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

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

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:
H40D
H40T
H45D
H45T
H50D
H50T

Format: ZIP, including:
Service Training Manual, PDF, 606 Pages
Diesel Trucks Circuit Diagrams, PDF, 204 Pages
LPG Trucks Circuit Diagrams, PDF, 225 Pages

Language: English

Contents:
0. Product information
   394 truck series
   Truck 394
   Truck 394 MPR
   Diagnostics
   LHC basic structure
1. Engine
   LPG engine
   Description of the drive
   BMFVR6 technical data
   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
   Cooling
   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
   Functions
   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)
   LPG shut-off valve
   LPG truck with a lambda control system
   Exhaust gases -composition
   Lambda control system
   Leakage test on LPG system
   LPGtank
   Removing and installing the level display and 80% filling stop valve
   The following safety measures must be observed
   Carrying out assembly operations
   Bleeding the LPG tank
   The following safety measures must be observed
   Procedure for bleeding
   BJCdiesel engine
   Description of the drive
   BJC technical data
   Particularities of the 1.9-litre engine
   The electronic engine control unit
   Sensors
   Coolant temperature sending unit 0B1
   Engine speed sensor 0B2
   Actual speed sensor 1B1
   Fuel temperature sending unit 0B3
   Sensor 0B4
   Needle stroke sensor 0B5
   Height sensor
   0B3 control gate valve travel sensor
   Glow plug system
   Pre-heater system
   Glow plugs- engine 0R1
   Fuel supply
   Fuel quantity regulation
   Fuel quantity actuator 0B3
   Fuel shut-offvalve 0Y1
   Injection timing device- replacement of O-ring on cover
   Start of injectionvalve 0Y2
   Start of injection -governing
   Start of injection -dynamic check and adjustment
   Injection nozzle -Two-spring nozzle holder
   Injection nozzles- removal and installation
   One-way restrictor
   Injection system - overview
   Injection system -supply voltage check
   Injection pump - removal and refitting, Exchanging the toothed belt
   Injection pump - removal and installation
   Injection pump - pump and toothed belt adjustment
   Engine block
   Ribbed V-belt- removal and fitting
   Crankshaft oil seal on pulley end -removal and installation
   Crankshaft sealing flange- removal and installation
   Checking the cylinder head
   Cylinder head - removal and fitting
   Cylinder head - compression check
   Valve gear
   Oil pressure and oil pressure switch -check
   Oil sump - removal and installation
   Checking hydraulic bucket tappets
   Camshaft- removal and installation
   Vacuum pump
   Air volumeter 0B6
   Solenoid valve for boost pressure limitation 0Y4
   Charge air system with exhaust turbocharger
   Cooling
   Coolant -draining and filling
   Coolant thermostat- removal and installation
   Water pump -removal and installation
   Coolant pump -Checking for wear
   Engine electrics
   Three-phase alternator
   Replacing the engine control unit/ immobilizer
   Self-diagnostics
   Self-test- introduction
   Self-diagnostics -troubleshooting
   Standardised measured value blocks
   Measured value block 01 -evaluation
   Measured value block 04 -evaluation
   Measured value block 05 -evaluation
   Measured value block 07 -evaluation
   Measured value block 10 -evaluation
   Measured value block 11 -evaluation
   Measured value block 12 -evaluation
   Measured value block 13 -evaluation
   CBJBdiesel engine (pump injection)
   Description of the drive
   CBJB technical data
   Sensors
   Checking the coolant temperature sensor 0B1
   Checking the engine speed sensor 0B2
   Removing and installing the engine speed sensor 0B2
   Actual speed sensor 1B1
   Checking the hall-effect sensor 0B8
   Checking the fuel temperature sensor 0B3
   Checking suction pipe temperature sensor 0B4
   Checking the suction pipe pressure sensor 0B4
   Glow plug system
   Ceramic glow plugs 0R4
   Fuel supply
   Rules for working on the direct fuel injection system
   Checking the tandem pump delivery pressure
   Removing and installing the tandem pump
   Pump injection unit- overview
   Pump/nozzle unit -Checking valves 0Y2
   Removing and installing the pump injection unit
   Changing the O-rings and thermal protection seal on the pump injection unit ..
   Engine block
   Cylinder block -overview
   V-ribbed belt- removal and fitting
   Removing and installing the free-wheel belt pulley
   Toothed belt -removal and fitting, tensioning
   Changing the crankshaft sealing ring on the toothed belt pulley side
   Removing and installing the crankshaft sealing flange
   Cylinder head -overview
   Cylinder head cover- removal and installation
   Removing and installing the cylinder head
   Cylinder head -checking the compression pressure
   Valve train - overview
   Valve stem covers- removal and installation
   Valves
   Checking the camshaft for axial play
   Removing and installing the camshaft sealing ring
   Removing and installing the camshaft
   Oil filter and oil cooler -overview
   Removing and installing the oil sump
   Suction pipe -overview
   Checking the suction pipe flap switchover
   Suction pipe flap -Checking switch valve 0Y16
   Vacuum hoses -connection diagram
   Air volumeter 0B6
   Checking the charge pressure limitation solenoid valve 0Y4
   Exhaust gas recirculation
