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Linde 336 Series Service Training Download Page 80

Service Training

Section

2.6

Page

26

2.6.4

VOLTAGE CONVERTER

The voltage converter (DC-DC converter) converts the 80 V battery voltage into a constant 24 V direct current
voltage. This voltage is used to power the electronic controls, fan and steering axle proximity switches.

The output voltage of the converter is not separated galvanically from the input voltage. The maximum output
current at 24 Volt is 3.3 Ampere (equals 80 Watt).
The green LED on the voltage converter is illuminated when the converter supplies the 24 V power output.
The converter is short-proof.

Specifications:

Input voltage:

50 - 150 Volt

Output voltage:

24 VDC

Power:

80 Watt

Intermittent rating:

100 %

Temperature range:

-35 to +70 °C

Type of protection:

IP 65 to DIN 40 050

Insulation voltage:

1500 V

Pin layout of 6-pin connector X8:
1

Input v80 V

2

Input, battery negative

3

Output v24 V

4

Output, battery negative

5

Not used

6

Not used

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Summary of Contents for 336 Series

Page 1: ...Training This document is only provided for your use during training and it remains the exclusive property of LINDE AG Werksgruppe Flurförderzeuge und Hydraulik Linde Electric Fork Truck E 20 25 30 Series 336 ...

Page 2: ......

Page 3: ...uction 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 g...

Page 4: ...e 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 C...

Page 5: ...dal 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 reduct...

Page 6: ...il 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 2...

Page 7: ...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 Wiring diagram 4 2 10 Specials 1 2 10 1 Pin Connectors 1 2 10 1 1 AMP Saab Pin Connectors 1 ...

Page 8: ...ServiceTraining ...

Page 9: ...nmotordirectionisreversedbyreversingthearmaturefield Aspeedsensorisinstalledontheleft handtractionmotorforsensingthemotorRPManddirectionofrotation 2 1 1 TRACTION MOTOR TO 6 95 Type DC series wound motor with armature reversal Model E 20 GF 144 14 5 4 E 25 30 GF 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 Type of protection IP00 IP23 DIN 40 050 Brushdi...

Page 10: ... 1B6 4 Thermal switch 160 C 1B6 5 Thermal switch 80 C 1B4 6 Thermal switch 80 C 1B4 7 Not used 8 Not used Armature terminals A1 and A2 Field terminals D1 and D2 Connector 1X7 for RH traction motor 1M1 1 Brush switch 6B1 2 Brush switch 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 Not used 8 Not used ...

Page 11: ...DIN 40 050 Brushdimensions 12 5x40x40 mm Permissiblewear down to 16 mm Collectordiameter original 104 mm Reworking down to 100 mm Components 1 thermal sensor potential free brush monitoring Connector 1X7 for RH traction motor 1M1 1 Brush switch 6B4 2 Brush switch 6B4 3 Thermal sensor 6B1 4 Thermal sensor 6B1 Connector 1X8 for RH traction motor 1M2 1 Brush switch 6B5 2 Brush switch 6B5 3 Thermal se...

Page 12: ...ServiceTraining Section 2 1 Page 4 ...

Page 13: ...etent 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...

Page 14: ...ServiceTraining Section 2 1 Page 6 2 1 4 TRACTIONMOTORDISASSEMBLY ...

Page 15: ...to 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 fa...

Page 16: ...nmotorsandpumpmotor Whenthetemperatureinoneofthethreemotors exceeds 80 C 24 V is applied to axial flow fan 9M1 and 9M2 via the combined instrument NOTE The fan operates only when the key switch is turned on i e the fan does not run when the key switch is turned off SPECIFICATIONS FOR FAN 9M1 Rated voltage 24 V Voltage range 12 24 V Powerconsumption 710 mA Power 17 W Temperaturerange 20 72 C Rated ...

Page 17: ...owered by two traction motors The two traction wheels are driven 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 ...

Page 18: ...ke 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...

Page 19: ...ServiceTraining Section 2 2 Page 3 ...

Page 20: ...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 mo...

Page 21: ...ServiceTraining Section 2 2 Page 5 ...

Page 22: ...ernately into the two access holes 9 and knock the bearing inner race 12 off the flange Remove and renew the shaft sealing ring 11 The O ring 4 is accessible after pressing out the washer 7 from the flange 10 Check and renew if necessary O rings 5 and 4 NOTE Thereareshims 3 mountedbetweentheflange 10 andwasher 7 Duringassemblyallshims must be installed again with the 0 5 mm shim on the profile sid...

Page 23: ...NTHETRACTIONMOTOR Install the O ring 17 in the housing Positiontheplanetaryhubreductiongearboxonthebearingplatewiththeplug 14 showingdown being sure that the holes are in alignment Wheninstallingthegearbox takecarethatthesungear 16 mesheswiththeinternaltoothingofthemotor shaft without damage Install the 14 socket head screws 13 and torque them to 86 Nm Install the oil drain plug 14 and copper seal...

Page 24: ... 13 with grease and drive it into the housing 19 Position the O rings 3 5 and 10 on the planetary carrier 12 and secure it with grease Carefully slide the flange 1 onto the planetary carrier 12 taking care not to damage the toothing Hit the washer 11 and O ring 2 into the flange making sure that the holes are in alignment Install the four hexagon head screws 4 and torque to 110 Nm 2 2 4 4 MOUNTING...

Page 25: ...e 2 O ring 3 O ring 4 Hexagon head screw 5 O ring 6 Plug 7 Sealing ring 8 Plug 9 Sealing ring 10 O ring 11 Washer 12 Planetary carrier 13 Shaft sealing ring 14 Socket head screw 15 Oil drain plug 16 Sealing ring 17 Sun gear 18 O ring 19 Housing ...

Page 26: ...th screw 7 Check the brake levers for ease of movement Insert the bolt with cotter 9 on the two brake shoes 5 and 6 Hook the parking brake cable 4 to the brake shoes 5 and 6 Adjust the parking brake cable 4 with the nut 2 and tighten the locknut 3 Mount the hose on the air duct Connect the cable connector to the fan Connect the cable connector to the speed sensor at the left hand traction motor Co...

Page 27: ...ServiceTraining Section 2 2 Page 11 ...

Page 28: ...ServiceTraining Section 2 2 Page 12 ...

