Still EXU H18, EXU H20, EXU H20S EXU H20 lithium-ion EXU H20S lithium Pallet truck Workshop Manual

Workshop literature

Pallet truck with auxiliary lift EXU H18, EXU H20, EXU H20S EXU H20 lithium-ion EXU H20S lithium-ion

0161 0162 11528012006 EN - 07/2017

History of changes g Edition 10/2010 • First Issue

Edition 12/2016 • Chapter 00: Addition of information on the lithium-ion battery (A1 and A2) • Chapter 00: Addition of information about electrical accreditation for technicians • Chapter 00: Addition of information on the lithium-ion battery (B1 and B2) • Chapter 00: Addition of lithium-ion battery CAN bus network • Chapter 00: Addition of list of lithium-ion battery error codes

• Chapter 01: Addition of maintenance plans • Chapter 42: Addition of adjustable stabilisers (option) • Chapter 60: Creation of Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) section • Chapter 60: Creation of Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) section • Chapter 60: Creation of Charger for lithium-ion batteries (option) section

Edition 07/2017 • Chapter 42: Slow speed (Creep Speed) function added

11528012006 EN - 07/2017

I

Table of contents g 00 Product information Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1 EXU-H 18 and EXU-H 20 electric pallet trucks with auxiliary fork lift . . . . . . . . . . . . . . . 00-1

Description of the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-3 Description of the lithium-ion battery A1 and A2

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Description of the lithium-ion battery B1 and B2

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Lithium-ion safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-5 Technician electrical accreditation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-5

01 Service Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 1000-hour/annual maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 3000-hour maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3 Standardised tightening torques for standard-pitch threads and fine-pitch threads . . . . 01-3 Measuring and testing equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4

02 Diagnostics Diagnostic tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-1 STEDS-Navigator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-1

Truck diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-2 Accessing truck information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-2 CAN box diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-3 Connecting a laptop to the USB CAN Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-4 CAN bus network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-5

Lithium-ion battery diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-6 Diagnostic connector of the Lithium-Ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-6 CAN bus network of the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-7 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-8 Indicator light for the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-9 Battery A1 and A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-10 Lithium-ion service base

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Error codes for the lithium-ion battery A1-A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-11 Troubleshooting flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-14 Battery B1 and B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-26 Error codes for the lithium-ion battery B1-B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-26 Troubleshooting flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-29 Analysing the battery condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-40 11528012006 EN - 07/2017

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Table of contents g Questionnaire to identify battery condition

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Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-42 Reading and deleting the error list

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Pictograms of error codes on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-44 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-45

11 Traction motor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Features of the traction motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Power module connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 Removing the traction motor

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Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 Rev sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7

23 Transmission Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1 Description of the drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1 Removing the drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2

Transmission gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3 Transmission gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3 Reducer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4 Removing the transmission gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-6 Changing the transmission gear seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-9 Draining the transmission gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-11

30 Truck structure Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1 Access to the technical compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

Driver's platform (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 Removing the platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6

Battery compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 Types of compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 Battery lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10

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Table of contents g 42 Steering, braking and wheels Tiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-1 1B7 tiller foot potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-2 "Cold store" resistors"" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-4 Removing the tiller head Gas damper

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Removing the tiller arm

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Electromagnetic brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-13 Electromagnetic parking brake Y1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-13

Stabilisers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-15 Stabilisers (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-15 Stabilisers (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-16 Adjusting the height of the stabiliser wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-17

Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-18 Description of the wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-18 Types of drive wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-19 Types of stabiliser wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-21 Types of load wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-22 Removing the drive wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-23 Removing the stabiliser wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-24 Removing the load arm components

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60 Electrical/electronic equipment Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1 Safety guidelines for electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1 Cleaning the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2 Insulation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-4 Electromagnetic compatibility

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General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-6 Functions of EXU-H trucks equipped with LAC 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-6 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-11 Electrical components mounting plate

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Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15 Traction and hydraulic controller - LAC 02/ 1A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15 Functions of the "Inputs/Outputs" of the LAC 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-16 Activation of the 1A1 controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-18 11528012006 EN - 07/2017

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Table of contents g Speed reductions

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Creep Speed function (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20

Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) . . . . . . . . . . . 60-22 Location of connectors for the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-22 BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-24 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-24 Replacing the BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-26 Replacing the BMU harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-28 Replacing the SMU harness (A1 battery)

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Replacing the SMU harness (A2 battery)

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Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-32 Lithium-ion module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-32 Replacing the A1 battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-33 Replacing the A2 battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-35 Power plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-37 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-37 Replacing the contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-39 Replacing the battery fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40 Lithium-ion battery socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41 Display for lithium-ion batteries

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) . . . . . . . . . . . 60-44 Location of connectors for the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-44 Replacing the cover provided . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-46 Replacing the push button provided . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-48 Replacing the diagnostic harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-49 Replacing the terminal block

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Replacing the power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51 BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-52 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-52 Replacing the BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-53 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-55 Lithium-ion module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-55 Disassembling the B1 and B2 battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-56 Reassembling the B1 and B2 battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-59 Replacing the shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-62 Power plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-64 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-64 Replacing the contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-66 Replacing the fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-68 Lithium-ion battery socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-69 Display for lithium-ion batteries

VI

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Table of contents g Replacing the power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72

Charger for lithium-ion batteries (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73 Using the side socket to charge the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-75 Charging lithium-ion batteries using an external charger . . . . . . . . . . . . . . . . . . . . . . 60-77 Installing the external charger

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81

Hydraulic controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-82 EXU-H

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-82

Automatic fork lifting/lowering option

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-84

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-86 Multifunction indicator 6P4 (CAN bus)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-86

Changing the multifunction indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-89

Electronic key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90 Digicode LFM GO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90 Changing the LFM box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-91

FleetManager™ (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-92 Description of Fleet Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-92 TDU: Access control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-93 FleetManager option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-95

On-board charger (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-97 On-board battery charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-97

70 Hydraulic Pump-motor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1 Disassembling the pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-2

81 Lifting system Initial Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-1 Initial lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-1 Removing the Initial Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-1 Removing the lift shaft assembly + push rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-4

Main Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-8 Main Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-8 Disassembling the main lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-9 Removing the fork carriage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-11

11528012006 EN - 07/2017

VII

Product information

00

a

Foreword EXU-H 18 and EXU-H 20 electric pallet trucks with auxiliary fork lift

The EXU-H retains the chassis base, drive unit, control tiller, stabilisers, LAC controller and hoods of the EXU. It is equipped with an additional mast to allow the pallet to be levelled, limiting incorrect posture during load handling.

The "S" versions are equipped with a folding platform Lift heights: • Load arms: 210 mm from the ground • Fork (mast): 760 mm from the ground Capacity of the EXU-H 18: • Load arms only: 1800 kg • Fork carriage only: 800 kg • Load arms + additional mast: 1800 kg maximum Capacity of the EXU-H 20: • Load arms only: 2000 kg • Fork carriage only: 800 kg • Load arms + additional mast: 2000 kg maximum Traction speed: • 6 km/h in both directions Traction motor power: • 1.2 kW (AC technology) 11528012006 EN - 07/2017

00-1

00

Product information

Foreword Pump motor power: • 1.2 kW (DC technology) Braking: • counter-current, upon accelerator release • counter-current, by switching the direction of travel • counter-current, controlled by the rear safety button (belly) • electromagnetic safety, controlled by the battery handle (emergency stop function) • electromagnetic safety, controlled by the upper or lower position of the tiller • electromagnetic parking, applied when the supply is cut Battery equipment: • Vertical access (types BS* and 2 Pzs) *: British Standard Options: • Folding platform • Lift table automatic levelling fixture • LFM Go • LFM Go + LFM Access/Basic + shock sensor • on-board charger • cold store protection

00-2

11528012006 EN - 07/2017

Product information

00

Description of the lithium-ion battery Description of the lithium-ion battery A1 and A2

This truck is equipped with a battery with lithiumion technology.

Battery type

Dimensions Length (mm) Height (mm) Depth (mm) Weight (kg)

Nominal voltage (V)

Nominal capacity (Ah)

A1 (1 module)

648

627

156

50.5

23.1

82

A2 (2 modules)

648

627

156

70.5

23.1

164

Benefits of the lithium-ion battery 1 Rapid charging 2 Double the battery life 3 More power 4 Twice the capacity 5 Increased efficiency 6 Maintenance-free

11528012006 EN - 07/2017

00-3

00

Product information

Description of the lithium-ion battery Description of the lithium-ion battery B1 and B2

Battery type B1 (1 module) B2 (2 modules)

Nominal capacity (Ah)

108

23,1

205

139

23,1

410

Length (mm) Height (mm) Depth (mm) Weight (kg) 718 718

618 618

210 210

.

00-4

Nominal voltage (V)

Dimensions

11528012006 EN - 07/2017

Product information

00

Lithium-ion safety guidelines Technician electrical accreditation Maintenance operations must always be carried out by a competent person.

DANGER Electrical danger Do not touch the lithium-ion battery when the battery is charging and do not wear rings or jewellery.

CAUTION Electrical accreditation regulations Comply with electrical accreditation regulations for the country. Depending on the country, electrical accreditation of the technician may not always be compulsory.

CAUTION Risk of accident Any work on the lithium-ion battery must be carried out by an authorised service engineer.

CAUTION

CAUTION Safety regulations When carrying out work inside the battery, do not wear clothes with metal objects (belt, shirt buttons).

CAUTION Safety regulations Use protection goggles and a mask with a protective visor.

Safety regulations Comply with the regulations in force in the country.

11528012006 EN - 07/2017

00-5

00

Product information

Lithium-ion safety guidelines

00-6

11528012006 EN - 07/2017

Service

01

a

Maintenance 1000-hour/annual maintenance plan Maintenance operations every 1000 hours Depending on the application, environmental conditions and driving style, the following procedures should be carried out every 1000, 2000, 4000, 7000 and 8000 hours Preparation Clean the truck (if necessary) Check the error codes (using the diagnostic tool) Traction motor Check that the cables and bundling are in good condition Transmission Check for any possible oil leaks from the transmission gear Grease the sprocket Steering/wheels/braking Check the level of wear on the tyre tread of the wheels Check the brake air gap Check the tightness of the nuts Electrical equipment Clean and blow out the electrical plate Check the mounting of the electrical connections Check the condition of the on-board charger Check that the cables and fuses are secure Check and adjust the battery electrolyte level Check the lift height switch Clean the sensors for the automatic lifting function Hydraulic system Check the system oil level Check the circuit for leaks Load lift system Check the level of wear on the rings and clevis pins Oil or generously grease the rings and clevis pins Final tasks Check the general condition of the forks and the chassis .

11528012006 EN - 07/2017

01-1

01

Service

Maintenance 3000-hour maintenance plan Additional maintenance operations every 3000 hours Depending upon use, environmental conditions and driving style, the following procedures must be performed every 3000, 6000 and 9000 hours Information Carry out all 1000-hour maintenance work Transmission Drain the transmission gear oil Hydraulic system Clean the return line filter for the circuit Replace the breather filter for the circuit Drain the hydraulic system .

01-2

11528012006 EN - 07/2017

Service

01

Tools Standardised tightening torques for standard-pitch threads and fine-pitch threads Standard Threads Tightening torque [Nm] Thread

Grade 4.6

Grade 4.8

Grade 5.8

Grade 6.8

Class 8.8

M4

1

1.3

M5

2.1

2.7

M6

3.6

M8

Grade 10.9 Grade 12.9

1.7

2

2.7

3.8

4.6

3.4

4.1

5.5

8

9.5

4.7

5.9

7.1

9.5

13

16

8.5

11

14

17

23

32

39

M10

17

23

29

34

46

64

77

M12

30

40

50

60

80

110

135

M14

47

62

78

94

125

180

215

M16

73

100

122

146

195

275

330

M20

145

192

240

289

385

540

650

M24

250

330

410

495

660

930

1110

M30

510

675

840

1000

1350

1850

2250

M36

880

1170

1470

1760

2350

3300

3900

.

