Linde E25 Manual

ServiceTraining
This document is only provided for your use during training and it remains the exclusive property of
LINDE AG WerksgruppeFlurförderzeugeund Hydraulik
Linde Electric Fork Truck
E 20 / 25 / 30
Series 336

ServiceTraining
TABLEOFCONTENTS
2 Linde electric fork truck E 20 / 25 / 30 Series 336 1
2.1 Drive - Motor 1
2.1.1 Traction motor to 6/95 1
2.1.2 Traction motor from 7/95 3
2.1.3 Checking and renewing the traction motor brushes 5
2.1.4 Traction motor disassembling 6
2.1.5 Fan 8
2.1.6 Speed sensor 8
2.2 Drive - Gearbox 1
2.2.1 Drive axle removal 2
2.2.2 Drive axle disassembly and assembly 4
2.2.3 Planetary hub reduction gearbox (from 1/95 to 5/95) 6
2.2.3.1 Removing the planetary hub reduction gearbox from the traction motor 6
2.2.3.2 Disassembly of the planetary hub reduction gearbox 6
2.2.3.3 Assembly of the planetary hub reduction gearbox 6
2.2.3.4 Installing the planetary hub reduction gearbox on the traction motor 7
2.2.4 Planetary hub reduction gearbox (from series 6/95) 8
2.2.4.1 Removing the planetary hub reduction gearbox from the traction motor 8
2.2.4.2 Disassembly of the planetary hub reduction gearbox 8
2.2.4.3 Assembly of the planetary hub reduction gearbox 8
2.2.4.4 Mounting the planetary hub reduction gearbox on the traction motor 8
2.2.5 Drive axle installation 10
2.3 Chassis 1
2.3.1 Seat switch 1
2.3.1.1 Renewing the seat switch 2
2.3.2 Cabin 3
2.3.2.1 Torsion bar springs 3
2.3.2.1.1 Removing and installing the torsion bar springs 4
2.4 Steering system 1
2.4.1 SteerIng axle 2
2.4.1.1 Steering axle removal 2

ServiceTraining
2.4.1.2 Steering cylinder and track rod link 4
2.4.1.3 Renewing the steering cylinder seals 6
2.4.1.4 Renewing the wheel hub tapered roller bearings and shaft sealing ring 8
2.4.1.5 Renewing the axle body tapered roller bearings and wipers 10
2.4.1.6 Installing the steering cylinder and track rod link 12
2.4.1.7 Installing the steering axle 14
2.4.2 Power steering control valve 16
2.5 Controls 1
2.5.1 Travel control 1
2.5.1.1 Accelerator sensor 1
2.5.1.1.1 Accelerator sensor output signals 3
2.5.1.1.2 Adjustment of the neutral position 3
2.5.2 Braking 4
2.5.2.1 Renewing the brake linings 4
2.5.2.2 Adjusting the foot brake 4
2.5.2.3 Adjusting the hand brake 4
2.6 Electrical system 1
2.6.1 Compact power module 2
2.6.1.1 Traction power module 2
2.6.1.2 Power module for lift control 4
2.6.1.3 Power module tests 6
2.6.1.4 Installation of the power modules 11
2.6.1.5 Arrangement of control panels in E 20 models 12
2.6.1.6 Arrangement of control panels in E 25 / E 30 model 13
2.6.1.7 Contactor panels 14
2.6.2 Contactors 16
2.6.2.1 Directional contactors 16
2.6.2.2 Regenerative braking contactor 1K5 18
2.6.2.3 Circuit breaker contactor 1K6 20
2.6.2.4 Testing the protective circuitry 21
2.6.3 Fuses 22
2.6.3.1 Main circuit fuses in model E 20 22
2.6.3.2 Main circuit fuses in model E 25 / E 30 22
2.6.3.3 Installation of the main circuit fuses 23
2.6.3.4 Control current fuses in model E 20 24
2.6.3.5 Control current fuses in model E 25 / E 30 25

