This is the COMPLETE Service Training Manual for the Linde Electric Reach Truck 115-02 AC Series: R14S, R14HDS, R16S, R16HDS, R16NS, R20S, R20NS. This manual provides detailed service information, step-by-step repair instruction and maintenance specifications. it has been prepared as an aid to improve the quality of repairs by giving the operator an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. YOU CAN DO THE REPAIRS YOURSELF AND SAVE MONEY $$$
Covered Models:
R14S
R14HDS
R16S
R16HDS
R16NS
R20S
R20NS
Service Training Manual Contains:
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1 Traction motor and brake
1.1 Traction motor
1.1.2 Traction motor removal
1.1.2.1 Traction motor refitting
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 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
3.1 Chassis
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 AC control – operating principle
6.1.1 Speed & direction control
6.1.2 Electro Magnetic Compatability (EMC)
6.2 Electrical components (under the top cover)
6.2.1 Electrical connections (drive unit)
6.2.2 Electrical components (pump motor & hydraulic tank area)
6.3 Fuses – control current
6.3.1 Fuses – ancillary circuits
6.3.2 Fuse duties and positions – ancillary circuits
6.4 Emergency isolator – S2
6.4.1 24 V power supply – U1
6.4.2 Electronic control module – A2
6.4.2.1 Connector X13 pin duties
6.4.3 Reservoir circuit capacitors, switching on and charging
6.4.3.1 Reservoir circuit capacitors, discharging
6.4.4 Main contactor – K1
6.5 Traction control (LDC)
6.5.1 Traction power module (LAC traction) – 1A1
6.5.1.1 Connector 1X17 pin duties
6.5.2 Traction enable signals
6.5.3 Direction of travel switch – 1S13
6.5.4 Parking brake switch – 1S4
6.5.5 Accelerator – 1A4
6.5.5.1 Accelerator electromechanical characteristics
6.5.5.2 Accelerator calibration and setting up
6.5.6 Traction motor speed sensor – 1B1
6.5.7 Brake pedal switch – 1S5
6.5.7.1 Regenerative electrical braking
6.5.8 Traction power module temperature monitoring
6.5.8.1 Traction motor temperature monitoring – 1B4
6.5.8.2 Traction system cooling fans – 9M1, 9M2
6.5.9 Switch controlled speed reduction & height sensor 8.5m – 2S13
6.5.10 Horn operation – 4H1
6.5.11 Battery lock sensor – B1
6.6 Load control (LLC)
6.6.1 Hydraulic power module (LAC lift) – 2A1
6.6.1.1 Connector 2X37 pin duties
6.6.2 Hydraulic enable signal
6.6.2.1 Reach carriage to chassis cable connector pin duties – 2X20
6.6.2.2 Hydraulic valve connector pin duties – 2X20
6.6.3 Joystick and valve voltage supply
6.6.4 Joysticks
6.6.5 Valve block electrical connections
6.6.6 Hydraulic pump motor speed sensor – 2B8
6.6.7 Hydraulic power module temperature monitoring
6.6.7.1 Hydraulic pump motor temperature monitoring – 2B4
6.6.7.2 Hydraulic system cooling fan – 9M4
6.6.8 Lock valve – 2Y31
6.6.9 Lift and lower joystick operation – 2B1
6.6.9.1 Lift
6.6.9.2 Lower
6.6.10 Reach joystick operation – 2B1
6.6.11 Tilt and sideshift joystick operation – 2B2
6.6.12 Auxiliary 1 and 2 (5th & 6th) joystick operation – 2B3
6.6.13 Lift stop sensor – 2B20
6.6.14 Reach slowdowns
6.6.14.1 Reach position value
6.6.14.2 Reach limits
6.6.14.3 Reach sensor mechanical adjustments
6.6.14.4 Reach sensor operation – 2B18 and 2B21
6.7 Steering system (LES)
6.7.1 LES circuit diagram
6.7.2 Steering safety sensors – 3B2, 3B3 and 3B4
6.7.3 Steering wheel unit
6.7.4 Steering wheel torque control
6.8 Operator’s display (LID)
6.8.1 Display indicators
6.8.2 Mode indicators & height commands
6.8.3 Display functions
6.8.3.1 Hour meters
6.8.4 Help prompts
6.9 Circuit diagram
6.10 Connector locations
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
7.7 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
7.10 Tilt and lift cylinder hoses
7.11 Hydraulic circuit
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 (187 mast)
8.14.1 Tilting sideshift unit removal (187 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 (183 and 186)
8.25.2 Mast removal (183 and 186)
8.25.3 Mast refitting (183 and 186)
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
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** Model Specification: Linde Electric Reach Truck 115-02 AC Series: R14S, R14HDS, R16S, R16HDS, R16NS, R20S, R20NS
** Language: English
** Total Pages: 214
** File Format: PDF
** Requirements: Adobe PDF Reader
** Compatible: All Versions of Windows & Mac, Linux OS, Iphone, Ipad, Android etc…
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