Fine threads Tightening torque [Nm] Thread

Grade 4.6

Grade 4.8

Grade 5.8

Grade 6.8

Class 8.8

Grade 10.9 Grade 12.9

M8x1

9.5

12

16

19

25

35

42

M10x1

20

26

32

39

52

72

95

M10x1.25

18

24

30

37

49

68

82

M12x1.25

33

44

55

66

88

125

150

M12x1.5

31

41

52

62

83

115

140

M14x1.5

52

70

87

105

140

195

235

M16x1.5

79

105

130

157

210

295

350

M18x1.5

115

150

190

230

305

425

510

M20x1.5

160

210

265

320

425

600

720

M22x1.5

215

285

355

425

570

800

960

M24x1

270

360

450

540

720

1000

1200

M27x1

395

525

655

785

1050

1500

1800

M30x2

540

725

905

1085

1450

2050

2500

M36x3

930

1250

1560

1870

2500

3500

4100

.

11528012006 EN - 07/2017

01-3

01

Service

Tools Measuring and testing equipment Diagnostics Description

Reference

USB CAN Box, unit with cables

50983605401

50983605400 USB CAN Box Adaptor cable, CAN Box for diagnostics on the truck, diagnostic con0171381 nector, 7-pin Adaptor cable, CAN Box for diagnostics on the truck, diagnostic con0625028 nector, four-pin .

Measuring devices Description

Reference

STILL multimeter with measurement leads

0009418737

.

Test adaptor Description Test adaptor, SAAB, 42-pin

Reference 8426527

.

Measuring equipment Description

Reference

Replacement MetraHit measuring lines, pair of red and black Measuring tips, pair of red and black

0143426

Crocodile clips, pair of red and black

0143427

Measurement cables, pair of red and black

0143425

.

Harness Description

Reference

1000 kg-round sling, L = 2 m (purple)

Hahn&Kolb 77200910

.

01-4

11528012006 EN - 07/2017

Diagnostics

02

a

Diagnostic tool STEDS-Navigator

STEDS-Navigator homepage 1 Document category 2 Document language

3 4 5

Document search by type carrier Document search by truck series Document selection

– Start the notebook and double-click the icon on the desktop.

– The STEDS-Navigator opens with the homepage (see above).

– If necessary, change the document language (2). We recommend that you select English as the second language.

– Select the required document category (1).

– Select the required truck series (4).

– In the document selection (5), select and launch the required document by double clicking.

It is also possible to search for documents directly via the "Document search by type carrier" option.

– Click the document search by type carrier option (3).

– Enter the required type carrier and confirm by pressing Start .

All documents relevant for the type carrier in question are listed and can be opened by double clicking.

11528012006 EN - 07/2017

02-1

02

Diagnostics

Truck diagnostics Accessing truck information The diagnostic tool uses a special Still software application for laptop PCs. It is connected to the truck by an interface box (CANBOX) and linked up to a single connector (6X7) located in the battery compartment.

NOTE

Before launching the software the truck must be switched on and connected to the laptop PC.

02-2

11528012006 EN - 07/2017

Diagnostics

02 Truck diagnostics

CAN box diagnostics CAN box, serial The serial CAN box is equipped with a 4-pin round plug (1) on the left-hand side that is connected to the truck diagnostic connector.

A 9-pin Sub-D plug (5) is provided on the right-hand side. This plug is connected to the notebook.

A reset button (6) for restarting the CAN box is fitted on the left-hand side.

CAN box, USB The USB CAN box is equipped with three connections on the left-hand side. The top connection is a 4-pin round connector (1), which is connected to the diagnostic connector on the truck. The bottom connection is a USB cable (8), which is connected to the notebook. The centre connection is not currently used.

LED displays Three LEDs indicate the communication status of the CAN box: • The LED (2) lights up once the CAN box is supplied with voltage via the diagnostic connector when the truck is switched on • The LED (4) indicates the status between the notebook and the CAN box • The LED (3) indicates the status between the CAN box (CAN 1) and the truck • The LED (7) indicates the status between the CAN box (CAN 2) and the truck. This LED is not used.

• Applies only to the USB CAN box: If all of the LEDs (2,3,4,7) are flashing, the CAN box is in programming mode. In this case, the CAN box must be restarted.

Resetting the CAN box Switching the truck off and on again will trigger a reset of the CAN box. The supply to the CAN bus is interrupted when the truck is switched off.

Exception: RX50 (5060-5066): The CAN box must be disconnected from the truck (diagnostic connector) in order to be reset. It is not sufficient to switch off the truck.

11528012006 EN - 07/2017

02-3

02

Diagnostics

Truck diagnostics Connecting a laptop to the USB CAN Box

1 2

Diagnostic connector, 7-pin Adaptor cable for diagnostic connector, 7-pin

The laptop (5) is connected directly to the CAN Box via the connecting line.

3 5

USB CAN Box Laptop

The CAN Box (3) is connected to the truck’s diagnostic connector (1) via the adaptor cable (2).

Connecting a laptop to the serial CAN Box

1 2 3 4a

Diagnostic connector, 7-pin Adaptor cable for diagnostic connector, 7-pin Serial CAN Box Connecting line, serial→serial

NOTE

The serial CAN Box has been replaced with a USB CAN Box, and can no longer be ordered.

The CAN Box (3) is connected to the truck’s diagnostic connector (1) via the adaptor cable (2).

4b 5

Connecting line, serial→serial and serial converter Laptop

will depend on the type of ports available on the laptop. Laptops equipped with Sub-D plugs are connected using a "serial→serial" connecting line (4a). Laptops that are not equipped with Sub-D plugs are connected using a "serial→serial" connecting line and a serial converter (4b).

The laptop (5) is connected to the CAN Box via the connecting line. The type of connection

02-4

11528012006 EN - 07/2017

Diagnostics

02 Truck diagnostics

CAN bus network

6X7 1A1 6P4

Diagnostic connector LAC controller Multi-function indicator

The CAN bus communication network between the multifunction indicator and the controller is composed of: • CAN HIGH • CAN LOW • Two 120- "Rt" terminating resistors fitted in parallel in the circuit.

Checking the CAN bus network: • Using an ohmmeter, the measured value of the diagnostic connector (6X7) between terminals (1) and (2) is 60 Ω. This value is measured between the CAN high and the CAN low when the truck is not under voltage • Using a voltmeter, the measured value of the diagnostic connector (6X7) between terminals (4) and (1) and between terminals (4) and (2) is 2.5 V when the truck is under voltage.

11528012006 EN - 07/2017

02-5

02

Diagnostics

Lithium-ion battery diagnostics Diagnostic connector of the Lithium-Ion battery

1 2 3 4

02-6

CAN high CAN low 12 V DC (for diagnosis with the CAN box) 0V

5 6 7

Emergency signal N/A N/A

11528012006 EN - 07/2017

Diagnostics

02 Lithium-ion battery diagnostics

CAN bus network of the lithium-ion battery

6X7 X33 1A1 6P4

Truck diagnostic socket Diagnostic connector of the lithium-ion battery Controller Multifunction indicator of the lithium-ion battery

The CAN bus network for communication between the lithium-ion battery and the controller is composed of: • CAN high • CAN low • Two 120-Ω"Rt" terminating resistors (one in the controller and one in the lithium-ion battery) fitted in parallel in the circuit Checking the CAN bus network of the lithium-ion battery: • Using an ohmmeter, the measured value of the diagnostic connector (X33) between terminals (1) and (2) is 60 Ω. This value is measured between the CAN high and the CAN low when the truck is not under voltage • Using a voltmeter, the measured value of the diagnostic connector (X33) between terminals (4) and (1) and between terminals (4) and (2)is 2.5 V when the truck is under voltage.

11528012006 EN - 07/2017

02-7

02

Diagnostics

Lithium-ion battery diagnostics Block diagram

Assignment of the battery diagnostic connector X33 X33:1 CAN-H X33:2 CAN-L X33:3 12 V DC X33:4 0 V X33:5 0 V if the contactor K10 is open, 24 V if the contactor K10 is closed

02-8

X30: L+ Battery connector (positive) X30: L- Battery connector (negative) F21 Power fuse K10 Contact switch S1 On/off push button

11528012006 EN - 07/2017

Diagnostics

02 Lithium-ion battery diagnostics

Indicator light for the lithium-ion battery Statuses of the green indicator light for the lithium-ion battery

C

Battery contactor status Open

CAN bus communication No

A

Closed

Activated

No

B

Closed

Activated

No

C

Open Open Closed if the contactor is stuck

Activated

No

Activated

Yes

Mode

Status

Off Usage and SOC > 30% Usage and SOC < 30% Stand by Safety

C

Alarm activated No

Battery contactor status Warning Alarm

Closed Open

When the contactor is open, the battery indicator light goes off.

However, even if the indicator light is off, the battery is not switched off.

11528012006 EN - 07/2017

02-9

02

Diagnostics

Lithium-ion battery diagnostics Battery A1 and A2 Lithium-ion service base Lithium-ion battery diagnostics

– Open the diagnostic tool and select the lithium-ion battery service base as shown in the illustration.

NOTE

Diagnostics can also be performed on the lithiumion battery only, without it being in the truck.

02-10

11528012006 EN - 07/2017

Diagnostics

02 Lithium-ion battery diagnostics

Error codes for the lithium-ion battery A1-A2 Reset levels: — Automatic reset: If required, move the battery to somewhere that is at ambient temperature.The battery will reset by itself.

— Truck reset: Press the button for over one second.

— ON/OFF reset (safe mode): Press the button for over one second OR over ten seconds. *BMS: Battery Management System = Assembly made up of the BMU and SMU *BMU: Battery Monitoring Unit = Battery controller *SMU: Safety and Monitoring Unit *SOC: state of charge *IMD: Maximum discharge current allowed *IMR: Maximum charging current Error number 100 101 102 103 110

111 113 114 115 116

118

Description

Activation condition Temperature of the A module is overheating module > 60°C for 1 — 1st level second Temperature of the A module is under module < -23°C for heated — 1st level 1 second A cell is overloading Voltage of a cell > 4.05 — 1st level V for 2 seconds Voltage of a cell < 2.9 A cell is under voltage V for 2 seconds Measured charging current of the battery Difference in charging > max (2.10000 x IMR*; current — 1st level 2.00000) for 5 seconds Measured charging current of the battery Difference in charging > max (2.20000 x IMR*; current — 2nd level 2.00000) for 5 seconds Minimum SOC ≤ 0% Low SOC* — 1st level for 5 seconds SOC * not authorised SOC not authorised for within the required time more than one month At least one BMS (SMU) BMS (SMU) communiassignment has failed cation problem more than three times Maximum temperature A module connection connection > 80°C for is overheating 1 second Maximum difference Inconsistent temperin temperature of the atures module > 10°C for 1 second

11528012006 EN - 07/2017

Reset levels Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset

02-11

02

Diagnostics

Lithium-ion battery diagnostics Error number 200

201 202 203 204 205 206 208

209

210

211

212

213

214

02-12

Description

Activation condition The redundant hardware Redundant safety events emergency chain is reported by the BMS active for more than (SMU modules 500 milliseconds Activation of the battery Battery current > 220 A or contactor after a short the voltage drops in the circuit (blown fuses) fuse > 5 V for 2 seconds Temperature of the A module is overheating module > 65°C for 1 — 2nd level second Temperature of the A module is under module < -25°C for heated — 2nd level 1 second A cell is overloading Voltage of a cell > 4.13 — 2nd level V for 2 seconds Voltage of a cell < 2.3 A cell is under voltage V for 2 seconds If the voltage of at least Cell voltage outside one cell is outside the the range range for 2 seconds A connection A connection temperature is outside temperature < -29°C the range or > 115°C for 1 second Inconsistency between the contactor control Unexpected status of (closed) and the actual battery contactor (open) state of the contactor (open) for 5 seconds Inconsistency between the control of the Unexpected status contactor (open) and of battery contactor the actual state of the (closed) contactor (closed) for 5 seconds Measured charging Excess current when current of the battery charging > max (2.10000 x IMR*; 2.00000) for 5 seconds Measured discharge Excess current during current of the battery > discharge max (1.00000 x IMD*; 2.00000) for 5 seconds Detection of a blown fuse (difference between the voltage of the fuse and Blown fuse the voltage of the battery > 4.00000 V) for more than 3 seconds CAN message not received correctly by the BMS (BMU) Communication with for 5 seconds when the truck lost the battery is outside the tolerance range (charging or discharging)

11528012006 EN - 07/2017

Reset levels ON/OFF reset

ON/OFF reset ON/OFF reset ON/OFF reset ON/OFF reset ON/OFF reset ON/OFF reset ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

Diagnostics

02 Lithium-ion battery diagnostics

Error number

Description

215

BMS (SMU) reconnection failure

216

A module connection is overheating

217

Self-testing failure

218

Pre-charge failure

222

Battery voltage above the limit

224

Battery current sensor outside the range (lost)

225

Low supply voltage of BMS (SMU)

Activation condition Number of attempts to reconnect greater than three for the BMS (SMU) Maximum temperature connection > 90°C for 1 second If the integrated tests (at start-up, continuously, on request, when switching off) have failed (1 unsuccessful attempt is regarded as a failure) If the voltage of the battery contactor is still > 4.00000 V three seconds after the command to close the main pre-charge contactor or if a contactor is open even though it was ordered to close Battery voltage > 28.35 V for 2 seconds The battery current is outside the range for 2 seconds or the main contactors are open and the battery current > 2.00000 A or < -2.00000 A for 2 seconds If the BMS (SMU) supply is active on the BMS (BMU) and the supply voltage is not detected in 0.2 seconds

Reset levels ON/OFF reset ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

.

