Service Training

Linde IC-Engined Fork Truck

H 20/25/30 D-02
Type 351

This training material is only provide for your use and remains the exclusive property of
LINDE AG Werksgruppe Flurförderzeuge und Hydraulik
Service Training 06.96

CONTENT

2.9 IC-engined trucks H 20/25/30 D-02, type 351 1

2.9.1 Engine 1
2.9.1.1 Engine specifications 1
2.9.1.2 Explanation of the engine serial number 2
2.9.1.3 Valve clearance check and adjustment 3
2.9.1.3.1 Schematic of valve clearance adjustment 3
2.9.1.4 Engine timing 4
2.9.1.5 Checking and tensioning the V-belt 4
2.9.1.6 Timing gear replacement 5
2.9.1.7 Cylinder head 6
2.9.1.7.1 Removal 6
2.9.1.7.2 Installation 6
2.9.1.8 Injection nozzles 8
2.9.1.8.1 Injection nozzles faults 8
2.9.1.8.2 Injection nozzle removal and installation 8
2.9.1.8.3 Check the injection nozzle injection pressure 9
2.9.1.8.4 Check the injection nozzles for leaks 9
2.9.1.9 Injection pump 10
2.9.1.9.1 Injection pump removal and installation 10
2.9.1.10 Explanation of the cold start advance (KSB) 12
2.9.1.11 Fuel pump 12
2.9.1.12 Cooling system 13
2.9.1.13 Special tools 14
2.9.2 Hydrostatic travel drive 15
2.9.2.1 Schematic diagram of drive unit 15
2.9.2.2 Specifications for compact axle type AK 30-01 16
2.9.2.3 Hydraulic circuit diagram 18
2.9.2.4 Hydraulic remote control 23
2.9.3 Circuit diagram 24
2.9.4 Engine speed control 27
2.9.4.1 Adjustment instructions for engine speed control 27
Service Training
 Section 2.9
Service Training Page 1

2.9 IC-ENGINED TRUCKS H 20/25/30 D-02, TYPE 351

2.9.1 ENGINE

2.9.1.1 ENGINE SPECIFICATIONS

Engine type Perkins 903.27

No. of cylinders 3
Displacement 2700 cc
Power 35 kW at 2100 RPM
Injection pressure 300 bar
Compression ratio 17.5 : 1
Compression 35 bar rating
wear limit 25 bar
Max. admissible pressure difference 4 bar
Lower idle speed 800 +50 RPM
Upper idle speed 2200 +50 RPM
Valve clearance (with engine cold or warm) intake 0.20 ± 0.05 mm
exhaust 0.45 ± 0.05 mm
Start of delivery 4 ° BTDC
Firing order 1-2-3
No. 1 cylinder opposite power output (timing gear end)
Thermostat opens at: 80 °C
fully open at: 96 °C
Section 2.9
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2.9.1.2 EXPLANATION OF THE ENGINE SERIAL NUMBER

The identification plate (1) is located on the right side between the injection pump and the fuel filter.

STRUCTURE OF THE ENGINE NUMBER

903 . 27

Displacement 2700 cc

900 series, no. of cylinders: 3

CP80776* U300381A*

Engine serial no.

Build list no.

 Section 2.9
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2.9.1.3 VALVE CLEARANCE CHECK AND ADJUSTMENT

Valve clearance is measured between the tappets and

cams with a feeler gauge. The engine can be either cold
or warm.

Valve clearance is adjusted at the setscrew on the

tappet. The setscrew can be adjusted after loosening
the locknut.

Valve clearance:
Intake valve 0.2 mm cold or warm
Exhaust valve 0.45 mm cold or warm

2.9.1.3.1 SCHEMATIC OF VALVE CLEARANCE ADJUSTMENT

Cylinder 1 Cylinder 2 Cylinder 3

Crankshaft position I

Crankshaft position II

Crankshaft position III

NOTE: Cylinder I is at timing gear end. Valve position

(Exhaust valve not yet closed. Intake valve just
opening.)

Not adjustable Adjustable

Section 2.9
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2.9.1.4 ENGINE TIMING

The camshaft, connected to the crankshaft by means

of an idler gear, controls the intake and exhaust valve
via the pushrods and tappets.

2.9.1.5 CHECKING AND TENSIONING THE V-BELT

CHECKING V-BELT TENSION

The condition and tension of the V-belt should be

checked during the scheduled routine maintenance.
The belt tension should be checked with tension gauge
00094/9435 (Perkins) for a tension of 355 N. If no
tension gauge is available, depress the belt midway
between the pulleys with a pressure of approx. 45 N
and measure the deflection. Belt deflection should be
approx. 10 mm.

