Linde 350 Series Manual

ServiceTraining
This training material is only provided for your use and remains the exclusive property of
LINDE AG Werksgruppe Flurförderzeuge und Hydraulik
H01 / Chapter 1
350 804 4701.0400
Linde IC Engined Truck
H 12/16/18/20 D-03/T-03
Series 350
with Linde Hydraulic Control (LHC)

Table of content
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IC-ENGINEDTRUCKSH12/16/18/20D-03/T-03,SERIES350
1 Diesel engine 1
1.1 Engine specifications 1
1.2 Crankshaft 2
1.2.1 Adjusting alternator V-belt tension 2
1.2.2 Removing toothed belt 2
1.3 Fuelinjectionpump 5
1.3.1 Removal and installation of the fuel injection pump 5
1.3.2 Removing and installing the crankshaft sprocket 7
1.3.3 Check and adjust static injection pump timing 8
1.3.4 Checking engine timing 9
1.3.5 Stop leaks from the adapter of the injection pump 10
1.3.6 Adjust the idling speed and the governed speed (without load) 10
1.4 Fuel injectors 11
1.4.1 Remove and install fuel injectors 11
1.4.2 Servicing fuel injectors 12
1.4.3 Fuel injector parts 12
1.4.4 Check injector needle tip (visual check) 12
1.4.5 Check of fuel pressure 13
1.4.6 Check for leakages 13
1.5 Cylinder head 14
1.5.1 Cylinder head removal 14
1.5.2 Check cylinder head for distortion 14
1.5.3 Markings of cylinder head gaskets 14
1.5.4 Check piston at TDC 15
1.5.5 Fitting the cylinder head 15
1.5.6 Check compression pressure 17
1.5.7 Check hydraulic tappets 18
1.6 Glow plug system 19
1.6.1 Checking the glow plugs 19
1.6.2 Check the glow plugs 19
1.6.3 Glow plugs with burnt electrodes 20
2 Transmission 1
2.1 Digital electric-hydraulic control (LHC) 1
2.1.1 General 1

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02.01
2.1.2 Electronic control of truck speed 2
2.2 Schematic diagram of the drive unit 4
2.3 Technical data of the travel drive system 5
2.4 Hydraulic circuit diagram 7
2.5 View of the variable pump 11
2.6 Cross sectional view of drive pump 12
2.7 Electric-hydraulic adjustment 13
2.7.1 Hydraulic adjustment with electronic control 15
2.7.2 Electric-hydraulic control 16
2.7.2.1 Begin of pump control 17
2.7.2.2 Swash angle of variable pump 17
2.7.2.3 Hydraulic zero position 17
2.7.2.4 Hydraulic brake valve 18
2.8 Towing device 19
2.9 Drive axle AH 20 -01 with wheel drive, multiple disc brake and hydraulic motor 20
2.9.1 Repairing the reduction gear, multiple disc brake and hydraulic motor 22
2.9.2 Renewing the radial sealing ring of the planetary gear 23
2.9.3 Removing and installing the multiple disc brake and hydraulic motor with
swashplate 02.01 26
2.10 Truck diagnostics and troubleshooting 30
2.10.1 Electrical system diagnostics 30
2.10.1.1 Working with the Linde Test Module 31
2.10.1.2 Diagnostics with a PC and the Linde Interface Converter 32
2.10.1.2.1 Linde Interface Converter 33
2.10.1.2.2 Installation of the Diagnostic software “Test & Setup”33
2.10.1.2.3 Selecting the Linde Program 34
2.10.1.2.4 Starting the Diagnostic Program “Test & Setup”02.01 35
2.10.1.3 Linde Diagnostic Program 02.01 36
2.10.1.3.1 Help Function 38
2.10.1.3.2 Overview of menu windows - LHC Software version 1.1 - 1.3 02.01 41
2.10.1.3.3 Menu windows in detail - LHC Software version 1.1 - 1.3 02.01 42
2.10.1.3.4 Overview of menu windows - LHC Software version 1.4 and 1.5 02.01 62
2.10.1.3.5 Menu windows in detail - LHC Software version 1.4 and 1.5 02.01 63
2.10.1.3.6 Overview of menu windows - LHC Software version 1.6 02.01 97
2.10.1.3.7 Menu windows in detail - LHC Software version 1.6 02.01 98
2.10.2 Hydraulic system diagnostics 131
2.10.2.1 Circuit diagram and overview for diagnostics 131