   Exhaust gas recirculation -overview
   Checking exhaust gas recirculation
   Checking the exhaust gas recirculation valve 0Y3
   Checking the mechanical exhaust gas recirculation valve
   Cooling
   Checking the cooling system for leaks
   Draining and filling coolant
   Removing and installing the coolant thermostat
   Removing and installing the coolant pump
   Self-diagnostics
   Self-diagnostics - introduction
   Error code table
   Standardised measured value blocks
   Measured value block 01 -fuel injection quantity
   Measured value block 03 -exhaust gas recirculation
   Measured value block 04 -pump/nozzle unit activation
   Measured value block 07 -temperatures
   Measured value block 10 -air variables
   Measured value block 11 -charge pressure control
   Measured value block 12 - heating status
   Measured value block 13 - idling smooth running control
   Measured value block 18— valve status of the pump/nozzle unit
   Measured value block 23 - BIP deviation (solenoid valve switching times)
2. Gearbox
   Description
   Technical data for traction drive
   System overview up to 06/2011
   MPR system overview from 07/2011
   Traction drive
   Travel drive - introduction
   The triplex pump
   Working hydraulics pump MPR 50
   MPR50 — general
   MPR50 — overview
   Hydraulic adjustment with electronic activation
   Auxiliary brake valves
   Auxiliary brake valve from 1 0/2006
   Start of regulation of the pump
   Bypass valve
   Output unit
   Hydraulic fan drive
   Removing and installing the HPV variable displacement pump coupling flange
   Hydraulic diagnostics on the truck
   Overview and explanations about diagnostics
   HPV 105-02 pressures -measurements
   Checking the hydrostatic traction drive
   Sealing the HMF 1 35 wheel motor
   Wheel motor HMF 135-2, central brake — sealing
   Gearbox GR6H - changing the shaft seal
3. Chassis, bodywork and fittings
   Chassis
   Axle suspension
   Instructions for working with gas springs
   Driver's seat
   Driver's seat — Isringhausen
   Driver's seat controls
   Service instructions
4. Chassis frame
   Steering system
   Steering system - functional description
   Brake system
   Brake release valve
   Brake cable pulls - Adjusting
   Checking the brake system
5. Operating devices
   Accelerator
   Function
   Replacement
   Stop screws
   Joysticks
   Joysticks up to 06/2011
   Joystick variants
   Functional description
   Replacement
   Joysticks from 07/2011
   Joystick configurations
   Joystick variants
   Joystick interlock
   Functional description
   Exchange
6. Electrics / Electronics
   General
   Safety instructions for electrical equipment
   EMC- Electromagnetic compatibility
   CAN bus
   CAN bus connection assembly X15
   Electrostatic charging
   Identifying components in electrical circuit diagrams
   Pin assignment for the LHC 10 controller with 121 contacts
   Pin assignment for the LHC 20 Tricor controller with 154 contacts
   MPR plug positions
   Central electrical system
   Linde Truck Control (LTC/LHC)
   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 up to 06/2010
   Display unit until 06/2010
   Display unit from 07/2010
   Display unit
   Checks
   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
   Function characteristics of control valve
   Overview
   Operating hydraulics circuit diagram
   Function characteristics
   Pressure relief valve
   DepressurisationAuxiliary 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 189
   Outer Mast Roller Clearance, Type 1 89
   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
9. Special equipment, accessories
   Lighting
   Working spotlight position
   Annex
10. Circuit diagrams
   Hydraulic circuit diagrams
   Traction, working and steering hydraulics
   Accumulator
   Electronic circuit diagrams
   Basic equipment for LPG — Sheet 01
   Basic equipment for LPG — sheet 02
   Basic equipment for LPG — sheet 03
   Basic equipment for diesel sheet 1
   Basic equipment diesel sheet 2
   Basic equipment for diesel sheet 3
   Basic equipment for diesel with pump injection engine — Sheet 01
   Basic equipment for diesel with pump injection engine — sheet 02
   Basic equipment for diesel with pump injection engine — sheet 03
   Special equipment sheet 01 — working spotlight
   Special equipment sheet 02 — Windscreen wipers, seat heater, seat with air suspension
   Special equipment sheet 03 — Heating system, air conditioning, flashing/rotating beacon, reversing signal, interior lighting/clipboard lighting
   Special equipment sheet 04 — hazard warning system for reverse travel, truck deact vation, mast positioning
   Special equipment sheet 05 — particle filter, radio
   Special equipment sheet 06 — Higher lighting, 12Vsocket, diesel filter water trap warning
   Special equipment sheet 07 -Truck data management, LPG volume display ....
   Special equipment sheet 08 - LPG volume display for volumetric filling with shut-off valve, changing particle filter, camera system
   Special equipment sheet 09 — battery main switch with display unit power supply, rear centre brake/tail light
   Special equipment sheet 10 — third auxiliary hydraulics with third joystick
   Special equipment sheet 11— Lighting, direction indicator and hazard warning system, brake light
   Special equipment sheet 12 — single lever for lifting/lowering, tilting, single auxiliary hydraulics and double auxiliary hydraulics
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