Page 29: ...seat which activates timer 1A3 when actuated In order to prevent a faulty operation of the switch on uneven roadways the timer cuts off the enable signal for the traction and lift control after a delay of approx 2 seconds when the seat switch is no longer actuated Timer 1A3 is mounted opposite the voltage converter on the contactor board The timer is connected to the main cable harness via a 8 pin...

Page 30: ... fastener on the driver s seat gaiter Push the gaiter up Remove the socket head screw 2 and washer 1 Renew the microscwitch 9 after disconnecting the cable tie 5 1 Washer 2 Socket head screw 3 Holding plug 4 Holding plug 5 Cable tie 6 Cable connector 7 Base plate 8 Bracket 9 Microswitch ...

Page 31: ...head guard roof pane front windscreen with wiper and washer rear windscreen with wiper and washer doors 2 3 2 1 TORSION BAR SPRINGS Atorsionbarspringpackislocatedinthearticulatedareaofthecabin Thisspringpacktwistswhenthecabin is closed The mass energy of the cabin is thus stored in the springs allowing easy opening of the cabin A gas filled shock absorber prevents the cabin from closing too fast D...

Page 32: ... the overhead guard in this position with the aid of a crane and a sling Remove the clamping plates on the right and left of the spring pack Install the correct number of torsion bar springs Install the correct fishplates and correct number of washers Fasten fishplates at the left and right of the spring pack Release the cabin from the crane A fine adjustment of the spring pack can be done with th...

Page 33: ...ServiceTraining Section 2 4 Page 1 2 4 STEERING SYSTEM ...

Page 34: ...oximity switches Place an oil pan underneath the truck Disconnect the two hydraulic hoses to the steering cylinder at the pipes NOTE Trucks without the optional higher driver s seat have an additional weight on the counterweight This weight must be removed before the removal of the steering axle otherwise the truck must be raised too high due to the large height of the steering axle Place a suppor...

Page 35: ...ServiceTraining Section 2 4 Page 3 ...

Page 36: ...ofthesteeringknucklearm 15 toprevent it from being damaged Remove the track rod link 5 along with the bearings 6 and sealing rings 4 from the steering knuckle arm 15 Unscrew the sensor nut and remove the sensor Mark the position of the two bearing brackets 8 in relation to the axle body 9 NOTE The two bearing brackets must not be interchanged during re assembly Unscrew the fastening screws 7 for t...

Page 37: ...ServiceTraining Section 2 4 Page 5 ...

Page 38: ...care not to damage the guide bushing Remove the O rings 5 and 6 U cup packing 3 wiper 2 and guide band 7 from the guide bushing Install new O rings U cup packing wiper and guide band taking care to position the single sealing parts correctly see detail 33604 03 Remove the sealing ring 11 and guide band 10 from the piston rod and renew them Remove the second retaining ring 1 Remove the guide bushin...

Page 39: ...ServiceTraining Section 2 4 Page 7 ...

Page 40: ...e space around the tapered roller bearing 2 with Linde heavy duty grease Grease the inner races of the tapered roller bearing 2 well and install carefully on the outer race Fill the inside of the new shaft sealing ring 1 with Linde heavy duty grease and install it in the wheel hub in the correct position sealing lip showing inside Slide the wheel hub onto the wheel shaft taking care not to damage ...

Page 41: ...ServiceTraining Section 2 4 Page 9 ...

Page 42: ...out the axle body 8 upwards Remove wiper 2 taking care that the inner race of the tapered roller bearing 3 does not fall out Remove wiper 6 and the inner race of the tapered roller bearing 5 Extract both outer races of the tapered roller bearing 3 and 5 NOTE Wheninstallingthetaperedrollerbearings makesurethattheouterandinnerracesofthetwo bearings are not interchanged Drive new outer races into the...

Page 43: ...at the rollers in the tapered roller bearings can come into alignment Move the axle body through the full swivel range several times so that the rollers in the tapered roller bearings can become aligned Tighten the retaining screw 7 to the full torque of 1100 Nm NOTE The steering axle of the E 20 truck has two retaining screws each of which must be torqued to 295 Nm ...

Page 44: ... rod links on the centre axle 9 Install the marked bearing brackets 8 correctly and fasten them with screws 7 torque to 425 Nm Coat the pin 3 with MoS2 grease and press it into the track rod link 5 and steering knuckle arm with the roller pin pointing up pressing force 4 38 kN NOTE When pressing in pin 3 support the steering knuckle arm from below to prevent any damage to it Secure pin 3 with a ro...

Page 45: ...ServiceTraining Section 2 4 Page 13 ...

Page 46: ... Nm Ontruckswithoutthehigherdriver sseat installtheadditionalweight 4 inthecounterweightfrombelow and safely support it Install the first fastening screw 2 through the hole for the trailer coupling pin NOTE On trucks from series 10 94 the mounting bolt 2 can be accessed from below at the ballast weight 4 Install the second fastening screw 7 along with the plate 6 Tighten both screws Connect the tw...

Page 47: ...ServiceTraining Section 2 4 Page 15 ...

Page 48: ...pthatmetersthehydraulicoilflowfromtheworkinghydraulicsystem in accordance with the rotation of the steering wheel Thesteeringcontrolvalveconsistsofthesteeringhousingwiththevalveboreandthespoolthatcanbeturned and moved axially in the bore The axial movement of the spool modulates the working pressure and the reversal of the oil flow depending upon the steering wheel direction of rotation Thespoolha...

Page 49: ...sormicroswitchisactuatedbyacontrolcamwhentravellingforward or reverse Aconductiveplasticpotentiometerconnectedtothemoveablecontrolcamisfittedtotheacceleratorsensor Thepotentiometerhasabuilt inreturnspring whichmovesthepotentiometerandthecontrolcamtoasafe positionwhenthelinkagerodisdisconnected Inthispositionthemicroswitchturnsthedirectionalcontactors off Thechangeinresistanceinthepotentiometerisco...

Page 50: ...ServiceTraining Section 2 5 Page 2 DESCRIPTION 1 Connector 2 Cable harness 3 Transducer 4 Microswitch 5 Control cam 6 Ball 7 Potentiometer ...

Page 51: ...or sensor is between 7 5 V and 11 25 V for reverse travel and between 7 5 V and 3 75 V for forward travel The following voltages are important for the control range when checking the traction control for proper function Reverse Forward Neutral position 7 5 V 7 5 V Contactormakes 8 2 V 6 8 V Clocking starts 8 4 V 6 6 V End point signal approx 11 25 V 3 75 V Contactorbreaks 8 0 V 7 0 V 2 5 1 1 2 ADJ...

