This is the COMPLETE Service Training Manual for the Lansing Linde Electric Reach Truck Type 113-02: R14, R16, R16N, R20, R20N. 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 $$$
Service Training Manual Contains:
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2.1 INTRODUCTlON
2.1.1 TRACTION MOTOR AND DRIVE UNIT BRAKE
2.1.1.1 TRACTION MOTOR REMOVAL
2.1.1.2 TRACTION MOTOR – DISMANTLING
2.1.1.3 COMPONENT INSPECTION
2.1.1.4 ARMATURE CHECKS
2.1.1.5 COMMUTATOR REFACING
2.1.1.6 TRACTION MOTOR RE-ASSEMBLY
2.1.1.7 SETTING THE BRUSH GEAR TO NEUTRAL
2.1.1.8 BEDDING OF MOTOR BRUSHES
2.1.2 COOLING FAN – TRACTION MOTOR
2.1.3 THE DRIVE UNIT BRAKE ASSEMBLY
2.1.4 DRIVE UNIT BRAKE ADJUSTMENT
2.1.4.1 BRAKE LEVER REMOVAL
2.1.4.2 BRAKE LEVER REFITTING
2.1.4.3 SETTING THE BRAKE PADS
2.1.5 BRAKE DRUM REMOVAL
2.1.5.1 BRAKE DRUM REFITTING
2.2 TRANSMISSION, DRIVE WHEEL AND TYRE
2.2.1 REMOVING THE GEARBOX
2.2.1.2 REPLACING THE GEARBOX
2.2.1.3 THE GEARBOX
2.2.1.4 DISMANTLING THE GEARBOX
2.2.1.5 GEARBOX ASSEMBLY
2.2.1.6 TOOTH BEARING CHECK
2.2.2 DRIVE WHEEL REMOVAL
2.2.2.1 DRIVE WHEEL RE-FITTING
2.3 CHASSIS, BODYWORK AND FITTINGS
2.3.1 CHASSIS
2.3.2 OVERHEAD GUARD
2.3.2.1 OVERHEAD GUARD REMOVAL
2.3.2.2 OVERHEAD GUARD – REPLACEMENT
2.3.3 DRIVER’S SEAT
2.3.4 BATTERY CARRIER
2.3.4.1 BATTERY CARRIER REMOVAL
2.3.4.2 BATTERY CARRIER LUBRICATION
2.3.4.3 BATTERY CARRIER REPLACEMENT
2.3.5 BATTERY CHANGING (HOIST METHOD)
2.3.5.1 BATTERY CHANGING (ROLL ON, ROLL OFF)
2.3.6 COVERS, COWLINGS AND PANELS
2.3.6 TRUCK SERIAL NUMBER
2.3.6.1 TRUCK SERIAL NUMBER POSITION
2.3.6.2 TRUCK SERIAL NUMBER FORMAT – PRIOR TO JANUARY 1999
2.3.6.3 TRUCK SERIAL NUMBER EXAMPLE – PRIOR TO JANUARY 1999
2.3.6.4 TRUCK SERIAL NUMBER FORMAT – AFTER JANUARY 1999
2.3.6.5 TRUCK SERIAL NUMBER EXAMPLE – AFTER TO JANUARY 1999
2.4 HYDROSTATIC POWER STEERING
2.4.1 POWER STEERING HYDRAULIC PIPING CIRCUIT
2.4.3 POWER STEERING HYDRAULIC HOSE CONNECTION TORQUES
2.4.4 POWER STEERING UNIT
2.4.4.1 MAINTENANCE
2.4.4.2 STEERING UNIT
2.4.4.2.1 PRESSURE RELIEF VALVE
2.4.4.2.2 SHOCK VALVES
2.4.4.2.3 SUCTION VALVES
2.4.5 STEERING CONTROL VALVE