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2.10.2.2 Test aids 133
2.10.2.2.1 Explanations to troubleshooting 133
2.10.2.3 Power-assisted steering 135
2.10.2.3.1 Troubleshooting without measurement of boost and maximum pressure 135
2.10.2.3.2 Troubleshooting with measurement of boost and maximum pressure 135
2.10.2.4 Hydraulic brake system 137
2.10.2.4.1 Functional test 137
2.10.2.4.2 Troubleshooting 137
2.10.2.5 Hydrostatic travel drive 140
2.10.2.5.1 Troubleshooting 140
4 Steering system 1
4.1 Schematic diagram of the steering system 1
5 Controls 1
5.1 Pedal stroke adjustment instructions 2
5.2 Adjustment instructions for the speed control 4
5.3 Engine speed sensor adjustment instructions 6
6 Electrical system 1
6.1 Basic diagram Diesel version 02.01 1
6.2 Basic diagram LPG version 02.01 7
6.3 Diagramforoptionalequipment 13
6.4 Layout of electrical installation 21
6.5 Composite instrument 22
7 Hydraulic system 1
7.1 Schematic 1
7.2 Sealing of the control valve 2
7.3 Setting of the pressure-limiting valve 3
9 LPG model of IC-engined fork truck H 12/16/18/20 T-03, series 350 1
9.1 Engine 1
9.1.1 Engine specifications 02.01 1
9.1.2 Toothedbelt 2
9.1.2.1 Overall view of toothed belt guard 2
9.1.2.2 Removing, installing, tensioning the toothed belt 3

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9.1.2.3 Adjusting the alternator V-belt tension 5
9.1.3 Cylinder head 6
9.1.3.1 Removing and installing the cylinder head 6
9.2 Electrical system 10
9.2.1 Electronic ignition 10
9.2.1.1 TSZ-H ignition system (transistorised ignition system) 11
9.2.1.2 Safety measures for TSZ-Hall system 12
9.2.1.3 Installation of distributor 12
9.2.1.4 Checking and adjusting the ignition timing 14
9.2.1.5 Checking the TSZ-H ignition system 15
9.2.1.5.1 Switch unit A1 16
9.2.1.5.2 Hall generator 18
9.3 LPG installation 20
9.3.1 Schematic 20
9.3.2 LPG mixer 21
Index 02.01

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1 DIESEL ENGINE
1.1 ENGINESPECIFICATIONS
EngineType VW ADG
Capacity 1896 cm3
Output 27 kW at 2200 rpm
InjectionPressure 130 +8 bar
Point of Injection 1.00 ± 0.02 mm stroke
CompressionRatio 23 : 1
Compression SpecifiedValue: 34.0 bar
WearLimit: 26.0 bar
Max.PermissiblePressureDifference 5 bar
Lower Idling Speed 1030 + 30 rpm
Upper Idling Speed 2350 rpm
Rated Speed 2200 rpm
ValveClearance HydraulicValveTimingBalance
Firing Order 1 - 3 - 4 - 2
Minimum Oil Pressure at Top Idling Speed
and Oil Temperature approx. 80 °C 2 bar
The engine number is stamped on the cylinder block
between the injection pump and the vacuum pump.
The engine number is always shown on the vehicle data
plate on the toothed belt cover.