Page 52: ...he brake linings are worn Open and tilt the overhead guard to the second detent Slowly press the lever 9 with the hand The lever must then be approx 20 mm from the end stop of the lever For the adjustment loosen the locknut 12 at the threaded pin 11 and adjust the threaded pin Tighten the locknuts 12 again 2 5 2 3 ADJUSTINGTHEHANDBRAKE Open and tilt the overhead guard to the second detent Slowly e...

Page 53: ...ServiceTraining Section 2 5 Page 5 ...

Page 54: ...ServiceTraining Section 2 5 Page 6 ...

Page 55: ...g diode easiertroubleshooting improved dissipation of heat Features of the power unit N type channel enhancement type MOSFET Zener diode for active overvoltage protection gate source Zener diode and resistor against static overvoltage at the gate integrated gate resistors against internal oscillations insulated aluminium base plate longer air gaps Regenerativebrakingisstandardequipmentforthisserie...

Page 56: ... terminals 1 Source 2 Drain 3 Anode of brake diode 1V51 for motor 1M1 4 Anode of brake diode 1V52 for motor 1M2 5 Anode of regenerative current diode 1V53 6 Cathode terminals of freewheel and brake diodes Connector 7 1 Auxiliary source S 2 Not used 3 Gate 4 Not used 5 Not used 6 Auxiliary drain D ...

Page 57: ... Regenerative braking diode 3 Braking diode 4 Braking diode 5 Zener diode 6 Diode 7 Ballast Zener diode 8 Leakage resistor 9 Zener diode 10 Protective diode 11 MOSFETtransistor 12 Gate ballast resistor Specifications Voltage 80 V Max current 430 A at 70 C ...

Page 58: ...2 6 1 2 POWER MODULE FOR LIFT CONTROL Main terminals 1 Source 2 Drain 3 Anode terminal of freewheel diode 6 Cathode terminal of freewheel diode Connector 4 1 Auxiliary source S 2 Not used 3 Gate 4 Not used 5 Not used 6 Auxiliary drain D ...

Page 59: ...1 Freewheel diode 2 Braking diode not used 3 Zener diode 4 Diode 5 Ballast Zener diode 6 Leakage resistor 7 Zener diode 8 Protective diode 9 MOSFETtransistor 10 Gate ballast resistor Specifications Voltage 80 V Max current 350 A at 70 C ...

Page 60: ...rforming the test with the modules on the truck disconnect the battery plug and disconnect the main circuit lines on the power module TESTING IF POWER MODULE IS OFF Connect the ohmmeter to source 1 and drain 2 lead to the drain and lead to the source If there is no voltage measured at the gate the module is off The impedance between source and drain is highly resistive If the impedance between sou...

Page 61: ...f there is positive voltage at the gate the module is on and the impedance between source and drain is zero If the impedance is highly resistive the module is not working properly CAUTION When connecting the 9 Volt block battery to gate terminal 3 and to auxiliary source terminal 1 of the 6 pin plug make absolutely sure that the polarity is correct To reduce the test current install a 1 kOhm 0 25 ...

Page 62: ...ththemultimetersettotheOhmrange leadconnectedtosource1 leadconnected to drain 2 The protective diode does not block low impedance indicated lead connected to drain 2 lead connected to source 1 The protective diode blocks high impedance is indicated If both readings are the same the diode is defective ...

Page 63: ...cted one after the other to 2 3 and 4 The diodes block high impedance is indicated lead connected to 6 lead connected one after the other to 2 3 and 4 The diodes do not block low impedance is indicated If both readings are the same the protective diode is defective TESTING THE FREEWHEEL AND BRAKE DIODES IN THE POWER MODULE ...

Page 64: ...DULE Perform the test with the multimeter set to the Ohm range lead connected to 5 lead connected to 1 The diodes block high impedance is indicated lead connected to 5 lead connected to 1 The diodes do not block low impedance is indicated If both readings are the same the diode is defective ...

Page 65: ...preventdamagetothecoolingareaandtotheconnector Clean the underside of the power module in the area of the heat sink of any dust and foreign objects Toreducetheheattransferresistancebetweenthepowermoduleandthecounterweight usingaspatula apply a thin coating of thermal compound WPV10 to the mounting area of the power module Position the power module correctly Tighten the M10x35 socket head screws al...

Page 66: ...rviceTraining Section 2 6 Page 12 2 6 1 5 ARRANGEMENT OF CONTROL PANELS IN E 20 MODEL 1 Lift control 2 Traction control 3 Control current fuses 4 Timer 1A3 to series 6 95 trucks only 5 Main circuit fuses ...

Page 67: ...iceTraining Section 2 6 Page 13 2 6 1 6 ARRANGEMENT OF CONTROL PANELS IN E 25 E 30 MODEL 1 Lift control 2 Traction control 3 Main circuit fuses 4 Timer 1A3 to series 6 95 trucks only 5 Control current fuses ...

Page 68: ...e 2F1 for pump motor 2 Circuit breaker 1K6 3 Directional contactors 1K11 1K12 4 Control current fuses 5 Timer 1A3 to series 6 95 trucks only 6 Voltage converter U1 7 Regenerative current contactor 1K5 8 Directional contactors 1K21 1K22 9 Main circuit fuse 1F1 for traction motors ...

Page 69: ...ServiceTraining Section 2 6 Page 15 ...

Page 70: ...ServiceTraining Section 2 6 Page 16 2 6 2 CONTACTORS 2 6 2 1 DIRECTIONALCONTACTORS Circuit diagram ...

Page 71: ... 1 and take off the cover 2 Note the position of the mark Remove the movable tip 4 along with the tip spring 3 Remove the tip plate 5 Renew the plastic part 6 Install new tip plate 5 Install a new tip 4 along with a new tip spring 3 Renew the fixed contacts on the cover 2 Install the cover 2 ensuring that the mark is correctly positioned NOTE The contactor tip kit consists of items 3 4 5 and 6 and...

Page 72: ...ng Section 2 6 Page 18 2 6 2 2 REGENERATIVEBRAKINGCONTACTOR1K5 Theregenerativebrakingcontactor1K5hasamicroswitch1S10 1 builtintothetopformonitoringthecorrect switching operation of the contactor Circuit diagram 1 1 ...

