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Linde H20D, H20T, H25D, H25T Diesel and LPG Forklift Truck 392-02 series Workshop Service Manual
Linde H20D, H20T, H25D, H25T Diesel and LPG Forklift Truck 392-02 series Workshop Service Manual
Illustrated Factory Workshop Service Manual for Linde IC-Engined Forklift Trucks 392-02 series, Models H20D-02, H20T-02, H25D-02, H25T-02
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, 503 pages
Covered models:
H20D
H20T
H25D
H25T
Contents:
0 Product information
Foreword
Truck 392-02
Diagnostics
LHC basic structure
Consumables
Diesel engine
Recommendations for consumables
LPG engine
Recommendations for consumables
1 Engine
LPG engine
Description of the drive
Technical data for VWBEF
Checking engine power rating
Checking the engine power rating in trucks with adjustable hydraulic pump MPR 50
Assessing the engine power rating via the engine utilisation
Setpoint values with tolerance
Comparison of emission values (in vol. %)
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 -draining and filling
Coolant thermostat- removal and installation
Water pump- removal and installation
Coolant pump - Checking for wear
Engine electrics
Three-phase alternator
Electronic ignition system - 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
Shut-off valve (solenoid valve) with gas filter
Evaporator -functions
Mixer -functions
CO measurement with full load setting
Settings and CO testing
Revolution control
LPG system with lambda control system
Exhaust gases -composition
Lambda control system
Checking and adjusting the mixer
Leakage test on LPG system
LPG tank
Removing and installing the level display and 80% filling stop valve
Level display with single replacement cylinders(special equipment)
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
Checking the engine power rating in trucks with adjustable hydraulic pump MPR 50
Checking engine power rating
Assessing the engine power rating via the engine utilisation
Setpoint values with tolerance
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 injectionvalve 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
Linde engine protection system (LEPS)
Linde Engine Protection System (LEPS)
2 Gearbox
Description of the gearbox
Technical data for drive unit
Drive unit
Travel drive - introduction
Working hydraulics pump MPR 50
MPR50 -overview
MPR50 — overview
MPR50 — overview
Hydraulic adjustment with electronic activation
Start of variation of the variable displacement pump
Start of rotation of drive wheels
Bypass valve
Output unit
Verstellpumpe HPV - Kupplungsflansch aus- und einbauen
Hydraulic truck diagnostics
Overview and explanations about diagnostics
HPV 55-02 pressures -tests
Checking the hydrostatic traction drive
Wheel motor HMF 360 R-02-dismantling
Wheel motor HMF 360 R-02- checking bearing, seals
Wheel motor HMF 360 R-02 -seal after check
Wheel motor HMF 360 R-02 -exchanging bearing
3 Chassis, bodywork and fittings
Chassis
Axle suspension
Instructions for working with gas springs
Driver''s seat
Driver''s seat controls
Service instructions
Changing the seat switch and switch plate
4 Chassis frame
Steering system
Steering system - functional description
Linde Curve Assistant (LCA)
Steering axle
Adjusting the steering stop
Steering axle — removal and installation
Repairs to the steering axle
Replacingthe steering cylinder seals
Steering axle 1602
Devices/tools for manual assembly
Process for manual removal
Removing the steering pivot pin (pressing out using a fixed press)
Removingthe 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 cable pulls - Adjusting
Checking the brake system
5 Operating devices
Accelerator
Function
Replacement
Stop screws
Joysticks
Joystick variants
Joystick interlock
Functional description
Exchange
6 Electrics/electronics
General
Safety information for the electrical system
Cleaning the electrical system
EMC- Electromagnetic compatibility
CAN bus
CAN bus connection assembly X15
LIN bus
Electrostatic charging
Functions
LHC 20 functional overview
Actual-value transmitter for speed 1B1
Accelerator potentiometer 1B2
1B4 hydraulic oil temperature sensor
Steering angle sensor 1B11
Brake pedal switches 1S1 and S2
Suction filter vacuum-operated switch S3
Water trap sensor 1B13
Single-pedal drive direction switch 1S2
Tilt angle sensor 2B3
Seat switch S4
Electrical fan with reverse function
Identifying components in electrical circuit diagrams
Pin assignment for the LHC 20 Tricor controller with 154 contacts
Plug positions in the overhead guard
Plug positions under the seat cover
Plug positions under the bottom plate
Truck control unit
Truck control unit overview
Linde Hydraulic Control (LHC)
Power supply
Power supply for external components
Enable signal
Truck coding
LHC controller with ECO mode
Arrangement of the interface connectors console -truck
Layout of relays and fuses for standard and optional equipment
Display unit
Checks
LHC testing (truck control unit and lift control)
Testing the VW controller and immobiliser (WFS)
Checking wiring harness
Testing sensors
Testing the indicator unit
7 Hydraulic system
Working hydraulics
Functional description of Linde control valve
Overview
Working hydraulics circuit diagram (Linde control valve)
Function characteristics
Pressure relief valve
Depressurisation Auxiliary hydraulics 1and 2
Hose layout for pump — control valve
Hose layout of control pressure supply
Increase of the volume flow rate - auxiliary hydraulics 1 and 2
Cleaning work on the Linde control valve - cast valve
Cleaning instructions
8 Load lift system
Lift mast
Measuring the lifting speed
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 1 85
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
Setting the tilt angle sensor