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1.2 CRANKSHAFT
1.2.1 ADJUSTINGALTERNATORV-BELTTENSION
- Loosen all security bolts (1) for tensioner (3) and alter-
nator by at least one turn.
ATTENTION
The alternator must be easily moveable by hand.
- TensionV-beltbytensioningnut(2)withatorquewrench.
Specification:
NewV-belt: 8 Nm
UsedV-belt: 4 Nm
and tighten tensioning nut securing bolt to 30 Nm.
- Tighten all tensioner and alternator securing bolts.
NOTE: Adjustmentisideallycarriedoutwiththetorque
wrench V.A.G. 1410 in connection with the
socketspanner V.A.G.1410/2.
1.2.2 REMOVINGTOOTHEDBELT
REMOVAL
- Remove upper belt guard and cylinder head cover.
- Turn crankshaft to TDC on No. 1 cylinder.
TheTDCmark(5)ontheflywheel(6)mustbeinlinewith
the boss (4) on the bell housing.
- Fix camshaft in position with setting bar (2065 A).
- Align setting bar as follows:
Turncamshaft until one endof bar touches thecylinder
head.Measurethegapattheotherendofthesettingbar
withthefeeler.Takehalfofgapmeasurementandinsert
feelerofthisthicknessbetweensettingbarandcylinder
head. Now turn the camshaft so that the setting bar
touches the feeler. Insert second feeler of the same
thicknessbetweentheotherendofthesettingbarandthe
cylinderhead.

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- Holdinjectionpumpsprocketinpositionwithdrift(2064).
- Loosentensioner.
- Remove pulley for coolant pump.
- Remove lower toothed belt guard.
- Removebelt guard.
INSTALLATION
- CheckandensureTDCmarkonflywheelisalignedwith
referencemark.
- Loosen camshaft sprocket bolt (2) by half a turn. Free
sprocket (1) on taper by tapping with hammer (using a
drift through the hole in the rear toothed belt guard).
- Fit toothed belt and remove pin from injection pump
sprocket.
- Install the idling pulley. Torque loading: 25 Nm.
- Turnthetensioningpulleyclockwisewithaspanner(egMatra
V159) until the notch and boss (arrows) are in line.
- Tighten the clamping nut at the tensioning pulley. Torque
loading: 20 Nm.
- Recheck if the TDC mark on the flywheel and the reference
mark are in line.
- Tighten fastening screw of valve timing sprocket to 45 Nm.
- Remove the setting bar.
- Turnthecrankshaftbytwoturnsinnormaldirectionand
checkthatthetensionofthetoothedbeltisinaccordance
withthespecification.
- InstallV-belt,toothedbeltguardandcylinderheadcover.
- Check the point of injection of the injection pump.

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CHECKINGTHESEMIAUTOMATICTENSIONINGPULLEY
TESTCONDITION
- Toothedbelt installed and tensioned
TESTPROCEDURE
- Pushdownon thetoothedbelt withthe thumb.Thenotch and
boss -arrow- should go out of line.
- Releasethepressureonthetoothedbelt.Thetensioningpulley
should return to its initial position. (Notch and boss are in line
again.)

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1.3 FUELINJECTIONPUMP
1.3.1 REMOVAL AND INSTALLATION OF THE FUEL INJECTION PUMP
NOTE: In case a defect is noted on the fuel injection
pumpthefuelinjectionpumphastobeexchan-
gedsincetorepairitafuelinjectiontestbedis
necessary.
REMOVAL
- TurncrankshafttoTDConNo.1cylinder.TheTDCmark
(2) on the flywheel (3) must be in line with the boss (1)
onthebellhousing. Fixcamshaft withsetting bar(2065
A). Align setting bar as follows:
Turncamshaftuntiloneendofthesettingbartouchesthe
cylinder head. Measure the gap at the other end of the
settingbarwiththefeelergauge.Insertthefeelergauge
withonehalfofthethicknessbetweenthesettingbarand
the cylinder head. Turn the camshaft now so that the
setting bar rests on the feeler gauge. Insert a second
feeler gauge with the same thickness at the other end
between the setting bar and the cylinder head.
- Removetoothedbeltfromcamshaftandinjectionpump
gears.
- Loosen nut of the fuel injection gear.
- Loosen the puller legs and put on puller (3032).
- Alignpullerlegswithholesinthefuelinjectionpumpgear
andtighten.
- Puttheinjectionpumpgearundertensionwiththepuller.
- Loosentheinjectionpumpgearfromthetaperofthefuel
injection pump by tapping slightly on the puller spindle
(seearrow).(Holdfuelinjectionpumpsprocketsothatit
does not fall down).
- Detach all fuel pipes from the fuel injection pump and
cover the holes with a clean cloth.
NOTE: Useopenringspanner(3035)tolooseninjec-
tionpipes.

