Linde Truck Type 009: K15-3, K15-3AC Service Training (Workshop) Manual

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

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