Page 73: ...tric cables Remove the microswitch from the regenerative braking contactor Remove the Phillips screws 2 and washers and take off the cover 3 Note the position of the mark Remove the movable tip 4 5 9 and 10 Remove the tip plates 10 Renew the plastic part 7 Install new tip plate 10 Install new movable tip 4 5 9 and 10 Install the cover 3 ensuring that the mark is correctly positioned Install the el...

Page 74: ...ServiceTraining Section 2 6 Page 20 2 6 2 3 CIRCUIT BREAKER CONTACTOR 1K6 Circuit diagram ...

Page 75: ... Disconnect the battery plug Disconnect the connector at the contactor coils Apply a voltage of approx 4 V to the coils 2 cells of the truck battery or a 4 5 V flat battery and measure the current Reverse the poles of the power source The protective circuit is okay if the two test readings are clearly different If both test readings are identical renew the protective circuitry ...

Page 76: ...cated on mounting plate for RH diode 1V1 2 6 3 2 MAIN CIRCUIT FUSES IN MODEL E 25 E 30 1 Main circuit fuse for pump motor 2F1 250 A 2 Main circuit fuse for traction motors 1F1 355 A 3 Main circuit fuse for regenerative braking 1F3 100 A located on mounting plate for RH diode 1V1 2 6 3 FUSES 2 6 3 1 MAIN CIRCUIT FUSES IN MODEL E 20 Remove the cover to gain access to the main circuit fuses ...

Page 77: ...Cable 2 6 3 3 INSTALLATION OF THE MAIN CIRCUIT FUSES Carry out the installation of the main circuit fuses plate fuses according to the following illustration The two plate fuses must each be mounted with brass washers 3 on the top and bottom Subsequently torque the hexagonal nut 1 to 20 Nm ...

Page 78: ...ey switch 2 6F1 15A Combinedinstrument 3 4F3 15A Horn circuit breaker and regenerative current contactor 4 1F4 5A Traction control curve sensors 5 2F5 5A Control of working hydraulics steering 6 1F6 5A Fan motors CAUTION Use only genuine Linde replacement fuses high voltage version 2 6 3 4 CONTROL CURRENT FUSES IN MODEL E 20 ...

Page 79: ...o the control current fuses 1 1 1F2 15A Main control fuse 2 6F1 15A Combinedinstrument 3 4F3 15A Horn circuit breaker and regenerative current contactor 4 1F4 5A Traction control curve sensors 5 2F5 5A Control of working hydraulics steering 6 1F6 5A Fan motors CAUTION Use only genuine Linde replacement fuses high voltage version ...

Page 80: ...maximumoutput current at 24 Volt is 3 3 Ampere equals 80 Watt The green LED on the voltage converter is illuminated when the converter supplies the 24 V power output The converter is short proof Specifications Input voltage 50 150 Volt Output voltage 24 VDC Power 80 Watt Intermittentrating 100 Temperaturerange 35 to 70 C Type of protection IP 65 to DIN 40 050 Insulationvoltage 1500 V Pin layout of...

Page 81: ...n motor right hand 1M2 Traction motor left hand 1R2 Resistor 1V1 Diode 1V6 Freewheel diode 1V51 Brake diode 1V52 Brake diode 1V53 Regenerative current diode G1 Battery S2 Emergency off switch 1A1 Power unit 1B3 Current sensor 1F1 Main circuit fuse 1F3 Fuse 1K5 Regenerative current contactor 1K11 Reverse contactor right hand 1K12 Forward contactor right hand ...

Page 82: ...F1 regenerativecurrentcontactor1K5 break contact currentsensor1B3 contactor1K12 makecontact andcontactor1K22 breakcontact motor armaturewinding1M1 A1 A2 andmotorarmaturewinding1M2 A2 A1 contactor1K11 breakcontact and contactor 1K21 break contact motor field winding 1M1 D1 D2 and motor field winding 1M2 D1 D2 power unit 1A1 battery G1 ...

Page 83: ...F1 regenerativecurrentcontactor1K5 break contact currentsensor1B3 contactor1K11 makecontact andcontactor1K21 makecontact motor armaturewinding1M1 A1 A2 andmotorarmaturewinding1M2 A2 A1 contactor1K12 breakcontact and contactor 1K22 break contact motor field winding 1M1 D1 D2 and motor field winding 1M2 D1 D2 power unit 1A1 battery G1 ...

Page 84: ...REEWHEELCIRCUIT WhentheFETsinthepowermoduleareturnedoff thetractionmotorsinduceavoltage Theinducedvoltage is negative at terminals A1 and A2 and positive at D2 Therefore a freewheel current can flow through freewheel diode 1V6 bypassing the motors ...

Page 85: ...rates with the traditional reverse current braking Theregenerativecurrentcontactor1K5makesandthecontactof1K5opens Atthestartofbraking the power module is on allowing a current to flow from the battery through resistor 1R2 and so exciting the field windings of the motor After their excitation the motors function as generators and they supply a generator voltage Contactor 1K6 makes at the same time ...

Page 86: ... CIRCUIT STAGE 2 As soon as the motors act as generators a regenerative current flows through the brake diodes 1V51 and 1V52 back to the battery The battery negative pole is connected to the armature winding of the motors via regenerative brake diode 1V53 ...

Page 87: ...r 1K6 and the truck is braked to a standstill with plugging The regenerative current flows over the two brake diodes 1V51 and 1V52 and the contact of the open regenerative current contactor 1K5 The generator voltage is regulated in the field winding by the current flow Iftheemergencystopswitchisoperatedduringbraking thegeneratorcurrentreturnstothebatteryviafuse 1F3 and diode 1V1 ...

Page 88: ...l unit contains the entire control logic for the evaluation of the sensor signals the control of the power module the directional contactors and the control of the regenerative braking The electronictractioncontrolunithasa42 pinconnectorformonitoringandcontrollingalltractionfunctionsand regenerativebraking ...

Page 89: ... 17 red green negative directional contactor 1K11 18 violet negative regenerative current contactor 1K5 19 not used 20 black yellow signal of right curve sensor 1B10 21 brown seat switch enable signal 22 white reverse direction signal single pedal models 23 black green signal of temperature switch 1B6 and 1B7 traction motors 24 red signal of accelerator sensor 1A4 desired value 25 white signal of ...

