Service Training LINDE E-FORK LIFT TRUCK E16P TYPE 322 This material is only provided for your use during training and remains exclusive property 0 LINDE AKTIENGESELLSCHAFT, GULDNER ASCHAFFENBURG DIVISIONf= Abschnitt . ws Seite Service Training bie convents 3.8 Linde Electric Fork Truck E 16 P, type 322 3.8.1 Technical pata for Electric Motors, Pumps and Fans 1 3.0.1.1 ‘Traction Motore 48 V (16 P) eee os eee eee oaea 3.8.1.2.1 Pump Motor for Working Hydraulics 3.2.1.2.2 bs 3.8.1.2.2 Pump Unit for Power Steering 1 3.8.1.3 Fans for Traction Motor 3.2.1.3 8 3.8.2 Wiring Diagrams for E 16 P, type 322 1 3.8.2.1 Wiring Diagram 3.2.2.2 2 aoe Wiring Diagram (Standard) to 12/83 2 3.8.2.3 Wiring Diagram (Optional Equipment) to 12/88 5 3.8.2.4 Wiring Diagram (Standard) from 1/89 6 3.8.2.5 Wiring Diagram (Optional Equipment) fron 1/89 9 3.8.3 Control Circuit 3.2.3 1 3.8.9.1 Connector 1a 3.231 2 3.8.3.3 Pin Arrangement 14 for Timer 3.234 6 for curve Switches 1 3.8.3.5 Battery Discharge Indicator 3.5 1 3.8.4 Battery Dimensions and Weight 1Abschnitt Section =a Seite . .s Shu Service Training 3.8.5 Adjusting the Blectronic system 3.5 2 3.8.5.1 Adjusting the Zero Posistion of travel Switch U2 3.2.5.2 2 3.8:5.2 Adjusting the Travel switch 3.2.5.2 6 3.8.5.3 Adjusting the Control Board U200 3.2.5.3 8 3.8.5.4 Measuring and setting prive current Fs 3.2.5.4 10 3.8.5.5 Testing and Setting Handbrake Current HBS 3.2.5.5 11 UL —— 3.2.5.6 12 3.8.5.7 Setting Braking current RS eee cca 3.8.5.8 Settings for u200 3.2.5.8 13 3.8.6 Maintenance and Repair Instructions, Removal and Refitting of Essential Components _ 3.8.6.1 Testing of Carbon Brushes on Traction Motors and Hydraulic Pump Motors 3.2.6.1 2 3.8.6.2 Changing the Brushes on the Traction _ 3.266.202 3.8.6.3 Changing the Brushes on Steering Pump Units 3.2.6.3 4 3.8.6.4 Replacing the Brake Linings 3.2.6.7 7 3.8.6.5 Replacing the Hydraulic Filter ee 7 3.8.6.6 Removing and Relifting 3.2.6.9 8 3.8.6.7 Complete Dismounting of the Motor with Wheel Drive 3.2.6.10 8 3.8.6.9 Steering Axle Maintenance and Repair Instructions 1 3.8.7 Hydraulic Circuit Diagram for Working and Steering Hydraulics 1Abschnitty 5 4. section 278+ == . w Seite F | Service Training a 3.8.1 TECHNICAL DATA OF ELECTRONOTORS 3.8.1.2.2 Pump Unit for Power Steering Al De El A2 DL - Compound-wound Motor make Schabmiller Type: p12 Technical Data: 48 V - 27,58 2400 min-2 0,9 KW by 83 = 27 & IP 00 Carbon brushes: 4 items, 8 x 12,5 x 22 Permissble wear: 12 mm = Pump Internal Gear pump make Eckerle Type: IPF 1/4,1 conveyer volume: 4,1 cm3/u= Service Training =‘Abschnitt Absent 3 gs . . sete Service Training - * WIRING DIAGRAMAbschnitt secten capiilo Seite $e Service Training 3.8.2.2 WIRING DIAGRAM (STANDARD) (to 12/88) Key: al Battery plug socket 1/4 Plug connector 15pole a2 Key switch 12/6 Plug connector 3pole 13 Measuring plug, 6pole bi Curve switch for m2 15 Plug connector’ 9pole b2 Curve switch for mi 16 Plug connector 3pole bli Directional switch, 16/7 Plug connector 6pole reverse 18 Terminal strip board biz Directional switch, for contactor forwards 19 Plug connector to m5 b24 Handbrake switch 135 Connector 6pole b25 Signal button B31) Switches for working mL Travel motor, right 34 hydraulics m2 Travel motor, left b4l Thermo-switch m3 Pump motor, working bad contactor at 80° c hydraulics 43) Thermo-switch m4 Pump motor, steering bag contactor at 160 °c hydraulics n5, Fan for drive motor 6 contactor for working m22 Choke hydraulics m23 Transformer e7 Contactor for steering hydraulics | ni Battery 48 V cu Contactor for m1, reverse na ing di 12 Contactor for ml, forwards nz) Decoupling diode 21 Contactor for m2, reverse 20 Main thyristor 622 Contactor for m2, forwards n22 Quench thyristor n24 Freewheel diode e1/2 Fuse for drive current n25 Brake diodes circuit n26 Brake diodes 23 Fuse for working hydraulics 35 Field plate trans- e4 Fuse for