Linde Forklift Truck 392 Series H20 H25 Service Training Manual PDF Download

Original Illustrated Factory Service Training Manual for Linde Forklift Trucks 392 Series with Diesel and LPG Engines

Covered Models:
H20D
H25D
H20T
H25T

Format: ZIP
Included:
Service Training manual PDF,459 pages
Diesel Truck Circuit Diagrams PDF, 247 pages
LPG Truck Circuit Diagrams PDF, 228 pages

Language: English

Table of contents:

0 Product information
\tPreface
\tThe vehicle
\tDiagnostics
\tLHC basic structure
1 Engine
\tLPG engine
\tDescription of the drive
\tTechnical data for VWBEF ....
\tEngine block
\tRibbed V-belt - removal and fitting
\tToothed belt- removal and fitting, tensioning
\tCylinder head -removal and fitting
\tCompression -check
\tChecking hydraulic bucket tappets
\tCooling
\tCoolant thermostat- removal and installation
\tWater pump- removal and installation
\tCoolant pump -Checking for wear
\tCoolant -draining and filling
\tEngine electrics
\tThree-phase alternator
\tElectronic ignition system up to 08/2005, overview
\tElectronic ignition control unit
\tElectronic ignition system from 09/2005, overview
\tShut-down due to lack of gas
\tLPG system
\tSafety guidelines for LPG (extract)
\tBasic rules when working with LPG
\tSealing plastic pipe unions
\tFunctions
\tLPG system - functions
\tShut-off valve- LPG
\tEvaporator -functions
\tMixer -functions
\tBasic setting of the butterfly valve until 12/2007
\tRevolution control (from 12/2007)
\tLPG system with lambda control
\tExhaust gases -composition
\tLambda control system
\tChecking and adjusting the mixer
\tInstallation positions -Overview until 12/2007
\tLeakage test on LPG system
\tLPG tank
\tLevel display with single replacement cylinders(special equipment)
\tRemoving and installing the level display and 80 filling stop valve
\tThe following safety measures must be observed
\tCarrying out assembly operations
\tBleeding the LPG tank
\tThe following safety measures must be observed
\tProcedure for bleeding
\tDiesel engine
\tDescription of the drive
\tTechnical data BEQ
\tParticularities of the 1.9-litre engine
\tElectronic engine control
\tSensors
\tCoolant temperature sending unit 0B1
\tEngine speed sensor 0B2
\tActual speed sensor 1B1
\tFuel temperature sending unit 0B3
\tSuction pipe temperature sensor 0B4
\tNeedle stroke sensor 0B5
\tHeight sensor
\t0B3 control gate valve travel sensor
\tGlow plug system
\tPre-heater system
\tGlow plugs- engine 0R1
\tFuel supply
\tFuel quantity regulation
\tFuel quantity actuator 0B3
\tFuel shut-off valve 0Y1
\tInjection timing device- replacement of O-ring on cover
\tStart of injection valve 0Y2
\tStart of injection -governing
\tStart of injection -dynamic checking and setting
\tInjection nozzle -Two-spring nozzle holder
\tInjection nozzles - removal and installation
\tOne-way restrictor
\tInjection system -overview
\tInjection system -supply voltage check
\tInjection pump - removal and refitting, Exchanging the toothed belt
\tInjection pump - removal and installation
\tInjection pump - pump and toothed belt adjustment
\tEngine block
\tRibbed V-belt- removal and fitting
\tCrankshaft oil seal on pulley end -removal and installation
\tCrankshaft sealing flange -removal and installation
\tChecking the cylinder head
\tCylinder head -removal and fitting
\tCylinder head -compression check
\tValve gear
\tOil pressure and oil pressure switch
\t- check
\tOil sump - removal and installation
\tChecking hydraulic bucket tappets
\tCamshaft- removal and installation
\tCooling
\tCoolant thermostat- removal and installation
\tWater pump - removal and installation
\tCoolant pump -Checking for wear
\tCoolant -draining and filling
\tEngine electrics
\tThree-phase alternator
\tReplacing the engine control unit/ immobilizer
\tSelf-diagnostics
\tSelf-test - introduction
\tSelf-diagnostics -troubleshooting
\tStandardised measured value blocks
2 Axles
\tDescription
\tTechnical data for traction drive
\tSystem overview
\tTraction drive
\tTravel drive - introduction
\tHydraulic adjustment with electronic activation- old version
\tHydraulic adjustment with electronic activation- Version with round solenoids
\tAuxiliary brake valve until 06/2003
\tAuxiliary brake valve from 07/2003
Auxiliary brake valve from 1 0/2006
\tStart of variation of the variable displacement pump
\tStart of rotation of drive wheels
\tRemoving and installing the HPV variable displacement pump coupling flange
\tBypass valve
\tOutput unit
\tHydraulic fan drive
\tHydraulic diagnostics
\tOverview and explanations about diagnostics
\tHPV 55-02 pressures -tests
\tChecking the hydrostatic traction drive
\tWheel motor HMF 360 R-disassembly
\tWheel motor HMF 360 R-checking bearing, seals
\tWheel motor HMF 360 R - sealing after inspection
\tWheel motor HMF 360 R-exchanging bearing
3 Chassis, bodywork and fittings
\tChassis
\tAxle suspension
\tInstructions for working with gas springs
4 Undercarriage
\tSteering system
\tSteering system - schematic function
\tSteering axle
\tSteering axle general (302 and 1 602)
\tSteering axle removal and installation
\tAdjusting the steering stop
\tRepairs to the steering axle
\tReplacing the steering cylinder seals