11528012006 EN - 07/2017

02-13

02

Diagnostics

Lithium-ion battery diagnostics Troubleshooting flow chart BIS: Battery Information Sheet

Error code 100 (Warning) Description: A module is overheating (1st level) Step

INSTRUCTIONS Error code 207 appears

YES Go to step 4

NO Go to step 2

Go to step 5

Go to step 3

END

END

4

Error code 118 appears High ambient temperature Stop using the battery until the temperature decreases Follow the procedure for error code 207

5

Follow the procedure for error code 118

INSTRUCTIONS Error code 207 appears

YES Go to step 4

NO Go to step 2

Go to step 5

Go to step 3

END

END

4

Error code 118 appears Low ambient temperature Expose the battery to a higher temperature so that it warms up Follow the procedure for error code 207

5

Follow the procedure for error code 118

YES

NO

1 2 3

NOTE

.

Error code 101 (Warning) Description: A module is under heated (1st level) Step 1 2 3

NOTE

.

Error code 102 (Warning) Description: A cell is overloading (1st level) Step

2

INSTRUCTIONS Discharge the battery for 10 minutes at a rate of 20 A Error code 102 still appears

3

Replace the battery, referring to the BIS

4

Error resolved (or corrected)

1

NOTE Go to step 2

Go to step 3

Go to step 4

END

END

.

Error code 103 (Warning) Description: A cell is under voltage Step

INSTRUCTIONS Charge the battery for 20 minutes at 10 A

YES

NO

1 2

Error code 103 still appears

Go to step 3

Go to step 5

3

Replace the battery

4

Refer to the BIS Error resolved (or corrected)

5

Go to step 4 END

.

02-14

NOTE Go to step 2

11528012006 EN - 07/2017

END

Diagnostics

02 Lithium-ion battery diagnostics

Error code 107 (Warning) Description: Invalid state of charge (SOC) Step 1

INSTRUCTIONS Switch the battery off and on again

YES

NO

2

Error code 217 appears

Go to step 6

Go to step 3

3

Go to step 4

Go to step 5

5

Error code 107 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

END

END

6

Follow the procedure for error code 217

YES Go to step 3

NO Go to step 2

END

END

YES Go to step 3

NO Go to step 2

END

END

INSTRUCTIONS Error code 103 appears

YES Go to step 4

NO Go to step 2

Go to step 5

Go to step 3

END

END

4

Error code 205 appears The battery charge level is low: charge the battery Follow the procedure for error code 103

5

Follow the procedure for error code 205

4

NOTE Go to step 2

.

Error code 110 (Warning) Description: Difference in charging current (1st level) Step 1 2 3

INSTRUCTIONS Error code 211 appears Charge or regeneration problem They do not meet the IMR thresholds After restarting, the battery should be functional Follow the procedure for error code 211

NOTE

.

Error code 111 (Warning) Description: Difference in charging current (2nd level) Step 1 2 3

INSTRUCTIONS Error code 211 appears Charge or regeneration problem They do not meet the IMR thresholds After restarting, the battery should be functional Follow the procedure for error code 211

NOTE

.

Error code 113 (Warning) Description: Low state of charge (1st level) Step 1 2 3

NOTE

.

11528012006 EN - 07/2017

02-15

02

Diagnostics

Lithium-ion battery diagnostics Error code 123 (Warning) Description: Low state of charge (2nd level) Step

INSTRUCTIONS Error code 103 appears

YES Go to step 4

NO Go to step 2

Go to step 5

Go to step 3

END

END

4

Error code 205 appears The battery charge level is very low: charge the battery Follow the procedure for error code 103

5

Follow the procedure for error code 205

INSTRUCTIONS Switch the battery off and on again

YES

NO

2

Error code 217 appears

Go to step 8

Go to step 3

3

Go to step 4

Go to step 7

7

Error code 114 still appears Charge the battery to SOC>95>% and wait 5 seconds (with or without current) Error code 114 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

8

Follow the procedure for error code 217

1 2 3

NOTE

.

Error code 114 (Warning) Description: State of charge not authorised within the required time Step 1

4

Go to step 5 Go to step 6

Go to step 7

END

END

YES

NO

1

INSTRUCTIONS Switch the battery off and on again

2

Error code 217 appears

Go to step 6

Go to step 3

3

Go to step 4

Go to step 5

5

Error code 115 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

END

END

6

Follow the procedure for error code 217

1

INSTRUCTIONS Error code 100 appears

YES Go to step 9

NO Go to step 2

2

Error code 202 appears

Go to step 10

Go to step 3

5 6

NOTE Go to step 2

.

Error code 115 (Warning) Description: Communication problem with the SMU card Step

4

NOTE Go to step 2

.

Error code 116 (Warning) Description: A module connection is overheating Step

02-16

11528012006 EN - 07/2017

NOTE

Diagnostics

02 Lithium-ion battery diagnostics

Step

YES

4

INSTRUCTIONS Check the tightening torque of the power connections for the module and wait 20 minutes Switch the battery off and on again

5

Error code 217 appears

Go to step 11

Go to step 6

6

Error code 116 still appears

Go to step 7

Go to step 8

END

END

INSTRUCTIONS Replace the module (see chapter 6: Lithium-ion battery, Module)

YES

NO

Refer to the BIS

END

END

YES

NO

1

INSTRUCTIONS Switch the battery off and on again

2

Error code 217 appears

Go to step 6

Go to step 3

3

Go to step 4

Go to step 5

5

Error code 121 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

6

Follow the procedure for error code 217

3

7

Replace the battery

8

Error resolved (or corrected)

9

Follow the procedure for error code 100

10

Follow the procedure for error code 202

11

Follow the procedure for error code 217

NO

NOTE Go to step 4 Go to step 5

.

Error code 118 (Warning) Description: Inconsistent temperatures Step 1 2

NOTE Go to step 2

.

Error code 121 (Warning) Description: The IMD/IMR charging/discharge currents of the algorithm are invalid Step

4

NOTE Go to step 2

Go to step 10 END

END

1

INSTRUCTIONS Error code 202 appears

YES Go to step 10

NO Go to step 2

2

Error code 205 appears

Go to step 11

Go to step 3

3

Error code 204 appears Cut off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery

Go to step 12

Go to step 4

Error code 200 still active?

Go to step 6

.

Error code 200 Description: Redundant safety events reported by the SMU card modules.

Step

4 5

NOTE

Go to step 5

11528012006 EN - 07/2017

Go to step 8

02-17

02

Diagnostics

Lithium-ion battery diagnostics Step

INSTRUCTIONS Replace the battery, referring to the BIS

YES

NO

Go to step 12

Go to step 9

END

END

10

Error code 200 still active?

Error resolved (or corrected) Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Follow the procedure for error code 202

11

Follow the procedure for error code 205

12

Follow the procedure for error code 204

INSTRUCTIONS Error code 224 appears

YES Go to step 6

NO Go to step 2

2

Error code 213 appears

Go to step 7

Go to step 3

3

Error code 211 or error code 212 appears

Go to step 4

Go to step 8

4

Error code 210 appears Follow the procedure for error code 210 Truck problem: IMR/IMD not met Follow the procedure for error code 224

Go to step 5

Go to step 8

END

END

INSTRUCTIONS Error code 207 appears

YES Go to step 4

NO Go to step 2

Go to step 5

Go to step 3

END

END

4

Error code 118 appears Ambient temperature too high Stop using the battery until the temperature decreases Follow the procedure for error code 207

5

Follow the procedure for error code 118

INSTRUCTIONS Error code 207 appears

YES Go to step 4

NO Go to step 2

Error code 118 appears Ambient temperature too low Expose the battery to a higher temperature so that it warms up

Go to step 5

Go to step 3

END

END

6 7 8 9

NOTE Go to step 7

.

Error code 201 Description: Activation of the battery contactor after a short circuit (fuse blown) Step 1

5 6 7 8

NOTE

Follow the procedure for error code 213 Replace the BMS (see chapter 6: Lithium-ion battery, BMS)

.

Error code 202 Description: A module is overheating (2nd level) Step 1 2 3

NOTE

.

Error code 203 Description: A module is under heated (2nd level) Step 1 2 3

02-18

11528012006 EN - 07/2017

NOTE

Diagnostics

02 Lithium-ion battery diagnostics

Step 4

INSTRUCTIONS Follow the procedure for error code 207

YES

NO

NOTE

5

Follow the procedure for error code 118

YES

NO

NOTE

2

INSTRUCTIONS Discharge the battery for 10 minutes at a rate of 20 A Switch the battery off and on again

3

Error code 204 still appears

Go to step 4

Go to step 5

4

Replace the battery, referring to the BIS

5

Error resolved (or corrected)

END

END

YES

NO

1

INSTRUCTIONS Replace the battery

2

Refer to the BIS

END

END

INSTRUCTIONS Switch the battery off and on again

YES

NO

Go to step 3

Go to step 9

4

Error code 206 still appears Switch off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 206 still appears

5

Replace the battery

Go to step 6

6

Go to step 7

7

Refer to the BIS Switch on the battery

8

Error code 206 still appears

Go to step 9

Go to step 9

9

Error resolved (or corrected)

END

END

YES

NO

1

INSTRUCTIONS Switch the battery off and on again

2

Error code 207 still appears

Go to step 3

Go to step 10

.

Error code 204 Description: A cell is overloading (2nd level) Step 1

Go to step 2 Go to step 3

.

Error code 205 Description: A cell is under voltage Step

NOTE Go to step 2

.

Error code 206 Description: Cell voltage outside the range Step 1 2

Go to step 12 Go to step 5

NOTE Go to step 2

Go to step 4 Go to step 9

Go to step 8

.

Error code 207 Description: Too many modules have a temperature that is outside the range Step

11528012006 EN - 07/2017

NOTE Go to step 2

02-19

02

Diagnostics

Lithium-ion battery diagnostics Step

4

INSTRUCTIONS Switch off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 207 still appears

5

Replace the battery

Go to step 6

6

Refer to the BIS

Go to step 7

7

Switch on the battery

Go to step 8

8

Error code 207 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

3

YES

NO

NOTE Go to step 4

Go to step 5

Go to step 10

Go to step 9

Go to step 10

END

END

INSTRUCTIONS Switch the battery off and on again

YES

NO

Go to step 3

Go to step 9

4

Error code 208 still appears Switch off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 208 still appears

5

Replace the battery

Go to step 6

6

Switch on the battery

Go to step 7

7

Error code 208 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

9 10 .