power steering ‘notor nitter 25 Fuse for control current 36 Charging thyriostr circuit 26 Fuse for U200 and r Series resistor directional contactors r12 Ceramic resistor e7 Fuse for working hydraulics and hour meter 20 Pulse main current 8 Fuse for power steering horn unit v25 Drive switch gi Hour meter 030 Timer for working and a2 Discharge indicator steering hydraulics u200 Pulse control board hl Control lamp 48 V n2s Horn x22 Quenching condensor x25 Suppressor condensormee‘exo= Suey aoIagService Training Abschnitt section capitol 3.8.2 Seite page Pagina 3.8.2.3 WIRING DIAGRAM (OPTIONAL EQUIPMENT) to 12/88 Key: 1 Lighting, Flasher, hazard flasher system E2 Low bean, left H10 Flasher, right front E3 Low beam, right Hil Flasher, right rear E4 Side light, left front M12 Flasher’ indicator light ES Side light, left rear 6 Side light, right front K2 Flasher unit 7 Side light, right rear ES License plate light $11 Light switch F5-9 Fuses u40 Voltage converter 48/24°V - 8.3 A HS Flasher, left front HS Flasher, left rear 2 Windshield Wiper F190 Fuse $12 Hazard flasher switch Fl2 Fuse S13. Flasher switch m6 Wiper motor 3 Work spotlight 9 Work spotlight Fll Fuse 4 Single-pedal operation bi3. Switch for single-pedal operation L10 Connector 3poles 5 Pulse control for working hydraulics b31 ) switch for F n20 Main thyristor p34.) working hydraulics n22. Quench thyristor . n24 Freewheel diode K22 Quenching condensor n36 Charging thyristor 120 Connector 15poles rll Series resistor 121 Gonnector 3poles ¥30 Distance transmitter 122 Connector 1pole 21 Main current unit, m22 Choke 1iftung pulse m23. ‘Transformer v201 Control board for lifting hydraulics 6 Speed limiter b70 Speed Limiter 170 Speed reducing resitorAbschnitt ‘section 3.8.2 cic sete : . pa Service Training 3:8.2-4 WIRING DIAGRAM (STANDARD) from 1/89 ey: al Battery plug socket L1/4 Plug connector 15pole a2 Key switen 12/" Bing Connector appre L3 Measuring plug, Gpole bl Curve switch for m2 LS Plug connector 9pole b2 Curve switch for ml L6/7 Plug connector 6pole Bi, BlrseeSdnal switch, te’ Rordinel"seeip pbsra biz Biectionat switch, 19 Blug connecter to ms forvaras > * Hosa1 lug connector Spole boa Handbrake switcn 1538/7 Blug connector ebote B33 -B2gnat bacon Ba Blud Connector B31 Switches “for working Blechsrge indicator b34 hydraulics 138 Plug connector 3pole b41 ) Thermo-switch 139 Plug connector 8pole Biz) Contactor at 30" c NM Travel motors right b43) Thermo-switch m2 Travel motor, left bea) contactor at 160 °c Bm Burp aotor, working b50, Sear switch hydraulics ce Contactor for working ma Pump motor, steering hydraulics hydraulics’ or batactoe tor steering ms Fn For Grive notor fydreuiies Be hexe ci. Gkntactor'tor mi, reverse 333.—«Sngh Stormer $12 Contactor for mi; forwards Si Gontactor for ma; reverse = m_—sBattery 48 V 22 Contactor for ma, forwards © né-) poceevine diode Be e1/2 Fuse for drive current n20 Main thyristor circuit n22 Quench thyristor 23 Fuse for working hydraulics n24 Freewheel diode e4 Fuse for power steering motor n25 Brake diodes eS Fuse for control current: n26 Brake diodes circuit n35 Field plate trans- es Face for v200 ana nitter * Aigectional contactors m6 Charging thyristor e7 Fuse for working hydraulics and hour meter a Series resistor os -—«Fause'for pover steering horn fi, Serasio'sesistor i Hour neter 120 Pulge main current g2 Discharge indicator unit u25 Drive switch nl Control lamp 48 V U30 Timer for working and n25, Horn steering hydraulics uso Mer for'geat switch 22 Quenching condensor u200 Pulse control board 22 Suppresede CondenserBururesy ao1Asag :Burulesy ao1Asasmgs 2 oa Cento Seite Service Training a 3.8.2.5 WIRING DIAGRAM (OPTIONAL EQUIPMENT) from 1/89 Key: 1 Lighting, Flasher, hazard flasher system 2 Low beam, left #10 Flasher, right front E3 Low beam, right W11 Flasher, right rear ES Side light, left front 12 Flasher’ indicator