Linde LPG and Diesel Forklift Truck H-Series Type 396-02: H50, H60, H70, H80 Service Training (Workshop) Manual

Linde LPG and Diesel Forklift Truck H-Series Type 396-02: H50, H60, H70, H80 Service Training (Workshop) Manual

Original Illustrated Factory Service Training (Workshop) Manual for Linde LPG and Diesel Forklift Truck H-Series Type 396-02.

Original factory manuals for Linde Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck

All files are printable

Covered models:

Format: ZIP, included files:
Service Training manual, PDF, 481 Pages
Air Conditioners Service Training, PDF, 92 Pages
DEUTZ Engine TCD 4.1 L4 Workshop manual, PDF, 298 Pages
Circuit Diagrams for LPG Trucks, PDF, 30 Pages
Circuit Diagrams for Diesel Trucks, PDF, 30 Pages

Language: English


0. Product information
Truck from series 396-02
The 396-02 truck
LTC basic structure
Software update for Canbox
Starting the diagnosis program
Guided diagnosis
Load controller
Log files
Code lists
Error code display
1. Engine
LPG engine
Description of the drive
Engine 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
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
Basic settings for the LPG system
Revolution control
Shut-off valve- LPG
LPG truck with a lambda control system
396-series 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
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
Diesel engine
DeutzTCD4.1 L4
Technical engine data, H50/60/70/80 D, H80-900 D, H80-1100 D
Functional overviews
Engine components
Bosch EDC electronic engine management
Repairing the fuel supply
Changing the V-ribbed belt
Rail pressure sensor- removal and installation
Repairing the engine
Checking the engine oil level
Changing the engine oil
Changing the engine oil filter
Draining water from the fuel pre-filter
Changing the fuel filter
Changing the fuel pre-filter
Bleeding the fuel system
Cleaning the fuel tank ventilation hose
Checking the coolant level
Changing the coolant
Adjusting the valve clearance
Cylinder head – checking the compression pressure
Checking the compression pressure
Special tool -Deutz engine TCD 4.1 L4
Diesel particle filter (DPF)
Particle filter- emissions
Particle filter- configuration
Particle filter and oxidation condenser
Particle filter- burner
Particle filter-fuel supply
Particle filter- airsupply
Particle filter- how it works
Particle filter- how it works
Particle filter- circuit diagram, sensors, actuators
Particle filter regeneration
Particle filter- service and maintenance
Particle filter- diagnostics
Changing the diesel particle filter (DPF)
Changing the diesel particle filter (DPF)
2. Gearbox
Description of the gearbox
Technical dates for traction drive
Hydrostatictraction drive
Schematic view of the drive
Explanation of the hydrostatic transmission function
Accelerator settings
Brake shaft on the accelerator
Symmetry of the accelerator- Start of rotation of the drive wheels
Pressure differential Ap/maximum swivel angle of the HPV
Start of rotation of drive wheels
Power limitation
Power limitation (control block N)
Oil motors -circuit and housing flushing
Servo cover adjustment function characteristics
Servo cover adjustment
Adjusting the hydraulic zero position
Reducing the driving speed
Speed reversing block- description
Speed reversing block -setting
Hydraulic braking
Hydraulic braking
Retarder valve function
HMV 1 05 oil motors function
Qmin valve of the oil motors
Exhaust valve 1Y9 (dual pedal) and 1Y8/1Y9 (single pedal)
Circuit diagram for troubleshooting
Overview of measuring points and positions of valves
Special tools required for the measurements
Measuring pressures and wheel speeds
Explanation of troubleshooting
Hydraulic parking brake
Pressure consistency and start of regulation
Checking the hydrostatic drive unit
Hydraulic primary and secondary adjustment – checking and adjustment regulations
HPV 1 05/75 pump unit
Sealing the pump unit
GR80-12 reduction gearbox
Drive wheel unit
Carrying out repairs to multi-disc brake
Repairing the reduction gearbox GR 80-12
3 Chassis, bodywork and fittings
Overhead guard
Overhead guard -torsion support
Instructions for working with gas springs
4. Chassis frame
Steering system
Steering system – functional description
304 series steering axle
Description of function
Removing the steering axle
Installing the steering axle
Repairs to the steering axle
Changing the wheel bearings
Axle stub – removal and installation
Steering cylinder
Steering cylinder- removal and installation
Steering cylinder -changing seals
Adjusting the steering stop
Brake system
Parking brake
Pipe assembly at the multi-disc brake
5. Operating devices
Setting the travel and brake control
Joystick configurations
Joystick variants
Joystick interlock
Functional description
6. Electrics/electronics
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 20 Tricor controller with 154 contacts
Central electrical system
Linde Truck Control (LTC/LHC)
Arrangement of relays and fuses – left step
Arrangement of relays and fuses for basic equipment and special equipment
Arrangement of the console to truck adaptor connectors
Display unit
Testing the electronic controllers and components
LHC testing (truck control unit and lift control)
Checking wiring harness
Testing sensors
Testing the indicator unit
7. Hydraulic system
Functional description of the control valve
Working hydraulic circuit diagram
Functional description
Pressure relief valves
Depressurisation Auxiliary hydraulics 1and 2
Pump / control valve hose layout
Hose layout of control pressure supply
Cleaning work on the Linde control valve – cast valve
Cleaning work on the Linde control valve – multi-layer valve
Tilt cylinder
Tilt cylinder – removing, installing, adjusting
Tilt cylinder – piston rod
Hose pulley
Removing and installing the hose pulley
Releasingthe tension on the hose pulley
Changing the hose line on the 4-way hose reel
Disposal of springs
8. Load lift system
Lift mast
Functional description
Setting the tilt angle sensor
Line break safety device in the triplex mast (throttle valve)
9. Special equipment, accessories
Working spotlight position

10. Circuit diagrams from 07/2012
Hydraulic circuit diagrams
Traction, working and steering hydraulics
Electric circuit diagrams
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
Special equipment sheet 01 Seat heater, seat with air suspension, lighting, direction indicator and hazard warning system, brake light
Special equipment sheet 02 Rearwindow heating, wipers
Special equipment sheet 03 Heating system, 12V socket
Special equipment sheet 04 heating system with air conditioning
Special equipment sheet 05 Stationary regeneration for diesel particle filter, single
lever for lifting/lowering, tilting, single auxiliary hydraulics and double auxiliary hydraulics
Special equipment sheet 06 Higher lighting, working spotlights
Special equipment sheet 07 Truck data management, radio, interior lighting
Special equipment sheet 08 Hazard warning system for reverse travel, truck deactivation, mast positioning
Special equipment sheet 09 Flashing beacon/rotating beacon, reversing signal, LPG volume display for volumetric filling, hydraulic oil microfilter indicator