STILL STED forklift EXV 10 Basic EXV10 EXV12 EXV 12i EXV 14C EXV 14i C Pallet Workshop Manual

: updates.

First issue.

: updates. : updates.

: updates.

: updates.

Added models EXV 10 Basic and EXV 12i; added the alarms list; updates. gear unit.

Changed the serial numbers and documentation codes.

: introducing new reduction : updates. : updates.

New nominal value designation plate.

Updates.

: updates.

: updates.

45728042302 EN - 10/2018

I

This document gives the danger warnings Each of such danger warnings consists of a graphic symbol, followed by a description of the danger and its consequences, and the description of how it can be avoided. The types of warnings used are described below.

It may be accompanied by additional comments.

This warning indicates serious risk of damaging the truck.

It may be accompanied by additional comments.

This warning indicates the risk of damaging the truck or parts of the same.

It may be accompanied by additional comments.

This symbol indicates important communications for the assistance technician.

The instructions given here must be followed in order to avoid causing damage to the environment.

Do the following before performing maintenance operations: Position the forklift on a at surface and ensure that it cannot move accidentally.

Lower the forks fully.

Turn off the truck.

Most accidents that occur in workshops are caused by failure to observe some simple and fundamental rules of prudence and safety.

paying attention to possible causes of accident and their consequences, scrupulously following the safety rules.

For this reason, accidents can be avoided in most cases by the necessary care and prudence,

A careful and wise mechanic is the best guarantee against accidents.

Keep the operating materials only in containers intended for this purpose and in a location that satis es the requirements.

Improper use and disposal of operating and cleaning materials can cause serious damage to the environment.

Always use and handle the operating materials in a suitable manner and follow the manufacturer's instructions for the product's use.

The operating materials may be ammable, so avoid contact with hot objects or open ames.

When topping up the operating materials, only clean containers should be used.

Follow the manufacturer's safety and disposal instructions regarding the operating and cleaning materials.

45728042302 EN - 10/2018

III

Do not disperse oils or other operating liquids!

Any spilt liquid must be immediately collected and neutralised with a binding material (such as an oil binder) and then disposed of in accordance with current regulations.

Always comply with anti-pollution regulations!

Before carrying out work that involves lubrication, lter replacement or hydraulic equipment interventions, the area in question must be thoroughly cleaned.

The replaced parts must always be disposed of in accordance with the anti-pollution laws.

Do not inhale the vapor: it is poisonous.

Use adequate means of individual protection to prevent contact with the skin.

Battery acid is corrosive: if it should come into contact with your skin, rinse abundantly with water.

The incorrect or unlawful use of brake uid is harmful to people's health and the environment.

Explosive gas mixtures can form when charging the battery; therefore, the rooms in which the battery is charged must be in compliance with the speci c regulations on the subject (e.g. EN 50272-3 etc.).

Do not allow to come into contact with the skin.

DO NOT smoke or use open ames and lights within a 2 m radius from the charged battery and in the battery charging area.

Do not inhale oil vapors.

Wear appropriate means of individual protection during forklift maintenance operations (gloves, goggles, etc.) to prevent the oil from coming into contact with your skin.

The used oils and relative lters contain substances that are hazardous to the environment and must be disposed of according to current regulations. We advise you to contact the authorised service network.

IV

For greater information, consult the speci c battery manual that comes with the battery.

The batteries contain substances that are hazardous to the environment. The replacement and disposal of the life-expired battery must be carried out as required by law. We advise you to contact the authorised service network that is equipped for eco-friendly disposal in accordance with current regulations.

45728042302 EN - 10/2018

A truck speci cally equipped for cold-storage rooms must be used when working at temperatures below +5°C. Forklifts equipped for working in cold climates and cold-storage rooms may be used at a minimum temperature of -5°C for continuous service in cold-storage rooms and at -32°C for non-continuous service in cold-storage rooms.

The forklift must always be turned off and parked outside the cold area/cold-storage room.

If the truck has been working in environments at temperatures below -5°C and it is taken outside the cold-storage room, let it stand either for a suf ciently long time to allow evaporation of any condensation (at least 30 minutes) or a suf ciently short time to prevent the formation of any condensation (less than 10 minutes).

Avoid the formation of ice on the forklift.

NEVER drive the truck into the cold-storage room when condensation has formed on it

45728042302 EN - 10/2018

V

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45728042302 EN - 10/2018

VII

VIII

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45728042302 EN - 10/2018

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45728042302 EN - 10/2018

IX

X

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45728042302 EN - 10/2018

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45728042302 EN - 10/2018

XI

a

This workshop manual essentially has two parts: General information on the product, diagnosis of malfunctions and special tools: Group 00 Repair instructions: Groups 02 to 100 Each part of the current manual is composed of a set of separate sheets that are led in a STILL binder according to their group number.

The manual is organised according to the same rules used for the spare parts catalogue, which is divided into sub-groups (assemblies or construction groups).

To make it as simple as possible to identify the assemblies presented in this manual, the number of each assembly is printed in the upper right-hand corner of each page.

Where necessary, we have included tables to provide the maintenance department with relevant technical data. These tables must also be consulted by experienced mechanics.

The manual contains a detailed description of truck design features, as well as component and assembly operating features.

To supplement the operations described in this manual, comments, instructions and explanatory diagrams have also been provided.

The diagnostic software makes it possible to quickly locate the source of a problem identi ed in the electrical system and to accurately determine its cause.

Consult the list of alarms that can be displayed in the diagnosis software in order to accurately determine the cause of the malfunction.

Diagrams of the hydraulic and electrical circuits are available in the relevant publications

This workshop manual addresses standard truck models, as well as particularly common variants of these vehicles.

Using this manual in accordance with our instructions does not guarantee a speci c result. It will have no bearing on STILL warranty conditions.

STILL continually strives to enhance and improve its products. The design and manufacture of our trucks are constantly evolving. As a result, the information contained in this manual may be modi ed without prior notice.

45728042302 EN - 10/2018

-1

1

2

3 20 4

19 5 6

18

7

17

8

16

9

15 14 0252_003-066

1 2 3 4 5 6 7 8 9 10

-2

Lift mast Mast chains Guard grille Tiller Emergency stop button Fuse holder Battery connector On-board charger (Optional) Pump motor Hydraulic oil tank

10 13

11

12 11 12 13 14 15 16 17 18 19 20

Stabilising wheel Drive wheel Reducer Traction motor Brake Forks Rollers Controller Battery Lifting cylinder

45728042302 EN - 10/2018

1 2 3 4

Handle "Raising" push button "Lowering" push button "Lowering" base lift push button (optional)

5 6 7 8

45728042302 EN - 10/2018

Warning horn "Raising" base lift push button (optional) Butter y valve Anti-crushing safety feature

-3

1 2 3 4 5

Battery charge level represented by 10 bars Service alarm (red) Red indicator light Green indicator light Error code

6 7 8 9

Fault case Hour meter STOP alarm (red) Temperature alarm (red)

Refer to the "Display" chapter for further information.

-4

45728042302 EN - 10/2018

1 Names used in the text: forward travel (1), reverse travel (3), to the right (2) and to the left (4) refer to the installation position of the components in relation to the driver's compartment, with the load positioned at the rear.

4

2

3

45728042302 EN - 10/2018

0252_003-008

-5

Complete serial number.

= plant in Luzzara (Italy). = plant in Montataire (France).

0251(*) / 0270 0252

(*)

0254

(*)

EXV 10 Basic

/ 0271

EXV 10

0253(*) / 0272

(*)

EXV 12

/ 0273

EXV 12i

0321

EXV 14 C

0322

EXV 14i C

Old Montataire serial numbers

= 2018 0

1

200x

L

M

201x

A

B

3

4

5

N

P

R

C

D

E

2

6

7

8

S

T

U

W

Z

F

G

H

J

V

9

202x

X

Y

K

L

M

N

P

R

S

T

203x

U

W

Z

A

B

C

D

E

F

G

.

= Number increasing from start of production. This is reset at the beginning of each calendar year.

-6

45728042302 EN - 10/2018

1

2

3

4

11

12

5

6

Please indicate the serial number for all technical enquiries.

*

7

8 9

10

13 2327

1 2 3 4 5 6 7 8 9 10 11 12 13

45728042302 EN - 10/2018

Model Rated capacity in kg Manufacturer Serial no.

Unladen weight (without battery) in kg Year of manufacture EC conformity symbol QR code Battery voltage V Nominal power rating in kW Minimum battery weight Maximum battery weight Additional weight (ballast) in kg

-7

The truck's serial number is marked on the chassis.

-8

45728042302 EN - 10/2018

Positioning on standard trucks (EXV 10 Basic, EXV 10, EXV 12, EXV 14 C):

Positioning on trucks with initial lift (EXV 12i, EXV 14i C):

45728042302 EN - 10/2018

-9

3PZS-240

65

240

210

555

580

210

795

3PZS-270

65

270

244

555

580

210

795

3PZS-315

65

315

263

555

580

210

795

3PZV-240

65

240

252

555

580

210

795

3PZV-285

65

285

286

555

580

210

795

3PZS-270

66

270

230

525

578

273

610

.

3PZS-315

66

315

249

525

578

273

610

3PZV-240

66

240

238

525

578

273

610

3PZV-285

66

285

272

525

578

273

610

3PZS-B165

68

165

200

548

578

228

560

.

-10

45728042302 EN - 10/2018

3PZS-B220

68

220

200

548

578

228

560

3PZS-B225

68

225

200

548

578

228

560

3PZV-B213 3PZV-B201 EVOLUTION

68

213

216

548

578

228

560

68

201

205

548

578

228

560

2PZS-B150

95

150

195

652

690

145

660

2PZS-B170

95

170

195

652

690

145

660

.

2PZS-B200

95

200

195

652

690

145

660

2PZV-B170 2PZV-B162 EVOLUTION

95

170

195

652

690

145

660

95

162

195

652

690

145

660

2PZS-230

112

230

212

612

627

212

624

2PZS-250

112

250

212

612

627

212

624

2PZV-200

112

200

217

612

627

212

624

2PZV-220

112

220

245

612

627

212

624

.

.

45728042302 EN - 10/2018

-11

Press emergency stop button (1).

1

0252_003-047

Open the battery cover (2).

2

0252_003-075

-12

45728042302 EN - 10/2018

Unplug the battery connector (3).

Proceed in reverse order.

45728042302 EN - 10/2018

-13

Do not park the truck on a slope.

Never leave the truck with the forks raised.

Park in pre-arranged and designated areas.

Lower the forks to the ground.

Turn off the truck using the start/stop key. If the Digicode option is tted, turn off the truck by pressing the # button for two seconds.

Press the emergency stop button.

-14

45728042302 EN - 10/2018

Pallet stackers are equipped with an eyelet, designed for lifting, that is located above the crossmember of the column .

Before using the hoist, make sure that it has suf cient capacity to lift and manoeuvre the load without risks/dangers.

Check that all of the features of the hoist are suitable before lifting/manoeuvring.

Make sure that the wire ropes/chains/slings have suf cient capacity to lift and manoeuvre the load without risks/dangers.

Make sure that the hook is inserted correctly and that the safety snap hook is closed correctly and works properly.

Take great care during the manoeuvre! Wear the necessary protective equipment and make sure that there is suf cient space to manoeuvre the truck without risk of damage to yourself, other people and objects.

If it is no longer possible to operate fork lowering from the tiller, a manual course of action is described in the following paragraphs.

45728042302 EN - 10/2018

-15

The emergency lowering function only operates on the main lift and not on the initial lift.

Do not walk under the suspended forks!

Before manually lowering the forks, check that there is nobody is in the danger area.

Remove the bonnet:

Use pliers and a 3-mm hexagon socket wrench:

-16

45728042302 EN - 10/2018

Unscrew the plug of the safety lowering solenoid valve (Y6):

Gradually unscrew the knob shown in the illustration:

45728042302 EN - 10/2018

-17

Gradually push the piston of the lowering proportional solenoid valve (Y1):

The fork lowering is directly proportional to the extent to which Y1 is pushed and Y6 is unscrewed.

Check that the forks are completely lowered.

Screw in the red knob.

Reposition the solenoid valve Y6 and screw in the plug.

Fit the bonnet.

-18

45728042302 EN - 10/2018

Remove the bonnet:

Use a 7-mm wrench:

45728042302 EN - 10/2018

-19

Unscrew the screw shown in the illustration:

The fork lowering is directly proportional to the extent to which the screw is unscrewed.

Check that the forks are completely lowered.

Tighten the screw to

.

Fit the bonnet.

-20

45728042302 EN - 10/2018

Key to symbols in table: = Every 1000 hours or at least every 12 months (whichever comes rst), unless local regulations require more frequent intervention.

During maintenance operations, follow the instructions provided in the "Safety guidelines relative to operating materials" section in "Chapter 2".

Reduction gear: check that it is correctly mounted Reduction gear: check for any oil leakage Drive motor: check that it is correctly mounted Check condition of forks Grease the rods and levers Check bushes and levers Steering: visually inspect the mounting of the tiller Steering unit bearing: grease (if there is a lubrication nipple) Wheels and rollers: check for any damage, foreign matter or signs of wear Wheels: check that they are at the correct tightness Rollers: check that they are correctly mounted Electromagnetic brake: check for signs of wear and adjust if necessary Check truck braking Battery: check the battery condition and that it is correctly mounted Battery: check the condition of the cables and sockets Battery: service the battery according to the manufacturer's instructions On-board charger (if present): clean On-board charger (if present): check that it is operating correctly Truck cables and connectors: check the condition and position Electrical components: clean Check insulation between chassis and electric motors Check insulation between chassis and electronic control Pump unit: check the general condition Pump unit: check the wear of the lifting motor brushes

45728042302 EN - 10/2018

-21

Hydraulic system: check the oil level Hydraulic system: check for any leakage from cylinders and hydraulic ttings Hydraulic system: check the condition of the pipe lines Mast: check that it is in good condition Mast: lubricate the sliding tracks of the mast pro les Mast: check that it is correctly mounted Lift cylinders, chains, rollers and end stops: check the condition, mounting and operation Lifting chain: check chain adjustment and maintenance (clean, adjust, grease) Fork holder: check that the fork holder is in good condition, is correctly mounted and is operating correctly Protective device: check that the anti-shearing protective guard is in place, is in good condition and is correctly mounted Mobile chassis: check that the fork holder is in good condition, is correctly mounted and is operating correctly

Replace hydraulic oil and hydraulic oil lter Servicing the lifting mast: check the lateral and axial clearance of the bearings

Replacing the reduction gear unit oil .

Reduction gear unit oil (for trucks produced until April 2018) Quantity [l] Reduction gear unit oil (for trucks produced from May 2018) Quantity [l] Oil for hydraulic lifting systems Quantity [l] Lubricant for lifting chains Generic lubricant .

-22

45728042302 EN - 10/2018

Reduction gear unit oil (for trucks produced until April 2018) Quantity [l] Reduction gear unit oil (for trucks produced from May 2018) Quantity [l] Oil for hydraulic lifting systems Quantity [l] Lubricant for lifting chains Generic lubricant .

Reduction gear unit oil (for trucks produced until April 2018) Quantity [l] Reduction gear unit oil (for trucks produced from May 2018) Quantity [l] Oil for hydraulic lifting systems Quantity [l] Lubricant for lifting chains Generic lubricant .

Reduction gear unit oil (for trucks produced until April 2018) Quantity [l] Reduction gear unit oil (for trucks produced from May 2018) Quantity [l] Oil for hydraulic lifting systems Quantity [l] Lubricant for lifting chains Generic lubricant .

45728042302 EN - 10/2018

-23

Reduction gear unit oil (for trucks produced until April 2018) Quantity [l] Reduction gear unit oil (for trucks produced from May 2018) Quantity [l] Oil for hydraulic lifting systems Quantity [l] Lubricant for lifting chains Generic lubricant .

Reduction gear unit oil (for trucks produced until April 2018) Quantity [l] Reduction gear unit oil (for trucks produced from May 2018) Quantity [l] Oil for hydraulic lifting systems Quantity [l] Lubricant for lifting chains Generic lubricant .

-24

45728042302 EN - 10/2018

DIN 912 / ISO 4762 DIN 931 / EN ISO 4014 DIN 933 / EN ISO 4017 8.8

10.9

12.9

8.8

10.9

12.9

M3 x 0.5

1.3

1.9

2.3

-

-

-

M4 x 0.7

3

4.5

5

-

-

-

MS x 0.8

6

8.5

10

-

-

-

M6 x 1

10

15

17.5

9

13

15.5

M8 x 1.25

25

36

42

22

32

37

M10 x 1.5

48

71

83

42

63

73

M12 x 1.75

84

123

144

74

108

126

M14 x 2

133

195

229

116

171

201

M16 x 2

206

302

354

181

264

309

.

DIN 7984 DIN 6912 8.8

10.9

12.9

M3 x 0.5

1

1.35

1.6

8.8 -

10.9 -

12.9 -

M4 x 0.7

2.1

3

3.5

-

-

-

M5 x 0.8

4.2

6

7

-

-

-

M6 x 1

7

10

12.5

6

8.8

11

M8 x 1.25

17.5

24.5

30

15.5

22

27

M10 x 1.5

34.5

49

59

30

43

52

M12 x 1.75

60

84

101

M14 x 2

95

137

161

53 -

74 -

89 -

M16 x 2

147

210

252

129

185

222

.

45728042302 EN - 10/2018

-25

Verbus-Ripp cl.100 -

10.9

-

-

10.9

-

M6 x 1

-

15

-

-

13.6

-

M8 x 1.25

-

37

-

-

33

-

M10 x 1.5

-

73

-

-

65

-

M12 x 1.75

-

-

-

-

-

-

111 -

-

M14 x 2

127 -

-

M16 x 2

-

311

-

-

272

-

.

For tightening screws in aluminium components, multiply the tightening torque by a factor of:

DIN 7991 cl.10.9 -

10.9

-

-

10.9

-

M6 x 1

-

11

-

-

9.5

-

M8 x 1.25

-

28

-

-

25

-

M10 x 1.5

-

56

-

-

50

-

M12 x 1.75

-

96

-

-

85

-

M14 x 2

-

156

-

-

137

-

M16 x 2

-

240

-

-

211

-

.

-26

45728042302 EN - 10/2018

ULS / ISO 7380 ULF -

10.9

-

-

10.9

-

M6 x 1

-

11

-

-

10

-

M8 x 1.25

-

27

-

-

25

-

M10 x 1.5

-

52

-

-

48

-

M12 x 1.75

-

100

-

-

90

-

.

DIN 7500

cannot be used for safety torques 10.9

M6 x 1

10

M8 x 1.25

24

M10 x 1.5

48

M12 x 1.75

83

M14 x 2

-

These tightening torques are provided for information only and may vary according to the support used. Test the tightening torques before con rming the torque to apply.

.

45728042302 EN - 10/2018

-27

e.g. : ECO SYN cannot be used for safety torques

D 2.5

0.8

D3

1.4

D 3.5

2

D4

3

D5

5.5

These tightening torques are provided for information only and may vary according to the support used. Test the tightening torques before con rming the torque to apply.

D6 9 If using an electric screwdriver: 600 rpm max. .

DIN 74361-2 (form G)

DIN 74361-2 (form A)

8.8

10.9

-

8.8

10.9

-

M12 x 1.5

83

125

-

83

125

-

M14 x 1.5

135

210

-

135

210

-

M14 x 2

M16 x 2

63

90

.