Page 90: ...mary side of battery positive The electronic traction control unit is supplied with 24 Volt at 1X13 13 via connector X8 3 and fuse 1F4 Battery negative is connected to the electronic traction control unit via the auxiliary source terminal 1A1 of the compact module 24 V from voltage converter U1 2 6 6 1 POWERSUPPLY ...

Page 91: ...rom the voltage converter This d c voltage supplies the electronic traction control unit the integrated circuits and otherelectroniccomponents This15Voltpowersupplyisalsorequiredfortheacceleratorsensor thecurrent sensor and the speed sensor Supply voltage for accelerator sensor and current sensor 15 V via 1X13 12 Negative via 1X13 27 ...

Page 92: ...ls the enable signals for the electronic traction and lift control unit Battery negative is applied to 1A3 5 via seat switch 1S50 and overhead guard switch 9S20 When the key switch is turned on battery positive is applied to 1A3 8 via line D The relay in timer 1A3 makes and applies battery negative to traction control unit 1X13 21 via 1A3 7 ...

Page 93: ...ynegativeisappliedtothetractionmodule1X13 21viaseatswitch1S50andoverheadguardswitch 9S20 When seat switch 1S50 or overhead guard switch 9S20 is opened the timer relay opens after a delay of approx 2 seconds in order to prevent inappropriate switching when travelling on an uneven roadway ...

Page 94: ...ServiceTraining Section 2 6 Page 40 ...

Page 95: ...5 of the accelerator sensor When the accelerator pedal is depressed either for forward or reverse travel battery positive is applied via microswitch 1S12 to the coils of the four directional contactors The field effect transistors in the electronic traction control unit control the appropriate directional contactors dependent upon the output voltage of the accelerator sensor ...

Page 96: ...t When the accelerator sensor output voltage is less than 7 5 V a logic circuit integrated in the electronic traction control applies battery negative to contactors 1K12 right hand motor and 1K22 left hand motor with the help of the two transistors for forward direction of travel Inthisway switch1S12intheacceleratorsensordoesnotcontrolthedirectionalcontactorsanditistherefore electricallywear free ...

Page 97: ...SE DIRECTION OF TRAVEL Whentheacceleratorpedalforreversetravelisdepressed theacceleratorsensoroutputvoltageatterminal 1X13 24isover7 5Volt Thetwotransistorsforreversetravelnowapplybatterynegativetocontactors1K11 right hand motor and 1K21 left hand motor ...

Page 98: ... control unit via 4 pin flat connector 1X9 The black blue cable coming from the electronic traction control unit 1X13 7 is connected to terminal 2 of 4 pin connector 1X9 The directional switch is used to apply battery negative to 1X13 8 when driving forward or to 1X13 22 when reversing This battery negative signal then takes over control of the directional transistors in the electronic traction co...

Page 99: ...ect the blue cable on terminal 1X9 2 and plug it on the unused terminal 1X9 4 Install directional switch 1S13 on the steering column Connect directional switch 1S13 to flat connector 1X9 according to the wiring diagram NOTE Fromseries7 95 twoindicatorlightsintheinstrumentshowthepreselecteddirectionoftravel They are controlled directly via the two terminals 1 and 3 on plug 1X9 ...

Page 100: ...d to battery negative via terminals X6 3 or X7 3 They are activated by the steering cylinder When travelling straight ahead both sensors are activated and battery negative is applied to terminals 6 and 20inconnector1X13oftheelectronictractioncontrolunit Whenthesteeringlockisover40 thesensor inquestion 1B9 left handsensor 1B10 right handsensor isnolongeractuatedandthebatterynegative signal at 1X13 ...

Page 101: ...is over the sensing area of the sensors steering lock under 40 the two sensors apply battery negative voltage to the electronic traction control Both sensors are connected to the main wiring harness via a 3 pin connector sensor X6 with 1B9 on left hand side sensor X7 with 1B10 on right hand side AnLEDisbuiltintothesensor whichindicatestheswitchingfunctionofthesensor TheLEDisnotilluminated when the...

Page 102: ...actuates microswitch 1S4 and cuts off the battery negative signal at 1X13 9 Whenthehandbrakeisappliedandtheacceleratorpedalisfullydepressed alimitedcurrentof250Aflows through the traction motors This allows starting uphill because the truck does not roll back when the brake is released ...

Page 103: ...ust not turn Read the current The maximum current must be approx 430 Ampere CAUTION Perform the measurement quickly in order to prevent damage to the traction motors The maximum measuring time should not exceed 30 seconds Handbrakecurrent Install the current measuring pliers as described above Engage the handbrake and fully depress the accelerator pedal Read the current The handbrake current must ...

Page 104: ... brush holders When the temperature ofatractionmotorreaches160 C thebatterynegativesignalnormallyappliedtoconnector1X13 23iscut off The maximum current or motor voltage is reduced to prevent damage to the traction motors However it is possible to drive the truck at reduced speed 2 6 6 7 1 TEMPERATURE MONITORING WITH THERMAL SWITCHES TO SERIES 6 95 ...

Page 105: ...the warm state less effectively than in the cold state The thermal resistance of the thermal sensor increases rapidly with rising temperature The resistance of the thermal sensor is evaluated by the combined instrument The two thermal sensors are connected to the combined instrument via terminals 6X9 12 and 13 When the temperature is 160 C the battery negative signal at 6X29 29 electronic traction...

Page 106: ... the truck until the motor reaches operating temperature Measure the resistance again When the motor is warm 80 C the resistance should be approx 800 Ohm 2 6 6 8 SPEEDREDUCTION To limit the speed of the electric fork trucks it is necessary to separate the bridge between 1X13 27 and 1X13 38 and to solder fixed resistor 1R1 This fixed resistor is switched via an auxiliary 24 V relay 1K7 As soonasreg...

Page 107: ... 24 V NOTE The components marked with a broken line are already installed in the truck Speed Resistance 6 km h 26 1 kW 7 km h 24 9 kW 8 km h 24 3 kW 9 km h 23 7 kW 10 km h 23 2 kW 11 km h 22 1 kW 12 km h 21 5 kW 13 km h 21 0 kW 14 km h 20 0 kW 15 km h 18 2 kW ...

