Linde Forklift Truck H-Series Type 394-02: H40, H45, H50 Service Training (Workshop) Manual

Original Illustrated Factory Service Training (Workshop) Manual for Linde Forklift Truck H-Series Type 394-02.

Original factory manuals for Linde Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck

Covered models:

Format: ZIP, containing:
Service Training Manual, PDF, 771 Pages
Circuit Diagrams LPG Truck, PDF, 39 Pages
Circuit Diagrams Diesel Truck, PDF, 37 Pages
Language: English

0. Product information
   Truck 394-02
   LHC basic structure
   LPG engine
   Recommendations for consumables
   Diesel engine
   Recommendations for consumables
1. Engine
   LPG engine
   Description of the drive
   BMFVR6 technical data
   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
   Comparison of emission values (in vol. %)
   Engine block
   V-ribbed belt — removal and installation
   Checking the compression pressure
   Cylinder head — removal and installation
   Checking and adjusting the timing
   Removing and refitting the cylinder head cover
   Installing and removing camshafts
   Engine cooling system
   Coolant -draining and filling
   Coolant regulator housing assembly and disassembly
   Engine electrics
   Three-phase alternator
   Electronic ignition system — overview
   LPG system
   Safety guidelines for LPG (extract)
   Basic rules when working with LPG
   Sealing plastic pipe unions
   LPG system - functions
   Shut-down due to lack of gas
   Evaporator -functions
   Mixer -functions
   Default settings for the LPG system
   Speed control (from chassis number H2X394U04459 onwards)
   Shut-off valve -LPG
   LPG truck with a lambda control system
   Exhaust gases -composition
   Lambda control system
   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 CPY A/D
   Glossary component designations Linde-VW
   Engine code letters/engine designations
   Technical data CPYA/CPYD
   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
   Sensors -overview
   Pin assignment oftheVW controller with 154 contacts
   Diesel particle filter system
   Features of self-diagnostics
   Self-diagnostics technical data
   Connect laptop with "Pathfinder" diagnostics program and select control unit
   Connect test adaptor for line test
   Reading out the error memory
   Delete the error memory
   Error code list
   Errorcode: P0016...P0092
   Error code: P0100...P0697
   Errorcode: P100E...P1698
   Errorcode: P2002...P2634
   Errorcode: P33C8...P3325
   Errorcode: U0001...U140A
   Perform actuator test
   Measured value blocks -safety measures
   Read measured value blocks
   Evaluate measured value blocks at idle speed
   Evaluating measured value blocks at full load (engine code letter CPYA/D) .
   Crank drive
   Dismantling and assembling the engine
   V-ribbed belt drive - assembly overview (with air-conditioning compressor) 
   V-ribbed belt - assembly overview (without air-conditioning compressor)
   Removing and installing V-ribbed belts
   Check ribbed belt
   Remove and install tensioner for V-ribbed belt (only engines with air-conditioning copressor)
   Removing and installing holderfor ancillary equipment
   Toothed belt drive -assembly overview
   Check the toothed belt drive
   Cylinder crankcase - assembly overview
   Remove and install sealing flanges and flywheel
   Sealing flange belt pulley side -assembly overview
   Changing the sealing ring for the crankshaft (belt pulley side)
   Remove and install sealing flange for crankshaft (belt pulley side)
   Sealing flanges and flywheel -assembly overview
   Changing sealing flange for crankshaft -flywheel side-
   Remove and install crankshaft sensor 0B13
   Cylinder head, valve train
   Cylinder head -assembly overview
   Remove and install camshaft sensor 0B11
   Cylinder head cover -assembly overview
   Toothed belt and toothed belt tensioning pulley for camshaft drive: Change: 
   Checking the compression pressure
   Removing and installing the cylinder head
   Removing and installing the vacuum pump
   Repairing the valve train
   Valve train -assembly overview
   Changing valve stem seals
   Removing and installing the camshaft
   Removing and installing the camshaft sealing ring
   Parts of the lubricating system
   Oil pump, oil sump -assembly overview
   Removing and installing the oil sump
   Oil filter support, oil cooler and oil pressure switch
   Removing and installing parts of the cooling system