M6 x 1 45 H

5

M8 x 1.25 M10 x 1.25 M12 x 1.75 10

20

.

-28

45728042302 EN - 10/2018

45

The values in this table only apply to assemblies involving two metal components.

If using washers, the tightening torque must be multiplied by the factor provided in the table.

When assembling aluminium components, multiply by the factor provided in the additional factor table.

When tting pre-bonded or pre-coated screws, use the tables without using the additional factor.

Should the information provided not apply to your speci c situation, please request additional information.

Tightening safety parts (wheel, motor, reducer and hydraulic cylinder mountings, tting loading frames on the chassis, mast bearings, steering stops, brake mountings, stabiliser wheel mountings, pump units and bogies): ±10% For other parts (cover, accessories etc.): ±20%

45728042302 EN - 10/2018

-29

-30

45728042302 EN - 10/2018

a

Before carrying out any work on the electrical components of the truck using the repair kit, raise the drive wheel from the ground using a jack so that it can turn freely.

For safety reasons, place wooden blocks under the chassis to prevent the truck from moving.

45728042302 EN - 10/2018

-1

A1 6P1 6X7

Traction and lifting electronic control (LAC) with CAN-bus terminating resistor (R) Display with/without CAN-bus terminating resistor (R) Diagnostic connector

A4 S1 S100 R

Li-ion battery electronic control (optional) with CAN-bus terminating resistor (R) Digicode (optional) TDU (optional) CAN-bus terminating resistor

The CAN-bus network consists of: CAN HIGH (CAN H) CAN LOW (CAN L) Two terminating resistors "R", ( connected in parallel in the circuit

each),

The CAN-bus network of the truck operates correctly only if there are (60 in total). The Li-ion battery electronic control is always tted with this type of resistor.

In such a case, a display is installed without a terminating resistor.

When using this communication bus, the components concerned continuously exchange information.

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Perform the measurement with the truck switched off.

Measure the resistance between pin (1) and pin (2) of the diagnostic connector '6X7': 1 2 3 4 5 6 7

60

120

0

>2000

CAN H CAN L 24 V 0V Not used Not used Not used

The CAN network is working correctly.

/

Check the connection of the electronic control (LAC) and One of the components in which the terminating resistor " " is of the display; if present, also present is not connected. check the connection of the Li-ion battery electronic control.

Disconnect the CAN network A component of the CAN network components one at a time to has short-circuited. identify which of them is faulty.

Check the connection of the None of the components in which electronic control (LAC) and the terminating resistor " " is of the display; if present, also present are connected. check the connection of the Li-ion battery electronic control.

.

Perform the measurement with the truck switched on.

Based on the battery charge status, the measured values may vary slightly from those indicated in the table.

Do not cause short circuits when measuring!

Measure the voltage between pin (1) and pin (4) of the diagnostic connector '6X7'.

1 2 3 4 5 6 7

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CAN H CAN L 24 V 0V Not used Not used Not used

-3

Measure the voltage between pin (2) and pin (4) of the diagnostic connector '6X7':

1 4

2.6

2 4

2.3

1 4/2 4

The CAN network is working correctly.

The CAN network is working correctly.

Other voltage values

TDU With CAN-bus terminating resistor GPRS module Shock sensor

The CAN bus network (Fleet Manager) consists of: CAN HIGH (CAN2 H) CAN LOW (CAN2 L) two terminating resistors (120 nected in parallel in the circuit

-4

/

Disconnect the CAN One of the components network components of the CAN network is not one at a time to identify working correctly. which of them is faulty.

.

S100 W2 6B1

/

each), con-

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Con guration A Con guration B

+

Con guration C

+

Con guration D

+

+

For more information, refer to the circuit diagram.

Perform the measurement with the truck switched off.

The resistances relative to the GPRS module and to the shock sensor cannot be measured.

Measure the resistance of the TDU between pin (11) and pin (12) of the '6X16' connector:

Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 Pin 14

24 V (red cable) Not used GND (black cable) Not used Not used Not used Not used Not used Not used Not used CAN2 H (white/black cable) CAN2 L (brown/black cable) CAN1 H (white cable) CAN1 L (brown cable)

120

The TDU is working correctly.

0

The TDU has short-circuited.

The TDU is not connected to the CAN bus network.

>2000

/ Replace the TDU. Check the TDU connection.

Replace it if necessary.

.

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-5

Perform the measurement with the truck switched on.

Based on the battery charge status, the measured values may vary slightly from those indicated in the table.

Do not cause short circuits when measuring!

Measure the CAN2 H voltage between pin (11) and pin (3) of the '6X16' connector.

Measure the CAN2 L voltage between pin (12) and pin (3) of the '6X16' connector: Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 Pin 14

11 3

2.5

12 3

2.5

11 3 / 12 3

24 V (red cable) Not used GND (black cable) Not used Not used Not used Not used Not used Not used Not used CAN2 H (white/black cable) CAN2 L (brown/black cable) CAN1 H (white cable) CAN1 L (brown cable)

The CAN2 network is working correctly.

The CAN2 network is working correctly.

Other voltage values

One of the components of the CAN2 network is not working correctly.

.

In order to execute the best troubleshooting, please always refer to the complete alarms list stored in the electronic controller memory.

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/ / Disconnect the CAN2 network components one at a time to identify which of them is faulty.

: codes from to ; they are never stored in the controller (LAC) memory and so they can only be viewed in the [F4:Measurement] [Current Status]. : codes from to ; they are stored in the controller memory but no repair is required. : codes from onwards; they are stored in the controller memory and repairs are required. They are split into four groups: from 200 to 301

Traction controller faults;

from 302 to 354 nents faults;

Controller power compo-

from 355 to 399 faults;

Lifting/lowering controller

from 400 to 499

Safety controller faults.

Fault codes use the following syntax:

The rst error present in the controller is fault code 451.

On the display, they can be displayed maximum 4 fault codes.

5

Initial condition not yet satis ed: butter y switch not in neutral position and/or belly switch ON and/or potentiometer supply voltage too low (< 3,5V) and/or creep speed switch ON (only trucks with creep speed switch) and/or tiller not in rest position.

Butter y switch in neutral position (according traction potentiometer signal or redundant switch signal).

Tiller in neutral position.

Tiller in neutral position and creep speed switch active (only trucks with creep speed switch).

Initial lift up sensor is active (1X1:6 < 3V).

6

Mast potentiometer

1 2 3 4

in neutral position.

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-7

7

8

9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 30 31 35 36 37 38

-8

One or more lifting/lowering commands are active at start-up. Depending on truck type con guration, following input signals are concerned: lifting switch active (1X1:5 = GND) and/or lowering switch active (1X1:19 = GND) and/or initial lift command active (1X1:4 = GND) and/or initial lowering command active (1X1:18 = GND) and/or mast potentiometer is not in neutral position (code #6 is not displayed).

Many lifting/lowering commands are active at same time. Depending on truck type con guration, following input signals are concerned: lifting switch active (1X1:5 = GND) and/or lowering switch active (1X1:19 = GND) and/or initial lift command active (1X1:4 = GND) and/or initial lowering command active (1X1:18 = GND) and/or mast potentiometer is not in neutral position (code #6 is not displayed).

Power save on: if tiller foot, belly switch are released and butter y switch is in neutral position, the power module (LAC) is deactivated.

Unsafe state for passive mode (LAC): truck speed higher than 0.4 km/h or hard braking is disabled.

LAC in passive mode.

Brake current too low (less than 75% of setpoint).

Butter y switch turned in tiller direction whereas tiller in rest position (for reset, turn butter y switchinto neutral position).

Safety controller (LAC) didn't nish start up procedure. Reasons may be: safety relay welded or damaged (fault code 400 must be present and S_OFF1/S_OFF2 are disabled) or safety relay disable test was not yet started on safety controller (S_OFF1 is enabled and S_OFF2 is disabled).

Tiller foot potentiometer is selected (by diagnosis).

Mast potentiometer in active position (1X1:11 > 40% of potentiometer supply voltage) but lifting/lowering buttons are not active (1X1:5 and 1X1:19 = open).

Mast sensor is active (1X1:28 = open). Note: to deactivate this state, following conditions must be true simultaneously: 1X1:28 = GND and forks lowering must be performed at least one time.

No speed signal though torque applied; reasons may be: speed sensor problem, motor/wheel/truck blocked.

Belly switch function activate.

Belly switch function active, reset not yet performed (for reset turn butter y switch into neutral position).

The Li-Ion battery has a low state of charge.

Belly switch function ready.

Tiller is now in working position but belly switch is pressed (for reset turn butter y into neutral position and release belly switch).

Belly switch function changed to stop: creep speed active.

Belly switch active Belly switch pressed (1X1:10 = potentiometer supply voltage) and/or tiller in working position (1X1:36 = GND and 1X1:38 = open).

Butter y turned (15s) in tiller direction whereas tiller in rest position (for reset turn butter y into neutral position).

Monitoring of rotor eld according motor model; traction motor not yet magnetized.

LAC is temporarily locked due to its error (usually locked for 1 second until next reset attempt).

Battery voltage too low, hysteresis: UBat < 11V low and UBat > 12V OK (1X1:2).

Battery charge less or equal than 20% (2 bars or less on the display).

Incorrect value for disable lifting at low state of charge . Check it in [F3:Setup] [BDI] Battery Discharge Indicator.

Incorrect value for speed reduction at low state of charge . Check it in [F3:Setup] [BDI] - Battery Discharge Indicator.

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39

Battery charge less or equal than 20% (2 bars or less on the display).

40

Warm powerpart (LAC) temperature (70°C...80°C).

41

Hot powerpart (LAC) temperature (>80°C).

42

44

High powerpart (LAC) temperature, hysteresis: T > 50°C ON and T < 40°C OFF. Only for trucks with creep speed function: if creep speed button is released and butter y keeps turned, truck acceleration is limited to get a smooth transition. Limitation of acceleration is switched off, when butter y is in neutral-position and truck-speed is less than 0,36 [km/h].

Warm powerpart (LAC) temperature (50°C...70°C).

45

High traction motor

46

Power reduction (tractive force) due to high powerpart (LAC) temperature (>65°C).

47

Power reduction (tractive force) due to high motor

48

54

Soft landing sensor is active (1X1:7 = GND).

Speed reduction commanded by input "Turtle/Hare" 1X1:21 (reduction active when input not connected).

Variable speed reduction requested from (truck data unit) via CAN.

55

Brake requested from

(truck data unit) via CAN.

56

Stop requested from

(truck data unit) via CAN.

57

Speed reduction requested from

43

50

58 60 61 62 65 66 67 68 69 70

temperature (>130°C). temperature (>115°C).

(truck data unit) via CAN.

(truck data unit) disabling function.

Creep speed active.

Creep speed active (and belly switch pressed); reset not yet performed (for reset turn butter y into neutral position and/or release the creep speed switch and/or release the belly switch).

Creep speed active, but butter y switch is not fully pushed.

Truck with speed reduction sensor or , or (depending on the truck type): sensor active (1X1:20 < 3V and 1X1:14 = open).

On CO (Customer Option)/UPA trucks: speed reduction sensor or , or (depending on the truck type) active (1X1:20 < 3V) and intervention on mast lifting enabled by diagnosis.

Mast sensor is active (1X1:28 = open).

Mast sensor is active and initial lift is not down (1X1:28 = open and 1X1:23 = open).

On CO (Customer Option)/UPA trucks: speed reduction sensor or , or (depending on the truck type) active (1X1:20 < 3V) and intervention on mast lowering enabled by diagnosis.

Discharging of power module (LAC) capacitors for test purposes is being performed.

73

Switching ON of main contactor could not be performed.

Discharging of power module (LAC) capacitors failed at start-up. Reasons may be: contactor welded, shortcut to 24V of capacitors circuit, wires of lift pump motor cut.

Power module (LAC) capacitors are in pre-charging via "charging circuit".

74

Main contactor

75

Brand-ID of controller (LAC) is invalid or does not match with truck type.

76

Lifting/lowering level parameters were changed by diagnosis.

78

Drive direction information unde ned, as truck is stopped.

On CO (Customer Option)/UPA trucks: "Tiller foot with Potentiometer & Platform" is activated and input 1X1:36 = GND; it means the driver is present and the tiller foot potentiometer works like a switch.

71 72

79

in power save mode.

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-9

80 81 82 83 84 85 86 90 91 92 93 94 96 97 98 99

Truck ID changed by diagnosis.

Only trucks with tiller foot potentiometer : tiller foot potentiometer teaching procedures have not been performed yet.

Creep speed settings changed by diagnosis.

Mast potentiometer teaching procedures have not been performed yet on function controller (LAC). (truck data unit) type changed by diagnosis. type changed by diagnosis.

Tiller foot potentiometer Traction potentiometer teaching procedures have not been performed for safety controller (LAC).

Mast potentiometer teaching procedures have not been performed yet on safety controller (LAC).

110

Electromagnetic brake actuator failure (measured current rise when actuator switched on does not match with correct/ideal current rise).

111

Electromagnetic brake

coil resistance too low (correct value 16,5 ).

112

Electromagnetic brake

coil resistance too high (correct value

113

Electromagnetic brake current too low (less than 75% of setpoint).

Mast potentiometer in active position (1X1:11 > 40% of potentiometer supply voltage) but lifting/lowering buttons , are not active (1X1:5 and 1X1:19 = open).

116

16,5 ).

118

Only trucks with Li-Ion battery: low state of charge ( rst level).

119

Only trucks with Li-Ion battery: low state of charge (second level).

Pre-charging of the powerpart (LAC) capacitors failed (voltage at + of powerpart < 15V; 2s). Reasons may be: at start up or wake up from power save a DTC (Diagnostic Trouble Code) was active and that has deactivated the safety relay; powerpart wiring error; misuse of the + pin of the powerpart (example: connection of electric consumers between + and - pins of powerpart). Note: the pre-charging of the powerpart capacitors is done with a pre-charging circuit that is integrated inside the LAC. Usually the pre-charging is done previously before switching ON the main contactor, for example when turning ON the truck or waking up from power-save mode. A failed pre-charging leads to a longer time until the main contactor switches ON to a reduction of the contactors lifetime.

Only trucks with Li-Ion battery: low state of charge (third level).

120

121 -10

Internal controller (LAC) error (SSC-watchdog is not correctly working for at least 200 [ms]).

Internal controller (LAC) error (different telegram-length detected in SSC-communication between function-controller and safety-controller for at least 200 [ms]. Reason: SSCversions of safety-controller/function-controller do not match).

Internal controller (LAC) error (different SSC-versions detected in SSC-communication between function-controller and safety-controller for at least 200 [ms]. Reason: SSCversions of safety-controller/function-controller do not match).

Safety controller (LAC) performs valve disable test.

Incorrect battery type from function controller (LAC). Reasons: type changed by diagnosis or internal controller error.

Incorrect power reset mode from function controller (LAC). Reasons: type changed by diagnosis or internal controller error.

Speed reduction sensor or , or (depending on the truck type) mode changed (1X1:20 or 1X1:23). Reason: type changed by diagnosis.

Traction potentiometer teaching procedures have not been performed yet.

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127

Butter y turned (15s) in tiller direction whereas tiller in rest position (for reset turn butter y into neutral position).

131

Internal driver error (LAC) together with code 31.

167

Li-Ion battery warning.

201

High supply voltage to pin 1X1:26 > 5.1V instead of 4.3V.

202

Low supply voltage to pin 1X1:26 < 3.5V instead of 4.3V. Tiller switch signals (1X1:36 and 1X1:38) not compatible or tiller foot potentiometer not compatible to truck type.

203 204

Creep speed switch

206

Battery voltage too low (< 9V): undervoltage or disconnection of input 1X1:2.

207

Driving speed too high (> maximum speed + 2 km/h = 8 km/h).

208

Perturbation of speed sensor signals detected (inputs 1X1:8 and 1X1:22).

Digital inputs (except butter y) switched with unrealistically high frequency (> 10Hz).

Reason: harness problems (bad/loose contacts) of inputs 1X1:36 / 1X1:38 / 1X1:23 / 1X1:34 / 1X1:35 / 1X1:21 / 1X1:14 / 1X1:7 / 1X1:20 / 1X1:28.

Internal controller (LAC) error (SSC-watchdog is not correctly working for at least 1000ms).

Internal controller (LAC) error (SSC-interface is not correctly working, because safety controller transmits no synchronization-byte).

Internal controller (LAC) error (different telegram-length detected in SSC-communication between function-controller and safety-controller for at least 1000 [ms]. Reason: software versions of safety controller/function controller do not match).

Internal controller (LAC) error (different SSC-versions detected in SSC-communication between function-controller and safety-controller for at least 1000 [ms]. Reason: SSCVersions of safety controller/function controller do not match).

Driver sensor (inside LAC) voltage less than 10.0V for more than 100ms (correct voltage should be 13V).

209 210 211 212 213 218 219 220 221 222 224 225

signals (1X1:34 and 1X1:35) not compatible.

Internal controller (LAC) error (no production test, OK-sign missing in EEPROM).

Belly switch signal (input 1X1:10) value out of tolerated range (20% < 1X1:10 < 80% of belly supply voltage). Possible reason: loose/defective contact on belly switch to 1X1:10.

Positive supply voltage of 5V (input 1X1:9) for belly switch not insured (USupply UBellySupp > 0.5V).

Belly switch signals (1X1:9 and 1X1:10) incompatible.

Analog butter y signal 1 (input 1X1:24) out of tolerated range (< 5% or > 95% of traction potentiometer supply voltage at 1X1:26).

Analog butter y signal 2 (input 1X1:39) out of tolerated range (< 5% or > 95% of traction potentiometer supply voltage at 1X1:26).

227

High voltage of traction potentiometer

(>105% from USens).

228

Low voltage of traction potentiometer

(<95% from USens).

230

No deceleration torque when required.

No speed signal though torque applied. Reasons may be: speed sensor problem, motor/wheel/truck blocked for longer than 5 seconds.

Speed reduction sensor or , or (depending on the truck type) signals (1X1:20 and 1X1:14 or 1X1:7 and 1X1:28) not compatible.

231 232

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234 235 237 238 240 241 242 244 245 246 247

High traction motor temperature signal (140°C < T < 200°C).

Traction motor temperature signal out of tolerated range (> 200°C). Reasons may be: wire short cut, wire open, temperature sensor problem.

Traction motor temperature signal out of tolerated range (< -50°C). Reasons may be: wire shortcut, wire open, temperature sensor problem.

251

Safety relay transistor (inside LAC) remains OFF whereas it is commanded to switch ON.

252

Safety relay transistor (inside LAC) remains ON whereas it is commanded to switch OFF. Safety relay (inside LAC) remains OFF whereas it is commanded to switch ON; reasons may be: contact oxidized or damaged.

Safety relay (inside LAC) remains ON whereas it is commanded to switch OFF; reasons may be: contact welded or short circuit to 24V. Only trucks with Li-Ion battery: lead or gel battery is selected in diagnosis but "BmsHeartbt" is received (check #2).

Only trucks with Li-Ion battery: Li-Ion battery is selected in diagnosis but "BmsHeartbt" is not operational (check #2).

Only trucks with Li-Ion battery: lead or gel battery is selected in diagnosis but "BmsHeartbt" is received (check #1).

