Still Diesel LPG forklift trucks R70-16 R70-18 R70-20 Workshop Manual

Thisworkshopmanualincludesonlythe functiongroupsthatdiffertechnicallyfrom thepreviousmodel. Allmissingfunctiongroupsaredescribed intheworkshopmanualR70(7052-7058, 7074-7079).

Forthemajorityoffunctionalgroups,thetype carriersdescribedaretechnicallythesameas thepreviousmodels.

Thefollowingfunctionalgroupsareexcluded:

Internalcombustionengine

Internalcombustionengine-attachmentparts

Internalcombustionengine-exhaustsystem Electrics/electronics(inparts)

Onlythesefunctionalgroupsaredescribedinthis workshopmanual.

Allotherfunctionalgroupsaredescribedinthe workshopmanualR70(7052-7058,7074-7079) andhavecompletevalidity.

Thesignalterms,,, and areusedinthisdocument ashazardwarningsorforunusualinformation thatrequiresspecialidentification:

meansthatfailuretocomplyinvolvesriskofserious injuryand/ormajordamagetopropertycanoccur.

meansthatfailuretocomplyinvolvesriskofmaterial damageordestruction.

meansthatparticularattentionisdrawntocombinationsoftechnicalfactorswhichmaynotbe evidenteventoaspecialist.

Theinstructionslistedheremustbecomplied withasotherwiseenvironmentaldamagemay result.

Foryoursafety,additionalsymbolsarealsoused. Pleaseheedthevarioussymbols.

Whenworkingatthefrontofthetruck,alwayssecure theforkcarriagetopreventitdropping.

Useonlychainswithadequateliftingcapacitytosecure theparticularliftmast.

Potentialdamagetotheceiling!

Notethemaximumliftheightoftheparticularliftmast.

Extendtheliftmast.

Routethechainalongthecrosstraverseofthe outermast(1)andconnectitunderneaththe crosstraverseoftheinsidemast(2).

Lowerinsidemastuntilitstrikesthechain.

Extendtheliftmasttoslackenthechain.

Extendtheliftmast.

Routethechainalongthecrosstraverseofthe outermast(1)andconnectitunderneaththe crosstraverseoftheinsidemast(2).

Lowerliftmastuntilitsttrikesthechain.

Lowerforkcarriagedowntothestop.

Extendtheliftmasttoslackenthechain.

Extendtheliftmast.

Routethechainalongthecrosstraverseofthe outermast(1)andconnectitunderneaththe crosstraverseofthemiddlemast(2).

Lowerliftmastuntilitsttrikesthechain.

Lowerforkcarriagedowntothestop.

Extendtheliftmasttoslackenthechain.

Theengineisaself-containedunitcomprising theinternalcombustionenginewithgenerator andhydraulicpump.Thehydraulicpumpisconnectedtothefaceofthegeneratorbymeansofa tappet.

Theinternalcombustionengineisconnectedto thegeneratorbymeansofabearingflangewithin whichthestarterringgearislocated.Thestarter motorisfastenedtothebearingflangebytwo screwsandengagesthestarterringgear.Above thebearingflangethereisanopeningthrough whichtheTDCmarkonthegeneratorcanbe checked.

Theengineliesatarightangletothedrivedirection.Itisscrewedtothetruckchassisatthree pointsusingrubber-metalbearingsandisvibration-free.

Differencesinthearrangementoftheengineunit resultbecauseofdifferentenginemodelsandthe attachedaccessories.

Therearetwodifferentenginemodels:

Dieselengine

R701.6-2.0twithVW-SDIengine

LPGengine

R701.6-2.0twithVW-LPGengineandthreewaycatalyticconverter

R701.6-2.0twithVW-LPGengineandtwowaycatalyticconverter

1Internalcombustionengine

2Bearingflange

3Enginemounting

4Drivedirection

Manufacturer

Enginetype

Displacement 1896cm3

Compression 19.5:1

Ignitionsequence 1342

Positionofcylinder1 Oppositethepowerreleaseside

EnginepowerratingP

28.5kWat2350rpm

RatedenginetorqueET 126Nmat1900rpm 2450rpmwhendriving

Upperidlespeed 2650rpmwithworkinghydraulics

Loweridlespeed 1050rpm

Speedlimitation 2650rpm

Diesel

Biodiesel

Coolant

AccordingtoDINEN590,min.cetanenumber>51 CN

60%waterand40%coolantadditiveG12+

Coolantvolume Approx.5-6litres

Fancut-intemperature

Coolantapprox.85°C

Openingstartat87°C

Thermostat Fullyopenedat102°C

Engineoil

SAE5W-30accordingtoVW50700

Totalamountofengineoilwithfilterchange4.5litres

Engineoilpressureat2000rpmandoiltemperatureof80°C min.2.0bar

Three-phasealternator

Starter

Batteries

Valeo,28V,55A

Bosch,12V,2.0kW

2pieces12V,43Ahminimumcapacity

Glowplugs 12V

Theenginecodelettersandenginenumberare stampedontheleftsideofthecylinderblock abovethefuelpump.Inaddition,thereisalabel onthetoothedbeltcover.

BXT/001018

Enginetype/serialnumber

Volkswagenindustrialenginewithengine codelettersBXT.

A1.9litre,water-cooled,four-cylinderinline dieselenginewithdirectinjectionformsthe basis.

Directvalveactuationviaoverheadcamshaft. Maintenance-freevalvetrainviahydraulic tappets.

Camshaft,injectionpumpandcoolantpump drivenviatoothedbelt.

Boschinjectionpumpwithelectroniccontrol. Intakeportdesignedasswirlduct.Thissets theintakeairintoaspinningmotion,causing intensiveairswirlinginsidethecombustion chamber.

Closedcoolingsystemwithseparateexpansionreservoirandhigh-pressurereliefvalve. Coolantpumpintegratedintocylinderblock.

Coolantthermostatintegratedintocylinder block.

Three-phasealternator

Specially-shapedpistonbowl(maincombustionchamber).

Anti-corrosionplastic-coatedinjectionlines. Vulcanisedvalvecoverseal. Oilsumpwithsiliconesealingagent. Exchangefilterforoilaspapercartridge.

Theenginecontrolunit(ElectronicControlUnit) isintwopartsandconsistsoftheA43engine controlunitandthe1A07immobiliser.Theenginecontrolunitisderivedfromcartechnology, albeitthattheimmobiliserisanimmobiliser inthecartechnologysenseofinteractingwitha transponderinthekey.

Theenginecontrolunitissecuredbehindthe steeringcolumnonthefrontstructure.

Theenginecontrolunitisanindependentcontrolunitwithitsownerrormanagementandown diagnosticsoftware,whichisstartedviathenavigator.

Theenginecontrolunitisresponsibleforthe followingenginemanagementtasks:

Immobiliser

Enginespeed,regulationandmonitoring

Coolanttemperaturesensor

Needlestroketransmitter(3rdcylinder)correctsthefuelinjectiontimingpointandduration

Glowplugstriggering,glowdurationmonitoring

Fueltemperatureandcontrolvalvetravel

Fuelcut-off

Fuelinjector

Suctionpipepressuretransmitter

Diagnosticsviadiagnosticconnector

Theimmobiliserissecuredbehindthesteering columnabovetheenginecontrolunitonthefront structure.

Theimmobiliseractivatestheenginecontrolunit, andonlythenistheignitionswitchedon.

Intheeventofamalfunction,theenginestarts, butshutsdownagainafterapprox.1second. Inadditionafaultisindicated.Itcanbeupto 30secondsbeforethishappens.

Theerrorcode17978,"enginecontrolunitdisabled",isloggedintheerrormemory-theimmobiliserhasnotactivatedtheenginecontrolunit. Inthiscasetheimmobilisermustbechanged.

Ifthereisafaultintheimmobiliser,itmustbe changed.Theimmobilisercanautomatically detecttheenginecontrolunit,codingisnotnecessary.

Ifthereisafaultintheenginecontrolunit,both theimmobilisertheenginecontrolunitmust bechanged.

Adaptationofanewenginecontrolunittothe oldimmobiliserisnotpossible,sincethenew enginecontrolunitwillsendanewcodetothe oldimmobiliser.Thisnewcodedoesnotmatch theoldcodeintheimmobiliser.Theimmobiliser doesnotrecognisethenewenginecontrolunit anddoesnotactivatetheenginecontrolunit.

Duringtheinitialcommissioningandafterareplacement,theenginecontrolunitandtheimmobiliserdetecteachotherautomaticallyassoonas theignitionisswitchedon.

Enginespeedisoneofthemostimportantparametersforcalculatingtheinjectionrateandthe startofinjection.Theinductive0B2enginespeed transmittermonitorsthecrankshaftsangularposition.

Awasherwithfourrecessesismountedonthe crankshaft.Thecorrectpositionisfixedwitha dowelpin.

Thetransmittermeasuresthedistancebetween twoconsecutivepulsesandtransmitsthevalues totheenginecontrolunit.Thecurrentpositionof thecrankshaftiscalculatedbyevaluationoffour pulses.

Theenginespeedsignalisusedtocalculatethe fuelvolumetobeinjectedandthestartofinjection.Thesignalfromtheenginespeedtransmitterisevaluatedinorderforthefunctionsof preheating,signaltoindicatorlightandexhaust gasrecirculation(TDIonly)tobecarriedout.

Theenginespeedtransmitteractsbothasenginespeedandreferencemarktransmitter.Ifthe transmittermalfunctions,theenginewillswitch off. Theenginecontrolunitstoresthefollowingerror causes:

Switchoffignition. Disconnectthe0B2connectorplug. Measurethetransmitterresistanceoncontacts1and2.

Referencevalue:1.1kto1.6k

Ifthereferencevalueisnotreached: Replacethe0B2transmitterforenginespeed.

Ifthereferencevalueisreached:

ConnectthemeasuringadaptortotheX27 SAABplugoftheenginecontrolunit.Theenginecontrolunitmustnotbeconnected.

Checkthelinesbetweenthemeasuringadaptorand0B2plugforinterruptions.

Lineresistance:1.5maximum

Inaddition,checkthelinesforshortcircuits toeachother,tothebatteryearthterminal,to theengineearthandtothebatterypositive terminal.

Referencevalue:

Ifnoerrorisdetectedinthelines: ReplacetheA43enginecontrolunit,seechapter"EnginecontrolunitECU".

Thesuctionpipepressuretransmitterislocated intheintakepipe.Thetransmittermeasuresthe vacuumintheintakepipe.Therecordeddata issenttotheenginecontrolunitasachangein voltage.

Ifthetransmittermalfunctions,theenginecontrol unitprovidesafixedvalueofaround20°Casa basisforcalculation.

Theenginecontrolunitstoresthefollowingerror causes:

Shortcircuittoearth Interruption/shortcircuit

Connectnotebookandstartdiagnostics. Switchontheignitionandlettheengineidle. Ifanunrealisticvalueisshowninthedisplayfield, checkthesuctionpipetemperaturetransmitter andthelineconnectionstothetransmitter.

Switchoffignition. Disconnectplug0B4.

Measurethetransmitterresistanceonthecontacts.

Rangedisplaystheresistancevaluesforthe temperaturerange0-50°C,rangedisplaysthe resistancevaluesforthetemperaturerange50100°C.

Asetpointvalueof30°Cinrangecorresponds toaresistanceof1.5-2.0k

Asetpointvalueof80°Cinrangecorresponds toaresistanceof275-375k.

Ifthesetpointvalueisnotreached:

Changethe0B4suctionpipetemperature transmitter.

Readtheenginecontrolunitserrormemory. Deleteerrormemory,ifnecessary.

Ifthesetpointvalueisreached:

ConnectthetestadaptortotheSAABplugof theenginecontrolunit.Theenginecontrolunit mustnotbeconnectedatthistime.

Checkthelinesbetweenthetestadaptorand plug0B4foropencircuits.

Lineresistance:1.5maximum

Inaddition,checkthelinesforshortcircuiting againsteachother,tothebatteryearth/engine earthandtothebatterypositiveterminal.

Setpointvalue:

Ifnoerrorisdetectedinthelines: ReplacetheA43enginecontrolunit,seechapter"EnginecontrolunitECU".

The0B5needlestroketransmitterislocatedin thefuelinjectorforthe3rdcylinderandmonitors theactualtimingoftheinjectoropening.The signalissenttotheenginecontrolunit.

Thetransmitterconsistsofamagnetcoil(2), whichisfedwithaconstantcurrentbytheengine controlunit,therebygeneratingamagneticfield. Athrustpinislocatedinthemagnetcoil,arranged asanextensionoftheinjectorneedle(1).The movementofthethrustpincausesachangein themagnetcoilvoltage.

Theenginecontrolunitcomparestheincoming signalwiththemappingforthestartofinjection andevaluatesthedifference.

Iftheneedlestroketransmitterfails,anemergencyrunningprogramisstarted.Thisdeterminesthestartofinjectionbyreferencetoa pre-setmapping.Inadditionthefuelinjection quantityisreduced.

Switchoffignition.

Disconnectthe0B5connectorplug.

Measurethetransmitterresistanceonthecontacts.

Referencevalue:80to120

Ifthereferencevalueisnotreached:

Replacetheinjectoroncylinder3,complete withthe0B5needlestroketransmitter.

Ifthereferencevalueisreached:

ConnectthemeasuringadaptortotheX27 SAABplugoftheenginecontrolunit.Theenginecontrolunitmustnotbeconnected.

Checkthelinesbetweenthemeasuringadaptorand0B5plugforinterruptions.

Lineresistance:max.1.5

Inaddition,checkthelinesforshortcircuits toeachother,tothebatteryearthterminal,to theengineearthandtothebatterypositive terminal.

Referencevalue:

Ifnoerrorisdetectedinthelines: ReplacetheA43enginecontrolunit,seechapter"EnginecontrolunitECU".

Theglowplugs(1)arepositionedsothatonly theirtipsprotrudeintothecombustionchamber. Aquickreleaseclampenablesyoutocheckand replaceglowplugsquickly.

The9K3glowplugrelayistriggeredviatheenginecontrolunit.Theglowplugrelaydetermines thepreheatingtime,glowtimeandpost-heating time.

Preheatingsystemerrorsarenotstored.Testing ofglowplugsandpreheatingsystemiscarried outviathe"Actuatortest"diagnosticsfunction.

Batteryvoltagemustbeatleast11.5V.

Switchoffignition. Removeglowplugconnectorsfromtheglow plugs.

Connectthelineofthediodetestlampwith thebatterypositiveterminalviatheauxiliary terminals.

Connecttheprobeofthediodetestlampwith eachglowpluginturn.

Diodelightsup:glowplugOK

Diodedoesnotlightup:replaceglowplug

Screwinglowplugswithaflexible-headspanner.

Tighteningtorque:15Nm

1Crankshaftpulleyscrew(90Nm+1/4rotation)

2Largeguidepulleyscrew(40Nm+1/4rotation)

3Coolantpumpscrew(15Nm)

4Lowerguidepulleyscrew(23Nm)

5Toothedbeltguard-bottompart

6Toothedbeltguardscrew(10Nm)

7Toothedbeltguard-centrepart

8Enginebracketscrew(45Nm)

9Enginebracket

10Toothedbeltguard-upperpart

11Toothedbelt

12Lowerguidepulley

13Fuelinjectionpumppulleyscrew(20Nm+1/4 rotation)

14Tensioningpulleyscrew(20Nm)

15Upperguidepulleyscrew(23Nm)

16Camshaftpulleyscrew(45Nm)

17Camshaftpulley

18Tensioningpulley

19Upperguidepulley

20Fuelinjectionpumppulley

21Toothedbeltguardscrew(25Nm)

22Toothedbeltguard-rear

23Coolantpump

24Largeguidepulley

25Crankshaftpulley

26Bush

27Injectionpump

28Compactbracket

29Compactbracketscrew(45Nm)

Toolkitaslistedintoolcatalogue

Restraintsupport(1)

Settingstraightedge(2)

Hexnutdriver(3)

Restraintpin(4)

Extractor(5)

Restraintsupport(6)

Torquewrench(5-50Nm)

Typesofmountingscrews:

Type"A"mountingscrewwithreliefonthreaded shankandtip. .

Type"A"mountingscrewsareanti-fatigue screwsandmustnotbere-used.Theymust alwaysbechanged.

Type"B"mountingscrewwithoutreliefon threadedshankandtip.

Type"B"mountingscrewsmaybere-used.

Parkthetrucksafely Switchoffignition

Disconnectthebattery.

Removethecoverplateontopofthecylinderhead(3xM8x25).

Removethevacuumpumpontopofthe cylinderhead(3xM8x35).

RelievetensionontheV-ribbedbeltbyrotating thetensionerbackwardandsecuringwitha 4mmAllenkey.

RemovetheV-ribbedbeltandmarkthedirectionoftravel,ifrequired.

Releasethetensionerandremoveit(3xM8x 35).

Removethebeltpulley(4xM8x35,Allenkey).

Removetheuppertoothedbeltguard (clamps).

Removethecentretoothedbeltguard(3xM6 x15withwasher).

Removethebottomtoothedbeltguard(2xM6 x15withwasher).