   Parts of the cooling system on the engine side
   Connection diagram for coolant hoses
   Cooling system: Checking frost protection and coolant level
   Draining and filling coolant
   Coolant pump: Change
   Removing and installing 4/2 directional control valve with coolant regulator 
   Checking the cooling system for leaks
   Check oil cooler for leaks
   Fuel supply
   Removing and installing parts of the fuel supply
   Safety measures when working on the fuel supply
   Sanitation regulations
   Behaviour during incorrect refuelling
   Draining water from the fuel filter
   Changing the fuel filter
   Removing and installing diesel supply pump 0M4
   Check diesel supply pump 0M4
   Charge air system with exhaust turbocharger
   Safety measures during work on the charge air system with exhaust turbocharger . . .
   Sanitation regulations
   Exhaust turbocharger with attachment parts - assembly overview
   Remove and install exhaust turbocharger
   Checking charge air system
   Check charge air system for leaks
   Checking boost pressure regulation
   Connection diagram for vacuum hoses
   Check vacuum system
   Checking boost pressure regulator valve 0Y7
   Check boost pressure sensor 0B1
   Checking position transmitter for boost pressure regulator 0B14
   Check exhaust gas temperature sensor 0B7
   Fuel preparation, injection
   Repairing the diesel direct injection system
   Instructions for working on the fuel system
   To avoid injuries to persons and/or destruction of the fuel injection and preheating systems, please note the following:
   Safety measures when working on the diesel direct injection system
   Sanitation regulations
   Suction pipe with attachment parts- assembly overview
   Fuel system
   Fuel system -assembly overview
   Correction values for injection units
   Check open injection units (injectors)
   Removing and installing injection unit (Piezo injector)
   Checking the return flow volume from high-pressure regulating valve 0Y5
   Removing and installing high-pressure regulating valve 0Y5
   Removing and installing distributor list pressure sensor CR 0B3
   Removing and installing high-pressure pump
   Filling/bleeding the fuel system
   Testing fuel system for leaks
   Checking pressure control valve in the fuel return line
   Checking high-pressure pump fuel dosage valve 0Y8
   Checking high-pressure regulating valve 0Y5
   Check distributor list pressure sensor CR0B3
   Checking injection valves (cylinder 1... 4) 0Y1...0Y4
   Check crankshaft sensor 0B13
   Checking camshaft sensor 0B11
   Check boost pressure sensor 0B1
   Checking coolant temperature sensor 0B10
   Check fuel temperature sensor 0B12
   Check air volumeter 0B6
   Check butterfly valve 0M1
   Checking power supply for engine control unit
   Changing the engine control unit
   Adjusting particle difference pressure sensor 0B2
   Reading out injector quantity adjustment values (IMA-ISA values) and registering them in the engine control unit
   Adapting diesel direct fuel injection system control unit 0N1 to the position transmitter
   for charge pressure plate 0B14
   Adapting diesel direct fuel injection system control unit 0N1 tothe EGRvalve 
   Adapting diesel direct fuel injection system control unit 0N1 to butterfly valve 0M1 
   Checking data bus
   Exhaust system
   Removing and installing parts of the exhaust system
   Diesel particle filter -assembly overview
   Changing the diesel particle filter: CPYA, CPYB
   Removing and installing exhaust gas temperature sensor 0B7
   Radiator for exhaust gas recirculation -assembly overview
   Checking exhaust gas recirculation
   Checking EGRvalve 0M2
   Checking lambda probe before cat 0B4
   Check heating system for lambda probe Z19 (in component 0B4 lambda probe before cat)
   Checking exhaust gas temperature sensor after oxi-catOB8
   Checking exhaust gas temperature sensor after DPF 0B9
   Checking particle differential pressure sensor 0B2
   Service diesel particle filter CPYA, CPYB
   Starter motor, power supply, GRA
   Line connectors on the magnet-operated switch
   Starter motor does not turn
   Starter motor turns too slowly and does not crank the engine
   Removing and installing the starter motor
   Three-phase alternator -assembly overview
   Checking three-phase alternator and voltage regulator
   Removing and installing three-phase alternator
   Removing and installing the voltage regulator
