This is the COMPLETE Service Training Manual for the Linde IC truck 1401 Series: H100, H120, H140, H150, H160. This manual provides detailed service information, step-by-step repair instruction and maintenance specifications. it has been prepared as an aid to improve the quality of repairs by giving the operator an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. YOU CAN DO THE REPAIRS YOURSELF AND SAVE MONEY $$$
Models Covered:
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H100
H120
H140
H150
H160
Service Training Manual Contains:
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0. Product information
Preface
The BR 1401 truck
Technical data
Dimensions
VDI datasheet H100-600, H120-600, H140-600
VDI datasheet H150-600, H160-600. H180-600
Diagnostics
LTC basic structure
Error code lists
Indicatorunit errorcodes
1. Engine
Diesel engine QSB 6.7
Engine identification
Technical data
Engine view
Engine identification – data plate
Engine identification -T4i
Technical data -T4i
Engine view-T4i
Engine identification plate -T4i
Cylinderhead
Rockercover-remove-install
Rocker levers and pushrods
Cylinder block
V grooved belt- remove
V grooved belt- install
Fuel system
Sectional view
Fuel injectors- remove- install
Fuel rail- remove -install
Fuel supply
Pumpfuel high-pressure
Electronic fuel control actuator- remove – install
Lubricating system
Sectional views
Pump -oil -remove -inspect -(install)
Cooler- oil -remove -(install)
Oil sump/pan seal – replace
Crankshaftoilseal-front-install
Crankshaft oil seal -front- remove
Cooling system
Sectional view
Pump -engine coolant- remove
Thermostat coolant -remove -test -(install)
Air intake system
Sectional view
Intercooler- remove -(install)
Exhaust system
Sectional view
Exhaust manifold -remove -inspection -install
Exhaust manifold
remove
inspection
install
Turbocharger exhaust -remove -install
Exhaust emission pre-treatment – T4i
Cooled Exhaust Gas Recirculation -T4i
Cooler EGR-T4i- remove
Cooler EGR-T4i- install
EGR valve -T4i- remove
EGR valve -T4i- install
Turbo charger variable geometry -VGT-T4i- remove
VGT-T4i- Inspection
VGT-T4i- install
Exhaust manifold- remove -T4i
Exhaust manifold install -T4i
Exhaust emission after-treatment -T4i
Combinded Diesel Oxidising Catalyst and diesel particulate filter- T4i
Combinded DOC and DPF -T4i – remove
DPF – install – T4i
Electrical system
Jump start procedure
Alternator -test
Alternator- remove- (install)
2. Drive axle
Description
Technical data for traction drive
Schematic view of the drive
Linde Truck Control (LTC)
Traction drive
Travel drive -introduction
Linde Truck Control (LTC)
LHC20 errorcodes
Variable displacement pump controller
Motorvariables controller
Pedal group
Towing
Variable displacement pump
HPV210-02Variable displacement pump
Electro-hydraulic remote control
Variable pump advance start
Variable motor
Variable motor HMV 210-02 and 280-02
Output unit function characteristics
Reduction gearbox
Reduction gearbox GR 26-01
Brake
Braking process -function characteristics
Retardervalve block components
Retarder valve block function
Checking the brake system
Hydraulic fan drive
Hydraulic fan drive
Checking the hydraulicfan drive
3. Chassis, bodywork and fittings
Counterweight options
Counterweight options
Chassis covers – right hand side – remove
Pannier covers right hand side -install
Tilting the cab
Cab tilt mechanism
Cab tilt -operation
4. Undercarriage
Wheel and tyre safety
Wheel removal drive axle
Wheel removal steer axle
Wheel assembly inspection
Wheel refitting drive axle
Wheel refitting steeraxle
Wheel fastenertorque setting table
Examples of restraining devices
Steering system
Function characteristics
Steering axle
Stub axle
King pin – install – adjust
Wheel hub bearing -adjust
Steering stop- adjust
Steercylinder- remove
Steer cylinder- install
Sealing the steering cylinder
5. Controls
Truck Status Display
Truck status display
Malfunctions during operation
Calibration
Calibration of joysticks using the MDL02
Calibration -fork side shift
Calibration -mast set angle
6. Electrics / Electronics
Central electrical system
Arrangement of relays and fuses for basic equipment and special equipment
Service station -fuses and relays
Checks
LHC testing (truck control unit and lift control)
Checking wiring harness
Testing sensors
Checking actuators
Testing the indicator unit
7. Hydraulics
Regulating pump HPR 210-02
Technical data for regulating pump
HPR 210-02 regulating pump
Load sensing regulation
Working hydraulic
Working hydraulic circuit diagram
Directional spool – main valve block
Hose layout
Hose layout, supply, valve block, working hydraulics
Lift lower- layout
Mast tilt -hose layout
Fork shift/spread – hose layout
Measurements and settings
Checking the P and LS pressure
Checking and adjusting delta P
8. Load lift
Mast
Fork shift/spread- hydraulic function schematic- 1401
Fork shift/spread -layout- 1401
Lift lower- layout
Lift/lower- hydraulic function schematic -1401
Mast assembly- remove- 1401
Mast – install – complete with lifting chains, carriage and carriers – 1401
Masttilt-hydraulicfunctionschematic-1401
Mast tilt -layout -1401
Lift cylinder- remove
Lift cylinder- install
Tilt cylinder- remove
Tilt cylinder- install
Lift cyli nder end cap seal – replace
Tilt cylinder end-cap seal -replace
Annex
10. Circuit diagrams
Hydraulic circuit diagrams
Hydraulic circuit drawing
Layout -whole truck hydraulics
Electrical circuit diagrams
Address links
How to use the schematics -continued
Electrical circuit drawing
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** Model Specification: Linde IC truck 1401 Series: H100, H120, H140, H150, H160
** Language: English
** Total Pages: 308
** File Format: PDF
** Requirements: Adobe PDF Reader
** Compatible: All Versions of Windows & Mac, Linux OS, Iphone, Ipad, Android etc…
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