253 254 257 258 259

265

Only trucks with Li-Ion battery: wrong battery status; battery isn t in nominal mode.

Main contactor transistor (inside LAC) remains OFF whereas it is commanded to switch ON. Main contactor transistor (inside LAC) remains ON whereas it is commanded to switch OFF. Main contactor remains OFF whereas it is commanded to switch ON; reasons may be: contact oxidized or damaged.

Main contactor remains ON whereas it is commanded to switch OFF; reasons may be: contact welded or short circuit to 24V. Only trucks with Li-Ion battery: battery discharge current too high.

266

Only trucks with Li-Ion battery: battery SOC (State of Charge) equal to 0%.

267

Only trucks with Li-Ion battery: battery alarm.

268

Only trucks with Li-Ion battery: "heartbeat" battery is not operational or not detected.

269

Only trucks with Li-Ion battery: battery brand ID not correspond to LAC brand ID.

270

Only trucks with Li-Ion battery: diagnosis of the charger heartbeat.

Creep speed switch (1X1:34 or 1X1:35) is enabled, but this truck has no creep speed switch.

260 261 262 263 264

271

-12

Only trucks with tiller foot potentiometer (Opti Speed): potentiometer signal 1 (input 1X1:37) out of tolerated range (< 25% or > 95% of supply voltage).

Only trucks with tiller foot potentiometer (Opti Speed): potentiometer signal 2 (input 1X1:40) out of tolerated range (< 25% or > 95% of supply voltage).

Only trucks with tiller foot potentiometer (Opti Speed): ratiometric set voltage of the signals 1 to 2 high (> 105% of supply voltage).

Only trucks with tiller foot potentiometer (Opti Speed): ratiometric set voltage of the signals 1 to 2 low (< 95% of supply voltage).

High MOSFETs temperature signal (90°C < T < 200°C): presumed MOSFETs overheat (inside LAC).

MOSFETs temperature signal (inside LAC) out of tolerated range (> 200°C); reasons may be: wire shortcut, wire open, sensor problem.

MOSFETs temperature signal (inside LAC) out of tolerated range (< -50°C); reasons may be: wire shortcut, wire open, sensor problem.

Discharging of power module (LAC) capacitors failed at start-up . Reasons may be: main contactor welded, shortcut of capacitor circuit to 24V, wires of lifting pump motor cut.

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272 274 275 281 282 283 284 285 286 290 291 292 293 294 295 296 297

A speed reduction input pin is active, but this input is not used. Depending on the truck type con guration, following input pins could be concerned: 1X1:6 = GND, 1X1:7 = GND, 1X1:20 = GND, 1X1:23 = GND, 1X1:28 = GND. Tiller foot switch (1X1:36 or 1X1:38) or potentiometer (1X1:37 or 1X1:40) is enabled, but on this truck no tiller foot switch or potentiometer is enabled; this truck has function "Tiller foot Potentiometer & Platform" (Customer Option).

Initial lowering sensor input pin is active (1X1:23 = open), but this input is not used.

Brake transistor (inside LAC) remains OFF whereas it is commanded to switch ON (coil current < 0,4A).

Brake transistor (inside LAC) remains ON whereas it is commanded to switch OFF (coil current > 0,4A).

No brake coil current whereas voltage applied (applied voltage > 3V, coil current < 0,4A).

Brake coil current whereas no voltage applied (voltage < 6V, coil current > 0,4A).

Brake actuator failure (measured current rise when actuator switched on does not match with correct/ideal current rise; iTop-iBot exceeds limit of 800mA).

Brake actuator failure: maximum brake current during rst 500ms after enabling is less than 1A. Binary input signals are different in main and safety controller (inside LAC).

Analogue input battery voltage is different in main and safety controller (inside LAC).

Analogue input signals for belly switch (1X1:10) and/or traction potentiometer (1X1:24) and/or tiller foot potentiometer (1X1:37) are different in main and safety controller (LAC).

Analogue input signal for electromagnetic brake (1X1:31) is different in main and safety controller (LAC).

Analogue input signal for capacitor voltage (UCAP), inside LAC, is different in main and safety controller (LAC).

Actual measured traction motor speed is different (> 100 rpm) in main and safety controller (LAC).

Main and safety controller (LAC) are not in the same mode.

Analogue input signal for main contactor is different in main and safety controller (LAC).

302

Current sensor problem (inside LAC), phase U: offset correction exceeds upper limit.

303

Current sensor problem (inside LAC), phase U: offset correction exceeds lower limit.

304

Current sensor problem (inside LAC), phase W: offset correction exceeds upper limit.

305

Current sensor problem (inside LAC), phase W: offset correction exceeds lower limit.

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-13

330

331

340

Internal driver error (inside LAC).

Capacitor voltage too high (inside LAC): voltage of + pin of powerpart > 32V, 500µs.

In case of overvoltage it could happen that this fault is present together with 330 when switching on the truck. Then, certain time must be waited (1 min 30 min, depending on the overvoltage level) until the powerpart capacitors discharged themselves. A discharging of the powerpart capacitors can be done manually by a service technician: ensure that the battery plug is unplugged, connect a 15 /5W resistor between + and - of powerpart for at least 30 seconds, remove resistor after discharging.

351

Traction motor phase U disconnected.

352

Traction motor phase V disconnected.

353

Traction motor phase W disconnected.

366 367 368

369 370 371 372 373

-14

Permanently error message of "driver" - hardware device inside LAC - (fault 331 could not be reset after 3 attempts). Possible reasons for an error message by the driver: shortcut at traction motor phases U / V / W (this shortcut can be from phase to phase, from phase to GND and/or from phase 24V); supply voltage for the driver is below 5,5V, 1µs 4µs (nominal voltage approximately 13V) fault 218 could be generated in parallel; overvoltage at + pin of the powerpart or at supply voltage for the driver (32V 35V, 10µs 25µs) fault 340 could be generated in parallel; undervoltage at GND reference of the driver device (-9,5V -10,5V, 10µs 20µs); bad tightening of the wires to the powerpart (bad tightening of the wires could lead to electric arcs during operation that are evaluated by the driver as shortcuts); speed sensor problems (they could lead to truck jerking and high current peaks that are evaluated by the driver as shortcuts) fault 208 could be generated in parallel; insulation problems at the drive train (wiring of U / V / W phases have shortcut to motor housing, speed sensor, motor phases).

Proportional valve (mast lowering valve ) under voltage but no current through it measured. Reasons may be: wire cut to 1X1:3, shortcut of 1X1:3 to GND. Current through proportional valve (mast lowering valve ) measured but no voltage over it measured. Reasons may be: shortcut of 1X1:3 to 24V or valve coil shortcut.

Divergence between mast lifting/lowering commands, and , at EXV 10 Basic truck (1X1:5 = open and 1X1:4 = open or 1X1:5 = GND and 1X1:4 = GND). Reasons may be: one or both wires cut, one or both wires shortcut to GND or command switch malfunction.

Divergence between mast lifting/lowering commands, and , at EXV 10 Basic truck (1X1:18 = open and 1X1:19 = open or 1X1:18 = GND and 1X1:19 = GND). Reasons may be: one or both wires cut, one or both wires shortcut to GND or command switch malfunction.

Initial lifting/lowering input signals are active at the same time (1X1:4 < 3V and 1X1:18 < 3V).

MOSFET (inside LAC) of digital valve (exchange valve ) remains ON whereas it is commanded to switch OFF. Reasons may be: MOSFET damaged, valve damaged, wire cut to 1X1:15, shortcut of 1X1:15 to GND. MOSFET (inside LAC) of digital valve (exchange valve ) remains OFF whereas it is commanded to switch ON. Reasons may be: MOSFET damaged, valve coil shorted, shortcut of 1X1:15 to 24V. Measured voltage over lift pump motor higher than voltage setpoint (voltage difference greater than 3V). Reasons may be: Powerpart damaged, coil of lift pump motor damaged, wires to lift pump motor cut or shortcut to GND.

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374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393

Measured voltage over lift pump motor lower than PWM, Pulse Width Modulation, setpoint (voltage difference greater than 3V). Reasons may be: powerpart (LAC) damaged, wires to lift pump motor shortcut to 24V. MOSFET (inside LAC) of proportional valve (mast lowering valve ) remains ON whereas it is commanded to switch OFF. Reasons may be: MOSFET shorted (damaged), wire cut to 1X1:3 or shortcut of 1X1:3 to GND. MOSFET (inside LAC) of proportional valve (mast lowering valve ) remains OFF whereas it is commanded to switch ON. Reasons may be: MOSFET open (damaged), valve coil shorten, wire cut to 1X1:3 or shortcut of 1X1:3 to GND. Lifting powerpart (LAC) error. Reasons may be: overcurrent, MOSFET shortcircuit.

Mast potentiometer signal too low (1X1:11 < 5% of potentiometer supply voltage 1X1:26). Reasons may be: wire cut or shortcut to GND. Mast potentiometer signal too high (1X1:11 > 95% of potentiometer supply voltage 1X1:26). Reason may be: shortcut to supply voltage.

Truck without mast potentiometer , but its input signal is active (1X1:11 > 0,5V).

Reasons may be: wrong harness installed or wrong truck type con gured.

Truck without initial lift switch , but its input signal is active (1X1:4 < 3V). Reasons may be: wrong harness installed or wrong truck type con gured.

Truck without initial lowering switch , but its input signal is active (1X1:18 < 3V).

Reasons may be: wrong harness installed or wrong truck type con gured.

Sum of mast potentiometer signals (1X1:11) out of range. Reasons may be: mast potentiometer damaged, 1X1:11 wire cut, shortcut of 1X1:11 to GND or to supply voltage.

MOSFET (inside LAC) of output 1X1:16 (mast lowering digital valve ) remains ON whereas it is commanded to switch OFF. Reasons may be: MOSFET damaged, valve damaged, wire cut to 1X1:16, shortcut of 1X1:16 to GND. MOSFET (inside LAC) of output 1X1:16 (mast lowering digital valve ) remains OFF whereas it is commanded to switch ON. Reasons may be: MOSFET damaged, valve shorted, shortcut of 1X1:16 to 24V. MOSFET (inside LAC) of output 1X1:33 (initial lowering digital valve ) remains ON whereas it is commanded to switch OFF. Reasons may be: MOSFET damaged, valve damaged, 1X1:33 wire cut, shortcut of 1X1:33 to GND. MOSFET (inside LAC) of output X1:33 (initial lowering digital valve ) remains OFF whereas it is commanded to switch ON. Reasons may be: MOSFET damaged, valve shorted, shortcut of 1X1:33 to 24V. Truck without mast lifting switch , but its input signal is active (1X1:5 < 3V). Reason may be: wrong harness installed.

Truck without mast lowering switch , but its input signal is active (1X1:19 < 3V).

Reason may be: wrong harness installed.

Difference of lifting pump motor and/or mast potentiometer measured voltages on function and safety controllers (LAC) too high. Reason may be: internal LAC error.

Difference of digital valve (exchange valve valve) measured voltages on function and safety controllers (LAC) too high. Reason may be: internal LAC error.

Difference of digital valve (mast lowering valve) measured voltages on function and safety controllers (LAC) too high. Reason may be: internal LAC error.

Difference of proportional valve (mast lowering valve) measured voltages on function and safety controllers (LAC) too high. Reason may be: Internal LAC error.

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400 401 402 403 404 405 406 407 408 410 411

SSC-watchdog is not correctly working for at least 1000ms (inside LAC).

SSC-interface is not correctly working because safety controller transmits no syncronisation-byte (inside LAC).

420

Binary input signals are different in main and safety controller (inside LAC).

421

Analogue input battery voltage (1X1:2) is different in main and safety controller (LAC).

Analogue input signals for belly switch (1X1:10) and/or traction potentiometer (1X1:24) and/or tiller foot potentiometer (1X1:37) are different in main and safety controller (LAC).

Analogue input signals for electromagnetic brake (1X1:31) and/or safety relays (inside LAC) and/or main contactor are different in main and safety controller (LAC).

Analogue input signals for pump motor and/or mast potentiometer voltage are different in main and safety controller (LAC).

Analogue input signals for proportional valve and/or digital valve are different in main and safety controller (LAC).

Analogue input signal for capacitor voltage (Ucap) is different in main and safety controller (LAC).

422 423 424 425 426 430

Positive torque setpoint > 20dNm but negative slip

Traction motor

431

Negative torque setpoint < -20dNm but positive slip

Traction motor

432

Low torque setpoint but slip beyond limits of 140 [rpm]

440

Lower force setpoint out of low limit Traction motor .

Higher force setpoint out of high limit Traction motor .

Tiller is in rest-position but there is no brake activity (this error is only forced if there is no creep speed request). Reasons may be: MOSFET damaged, 1X1:36 wire cut.

Tiller is in working position and belly switch is pressed. Truck is not moving in forks direction within 1,5[s].

441 442 443 444 445 450

-16

Safety relay transistor (inside LAC) remains ON whereas it is commanded by safety controller (LAC) to switch OFF at startup check.

Main contactor remains closed/welded whereas it is commanded by safety controller (LAC) to open at startup check.

Disabling test of digital valve (exchange valve) failed. Reasons may be: MOSFET damaged, valve damaged, 1X1:15 wire cut, shortcut of 1X1:15 to GND. Disabling test of proportional valve (mast lowering valve) failed. Reasons may be: MOSFET damaged, valve damaged, 1X1:3 wire cut, shortcut of 1X1:3 to GND. Disabling test of digital valve (mast lowering valve) failed. Reasons may be: MOSFET damaged, valve damaged, 1X1:16 wire cut, shortcut of 1X1:16 to GND. Disabling test of brake failed. Reasons may be: MOSFET damaged, valve damaged, wire cut to 1X1:31, shortcut of 1X1:31 to GND. Different telegram length detected in SSC communication between function controller and safety controller (inside LAC). Reason: software versions of safety controller/function controller do not match.

Sensors supply voltage (1X1:26) is outside 3500...5100 [mV].

Lifting/lowering delay times out of range or invalid truck-ID or truck-ID changed during run time on safety controller (LAC).

Traction motor

. .

Stop requested but no positive deceleration.

Stop requested but no negative deceleration.

Supervision of pump motor : if pump motor is running (Ucap - Uds > 3.0 V) but lifting is not commanded (if trucks with Y3 , initial lift is not commanded) or belly switch is pressed, error is generated.

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451 452

Supervision of proportional valve (mast lowering valve): if proportional valve is active but lowering is not commanded or belly switch is pressed, error is generated.

Supervision of digital valve (exchange valve): if digital valve is active but lifting is not commanded or belly switch is pressed, error is generated.

.

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-17

The following alarms do not appear on the display but instead appear only in the speci c diagnostics for Li-Ion batteries.

100 101 102 103 104 105 106 107 108

-18

Module temperature > 55°C. Module temperature < 10°C. Cell voltage > 4.05 V. Cell voltage < 2.7 V. "+" connector voltage < 15 V or > 32 V. BMU supply voltage > 32 V. BMU supply voltage < 8 V. SOC calculation not valid.

SOH calculation not updated after 72 h.

45728042302 EN - 10/2018

109 110 111 112 113 114 115 116 118 120 121 122 123

200 201 202 203 204 205 206

BMU supply voltage < 16 V. Measured charging current > maximum current.

Measured charging current > maximum current.

Number of dissipating cell resistors is above the permitted threshold.

SOC < 20% SOC not adjusted for over a month.

At least one SMU assignment has failed more than three times.

Maximum connection temperature > 80°C. Difference in maximum module temperature > 10°C. Difference in cell voltage > 100 mV, and minimum cell voltage > 3.5 V.

Error with IMD/IMR calculation function and reset failed.

Error with power estimate.

SOC < 10%

Safety channel for redundant hardware active for 500 ms.

Battery current > 220 A, or difference in voltage between the cells and fuse > 5000 V. Module temperature > 65°C. Module temperature < -25°C. Cell voltage > 4.13 V. Cell voltage < 2.5 V. The voltage of at least one cell is outside the tolerance.

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-19

207 208

The number of modules with a temperature out of tolerance is greater than one.

Connection temperature < -29°C or > 115°C.

209

Inconsistency between the contactor controller (closed) and the actual contactor status (open).

210

Inconsistency between the contactor controller (open) and the actual contactor status (closed).

211 212 213 214 215 216

Measured charging current > maximum current.

Measured discharge current > maximum current.

Found damaged fuse (open).

CAN messages not correctly received by the BMM (Battery Management Module) during a gap in the baud rate.

Number of reconnections attempted is greater than 3.

Maximum connection temperature > 90°C.

217

Internal tests failed after three consecutive attempts (PowertON, Continuous, Initiated, PowerOFF).

218

Battery contactor voltage > 2000 V after the command to close the precharge contactor, or contactor remains open even if it is commanded to close.

219 220 221 222 223 224 225

Number of dissipating cell resistors is well above the permitted threshold.

The total number of cells is not equal to 14.

Battery voltage > 28.35 V. Duration of software cycle is greater than expected.

Battery current out of tolerance, or main contactor open with a battery current > 1000 A or < -1000 A. SMU power supply enabled but SMU module power not detected.

.

-20

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CANBOX-BT with Bluetooth USB Stick

CANBOX-USB

CANBOX

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-21

7-pin diagnosis cable

RS 232 serial cable

-22

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The .ptx les contain the truck's con gurations.

Before adjusting the truck's settings, you are advised to save the relevant .ptx les on your PC, so that you can easily re-programme the original parameters.

.ptx les can be: Loaded onto the truck (Load) Saved on a PC or saved to the truck's memory(Save) Print (Print)

Once the .ptx le is on a PC, it can then be loaded to the truck.

When the le has been loaded, you must save the truck's con guration by pressing the (Save) button in order not to lose the changes made.

A .ptx le can be saved: To the truck, by selecting option (Device) In a PC text le, by selecting option (Text le)

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If saving the le as a text le, it is possible to choose whether to download the complete set of the truck's con gurations, or just a section, by selecting the desired parameters under the heading (Parameter).

For the changes to take effect, it is necessary to save the truck's con gurations before disconnecting the diagnosis program.

You can print the .ptx le by selecting the (Print) command.

By printing the .ptx le it is possible to choose whether to download the complete set of the truck's con gurations, or just a section, by selecting the desired parameters under the heading (Parameter).

-24

45728042302 EN - 10/2018

Before the software can be started, the notebook must be connected to the truck.

Open "STEDS Navigator" Click on the Diagnosis symbol.

Choose the type of truck and double-click (automatically launches Diagnosis).

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-25

Wait for the program to load until the following window is displayed:

If you cannot see the window, check that the diagnostic interface is working and properly connected to the truck.

The software has three main menus: F2:Diagnosis : Test menu and fault diagnosis.

F3:Setup : Truck parameterisation menu (con guration of the truck).

F4:Monitor : Test menu (test of inputs and

outputs).

For the selection press the short-cut keys (F2, F3, F4) or click the appropriate button.

-26

45728042302 EN - 10/2018

From the diagnosis menu you can access the following functions:

Sub-menus "Jobs" "Clear errorlist" "Controller base con guration" "Reconnect"

From this menu it is possible to clear the truck's error list.

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-27

From this menu you can access guided calibration of the truck's potentiometers.

You must choose the type of truck from the drop-down menu and then follow the instructions for con guration.

