Linde Truck Type 009: K15-3, K15-3AC 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:
K15-3
K15-3AC

Format: PDF, 569 Pages
Language: English

Contents:

•List of chapters...
•Guide to components
• Chapter 1: Vehicle data
    - Guide to information plates and vehicle number 
    - Hydraulic settings 
    - Hydraulic settings
    - Vehicle speed 
    • Outside aisle 
    • Inside aisle 
• Chapter 2: Drive motor
    - General
    - Technical data for the drive motor 
    - Drive mor terminals 
    - Temperature sensor integrated in the 
    carbon brush yoke 
    - Carbon brush monitoring 
    - Replacing the carbon brushes
    - Checking the brush springs 
    - Removing the drive motor 
    - Installing the drive motor 
    - Drive motor maintenance 
    For Alternating Current only:
    - General
    - Terminals
    - Speed monitoring
    - Removal 
    - Technical data
    - Temperature monitoring
    - Speed sensor
    • Removal
    • Installation
• Chapter 3: Drive wheel
    - Replacing the drive wheel 
    - Removing the drive wheel 
    - Replacing the idling wheels
    - Removing the idling wheels 
    - Installing the idling wheels 
• Chapter 4: Gear
    - Oil change 
    - Removing the gear 
• Chapter 5: Brake
    - Electromagnetic brake
    • Function 
    • Removal 
    • Replacing the brake linings 
    • Adjusting the brake clearance
    • Mechanical brake release 
    • Testing the brake coils 
    • Continuous release of the second stage
    • Continuous release of the second stage
    • Measuring the braking deceleration 
    • Checking the braking deceleration
    • Checking the braking deceleration
    • Adjusting the braking deceleration 
    • Adjusting the braking deceleration
• Chapter 6: Steering
    - Adjusting the steering 
    • General 
    • Adjusting sequence
    • Turning the potentiometer of the steering controller
    to the centre position 
    • Adjusting the rotary force at the handwheel
    • Adjusting the retaining force in the straight-on position 
    • Adjusting potentiometers R11/R12 
    • Adjusting the setpoint potentiometers 
    • Adjusting the actual value potentiometer (to approx. 11/02) 
    • Adjusting the actual value potentiometer (from approx. 11/02)
    • Adjusting the max. steering angle 
    • Correction of straight-on
    - Rail guidance 
    - Free travel
    • Teaching-in the wheel position display 
    - Steering controller 
    • Block diagram of steering
    • Block diagram of steering controller 
    • Description 
    • Guide to the potentiometer and LEDs
    • Service switch 
    • Pin assignment
    • Main current terminals
    • Maintenance
    - Steering motor 
    • General 
    • Terminal designations on terminal board 
    • Replacing the carbon brushes 
    • Emergency steering 
    • Maintenance
• Chapter 7: Mast
    - Removing the mast
    - Installing the mast
    - Mast table 
• Chapter 8: Vehicle control system 8U60
    - General 
    - Description
    - Replacing the FZS
    - Pin assignment 
• Chapter 9: Travel and pump controller A10
    - General 
    - Terminals 
    - Pin assignment 
    - Block diagram
    - Signal processing 
    - Response of the main contactors 
    - Control OK 
    - Temperature monitor fo the drive and pump motors 
    • General 
    • Description 
    • Testing the temperature sensors 
    • Contact assignment MARKII
    - Temperature monitor for the travel and pump controller 
    - Carbon brush monitor for the drive and pump motors 
    - Incremental encoder monitor 
    • General 
    • Description 
    • Testing the incremental encoder of the drive motor
    • Testing the incremental encoder of the pump motor
    - Instructions for repair
    • Power unit 
    • Control card
    • Field regulator 
    - Table of errors 
    - Removing the FPS 
    - Installing the FPS 
    - Removing the control card 
    - Installing the control card 
    - Removing the field regulator 
    - Installing the field regulator 
    For Alternating Current only:
    - General
    - Block diagram
    - Switching on the main contactors
    • Step-by-step procedure
    • Activation of the convertors
    - Phase monitoring
    - Pin assignment for X1
• Chapter 10: Operating console 8U62
    - Operating elements 
    - Block diagram
    - Operating console board 
