Linde Electric Forklift Truck 336-03 Series: E25 S, E30 S (Included Panorama version) Workshop Service Manual

Service Training Electric Lift Truck E 25/30 S Series 336 -03 with Three-Phase Current Drive (Panorama Version included)

Table of Content Page 1 Service Training 11.06 E 25/30 S, SERIES 336 -03 1 Drive motor 1 1.2 Drive axle 2 1.3 Traction motor 4 1.3.1 Traction motor disassembly 6 1.4 Checking of three-phase motor 8 1.4.1 Visual check 8 1.4.2 Checking during operation 8 1.4.3 Winding measurements of Stator 8 1.4.4 Insulation test 9 1.4.5 Rotor test 9 1.5 Terminals 10 1.6 Cleaning 10 1.7 Thermal sensor 11 1.8 Speed sensor 11 1.9 Assembly of drive units 11 2 Drive gearbox 1 2.1 Planetary gear GR3E-04 1 2.1.1 Renewing the radial shaft sealing ring 2 2.1.2 Oil level check and oil change 11.06 5 2.1.3 Disassembly and assembly of the traction motor 11.06 6 3 Truck design 1 3.1 Seat switch 1 3.1.1 Replacement of seat switch 2 3.2 Driver's cabin 3 3.2.1 Torsional leaf springs 3 3.2.1.1 Mounting and dismounting the leaf springs 4 3.2.2 Setting instructions of overhead guard drive 4 4 Steering system 1 4.1 Steering axle 2 4.1.1 Steering axle removal 2 4.1.2 Disassembly of the steering cylinder and track rod link 4 4.1.3 Renewing the steering cylinder seals 6

Service Training Table of Content Page 2 4.1.4 Renewing the wheel hub tapered roller bearings ring 8 4.1.5 Renewing the axle body tapered roller bearings and wipers 10 4.1.6 Installing the steering cylinder and track rod link 12 4.1.7 Installing the steering axle 14 4.2 Servostat 16 4.2.1 Steering control valve with inductive Sensor 18 4.3 Renewing of steering position potentiometer 20 5 Controls 1 5.1 Travel control 1 5.1.1 Truck speed controller 1 5.1.1.1 Adjustment of the pedal stop screws 3 5.1.2 Single-pedal direction switch 3 5.2 Braking 4 5.2.1 Renewing the brake linings 4 5.2.2 Adjusting the foot brake 4 5.2.3 Adjusting the hand brake 4 6 Electrical equipment 1 6.1 Introduction 1 6.2 General 2 6.2.1 Operating principle of three-phase current drive 2 6.2.2 EMC - Electro Magnetic Compatibility 4 6.3 Power units 5 6.3.1 General information 5 6.3.2 Power unit 6 6.4 Connector positions 12 6.5 Fuses 14 6.6 Control circuit 15 6.6.1 General information 15 6.6.2 Pin assignment of connector X13 16 6.6.3 Traction function 18 6.6.3.1 Charging of the capacitors in the intermediate circuits 19 6.6.3.2 Discharging of the capacitors in the intermediate circuits 19 6.6.3.3 Enabling signal 19 6.6.3.4 Supply voltage for accelerator and steering sensor 19 6.6.3.5 Accelerator 19

Table of Content Page 3 Service Training 6.6.3.6 Single-pedal switch 20 6.6.3.7 Steering sensor 20 6.6.3.8 Hand brake switch 20 6.6.3.9 Stop pedal switch 21 6.6.3.10 Switch-controlled speed reduction 21 6.6.3.11 Truck coding 21 6.6.3.12 Relay drivers 21 6.6.3.13 Panorama truck 22 6.6.4 Working hydraulics function 23 6.6.4.1 Joystick signals 23 6.6.4.2 Valve activation 23 6.6.4.3 Switch-controlled speed reduction 24 6.6.4.4 Reduction of lifting speed with low battery charge 24 6.6.4.5 Sensor 3B1 steering control valve 24 6.7 Software versions series 336 -03 25 6.8 Truck diagnosis 26 6.8.1 Traction window 26 6.8.1.1 Status Information 26 6.8.1.2 Information and fault messages 27 6.8.1.3 Stored fault numbers 28 6.8.1.4 Description of operator error 28 6.8.1.5 Overall fault memory 29 6.8.1.6 Clearing the overall fault memory 29 6.8.1.7 Switch inputs 30 6.8.1.8 Switch outputs 31 6.9.1.9 General analog signals 31 6.8.1.10 Analog signals related to the traction motors 32 6.8.1.11 Temperature signals 32 6.8.1.12 Setting of general parameters of the truck 33 6.8.1.13 Setting of special truck parameters 35 6.8.1.14 Display of controller information 36 6.8.1.15 Calibration of accelerator pedal neutral position 37 6.8.1.16 Calibration of steering end stops 38 6.8.1.17 Panorama truck diagnosis Window 39 6.8.2 Fault codes - traction 41 6.8.2.1 Summary of faults (LDC50C00) 41 6.8.2.2 Description of faults (LDC50C00) 43