Allows you to re-establish the connection with the truck if the connection is lost in the event of re-start or disconnection

-28

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From the "General" menu you can display: The installed control LAC version, the software installed and the truck's con guration code "File .ptx"

From the "General" menu you can adjust: The vehicle's " truck type" The control of the tiller's position "Tiller Foot": either with the potentiometer or the microswitch The type of battery tted to the truck Whether the TDU system is installed on the truck or not

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-29

From the "Error since last service" menu you can display the errors the truck was found to have at its last service.

On the right-hand side of the screen you can scroll through the entire list of the truck's errors.

From the "Error History" menu you can display the errors that have occurred in the truck since the last time the error list was cleared

On the right-hand side of the screen you can scroll through the truck's entire error history.

-30

Use the "Reset error code" button to clear the error list.

Use the "Reset error code" button to clear the error history.

45728042302 EN - 10/2018

From the "Traction - Speed / Acceleration /Deceleration" menu you can adjust:

The forward and reverse speeds in "Tortoise" mode - "Speed (Tortoise)"

The forward drive speed in "Hare" mode "Speed Forward (Hare)"

The forward and reverse acceleration in "Tortoise" mode - "Acceleration (Tortoise)"

The reverse speed in "Hare" mode - "Speed Backward (Hare)"

The forward and reverse deceleration in "Tortoise" mode - "Deceleration (Tortoise)"

The truck's acceleration in "Hare" mode "Acceleration (Hare)"

The truck's speed with the belly button switch activated - "Speed - Belly Switch Activated"

The truck's deceleration in "Hare" mode"Deceleration (Hare)"

The maximum reversing time after pushing the belly button switch "Belly active time"

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From this menu you can set the angle of the tiller, which will allow the truck to reach maximum speed.

In this menu it is possible to adjust the slow speeds for special machines (UPA)

As the "Vertical range" and "Horizontal range" parameters are increased, the tilt of the tiller necessary to reach maximum speed will become more restricted.

PIN 1X1:23 is the sensor input for the lower initial lift stopper

PIN 1X1:20 is the sensor input for the lift block or the speed reduction with raised forks

PIN 1X1:28 is the sensor input for speed reduction with h3>400 mm

PIN 1X1:6 is the sensor input for the upper initial lift stopper

For these parameters, it is possible to adjust the truck's maximum speed, acceleration and deceleration.

-32

45728042302 EN - 10/2018

This menu allows you to enable and disable the slow speed option using the "Creep Speed" button.

This menu is divided into three parts: "Speed Lifting/Lowering": Setting the lifting and lowering speed in "Hare - (Hare)" and

"Tortoise (Tortoise)" modes by selecting from the pre-set levels "Setting Lifting/Lowering": Setting the lifting and lowering acceleration by selecting from the pre-set levels "Speed initial lifting": Setting the lifting speed of the arms

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To con gure the desired settings for speed and acceleration, consult the table summarising

the different levels on the right-hand side of the screen.

This menu allows you to choose whether to enable or disable lifting or lowering in correspondence with the operation of the lifting

locking sensor (Only for special machines UPA)

This menu allows you to set the neutral position of the drive potentiometer.

To correctly set this value you must:

-34

Release the tiller to the rest position.

Leave the butter y valve in the neutral position.

45728042302 EN - 10/2018

Press the value.

button to save the displayed

This menu allows you to set the neutral position of the lifting potentiometer.

To correctly set this value you must:

Do not press the lifting or lowering buttons.

Press the value.

button to save the displayed

Release the tiller to the rest position.

45728042302 EN - 10/2018

-35

This menu allows you to pick up analogue signals from the tiller potentiometer in both vertical and horizontal positions.

To correctly set this value you must:

This menu allows you to enable or disable the energy-save mode.

Bring the tiller to the position required as shown by the diagram in the diagnostics handbook.

Press the value.

The energy-save mode automatically turns off the truck if it is not used for a set length of time.

This menu allows you to set how to increase working hours and to set an offset for the hour meter.

-36

button to save the displayed

45728042302 EN - 10/2018

It is possible to enable the counting of working hours when: The tiller is in the operating position.

The truck is being driven.

The truck is being driven or is lifting.

In this menu you can adjust the display of the battery level shown on the screen and adjust the intervention threshold of the "Low state of charge" parameter.

The parameter allows you to program an offset to change the intervention point of "Low state of charge".

0

20

10

30

20

40

30

50

40

60

The parameter allows you to set an offset to change the battery charge status displayed.

0

20

20

+10

20

30

-10

20

10

The "Low state of charge" parameter allows you to select from the following options, which are enabled once the battery charge status has reached an actual value of 20%, or an enabling value of' "Offset of battery charge near 20%" "Disable lifting and speed reduction OFF" Disables the lifting function and not initiate a slow drive speed.

"Lifting and speed reduction ON" - Does not limit the lifting function and initiates slow drive speed.

"Disable lifting and speed reduction ON" Disables the lifting function and initiates slow drive speed.

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This menu allows you to reset the truck to its original settings by pressing the button.

-38

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This menu allows users to check the current status of the truck (active input and output) and to see if there are active errors or warnings.

Codes relating to the current status, errors and warnings of the truck are displayed on the left.

The descriptions of these codes are listed on the right of the screen.

This menu shows whether the truck is in Hare "Hare" or tortoise "Tortoise" mode

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-39

This menu shows the voltages of the following components: "1X1:2 - Battery" Display of the battery voltage "Capacitor" Display of the capacitor charging voltage

-40

"1X1:26 - Tillerpoti" Display of the supply voltage of the traction potentiometer "1X1:1 - Supply valve and K1" Display of the supply voltage of the general K1 switch The menu also allows users to check the K1 switch is being used correctly with the two LEDs on the right side of the screen.

45728042302 EN - 10/2018

The menu shows the following parameters of the traction motor:

"Motor temperature" - Shows the temperature of the traction motor

"Phase current" - Shows the current being delivered to the motor phases

"Truck speed" - Shows the current speed of the traction motor rotation

"Controller temperature" - Shows the temperature of the electronic control

"Motor speed" - Shows the current speed of the traction motor rotor

This menu shows: "1X1:31" The supply voltage of the electromagnetic brake "1X1:31" The current passing through the coil of the electromagnetic brake "Brake applied" If the electromagnetic brake is activated

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This menu shows the supply voltage of the anti-crush button "Belly"

When pressed, the button measures 1X1:9 = 4.3 V and 1X1:10 = 4.3 V

In rest mode, the button measures 1X1:9 = 4.3 V and 1X1:10 = 0 V

This menu shows the voltages of two redundant traction potentiometers, the percentage of the actuation of the accelerator and the percentage of the maximum speed required.

-42

The two potentiometer signals vary between 1.1 V and 3.1 V according to the position of the accelerator.

The signals of the potentiometer are redundant; when one of the signals increases, the other lowers proportionally, and vice versa.

45728042302 EN - 10/2018

This menu shows the voltages of two potentiometers of the redundant tiller.

The signals of the two potentiometers vary between 0.7 V and 3.5 V according to the position of the tiller

This menu shows if input signals that may result in slow speeds on special trucks are active "(UPA)"

The signals of the potentiometer are redundant; when one of the signals increases, the other lowers proportionally, and vice versa.

When the tiller is in the vertical position, the signals are 1X1:37=3.5 V and 1X1:40=0.7 V

Pin 1X1:6 corresponds to sensor S5 of the upper limit of the initial lift Pin 1X1:20 corresponds to sensor S10 to limit speed and block lifting

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Pin 1X1:23 corresponds to sensor S6 of the lower limit of the initial lift Pin 1X1:28 corresponds to sensor S7 forks lifted h3>400 mm

This menu shows the activation status of the two "Creep Speed" microswitch signals

If the "Creep Speed" button is pressed, pin 1X1:35 is active

The two signals are redundant; when one signal is active, the other is inactive and vice versa.

If the "Creep Speed" button is pressed, pin 1X1:34 is active

This menu shows the supply voltage of the hydraulic controller.

-44

45728042302 EN - 10/2018

This menu shows:

The stop lifting digital signal "UPA" 1X1:20

The potentiometer signal of lift potentiometer 1X1:11

The digital signal for the forks at h3>400 mm 1X1:28

The lifting/lowering digital signals for 1X1:5 and 1X1:19

This menu shows the activation status of the initial lift sensors and the switches "1X1:18 - Initial lowering (Switch)" is the button for lowering the initial lift 2S81

"1X1:23 - Initial down (Sensor)" is the sensor for the lower limit of the initial lift S6 "1X1:6 - Initial high (Sensor)" is the sensor for the upper limit of the initial lift S5

"1X1:14 - Initial lifting (Switch)" is the button to raise the initial lift 2S80 45728042302 EN - 10/2018

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In the rest position, the valves measure 24 V. When a proportional valve is energised, the voltage falls in a linear manner and proportionally with said increase.

When an ON/OFF valve is energised, the voltage is close to 0 V

This menu shows the voltage of the power supply to the valves: Valve "Y1" - Pin 1X1:3 . Is the proportional valve for lowering the forks Valve "Y3" - Pin 1X1:15 . Is the exchange valve for raising straddles or forks Valve "Y5" - Pin 1X1:33 . Is the valve for lowering the straddles Valve "Y6" - Pin 1X1:3 . Is the safety valve for lowering the forks

-46

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-48

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-49

-50

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a

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-1

1 2 3 4

Electromagnetic parking brake Traction motor electrical harness Speed sensor M8X25 8.8 DIN 912 socket head screw (quantity: 3)

-2

5 6 7 8 9

Connector Traction motor Reducer breather ( 47 mm) Motor bearing seal (35 X 62 X 7) Gearbox

45728042302 EN - 10/2018

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-3

-4

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The truck has an alternating current traction motor.

The direction of rotation of the motor is changed by reversing two phases.

The traction speed depends on the controller.

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-5

AF 4E4-R1-5 14V 76 A 2720 1.2 kW S2 - 60 mins* IP 44 Class F *S2-60: operation of motor with full load for an hour followed by an hour's rest.

-6

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Once the traction motor has been removed, the machine is no longer braked. It is necessary to chock the vehicle to stop it from moving.

Chock the truck using a jack.

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover (2) (plastic cover only), the tiller housing (3) and the motor cover (1) (see Chapter "Coperchio", P. 31- 1 ).

Disconnect connectors (1), (2), (3), (4) and (5).

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-7

Disconnect cables U, V and W from the electronic control.

Cut all the clips holding the cables (Note: not all the clips are shown in this view).

Unclip the cable guide chain using a screwdriver.

-8

45728042302 EN - 10/2018

Remove the unclipped section.

Remove cables U, V, W, the temperature sensor cable, the speed sensor cable and the brake chain of the cable guide.

Remove the tiller's housing support (4) by taking out the two screws (5) located on the sides.

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-9

Remove the tiller arm support (6) by taking out the three screws (7).

Remove the electromagnetic brake (see Chapter "Removal", P. 49- 6 ).

Remove the two screws (2) on the steering stop (3) and remove the stop.

Remove the three xing screws (4) at the foot of the traction motor.

Disengage the traction motor from above.

-10

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In case of electrical malfunction, or if the battery is not inserted, screw in two M5 X 40 screws into the (1) holes to manually release the brake.

To re-establish brake operation, unscrew and remove the two screws.

For reassembly proceed in reverse order.

Do not pollute the reducer oil.

Put the drive wheel on the truck axle.

Check the reducer oil level. The maximum level corresponds to half the height of the pinion gear. The min. level corresponds to 2 mm from the bottom of the pinion.

Before re tting, note the way the motor is facing on the reducer: put the right-hand drive wheel (on the fork axis) with the cables on the left-hand side.

The motor should be guided while it is being tted to the reducer in order to prevent the shaft pinion from being damaged (otherwise, there is a risk of noise during operation).

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-11

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover (2) (plastic cover only), the tiller housing (3) and the motor cover (1) (see Chapter "Coperchio", P. 31- 1 ).

Disconnect the connector (1).

-12

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Cut all the clips holding the cables (Note: not all the clips are shown in this view).

Unclip the cable guide chain using a screwdriver.

Remove the unclipped section.

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-13

Unscrew the xing screw from the speed sensor.

Remove the speed sensor and pull its cable to release it from the cable guide chain.

For reassembly proceed in reverse order.

-14

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Remove the bonnet of the truck Access the motor's power cables and unscrew the mounting screws of the power cable plate.

Cut the cable of the old sensor as close as possible to the winding.

Fit the new sensor to the motor's winding using a bi-component paste for high temperatures to secure it.

The codes needed to order the parts required for mounting the sensor are given in the following table:

0171857

Bi-component adhesive Adhesive gun

0171858

Adhesive mixer tube

0171856

Leave the paste until it is completely set.

Use the existing cable guide as an outlet for the new motor temperature sensor cables.

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-15

Re t the motor plate.

Check that the resistance between pins 5 and 6 of the 7X6 connector complies with the following table:

-16

0

493.00

5

512.84

10

533.27

15

554.27

20

575.86

25

598.02

30

620.76

35

644.03

40

667.98

45

692.48

50

717.53

55

743.16

60

769.38

65

796.18

70

823.56

75

851.52

80

880.05

85

909.17

90

938.87

95

959.14

100

1000.00

105

1031.43

110

1063.45

115

1096.04

120

1129.22

125

1162.97

130

1197.30

135

1232.21

140

1267.70

145

1303.77

150

1340.43

155

1377.65 45728042302 EN - 10/2018

160

1415.46

165

1463.85

170

1492.62

175

1532.37

180

1572.50

185

1613.20

190

1654.49

195

1698.35

200

1738.80

.

45728042302 EN - 10/2018

-17

-18

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a

20.4 6000 900 TUTELA TRANSMISSION W90/LA 29.85 10000 900

45728042302 EN - 10/2018

-1

600 150

There is no screw plug for draining the used oil and there is no plug for checking the oil level.

-2

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-3

1 2 3 4 5 6 7 8 9 10 11 12

-4

Sealing ring 35 x 62 x 7 Breather ( tted with loctite 603) Tapered roller bearing Cylinder head mounting screws M8 x 25 (tightening torque: 33 Nm) Stop ring Helical teeth wheel ( z=96) Bevel pinion shaft Tapered roller bearing Spacing washer Reducer housing Sealing ring 100 x 140 x 1 Wheel shaft (tapered torque)

13 14 15 16 17 18 19 20 21 22 23

H M14 x 1.5 x 55 head screw (tightening torque 195 Nm) Locking washer 59 mm M12 x 1.5 x 25 wheel stud (tightening torque 35 Nm) Tapered roller bearing Guide pin Cylinder head mounting screws M8 x 25 (tightening torque: 23 Nm) Turntable (Note: permanently lubricated) M10 chassis mounting tapped holes Stop ring Bearing casing for the traction motor Gasket

45728042302 EN - 10/2018

When the traction motor is removed, the truck is not braked. The machine should therefore be secured to prevent it from moving.

Open the battery cover.

Disconnect the battery connector.

Remove the housing and the engine cover (see Chapter "Coperchio", P. 31- 1 ).

Loosen the nuts on the drive wheel (optional).

Remove the two screws (2) on the steering stop (3) and remove the stop.

Remove the three mounting screws (4) at the end of the traction motor.

Uncouple the traction motor from the reducer.

Place a clean cloth in the opening of the reduction gear unit to prevent oil from spilling on the ground during removal.

Unscrew the six reduction gear unit screws.

Raise the truck.

Remove the reducer gearbox.

For reassembly proceed in reverse order.

Position the drive wheel in front of the chassis opening (for trucks produced until July 2015 only).

Tighten the six mounting screws with a torque of .

Check and adjust the oil level.

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-5

Before tting the reduction gear unit, check that its opening and air vents are clean.

Remove the metal cap (1) to access the nut of the central hub.

Remove the screw (2).

Remove the washer and seal (3) using a at-head screwdriver.

-6

45728042302 EN - 10/2018

Remove the pressure seal (4) using a at-head screwdriver.

Position a very ne at-head screwdriver so as to remove the ribs of the seal (5) from the reduction gear unit groove.

Completely remove the groove seal with care.

It is not necessary to remove the reducer to take out the seal (5).

Position and tighten the transmission gear housing (10) in the vice as shown opposite

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-7

Remove the protective cap from the screw (13)

Unscrew the transmission gear screw (13)

Remove the thread protection ring (23).

Use a screwdriver to pry off the metal ring to release it.

-8

45728042302 EN - 10/2018

Remove the transmission gear seal(11) using a screw driver

Detach the last stage of the transmission gear(12) Drain and clean the transmission gear

Clean and check the mating face of the seal.

Before tting the transmission gear, ensure that the housing (10) is completely clean.

Fit the last stage of the transmission gear (12) into the housing (10) Screw in and tighten the mounting screw (13) to a torque of 195 Nm

It is not necessary to adjust the pinion gear or bearing for the wheel shaft.

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-9

Fit the new seal(11) in the housing (10)

Position the sealing ring from the edge of the transmission gear housing (10)

-10

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It is possible to manufacture a tool (see diagram opposite) to ensure that the sealing ring is correctly positioned in the transmission gear housing: Fit the thread protection ring (23).

Fit a new protective cap on the wheel shaft screw.

Remove the seal (1) using a screwdriver Fit a new seal in the place of the old seal

Park the truck on a at surface and secure it to stop it from moving.

Open the battery cover.

Unplug the battery connector.

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-11

Remove the covers (see chio", P. 31- 1 ).

Chapter "Coper-

Remove the traction motor.

Check that the level reaches 1/3 of the gear (6) (if not, add oil):

Do not over ll the reduction gear unit! Over lling may damage the seals and prevent the correct operating temperature being maintained.

The reduction gear unit oil must be changed after .

To change the oil, you must rst: Remove the bonnet Remove the engine Pull out the reduction gear unit Use a container that is large enough for the used oil To remove the used oil, tilt the reduction gear unit and wait until it is completely empty.

Avoid contact with the oil without adequate personal protective equipment.

-12

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Collect the hydraulic oil from the reduction gear unit in the container. Dispose of the oil in accordance with the regulations in force.

Reassemble the reduction gear unit on the chassis.

Using a funnel or another suitable item, ll the reduction gear unit with the oil speci ed in the table: Oil type

Quantity

Check the oil level as described in the previous paragraph.

Install the traction motor.

Assemble the bonnet.

Remove all of the oil from the reduction gear unit.

Unscrew the two grease nipples of the steering turntable (they will be used for the new one).

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-13

Use a ratchet with a 6-mm hexagon socket insert:

Unscrew the eight inner screws shown in the illustration:

-14

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-15

Rotate the steering turntable so that the bevel aligns with the two outer screws:

-16

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-17

Rotate the steering turntable again to access the two remaining screws:

-18

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Using a rubber mallet, lightly hit the cover of the reduction gear unit on both sides until you can pull it out:

The steering turntable and the cover of the reduction gear unit are all one part.

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-19

-20

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-21

-22

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Remove the three locking pins from the cover using pliers and a hammer:

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-23

-24

45728042302 EN - 10/2018

Speci c tools must be used for disassembly/assembly (code www.hoffmann-group.com):

Pull out the plug (breather):

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-25

Remove the locking ring (seeger) using the designated extraction tool:

Pull out the shimming ring and measure it:

Performing this operation allows you to choose the correct shimming ring to pre-load the tapered roller bearing when installing the new kit.