TIGHTENING THE V-BELT

- Loosen the alternator fastening screw (1) and adjusting

bracket screw (3).
- Pivot the alternator until a belt tension of 355 N or a
deflection of 10 mm with a pressure of 45 N is
obtained.
- Retighten screws (1) and (2).
 Section 2.9
Service Training Page 5

2.9.1.6 TIMING GEAR REPLACEMENT

TIGHTENING TORQUES

Injection pump gear (1): 80 Nm

Crankshaft gear (2)

(crankshaft pulley): 325 Nm

Idler gear (3): 65 Nm

Camshaft gear (4): 27 Nm

ATTENTION
When replacing the timing gears (re-
assembly), note the position of the
markings.
Section 2.9
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2.9.1.7 CYLINDER HEAD

2.9.1.7.1 REMOVAL

- Loosen the cylinder head screws evenly and in

stages in the specified sequence. First loosen the
M12 cylinder head screws (12 - 9), then the M14
cylinder head screws (8 - 1), refer to schematic.

- Check the cylinder head screw with a ruler (1) for

distortion of the screw shank (2).
- Check the screw for a visible reduction of the thread
diameter near the shank (3).
- Replace any distorted cylinder head screws.

2.9.1.7.2 INSTALLATION

- Clean the sealing face of the cylinder head and

engine block. The sealing face must be free of any
gasket remnants.
- Check the cylinder head for distortion with a steel
ruler and a set of gauges.
Maximum distortion is 0.05 mm.
 Section 2.9
Service Training 06.96 Page 7

- Put the cylinder head and engine block in place and

align them.

- Torque the M14 cylinder head screws (1 - 8) to 60 Nm

in the specified sequence.

- Retorque to 60 Nm (check).

- Continue to tighten the M14 cylinder head screws a

further 60 ° with the angle gauge in the specified
sequence.

- Continue to tighten the fastening screws a further

60° with the angle gauge in the specified sequence.

- Torque the M12 cylinder head screws (9 - 12) to

60 Nm in the specified sequence.

- Retorque to 60 Nm (check).

- Continue to tighten the M12 cylinder head screws a

further 60 ° with the angle gauge in the specified
sequence.

NOTE: The cylinder head screws do not need to

be retightened with the engine warm after
50 service hours.
Section 2.9
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2.9.1.8 INJECTION NOZZLES

2.9.1.8.1 INJECTION NOZZLES FAULTS

NOTE: Faulty injection nozzles can be the cause of the following malfunctions:
- misfiring
- knocking in one or more cylinders
- engine overheating
- drop in performance
- excessive black smoke
- high fuel consumption
- excessive blue smoke during starting

Faulty injection nozzles can be identified by loosening the high-pressure union nuts in turn while the engine
is running at high idling speed. An injection nozzle is faulty if the engine speed remains constant after the
union nut is loosened.

2.9.1.8.2 INJECTION NOZZLE REMOVAL AND INSTALLATION

REMOVAL

- Disconnect the leakage oil line.

- Remove the fuel injection line. Do not change the
bent of the line.
- Unscrew the hexagonal screw (1) and remove along
with the injection holder (2).
- Remove the injection nozzle (3) with sealing washer
(4).

INSTALLATION

ATTENTION
Always renew the sealing washer (4).

- Fit the injection nozzle (3) with sealing washer (4) in

the cylinder head.
- Install the injection holder (2) and torque the hexago-
nal screw (1) to 22 Nm.

ATTENTION
Do not jam the nozzle and nozzle holder.

- Install the fuel injection line and torque the union nut
to 22.5 Nm.
- Install the leakage oil line.
- Start the engine and watch for leaking fuel and air.
 Section 2.9
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2.9.1.8.3 CHECK THE INJECTION NOZZLE INJECTION PRESSURE

CAUTION
When testing the injection nozzles, be
sure that the fuel jet does not contact the
hands as, due to the high pressure, the
fuel can enter the skin and cause serious
injury.

- Install the injection nozzle on the tester.

- Slowly press the lever down. Read the pressure at
the start of ejection and correct, if necessary, by
replacing the shims.