:RotatethecrankshaftuntiltheTDCmarkonthealternatorrotor flangeisinlinewiththemarkontheintermediatehousing.

camshaftposition.

Thecamshaftslotisoffcentreandmustlieabove thecamshaftaxis,i.e.thelargerchamferfaceis thelowerone.

Iftheslotliesbelowthecamshaftaxis,rotate thecrankshaftafurther360°.

Screwthefitbolts(1)intothecylinderhead untilfinger-tightagainstthestop.

Placethesettingstraightedge(2)inposition androtatethecamshaft(onthecrankshaft) untilthesettingstraightedgeeasilyfitsintothe camshaftslot.

Removethesettingstraightedge.

ChecktheTDCpositionofcylinder1atthe alternatorrotorflange.

Slackenthecamshaftpulleymountingscrew (SW19)byoneturn.Toslackenthescrew, holdthecamshaftpulleywiththerestraintsupport.

Slackenthe3screwsonthefuelinjection pumppulley,butdonotunscrewthem

Releasethetensioningpulley(nutM8)using ahexnutdriverandacombinationspanner (SW13).

Neverusethesettingstraightedgeasatoolfor slackeningandtighteningthecamshaftpulley! Useexclusivelytherestraintsupportforthispurpose.

Placethesettingstraightedgeinpositionand rotatethecamshaft(onthecrankshaft)untilthesettingstraightedgeeasilyfitsintothe camshaftslot.

Thesettingstraightedgeisleftinthecamshaft slotfortheremainingstepsandisonlyremoved later.

Positiontheextractorwiththesingle-armclaw (A)andthedouble-armclaw(B)centrallyon thecamshaftpulley

Useanopen-endedspanner(C)topullthe camshaftpulleyofftheconicaltaper.

Markthedirectionoftravelofthetoothedbelt. Removethetoothedbelt.

Markthedirectionoftravelofthetoothedbeltifit istobere-used.

Theprocedureforchangingallotherwearing partsisdescribedinchapter"Exchangingthe toothedbelt-wearingparts".

Aprerequisiteforallremainingstepsisthatthe settingstraightedgeisrestingintheslotinthe camshaft.

Securethefuelinjectionpumppulleywiththe restraintpin(2).

Placethefuelinjectionpumppulleyinabout themiddleoftheslottedholes.

Insertnew,unusedmountingscrews(1)for thefuelinjectionpumppulleyandtightenthem gently.

Type"A"mountingscrewsareanti-fatigue screwsandmustnotbere-used.Theymust alwaysbechanged.

ChecktheTDCpositionofcylinder1atthe alternatorrotorflange.

Adjustthetensioningpulley,makingsurethat itiscorrectlyseated.

Positionthetoothedbeltonthecrankshaft pulley(3),guidepulleys(1),coolantpump pulley(4),fuelinjectionpumppulley(2)and tensioningpulley(5).

Slidethecamshaftpulley(6)togetherwiththe toothedbeltontothecamshaftconicaltaper.

Ifthecamshaftpulleydoesnotslideoneasily: Thetoothedbeltisnotseatedcorrectlyonthe toothedbeltpulleys.

Thetensioningpulleyisnotintheuntensioned position(untensionedleft).

Securethecamshaftpulleylightlyusingthe mountingscrew;thecamshaftpulleymuststill beabletoturnontheshaft.

Tensionthetoothedbeltbyturningthehexnut driverontheeccentricanti-clockwiseuntilthe notchandmarkareoppositeeachother.

Iftheeccentricisturnedtoofar,thetensioning pulleymustbefullyreleasedandretensioned. Theeccentricmustneverbeturnedbackwards.

Tightentheclampingnutonthetensioning pulley.

Checkthatthetensioningpulleyiscorrectlyalignedrelativetotherearofthetoothedbeltguard.

Checkallsettings:

ChecktheTDCpositionofcylinder1atthe alternatorrotorflange.

Checkthattherestraintpin(2)inthefuelinjectionpumppulleyissittingcentrallyinthe slottedholeandadjustthetoothedbeltbyone toothasnecessary.

Removethesettingstraightedgefromtheslot inthecamshaft.

Tightenthecamshaftpulley,usingarestraint support.Thecamshaftpulleymustnotmove, Fuelinjectionpumppulley,mountingscrewstype"B",

Removetherestraintpinfromthefuelinjection pumppulley.

Rotatethecrankshaftafurthertworotationsin therunningdirectionoftheengineandresetit tocylinder1TDC.

Checkallsettings:

ChecktheTDCpositionofcylinder1atthe alternatorrotorflange.

Thesettingstraightedgemustfiteasilyintothe slotinthecamshaft.

Therestraintpinmustfiteasilyintothefuel injectionpumppulley.

Thesettingofthetensioningpulley-notchto mark-mustcorrespond

Ifthesettingsareincorrect,startthesettingprocedureagainandrepeatthechecks.

Whenallthesettingsarecorrecttospecification, theassemblycanbeconsideredcomplete: Removealltoolsandgauges.

Fitthebottom,middleandtoptoothedbelt guards.

SecuretheV-ribbedbeltpulleyinposition.

FitthetensionerfortheV-ribbedbelt.

Pre-loadthetensionerandlockitwithanAllen key.

PositiontheV-ribbedbelt.

Slackenthetensionerandtensionthebelt.

Fitthecoverplateontopofthecylinder head(3xM8x25).

Fitthevacuumpumpontopofthecylinder head(3xM8x35).

Performadynamiccheckofthestartofinjection,seechapter"Checkingthestartof injection".

Wheneverworkisperformedonthetoothedbelt, allmovingpartsmustbecheckedandreplacedin theeventofvisiblewear.

Toothedbelt

Upperguidepulley(3)

Lowerguidepulley(5)

Largeguidepulley(6)

Tensioningpulley(1)

Fuelinjectionpumppulley(4)

Crankshaftpulley(7)

Duringmaintenance,thecoolantpumpmustbe checkedforleaksandchangedifnecessary.

Coolantpump(2)

1Tensioningpulley

2Coolantpump

3Upperguidepulley

4Fuelinjectionpumpgear

5Lowerguidepulley

6Largeguidepulley

7Crankshaftpulley

Typesofmountingscrews:

Type"A"mountingscrewswithreliefonthreaded shankandtip.

TypeAmountingscrewsareanti-fatiguescrews andmustnotbere-used.Theymustalwaysbe renewed.

Type"B"mountingscrewswithoutreliefon threadedshankandtip. .

TypeBmountingscrewsmaybere-used.

Upperguidepulley,M8x35

Lowerguidepulley,nutM8

Largeguidepulley,M10x55-typeA,change screw

Thecompleteinstallationisdescribedinchapter "Exchangingthetoothedbelt".

Tensioningpulley,clampingnut

Checkthecoolantpumpforleaksandfree running.

Coolantpump,3xM7x1x20

Thecompleteinstallationisdescribedinchapter "Exchangingthetoothedbelt".

Injectionpumpimpeller,mountingscrewstype"B",

Forremovaloftheinjectionpumpimpeller, theinjectionpumpmustnotbelockedwiththe restraintpin.

Thecentrenut(2)determinesthebasicsettingsoftheinjectionpump.

Thenutissecuredwithpaintandmustnotbe loosened!

Ifthebasicsettingsaredisturbed,thefuelinjectionpumpshouldbereplaced.

Loosenthethreeouterscrews(1)(3xM8x15, SW13)whileholdingthefuelinjectionpump impellerinposition.

Whenremovingthefuelinjectionpumpimpellerit ispermissibletorestrainthecentrenut(SW22). Removethefuelinjectionpumpimpeller.

Placethenewfuelinjectionpumpimpellerin positionandlockwiththerestraintpin(2).

Mountingscrews-type"B",

Thecompleteinstallationisdescribedinchapter "Exchangingthetoothedbelt".

Tightenthecrankshaftpulley,usingarestraint support.

Donotapplyadditionaloilorgreasetothethread orcollar.

Manufacturer

Enginetype

Displacement

Compression

Ignitionsequence

Positionofcylinder1

1984cm3

10.5:1

1342

Oppositethepowerreleaseside

Valves 8(2percylinder)

Controlled:34.5kWat2350rpm

EnginepowerratingP

Compressionpressure

Uncontrolled:

Referencevalue:1013bar

Wearlimit:7.5bar

Maximumpermissiblepressuredifference3bar

Upperidlespeed

Loweridlespeed

Speedlimitation

Valveclearance

Ignition

Ignitiontiming

2450rpmwhendriving

2650rpmwithworkinghydraulics

1150rpm

2650rpm

Hydraulicvalve-clearancecompensation

Electronicignitionsequence

12°beforeTDCat1000rpmwiththrottlevalvesensor removed

20°beforeTDCat1000rpmwiththrottlevalvesensor fitted

Allsettingsaredesignedforuseofpropane

Coolant

60%waterand40%coolantadditiveG12+

Coolantvolume Approx.5-6litres

Fancut-intemperature

Thermostat

Engineoil

Coolantapprox.85°C

Openingstartat87°C

Fullyopenedat102°C

SAE5W-30accordingtoVW50700

Totalamountofengineoilwithfilterchange4.0litres

Engineoilpressureat1000rpmandoiltemperatureof80°C min.2bar

Engineoilpressureat2000rpmmin.34.5bar

Three-phasealternator

Starter

Valeo,28V,55Ah

Bosch,12V,1.8kW

Battery 2pieces,12V,45Ahminimumcapacity

Glowplugs

12V

Theenginecodelettersandenginenumberare stampedontheleftsideofthecylinderblock.In addition,thereisalabelonthetoothedbeltcover.

BEF/001018

Enginetype/serialnumber

Volkswagenshortblockenginewithengine codeBEF.

Basedona2.0litrewater-cooledfour-cylinder in-linespark-ignitionengine.

Directvalveactuationviaoverheadcamshaft. Camshaft-drivenviatoothedbelt.

Maintenance-freevalvetrainviahydraulic tappets.

Closedcoolingsystemwithseparateexpansionreservoirandhigh-pressurereliefvalve. Coolantpumpintegratedintocylinderblock. Coolantthermostatintegratedintocylinder block.

Three-phasealternator

LPGsystemandenginemanagementbyIMPCO

Theenginecontrolunitisacomponentofthe LPGsystemandissuppliedbyIMPCO.Thisindependentcontrollerisresponsiblefortheentire enginemanagement.

Theenginecontrolunitisfittedbehindthesteeringcolumnonthefrontstructure.Theengine controlunitisanindependentcontrolunitwithits ownerrormanagementsystemanddiagnostic software,whichisstartedviathenavigator.

Theenginecontrolunitisresponsibleforthe followingenginemanagementtasks:

Ignition

Lambda1-control

Pulsevalve

Activationoftheelectronicbutterflyvalve

Coolanttemperaturesensor

Enginespeed,regulationandmonitoring

MAP/MATsensor

Phasesensor

LPGshut-offvalve

Own12Vpowersupplydirectlyfromthestarter battery

Diagnosticsviadiagnosticconnector

Theenginecontrolunitstoresandanalysesall data.Thisenablesenginestrainandanydamage andweartobedetectedandcorrectionmeasures tobetaken.

Apartfromthebasicsetting,noadjustmentsto theLPGsystemortheignitionsystemarenecessary.

Theenginecontrolunitcansimplybereplaced. Nofurthermeasuresapply.(PlugandPlay)

Theengineisequippedwithanintegratedelectronicignitionsystemthatisoperatedcontactfree.Duetoitsdesign,theignitionsystemisreliable,non-adjustableandoffersthefollowing benefits:

Nocentrifugaladvance

Ignitiontimingcurvepermanentlystable

Highsecondaryvoltage

Non-wearingcontrollerviacontact-freemagneticpulsetransmitter.

Ignitionandignitioncontrolaretriggeredby anelectroniccontrolunitthatisprogrammed accordingtotheenginecharacteristics.

Ignitiontimingisadjustedaccordingtoengine speedandthrottlevalveposition(load).

Theenginespeedtransmittertransmitstheactualenginespeedtotheenginecontrolunit.This enginecontrolunitdeterminesignitiontimingvia theignitionmap.

Thephasesensortransmitsthecamshaftpositiontotheenginecontrolunit.Thetransmitter discforthephasesensorispartofthecamshaft sprocket.Thisensuresthattheignitionsparkis directedtothecorrectcylinder.

Thethrottlevalvepotentiometerchangesthe voltage(signal)totheenginecontrolunitviathe throttlevalveposition(engineload).

1Toothedbeltguard-upperpart

2Toothedbeltguard-centrepart

3Tensioningpulleyclampingnut(20Nm)

4Washer

5Tensioningpulley,semi-automatic

6Toothedbelt

7Toothedbeltguardscrew(20Nm)

8Toothedbeltguard-rear

9O-ring 10Coolantpump

11Coolantpumpscrew(15Nm)

12Crankshaftpulley

13Crankshaftpulleyscrew(90Nm+1/4rotation)

14Toothedbeltguard-bottompart

15Toothedbeltguardscrew(10Nm)

16V-ribbedbelt

17Beltpulley

18Beltpulleyscrew(40Nm)

19V-ribbedbelttensioner

Pin-typefacewrench(1)

Torquewrench(5-50Nm)

Torquewrench(40-200Nm)

Typesofmountingscrews:

Type"A"mountingscrewwithreliefonthreaded shankandtip.

Type"A"mountingscrewsareanti-fatigue screwsandmustnotbere-used.Theymust alwaysbechanged.

Type"B"mountingscrewswithoutreliefon threadedshankandtip.

Type"B"mountingscrewsmaybere-used.

Parkthetrucksafely. Switchoffignition.

Disconnectthebatterywhiletakingnoteofthe sequence.

Disconnectingthebatteryandlosingthebatterynegativeasaresultcandestroytheenginecontrolunit.

Itisessentialthatthesequenceisobserved: Batt.24V-batt.12V-batt.-

Seechapter"Starterbattery"

Disconnectthewirefromthephasesensoron rearofthetoothedbeltguard.

Removetheuppertoothedbeltguard (clamps).

RelievethetensionontheV-ribbedbeltby rotatingthetensionerbackwardandsecuring withanAllenkey.

RemovetheV-ribbedbeltandmarkthedirectionoftravel,ifrequired.

Relievetensionontensionerandthenremove.

:RotatethecrankshaftuntiltheTDCmarkonthealternatorrotor flangeisinlinewiththemarkontheintermediatehousing.

:Observethe camshaftposition.

Removethecentretoothedbeltguard(3xM6 x15withwasher).

Removethebottomtoothedbeltguard(2xM6 x15withwasher).

Removethebeltpulley(4xM8x35,Allenkey).

Releasethetensioningpulley(nutM8)using ahexnutdriverandacombinationspanner (SW13).

Markthedirectionoftravelofthetoothedbelt. Removethetoothedbelt.

Markthedirectionoftravelofthetoothedbeltifit istobere-used.

Theprocedureforchangingallotherwearing partsisdescribedinchapter"Exchangingthe toothedbelt-wearingparts".

Positionthetoothedbelt,observingthedirectionoftravelifrequired.

Setthecrankshafttocylinder1TDCposition.

Checkthe ;theTDC markonthealternatorrotorflangemustbein linewiththemarkontheintermediatehousing.

:Observethe camshaftposition.

Usingthehexnutdriver,rotatethetensioning pulleyontheeccentricfivetimestothestopin eachdirection.

Tensionthetoothedbeltbyrotatingthehexnut driverleft(arrowdirection)ontheeccentricto thestop.

Relievethetensiononthetoothedbeltuntilthe notch(1)andpointer(2)lineup(useamirror).

Iftheeccentricwasrotatedtoofar,thetensioning pulleymustbefullytensionedandreset.The eccentricmustneverberotatedbackwards. Tightenfasteningnut.

Turnthecrankshafttworevolutionsintherunningdirectionoftheengineuntiltheengine reachescylinder1TDCpositionagain.Itis importantthatthefinal45°arerotatedwithout interruption.

Checktoothedbelttensiononcemore:pointer andnotchlineup.

Fitbottomtoothedbeltguard(2xM6x15with washer).

Fitcentretoothedbeltguard(3xM6x15with washer).

Fitbeltpulley(4xM8x35,Allenkey).

Fittensioner.

Rotatetensionerbackwardandsecureusing anAllenkey.

PositiontheV-ribbedbelt,observingthedirectionoftravelifrequired.

Relievetensionontensioner.

Fittheuppertoothedbeltguard(clamps). Connectthebattery.

Wheneverworkisperformedonthetoothedbelt, allmovingpartsmustbecheckedandreplacedin theeventofvisiblewear.

Toothedbelt

Camshaftpulley(1)

Tensioningpulley(2)

Crankshaftpulley(4)

Duringmaintenance,thecoolantpumpmustbe checkedforleaksandchangedifnecessary.

Coolantpump(2)

Typesofmountingscrews:

Type"A"mountingscrewswithreliefonthreaded shankandtip.

TypeAmountingscrewsareanti-fatiguescrews andmustnotbere-used.Theymustalwaysbe renewed.

Type"B"mountingsscrewwithoutreliefon threadedshankandtip. .