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- Remove securing bolts (2) from bracket (3 bolts).
- Remove securing bolt (1) from rear support bracket.
NOTE: Loosenthelowerandright-handsecuringbolt
from the front.
ATTENTION
Under no circumstances should the securing
bolts(seearrows)holdingthefuelinjectionpump
headbe loosened.
Loosening the securing bolts would allow the
head to move and would cause the breakage of
thedistributorplunger.
INSTALLATION
- Install the fuel injection pump and align centrally in the
elongatedflangeholes.
Tighteningtorques:
Pumpmounting bolts: 25 Nm
Fuelpipes: 25 Nm
Injectionpumpsprocket: 45 Nm
ATTENTION
Donotinterchangethefeedandreturnpipebanjo
bolts.Theinsidediameteroftheboltforthereturn
pipeis smaller and thehexagon head is marked
"OUT".
- Install injection pump sprocket and fix position with
positioningpin(2064).
- Loosen bolt of camshaft sprocket by half a turn. Free
camshaft sprocket from the taper by tapping with a
hammer(usingadriftthroughtheholeinthereartoothed
beltguard).
- CheckthatTDCmarkontheflywheelisalignedwiththe
referencemark
- Installtoothedbelt and remove the positioning pin from
the fuel injection pump sprocket.

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- Install the pulley. Torque loading: 25 Nm.
- Turnthetensioningpulleyclockwisewithaspanner(egMatra
V159) until the notch and boss (arrows) are in line.
- Tighten the clamping nut at the tensioning pulley. Torque
loading: 20 Nm.
- Recheck if the TDC mark on the flywheel and the reference
mark are in line.
- Tighten the camshaft pulley fastening screw to 45 Nm.
- Removethe adjustment ruler.
- Rotate the crankshaft another two turns in the direction of
engine rotation and recheck the tension of the toothed belt.
- Check the operation of the tensioning pulley.
- Check the start of delivery.
- Check and adjust the idling speed and stall speed.
1.3.2 REMOVINGANDINSTALLINGTHECRANKSHAFTSPROCKET
Precondition:
- The toothed belt (3) is removed.
REMOVAL
- Remove the fastening screw (1).
- Take the sprocket (2) off the crankshaft.
INSTALLATION
- Slide the sprocket (2) onto the crankshaft.
- Use a new fastening screw (1).
- Oilthethreadandheadmatingsurfaceandinstall
thescrew.
Tightening procedure: 90 Nm + 90°

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1.3.3 CHECKAND ADJUST STATIC INJECTION PUMP TIMING
CHECKANDADJUSTMENTCONDITIONS
Toothed belt tension OK.
Operating lever of fuel injection pump on stop.
Set engine to TDC on No. 1 cylinder.
Engineinstalled:
- TurnthecrankshaftuntilTDCmark(2)ontheflywheel (3)
is in line with the boss (1) on the bell housing.
CHECKINGANDADJUSTING
- Unscrew plug from fuel injection pump head.
ATTENTION
Alwaysfitanewwasherwheninstallingtheplug.
Tighteningtorque 15Nm. Ifleaks occurthe plug
canbetightenedtoamaximumtorqueof25Nm.
- Install adaptor (2066) and small dial gauge (measuring
range 0 ... 3.0 mm) in place of the plug and preload the
dial gauge to about 2.5 mm.
- Turn the crankshaft slowly anticlockwise (opposite to
normal rotation) until the dial gauge needle does not
move any more.
- Adjust the dial gauge with approx. 1 mm preload to "0".
- Turnthecrankshaftclockwise(normalrotation)untilthe
TDC mark on the flywheel is aligned with the reference
mark.
- Read the point of injection from the dial gauge.
Testfigure = 0.93 ... 1.07 mm stroke
Settingfigure = 1.00 ± 0.02 mm stroke
ATTENTION
Incasethevalueiswithinthespecifiedtolerance
an adjustment is not required.
- Toadjustloosenthethreescrewsonthebracketandthe
screw holding the rear support.