    - Pin assignment 
    - Keyboard boards 1, 2 and 3 
    - Operating console display 
    • General 
    • Basic display 
    • Operating hours 
    • Remaining battery capacity
    • Wheel position display 
    • Display LED for manual steering
    • Status and maintenance symbols 
    • "Deadman switch not actuated" display 
    • "Creep speed" display
    • "2-handed operation not actuated" display 
    • "Barrier open" display
    • "Maintenance" display
    • "LR80 error" display 
    • "Acknowledgement required" display
    • "Reserve1" display 
    • "Reserve2" display 
    - Operating console display 
    • Error display 
    • Information display 
    • Switching-on test
    • Switching over the operating console display 
    • LR80 operating status display
    - Replacing the setpoint potentiometer 
    • Removing the setpoint potentiometer 
    • Installing the setpoint potentiometer 
    • Rough adjustment of the setpoint potentiometer 
    • Fine adjustment of the setpoint potentiometer 
    • Teaching-in the setpoint potentiometer
    • Operating console display menu
    - LR80 board (option)
    • Description 
    • Pin assignment
• Chapter 11: Load handling control 8U61
    - General 
    - Description
    - Pin assignment 
• Chapter 12: EMERGENCY-STOP and amplifier module 7A22
    - General 
    - Description
    - Pin assignment 
    - Safety relays K33 and K34 
    - Safety relay K35 
    - Key switch relay K36 
    - Relay K37 (steering error) 
    - "Enable hydraulics" signal 
    - Chain monitoring
    - Adaptation of the steering setpoint 
    - Control of the electromagnetic brake
    - Evaluation of the potentiometer value for the
    height measuring system of themain lift 
    - Adaptation of incremental encoder signals
• Chapter 13: Distributor board A13
    - General 
    - Structure 
    - Replacement for distributor board A13 
• Chapter 14: Negative feeder module A14
     - General 
     - Description
     - Terminals 
     - Pin assignment X1
• Chapter 15: Main contactors K1 and K2
    - General 
    - Coil holder suppression 
    - Spacing distance 
    - Contact pressure 
• Chapter 16: DC/DC converter
    - General 
    - Description
    - Electrical connections 
    - Technical data 
• Chapter 17: Distance sensor for the main lift
    - General 
    - Location 
    - Identification
    - Technical data 
    - Pin assignment 
    - Monitor
    - Safety instructions 
    - Description of errors 
    - Removing and installing the distance sensor 
    - Repair instructions
    • 1. Replacing the potentiometer 
    • 2. Replacing the cable
    • 3. Replacing the incremental encoder
    • 4. Replacing the belt 
    • 5. Replacing the spring 
• Chapter 18: Distance sensor the for additional lift
    - General 
    - Monitor
• Chapter 19: Distance sensor for swivelling
    - General 
    - Monitoring 
• Chapter 20: Distance sensor for side shifting
    - General    
    - Monitor
• Chapter 21: SERVICE mode
     - Description
     - Activating SERVICE mode 
     - Deactivating SERVICE mode 
• Chapter 22: Teaching-in process
    - General 
    - Commissioning 
    - Deleting teaching-in values
    - Preparation for teaching in
    - Teaching in the main lift distance sensor
    - Teaching in the additional lift distance sensor 
    - Teaching in the swivelling distance sensor
    - Teaching in the side shift distance sensor
• Chapter 23: Reference sequence
    - General 
    - Reference sequence for the main lift
    - Reference sequence for the additional lift 
• Chapter 24: Chassis valve block
    - Mounting instructions
    - Functional elements
    - Setting the maximum pressure
    - Parameterising the main lift
    - Soiling indicator 
    - High presure filter 
    • Changing the filter - removal
    • Changing the filter - installation 
    - Removing the chassis valve block 
    - Fine control of lowering main lift
• Chapter 25: Attachment valve block
    - Mounting instructions
    - Functional elements
    - Adjusting work 
    - Parameterising the ancilliary movements 
• Chapter 26: Pump motor
    - General
    - Technical data for the pump motor
    - Pump motor terminals 
    - Temperature sensor integrated in carbon brush yoke
    - Carbon brush monitoring
    - Replacing the carbon brushes
    - Checking the brush springs 