ServiceTraining
2.6.4 Voltage converter 26
2.6.5 Main circuit section traction control 27
2.6.5.1 Current path for forward travel direction 28
2.6.5.2 Current path for reverse travel direction 29
2.6.5.3 Freewheel circuit 30
2.6.5.4 Regerative current braking 31
2.6.5.4.1 Brake circuit stage 1 31
2.6.5.4.2 Brake circuit stage 2 32
2.6.5.4.3 Brake circuit stage 3 33
2.6.6 Electronic traction control unit 34
2.6.6.1 Power supply 36
2.6.6.2 TRACTION ENABLE 38
2.6.6.2.1 Traction enable to series 6/95 38
2.6.6.2.2 Traction enable from series 7/95 39
2.6.6.3 Control of direction contactors 41
2.6.6.3.1 Forward direction of travel 42
2.6.6.3.2 Reverse direction of travel 43
2.6.6.4 Single Pedal Models 44
2.6.6.4.1 Modification to single pedal model 45
2.6.6.5 Driving around corners 46
2.6.6.5.1 Sensors for steering position 47
2.6.6.6 Handbrake current 48
2.6.6.6.1 Checking the maximum current and handbrake current 49
2.6.6.7 Temperature monitoring traction motors 50
2.6.6.7.1 Temperature monitoring with thermal switches to series 6/95 50
2.6.6.7.2 Temperature monitoring with thermal sensors from series 7/95 51
2.6.6.8 Speed reduction 52
2.6.6.9 Regenerative braking 54
2.6.6.9.1 Speed sensor in the traction motor 55
2.6.6.10 Current sensor 56
2.6.7 LTM control for working hydraulic system and steering 58
2.6.7.1 Electronic lift control 59
2.6.7.1.1 Power supply 60
2.6.7.1.2 Enable signal, thermal switch and cut-off when battery is discharged (to series 6/95) 61
2.6.7.1.3 Enable signal, thermal sensor and cut-out with discharged battery (from series 7/95) 62
2.6.7.1.4 Control of the various work functions 63
2.6.7.1.5 Adjustments 65
2.6.7.2 Control of steering function 66

ServiceTraining
2.6.7.2.1 Operation of speed sensor 2B8 67
2.6.8 Fans 68
2.6.8.1 Fan method of operation until series 6/95 68
2.6.8.2 Fan method of operation from series 7/95 69
2.6.9 Location of connectors 70
2.6.9.1 Location of connectors to series 6/95 70
2.6.9.2 Location of connectors from series 7/95 72
2.6.10 Combinedinstrument 75
2.6.10.1 Indicator lights 75
2.6.10.1.1 Field weakening active indicator light (option) 76
2.6.10.1.2 Turn signal indicator light (from series 7/95) 76
2.6.10.1.3 Parking brake warning light (from series 12/94) 76
2.6.10.1.4 Brake shoe warning light (option) 76
2.6.10.1.5 Motor brush warning light 76
2.6.10.1.6 Engine temperature warning light (from series 7/95) 76
2.6.10.1.7 Travel direction indicator (option) 77
2.6.10.1.8 Hydraulic oil temperature warning light (option) 77
2.6.10.1.9 Hydraulic oil level warning light (option) 77
2.6.10.1.10 Fan warning light (from series 7/95) 77
2.6.10.1.11 Service interval indicator light 77
2.6.10.2 Battery discharge indicator 78
2.6.11 Linde Diagnostic Unit 80
2.6.11.1 Operation of the diagnostic unit in connection with the combined instrument 82
2.6.11.1.1 Programming of menu functions 11 to 24 84
2.6.11.1.2 Resetting the service interval indicator with menu function 31 85
2.6.11.1.3 Programming and reading the service hour menu functions 32 to 35 86
2.6.11.1.4 Read-out functions with menu functions 41 to 43 87
2.6.12 Brush monitoring 88
2.6.12.1 Traction motor switching contacts 89
2.6.12.2 Working hydraulics pump motor switching contacts 89
2.6.13 Wiringdiagram 90
2.6.13.1 Wiring diagram to series 6/95 90
2.6.13.2 Wiring diagram from series 7/95 92
2.7 Hydraulic system 1
2.7.1 Hydraulic pump motor 1
2.7.2 Renewing the hydraulic pump motor brushes 1

ServiceTraining
2.7.3 Removing the hydraulic pump unit 1
2.7.4 Control valve 2
2.7.4.1 Removing the control valve 2
2.7.4.2 Adjusting the pressure relief valve 2
2.7.5 Working and steering hydraulivs circuit diagram 6
2.9 Options 1
2.9.1 Lighting, wipers and heater 1
2.9.1.1 Voltage converter 1
2.9.1.2 Switches 2
2.9.1.3 Fuse boxes 3
2.9.1.4 Wiringdiagram 4
2.10 Specials 1
2.10.1 Pin Connectors 1
2.10.1.1 AMP-Saab Pin Connectors 1