TypeBmountingscrewsmaybere-used.

Thecompleteinstallationisdescribedinchapter "Exchangingthetoothedbelt".

Camshaftpulleyscrew,

IfthecrankshaftisinTDCposition,thereisariskof damagetovalvesandthepistoncrown. Beforereleasingthescrewonthecamshaftpulley, rotatethecrankshafttoslightlyoutofTDCposition.

Thesensordiskmustnotbedamaged. Usetherestraintsupportcarefullywhilstchangingthe camshaftpulley.

Usetherestraintsupportduringremoval.

Thecorrectpositionofthecamshaftpulleyis determinedbytheparallelkey.

Thecompleteinstallationisdescribedinchapter "Exchangingthetoothedbelt".

Tensioningpulley,clampingnut,

Thecompleteinstallationisdescribedinchapter "Coolantpump".

Coolantpump,3xM7x1x20,

Checkthecoolantpumpforfreerunning.

Tightenonlythetwolowerscrewsforinstallation.

Installthereartoothedbeltguardandfastento thecoolantpumpwiththethirdscrew.

Thecompleteinstallationisdescribedinchapter "Exchangingthetoothedbelt".

Crankshaftpulley, Donotapplyadditionaloilorgreasetothethread orcollar.

Theincorrectuseofcoolantsandtheiradditiveswill leadtodamagetoequipment. Complywithallinstructionsregardingtheuseof coolant.

Coolantconsistsofwaterandaspecialcoolant additive.Thequalityofthecoolantadditiveis determinedbytheenginemanufacturer.This descriptionappliestoallVolkswageninternal combustionengineslistedinthetable.

VW1.9lSDIBXTR70-16-20

RX70-22-25

VW1.9lTDIBEURX70-22-35

VW2.0lTDICBHARX70-22-35

VW2.0lTDICBJBR70-40-50

VW2.0lSPIBEFR70-16-20T

RX70-22-35T

VW3.2lVR6BMFR70-40-50T

VWG12+ Pinkcolour

Thecoolantadditiveissilicate-free andcomplieswithquality

Asarule,silicate-freecoolantadditivesshould neverbemixedwithcoolantadditivescontainingsilicate.

Exception:

CoolantadditiveVWG11,blue/green,canbe addedtoVWG12+,pink.

QualityG48orG30canbeaddedtoG30+.

Prohibited:

ItisstrictlyprohibitedtoaddqualityG30or G30+toqualityG48.

Allsilicate-freecoolantadditivescanbemixed togetherwithoutaproblem.

QualitiesG30,G30+,G33andG34areall silicate-free

However,itisimportanttobearinmindthatthe differentcoloursofthecoolantadditivescan

createanundefinedmixofcolours,makingidentificationofthecoolantadditivedifficult.This cancauseproblemswiththemanufacturerinthe eventofawarrantyclaim.

Itisrecommendedtoalwaysusethesamequality asfoundinthecoolingsystem.Itisalsorecommendedtokeepusingthesamequalitythathas beenusedinthecoolingsystemforalongtime, evenafteracompleterefill.

Coolantadditivespreventfreezing,corrosionrelateddamageandlimescaledeposits.They alsoincreasetheboilingtemperature.The coolingsystemmustthereforebekepttopped upwithcoolantadditiveall-year-round.

Particularlyintropicalcountries,thecoolant increasesoperationalsafetybyincreasingthe boilingtemperatureinheavilyloadedengines.

Frostprotectionmustbeensureddownto around-25°C(incountrieswithanArcticclimate,downtoaround-35°C).

Takecarethattheconcentrationofadditive doesnotbecomereducedduetorepeated toppingupwithwaterduringthewarmsummermonthsorinwarmcountries.Theproportionofcoolantadditivemustbeatleast40% throughouttheyear.

Ifgreaterfrostprotectionisrequiredforclimaticreasons,thepercentageofcoolantadditivecanbeincreasedtoupto60%(frost protectiondowntoabout-40°C).Atahigher concentration,thefrostprotectionandcooling effectisreduced.

Usedcoolantshouldbedisposedofasper environmentalregulationsandmustnotbe reused.

Dependingonthetruckequipment,thecoolantvolumemaydeviatefromthisamount.

Hotsteammayescapewhentheexpansionreservoir isopened,causingseriousscalding. Coverthefillercapwithaclothandcarefullyopenthe container.

Openthefillercapofthecoolantexpansion reservoir.

Removelowercoolanthosefromtheradiator. Todrainthecoolantfromtheengine,alsoremovethepipeconnectionwiththecoolant regulator(seearrows).

Installpipeconnectionwithcoolantregulator

Filltheexpansionreservoirwithcoolanttothe max.fillinglevel.

Closetheexpansionreservoir.

Allowtheenginetorununtilthefanspeed increasesandthecoolantregulatoropens Checkthecoolantlevelandtopupifnecessary.

Whentheengineisatoperatingtemperature,the coolantlevelmustreachthemax.fillinglevel. Whentheengineiscold,thecoolantlevelmust bebetweenthemin.andmax.fillinglevels.

Observedisposalspecificationsforthecoolant.

Fastencoolanthosetotheradiator

AlwaysreplacethesealsandO-rings. Thetoothedbeltguardbottompartdoesnot havetoberemoved.

Thetoothedbeltdoesnothavetoberemoved fromthecrankshafttoothedbeltpulley. Beforeremovingthecoolantpump,coverthe toothedbeltwithaclothtoprotectitagainst splashingwithcoolant.

Drainthecoolant.

Removethetoothedbelt,seechapter"Replacingthetoothedbelt"

Unscrewthefixingscrew(1)andremovethe deflectionpulley(2).

Unscrewthefixingscrews(3)andcarefully takeoutthecoolantpump(4).

WetthenewO-ring(5)withcoolant.

Insertthecoolantpump(4)intothecylinder blockandtightenthefixingscrews(3).

Tighteningtorque:15Nm

Thecoolantpumpsealingplugshouldpoint downwards.

Installthedeflectionpulley(2)andtightenthe fixingscrew(1),seechapter"Toothedbeltwearingparts"

Tighteningtorque:40Nmand¼rotation

Installthetoothedbeltandtensionit,seechapter"Replacingthetoothedbelt" Fillupwithcoolant,seechapter"Coolant".

The0B3coolanttemperaturetransmitterislocatedinthecylinderheadcoolantspigot.The transmitterisaresistorwithanegativetemperaturecoefficient.Thevoltagedropcommunicates

theinstantaneousvalueofthecoolanttemperaturetotheenginecontrolunit.

Thesignalforthecoolanttemperatureisusedin thecalculationofthefuelquantitytobeinjected, thestartofinjectionandthepreheatingtime.

Ifthesignalisinvalid,thefueltemperatureis usedasabackupsignal.Thepreheatingtime takesthevaluesofthemaximumavailabletime.

Theenginecontrolunitstoresthefollowingerror causes:

Shortcircuittoearth

Interruption/shortcircuit

Connectnotebookandstartdiagnostics. Switchontheignitionandlettheengineidle. Thetemperaturevaluemustrisesteadilywithout interruption.

Ifanunrealisticvalueoranegativebackuptemperatureisdisplayed,checkthecoolanttemperaturetransmitterandthelineconnectionstothe transmitter.

Switchofftheignition. Disconnectthe0B1connectorplug. Measurethetransmitterresistanceoncontacts1and2.

Areadisplaystheresistancevaluesforthe temperaturerange0-50°C,areadisplaysthe resistancevaluesforthetemperaturerange50100°C.

Referencevalueof30°Cinareacorresponds toaresistanceof1.5-2.0k

Referencevalueof80°Cinareacorresponds toaresistanceof275-375k

Ifthereferencevalueisnotreached:

Replacethe0B1coolanttemperaturetransmitter.

Ifthereferencevalueisreached:

ConnectthemeasuringadaptortotheX27 SAABplugoftheenginecontrolunit.Theenginecontrolunitmustnotbeconnected.

Checkthelinesbetweenthemeasuringadaptorandthe0B3connectorforinterruptions.

Lineresistance:1.5maximum

Inaddition,checkthelinesforshortcircuits toeachother,tothebatteryearthterminal,to theengineearthandtothebatterypositive terminal.

Referencevalue:

Ifnoerrorisdetectedinthelines:

ReplacetheA43enginecontrolunit,seechapter"Enginecontrolunit,ElectronicControlUnit ECU".

Drainthecoolant,seechapter"Coolant".

Pullthecoolanthoseofftheconnectionspigot (2).

Unscrewtheconnectionspigot(2)fastening screws(1).

Removetheconnectionspigot(2)withthe coolantregulator(4).

Turnthecoolantregulator(4)¼rotation(90°) totheleftandremoveitfromtheconnection spigot.

WetthenewO-ring(3)withcoolant.

Insertthecoolantregulator(4)intotheconnectionspigot(2)andturnit¼rotation(90°)tothe right.

Thecoolantregulatorbracketsmuststandalmost vertical.

Inserttheconnectionspigot(2)withthecoolant regulator(4)intotheengineblock.

Tightenthefixingscrews(1).

Tighteningtorque:15Nm

Fillupwithcoolant,seechapter"Coolant".

1A43enginecontrolunit

2Fuelinjectorwith0B5needlestroketransmitter

30B4suctionpipepressuretransmitter(SDI)

30B4suctionpipepressureandtemperature transmitter(TDI)

Theenginecontrolunitcontainsanerrormemory.Beforeperformingrepairs,adjustmentsor fault-finding,theerrormemorymustbeconsulted andanactuatordiagnosticsperformed.

Theenginecontrolunitcanrecogniseandlog anyfaultsthatoccurduringtestandrepairwork. Oncompletionofalltestandadjustmentworkitis thereforeessentialtoerasetheerrormemory.

40B1coolanttemperaturetransmitter

50B2enginespeedtransmitter

60Y2valveforstartofinjection

70Y1fuelcutoffvalve

8Fueltemperaturetransmitterand0B3control gatevalvesensor

Iftheengineisbeingdrivenatstartermotorspeedwithouttheenginestarting(forexamplewhenperforming acompressiontest),fuelcanbeexpelledfromtheinjectorsandleadtoseriousinjuriestotheskin.

Disconnectthefuelcutoffvalveconnectorplugfrom theinjectionpump.

Shortcircuitsmayoccurduringmeasurementsonthe injectionandpreheatingsystem.

Alwaysswitchofftheignitionbeforeconnectingand disconnectingwiringtotheinjectionandpreheating system.

Whenworkingonthefuelsupplyandinjection systemsbesuretocomplywiththefollowingfive rules:

Beforeopeninganyconnection,thoroughly cleanitandallaroundit.

Placepartsthathavebeenremovedonaclean baseandcoverthemup.Neverusefraying cloths!

Ifrepairstopartsthathavebeenremovedare notperformedstraightaway,coveruporclose thepartcarefully.

Installpartsonlyiftheyareclean.Donotremovepartsfromtheirpackaginguntilimmediatelybeforeinstallingthem.Neveruseparts thatwerestoredunpackaged(e.g.intoolboxesetc.).

Whenthesystemisopen:ifatallpossible,do notusecompressedair.Ifatallpossible,do notmovethevehicle.

Becarefulnottoallowdieselfueltocomeinto contactwithcoolanthoses.Ifdieselfueldoes comeintocontactwithcoolanthoses,clean thehosesimmediately.Hosesdamagedby dieselfuelmustbereplaced.

BatteryvoltageOK

Measurethesupplyvoltages.X26pin1and2 againstnegativebatteryterminal.

Ifthereferencevalueof12Visnotreached:

Checkterminal30voltagesupply9K08relay. Usingthecircuitdiagram,checkthelineconnectionsforinterruptions,shortcircuitsand contactresistanceoncontacts.

Ifnoerrorisdetectedinthelinesandontherelay:

ReplacetheA43enginecontrolunit,seechapter"EnginecontrolunitECU".

Dynamicallycheckingandcorrectinginjection timingisonlypossibleviatheenginediagnostics inthe"Defaultsettings".

Theinjectiontimingmustbecheckedand,ifnecessary,re-setaftereachchangeoftoothedbelt andafterlooseningscrewjointsontheinjection pumporthetoothedbeltpulleys.

Torquewrench(550Nm)

Enginediagnosticsvianavigator

Adaptorcable

MechanicaldefaultsettingsofengineOK ToothedbelttensionOK

Connectnotebookanddiagnosticconnector totheadaptorcable.

Startthediagnosticprograminthenavigator. Select"Defaultsettings"menu.

Onlystarttestoncenormalcoolanttemperaturehasbeenreached.

Observethesoftwareinstructions.

Readtheenginediagram. Theinjectiontimingdependsonthefueltemperature.

AInjectiontimingdisplayfield

BFueltemperaturedisplayfield

CReferencevaluerangeforinjectiontiming

Readingexample: Anumericvalueof90inthedisplayfield(B) correspondstoanumericvalueof3473inthe displayfield(A).

Iftheinjectiontimingiswithinthereference valuerangeduringtesting,noadjustmentis necessary.

Theinjectiontimingmustbere-settothemean ofthereferencevaluerangeeachtimework hasbeencarriedoutontheinjectionpump,the toothedbeltandthecontroltime.

Iftheinjectiontimingfallsoutsidethereference valuerange,re-setitinthefollowingway:

SwitchofftheignitionviathekeyswitchS1.

Disconnectthebattery.

Removeuppertoothedbeltguard.

Loosentwoofthethreefixingscrews(1)ofthe injectionpumpgear.

Thecentrenut(2)locksthebasicsettingsof thefuelinjectionpump.

Thenutissecuredwithlacquerandmustnot beundone!

Ifthebasicsettingsaredisturbed,thefuelinjectionpumpshouldbeexchanged.

Evensmallchangeshaveamajoreffectontheinjectiontiming!

Beforelooseningthescrews,thepositionoftheinjectionpumpshaftinrelationtotheinjectionpumpgear mustbecheckedandmarked.

Whenthethirdscrewisreleased,theresilienceinthe injectionpumpmaycausethepumpshafttorotateits positioninrelationtothepumpgear.

Releasethethirdfixingscrewontheinjection pumpgearandslightlyrotatethepumpshaft.

Anticlockwise=retardedinjectiontiming(later) -smallervalue.

Clockwise=advancedinjectiontiming(earlier) -greatervalue.

Type"B"fixingscrewsmustnotbechanged.

Fuelinjectionpumpgear,fixingscrews-version"B",

Connectthebattery,switchontheignition.

Checkwhethertheinjectiontimingreaches themeanvalueofreferencevaluerangeC andrepeatadjustment,ifnecessary.

Switchoffignition.

Disconnectthebattery.

Re-fituppertoothedbeltguard.

Defectiveinjectorscausethefollowingmalfunctions:

Misfiring

Knockinginoneorseveralcylinders

Engineoverheating

Lossofpower

Excessivesmokefromtheexhaust

Increasedfuelconsumption

Excessivebluesmokeduringcold-starts

Wrenchtorque(550Nm)

Box-endwrench

Connectnotebookanddiagnosticconnector totheadaptorcable.

Startthediagnosticprograminthenavigator.

Selectgroup13"engine-smoothnessregulation"fromthe"standardisedmeasuredvalue blocks"menu.

Ifthediagnosticshowsthattheengine-smoothnessregulationisactive,thisisanindicationof unequalcompressionoradefectiveinjector.

Checkingcompression

Replacinginjectors

Allinjectorsmustbereplacedatthesametime.

Removeinjectionlineswiththeopenended box-endwrench.

Alwaysremovecompletewiringharness.Donot alterthebendingshape.

Loosenthefixingscrew.

Removetheclampandtheinjector.

Thethermalprotectionsealsbetweenthecylinderheadandtheinjectorsmaynotbere-used andmustbereplaced.

Inserttheinjectors.

Ensurethecorrectpositionofthebearing blocksinthecylinderhead.

Inserttheclamp.

Injectionlines:25Nm

Clampscrew:20Nm

Placeacleanclothundertheinjectionpump. Unscrewthecoverscrews(1).(Torx)

Removethecover(2)andclean. ReplacetheO-ring(3)andfitcoverwiththe adjustmentshims(4).

1Fuelinjectionpumppulleyscrew(25Nm+1/4 turn)

2Fuelinjectionpumppulley

3Hubfasteningnut

4Supplylinepipeconnection

5Injectionpump

6Fuelcut-offvalve(40Nm)

7Returnlinepipeconnection(25Nm)

8Fuelfilter/Closedloopcontrolvalvereturn line

9Screw(25Nm)

10Injectionlines(25Nm)

11Pipeconnectionwithpressurevalve(45Nm)

12Screw(25Nm)

13Cylinder3injectorwithneedlestroketransmitter

14Screw(20Nm)

15Clamp

16Bearingblock

17Thermalprotectionseal

18Screw(19Nm)

19Valveforstartofinjection

20Strainer

21O-ring

22Screw(25Nm)

23Injectiontimingcover

24Bushwithfasteningnut

25Compactbracket

26Screw(25Nm)

Toolsaslistedintoolcatalogue

Adaptor(1)

Manualvacuumpump(2)

Box-endwrench(3)

Typesofmountingscrews:

Type"A"mountingscrewswithreliefonthreaded shankandtip. .

