Linde Electric Counterbalance Truck E35 – E40 – E48 Type 337-02 (LDC) Service Training Manual

Download Complete Service Training Manual for Linde Electric Counterbalance Truck E35 – E40 – E48 Type 337-02 (LDC)

This Factory Service Training Manual offers all the service and repair information about Linde Electric Counterbalance Truck E35 – E40 – E48 Type 337-02 (LDC)

The information on this manual covered everything you need to know when you want to repair or service Linde Electric Counterbalance Truck E35 – E40 – E48 Type 337-02 (LDC)

Models Covered:

Electric Counterbalance Truck
E 35 – E 40 – E 48
Type 337-02 (LDC)

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Manual Contents:

4

6 INTRODUCTION ……………………………………………………………………………………………… 1
461 PRINCIPLE OF THE FIELD EFFECT TRANSISTOR……………………………………………

3
4611 CONTROL OF FIELD-EFFECT TRANSISTORS…………………………………………………… 3
4612 TRANSISTOR MODULE TERMINALS ………………………………………………………………… 4
4

613 INSTALLATION OF THE TRANSISTOR MODULES ……………………………………………… 4
4614 COMPACT POWER MODULES ………………………………………………………………………… 5
4

615 TRACTION AND LIFT POWER MODULE …………………………………………………………… 5
4616 POWER MODULE TESTS (Traction module illustrated) ……………………………………… 6
4617 TEST CONDITIONS…………………………………………………………………………………………

6
4618 TESTING IF POWER MODULE IS OFF ……………………………………………………………… 6
4619 TESTING IF THE POWER MODULE IS ON ………………………………………………………… 7
4

6110 TESTING THE PROTECTIVE DIODE IN THE POWER MODULE ………………………… 8
46111 TESTING THE FREEWHEEL AND BRAKE DIODES IN THE POWER MODULE …… 9
46112 TESTING THE REGENERATIVE CURRENT DIODE IN THE POWER MODULE……… 10
4

6113 INSTALLATION OF THE TRANSISTOR MODULES ……………………………………………… 11
462 TRACTION CIRCUIT ………………………………………………………………………………………… 12
4

621 TRACTION CIRCUIT – FORWARD DIRECTION…………………………………………………… 13
4622 TRACTION CIRCUIT – REVERSE DIRECTION …………………………………………………… 14
4

623 TRACTION CIRCUIT – FREEWHEEL………………………………………………………………… 15
4624 TRACTION CIRCUIT – REGENERATIVE BRAKING (STAGE 1)……………………………… 16
4625 TRACTION CIRCUIT – REGENERATIVE BRAKING (STAGE 2)……………………………… 17
4

63 DIRECTION CONTACTOR ………………………………………………………………………………… 18
4631 DIRECTION CONTACTOR – TIP REPLACEMENT ………………………………………………

18
464 REGEN CONTACTOR ……………………………………………………………………………………… 19
465 ELECTRONIC TRACTION CONTROL UNIT 1A1 …………………………………………………

20
4651 OPTIONAL OUTPUT ………………………………………………………………………………………… 20
4652 SWITCH CONTROLLED SPEED RESTRICTION …………………………………………………

20
4653 TRACTION CONTROL MODULE CONNECTOR PIN DESIGNATIONS…………………… 21
4654 TRACTION MODULE POWER SUPPLY …………………………………………………………… 22
4655 NEGATIVE TRACTION ENABLE ………………………………………………………………………… 23
4

66 24 VOLT ELECTRONIC VOLTAGE REGULATOR ………………………………………………… 24
467 ALARM OPTION ………………………………………………………………………………………………

25
4671 OPERATION OF AUDIBLE ALARM (OPTION) …………………………………………………… 25
468 HANDBRAKE INTERLOCK………………………………………………………………………………… 26
4

69 TRACTION MOTOR TEMPERATURE INTERLOCKS AND WARNINGS ………………… 27
4610 ACCELERATOR OPERATION …………………………………………………………………………… 28
46101 ACCELERATOR UNIT ………………………………………………………………………………………

29
46102 SINGLE PEDAL OPERATION…………………………………………………………………………… 30
46103 FORKS FORWARD DIRECTION SELECTED………………………………………………………

30
46104 FORKS TRAILING DIRECTION SELECTED………………………………………………………… 30
46105 CHECKING OPERATION OF THE ACCELERATOR UNIT …………………………………… 31
4

611 CURRENT SENSOR ………………………………………………………………………………………… 32
46111 CURRENT SENSOR DESCRIPTION …………………………………………………………………

32
46112 CURRENT SENSOR OPERATION ……………………………………………………………………… 33
46113 FORMULA FOR CURRENT SENSOR CHECK ……………………………………………………

33
4612 OPERATION AND SETUP OFF SPEED SENSOR (1B8) ……………………………………… 34
46121 TRACTION SPEED & DIRECTION SENSOR 1B8 ………………………………………………… 35
4

6122 CHECKING SENSOR WITHOUT LAPTOP OR LINDE TEST ADAPTOR ………………… 36
4613 FIELD DIVERT ………………………………………………………………………………………………… 36
4

6131 DIVERT REQUIREMENTS ………………………………………………………………………………… 37
46132 FIELD DIVERT CONTACTOR PART …………………………………………………………………… 38
4

614 HYDRAULIC PULSE LTM ………………………………………………………………………………… 39
46141 ELECTRONIC LIFT CONTROL …………………………………………………………………………

40
46142 HYDRAULIC MODULE REMOVAL ……………………………………………………………………… 40
46143 HYDRAULIC MODULE REPLACEMENT ……………………………………………………………

