Linde IC-Engined Truck Series 358 H120_1200 To H160_1200 Service Training 3588044601

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Linde IC-Engined Truck Series 358 H120_1200 To H160_1200 Service Training 3588044601
Size: 22.4 MB
Format: PDF
Language: English
Brand: Linde
Type of Machine: IC-Engined Truck
Type of Manual: Service Training, Hydraulic Circuit Digarm, Electrical Circuit Diagram
Model: Linde Series 358 IC-Engined Truck
H120_1200 ; H140_1200 ; H160_600 ; H160_1200
Engine:
Perkins 1006-60 T (Turbocharged) Engine
Perkins 1006-60 TW (Turbocharged) Engine
Part Number: 3588044601
Number of Pages: 532 Pages

Contents:
1 General information
Introduction
Engine views (side mounted turbo)
Engine views (top mounted turbo)
Engine identification
Safety precautions
Engine lift equipment
Viton seals
POWERPART recommended consumable products
2 Specifications
Basic engine data
Data and dimensions
Thread sealant
Standard torque values
Specific torque values
Compression test data
3 Cylinder head assembly
General description
Rocker cover
Operation 3-1 To remove and fit the rocker cover
Rocker assembly
Operation 3-2 To remove and to fit
Operation 3-3 To dismantle and to assemble
Operation 34 To inspect
Valve tip clearances
Operation 3-5 To check and to adjust
Valve springs
Operation 3-6 To change the valve springs (with cylinder head fitted)
Manifolds
Operation 3-7 To remove and to fit an intake manifold
Operation 3-8 To remove and to fit an exhaust manifold (two-piece)
Operation 3-9 To remove and to fit an exhaust manifold (three-piece)
Cylinder head assembly
Operation 3-10 To remove
Operation 3-11 To fit
Valves and valve springs
Operation 3-12 To remove
Operation 3-13 To fit
Operation 3-14 To inspect and to correct
Valve guides
Operation 3-15 To inspect
Operation 3-16 To remove
Operation 3-17 To fit
Cylinder head
Operation 3-18 To inspect and to correct
Operation 3-19 To correct a valve seat with a valve seat cutter
Operation 3-20 To fit valve seat inserts
4 Piston and connecting rod assemblies
General description
Big end bearing
Operation 4-1 To remove
Operation 42 To fit
Operation 4-3 To inspect
Piston and connecting rod
Operation 4—4 To remove
Operation 4-5 To fit
Operation 4-6 To check the piston height above the cylinder block
Piston rings
Operation 4-7 To remove
Operation 4-8 To fit
Piston and connecting rod assembly
Operation 4-9 To dismantle
Operation 4-10 To assemble
Operation 4-11 To check the length of a connecting rod
Piston and piston rings
Operation 4-12 To inspect
Connecting rod
Operation 4-13 To inspect
Partially finished small end bush
Operation 4-14 To remove and to fit
Piston cooling jets
Operation 4-15 To remove and to fit
Operation 4-16 To check thejet alignment
5 Crankshaft assembly
General description
Crankshaft pulley
Operation 51 To remove
Operation 52 To fit
Crankshaft vibration damper
Operation 53 To remove and to fit
m
Operation 5-4 To remove and to fit the rear and oil seal assembly
Operation 5-5 To remove and to fit a crankshaft palm wear sleeve
Thrust washers
Operation 5-6 To check crankshaft end-float
Operation 5-7 To remove (with the crankshaft in position)
Operation 5—8 To fit (with the crankshaft in position)
Main bearings
Operation 5-9 To remove (with the crankshaft in position)
Operation 5-10 To fit
Operation 5-11 To inspect
Crankshaft
Operation 5-12 To remove
Operation 5-13 To fit
Operation 5-14 To inspect
Crankshaft timing ring
Operation 5-15 To remove
Operation 5-16 To fit
6 Timing case and drive assembly
General description
Timing case cover
Operation 6-1 To remove
Operation 6-2 To fit
Front oil seal
Operation 6-3 To remove
Operation 6-4 To fit
Operation 6-5 To remove and to fit a crankshaft pulley wear sleeve
Idler gear and hub
Operation 6-6 To remove
Operation 6-7 To fit
Idler gear and hub for the compressor
Operation 6-8 To remove
Operation 6-9 To fit
Fuel pump gear
Operation 6-10 To remove
Operation 6-11 To fit
Camshaft gear
Operation 6-12 To remove and to fit
Crankshaft gear
Operation 6-13 To remove and to fit
Timing case
Operation 6-14 To remove
Operation 6-15 To fit
Camshaft and tappets
Operation 6-16 To remove
Operation 6-17 To fit
7 Cylinder block assembly
General description
Cylinder block
Operation 7—1 To dismantle
Operation 7—2 To assemble
Operation 7-3 To inspect
Operation 7-4 To remove and to fit a new type ‘D' plug to the tappet chamber
Cylinder liner
Operation 7-5 To inspect
Operation 7-6 To remove
Operation 7-7 To fit a service liner
Operation 7-8 To fit a partially finished liner
8 Engine timing
General description
Engine timing
Operation 8-1 Method 1 - To set number 1 piston to TDC on the compression stroke
Operation 82 Method 2 - To set number 1 piston to TDC on the compression stroke