Error code 208 Description: A connection temperature is outside the range Step 1 2 3

Go to step 4 Go to step 5

Go to step 9

Go to step 8

Go to step 9

END

END

YES

NO

1

INSTRUCTIONS Switch the battery off and on again

2

Error code 217 appears

Go to step 10

Go to step 3

3

Error code 209 appears Switch off the battery Disconnect and reconnect the signal connector for the power plate Switch on the battery

Go to step 4

Go to step 9

8 9

NOTE Go to step 2

.

Error code 209 Description: Unexpected status of battery contactor (open) Step

4

02-20

11528012006 EN - 07/2017

NOTE Go to step 2

Go to step 5

Diagnostics

02 Lithium-ion battery diagnostics

Step

INSTRUCTIONS Error code 209 appears Replace the contactor (see chapter 6: Lithium-ion battery, power plate)

YES Go to step 6

Error code 209 appears

Go to step 8

Go to step 9

9

Replace the BMU harness (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

END

END

10

Follow the procedure for error code 217

YES

NO

5 6 7 8

NO Go to step 9

NOTE

Go to step 7

.

Error code 210 Description: Unexpected status of battery contactor (closed) Step 1 2

INSTRUCTIONS Check that the truck is disconnected during the test Press the button to switch off the battery Press the button to switch on the battery Error code 217 appears

9

Error code 210 appears Switch off the battery Disconnect and reconnect the signal connector for the power plate Switch on the battery Error code 210 appears Replace the contactor (see chapter 6: Lithium-ion battery, power plate) Error code 210 appears Replace the BMU harness (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

10

Follow the procedure for error code 217

3 4 5 6

Go to step 2 Go to step 10

Go to step 3

Go to step 4

Go to step 9 Go to step 5

Go to step 6

Go to step 9 Go to step 7

Go to step 8

Go to step 9

END

END

1

INSTRUCTIONS Error code 224 appears

YES Go to step 6

NO Go to step 2

2

Error code 210 appears

Go to step 7

Go to step 3

3

Restart the battery

4

Error code 210 appears Charge or regeneration problem They do not meet the IMR thresholds After restarting, the battery should be functional

7 8

NOTE

.

Error code 211 Description: Excess current when charging Step

5

NOTE

Go to step 4 Go to step 8

Go to step 5

END

END

11528012006 EN - 07/2017

02-21

02

Diagnostics

Lithium-ion battery diagnostics Step 6

INSTRUCTIONS Follow the procedure for error code 224

YES

NO

NOTE

7

Follow the procedure for error code 213

8

Follow the procedure for error code 217

YES Go to step 6

NO Go to step 2

NOTE

1

INSTRUCTIONS Error code 224 appears

2

Error code 213 appears

Go to step 7

Go to step 3

3

Restart the battery

4

6

Error code 217 appears Discharge problem: The IMD thresholds have not been met After restarting, the battery should be functional Follow the procedure for error code 224

7

Follow the procedure for error code 213

8

Follow the procedure for error code 217

.

Error code 212 Description: Excess current during discharge Step

Go to step 4 Go to step 8

Go to step 5

END

END

INSTRUCTIONS Switch the battery off and on again

YES

NO

Error code 213 appears Check that the battery fuse is in good condition

Go to step 3

Go to step 7

Fuse OK? Error code 213 appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Replace the battery fuse (see chapter 6: Lithium-ion battery, power plate)

Go to step 5

Go to step 8

Go to step 6

Go to step 7

END

END

YES

NO

1

INSTRUCTIONS Switch the battery off and on again

2

Error code 217 appears

Go to step 6

Go to step 3

3

Error code 215 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS)

Go to step 4

Go to step 5

5

.

Error code 213 Description: Blown fuse Step 1 2 3 4 5 6 7 8

NOTE Go to step 2 Go to step 4

.

Error code 215 Description: SMU card reconnection failure Step

4

02-22

11528012006 EN - 07/2017

NOTE Go to step 2

Diagnostics

02 Lithium-ion battery diagnostics

Step 5

INSTRUCTIONS Error resolved (or corrected)

YES

NO

6

Follow the procedure for error code 217

END

END

INSTRUCTIONS Error code 100 appears

YES Go to step 9

NO Go to step 2

Error code 202 appears Check the tightening torque of the power connections for the module and wait 30 minutes Switch the battery off and on again

Go to step 10

Go to step 3

5

Error code 217 appears

Go to step 11

Go to step 6

6

Error code 216 still appears

Go to step 7

Go to step 8

7

Replace the battery

8

Error resolved (or corrected)

END

END

9

Follow the procedure for error code 100

10

Follow the procedure for error code 202

11

Follow the procedure for error code 217

YES

NO

1

INSTRUCTIONS Switch the battery off and on again

2

Error code 217 appears

Go to step 4

Go to step 3

3

Error resolved (or corrected)

END

END

4

Follow the procedure for error code 217

YES

NO

END

END

NOTE

.

Error code 216 Description: A module connection is overheating Step 1 2 3 4

NOTE

Go to step 4 Go to step 5

.

Error code 224 Description: Battery current sensor outside the range (lost) Step

NOTE Go to step 2

.

Error code 217 Description: Self-testing failure Step 1

INSTRUCTIONS Dump the BMU Black Box and contact SAFT (Linde support maintenance technician contacts and SAFT support contacts)

NOTE

.

Error code 218 Description: Pre-charge failure

11528012006 EN - 07/2017

02-23

02

Diagnostics

Lithium-ion battery diagnostics

Step

INSTRUCTIONS

YES

2

Switch off the battery Check that no additional electrical components are connected to the battery Switch on the battery Error code 218 appears

3

Disconnect the battery from the truck

4

Switch the battery off and on again

5

7

Error code 218 appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

8

Problem on the truck electrical harness

1

6

NO

NOTE

Go to step 2 Go to step 3

Go to step 7 Go to step 4 Go to step 5

Go to step 6

Go to step 8

END

END

INSTRUCTIONS Switch the battery off and on again

YES

NO

Error code 225 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

Go to step 3

Go to step 4

END

END

INSTRUCTIONS Switch the battery off and on again

YES

NO

Error code 221 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

Go to step 3

Go to step 4

END

END

YES

NO

.

Error code 225 Description: Low supply voltage of the SMU card Step 1 2 3 4

NOTE Go to step 2

.

Error code 221 Description: Total number of invalid cells Step 1 2 3 4

NOTE Go to step 2

.

Error code 222 Description: Battery voltage above the limit Step 1

INSTRUCTIONS Switch the battery off and on again

2

Error code 222 still appears

Go to step 3

Go to step 6

3

Error code 102 appears

Go to step 7

Go to step 4

4

Error code 204 appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

Go to step 8

Go to step 5

END

END

5 6

02-24

11528012006 EN - 07/2017

NOTE Go to step 2

Diagnostics

02 Lithium-ion battery diagnostics

Step 7

INSTRUCTIONS Follow the procedure for error code 102

8

Follow the procedure for error code 204

YES

NO

NOTE

.

11528012006 EN - 07/2017

02-25

02

Diagnostics

Lithium-ion battery diagnostics Battery B1 and B2 Error codes for the lithium-ion battery B1-B2 Reset levels: — Automatic reset: If required, move the battery to somewhere that is at ambient temperature.

The battery will reset by itself.

— Truck reset: Press the button for over 1 second.

— ON/OFF reset (safe mode): Press the button for over 1 second OR over 10 seconds. *BMS: Battery Management System = Unit made up of the BMU and SMU. *BMU: Battery Monitoring Unit = Battery controller. *SMU: Safety and Monitoring Unit. *SOC: State Of Charge. *IMD: Maximum discharge current allowed. *IMR: Maximum charging current allowed.

Error number 100 101 102 103 110

111 113 115 116

118

02-26

Description

Activation condition Temperature of the A module is overheating module > 60°C for 1 — 1st level second Temperature of the A module is under module < -23°C for heated — 1st level 1 second A cell is overloading Voltage of a cell > 4.05 V — 1st level for 2 seconds Voltage of a cell < 2.9 V A cell is under voltage for 2 seconds Measured charging current of the battery Difference in charging > max (1.05 x IMR*; current — 1st level 2.00000) for 5 seconds Measured charging current of the battery Difference in charging > max (1.1 x IMR*; current — 2nd level 2.00000) for 5 seconds Minimum SOC ≤ 0% Low SOC* — 1st level for 5 seconds At least one BMS (SMU) BMS (SMU) communiassignment has failed cation problem more than three times Maximum temperature A module connection connection > 80°C for is overheating 1 second Maximum difference Inconsistent temperin temperature of the atures module > 10°C for 1 second

11528012006 EN - 07/2017

Reset levels Automatic reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset

Diagnostics

02 Lithium-ion battery diagnostics

Error number 200

201 202 203 204 205 206 208

209

210

211

212

213

214

Description

Activation condition The redundant hardware Redundant safety events emergency chain reported by the BMS is active for 500 (SMU) modules milliseconds Activation of the battery Battery current > 340 A or contactor after a short the voltage drops in the circuit (blown fuses) fuse > 5 V for 2 seconds Temperature of the A module is overheating module > 65°C for 1 — 2nd level second Temperature of the A module is under module < -25°C for heated — 2nd level 1 second A cell is overloading Voltage of a cell > 4.13 V — 2nd level for 2 seconds Voltage of a cell < 2.3 V A cell is under voltage for 2 seconds If the voltage of at least Cell voltage outside one cell is outside the the range range for 2 seconds A connection A connection temperature is outside temperature < -29°C the range or > 115°C for 1 second Inconsistency between the contactor control Unexpected status of (closed) and the actual battery contactor (open) state of the contactor (open) for 5 seconds Inconsistency between the control of the Unexpected status contactor (open) and of battery contactor the actual state of the (closed) contactor (closed) for 5 seconds Measured charging Excess current when current of the battery charging > max (1.15 x IMR*; 2.00000) for 5 seconds Measured discharge Excess current during current of the battery discharge > max (1.10 x IMD*; 2.00000) for 5 seconds Detection of a blown fuse for more than 3 seconds (difference between the voltage of the fuse Blown fuse and the voltage of the battery > 4 V for more than 3 seconds) CAN message not received correctly by the BMS (BMU) Communication with for 5 seconds when the truck lost the battery is outside the tolerance range (charging or discharging)

11528012006 EN - 07/2017

Reset levels ON/OFF reset

ON/OFF reset ON/OFF reset ON/OFF reset ON/OFF reset ON/OFF reset ON/OFF reset ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

02-27

02

Diagnostics

Lithium-ion battery diagnostics Error number

Description

215

BMS (SMU) reconnection failure

216

A module connection is overheating

217

Self-testing failure

218

Pre-charge failure

222

Battery voltage above the limit

224

Battery current sensor outside the range (lost)

225

Low supply voltage of BMS (SMU)

Activation condition Number of attempts to reconnect greater than three for the BMS (SMU) Maximum temperature connection > 90°C for 1 second If the integrated tests (at start-up, continuously, on request, when switching off) have failed (one unsuccessful attempt is regarded as a failure) If the voltage of the battery contactor is still > 4.00000 V 3 seconds after the command to close the main pre-charge contactor or if a contactor is open even though it was ordered to close Battery voltage > 28.35 V for 2 seconds The battery current is outside the range for 2 seconds or the main contactors are open and the battery current > 2.00000 A or < -2.000 A for 2 seconds If the BMS (SMU) supply is active on the BMS (BMU) and the supply voltage is not detected in 0.2 seconds

.