    - Pump motor maintenance 
    For Alternating Current only:
    - General
    - Terminals
    - Speed monitoring
    - Technical data
    - Temperature monitoring
• Chapter 27: Hydraulic motor
    - Function
    - Commissioning
    - Technical data 
    - Checking for leaks 
    - Mounting instructions
    - Removal
• Chapter 28: Pump
    - Removing the pump 
    - Mounting instructions
• Chapter 29: Oil level indicator
    - -Oil level indicator 
• Chapter 30: Ventilation filter
    - Function
    - Removal 
    - Maintenance
• Chapter 31: Trilateral head (TLH)
    - Adjusting work on the TLH 
    - Adjusting the tooth profile play 
    - Adjusting the eccentric rollers for the overshift function 
    - Adjusting the swivel shaft for the additional lift
    - Removing the lift carriage
    - Adjusting the radial play on the lift carriage
    - Adjusting the axial play on the lift carriage 
    - Adjusting the potentiometer for side shifting 
    - Adjusting the poentiometer for swivelling 
    - Adjusting the 90° swivelling range
    - Adjusting the switching lug for side shifting
    - Adjusting the limit switches for swivelling
    - Adjusting the magnetic sensors 
• Chapter 32: Lubrication plan
    - Guide to iols and lubricants 
    - Lubrication plan 
    - Disposal of oils and lubricants 
• Chapter 33: Chains
    - Lifting chains
    • General 
    • Checking the lifting chains for damage 
    • Checking the chain elongation 
    • Replacing the lifting chains 
    • Lubricating the lifting chains
    - Cleaning the chains 
    - Roller chains 
    • General 
• Chapter 34: Inductive automatic steering
    - 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
    • Recognition process in the drive wheel
    side (DWS) travel direction
    •Recognition process in the load side (LS) travel direction 
    •1.Very flat approach angle 
    •2.Flat approach angle 
    •3.Steep approach angle to 40° 
    •Displays on operating console during detection 
    process on detection curves
    - Block diagram 
    -Test operating unit (TBE)
    •Test mode positions 
    - Guide to components in the automatic inductive steering 
    - Adjusting chart 
    - Checking the mechanical elements 
    • Steering bearing 
    • Gearwheels
    • Wheels 
    - Checking the LR80 display 
    - LR80 display and LED displays 
    - Balancing the digital filter 
    - Central processing unit - CPU board 
    - Central proccessing unit - DC/DC-converter
    - Central proccessing unit - baseplate
    • Counting method for connectors and sockets 
    - Central unit
    • View from the front with front panel mounted 
    • View from the front with front panel removed 
    • View of the baseplate 
    • Switching outputs
    • Meaning of the switching outputs 
    • "Steering enable" switching output 
    • Switching outputs
    .- Testing the switching outputs with the 
    . operating mode switch
    - Testing the speed sensor
    - Incremental encoder 
    • General 
    • Monitoring 
    - Loading standard parameter set
    - Language selection
    - Steering output stage
    • Setting the service switch 
    • Enable LED
    • Input/output signals
    • Signals from the LR80 central processing unit 
    - Maximum steering angle
    • Allocation of value
    • Storing 
    - Adjusting the setpoint potentiometer
    • Adjusting the turning force of the handwheel
    • Adjusting the retaining force of the centre
    detent mechanism
    • End stop
    • Adjustment of straight-on travel with the setpoint 
    potentiometer in centre detent mechanism
    - Setpoint potentiometer (to approx. 11/02) 
    • General 
    - Setpoint potentiometer (from approx. 12/02) 
    • General 
    - Setting the offset potentiometer for "Straight-on in 
     DWS and LS direction" to "00" 
    -Adjusting the actual value potentiometer (to approx. 11/02) 
    -Adjusting the actual value potentiometer (from approx. 12/02)
    - Actual value potentiometer (to approx. 11/02) 
    • General 
    • Testing the potentiometer 
    - Actual value potentiometer (from approx. 12/02) 
    • General 
    • Testing the potentiometer 
    - Guide frequency generator 
    • The frequency generator viewed from the front 
    • Battery buffer
    • Commissioning the guide frequency generator
    • Adapting the output filter to a wire loop