2.4.5.1 STEERING CONTROL VALVE REMOVAL
2.4.5.2 STEER CONTROL VALVE REFITTING
2.4.6 STEER MOTOR REMOVAL
2.4.6.1 STEER MOTOR REFITTING
2.4.6.2 STEER MOTOR
2.4.7 STEERING CHAIN ADJUSTMENT
2.4.8 STEERING INDICATOR GEAR
2.4.8.1 STEERING INDICATOR GEAR REMOVAL.
2.4.8.2 STEERING INDICATOR GEAR REFITTING
2.4.8.3 SETTING THE STEERING INDICATOR
2.4.9 LOAD WHEEL REMOVAL
2.4.9.1 LOAD WHEEL REPLACEMENT
2.5 CONTROLS
2.5.1 ACCELERATOR AND BRAKE PEDALS
2.5.2 REMOVING THE FLOORPLATE
2.5.2.1 REFITTING THE FLOORPLATE
2.5.3 THE ACCELERATOR UNIT
2.5.3.1 ACCELERATOR UNIT REMOVAL
2.5.3.2 ACCELERATOR UNIT REFITTING
2.5.4 THE HYDRAULIC BRAKING SYSTEM
2.5.4.1 PREVENTIVE MAINTENANCE – HYDRAULIC BRAKES
2.5.4.2 MASTER CYLINDER REMOVAL
2.5.4.3 MASTER CYLINDER REFITTING
2.5.4.4 MASTER CYLINDER
2.5.4.5 MAINTENANCE NOTES – MASTER CYLINDER
2.5.4.6 FOOTBRAKE ADJUSTMENT
2.5.5 BLEEDING THE BRAKES
2.5.6 THE LOAD WHEEL BRAKES
2.5.6.1 WHEEL CYLINDERS
2.5.6.2 MAINTENANCE
2.5.6.3 REPAIR INSTRUCTIONS
2.5.6.4 BRAKE SHOES (LOAD WHEELS)
2.5.6.5 MAINTENANCE AND INSPECTION
2.4.6.6 BRAKE SHOE REMOVAL
2.5.6.7 BRAKE SHOE – FITTING
2.5.6.8 BRAKE DRUMS
2.5.7 HANDBRAKE AND CABLE
2.5.7.1 HANDBRAKE CABLE REMOVAL
2.5.7.2 HANDBRAKE CABLE REFITTING
2.5.8 HYDRAULIC CONTROLS
2.5.8.1 HYDRAULIC CONTROL LEVER REMOVAL
2.5.8.2 HYDRAULIC CONTROL LEVER REFITTING
2.6 ELECTRICAL SYSTEM
2.6.1 INTRODUCTION
2.6.2 POWER CIRCUITS
2.6.3 PRINCIPLE OF THE FIELD EFFECT TRANSISTOR
2.6.3.1 CONTROL OF FIELD-EFFECT TRANSISTORS
2.6.3.2 TRANSISTOR MODULE TERMINALS
2.6.3.3 INSTALLATION OF THE TRANSISTOR MODULES
2.6.4 COMPACT POWER MODULES
2.6.4.1 TRACTION POWER MODULE
2.6.4.2 HYDRAULIC POWER MODULE
2.6.4.3 POWER MODULE TESTS
2.6.4.3.1 TEST CONDITIONS
2.6.4.3.2 TESTING IF POWER MODULE IS OFF
2.6.4.3.3 TESTING IF THE POWER MODULE IS ON
2.6.4.3.4 TESTING THE PROTECTIVE DIODE IN THE POWER MODULE
2.6.4.3.5 TESTING THE FREEWHEEL AND BRAKE DIODES IN THE POWER MODULE
2.6.4.3.6 TESTING THE REGENERATIVE CURRENT DIODE IN THE POWER MODULE
2.6.4.4 INSTALLATION OF THE TRANSISTOR MODULES
2.6.5 TRACTION CIRCUIT
2.6.5.1 TRACTION CIRCUIT – FORWARD DIRECTION
2.6.5.2 TRACTION CIRCUIT – REVERSE DIRECTION
