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

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 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