Type"A"mountingscrewsareanti-fatigue screwsandmustnotbere-used.Theymust alwaysberenewed.

Type"B"mountingscrewswithoutreliefon threadedshankandtip.

Type"B"mountingscrewsmaybere-used.

Removethetoothedbelt,seechapter"Exchangingthetoothedbelt"fordetails.

Removeallinjectionlinesbetweeninjection pumpandinjectors.

Loosentheinjectionlinesusingtheopenended box-endwrench.

Disconnectthesupplyandreturnlinesfrom theinjectionpumppipeconnection.

Unscrewthereturnlinepipeconnectionfrom theinjectionpump.

Closeopenlinesinordertopreventdirtfrom enteringthefuelsystem.

Covertheopeningswithacleancloth.

Disconnectthe0B3plugconnectorfromthe injectionpumpanduncliptheplugfromits supportmounting.

Unscrewtheloosenedmountingscrews(1) fromthefuelinjectionpumppulley.

Whenthefuelinjectionpumppulleyisbeing removed,thefuelinjectionpumpmustnotbe securedwiththerestraintpin.

Thecentrenutlocksthebasicsettingsofthe fuelinjectionpump.

Thenutissecuredwithpaintandmustnotbe undone!

Ifthebasicsettingsaredisturbed,thefuelinjectionpumpshouldberenewed.

Unscrewthemountingscrews(1)fromthe compactbracket.

Unscrewthemountingscrewfromtherear support.

Removetheinjectionpump.

Fittheinjectionpumptothecompactbracket andtightenthescrewontherearsupportwith thefasteningnut. .

Fitandtightenthemountingscrews(1).

Fitandtightentheinjectionlines.

Attachthesupplylinetotheinjectionpump pipeconnection.

Connectthe0B3plugconnectortotheinjectionpumpandcliptheplugintoitssupport mounting.

Fitthetoothedbelt,seechapter"Exchanging thetoothedbelt".

Screwtheadaptorintotheopeningforthe injectionpumpreturnline.

Connectthemanualvacuumpumptothe adaptorwithapprox.onemetreoftransparent plasticpipe.

Operatethemanualvacuumpumpuntilfuel comesoutoftheopeningforthereturnline.Do notdrawfuelintothemanualvacuumpump.

Removetheadaptor.

Fitthepipeconnectionwiththereturnline.

Fitthefuelinjectionpumppulleywithouttighteningthescrews,seechapter"Toothedbelt wearingparts"

Fitthetoothedbelt,seechapter"Exchanging thetoothedbelt".

Dynamicallycheckthestartofinjectionand adjustifnecessary,seechapter"Checkingthe startofinjection"

Finally,readtheenginecontrolunitserror memoryanddelete,ifnecessary.

Thefueltemperaturetransmitterisacomponent oftheinjectionpumpandcanonlybereplaced whentheinjectionpumpiscompletelyreplaced.

The0B3fueltemperaturetransmittermeasures thefueltemperatureintheinjectionpump.The recordeddataissenttotheenginecontrolunitas achangeinvoltage.Fueltemperatureisimportant,asfueldensityisdirectlydependentonit.

Thefueltemperaturetransmittersignalisusedto calculatethefuelvolumetobeinjectedandthe startofinjection.

Ifthetransmittermalfunctions,theenginecontrol unitprovidesafixedvalueascalculationbasis.

Theenginecontrolunitstoresthefollowingerror causes:

Shortcircuittoearth

Interruption/shortcircuit

Connectnotebookandstartdiagnostics.

Switchontheignitionandlettheengineidle. Ifanunrealisticvalueoranegativebackuptemperatureisdisplayed,checkthefueltemperature transmitterandthelineconnectionstothetransmitter.

Switchoffignition.

Disconnectthe0B310-pinconnectorplug (connectorplugtotheinjectionpumpsfuel quantityactuator).

Measurethetransmitterresistanceoncontacts4and7.

Areadisplaystheresistancevaluesforthe temperaturerange0-50°C,areadisplaysthe resistancevaluesforthetemperaturerange50100°C.

Referencevalueof30°Cinareacorresponds toaresistanceof1.5-2.0k.

Referencevalueof80°Cinareacorresponds toaresistanceof275-375k

Ifthereferencevalueisnotreached:

Replacetheinjectionpump,seechapter"Injectionpump".

Readerrormemoryofenginecontrolunit. Deleteerrormemory,ifnecessary.

Ifthereferencevalueisreached:

ConnectthemeasuringadaptortotheX27 SAABplugoftheenginecontrolunit.Theenginecontrolunitmustnotbeconnected.

Checkthelinesbetweenthemeasuringadaptorandthe0B3plugforinterruptions.

Lineresistance:1.5maximum

Inaddition,checkthelinesforshortcircuits toeachother,tothebatteryearthterminal,to theengineearthandtothebatterypositive terminal.

Referencevalue:

Ifnoerrorisdetectedinthelines:

ReplacetheA43enginecontrolunit,seechapter"EnginecontrolunitECU".

The0B3controlvalvetraveltransmittermonitors theangleofrotationofthefuelquantityactuator eccentricshaftintheinjectionpump.

Itisanon-contacttransmitterthatworksviatwo inductiveprobesandtransmitsitssignalsdirectly totheenginecontrolunit.

AnalternatingmagneticfieldisgeneratedbyAC voltagealongaspeciallyformedironcore.An ironringthatcanbemovedalongtheironcoreis attachedtotheeccentricshaft.Thealternating magneticfieldchangesdependingonthepositionofthemoveableironring.Thisinducesan ACvoltageinthecoil.

Thephaseshiftbetweeninducedvoltageand specifiedvoltageisusedasabasisforsettingthe fuelquantityactuator.

Thetransmittersignalcorrespondstotheactual fuelquantityactuatorsetting.Forregulation, theactualsettingofthefuelquantityactuator iscomparedwiththesettingcalculatedbythe enginecontrolunit.Ifadiscrepancybetween specifiedandactualsettingisdetected,thefuel quantityactuatoradjuststhesetting.

Iftheenginecontrolunitfailstoreceiveasignal fromthecontrolvalvetraveltransmitter0B3,the engineisshutdownforsafetyreasons.

Connectnotebookandstartdiagnostics.

Switchontheignitionandlettheengineidle. Checkthecoolanttemperatureonthedisplay field.Continuewiththetestassoonasthetest temperaturehasbeenreached.

Setpointvalue:80°Cminimum.Whenthe thickcoolanthosesleadingtotheradiatorare warmtothetouch,thetemperaturehasbeen reached.

Checkthedisplayinthedisplayfield(Setup/ Pumpvoltagepage).

EnginecodelettersBEU

Setpointvalue:1.92-2.19V

EnginecodelettersBEQ

Setpointvalue:1.60-2.10V

Ifthesetpointvalueisnotreached,checkboth thecontrolvalvetraveltransmitterandthefuel quantityactuatortransmitter.

Disconnectthe10-pinplugconnector0B3 (plugconnectortotheinjectionpumpfuel quantityactuator).

Measuretheresistancebetweencontacts1 and2andcontacts2and3.

Setpointvalue:4.9to7.5

Ifthesetpointvalueisnotreached: Changetheinjectionpump,seechapter"Injectionpump".

Readerrormemoryofenginecontrolunit. Deleteerrormemory,ifnecessary.

Ifthesetpointvalueisreached:

ConnectthetestadaptortotheSAABplugX27 oftheenginecontrolunit.Theenginecontrol unitmustnotbeconnectedatthistime.

Checkthelinesbetweenthetestadaptorand plug0B3foropencircuits.

Lineresistance:1.5maximum

Inaddition,checkthelinesforshortcircuiting againsteachother,tothebatteryearth,engine earthandtothebatterypositiveterminal.

Setpointvalue:

Ifnoerrorisdetectedinthelines:

ChangetheA43enginecontrolunit,seechapter"EnginecontrolunitECU".

Thefuelquantityactuatorisfittedontheupper partoftheinjectionpump.Itconvertsthesignalstransmittedbytheenginecontrolunitintoa changeofthecontrolsleevesetting.Toachieve this,incomingelectricalsignalsareconverted intodefinedmovementsofthedriveshaftusing theelectromotiveprinciple.

Thedriveshaftcancarryoutmovementstoa maximumrotationangleof60°.Aspringprovides apermanentaligningtorqueofthedriveshaft towardsitsinitialposition.Theeccentricballjoint pushestheaxiallymovingcontrolsleeveback andforthalongthedistributorpiston.Inthisway, thecontrolcross-sectioncanbefullyopened (switch-off)orfullyclosed(fullload).

The"CANsignalfromtheLTCcontroller"andthe enginespeedsignalareusedasparametersfor regulationoftheinjectionquantity.

Inaddition,thefollowingcorrectionvaluesare used:

Coolanttemperature

Fueltemperature.

Thisdataisusedbytheenginecontrolunitto calculateacontrolvariablethatistransmittedto thefuelquantityactuator.

Ifthefuelquantityactuatormalfunctions,theenginewillswitchoff.

Ifthevoltagesupplyfails,thealigningtorquefrom thespringreturnsthedriveshafttoitsinitialposition.Thisfullyopensthecontrolcross-section andtheengineisswitchedoff.

Theenginecontrolunitstoresanyoccurringmalfunctionsaserrors.

Disconnectthe0B310-pinconnectorplug (connectorplugtotheinjectionpumpsfuel quantityactuator).

Measuretheresistancebetweencontacts5 and6.

Referencevalue:0.5to2.5

Ifthereferencevalueisnotreached: Replacetheinjectionpump,seechapter"Injectionpump".

Readerrormemoryofenginecontrolunit. Deleteerrormemory,ifnecessary.

Ifthereferencevalueisreached:

ConnectthemeasuringadaptortotheX27 SAABplugoftheenginecontrolunit.Theenginecontrolunitmustnotbeconnected.

Checkthelinesbetweenthemeasuringadaptorandthe0B3plugforinterruptions.

Lineresistance:1.5maximum

Inaddition,checkthelinesforshortcircuits toeachother,tothebatteryearthterminal,to theengineearthandtothebatterypositive terminal.

Referencevalue:

Ifnoerrorisdetectedinthelines:

ReplacetheA43enginecontrolunit,seechapter"EnginecontrolunitECU".

Anauto-ignitionenginecanonlybeswitchedoff bycuttingoffthefuelsupply.Thisiscarriedout viathe0Y1fuelcutoffvalve.

Thefuelcutoffvalveismountedontheupperpart oftheinjectionpumpandcutsoffthefuelsupply totheinjectionpumpwhenthepowersupplyis cutoff.

Thefuelcutoffvalveisasolenoidvalve.Thearmature(3)alsoactsasastopvalve.Ifthecoil(1) isexcited,thearmatureisattracted,thespring tensionisovercomeandthefuelsupplyisactivated.

Thefuelcutoffvalveiscontrolledviaacontactin theenginecontrolunit.Ifthecontactisopened, thepowersupplytothefuelcutoffvalveiscut thuscuttingthefuelsupply.

Intheeventofmalfunction,thefuelsupplyiscut andtheenginestops.

Errorsareloggedbytheenginecontrolunit.Duringtheuseoftheenginediagnostic,thecorrect stateofthefuelcutoffvalveisverifiedwiththe "Actuatortest"function.

1A43enginecontrolunit

2Solenoidcoil

3Spring

40Y2valveforstartofinjection

5Piston

6Fuelunderpressureinsidepump

7Camplate

The0Y2valveforstartofinjectionismountedon thelowerpartoftheinjectionpump.

Itconvertsthedutycycleintoachangeincontrol pressure.Thischangeaffectsthenon-tensioned partoftheinjectiontimingpiston.

Thevalveisasolenoidvalve.Itconsistsofa piston,aspringandasolenoidcoil.Intheinactive position,thepistonstopsfuelrefluxviathespring force.Therefluxopeningisopenedbyactivating thesolenoidcoilviatheenginecontrolunit.

Duetofuelpressurepushingonthepiston againstthespringforce,apressurebalanceis achievedforallfuelpressurelevels.Thebalance offorcesdeterminesapositionfortheinjection timingpistonandthusshiftsthestartofinjection. Thechangeinpositionoftheinjectiontiming pistonshiftsthebolt.Thisshiftistransferredto theradial-mountedcamplateinsidetheinjection pump.Thepathoftheboltistransformedinto atwistedanglebytheboltandcamplateconnection.Thistwiststhecamplateinan"early"

8Bolt

9Injectiontimingpiston

10Spring

11tosuctionsideofvanepump

12Pressureroller

13Injectionpump

or"late"direction,whichinturnshiftsthestartof injection.

Thesignalfromtheneedlestroketransmitteris usedastheactualvalueparameterforcalculatingthesolenoidvalvevalue.Apulsesequence withconstantfrequencyandvaryingphaseanglesistransmittedtothesolenoidvalvefromthe enginecontrolunit.

Malfunctionsrelatingtothestartofinjectionregulationareloggedintheerrormemory.

Connectnotebookandstartenginediagnostics.

Switchontheignitionandlettheengineidle. Selectmenuitem"Guideddiagnosis-Actuator test".

Actuatingthevalveresultsinaclearlyaudiblechangeinthecombustionnoise(knocking sound).

Ifnochangeinthecombustionnoiseisaudible, checkthevalve.

Disconnectthe0B310-pinplugconnector (plugconnectortotheinjectionpumpfuel quantityactuator).

Measuretheresistancebetweencontacts9 and10.

Setpointvalue:12to20

Ifthesetpointvalueisnotreached: Replacethe0Y2valveforstartofinjection. Readerrormemoryofenginecontrolunit. Deleteerrormemory,ifnecessary.

Ifthesetpointvalueisreached: ConnectthetestadaptortotheSAABplugX27 oftheenginecontrolunit.Theenginecontrol unitmustnotbeconnectedatthistime.

Checkthelinesbetweenthetestadaptorand plug0B3foropencircuits.

Lineresistance:1.5maximum Inaddition,checkthelinesforshortcircuiting againsteachother,tothebatteryearth/engine earthandtothebatterypositiveterminal.

Setpointvalue:

Ifnoerrorisdetectedinthelines: ChangetheA43enginecontrolunit,seechapter"EnginecontrolunitECU".

TheLPGsystemhasthetaskofevaporating liquidLPGfromthegascylinderanddelivering agas/airmixturetotheLPGengine.TheLPG systemconsistsofthefollowingmainunits:

Gascylinderorgastank

Chassismodule,controlled/uncontrolled

Suctionmodule

Enginecontrolunit

Three-waycatalyticconverter(onlyincontrolledsystems)

LPGfromthegascylinderpassesthroughthe openedgascylindervalve(1)atapressureof68 bar.Fromhere,theLPGflowsintothechassis modulethroughahighpressuregashose(3). Betweenthegascylinderandevaporator,there isa30barexcesspressuresafetydevice(2). Theexcesspressuresafetydevicepreventsthe pressureoftheresidualgasinthehosefrom risingabove30barthroughoverheating.The excesspressuresafetydeviceopensandsafely divertstheLPGunderthetruckthroughahose.

1Gascylinder 2Chassismodule 3Suctionmodule

1Gascylindervalve 2Excesspressuresafetydevice 3HPgashose

Therearetwodifferentchassismodules.

Thechassismoduleofthecontrolledgassystem withathree-waycatalyticconverterconsistsof thefollowingmainunits:

Evaporator

Gasshut-offvalveunit

Actuator

Thechassismoduleoftheuncontrolledgassystemconsistsofthefollowingmainunits:

Evaporator

Gasshut-offvalveunit

Thegasshut-offvalveunitconsistsofthefollowingcomponents:

Solenoidshut-offvalve

LPGfilter

Thesuctionmoduleisacompleteunit,consisting ofthefollowingmainunits:

Suctionpipe

Temperature/pressuresensor

MAP/MATsensor(ManifoldAbsolutePressure/Temperature)

Electronicbutterflyvalve

Gasmixer

Thegasmixersfor"controlled"and"uncontrolled"gassystemsdifferfromeachotherand arenotinterchangeable.

Gaspressureswitch 1Suctionpipe 2MAP/MATsensor

Incombinationwiththelambdacontrolsystem, thethree-waycatalyticconverterrepresentsthe mosteffectiveexhaustgascleaningprocess currentlyavailable.

Thethree-waycatalyticconverterconsistsof:

Exhaust

Catalyticconverter

Lambdasensor

Thelambdacontrolsystemcontrolsthefuel quantitysothattheair/fuelmixtureachieves virtuallycompletecombustion,therebyreducing theamountofharmfulsubstancesintheexhaust gas.

Thethree-waycatalyticconverterhasthecapabilityofsimultaneouslyremovingahighproportionofallthreeharmfulcomponentshydrocarbons(HC),carbonmonoxide(CO)andnitrogen oxide(NOx)fromtheexhaustgas.

Theevaporatorreducesgaspressureand changestheLPGsphysicalstatefromliquidto gas.Itconsistsofatwo-stagepressureregulator andaheatexchanger.