2.6.5.3 TRACTION CIRCUIT – FREEWHEEL
2.6.5.4 TRACTION CIRCUIT – REGENERATIVE BRAKING (STAGE 1)
2.6.5.5 TRACTION CIRCUIT – REGENERATIVE BRAKING (STAGE 2)
2.6.6 CONTROL UNIT LAYOUT
2.6.7 DIRECTION CONTACTOR
2.6.7.1 DIRECTION CONTACTOR – TIP REPLACEMENT
2.6.8 REGEN CONTACTOR
2.6.8.1 REGEN CONTACTOR – TIP REPLACEMENT
2.6.9 POWER SUPPLY (TRACTION)
2.6.10 TRACTION ENABLE
2.6.11 ACCELERATOR OPERATION
2.6.11.1 ACCELERATOR UNIT
2.6.12 CURRENT SENSOR
2.6.13 DIRECTION SELECTION
2.6.14 REGENERATIVE BRAKING
2.6.15 HANDBRAKE SWITCH 1S4
2.6.16 LEFT FOOT SWITCH 1S11
2.6.17 TRACTION MOTOR TEMPERATURE SENSORS 1B11 AND 1B12
2.6.18 HEIGHT SENSOR 2S13
2.6.19 HORN OPERATION
2.6.20 COOLING FANS
2.6.21 ELECTRONIC TRACTION CONTROL UNIT
2.6.21.1 OPTIONAL OUTPUT
2.6.21.2 TRACTION CONTROL MODULE CONNECTOR PIN DESIGNATIONS
2.6.22 HYDRAULIC CONTROL SYSTEM
2.6.22.1 SAFETY FEATURES
2.6.22.2 FAULT DETECTION
2.6.22.3 PUMP CONTROL
2.6.22.4 VALVE CONTROL
2.6.23 HYDRAULIC CIRCUIT MOSFET ON
2.6.23.1 HYDRAULIC CIRCUIT MOSFET OFF
2.6.24 POWER MODULE FOR LIFT CONTROL
2.6.25 ELECTRONIC HYDRAULIC CONTROL UNIT
2.6.25.1 HYDRAULIC CONTROL MODULE CONNECTOR PIN DESIGNATIONS
2.6.26 HYDRAULIC ENABLE
2.6.27 LIFT/LOWER OPERATION
2.6.28 REACH OUT/REACH BACK OPERATION
2.6.29 TILT/SIDESHIFT
2.6.30 5TH AND 6TH HYDRAULICS (IF FITTED)
2.6.31 LIFT SLOW/STOP SENSOR
2.6.32 HYDRAULIC PUMP MOTOR TEMPERATURE SENSOR 2B11
2.6.33 HYDRAULIC PUMP MOTOR SPEED SENSOR 2B8
2.6.34 INTERLOCKS
2.6.35 POWER STEERING CONTROL
2.6.35.1 POWER STEERING MODULE CONNECTOR PIN IDENTIFICATION
2.6.35.2 HYDRAULIC POWER STEERING
2.6.36 CURTIS 804 COMBINED BATTERY DISCHARGE INDICATOR, HOUR METER, BRUSH WEAR, BRAKE FLUID LEVEL AND MOTOR OVER-TEMPERATURE INDICATOR
2.6.36.1 BATTERY DISCHARGE INDICATOR AND HOUR METER FAULT FINDING
2.6.36.2 FAULT ANALYSIS
2.6.36.2.1 BATTERY DISCHARGE INDICATOR WILL NOT RESET
2.6.36.2.2 BATTERY DISCHARGE INDICATOR ALWAYS RESETS TO FULL CHARGE AFTER A BREAK IN THE BATTERY LINE
2.6.36.2.3 NO DISCHARGE – BATTERY DISCHARGE INDICATOR WILL NOT RUN DOWN
2.6.36.2.4 REDUCED HYDRAULIC PERFORMANCE CIRCUIT WILL NOT WORK
2.6.36.2.5 CONTINUOUSLY REDUCED HYDRAULIC PERFORMANCE CIRCUIT WORKS