Page 108: ... one of two ways 1 By selecting the opposite direction with the accelerator pedal or the directional switch Whenthetruckreverses theacceleratorsensorsignalat1X13 24changestotheoppositedirection causing regenerative braking to be initiated On trucks with a directional switch regenerative braking is controlled via the terminals 1X13 22 and 1X13 18 ...

Page 109: ...generative braking can only be started when truck speed is over 0 9 km h 2 6 6 9 1 SPEED SENSOR IN THE TRACTION MOTOR The speed sensor is powered with a d c voltage of 5 Volt via an amplifier circuit The sensor supplies two outputsignals whichhaveadifferentfrequencyorphaserelationship dependinguponthemotorspeedand direction of rotation FUNCTIONALCHECK Power supply Jack up the truck and support it ...

Page 110: ... be measured at the side of the semiconductor plate This Hall voltage increases with the force of the magnetic field or of the motor current AstheHallvoltagerangesonlywithinarangeofafew100mV itisamplifiedbytheintegratedadaptivecircuit and fed back to the electronic traction control unit The adaptive circuit is integrated in the current sensor and it supplies the following output voltages output si...

Page 111: ...ServiceTraining Section 2 6 Page 57 Connector 1X6 1 15 V 2 Output signal 3 ...

Page 112: ...LICS Toachieveahighdegreeofeffectivenessofthehydraulicsystem thepumpshouldonlydelivertheamount of oil that is actually needed for the work cycle in question This requirement can be fulfilled by controlling the speed of the pump motor with an LTM control as required by the hydraulic load The installation of an LTM control for the lift hydraulics brings measurable energy savings and as a result a lo...

Page 113: ...l from seat switch timer 11 white yellow reed switch 3S1 signal steering control valve 12 not used 13 not used 14 white red sensor 2B14 signal auxiliary hydraulics 2 15 green red sensor 2B13 signal auxiliary hydraulics 1 16 violet sensor 2B12 signal tilting 17 not used 18 green blue discharge indicator cut off contact 19 black white sensor 2B11 signal lifting 20 blue red speed sensor 2B8 signal 21...

Page 114: ...ol is supplied with batterynegativeviathesourceterminalofthepowerunit Sensorsonthecontrolvalvesensethemovement of the hydraulic control levers Furthermore a speed sensor is mounted in hydraulic motor 2M1 to control themotorspeedduringsteering Thesesensorsaresuppliedwithad c voltageassoonasthesupplyvoltage is applied to the control unit The sensors are provided with 15 V via terminal 2X1 8 The nega...

Page 115: ...tor 2X1 10 This signal is also applied to terminal 2X1 18 via the cut off contact for the combined instrument 6P2 When the battery charge indicator with battery discharged 80 is cut off and the speed motor rpm for all work movements is reduced It is possible to continue work at reduced working speed The speed of the working hydraulics is also reduced to 50 when thermal switch 2B6 opens breaker at ...

Page 116: ... trucks from series 7 95 it is no longer necessary to actuate the seat switch to be able to work with the working hydraulics As soon as the battery is discharged over 80 or the temperature in the pump motor exceeds 160 C the speed of the working hydraulics is cut in half with a cut out contact in the combined instrument In these cases the battery negative signal applied to 2X1 9 is disconnected by...

Page 117: ...ntrol A distance sensor in eachvalveblockofthecontrolvalveblocksenseshowfarthecontrolleverinquestionhasbeenmovedand then sets the motor speed via the electronic control accordingly The motor speed is sensed with the speed sensor in the pump motor and adjusted as required The output signal of the distance sensors 2B11 2B12 2B13 and 2B14 ranges from 3 75 V to 11 25 V ...

Page 118: ...esensorsaresuppliedwith15Voltat2X1 8bytheelectronicliftcontrolunit Batterynegativeisprovided for the sensors via terminal 2X1 6 Output signals Neutral position of control spool 7 5 V Extended control spool max 3 75 V Retracted control spool max 11 25 V Sensor 2B11 lifting output signal at 2X1 19 and 2X1 6 Sensor 2B12 tilting output signal at 2X1 16 and 2X1 6 Sensor 2B13 auxiliary hydraulics 1 outp...

Page 119: ...tentiometer 3 it is possible to adjust the motor speed for function 1 rotate clockwise shift to the right etc With potentiometer 4 it is possible to adjust function 2 rotate anti clockwise shifting to the left The settingofthemotorspeeddependsonthetypeofattachmentanditshouldbetakenfromthespecifications of the manufacturer of the attachment AUXILIARY HYDRAULICS 2 The work cycle is enabled with sens...

Page 120: ...working hydraulics are being operated a priority valve for the steering system is installed in the steering control valve As soon as the steering is operated reed switch 3S1 in the steering control valve is actuated This switch is connected to the working hydraulics electronics and it lets the pump motor run at 600 rpm If the working hydraulics are not in operation the pump motor speed is controll...

Page 121: ...nt of the diaphragm is in front of the sensing area of the sensor In this way the frequency of the output signal changes with the speed of the motor FUNCTIONALCHECK Power supply Connect a voltmeter to 2X1 6 and 2X1 8 The supply voltage must be 15 Volt Output signal Connect a voltmeter to 2X1 20 and 2X1 6 Turn on the key switch Operate the steering When the pump motor is running the output signal m...

Page 122: ...ERATION UNTIL SERIES 6 95 The fans 9M1 and 9M2 are supplied with 24 V on the positive side by voltage converter U1 via fuse 1F5 Whenthetemperatureofthetractionmotorsorpumpmotorsrisestoover80 C temperatureswitches1B4 1B5 and 2B5 make connecting battery negative to the fans ...

Page 123: ...5 Thefans9M1and9M2usedforcoolingthetractionandpumpmotorsaresuppliedwithpoweronthepositive side with 24 V by voltage converter U1 via fuse 1F6 When the temperature of the traction motors or pump motors exceeds 80 C the combined instrument 6P2 applies 24 Volt to the two fans 9M1 and 9M2 ...

Page 124: ...ServiceTraining Section 2 6 Page 70 2 6 9 LOCATION OF CONNECTORS 2 6 9 1 LOCATION OF CONNECTORS TO SERIES 6 95 ...