02-28

11528012006 EN - 07/2017

Reset levels ON/OFF reset ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

Diagnostics

02 Lithium-ion battery diagnostics

Troubleshooting flow chart BIS: Battery Information Sheet

Error code 100 (Warning) Description: A module is overheating (1st level) Step

INSTRUCTIONS Error code 207 appears

YES Go to step 4

NO Go to step 2

Go to step 5

Go to step 3

END

END

4

Error code 118 appears High ambient temperature Stop using the battery until the temperature decreases Follow the procedure for error code 207

5

Follow the procedure for error code 118

INSTRUCTIONS Error code 207 appears

YES Go to step 4

NO Go to step 2

Go to step 5

Go to step 3

END

END

4

Error code 118 appears Low ambient temperature Expose the battery to a higher temperature so that it warms up Follow the procedure for error code 207

5

Follow the procedure for error code 118

YES

NO

1 2 3

NOTE

.

Error code 101 (Warning) Description: A module is under heated (1st level) Step 1 2 3

NOTE

.

Error code 102 (Warning) Description: A cell is overloading (1st level) Step

2

INSTRUCTIONS Discharge the battery for 10 minutes at a rate of 20 A Error code 102 still appears

3

Replace the battery, referring to the BIS

4

Error resolved (or corrected)

1

NOTE Go to step 2

Go to step 3

Go to step 4

END

END

.

Error code 103 (Warning) Description: A cell is under voltage Step

INSTRUCTIONS Charge the battery for 20 minutes at 10 A

YES

NO

1 2

Error code 103 still appears

Go to step 3

Go to step 5

3

Replace the battery

4

Refer to the BIS Error resolved (or corrected)

5

NOTE Go to step 2 Go to step 4

END

END

.

11528012006 EN - 07/2017

02-29

02

Diagnostics

Lithium-ion battery diagnostics Error code 107 (Warning) Description: Invalid state of charge (SOC) Step 1

INSTRUCTIONS Switch the battery off and on again

YES

NO

2

Error code 217 appears

Go to step 6

Go to step 3

3

Go to step 4

Go to step 5

5

Error code 107 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

END

END

6

Follow the procedure for error code 217

YES Go to step 3

NO Go to step 2

END

END

YES Go to step 3

NO Go to step 2

END

END

INSTRUCTIONS Error code 103 appears

YES Go to step 4

NO Go to step 2

Go to step 5

Go to step 3

END

END

4

Error code 205 appears The battery charge level is low: charge the battery Follow the procedure for error code 103

5

Follow the procedure for error code 205

4

NOTE Go to step 2

.

Error code 110 (Warning) Description: Difference in charging current (1st level) Step 1 2 3

INSTRUCTIONS Error code 211 appears Charge or regeneration problem They do not meet the IMR thresholds After restarting, the battery should be functional Follow the procedure for error code 211

NOTE

.

Error code 111 (Warning) Description: Difference in charging current (2nd level) Step 1 2 3

INSTRUCTIONS Error code 211 appears Charge or regeneration problem They do not meet the IMR thresholds After restarting, the battery should be functional Follow the procedure for error code 211

NOTE

.

Error code 113 (Warning) Description: Low state of charge (1st level) Step 1 2 3

.

02-30

11528012006 EN - 07/2017

NOTE

Diagnostics

02 Lithium-ion battery diagnostics

Error code 123 (Warning) Description: Low state of charge (2nd level) Step

INSTRUCTIONS Error code 103 appears

YES Go to step 4

NO Go to step 2

Go to step 5

Go to step 3

END

END

4

Error code 205 appears The battery charge level is very low: charge the battery Follow the procedure for error code 103

5

Follow the procedure for error code 205

INSTRUCTIONS Switch the battery off and on again

YES

NO

2

Error code 217 appears

Go to step 6

Go to step 3

3

Go to step 4

Go to step 5

5

Error code 115 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

END

END

6

Follow the procedure for error code 217

INSTRUCTIONS Error code 100 appears

YES Go to step 9

NO Go to step 2

Error code 202 appears Check the tightening torque of the power connections for the module and wait 20 minutes Switch the battery off and on again

Go to step 10

Go to step 3

5

Error code 217 appears

Go to step 11

Go to step 6

6

Error code 116 still appears

Go to step 7

Go to step 8

7

Replace the battery

8

Error resolved (or corrected)

END

END

9

Follow the procedure for error code 100

10

Follow the procedure for error code 202

11

Follow the procedure for error code 217

1 2 3

NOTE

.

Error code 115 (Warning) Description: Communication problem with the SMU card Step 1

4

NOTE Go to step 2

.

Error code 116 (Warning) Description: A module connection is overheating Step 1 2 3 4

NOTE

Go to step 4 Go to step 5

.

Error code 118 (Warning) Description: Inconsistent temperatures

11528012006 EN - 07/2017

02-31

02

Diagnostics

Lithium-ion battery diagnostics Step 1

INSTRUCTIONS Replace the module (see chapter 6: Lithium-ion battery, Module)

YES

Refer to the BIS

END

END

2

NO

NOTE Go to step 2

.

Error code 121 (Warning) Description: The IMD/IMR charging/discharge currents of the algorithm are invalid Step

INSTRUCTIONS Switch the battery off and on again

YES

NO

1 2

Error code 217 appears

Go to step 6

Go to step 3

3

Go to step 4

Go to step 5

5

Error code 121 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

6

Follow the procedure for error code 217

4

NOTE Go to step 2

Go to step 10 END

END

1

INSTRUCTIONS Error code 202 appears

YES Go to step 10

NO Go to step 2

2

Error code 205 appears

Go to step 11

Go to step 3

3

Error code 204 appears Cut off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery

Go to step 12

Go to step 4

Error code 200 still active?

Replace the battery, referring to the BIS

Go to step 6

Error code 200 still active?

Error resolved (or corrected) Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Follow the procedure for error code 202

Go to step 12

Go to step 9

END

END

1

INSTRUCTIONS Error code 224 appears

YES Go to step 6

NO Go to step 2

2

Error code 213 appears

Go to step 7

Go to step 3

.

Error code 200 Description: Redundant safety events reported by the SMU card modules.

Step

4 5 6 7 8 9 10 11

Follow the procedure for error code 205

12

Follow the procedure for error code 204

NOTE

Go to step 5 Go to step 8 Go to step 7

.

Error code 201 Description: Activation of the battery contactor after a short circuit (fuse blown) Step

02-32

11528012006 EN - 07/2017

NOTE

Diagnostics

02 Lithium-ion battery diagnostics

Step

INSTRUCTIONS Error code 211 or error code 212 appears

YES Go to step 4

NO Go to step 8

Error code 210 appears Follow the procedure for error code 210 Truck problem: IMR/IMD not met Follow the procedure for error code 224

Go to step 5

Go to step 8

END

END

INSTRUCTIONS Error code 207 appears

YES Go to step 4

NO Go to step 2

Go to step 5

Go to step 3

END

END

4

Error code 118 appears Ambient temperature too high Stop using the battery until the temperature decreases Follow the procedure for error code 207

5

Follow the procedure for error code 118

INSTRUCTIONS Error code 207 appears

YES Go to step 4

NO Go to step 2

Go to step 5

Go to step 3

END

END

4

Error code 118 appears Ambient temperature too low Expose the battery to a higher temperature so that it warms up Follow the procedure for error code 207

5

Follow the procedure for error code 118

YES

NO

2

INSTRUCTIONS Discharge the battery for 10 minutes at a rate of 20 A Switch the battery off and on again

3

Error code 204 still appears

Go to step 4

Go to step 5

4

Replace the battery, referring to the BIS

5

Error resolved (or corrected)

END

END

3 4 5 6 7 8

NOTE

Follow the procedure for error code 213 Replace the BMS (see chapter 6: Lithium-ion battery, BMS)

.

Error code 202 Description: A module is overheating (2nd level) Step 1 2 3

NOTE

.

Error code 203 Description: A module is under heated (2nd level) Step 1 2 3

NOTE

.

Error code 204 Description: A cell is overloading (2nd level) Step 1

NOTE Go to step 2 Go to step 3

.

Error code 205 Description: A cell is under voltage

11528012006 EN - 07/2017

02-33

02

Diagnostics

Lithium-ion battery diagnostics Step

YES

NO

1

INSTRUCTIONS Replace the battery

NOTE Go to step 2

2

Refer to the BIS

END

END

INSTRUCTIONS Switch the battery off and on again

YES

NO

Go to step 3

Go to step 9

4

Error code 206 still appears Switch off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 206 still appears

5

Replace the battery

Go to step 6

6

Go to step 7

7

Refer to the BIS Switch on the battery

8

Error code 206 still appears

Go to step 9

Go to step 9

9

Error resolved (or corrected)

END

END

INSTRUCTIONS Switch the battery off and on again

YES

NO

Go to step 3

Go to step 10

4

Error code 207 still appears Switch off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 207 still appears

5

Replace the battery

Go to step 6

6

Refer to the BIS

Go to step 7

.

Error code 206 Description: Cell voltage outside the range Step 1 2

Go to step 12 Go to step 5

NOTE Go to step 2

Go to step 4 Go to step 9

Go to step 8

.

Error code 207 Description: Too many modules have a temperature that is outside the range Step 1 2 3

7

Switch on the battery

8

Error code 207 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

9 10

Go to step 4 Go to step 5

Go to step 10

Go to step 8 Go to step 9

Go to step 10

END

END

.

Error code 208 Description: A connection temperature is outside the range

02-34

NOTE Go to step 2

11528012006 EN - 07/2017

Diagnostics

02 Lithium-ion battery diagnostics

Step

INSTRUCTIONS Switch the battery off and on again

YES

NO

Go to step 3

Go to step 9

4

Error code 208 still appears Switch off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 208 still appears

5

Replace the battery

Go to step 6

6

Switch on the battery

Go to step 7

7

Error code 208 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

1 2 3

Go to step 4 Go to step 5

Go to step 9

Go to step 8

Go to step 9

END

END

YES

NO

1

INSTRUCTIONS Switch the battery off and on again

2

Error code 217 appears

Go to step 10

Go to step 3

3

Error code 209 appears Switch off the battery Disconnect and reconnect the signal connector for the power plate Switch on the battery Error code 209 appears Replace the contactor (see chapter 6: Lithium-ion battery, power plate)

Go to step 4

Go to step 9

Error code 209 appears

Go to step 8

Go to step 9

9

Replace the BMU harness (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

END

END

10

Follow the procedure for error code 217

YES

NO

8 9

NOTE Go to step 2

.

Error code 209 Description: Unexpected status of battery contactor (open) Step

4 5 6 7 8

NOTE Go to step 2

Go to step 5 Go to step 6

Go to step 9 Go to step 7

.

Error code 210 Description: Unexpected status of battery contactor (closed) Step 1 2

INSTRUCTIONS Check that the truck is disconnected during the test Press the button to switch off the battery Press the button to switch on the battery Error code 217 appears

NOTE Go to step 2

Go to step 10

11528012006 EN - 07/2017

Go to step 3 02-35

02

Diagnostics

Lithium-ion battery diagnostics Step

9

INSTRUCTIONS Error code 210 appears Switch off the battery Disconnect and reconnect the signal connector for the power plate Switch on the battery Error code 210 appears Replace the contactor (see chapter 6: Lithium-ion battery, power plate) Error code 210 appears Replace the BMU harness (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

10

Follow the procedure for error code 217

3 4 5 6

YES Go to step 4

NO Go to step 9

Go to step 5 Go to step 6

Go to step 9 Go to step 7

Go to step 8

Go to step 9

END

END

1

INSTRUCTIONS Error code 224 appears

YES Go to step 6

NO Go to step 2

2

Error code 210 appears

Go to step 7

Go to step 3

3

Restart the battery

4

6

Error code 210 appears Charge or regeneration problem They do not meet the IMR thresholds After restarting, the battery should be functional Follow the procedure for error code 224

7

Follow the procedure for error code 213

8

Follow the procedure for error code 217

7 8

NOTE

.

Error code 211 Description: Excess current when charging Step

Go to step 4 Go to step 8

Go to step 5

END

END

1

INSTRUCTIONS Error code 224 appears

YES Go to step 6

NO Go to step 2

2

Error code 213 appears

Go to step 7

Go to step 3

3

Restart the battery

4

6

Error code 217 appears Discharge problem: The IMD thresholds have not been met After restarting, the battery should be functional Follow the procedure for error code 224

7

Follow the procedure for error code 213

8

Follow the procedure for error code 217

5

NOTE

.

