Linde E 20-02 Operating Instructions Manual Download Page 1

Page: 1 / 96

With Electric Motors

336 804 3001 GB

E 20 - 02 / E 25 - 02 / E 30 - 02

E 20/600 - 02 / E 25/600 - 02 / E 30/600 - 02

Operating Instructions

0704

Linde Fork Lift Truck

e336-02/01

Summary of Contents for E 20-02

Page 1: ...With Electric Motors 336 804 3001 GB E 20 02 E 25 02 E 30 02 E 20 600 02 E 25 600 02 E 30 600 02 Operating Instructions 0704 Linde Fork Lift Truck e336 02 01...

Page 2: ......

Page 3: ...ndustrial trucks and hydraulics It includes eight manufacturing plants in the Federal Republic of Germany France and Great Britain as well as subsidiaries and bran ches in all economically im portant...

Page 4: ...lubricants To keep your warranty valid all maintenance services must be performed by qualified persons authorised by Linde The terms front rear left and right refer to the position in which the item...

Page 5: ...be copied translated or transmitted to third parties after prior written approval by the manufacturer Linde pursues a policy of continuous progress in the design and construction of its products As a...

Page 6: ...336 804 3001 0704 4...

Page 7: ...applicable guidelines are fulfilled 4 Serial No year 5 Unladen mass 6 Battery voltage 7 Min battery mass 8 Max battery mass 9 Rated capacity 10 Type 11 Mast number glued 12 Working hydraulics and powe...

Page 8: ...h about 9600 employees in eight plants The driver s position and the controls are arranged in accord ance with state of the art human engineering The arrange ment and operation of each control is adap...

Page 9: ...l model 32 Steering system 34 Steering 34 Braking system 35 Service brake regenerative brake 35 Foot brake 35 Operating the electric motor brake LBC 35 Handbrake 35 Engaging the handbrake 35 Releasing...

Page 10: ...336 804 3001 0704 8...

Page 11: ...der pivots 68 Retighten the mast fastening bolts 68 Sideshift Clean grease and check the mounting 69 Check the braking system 69 Check the brake linings lubricate the brake lever pivot 69 Visual check...

Page 12: ...ight 5 kg 6 6 Power consumption in acc with VDI cycle kWh h 8 1 Type of drive control 8 2 Working pressure for attachments bar 8 3 Oil supply for attachments l min 8 4 Mean noise level at driver s ear...

Page 13: ...heights retracted with 150mm free lift Standard h1 2154 2254 2454 2754 3004 2072 2222 2472 2072 2222 2472 2672 2922 Lift heights extended h4 3507 3707 4107 4707 5207 3513 3813 4313 4913 5303 5953 6553...

Page 14: ...conformance with EN 13059 on trucks with standard equipment according to the technical data sheet driving over test course with bumps Frequency characteristic acc to EN 12096 Measured frequency charac...

Page 15: ...g digital controller LDC make this truck a valu able tool The truck is of compact design has good visibility and maximum load and curve stability due to its long wheelbase The combined articulating ax...

Page 16: ...d tiltable 3 Steering wheel 4 Driver s seat 5 Cover electrical system 6 Counterweight 7 Steering axle 8 Chassis with battery compartment 9 Left reduction gearbox 10 Fork carriage 11 Tilt cylinder 12 F...

Page 17: ...ntrol lever joystick for working hydraulics 8 Symbol label for working hydraulics 9 Control lever joystick for auxiliary hydraulics attach ments 10 Symbol label for auxiliary hydraulics 11 Handbrake 1...

Page 18: ...single pedal model Possible cause Perform the appropriate inspection and service Electric fan defective fuse blown brushes worn thermal sensors faulty cables broken Too little oil in hydraulic circui...

Page 19: ...ssible to set the replacement hour meter so that the actual aggregate service hours are displayed Please contact your authorised dealer in this regard Thecompositeinstrumentalsocontainsthefollowingind...

Page 20: ...d by the manufacturer Only store fluids and lubricants in approved containers at specified storage places As they could be inflammable do not contact them with hot objects or a naked flame Follow the...

Page 21: ...heck tyre inflation pressure Tighten wheel nuts Check hydraulic oil level Check steering system Check braking system Check mast and attachments Check condition and tightness of electric cables connec...

Page 22: ...20 336 804 3001 0704...

Page 23: ...ation Check the tyre inflation pressure ATTENTION Low inflation pressure reduces tyre service life and truck stability Check the tyres for correct inflation pressure If required inflate the tyres acco...