Specified injection pressure 300 bar

Re-usability 285 bar

2.9.1.8.4 CHECK THE INJECTION NOZZLES FOR LEAKS

- Slowly press the lever down and hold for approx. 10 -

15 seconds. No fuel should eject from the nozzle
opening.
Section 2.9
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2.9.1.9 INJECTION PUMP

2.9.1.9.1 INJECTION PUMP REMOVAL AND INSTALLATION

INJECTION PUMP REMOVAL

- Set the crankshaft to TDC of cylinder 1 (valves

closed) and secure against turning with locking pin
(1) (Part No. 000 008 6100).

- Slacken the injection pump lock screw (1) about ½

turn.
- Move the holding plate (2) so that it fits over the large
cut-out on the screw head.
- Tighten the lock screw to lock the injection pump
shaft in place.
- Disconnect all fuel lines at the pump.
- Disconnect the electric cables at the shutoff valve
and the cold start accelerator.
- Disconnect the governor linkage.

- Remove the cover for the injection pump drive gear

at the timing gear cover.
- Unscrew the nut on the injection pump drive shaft and
remove the snap ring.
 Section 2.9
Service Training 06.96 Page 11

- Remove the hexagonal nuts at the pump flange and

at the rear pump mounting on the engine block.
- Using a puller WM 146, Part No. 000 941 91 08,
loosen the injection pump drive gear from the pump
shaft.
- Remove the pump, taking care that the key (2) does
not fall from the shaft.

INJECTION PUMP REMOVAL

- Set the crankshaft to TDC of cylinder 1 (valves

closed) and secure against turning with the locking
pin.
- The injection pump is blocked at start of delivery for
cylinder 1, even in the delivery state.
- Fit the injection pump into the engine block, paying
attention to the key (2) and O-ring (1).
- Install the snap ring and hexagonal nut on the pump
drive shaft. Torque the nut to 80 Nm.
- Turn the pump towards the engine block to eliminate
any play. The three fastening nuts must be tightened
in this position.
- Recheck the torque of the drive shaft nut and install
the cover.
- Install the rear pump mounting.
- Unlock the pump and put the holding plate in place
(drive shaft released = small elongated hole in holding
plate).
- Remove the crankshaft locking pin.
- Install the fuel lines.
- Install the governor linkage.
- Connect the electric cables.
Section 2.9
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2.9.1.10 EXPLANATION OF THE COLD START ADVANCE (KSB)

The Lucas injection pump is equipped with a starting

aid (KSB), which advances the fuel injection timing to
prevent the formation of white smoke and to facilitate
starting. This device is operated electrically and it
works with an expansion element filled with wax.
The injection timing point of a cold engine, coolant
temperature below 50 °C, is at 11° BTDC. When the
engine reaches its normal operating temperature, a
sensor in the cylinder head cooling circuit sends a
voltage of 12 V. This current heats the element filled
with wax, which returns the ignition advance from 11°
to 4 °.

2.9.1.11 FUEL PUMP

REMOVAL

- Disconnect the fuel lines from the fuel pump.

- Remove the four fastening screws (3) and take off the
fuel pump at the two retaining plates. In some cases
the fuel pump may be difficult to remove. In this case
turn the crankshaft until the cam on the camshaft
releases the fuel pump drive lever.

INSTALLATION

- Before installing the fuel pump, check that the cam on

the camshaft is at the minimum fuel delivery position.

- Clean the sealing face of the fuel pump and cylinder

block.

- Mount the fuel pump (new gasket) with the retaining

plates (2) and the four fastening screws. Torque the
screws (3) to 22 Nm.

- Connect both fuel lines.

 Section 2.9
Service Training 06.96 Page 13

- Loosen the bleeder screw in the fuel filter head.

- Operate the fuel pump priming lever (1) to eliminate

the air between the fuel pump and filter. Fuel without
air bubbles must emerge at the bleeder screw.

- Tighten the bleeder screw.

- Start the engine and watch for leaking fuel and air.

2.9.1.12 COOLING SYSTEM

If for some reason the coolant must be drained and the

cooling system refilled, do not forget to eliminate any air
in the system. The bleed screw (1) is located at the
thermostat.
Section 2.9
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2.9.1.13 SPECIAL TOOLS

Part Number Description

000 941 8724 Graduated scale for tightening the cylinder head
(1/2" socket)

000 008 6100 Fixing drift for TDC position

000 941 91 08 WM 146: Puller for injection pump drive gear

 Section 2.9
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2.9.2 HYDROSTATIC TRAVEL DRIVE

This information applies only to the truck equipped with a Perkins engine.