Remove the outer ring:

-26

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Install the bearing:

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-27

Insert the locking ring (seeger):

Install the wiper seal:

Insert the locking ring:

-28

45728042302 EN - 10/2018

Choose the ring with the same thickness of the one installed in the previous kit:

Insert the shimming ring:

Install the outer ring:

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-29

Insert the plug after applying sealant to the edges:

Install the three locking pins in the cover of the reduction gear unit.

Carefully clean the coupling pro les of the reduction gear unit and its cover:

Apply sealant along the pro les of the reduction gear unit and the cover: Assemble the new kit on the reduction gear unit and tighten the 12 screws to a torque of .

Install the two grease nipples of the steering turntable (code 0502689).

Fill the reduction gear unit with 0.9 litres of TUTELA TRANSMISSION W90/LA oil.

Install the reduction gear unit in the truck.

-30

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19.6 10,000 1100 FUCHS TITAN SUPER GEAR SAE 80W-90 27.84 1100 25...+45 Primer RAL9005

There is no screw plug for draining the used oil and there is no plug for checking the oil level.

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-31

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-33

1 2 3

Reduction gear unit Steering turntable Hexagon socket screw (tightening torque: )

4 5

Breather Threaded stud (tightening torque:

Secure the truck (press the emergency stop button and remove the battery connector).

Remove the bonnet as described in the section Chapter "Coperchio", P. 31- 1 .

-34

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)

Lift the truck and loosen the nuts of the drive wheel (optional).

Remove the traction motor.

Ratchet 8-mm hexagon socket insert

Using a ratchet with an 8-mm hexagon socket insert, unscrew the six screws that anchor the reduction gear unit to the chassis plate:

45728042302 EN - 10/2018

-35

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Carefully lift the truck using a hoist (see the section Chapter "Slinging and lifting the truck using a hoist", P. 00-15), so that there is suf cient space to pull out the reduction gear unit:

Manually move the reduction gear unit and pull it out of the truck:

Carefully lift the truck using a hoist (see the section Chapter "Slinging and lifting the truck using a hoist", P. 00-15), so that there is suf cient space to insert the reduction gear unit.

Slightly lower the truck, insert the six retaining screws (after cleaning them and applying medium threadlock) and tighten them slightly by hand (if necessary, use an 8-mm hexagon socket insert).

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-37

Once all the screws have been inserted, tighten them using a ratchet and an 8-mm hexagon socket insert (gradually tighten the six screws in sequence from 1 to 6, several times):

Using a torque wrench, tighten the six screws to a torque of : Lower the truck to the ground.

-38

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Remove the reduction gear unit from the truck.

Using a ratchet with a 6-mm hexagon socket insert, unscrew the ve mounting screws on the steering turntable:

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-39

In order to uncouple the steering turntable from the reduction gear unit, gradually tap it on both sides using a rubber mallet:

-40

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-41

To install the steering turntable correctly, follow the steps for removal in reverse order.

Be aware of the polarity of the steering turntable:

Be aware of the polarity of the ve screws (the remaining three are used to mount the motor): Tighten the ve screws to a torque of

.

Install the two grease ttings (code 0502689).

-42

45728042302 EN - 10/2018

Remove the reduction gear unit from the truck.

Uncouple the steering turntable from the reduction gear unit as described in the section Chapter "Removing the steering turntable of the reduction gear unit", P. 22-39.

Use a small at-head screwdriver to gently prise the cover off by its pro le:

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-43

To t the cover correctly, simply insert it into the seating and apply pressure with your hands (make sure that the entire perimeter of the cover is in the seating).

Before checking, the bonnet and the engine must be removed.

Check that the level reaches 1/3 of the gear (if not, add oil):

-44

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Do not over ll the reduction gear unit! Over lling may damage the seals and prevent the correct operating temperature being maintained.

The reduction gear unit oil must be changed after .

To change the oil, you must rst: Remove the bonnet Remove the engine Pull out the reduction gear unit Use a container that is large enough for the used oil To remove the used oil, tilt the reduction gear unit and wait until it is completely empty.

Avoid contact with the oil without adequate personal protective equipment.

Collect the hydraulic oil from the reduction gear unit in the container. Dispose of the oil in accordance with the regulations in force.

Reassemble the reduction gear unit on the chassis.

Using a funnel or another suitable item, ll the reduction gear unit with the oil speci ed in the table: Oil type

Quantity

Check the oil level as described in the previous paragraph.

Fit the traction motor.

Assemble the bonnet.

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-45

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a

Il coperchio è composto da tre sottoelementi: Coperchio motore (1) Cofano batteria (2) Coperchio timone (3)

Aprire il cofano batteria (2).

2

0252_003-075

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-1

Sollevare il perno di bloccaggio per sganciare l'imboccatura dal relativo albero.

Sganciare il cofano batteria dal lato superiore.

Per il rimontaggio procedere nell'ordine inverso.

Questa procedura è necessaria solo per la sostituzione del cofano batteria. Quando viene data l'istruzione di "rimuovere il cofano batteria" nel presente manuale, essa si riferisce esclusivamente al cofano in plastica.

Aprire il cofano batteria (1) ruotando la serratura (2).

A seconda del tipo di batteria, si avrà o meno accesso alle viti di ssaggio delle staffe di montaggio cofano batteria: Se tali viti non sono accessibili, rimuovere la batteria; Se tali viti sono accessibili, non è necessario rimuovere la batteria.

-2

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Rimuovere le viti (3) e le rosette (4) di ritegno di una delle staffe di montaggio (5) sul cofano batteria (non è necessario rimuovere entrambe le staffe di montaggio, anche solo una è suf ciente).

Sganciare i perni(6) del cofano.

Sganciare il cofano batteria.

Per il rimontaggio procedere nell'ordine inverso.

Chiudere sempre il cofano batteria.

Ruotare il timone sul necorsa destro.

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-3

Rimuovere entrambe le viti a testa cilindrica (1).

Rimuovere la semiscatola del timone quindi porre il timone sul punto di arresto sinistro in modo da poter rimuovere l'altra semiscatola.

Per il rimontaggio procedere nell'ordine inverso.

Non maneggiare mai quando il veicolo è acceso.

Aprire il cofano batteria.

Staccare il connettore della batteria.

Se necessario, scollegare il caricabatteria di bordo (opzionale).

Rimuovere il coperchio del timone (vedere la procedura di rimozione descritta sopra).

Abbassare il timone quindi rimuovere le viti e le rondelle (1).

Rimuovere le viti e le rondelle (2).

-4

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Sollevare il coperchio separando l'apertura fornita per il timone.

Per il rimontaggio procedere nell'ordine inverso.

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-5

-6

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a

The tiller head consists of a moulded housing (1) containing an electronic card(2) with three or ve buttons (lifting, lowering and horn, "lowering" and "lifting" for the initial lift option), two traction throttles, and a safety microswitch tted with a Belly button (12) and three mounting anges (4), (5) and (6).

When the throttles are activated, they are connected to a potentiometer which varies the setting point value according to the angle of rotation of the throttles. It is the same for the 2 hydraulic controls that dictate the progressive functions according to the travel. The horn is controlled using a micro-switch.

1: Safety micro-switch 2: Traction throttle 3: Horn push button 4: Push button for raising forks 5: Push button for lowering forks 6: Button for "lifting" the basic lift (optional) 7: Button for "lowering" the basic lift (optional) 8: Week and year of production

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-1

Trucks for "cold-storage rooms" have PC boards (1) with heating resistors (2). These receive power directly from the connector ' '.

-2

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Remove the battery plug.

Dismantle the two halves (1) and (2) of the ange by inserting a at-head screwdriver into the notch located between the two halves as shown in the photos opposite.

Several notches located at various points around the two halves allow them to be dismantled.

The photo opposite shows how the two halves of the ange are attached to each other.

Remove the upper half (1) of the ange.

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-3

Remove the 2 socket head screws (3).

Remove the ange (4).

To remove the safety button shield (7), simply pull it upwards. This button is embedded.

-4

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Unscrew the screw (5) located below the unit.

Disconnect the connector (6) located below the tiller plate.

Then remove the printed circuit board.

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-5

Unscrew the two screws (8).

The tiller head is now removed.

To remove the lower half of the ange, unscrew the 7 screws (12) using a cross-tip screwdriver.

Pull rmly outwards to remove the two throttles (9).

The throttles cannot be dismantled until the printed circuit board unit has been removed from its housing.

For reassembly, proceed in reverse order to removal.

When reassembling, the two throttles are clipped back on using the guiding pins and contact studs.

-6

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The gas damper in the tiller arm is at a high pressure.

During removal, leave the tiller in the rest position.

Dismantle the two halves (1) of (2) the ange by inserting a at-head screwdriver into the notch located between the two halves (see chapter "Removing the tiller head").

Remove the upper half (1) of the ange.

Unscrew the screw (3).

Also unscrew the two bottom screws (4) at the foot of the tiller.

Remove the tiller cover (5).

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-7

Release the two ball joint locks (6) and (7).

Use a screwdriver as a lever to release the two locks (avoid removing them completely as they are dif cult to put back in place).

Remove the upper part of the damper using a at-head screwdriver.

Then remove the bottom part of the damper.

-8

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Reassembly is carried out in the opposite order: Insert and lock the bottom part of the damper.

Then insert and lock the upper part of the damper.

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-9

Before anything else, it is essential to disconnect the tiller cable.

Remove the tiller head to disconnect the harness from the tiller card (see the chapter entitled "Removing the tiller head").

Open the tiller arm and remove the upper part of the gas-charged shock absorber from its housing (see the chapter entitled "Gas-charged shock absorber").

Remove the pin (1) from the tiller foot.

Remove the axle (2) from the tiller foot.

Remove the tiller arm.

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Remove the battery cover (2) (plastic cover only), the tiller housing (3) and the motor cover (1) (see "Covers" chapter).

Disconnect the battery connector.

Remove the tiller arm (see "Removing the tiller arm" chapter).

Unscrew the three screws (4).

Lift the tiller support (5).

For reassembly proceed in reverse order.

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-11

-12

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a

1 2

Drive wheel Stabilising roller

3 4

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Simple support roller Dual rollers

-1

Initial dimensions: Ø 230 x 75 [mm]

The drive wheel must be replaced if: The tyre tread is cut, unglued or out of round.

The wheel diameter is reduced by 6.5% ( ).

Vulkollan ® (standard)

Notched Vulkollan ® (variant) Rubber (variant) Notched rubber (variant) Non-marking natural rubber (variant) Notched non-marking natural rubber (variant)

Open the battery cover.

Unplug the battery connector.

Remove the covers (see "Covers" chapter).

Loosen the nuts with the wheels on the oor.

Jack up the machine.

-2

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Turn the drive wheel to allow the nuts to be unscrewed from inside the chassis.

Remove the drive wheel from the lower side of the chassis for the 1400-kg version. For all other versions, you can remove the wheel from both the upper side and the lower side.

Use a ratchet tted with an extender and a 17-mm hexagonal insert:

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-3

Lift the truck with a hoist (see the section Chapter "Slinging and lifting the truck using a hoist", P. 00-15) at least from the ground and place it on trestles with suf cient capacity:

-4

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Turn the drive wheel in the direction indicated in the illustration (nuts towards the operator):

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-5

Use a ratchet with a 17-mm hexagonal insert:

Unscrew the ve nuts:

-6

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To remove the wheel, gradually tilt it by 90°:

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-7

-8

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To install the wheel, proceed in reverse order.

Before installation, clean the seating and check that it is in perfect condition.

Install the drive wheel and tighten the mounting nuts with a torque of .

If the thread of a nut or stud bolt is damaged, replace it.

After replacing the drive wheel, the crosswise tilt of the lift mast must be checked, as described in the section Chapter "Adjusting the tilt of the column", P. 81- 1

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-9

Park the truck on at, clear ground.

Attach a magnetic spirit level to the mast.

Do not place the spirit level on the guard grille!

The lifting column's tolerances for transverse tilt can be found in the chapter: Chapter "Adjusting the tilt of the column", P. 81- 1

Loosen the roller support locking screw (1) with a ratchet wrench using a 24 insert.

-10

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Tighten or loosen the stop screw (2) until the mast is vertical. The mast is vertical when the bubble on the spirit level is between the two markers.

Tighten the screw (1) (see the tightening torque table).

Tighten the stop screw (2).

The drive wheel can be partially compensated for by adjusting the stabiliser rollers. After re tting the roller, check that it is working properly. When the driver changes direction, the stabiliser roller should rotate through 180° after moving a short distance.

Dimensions of a new stabiliser roller: 140 x 54 mm To remove the ball bearing (20), unscrew the screw (50) and the nut (60) then remove the spacer rings (40) and protective disks (30).

The pivot (11) is dismantled by removing the ring (14),the ball bearings (13) and the spacer (12). These parts must be removed using a bearing puller.

For reassembly, proceed in reverse order to removal.

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-11

Depending on the customer's requirements, the EXV can be tted with two models of support roller (single or dual).

It is necessary to replace the support rollers when: the tread is worn, their diameter reaches 76.5 mm, their bearings are faulty.

Initial dimensions: 85 x 100 mm

6 7 8 9

-12

Pin Shaft Roller Washers

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Lift the fork carriage and secure it using a chock.

Lift the fork with a jack and place a chock under the fork.

Open the battery cover.

Unplug the battery connector .

Drive out the pin using a drift punch.

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-13

Remove the shaft, roller and shim rings if there are any.

Shim rings are not always present. They are only tted where necessary.

For reassembly proceed in reverse order.

Initial dimensions: 85 x 60 mm Lift the fork carriage and secure it using a chock.

Lift the fork with a jack and place a chock under the fork.

Open the battery cover.

Unplug the battery connector .

Remove the two screws (1).

Remove the two rollers (2).

Remove the two roller supports (3) with their spacer rings (4).

For reassembly proceed in reverse order.

After reassembly, it is essential to check the mobility of the roller supports (3).

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a

Braking torque

16 Nm

Coil power at 20°C

25W +/- 10%

Voltage Weights

20 V 1.9 Kg

Air gap

0.2 mm 0.05 mm/+0.1 mm.

Coil impedance

16 at 20°C

.

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-1

The diagram above shows the inactive brake, i.e in the braking position.

The pressure springs (1) pin the brake plate (2) on its axis to the lining (3) and the lining to the plate attached to the engine.

If the tiller is moved from the rest position to the work position, the value of the tiller foot potentiometer is modi ed using a cam.

The potentiometer signal is received by the controller which controls the electromagnetic brake coil (5).

-2

When the electromagnetic brake coil is energised by a continuous current, the magnetic circuit between the brake plate (2) and the magnetic section (5) is closed.

The brake plate (2) moves on its axis in the direction of the xed magnetic section, air gap "a" becomes "zero" and the lining (3) becomes free.

The air gap of this brake is adjustable. Refer to the air gap adjustment procedure.

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The braking device is designed according to the principle of the presence pedal.

The tiller is returned to the vertical position by a gas spring and the electromagnetic brake is immediately deactivated. The electromagnetic brake is also deactivated when the tiller is in the horizontal position.

This brake serves as a parking brake and a service brake.

Fold down the driving platform (optional) and take your position, both feet must remain on the guide on the platform.

Lower the tiller.

The truck is only in driving position in areas II and III. In the lower area IV or the upper area I, the brake is applied and the traction motor is switched off.

In area III, the truck is at full speed.

In area II, the speed of the truck varies according to the angle of the tiller.

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-3

Correct adjustment of the electromagnetic brake must ensure the minimum travel to release the lining correctly and ensure that it is worn as little as possible.

Distance "a"(1) refers to the air gap (brake travel) which must be set to 0.2 mm during a new setting or readjustment.

Measure the brake air gap with an adjustment shim at three different points separated by 120°.

Minimum thickness for the rotor: 7 mm If necessary, adjust with the screws (2).

If the air gap cannot be satisfactorily adjusted, change the entire brake assembly.

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Set distance "a" to 0.2 mm using adjustment screws and threaded fasteners (6).

Measure distance "a" using a feeler gauge at three points separated by 120°.

While replacing the brake lining, check the mobility of the hub. Replace the brake disc if its residual thickness is less than 7 mm.

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-5

Open the battery cover.

Unplug the battery connector .

Chock the truck to prevent it from rolling.

Remove the covers (see chapter "Covers").

Disconnect the supply cable (1) from the electromagnetic brake.

Remove the tiller arm (see chapter "Removing the tiller arm") and the tiller arm support (see chapter "Tiller support").

Unscrew the three xing screws (2).

Remove the electromagnetic brake from above.

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45728042302 EN - 10/2018

Take out the brake lining (3).

For reassembly proceed in reverse order.

Never touch the disc pads (6)!

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-7

-8

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a

The safety microswitch (1) activated by the "anticollision" push-button (4) is a safety device which operates in accordance with recommendations on the prevention of accidents.

This is why it is essential to check it is operating correctly during every maintenance operation.

When the safety microswitch is activated, the travel direction changes from forward gear (3) to reverse gear (2). As soon as the safety microswitch (anti-collision bumper) is released, the truck stops. This function is activated only when the truck is being driven in forward gear (3).

To make the truck operational again, switch the throttles to the neutral position.

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-1

The traction potentiometer consists of two identical individual potentiometers tted crosswise and operated by the travel throttle. They are supplied with a voltage of approximately 4.3 V and conditioned so that there is a voltage of 2.1 V at the output (slider) on each one when the travel throttle is in park position and 1.2 V or 3.1 V respectively when the travel throttle is at maximum excursion. The function chart shows the speci c relationship between traction potentiometer excursion and the traction controller set point.

The traction potentiometer connections are identi ed as follows : red (rt): 4.3 V blue (bl): 0 V white (ws): voltage 1, 1.2... 3.1 V green (gn): voltage 2, 3.1... 1.2 V

A B C

Traction potentiometer set point voltages Rotating potentiometer excursion angle Traction motor set points

-2

ZN MAR MAV

Throttle neutral zone "Reverse travel" "Forward travel"

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Open the battery cover.

Unplug the battery connector .

Remove the tiller bell housing (see chapter "Covers").

Remove the two microswitch supply plugs (1), after marking them.

Unscrew the two screws (2) from the microswitch.

Adjust the microswitch to give the correct driving angles.

For reassembly proceed in reverse order.

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-3

Open the battery cover.

Unplug the battery connector.

Cut all of the clips holding the cables (Note: not all of the clips are shown in this view).

Unclip the cable guide chain using a screwdriver.

-4

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Remove the unclipped section.

Dismantle the two halves (1) and (2) of the ange by inserting a at-head screwdriver into the notch located between the two halves, as shown in the photos opposite.

Remove the upper half (1) of the ange.

Unscrew the screw (3).

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-5

Unscrew the two screws (4) at the foot of the tiller.

Remove the tiller cover (5).

Remove the upper part of the gas cylinder from its housing (see chapter Chapter "Gas damper", P. 42- 7 ).

Unscrew the two xing screws from the tiller foot potentiometer.

For reassembly, proceed in the reverse order.

-6

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a

The main functions of the display are: Battery charging rate display, Number of service hours display, Error code display, Indicator lights (LED), pictograms and error messages, Battery charger status display, Backlighting.

Information concerning the battery charge level, hour meter and errors are sent by the controller on the CAN-bus.

1

Battery charge level represented by 10 bars

Full charge: 100% Low charge: 10% Discharged: 0%

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91% - 100%: 10 bars 1% - 10%: 1 bar 0%:1 ashing bar (lift function not permitted) NB: To protect the battery, 0% corresponds to a maximum of 80% of the discharge.