Page 24: ...e first lock in position and release it Daily checks and servicing before operation Beginning operation Second lock in position Battery change Stand behind the truck on the left hand side Seize the ov...

Page 25: ...locking position 6 Push the lever 7 up until the lock 6 for the 2nd lock in position is free Tilt the overhead guard forward until it reaches the first lock in position Push the cabin slightly forward...

Page 26: ...case acid contacted the eyes seek medical aid at once Neutralise spilt battery acid Gases are released when batteries are being charged Do not expose the battery to sparks or open flames as an explos...

Page 27: ...Beginning operation Check the condition electrolyte level and specific gravity of the battery Check the battery for casing cracks lifted plates and electrolyte leakage Unscrew the caps and check the...

Page 28: ...d remove to the side Battery change When changing the battery at least 6 minutes must elapse between the disconnection and connection of the batteries Otherwise the battery discharge indicator will di...

Page 29: ...8 1 2 3 4 Adjusting armrest of the driver s seat NOTE After the clamping screw 1 is loosened the armrest is automatically moved upward by spring pressure Sit on the driver s seat and loosen the clampi...

Page 30: ...smooth movement Place the seat belt over the loin area not over the belly Engage the tongue 2 in the lock 4 Check seat belt tension The belt should be snug on the body CAUTION The webbing should not b...

Page 31: ...letely Pull the emergency isolator button Depress the emergency isolator button 1 as far as possible turn clockwise and pull it out This actuates the emergency isolator button and makes the truck read...

Page 32: ...this truck NOTE Only when the proper procedure is followed can the emergency stop be disengaged and the truck can again be operated 1 2 3 4 e336 02 39 5 6 Driving Operation Apply the seat belt Insert...

Page 33: ...ls can be operated directly from one direction to the other NOTE Depressing the accelerator pedal fully does not increase the rate of acceleration as maximum acceleration is controlled automatically R...

Page 34: ...g on steeper slopes The climbing ability rates given in the data sheet were derived from the tractive force of the truck and they apply only for crossing obstacles and for small differences in level N...

Page 35: ...ng warning lights in the combined instrument illuminates during operation stop the truck and remedy the fault without delay Refer to Malfunctions causes remedy Brake shoe wear indicator 1 Motor temper...

Page 36: ...benefit when working in narrow aisles Take the truck into operation drive and turn the steering wheel left and right through the full cycle WARNING Contact your authorised distributor if the steer in...

Page 37: ...park the fork truck Both external shoe brakes at the drive motors are applied by means of a cable NOTE When the parking brake is operated the drive current is reduced at the same time with an electri...

Page 38: ...Raising the fork carriage WARNING Donotstepontheraisedforks Increaseddanger of falling and being squeezed Push control lever 1 to the right Lowering the fork carriage Push control lever 1 to the left...

Page 39: ...lever 2 forward Tilting the mast back Pull the control lever 2 back Operating the attachments Attachments e g sideshift clamp etc can be fitted on the lift truck as optional equipment Observe the ope...

Page 40: ...OTE The switches I and II can be arranged in a different order on the instrument panel depending on the model Please observe the switch symbols Turning on the front working lights The working lights a...

Page 41: ...epending on the position of the control lever 1 Heater selector switch 3 The desired temperature can be selected with the selector switch when the heating is switched on The heater shuts off automatic...

Page 42: ...he PIN number and the setting of the truck NOTE If you notice one of these conditions eg driving problem only after you have first logged in with condition code 0 truck in working order you must first...

Page 43: ...er Turn the rotary knob 5 clockwise as far as possible and start the truck NOTE If the truck does not start properly at the first attempt the starting procedure can be repeated until the rotary knob 5...

Page 44: ...wise as far as possible and start the truck NOTE If the truck does not start properly at the first attempt the starting procedure can be repeated until the rotary knob 5 is returned to zero and the PI...

Page 45: ...at junctions Pressing the horn button will sound the horn Opening the electrical compartment cover Pull the cover 1 back out of the latch 2 and open upwards Engage the stay 3 by hand Closing the elect...

Page 46: ...be easily accessed from the battery side when the overhead guard is in the 2nd lock in position The fuse box with the automotive fuses is located on the truck right hand side and the two main circuit...

Page 47: ...1 Remove the fuse box covers NOTE Depending on the equipment installed there can be one or two fuse boxes Fuse box I 1 Working light 9F11 15 A 2 Working light 9F12 15 A 3 Working light 9F13 15 A 4 Vo...

