Service Training Electric Forklift Truck Series 335 E16C-03, E16P-03, E20P-03 Edition 10/2012 ‘This service dacumentis provided for use only and remains the exclusive property of Linde Material Handing. 385 8012001 EN- 1012012Exe Header Linde — Your Partner With over 100,000 fork lift trucks and ware- house machines sold annually, Linde is one of the world's leading manufacturers of material handling equipment. There are many reasons for this success: Linde products are renowned not ‘only for their innovative, cutting-edge technology, but also for their low energy and operating costs, which are up to 40 per cent lower than those of. their competitors. ‘The high quality of Linde products is also matched by the quality of our service. With ten production plants worldwide and an extensive network of sales partners, we are at your service round the clock and around the world. ‘Your local Linde partner can offer you a com- plete package from a single source; ranging from ‘expert advice on all aspects of sales and ser- vice through, of course, to appropriate finance ‘options. Our leasing, hire or lease-purchase agreements provide you with the flexibility to tai= lor decision-making to your individual business requirements, Linde Material Handling GmbH Carl-von-Linde-Platz 63743 Aschatfenburg Telephone +49 (0) 6021 89-0 Fax +49 (0) 6021 99-1570, Mail: info@linde-mh.com ‘Web: httpsiivwwrJinde-mh.com ining 095 BOT D001 EN= TOBOTZx Table of contents 0 Product information Technical data... eee cceseeeeeeeseteestesesestestsrestereses Of ‘Technical description beeen eee teeter eee eeeeee neers OF Wontteatlon pte... ec eece cece ect eeet cette teeeeeeeeee 08 Inspection and maintenance 05 SOhourmalntenance plan... eee ee eevee eee eteeeeeeeeeeee ees OS 1000hourmaintenance plan... ..ecesceeeeeesseseeseserstestseterses 06 3000 hour malntenance plan 08 Recommended fuels and ofS ........0. 0c cccccesecseeeeseeseseeseess O40 Recommended lubricants 0-10 1 Motor Drive axle 1 a Disassembling the drive axle brake 12 Tractlon motor 13 Traction motortechniealparameters 6... ees ccceeeceeeseeeeeeeeeesee 18 Disassembled right traction motor 14 il pump motor 15 Technical parameters of of pump Motor... cece eee este eee teens 1B Motor test 16 Preparations for motor test 18 ‘Visually Inspecting the motor wee eee wee eee 16 Rotortest 16 Motorterminal ........0.c0cccccseesessesessessessesessetesteatsresee 47 ‘ractlon motor terminals . ‘Traction motor power unit terminals ‘Ol pump motor terminals Pump motor power unik terminal 18 Cleaning eee e eee eece ee eeeeeeeeeeeeeeeeeeee 19 Cleaning 19 SONOS oes eeee see eeeetes test eeetsesetetereseeatererses 140) ‘Speed sensors 1-102 Wheel transmission General Overview Technical data Description Drive axle toollist Disassembling the drive axle Disassembling the traction motor Removing the planetary transmission ‘Traction motor —removing the rotor o ‘Traction motor — Changing the bearings and shaft seal Planetary transmission —Changing the shaft seal Dismantling the brake Assembling the drive axle Assembling the traction motor ‘Traction motor installing the rotor ‘Assembling the brake Fitting the planetary transmission Filing with oil Determining the breakaway torque Bodywork parts and installation Frame Datasheet Frame design Cover plate Seat Seatewitch . Replacing the seat switch . Chassis frame Steering system Functional Characteristics Steering controlvae ........ Replacing the steering controlvalve Steering column assembly Compactsteering axle .. Compactsteering axle features assembling the compact steering axle Table of contents SS 24 24 24 22 24 28 28 28 240 243 247 2.20 2.20 2-20 222 2.26 207 2.28 at at 32 38 34 34 34 a4 a4x Table of contents Disassembing the compactsteering axe... cece ee eee e steers 49 Installing the compact steering axle - 440 Swing steering axle 412 Swhng steerhng axl features 6... ec eee cceeeeceeeteeeeeeeeeene BAZ Removing the swing steering axle 413 DisassembIng the swing steering axle a4 Installing the swing steering axle 417 TYOS ooo eee eect e nett ttetetetteeecetereeeeens $18 ‘Tyre specifications 448 ‘Checkhng the status ofthe antt-statlcbetts* (only for trucks fitted with super clean tyres) 418 5 Truck control Acceleration Sensor... eee cece ec teeetteetteeeee St ‘Acceleration sensor function a Replacing the acceleration sensor 52 Lmitbots 53 Brake system 54 Brake system overview 54 ‘Adjusting the foot brake 55 ‘Adjusting the hand brake lever 55 Replacing the brake Mull... eeeeeec eee ete eee tteeee ees BB Joystick types ooo cece ee eeeetteeeteeetteeesteerse ST Replacing the controthandle 57 6 Electrical system Power unit oe CE) Installing the power uni. et Plug connector pln assignment 65 Powerunit exckation signal 67 Plugconnector postions ...........00cccsecceec cece tete sete rres 68) Plug connector postions 69 Fuses 641 Fuse 641 Controller 6-12 Overview ofthe electronke controller... 2... es ccceeeeeccseeeseeeesessees G2Table of contents SS Controller plug connector phn assignment... 6 csc ecceeeseeeeesseeees 68 Traction functlon eee eee ee cee eee etteee eset etree ress 66 Charging clrcult 616 Excatfon signal 17 ‘Acceleration sensor 18 Drive direction selector switch on single-pedal trucks 619 Hand brake switch 620 Footbrake switch 0... ecc ec ceeeceeessetesseeesseeessseeess 620 ‘Switch-controlled speed Imi function 620 Relay drive 620 Hydraullefunctlons 2.0... cece ees eecsseecteeeeseeeersee 622 Hydraulle Joystick signal 622 Solenold valve operation 623 Steering sensor 6-24 Steering control valve sensor 382 625 Display unit 626 Display untt 6.26 Error codes 630 Ezror code ist 630 7 Hydraulic system Hydraulle system 4 foe foe m4 Hydraulic system overview 74 72 Description ofthe working hydraulic system 72x Table of contents Working hydraulles emergency lowerlngfunction 2.2... cccccessese Ted Manually titing the mast and lowering the fork ....... 00... 6.05 . eee TH Controtvalve 16 Controlvalve schematle diagram... ...ccceceseeteseesestesteetesese TS Description ofthe control valve functions 7 Mabitenance ofthe control valve block ™ Replacement ra Pressure setting ......... vee e ee eeeteeeeeeceeeeeeess 76 Pressure setthg ofthe prossure relat valve 78 8 Load lifting system Liftmast .......... ceteeeeereee BA ‘Adjusting the length ofthe If chalns, and lubricating ushig chalh spray ............. 