-1

2

Service alarm (red)

3

Red indicator light

4

Green indicator light

5

6

7

8 9

1) Flashing: less than 50 hours' truck operation until the next service 2) Constant: service date overdue Switched on: default or alarm Switched off: truck switched off Switched on: truck switched on

-

These codes help the service department to decide on the Breakdown code appropriate response from the service engineer Do not operate the truck Breakdown - The meter runs from when the truck is switched on and a control is used - When counting, the dot next to the tenths of an Indicates the number of hour ashes Hour meter operating hours of the -The hour meter displays machine hours and tenths of an hour - When the power supply is disconnected, the hours are stored in the memory STOP alarm (red) Misc. problems Do not operate the truck -> Truck is stopped Constant: control In general, wait a few Temperature alarm (red) module overheating minutes and then continue LED and pictogram illuminated as soon Tortoise as "tortoise" mode is selected.

.

-2

-

45728042302 EN - 10/2018

4-pin connector: Pin 1: Pin 2: + Pin 3: CAN_L Pin 4: CAN_H 2 pin connector (only where there is an on-board charger): Pin 1: green LED Pin 2: red LED

45728042302 EN - 10/2018

-3

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover (2) (plastic cover only), the tiller housing (3) and the motor cover (1) (see "Covers" chapter).

Unscrew the two screws located on top of the wiring harness cover.

-4

45728042302 EN - 10/2018

Unscrew the screw (1).

Unscrew the two plastic screws and remove the mounting plate located at the rear of the display.

Release the display from its housing.

45728042302 EN - 10/2018

-5

Remove the connector.

For reassembly, proceed in the reverse order.

-6

45728042302 EN - 10/2018

1 2 3 4 5

Switch ON (operating mode) Switch OFF and awaiting code Programming mode active Key fault or incorrect code Time delay of automatic switch-off

Operation

ON OFF

Key in

* 0 0 0 0 0 # or * 1

2 3 4 5 # (by default) # (3 seconds)

* 0 0 0 0 0 0 0 0 # (by default)

New operator code Allocating operator codes Deleting operator codes Modifying administrator codes

* 0 * 4 5 6 7 8 # * 2 * 5 4 3 2 1 # * 2 * # * * 9 * 1 2 3 4 5 6 7 8 #

LED status red off continuous green (1)(correct PIN) red ashing green off (4)(incorrect PIN) red off green ashing (2)

continuous red continuous green (3) red off green ashing (2) (code accepted) red off green ashing (2) (code accepted) red off green ashing (2) (deletion accepted) red off green ashing (2) (code accepted)

Restoring the initial administrator code Activating the automatic switch-off

* * 2 * 1 #

red ashing green ashing (5) (5 s before switch-off)

45728042302 EN - 10/2018

Notes

0 0 0 0 0 or 1 2 3 4 5 PIN code by default

Truck power off

Once the diodes have gone out, the electronic key automatically reverts to "operating mode" Example of new operator code: 45678 *2*: operator reference 10 options from 0 to 9 *2*: operator reference (between 0 and 9)

To reactivate the default administrator code (00000000), please contact your agent or nearest dealer.

Power switches off automatically after 10 mins (600 s by default) if the truck is not being used.

-7

Setting the time delay of the automatic switch-off

* * 3 * 6 0 #

red off green ashing (2) (value accepted)

Deactivating the automatic switch-off

* * 2 * 0 #

red off green ashing (2) (command accepted)

.

-8

45728042302 EN - 10/2018

Example: automatically switches off after 1 min.

(60s) when not used.

Minimum setting = 10 s / maximum = 3000 s

a

1 2 3 4 5

Potentiometer Brake / Temperature sensor / Speed sensor Tiller Fork initial lift option Emergency stop control / Line switch

45728042302 EN - 10/2018

-1

1

Electronic control

-2

45728042302 EN - 10/2018

1 2 3 4 5

+24 V" " power supply terminal for the power unit " " phase L1 of the traction motor " " phase L2 of the traction motor " " phase L3 of the traction motor " " control terminal for the lift motor

6 7 8

Negative " " power supply terminal for the power unit Negative " " power supply terminal for various electrical equipment " "control module connector

The LAC (Linde Asynchronous Control) controller is made up of a control stage and a power stage for traction and hydraulics.

Transistors are controlled by an electronic circuit called DRIVER, which acts as an interface between the power element and the control element.

The control module ( on the diagram) uses two micro-processors (for traction and lift) that monitor themselves. If an error occurs, it is instantly detected and the control system places the truck in safety mode, which may lead to a reduction in performance or stop a controller depending on the type of fault. The control module is equipped with a 42-pin connector.

45728042302 EN - 10/2018

-3

1 2 3

Positive power supply to K1 contactor +24 V Digicode power supply Power supply for Y1 solenoid lowering valve

24 V

24 V

0V

24 V

24 V

Depends on engagement

4

2S80 initial lift control

24 V

0V

5

2S2 fork lift control S5 superior initial lift travel

24 V

0V

24 V

0V

S8 soft landing sensor 1B2 channel A of the traction motor encoder

24 V

0V

6 7 8 9 10 11 12 13 14

-4

Positive power supply of the anti-crush button and potentiometer

Only detectable by an oscilloscope or a frequency meter 4.3 V

0V 1S30 Tiller anti-crush button Analogue signal for the 0.5 V fork-lifting potentiometer 1B4 motor temperature sensor 575 Ohm at 20°C +24 V key/Digicode power 0V supply Unlock button for lifting 24 V (pre-selected by UPA)

45728042302 EN - 10/2018

4.3 V 4.3 V Varies from 0.5 V to 3.8 V depending on engagement Variable signal 24 V 0V

Y3 solenoid shuttle valve for the 24 V (with initial lift enabled) 0 V (with fork lifting enabled) lifting arms/forks Y6 Solenoid safety valve for 24 V (with fork lifting disabled) 0 V (with fork lowering enabled) 16 fork-lowering 0 V for a few seconds, then 17 K1 Negative contactor 24 V approximately 9 V 18 2S81 arm-lowering control 24 V 0V 15

19 Fork lowering control 24 V 0V Speed reduction and lifting20 24 V 0V block sensor (UPA) +24 V key/Digicode power 21 0V 24 V supply 1B2 channel B of the traction Can only be detected with an oscilloscope or a 0 V frequency 22 motor encoder meter 24 V (with raised arms) 0 V (with lowered arms) 23 S6 arms lowered sensor Analogue signal 1 from traction Varies from 1.1 V to 3.1 V Approximately 2 V 24 potentiometer depending on engagement 25 Not Used 26

1B1 power supply for +4.3 traction potentiometer

4.3 V

4.3 V

27 CAN HIGH S7 forks lifted sensor h3 28 >400 mm Y2 +24 V electromagnetic 29 brake power supply +24 V key/Digicode power 30 supply

Approximately 2.6 V

Approximately 2.6 V

24 V (with h3>400 mm)

0 V (with h3<400 mm)

24 V

24 V

0V

24 V

31 Y1 brake control

24 V

0 V for a few seconds, then approximately 6.5 V

24 V (fork-lowering disabled)

0 V (fork-lowering enabled)

24 V

0V

0V

24 V

0V Varies from 0.5 V to 3.8 V depending on tiller position

24 V Varies from 0.5 V to 3.8 V depending on tiller position

38 1S4 tiller microswitch 24 V Analogue signal 2 from traction Approximately 2 V 39 potentiometer Analogue signal 2, tiller Varies from 0.5 V to 3.8 V 40 potentiometer P3 depending on tiller position

0V Varies from 1.1 V to 3.1 V depending on engagement Varies from 0.5 V to 3.8 V depending on tiller position

Negative power supply 41 for anti-crush button and potentiometers.

0V

0V

42 CAN Low

Approximately 2.4 V

Approximately 2.4 V

32 Not Used Y5 ON/OFF fork-lowering 33 solenoid valve Creep speed - drive enabled 34 with tiller raised Creep speed - drive enabled 35 with tiller raised 36 1S4 tiller microswitch Analogue signal 1, tiller 37 potentiometer P3

.

45728042302 EN - 10/2018

-5

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover (2) (plastic cover only), the tiller housing (3) and the motor cover (1) (see "Covers" chapter).

Turn the emergency shut-down handle to align the hole with the window into which the screwdriver will be inserted.

Insert a screwdriver into the hole to lock the handle.

Unscrew the handle.

For reassembly, proceed in the reverse order.

-6

45728042302 EN - 10/2018

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover (2) (plastic cover only), the tiller housing (3) and the motor cover (1) (see "Covers" chapter).

Disconnect the connector (4) then unscrew the cable shoes (5) and the two xing screws (6).

45728042302 EN - 10/2018

-7

Remove the fuse (7) by lifting it with a screwdriver.

Remove the emergency stop unit.

For reassembly, proceed in the reverse order.

The tightening torque for the power contact screws is .

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover (2) (plastic cover only), the tiller housing (3) and the motor cover (1) (see "Covers" chapter).

-8

45728042302 EN - 10/2018

Unscrew the cable shoes (1) and change the fuse (2).

For reassembly, proceed in the reverse order.

The tightening torque for the power contact screws is .

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover (2) (plastic cover only), the tiller housing (3) and the motor cover (1) (see "Covers" chapter).

45728042302 EN - 10/2018

-9

Remove the cap using a screwdriver.

Change the fuse.

For reassembly, proceed in the reverse order.

-10

45728042302 EN - 10/2018

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover (2) (plastic cover only), the tiller housing (3) and the motor cover (1) (see "Covers" chapter).

Unscrew the two screws located on top of the wiring harness cover.

45728042302 EN - 10/2018

-11

Unscrew the screw (1).

Unscrewing the ring nut

Release the key switch from the rear and disconnect it.

For reassembly, proceed in the reverse order.

Ensure that the key switch is correctly lined up with the centring pin.

-12

45728042302 EN - 10/2018

Open the battery cover.

Unplug the battery connector.

Unscrew the cap and the lock-nut.

Remove the connector from its housing.

For reassembly, proceed in the reverse order.

45728042302 EN - 10/2018

-13

Unscrew the warning horn using a screwdriver, an Allen key and a at wrench (to hold the base).

Disconnect the two connectors located at the rear of the warning horn.

For reassembly, proceed in the reverse order.

-14

45728042302 EN - 10/2018

Battery charging

The most favourable operating temperature is between 25 °C and 40 °C. To avoid lasting damage to the battery, the maximum acceptable temperature of the electrolyte, 55 °C, must never be exceeded.

If there is great stress and use in winter temperatures, the battery should be charged every day even if less than 80% of the rated capacity has been used up.

It is essential to take off or open the chassis lid or the battery covering before charging or during interim charging.

During battery charging, a rise in temperature of 10 to 12°C should be expected. For batteries under great stress, this can lead to a rise in the temperature of the electrolyte to over 50 °C. If necessary, stop the battery charging and allow it to cool. Unsuitable lifting gear damages the battery (deformation of the case and damage to the insulation).

During charging, the stoppers of the cells may remain in place.

Close the chassis lid or the battery covering 1/2 an hour before the end of charging at the earliest.

Always connect the charger with the correct polarity to avoid destroying the battery and the charger (+ to +).

Only charge using direct current.

Checking electrolyte level. If necessary: ll up the distilled water towards the end of charging.

This lling must be carried out when the level of the electrolyte reaches the height of the de ector, at the latest.

Towards the end of charging, check if effervescence at rest in all the cells is regular. When charging is nished, measure the acid density and the temperature, and record the difference compared with the recommended values.

When charging is nished, measure the temperature of the electrolyte in all the cells. If a cell shows a large difference in comparison with neighbouring cells, it must be checked separately. The insulation resistance of the battery must be measured in accordance with the VDE, external current circuit cut. The lower limit value is 50 Ohms per volt, rated voltage. However, you must not go below 1000 Ohms. If the insulation resistance is less, the cells and the container must be cleaned.

Check the operation of the charger, and particularly the level of charging current and the start of intense effervescence (2.4 V/cell). Check that the operation of the plugs and plugging devices is correct.

To avoid leakage currents, the batteries must always be kept clean and dry (Neutralo spray).

The terminals and connections must be cleaned with a terminal spray, to avoid any oxidation and formation of sulphates.

Unsuitable lifting gear damages the battery (deformation of the case and damage to the insulation).

Protect the battery from impurities, metallic dust and ammonia vapours, for example.

If in doubt, contact the after-sales service of the battery supplier.

Apart from these basic recommendations, those of the battery manufacturer should generally be observed.

If the mixture is correct, the density of the acid gives an indication of the battery charge status.

But it only increases strongly enough towards the end of charging. This is due to effervescence which starts at around 2.4 V/ cell.

The density of the acid is measured with a hydrometer (siphoning density).

Acid density in the battery completely:

45728042302 EN - 10/2018

-15

Charged 1.27 kg/l Discharged: 1.13 kg/l During measurement, the oater must not touch laterally or above. The correct value for the acid density is obtained about 1/2 hour after charging nishes.

Measures to be taken: Do not eat or drink where batteries are charged, always wash your hands after working on batteries.

If the correct value is to be ensured, avoid measuring immediately after topping up with water, because the water and the acid must be mixed.

The battery temperature must not differ much from 30 °C during measurement.

Measures to be taken: Only use appropriate, safe lifting gear. When transporting, provide appropriate protection to prevent the batteries from tipping over or slipping off the load platform of the means of transport.

When handling batteries, you are exposed to a high risk of accident. For this reason it is essential the following points are observed.

Measures to be taken: Good ventilation, avoid electrical sparks, no naked ames in battery compartments, no smoking.

Measures to be taken: Wear protective clothing against acids, rubber gloves and safety glasses, keep neutralisation products close at hand. Have water ready for rinsing eyes (if there is any injury to the eyes call a doctor immediately).

Measures to be taken: Do not touch current conducting elements, inform the personnel. Respect VDE 0100 and VDE 0105.

After removing the closing stoppers, all the cells must be lled regularly with sulphuric acid, density 1.25 kg/l, up to the lower acid level marker, (using a cell lling system or a plastic hopper).

The lling acid must have a temperature greater than or equal to 15 °C. After a rest period of 5 to 6 hours, possibly add a little acid.

The rise in temperature must be measured using a thermometer dipped into the electrolyte of a cell in the middle of the battery. If the rise in temperature is less than 10 °C, the battery can be connected to the charger for recharging.

The charging time is from 6 to 12 hours, until automatic stoppage by the charger control switch.

The temperature must be monitored during charging. It must not exceed 55 °C. if it does the charging process must be stopped so that the battery can cool down.

At the end of the charging process, the acid density must be 1.27 kg/l plus or minus 0.01 kg/l. If it is not, charging must be continued until a uniform acid density of 1.27 kg/l is reached.

The battery is then ready to operate. If necessary, bring the electrolyte up to the nominal level, using distilled water. If the acid density is too high, remove some acid and add distilled water.

-16

45728042302 EN - 10/2018

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover (2) (plastic cover only), the tiller housing (3) and the motor cover (1) (see "Covers" chapter).

Unscrew the ve screws holding the wiring harness cover.

Cut the clips holding battery connector cables to the wiring harness cover.

45728042302 EN - 10/2018

-17

Unscrew the emergency stop terminals.

Unscrew the controller "-" cable.

Pull on the cables to free them.

Remove the battery from its case.

Unscrew the battery connector (screw access via the inside of the battery case).

For reassembly, proceed in the reverse order

Tighten the screws of the contactor to a torque of

-18

45728042302 EN - 10/2018

It is strictly prohibited to use an on-board charger other than the one recommended.

The Charis HF 2+ on-board charger can be connected to any 2P+T 230 V 16 A socket.

However, before charging this way, the user must ensure that the location selected for charging satis es all the required safety guarantees: The electrical system must comply with the standards of the country in which the truck is being used.

The electric wall socket must be a 2 pole + earth 16 A 230 V type that is correctly connected and protected.

Before charging, check the condition of the connections and cables (retighten, as required).

The mains cable must not be taut when in use on the mains.

The mains cable must be checked regularly as part of periodic statutory checks and maintenance operations.

Charging must be carried out in an area where there is no condensation or pollution and there must be suf cient ventilation.

The charger must not be exposed to oil, grease or other similar substances.

Charging must be carried out with the truck stopped.

The increase in the temperature of the unit in relation to the ambient temperature is 10°C maximum. The temperature of the expelled air is 25 °C maximum. Wait 10 minutes after stopping the charger before touching the unit.

As the charger is cooled by forced ventilation, do not block the air inlets and outlets. There must be suf cient air circulation to the outside.

The Charis HF 2+ charger is designed: To be incorporated inside an industrial truck.

The charger must never be used alone (out of the truck).

To stay connected permanently to the battery.

To operate in all positions.

45728042302 EN - 10/2018

-19

To stay connected to the mains during periods when the truck is not being used to ensure the availability of the machine (see section on "Other charging details").

To tolerate "opportunity charging".

Risk of damage to the mains cable resulting in electric shock and/or burns!

Park the truck suf ciently close to the mains wall socket to ensure that the mains cable on the on-board charger is not taut when connected and charging.

Risk of damage to the mains cable due to frequent operator handling. Risk of electric shock and/or burns!

The mains cable must be checked regularly as part of periodic statutory checks and maintenance operations.

Manual connection of the on-board charger plug to the 230 V mains power supply.

When charging, the truck is connected to the 230 V mains supply.

Mains voltage Network frequency Maximum output power

190 V < U < 260 V 50 / 60 Hz +/-1% (automatic adaptation) No inrush current to the mains connection 1040 W +/-3%

Maximum output current Nominal battery voltage

35 A +/-2%

Tolerance on the voltage of bearing U

1%

Battery type

Gel or open lead-acid traction battery

Number of components

12 x 2 V components 140 Ah minimum to 375 Ah maximum (adaptation of the charging curve by a selector)

24V

.

Capacity .

Storage temperature

-45° C to +80° C

Operating temperature

-15° C to +40° C

-20

45728042302 EN - 10/2018

Relative humidity Weight

90% 2 kg

Volume

1.4 litres

.

Protection against reversal of battery polarity: the charger is protected by an output relay.

After the battery is reconnected in the right direction, the charger restarts charging without requiring human intervention.

Mains protection: by a 250 V 10 A 5x20 timed fuse. The mains fuse is tted directly to the electronic card. The user is not authorised to change this fuse. If this fuse is faulty, the charger must be returned to the service centre.

The charger is supplied without indicator lights.

Only a 2x0.5 mm2 lead can be used to connect the charger to the truck LED. Operation of the LEDs: Disconnected mains socket Phases I1, P, U1, I2, U2

Off Flashing

Off

Off Equalisation

Continuously lit

Off

Continuously lit

Off

Maintenance phase

Continuously lit

Charging too long Charger polarity reversed (+bat and -bat charger cables reversed, with the battery remaining normally connected to the truck assembly) Battery polarity reversed

Off

Off Continuously lit

Continuously lit

Continuously lit

Off Flashing

Off Flashing

Selector in neutral position

Off

(see wiring diagram)

A 2x1.5 mm2 lead can be used to connect the safety relay. The relay has a maximum cut-off power of 16 A. Contact A: blue wire Contact B: brown wire When the charger is not connected either to the mains or to the battery, the "contact A" and

45728042302 EN - 10/2018

-21

"contact B" outputs are electrically insulated from one another.

When the charger is connected to the battery only, the "contact A" and "contact B" outputs are electrically connected.

