Linde H25D, H30D, H35D, H25T, H30T, H35T Forklift Truck 393 Series Service Training Workshop manual

Original Illustrated Factory Service Training Manual and Schematic Diagrams for Linde Forklift Truck with Diesel and LPG Engine 393 Series, Models H25D, H30D, H35D, H25T, H30T, H35T.

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:
   H25D
   H30D
   H35D
   H25T
   H30T
   H35T

Format: ZIP, included files:
   Service Training Manual: PDF, 528 pages
   Circuit Diagrams LPG Truck, PDF, 209 pages
   Circuit Diagrams Diesel Truck, PDF, 180 pages
   LTC Unit Replacement Manual, PDF, 126 pages

Language: English

Contents:
   0. Product information
    Foreword
    The truck
    Truck operation when using a shovel
    Diagnostics
    LTC basic structure
   1. Engine
    LPG engine
    Description of the drive
    Technical data for VWBEF ....
    Engine block
    Ribbed V-belt - removal and fitting
    Toothed belt- removal and fitting, tensioning
    Cylinder head - removal and fitting
    Compression - check
    Checking hydraulic bucket tappets
    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
    Electronic ignition system up to 08/2005, overview
    Electronic ignition control unit
    Electronic ignition system from 09/2005, overview
    Shut-down due to lack of gas
    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 mixer
    Revolution control (from 12/2007)
    LPG shut-off valve
    LPG system with lambda control system
    Exhaust gases -composition
    Lambda control system
    Checking and adjusting the mixer
    Locations - overview
    Leakage test on LPG system
    LPGtank
    Level display with single replacement cylinders(special equipment)
    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
    BEU diesel engine
    Description of the drive
    BEU 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 metering
    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 charge pressure limitation 0Y4
    Turbocharging system exhaust turbocharger
    Exhaust gas recirculation - removal and installation
    Exhaust gas recirculation -check
    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 03 -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
    CBHAdiesel engine (pump injection)
    Description of the drive
    CBHA 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 injection 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
    Checking the switch valve for suction pipe flap 0Y11
    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 pump injection units
    Measured value block 23 - BIP deviation (solenoid valve switching times)
   2. Drive axle
    Description
    Technical data about traction drive
    System overview
    Drive unit
    Hydraulic remote control with electronic activation- old version
    Hydraulic remote control with electronic activation- Version with round solenoids
    Auxiliary brake valve up to 09/2006
    Auxiliary brake valve from 1 0/2006
    Start of delivery of the pump
    Removing and installing the HPV variable displacement pump coupling flange .
    Bypass valve
    Output unit
    Hydraulic fan drive
    Hydraulic truck diagnostics
    Overview and explanations about diagnostics
    HPV 75 -02 pressures -tests
    Hydrostatic travel drive - check
    Wheel motor HMF 550 R-disassembly
    Wheel motor HMF 550 R-checking the bearing, seals
    Wheel motor HMF 550 R-sealing after inspection
    Wheel motor HMF 550 R - exchanging the bearing
   3. Chassis, bodywork and fittings
    Chassis
    Axle suspension
    Instructions for working with gas springs
    Driver`s seat
    Driver`s seat controls
    Service instructions
   4. Steering, brake and wheels
    Steering system
    Steering system - functional description
    Brake system
    Brake release valve
    Brake cables - adjustment
    Checking the brake system
   6. Electrics / Electronics
    General
    Safety instructions for electrical equipment
    EMC- Electromagnetic compatibility
    Electrostatic charging
    CAN bus
    Central electrical system
    Linde Truck Control (LTC)
    Arrangement of the interface connectors console -truck
    Layout of relays and fuses for standard and optional equipment
    Indicator unit
    Checks
    Testing the LTC (vehicle and lift controller)
    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
    Overview
    Operating hydraulics circuit diagram
    Function characteristics
    Pressure relief valve
    DepressurisationAuxiliary hydraulics 1and 2
    Hose layout pump - control valve
    Hose layout control pressure supply
    Cleaning work on the Linde control valve
   8. Load lift system
    Lift mast
    Lift mast - identification
    Mast - removal and installation (all series)
    Installation of mast type 188
    A dusting the lift chain (all series)
    Setting the roller play
    Roller clearance - fork carrier in the inner mast, type 1 88
    Roller play - centre mast, inner mast profile, family 1 88
    Roller play - outer mast profile, family 1 88
    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 sensor
    Tilt cylinders
    Hose reservoir- removal, exchanging hose, sealing, fitting
   Annex
   10 Circuit diagrams
    Hydraulic circuit diagrams
    Wiring diagrams up to 08/2005
    Wiring diagram (basic equipment for LPG engine), page 1
    Circuit Diagram Standard Equipment LPG Engine, Sh. 2
    Circuit Diagram Standard Equipment, LPG Engine, sheet 3
    Wiring diagrams (LPG)