Linde H20D, H20T, H25D, H25T Diesel and LPG Forklift Truck 392 series Workshop Service Manual

Illustrated Factory Workshop Service Manual for Linde IC Engined Forklift Trucks 392 series, Models H20D, H20T, H25D, H25T

This manual contains high quality images, circuit diagrams, diagnostic procedures to help you to diagnostic, troubleshoot and repair your truck. This document is printable, without restrictions, contains searchable text.

Language: English
Format: PDF, 459 pages

Covered models:
   H20D
   H20T
   H25D
   H25T

Contents:
   0 Product information
      Preface
      The vehicle
      Diagnostics
      LHC basic structure
   1 Engine
      LPG engine
      Description of the drive
      Technical data for VWBEF
      Engine block
      Ribbed V-belt - removal and fitting
      Toothed belt- removal and fitting, tensioning
      Cylinder head -removal and fitting
      Compression -check
      Checking hydraulic bucket tappets
      Cooling
      Coolant thermostat- removal and installation
      Water pump- removal and installation
      Coolant pump -Checking for wear
      Coolant -draining and filling
      Engine electrics
      Three-phase alternator
      Electronic ignition system up to 08/2005, overview
      Electronic ignition control unit
      Electronic ignition system from 09/2005, overview
      Shut-down due to lack of gas
      LPG system
      Safety guidelines for LPG (extract)
      Basic rules when working with LPG
      Sealing plastic pipe unions
      Functions
      LPG system - functions
      Shut-off valve- LPG
      Evaporator -functions
      Mixer -functions
      Basic setting of the butterfly valve until 12/2007
      Revolution control (from 12/2007)
      LPG system with lambda control
      Exhaust gases -composition
      Lambda control system
      Checking and adjusting the mixer
      Installation positions -Overview until 12/2007
      Leakage test on LPG system
      LPG tank
      Level display with single replacement cylinders(special equipment)
      Removing and installing the level display and 80% filling stop valve
      The following safety measures must be observed
      Carrying out assembly operations
      Bleeding the LPG tank
      The following safety measures must be observed
      Procedure for bleeding
      Diesel engine
      Description of the drive
      Technical data BEQ
      Particularities of the 1.9-litre engine
      Electronic engine control
      Sensors
      Coolant temperature sending unit 0B1
      Engine speed sensor 0B2
      Actual speed sensor 1B1
      Fuel temperature sending unit 0B3
      Suction pipe temperature sensor 0B4
      Needle stroke sensor 0B5
      Height sensor
      0B3 control gate valve travel sensor
      Glow plug system
      Pre-heater system
      Glow plugs- engine 0R1
      Fuel supply
      Fuel quantity regulation
      Fuel quantity actuator 0B3
      Fuel shut-off valve 0Y1
      Injection timing device- replacement of O-ring on cover
      Start of injection valve 0Y2
      Start of injection -governing
      Start of injection -dynamic checking and setting
      Injection nozzle -Two-spring nozzle holder
      Injection nozzles - removal and installation
      One-way restrictor
      Injection system -overview
      Injection system -supply voltage check
      Injection pump - removal and refitting, Exchanging the toothed belt
      Injection pump - removal and installation
      Injection pump - pump and toothed belt adjustment
      Engine block
      Ribbed V-belt- removal and fitting
      Crankshaft oil seal on pulley end -removal and installation
      Crankshaft sealing flange -removal and installation
      Checking the cylinder head
      Cylinder head -removal and fitting
      Cylinder head -compression check
      Valve gear
      Oil pressure and oil pressure switch
      - check
      Oil sump - removal and installation
      Checking hydraulic bucket tappets
      Camshaft- removal and installation
      Cooling
      Coolant thermostat- removal and installation
      Water pump - removal and installation
      Coolant pump -Checking for wear
      Coolant -draining and filling
      Engine electrics
      Three-phase alternator
      Replacing the engine control unit/ immobilizer
      Self-diagnostics
      Self-test - introduction
      Self-diagnostics -troubleshooting
      Standardised measured value blocks
   2 Axles
      Description
      Technical data for traction drive
      System overview
      Traction drive
      Travel drive - introduction
      Hydraulic adjustment with electronic activation- old version
      Hydraulic adjustment with electronic activation- Version with round solenoids
      Auxiliary brake valve until 06/2003
      Auxiliary brake valve from 07/2003
   Auxiliary brake valve from 1 0/2006
      Start of variation of the variable displacement pump