Error code 212 Description: Excess current during discharge Step

5

Go to step 4 Go to step 8

Go to step 5

END

END

.

02-36

NOTE

11528012006 EN - 07/2017

Diagnostics

02 Lithium-ion battery diagnostics

Error code 213 Description: Blown fuse Step

INSTRUCTIONS Switch the battery off and on again

YES

NO

Error code 213 appears Check that the battery fuse is in good condition

Go to step 3

Go to step 7

Fuse OK? Error code 213 appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Replace the battery fuse (see chapter 6: Lithium-ion battery, power plate)

Go to step 5

Go to step 8

Go to step 6

Go to step 7

END

END

YES

NO

1

INSTRUCTIONS Switch the battery off and on again

2

Error code 217 appears

Go to step 6

Go to step 3

3

Go to step 4

Go to step 5

5

Error code 215 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

END

END

6

Follow the procedure for error code 217

INSTRUCTIONS Error code 100 appears

YES Go to step 9

NO Go to step 2

Go to step 10

Go to step 3

4

Error code 202 appears Check the tightening torque of the power connections for the module and wait 30 minutes Switch the battery off and on again

5

Error code 217 appears

Go to step 11

Go to step 6

6

Error code 216 still appears

Go to step 7

Go to step 8

END

END

1 2 3 4 5 6 7 8

NOTE Go to step 2 Go to step 4

.

Error code 215 Description: SMU card reconnection failure Step

4

NOTE Go to step 2

.

Error code 216 Description: A module connection is overheating Step 1 2 3

7

Replace the battery

8

Error resolved (or corrected)

9

Follow the procedure for error code 100

10

Follow the procedure for error code 202

11

Follow the procedure for error code 217

NOTE

Go to step 4 Go to step 5

.

11528012006 EN - 07/2017

02-37

02

Diagnostics

Lithium-ion battery diagnostics Error code 224 Description: Battery current sensor outside the range (lost) Step

INSTRUCTIONS Switch the battery off and on again

YES

NO

2

Error code 217 appears

Go to step 4

Go to step 3

3

Error resolved (or corrected)

END

END

4

Follow the procedure for error code 217

YES

NO

END

END

YES

NO

1

NOTE Go to step 2

.

Error code 217 Description: Self-testing failure Step 1

INSTRUCTIONS Dump the BMU Black Box and contact SAFT (Linde support maintenance technician contacts and SAFT support contacts)

NOTE

.

Error code 218 Description: Pre-charge failure

Step

INSTRUCTIONS

2

Switch off the battery Check that no additional electrical components are connected to the battery Switch on the battery Error code 218 appears

3

Disconnect the battery from the truck

4

Switch the battery off and on again

5

7

Error code 218 appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

8

Problem on the truck electrical harness

1

6

NOTE

Go to step 2 Go to step 3

Go to step 7 Go to step 4 Go to step 5

Go to step 6

Go to step 8

END

END

INSTRUCTIONS Switch the battery off and on again

YES

NO

Error code 225 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

Go to step 3

Go to step 4

END

END

.

Error code 225 Description: Low supply voltage of the SMU card Step 1 2 3 4 .

02-38

11528012006 EN - 07/2017

NOTE Go to step 2

Diagnostics

02 Lithium-ion battery diagnostics

Error code 221 Description: Total number of invalid cells Step 1 2 3 4

INSTRUCTIONS Switch the battery off and on again

YES

NO

Error code 221 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

Go to step 3

Go to step 4

END

END

NOTE Go to step 2

.

Error code 222 Description: Battery voltage above the limit Step

INSTRUCTIONS Switch the battery off and on again

YES

NO

1 2

Error code 222 still appears

Go to step 3

Go to step 6

3

Error code 102 appears

Go to step 7

Go to step 4

4

Go to step 8

Go to step 5

6

Error code 204 appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

END

END

7

Follow the procedure for error code 102

8

Follow the procedure for error code 204

5

NOTE Go to step 2

.

11528012006 EN - 07/2017

02-39

02

Diagnostics

Lithium-ion battery diagnostics Analysing the battery condition CAUTION The battery or the module must be stored for a minimum of four hours prior to completing the checklist.

Diagnostic help: Determination of damage or fault

▼ Not damaged or faulty

▼ Damaged or faulty

▼

▼

▼

▼ No warning, no alarm

▼ Warning (no alarm)

▼ Measures to take

▼

▼ ▼

▼

▼

▼

◄

▼

▼

▼

▼

New

Used

For destruction or recycling

Category 3

▼

▼

▼

Category 1

Category 2

Category 6

Determination of risk ▼ ▼ No risk

Risk

▼

▼

Category 4

Category 5

There are six categories: Category 1

Function New battery or new module

2

Used battery or module

3

Battery with warning

4 5 6

Damaged or faulty battery or module without risk Damaged or faulty battery or module with risk Battery or module for destruction or recycling

.

02-40

11528012006 EN - 07/2017

Associated error codes No error codes activated No error codes activated 100, 101, 102, 103, 110, 111, 113, 115, 214, 215, 216 No error codes activated 200, 202, 204, 205+100, 210, 218, 224 No error codes activated

Diagnostics

02 Lithium-ion battery diagnostics

Questionnaire to identify battery condition 1 Determination of damage or fault

Other *

Has the product been identified as faulty for safety reasons? NO YES Not determined

(*) Description of measures

Is electrolyte leaking from the product? NO YES Not determined

3 Determination of risk

Has the product suffered material or mechanical damage? NO YES Not determined

Vapour or fumes observed? NO YES

Was it not possible to carry out the diagnostic before transport? NO YES Not determined

YES

Is at least one alarm activated? (not applicable for a single module) NO YES Not determined Could the anomaly or fault impact the results of UN test certification? NO YES Not determined Could the battery be damaged or faulty? NO YES Not determined

Conclusion:

Abnormal heat or increased temperature? NO Abnormal, combustion-like smell? NO YES Is one of the following error codes active? NO YES Not determined

Error codes: 200, 202, 204, 205+100, 210, 218, 224 Do the following apply? LED illuminated + no communication with the battery (no signal from the BMU) NO YES Not determined

• 100% NO: Battery not damaged or faulty = CATEGORY 1, 2, 3 or 6, go to step 4

NO YES

• At least one YES or one "Not determined": Battery damaged or faulty = CATEGORY 4 or 5, go to step 2

4 Decision Category 1: New battery or new module Category 2: Used battery or module

2 Business measures carried out on the product (if applicable)

Category 3: Battery with warning

Rest period after a fault or non-compliance:

Category 4: Damaged or faulty battery or module without risk

Repair/exchange to obtain the initial design? NO

Category 5: Damaged or faulty battery or module with risk

Product deactivated? NO YES N/A

Category 6: Battery or module for destruction or recycling

N/A

YES N/A

11528012006 EN - 07/2017

02-41

02

Diagnostics

Error codes Reading and deleting the error list

1 2 3

Error lists 4 Read error list 4 Delete error list 4 Read error ring buffer

F2: Diagnostics Jobs Execute

– Connect the laptop to the truck and start the truck diagnostics:

F2: Diagnostics

Read error list Different types of error list can be selected: 1

▼

Jobs

Details all errors that are currently active 2

▼ Select job (4) ▼

Execute

Current errors Errors since the last start-up Details all errors that have occurred since the truck was switched on

3

All memorised errors Details all errors that have occurred since the error list was last deleted

The corresponding error list is then displayed depending on the type of error list selected All of the errors from all control units are displayed in this list It is not possible to select individual controllers

02-42

11528012006 EN - 07/2017

Diagnostics

02 Error codes

Delete error list The error list for all controllers is deleted It is not possible to select individual controllers

11528012006 EN - 07/2017

02-43

02

Diagnostics

Error codes Pictograms of error codes on the display

When a fault occurs on the truck, an error code appears on the display.

There are three types of error: – (1) : Traction – (2) : Lifting – (3) : Steering The display can only show four error codes, one after another.

The error code consists of the following: – (1) : Type of error – (4) : Reference number for the type of error – (5) : Error code number

02-44

11528012006 EN - 07/2017

Diagnostics

02 Error codes

Fault codes Description of the error codes The PathFinder diagnostic system uses error codes from 1 to 499 to facilitate troubleshooting. ∙Codes from 1 to 99 are information codes:

∙Codes between 200 and 499 are error codes, split into three groups:

Control status codes : instant information on the Error codes : locating faults. status of the actuators.

They are never stored in the memory of the con- ∙From 200 to 299: fault on a controller input or troller and therefore can only be seen in [inputs/out- output (external component faulty, defect in the internal transistor for controlling the output). puts]=>[current error codes]. ∙From 300 to 399: fault in the power element of the ∙Codes between 100 and 199 are warning codes: controller. ∙From 400 to 499: internal fault between the two Warning : alerts for conditions requiring maintemicroprocessors. nance These are stored and do not concern faults that may require a repair; they concern truck maintenance: for example, adjusting the electromagnetic brake air gap.

1

Control statuses Initial condition not yet satisfied

2

Driving potentiometer is released

3

Tiller is released

4

Tiller is in neutral position and creep speed button pressed

5

Initial forks up: lifting is not released

6

Mast potentiometer is in neutral position

7

One or more lifting/lowering commands are active at start-up.

8

Several lifting/lowering commands are active at same time during operation.

9 10

Power save mode is activated Traction motor is energized

11

Truck in programming mode

12

Initial forks up sensor is NOT active (X1:04 = GND)

14

Power-up test is not completed

15

18

Tiller base potentiometer option is activated in PathFinder in guided diagnosis Mast potentiometer is activated (X1:11 > 40% of the potentiometer supply voltage, but auxiliary buttons lifting/lowering are not pressed (X1:5 and X1:19 = open) Forks up sensor is activated (X1:14 = open). No lifting is possible. Lifting is possible only if X1:14 = GND. Inching mast lifting is active

19

No speed signal though torque applied

20 21 22

Belly switch function is active Belly switch function is active continuously Low battery state of charge

23

Belly switch function is ready

24

Belly switch is pressed while tiller is moved to working position

25

Belly switch function is deactivated

26

Belly switch is pressed

16 17

11528012006 EN - 07/2017

02-45

02

Diagnostics

Error codes

29

Control statuses The driving potentiometer is pressed (more than 15sec.) but the tiller is not in working position Autolift cannot be activated if: tiller or creep switch is activated OR accelerator is actuated OR truck is in motion Inching mast lowering is active

30

Traction motor is not yet magnetized

31 32

Power unit is disabled Automatic mast lifting or automatic mast lowering is selected and start button is OFF

33

Automatic mast lifting is selected (X1:20 = GND) and start button is ON .

34

Automatic mast lowering is selected (X1:28 = GND) and start button is ON.

