Linde Truck Type 009: K15-4 Service Training (Workshop) Manual

Original Illustrated Factory Service Training (Workshop) Manual for Linde Truck Type 009.

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:
K15-4

Format: PDF, 427 Pages
Language: English

Contents:

A Travel drive
    Travel motor
    - Travel motor, technical data
    - Travel motor connections
    Speed sensor
    - Speed sensor connections
    - Testing the speed sensor
    Temperature sensor integrated in the carbon brush yoke
    Removing the travel motor
    Replacing the travel motor
    Removing the gear
    Munter-friction-hitch
    Half Munter-friction-hitch
    Removing the gear
    Changing the gear oil
    Replacing the drive wheel
    - Removal
    Carbon brush monitor
    Replacing the carbon brushes
    Checking the brush springs
    Travel motor maintenance

B Steering system
    Block diagram of standard steering
    Block diagram of steering controller
    Description of steering controller
    - Safety test
    - External enable
    - Manual steering
    - Driving onto the rail guide
    - Rail travel
    - Guide to potentiometers and LEDs
    • Service switch
    - Pin assignment
    - Main current connections, steering controller
    Adjusting the steering
    - Gear ring steering
    • General
    • Steering angle correction
    • Installing the eccentric toothed wheel
    - Setting the steering controller potentiometer to the centre position
    - Adjusting the turning force of the handwheel
    - Setting the retaining force of the handwheel
    - End stop
    - Adjusting the potentiometer R19/R20
    - Adjusting the setpoint potentiometer
    - Adjusting the actual value potentiometer
    - Setting the maximum steering angle
    - Straight-on travel correction
    • Rail travel
    • Free travel
    Steering motor
    - Replacing the carbon brushes
    - Maintenance

C Brake system
    Electromagnetic brake
    - Function
    - Removal
    - Replacing the brake lining
    - Setting the brake clearance
    - Releasing the brakes mechanically
    - Testing the brake coils
    - Measuring the brake deceleration
    - Electromagnetic brake - checking the brake deceleration
    - Testing the 1st and 2nd braking stage together
    - Testing the 1st braking stage
    - Adjusting the braking deceleration
    - Summary of the braking modes
    Automatic inductive braking at end of aisle (EASS)
    - General
    -Function
    - Vehicle is switched on on the floor plates
    - Vehicle is switched on in the fast travel area
    -Errors
    - Mounting the proximity switch
    - Testing the proximity switch
    - Procedure for determining the length of the floor plates and installation
    - Guide to inputs in the PLC
    - Summary of magnetic end-of-aisle braking (EASS) with rail guidance
    • Without absolute and temporary stop
    • With absolute and without temporary stop
    • With absolute and temporary stop
    - Summary of magnetic end-of-aisle braking (EASS) with
    inductive automatic steering
    • Without absolute and temporary stop
    • With absolute and without temporary stop
    • With absolute and temporary stop
    Automatic end-of-aisle braking with magnetic switches
    - General
    - Function
    - Absolute stop
    - Aisle detection
    - Errors
    - Magnetic switches
    - Switching magnet
    - Summary of magnetic end-of-aisle braking (ZAG) with rail guidance
    • Without absolute and temporary stop
    • With absolute and without temporary stop
    • With absolute and temporary stop
    - Summary of magnetic end-of-aisle braking (ZAG) with
    inductive automatic steering
    • Without absolute and temporary stop
    • With absolute and without temporary stop
    • With absolute and temporary stop
    Automatic end-of-aisle braking with reflective light barriers
    - General
    - Function
    - Errors
    - Stop
    - Temporary stop
    - Absolute stop
    - Interlock module 8U40
    • Terminals
    • Display
    - Installation of the reflectors in an aisle
    - Distance between reflectors
    - Summary of ZAG reflexli with rail guidance
    • With absolute stop and check
    - Summary of ZAG reflexli with inductive automatic steering
    • With absolute stop and check

E Assembly
    Assembly before commissioning
    • Delivery
    • Chassis
    • Lifting device
    • Attachment
    • Preparation
    • Tests before assembly
    • Installing the mast
    • Installing the sensors (EASS) and battery roller track
    • Installing the trilateral head
    • Procedure prior to handing over the vehicle
    Changing the idling wheels
    • Removal
    • Installation
    Removing the cab with a fork-lift truck
    Guide rollers on the support carriage
    • Lateral guide rollers
    • Central guide rollers
    Guide rollers on the outer mast
    Adjusting the eccentric rollers
    Guide rollers on the inner mast
    Chains
    • General
    • Testing the flyer chains
    • Maintenance on the chain
    Adjusting work on the drive plate
    'General
    • Adjusting the axle clearance
    • Adjusting the tilting range