ServiceTraining

ServiceTraining Page 1
Section 2.1
2 LINDE ELECTRIC FORK TRUCK E 20 / 25 / 30 SERIES 336
2.1 DRIVE - MOTOR
The electric fork trucks are powered by DC series-wound motors. DC series-wound motors develop the
highesttorqueofall electricmotors.Inseries-woundmotorsthefieldwinding isconnectedinseriestothe
armature.
Thefield windings terminalsD1andD2 and thearmaturewindingterminals A1 andA2aremarked. They
areleadoutofthemotorseparately.Thetractionmotordirectionisreversedbyreversingthearmaturefield.
Aspeedsensorisinstalledontheleft-handtractionmotorforsensingthemotorRPManddirectionofrotation.
2.1.1 TRACTION MOTOR TO 6/95
Type: DC series-wound motor witharmaturereversal
Model: E 20 GF144-14/5.4
E 25 / 30 GF146-14/7.8
Voltage: 80 V
Power: E 20 5.0 kW S2 (60 min rating)
E 25 / 30 6.4 kW S2 (60 min rating)
Typeof protection: IP00 / IP23 DIN 40 050
Brushdimensions: 12.5x40x40mm
Permissiblewear: down to 16 mm
Collectordiameter: original 104 mm
Reworking downto: 100 mm
Components: 2 thermal switches; 1 normally open operates at 80 °C; 1 normally closed
operates at 160 °C; brush monitoring, speed sensor on left-hand motor

ServiceTraining
Section 2.1
Page 2
Right-handtractionmotor1M1
Connector 1X8 for LH traction motor 1M2
1 Brushswitch 6B3
2 Brushswitch 6B4
3 Thermal switch 160 °C 1B6
4 Thermal switch 160 °C 1B6
5 Thermal switch 80 °C 1B4
6 Thermal switch 80 °C 1B4
7 Notused
8 Notused
Armature terminals A1 and A2
Field terminals D1 and D2
Connector 1X7 for RH traction motor 1M1
1 Brushswitch 6B1
2 Brushswitch 6B2
3 Thermal switch 160 °C 1B7
4 Thermal switch 160 °C 1B7
5 Thermal switch 80 °C 1B5
6 Thermal switch 80 °C 1B5
7 Notused
8 Notused

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Section 2.1
2.1.2 TRACTIONMOTORFROM 7/95
Type: DC series-wound motor witharmaturereversal
Model: E 20 Juli GF144-14/5.4
E 25 / 30 JuliGF 146-14/7.8
Voltage: 80 V
Power: E 20 5.0 kW S2 (60 min rating)
E 25 / 30 6.4 kW S2 (60 min rating)
Typeof protection: IP00 / IP23 DIN 40 050
Brushdimensions: 12.5x40x40mm
Permissiblewear: down to 16 mm
Collectordiameter: original 104 mm
Reworking downto: 100 mm
Components: 1 thermalsensor;potential-freebrush monitoring
Connector 1X7 for RH traction motor 1M1
1 Brushswitch 6B4
2 Brushswitch 6B4
3 Thermalsensor6B1
4 Thermalsensor6B1
Connector 1X8 for RH traction motor 1M2
1 Brushswitch 6B5
2 Brushswitch 6B5
3 Thermalsensor6B2
4 Thermalsensor6B2
Armature terminals A1 and A2
Field terminals D1 and D2

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Section 2.1
Page 4

ServiceTraining Page 5
Section 2.1
2.1.3 CHECKINGAND RENEWINGTHETRACTIONMOTORBRUSHES
Themotorbrushescanbecheckedforwearandfreemovementafteropeningthedriver’soverheadguard.
- Block up the truck at the axle.
- Raise the fork carriage and secure against inadvertent lowering.
- Chockthe wheels
- Turn off the key switch.
- Disconnectthe battery plug.
- Open the overhead guard as far as the second detent position.
- Lift up the rubber covers (4) over the traction motors.
- Remove the brush cover on the traction motors (1) and (5).
- Lift up the pressure springs (2).
NOTE: When lifting the springs from the motor brushes and putting them on the holder, be sure that
theydonotslideoffandopen,ascompressingthemwhenthemotorsareinstalledisextremely
difficult
- Pull the motor brushes (3) out of the guide.
- Check the length of the motor brushes (minimum length 16 mm).
- Renew worn motor brushes only as a set.
- After renewing the brushes, check the brushes for free movement in the guides and the brush leads for
security.

ServiceTraining
Section 2.1
Page 6
2.1.4 TRACTIONMOTORDISASSEMBLY

ServiceTraining Page 7
Section 2.1
1 Brakedisc
2 Hexagonalscrew
3 Bearingplate
4 Hexagonalscrew
5 Brushholder
6 Brushspring
7 Bearing
8 Retainingring
9 Shim
10 Armatureassembly
11 Housing
12 Gasket
13 Hexagonalscrew
14 Cover
15 Sealingring
16 Bearingplate
17 Groovedball bearing
18 Retainingring
- Remove the speed sensor when dismantling the left-hand traction motor.
- Remove the cover strap.
- Remove the four brushes.
- Screw two M10x50 press-off screws into the brake disc (1).
- Remove the brake disc with the press-off screws. Turn the screws alternately to prevent the brake disc
from seizing (brake disc is pressed on with 30 kN).
- Remove the retaining ring (18).
- Mark the position of the bearing plate (16) to the motor housing (11).
- Remove the bearing plate (16).
- Press out the armature assembly (10).
- Do not lose the shim (9) and re-use it during re-assembly.
- Remove the 8 fastening screws (2) (torque 110 Nm, secured with Loctite 243).
- Mark the position of the inner bearing plate (3) to the motor housing (11).
- Disconnect the field leads at the brush holder (5).
- Remove the inner bearing plate (3).
- Remove the retaining ring (8).
- Drive out the bearing (7).