Reducingthepressuretoapprox.1.2.to2.5 mbarcausestheLPGtoexpandandbecome gaseous.Duringthisprocessproduceslatent heat,whichmustbedissipated.Forthisreason, theevaporatorfeaturesaheatexchangerthatis connectedtotheenginescoolingcircuit.Inthe heatexchanger,latentheatisdischargedintothe coolingwater.

Atmosphericcompensation(d)forcompression chamber1isrelayedinwardforcompression chamber2viathecompensationline(3).Referencepressureforpressurestage1isinfluenced bythepressureinthecompensationlineandatmosphericcompensationinpressurestage2.

Atidle,thestopvalveofthefirstcompression chamber(1)isopenedandthestopvalveofthe secondcompressionchamber(2)isclosed.

TheLPGfromthegascylinder(3)entersthefirst compressionchamberthroughitsopenedstop valve(1)atapressureof6to8bar.Theliquid LPGexpands,becomesgaseousandbuildsup pressureinthefirstcompressionchamber.

Therisingpressureactsonthemembraneplate (5),thatclosesthestopvalve(6)viathevalve lever(1).Thesurfaceareaofthemembraneplate (5),thedimensionoftheshutoffspring(7),and thetransmissionratioofthevalvelever(6)determinethemaximumpossiblepressureinthefirst compressionchamber(4)between0.1to0.2bar.

Thesuctionvacuumcreatedbytheenginesoperationeffectsviatheconnectingline(9)and buildsupavacuuminthepressureregulator(8).

Thevacuumactsonthemembraneplate(10), thatopensthestopvalve(12)viathevalvelifter (2).Thesurfaceareaofthemembraneplate (10),thedimensionoftheshutoffspring(11), andthetransmissionratioofthevalvelifter(12) determinethemaximumpossiblepressureinthe firstcompressionchamber(8)between1.2to2.5 mbar.

Aslongasasufficientvacuumispresentinthe connectingline,gasfromcompressionchamber 1enterscompressionchamber2.Ifpressure intheconnectinglineincreases,thestopvalve inthesecondcompressionchambercloses.If pressuredecreasestothepreselectedlevel,the valveopensfurtherandmoregascanenter.In thisway,thegaspressureintheconnectingline tothemixeriskeptconstant.

Thegasentersthemixerfromtheconnectingline (2)viaafull-loadscrew(1)designedasathrottle.

Whentheengineisatstandstill,theshutoffspring (5)keepsthegasregulatorvalve(3)inclosed position,sogascannotentertheventuritube(4) totheengine.

Whentheengineisrunning,thevacuuminthe suctionpipe(6)actsdirectlyonthepiston(7). Thevacuumdrawsthepistondownwardsagainst thespringtension,causingtheventuritube(4)to open.

Thevacuuminthesuctionpipeinfrontofthe throttlevalve(9)isresponsibleforthepiston strokeanddependantonthespringtensionand theairresistanceoftheairfilterandthemixers upperpart.

Springtensionandtheconeshapeandsections inthemixerarematchedtotherespectiveengine.Duetotheshapeofpistonandcone(10), onlyaspecificsectionofthegasoutletpipeis releasedineachpositionthusdeterminingthe fuel/airratio.

Basiccalibrationiscarriedoutviatwoscrews. Thegasandairmixtureforfullthrottleissetvia thefull-loadmixtureadjustmentscrew(1).The idlerunningmixtureissetinthebypass(12)via theidlemixtureadjustmentscrew(10).

Thebalancingline(11)connectsthemixerwith theevaporator.Incontrolledgasfuelsystems, theactuatorisconnectedtothelevellingline(11) andthevacuumline(13).

Inthegasmixer(3),theintakecombustionair iscombinedwithgasfromtheevaporatorata constantratioandthensenttotheengineviathe butterflyvalve(2)andtheintakepipe(1).

Thegasmixersfor"controlled"and"uncontrolled"gassystemsdifferfromeachotherand arenotinterchangeable.

TheMAP/MATsensor(4)detectsthevacuumin theintakepipe.Thismeasuredvalueenablesthe enginecontrolunittocalculatethecurrentengine powerrating.

Enginespeedandpowerratingiscontrolleddirectlybytheenginecontrolunitviatheelectronic butterflyvalve.Thebutterflyvalvecannotbeset oradjustedmanually

1Intakepipe

2Electronicbutterflyvalve

3Gasmixer

4MAP/MATsensor

Thegasmixer(1)canbedisconnectedfromthe throttlevalvehousing(2)bylooseningthefour mountingscrews(7).

Thegasmixersfor"controlled"and"uncontrolled"gassystemsdifferfromeachotherand arenotinterchangeable.

Itisnotpossibletorepairthegasmixer,sothe wholeunitmustbechangedintheeventof damage.

Thegasmixermustbedismantledforcleaning.

Unscrewthefourscrews(8)whileholding ontotheintermediateflange(9)andcarefully removefromthegasmixer(1).

Togetherwiththesealandtheguidering,the intermediateflangeispushedupwardsbythe spring.

Removethegasregulatorvalvefromthegas mixerhousing. Cleanallparts.

Intheeventofvisiblewearonthegasregulator valveandgasmixerhousing,changetheentire gasmixer.

Re-assembleallparts. Tightenscrews(8)crosswise.

Itisnotpossibletorepairthebutterflyvalve,so thewholeunitmustbechangedintheeventof damage.

Thebutterflyvalveelectronicsmustnotbe openedup.

Thebutterflyvalvecannotbeadjustedmechanicallyandiscontrolledviathebutterflyvalve electronics(2).

Intheeventofmalfunctionorwear,theentire butterflyvalveunitmustberemovedfromthe intakepipeandthegasmixer,andthenchanged.

1Butterflyvalvehousing

2Butterflyvalveelectronics

3Mountingscrews

4Seals

TheMAP/MATsensorisfittedtothetopofthe suctionpipeandsecuredwithascrew.

Thesensorismaintenance-free.Intheeventof repairsitmustbecompletelyreplaced.

Disconnecttheplug

Loosenthescrew

Carefullyremovethesensorfromthesuction pipe.

Thechassismoduleisacompleteunitavailable intwodifferentversions.

Thechassismoduleofthecontrolledgassystem consistsofthefollowingmainunits:

Evaporator(1)

Gasshut-offvalveunit(2)

Actuator(3)

Thechassismoduleoftheuncontrolledgassystemhasnoactuator.

Thechassismoduleisboltedtothechassisviaa support(4)andcanberemovedasonecomplete unit.

Disconnectallhosesbetweentheevaporator andmixer.

Disconnectthecoolanthoses.

Disconnecttheplugsonthesolenoidvalve, pressureswitchandactuator,ifapplicable.

Unscrewandremovethegassupply.

Unscrewandremovethechassismodulecompletewiththesupportfromthechassis.

Unscrewgasshut-offvalveunitbyopening screwplug(SW16)fromthetop.

Removethecompletegasshut-offvalveunit.

Unscrewthegassupply(banjoboltSW16) fromtheevaporator.Thebanjoboltisgluedin place.

IncontrolledLPGsystems,unscrewtheactuatorfromthesupportanddisconnectthe compensatinglinefromtheevaporator.

Unscrewthesupportfromtheevaporator.

Unscrewthetestconnectorwiththehigh-pressurereliefvalvefromtheevaporator.

Screwthetestconnectorwiththehigh-pressurereliefvalveontotheevaporator.

Screwthesupportontotheevaporator.

IncontrolledLPGsystems,unscrewtheactuatoronthesupportandconnectthecompensatinglinetotheevaporator.

Screwthegassupply(banjoboltSW16)into theevaporator.Securethebanjoboltwith Loctite.

Insertthecompletegasshut-offvalveunit.

Screwthegasshut-offvalveunitintoplaceby closingscrewplug(SW16)onthetop.

Screwchassismodulecompletewithsupport ontothechassis.

Connectthegassupply.

Connecttheplugsonthesolenoidvalve,pressureswitchandactuator,ifapplicable.

Connectthecoolanthoses.

Connectallhosesbetweentheevaporatorand mixer.

Theactuatorunitispartofthechassismodule andisonlyinregulatedgasfuelsystems.

Thepulsevalve(2)isconnectedtothemixervia thebalancingline(3)andthevacuumline(1). Membranesareventilatedviathemodulation lines(5).

Inaddition,ashortcircuit(6)islaidviathepulse valvetothebalancingline.Inthisway,additional ventilatingofthemembraneisachievedviathe shortcircuit.Thisachievesaquickerregulation reactiontowardsarichgasmixture.

Thecyclevalveisactivatedviatheenginecontrol unit(4).

Thepulsevalveismaintenance-freeandmustbe replacedcompletelyintheeventofdamage.

Usingtwomagneticpins,thepulsevalveregulatesacontrolpinwhichsteersthevacuuminto theevaporator.Thispromptsthegasmixtureto becomericherorleaner.

Themagneticcoilsareregulatedviatheengine controlunit.Thecontrolpinoperatesinincrements,withupto200incrementsperminute. Duringthisprocess,thecontrolpinmovesby 0.0416mm.

Aftertheswitchlatchisswitchedon,thecontrol pinmovesfromitsstartingpositiontothecontrolposition.Asaresult,theenginecontrolunit recognisestheposition.

The isactivatedbythe enginecontrolunit.Inthedeactivatedstatethe solenoidshut-offvalveisclosed.Assoonasthe ignitionisswitchedon,thesolenoidshut-offvalve isopenedandallowsLPGtoflowtothechassis module.

The sensestheactual gaspressureinthesystem.Ifthegaspressure fallsbelowacertainvalue,anindicationappears inthedisplay.

Thesolenoidshut-offvalveandgaspressure switcharemaintenance-free.

ThecleanstheLPGofcontaminationthatmayhavebeenintroducedduring transportandstorage.

Acloggedfilterreducestheenginepower

Thefiltermustbechangedevery1000operatinghours. Ifthegasisverydirty,changethefiltermorefrequently.

Aftertheenginehasbeenshutdown,theshutdownduetolackofgasfunctionensuresthatthe gassystemthroughtotheevaporatoriscleared ofresidualgas.

Ifwhentheengineisswitchedoffgaswereto remainintheLPGsystem,theresidualengine heatcouldcausethegaspressuretoriseand leadtoleaks.

AftertheLPGenginehasbeenswitchedoffusing thekeyswitchS1,thetruckcontrolsystemplaces anelectricalblockonallvehiclefunctions.

Theenginecontrolunitremainsswitchedonfor amaximumof60secondsandsuppliesthe9A1 ignition,sothattheenginecanrunon.

Assoonastheignitionswitchisswitchedoff,the enginecontrolunitimmediatelyclosesthe9Y4 LPGshut-offvalve.Theenginerunsonuntilthe gasinthegasfuelsystemisusedup.

DependingonthetemperatureoftheLPG,the enginecanrunonfor2secondsuptoamaximum of20secondsafterbeingswitchedoff.

Iftheshut-downduetolackofgasfunction failstooperatecorrectly,theenginecontrolunit switchesoffthe9A1ignitionafteramaximumof 65seconds.

Theshut-downduetolackofgasfunctionisnota substituteforclosingthegascylindervalve. Afterusingthetruck,alwaysclosethegascylinder valve.

Iftheenginerunsonforlongerthan20seconds, theshut-downduetolackofgasfunctionmalfunctions.

ApossiblecauseisleakagepasttheLPGshut-off valve.

Anerrorwillbeindicatedinthediagnosticssoftware.

Remedythefault

ThelegalbasisfortheuseofLPGininternal combustionenginesinGermanyisestablished inaGeneralEmployersLiabilityInsurance Associationregulation(BGV).

Inaccordancewith,thefollowing appliestovehicleswithLPGinternalcombustion engines:

Itistheoperatorsresponsibilitytoensure thattruckLPGsystemsareinspectedbya specialistatregularintervals,butatleastonce ayear.

Theinspectionistobebasedonthefollowing criteria:

Leaks

Propercondition

Operationandfunctionalityofsafetydevices

Itistheresponsibilityoftheoperatortoensure thatthepollutantlevelsintheexhaustgases arecheckedbyaknowledgeablespecialistat regularintervals,butatleasteverysixmonths, andadjustedtothelowestattainablevalue.

COlevel0.1vol.%withtheengineidlingat operatingtemperature

CheckCOlevelinexhaustgases

ChecktheLPGsystemforleakswithleak spray.

ChecktheconnectionsoftheLPGsystemfor secureseating. Thisisaninspectionthatismandatoryaccording toBGVD34,§37,anditistheoperatorsresponsibilitytocarryitout.

ChangetheLPGfilter.

30bar-checkthehigh-pressurereliefvalveon thesolenoidshut-offvalve.

1.7bar-checkthehigh-pressurereliefvalve ontheevaporator/pressureregulator. Checksolenoidshut-offvalveoperation. Overhaul/serviceevaporator/pressure regulator.

Checkrun-onoftheengineuntiltheengine stops.

CheckCOlevelinexhaustgases

ChecktheLPGsystemforleakswithleak spray.

ChecktheconnectionsoftheLPGsystemfor secureseating.

Thisisarecommendedinspection,anditisthe operatorsresponsibilitytocarryitout.

ChecktheLPGsystemforleakswithleak spray.

ChecktheconnectionsoftheLPGsystemfor secureseating.

Thisisaninspectionthatismandatoryaccording toBGVD34,§37,anditistheoperatorsresponsibilitytocarryitout.

Performalltasksspecifiedforthe1000 operatinghour/annualmaintenance. ReplacehosesoftheLPGsystem.

SubjectLPGtanktoTÜVinspection.

TheLPGfiltercleanstheLPGofcontamination thatmayhavebeenintroducedduringtransport andstorage.

Acloggedfilterreducestheenginepower

Thefiltermustbechangedevery1000operatinghours. Ifthegasisverydirty,changethefiltermorefrequently.

Whenfittingthefilter,alwaysfitnewsealsfrom theoriginalSTILLmaintenancekit.

Parkthetrucksafely.

Switchofftheengine

Closethegascylindervalve.

Openthebonnet

Unscrewthefilterwitharingspanner(22AF)

Changethefilter,payingattentiontotheinstallationposition.

Thesealingringmustfitintotherecessonthe filtercorrectly

TheLPGsystemcanbedamagedbyunfilteredLPG. Payattentiontothepositioningofthefilterandsealing ring

Tightenthefilterhandtightwitharingspanner (22AF)

ChecktheLPGsystemforleakswithleak spray.

Theexcesspressuresafetydevicemustbe testedevery1000operatinghours,butatleast onceayear.Aspecialpressuretesterandpressuregaugeareneededforthistest.Bothare containedintheSTILLHydraulicMeasurement ToolCase.

ThetestequipmentfromtheSTILLHydraulic MeasurementToolCaseshouldbeusedforthis test.

Parkthetrucksafely

Switchofftheengine. Closegascylindervalve.

Removetheexcesspressuresafetydevice. Ifnecessary,useTeflontapetosealthe hexagonheadscrew(1).

Fillthepressuretester(2)withoil.

Screwtheexcesspressuresafetydevice(4) intothepressuretester(2).

Tightenthehexagonheadscrewandreadthe maximumpressureonthepressuregauge(3). Thevalvemustopenat.

Reinstalltheexcesspressuresafetydevice.

ChecktheLPGsystemforleakswithleak spray.

TheCOvaluesaretestedinaccordancewith BGVD34,par.37(2)every6months.

Themanufacturerpresetsthemixerstopropane operationand"rich".

Idlemixtureadjustmentscrew(1)highestpurity

Full-loadmixtureadjustmentscrew(2)toR

TherequiredCOlevelsareusuallyachievedwith thesesettings,withoutanyadjustmentsbeing made.

Intheeventoflargediscrepanciesoutsideof thecontrolrange,thegasmixturecanbesetto aleanermixtureviatheidlemixtureadjustment screwandthefull-loadmixtureadjustmentscrew.

Starttheengineanddrivethetruckuntiltheradiatorhosesbetweentheengineandradiator havenoticeablywarmedup.

Stopthetruck,applytheparkingbrake.

Lettheenginerunatidlespeed.

InsertaCOtesterintoexhausttailpipe,followingthemanufacturersspecificationsregardingusage.

Onlycarryouttestingoncetheenginespeed hasreachedasteadystate.

Ifnecessary,openthebonnetandadjustvia theidlemixtureadjustmentscrew.

Unscrewtheidlemixtureadjustmentscrew(1) asfarasrequired.

Starttheengineanddrivethetruckuntiltheradiatorhosesbetweentheengineandradiator havenoticeablywarmedup.

Stopthetruck,applytheparkingbrake.

Runtheengineunderload(liftingagainstexcesspressure).

InsertaCOtesterintoexhausttailpipe,followingthemanufacturersspecificationsregardingusage.

Onlycarryouttestingoncetheenginespeed hasreachedasteadystate.

Theenginemustrunevenly,withenginespeed continuallyrisingto2400±50rpm.Speedfluctuationsmustnotexceed30rpm.

Theenginecanreachoverload. Donotlettheenginerununderfullloadforlongerthan 60seconds.

Ifnecessary,openthebonnetandadjustvia thefull-loadmixtureadjustmentscrew.

