Illustrated Factory Service Training (Workshop) Manual for Linde Electric Reach Truck Type 115.

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:

R14
R14HD
R16
R16HD
R16N
R20
R20N

Format: PDF, 357 Pages
Language: English

Contents:

1. Traction motor and brake
1.1 Traction motor
1.1 .2 T raction motor removal
1.1.2.1 Traction motor refitting
1.1 .3 T raction motor dismantling
1.1 .4 T raction motor component inspection
1.1 .5 Traction motor armature checks
1.1.6 T raction motor commutator refacing
1.1.7 Traction motor reassembly
1.1 .8 Traction motor - bedding the brushes
1.2 Parking brake adjustment
1.3 Parking brake drum removal
1.4 Parking brake friction plate seal renewal
1.5 Parking brake drum replacement
1.6 Traction motor cooling system
2. Transmission
2.1 Drive wheel removal
2.1.1 Drive wheel refitting
2.2 Gearbox removal
2.2.1 Gearbox refitting
2.3 Gearbox
2.3.1 Steer bearing removal
2.3.1.1 Steer bearing refitting
2.3.2 Gearbox dismantling
2.3.3 Gearbox reassembly
2.3.4 Gearbox tooth bearing check
2.4 Setting the steering stop bolts
3. Chassis and bodywork

