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

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Basic Information Identification Make: Linde Model: Forklift Truck 392 Series Covered Models: H20D, H25D, H20T, H25T Codes Series Code: 392 Introduction Market Position Positioning: The Linde 392 Series forklifts are...

Type: Material Handling

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Sku: 68096

Tags: 392 Series Forklifts Linde

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Description

Basic Information
Identification
Make:	Linde
Model:	Forklift Truck 392 Series
Covered Models:	H20D, H25D, H20T, H25T
Codes
Series Code:	392

Introduction
Market Position
Positioning:	The Linde 392 Series forklifts are known for their robust construction, reliability, and efficiency in demanding industrial environments. This manual targets professional technicians and service personnel responsible for maintaining and repairing these units.
Competitive Analysis
Competitors:	Competes with similar heavy-duty forklift models from manufacturers like Toyota, Hyster, Yale, and Clark.
Key Features
Features Of Truck:	Designed for durability, efficient operation with both Diesel and LPG engines, advanced Linde Hydraulic Control (LHC) for precise operation, and ergonomic operator stations. The manual highlights the versatility and advanced engineering of these forklifts.

Manual Details
Coverage Areas
Primary Coverage:	Service Training and Diagnostics
Specific Diagrams:	Includes separate, comprehensive PDF documents for Diesel Truck Circuit Diagrams and LPG Truck Circuit Diagrams, essential for electrical troubleshooting.
Page Count
Total Pages:	919
Service Training Manual Pages:	459
Diesel Circuit Diagrams Pages:	247
Lpg Circuit Diagrams Pages:	228
Manual Type
Type:	Factory Service Training Manual
Language
Language:	English
Format
Format:	ZIP Download