Turnthefull-loadmixtureadjustmentscrew(2) towardsL(lean)asfarasrequired.

Maintenanceand/ortestingofthegasfuelsystemmustbecarriedoutbyaspecialistatregular intervalsevery1000hours,atleastonceayear.

OnlysparepartsfromgenuineSTILLmaintenancekitsmustbeused.

Sparepartsforthisevaporatorarenotinterchangeablewiththosefrompreviousmodels.

Onlyoriginalscrewsmustbeusedforassemblyoftheevaporator.

ThreadsmustonlybesealedwithLoctite(Loctite577und5331).

Followingrepairs,allscrewjointsmustbecheckedforleaks.

Unscrewsixscrews(2)fromthecover(1). Carefullyremovethecover;indoingso,the membrane(3)isloosened.

Carefullyunhooktheleverattachedtothe membrane(4).Avoiddamagingthelever.

Disposeoftheusedmembraneinanenvironmentallyfriendlymanner.

Unscrewthescrew(5)andloosenthelever (4).

Theleverliesonthespring(8).Theleveris shapedinawaythatpreventsthespringfrom slipping.

Removethespringwiththepin(7)andput themaside.

Turntheevaporatoraroundandunscrew sevenscrews(10)fromthecover(9). Carefullyremovethecover(9)withthemembrane(15).

Aleverplatethatpushesthevalvepin(12)and thespring(11)downwardisattachedtothe membrane(15).Thepenpointstotheopening ofthepressureregulator.

Disposeoftheusedmembraneinanenvironmentallyfriendlymanner.

Removetheplate(14)withthesealfromthe housing.

Removetheseal(13)fromtheplate(14).

Disposeofthesealinanenvironmentally friendlymanner.

Cleantheplateandre-insertintothehousing withanewseal.

Placenewmembrane(15)onhousing.

Securethecover(10)withsevenscrews(9).

Screwlength:30mm Tighteningtorque:2.3Nm

Disconnecttheregulatorbase(X)fromthe lever(4).

Disposeofusedregulatorfitinanenvironmentallyfriendlymanner.

Pushnewregulatorbase(X)intheopeningof thelever(4).

Insertspring(8)andpin(7)intothehousing.

Securespringandpininthehousingwiththe screw(5).

Pushnewslottedmembrane(3)overthe lever(4)andfit.Carefullychecktheposition ofthelever.

Fitcover(1)andsecurewithsixscrews(2).

Tightenthescrewsdiagonallyacrossfromone anotherwithatighteningtorqueof2.3Nm. Performaleakagetest.

Afteranyworkontheevaporator,suchasmaintenanceandrepair,alwaysperformaleaktest.

Checkthegaspressureintheevaporatoratpressurestage1byconnectingtheIMPCOmeasuringdevicetothetestcoupling(1).

Checkthegaspressureintheevaporatoratpressurestage2usingthetestcoupling(2).

Toguardagainstdamageandcontamination,the testcouplings(valves)mustalwaysbefittedwith protectivecaps.

ConnecttheIMPCOmeasuringdevicetothe handpump(3).

ConnecttheIMPCOmeasuringdeviceandthe handpumptotheevaporator(1,2).

OpentheLPGcylinder.

Removethehosefromconnection2ofthe IMPCOmeasuringdeviceandkeepitclosed withthethumb.

PressurepeakscandamagetheIMPCOmeasuring device.

Connection2mustalwaysbedisconnectedbefore switchingontheignition.

Switchontheignitionbutdonotstarttheengine.

Thesolenoidshut-offvalvewillopenforabout10 secondsandthencloseagain.

Attachthehosetoconnection2oftheIMPCO measuringdevice.

RemainingLPGinthelinemayflowoutandcause frostbiteontheskin. Alwayswearprotectivegloves.

Usethehandpumptodrawavacuuminpressurestage2.

Iftheevaporatorisfreefromleaks,thefollowing measuredvaluesshouldbeshownonthepressuregauges:

Measuredvalue=1.5-3.0psi

dependingonthepressureinthegascylinder

Measuredvalue=-1.8inchwc

Maximumvaluegeneratedbythehandpump

Afterthetestbesuretocloseoffallthetestcouplingsagainwithprotectivecaps.

Thesafetyvalve(b)isa1.7-barhigh-pressure reliefvalve.

Gaspressureintheevaporators1stand2nd compressionchamberscanbecheckedviathe testcoupling(c).

Thesafetyvalvemustbecheckedforcontaminationevery1000operatinghours,andatleast onceayear.

Assoonasthevalvenolongerclosescorrectly duetocontaminatedLPG,thevalvemustbe cleaned.

Removingthevalve

Blowoutthevalvewithcleancompressedair.

Re-fittingthevalve

Asarule,allvalvesmusthavecaps.

LPGfromthegascylinderpassesthroughthe openedgascylindervalve(1)atapressureof68 bar.Fromhere,theLPGflowsintothechassis modulethroughahighpressuregashose(3).

A30barover-pressuresafetydevice(2)protects thehighpressuregashoseagainstinadmissible overpressure. Gascylindersshouldonlybechangedbypersonswhohaveundergonetraining.

Whenchangingthegascylinder,makesurethere isaminimumdistanceof3mfromcellaropenings,pits,manholesandanysourcesofsparks.

Itisprohibitedtochangegascylindersinstorage rooms!

LPGishighlyflammable!

DuringworkontheLPGsystem,smokingandtheuse ofopenflamesandlightsourcesisstrictlyprohibited.

Closegascylindervalve.

Securelygriptheconnectionnipplewiththe handholdandcarefullyundotheunionnut (SW32).

Theunionnuthasaleft-handthread.

RemainingLPGinthelinemayflowoutandcause frostbiteontheskin!

Alwayswearprotectivegloves.

Swingthehandleofthetensioningdeviceupwardsandremovethehookfromthesupport mounting.

Removetheupperpartofthecylindersupport mounting.

Changetheemptygascylinderforafullone.

Wheninstallingthegascylinder,makesurethat theconnectionscrewjointofthecylindershut-off valvepointsverticallydownwards.

Securethegascylinderinthesupportmountingaccordingtoregulations.

Checkallconnectionsforleaks.

Thelambdasensorreturnsavoltagesignal (200-800mV)totheenginecontrolunit.Theenginecontrolunit(4)sendsaPWM(PulseWidth Modulation)signaltothecyclevalve(2).

Thecyclevalvecausesthemixturetobecome richerorleaner.Forthispurposeacontrolthresholdofabout500mVisprogrammedintheengine controlunit.Ifthevoltagereturnedbythelambda sensorislessthanthisvalue(mixturetoolean), moreLPGisadmitted.Ifthevalueisexceeded (mixturetoorich),thecyclevalvereducesthe amountofLPG.

ThechangeintheLPGquantityisachievedusing thecyclevalve,whichviathemodulationlines(5) operatesonthemembraneplateinthepressure stage2intheevaporator.IfmoreLPGisrequired (richermixture),themodulationlineisclosed. Thiscausesonlytheintakeairvacuumtoacton thepressurestage2intheevaporatorandthe stopvalvetobefullyopened.

IflessLPGisrequired(leanermixture),themodulationlines(5)areopened.Thiscausesavacuuminthecompensatingchamber,whichcounterstheintakeairvacuumonthemembraneplate inpressurestage2.Thestopvalvecloses,causinglessLPGtopassthroughthemixer,andthe mixturebecomesleaner.

Changesintheair-fuelratiomusthowevernotbe madeabruptly,otherwisethetruckwouldbehave jerkily.Thereforetheenginecontrolunitincludes anintegratorwhichslowlychangesthemixture compositionbymeansofatimefunction.

Acertaintime(thedeadtime)elapsesfromthe timeofestablishingafreshmixtureinthegas mixertothetimethelambdasensorrecordsthe resultofcombustionintheexhaust.Thisisdue tothetransittimeofthemixturetotheengine, theresidencetimewithintheenginesoperating cycle,thetransittimefortheexhaustgasesfrom enginetothelambdasensorandtheresponse timeofthelambdasensor.Theresultofthisdead timeisthatitisnotpossibletomaintainaconstant precisemixture.

Theair-fuelratioconstantlyfluctuatesbyafew tenthsofapercentaroundlambda=1.Whenthe integratoriscorrectlytuned,theaveragevalueof theair-fuelratioremainshoweverexactlywithin thelambdawindow,whichisthezoneinwhich

thecatalyticconverterachievesitshighestconversioneffectiveness.

Thecontrolunit readsthecurrentlambdavalue performsthelambda1control activatesthecyclevalveintheactuator

InautomotivetechnologytheGreekletterlambda ""isusedtodesignatetheproportionofairinthe air-fuelmixtureofaninternalcombustionengine. Thisisalsoreferredtoasthe"stoichiometricratio".

Thestoichiometricratiolambda=1istheoptimummassratioforcompletecombustion.Thisis 14.7kgairto1kgfuel.

Lambda=inducedairmass:theoreticalair mass

Thelambdavalueindicateshowfartheactual air-fuelmixturedeviatesfromtheoptimum.A lambdavaluegreaterthan1indicatesanexcess ofair(leanmixture).Alambdavaluelessthan1 indicatesadeficiencyofair(richmixture).

Forengineswithexhaustgascontroltheoptimum ratioisdeterminedusingthelambdasensor.

Thelambdasensorconsistsofasteelhousingwithinwhichaceramicpartisinstalled.The lambdasensormonitorstheexhaustgasinthe exhaustpipefromallcylindersequally.

Thesurfaceoftheceramicbodyisprovidedwith electrodesofagas-permeableplatinumlayer.

Onthefaceexposedtotheexhaustgasaporous ceramiclayerisappliedtoguardagainstthe productsofcombustion.

Thelambdasensorheaterensuresthattheceramicisquicklyheatedup,sothatitachievesis operatingtemperaturewithin15-60seconds aftertheengineisstarted,atwhichpointthe lambdacontrolsystemisactivated.

Withheatedlambdasensorstheceramictemperatureatlowengineloads(lowexhaustgas temperatures)isachievedbyelectricheating;the

exhaustgasisreliedonforheatingonlyathigh engineloads(highexhaustgastemperatures).

Thisallowsthelambdasensortobeinstalleda longdistancefromtheengine,andremovesthe dependenceoncontinuousfullloadoperation.

Themeasurementisbasedontheresidualoxygencontentoftheexhaustgas.Theresidual oxygencontentoftheexhaustgasisstronglydependentontheair-fuelratioofthemixture.This dependencyallowstheoxygenproportioninthe exhaustgastobeusedasanindexoftheair-fuel ratio.

Theouterpartoftheceramicbodyofthelambda sensorliesintheexhaustgasflow,theinnerpart isincontactwiththeambientair.

Fromabout300°Ctheceramicmaterialisconductivetonegativeoxygenions.

Iftheoxygenproportionisdifferentonthetwo facesofthelambdasensor,iondiffusionoccurs, wherebyonlythepositiveoxygenatomicnuclei passthroughtheceramic.Thenegativeelectronsarepreventedfrompassingthrough.

Thiseffectcausesanelectricvoltagetobegeneratedandmeasuredattheelectrodes.

Thisvoltageisthemeasureoftheair-fuelratio andiscommunicateddirectlytotheenginecontrolunit.

Voltagerangescorrespondingtotheoxygen proportionintheexhaustgas:

richmixture(lambda<1)

800-1000mV

leanmixture(lambda>1)

0-150mV

Controlthresholdapprox.lambda1

500mV

Inaverynarrowcross-overrangearoundlambda =1,arangereferredtoasthelambdawindow,the characteristiccurveisextremelysteep.Within thisrangethevoltagechangesalmostabruptly asafunctionoftheair-fuelratio.Theharmful substancesreducebyupto90%withinthisnarrowrangeofthelambdawindow.

Aswellastheoxygenproportionintheexhaust gas,thetemperatureoftheceramicbodyalso playsacriticalrole.

Itisthereforeimportantthatthelambdasensor achievestheoptimumoperatingtemperatureof approx.600°Casquicklyaspossible;thisisdone byheatingthelambdasensor.

Thetemperatureinfluences:

theconductivityoftheoxygenions

theresponsetimetoachangeinvoltage

Atceramictemperaturesbelow350°C,theresponsetimeisseveralseconds,whereasatnormaloperatingtemperaturesitislessthan1ms.

Aftertheengineisstarted,thelambdacontrol systemisthereforenotactivateduntilaminimumoperatingtemperatureofabout350°Cis achieved.Untilthistimetheengineiscontrolled usingthedefaultsettings.Temperaturesthat aretoohighreducetheworkinglife.Therefore thelambdasensormustbeinstalledsothatsustainedfull-throttleoperationdoesnotcausethe temperaturetoexceed900°C-1000°C.1200°C canbepermittedforshortperiods.

1Metalhousing

2Carriermats

3Ceramicbody

Thecatalyticconverterconsistsofaceramic body(3),whichbymeansofcarriermats(2)is fittedintoametalhousing(1).Thecatalyticconverteriseasilydamagedbyimpactsandmustbe protectedagainstmechanicaldamage.

Thethree-waycatalyticconverterhasthecapabilityofsimultaneouslyremovingallthreeharmful components(CO,HC,NO)toahighdegreeofup to90%.Thepre-conditionforthisisaconstant air-fuelmixturewitharatiooflambda1.

Carbonmonoxide(CO)

Hydrocarbon(HmCn)

Nitrogenoxides(NOx)

Athermallystableceramic"monolith"honeycombbodyservesasacarrier,withmanythinwalledchannelsrunningthroughit.

Thecarriersupportstheintermediatelayer,the "washcoat".Thewashcoatconsistsofhighly porousaluminiumoxide,whichincreasesthe effectivesurfaceareaofthecatalyticconverter byafactorofsome7000.

Thecatalyticallyactivenoblemetalsareembeddedinthiswashcoat.Inthiscase,theseare platinumandrhodium.

Platinumacceleratestheoxidationofhydrocarbons(HmCn)andcarbonmonoxide(CO); rhodiumacceleratesthereductionofnitrogen oxides(NOx).

Thenoblemetalcontentofacatalyticconverter isabout2to3grams.

Significantconversionofharmfulsubstances doesnotcommenceuntiltheoperatingtemperatureexceeds250°C.Theidealoperatingconditionsareinthetemperaturerangefromapprox. 400°Cto800°C.

Thermalageingbysinteringthenoblemetalsand thecarrierlayerissignificantlyacceleratedinthe range800°C-1000°C,leadingtoareductionin theactivesurfacearea.

Theoperatingtimeinthistemperaturerange hasamajorinfluencehere.Attemperaturesin excessof1000°Cthethermalageingincreases verysharply,leadingtothecatalyticconverter becomingcompletelyineffective.

Enginemalfunctions,e.g.misfiring,andmotoroil residues(duetohighoilconsumption)canalso leadtothecatalyticconverterbeingdestroyed (poisoned).

Dependingontheversionandvariant,theconsolecontainsvariousoperatinganddisplayelements.

Drivedirectionswitchesanddrivedirection indicatorlights

Turnindicatorswitchesandturnindicator lights

Hazardwarningbutton

FleetManager

Display

Membraneswitches

Theoperationandversionoftheoperatinglever andindicatorlightsvariesdependingonthetruck equipment.

Thestandarddrivedirectionswitchesoperateas ,i.e.afteractuation,levers(1)and (2)returntotheirinactivepositions.

Optionally,thedrivedirectionswitchescanbe convertedto switches.Inthis case,therightdirectionselectionlever(2)isnot fitted.

Theselectedforward/reversedrivedirectionis indicatedbyyellowindicatorlights(8)or(9)inthe console.

1Directionselectionlever

2Directionselectionlever,notfittedincaseof maintained-contactoperation

3Turnindicatorlever,optional

4Hazardwarningbutton

5Hornbutton,optional

6Leftturnindicatorlight

7Rightturnindicatorlight

8Drivedirectionindicatorlight,reverse 9Drivedirectionindictorlight,forwards

Theturnindicatorlever(3)ispresentonlyin truckswithlighting.Intheillustration,theleveris replacedbyacover.

Theturnindicatorswitchoperatesasa switchasstandard.

Optionally,theturnindicatorswitchcanalsobe convertedtoa switch.

Theselectedturnindicatorpositionisindicated bytheflashinggreenindicatorlight(6)or(7)in theconsole.

Thehazardwarningsystemisactivatedviathe hazardwarningsystembutton(4).Thisispossibleonlyintruckswithlighting.

Theactivehazardwarningsystemisindicated bysimultaneousflashingofthegreenindicator lights(6)and(7)intheconsole.

IfthetruckisfittedwithFleetManager,thecard holderislocatedontheupperleftoftheconsole. Thecardreaderisintegratedintotheconsoleis thisvariant.Itisnotpossibletoretrofittheconsole.

Theconsoleisfittedwithintegralheatingresistorsinthecoldstorevariant.Itisnotpossibleto retrofittheconsole.

InformationisdisplayedintheconsoleonanLCD panel.

Afterbeingswitchedon,thedisplaypresents truck-specificinformationbeforeswitchingto displaylevel1.