Page 48: ...e diagram apply to both forks and even distribution of loads Check the load capacity diagram 1 before picking up a load If attachments are fitted first check the respective load capacity plate 2 DANGE...

Page 49: ...picked up so that they do not project beyond the loading area of the truck and will not fall over or off If needed a load backrest must be used Approach the load carefully and as accurately as possibl...

Page 50: ...ing pallets etc The hauler is responsible for safe loading Do not transport an off centre load e g if a sideshift is fitted Transport the load near the ground When travelling on slopes always drive th...

Page 51: ...k 1 2 335 103 3 4 e336 02 60 Forced opening of overhead guard without Bowden cable NOTE Is only required if the overhead guard can not be opened via the Bowden cable with lever 4 Lower the mast If a t...

Page 52: ...5 Transporting the truck on a lorry or low bed trailer Lower the mast Apply the parking brake Chock the truck Lash down the truck e3363412 e3352303 1 2 3 4 5 1 6 Hoisting the truck with the eyebolts C...

Page 53: ...with a sufficient load capacity Minimum load capacity is 3600 kg CAUTION If for a wheel change not antistatic wheels are mountedthetruckmustbefittedwithanantistatic ribbon because these wheels are no...

Page 54: ...ing A rope can also be attached at the bottom of the mast CAUTION When towed the truck can only be braked mechanically with the brake pedal or the hand brake Towing procedure NOTE The power steering i...

Page 55: ...the overhead guard Turn the cheese head screw 2 clockwise as far as possible NOTE Immediately screw the cheese head screw 2 back to the initial position when finished otherwise the tilting cylin der c...

Page 56: ...iously break the window pane WARNING Risk of injury Remove any pane remnants Carefully dismount from the truck through the rear window 1 2 3 E335 2 165 e336 2 082 1 Emergency exit for trucks with poly...

Page 57: ...ng the truck back into operation Thoroughly clean the truck Lubricate the truck Coat the battery terminals with non acidic grease Check the condition and electrolyte level of the battery Check the hyd...

Page 58: ...safety precautions are only limited to the general servicing of your truck checks and lubrication For repairs e g chain replacement lift cylinder removal further safety precautions are necessary Plea...

Page 59: ...ht by the centre cylinder via the chain guide roller Then the two lift cylinders raise the inner mast When the inner mast is fully extended two further lift cylinders raise the centre mast which is ra...

Page 60: ...58 336 804 3001 0704...

Page 61: ...leaks Change the wheel drive oil Check the working and steering hydraulics for leaks Check the mounting of the steering axle electric motors wheel drives counterweight and overhead guard Lubricate the...

Page 62: ...es See page 59 for the services Check the battery charge Check the tyre inflation pressure Check seat belt for condition and operation Clean the lift truck Clean and spray the lift chain Tighten the w...

Page 63: ...f mast lift chain and end stops Adjust the lift chain length and lubricate with chain spray Check the fork quick releases and fork stops Check the pre tension of double hoses if attachments are fitted...

Page 64: ...truck with a faulty seat belt Have a defective seat belt replaced immediately by your authorised dealer CAUTION To prevent back injury the weight setting should be set to the individual weight of the...

Page 65: ...c motors and insulating material to the jet cover them first Clean the oil filler openings along with the surrounding area and the grease nipples prior to lubrication When cleaning with compressed air...

Page 66: ...heir guides Replace the brushes Pretension the springs and check the brush connections for firm seating NOTE Renew the brushes only in sets Fit the cover bands Inspection and maintenance as required M...

Page 67: ...is recommanded but it is required at least every 12 month In an environment with dust dirt water and possibly de icing salt or chemicals weekly lubrication will extend the service life of the bearings...

Page 68: ...track rods with grease at the lubricating nipples arrowed on the left and right side Lubricate with a grease gun until new grease emerges at the bearings Inspect the joystick boot Checkthebootforprop...

Page 69: ...otors neverthe less either operate the lift truck drying with own heat or dry the motors with heat air jet etc in order to avoid corrosion damage Clean the traction motor and tractor com partment fans...

Page 70: ...tighten the mast fastening bolts Elevate the fork carriage and secure against inadvertent lowering Check the fastening bolts 3 2 on each side of the mast pivot bearing shells for tightness Torque 275...

Page 71: ...brake pedal 2 must always be ensured If faults due to mechanical wear become evident e g worn brake linings or scored brake discs please contact your authorised distributor CAUTION Do not operate your...

Page 72: ...s and bolts Renew any damaged parts Touch up the paint if required Visual check of the motor brushes Elevate the fork carriage and secure it against inadvertent lowering Open the overhead guard to the...