Manual Coverage
Systems Covered
Engine Lpg:	Complete coverage including drive description, technical data (VWBEF), engine block, V-belt, toothed belt, cylinder head, compression checks, hydraulic tappets, cooling system (thermostat, water pump, coolant), and engine electrics (alternator, ignition systems, shut-down).
Lpg System:	Detailed coverage of LPG system functions, safety guidelines, working rules, pipe union sealing, shut-off valve, evaporator, mixer (basic setting, revolution control, lambda control), exhaust gases, mixer adjustment, installation positions, leak testing, LPG tank operations (level display, filling stop valve, bleeding).
Engine Diesel:	Comprehensive coverage of diesel engines including drive description, technical data (BEQ), 1.9-litre engine specifics, electronic engine control, sensors (coolant temp, engine speed, fuel temp, etc.), glow plug system, fuel supply (quantity regulation, actuators, shut-off valve), injection timing, injection nozzles, injection pump, engine block, V-belt, crankshaft seals, cylinder head, valve gear, oil pressure, oil sump, cooling system, and engine electrics (alternator, control unit replacement, self-diagnostics).
Axles:	Detailed information on traction drive and axles, including technical data, system overview, travel drive operation (hydraulic adjustment, auxiliary brake valves), variable displacement pump, wheel motor disassembly and maintenance, and hydraulic fan drive.
Chassis Bodywork:	Covers chassis components and bodywork fittings, including axle suspension and instructions for working with gas springs.
Undercarriage Steering:	In-depth coverage of the steering system, including schematic function, steering axle design (302 and 1602 series), removal/installation, adjustment of steering stops, repairs, cylinder seal replacement, stub axle procedures, wheel bearing replacement, and detailed assembly processes for various steering axle components.
Undercarriage Brakes:	Details on the brake system, including brake release valve, brake cable adjustment, and general brake system checks.
Operating Devices:	Information on operating controls such as accelerator function and replacement, stop screws, and joystick variants with functional descriptions and replacement procedures.
Electrics Electronics:	Extensive coverage of the electrical and electronic systems, including general safety, EMC, electrostatic charging, identifying components, CAN bus, central electrical system, Linde Hydraulic Control (LHC) with ECO mode, controller interfaces, relay/fuse layouts, display unit information (various versions), LHC testing, controller/immobilizer testing, wiring harness checks, sensor testing, and indicator unit testing.
Hydraulic Equipment:	Detailed breakdown of operating hydraulics, including control valve functions (pre and post 11/2005), pressure relief valves, circuit diagrams, hose routing, fault finding, depressurization, and cleaning instructions for cast valve components.
Load Lift System:	Comprehensive coverage of the load lift system, including lift mast identification, mast removal/installation, specific mast type installations, lift chain adjustment, roller play settings (fork carriage, middle/inner mast, outer mast), slide pad removal for various mast types, lift cylinder removal/installation and sealing, tilt cylinder procedures, tilt angle sensor adjustment, and line break safety device.
Special Equipment:	Information on special equipment and accessories, including lighting positions.
Circuit Diagrams:	Dedicated section for hydraulic and wiring diagrams, covering traction, working, and steering hydraulics, as well as detailed wiring diagrams for basic equipment (diesel/LPG) and various special equipment options (lighting, heating, auxiliary hydraulics, safety systems, etc.).
Vehicle Information:	Section 0 'Product Information' includes 'The vehicle', providing foundational details about the forklift itself.
Brake System:	Covers brake release valve, brake cable adjustments, and general brake system checks.
Hydraulic Fan Drive:	Specific mention of the hydraulic fan drive within the Axles section.
Lift Mast Components:	Comprehensive coverage of lift mast components, including chains, rollers, slide pads, lift cylinders, and tilt cylinders, with detailed removal, installation, and adjustment procedures.
Procedures Included
Maintenance:	Removal and installation of V-belts, toothed belts, cylinder heads, water pumps, fuel injectors, injection pumps, steering axles, wheel hubs, lift masts, lift cylinders, tilt cylinders, and various sensors.
Diagnostics:	Troubleshooting guides for engine self-diagnostics, LHC system testing, controller and immobilizer testing, wiring harness checks, sensor testing, indicator unit testing, and hydraulic system diagnostics (e.g., HPV 55-02 pressures).
Adjustments:	Procedures for adjusting toothed belt tension, mixer butterfly valve, revolution control, injection timing, brake cables, and lift chain roller play.
Safety Procedures:	Emphasis on safety guidelines for LPG systems, working with LPG, electrical system safety, EMC, electrostatic charging, and specific safety measures for tasks like bleeding LPG tanks.
Troubleshooting:	Detailed troubleshooting guides for engine systems (including self-diagnostics), electrical faults, and hydraulic system issues are a core component of this manual.
Component Replacement:	Instructions for replacing virtually every major component, from engine parts and transmission components to steering and lift system parts, are provided.
Leakage Testing:	Specific procedures for leakage testing on the LPG system are detailed.
Tank Maintenance:	Procedures for LPG tank level display replacement, filling stop valve, and bleeding the LPG tank are included.
Steering Axle Repair:	Extensive procedures for steering axle repair, including seal replacement, stub axle procedures, and detailed assembly steps for both older (302) and newer (1602) steering axle designs.
Wheel Motor Service:	Detailed disassembly, inspection, sealing, and bearing exchange procedures for the HMF 360 R wheel motor.
Mast Adjustment:	Specific instructions for adjusting lift chain slack and roller play on various mast configurations (standard, duplex, triplex).
Technical Depth
Depth:	Comprehensive. Covers basic maintenance, detailed repair procedures, advanced diagnostics, system overviews, technical data, and troubleshooting for all major vehicle systems.
Diagnostic Tools:	The manual implicitly guides the use of diagnostic tools by detailing sensor checks, control unit testing, and specific pressure tests for hydraulic systems.
Control Systems:	Deep dive into Linde Hydraulic Control (LHC) systems, including controller functions, diagnostics, and integration with other truck systems.

Manual Specifications
File Format
Format:	PDF (within ZIP archive)
Searchability:	Likely searchable text within PDFs, assuming proper OCR if scanned.
Print Quality
Quality:	Original Illustrated Factory Manual quality (typically high-resolution for diagrams and images).
Binding Type
Type:	N/A (Digital Download)
Paper Type
Type:	N/A (Digital Download)

Engine Specifications
Primary Engine
Diesel Engine Type:	Likely a 1.9-litre diesel engine (as indicated in table of contents), common in industrial applications for its torque and durability.
Lpg Engine Type:	VWBEF series LPG engine (as indicated in table of contents), known for its reliability in forklift applications.
Performance
Diesel Performance Notes:	Focus on torque delivery for load handling. Specific HP/Torque figures would be detailed within the manual under 'Technical data BEQ'.
Lpg Performance Notes:	Balanced performance for industrial use. Specific HP/Torque figures would be detailed within the manual under 'Technical data for VWBEF'.
Fuel System
Lpg System Components:	Includes shut-off valves, evaporators, mixers (with and without lambda control), and LPG tanks. Detailed procedures for leak testing and tank management.
Diesel Fuel System Components:	Features electronic engine control, fuel quantity regulation, injection pumps, injection nozzles, and related sensors. Specific maintenance for injection timing devices and pumps is covered.
Engine Block
Diesel Block Details:	Specific information on the engine block, including crankshaft oil seal and sealing flange removal/installation for the diesel engine is present.
Cooling System
Lpg Cooling Details:	Details on thermostat, water pump, and coolant draining/filling for the LPG engine are provided.
Ignition System
Lpg Ignition Overview:	Covers electronic ignition systems up to 08/2005 and from 09/2005, including control units and shut-down logic.