3.2 Seat
3.2.1 Seat adjustment
3.2.2 Seat removal
3.3 Floorplate removal
3.3.1 Floorplate refitting
3.4 Battery carrier
3.4.1 Battery carrier removal
3.4.2 Battery carrier lubrication
3.3.3 Battery carrier replacement
3.5 Battery changing (hoist method)
3.6 Battery changing (roll on, roll off)
3.7 Covers and panelling
3.8 Top cover, opening
3.9 Binnacle removal
3.10 Consol removal
3.11 Serial number format
3.11.1 Serial number example
4. Steering and load wheels
4.1 Steering
4.2 Steer motor removal
4.2.1 Steer motor refitting
4.3 Steering encoder removal
4.4 Load wheel
4.4.1 Load wheel removal
4.4.2 Load wheel reftting
5. Controls
5.1 Accelerator and brake pedals
5.1.1 Accelerator unit removal
5.1.2 Accelerator unit refitting
5.2 Hydraulic braking system
5.2.1 Hydraulic brakes - preventative maintenance
5.2.2 Master cylinder removal
5.2.3 Master cylinder refitting
5.3 Brake bleeding
5.4 Load wheel brakes
5.4.1 Load wheel brake cylinders
5.4.2 Load wheel brake cylinder maintenance
5.4.3 Load wheel brake cylinder repair instructions
5.5 Load wheel brake shoes
5.5.1 Load wheel brake shoes maintenance and inspection
5.5.2 Load wheel brake shoe removal
5.5.3 Load wheel brake shoe - fitting
5.6 Load wheel brake drums
5.7 Footbrake assembly
5.7.1 Footbrake shoe removal
5.7.2 Footbrake shoe adjustment
5.8 Hydraulic controls
5.8.1 Hydraulic control lever removal
5.8.2 Hydraulic control lever refitting
6. Electrical control
6.1 Control system for LDC traction drive unit
6.1.1 Operating principle
6.1.1.1 Speed & direction control
6.1.1.2 Field control
6.1.1.3 Armature control
6.1.2 Electrical components (under the top cover)
6.1.2.1 Electrical components (motor compartment)
6.1.2.2 Electrical components (pump motor & hydraulic tank area)
6.1.3 Fuses - control current
6.1.3.1 Fuses - ancillary circuits
6.1.3.2 Fuse duties and positions - ancillary circuits
6.1.4 Power unit connections
6.1.4.1 1X13 Pin connections
6.1 .5 Intermediate circuit capacitors, switching on and charging
6.1.5.1 Intermediate circuit capacitors, discharging
6.1.5.2 K1 Main contactor
6.1.5.3 Forward direction of travel
6.1.5.4 Reverse direction of travel
6.1.5.5 Freewheel circuit
6.1.5.6 Regenerative electrical braking (useful current braking)
6.1.5.7 Electrical braking - Selecting opposite direction of travel.
6.1.6 Control circuit
6.1.6.1 1X1 1, 29 way connector
6.1.6.2 1X12, 29 way connector
6.1.7 Program memory replacement
6.1.8 Emergency off microswitch
6.1.9 Traction enable signal
6.1.10 Parking brake switch 1S4
6.1.11 Brake pedal switch 1S5
6.1.12 Direction of travel switch (1S13), single pedal operation
6.1.13 Power unit temperature monitoring
6.1.13.1 Traction & hydraulic motors temperature signal
6.1.14 Brush wear switch
6.1.15 Cooling system
6.1.16 Accelerator
6.1.16.1 Accelerator electromechanical characteristics
6.1.16.2 Accelerator calibration and setting up
6.1.17 Direction of travel switch (1S13), single pedal operation
6.1.18 Traction motor speed control
6.1.19 Power supply
6.1.20 Switch controlled speed reduction & Height sensor 8.5m
6.1.21 Horn operation
6.1.22 Battery lock sensor
6.2 Load control (LLC)
6.2.1 LLC Safety features
6.2.2 LLC Fault detection
6.2.3 Pump control
6.2.4 Valve control
6.2.5 Valve block
6.2.6 LLC Control
6.2.6.1 Control circuit
6.2.6.2 2X1 Pin designations
6.2.7 Hydraulic circuit MOSFET on
6.2.7.1 Hydraulic circuit MOSFET off (freewheel circuit)
6.2.7.2 Hydraulic electrical circuit
6.2.8 Hydraulic enable signal
6.2.8.1 Hydraulic release signal
6.2.9 Hydraulic power supply
6.2.10 Hydraulic control circuit
6.2.10.1 LLC Voltage supply
6.2.11 Joysticks
6.2.1 1.1 Single axis lever bracket and connector positions
6.2.11.2 Dual axis lever bracket and connector positions
6.2.11.3 Joystick
6.2.12 Joystick operation lift / lower
6.2.12.1 Lift / lower operation
6.2.12.2 Lift
6.2.12.3 Lower
6.2.12.4 Joystick operation reach out/reach back
6.2.12.5 Joystick operation tilt / sideshift
6.2.12.6 Joystick operation for auxiliary 1 and 2 functions
6.2.12.7 UPA Joystick operation for clamp rotate
6.2.13 Reach slowdowns
6.2.13.1 Reach position value
6.2.13.2 Reach limits
6.2.13.3 Reach mechanical adjustments
6.2.13.4 Reach sensor operation
6.2.14 Hydraulic speed sensor 2B8
6.2.14.1 Hydraulic speed sensor function test
6.2.14.2 Hydraulic speed sensor output signal.
6.2.14.3 Hydraulic speed sensor setting 2B8
6.2.15 Lift stop sensor
6.2.16 Lock valve operation
6.3 Steering system (LES)
6.3.1 LES Circuit diagram
6.3.2 Steering safety sensors
6.3.3 Steering wheel unit
6.3.4 Steering force feedback
6.4 Drivers display (LID)
