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

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 (4×21)
– Proportional amplifier module (2×1 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 A4.3

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