Linde Electric Forklift Truck 386 series: E12, E14, E16, E18, E20, E16P, E18P, E20P Service Training Manual

Linde Electric Forklift Truck 386 series: E12, E14, E16, E18, E20, E16P, E18P, E20P Service Training Manual

Original illustrated factory service Training Manual for Linde Electric Forklift Truck 386 series

Covered models:
E12
E14
E16
E18
E20
E16P
E18P
E20P

Format: PDF, 558 pages
Language: English

Included chapters:

0 Product information
Technical data
Type overview
Seriennummer
Inspection and maintenance
Service overview
Activities within scope of service
Operating material
Lubricants and operating materials
Tightening torques
Tightening torques for standard pitch threads
Tightening torques for fine pitch threads
Tightening torques for units
Special tools
Special tools and measuring instruments
Diagnostics
Overview
Canbox
Software update for Canbox
Pathfinder
Starting the diagnosis program
Guided diagnosis
Load controller
Log files
Code lists
Error code display
Driving codes
Working hydraulics codes
Codes display
Traction power module codes
Working hydraulics power module codes
Battery charger codes
End diagnostic program
1 Motor
Drive axle
Overview
Connector positions on drive axle
Special tools, drive axle
Dismantling the drive axle
Traction motor
Technical data
Changing bearings and shaft seal
Pump motor
Technical data
Changing bearings and shaft seal
Motor testing
Preparation
Visual inspection
Winding test
Rotor testing
Motor connection
Traction motor terminal board
Traction motor power module
Terminal board pump motor
Power module pump motor
Cleaning
Cleaning the motor – drive axle
Sensors
Rev sensor
Temperature sensor
Forced ventilation
Overview
Replacing the fan
2 Drive wheel unit
Planetary transmission AK20E-01
Function characteristics
Checking the gearbox oil level
Changing the gear lubricant oil
Changing the shaft seal
3 Chassis, bodywork and fittings
Chassis
Variants
Chassis design
Battery door
Spring elements
Torque strut
Cladding
Driver’s seat
Changing the seat switch and switch plate
4 Chassis frame
Steering system
Function characteristics
Steering actuation
Steering control valve
Steering column
Turntable steering
Function characteristics
Dismantle turntable steering axle
Disassembling and sealing the turntable steering axle
Sectional image of the turntable steering axle
Installing the fifth-wheel steering axle
Combi-axle
Function characteristics
Dismantle combi-steering axle
Remove the steering cylinder and tie rod
Replacing the steering cylinder seals
Installing the steering cylinder and tie rod
Replace tapered roller bearing and wipers of beam axle body
Replace tapered roller bearing and shaft seal on axle stub
Installing the combi steer axle
Set steering lock
Steering angle sensor
Steering angle sensor 3B1
Replacing the steering angle sensor
Tyres
Speed restriction, solid tyres
Electrostatic charging
Operating devices
5 Controls
Controls
Accelerator
Function
Replacement
Stop screws
Brake system
General
Electric brake
Functional description
Hydraulic service brake
Function characteristics
Brake valve
Towing
Adjustment
Brake valve (without towing lever)
Towing
Setting
Joysticks
Joystick variants
Functional description
Replacement
6 Electrics / Electronics
General
Safety instructions for electrical equipment
Cleaning the electrical system
Insulation testing
EMC – Electromagnetic compatibility
CAN bus
Operational overview
Basic-truck plug positions
Power modules
Description
Assembly
Signals
Electrical components of board contactor
Contactor carrier
Central negative point X31
Central positive point X30
Emergency stop switch
Voltage transformer
Current sensor
Main current fuses
Control current fuses
Fuses, special equipment
Charging circuit
Main contactor
Battery plug connector
Adaptor connector special equipment 9X15/9X16
Truck control unit
Overview
Plug pin assignment X13
Power supply
Charging circuit
Enable signal
Powersupply of external components
Accelerator 1A4
Single-pedal drive direction switch, 1S13
Parking brake switch 1S2
Switch Stop pedal 1 S3
Truck coding
Relay drivers Traction
Battery discharge condition
Joysticks
Output signals
Valve activation
Accumulator charging valve
Tilt angle sensor