6.4.1 Display indicators
6.4.2 Mode indicators & height commands
6.4.3 Display functions
6.4.3.1 Hour meters
6.4.4 Help prompts
6.4.5 Fan control
6.5 Diagnostic concept
6.5.1 Help files
6.5.2 Truck Onboard Diagnostics (TOD)
6.5.3 LDC diagnostic windows
6.5.3.1 LDC fault codes
6.5.4 LLC Diagnostic windows
6.5.4.1 LLC fault codes
6.5.5 LID Diagnostic windows
6.5.5.1 LID fault codes
6.5.6 LES Diagnostic windows
6.5.6.1 LES Fault Codes
7. Hydraulic system
7.1 Hydraulic overview
7.2 Hydraulic control valve connections
7.3 Hydraulic control block removal
7.3.1 Hydraulic control valve re-fitting
7.4 Hydraulic unit and tank
7.4.1 Hydraulic tank filter renewal
7.5 Hydraulic fluid changing
7.6 Hydraulic pump and motor removal
7.6.1 Hydraulic pump and motor re-fitting
7.6.2 Hydraulic pump motor dismantling
7.6.3 Hydraulic motor component inspection
7.6.4 Hydraulic motor armature checks
7.6.5 Hydraulic motor commutator refacing
7.6.6 Hydraulic motor re-assembly
7.6.7 Hydraulic motor brush bedding
7.7 Hydraulic pump
7.7.1 Hydraulic pump - introduction
7.7.2 Hydraulic pump routine maintenance
7.7.3 Hydraulic pump direction of rotation
7.8 Reach cylinder removal
7.9 Reach cylinder re-fitting
7.9.1 Reach cylinder
7.9.2 Reach cylinder dismantling
7.9.3 Reach cylinder reassembly
7.10 Tilt and lift cylinder hoses
8. Mast unit and attachments
8.1 Introduction
8.2 Forks removal
8.2.1 Forks refitting
8.2.2 Forks inspection
8.2.3 Fork latches
8.3 Mast unit removal
8.4 Mast unit refitting
8.5 Mast unit dismantling
8.5.1 Mast unit reassembly
8.6 Mast roller sizing
8.6.1 Mast roller shimming
8.7 Mast rubbing pads
8.8 Primary lift jack removal
8.8.1 Primary lift jack replacement
8.9 Secondary lift jack removal
8.9.1 Secondary lift jack refitting
8.10 Primary and secondary lift jack dismantling
8.10.1 Primary and secondary lift jack reassembly
8.11 Lift jack bleeding
8.12 Chains
8.12.1 Chain inspection
8.12.2 Chain service life
8.12.3 Chain replacement and shortening
8.13 Chain adjustment
8.13.1 Chain associated equipment check
8.13.2 Mast chain adjustment
8.13.3 Carriage chain adjustment
8.14 Tilting sideshift assembly (1 87 mast)
8.14.1 Tilting sideshift unit removal (1 87 mast)
8.14.2 Tilting sideshift unit refitting (187 mast)
8.14.3 Tilting sideshift unit dismantling 187 mast
8.14.4 Tilting sideshift reassembly 187 mast
8.15 Tilting sideshift assembly (184 mast)
8.15.1 Tilting sideshift unit removal (184 mast)
8.15.2 Tilting sideshift unit-replacement (184 mast)
8.15.3 Tilting sideshift unit dismantling (184 mast)
8.15.4 Tilting sideshift reassembly (184 mast)
8.16 Tilt jack dismantling
8.16.1 Tilt jack reassembly
8.17 Sideshift jack dismantling
8.17.1 Sideshift jack reassembly
8.18 Load backrest
8.19 Mast serial number
8.19.1 Mast serial number format
8.19.2 Mast serial number example
8.20 Mast hydraulic hoses
8.20.1 Hose replacement
8.20.2 Mast hoses removal
8.20.3 Mast hoses refitting
8.21 Reach frame
8.22 Reach frame adjustment
8.23 Reach side rollers adjustment
8.24 Reach frame roller lubrication
8.25 Mast unit optional versions types 183 and 186
8.25.1 Reach carriage rollers (1 83 and 186)
8.25.2 Mast removal (1 83 and 186)
8.25.3 Mast refitting (183 and 186)
9. Options and accessories
9.1 Cold store cabin
9.1.1 Cabin interior temperature control.
9.1.1.1 Cabin temperature setting/configuration
9.1.2 Cabin speaker volume control
9.1.3 Cabin glass heater timer
9.1.3.1 Cabin glass heater timer setting/configuration
9.1.4 Cabin heater unit
9.1.5 Cabin interior lights
9.1.6 Cabin exterior lighting
9.1.7 Cabin loudspeakers and microphone
9.1.8 Cabin control module 4A1
9.1 .8.1 Cabin control module pin duties
9.1.9 Cabin fuses
9.1 .9.1 Cabin fuse duties and positions
9.2 Height preselection (LPS) and lift height indicator (LHI)
9.2.1 LPS System overview
9.2.2 LPS Parameter windows
9.2.3 LPS - Setting the reference height
9.2.4 LPS - Configuring
9.2.5 LPS - Programming shelf levels using laptop computer
9.2.6 LPS - Deleting shelf levels
9.2.7 LPS - Setting the stack - destack distance
9.2.8 LPS - Adjusting operational characteristics
9.2.9 LPS Operation
9.2.9.1 LPS shelf selection (destack)
9.2.9.2 LPS shelf selection (stack)
9.2.9.3 LPS - cancel shelf selection / operation
9.2.9.4 LPS - view an a zone
9.2.9.5 LPS - selecting a zone
9.3 Closed circuit television
9.3.1 Closed circuit television - circuit diagram
9.4 Lighting
9.4.1 Lighting circuit
10 Miscelaneous
10.1 AMP-SAAB Connectors
10.2 Standard torques
10.3 Non standard torques
10.4 Special tools, sealants and compounds
10.5 Recommend lubricants