F Cylinders
    Cylinder support
    Removing the main lift cylinder
    Dismantling the main lift cylinder
    Removing the additional lift
    Removing the additional lift cylinder
    Dismantling the additional lift cylinder
    Dismantling the pulling cylinder
    Line break protection type LB3
    Lowering brake valve SB17-C-14

I Inductive automatic steering
    LR80
    - General
    - Description of the operating modes
    • Self-test
    • Manual operation
    • Automatic operation
    - Wire search
    - Preparatory aisle travel
    - Aisle travel
    • Switching back to manual steering
    -Version 10.X
    • Improved detection mode
    • Detection procedure, drive wheel side
    • Detection procedure, load side
    • Display on operating console during detection with LKF curve
    Block diagram
    - Guide to components in the inductive automatic steering
    - Test operating unit (TBE)
    - Adjustment guide
    - Checking the mechanical elements
    - LR80 display for inductive automatic steering
    - LR80 display and LED displays
    - Balancing the digital filter
    - Central processing unit - CPU board
    - Central processing unit - DC/DC converter board
    - Central processing unit - base plate (with aisle detection)
    - Central processing unit
    • Switching outputs
    • Testing the switching outputs with the operating mode switch
    - Testing the speed sensor
    - Speed sensor
    - Loading a standard parameter set
    • General
    • Standard parameter set
    - Language selection
    - Steering output stage
    - Maximum steering angle
    - Setting the setpoint potentiometer
    - Setpoint potentiometer
    - Setting the offset potentiometer for "Straight on forwards and reverse" to "00"
    - Setting the actual value potentiometer
    - Adjusting the actual value potentiometer (from 08/2000)
    - Actual value potentiometer
    - Actual value potentiometer (from 08/2000)
    - Guide frequency generator
    • Battery buffer
    • Commissioning the guide frequency generator
    • Adapting the output filter to a wire loop
    • Connecting a wire loop
    • Technical data
    - Mounting and adjusting the aerials
    • Finding the centre marking for mounting the front aerials
    • Adjusting the front aerials
    • Setting the offset potentiometer for "Straight on forwards"
    • Mounting and adjusting the rear aerial
    • Setting the offset potentiometer for "Straight on reverse"
    - Aerials
    - Emergency-stop parameters - General
    - Emergency-stop parameter - XE59
    - Emergency-stop parameter - XE5B
    - Emergency-stop parameter - XE5A
    - Emergency-stop parameter - XE5D
    - Steering angle limiter
    • Adjustment
    • Control board 3A24
    • Overview of the LEDs on control board 3A24
    • Pin assignment for control board 3A24
    • Detent control
    • Aisle detection
    - Aisle detection
    • Function
    • Aisle detection sensors
    • Mounting the reflectors
    - Table of LR80 situations
    - Notebook - preparation for programming the LR80
    - Programming / Changing parameters / Test selection for LR80 with TEWAK..
    - Summary of all the LR80 parameters for electrical steering
    - Storing parameters
    - Error messages

J Battery lock
    General
    Components of the battery lock
    Different vehicle versions built before approx. 10/99
    Preparatory work
    Pushing the battery out half way
    Swivelling out the pump unit
    Swivelling in the pump unit
    Pushing back the battery