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- Adjustthepointofinjectionbyturningthefuelinjectionpump
togivethesettingvalue.
- Tightentheboltsto25Nm.
1.3.4 CHECKINGENGINETIMING
- Removecylinderheadcover.
- Checkthetensionofthetoothedbelt.
- Settheengineto TDC on thecylinderNo.1.
Thesettingbar(2065A)mustfitintotheslotonthecamshaft.
Ifthesettingbarcannotbeinsertedadjustthevalvetiming
asfollows:
- Turnthecrankshaftsothatthesettingbarcanbeinsertedand
alignthesettingbaras follows:
Turnthecamshaftsothatoneendofthesettingbartouches
thecylinderhead.Measurethegapattheotherendofthe
settingbarwithafeelergauge.Insertafeelergaugewithone
half of the measurement between the setting bar and the
cylinderhead.Nowturnthecamshaftsothatthesettingbar
touchesthefeelergauge.Insertasecondfeelergaugewith
thesamemeasurementattheotherendbetweenthesetting
barandthecylinderhead.
- Loosenboltofthevalvetimingsprocketbyhalfaturn.Free
thesprocketfromtaperbyinsertingadriftthroughthehole
inthereartoothedbeltguardandbystrikingthedriftwitha
hammer.
- Fixinjectionpumpsprocketwiththe fixingpin(2064).
- CheckTDCposition;if necessary turnthecrankshaftuntil
TDCmark(2)ontheflywheel(3)isalignedwiththeboss(1)
onthebellhousing.
NOTE: To adjust the injection pump sprocket and the
TDCmarkontheflywheelitmaybenecessaryto
removethetoothedbelt.
- Removefixingpin.
- Tension the toothed belt and tighten the bolt of the valve
timingsprocketto 45 Nm.
- Removethesettingbar.
- Checkthetimingoftheinjectionpump.

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1.3.5 STOP LEAKS FROM THE ADAPTER OF THE INJECTION PUMP
1 Sealingring
2 Pressurevalve
3 Adapter
- Loosen the injection pipe.
- Tighten the adapter to 45 Nm.
- Tighten the injector pipe to 25 Nm.
Incasetheleakisnotbeingstoppedinstallnewadapter
and new washer.
ATTENTION
When replacing the new adapters do not
interchangethe pressurevalve.
1.3.6 ADJUST THE IDLING SPEED AND THE GOVERNED SPEED (WITHOUT LOAD)
Engine oil temperature minimum 60 °C.
Theenginespeedcanbemeasuredwiththeignitiontester
(V.A.G. 1367) using the TDC sender or the adapter (VW
1324).
ADJUST THE IDLING SPEED OR MIN. GOVERNED
SPEED(WITHOUTLOAD)
- Adjusttheidlingspeedwiththeidlingadjustmentscrew (4)
accordingto the engine specifications.
- Lock the adjusting screw.
ADJUST GOVERNED SPEED OR MAX. GOVERNED
SPEED(WITHOUTLOAD)
- Openthethrottlefullyandsettheenginespeedwiththe
adjustment screw (5) according to the engine
specifications.
- Lockthe adjustment screw.

