Linde H40D, H40T, H45D, H45T, H50D, H50T Forklift Truck 394 Series Service Training Workshop Manual

Original Illustrated Factory Service Training (Workshop) Manual for Linde Diesel and LPG Forklift Trucks 394 Series Models H40D, H45D, H50D, H40T, H45T, H50T

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