2.6.36.2.6 REDUCED HYDRAULIC PERFORMANCE CIRCUIT WORKS EARLY
2.6.36.2.7 LEDS DO NOT LIGHT
2.6.36.3 HOUR METER
2.6.36.3.1 NO DISPLAY
2.6.36.3.2 HOUR GLASS SYMBOL DOES NOT FLASH
2.6.36.3.3 HOUR GLASS SYMBOL FLASHES CONTINUOUSLY
2.6.37 ELECTRICAL MAINTENANCE
2.6.37.1 EARTH FAULTS
2.6.37.2 FITTING AUXILIARY ELECTRICAL EQUIPMENT
2.6.37.3 CABLE RUNS
2.6.37.4 INTERMITTENT FAULTS
2.6.37.5 CABLES
2.6.37.6 CABLES – INSPECTION
2.6.37.7 FAULT ANALYSIS
2.6.38 TRUCK DIAGNOSTICS
2.6.38.1 DIAGNOSIS WITH THE LINDE DIAGNOSIS MODULE
2.6.38.2 LINDE INTERFACE CONVERTER
2.6.38.3 INSTALLATION OF THE DIAGNOSIS SOFTWARE “TEST & SETUP”
2.6.38.4 INSTALLATION INSTRUCTIONS
2.6.38.5 STARTING AND SELECTING LINDE PROGRAM
2.6.38.6 STARTING THE DIAGNOSIS PROGRAM “TEST & SETUP”
2.6.38.7 LINDE DIAGNOSIS PROGRAM
2.6.38.8 HELP FUNCTION
2.6.39 TRACTION DIAGNOSTICS
2.6.39.1 INDEX TO TRACTION DIAGNOSTIC WINDOWS
2.6.39.2 INTERFACE:
2.6.39.3 INTERFACE CONVERTER STATUS:
2.6.39.4 WINDOWS
2.6.39.4.1 WINDOW 1 STATUS INFORMATION
2.639.4.2 WINDOW 2 TEST DATA AND FAULT DIAGNOSIS
2.6.39.4.3 WINDOW 3 STORED FAULT DIAGNOSIS
2.6.39.4.4 WINDOWS 31 & 32
2.6.39.4.5 WINDOW 4 SWITCHING POSITION OF MICROSWITCHES
2.6.39.4.6 WINDOW 41 ADDITIONAL CONTROL SIGNALS (MASTER VERSION ONLY)
2.6.39.4.7 WINDOW 5 SWITCHING POSITION OF SWITCHED OUTPUTS
2.6.39.4.8 WINDOW 51 INTERNAL CONTROL SIGNALS (MASTER VERSION ONLY)
2.6.39.4.9 WINDOW 6 ANALOGUE CONTROL SIGNALS
2.6.39.4.10 WINDOW 61 & 62 INTERNAL CONTROL SIGNALS (MASTER VERSION ONLY)
2.6.39.4.11 WINDOW 7 ADJUSTING TRUCK PARAMETERS
2.6.39.4.12 WINDOW 71 SETTING TRUCK PARAMETERS FROM WINDOW 7 TO DEFAULT SETTINGS
2.6.39.4.13 WINDOW 72 DISPLAY OF FURTHER PARAMETERS
2.6.39.4.14 WINDOW 73 SET VALUES IN 7 AND 72 TO DEFAULT
2.6.39.4.15 WINDOW 74 SETTING SPECIAL TRUCK PARAMETERS
2.6.40 HYDRAULIC DIAGNOSTICS
2.6.40.1 INDEX TO HYDRAULIC DIAGNOSTIC WINDOWS
2.6.40.2 INTERFACE:
2.6.40.3 INTERFACE CONVERTER STATUS:
2.6.40.4 WINDOWS
2.6.40.4.1 WINDOW 1 STATUS INFORMATION
2.6.40.4.2 WINDOW 2 TEST DATA AND FAULT DIAGNOSIS
2.6.40.4.3 WINDOW 3 FAULT HISTORY
2.6.40.4.4 WINDOW 31 FAULT HISTORY (MASTER LEVEL)