light ES Side light, right tront 6 Side light, left rear Ki Flasher unit ET Side light, right rear EB License plate Light $11 Light switch $12 Hazard flasher switch F5-10 Fuses 813 Flasher switch HB Flasher, left front U40 Voltage converter HO Flasher, left rear 48/24-V - 8.3 A H20 Stop light H21 Stop light S14 Stop light switch 2 windshield wiper Fl2 Fuse m6 Wiper motor 3 Work spotlight E21 Work spotlight Fll Fuse 4 Single~pedal operation bi3 switch for single-pedal operation 113 Connector 3poles 5 Pulse control for working hydraulics . j n20 Main thyristor b31) Switch for n22 Quench thyristor 34) working hydraulics n24 Freewheel diode n36 Charging thyristor K22 Quenching condensor . . rll Series resistor 120 Connector 15poles 30 Distance transmitter 121 Connector 3poles 122 Connector ipole v2l Main current unit, Liftung pulse m22 Choke v201 Control board for m23° ‘Transformer lifting hydraulics 6 Speed limiter b70 Speed Limiter x70 Speed reducing resitorAbschnitt ceptelo : Seite = ara Service Training : =)) Abschnitt ; Ascintt 59.3 . .. sete i Service Training = 7 3.8.3.4 Connection of Micro-Switch bl and b2 for Curve Switches Adjust the ball socket on the threaded rod for a length of 176,5 mm.en wird. Note: When the wheels of the jointed cross-shaft axle are straight, the fastening nut on the ball socket lies just above the mark on the micro-switch housing. Diagram of connections: The micro-switch is close-fitted; it can only be replaced completely as a replacement part. ‘The RC network protecting the micro-switch is mounted on the cable harness of the pulse control.‘Abschnitt fection capo Seite age apne Service Training= et a4 = capitolo . aos Sette 1 5 Service Training fale 3.8.4 BATTERY DIMENSTONS AND WEIGHTS eye Ee 2) 2 E16 P| Capacity | Dimension A | Battery | 5 PZs When installing batteries with different dimensions and weights, the compensating weights must be dimensioned so that the rear axle load acc. to the data sheet is ensured. Secure the battery against sliding.=. Service Training = Pege paginaAERO 9g epitlo Seite Service Training a 3.8.6.9 STEERING AXLE, ASSEMBLY AND INSTRUCTIONS FOR REPAIR Instructions for lubrication: Grease to be used: Multipurpose grease, penetration grade 2 following ATSM 265 - 295 1/10nm Grease before assembly: - tapered roller bearing with inner race and cage - all needle roller bearings - seals lips of all radial seal rings ‘or installation of wheel bearings: Fill all grease chambers around tapered roller bearings with grease as shown on l illustration. Iubricate all joints through grease nipple until grease emerges between seals. Lubricate piston rod with lithium based grease. Move steering while greasing. Instructions for installation of wheel bearings: = tighten bolt ma x 25 white turning hub = forque: 22,6 NmAbschnitt caproto Seite Page paaina Service Training Jfosenit 3 9.7 aa Seite Page: Service Training ao 3.8.7 HEU DD REA CUP) ce C teR(CUstetle DIT TAG Ran M1 P20; RI WORKING AND STEERING HYDRAULIC‘Abschnitt an 3.8.7 pitta = Seite e z a Service Training —8"5, Gree R YD, R ACU 0) ce Ten (C10 Tet! bz A Gl RUA M) | (FO) WORKING AND STEERING SYSTEM A WORKING HYDRAULIC SYSTEM 1 Hydraulic oil reservoir Breather filter Electric motor 4 Hydraulic pump (11 cm3/u) 5 Suction filter (25 ym) 6 Control valve (2, 3 or 4-way, depending on model) 7 Relief valve 215 bar 8 Check valve 8 Tilt cylinder 10 Sideshift 11 Lowering brake valve 12-1 Lift cylinder, standard mast, Typ 160 12-2 Lift cylinder, duplex mast, ‘Typ 161 12-3 Lift cylinder, triplex mast, Typ 162 B STEERING HYDRAULIC SYSTEN 13 Hydraulic pump (1,4 cm?/u) 14 Electric motor 15 Hydrostatic steering Adjustment pressure, a0 +5 har Shock valve, 150 +20 bar 16 Steering cylinder3.8.7 Abschnitt section Service Trainingps) LINDE AG - Werksgruppe Gildner Aschatfenburg ‘ase Avcnaenbry ost 6 Seon 06521) 9:0 Tenrane er 4180.0 322 804 2561.02.90