Linde Forklift Truck 392 Series H20, H25 Service Training manual

Table of contents 0 Product information Preface 0-1 The vehicle 0-1 Diagnostics 0-3 LHC basic structure 0-3 1 Engine LPG engine 1-1 Description of the drive Technical data for VWBEF .... Engine block Ribbed V-belt - removal and fitting Toothed belt- removal and fitting, tensioning 1-3 Cylinder head -removal and fitting 1-6 Compression -check 1-9 Checking hydraulic bucket tappets 1-10 Cooling 1-12 Coolant thermostat- removal and installation 1-12 Water pump- removal and installation 1-13 Coolant pump -Checking for wear 1-14 Coolant -draining and filling 1-14 Engine electrics 1-16 Three-phase alternator 1-16 Electronic ignition system up to 08/2005, overview 1-18 Electronic ignition control unit 1-19 Electronic ignition system from 09/2005, overview 1-24 Shut-down due to lack of gas 1-26 LPG system 1-28 Safety guidelines for LPG (extract) 1-28 Basic rules when working with LPG 1-29 Sealing plastic pipe unions 1-31 Functions 1-32 LPG system - functions 1-32 Shut-off valve- LPG 1-33 Evaporator -functions 1-34 Mixer -functions 1-36 Basic setting of the butterfly valve until 12/2007 1-38 Revolution control (from 12/2007) 1-40 LPG system with lambda control 1-42 Exhaust gases -composition 1-42 Lambda control system 1-43 Checking and adjusting the mixer 1-49 Service Training -392 804 24 01 EN-10/2012 V

Table of contents Installation positions -Overview until 12/2007 1-50 Leakage test on LPG system 1-52 LPG tank 1-55 Level display with single replacement cylinders(special equipment) 1-55 Removing and installing the level display and 80% filling stop valve 1-57 The following safety measures must be observed 1-57 Carrying out assembly operations 1-58 Bleeding the LPG tank 1-61 The following safety measures must be observed 1-61 Procedure for bleeding 1-62 Diesel engine 1-65 Description of the drive 1-65 Technical data BEQ 1-65 Particularities of the 1.9-litre engine 1-66 Electronic engine control 1-67 Sensors 1-68 Coolant temperature sending unit 0B1 1-68 Engine speed sensor 0B2 1-70 Actual speed sensor 1B1 1-72 Fuel temperature sending unit 0B3 1-72 Suction pipe temperature sensor 0B4 1-75 Needle stroke sensor 0B5 1-77 Height sensor 1-79 0B3 control gate valve travel sensor 1-80 Glow plug system 1-83 Pre-heater system 1-83 Glow plugs- engine 0R1 1-84 Fuel supply 1-85 Fuel quantity regulation 1-85 Fuel quantity actuator 0B3 1-87 Fuel shut-off valve 0Y1 1-89 Injection timing device- replacement of O-ring on cover 1-90 Start of injectionvalve 0Y2 1-90 Start of injection -governing 1-93 Start of injection -dynamic checking and setting 1-94 Injection nozzle -Two-spring nozzle holder 1-97 Injection nozzles - removal and installation 1-99 One-way restrictor 1-100 Injection system -overview 1-101 Injection system -supply voltage check 1-102 Injection pump - removal and refitting, Exchanging the toothed belt 1-103 Injection pump - removal and installation 1-108 Injection pump - pump and toothed belt adjustment 1-112 VI Service Training - 392 804 24 01 EN- 10/2012

Table of contents Engine block 1-114 Ribbed V-belt- removal and fitting 1-114 Crankshaft oil seal on pulley end -removal and installation 1-116 Crankshaft sealing flange -removal and installation 1-120 Checking the cylinder head 1-123 Cylinder head -removal and fitting 1-125 Cylinder head -compression check 1-127 Valve gear 1-128 Oil pressure and oil pressure switch - check 1-130 Oil sump - removal and installation 1-131 Checking hydraulic bucket tappets 1-133 Camshaft- removal and installation 1-135 Cooling 1-136 Coolant thermostat- removal and installation 1-136 Water pump - removal and installation 1-137 Coolant pump -Checking for wear 1-138 Coolant -draining and filling 1-138 Engine electrics 1-140 Three-phase alternator 1-140 Replacing the engine control unit/ immobilizer 1-141 Self-diagnostics 1-142 Self-test - introduction 1-142 Self-diagnostics -troubleshooting 1-143 Standardised measured value blocks 1-144 Service Training -392 804 24 01 EN-10/2012 VII