35

Battery voltage is too low

36

Battery voltage charge is close to 0% (1 flashing bar on display)

37

39

The option selected in PathFinder that shuts down lifting if the battery is discharged is invalid The option selected in PathFinder that reduces the speed if the battery is discharged is invalid Battery voltage charge is less than 20% (2 bars on display)

40

The temperature of the power section of the LAC is high (> +70°C, < +80°C)

41

The temperature of the power section of the LAC is too high (> +80°C)

42

The temperature of the power section of the LAC is high (> 50°C)

43

Truck accelerates gently

44

Power unit temperature is high (warm) (> +50°C and < +70°C)

45

Motor temperature is high (> +130°C)

46

Power is reduced due to high power unit temperature (>65°C)

47

Power is reduced due to high motor temperature (> 100°C)

48

Forks are below 200mm and/or no speed reduction (X1:7 = GND and X1:23 = open)

49

Forks above 200mm and/or speed reduction is active (X1:7 = open, and X1:23 = closed)

50

54

Speed reduction is active (X1:21 = open) No load detected by both optical sensors (2B12: X1:19 = open, X1:5 = GND and 2B13: X1:36 = open, X1:38 = GND) Load detected by one of the optical sensors on the forks. (2B12 or 2B13) Load detected by both optical sensors (2B12: X1:19 = GND, X1:5 = open and 2B13: X1:36 = GND, X1:38 = open) Speed reduction is requested by DataLogger (via )CAN

55

Braking is required by the DATA LOGGER data collector (via the CAN)

27 28

38

51 52 53

56

The DATA LOGGER option causes the truck to stop (via the CAN)

57

Speed reduction is required by the DATA LOGGER data collector (via the CAN)

58

Lifting function shutdown required by the DATA LOGGER data collector (FDE) (via the CAN)

59

Settings for mast lifting/lowering in creep speed have been changed by Diagnosis

60

Creep speed button is pressed

61

Button creep speed and belly switch are pressed at the same time

62

Signals for automatic mast lifting/lowering are not compatible

64

The driver is sat on the cover

65

Reduction input is active

67

The input for reduction is active (X1:20 = 0 V). Lift speed reduction is selected in the PathFinder Fork carrier above 30 cm

68

Fork carrier above 30 cm and initial lift is not lowered

66

02-46

11528012006 EN - 07/2017

Diagnostics

02 Error codes

69 70 71

Control statuses The speed reduction sensor (option) is active and the mast lowering is available in PathFinder Self-test is in progress

72

Main contactor cannot be switch on Capacitors in power unit could not be discharged

73

Pre-charging via "charging circuit" is in progress

74

Contactor in power save mode

75

Brand-ID does not match correct truck type

76

Only for mast trucks: lifting or lowering parameters were changed The self-lifting or self-lowering is activated while the truck is in motion or starting. The truck stops depending on the time set in the PathFinder The direction of traction information is not defined, because the truck is stationary. The CO/UPA "Direction of traction" function and the control of outputs X1:15/X1:16/X1:33 are involved Tiller base potentiometer & platform is activated and input X1:36 = GND, means driver is present and tiller base potentiometer acts like a switch

77 78 79 80

Internal controller error

81

Internal controller error

82 83

Internal controller error Self-test is in progress

84

Wrong battery type

85

87

Wrong "power reset" type Speed reduction sensor mode changed (X1:20 or X1:23). Reasons: type changed by Pathfinder Settings for "travelling in fork direction information" have been changed by diagnostics

88

Settings for "travelling in tiller direction information" have been changed by diagnostics

89

The parameterising of the truck for lifting/lowering has just been changed in PathFinder

90

Accelerator potentiometer is not calibrated

91

Truck ID (stored in the controller) is incorrect

92

Tiller potentiometer is not calibrated

93

Creep speed option is not yet configured

94

Mast potentiometer is not calibrated

95

Speed reduction is active (pin X1:21)

96

Incorrect data collector setting in the PathFinder

97

Incorrectly calibrated tiller potentiometer Internal error: traction potentiometer calibration procedure was not performed on safety controller Internal error: mast potentiometer calibration procedures has not been performed yet on safety controller

86

98 99

103

Warning Signals of optical load sensor 1 of mast forks are not compatible when manual mode is selected Signals of optical load sensor 2 of mast forks are not compatible when manual mode is selected Start button signal is active for more than 10 seconds while automatic lifting mode is selected

110

Error detected in brake control and/or brake setting is defective

111

Brake coil resistance is too low

101 102

11528012006 EN - 07/2017

02-47

02

Diagnostics

Error codes Warning 112

Brake coil resistance is too high

113 115

Brake current is too low Truck is in wheel change mode

116

Mast potentiometer is actuated and signals of load sensors (optical) are incompatible

117

Battery mode reduced because the current consumption is too high

120

Pre-charging via controller failed

127

The driving potentiometer is turned whereas the tiller still in rest position

131 140

Internal control error: see additional active errors Accelerator sum voltage exceeds tolerance

201

Faults Supply voltage too high at X1:26 > 5.1V instead of 4.3V

202

Supply voltage too low at X1:26 < 3.5V instead of 4.3V

203

Tiller switch signals (X1:36 and X1:38) are incompatible or wrong tiller type is selected

204

Creep switch signals (X1:34 and X1:35) are incompatible

205

Lifting height is above 1500 mm and below 300 mm at the same time

206

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

207

Truck speed is too high

208

Interference of speed sensor signals (inputs X1:08 and X1:22)

209

Digital inputs switch with unrealistically high frequency

210

Internal controller error

211

Internal controller error

212

Internal controller error

213

Internal controller error Driver voltage is too low (< 10 V)

218

221

Internal controller error. Entry "Production test PASSED" is missing in EEPROM Input X1:10 (analog belly signal) out of admissible range (> 20% of supply voltage AND < 80% of supply voltage).

Voltage difference is at least 0.5 V between pins :26 and :9

222

Signal at 1X1:10 is incompatible

224

Input X1:24 (accelerator) is out of admissible range

225

Input X1:39 (accelerator) is out of admissible range

226

Signal of accelerator are incompatible

227

Accelerator potentiometer voltage is too high

228

Accelerator potentiometer voltage is too low

230

No reduction of motor torque though required

231

234

No speed signal though torque is applied Speed reduction signals (X1:7 and X1:28) are incompatible (error only active with CO controller) Input X1:37 (signal of tiller potentiometer 1) is out of admissible range

235

Input X1:40 (signal of tiller potentiometer 1) is out of admissible range

237

Sum voltage at tiller base is too high

238

Sum voltage at tiller base is too low

240

Increased temperature in the controller

241

Temperature error in the controller

242

Temperature error in the controller

219 220

232

02-48

11528012006 EN - 07/2017

Diagnostics

02 Error codes

243

Faults Truck could not be switch into "wheel change mode"

244

Discharging of power module capacitors at start-up failed

245

Motor temperature is too high

246

Motor temperature error

247

Motor temperature error

248

Error when using wheel change mode

251

Internal error control safety relay

252

Internal error control safety relay

253

Error control safety relay

254

Error control safety relay

260

Incorrect battery status. The battery is not ready for use

261

Error control main contactor

262 263

Error control main contactor Switching contact main contactor defective

264

Switching contact main contactor defective

265

Battery discharge current too high

266

Battery discharge current too high

267

Battery alarm The Lithium-Ion battery is selected in the base service of the truck, but the BMU answers via CAN to LAC 02 The lead battery or gel battery is selected in PathFinderbut the BMUCAN answers via to LAC 02 "Configuration error: creep speed switch (X1:34 or X1:35) is enabled, but this truck has no creep speed switch" Configuration error: speed reduction is enabled, but this input is not available. Depending on the truck type configuration, the following pins may be concerned: X1:06, X1:07, X1:20, X1:23, X1:28 Configuration error: cover monitoring is active, but there is no monitoring (X1:7 and/or X1:23) Configuration error: wrong selection in guided diagnosis. Instead of switch (X1:36, X1:38), potentiometer (X1:37, X1:40) was selected or vice versa.

Configuration error: speed reduction switch ( X1:23) is enabled, but this truck has no speed reduction switch With activated brake, the coil current is > 0.4A

268 269 271 272 273 274 275 281 283

With deactivated brake, the coil current is > 0.4A There is no brake coil current though voltage is applied (voltage > 3V; current < 0.4A)

284

There is brake coil current though voltage is applied (voltage > 3V; current < 0.4A)

285

Error during release of brake

286

Error during release of brake

290

Internal error: digital input signals are different in main and safety controller

291

295

Internal error: analog input battery voltage is different in main and safety controller Internal error: analog input signals for belly switch (X1:10) and/or butterfly switch (X1:24) and/or tiller base potentiometer (X1:37) are different in main and safety controller Internal error: analog input signal for brake (X1:31) and/or main contactor is different in main and safety controller Internal error: analogue input signal for capacitor voltage (UCAP) is different in the main controller and the safety controller Internal error: identified motor speed is different in main and safety controller

296

Internal error: main and safety controller identifies different signals for wheel change mode

282

292 293 294

11528012006 EN - 07/2017

02-49

02

Diagnostics

Error codes 297

Faults Internal error: analog input signals are different in main and safety controller

302

Current sensor error (current is too high)

303

Current sensor error (current is too low)

304

Current sensor error (current is too high)

305

Current sensor error (current is too low)

330

Driver circuits of power transistors show permanent error

340

The capacitor voltage is too high (>33V)

351

Phase U is interrupted

352

Phase U is interrupted

353

Phase U is interrupted

355

Signals of mast sensors (200 mm, 800 mm and 1500 mm) do not match

356

Mast sensor 1500 mm recognizes the forks. The sensors 200 mm and 800 mm do not.

357

Mast sensor 800 mm recognizes the forks. The sensor 200 mm does not.

358

Mast sensor 800 mm and 1500 mm recognize the forks. The sensor 200 mm does not.

359

365

Mast sensor 1500 mm recognizes the forks. The sensor 800 mm does not.

At same time forks up detected (X1:14 = open) and forks down / below 200 mm detected (X1:07 = GND and X1:23 = open) Troubleshooting procedure Put the connector wires 1X7 properly. The wires of the pin :2 and the pin :4 are reversed (Pin:2 = no wire and pin :4 = black wire) Automatic lifting/lowering is selected at same time (X1:20 = GND and X1:28 = GND) Signals of selector button for automatic mast lifting/lowering are not compatible: X1:6 = open and X1:20 = open and X1:28 = open Signals of load sensor 1 of forks are not compatible with selected automatic mast lifting.

X1:5 and X1:19 are both open or closed (GND).

Signals of load sensor 2 of forks are not compatible with selected automatic mast lifting.

X1:36 and X1:38 are both open or closed (GND).

Signals of forks at 200 mm are not compatible (X1:7 and X1:23 are both open or closed)

366

Voltage is applied to the proportional valve but there is no current.

367

Current measured in proportional valve but no voltage applied

368

Inconsistency

369

Inconsistency

370

Initial lifting/lowering inputs are simultaneously active

371

GND applied to X1:15 though no request exists

372

No GND applied to X1:15 though request exists

373

The lift motor voltage is more important than setpoint

374

The lift motor voltage is lower than setpoint

375

X1:3 is switched though no request exists

376

X1:3 is not switched though request exists

377

Over-current in power unit lifting

378

Voltage at lifting potentiometer (X1:11) is too low

379

Voltage at lifting potentiometer (X1:11) is too high

380

Configuration error: truck without mast, but mast potentiometer signal is active (X:11 > 0.5V)

381

Configuration error: truck without initial lifting button, but input signal is active (X1:4 < 3V) Configuration error: truck without initial lowering button, but initial lowering button is active (X1:18 < 3V)

360

361 362 363 364

382

02-50

11528012006 EN - 07/2017

Diagnostics

02 Error codes

383

Faults Mast potentiometer signals (X1:11 and X1:25) out of admissible range (<92.5% or >107.5%)

384

GND applied to switch-over valve (X1:16), though no request exists

385

GND not applied to switch-over valve (X1:16), though request exists

386

GND applied at the valve 2Y4 (X1:33) though no request exists

387

GND not applied at the valve 2Y4 (X1:33) though request exists

388

Configuration error: input signal is active (X1:5 < 3V), must, however, not be connected

389

395

Configuration error: input signal is active (X1:19 < 3V), must, however, not be connected Analog input signals for pump motor and/or mast potentiometer voltage are different in main and safety controller Analog input signals for proportional valve and/or black/white valve are different in main and safety controller The differential voltage to "digital valve 2" between the main processor and the safety processor is too high Analog input signals for proportional valve are different in main and safety controller Initial stroke not lifted (1X1:04= earth) and mast stroke not lowered/above 200 mm (1X1:07 = open and 1X1:23 = earth) Voltage at the lifting potentiometer (X1:25) is too low

396

Voltage at the lifting potentiometer (X1:25) is too high

399

402

Obsolete hydraulic parameter combination selected in diagnostics Self-test failed. Safety relay coil continues to be energized though safety controller requested switch-off Self-test failed. Contactor remains closed/welded whereas it is commanded by safety controller to open at power-up test Self-test failed. Cut-off test of digital valve 1 failed.

403

Self-test failed. Cut-off test of proportional valve failed.