40
46144 HYDRAULIC THERMAL SWITCH 2B11 ……………………………………………………………… 42
46145 HYDRAULIC MODULE PIN DESIGNATION …………………………………………………………

43
46146 MODULE VOLTAGES TO AND FROM HYDRAULIC CONTROL
POTENTIOMETER 2B1 …………………………………………………………………………………… 44
46147 HYDRAULIC CONTROL MODULE ADJUSTMENTS ……………………………………………

45
4615 BATTERY DISCHARGE INDICATOR & USE OF THE SERVICE TOOL…………………… 46
46151 REPROGRAMMING THE COMBINATION INSTRUMENT WITH THE
DIAGNOSIS UNIT ……………………………………………………………………………………………

47
46152 DIAGNOSTIC MODULE…………………………………………………………………………………… 48
46153 COMBINED BATTERY DISCHARGE INDICATOR HOUR METER BRUSH
WEAR BRAKE FLUID LEVEL MOTOR OVER-TEMPERATURE INDICATOR
AND VEHICLE STATUS INDICATOR

………………………………………………………………… 50
4616 POWER STEERING ………………………………………………………………………………………… 51
46161 POWER STEERING CONTROL…………………………………………………………………………

52
46162 POWER STEERING CONTROL………………………………………………………………………… 53
4617 BRAKE WEAR INDICATOR 6A1 (OPTIONAL) ……………………………………………………… 54
4

618 EARTH FAULTS ……………………………………………………………………………………………… 55
46181 FITTING AUXILIARY ELECTRICAL EQUIPMENT ………………………………………………… 55
4

6182 CABLE RUNS…………………………………………………………………………………………………… 55
46183 INTERMITTENT FAULTS…………………………………………………………………………………… 56
4

6184 CABLES ………………………………………………………………………………………………………… 57
46185 CABLES – INSPECTION ……………………………………………………………………………………

58
46186 FAULT ANALYSIS …………………………………………………………………………………………… 58
4619 LIGHTING AND AUXILIARY 12 VOLT CIRCUITS …………………………………………………

59
CIRCUIT DIAGRAM …………………………………………………………………………………………………… 61
4620 TRUCK DIAGNOSTICS ……………………………………………………………………………………

64
46201 DIAGNOSIS WITH THE LINDE DIAGNOSIS MODULE …………………………………… 65
46202 LINDE INTERFACE CONVERTER ………………………………………………………………… 66
4

6203 INSTALLATION OF THE DIAGNOSIS SOFTWARE “TEST & SETUP” ………………… 66
46204 FIRST TIME INSTALLATION INSTRUCTIONS ………………………………………………… 66
462041 UPDATE INSTALLATION INSTRUCTIONS …………………………………………………

67
46205 STARTING AND SELECTING LINDE PROGRAM ……………………………………………… 67
46206 STARTING THE DIAGNOSIS PROGRAM “TEST & SETUP” ………………………………… 68
4

6207 LINDE DIAGNOSIS PROGRAM ………………………………………………………………………… 69
46208 HELP FUNCTION……………………………………………………………………………………………… 70
4

6209 TRACTION DIAGNOSTICS ……………………………………………………………………………… 72
462010 INDEX TO TRACTION DIAGNOSTIC WINDOWS …………………………………………… 72
4

62011 INTERFACE: …………………………………………………………………………………………………… 72
462012 INTERFACE CONVERTER STATUS: …………………………………………………………………

72
4621 WINDOWS ……………………………………………………………………………………………………… 73
46211 WINDOW 1 STATUS INFORMATION…………………………………………………………………

73
46212 WINDOW 2 TEST DATA AND FAULT DIAGNOSIS ……………………………………………… 73
46213 WINDOWS 3 AND 31 STORED FAULT DIAGNOSIS …………………………………………… 75
4

62131 WINDOW 32 DELETION OF STORED FAULT DIAGNOSIS
(MASTER VERSION ONLY) ……………………………………………………………………………… 75
46214 WINDOW 4 SWITCHING POSITION OF MICROSWITCHES ………………………………… 76
4

62141 WINDOW 41 ADDITIONAL CONTROL SIGNALS (MASTER VERSION ONLY) …… 77
46216 WINDOW 6 ANALOGUE CONTROL SIGNALS ………………………………………………… 78
462161 WINDOW 61 INTERNAL CONTROL SIGNALS (MASTER VERSION ONLY) ……… 79
4

62162 WINDOW 62 INTERNAL CONTROL SIGNALS (MASTER VERSION ONLY) ……… 79
46217 WINDOW 7 ADJUSTING TRUCK PARAMETERS …………………………………………… 80
462171 WINDOW 71 SETTING TRUCK PARAMETERS FROM WINDOW 7TO
DEFAULT SETTINGS ………………………………………………………………………………………

81
462172 WINDOW 72 DISPLAY OF PARAMETERS FROM SPECIAL VERSION ………… 82
462173 WINDOW 73 TRACTION DEFAULTS (SETS ADJUSTMENT IN PAGE 7 TO
DEFAULT VALUES) (MASTER VERSION ONLY) …………………………………………………

83
462174 WINDOW 74 UPA PARAMETERS ONLY ……………………………………………… 84

Total Pages: 93

This manual can be used by anyone from a first time owner/amateur to a professional technician

Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawingsKeep this manual handy and use it often Performing routine preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs

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