Transmission
Standard
Transmission Type:	Hydrostatic transmission is standard on Linde forklifts, utilizing HPV variable displacement pumps and wheel motors for precise control of travel speed and power.
Optional
Optional Features:	The manual details variations in hydraulic adjustment systems for the travel drive, suggesting potential updates or different control strategies over the production run.
Features
Transmission Features:	Features hydraulic adjustment with electronic activation (both old and new versions with round solenoids), auxiliary brake valves, and detailed diagnostics for the hydrostatic traction drive, including specific pressure tests for the HPV 55-02 pump.

Dimensions
Exterior
Lift Capacities:	H20D/H20T indicate approximately 2000 kg (4400 lbs) capacity, H25D/H25T indicate approximately 2500 kg (5500 lbs) capacity. Specific dimensions (length, width, height, mast height) are typically model-specific and would be found within the manual's 'Product Information' or chassis sections.
Weights
Operating Weight:	Varies based on engine, mast configuration, and optional equipment. Exact operating weights would be detailed in the 'The vehicle' section.

Safety Features
Ratings
Safety Standards:	The manual emphasizes safety procedures for hazardous materials (LPG) and electrical systems, adhering to industry safety standards for forklift operation and maintenance.
Active Features
Active Safety Systems:	Features like electronic control systems, precise hydraulic control (LHC), and potentially integrated safety interlocks are implied by the advanced nature of the manual's content.
Passive Features
Passive Safety Features:	Robust chassis construction, operator protection features within the cabin (not explicitly detailed but standard for forklifts), and line break safety devices in the lift mast are mentioned.

Technology Features
Infotainment
Infotainment Features:	While not a primary focus for forklifts, the manual mentions optional equipment such as radios, indicating potential for operator comfort features.
Driver Assistance
Assistance Systems:	The Linde Hydraulic Control (LHC) with ECO mode represents advanced technology for precise operation and efficiency. The manual details its control unit, interface connectors, and diagnostic procedures.
Connectivity
Connectivity:	CAN bus connectivity is mentioned, indicating modern electronic communication within the truck's systems, facilitating diagnostics and control.

Maintenance
Service Intervals
General Maintenance:	The manual provides procedures for all routine maintenance tasks, including belt replacement, fluid changes (coolant, hydraulic oil - though specific capacities and fluid types are not listed here but would be in the manual), filter changes, and component inspections. Specific interval recommendations would typically be in a separate owner's or maintenance schedule document, but the procedures are fully covered.
Fluid Specifications
Engine Oil Spec:	Specific engine oil viscosity grades (e.g., 15W-40) and API service classifications would be detailed in the 'Technical Data' sections for both diesel and LPG engines.
Hydraulic Oil Spec:	The manual covers hydraulic system diagnostics and repair. Specific hydraulic fluid types and viscosity grades would be detailed within the relevant sections, crucial for maintaining the hydrostatic transmission and operating hydraulics.
Coolant Spec:	Coolant type (e.g., ethylene glycol based) and mix ratio with water for optimal protection would be specified in the cooling system sections.
Known Issues
Common Wear Items:	Common wear items for forklifts of this era and type include hydraulic cylinder seals, steering axle components (bearings, seals), lift mast chains and rollers, and engine belts. The manual provides specific procedures for their inspection and replacement.
Diagnostic Focus:	The extensive diagnostic sections for both engine and hydraulic systems suggest that common issues often relate to sensor failures, control unit malfunctions, and hydraulic system performance degradation.

Vehicle History
Brand Heritage
Linde Heritage:	Linde Material Handling is a globally recognized leader in forklift manufacturing, known for its engineering innovation, particularly in hydrostatic drive systems and material handling technology.
Model Evolution
392 Series Evolution:	The 392 Series represents a significant generation of Linde's compact, powerful forklifts, evolving with advancements in engine technology, electronic controls, and hydraulic systems, as indicated by the different versions of control valves and hydraulic adjustment systems mentioned.
Production
Production Period:	The manual's detail on different versions of control valves and electronic systems (e.g., ignition systems up to 08/2005 and from 09/2005) suggests this series spans several years, likely from the early to mid-2000s.

Awards & Recognition
Recognitions
Industry Recognition:	Linde forklifts are consistently recognized for their innovation, efficiency, and operator comfort. While specific awards for the 392 Series are not listed here, Linde as a brand holds a strong reputation in the material handling industry.