8-4 ‘Checking the truck’s releasing and locking equipment... eee eeeeeeee BD Annex 10 Schematic diagrams Electrical dlagrams 10-4 ‘Clroult diagrams ... beeen eee eee eee 104 Circuitdiagrams ... teens werent eee 108) ‘Chroult dlagrams 104 Hydraulic dlagrams ...... bose bose » 105 Working and steering hydraulic system circuit diagrams ........... 6. cee 105 Working and steering hydraulle system clrcult diagrams 106x Product information Technical data Technical description ‘The corresponding maximum load for the 335-3 Series battery forklift E16C, E16P is 1.6 tons; the corresponding maximum load for the E20P is 2.0tons, (B) sore Refer to the safe working load diagram for the contre of gravity data, Open structure cabin designed according to the latest engineering techniques, energy saving ‘control system (LDC) as standard, ensuring the value for money of the truck's equipment. Its features include its compactness, excellent Visibility, optimum stability on sharp turns and ccomering stability, These advantages all benefit from the truck's various different wheel bases. ‘The electric forklift truck is available with two different steering axle designs: [Compact steering axle [Model no, E 16C ‘The compact steering axle has a low consump- tion, and tyre wears minimal due to the mutual ‘compensation of the dual rear wheels. The body width is small, and the steering is light and flex- ible, making it especially suitable for working in narrow spaces, [Compound steering axle E16P, E20P ‘The compound steering axle ensures that the ‘entire axle has alarger swing range, stronger grip ‘and increased driving safety, making it especially ‘Suited to operating on uneven road surfaces. ‘The truck has an electrical towing device, in addition to a motor and hydraulic pump used to provide the needed power to the power steering and working hydraulics. Drive ‘The truck is driven by two AC motors, which aro ‘automatically controlled according to their motor characteristic curve. These two motors drive the right and left transmission, the power from which is then transmitted from the transmission to the wheels, Electrical power is provided by the storage battery installed inside the truck. Forward and reverse stepless speed regulation ‘can be carried out extremely lightly by means of the digital traction controller (LOC), operated by the right and left accelerator pedals. Steerhng Operating the truck's steering wheel allows free and easy control ofthe hydrostatic steering system's steering cylinder, allowing the truck toturn Hydraulic equipment ‘The hydraulic system includes a motor and hydraulic pump that provide power steering, mast liting and cylinder titing, and a fier with ventilation. The dipstick and oil-absorption fier land the pressure fiter's hydraulictank. ‘A DANGER ‘Connecting any device whose safety i at tho safety ctical pont tothe thd auelary hydraulic manifold silly prohibited. These safety cical pohnt devices, ‘such as olldrum clamps or rotary devices, may cause Inadvertent misuse ofthe clamps, or rotation. lWadovice located at the safety etical point must be ‘connectedto the third auxiliary hydraullemanifold, then this device must frst pass the third auxilary marifold ‘and then be connected. Operation ‘The traction motor is controlled by the forward and reverse travel pedals. Both forward and reverse speeds can be regulated steplessly from rest to maximum speed. Both hands can be used ‘specifically for steering operation and its auxiliary ‘operation, enabling rapid direction raversal and high-efficiency stacking. The lifting, lowering and titing of goods can be controlled by using just one operating lever (centralised joystick), ‘The truck's attachments can be controlled by the other operating lever. ‘Another operating lever (joystick) can be fitted to ‘operate additional attachments. desired, all work devices (liting, lowering ‘and titing) can also be controlled by individual operating levers. Brake ‘The truck has muttiple independent braking systems. These braking systems can be divided0 Product information SS Technical data into electrical brakes and hydraulic brakes, as well as the parking brake. Depressing the brake pedal activates the hydraulic servo, inorder to control the mult-disc brakes in the drive unit axle. When the river reverses direction and de- presses the accelerator pedal, the truck produces ‘electric braking (regenerative braking). ‘This truck provides an energy feedback system asa standard device. When braking, or when the driver changes the direction of movement, the energy is transformed into electrical energy and recharges the storage battery When the accelerator pedalis released, the truck performs electrical braking by means of the Linde braking controls (LBC). Ifrequired, a diagnostic unit can be used to cancel LBC braking (sore After cancelling LBC braking, a No LBC braking’ label must be stuck in a place that willbe easily seen by the driver. Please contact you Linde dealer for assistance, Parking brake ‘The multi-dise brakes in the drive unit axle can be controlled by manually pulling on the parking lever. Electrical system ‘The electrical system is mounted in the counter- weight. The needed power's provided by a 48 V rechargeable battery mounted in the chassis. ‘The ling overhead guard guarantees rapid re~ placement of the rechargeable battery. (B) wore The housing of electrical parts must not be ‘opened during the warranty period or the terms of ‘the warranty willbe void.x Product information O Technical data Identification plate 11 Mastnumber (stamped) 44 Traction moto, lft sido 42 Working and power tering hydraulicpump 18. Traction motor, right sido motor nameplate 18 Gearbox, right side 18 Gearbox leftside 17 Ghassis serialnumber (stamped)0 Product information SS Technical data (vote The CE mark confirms compliance with the EC machinery directive and with all regulations applicable fo forkin trucks. Identification plates Manufacturer (CE mark (This markindicatos compliance with EC mechanical regulations and all relevant regulations) ‘Serial numberiyear Truck weight Battery Voltage Minimum battery weight Maximum battery weight Rated load capacity 0 Made! jnng= 35601 DOO EN= TROTx Product information Inspection and maintenance ‘50 hour maintenance plan [At operating hours [Caried out so] | TT TT TT TT [Tv 1 * Before starting maintenance work: (Clean the fork lf truck ifnecessary [Check the time and date settings on the display unit, adjust f necessary. [Check for error codes on the diagnostic