\tSteering axle 302 up to 08/2009
\tSteering axle design
\tSteering axle number
\tStub axle
\tReplacement of wheel bearings
\tSteering axle 1 602 from 09/2009
\tSteering axle 1602
\tDevices/tools for manual assembly
\tProcess for manual removal
\tRemoving the steering pivot pin (pressing out using a fixed press)
\tRemoving the axle stub from the axle beam
\tAssembly process
\tAssembling the upper axle stub bearing and wiper
\tAssembly axle stub
\tAssembly lower axle stub bearing wiper
\tAssembling (pre-assembling) the steering pivot pin (pressing in using a fixed press)
\tAssembling the steering pivot pin (pressing in using a fixed press)
\tAssembling the lower axle stub bearing/flange cover
\tAssembly steering angle sensor/cover
\tRemoval/assembly of the wheel hub/wheel bearing
\tBrake system
\tBrake release valve
\tBrake cables -adjustment
\tChecking the brake system
5 Operating devices
\tAccelerator
\tFunction
\tReplacement
\tStop screws
\tJoysticks
\tJoystick variants
\tFunctional description
\tReplacement
6 Electrics/Electronics
\tGeneral
\tSafety information for the electrical system
\tEMC- Electromagnetic compatibility
\tElectrostatic charging
\tIdentifying components in electrical circuit diagrams
\tCAN bus\t
\tCAN bus connection assembly X15
\tCentral electrical system
\tLinde Hydraulic Control (LHC)
\tLHC cont\troller with ECO mode
\tArrangement ofthe interface connectors console -truck
\tLayout of relays and fuses for standard and optional equipment
\tDisplay unit up to 06/2010
\tDisplay unit until 06/2010
\tDisplay unit from 07/2010
\tDisplay unit
\tChecks
\tLHC testing (truck control unit and lift control)
\tLHCcontrollerwithECOmode
\tTesting the VW controller and immobiliser (WFS)
\tChecking wiring harness
\tTesting sensors
\tTesting the indicator unit
7 Hydraulic equipment
\tOperating hydraulics
\tFunctional characteristics of control valve until 10/2005
\tOverview
\tFunctional description of control valve up to 1 0/2005
\tPressure relief valve
\tOperating hydraulics circuit diagram until 1 0/2005
\tHose routing of pump- control valve
\tHose routing of pilot oil pressure supply
\tFaultfinding the working hydraulic system
\tFunctional characteristics of Linde control valve from 1 1/2005
\tOverview
\tFunction characteristics
\tPressure relief valve
\tWorking hydraulics circuit diagram (Linde control valve)
\tDepressurisation Auxiliary hydraulics 1 and 2
\tHose layout pump -control valve
\tHose layout control pressure supply
\tGleaning work on the Linde control valve -cast valve
\tCleaning instructions
8 Load lift system
\tLift mast
\tLift mast - identification
\tMast - removal and installation (all series)
\tInstallation of mast type 185
\tA dusting the lift chain (all series)
\tSetting the roller play
\tRoller clearance -fork carriage in inner mast
\tRoller clearance -middle and inner mast channel, type 185
\tRoller play -outer mast profile, series 185
\tRemoval of slide pads - standard mast
\tRemoval of slide pads - duplex mast
\tRemoval of slide pads -triplex mast
\tLift cylinder (outer)
\t- removal and installation
\tLift cylinder (centre) - removal and installation
\tLift cylinder -sealing
\tTilt cylinder
\tSetting the tilt angle sensor
\tHose reservoir - removal, exchanging hose, sealing, fitting
\tLine break safety device in the lift mast (butterfly valve)
9 Special equipment, accessories
\tLighting
\tWorking spotlight position
\tAnnex
10 Circuit diagrams
\tHydraulic circuit diagrams
\tTraction, working and steering hydraulics
\tAccumulator
\tWiring diagrams
\tBasic equipment for diesel sheet 1
\tBasic equipment for diesel sheet 2
\tBasic equipment for diesel sheet 3
\tBasic equipment for LPG sheet 1
\tBasic equipment for LPG sheet 2
\tBasic equipment for LPG sheet 3
\tSpecial equipment sheet 01 -Working spotlights, interior light
\tSpecial equipment sheet 02 - Windscreen wiper, seat heater, radio
\tSpecial equipment sheet 03 - Heating system, air conditioning, flashing beacon / rotating

beacon, reversing signal
\tSpecial equipment sheet 04 - Hazard warning system for reverse travel
\tSpecial equipment sheet 05 - Lift mast positioning, hydraulic oil microfilter indicator, truck

deactivation, truck data management
\tSpecial equipment sheet 06 - Particle filter, diesel filter water trap warning .
\tSpecial equipment sheet 07 - Amount of gas display, 12V socket, coolant and engine oil level

monitoring
\tSpecial equipment sheet 08 - Battery mainswitch with display unit powersupply, changing

particle filter, rear window heating, camera system
\tSpecial equipment sheet 09 - Third auxiliary hydraulics with third joystick, centre rear

brake/tail light
\tSpecial equipment sheet 1 0
\t- Single lever locked, third auxiliary hydraulics via joystick
\tSpecial equipment sheet 11- Single lever locked, third auxiliary hydraulics via switch
\tSpecial equipment sheet 1 2
\t- Lighting, direction indicator and hazard warning system, brake light
\tSpecial equipment sheet 13 - Higher lighting, higher direction indicator and hazard warning

system, higher brake light and reversing light
\tSpecial equipment sheet 14 - Higher front / standard rear lighting