasheet BR318 - C90/7

1.4 Operation: manual,pedestrian,stand-on,seated,order picker Rider seated

3.5 Wheels, number, front/rear (x = driven) 4x - 2

3.6 Track width, front b10 (mm) 2,900

4.33 Stacking aisle, 20' containers Ast (mm) 9702

5.3 Lowering speed, with/without load m/s 0.54/0.54

7.4 Number of cylinders/displacement / cm³ 6/5900

8.4 Noise level, at operator's ear, Overhead guard/Cab dB(A) /

Datasheet BR318 - C90/8

1.4 Operation: manual,pedestrian,stand-on,seated,order picker Rider seated

3.5 Wheels, number, front/rear (x = driven) 4x - 2

3.6 Track width, front b10 (mm) 3,300

4.33 Stacking aisle, 20' containers Ast (mm) 9702

5.3 Lowering speed, with/without load m/s 0.54/0.54

7.4 Number of cylinders/displacement / cm³ 6/6700

8.4 Noise level, at operator's ear, Overhead guard/Cab dB(A) /

1 Integrated drive/lift control — LTC module N1 6 Indicator unit

Service Training – 359 807 50 01 EN – 03/2009 0-15

1 LTC module N1 4 Display

LTC modules N1 (1) and N2 (2) and the diag-

0-16 Service Training – 359 807 50 01 EN – 03/2009

Error codes and possible error correction is outli-

Service Training – 359 807 50 01 EN – 03/2009 0-17

0-18 Service Training – 359 807 50 01 EN – 03/2009

Service Training – 359 807 50 01 EN – 03/2009 0-19

0-20 Service Training – 359 807 50 01 EN – 03/2009

Service Training – 359 807 50 01 EN – 03/2009 0-21

0-22 Service Training – 359 807 50 01 EN – 03/2009

Service Training – 359 807 50 01 EN – 03/2009 0-23

0-24 Service Training – 359 807 50 01 EN – 03/2009

Service Training – 359 807 50 01 EN – 03/2009 0-25