Service Training Table of Content Page 4 6.8.3 Fault codes - traction, Panorama trucks 68 6.8.3.1 Summary of faults (LDC50C02) 68 6.8.3.2 Fault description (LDC50C02) 70 6.8.4 Windows displaying information about the working hydraulics 75 6.8.4.1 Status Informationen 75 6.9.4.2 Current information and fault messages 76 6.8.4.3 Stored fault numbers 77 6.8.4.4 Fault memory - operator errors 77 6.8.4.5 Overall fault memory 78 6.8.4.6 Clearing the fault memory 78 6.8.4.7 Switch inputs 79 6.8.4.8 Switch outputs 80 6.8.4.9 Analog signals 81 6.8.4.10 Analog signals for the working functions 82 6.8.4.11 Setting of parameters for auxiliary hydraulics 83 6.8.4.12 Adjustment of parameters for lifting/ lowering and tilting 84 6.8.4.13 Switch-controlled working speeds 85 6.8.4.14 Adjustment of discharged battery parameter 87 6.8.4.15 Calibration of Joystick 1 88 6.8.4.16 Calibration of Joystick 2 88 6.8.4.17 Depressurising the hydraulic system 89 6.8.4.18 Switch off pump motor 90 6.8.5 Fault codes - working hydraulics 91 6.8.5.1 Summary of faults (LDC50C50) 91 6.8.5.2 Fault description (LDC50C50) 93 6.9 Composite instrument 111 6.9.1 Description 111 6.9.2 Display messages 112 6.9.3 Programming of the composite instrument 115 6.9.4 Battery discharge indicator 116 6.9.5 Programming of the composite instrument with the diagnostic instrument 118 6.9.6 Diagnosis of the composite instrument with the Truck doctor diagnostic software 120 6.10 Circuit diagrams 126 6.10.1 E25/30 S 126 6.10.2 E 25/30 S Panorama version 130 6.11 Window structure for the controllers 134

Table of Content Page 5 Service Training 11.06 7 Hydraulic system 1 7.1 Functional description of the working hydraulics 2 7.2 Pump unit 4 7.2.1 Pump motor 4 7.2.1.1 Pump unit assembly 5 7.2.1.2 Pump motor disassembly 6 7.2.1.3 Terminals 8 7.2.1.4 Thermal sensor 8 7.2.1.5 Speed sensor 8 7.3 Circuit diagram of working hydraulics 10 7.4 Emergency lowering functions of the working hydraulics 12 7.4.1 Manual tilting of lift mast 12 7.4.2 Manual lowering of the fork carrier 12 7.5 Control valve 14 7.5.1 Functional description of the control valve 16 7.5.2 Depressurising of the working hydraulics 19 7.5.3 Repair work at the valve block 20 7.5.3.1 Replacing the valve cartridge of safety valve 2Y9/2Y10 21 7.5.3.2 Replacing the valve coil of 'tilting / additional hydraulic system 2Y3 to 2Y8' 21 7.5.3.3 Replacing the valve coil of 'lifting / lowering 2Y1 / 2Y2' 21 7.5.3.4 replacing the brake valve 22 7.5.3.5 Replacing the valve coil of 2Y9/2Y10 22 7.5.3.6 Setting the pressure relief valve 23 7.6 Replacing the micro-filter 11.06 23 7.7 Troubleshooting control valve 24 8 Lift mast 1 8.1 Mounting and dismounting the lift mast 2 8.2 Limit position damping 3 8.3 Dismounting, mounting the outer lift cylinders 4 8.4 Dismounting, mounting the center lift cylinder 5 8.5 Sealing the lift cylinder 6 8.6 Setting of mast chain 7 8.7 Setting the roller clearance 8 8.7.1 Outer, inner and center mast roller clearance 9 8.7.2 Outer mast clearance 10 8.8 Sliders 11

Service Training Table of Content Page 6 8.8.1 Dismounting the slider of the standard mast 11 8.8.2 Dismounting the slider of the duplex mast 12 8.8.3 Dismounting the slider of the triplex mast 13 8.9 Tilt cylinder 16 8.9.1 Dismounting the tilt cylinder 16 8.9.2 Sealing the tilt cylinder 17 8.9.3 Setting the tilt angle 18 9 Special equipment 1 9.1 Electric special equipment 1 9.1.1 Installation positions of the working lights 1 9.1.2 Console of the special equipment 2 9.1.3 Converters 3 9.1.4 Fuses 5 9.1.5 Working lights and lighting system 6 9.1.6 Electric heating unit 12 9.1.7 Circuit diagram special equipment 16 9.1.8 Circuit diagram special equipment switchable 20

Service Training Page 1 Section 1 1 DRIVE MOTOR Three-phase asynchronous motors are used as drive motors. Speed and torque of the motors are controlled by the two power units 1A1 and 1A2. The power units generate a rotary field in the motor stator, which sets the rotor into motion. The terminals U V W are separately lead out of the motor. The traction motor direction is reversed by reversal of the rotary field. NOTE: The right-hand and the left-hand traction motors are not the same, due to a different mast bearing shell.

Service Training Section 1 Page 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1.2 DRIVE AXLE

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Linde Electric Forklift Truck 336-03 Series: E25 S, E30 S (Included Panorama version) Workshop Service Manual

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