    • Connecting the wire loop
    - Mounting and adjusting the aerials 
    • 1. Determining the centre marking for mounting the 
    DWS antennas 
    • 2. Adjusting the DWS antenna 
    • 3. Setting the offset potentiometer for Straight-on 
    in direction of the drive wheel side" travel 
    • 4. Mounting and adjusting the LS antenna
    • Setting the offset potentiometer for "Straight-on in 
    direction of the load side" trave 
    - Aerials 
    • General 
    • Function 
    • Pin assignment
    • Technical data
    - Emergency-off parameters
    • General 
    • XE59 
    • XE5B
    • XE5A
    • XE5D
    - Steering angle limiter 
    • Description of function / An introduction to the component
    • Block diagram for vehicles with distributor board A13 
    • Block diagram for vehicles without distributor board A13 
    • Conditions required for the detent to lock 
    • Conditions required for the detent to release 
    • Pin assignment for connector X1 
    • Monitoring 
    • Adjustment 
    • Modification to the steering angle limiter
    - Modified trip cams 
    - Modified end stop 
    - Aisle recognition
    • Aisle recognition sensors 
    • Mounting the reflectors - aisle with two open ends 
    • Mounting the reflectors - aisle with one open end
    • Aisle recognition error 
    • Aisle recognition signal at LR80
    - Table of LR80 situations 
    - Notebook 
    • Preparing for programming the LR80
    - Programming/changing parameters/test selection for LR80 with TEWAK 
    - Storing parameters
    - Error messages
    - Test selection with operating mode and frequ. switch 
    - Test selection with a notebook 
    - Table for convers. from hexadecimal to decimal values 
• Chapter 35: Error codes
    - General 
    - Error classification 
    - Errors in FPS and converters in alternating current vehicles
    • General 
    • Error classes 
    • Cancelling errors 
    - Travel errors 
    - Steering errors 
    - Main lift errors 
    - Additional lift errors 
    - Reaching errors 
    - Rotating errors 
    - Errors in synchronours rotating/reaching movement 90°/180° 
    - Error configuration and automatic braking at end of aisle (EASS) 
    - Can bus errors 
    - General errors
    - Errors in automatic braking at end of aisle (EASS) 
    - Travel and pump controller (FPS) errors 
    - Load handling controls (LAS) errors 
    - Operating console (BPS) errors
• Chapter 36: Troubleshooting guide
    - Power supply function
    • General 
    • Battery voltage 
    • Battery voltage after key switch 
    • 1+battery voltage after key switch
    • 1+24V
    • 1+battery voltage after 1+24V
    • EMERGENCY-STOP chain 
    • 2+battery voltage 
    • 2+24V
• Chapter 37: WINFLASH
    - General 
    - Block diagram
    - Description
    - Setting up a connection with the vehicle
    - Loading the vehicle program 
    - Updating programs 
• Chapter 38: ParaDig 133 / ParaDig 153
    - General 
    - Setting up a connection with the vehicle
    - Opening the software
    - Starting parameterising and diagnosis 
    - Errors when starting parameterising and diagnosis
    • Outdated vehicle software
    • ParaDig does not match the vehicle model
    - Old software version of vehicle program 
    - Working with ParaDig 
    • Page selection
    • Parameterising 
    - General 
    - Combination field 
    - Direct entry
    - Parameter value outside the permissible range
    - Default value 
    • Saving changes
    - General 
    - Saving for test purposes 
    - Saving permanently 
    • Loading parameters from the vehicle
    • Saving vehicle settings in a file 
    • Loading vehicle settings from a file 
    • Diagnosis 
    - Starting diagnosis
    - Working with diagnosis 
    - Closing diagnosis 
    • Working with ParaDig in offline mode 
    • Closing parameterising and diagnosis 
    • Closing the ParaDig service software 
• Chapter 39: Telescopic fork
    - Functional description
    - Component names 
    - Home position
    - Measurement of the extension depth Distance sensor
    - Adjusting the middle carriage 
    - Adjusting the upper carriage
    - Adjusting the position switch for the home position 
    - Adjusting the distance sensor for reaching
    - Teaching in the distance sensor for reaching 