2.6.40.4.5 WINDOW 32 CLEAR ENTIRE FAULT HISTORY
2.6.40.4.6 WINDOW 4 DIGITAL INPUTS
2.6.40.4.7 WINDOW 41 SAFETY PROCESSOR INPUTS
2.6.40.4.8 WINDOW 5 DIGITAL OUTPUTS
2.6.40.4.9 WINDOW 51 SAFETY PROCESSOR OUTPUTS
2.6.40.4.10 WINDOW 6 ANALOGUE INPUTS
2.6.40.4.11 WINDOWS 61 to 66 ANALOGUE INPUTS – EACH CHANNEL
2.6.40.4.12 WINDOW 7 FUNCTION SPEEDS LIFT, LOWER & REACH
2.6.40.4.13 WINDOW 71 FUNCTION SPEEDS TILT AND SIDESHIFT
2.6.40.4.14 WINDOW 72 FUNCTION SPEEDS 5th & 6th
2.6.40.4.15 WINDOW 73 RESETS TO DEFAULTS
2.6.40.4.16 WINDOW 8 LIFT/REACH CALIBRATE
2.6.40.4.17 WINDOW 81 TILT/SIDESHIFT CALIBRATE
2.6.40.4.18 WINDOW 82 5th/6th CALIBRATE
2.7 HYDRAULIC SYSTEM
2.7.1 HYDRAULIC CONTROL VALVE CONNECTIONS
2.7.1.1 HYDRAULIC CONTROL VALVE CONNECTIONS – Keycode
2.7.2 HYDRAULIC CONTROL BLOCK REMOVAL
2.7.2.1 CONTROL VALVE RE-FITTING
2.7.3 VALVE BLOCK OVERHAUL
2.7.4 HYDRAULIC UNIT AND TANK
2.7.4.1 RENEWING THE HYDRAULIC TANK FILTER
2.7.5 CHANGING THE HYDRAULIC FLUID
2.7.6 THE LIFT PUMP AND MOTOR REMOVAL
2.7.6.1 LIFT PUMP AND MOTOR RE-FITTING
2.7.6.2 PUMP MOTOR DISMANTLING
2.7.6.3 COMPONENT INSPECTION
2.7.6.4 ARMATURE CHECKS
2.7.6.5 COMMUTATOR REFACING
2.7.6.6 PUMP MOTOR RE-ASSEMBLY
2.7.6.7 BEDDING OF MOTOR BRUSHES
2.7.7 THE PUMP
2.7.7.1 INTRODUCTION
2.7.7.2 ROUTINE MAINTENANCE
2.7.7.3 DIRECTION OF ROTATION
2.7.7.4 DISMANTLING THE UNIT
2.7.7.5 INSPECTION AND REPAIR
2.7.7.6 ASSESSMENT
2.7.7.7 BODY
2.7.7.8 MOUNTING FLANGE AND END COVER
2.7.7.9 BUSHES AND BALANCE PLATE
2.7.7.10 GEARS
2.7.7.11 RE-ASSEMBLING THE UNIT
2.7.7.12 RUNNING-IN
2.7.7.13 TYPICAL PUMP TEST CIRCUIT
2.7.8 POWER STEERING PUMP AND MOTOR REMOVAL
2.7.8.1 POWER STEERING PUMP AND MOTOR RE-FITTING
2.7.8.2 POWER STEERING PUMP MOTOR
2.7.8.3 POWER STEERING PUMP MOTOR DISMANTLING
2.7.8.4 COMPONENT INSPECTION
2.7.8.5 ARMATURE CHECKS
2.7.8.6 COMMUTATOR REFACING
2.7.8.7 POWER STEERING PUMP MOTOR RE-ASSEMBLY
2.7.8.8 BEDDING OF MOTOR BRUSHES
2.7.9 THE POWER STEERING PUMP
2.7.9.1 DISMANTLING THE PUMP
2.7.9.2 SERVICING THE PUMP
2.7.9.3 PRESSURE PLATE AND WEAR FACE OF BODY
2.7.9.4 RING
2.7.9.5 VANES
2.7.9.6 ROTOR
2.7.9.7 PRESSURE PLATE SPRING