Table of contents 2 Axles Description 2-1 Technical data for traction drive 2-1 System overview 2-2 Traction drive 2-3 Travel drive - introduction 2-3 Hydraulic adjustment with electronic activation- old version 2-5 Hydraulic adjustment with electronic activation- Version with round solenoids 2-9 Auxiliary brake valve until 06/2003 2-12 Auxiliary brake valve from 07/2003 2-13 Auxiliary brake valve from 1 0/2006 2-15 Start of variation of the variable displacement pump 2-17 Start of rotation of drive wheels 2-20 Removing and installing the HPV variable displacement pump coupling flange ...... 2-21 Bypass valve 2-23 Output unit 2-24 Hydraulic fan drive 2-26 Hydraulic diagnostics 2-28 Overview and explanations about diagnostics 2-28 HPV 55-02 pressures - tests 2-31 Checking the hydrostatic traction drive 2-32 Wheel motor HMF 360 R- disassembly 2-36 Wheel motor HMF 360 R- checking bearing, seals 2-46 Wheel motor HMF 360 R - sealing after inspection 2-47 Wheel motor HMF 360 R- exchanging bearing 2-52 3 Chassis, bodywork and fittings Chassis 3-1 Axle suspension 3-1 Instructions for working with gas springs 3-2 4 Undercarriage Steering system 4-1 Steering system - schematic function 4-1 Steering axle 4-4 Steering axle — general (302 and 1 602) 4-4 Steering axle — removal and installation 4-4 Adjusting the steering stop 4-6 VIII Service Training - 392 804 24 01 EN- 10/2012

Table of contents Repairs to the steering axle 4-7 Replacing the steering cylinder seals 4-9 Steering axle 302 up to 08/2009 4-11 Steering axle — design 4-11 Steering axle number 4-12 Stub axle 4-13 Replacement of wheel bearings 4-14 Steering axle 1 602 from 09/2009 4-15 Steering axle 1602 4-15 Devices/tools for manual assembly 4-16 Process for manual removal 4-19 Removing the steering pivot pin (pressing out using a fixed press) 4-20 Removing the axle stub from the axle beam 4-21 Assembly process 4-23 Assembling the upper axle stub bearing and wiper 4-24 Assembly — axle stub 4-26 Assembly — lower axle stub bearing wiper 4-28 Assembling (pre-assembling) the steering pivot pin (pressing in using a fixed press) .. 4-29 Assembling the steering pivot pin (pressing in using a fixed press) 4-33 Assembling the lower axle stub bearing/flange cover 4-34 Assembly — steering angle sensor/cover 4-36 Removal/assembly of the wheel hub/wheel bearing 4-38 Service Training -392 804 24 01 EN-10/2012 IX

Table of contents Brake system 4-4 1 Brake release valve 4-41 Brake cables -adjustment 4-47 Checking the brake system 4-49 5 Operating devices Accelerator 5-1 Function 5-1 Replacement 5-2 Stop screws 5-3 Joysticks 5-4 Joystick variants 5-4 Functional description 5-4 Replacement 5-6 6 Electrics/Electronics General 6-1 Safety information for the electrical system 6-1 EMC- Electromagnetic compatibility 6-2 Electrostatic charging 6-3 Identifying components in electrical circuit diagrams 6-4 CAN bus 6-5 CAN bus connection assembly X15 6-5 Central electrical system 6-10 Linde Hydraulic Control (LHC) 6-10 LHC controller with ECO mode 6-12 Arrangement ofthe interface connectors console -truck 6-14 Layout of relays and fuses for standard and optional equipment 6-14 Display unit up to 06/2010 6-17 Display unit until 06/2010 6-17 Display unit from 07/2010 6-22 Display unit 6-22 x Service Training - 392 804 24 01 EN- 10/2012

Linde Forklift Truck 392 Series H20, H25 Service Training manual

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