Page 125: ...mal switch brush switch 1X9 4 pin Under RH switch cover at console Single pedal directional switch 1X10 6 pin Under floor groupAcceleratorsensor 1X11 2 pin Under RH switch cover at console Single pedal directional switch Baker 1X12 6 pin Electrical system centre Connector for traction power unit 1X13 42 pin Electrical system centre Connector for traction control unit 1X14 3 pin Under floor group B...

Page 126: ...ServiceTraining Section 2 6 Page 72 2 6 9 2 LOCATION OF CONNECTORS FROM SERIES 7 95 ...

Page 127: ... switch cover at console Single pedal directional switch 1X10 6 pin Under floor group Acceleratorsensor 1X11 2 pin Under RH switch cover at console Single pedal directional switch Baker 1X12 6 pin Electrical system centre Connector for traction power unit 1X13 42 pin Electrical system centre Connector for traction control unit 1X14 3 pin Under floor group Brake pedal switch 2X1 25 pin Electrical s...

Page 128: ...ServiceTraining Section 2 6 Page 74 ...

Page 129: ...elapsed service hours and other data With the aid of the diagnostic unit it is possible to communicate with the combined instrument via interface connector 6X6 Two relays are also installedwhichcontrolthetwofans fromseries7 95 Thesignalsfromthethermalsensorsandbrushwear switches are evaluated over various analogue and switching inputs 1 Field weakening active indicator light 2 Service interval ind...

Page 130: ...arkingbrakeswitch1S4isopened Thiscutsoffthebatterynegative signal applied to 6X9 23 and the lamp is illuminated 2 6 10 1 4 BRAKE SHOE WARNING LIGHT OPTION 2 6 10 1 5 MOTOR BRUSH WARNING LIGHT Abrushwearswitchisinstalledoneachmotorbrush Whenabrushisworndownto60 ofitsoriginallength the respective brush switch is activated The brush wear is signalled by the illumination of the lamp Information regard...

Page 131: ...ied to terminal 6X9 25 which illuminates the light 2 6 10 1 9 HYDRAULIC OIL LEVEL WARNING LIGHT OPTION Whenthehydraulicoillevelistoolow abatterynegativesignalisappliedtoterminal6X9 24ofthecombined instrument by a float switch 2 6 10 1 10 FAN WARNING LIGHT FROM SERIES 7 95 Whenthetemperatureinamotorexceeds140 C thislightisilluminatedinadditiontothemotortemperature warning light to signal that the o...

Page 132: ...oredintheoperatingsoftwareofthecombinedinstrumentforvarious typesofbatteries Thecorrectcurvemustbechosenforthebatteryinstalled Thebatterytypecanbemodified with menu item 21 1 Standard wet cell Varta factory setting 2 Standard wet cell Deta 3 Performance enhanced battery 4 Gel battery The discharge period and the age of the battery also affect the discharge characteristic The programmed discharge c...

Page 133: ...dified with menu item 22 The cell voltage value must be applied for a certain period of time after turning on the key switch before the discharge indicator is reset When the truck is delivered this value is set to 0 1 min This time can be changed with menu item 24 Type of Application Time for Reduction Change in Menu Change in Menu and Battery No 22 No 23 Particularly heavy duty Too early Reduce I...

Page 134: ...EPROM and it controls the input output and display No adaption of the operating software to newly developed or modified components is required The diagnostic unit is equipped with an LCD liquid crystal display with 4 lines each consisting of 20 digits and a foil keyboard with 20 keys A cable supplied with the diagnostic unit is used to connect the unit to the Linde component in question Power is s...

Page 135: ... 2 6 Page 81 DATEN NEU ENTER CE 0 9 RESET EIN AUS LICHT Switching on the diagnostic unit Switching off the diagnostic unit Resetting diagnostic unit Display lighting Data transmission No function Input keys Start a new input ...

Page 136: ...h 14 Number of motors 2 2 Two traction motors installed in truck 1 One traction motor installed in truck 15 Thermal sensors 1 1 Thermal sensor installed in motor 0 No thermal sensor installed in motor 21 Type of battery 1 1 Battery characteristic for standard PsZ cell Varta 2 Battery characteristic for standard PsZ cell Deta 3 Battery characteristic for enhanced PsZ cell 4 Battery characteristic f...

Page 137: ...function is implemented with each software version Only the combined instrument with the latest software version is available as replacement part Menu No Function Active from Software Version Implemented in truck since 11 Fan version 3 1 7 95 12 Hour meter 3 1 7 95 Variant 13 Service interval 2 1 4 94 14 Number of motors 3 1 15 Thermal sensor 3 1 7 95 21 Battery type 3 1 4 94 22 Upper end of chara...

Page 138: ...utton Enter the menu number The selected menu number MN will appear and the current value EW The programmed value can be modified with the and buttons The new value NW will appear in the second line of the display 2 6 11 1 1 PROGRAMMING OF MENU FUNCTIONS 11 TO 24 Connect the diagnostic unit to the truck data connector The data connector is located behind the left switch cover at the instrument pan...

Page 139: ...so the current service interval setting factory setting is 250 hrs The service hours at which the service interval indicator was last reset are shown in the second line of the display 31 250 XXXXXX After the battery test there will appear 31 250 XXXXXX XXXXXX Data end 2 6 11 1 2 RESETTING THE SERVICE INTERVAL INDICATOR WITH MENU FUNCTION 31 Connect the diagnostic unit to the truck data connector T...

Page 140: ...w combined instrument whose total service hour count is between 9999 7 and 00000 0 hours Connectthediagnosticunittothetruckdataconnector Thedataconnectorislocatedbehindtheleftswitch cover at the instrument panel Turn on the key switch Depress the EIN on button If the internal batteries are OK the following message will appear on the display MN BH ES Depress the DATEN NEU new data button Enter the ...

Page 141: ...number and the service hours are displayed Connect the diagnostic unit to the truck data connector The data connector is located behind the left switch cover at the instrument panel Turn on the key switch Depress the EIN on button If the internal batteries are OK the following message will appear on the display After the battery test there will appear Depress the DATEN NEU new data button Enter th...

Page 142: ...negative on one side When one brush is worn down to 60 of its original length the pressure spring touches the switching contact thus cutting off the battery negative signal at the combined instrument Pressing Spring Switching Contact The lamp in the combined instrument is illuminated and signals the wear of a motor brush Even if only a brief triggering of the switching contact at a motor brush occ...