Tilt cylinder
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
1.1 Hydraulic circuit diagram
Traction, working and steering hydraulics
Accumulator
1.2 Wiring diagram
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, 503 pages
Covered models:
H20D
H20T
H25D
H25T
Contents:
0 Product information
Foreword
Truck 392-02
Diagnostics
LHC basic structure
Consumables
Diesel engine
Recommendations for consumables
LPG engine
Recommendations for consumables
1 Engine
LPG engine
Description of the drive
Technical data for VWBEF
Checking engine power rating
Checking the engine power rating in trucks with adjustable hydraulic pump MPR 50
Assessing the engine power rating via the engine utilisation
Setpoint values with tolerance
Comparison of emission values (in vol. %)
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 -draining and filling
Coolant thermostat- removal and installation
Water pump- removal and installation
Coolant pump - Checking for wear
Engine electrics
Three-phase alternator
Electronic ignition system - 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
Shut-off valve (solenoid valve) with gas filter
Evaporator -functions
Mixer -functions
CO measurement with full load setting
Settings and CO testing
Revolution control
LPG system with lambda control system
Exhaust gases -composition
Lambda control system
Checking and adjusting the mixer
Leakage test on LPG system
LPG tank
Removing and installing the level display and 80% filling stop valve
Level display with single replacement cylinders(special equipment)
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
Checking the engine power rating in trucks with adjustable hydraulic pump MPR 50
Checking engine power rating
Assessing the engine power rating via the engine utilisation
Setpoint values with tolerance
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 injectionvalve 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
Linde engine protection system (LEPS)
Linde Engine Protection System (LEPS)
2 Gearbox
Description of the gearbox
Technical data for drive unit
Drive unit
Travel drive - introduction
Working hydraulics pump MPR 50
MPR50 -overview
MPR50 — overview
MPR50 — overview
Hydraulic adjustment with electronic activation
Start of variation of the variable displacement pump
Start of rotation of drive wheels
Bypass valve
Output unit
Verstellpumpe HPV - Kupplungsflansch aus- und einbauen
Hydraulic truck diagnostics
Overview and explanations about diagnostics
HPV 55-02 pressures -tests
Checking the hydrostatic traction drive
Wheel motor HMF 360 R-02-dismantling
Wheel motor HMF 360 R-02- checking bearing, seals
Wheel motor HMF 360 R-02 -seal after check
Wheel motor HMF 360 R-02 -exchanging bearing
3 Chassis, bodywork and fittings
Chassis
Axle suspension
Instructions for working with gas springs
Driver''s seat
Driver''s seat controls
Service instructions
Changing the seat switch and switch plate
4 Chassis frame
Steering system
Steering system - functional description
Linde Curve Assistant (LCA)
Steering axle
Adjusting the steering stop
Steering axle — removal and installation
Repairs to the steering axle
Replacingthe steering cylinder seals
Steering axle 1602
Devices/tools for manual assembly
Process for manual removal
Removing the steering pivot pin (pressing out using a fixed press)
Removingthe 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 cable pulls - Adjusting
Checking the brake system
5 Operating devices
Accelerator
Function
Replacement
Stop screws
Joysticks
Joystick variants
Joystick interlock
Functional description
Exchange
6 Electrics/electronics
General
Safety information for the electrical system
Cleaning the electrical system
EMC- Electromagnetic compatibility
CAN bus
CAN bus connection assembly X15
LIN bus
Electrostatic charging
Functions
LHC 20 functional overview
Actual-value transmitter for speed 1B1
Accelerator potentiometer 1B2
1B4 hydraulic oil temperature sensor
Steering angle sensor 1B11
Brake pedal switches 1S1 and S2
Suction filter vacuum-operated switch S3
Water trap sensor 1B13
Single-pedal drive direction switch 1S2
Tilt angle sensor 2B3
Seat switch S4
Electrical fan with reverse function
Identifying components in electrical circuit diagrams
Pin assignment for the LHC 20 Tricor controller with 154 contacts
Plug positions in the overhead guard
Plug positions under the seat cover
Plug positions under the bottom plate
Truck control unit
Truck control unit overview
Linde Hydraulic Control (LHC)
Power supply
Power supply for external components
Enable signal
Truck coding
LHC controller with ECO mode
Arrangement of the interface connectors console -truck
Layout of relays and fuses for standard and optional equipment
Display unit
Checks
LHC testing (truck control unit and lift control)
Testing the VW controller and immobiliser (WFS)
Checking wiring harness
Testing sensors
Testing the indicator unit
7 Hydraulic system
Working hydraulics
Functional description of Linde control valve
Overview
Working hydraulics circuit diagram (Linde control valve)
Function characteristics
Pressure relief valve
Depressurisation Auxiliary hydraulics 1and 2
Hose layout for pump — control valve
Hose layout of control pressure supply
Increase of the volume flow rate - auxiliary hydraulics 1 and 2
Cleaning work on the Linde control valve - cast valve
Cleaning instructions
8 Load lift system
Lift mast
Measuring the lifting speed
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 1 85
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
Setting the tilt angle sensor
Tilt cylinder
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
1.1 Hydraulic circuit diagram
Traction, working and steering hydraulics
Accumulator
1.2 Wiring diagram
1 file (137.7MB)