ServiceTraining
Section 2.1
Page 8
2.1.5 FAN
Fan method of operation to 6/95:
The traction motors and pump motor are forced-air ventilated by axial-flow fan 9M1. When the operating
temperatureofoneofthethreemotorsexceeds80°C,batterynegativeisappliedtothefansviathreethermal
switches(1B4,1B5and2B5)connectedinparallel.Thefansaresuppliedwith24Vdirectcurrentovervoltage
converter U1. The 80 °C thermal (make) switches are mounted on the motor brush holders.
Fan method of operation from 7/95:
Incontrasttotheabovefanmethodofoperationupto6/95,thermalsensors6B1,6B2and6B3aremounted
onthebrushholdersofthetractionmotorsandpumpmotor.Whenthetemperatureinoneofthethreemotors
exceeds 80 °C, +24 V is applied to axial-flow fan 9M1 and 9M2 via the combined instrument.
NOTE: Thefanoperatesonlywhenthekeyswitchisturnedon,i.e.thefandoesnotrunwhenthekey
switch is turned off.
SPECIFICATIONSFORFAN9M1
Ratedvoltage: 24 V
Voltagerange: 12 - 24 V
Powerconsumption: 710 mA
Power: 17 W
Temperaturerange: -20 ... +72 °C
Ratedspeed: 3400 rpm
2.1.6 SPEEDSENSOR
A differential speed sensor (1B8) is installed on the left-hand motor. The speed sensor senses the brake
disc bridges and supplies information regarding the motor speed and direction of rotation.
Adjustment:
Thespeedsensorismountedonanangleplateontheinsidebearingplate.Theairgapbetweentheactive
sensor area and a web on the brake disc must be 1.0+0.3 mm.

ServiceTraining Section 2.2
Page 1
2.2 DRIVE-GEARBOX
Theseries336electricforktrucksarepoweredbytwotractionmotors. Thetwotractionwheelsaredriven
by two planetary hub reduction gearboxes mounted on the traction motors. The motor and the reduction
gearbox together form one drive unit that is bolted to the truck chassis. For repairs, the drive axle can be
removed as a single unit.

ServiceTraining
Section 2.2
Page 2
2.2.1 DRIVEAXLEREMOVAL
- Remove the mast and the front wheel bolts.
- Jack up and secure the truck.
- Tilt the overhead guard back to the second detent.
- Unscrew the wheel bolts and remove the wheels.
- Loosenthelocknut(3)ontheparkingbrakelever(1)andtheadjustmentnut(2)ontheparkingbrakecable
(4).
- Unhook the parking brake cable (4) at the bottom of the brake shoes (5) and (6).
- Remove one pin retainer (9) on each of the two brake shoes (5) and (6).
- Unscrewthesocketheadscrew(7)atthebearingplatesandremovethelever(8)alongwiththeconnecting
rod (11).
- Disconnect the cables at the traction motors.
- Disconnect cable connectors 1X7 and 1X8 at the traction motors.
- Disconnect the cable connector for the speed sensor on the left-hand traction motor.
- Disconnect the cable connector for the fan.
- Remove the air duct hose.
- Support the drive axle with a pallet truck and blocks of wood.
- Remove the eight fastening screws on each bearing plate.
- Lower the drive axle.

ServiceTraining Section 2.2
Page 3

ServiceTraining
Section 2.2
Page 4
2.2.2 DRIVEAXLEDISASSEMBLYANDASSEMBLY
Disassembly:
- Remove the motor brush cover on each traction motor.
- Remove the fan along with the air duct.
- Remove the two lower socket head screws (3).
- Remove socket head screws (8).
- Take out the brake shoes (4) and (5) with bushings (6) and (7).
- Separate the two drive halves (1) and (2).
Assembly:
- Join the two drive halves (1) and (2) and bring them into alignment.
- Insert the brake shoes (4) and (5) with bushings (6) and (7).
- Screw in socket head screws (8).
- Screw in the lower socket head screws (3).
- Torque socket head screws (3) and (8) to 540 Nm.
- Install the fan along with the air duct.
- Fasten the motor brush cover on each traction motor.