Operation 8-3 To set number 1 piston to 4° after TDC on the compression stroke
Operation 8-4 To check the valve timing
Operation 8-5 To check the timing of the fuel injection pump
9 Aspiration system
General description
Turbocharger
Operation 9-1 To remove
Operation 9-2 To fit
Operation 9-3 To clean the impeller and the compressor casing
Operation 9—4 To check the operation of the waste-gate
Turbocharger faults
List of possible causes
Exhaust elbow
Operation 9-5 To remove and fit an exhaust elbow
Closed Circuit Breather System
Operation 9-6 To remove and fit the breather assembly
Operation 9-7 To remove and fit the closed circuit drain valve
1O Lubrication system
General description
Lubrication system flow diagram
Lubrication system flow diagram for the compressor
Filter canister
Operation 10-1 To renew
Filter head
Operation 10-2 To remove and to fit
High position filter canister
Operation 10-3 To renew
High position oil filter head and adaptor plate
Operation 10-4 To remove and to fit
High position filter head by-pass valve
Operation 10-5 To dismantle and assemble
Filter head all test valve
Sump
Operation 10-6 To remove
Operation 10-7 To fit an aluminium sump
Operation 10-8 To fit a cast iron sump
Dipstick tube
Operation 10-9 To remove and fit
Oil strainer and suction pipe
Operation 10-10 To remove and to fit
Operation 10-11 To inspect and to correct
Lubricating oil pump
Operation 10-12 To remove
Operation 10-13 To fit
Operation 10-14 To inspect
Lubricating oil pump idler gear shaft
Operation 10-15 To remove
Operation 10-16 To fit
Relief valve
Operation 10-17 To remove and to fit
Operation 10-18 To dismantle and to assemble
Operation 10-19 To inspect
Flexible oil pipes
Operation 10-20 To remove
Operation 10-21 To fit
Operation 10-22 To Inspect
1 1 Fuel system
General description
Typical fuel system
Fuel filter
Operation 11-1 To renew the fuel filter canister
Atomisers
Operation 11-2 To remove
Operation 11-3 To fit
Fuel lift pump
Operation 11-4 To remove and to fit
Operation 11-5 To dismantle
Operation 11-6 To assemble
Operation 11-7 To test
Bosch fuel injection pump
Operation 11-8 To remove
Operation 11-9 To fit
Air in the fuel system
Operation 11-10 To eliminate air from the fuel system
12 Cooling system
General description
Thermostat
Operation 12-1 To remove
Operation 12-2 To fit
Operation 12—3 To test
Thermostat housing
Operation 12—4 To remove and to fit
Coolant pump
Operation 12—5 To remove
Operation 12-6 To fit
Operation 12—7 To dismantle
Operation 12-8 To assemble
Fan
Operation 12—9 To remove and to fit
Fan drive
Operation 12—10 To remove and to fit
Lubricating oil cooler
Operation 12—11 To remove
Operation 12-12 To fit
Operation 12-13 To dismantle and to assemble
13 Flywheel and housing
General description
Flywheel
Operation 13-1 To remove and to fit
Ring gear
Operation 132 To remove and to fit
Flywheel housing
Operation 133 To remove and to fit
14 Electrical equipment
Alternators
Operation 14-1 To check the drive belts
Operation 14-2 To adjust drive belt tension
Operation 14-3 To remove and to fit the drive belts
Operation 14-4 To remove and to fit the altemator
Operation 14-5 To maintain
Operation 14-6 Fault diagnosis for the alternator
Starter motors
Operation 14-7 To remove and to fit
Operation 14-8 To maintain the brush gear and the commutator
Operation 14-9 To test on the engine
Starting aid
Operation 14—10 To remove and to fit a fuelled starting aid
Operation 14-11 To check the fuelled starting aid
Electronic components
Operation 14—12 To remove and to fit the Engine Control Module (ECM)
Operation 14—13 To remove and to fit the Voltage Load Protection Module (VLPM)
Operation 14—14 To program a new ECM
Operation 14—15 To remove and to fit the engine speed and timing sensor
Operation 14—16 To remove and to fit a pressure sensor
Operation 14-17 To remove and to fit a temperature sensor
Wiring harness
Operation 14—18 To repair a sensor connector
Operation 14-19 To repair 8 Diagnostic, an ECM, or a MIC connector
Operation 14-20 To connect a new wire or connector to the wiring harness
15 Auxiliary equipment
Compressor
Operation 151 To remove
Operation 152 To fit
Operation 15—3 To remove the reed valves
Operation 15-4 To fit the reed valves
Operation 15-5 To remove the top unloader valve
Operation 15—6 To fit the top unloader valve
Operation 15-7 To remove the crankshaft / connecting rod / piston/ piston rings
Operation 15—8 To fit the crankshaft / connecting rod / piston / piston rings
Power steering pump
Operation 15—9 To remove and to fit
Adaptor for a hydraulic pump or a steering pump
Operation 15-10 To remove and to fit
Operation 15-11 To dismantle
Operation 15-12 To assemble
Exhauster
Operation 15-13 To remove and to fit
16 Special tools
List of special tools