2.9.2.1 SCHEMATIC DIAGRAM OF DRIVE UNIT

1 Engine 6 Oil reservoir

2 Variable displacement hydraulic pump 7 Suction filter
HPV 90 S 8 Gear pump 16 cc
3 Fixed displacement hydraulic motor 9 Gear pump 28 cc
HMF 43 S 10 Priority flow regulator, 20 l/min
4 Wheel drive with disc brake itot = 11.56 11 Check valve
5 Drive wheels
Section 2.9
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2.9.2.2 SPECIFICATIONS FOR COMPACT AXLE TYPE AK 30-01

VARIABLE DISPLACEMENT PUMP

Type HPV 90 S
Definition of type designation H = High pressure
P = Pump
V = Variable displacement
90 = max. displacement = 90 cc/rev
S = Swashplate
Number of pistons 9
Piston diameter 22.5 mm
Max. working pressure 420 bar
Feed/pilot pressure 16 bar
Max. swash angle 15 °
Stroke of servo piston 11.7 mm
Max. speed in truck 2200 +50 RPM
Qmax at maximum speed 198 l/min
Q of feed pump 14 cc/rev
Qmax of feed pump 20 l/min
Type of control hydraulic
Actuation hydraulic remote control
Pump drive direct via flexible coupling

FIXED DISPLACEMENT HYDRAULIC MOTORS

Type HMF 43 S
Definition of type designation H = High pressure
M = Motor
F = fixed (constant)
43 = capacity = 43 cc/rev
S = swashplate
Fixed capacity 43 cc/rev
Number of pistons 7
Piston diameter 19 mm
Fixed swash angle 18 °
 Section 2.9
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TANDEM GEAR PUMP

Pump for working hydraulics 28 cc/rev

Pump for steering, feed and control 16 cc/rev

WHEEL DRIVES

Gear reduction 2-stage

Total ratio 11.56

OIL PRESSURE DISC BRAKES

- on extended drive shaft

- fully encapsulated, oil-bathed with flushing
- only required as parking brake and as emergency brake
Section 2.9
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2.9.2.3 HYDRAULIC CIRCUIT DIAGRAM

A WORKING HYDRAULICS

1 Control valve block assy. consisting of:

2 2/2-way valve (pressure balance)
3 Pressure relief valve
Mast Type H 20 H 25 H 30

Standard 163 170 170 200

Duplex 164 170 170 200
Triplex 165 170 185 215
Standard 183 150 170 -
Duplex 183 160 180 - All values
Triplex 183 160 180 - in bar

4 Pressure reducing valve

5 Check valve, pilot-operated
6 Spool valve - lifting
7 Spool valve - tilting
8 Spool valve - auxiliary hydraulics
9 Way valve - auxiliary hydraulics
10 Changeover valve
11 Working cylinder
Auxiliary hydraulics
12 Working cylinder
13 Tilt cylinder
14-1 Standard hydraulic cylinder
14-2 Duplex hydraulic cylinder
14-3 Triplex hydraulic cylinder
15 Slow lowering valve

B COMPACT AXLE AK 30-01, ASSEMBLY

16 Variable displacement hydraulic pump HPV 90 S

17 Control piston
 Section 2.9
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18 Combined feed - pressure relief valve, 420 bar

19 Feed pressure valve, 16 bar
20 Pilot
21 Servo piston
22 2/2-way valve
Lockout logic
23 3/2-way valve
23a Bypass valve
24 Fixed-displacement hydraulic motor HMF 43 S
25 Disc brake

C TANDEM PUMP ASSEMBLY

26 Gear pump, 16 cc
27 Gear pump, 28 cc
28 Priority flow regulator
28 a 2/2-way valve
29 Check valve

D CHANGE FILTER 10 µm

E SUCTION FILTER 20 µm

G OIL RESERVOIR

30 Suction valve - steering

31 Breather with suction and pressurizing valve

H TRAVEL CONTROL UNIT ASSEMBLY

32 2/2-way valve
33 Orifice gauge
34 Pressure relief valve
35 Pressure reducing valve
Section 2.9
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37 4/3-way valve - travel direction

38 3/2-way valve - signal for speed control
37a 4/2-way valve
Single pedal model
38a 4/3-way valve - electrical actuation
38b 2/2-way valve - brake release

J IC ENGINE

K SERVO CYLINDER - ENGINE SPEED CONTROL

L CHANGEOVER VALVE

M PRESSURIZING VALVE, 1 BAR - COOLER BYPASS

N OIL COOLER

O HYDRAULIC DAMPER

P STEERING CONTROL VALVE

39 Power steering control valve
40 Pressure relief valve, 130 bar
41 Hose safety valve, 190 bar
42 Suction valve

Q STEER CYLINDER
 Section 2.9
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HYDRAULC CIRCUIT DIAGRAM H 20/25/30 D-02, TYPE 351