software and delete, (Calibrate the potentiometer and joysticks. ‘Seta reminder for the next maintenance check on dlagnostic software. [Gearbox [Replace the gearbox olin the speed reduction gearbox. [Check whether the speed reduction gearboxis leaking. (Chassis, bodywork and fitings (Check the fastenings ofthe tit cylinders atthe it mast (Check the counterweight, motors, chassis, speed reduction gearbox, overhead guard land steering axle fastenings. Lubricate the overtiead guard pin shaft (Check and lubricate other pins and swivel points, [Check the condition ofthe antistatic belt [Chassis frame (Check for correct operation ofthe parking brake and readjust fnecassary. (Check the wheel fastenings and tighten. [Check the release of the mulli-dise brake forthe towing procedure: press the brake lever atthe brake valve several times. (Checklubricate the compact steering axle. [Checkfubricate the movable steering axle. [Operating devices (Checking the joystick pad (Checking and lubricating the pedal mechanisms, control linkage mechanisms andthe loverhead guard locking devices. [Check the hom for correct function. Blectrics ‘Check the condition and tightness of the electrical cables, electrical connections and plug connectors. (Check the fastenings ofthe cables and connectors connecting the power module and the motor. Battery: check the charge status, ud level and proportion. (Check the fans for correct operation. Hydraulics | (Check the hydraulic olllevel (Check the hydraulic system, drive axle, hydraulic pumps and lines for leaks (visual inspection). [Change the hydraulic oll filer Load It system [Check the condition, tightness and function of the lift mast, lif chains and stop block, [Adjust the length of the lift chains, and lubricate using chain spray.0 Product information SS Inspection and maintenance [Atoperating hours [Carried out 50 ~* [Check the wuts releasing and locking equipment [Chock the tit cyinder bearing (visvalinspecton)forwear, and lean, Special equlpment [Check that the side moving forks are operating normally; clean, lubricate and check thei fastenings. [Check the pre-ightoning status ofthe double hose in rucks equipped witv attachments | Subsequent tasks [Camry outa functional test and test ive [Attach the maintenance sticker 1000 hour maintenance plan [At operating hours 1000) 2000 4000 5000 7000 ‘2000 10000 11000 13000 14000 16000! 17000| | carried out 19000 20000 vie [Maintenance plan information Maintenance intervals are set according to the type of oll used, driving habits and opera- ting requirements, but maintenance should be carried out according to this maintenance plan atleast every 1,2,4,5,7,8, 10,11, 13, 14, and 16 working years, Please refer to the oil use recommendations, [Before starting maintenance work: [Clean the fork ifttruck ifnecessary [Check the time and date settings on the display unit; adjust necessary [Check for error codes on diagnostic software and delete. [Calibrate the potentiometer and joysticks. ‘Set a reminder for the next maintenance check on diagnostic software [Reduction gearbox [Check whether the speed reduction gearboxs leaking [Check the drive axle and reduction gearbox fastenings [Clean both sides of the traction motor, the power steering and working hydraulic pump motor [Frame and Installation [Chassis, tit cylinders and steering axle: Check fastening, [Check the countenveight, motors, chassis, speed reduction gearbox, overhead guard land steering axle fastenings. Lubricate the overhead guard pin shaft [Check and lubricate the other pins and swivel points [Check the condition of the antistatic bet [Chassis frame [Check for correct operation of the parking brake and readjust ifnecessary. (As required) Check wheel fastenings and tighten ifnecessary (after each maintenance lor repair, at the latest after 100 hours). [Check the brake system (As required) Wheel change [Check the release of he multi-disc brake for the lowing procedure: press the brakelever at the brake valve several times,x Product information Inspection and maintenance [At operating hours 1000) 2000 “4000 ‘5000 7000 ‘2000 10000 11000 13000 14000! 16000 17000| | carried out 19000 ‘20000 vf hecktubicae the compact steering ae, [Checktubricate the movable steering ano [Operating devices heckng the oystekpad [Checking and bicating tho pedal machaniam, contalinkage mechaniams andthe overhead guard locking devices, [check the hom fr corectuncton Bectes check he Tastoning othe cables and connectors conneding te power module and Shock he conaion and gre ot local abs, Satis cannon and plug connectors Battery: check the charge status, ud level and proportion. (Check the fans for correct operation. [As required) Clean the power modules of the traction and lft control, the fans andthe heat sink with compressed air (Clean the contactor mounting board with compressed air. Inspect the contactor contacts, and replace ifnecessary Hydraulics | (Check the hydraulic olllevel (Check the leak resistance of the working and steering hydraulic systems. (Check that the breather fiter on the hydraulie oll tank is working normally [Check the control unit for correct function, Replace the pressure and suction fiters. [Load it system [Check the condition, tightness and function of the lift mast, lit chains and stop block. [Adjust the length of the lif chains, and lubricate using chain spray. [Check the truck's releasing and locking equipment. ‘Check the tilt cylinder bearing (particularly for any abnormal sounds when tiling forward lorbackward) for wear, and clean. [Spectal equipment (Check that the side moving forks are operating normally, clean, lubricate and check their fastenings, (Check the pre-tightening status ofthe double hase in rucks equipped with attachments, [Subsequent asks (Carry out a functional test and test drive. [Attach the maintenance sticker.0 Product information SS Inspection and maintenance 3000 hour maintenance plan [At operating hours [carted out 3000] | 6000[ | 9000] | 12000] | t5000] | teooo] | v | = Maintenance plan Information Maintenance intervals are set according tothe type of oll used, driving habits and opera- ting requirements, but maintenance should be carried out according to this maintenance plan at least every 3, 9, and 15 working years. Please refer tothe oll use recommenda- ions, Before starting maintenance work [Clean the fork ifttruck ifnecessary [Check the time and date settings on the display