2.7.9.8 DRIVE SHAFT DISMANTLING
2.7.9.9 DRIVE SHAFT INSPECTION
2.7.9.10 SHAFT SEAL CONTACT
2.7.9.11 SHAFT BEARINGS
2.7.9.12 SHAFT SEAL
2.7.9.13 PUMP RE-ASSEMBLY
2.7.10 REACH CYLINDER REMOVAL
2.7.10.1 REACH CYLINDER RE-FITTING
2.7.10.2 REACH CYLINDER
2.7.10.3 REACH CYLINDER DISMANTLING
2.7.10.4 REACH CYLINDER REASSEMBLY
2.7.10.5 REPLACING THE REACH SLOWDOWN SENSORS
2.7.11 TILT AND LIFT CYLINDER HOSES
2.7.12 HYDRAULIC CIRCUIT DIAGRAM
2.9 OPTIONS AND ACCESSORYS
2.9.1 360° STEERING.
2.9.1.1 360° STEERING CIRCUIT DIAGRAM
2.9.1.2 360° STEERING INDICATOR GEAR
2.9.1.3 STEERING INDICATOR GEAR REMOVAL
2.9.1.4 STEERING INDICATOR GEAR REFITTING
2.9.1.5 SETTING THE STEERING INDICATOR
2.9.1.6 360° STEERING FAULT CODES
2.9.2 LPSO
2.9.2.1 SYSTEM OVERVIEW
2.9.2.2 STANDARD HEIGHT ENCODER
2.9.2.3 UPA HEIGHT ENCODER
2.9.2.4 INTERFACING INTO TRUCK
2.9.2.5 KEYBOARD UNIT
2.9.2.6 CONTROL MODULE
2.9.2.7 INTERFACE BOARD
2.9.2.8 LOAD SENSOR UPA
2.9.2.9 OPERATION
2.9.2.10 COMMISSIONING & PROGRAMMING
2.9.2.11 TROUBLE SHOOTING
2.9.2.12 CONNECTION DETAILS
2.9.2.13 OPERATING METHOD AND VOLTAGES
2.9.2.14 ELECTRICAL INTERFACING
2.9.2.15 WIRING
2.9.3 LH1-02
2.9.3.1 INTRODUCTION
2.9.3.2 COUNT LIMITS IN SHELF MODE
2.9.3.3 HEIGHT INDICATOR SYSTEM
2.9.3.4 COMPONENTS
2.9.3.4.1 DISPLAY UNIT
2.9.3.4.2 INCREMENTAL ENCODER
2.9.3.4.3 STANDARD UNIT
2.9.3.4.4 BELT TENSION
2.9.3.4.5 REFERENCE SWITCH
2.9.3.4.6 REWIND ENCODER AND REFERENCE SWITCH
2.9.3.5 COMMISSIONING AND PROGRAMMING
2.9.3.5.1 COMMISSIONING
2.9.3.5.2 KEY FUNCTIONS
2.9.3.5.3 PROGRAMMING
2.9.3.6 SYSTEM CHECKS
2.10 MISCELANEOUS
2.10.1 AMP-SAAB CONNECTORS
2.10.2 STANDARD TORQUES
2.10.3 NON STANDARD TORQUES
2.10.4 SPECIAL TOOLS, SEALANTS AND COMPOUNDS
2.10.5 RECOMMEND LUBRICANTS
2.10.6 SERVICE SCHEDULE
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** Model Specification: Lansing Linde Electric Reach Truck Type 113-02: R14, R16, R16N, R20, R20N
** Language: English
** Total Pages: 248
** File Format: PDF
** Requirements: Adobe PDF Reader
** Compatible: All Versions of Windows & Mac, Linux OS, Iphone, Ipad, Android etc…
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