 Section 2.9
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2.9.2.4 HYDRAULIC REMOTE CONTROL

1 Pilot
Hydraulic neutral of remote control
2 Grooved nut
3 Hollow screw (pilot housing)
4 Servo piston
5 Servo piston springs
6 Power limiter springs
7 Power limiter piston
8 Power limiter assembly
9 Shims for power limiter
10 Shims for wheel begin = Dp 4 bar
11 Setscrew for swash angle
13 Nozzle 0.9 mm
Section 2.9
Page 24 Service Training
2.9.3 CIRCUIT DIAGRAM

E2 Dip beam, left 44 R2 Wax motor heating element 27

E3 Dip beam, right 45 S1 Ignition switch 8-11
E4 Side lights, front left 46 S2 Engine temperature switch 15
E5 Side lights, front right 48 S3 Oil temperature switch 16
E6 Side lights, rear left 47 S4 Oil pressure switch 17
E7 Side lights, rear right 49 S5 Suction filter vacuum switch 18
E8 License plate light 50 S6 Low fuel switch 19
E21-24 Working lights 36-41 S7 Directional switch
(single-pedal model) 28-29
F1-14 Fuses S8 Horn button 30
S9,9.1 Switch for working lights 37-41
G1 Alternator with regulator 2 S10 Windscreen wiper switch 32-35
G2 Battery 4 S11 Light switch 45-48
S12 Hazard flasher switch 52-56
H1 Charging indicator lamp 13 S13 Directional indicator switch 54
H2-H3 Engine temperature S14 Switch for start inhibitor 8
warning lamp 14-15 S15 Switch for revolving light 57
H4 Hydraulic oil temperature S16 Temperature switch 50 °C 27
warning lamp 16
H5 Oil pressure warning lamp 17 V1-3 Decoupling diodes 13,15,20
H6 Suction filter vacuum V4 Freewheel diode 26
indicator 18
H7 Horn 30 X15 Connector
H8 Indicator light, front left 52
H9 Indicator light, rear left 53 Y1 Fuel shutoff valve 25
H10 Indicator light, front right 55 Y2,3 Solenoid, single-pedal
H11 Indicator light, rear righ 56 model 28-29
H12 Indicator repeat ligh 23
H13 Low fuel warning light 19
H14 Revolving light 57 CABLE COLOURS
H15-19,23 Switch lighting, 1.2 W 35-58
H24 Fan indicator light 20 BU blue
H25 Preheating 21 BN brown
H26 Soot filter prewarning 22 YE yellow
GN green
K1 Indicator switch 55-56 GY gray
K2 Start inhibitor relay 7-8 RD red
BK black
M1 Starter motor 6 WH white
M2 Wiper motor, rear 32 VT violet
M3 Wiper motor, front 31
M4 Washer 34

P1 Hour meter 12
6P3 Indicator 12-24
 Section 2.9
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CIRCUIT DIAGRAM H 20/25/30 D-02, TYPE 351

 Section 2.9
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2.9.4 ENGINE SPEED CONTROL

2.9.4.1 ADJUSTMENT INSTRUCTIONS FOR ENGINE SPEED CONTROL

Before starting work: Engine shut down, servo cylinder fully retracted.

Adjustment:

1. Mount the threaded rod (4) with ball-and-socket joints at the outer bore of the fuel pump lever (3) and
at the second bore from the bottom on the bellcrank (5).

2. Turn the threaded rod (4) to bring the injection pump control lever (3) to the idle stop (1) and to the stop
of the servo cylinder (6).

3. Start the engine and extend the servo cylinder as far as the stop.

4. The injection pump control lever must contact the stop (2) for maximum speed or press against the
overload stop.

5. If the stop is not reached: Mount the threaded rod (4) one or two bores further up on the bellcrank (5).

6. Repeat the adjustment from step 2 until the requirement in step 4 is fulfilled.

7. Tighten the locknut on the threaded rod (4) and ball-and-socket joints.
Section 2.9
Page 28 Service Training
LINDE AG
Werksgruppe Flurförderzeuge und Hydraulik
63701 Aschaffenburg
Postfach 10 01 36
Telefon (0 60 21) 99-0
Telefax (0 60 21) 99-15 70
http://www.linde.de/linde-stapler
eMail: service.training@linde-fh.de 351 802 2421.0696