DieseltrucksDFG

GLOWflashing

STARTflashing

OILPRESSURE

Switchtodisplaylevel1

LPGtrucksTFG

STARTflashing

OILPRESSURE

Switchtodisplaylevel1

Afterswitchingoffusingthekeyswitch,thedisplayremainsonforabout50secuntilthecontrollerhasshutdowncompletely.

Displaylevel1isthestandarddisplayforthe driver.

|PROG315:54

|TANK:

Additionalinformationispresentedindisplay level2:

|SERVICEIN49h

|00012.8h3bar

Itispossibletoswitchbetweendisplaylevels1 and2bypressingtheENTERbutton.

Differentinformationcanbepresentedinthe displaylevels,dependingonrequirementsand customerrequest.

Theconsolehas12membraneswitchestooperateadditionalelectricalinstallations.Thefunctionsassignedtothebuttonsarecalledupone aftertheotherbypressingthebuttonsseveral times.

1F1button

2Hare

3Tortoise

4Rearsearchlight

5Rotatingbeacon

6Rearwiper/washer

7Nofunction

8Parkinglight

9Drivinglight

10Frontsearchlight

11Heatingsystem,defroster

12Frontwiper/washer

F1button(1)

F2button(7)

Nofunctionasstandard,functionscanbeparameterised

Hare(2) Switchestohighacceleration,shiftsupfromdriveprogram1to5

Tortoise(3) Switchestolowacceleration,shiftsdownfromdriveprogram5to1

Rearsearchlight(4)

Frontsearchlight(10)ON-OFF

Rotatingbeacon(5)ON-OFF

Rearwiper/washer(6)

Frontwiper/washer(12)

Intermittent-continuous-OFF Extendedoperation: Washeroperationfollowedbyreturntopreviousoperatingstatus

Parkinglight(8) ON-OFF

Drivinglight(9) ON-OFF

Heatingsystem,defroster(11)ON-OFF

Theconsolehas8membraneswitchesforsettingtheperformanceandadditionalfunctions, readingouterrorlistsandparameterising.

1F1button

2Hare

3Tortoise

4Rearsearchlight

5Rotatingbeacon

6Rearwiper/washer

5Arrowbutton(-Up):scroll/countup,edit 6Arrowbutton(-Down):scroll/countdown, edit

7ENTERbutton

8ESCAPEbutton

F1button(1) Field3-button:activatesdisplayfield3and7

Hare(2) Field1-button:activatesdisplayfield1and5

Tortoise(3) Field2-button:activatesdisplayfield3and6

Rearsearchlight(4)Field4-button:activatesdisplayfield4and8 Rotatingbeacon(5)Arrowbutton(-Up):scroll/countup,edit Rearwiper/washer(6)Arrowbutton(-Down):scroll/countdown,edit

PRGbutton(7)ENTERbutton:switchesbetweendisplaylevel1and2. Inprogrammingmode:confirmation,YES

PRGbutton(8)ESCAPEbutton:inprogrammingmode:termination,NO

Invarioussituations,thedisplaypresentsinstructionsanderrormessagesinplaintext.

1Field3-button

2Field1-button

3Field2-button

4Field4-button

Tolaunchandexittheprogrammingmode,press theESCandENTERbuttonssimultaneously. Thedisplayswitchesimmediatelytoprogramminglevel0,thedriverlevelwithoutapassword. Enabledmenuitemscanbeselectedbyscrolling withtheUp/Downbuttons.Activelinesorfields flashorarehighlightedingrey.

Launchtheprogrammingmodebypressing theESCandENTERbuttonssimultaneously.

LANG.GERMANappearsinthedisplay. Selectthedesiredmenuitembyscrollingwith theUp/Downbutton.

Activatefield2withtheField2-button.Activatedfieldsflash.

Field2flashesandcanbeeditedwiththe Up/Downbutton.

ConfirmthenewvaluewiththeENTERbutton.

5Arrowbutton(-Up)

6Arrowbutton(-Down)

7ENTERbutton

8ESCAPEbutton

Withmulti-digitnumbers,confirmingautomaticallyadvancesthedisplaytothenextdigit. Everydigitmustbeconfirmedindividually. Oncethisprocesshasbeencompleted,the entirelineflashesafterconfirmation.

Additionalprogrammingmayfollow.

Exittheprogrammingmodebypressingthe ESCandENTERbuttonssimultaneously.

Changestakeeffectinthetruckcontrolunitonly afterthetruckandtheentireelectricalsystem havebeenswitchedoffusingthekeyswitch.

Higherpasswordlevelswhereadditionalmenu itemsareenabledcanbeaccessedfrompasswordlevel0.

UsingtheUp/Downbuttontoaccessmenu items:

UsingtheField2-button,activatefield2in ordertoselectthepasswordlevel

UsetheUp/Downbuttontoeditandthen confirmwiththeENTERbutton

UsingtheField4-button,activatefield4in ordertoenterthecode

UsetheUp/Downbuttontoeditandthen confirmwiththeENTERbutton

Thedisplaychangestothefirstmenuitemofthe selectedpasswordlevel.Itisnotnecessaryto resetthetruck.

Thedisplaylanguageissetusingthelanguage selectionlist.

Toselectthelanguage,activatefield2using thefield2-button

SelectthelanguageusingtheUp/Downbutton andconfirmbypressingtheENTERbutton

Thenumberoflanguagesislimited.Missinglanguagescanbeselectedbyparameterchanges. Todoso,switchtopasswordlevel2.

Withtheintroductionofadditionallanguages, thelanguageselectionlistisdividedintotwolanguagegroups.Theconsolealwaysonlyshows thelanguagesinonegroup.Thelanguagesinthe othergroupcannotbeselectedintheconsole.

Toswitchbetweenthelanguagegroupsand selectthedesiredlanguage,thevalueintheparameteraddresshastobeparameterised. Afterparameterisinganotherlanguage,thecorrespondinggroupisdeterminedandatextdownloadisinitiatedintheconsoleasnecessary.

|DATE18/04/03

Tosetthedate,activatefield2usingthefield2 button

SetthedateusingtheUp/Downbuttonand confirmbypressingtheENTERbutton

Thecursormovesoneplacetotheleft

Repeatuntilalldigitsareedited

|TIME14:34

TosettheTIME,activatefield2usingthefield 2button

SetthetimeusingtheUp/Downbuttonand confirmbypressingtheENTERbutton

Thecursormovesoneplacetotheleft

Repeatuntilalldigitsareedited

|DAY-HRRESET

Toresetthedailyhourscounter,activatefield 2usingthefield2button

ResetthecounterbypressingtheENTER button

|DAY-KMRESET

Toresetthedailykilometrescounter,activate field2usingthefield2button

ResetthecounterbypressingtheENTER button

|CONFIGURATION0

Hereitispossibletoblockchangestoentriesfor theinformationdisplayedinpasswordlevel0. ThisappliestotheTime/DateandLanguage displays.

Usingthefield2-button,activatefield2

SelectthedesiredvalueusingtheUp/Down button

0Alldisplaysareenabledforchanges

1TheTimeandDatedisplaysarelockedagainstchanges

2TheLanguagedisplayislockedagainstchanges

3TheTime,DateandLanguagedisplaysarelockedagainstchanges

Theinformationisdisplayedintwolevels.Inlevel 1,displayfields1to4arepresented;inlevel2, displayfields5to8.Differentinformationcanbe assignedtothefields.

Toselectthedisplayfield,activatefield2using thefield2-button

SelectthedisplayfieldusingtheUp/Down buttonandconfirmbypressingtheENTER button

Usingthefield3-button,activatefield3

SelectthedisplaytextusingtheUp/DownbuttonandconfirmbypressingtheENTERbutton

|MAXPROGRAMS5

Thenumberofdriveprogramsavailableforthe driverisspecifiedbychangingthevalue(1...5).

Example:value3-driveprograms1,2and3are availableforthedriver.

Toselectthemaximumnumberofdriveprograms,activatefield2usingthefield2-button

SelectthevalueusingtheUp/Downbuttonand confirmbypressingtheENTERbutton

|PROG1

|VMAX,FW24.0km/h

Thedriveprograms1to5canbeadjustedas necessaryforspecialtruckhandling. Thevaluesformaximumspeed,accelerationand decelerationcanbesetindividuallyforforward andreverse.

Inaddition,thedrivemode(MODE)andthezero brakingcharacteristicscanbesetindividuallyfor eachdriveprogram.

Toselectthedriveprogram,activatefield1 usingthefield1-button

SelectthedriveprogramusingtheUp/Down buttonandconfirmbypressingtheENTER button

Toselectthehandling,activatefield3using thefield3-button

SelectthedesiredvalueusingtheUp/Down button

|VMAX,FW24.0km/h

|VMAX,RV24.0km/h

|ACCEL,FWD24%

|ACCEL,REV24%

Confirmthedesiredhandlingbypressingthe ENTERbutton

Tochangethehandling,activatefield4using thefield4-button

SelectthevalueusingtheUp/Downbuttonand confirmbypressingtheENTERbutton

Forfurtherinformationabouthandlingandthe drivemode,seechapter600"Electrics(general)".

Mode0

Mode1

Mode2

Speed-controlled

Speed-controlledwithzerobrakeoperationinthedrivedirection

Speed-controlledwithzerobrakeoperationinthedrivedirectionandadrive directionofneutral

|DRIVE |ACCEL.X30%

Thisdisplayhasnofunctioninallsoftwareversions

|HYDRAULICS |LIFTING100%

Thespeedsfortheindividualhydraulicfunctions areadjustable.

LIFTING

Valuerange:0100% 0%-loweridlespeed 100%-max.internalcombustionenginespeed

TILTINGValuerange:300...2550rpm

EXT1

EXT2

Valuerange:300...2550rpm

Valuerange:300...2550rpm

|VERSION1 | V3.40

Thesoftwareversionscanbedisplayedfor4 differentcomponentsinsuccession

Toselecttheversion,activatefield2usingthe field2-button

SelectthecomponentusingtheUp/DownbuttonandconfirmbypressingtheENTERbutton

Thecurrentsoftwareversionisdisplayedin field4

Version4Inverter(onlyforAC)

Allaccidentsstoredinthememoryareerased withAccidentReset.Thisdisplayisactiveonly ontruckswithFleetManagerandtheaccident recorder.

Activatefield4withthefield4-buttonandselectYESusingtheUpbutton.

PressingtheENTERbuttonerasestheerror memory.

Loadmeasurementisprovidedforstatistical evaluationonlyinvariantswithFleetManager.A loadweighingmechanismisnotfitted!

Acompleterestartoftheelectricalsystemis calledaTruckReset.ATruckResetisnecessaryinordertoactivateparameterchangesinthe controlunit.

Activatefield2withthefield2-buttonandselectYESusingtheUpbutton.

PressingtheENTERbuttonresetstheelectricalsystem.

Thepasswordcanbechangedasdesiredin passwordlevel1.Thepasswordcanbereadout onlyviathediagnosticsystem.

|SERVICEIN49h

Thetimeintervaluntilthenextservicecanbe setintheupperline.Themaximumvalueis990 hours.Thesetnumberofhourscountsdown fromthesettingonthehourmeter.

Oncetheserviceintervalhaspassed,thefollowingmessageappearsinthedisplayforthedriver:

|F-ID7092000041

Thetrucksserialnumberisdisplayedinthelower line.Theserialnumbercanonlybechangedwith theaidofthediagnosticsystem.

Activatefield1usingthefield1button

Additionalinformationcanberetrievedwith theUp/Downbutton

Softwareversionfortheconsole:VERSION 1.14

Partnumberforthecontrolunit:S-ID 0160150 |ERRORLIST

Allstorederrorsareerasedfromtheerrormemorywiththeerrorlistresetfunction.

Activatefield4withthefield4-buttonandselectYESusingtheUpbutton.

PressingtheENTERbuttonerasestheerror list

Indiagnosticmode,differenterrorlistscanbe readout.Detailsaregivenintheseparateerror list.

|COUNTERMODE0

Thecountermodeisusedtoestablishthestarting conditionsforthehourmeter.

Mode0

Mode1

Themeterstartscountingwhenthe keyswitchorthehazardwarning systemisswitchedon.

Themeterstartscountingwhen theinternalcombustionengineis running

Parametersforthetruck,lightingandadditional electricalinstallationscanbechangedviathe serviceaddresses.

Thepasswordcanbechangedasdesiredin passwordlevel2.Thepasswordcanbereadout onlyviathediagnosticsystem.

Changesinthisdisplaycanresultinmalfunctions. Thedisplayhasnofunctionandmustnotbechanged |VALUE00013.9h

|SET00000.0h

Thecontrolcomputerhas2independenthour meters.Thestartingconditionforbothhourmetersisestablishedviathecountermode.

Theupperlinedisplaystheactualoperating hoursofthecontrolprocessorascountedin accordancewiththesettinginthecountermode. Thisvaluecannotbechangedandcanberead onlyinthismenuitem.

Inthelowerline,theoperatinghourscanbe changedinincrementsof10asoftenasdesired. Onlythisvariablevalueappearsinthedisplayfor thedriver.

Activatefield4withthefield4-button,thefirst 10spositionflashes.

EditusingtheUpbuttonandconfirmbypressingtheENTERbutton

Thecursermovestothenextposition. Repeattheprocessuntilallpositionshave beenconfirmedonce.

Oncethisprocesshasbeencompleted,the entirelowerlineflashes.

Functionalcheckoftheaccelerationsensorin trucksfittedwithFleetManagerandanaccident recorder.DetailsaredescribedintheFleetManagerworkshopmanual.

Controlelectronics

Digitaltruckcontrolunit

TractionmotorspeedcontrolTruckcontrolunit

Internalcombustionenginespeed control

LPG:IMPCO-enginecontrolunit

Diesel:VW-enginecontrolunit

Wheelspeed(withonesidejackedup)470rpm

Three-phasealternator28Volt/55A

Starterbattery(2pieces)12Volteach/45Ah

On-boardvoltage 24Volt

Preheating

30-50Aintotal 7-10Aforeachglowplug

Starting Approx.185A/12V

Motorfieldexcitation Max.30A/24V

GeneratorfieldexcitationMax.21A/24V Currentlimitation/armaturecurrentMax.400A

Motor/generatorcircuitelectrical system

inaccordancewithEN1175part1and3

Electricalequipment Min.1000/volt-approx.150k

AccordingtoDIN40050

Electricalequipment IP23,incl.IP54cover IP23

Electricalsystem

Calibrationisaprocedurebymeansofwhichthe controllerregistersthereferencepositionofall

internalandexternaltransmittersandsensors, thusestablishingabasisvalue.

Thereare2typesofcalibrationprocedure:

automaticcalibration manualcalibration

EverytimethekeyswitchS1isswitchedon,the controllerperformsanautomaticcalibrationof thefollowingsensors:

Armaturecurrentsensor1U1 Generatorfieldsensor(inthecontrolunit) Motorfieldsensor(inthecontrolunit).

Automaticcalibrationisperformedonlyifthe followingconditionsaresatisfied:

Internalcombustionengineisnotrunning Truckisatastandstill;itmustnotberolling 24Vbatteryvoltageisavailable

Safetyrelayinthecontrolunithasnotbeen activated

Manualcalibrationisstartedintentionallyby changingparametersviathedisplay.

Manualcalibrationisabsolutelynecessarywheneveroneofthefollowingcomponentsisrepaired, exchangedoradjusted:

Transmittercalibration

Brakesensor1B2

Hydraulicsensors2B1-2B4

A4controlunit

Dual-pedalcontrol

Thecalibrationprocedureisperformedonly once,withthevaluebeingresetto00automatically.Toperformanothercalibration,theparametermustbechanged.

Errorsthatoccurduringcalibrationappearinthe displayandareexplainedintheseparateerror list.

Parkthetrucksafely.

Applytheparkingbrake.

Changeaparameteraddressviatheconsole.

|ADDR.151VALUE04

Startcalibrationbypressing

Thedrivedirectionindicatorlightsintheconsole indicatewhatactionstotake.Thereare3possibilities:

Bothdrivedirectionindicatorlightsflashacceleratorpedalsareininactiveposition. Forwardsdrivedirectionindicatorlightflashes -depresstheforwardacceleratorpedaltothe fullmechanicalstoppositionandholditthere untilbothdrivedirectionindicatorlightsflash. Reversedrivedirectionindicatorlightflashes -depressthereverseacceleratorpedaltothe fullmechanicalstoppositionandholditthere untilbothdrivedirectionindicatorlightsflash.

Thecalibrationprocedureisperformedonly once,withthevaluebeingresetto00automatically.Toperformanothercalibration,theparametermustbechanged.

Theprocedureusedforcalibrationwithdualpedalcontroldiffersfromsimpletransmitter calibration.

Parkthetrucksafely

Applytheparkingbrake.