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1.4 FUELINJECTORS
1.4.1 REMOVEANDINSTALLFUELINJECTORS
NOTE: Defective fuel injectors cause the following
troubles:
- Misfiring
- Knocking in one or more cylinders
- Engineoverheating
- Loss of power
- Excessivelysmokyblackexhaust
- Increasedfuelconsumption
- Excessive blue smoke on cold start
Defectivefuelinjectorscanbelocatedbylooseningthefuel
pipeunionsoneachfuelinjectorwhentheengineisrunning
at a fast idle. If the engine speed remains constant after
looseningapipeunionthisdenotesthefaultyfuelinjector.
REMOVAL
- Detach the injector pipes with the slotted ring spanner
(3035)
- Remove the fuel injectors with the SW27 socket.
ATTENTION
Alwaysremovethefuelpipesetcomplete.Donot
alter the shape of the fuel pipes.
INSTALLATION
ATTENTION
Alwaysfitnewheatshieldsbetweenthecylinder
head and the fuel injectors.
Fitting position of the heat shields: The arrow points
towards the cylinder head.
Tighteningtorques:
Fuel injectorpipes: 25 Nm
Fuelinjectors: 70 Nm

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1.4.2 SERVICINGFUELINJECTORS
- Clamptheupperpartofthefuelinjectorinviceandloosen
thehexagon.
- Topreventthepartsfromfallingoutclampthelowerpart
in vice and dismantle injector. When dismantling the
injector keep all individual parts together and do not
interchange with parts from other injectors.
Tighteningtorquefortheupperandthelowerpartofthefuel
injector: M = 70 Nm.
1.4.3 FUELINJECTORPARTS
1 Upper part of injector
2 Settingwasher
3 Injectorspring
4 Thrustpin
5 Nozzleholder insert
6 Injectorneedle
7 Nozzlebody
8 Lower part of injector
9 Heatshield
1.4.4 CHECKINJECTORNEEDLE TIP (VISUAL CHECK)
Iftheneedletipisbrokenofforbentreplacefuelinjectoror
nozzlewith needle.

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1.4.5 CHECKOFFUEL PRESSURE
ATTENTION
Whentestingtheinjectorstakecarenottoexpose
thehandstotheinjectorsprayasthehighpressure
willcausethefuelspraytopenetratetheskinand
causesevereinjuries.
Gaugevalve open:
- Movepumplever downslowly.Wheninjectingread the
injectionpressurefromthegaugeandadjustifnecessary
by changing the setting washer.
Specifiedpressurevalue:
Newinjectors: 130 ... 138 bar
Wearlimit: 120 bar
Thickersettingwasher=increasestheinjectionpressure
Thinnersettingwasher=decreasestheinjectionpressure
Increasingthethicknessofthesettingwasherby0.05 mm
increases the injection pressure by approx. 5.0 bar.
Setting washers are available in thicknesses from
1.00 ... 1.95mminstepsof0.05mm.Thebox3065should
be used to store the washers.
NOTE: Whenservicingusedinjectorssettheinjection
pressure to the value of new injectors.
1.4.6 CHECKFORLEAKAGES
Gaugevalve open:
- Press the pump lever down slowly and hold a pressure
ofabout110barfor10seconds.Thennofuelshouldleak
from the nozzle tip.

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1.5 CYLINDERHEAD
1.5.1 CYLINDERHEADREMOVAL
NOTE: Thecylinderheadcanberemovedandinstalledwith
theengineinstalled.Ifareplacementcylinderhead
is installed with the camshaft mounted, the mating
surfacesof cuptappetsandcamsmustbeoiledafter
installationofthehead.Thesuppliedplasticcovers
for the protection of the open valves may only be
removed immediately before the installation of the
cylinderhead.Ifthecylinderheadistobereplaced,
the entire coolant must be drained. Check
compressionpressure.
1.5.2 CHECKCYLINDERHEAD FOR DISTORTION
- max 0.1 mm
NOTE: It is not allowed to rework cylinder heads of
Dieselengines.
1.5.3 MARKINGSOFCYLINDER HEAD GASKETS
Sparepart number = (1)
Notches/holes = (2)
Depending of the piston height cylinder head gaskets of
differentthicknesseshavetobeinstalled.Whenreplacing
thecylinderheadgasketinstallnewgasketwiththesame
marks