Linde H40D, H45D, H50D, H40T, H45T, H50T Forklift Truck 394-02 Ser. Service Training Workshop Manual

Original Illustrated Factory Service Training (Workshop) Manual for Linde Forklift Truck Series 394-02 Models H40, H45, H50

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-02
   H40T-02
   H45D-02
   H45T-02
   H50D-02
   H50T-02

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

Contents:
   0. Product information
    Foreword
    Truck 394-02
    Diagnostics
    LHC basic structure
    Consumables
    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
    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)
    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
    Introduction
    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
    Self-diagnostics
    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
    Cylinderhead
    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
    Valves
    Changing valve stem seals
    Removing and installing the camshaft
    Removing and installing the camshaft sealing ring
    Lubrication
    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
    Cooling
    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
    Charging
    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
    Description
    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
    Chassis
    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
    Accelerator
    Function
    Replacement
    Stop screws
    Joysticks
    Joystick variants
    Joystick interlock
    Functional description
    Exchange
   6. Electrics/electronics
    General
    Safety information for the electrical system
    Cleaning the electrical system
    EMC-Electromagnetic compatibility
    CAN bus
    CAN bus connection assembly X15
    LIN bus
    Electrostatic charging
    Functions
    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
    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
    Functional description of the control valve
    Overview
    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
    Lighting
    Working spotlight position
    Annex
   10. Circuit diagrams
    1 . 1 Hydraulic circuit diagram
    Traction, working and steering hydraulics
    Accumulator
    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