When the charger is connected to the mains and the battery, the "contact A" and "contact B" outputs are electrically insulated from one another.

When the charger is connected to the mains only, the "contact A" and "contact B" outputs are electrically insulated from one another. (see wiring diagram)

The curve is selected using the selector located on the front face of the charger. The curve selector is protected by a cap.

Risk of damaging the battery prematurely!

It is essential to select the correct type of battery on the selector.

The four thin lines indicate neutral positions. The charger does not ow and the two LEDs ash simultaneously to indicate that no curve has been selected.

The four thick lines indicate the four charging curves: open lead-acid battery with a capacity below 210 Ah, open lead-acid battery with a capacity greater than 210 Ah, gel battery with a capacity below 210 Ah, gel battery with a capacity greater than 210 Ah.

The charger is supplied in the NEUTRAL position.

If the charger stays connected to the mains, it restarts a charging cycle every 48 hours after the end of the previous charge in order to compensate for self-discharge.

The Charis HF 2+ charger adapts automatically to the battery discharge situation and therefore

-22

45728042302 EN - 10/2018

allows any type of partial charging to be carried out ("opportunity charging").

The overcharging calculation takes into account partial recharging. The mixture is always sufcient, without needless water consumption, which prevents premature wear of the batteries (often due to overlong charging periods) and reduces the need for maintenance.

If the mains power is cut off, all the existing charging parameters are stored in the memory for 13 minutes. As soon as the mains power returns, charging resumes from the point (I, U) at which it was cut off, with the number of Ah already injected stored in the memory.

If the cut-off period is longer than 13 minutes (the truck could have been used), a complete charging cycle is initialised.

If the duration of phases I1 + P + U is more than 16 hours, the charger automatically stops. This can happen when a battery has a short-circuited component. Simply reset the mains to clear the fault.

As the charger is cooled by ventilation, the air inlets and outlets must never be blocked.

The fan runs when the mains power is connected.

It stops when charging is complete or when the mains power is disconnected.

The charger supplies reduced power if the ambient temperature exceeds the usage temperature range in order to protect itself (the charging period will be extended in this case).

The charger stops if the micro-controller detects a temperature measurement fault.

45728042302 EN - 10/2018

-23

The tiller rotary potentiometer is operated by the tiller. It consists of two identical, cross-mounted single potentiometers. They are supplied with a voltage of +10 V. The exact relationship between inclination of the tiller and the voltage of the tiller rotary potentiometer is shown in the functional diagram for tiller inclination.

The tiller rotary potentiometer is connected via connector X10.

The leads of the tiller rotary potentiometer are marked as follows: Red (rt): + 10 V Blue (bl): 0 V White (ws): Voltage 1, 0...10 V Green (gn): Voltage 2, 10...0 V

-24

45728042302 EN - 10/2018

U 1 U 2

Output voltage at the tiller rotary potentiometer with tiller inclination 1 Output voltage at the tiller rotary potentiometer with tiller inclination 2

U 3 1 2 3

Output voltage at the tiller rotary potentiometer with tiller inclination 3 Angle of tiller inclination Angle of tiller inclination Angle of tiller inclination

Depending on the tiller inclination, the output voltage at the tiller rotary potentiometer ranges from 2 to 10 V. The following 4 voltage ranges are given through the de nition of 3 speci c angles of inclination:

Upper braking range

90° - 1

45728042302 EN - 10/2018

2V -U 1

-25

Driving range with speed limitation Driving range with no speed limitation Lower braking range

1- 2

U 1-U 2

2- 3

U 2-U 3

3 - 0°

U 3-8V

.

U 1 U 2

Output voltage at tiller potentiometer with tiller inclination 1 Output voltage at tiller potentiometer with tiller inclination 2

U 3 Us

Output voltage at tiller potentiometer with tiller inclination 3 Desired value for traction motor controller

The functional diagram for desired value reduction shows how the desired value is in uenced by the output voltage of the tiller rotary potentiometer in each range. If 100% of the desired value is speci ed, it is possible to accelerate to full speed.

The lower the desired value, the more the maximum possible travel speed is reduced.

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover and the motor cover (see Chapter "Coperchio", P. 31- 1 ).

Remove the battery from its case.

-26

45728042302 EN - 10/2018

Inside the battery case, unscrew the retaining bar from the sensors.

Remove the retaining bar.

Unscrew the sensors.

45728042302 EN - 10/2018

-27

Unclip the connector (4).

Pull on the connector cable.

To re t, proceed in reverse order.

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover and the motor cover (see Chapter "Coperchio", P. 31- 1 ).

Remove the battery from its case.

Unscrew the two screws (1) to remove the retaining bar from the sensor.

Cut the three clips (2) securing the sensor cable.

Unscrew the screw (3) positioned across the sensor to detach the sensor from the retaining bar.

-28

45728042302 EN - 10/2018

Unclip the connector (4).

Pull on the connector cable.

To re t, proceed in reverse order.

45728042302 EN - 10/2018

-29

-30

45728042302 EN - 10/2018

a

Type of traction motor

AC

Type of pump hydraulic motor

Supply voltage

Serial excitation DC 1.2 kW/2 kW: EXV 10 basic 1.2 kW/2.5 kW: EXV 10 1.2 kW/3 kW: EXV 12 1.2 kW/3 kW: EXV 14 C 24V

Power for traction motor/pump

Pump/traction motor max. output current

150 A / 225 A

Permissible operating temperature range:

- 30°C to + 40°C

Max. internal temperature

75°C 190 x 150 x 60.5 (L x l x h) in mm

Dimensions The microprocessor controls the power transistors according to the input set point up to the value of the pre-set current limit.

To be able to adjust the speed and power of the motors from 0 to 100%, the control of the transistors is modi ed in stages.

The controller uses internal and external safety monitoring, which stops the truck if a fault occurs.

Fault nding is assisted by the display on the dashboard.

The controller adjustment procedures are carried out using Diagnostics.

The cover must rst be removed to access the controller, similar to any other electrical component.

45728042302 EN - 10/2018

-1

+B

Input

-B

Input

Li

Output

U

Output

V

Output

W

Output

Positive after main switch Negative after battery socket Connected to A2 of the M2 hydraulic motor Connected to U of the traction motor Connected to V of the traction motor Connected to W of the traction motor

.

-2

45728042302 EN - 10/2018

+ 24 V 0V

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover (2) (plastic cover only), the tiller housing(3) and the motor cover (1) (see "Covers" chapter).

Disconnect the six power cables (1) from(6), the earth wire (7) and the SAAB connector (8).

45728042302 EN - 10/2018

-3

Remove the four nuts (9).

Proceed in reverse order for reassembling and apply paste for heat distribution between the chassis and the front plate before re tting it.

The bolts of the power contacts must be tightened to a torque of

-4

45728042302 EN - 10/2018

a

45728042302 EN - 10/2018

-1

1 2 3 4 5 6 7 8 9

Fitted pump support Solenoid valve Flow limiter Coil Pump motor Oldham couplings Hydraulic pump Connection Intake pipe

-2

10 11 12 13 14 15 16 17 18

Suction lter Return pipe Oil tank Plug Tank xing assembly Block STILL barcode label Label Product identi cation plate

45728042302 EN - 10/2018

45728042302 EN - 10/2018

-3

1 1a 2 3 4 4a 4b 5 5a 5b 6 6a 6b 6c 7 7a 7b 7c

-4

Pump motor Set of brushes Oldham couplings Fitted pump support Proportional valve Coil Gasket set Solenoid valve Coil Gasket set Non-return valve O-ring Anti-extrusion seal O-ring Pressure limiter O-ring Anti-extrusion seal O-ring

8 8a 9 9a 9b 10 10a 10b 10c 10d 11 12 13 14 14a 15 15a

Plug O-ring Non-return valve O-ring Anti-extrusion seal Fitted tank Oil tank O-ring Tank clip Breather plug Suction pipe with nozzle Flow limiter return pipe Pressure limiter return pipe Flow limiter O-ring Fitted emergency control O-ring

45728042302 EN - 10/2018

45728042302 EN - 10/2018

-5

1 1a 1b 2 3 4 4a 4b 5 5a 5b 6 6a 6b 6c 7 7a 7b

-6

Pump motor Set of brushes Fitted rear mounting ange Oldham couplings Fitted pump support Proportional valve Coil Gasket set Solenoid valve Coil Gasket set Non-return valve O-ring Anti-extrusion seal O-ring Pressure limiter O-ring Anti-extrusion seal

7c 8 8a 9 9a 9b 10 10a 10b 10c 10d 11 12 13 14 14a 15 15a

O-ring Plug O-ring Non-return valve O-ring Anti-extrusion seal Fitted tank Oil tank O-ring Tank clip Breather plug Suction pipe with nozzle Flow limiter return pipe Pressure limiter return pipe Flow limiter O-ring Fitted emergency control O-ring

45728042302 EN - 10/2018

45728042302 EN - 10/2018

-7

1 1a 1b 2 3 4 4a 4b 5 5a 5b 6 6a 6b 6c 7 7a 7b 7c 8 8a 9 9a

-8

Pump motor Set of brushes Fitted rear mounting ange Oldham couplings Fitted pump support Hydraulic valve Coil Gasket set Solenoid valve Coil Gasket set Non-return valve O-ring Anti-extrusion seal O-ring Pressure limiter O-ring Anti-extrusion seal O-ring Plug O-ring Non-return valve O-ring

9b 10 10a 10b 10c 10d 11 12 13 14 14a 15 15a 16 17 17a 17b 18 18a 18b 18c 18d 19

Anti-extrusion seal Fitted tank Oil tank O-ring Tank clip Plug Intake pipe Flow limiter return pipe Pressure limiter return pipe Flow limiter O-ring Fitted emergency control O-ring Flow limiter Hydraulic valve Coil Gasket set Hydraulic valve Coil O-ring O-ring Seal Return pipe

45728042302 EN - 10/2018

45728042302 EN - 10/2018

-9

-10

45728042302 EN - 10/2018

45728042302 EN - 10/2018

-11

-12

45728042302 EN - 10/2018

a

EXV 10 Basic

EXV 10

Displacement (cm3/rev)

2

2

Pressure limiter setting (bar)

200

205

12 3/8'' gas

15 1/2'' gas

2.3 l useable C97 compound

6 l useable

Flow limiter (L/mn) Connection Tank volume Designation and type of motor

DS2 series

Power (kW)

2

1.5

S3 service rate Operating voltage (V)

5%

7%

24

24

Amperage at 100 bar (A)

90

90

IP

12

12

Insulation class Manifold diameter (mm)

F

F

41

42

Min. dimension of brushes (mm)

11

10.5

6 Azolla ZS32 as standard Equivis XV32 in cold store 90 µm

4 Azolla ZS32 as standard Equivis XV32 in cold store 450 µm

EXV 12

EXV 12i

Max. wear of brushes (mm) Type of oil Suction lter

Displacement (cm3/rev)

3

3

Pressure limiter setting (bar)

240

240

17.5 1/2'' gas

17.5 1/2'' gas and 1/4'' gas

Flow limiter (L/mn) Connection Tank volume Designation and type of motor Power (kW) S3 service rate Operating voltage (V)

6 l useable

6 l useable

CS2 series

CS2 series

3.2 10%

3.2 10%

24

24

Amperage at 100 bar (A)

120

120

IP

12

12

Insulation class Manifold diameter (mm)

F

F

48.5

48.5

Min. dimension of brushes (mm)

15

15

4 Azolla ZS32 as standard Equivis XV32 in cold store 450 µm

4 Azolla ZS32 as standard Equivis XV32 in cold store 450 µm

EXV 14 C

EXV 14i C

Max. wear of brushes (mm) Type of oil Suction lter

Displacement (cm3/rev)

4

4

Pressure limiter setting (bar)

215

215

Flow limiter (L/mn)

22

22

45728042302 EN - 10/2018

-1

Connection Tank volume Designation and type of motor

1/2'' gas

1/2'' gas and 1/4'' gas

10.5 l useable

10.5 l useable

CS2 series

CS2 series

Power (kW)

3.2

3.2

S3 service rate Operating voltage (V)

10%

10%

24

24

Amperage at 100 bar (A)

120

120

IP

12

12

Insulation class Manifold diameter (mm)

F

F

48.5

48.5

Min. dimension of brushes (mm)

15

15

4 Azolla ZS32 as standard Equivis XV32 in cold store 450 µm

4 Azolla ZS32 as standard Equivis XV32 in cold store 450 µm

Max. wear of brushes (mm) Type of oil Suction lter .

-2

45728042302 EN - 10/2018

Lower the forks. Press the lowering button several times so that there is no more pressure in the system.

Open the battery cover.

Disconnect the battery connector.

Remove the covers (see chio", P. 31- 1 ).

Chapter "Coper-

Disconnect the power supply cables (1) and (2), clearly marking their respective positions for re tting.

Disconnect the solenoid valve connectors (3).

45728042302 EN - 10/2018

-3

Disconnect the connection (4).

Loosen the mounting clip (5).

Remove the pump unit.

For reassembly, proceed in the reverse order.

Remember to check the oil level.

Oil may escape.

.

-4

45728042302 EN - 10/2018

Lower the forks. Press the lowering button several times so that there is no more pressure in the system.

Open the battery cover.

Disconnect the battery connector.

Remove the covers (see chio", P. 31- 1 ).

Chapter "Coper-

Disconnect the power supply cables (1) and (2), clearly marking their respective positions for re tting.

Disconnect the solenoid valve connections (3) and (4).

45728042302 EN - 10/2018

-5

Disconnect the hydraulic connections (5) and (6).

Loosen the mounting clip (7).

Remove the pump unit.

For reassembly, proceed in the reverse order.

The hydraulic controller power cables must be tightened to

Remember to check the oil level.

Oil may escape.

-6

45728042302 EN - 10/2018

.

Lower the forks. Press the fork lowering and straddle lowering button several times to eliminate any residual pressure in the system.

Open the battery cover.

Disconnect the battery connector.

Remove the covers (see chio", P. 31- 1 ).

Chapter "Coper-

Disconnect the power supply cables (1) and (2), clearly marking their respective positions for re tting.

Disconnect the solenoid valve connections (3) and (4).

45728042302 EN - 10/2018

-7

Disconnect the connection (5).

Disconnect the connection (6).

Loosen the mounting clip (7).

Remove the pump unit.

For reassembly, proceed in the reverse order.

The hydraulic control power cables must be tightened to

Remember to check the oil level.

Oil may escape.

-8

45728042302 EN - 10/2018

Remove the pump unit (see above).

Loosen the mounting clip (1).

Remove the hydraulic oil tank pump motor.

For reassembly proceed in reverse order.

When reassembling, remember to: Clean the suction lter, Remove any dirt from the pipes, Fill the oil pump, Please refer to the tightening torque tables for the tightening torques.

Remove the pump unit (if necessary; see above) and the hydraulic pump.

Remove the two screws (1).

Uncouple the hydraulic pump motor.

45728042302 EN - 10/2018

-9

Remove the coupling plug (2).

For reassembly, proceed in the reverse order.

Disconnect the connector for solenoid valve Y1 (1) and the connector for solenoid valve Y6 (2).

Unscrew the coils and remove them.

Unscrew the bodies of the solenoid valves.

Take the solenoid valves out of their housings.

For reassembly, proceed in the reverse order.

-10

45728042302 EN - 10/2018

Disconnect the Y6 solenoid valve connector.

Unscrew the nut with a no. 19 spanner.

45728042302 EN - 10/2018

-11

Remove the coil.

Unscrew the solenoid valve body using a no.

26 spanner.

Remove the solenoid valve from its housing.

For reassembly, proceed in the reverse order.

-12

45728042302 EN - 10/2018

Disconnect the two solenoid valve connectors.

Unscrew the Y6 solenoid valve nut using a no.

19 spanner.

45728042302 EN - 10/2018

-13

Remove the Y6 solenoid valve coil.

Unscrew the Y1 solenoid valve nut using a no.

19 spanner.

Remove the Y1 solenoid valve coil.

-14

45728042302 EN - 10/2018

Unscrew the Y1 solenoid valve body with a no.

22 ring spanner.

Remove the Y1 solenoid valve from its housing.

For reassembly, proceed in the reverse order.

Lower the forks.

Open the battery cover.

Disconnect the battery connector.

Chock the machine.

Remove the motor cover (see erchio", P. 31- 1 ).

Chapter "Cop-

Disconnect the hydraulic connection and then insert a pressure gauge between the pump unit and the cylinder supply.

Reconnect the battery connector.

Place the forks at the upper stop.

Check the pressure obtained.

45728042302 EN - 10/2018

-15

To adjust the pressure relief valve, loosen the locknut with a no. 23 spanner and adjust the pressure using an Allen key.

Gradually increase or reduce the pressure until the appropriate pressure setting is obtained.

Pressure limiter setting (bar)

EXV 10 Basic

EXV 10

EXV 12 and EXV 12i

EXV 14 C and EXV 14i C

175

205

240

215

The pressure must always be increased slowly. Never increase the pressure too suddenly or there is a risk of exceeding the maximum pressure and damaging the pump unit.

This operation should only be carried out by a person authorised by STILL.

The emergency control (1) allows the cylinders and masts to be lowered manually (with a no. 7 spanner) if a problem occurs.

The emergency screw has a tightening torque of 0.24 ± 0.04 daNm.

The emergency screw can only be used a maximum of three times during the service life of the pump unit.

Brush length must not be less than the minimum length: Minimum brush length 1.5 kW motor

-16

10.5 mm

45728042302 EN - 10/2018

2.2 kW motor

11 mm

3.2 kW motor

15 mm

.

Remove the pump unit (if necessary; see above).

Unscrew the two screws on the pump motor cover and release the stator.

Open the cover.

45728042302 EN - 10/2018

-17

Release the rotor to free the brushes.

Release the brush from its housing.

Unscrew the brush, release it from its support using pliers and replace it.

-18

45728042302 EN - 10/2018

Remove the pump unit (if necessary; see chapter "Dismantling the pump unit").

Remove the guard grille (1) by unscrewing the screw (2).

Lift the pressure springs (1) and release the brushes (2) using a screwdriver. Loosen the screws (3).

Change the brushes when they have reached the minimum permitted length. Before reassembling, check that there are no traces of burning on the manifold. The new brushes must be bedded in before reassembly. If the old brushes are re tted, do not reverse them or turn them over. Consult the service department.

You are advised to blow-clean the manifold once a year.

45728042302 EN - 10/2018

-19

Draining is recommended every 2000 hours or at least every year (even if 2000 hours have not been reached) due to water absorption by the oil.

The hydraulic oil is harmful to health and the environment.

Follow the safety instructions.

Place the truck on a horizontal surface.

Lower the forks.

Unplug the battery connector.

Remove the front cover (see "Covers" chapter).

Remove the pump unit (see "Dismantling the pump unit" chapter).

Loosen the mounting clip (1).

-20

45728042302 EN - 10/2018

Remove the hydraulic oil tank pump motor (4).

Replace the lter (6).

Remove out the tank (4).

Recover the hydraulic oil (approximately 5 litres) and drain it in accordance with the safety and environmental protection instructions.

Re t the pump unit.

1 7

Unscrew the gauge (3) and top up the hydraulic oil until the max. mark. on the gauge is reached.

2 Drain off the used oil in accordance with the instructions.

3 6

4

0252_003-084.eps

45728042302 EN - 10/2018

-21

Lower the forks. Press the lowering button several times so that there is no more pressure in the system.