unit, adjust ifnecessary. [check for error codes on the diagnostic software and delete, [Calibrate the potentiometer and joysticks. Set a reminder for the next maintenance check on diagnostic software, [Reduction gearbox [Check whether the speed reduction gearbox leaking [Check the drive axle and reduction gearbox fastenings: [Clean both sides of the traction motor, the power steering and working hydraulic pump motor Drive axle: Check the side stops and adjust as necessary. [Check the condition of the axle bearings. [Changing the gearbox ollin the speed reduction gearbox [Frame and Installation [Check the fastenings ofthe tit oyinders atthe lift mast [Check the countenweight, motors, chassis, speed reduction gearbox, overhead guard and steering axle fastenings Lubricate the overhead guard pin shaft. [Check and lubricate the other pins and swivel points [Check the condition ofthe antistatic belts (only for trucks fitted with super clean tyres). [Chassis frame [Check for correct operation of the parking brake and readjust ifnecessary. [Check the brake system (As required) Check the wheel fastenings and lighten i necessary (aller each mainten- Jance or repair, tthe latest after 100 hours). (As required) Wheel change [Check the release ofthe muledisc brake for the towing procedure: press the brakelever at the brake valve several times. [Check/lubricate the compact steering axle [Checkllubricate the movable steering axle, Replacing the brake fluid [Operating devices [Checking the joystick pad [Checking and lubricating the pedal mechanisms, conirollinkage mechaniams and the loverhead guard locking devices. [Check the horn for correct function. [Erectrical system [Check the fastenings of the cables and connectors connecting the power module and the motor.x Product information Inspection and maintenance [At operating hours [Carried out 3000 6000 2000 712000 75000 718000 vy [* (Check the condition and tightness of he electrical cables, electrical connections and plug connectors Battery: check the charge status, fuld evel and proportion (Check the fans for correct operation. (As required) Clean the power modules of the traction and it control, the fans and the heat sink with compressed ar. (ean the contactor mounting board wth compressed ar. Inspectthe contactor contacts, and replace ifnecessary Hydraulic system (Check the hydraulic oillevel (Check the leak resistance of the working and steering hydraulic systems. (Check the control unit for correct function. Replace the air, pressure and suction fiers Replace the hydraulic oll fitis Bio hydraulic ol he Aral Farbex SE4S is 6000operating hours) Load iftystem (Check the concition tightness and function ofthe it mast, it chains and stop block. [Adjust the length ofthe lif chains, and lubricate using chain spray. (Check the truck's releasing and locking equipment. (Check the il cylinder bearing (particularly for any abnormal sounds when tiling forward lor backward) for wear, and clean, [Special equipment (Check that the side moving forks are operating normally, lean, lubricate and check their fastenings. (Check the pre-lightening status of he double hose in tucks equipped with attachments. [Subsequent tasks Carry out a functional test and test drive. [Attach the maintenance sticker.0 Product information SS Recommended fuels and oils Recommended lubricants Hydraulic of (ACAUTION Damage to the hycraulic systom due to unapproved hydraulic ol ‘Only use approved hydraulic oll. Only the folowing ty- pes of hydraulic oll have been approved by the manu facturer Donot mixhydrautic ols. Please contact your authorised dealer you have any questions. Approval for any suggestions given by ailcompary represental'- ‘yes must also ba sought rom the authorised dealer. ‘Standard (average constant ofl temperature 40-60°C) Under normal loads, we recommend the use of Hydraulic oll SO-L-HM 46, in compliance with 1s0 6743-4; or hydraulic oll HLP ISO VG46, in compliance with DINS1524 T.2Standard (factory filing) Heavy duty (average constant oll temperature above 60°C) Hydraulic oll SO-L-HM 68, in compliance with 180 6743-4; or hydraulic oll HLP IS VG68, in compliance with DIN51524 T.2Standards, ght duty (average constant oll temperature below 50°C) Hydraulic oil SO-L-HM 32, in compliance with 180 6743-4; or hydraulic oll HLP ISO VG 32, in compliance with DIN51524 T,2 Standards, Variable load situations (W) nore This type of hydraulic ollhas a very high viscosity (mutttpurpose hydraulic ol). 1SO-L-HV 46 can be used in all of the above ‘operating situations in compliance with ISO 6743-4; or hydraulic oll HVLP ISO VG 46 in compliance with DINS1524 7.3 standards can be used as a substitute. Blo-hydraull off Aral Forbex® SE 46 highly biodegradable hydraulic oil Damage to the hydraulic system due to mixing bio- hydraulic ol with mineral of ‘Only use approved pure blo-hydraulc ol (@) wore ‘The oils recommended above are for reference only. Please contact your Linde dealer if you have any questions. Your Linde dealer should also be contacted before using any oils recommended by the oil manufacturer. ‘The fork it ruck manufacturer only consents to theuse ofthe above oils, Expensive damage may resultif other hydraulic olls are used or hydraulic, oils are mixed. Gearbox oll Gearbox oll SAE 80 W-90APIGLS , or SAEBS W-- 90 API GLé4 (in compliance with DIN 51512 standards). ® ewromenrvore Used oll should be far away from children before being discarded according to regulations. Do not allow engine oil fo permeate into the main drainage channel or the ground. Ideally, gearbox oil should be changed by an authorised dealer due to thair expert knowledge and experience in handling problems with disposal. Lubricating grease Linde Ithium-saponified lubricating grease KPF2K (taking DIN 51825 as the standard) Linde spare part no., see spare parts cata- logue Linde heavy-duty grease, lithium-saponified with EP active ingredients and MOS2. KPF2N-20{taking DIN $1825 as the standard) Linde spare part no., see spare parts cata- logue () note ‘Mixing with scap-based lubricating grease types ‘other than lithium-saponified is not permitted.x Product information O Recommended fuels and olls Battery grease Brake fuid ‘Aci-ree lubricating grease (battery grease) Dot 3 brake fd, in compliance with SAE 41708 (auch as Ate model S) or, Dot 4 brake fuid, in compliance with SAE ‘Chain spray for chains 1704 or FMVSS 116 (such as Ate model SL) Linde standard