Steering column sensor
Steering angle sensor
Axle temperature
Rear cover monitoring
Display unit
First version
Display unit overview
Second version
Display unit overview
Third version
Display unit overview
Display unit, general
Hour meter
Service interval indicator
Time
Speed indicator
Steering angle display
Lift mast symbol
Parking brake symbol
Discharge indicator
Warning lights
Internal hour meter
Connector plug
Replacing the indicator unit
7 Hydraulics
General
Adjusting the auxiliary hydraulics
Contamination in the hydraulic system
Control valve
Overview
Function characteristics
Adjusting pressure relief valve
Valve coils
Emergency lowering screw Lower
Adjusting the maximum lifting and lowering speed
Hydraulic components
Hydraulic pump
Accumulator
Pressure sensors
Replacing the high pressure filter
Hydraulic tank
Tilt cylinders
Variants
Remove tilt cylinders
Seal tilt cylinder
Install tilt cylinders
8 Load lift system
Lift mast
Remove lift mast
Fitting the lift mast
Lift mast chains
Adjust lift mast chain
Roller play
Sealing the lift cylinders (lift masts before 01/2007)
Sealing the lift cylinders (lift mast from 02/2007 onwards)
Line breakage protection
End damping
Triplex mast
Extension sequence triplex mast
Extension sequence for triplex masts from 02/2007 onwards
Removing the centre lift cylinder
Removing the inner mast lift cylinder
Removing the centre mast lift cylinder
Tilt angle sensor
Functional description
Alignment of the tilt angle sensor
Backwards tilt angle
Hose carriage
Operating principle
9 Special equipment, accessories
Truck control unit special functions
Plug special functions
Reduced driving speed
Reduced operating speed
Lift mast positioning
Lift height restriction
Components of special electrical equipment
Voltage transformers
Wiring harness of voltage transformer
Relay box
Plug plate
Relay slots
Relays
Fuses
Potential dividers
Switches (special equipment)
Multifunction lever
Lighting
Front headlights
Rear lights
Working headlights
Working headlight wiring harness position 1/2
Working headlight wiring harness positions 3/4 and 7/8
Working headlight wiring harness position 5/6
Wiring harness for standard lighting
High lighting wiring harness
Integrated charger
Safety information, battery and battery charger
Testing the battery charger
Requirements for “qualified individuals”
Inspection procedure
Visual inspection
Measurement
Testing
Evaluation and documentation
Functional description
Types
Assignment of battery chargers
Settings
Battery charger wiring harness
Plug pin assignment 9X2
Battery temperature sensor
Batteries
Equalising und maintenance charges
Charging
Charging characteristic curves
Assignment of charging characteristic curves
Charging characteristic curves
Washer system
Wiring harness for washer system
Warning signals
Wiring harness for rotating beacon and buzzer
Wiring harness for reversing signal
Heating system
Heater 48 V
Wiring harness for heater and blower
Miscellaneous
Linde Forklift Data Management
Linde Forklift Data Management wiring harness
3rd auxiliary hydraulics
12V wiring harness socket
Radio wiring harness
Camera system wiring harness
Annex
10 Circuit diagrams
Wiring diagrams
Basic truck from H2X386A02236 onwards
Basic equipment sheet 1-4
Basic equipment sheet 2-4
Basic equipment sheet 3-4
Basic equipment sheet 4-4
Special equipment
Special equipment, voltage transformer
Special equipmentworking spotlights, warning signals
Special equipment, hazard warning lights, brake light, sidelight and camera system
Special equipmentstandard lighting
Special equipmenthigher lighting
Special equipmentwindscreen wiper and rear window heating
Special equipmentheating system
Special equipmentLinde truck data management, battery data management
Built-in battery charger 24 V /100 A, special equipment
Special equipment, built-in battery charger 48 V/ 65 A
Special equipment, built-in battery charger48 V/120 A
Special equipment, depressurisation / 3rd auxiliary hydraulic
Special equipment, lift height restriction/lift speed limitation, lift mast positioning, driving speed limitation
Hydraulic circuit diagrams
Hydraulic circuit diagram for basic truck

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