M Electrical system
    Guide to components - driver's cab and attachment
    Guide to components - load carriage
    Guide to components - assembly compartment
    Block diagram (complete vehicle)
    Key-operated switch, Deadman's switch and Barrier switches
    Electrical switchboard for main current
    Main contactors, pump contactor
    DC/DC converter 80/24V
    Diode module 1V21
    Current sensor 1U1
    The basics of multiplex technology
    - Data transfer
    - Block diagram of serial data transfer (demonstrates the principle)
    Location of the MUX modules
    Input module (8U21, 8U22, 8U23, 8U25)
    - Connector assignment
    Output module (8U32, 8U33)
    - Decoder module
    - Binary output module (4x21)
    - Proportional amplifier module (2x1 A)
    Distributor board chassis A21
    - Safety relays K33/K34 and K35
    - Steering error relay 3K1 1
    Logic board A21L
    - Pin assignment X51
    - Pin assignment X53
    - MUX data word (channel 8)
    - "Error" output
    - Speed reduction monitoring (K100)
    - Block diagram
    - Speed code
    - Combinations of the position switches on the mast
    - Chain control
    - Chain control - Block diagram
    - Togglebit monitor
    - Adaptation of the speed signals
    Distributor board A23
    Logic controller 8U43
    - Function
    - Functional diagram of operating principle
    - Diaplay LEDs, Potentiometer, other components, Test points
    - Pin assignment
    - Output signals from SPS to FPS
    - Relay K201
    - Truth table for 8U43
    Valve changeover 2A10
    Operating console 8U42
    - Operating elements
    - Block diagram
    - Operating console pcb
    - Pin assignment for the black connectors
    on the operating console pcb
    - Pin assignment for the red ribbon cable connectors
    on the operating console pcb
    - Keyboard pcb 1, 2 and 3
    - LR80 board (optional)
    - Lever
    - Hydraulics and travel potentiometers
    - Operating console display
    • General
    • Basic display, Operating hours, Remaining battery capacity,
    Wheel position display
    • Display LED for manual steering, Status and maintenance symbols
    • Switching-on test, Operating status display for inductive wire
    guidance system (optional LR80)
    - Error display
    - Guide to the error codes that are shown on the operating console
    - Removing the setpoint potentiometer for travel or hydraulics
    - Installing the setpoint potentiometer for travel or hydraulics
    - Setting the setpoint potentiometer for travel or hydraulics
    Travel and pump control system A10
    - General
    - Connections
    - Pin assignment X1 1
    - Block diagram
    - Main contactor response
    - "Control unit OK" signal
    - Speed sensor monitoring
    - Travel programs
    - Deceleration 1, 2 and 3
    - Selection of travel parameters
    - Travel direction (forwards, reverse)
    - Setpoint for travel and hydraulics
    - Adapting the travel setpoint
    - Reading the setpoints out of the FPS
    - Carbon brush monitor
    - Tmperature monitoring
    - Standard parameter set
    - Battery type
    - Reprogramming the operating and service hours
    - Error memory
    - Error list for error memory
    - Description of errors
    - Status displays
    ST-STAT
    • EIN-1
    • EIN-2
    • AUS-1
    - Summary of all the FPS addresses
    - Summary of all travel parameters
    - Notebook (WIN95) - preparation for programming the FPS
    - Notebook (WIN95) - programming the FPS
    • Reading out parameters
    • Programming parameters
    • Guide to the parameter settings in the terminal program (TEWAK95)

N Hydraulic system
    Block diagram of the hydraulic system
    Chassis valve block
    -Illustration of chassis valve block
    - Functional elements
    - Adjustment work
    - Emergency drain valve
    - Electrical data of the valve coils on the chassis valve block
    Valve block attachment
    - Illustration of attachment valve block
    - Functional elements
    - Adjustment work
    Oil filter
    Checking the hydraulic oil level
    Replacing the carbon brushes in the pump units
    Removing the pump units

Q Telescopic fork
    Adjusting the telescopic fork
    - General
    - Adjusting the position switches
    - Adjusting the middle carriage
    - Adjusting the upper carriage
    - Adjusting the actual value potentiometer
    - Adjusting the WA1 IN-Q module
    - Maximum extension depth
    - Extension speed
    - Ramp start
    - Centre position stop
    - Table of parameters
    INPUT WA1IN-Q
    - General
    - Operating principle

T Trilateral head
    Removing the trilateral head
    Guide rollers, load-bearing rollers and lateral guide rollers
    Adjusting the tooth profile play
    Guide roller adjustment
    Mounting the shaft coupling
    - Setting the swivel shift fork perpendicular with the shaft coupling
    - Removing the shaft coupling
    Removing the toothed shaft
    Removing the additional lift
    Adjusting the pulling cylinders
    Hydraulic motor OMP 160
    Adjusting synchronised swivelling/shifting
    - Adjusting the system pressure
    - Adjusting the hydraulic back-pressure valves
    Back-pressure valve for swivelling
    • Adjusting the lowering brake valves for shifting
    • Adjusting back-pressure valve for synchronised swivelling/shifting
    - Adjusting the pump speed and proportional valve values
    - Parameters for synchronised swivelling/shifting
    - Degree Meter to adjust the 30° angle of the ramp limit switch for swiveling

V PLC
    MUX-PLC
    - General
    - CPU card
    - Input and output card
    - DIAG-LED
    - +5V-LED
    - Function monitor for serial transmission
    - Processing of analogue values
    - 7-digit binary number table
    - Source table for the inputs
    - Symbol table - inputs
    - Source table for the outputs
    - Symbol table - outputs
    Programming and setting parameters
    - Interface adapter
    - Preparing the notebook for working with the MUX-PLC
    -Notebook - loading a new program into the PLC
    - Notebook - Changing parameters in the PLC
    - Guide to all the PLC parameters that can be adjusted (A block)
    - Guide to all the option markers in the standard program (B block)

Z Trouble-shooting
    Notebook-Current flow diagram
    - Explanation of the network for A4.321+
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