chain spray ‘The brand of brake oll tobe used n the arive Linde spare part no., see spare parts cata- shaftis "Shell DONAX TX" logue0 Product information SS Recommended fuels and olls oe ‘Sevics Taiing -S95607 001 EN TOOTx Motor 1 Drive axle Drive axle 14 1 2 3 45 6 7 8 9 10 11 12 13 1 Left planetary gear accelerator 9 Right motor U phase terminal post 2 Terminalblock forthe lett mator power ine 410 Terminal block fr the right motor powerlina 3 ——_LoftmotorW phase torminal post 44 RightmotorV phase terminal post 4 Leftmotor V phase terminal post 42 RightmotorW phase terminal post 5 ——_Leftmotor U phase terminal post 18 Right planetary gear accelerator & Speed sensor 182 14 Lofttraction motor 1M2 7 Speed sensor 181 18 Brakerod 8 Temperature sensor 133, 16 Reght traction motor 1M1 Serves Tearing 335801 2001 EN- 102012 ¥1 Motor SS Drive axle Disassembling the drive axle brake > First, drain the brake oil inside the drive axle. Tighten the stopper to a torque of 20Nm, > Remove the four screws2) M16X60connecting the left and right drive motors. The tightening torque of the screws is 275 Nm. > Use a screwdriver to pry open the left and right motors, hold the brake pads in your hands, then separate them. > Remove, in the following order, the brake pad (7), brake disc (6), brake pad (5), and shim ring (10, 11), untl you can see the brake lever (13). > Using lacking pliers, remove the circip (20), unfasten the gater (19), then use an Allen key toloosen the screw plug. Take another M6 screw and serew tint the bol, pullout the bolt (14) and finally remove the brake lever (13). (@) nove After reassembling the drive axle, approximately 0.2L ofbrake fuid must be added via the fuel filer opening. jnng= 35601 DOO EN= TROTx Motor Tractlon motor Traction motor technical parame- ters Technical parameters of 48 V tractlon motor: FThree-phase asynchronous Type I iy motor Battery voltage [48 V Effective voltage 28V Fates savar fama Fatedsped [200m insane |F Preerion [ipo Se ey etd 82.60 min 202 Delta connection1 Motor SS Tractlon motor Disassembled right traction motor 1 Stator 10 Elasticretaining ing 2 Rotor 11 Threaded pin 3 O-shape sealing ring 42 Threaded pin 4 Bearing fange 13 Seal 5 O-shape seating ring 14 Terminal block 8 Greoved ball bearing 18 Block 7 Elasticwasher 18 Elastiowashor 8 17 Hexagon head bot 9 Elastic retaining ring S001 2001 EN TOOTSOil pump motor Technical parameters of oil pump motor Technical parameters of ofl pump motor Three:phase asynchronous Type motor Battery volage [48 V Effective voltage 28 V Raton sew Fatcioeel 280mm Prteion rons its re rok 83-15% 102H2 Delta connection1 Motor SS Motor test Preparations for motor test Ifthe traction motor does not accelerate when the accelerator pedalis depressed, there may be a malfunction in the power unit, contral system or wiring harness. ‘These electrical structures must be checked before testing the motor. (@) nove This is just an approximate test for three-phase ‘motors that tests to the limit value range without the need for measurement and testing tools. Visually Inspecting the motor Ifyou suspect that the motorhas a malfunction, be sure to check the following points: visually inspect the following motor components. for external corrosion, contaminants, breakage ‘and poor contacts: > Motor terminals U, V, W > Correct installation of temperature sensor > Temperature sensor plug > Correct installation of speed sensor > Speed sensor cable connector Atthe same time, check the following: > After disassembly of the wheel transmission and hydraulic pump, ensure that the rotor rotates freely (check for bearing damage) > Cleanliness ofthe motor (oll, grease, drt) Rotor test After disassembly, the rotor must be thoroughly cleaned and checked. Special attention must be paid to cracking ofthe end par. Iferacks appear, the current will drap due to increased resistance, In addition, the rotor must also be checked for excessive temperature rise or traces of overheat- ing, which can be determined by the colour of the rotor.x Motor Motor terminal Traction motor terminals ‘The six wiring haresses from power unit 1Atare respectively connected to terminals U, V and W ‘of the left and right pump motors. The motor ter- ‘minals contain a copper bolt. The eye connectors ‘of the wiring hamesses are secured by means ‘of a hexagon cap nut (tightening torque 9 Nm). Do not confuse the wiring harness connections. ‘After tightening the hexagon cap nut, cover the ‘copper bolt wth the protective cover. (B) sore When checking or tightening the hexagon nut, only use @ torque wrench of appropriate adjust- ment range e.g. 1-20Nm. Torque wrenches with ‘an adjustment range that is too large are not precise enough and must not be used. Ifthe tigh- ‘ening torque is greater than or equal to 17 Nm, ‘the copper bolt may break. Because the range of 9-17 Nmis very small, itis impossible (o achieve a lightening torque of 9Nm by hand. Traction motor power unit termi- > nals ‘The power unit terminals are connected to the traction motor and battery voltage. The power Unit terminals contain a copper bolt. The eye ‘connector af the wiring harnesses is secured by means of a hexagonal cap nut (tightening torque 9 Nm), Do not confuse the wiring harness ‘connections. After tightening the hexagon cap nut, cover the copper bolt withthe protective (B) sore When checking or tightening the hexagon nut, only use a torque wrench of appropriate adjust- mentrange e.g. 1-20Nm. Torque wrenches with an adjustment range that is too large are not precise enough and must not be used. Ifthe tigh: ‘ening torque is greater than or equal to 17 Nm, ‘tho copper bolt may break. Because the range of 9-17 Nmis very small, itis impossible to achieve a tightening torque of 9 Nm by hand.1 Motor SS Motor terminal Oil pump motor terminals. ‘The three wiring harnesses from power unit 2Atare respectively connected to terminals U, Vand W of the pump motor. The motor terminals ‘contain a copper bolt. The eye connectors of the wiring harnesses are secured by means of ‘a hexagon cap nut (tightening torque 9 Nm) Do not confuse the wiring harness connections. Alter tightening the hexagon cap nut, cover the ‘copper bolt wth the protective cover. (@) nove When checking or tightening the hexagon nut, only use @ torque wrench of appropriate adjust- mentrange e.g. 1-20Nm. Torque wrenches with an adjustment range thatis too large are not precise enough and must not be used. Ifthe tigh- toning torque is graater than or equal to 17Nm, the copper bolt may break. Because the range of 9-17Nmis very small, it’s impossible to achieve a tightening torque of 9 Nm by hand. Pump motor power unitterminal > ‘The power unit wiring harnesses are respectively ‘connected to the cil pump motor and power sup- ply. The terminal contains a copper screw. The ‘eye connector of the wiring harness is secured by means of ahexagonal nut (nut tightening torque 91Nm), Do not confuse the wiring harness con- nections. After tightening the hexagon nut, cover the copper screw with the protective cover, (@) nove Wien checking or tightening the hexagon nut, only use @ torque wrench of appropriate adjust- ment range e.g. 1.