Page 73: ...guide roller of fork carriage may project a maximum of 25 mm from inner mast channel Tighten the locknut 1 firmly Adjust the second chain Lubricate the lift chain with chain spray Spray the guiding s...

Page 74: ...arts Check the hydraulic oil level ATTENTION Follow the precautions for handling fluids and lubricants ATTENTION Check the hydraulic oil level only with the mast vertical and the fork carriage lowered...

Page 75: ...rised distributor Open the overhead guard to the 2nd lock in position Check the pin and joint retainers for security Lightly oil the lever pivots and clevises as required Inspect the tension springs 3...

Page 76: ...he electric cables cable connectors and connections for condition and tight ness NOTE Apply the handbrake and depress the emergency button before every servicing Open the overhead guard to the 2nd loc...

Page 77: ...nstall it Refit the filter cover and clamping strap and secure with the fastening nut Check the filter for leaks in a trial run Remove the breather filter 1 and dipstick 4 and check the oil level If n...

Page 78: ...ives at the filler drain and level plugs the housing cover and at the end of the drive shafts for oil leaks NOTE Contact your authorised distributor in case of leaks Inspection and maintenance every 5...

Page 79: ...ve the breather filter cover Withdraw the suction filter slowly so that the oil can flow back into the tank Pump out the hydraulic oil with the appropriate hand pump Fill new hydraulic oil into the hy...

Page 80: ...nd level plugs Position an oil catch tray under drain plug 3 Remove the level plug 1 filler plug 2 and drain plug 3 and drain the gear oil completely Clean the magnetic plug on the drain plug 3 Refit...

Page 81: ...raction motor Fuse 1 x 250 A Discharge circuit Fuse 2 x 5 A Discharge circuit Fuse 1 x 10 A Discharge indicator Fuse 1 x 10 A Control current Fuse 1 x 10 A Fan Fuse 1 x 5 A Horn Fuse 1 x 5 A 6 Electri...

Page 82: ...tinuous oil temperature over 60 C Recommendation for light duty at low ambient temperatures Hydraulic oil ISO L HM 32 to ISO 6743 4 or HLP ISO VG 32 to DIN 51524 T 2 average continuous oil temperature...

Page 83: ...ery discharge at 80 hydraulic system Faulty fuse Truck does not start Battery is discharged Loose electrical connections Overhead guard not locked correctly Fuses blown Clean or replace filter Tighten...

Page 84: ...336 804 3001 0704 82...

Page 85: ...reewheel diode relay X1 Connector 42 pins X2 Connector 10 pins X3 Connector S2 2 pins X4 Terminal contactor coil K1 2 pins X7 Terminal curve sensor 4 pins X8 Terminal voltage converter 4 pins X9 Termi...

Page 86: ...84 336 804 3001 0704 Electric circuit diagram standard equipment 336 802 6006a_1...

Page 87: ...85 336 804 3001 0704 Electric circuit diagram standard equipment 336 802 6006a_2...

Page 88: ...86 336 804 3001 0704 Electric circuit diagram standard equipment 336 802 6006a_3...

Page 89: ...87 336 804 3001 0704 Electric circuit diagram standard equipment 336 802 6006a_4...

Page 90: ...Stop light switch 9S1 9S2 Working light switch 9S3 Front wiper washer switch intermittent cont 9S4 Rear wiper washer switch intermittent cont 9S7 Switch working lights 9U1 Voltage converter 9U2 Voltag...

Page 91: ...89 336 804 3001 0704 Electric circuit diagram options 336 802 0136c...

Page 92: ...g system 23 2 E 20 600 standard mast series 183 2 0 t lifting system E 25 600 E 30 600 standard mast series 186 3 0 t lifting system 23 3 E 20 duplex mast series 183 2 0 t lifting system E 25 E 30 dup...

Page 93: ...91 336 804 3001 0704 336 802 0226b Hydraulic circuit diagram...

Page 94: ...c oil tank 65 Check the tightness of the wheel nuts 21 Check the tyre inflation pressure 21 Check the tyres for damage and foreign objects 64 Check the wheel drives for oil leaks 76 Check the working...

Page 95: ...nd pressure filter 75 Renew the hydraulic oil 77 Retighten the mast fastening bolts 68 Reversing direction 31 Reversing the direction of travel 31 Running in instructions 19 S Safety information 18 Sa...

Page 96: ...336 804 3001 0704 94...

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Linde E 20-02, Operating Instructions Manual

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