    • Set vehicle control system to SERVICE mode
    • Delete values that are already taught in
    • Teach in the distance sensor for reaching again 
    - Parameterising
    - Definitions 
    - Maximum mech. extension parameter
    - Monitoring of the distance sensor for reaching
    - Load handling controls LAS
    - Attachment valve block
    - Additional lift distance sensor 
    • Monitoring 
    • Teaching in the additional lift distance sensor 
    - Maintenance instructions for drive chains and 
    return chains 
    - Reliable lubricants and mineral oils 
• Chapter 40: Filling aid
    - Functional description / Component names 
    - Preparation 
    - Draining hydraulic oil out of the tank
    - Filling the tank with hydraulic oil 
• Chapter 41: Converter (for Alternating Current only)
    - General
    - Testing the CAN bus
    - Speed monitoring
    - Speed sensor
    - Temperature monitoring
    • Testing the temperature sensors
    - Charging the bank of capacitors
    - Discharging the bank of capacitors
    - Function of the LED
    - Main current terminals
    - Power recovery
    - Pin assignment
    • X1
• Chapter 42: Panel
    - Main current component panel (to approx. 11/02)
    - Control current component panel (to approx. 11/02) 
    - Component panel (form approx. 12/02)
    - Main current component panel
    • Chapter 43: EASS
    - EASS inductive 
    • General
    • Setting the "EASS inductive" option 
    • Proximity switches
    • Calculating the length of the steel plates
    • Calculating the maximum braking distance
    • Mounting the steel plates 
    - Without absolute stop
    - With absolute stop at closed aisle end only 
    - Without absolute stop at the open and closed aisle end 
    • Division into zones / General
    - General
    - Zone 0 
    - Zone 1 
    - Zone 2 
    - Zone 3 
    - Zone 4 
    - Zone 5 
    - Guide to maximum speeds in the various zones
    • Suppression of metal elements that cause interference 
    • Diagnosis 
    - EASS magnetic
    • General 
    • Setting the "EASS magnetic" option
    • Magnetic switches 
    - General
    - Mounting the switches
    • Switching magnets 
    - General
    • Calculating the maximum braking distance
    - Definitions
    • Mounting the switching magnets 
    - Without absolute stop
    - With absolute stop at closed aisle end only 
    • Division into zones 
    - General
    - Zone 0 
    - Zone 1 
    - Zone 3 
    - Zone 5 
    • Diagnosis
    - EASS reflexli 
    •General
    • Setting the "EASS reflexli" option
    • Reflector types 
    - Reflector types A and B
    - Reflector type C - Check 
    - Reflector type C - Stop 
    - Reflector type D4 - Absolute stop
    • Mounting heights for reflector installation 
    on the shelves - both sides
    • Mounting heights for reflector installation
    on the shelves - one side
    • Reflective light barriers
    - Arrangement of the reflective light barriers 
    for automatic braking at the aisle end
    - Arrangement of the reflective light barriers for automatic  braking at he aisle end, stop and absolut stop and check
    - Arrangement of the reflective light barriers for reflector  installation on one side of the aisle with automatic braking at the aisle end 
    - Arrangement of the reflective light barriers for reflector installation on one side of the aisle with automatic braking at the aisle end, stop and absolute stop and check
    • Calculating the maximum braking distance
    - Definitions 
    • Mounting the reflectors
    - Arrangement of the reflectors for automatic end of aisle braking 
    - Arrangement of the reflectors for automatic end ofaisle braking and speed monitoring
    - Arrangement of the reflectors for automatic end of aisle braking and stop 
    - Arrangement of the reflectors for automatic end of aisle braking and absolute stop
    • Division into zones 
    - General 
    - Zone 1 
    - Zone 0 
    - Zone 2 
    • Important rules 
    • Diagnosis 
• Chapter 44: Individual driving settings
    -General
    - Setting the "Individual driver settings" option 
    - Changing the speed settings for the hydraulic functions 
    - Changing the speed settings for travel
    Changing the Optispeed adaptation 
    - Saving the changed speed settings 
    - Setting ranges 
    - Diagnosis
Powered by