-20Nm. Torque wrenches with an adjustment range that is too large are not precise enough and must not be used. Ifthe {ightaning torque is graater than or equal to 17 ‘Nm, the copper screw may break. Because the range of 9-17 Nm is very small, itis impossible to achieve a tightening torque of 9Nm by hand.x Motor Cleaning Cleaning ‘Cleaning the motor—drive axle ‘The drive axle must be cleaned during inspection land maintenance, after making sure that the motoris sufficiently cooled, ‘The outside of he drive axle needs to be cleaned, preferably using oil-free compressed air. Ifthe ‘outside ofthe drive axle housingis heavily soiled, a pressure washer can be used, Depending on the level of soiling, remove the exhaust pipe, ower unit and other components. Make sure that the heatsink vents are free of dit and dust, to ensure proper motor cooling. Only water is needed for cleaning; if using a pressure washer, donot add any chemical cleaning agents as they ‘may stick to the plastic parts of the motor. Keep the jet nozzle at a safe distance from the moter. (B) nore Ifthe conductor rail has been removed, tho- roughly clean the electrical contact surfaces and coupling screws of the conductor rail before reinstalling it. Avoid excessively high contact resistance, which may cause damage and the generation of erroneous information When using a pressure washer to carry outhigh power cleaning, avoid the connectors around the moter. Do not allow the inside of the motor to become wet. Ifthe motor gets wet, it must be run for a period of time (to dry it using the heat ‘generated by the truck), or dried with a hot air blower or heater to prevent corrosion damage. When cleaning the stator after disassembling the motor, the use of a pressure washer is strictly prohibited. Compressed air must not be used either since it may contain oil or moisture. First clear away larger impurities on the external surface. When pre-cleaning the stator, use a ‘loth and oxide or sulphide solvent to remove oll and grease-based dirt, When carrying out final cleaning of the stator, be sure to use an ‘electronic component cleaner (such as SLX, available from www-rivolta.de). This type of ‘electronic component cleaneris freresistant, has, adiclectriostrangth of 100000Viem, and contains no hydrocarbons (CHCs-CFCs, aromatics, PCBIPCTs) or other harmful substances, It can help to thoroughly wash away dirt from the coll windings. After washing, the stator must also be blow-dried with a hot air blower. The temperature ‘of the hot air blower should not exceed 150°C, ‘otherwise the insulating lacquer coating on the coil windings willbe damaged. ‘The rotor may be cleaned using conventional methods. + PCBs - Polychlorinated biphenyls, + PCTs «Polychlorinated terphenyls + CHCs- Chlorinated hydrocarbons + OFCs-ChloroftuorocarbonsSensors Speed sensors Speed sensors are mounted externally on the {wo traction motors and the oil pump motor. ‘The speed sensors are triggered by aring gear mounted on the rotor shaft, and are connected to power units 1Atand 241 Installation position ‘The speed sensors are mounted on the traction motors, and one sensor is also mounted on the cll pump motor. Function ‘The sensor (2) is formed of two integral inductive sensors that measure the speed and direction of rotation of the motor by means ofa ring gear (1) ‘on the rotor shat. ‘The rotation speed depends on the frequency of the output signals, whereas the direction of rotation is determined by the sequence of the ‘output signals. The direction of rotation is only used to analyse the two traction motors. The connector plug (3) of pin Aé is used to connect, the speed sensorto power module 1Ator 2A1 Speed sensor connector plug Ph Function [+13 V voltage supply 1 Motor SS [Output signal A Voltage negative [Output signalx Motor 1 Sensors Output signals > ‘The motor speed depends on the frequency of ‘output signals A and B. The sequence signal is derived fram the respective difference of the ‘output signals A and B according tothe direction ‘of motor rotation. A When the motor rotates anticlockwise, output signal B is switched on first, followed by output signal A. Output signal B is then switched off, followed by output signal A, —t Replacement (wore When replacing the speed sensor, check that the spare part numbers correct. Do notuse speed ‘sensors from other truck models. » Disconnect the speed sensor connector plug, > Unfasten the M6x16 screw (2) and washer. > Remove the speed sensor from the housing, paying attention to the wiring harness and O-ring, > Fitthe new speed sensor with sealing rings (note the arrangement of the seals) > Screw down the M6x16 screw with washer and tighten to a torque of 9.6 Nm. (@) nore This description applies to the replacement ofthe oi pump motor speed sensor. The procedure for replacing the traction motor sensors is the same. The speed sensors do not require adjustment during fitting.1 Motor SS Sensors or ‘Sevics Taiing -S95607 001 EN TOOTx Wheel trans! in General Overview Technical data (axe Permissible axe load tkol__|4a70 Maximum speed km/h} 46 Tyres (alternative) [200/50-10 (Tax7-8) Dynamictyre radius from) |220 211) rack width rom} [910 (970) Driving torque [Nj [2100 Maximum wheel speed teem) [185 (Gear transmission 20.45 (Oitcontent per gearbox ios (Gearbox it [SAEBOW-90 API-GLA 3000 Oil change interval aaa ce at 1000'n [Blectric motor Battery voltage Mae Type [Asynchronous mator Phase voltage IM [3x28 (Maximum number ofrevolutions [[tpm] |3800 Brake Static braking torque INn]_|2700, with force F2 IN| [1525 Dynamic braking torque [Nm] [see characteristic curve with force F1 IN] [see characteristic curve (il content m_o2 Brake oil [Shell Spirax S4 ATF HOX2 