Page 143: ...e two switching contacts 6B4 and 6B5 in the two traction motors cut off the appropriate battery negative signal at the combined instrument when the brushes are worn 2 6 12 2 WORKING HYDRAULICS PUMP MOTOR SWITCHING CONTACTS On the working hydraulics pump motor the brush wear switch 6B6 cut off the battery negative signal to the combinedinstrument ...

Page 144: ...rcuit 62 1Z22 Quench circuit 64 Colourcode BK black GN green WH white VT violet BU blue RD red OG orange YE yellow BN brown GY grey A1 Converter protective circuit 41 43 1A1 Tractioncontrolpowermodule 3 11 1A2 Tractioncontrol 56 102 1A3 Time relay 51 55 1A4 Acceleratorsensor 62 68 1A5 Amplifier for speed sensor 99 102 2A1 Lift control power module 15 20 2A2 Lift control 20 37 1B1 Acceleratorsensor...

Page 145: ...Section 2 6 Page 91 ...

Page 146: ......

Page 147: ......

Page 148: ... stop switch 1 1S4 Parking brake switch 153 1S5 Brake pedal switch 156 1S10 Regenerativecurrentswitch 163 1S12 Accelerator sensor switch 118 1S13 Directionalswitch 110 113 single pedalmodel 134 137 1S50 Seat switch 102 3S1 Steering switch 34 4S1 Hornbutton 180 9S20 Overheadguardswitch 102 U1 Voltageconverter 77 79 1V6 Tractionfreewheeldiode 8 1V51 Armaturediode 1M1 9 1V52 Armaturediode 1M2 11 1V53...

Page 149: ...Section 2 6 Page 93 ...

Page 150: ......

Page 151: ... to the 2nd detent Remove the hydraulic pump motor brushes Lift up the brush springs Pull the brushes out of their guides Renew the brushes 2 7 3 REMOVING THE HYDRAULIC PUMP UNIT Tilt the overhead guard to the 2nd detent Loosen the hose clamp on the hydraulic reservoir and disconnect the suction line Screw off the hydraulic pump supply line P at the steering control valve Remove the air duct Disco...

Page 152: ...4 2 ADJUSTINGTHEPRESSURE RELIEFVALVE The pressure relief valve is installed in the control valve block end plate Install a pressure gauge on the working hydraulics if equipped with auxiliary hydraulics preferably at the quick disconnectcoupling Remove the cap 1 on the adjusting screw 2 Loosen the locknut 3 on the adjusting screw 2 Operate the control lever for the working hydraulics Set the pressu...

Page 153: ...ServiceTraining Section 2 7 Page 3 ...

Page 154: ...ar and support the valve Disconnect the connector on the distance sensor 1 Remove the two socket head screws 4 and lock washer 5 Carefullypullthedistancesensordownandoutofthesleeveretainer 3 takingcarenottoloseanyshims 6 NOTE Theshimsarenecessaryforthemechanicaladjustmentofthedistancesensor Dependingon the version of the control valve one or more shims may be installed These shims must be re insta...

Page 155: ...on of the shims is correct Retain the original connector position Screw in and hand tighten the two socket head screws 4 and lock washers 5 Install the plug on the distance sensor Remove the support at the control valve and lower the control valve The control of the distance sensor output signal is described in the section 2 6 on the electrical system ...

Page 156: ...ngle auxiliary hydraulics 9 6 3 way valve for tilting 10 6 3 way valve for lifting 11 Restrictor 12 Make up valve 13 Maximum pressure valve 14 Pressure holding valve 15 Tilt jack 16 Brake lower valve 17 Pipe safety valve 18 1 Lift jack standard mast 18 2 Lift jack duplex mast 18 3 Lift jack triplex mast B Steeringhydraulics 19 Steering control valve 20 7 3 way valve 21 Non return valve 22 Shock va...

Page 157: ...ServiceTraining Section 2 7 Page 7 ...

Page 158: ...ServiceTraining Section 2 7 Page 8 ...

Page 159: ...tage is indicated by a light emitting diode The output fuse makes the converter short proof There is a false pole protection at the input side of the converter CAUTION Themaximumpowerofthevoltageconverteris200W Iftherequiredpowerishigher asecond voltage converter must be installed This voltage converter must not be connected in parallel totheexistingone Thetwovoltageconvertersmustbeseparatedonthes...

Page 160: ...ghting 2 Working light switch 9S2 Switch lighting 3 Front wiper switch 9S3 Switch lighting 4 Rear wiper switch 9S3 Switch lighting 5 Light switch 5S11 Switch lighting 6 Hazard warning flasher switch 5H19 Switch lighting NOTE The switches can be arranged in different sequences depending on the version ...

Page 161: ... Page 3 2 9 1 3 FUSE BOXES Top view of fuse boxes I and II Fuse Output A F Fuse Input 1 6 Fuse Input 1 6 Fuse Output A F Wire harnesses 1 Front wiper 1a Rear wiper 2 Lighting 3 Working lights 4 Voltageconverter 5 Voltageconverter ...

Page 162: ...5H18 5H19 Switchlighting 22 23 5H20 Stoplight left 27 5H21 Stoplight right 28 9H1 4 Switchlighting 14 15 53 67 9H5 Switchlighting 39 5K1 Flasher 33 34 9K1 Frontwiperintermittentrelay 41 45 9K2 Rear wiper intermittent relay 55 59 9M1 Front wiper motor 45 47 9M2 Rear wiper motor 59 61 5S11 Light switch 20 22 5S12 Hazard warning switch 30 34 5S13 Turn signal switch 31 32 5S14 Stop light switch 28 9S1...

Page 163: ...Section 2 9 Page 5 ...

Page 164: ......

Page 165: ...rect position on the insulated wire With the aid of a pair wire strippers remove 5 mm the insulation taking care not to demage the inner wire The insulation of the wire must protude 1 mm from the seal 2 Place the wire 3 with the seal 2 into the connector pin 1 as illustrated below With the crimping pliers WM 145 first crimp the connector pin onto the seal 2 in the area marked 4 Secondly the contac...

Page 166: ...ServiceTraining Section 2 10 Page 2 ...

Page 167: ......

Page 168: ...804 2401 1295 LINDE AG Werksgruppe Flurförderzeuge und Hydraulik 63701Aschaffenburg Postfach100136 Telefon 06021 99 0 Telefax 06021 99 1570 http www linde de linde stapler eMail service training linde fh de ...

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