Changeparametersusingthedisplay

|ADDR.151VALUE03

Switchfromtheprogrammingmodetothe displaymodebysimultaneouslypressingthe and

Startcalibrationbypressing

TheLEDforbuttonF1lightsupfortheduration ofthecalibration

Ifanerrorisdetectedbythecontrollerduring calibration,anerrormessageappearsinthe display.

|ADJUSTERROR09

Possiblecauses:

Operatingerrorduringcalibration

Timeoutduringcalibration

Acceleratorvoltageisnotattained

Potentiometeradjustmenterror Bottomplateimproperlyinstalledmechanically

Thetruckparametersetisstoredinthetruckcontrolunit(2).Inordertopreventaparameterloss, acopyofthisparametersetisavailableinthe console(1).Whenoneofthetwocomponentsis changed,theparametersetmustbecopiedfrom theremainingcomponent.

Parameterloss

Ifthetruckcontrolunitandconsolearechangedatthe sametime,thetruckparameterswillbelost.Inthis case,atruckparametersetmustbeloadedviathe notebook.

TheenginecontrolunitECUhasitsownparametersetthatisnotinfluencedbytheparameter management.ThiscomponentandallotherCAN busnodescanbechangedwithouthavingto copytheparameters.

Therearetwowaysofcopying:

Automatictransfer

Automatictransferstartsforcomponentswithoutanoperableparameterset.Thisgenerallyappliestobrand-newcomponents,spare parts.

TheautomatictransferisindicatedinthedisplaybythePLEASEWAITmessage.This processcantakeseveralminutesandends withareset.

Manualtransfer

Manualtransferstartsforcomponentswithan operableparameterset.Thisisanindication thatthecomponenthasalreadybeeninstalled onceinaforklifttruck.

Themanualtransferstartswithaquestion inthedisplayD–EEPROMVALID?.This means:"Aretheconsoleparameterstobe used?".

Aretheconsoleparameterstobeused?

Usingtheconsoleparameters

PressENTERtoconfirm

Copyingtheparametersfromtheconsoleto thetruckcontrolunit

Usingthetruckcontrolunitparameters

NegateusingtheESCbutton

Copyingtheparametersfromthetruckcontrol totheconsole

1Console 2Truckcontrolunit

Confirmyouranswertothesecurityquestion AREYOUSURE?again.Incaseofanydoubt, theoperationcanstillbeinterrupted.

7094-70997065-70677090-7092

Mode0

Speed-controlled

Mode1

Speed-controlled,zerobrakeoperation1

Zerobrakeoperationindrivedirection

Mode2

Speed-controlled,zerobrakeoperation2

Zerobrakeoperationindrivedirectionandadrive directionofneutral

Stoppingonaslope

RX70drivingbehaviour

Speed-controlledwithoptimisedperformanceSeriesavailablefromSW-V4.42notavailable

RX70drivingbehaviour

BrakingcharacteristicswhenreversingSeriesavailablefromSW-V4.42notavailable

Thedrivemodeslistedherecanonlybeactivated ordeactivatedbymeansofparameterisationusingaddressesandvalues.Theparameterisation isdependentontrucktypeandthetrucksoftware. Parameterisationviathediagnosticsinthenotebookisonlyavailableforthedrivingbehaviour. Thedrivemodesanddrivingbehaviourdifferdue todifferentstartingandbrakingcharacteristics. Acceleration,decelerationandreversingarelimitedbythesettingsoftherelevantdriveprogram, regardlessofthemode.

Thedrivingbehaviourcanbechangedtosuit thedifferentdrivemodes.Notallvariantscanbe recommended.Theimportantvariantsarelisted here:

Isstandardinalldrivemodesandcannotbe switchedoff.

Parameterisingwithsupportfromthemain factory.

Theacceleratorpositionhasnoinfluenceon thedynamicsofthedrivingbehaviour.The accelerationvaluesanddecelerationvaluesare specifiedintheselecteddriveprogram.

Accelerationwithoutinfluenceoftheaccelerator:

Assoonastheacceleratorpedalisactuated, accelerationisreachedimmediatelyinaccordancewiththedriveprogramsetting.

Theacceleratorpedalpositionhasnoinfluenceonthedynamics.

Thevaluesareappliedasperthedrive programsetting,irrespectiveoftheaccelerator position.

Thedrivingbehaviourtendstobemore aggressiveandnotassmooth.

Reversingwithouttheinfluenceoftheaccelerator onthedynamics

Forsingle-pedalcontrol,actuatingtheacceleratorpedalduringreversing(changeofdriving direction)isimmediatelyrecognisedasreversedeceleration.

Fordual-pedalcontrol,actuatingthecontrary acceleratorpedalisimmediatelyrecognised asreversedeceleration.

Thereversedecelerationvaluecomesinto play,asperthedriveprogramsetting,irrespectiveoftheacceleratorposition.

Decelerationcanbeincreasedifthereverse decelerationisgreaterthanthedecelerationin thedriveprogram.

pedalisactuatedduringreversing(changeof drivingdirection).

Fordual-pedalcontrol,thebrakingeffect becomesgreaterthefurtherthecontrary acceleratorpedalisactuated.

Commentonoptimisedreversingbehaviour

Fordual-pedalcontrol,justaslightactuationof thecontraryacceleratorpedalisregisteredas pedaloperation.

Lessacceleratorpedaloperationenables reversingwithminimumdeceleration.

Inexperienceddriversmayfindthattheirforklift truckstartstocoast.

ItishelpfulinthissituationtoswitchtotheR70 drivingbehaviour.

The"Stoppingonaslope"drivingbehaviouris switchedonasstandard.Thedrivingbehaviour cannotbechangedandappliestoalldriveprograms.

Thisdrivemodehasbeendevelopedespecially fortraileroperationwithsingle-pedalcontrol.The modeappliestothatparticulardriveprogram andcannotbechangedbythedriver.Itisonly possibletoswitchtootherdrivemodesthrough parameterchanges.

Effects

Thedrivemode"Speed-controlledwithoptimised performance"and"Brakingcharacteristicswhen reversing"appliestotherespectivedriveprogramandcannotbechangedbythedriver.It isonlypossibletoswitchtootherdrivemodes throughparameterchanges.

Effects:

Thefurthertheacceleratorpedalisactuated, thegreatertheacceleration,untiltherespectivedriveprogramsettingisreached.

Whentheacceleratorpedalisdepressed,the forklifttruckbrakesimmediatelydependingon therespectivedriveprogramsetting.

Forsingle-pedalcontrol,thebrakingeffect becomesgreaterthefurthertheaccelerator

Whentheacceleratorpedalisdepressed,the forklifttruckrollstoastop(zerobraking)

Zerobrakingonlyiftheselecteddrivedirection isthesameasthedirectionofmovementof theforklifttruck.

Ifthedrivedirectionisneutral,thetruckbrakes electrically.

Thisdrivemodehasbeendevelopedespecially fortraileroperationwithdual-pedalcontrol.The modeappliestothatparticulardriveprogram andcannotbechangedbythedriver.Itisonly possibletoswitchtootherdrivemodesthrough parameterchanges.

Effects

Whentheacceleratorpedalisdepressed,the forklifttruckrollstoastop.

Zerobrakingiftheselecteddrivedirectionis thesameasthedirectionofmovementofthe forklifttruckandifthedrivedirectionisneutral.

ThecurrentsensorisaringcorewithaHallsensorinaplastichousingandisfittedontheleftside wallofthechassisunderthebottomplate.

Thecurrentsensormeasuresthecombinedarmaturecurrentfromthegeneratorandthetractionmotor.Themeasuredvalueisrequiredinthe truckcontrolunittoregulatethetractiondrive.

Thearmaturecurrentisoneofthevaluesthat affectsthemodelcalculation.Adefectivemeasuredvaluecausesanerror,ERROR205inthe modelcalculation.

Theringisthreadedontooneconductorofthe armaturecircuit.Whenanelectriccurrentis presentinthearmaturecircuit,theconductor generatesanoutputvoltageproportionaltothe current.Whennocurrentflowsinthearmature circuit,thecurrentsensordeliversacalibrated outputofapprox.4.8Voltatitsoutput.Thiscorrespondstohalfofthesupplyvoltage(10.0Volt), lesstheinternalload.

Theredundantsensorhasasecond,uncalibratedoutputformonitoringtheoutputsignal. Thesignalfromthecalibratedoutputisthenonly interpretedbythecontrollerasarmaturecurrent iftheuncalibratedoutputhasalsodetectedacurrentinthearmaturecircuitinthesamedirection.

Ifthereisanerror,suchasafaultysignalatthe calibratedoutputcausedbyadefectiveHallsensor,thecheckmeasurementattheuncalibrated outputpreventsunwantedmotion.

Thecurrentislimitedto400A.

Assoonasanarmaturecurrentispresent,the outputvoltagechangesbyapprox.4.65mV/A.

Example: 400A×4.65mV/A=1860mV=1.86V

Atanarmaturecurrentof400Amperes,atypical forwardvoltageof5.76.8Visgenerated:

Thefollowingvalueiscalculated: 4.65Vhalfsupplyvoltage

1.86Vat400Amperes

6.51V

Atanarmaturecurrentof400Amperes,atypical reversevoltageof3.2Visgenerated.Avalueof 2.79V(4.65V1.86V)iscalculated.

EachtimekeyswitchS1isactivated,thepresent zeropositionofthecurrentsensorisautomaticallyequalised.Thismeansthateventhevalues specifiedabovealwaysdeviatefromthesample calculation.

4-pinJPTplug

1U1/1GND

1U1/2X20/183.904.85Volt

1U1/3X20/174.90-5.10Volt

1U1/4X20/20approx.10Volt

Alwaysnotethearrowdirectionofthesensor beforeremoval.

Serviceaddress155atvalue01

Thefuseplateisinstalledasamodularunittothe leftofthesteeringcolumninthefrontstructure andisprotectedbyaplasticpanellingagainst environmentalinfluences.Thefuseplatealso servesasadistributorplateforthesupplyofthe additionalelectricalequipment.

ThefuseplateA7includesthefollowingcomponents:

Relays

Switchlock

Starter

EnginecontrolunitECU

Relaybox1

Relaybox2

Mainfuses

Controlfuses

Fusesforvariants

Fuseplatesthatweremanufacturedbefore December2006havenodiodesV4andV5atthe pointsindicated.Theconsequenceofthisisthat theenginecontrolunitIMPCOcanbedestroyed inLPGtruckswhendisconnectingthestarter batteries.

Whendisconnectingthestarterbatteries,theengine controlunitIMPCOcanbedestroyed.

CheckwhetherthefuseplateisequippedwithdiodesV4andV5.

IfthediodesV4andV5aremissing,aspecificorder mustbefollowedwhendisconnectingthebatteries.

Seethechapter"Starterbattery"

Allmainfusesandcontrolfusesrequiredforthe electricalsystemarelocatedonfuseplateA7.

F21A24Volt-chargebalancingtestlead

F41A12Volt-chargebalancingtestlead

F520A12Volt-batteryfortruckcontrolunitA4

1F1110AFanmotor9M16forforcedventilation

1F1410A24Volt-batteryfortruckcontrolunitA4

1F155ATerminalD+DCgenerator

1F1610AComponentsofenginecontrolunitECU

1F1710A24Volt-additionalconsumers Variant

1F1825ASwitchlock30/S1at24Volt

1F2010ASwitchlock15/S1attruckcontrolunitA4

1F2120AComponentsofenginecontrolunitECU

4F110AHorn

5F1120ASupplyforrelaybox2

5F1220ASupplyforrelaybox1

7F120AFanmotor9M1

9F380ATruckcontrolunitA4

9F410A24Volt-startermotor

9F680AExternalglowplugrelay

Variant

Variant

Variant

Onlyfordieselforklifttrucks

9F85A12Volt-additionalconsumer(radio)Variant

9F1220A12Volt-startermotor

9F165AStartvalve9Y7incatalyticconverterVariant,onlyforLPGforklift trucks

Allrelaysrequiredfortheelectricalsystemare locatedonfuseplateA7.

Theglowplugrelay9K3indieselforklifttrucksis locatedtotheleftofthebrakefluidreservoiron thefrontstructure.

9K224V/255Starter

9K1624V/130Enginecontrolunit

9K2624V/255Keyswitch

9K324V/130Glowplugrelay Onlyfordieselforklifttrucks

Thetruckisequippedwithtwo12Voltstarter batteriesG1andG2.Thebatteriesarelocated inthefrontstructureunderthebottomplateand atanangleinfrontoftheinternalcombustion engine.

Thebatterieshavescrewconnections,areconnectedinseriesandsupplytheelectricalsystem witha24Voltoperatingvoltage.

ThecentretapP/G1suppliesthestarter,the enginecontrolunitandthesootburner(variant) with12Volt.TheincreasedloadonbatteryG1 associatedwiththisisbalancedoutincontrolunit A4bymeansofchargebalancingswitching.

Thechargebalancingswitchingisonlyactiveif theignitionisswitchedonandthekeyswitchis ON.Foradequatechargebalancing,thetruck mustbeinoperationforsometime.Fortrucks thatareseldomused,thechargingvoltagein batteriesG1andG2maybeveryuneven.

IfG1isalmostcompletelydischargedandG2is stillfullycharged,thisasymmetricalchargingvoltagecancauseadefectivechargingprocess.The chargingcontrollerstopsprematurelybecause thesumofthevoltagesofG1andG2reachesthe finalchargedvoltageearly.

Whencarryingoutrepairs,alwaysdisconnectboth batteries.

Riskofshort-circuiting

Whenscrewingontothepositiveterminals,avoid contactwithearth.

Incorrectdisconnectionsandloosebatteryconnectionscandestroythethree-phasealternatorandthe controlunits.

Donotdetachthebatteryconnectionswhenthe internalcombustionengineisrunning.

FortrucksthatwerebuiltbeforeDecemberago2006, theIMPCOenginecontrolunitcouldbedamaged. CheckwhetherthefuseplateisequippedwithdiodesV4andV5.

Observethesequencewhendisconnectingthe batteries.

Alwaysuseinsulatedtools.

Theuserinstructionsprovidedbythebatterymanufacturermustbeobservedwhendisposingof batteries!Werecommendworkingwithawaste managementcompanyfordisposalpurposes.

Batterynegative

DisconnectBattery12Vpositive

Battery24Vpositive

Battery24Vpositive

ConnectBattery12Vpositive

Batterynegative

Fuseplatesthatweremanufacturedbefore December2006havenodiodesV4andV5atthe pointsindicated.Asaresult,whendisconnecting thestarterbatteriesintheusualsequence,the IMPCOenginecontrolunitinLPGtruckscould bedamaged.

,untilDecember2006

Battery24Vpositive

DisconnectBattery12Vpositive

Batterynegative

Batterynegative

ConnectBattery12Vpositive

Battery24Vpositive

Takeparticularcareduringthisoperation,as comingintocontactwithearthwhilescrewing ontothepositiveterminalsmayleadtoashort circuit.

Batterymaintenanceiscarriedoutinaccordance withthebatterymanufacturersuserinstructions.

Theacidlevelandaciddensityofthebattery shouldbecheckedatregularintervals.

Checktheacidlevel.

Thebatteryacidmustbeuptotheloweredge oftheinsertinthebatteryhousingorupto5mm abovetheupperedgeoftheplates.

Fillupmissingfluidwithdistilledwateronly.

Unscrewthebatterycellcoversandcheckthe aciddensitywithanacidsiphon.

Thedensityoftheacidmustachievethevaluein thetable.Thelisteddensityoftheacidrefersto 27°Cacidtemperature.

Normal1.131.28

Tropics1.081.23

Dischargedbatteriesmustbeimmediately recharged,untiltheyareoncemorefully charged.

Thechargingcurrentshallnotexceed1/10of capacity.

Keepthebatterycellcoverdryandclean.

Anyspiltbatteryacidshouldbeneutralised straightaway.

Keeptheterminalsandthecableshoesclean, lightlyapplybatterygreaseandscrewon firmly.

Aspartofthetruckcontrolunit,thecontrolunit A4actsasmaster(mainprocessor)andisresponsibleforthecontrol,regulation,monitoring andreleaseofthetractiondriveandworkinghydraulics.

Theenginecontrolunitisresponsibleforthe controlandmonitoringoftheinternalcombustion engine.Thisisconnectedviaanindependent CANbustothecontrolunitA4.

ThecontrolunitA4cannotbechangedforthe 7074-7079previousmodel.

Theindividualtasksofthecontrolunitarelisted byfunction:

Thepowerstageformotorfieldandgenerator fieldcontrollerwithcurrentsensorsforboth fieldcurrents

Brushmonitoringoftractionmotorandgenerator

Chargebalancingswitchingforthebatteries

Hydraulicdrive

Processinginputsignalsfrom:

Accelerator,brakesensor,hydraulicsensor

Drivedirectionswitch

Alltransmittersandswitchesoftheelectric systemandmachines

Errormanagement

Managementoferrors

Additionalelectricalinstallationevaluation

ProcessingFleetManagerdata(variant)

Diagnostic,download

Storingtruckparameters

Refertochapter"Parametermanagement"

X22/1Bussignalapprox.2-3Volt

X22/2Bussignalapprox.2-3Volt

X22/3+24Volt

X22/4GND

X21/12VWCANhighX26/43

X21/13VWCANlowX26/44

F2,F3Generatorarmaturevoltage

F4,F7Tractionmotorarmaturevoltage

Berzeliusstrasse10

D-22113Hamburg

Identno.171121EN