Wheel transmission General Description Right-hand planatary transmission Right action motor Brake contro! Left action motor ‘The drive axle consists ofthe two traction mo- tors (2) and (4) (three-phase AC asynchronous ftchand planotary transmission ‘Spoed sensors ‘Temperature sensor @x Wheel transmission 2 General ‘motors) with the flange-mounted two-stage plan- ‘etary transmission systems (1) and (5). Between the traction motors, there is an inte- ‘grated mult-disc brake that serves as the service brake and parking brake. ‘The two traction motors are connected to the ‘output modules via the terminal boards. The speed and direction of rotation ofthe traction motors is reported back to the power module by a speed sensor on each electric motor. The temperature Is monitored by a temperature sensor (7) in the coil end. Drive direction Inthe drive direction ofthe axl, the traction motor ‘connecting boxes are facing towards the rear, ‘The left traction motor contains the actuating lever of the brake. Identification plates ‘Axle Identification plate ‘The identification plate for the axle is located on the top of the right traction motor. ee || | Ears La ST nH ‘Tracton motor Klentification plate ‘The identification plate for the traction motors is located on the respective connection box. iaDare 22 Wheeltrans General Drive axle tool list ‘See below fora lst of tools that are required for working on the drive axle: + Cilcollection container 11 + Hexagon socket wrench 4mm, 5mm, 6mm, &mm, 14mm. + 2MBx35 screws + 2-claw extractor + Inner circip pliers + Outer circip pliers + Torque multiplier + Torque wrench + 2M10x110 threaded rods + MBx80 screw + 250x20 mm copper bar ‘Special tools Extractor strip WM10_ Part number 000 941 94.24 Tensioning screw WM101 (Ma) Part number 000 941 91 07 a ‘Seve Waiing 535807 ENS T0202Ejector rod WM109 Part number 000 941 94.69 Handle wM170 Part number 000 941 97 67 ‘Slotted nut spanner Universal sleeve WM449 Part number 000 916 77 16 Serves Tearing 335601 2001 EN- 1020122 Wheeltrans General Tube WM450 Part number 000 917 56 00 Tube WM451 Part number 000 917 31 00 Pressure segment WM452 Part number 000 964 45 30 Insertion tool WM455 art number 000 953 51 07 ‘evicsTaiing -S95601 2001 EN TORO?x Wheel transmission 2 General TYPE GO installation tool for Mubea spring band > clamps Serves Tearing 335601 2001 EN- 102012 22 Wheel trans: Disassembling the drive axle Disassembling the traction motor Removing the planetary transmission > Place a suitable collection container (> 11) > under the oil drain opening. > Unscrew oil filler plug (1) and oll drain plug (2) ® ewnommecrnore Dispose of drained oil in accordance with regula- tions. > Ifthe axle is notftted, secureit againsttwisting > Using a suitable tool and loosen and unscrew the 16 mounting screws on the planetary transmission. > Remove the two plugs from the threaded holes > located opposite. > Screw in two M&x35 screws and, in doing so, disconnect the planetary transmission from the motor housing, > Pullthe planetary transmission outofthe motor o> housing. jnng= 35601 DOO EN= TROTx Wheel transi in Disassembling the drive axle Tractlon motor —removing the rotor Remove grub screw (1) in orderto access the > locking serew (2) located undemeath, Twist the locking screw back into the housing. > Fitthe extractor strip WM10 using M10x110 > ‘threaded rods. Ensure that the recess in the ‘middle is centred on the rotor shaft. > Remove the rotor from the motor housing Using an M8 tensioning screw. > Pull out the rotor using the extractor strip. > Remove the washer and shaft washers (x2) > from the motor housing,2 Wheel trans: Disassembling the drive axle Traction motor — Changlng the bearings and shaft seal > Pullthe rear bearing out ofthe rotor shaft using >> the 2-claw extractor (7) nore The bearing will be damaged as itis pulled out over the outerring. Use anew bearing. > Remove the shaft seal from the bearing shield. > Todo so, eitherleverit outusing a screwdriver ‘or drill a hole in the shaft seal, cut the thread and then pul it out using ejector rod WM109. > Ifnecessary, remove drilng chips. > Remove the innerlocking ring(1) and outer > ff locking ring (2), > Pross the rotor shaft out of the bearing shield. > Par envee Tan ENS 02079x Wheel transi n 2 Disassembling the drive axle > Strike the frontbearing outofthebearing shield > using assembly sleeve WM451 (9) nore The bearing willbe damaged as itis knocked out ‘over the inner ing. Use anew bearing. % Remove the O-ring. Oilanew O-ring and b> place itinto the rear groove, Make sure that the O-ringis sitting correctly in the groove, > Press anew bearing into the bearing shield > using assembly sleeve WM450. Press the bearing in over the bearing outer ring, as, otherwise the bearing willbe damaged, > Pross the bearing shield onto the rotor using > assembly sleeve WM451. When doing so, ‘the bearing shield must be pressed in over the bearing inner ring onto the shat, as otherwise the bearing will be damaged. Serves Tearing 055601 2001 EN= 1OBOT2 a2 Wheeltrans Disassembling the drive axle > Fitthe inner locking ring (1) and outer locking ring (2) > Coat the outside of the new shaft seal wth Loctite 243 liquid glue. > Use the universal sleeve WM449 and han- dle WM170 to press the shaft seal into the bearing shield > Press on the front bearing using assembly sleeve WM451, Press the bearing in overthe bearing inner ring, as otherwise the bearing will be damaged, ze ENS 02079x Wheel transmi n 2 Disassembling the drive axle Planetary transmission —Changlng the shaft seal Disassembling the planetary transmission > Lift the first planetary gear set out of the > annular gear. > Loosen and unscrew the mounting screw from > the second planetary gear set, > Pullthe second planetary gear set outofthe > housing > Mount the planetary transmission housing on > suitable fixture, > Warm the slotted nut to release the Loctite. ‘The hot slotted nut can cause burns. Wear suitable protective gloves, Serves Tearing 335801 2001 EN- 102012 22 Wheel trans: Disassembling the drive axle > Loosen the slotted nut using a slotted nut > ‘spanner and torque multiplier. > Remove the slotted nut. > Support the planetary transmission housing in > order to press the wheel shaft out downwards. > Pross out the wheel shaft > Drill ahole in the shaft seal, cutthe thread and > then pull t out using ejector rod WM109. Assembling the planetary transmission > Coat the