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WL - 318 Service Training Manual
WL - 318 Service Training Manual
Series 318
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
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
CAUTION
indicates hazards that may result in damage to or
destruction of the product.
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 . . . . . . . . . . . . . . . . . . . . . . . .
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
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
Annex
10 Circuit diagrams
Hydraulic circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
0 Product information
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.
0
Product information 0
Technical data
0
Product information 0
Diagnostics
LTC basic structure
NOTE
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
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)
5 Invalid vehicle type
11 Control unit in programming mode
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
239 Incompatibility between seat switch signal/reference signal
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
Statuses
1 Power On, procedure not completed.
2 Joystick neutral
5 Invalid vehicle type
11 Control unit in programming mode
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
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
222 Joystick not in neutral for over 2 seconds after Power On
230 Additive 3 joystick cable break
231 Additive 4 joystick cable break
232 Additive 1 joystick cable break
233 Additive 2 joystick cable break
235 Incompatibility between additive 3 signal/reference potentiometer
236 Incompatibility between additive 4 signal/reference potentiometer
237 Incompatibility between additive 1 signal/reference potentiometer
238 Incompatibility between additive 2 signal/reference potentiometer
239 Incompatibility between seat switch signal/reference signal
254 Additive 3 magnetic current too low
255 Additive 4 magnetic current too low
256 Additive 1 magnetic current too low
257 Additive 2 magnetic current too low
258 Additive 3 magnetic current too high
259 Additive 4 magnetic current too high
260 Additive 1 magnetic current too high
261 Additive 2 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
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
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
Diesel engine QSB 5.9
View of engine
1
2
8
4
6
5
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
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.
NOTE
NOTE
NOTE
NOTE
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.
ENVIRONMENT NOTE
NOTE
NOTE
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
NOTE
NOTE
CAUTION
Overtightening of the pressure relief valve can cause
leaks.
Apply correct tightening torque.
Engine block
Removing and fitting the V-ribbed belt
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.
WARNING
The exhaust turbocharger weighs more than 23 kg.
Use a hoist.
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.
NOTE
NOTE
NOTE
NOTE
NOTE
Prerequisites
• Coolant temperature below 60°C
• Valve cover removed
(E = Exhaust, I = Intake)
1I, 1E, 2I, 3E, 4I and 5E.
NOTE
Removal
Slacken the lock nut and undo the adjustment
screw as far as the stop.
NOTE
CAUTION
Bent pushrods cause engine damage.
¾ Do not straighten bent pushrods; change them.
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.
NOTE
NOTE
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.
WARNING
The cylinder head weighs more than 23 kg.
Use a hoist.
NOTE
WARNING
The cylinder head weighs more than 23 kg.
Use a hoist.
Tightening sequence:
• Step 1: 90 Nm
• Step 2: 90 Nm (monitor)
• Step 3: + 90°
NOTE
NOTE
Removing valves
¾ Remove the cylinder head.
NOTE
DANGER
Eye injuries can be caused by valve springs which can
fly through the room like projectiles.
Wear industrial goggles with side protection.
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.
Installing valves
¾ Oil the valve stem and install valves in the cor-
rect position.
CAUTION
Incorrectly fitted valve stem seals may cause engine
damage.
Note the original installation position.
DANGER
Eye injuries can be caused by valve springs which can
fly through the room like projectiles.
Wear industrial goggles with side protection.
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!
Installation
¾ Seal connection points between the oil sump
and control housing and between the oil sump
and the shaft seal housing with sealant.
Description
Technical data for traction drive
Variable motors
Manufacturer Linde
Model
HMV 280-02
Piston diameter 27 mm
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
1
A
2 B
4 C
10 9 8 7 7 8 9 10
11 11
359_02-005
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.
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.
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
T1 14
13
T3
11
U1 Mp 1 359_02-016
10
11
L1
P1
S1
359_02-034
24 17
18
23
22 21 20 19 359_02-035
21 20 25 5
26
U1 359_02-036
1 2
A
4 4
T1
11 12 7 6
10
9
1
2
359_02-013
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
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.
NOTE
100
50
2 0 2 4 6 8 10 12 14 16 18
3 435 ± 10 1095
359_02-015
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
3 2
X1
L B 359_02-022
11 12
15
14 13
359_02-030
11 Control piston
12 Cylinder block
13 Port plate
14 Cradle
15 Shaft
14
16
11
17
11 359_02-031
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
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
PBL U
TL
359_02-025
3 4 5 6 7 8 9 10 11
2
1
12
21
20
19 18 17 16 15 14 13 359_02-026
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
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 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
8 P2
5
4
F
P3
1
T1 6
3
LS o 2 359_02-021
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
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
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
• 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
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
• 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
4 5
LS 1 LS F P3
T1
LS 0
80
340 bar
bis
Mp 340
2 45+5 bar
bar 7
P2
A
B
8 C
D
359_02-012
• 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).
3
4 4
2 1
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.
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.
359_02-019
NOTE
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,
10 Pressure on connection
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
11 Pressure on connection
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?
Pressure on connection
BR: 0 bar?
Release parking brake.
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
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.
WARNING
The fan motor will start.
Do not reach into the fan.
Keep your distance.
Steering system
Function characteristics
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
L
R
LS T
P
PL
LS L
10
359_04-011
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.
359_04-003
359_04-004
NOTE
NOTE
Thickness of fitted
0.7 mm
washers:
Measured axial play: 0.5 mm
Final washer
0.2 mm
thickness:
X
3
501_10-001
359_04-007
NOTE
2 3 4
1
501_10-002
359_04-008
NOTE
1 2 3
9 7 6
8
3
5 4
359_04-009
501_10-003
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).
359_04-010
Display elements
Indicator unit
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.
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
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)
3 AC K3 Air conditioning system fan level 2 (12 V)
4 AC K4 Air conditioning system fan level 3 (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)
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.
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
NOTE
2. Electrical testing
¾ Check for correct wiring according to the con-
figuration and wiring diagram for the truck.
NOTE
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).
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)
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
NOTE
Manufacturer Linde
Model HPR 210 -02
Maximum delivery volume 210 cm3/U
Number of pistons 9
Piston diameter 27 mm
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
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
Page 2
Circuit diagrams 7
Elme hydraulic circuit