Linde Truck Type 008: K10, K13 Service Training (Workshop) Manual

Original Illustrated Factory Service Training (Workshop) Manual for Linde Truck Type 008.

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:
K10
K13

Format: PDF, 381 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
    Changing the gear oil
    Lubricating the bogie bearing
    Replacing the drive wheel
    Carbon brush monitor
    Replacing the carbon brushes
    Checking the brush springs
    Travel motor maintenance
    - General
    - Cleaning
    - Visual inspection, replacing damaged parts
    - Checking the brush unit, replacing the carbon brushes
    - Commutator
    - Bearings

B Steering system
    Block diagram of standard steering
    Block diagram of steering controller
    Description of steering controller
    - Safety tests
    - 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
    - Adjusting the chain tension
    - Replacing the steering chain
    - 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
    - Steering motor specifications

C Brake system
    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
    - 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 - vehicle
    Removing the load carriage
    Assembly - Telescopic load carriage
    Assembly - Swivel shift fork
    Replacing the idling wheels
    - Removal
    - Installation
    Chains
    - general
    - Checking the flyer chains
    - Chain maintenance

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 (attachment)
    Line break protection type LB-3C
    - General
    - Valve for full support of the load
    Lowering brake valve SB17-C-14

I Inductive automatic steering
    - Setting the setpoint potentiometer
    - Setpoint potentiometer
    - Setting the offset potentiometer for "Straight on forwards and reverse"
    to "00"
    - Setting the actual value potentiometer
    - Actual value potentiometer
    - 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
    - Setting the steering angle limitation
        • Switch for steering angle limitation ±3° (3S35)
        • Detent-on stop
        • Stopping rod
        • Switch "blocked" (3S34)
        • Switch "released" (3S33)
    - Steering angle limitation - General
    - Steering angle limitation - Pin assignment for control board 3A24
    - Steering angle limitation - Detent control
    - Steering angle limitation - Detent control when switching on
    - Steering angle limitation - Aisle detection
    Aisle detection
        • Function
        • Aisle detection sensors
        • Mounting the reflectors
        • Guide to the LR80 operating modes and max. travel speeds.
    Notebook - preparation for programming the LR80
    Programming / Changing parameters / Test selection
    Summary of all the LR80 parameters for electrical steering
    Storing parameters
    Error messages

M Electrical system
    Guide to components - driver's cab and attachment
    Guide to components - load carriage
    Guide to components - assembly compartment
    Main current switchboard
    - Guide to components
    - Fuses
    - Main contactors
    Deadman's switch
    Barrier switch
    Electrical switchboard
    - Guide
    - DC/DC converter 48/24V
    - Safety relay board 7A21
    • General
    • Description
    • Pin assignment
    • Monitoring the deceleration
    • Dependency of the travel speed on the height,
    fork and rail switch
    • Speed code
    • Combinations of position switches on the mast
    • Chain breakage switches 2S60 and 2S61
    • Function of chain breakage switches 2S61 and 2S61
    • Adjusting the chain breakage switches 2S60 and 2S61
    • Checking the slack chain and chain breakage function
    • Speed sensor adaptation
    • Speed sensor signal for the PLC
    • Travel direction (actual direction)
    - Safety relay board 7A22
    • Description
    • Components and guide to connectors
    • Brake amplifier
    - Chassis distributor board A21
    • Guide to components (to approx. 9/99)
    • Guide to components (from approx. 10/99)
    • Guide to connectors (to approx. 9/99)
    • Guide to connectors (from approx. 10/99)
    • Function of the "Steering error" relay 3K1 1
    - PLC distributor A40 (Option)
    • General
    • Guide to connectors
    -  Distributor board A23
    • Guide to connectors
    • Test points and fuse
    Operating console
    - Operating elements
    - Special versions
    - Id. nos. of different operating console versions
    - Block diagram
    - Operating console board
    - Pin assignment
    - Keypad boards 1, 2 and 3
    - Potentiometer for hydraulics and travel
    - Operating lever
    • Function
    • Description
    • Removing the operating lever
    - Operating console display
    • General
    • Operating hours
    • Battery charge status
    • Wheel position display
    • Status symbols and maintenance symbols
    • Start-up test
    • Display of inductive automatic steering operating status
    • Error display
    Travel and pump control system
    - Connections
    • Control and logic section
    • Power section
    - Pin assignment X1 1
    - Block diagram peripheral travel and pump control system
    - Description
    - Travel setpoint
    - Travel direction (forwards, reverse)
    - Travel enable
    - Travel programs
    - Decelerations 1, 2 and 3
    - Deceleration 1 (v = 0 km/h)
    - Deceleration 2 (v = 2.5 km/h)
    - Deceleration 3 (v = 1 km/h)
    - Setpoint, hydraulic functions
    - Operating hours counter on lowering
    - Carbon brush monitoring
    - Temperature monitor
    - Status displays
    • ST-STAT
    • EIN-1
    • EIN-2
    • AUS-1
    - Standard parameter set
    - Battery type
    - Setting operating hours
    - Error memory
    - Error list for error memory
    - Description of errors
    - Reading the setpoints out of the FPS
    - Carbon brush monitor
    - Summary of all the FPS addresses
    - Summary of all travel parameters
    Notebook (WIN95) - Preparation for programming the FPS
    - Preparing the terminal program (TEWAK95) for reading out and programming parameters
    Notebook (WIN95) - Programming the FPS
    - Reading out parameters
    - Programming parameters
    - Guide to parameter settings for the terminal program (TEWAK95)

N Hydraulic system
    Block diagram of hydraulic system
    Hydraulics installation plan - Swivel shift fork
    Hydraulics installation plan - Chassis
    HMC-33 module
    - Functional elements
    - Adjustment work on the HMC-33 module
    - Emergency relief valve
    - Technical data
    SWR module
    DRH-CS2 module
    Checking the hydraulic oil level
    Oil filter
    Removing the hydraulic unit
    Hydraulic motor, technical data

Q Telescopic fork
    Electrical adjustment of the telescopic fork
    - General
    - Electrical pre-adjustment
    - Maximum extension depth
    - Extension speed
    - Ramp start
    - Centre position stop

R Lubrication plan
    Guide to oils/lubricants
    Lubrication plan
    Disposal of oil/lubricants

T Swivel shift fork
    Plan of the guide, load-bearing and lateral guide rollers
    Adjusting the tooth profile play
    Adjusting the guide block
    Mounting the shaft coupling
    Straightening the swivel shift fork with the shaft coupling
    Removing the shaft coupling
    Adjusting the pulling cylinders
    Removing the toothed shaft
    Removing the swivel shift fork
    Hydraulic motor OMP 160

V PLC
    Commissioning a new PLC
    Front panel of the PLC
    Input/output assignments 1st binary I/O module
    2nd binary I/O module
    3rd binary I/O module
    1st analogue I/O module
    PLC error messages
    Programming adapter
    - Description
    - Sketch of connections
    Notebook (MSDOS) - "DIGSY" software
    - Installing the "DIGSY" software
    - Loading operating program files
    - Starting the "DIGSY" software
    - Copying an application program file
    - Changing parameters in the PLC and programming
    - Loading a new program in the PLC
    - Current flow diagram
    • Examples for troubleshooting
    - MW8 - List of error bits
    • Description of the error bits
    • Reading out the error bit bar
    Table of PLC marker words
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