inside of the new shaft seal between the sealing lip and the dustlip wth lithium soap grease. Fillthe space to.amaximum of 50%, A) nore The grease must not be added to the spring chamber. > Position the shaft seal on insertion > tool WM4S5, > Apply FKS Loctite 243 liquid glue to the outside ofthe shaft seal. _ ENS 02079 Ears ‘ervee Traningx Wheel transmission 2 Disassembling the drive axle > Position the shaft seal onthe wheel shaftwith > jy insertion tool WM455. > Attach insertion tool WM455 to the wheel shaft using three wheel screws. (B) nore The shaft seals fited in the whee! shaft by tightening the whee! screws. Tighten the wheel screws aitemately o prevent the shaft seal from canting. > Remove the wheel screws and insertion tool ‘from the wheel shaft, > Remove Loctite residues from the slotted nut and the thread of the wheel shaft. Use brake cleaner if necessary. > Place the planetary transmission housing on the wheel shaft, > Insert the spacer ring, > Insert the tapered roller bearing. > Coat the thread of the slotted nut with Loc- tite FK2. Screw in the slotted nut and tighten by hand. > Secure the planetary transmission housing fon a suitable fixture and tighten the slotted ‘nut using the slotted nut spanner and torque ‘multiplier toa tightening torque of 650 *2° Nm. > Turn the planetary transmission housing by 10 revolutions and retighten the slotted nut to tightening torque of 650 *?° Nm. > Insert the second planetary gear set. TESEOT DOOTEN- TODO? 22 Wheel transmi Disassembling the drive axle > Coatthe second planetary gear set mounting > ‘screw with Loctite F2, screw in and tighten to tightening torque of 23 Nm. > Insert the first planetary gear set into the > housing. Pay Tarver GOT EN TOOTSx Wheel transmi in Disassembling the drive axle Dismantling the brake Draining the oil > Place a suitable collection container (>0.51) > under the oil drain opening. > Unscrew the oll drain plug, © woironmentnore Dispose of drained oil n accordance with regula- fons. Disconnecting the traction motors > Secure the axle against twisting and loosen and unserew the 4 mounting serews. > Loosen and pull apart the housing halves with suitable tool. > Remove the brake package (brake disc sup- > ports (1) and impulse transmitter wheels (2)). > Remove any remaining brake oil. > Unscrew speed sensor(1). > Take out the pressure plate (2) Serves Tearing 335801 2001 EN- 102012 BT2 Wheel transmission SS Disassembling the drive axle Removing the brake lever > Unscrew the brake cableholder(1). Todoso, > release the two Seeger rings from the bolts (2) and remove together with the bolts. Remove the locking ring (1) using the installa- >> tion tool. > Carefully remove the cable tie (2). Do not damage the cover while doing so > Loosen and remove the screw plug, > Pull out the brake lever axle with a M6x80 screw. Ifnecessary, use ejector rod WM109. ze ‘Geri Waring “S05 607 OT EN TOOTSx Wheel transmission 2 Disassembling the drive axle > Remove the brake lever. >} Take out the shaft seal. Serves Tearing 335801 2001 EN- 1020122 Wheel trans: Assembling the drive axle Assembling the traction motor Tractlon motor — Installing the rotor > First insert the washer and then the shaft ‘washers (2 pieces) into the motor housing. > Mark the position ofthe rotation lock on the motor housing. > Insert the rotor into the motor housing, > Insert anew seal and coat with grease. > Place the bearing shield on the axle casing in such away that the position of the rotation lock aligns with the notch on the bearing shield, > Press the bearing shield into the housing. 20 ining 395601 DOO EN= ROT> Place the extractor strip WM10 (1) onthe => pressure segments WM452 (2) and press the bearing shield into the axle casing using ‘two M10 threaded rads with washers until it will noticeably move no further. } Remove the extractor strip, > Screw in the MBx16 threaded pin (1) (rotation > lock) and tighten. > Screwinthe M&x8 threaded pin (2) cover) and tighten. > Coverthe outside of tho shatt soal with Loctite. Goat the inner lp with some grease. > Install the shaftseal with handle WM170 and > universal sleeve WM4d9. = BOT DOT EN TOOT ro2 Wheel transmission SS Assembling the drive axle Assembling the brake Installing the brake lever > Fitthe brake lever. > > Screw in the screw plug and tighten toa => tightening torque of 25 Nm. > Pullthe dust protection cover carefully overthe > brake lever. > Make sure that the coveris correctly seated. > Fitlocking rng (1) using the installation tool, > > Fit cable tie 2) 2 ‘Geri Waring “S05 607 OT EN TOOTSx Wheel transi n 2 Assembling the drive axle > Fitbrake cable holder (1). Todotthis, secure > the two bolts (2) with the Seegerrings. Inspecting the brake Ift play ‘When replacing the brake dises, the brake lftplay must be inspected and, ifnecessary, adjusted. > Place the traction motors upright. > Insert the pressure plate into the left traction ‘motor. Make sure that the guide pin engages inthe leftbore, > Remove the compression springs from the ‘middle brake dise support. > Insert the left brake disc suppor, leftimpulse transmitter wheel and middle brake disc support, right impulse transmitter wheel and right brake disc support. > Load the brake package with aweightof6kg. > > Determine the height of the brake package above the housing edge. > Determine the depth of the brake chamber in the lefttraction motor housing, ‘The difference between the depth and height measurements can be max. 0.8"? mm, > necessary, insert shim rings between the pressure plate and left brake disc support Attach the compression springs to the brake disc support, Assembling the tractlon motors > Insert the pressure plate into the left traction ‘motor. Make sure that the guide pin engages inthe left bore. = BOT DOT EN TOOT 22 Wheel trans: ‘Assembling the drive axle > Insert the left brake disc support, leftimpulse transmitter wheel and middle brake dise ‘support into the left traction motor. Ensure that all compression springs (1) are seated correctly and ina straight line. > Secure against falling using a suitable cord or wire (2), > Insert the brake disc (3) and impulse transmit- terwheel (2) nto the right traction motor. > Oiland insert a new O-ring (1). > Position the traction motors opposite one another, Use suitable devices to align. > Push the traction motors together so that the ‘cordi/wire can still be removed. > Remove the cordiwire, > oe ining 395601 DOO EN= ROT