      Start of rotation of drive wheels
      Removing and installing the HPV variable displacement pump coupling flange
      Bypass valve
      Output unit
      Hydraulic fan drive
      Hydraulic diagnostics
      Overview and explanations about diagnostics
      HPV 55-02 pressures -tests
      Checking the hydrostatic traction drive
      Wheel motor HMF 360 R-disassembly
      Wheel motor HMF 360 R-checking bearing, seals
      Wheel motor HMF 360 R - sealing after inspection
      Wheel motor HMF 360 R-exchanging bearing
   3 Chassis, bodywork and fittings
      Chassis
      Axle suspension
      Instructions for working with gas springs
   4 Undercarriage
      Steering system
      Steering system - schematic function
      Steering axle
      Steering axle — general (302 and 1 602)
      Steering axle — removal and installation
      Adjusting the steering stop
      Repairs to the steering axle
      Replacing the steering cylinder seals
      Steering axle 302 up to 08/2009
      Steering axle — design
      Steering axle number
      Stub axle
      Replacement of wheel bearings
      Steering axle 1 602 from 09/2009
      Steering axle 1602
      Devices/tools for manual assembly
      Process for manual removal
      Removing the steering pivot pin (pressing out using a fixed press)
      Removing the axle stub from the axle beam
      Assembly process
      Assembling the upper axle stub bearing and wiper
      Assembly — axle stub
      Assembly — lower axle stub bearing wiper
      Assembling (pre-assembling) the steering pivot pin (pressing in using a fixed press)
      Assembling the steering pivot pin (pressing in using a fixed press)
      Assembling the lower axle stub bearing/flange cover
      Assembly — steering angle sensor/cover
      Removal/assembly of the wheel hub/wheel bearing
      Brake system
      Brake release valve
      Brake cables -adjustment
      Checking the brake system
   5 Operating devices
      Accelerator
      Function
      Replacement
      Stop screws
      Joysticks
      Joystick variants
      Functional description
      Replacement
   6 Electrics/Electronics
      General
      Safety information for the electrical system
      EMC- Electromagnetic compatibility
      Electrostatic charging
      Identifying components in electrical circuit diagrams
      CAN bus   
      CAN bus connection assembly X15
      Central electrical system
      Linde Hydraulic Control (LHC)
      LHC cont   roller with ECO mode
      Arrangement ofthe interface connectors console -truck
      Layout of relays and fuses for standard and optional equipment
      Display unit up to 06/2010
      Display unit until 06/2010
      Display unit from 07/2010
      Display unit
      Checks
      LHC testing (truck control unit and lift control)
      LHCcontrollerwithECOmode
      Testing the VW controller and immobiliser (WFS)
      Checking wiring harness
      Testing sensors
      Testing the indicator unit
   7 Hydraulic equipment
      Operating hydraulics
      Functional characteristics of control valve until 10/2005
      Overview
      Functional description of control valve up to 1 0/2005
      Pressure relief valve
      Operating hydraulics circuit diagram until 1 0/2005
      Hose routing of pump- control valve
      Hose routing of pilot oil pressure supply
      Faultfinding the working hydraulic system
      Functional characteristics of Linde control valve from 1 1/2005
      Overview
      Function characteristics
      Pressure relief valve
      Working hydraulics circuit diagram (Linde control valve)
      Depressurisation Auxiliary hydraulics 1 and 2
      Hose layout pump -control valve
      Hose layout control pressure supply
      Gleaning work on the Linde control valve -cast valve
      Cleaning instructions
   8 Load lift system
      Lift mast
      Lift mast - identification
      Mast - removal and installation (all series)
      Installation of mast type 185
      A dusting the lift chain (all series)
      Setting the roller play
      Roller clearance -fork carriage in inner mast
      Roller clearance -middle and inner mast channel, type 185
      Roller play -outer mast profile, series 185
      Removal of slide pads - standard mast
      Removal of slide pads - duplex mast
      Removal of slide pads -triplex mast
      Lift cylinder (outer)
      - removal and installation
      Lift cylinder (centre) - removal and installation
      Lift cylinder -sealing
      Tilt cylinder
      Setting the tilt angle sensor
      Hose reservoir - removal, exchanging hose, sealing, fitting
      Line break safety device in the lift mast (butterfly valve)
   9 Special equipment, accessories
      Lighting
      Working spotlight position
      Annex
   10 Circuit diagrams
      Hydraulic circuit diagrams
      Traction, working and steering hydraulics
      Accumulator
      Wiring diagrams