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover and the motor cover (see Chapter "Coperchio", P. 31- 1 ).

Remove the battery from its case.

Unscrew the connection (1) located under the central cylinder.

Unscrew the connection (2) located between the pipes and the hose.

Unscrew the connection (3) going to the pump unit.

Take the pipes out by the battery case.

For reassembly, proceed in the reverse order.

-22

45728042302 EN - 10/2018

Lower the forks. Press the lowering button several times so that there is no more pressure in the system.

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover and the motor cover (see Chapter "Coperchio", P. 31- 1 ).

Unscrew the two connections (1) located under each side cylinder.

Unscrew the connection (2) going to the pump unit.

Free the pipes.

For reassembly, proceed in the reverse order.

Lower the forks. Press the lowering button several times so that there is no more pressure in the system.

Open the battery cover.

Disconnect the battery connector.

Remove the motor cover (see erchio", P. 31- 1 ).

Chapter "Cop-

Unscrew the connection (1) located at the top of the hollow side cylinder.

Unscrew the mounting bracket (2).

Unscrew the connection (3) located under the central cylinder.

45728042302 EN - 10/2018

-23

Unscrew the connection (4) going to the pump unit.

Remove the pipes.

For reassembly, proceed in the reverse order.

Lower the forks. Press the lowering button several times so that there is no more pressure in the system.

Open the battery cover.

Disconnect the battery connector.

Remove the motor cover (see erchio", P. 31- 1 ).

Chapter "Cop-

Unscrew the connection (1) located under the central cylinder.

Unscrew the connection (2) located between the pipes and the hose.

Remove the clips (3) from the central cylinder.

Remove the clip (4) holding the pipes.

Unscrew the connection (5).

Unscrew the connection (6).

-24

45728042302 EN - 10/2018

Unscrew the connection (7) going to the pump unit.

For reassembly, proceed in the reverse order.

Lower the forks. Press the lowering button several times so that there is no more pressure in the system.

Open the battery cover.

Disconnect the battery connector.

Remove the battery cover and the motor cover (see Chapter "Coperchio", P. 31- 1 ).

Remove the battery from its case.

Disconnect the "initial lift" connection of the pump unit.

Disconnect the T union hoses located in the battery compartment.

45728042302 EN - 10/2018

-25

Disconnect the connections located below the basic lift cylinders.

For reassembly, proceed in the reverse order.

-26

45728042302 EN - 10/2018

a

The longitudinal tilt of the column must be within the tolerances expressed in the following table.

89.9° + 0.1°

between 89.5° and 89.9°

.

The measurement must be taken with an electronic spirit level as shown in the gure.

Always measure the tilt values directly on one of the masts, and not on the guard grille.

45728042302 EN - 10/2018

-1

To adjust the longitudinal tilt of the column, add to or remove the shim rings present between the column and the chassis frame, near the mounting screws of the column.

To insert the shim rings, it is necessary to loosen the mounting screws xing the column to the chassis frame.

You must check and, if necessary, adjust the number of shims in the lifting column in the event of replacing one or more of the lift masts.

The transverse tilt of the lifting column must be between

-2

45728042302 EN - 10/2018

The measuring must be carried out with an electronic spirit level like the one shown in the gure.

Always measure the tilt values directly on one of the uprights, and not on the guard grille.

To adjust the transverse tilt of the lifting column, you must change the adjustment of the swivel wheel as described in the paragraph: Chapter "Stabiliser roller", P. 46-10 You must check and, if necessary, adjust the swivel wheel regularly, on the basis of the tyre tread of the drive wheels and the pivot wheel.

45728042302 EN - 10/2018

-3

Lift the front by approximately 50 cm to facilitate access to the harness.

Lower the fork arms until they rest on the retaining plate of the mast, supported by a suitably sized block of wood. Drain the hydraulic circuit by pressing and holding the fork-lowering button for several seconds.

Sling the front panel to the hoist with strong ropes as shown in the image.

Unscrew the two bolts that secure the front panel to the lift mast.

-4

45728042302 EN - 10/2018

Unscrew the expansion bolt from the upper part of the column.

Lift the front panel with the hoist until it detaches from the lift mast.

To t the front panel to the lifting column, repeat the removal operations in reverse order.

If the bearings or the front panel are replaced, you must check the thickness of the bearings as described in chapter Chapter "Lift mast assembly and disassembly Triplex 14 kg version", P. 81- 8

Raise the front of the truck by approximately 50 cm to allow for easier harnessing.

Lower the forks so that they rest on the retaining plate of the mast, supported by a reasonably-sized block of wood. Drain the hydraulic circuit by pressing and holding the fork-lowering button for several seconds.

With strong ropes, harness the front panel to a hoist, as shown in the image.

Do not use the truck's hydraulic functions to lift the front panel. Danger of spillage of oil under pressure by the hydraulic line.

45728042302 EN - 10/2018

-5

Loosen the mounting screws holding the lifting column to the truck's base, without unscrewing them completely.

Unscrew the hydraulic connection pipe from the lifting column. Be careful of possible oil spillages.

With a hoist, carefully lift the front of the truck to remove the block of wood. Lower the front of the truck onto the ground.

Remove the non-metallic ropes from the front panel and use them to harness the lifting column to the appropriate hook on the upper part of the column.

Now completely unscrew the mounting screws on the lifting column at the base of the truck.

-6

45728042302 EN - 10/2018

Slide the lifting column upwards until it is completely detached from the chassis.

Mark the number and position of the shims in the lifting column in order to avoid repeating the spacing process when re tting the lifting column.

Do not stand under suspended parts when disassembling the lifting column.

To re t the lifting column, follow the instructions for disassembly in reverse order.

Check that the tension of the chains is correct once the lifting column has been re tted. The chains must have the same tension.

45728042302 EN - 10/2018

-7

Remove the limit switch retaining screws

Remove the protection cover of the pulley

Loosen the nuts of the chain and remove the chain

-8

45728042302 EN - 10/2018

Remove the pulley from the central cylinder

Harness the carriage and remove it from the mast

Mark the position of the bearings and the number of shim rings so that the shimming operation for the carriage and the masts do not have to be repeated.

The shimming operation only needs to be carried out when a mast, the carriage and/or the bearings need to be replaced

Remove the clips on the chain of the carriage

Remove the protective guard for the pulley on the lateral cylinders

45728042302 EN - 10/2018

-9

Remove the retaining clip of the chain

Loosen the nuts of the chain and remove the chain

Remove the pipe clips

Remove the hose that connects the central cylinder and the lateral cylinder

-10

45728042302 EN - 10/2018

Remove the clips of the central cylinder

Remove the hydraulic line of the central cylinder Remove the central cylinder

Remove the brackets of the lateral cylinders

Remove the mounting Seeger from the top of the lateral cylinders

45728042302 EN - 10/2018

-11

Remove the lateral cylinders from the lift mast

Remove the ttings from the lateral cylinders

Remove the hose break valves from the lateral cylinders with the appropriate tool

-12

45728042302 EN - 10/2018

Remove the hose break valves from the central cylinder with the appropriate tool

Remove the pulley block from the central cylinder and remove the elastic pin

Now the masts can be lifted up and removed one after another

Mark the position of the bearings and the number of shim rings so that the shimming operation for the carriage does not have to be repeated

45728042302 EN - 10/2018

-13

Apply Loctite 542 on the tting of the lateral cylinder

Fit the hose break valves on the lateral cylinders

-14

45728042302 EN - 10/2018

Apply Loctite 52A43 and screw the pulley support to the central cylinder

Lock the pin of the pulley support with the elastic pin

45728042302 EN - 10/2018

-15

Fit the hose break valve to the central cylinder with the appropriate tool

Lubricate the bearing guides of all stages of the lift mast with grease

Insert the middle mast into the outer mast.

Insert the outer mast into the top part of the column Insert the inner mast into the middle mast.

Insert this into the column

-16

45728042302 EN - 10/2018

If necessary, clean the seat of the bearings with a piece of abrasive card

Check the tolerance inside the mast is not too high by sliding a new bearing along the entire length. If the bearing seems to have too much play, repeat with a bearing of a greater diameter. If the bearing with the bigger diameter seems too big, use the bearing with the smaller diameter.

Fit the chosen bearing into its seat with two shim rings and ensure the correct uidity along the entire length.

If the inner mast struggles to slide freely, remove one shim ring at a time, or add evenly spaced shim rings, to have perfect shimming throughout the mast

Measure the minimum distance between the bearings and the mast as shown in the diagram. At its tightest, there must never be a space of less than If there are points where the play is less than 0.5 mm, the shimming of the bearings must be reduced in order to obtain the desired tolerance along the entire length of the lift mast.

45728042302 EN - 10/2018

-17

The table opposite shows the permitted tolerances between the bearings and masts Repeat the operation for every stage of the lift mast and for the carriage.

Once the shimming operation is complete, the assembly of the parts of the lift mast can begin

Fit the lateral cylinders and shim rings to the upper end piece. Use four shim rings for solid cylinders and two shim rings for hollow cylinders

Secure the lateral cylinders to the lift mast with the appropriate mounting Seeger

Install the ttings onto the lateral cylinder and apply liquid Te on to the threads

-18

45728042302 EN - 10/2018

Fit the containment bracket of the lateral cylinders, making sure that cylinder is turned the right way so the bleed screw can be accessed

Fit the central cylinder to the lift mast, securing it with the appropriate metal clip

Attach the bottom connection to the central cylinder

Attach the power supply line for the central cylinder and the related support clip

45728042302 EN - 10/2018

-19

Attach the hose that connects the central cylinder and the lateral cylinders

Attach the clip that secures the hose to the mast

Attach the chain to the carriage. Attention: the two pins are of different lengths. The longer pin must go on the

Install the pulley for the chains of the lateral cylinders

-20

45728042302 EN - 10/2018

Install the chains for the lateral cylinders Fit the chains to the pulley and secure them with nuts

Attach the protection guard for the pulley

Fit the retention clip for the chains of the lateral cylinders

Fit the clips for the chains of the carriage

45728042302 EN - 10/2018

-21

Attach the carriage to the lift mast. The instructions for shimming the masts can also be used to shim the carriage

Install the pulley on the central cylinder Fit the chain and tighten the bolts that fasten it to the lift mast

Attach the protection cover of the pulley

Install the stopper screw

-22

45728042302 EN - 10/2018

To your lift truck you can t one of the following lifts: Simplex Telescopic NiHo Triplex

When you press the "Lift command button, the fork carriage rail is lifted by the internal cylinder and the chain to a height of h3. h3 0252_003-097

When you push the "Lift" command button, the inner mast is lifted by the lateral lifting cylinders, lifting the fork carriage rail (h3) using the chain (the speed of the fork carriage rail is double that of the inner mast).

h3 h2

In areas with low ceilings you must take into consideration the travel of the inner mast which can reach a greater height than the fork carriage rail.

0252_003-098

When you push the Up button, the inner cylinder is lifted to the free-lift (h 2) and then the outer cylinders lift the inner mast directly to the maximum height (h3).

When being raised to its maximum elevation, the fork carriage rail always remains on the uppermost tip of the mast that is extended.

h3

h2'

0252_003-099-V2

In areas with low ceilings you must take into consideration that the load being lifted may protrude above the fork carriage rail.

45728042302 EN - 10/2018

-23

-24

45728042302 EN - 10/2018

20 40 110 130 150 160 170 175 180 190 200 210

Inner mast Chain Chain pulleys Screw Washers with teeth Circlips Circlips Bushings Roller Roller Adjustment shims Adjustment shims

220 230 240 250 270 280 290 300 310 320 330 340

45728042302 EN - 10/2018

Chain anchor Bolt Pins Nuts Threaded unions Hose Hose T union Coupling Guard Guard End stop

-25

-26

45728042302 EN - 10/2018

20 60 100 105 110 120 130 150 160 170 180 190 200 210 220 230 240 250

Inner mast Chain Chain pulley Screw Bolt Washer Screw Screw Coupling Sleeves Washers with teeth Circlips Circlips Bushings Roller Roller Adjustment shims Adjustment shims

260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420

45728042302 EN - 10/2018

Traction bar Bolt Pins Nuts Clip Screw Washer Threaded union Threaded unions Pipe Hose Hose T union Coupling Guard grille Nuts Screw

-27

-28

45728042302 EN - 10/2018

20 30 60 70 100 120 130 140 150 160 180 190 200 210 220 230 240 250 260 270 285 290 300

Centre mast Inner mast Chain Chain Screw Chain pulley Bolt Washer Screw Chain pulleys Screw Screw Washers with teeth Circlips Circlips Sleeves Roller Roller Adjustment shims Adjustment shims Traction bar Bolts Pins

310 315 320 321 322 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500

45728042302 EN - 10/2018

Nuts Chain anchor Support Bracket Bolt Hose pulley Washer Retaining ring Bracing Clip Screw Washers Threaded unions Hose Hose Hose Coupling Coupling Stop edge ring Guard Guard Clip Guard grille

-29

Lower the fork carriage. Press the lowering button several times so that there is no more pressure in the system.

Remove the protective screen.

Remove the stop screw (1).

Slacken the central cylinder chain using the nut.

-30

45728042302 EN - 10/2018

Remove the pin (3) and the chain shaft (1) then take the chain (2) off the pulley.

Unscrew the screw (2). The washer (3) will come out with the screw (2). Push the shaft (4) to dislodge it.

Undo the screw, (2) then remove the shaft (3) and the pulley (4).

Strap the fork carriage and remove from the mast from above using a hoist.

To re t, proceed in reverse order.

Lower the fork carriage. Press the lowering button several times so that there is no more pressure in the system.

Remove the stop screw (1).

Slacken the chains using the nuts.

Remove the protective screen.

45728042302 EN - 10/2018

-31

Remove the pins and the chain shafts.

Remove the chains from the pulleys.

Lift the mast until the fork carriage is freed from the bottom.

To re t, proceed in reverse order.

After removing the fork carriage, lower the mast again as far as possible.

Remove the circlips located at the top of the side cylinders.

Unscrew the hydraulic connections located at the bottom of the side cylinders.

Strap the mobile mast and lift it using a hoist.

Remove the side cylinders (see ter "Side cylinders", P. 81-41).

Chap-

Lower the mobile mast again.

Remove the upper and lower rollers.

Take out the mobile mast from above using a hoist.

To re t, proceed in reverse order.

-32

45728042302 EN - 10/2018

Lower the fork carriage. Press the lowering button several times so that there is no more pressure in the system.

Remove the protective screen.

Remove the stop screw (1).

Slacken the central cylinder chain using the nut.

Remove the pin and the chain shaft.

45728042302 EN - 10/2018

-33

Take the chain off the pulley.

Undo the screw (2) and then remove the washer (3) and the pulley (4).

Lift the mast until the fork carriage is freed from the bottom.

To re t, proceed in reverse order.

After removing the fork carriage, lower the masts again as far as possible.

Remove the upper protective screen.

Remove the circlips located at the top of the side cylinders.

Remove the rigid pipes supplying the central cylinder (see Chapter "Hydraulic pipes and hoses", P. 71-22).

Strap the mobile mast and lift it using a hoist.

Disconnect the side cylinders.

Take out the mobile mast.

Disconnect the hydraulics.

Remove the circlips located at the bottom of the side cylinders.

Remove the side cylinders.

Lower the mast.

Remove the upper and lower rollers.

Take out the mast from above using a hoist.

To re t, proceed in reverse order.

Lower the fork carriage. Press the lowering button several times so that there is no more pressure in the system.

Remove the protective screen.

Remove the stop screw (1).

-34

45728042302 EN - 10/2018

Slacken the central cylinder chain using the nut.

Remove the pin and the chain shaft.

Take the chain off the pulley.

Undo the screw (2) and then remove the washer (3) and the pulley (4).

Lift the mast until the fork carriage is freed from the bottom.

To re t, proceed in reverse order.

After removing the fork carriage, lower the masts again as far as possible.

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At the point where the central cylinder is supplied, disconnect the connection (1) located between the rigid pipes and the hoses.

Remove the upper protective screen.

Strap the masts.

Slacken the chains using the nuts.

Remove the pins and the chain anchor shafts.

Remove the chains from the pulleys.

Remove the circlips located at the top of the side cylinders.

Lift the masts with the hoists until the chain fasteners of the mobile mast are accessible.

Remove the pins and shafts.

Remove the chains.

Lower the masts as far as possible.

Remove the upper and lower rollers.

Take out the mobile mast from above using a hoist.

To re t, proceed in reverse order.

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45728042302 EN - 10/2018

Remove the rigid pipes from the side cylinder (see Chapter "Hydraulic pipes and hoses", P. 71-22).

Strap the intermediate mast and lift it using a hoist.

Remove the side cylinders (see ter "Side cylinders", P. 81-41).

Chap-

Lower the intermediate mast.

Remove the rollers.

Take out the intermediate mast from above using a hoist.

To re t, proceed in reverse order.

Lift the fork carriage and wedge it so that access from below is possible.

Unbolt the mast from the chassis.

Lower the fork carriage.

Disconnect the mast hydraulics (2).

Remove the loading frame assembly.

Position the loading frame assembly horizontally to facilitate operations.

Refer to previous procedures.

Once the loading frame assembly has been removed, it is no longer possible to use the truck hydraulics.

Always secure the unit to be removed with straps and a hoist.

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With the fork carriage resting on the side members, tighten the chain using the chain tensioner (1).

Check the chain wear using a wear checking ruler.

The wear condition of the lifting chains and their extension (3% maximum) must be checked in compliance with the regulations governing the prevention of accidents at work.

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Lower the fork carriage. Press the lowering button several times so that there is no more pressure in the system.

Remove the protective screen.

Remove the pin (3) and the chain shaft (1) then take the chain (2) off the pulley.

Unscrew the screw (2). The washer (3) will come out with the screw (2). Push the shaft (4) to dislodge it.

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Unscrew the connection located under the central cylinder.

Remove the screws (5).

Remove the central cylinder.

For reassembly, proceed in the reverse order.

After re tting the cylinders, bleed the air from the system using the drain screws.

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45728042302 EN - 10/2018

Remove the circlips located at the top of the side cylinders.

Unscrew the hydraulic connections located underneath the side cylinders.

Strap the mobile mast and lift it using a hoist.

Lift the side cylinders out by the top.

For reassembly, proceed in the reverse order.

After re tting the cylinders, bleed the air from the system using the drain screws.

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Lower the initial lift and the fork carriage completely.

Disconnect the battery.

Remove the battery from the truck.

Remove the pin holding the cylinder using a pin punch.

Unscrew the connection at the bottom of the cylinder.

Raise the initial lift using a hoist to free the cylinder rod.

Turn the cylinder by a 1/4 turn to be able to remove it from its housing.

To re t, proceed in reverse order.

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45728042302 EN - 10/2018

Initial lift cylinders Disassembly . . . . . . . . . . . . . . . . . .

Central cylinder Disassembly . . . . . . . . . . . . . . . . . .

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- 39 Lifting chains

Digicode option (LFM Go) . . . . . . . . . . . .

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Adjustment . . . . . . . . . . . . . . . . . . .

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Side cylinders

Initial lift Sensor system . . . . . . . . . . . . . . . . .

- 26

Disassembly . . . . . . . . . . . . . . . . . .

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STILL GmbH 45728042302 EN 10/2018