   Removing and installing the ribbed V-belt pulley
   Check function of the free-wheel clutch
   Preheating system
   Preheating system
   Removing, installing and checking sheathed-element heater plugs
   Linde engine protection system (LEPS)
   Linde Engine Protection System (LEPS)
2. Gearbox
   Technical data for drive unit
   Drive unit
   Travel drive - introduction
   Working hydraulics pump MPR 50
   MPR50 — general
   MPR50 — overview
   Hydraulic adjustment with electronic activation
   Auxiliary brake valve
   Start of regulation of the pump
   Bypass valve
   Output unit
   Removing and installing the HPV variable displacement pump coupling flange
   Hydraulic truck diagnostics
   Overview and explanations about diagnostics
   HPV 1 05-02 pressures - measurements
   Checking the hydrostatic traction drive
   Sealing the HMF 135 wheel motor
   Wheel motor HMF 1 35-2, central brake — sealing
   Gearbox GR6H- changing the shaft seal
3. Chassis, bodywork and fittings
   Axle suspension
   Instructions for working with gas springs
   Driver's seat
   Driver's seat — Isringhausen
   Driver's seat controls
4. Chassis frame
   Steering system
   Steering system - functional description
   Linde Curve Assistant (LCA)
   Steering axle 1 603
   Adjusting the steering stop
   Steering axle — removal and installation
   Repairs to the steering axle
   Replacingthe steering cylinder seals
   Functional description
   Devices/tools for manual assembly
   Process for manual removal
   Removingthe 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
   Assembling the 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
   Stop screws
   Joystick variants
   Joystick interlock
   Functional description
6. Electrics/electronics
   Safety information for the electrical system
   Cleaning the electrical system
   EMC-Electromagnetic compatibility
   CAN bus
   CAN bus connection assembly X15
   LIN bus
   Electrostatic charging
   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 console to vehicle adaptor connectors
   Arrangement of relays and fuses for basic equipment and special equipment
   Display unit
   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 the control valve
   Operating hydraulics circuit diagram
   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
   Lift mast - identification
   Lift mast installation and removal
   A dusting the lift chain (all series)
   Setting the roller play
   Roller play - fork carriage in the inner mast,family 1 89
   Roller play - middle and inside mast profile, Series 1 89
   Outer Mast Roller Clearance, Type 189
   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 transmitter
   Tilt cylinders
   Hose reservoir - removal, exchanging hose, sealing, fitting
   Line break safety device in the lift mast (butterfly valve)
9. Special equipment, accessories
   Working spotlight position
10. Circuit diagrams
   1 . 1 Hydraulic circuit diagram
   Traction, working and steering hydraulics
   1 .2 Wiring diagram
   Basic equipment for diesel — Sheet 01
   Basic equipment for diesel — Sheet 02
   Basic equipment for diesel — Sheet 03
   Basic equipment for diesel — Sheet 04 (particle filter)
   Basic equipment for LPG, sheet 01
   Basic equipment for LPG, sheet 02
   Basic equipment for LPG, sheet 03
   Basic equipment for LPG, sheet 04
   Special equipment sheet 01 - Working spotlights, interior/clipboard lighting .
   Special equipment sheet 02 — Windscreen wipers, seat heater, seat with air suspension
   Special equipment sheet 03 — Heating system, air conditioning, flashing beacon/rotating beacon/BlueSpot, reversing signal, warning sound when reversing
   Special equipment sheet 04 — Hazard warning system for reverse travel, truck deactivation, mast positioning
   Special equipment sheet 05
   - Lighting, turn indicator and hazard warning system, brake light, radio
   Special equipment sheet 06 -Higher lighting, 12V socket
   Special equipment sheet 07 -Truck data management, camera system
   Special equipment sheet 08 — Battery main switch with display unit power supply, rear centre brake/tail light, hydraulic oil microfilter indicator
   Special equipment sheet 09 — Single lever for lifting/lowering, tilting, single auxiliary hydraulics and double auxiliary hydraulics, sweeper function
   Special equipment sheet 1 0 — Third auxiliary hydraulics with third joystick
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