390 391 392 393 394

400 401

404

Cut-off test of X1:16 failed

405

Cut-off test of brake failed.

406

Internal error Internal error: sensor supply voltage is out of admissible range (3.5 to 5.1mV) Unvalid truck ID or truck ID changes during operating time in the safety controller or lifting/lowering delay times out of range

407 408 410

Internal error

411 420

Internal error Different values of digital inputs of main and safety processor

421

Different values of analog battery voltage of main and safety processor

422

Analog input signals of main and safety processor deviate from each other

423

Analog input signals of main and safety processor deviate from each other

424

Analog input signals of main and safety processor deviate from each other

425

Analog input signals of main and safety processor deviate from each other

426

Analog input signals of main and safety processor deviate from each other

430

Positive torque setpoint, but negative slip.

431

Negative torque setpoint, but positive slip.

432

Low torque setpoint, but slip exceeds limit value

440

Calculated motor characteristics were fallen below

441 442

Calculated motor characteristics were exceeded Tiller is in rest position, but the brake is not applied

443

Tiller is in working position and belly switch is pressed, truck is not moving

11528012006 EN - 07/2017

02-51

02

Diagnostics

Error codes Faults 444

Stop requested but no deceleration

445

451

Stop requested but no deceleration There is a difference between voltage at power part of the LAC 02Band the voltage at the pump motor X1:3 is switched though no request exists

452

GND applied to X1:15 though request exists

453

Compatibility problems with sensor fork at 200 mm

455

Mast lifting is active though no request exists

456

Mast lowering is active though no request exists

457

Initial lifting is active though no request exists

458

Initial lowering is active though no request exists

450

.

02-52

11528012006 EN - 07/2017

Traction motor

11

a

Description Features of the traction motor

1 2 3 4 5

Rotor Grooved ball bearing 6204-2RS-C3 Lock ring 47x1.75 Lock ring 20x1.2 Parallel key A6x6x16

Asynchronous (AC) traction motor fitted vertically onto the transmission gear.

Electromagnetic parking brake fitted directly onto the end of the motor shaft.

Maintenance-free motor controlled by: • One rev sensor 1B2 (7) — Connector (7X6) and screw (8) (tightening torque: 9.5 Nm) • One 1B6 temperature sensor integrated into the stator windings (not removable) — Connector (7X6)

6 7 8 9

Guard plate (assembly) Rev sensor Screw EE-M8x20-St-A3B Rev sensor mounting clip

Technical features Operating voltage (V)

Three-phase asynchronous motor 24

Power rating (kW)

1.2

Amperage (A)

76

Nominal speed (rpm)

2720

Service rate Power supply frequency (Hz)

S2 - 60 mins*

Model

95

*: operation of the motor at full load for an hour followed by a rest of an hour.

11528012006 EN - 07/2017

11-1

11

Traction motor

Description Overview

1 2 3 4

11-2

Stator Rotor Roller bearing 6204 - 2RS2 Lock ring 47 X 1.17

5 6 7 8

Parallel key 6 X 6 X 16 Lock ring 20 X 1.2 Motor supply cable sleeves Inspection covers

11528012006 EN - 07/2017

Traction motor

11 Description

Power module connections

The power supply for the power module is provided by two main power lines (L+) and (L-).

The connections of the traction motor are connected to the LAC 1A1 power module (terminals U, V, W).

These connections are secured with a nut (tightening torque for hexagon nut: 9 Nm).

CAUTION The wiring nuts may be damaged if the tightening torque is too high.

When checking or tightening the nuts, a torque wrench with a suitable adjustment range (e.g. 1 - 20 Nm) should always be used. Torque wrenches with greater adjustment ranges are too imprecise and must not be used. The connecting nuts may be damaged if the tightening torque is above 17 Nm. Tightening by hand is not permitted due to the limited torque range (10–17 Nm).

11528012006 EN - 07/2017

11-3

11

Traction motor

Description Removing the traction motor – Disconnect the battery connector.

– Remove all the covers from the technical compartment (see chapter 30.2: Accessing the technical compartment).

– Disconnect the motor power cables (U), (V) and (W) on the LAC 02 controller (1) (tightening torque: 9 Nm).

– Disconnect connectors (1X3), (X6) and (7X6).

– Remove the cable ties.

– Unscrew the four mounting screws (2) from the tiller joint support.

– Uncouple the tiller assembly without disconnecting it (3).

– Unscrew the four screws (4) (tightening torque: 23 Nm).

– Unscrew the three mounting screws (5) from the motor (tightening torque: 23 Nm).

– Loosen the hexagon head screw (6) (tightening torque: 23 Nm).

– Remove the electromagnetic parking brake Y1 (see chapter 42.2: Removing the electromagnetic parking brake).

– Remove the hub (7).

WARNING Dangerous materials handling procedure. The motor is heavy.

Ensure that you: – Act with a sufficient degree of safety.

– Take care when removing the motor from the transmission gear.

The wearing of gloves is recommended.

– Remove the traction motor from above.

Installation: To fit the traction motor, proceed in the reverse order to removal.

Check the adjustment of the air gap of the electromagnetic brake Y1 (see operating instructions — chapter: Maintenance -> Steering/Wheels/Brakes).

CAUTION Risk of short circuit!

– It is important to tighten the three terminals (U), (V) and (W) of the traction motor power cables well (tightening torque: 9 Nm).

11-4

11528012006 EN - 07/2017

Traction motor

11

Sensors Rev sensor

The rev sensor is an external component that senses the direction of rotation and number of revolutions of the corresponding electric motor.

The sensor is dust-proof and splash-proof and is connected to the power modules 1A1 by a connecting cable.

The rev sensor (1B2) is located at the rear of the traction motor.

Removing the sensor – Disconnect the battery connector.

– Remove all the covers from the technical compartment (see chapter 31.1: Accessing the technical compartment).

– Disconnect the motor power cables (U), (V) and (W) (1) on the LAC 02 controller (tightening torque: 9 Nm).

– Disconnect the connector (7X6).

– Remove the cable ties.

– Unscrew the socket head screw (2).

11528012006 EN - 07/2017

11-5

11

Traction motor

Sensors – Remove the sensor (3) from the housing and check the connecting cable and O-ring.

Installation: To refit the sensor, proceed in the reverse order to the removal process.

CAUTION When replacing the sensor, check that the spare part number is correct.

Rev sensors from other trucks should not be used.

CAUTION Risk of short circuit and overheating.

It is important to tighten the three terminals U, V and W of the traction motor power cables well (tightening torque: 9 Nm).

NOTE

The rev sensor does not have to be adjusted on installation.

11-6

11528012006 EN - 07/2017

Traction motor

11 Sensors

Temperature sensor NOTE

The temperature sensor cannot be replaced. If this sensor is faulty, the complete traction motor must be changed.

Checking resistance – Check the resistance between pins 5 and 6 of the 7X6 connector.

T : °C

R : Ohm ( )

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 R : Ohm ( )

T : °C 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

160

1415,46

165

1463,85 11528012006 EN - 07/2017

11-7

11

Traction motor

Sensors 170

1492,62

175

1532,37

180

1572,50

185

1613,20

190

1654,49

195

1698,35

200

1738,80

.

11-8

11528012006 EN - 07/2017

Transmission

23

a

Drive unit Description of the drive unit

1 2 3 4 5

Electromagnetic parking brake Traction motor (1.2 kW) Transmission gear Washer Socket head screw M8x25-8.8-A2C (tightening torque: 23 Nm)

6 7 8 9 10 11

Spring washer B8-A2C Hexagon head screw M10x30-8.8-A2C Spring washer B10-A2C Connector 7X6 Cable grommet Mounting clip

1.2 kW asynchronous traction motor (2) fitted vertically to the transmission gear (3).

Turning is provided by the tiller.

Drive wheel driven by a transmission gear (3).

This mounting clip to hold the rev sensor cable is fitted on the following trucks: EXU type From W40153C01473 EXU-H type From W40161E04847 EXD type From NC* *: Not Communicated

11528012006 EN - 07/2017

23-1

23

Transmission

Drive unit Removing the drive unit – Disconnect the battery connector.

– Remove all the covers from the technical compartment (see chapter 30.1: Accessing the technical compartment).

– Disconnect the motor power cables (U), (V) and (W) on the LAC 02 controller (1) (tightening torque: 9 Nm).

– Disconnect connectors (1X3), (X6) and (7X6).

– Remove the cable ties.

– Unscrew the socket head screws (2) securing the tiller joint support (tightening torque: 17 Nm).

– Uncouple the tiller assembly (3) without disconnecting it.

– Unscrew the hexagon head screw (4) (tightening torque: 23 Nm).

– Fit a lifting eye bolt (5).

– Sling the motor.

– Unscrew the six screws (6).

– Sling the truck at least 70 cm from the ground and chock on trestles.

– Remove the nuts on the drive wheel (7).

– Remove the drive wheel.

WARNING Dangerous materials handling procedure. The drive unit is heavy. Proceed with caution when removing it from the chassis.

Wearing gloves is recommended.

– Remove the drive unit from below.

Installation: To refit the drive unit, proceed in the reverse order to removal.

CAUTION Risk of short circuit and overheating.

It is important to correctly tighten the three terminals U, V and W of the traction motor power cables.

23-2

11528012006 EN - 07/2017

Transmission

23

Transmission gear Transmission gear

Drive wheel driven by a transmission gear.

Maintenance: There are two grease nipples on the transmission gear.

Technical data The type and serial number are indicated on a plate fitted to the transmission gear.

11528012006 EN - 07/2017

23-3

23

Transmission

Transmission gear Reducer unit

23-4

11528012006 EN - 07/2017

Transmission

23 Transmission gear

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

Sealing ring 35 x 62 x 7 Breather (fitted with loctite 603) Tapered roller bearing 30204 DIN 720 M8 x 25 mounting socket head screw of the reducer housing / turntable (tightening torque 23 Nm) Stop ring Helical teeth wheel ( z=96) Bevel pinion shaft Tapered roller bearing 30303 DIN 720 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

11528012006 EN - 07/2017

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 32010 DIN 720 Guide pin M8 x 25 mounting socket head screw of the reducer housing / turntable (tightening torque 23 Nm) Turntable (Note: permanently lubricated) M10 chassis mounting tapped holes Stop ring Traction motor bearing casing 6007 DIN 625 Thread protection ring

23-5

23

Transmission

Transmission gear Removing the transmission gear Equipment required • A power screwdriver and a size 17 bit • A power screwdriver and a size 8 bit • A jack • A wooden wedge – Remove the traction motor (see chapter 11: Removing the traction motor).

– Use a power screwdriver with a size 17 bit to loosen the nuts on the drive wheel (1) without removing them (tightening torque: 80 Nm).

– Remove the drive wheel.

– Fit a plug in the motor bearing lipped ring (2).

23-6

11528012006 EN - 07/2017

Transmission

23 Transmission gear

– Use a power screwdriver with a size 8 bit to unscrew the six screws securing the transmission gear to the chassis (3) (tightening torque: 46 Nm).

– Lift the fixed chassis to approximately 20 cm off the ground using a jack (4).

– Chock the truck using wooden wedges (5).

WARNING Dangerous materials handling procedure.

The transmission gear is heavy. Be careful when removing it from the chassis. Wearing gloves is recommended.

– Carefully remove the transmission gear from below – Drain the transmission gear (see chapter 23: Draining the transmission gear).

Refitting: To fit the transmission gear on the chassis, proceed in reverse order to removal.

– Lubricate the bearing of the transmission gear.

11528012006 EN - 07/2017

23-7

23

Transmission

Transmission gear – Refill the transmission gear with oil of the recommended quality (SAE 85W90, API GL4).

NOTE

The maximum oil level corresponds to half way up the pinion gear (6). The minimum oil level corresponds to 2 mm above the bottom of the pinion gear.

The drive wheel is located on the right (7) and the transmission gear is on the left (8) of the chassis.

23-8

11528012006 EN - 07/2017

Transmission

23 Transmission gear

Changing the transmission gear seals Removing the wheel shaft sealing ring – Remove the transmission gear (see chapter 23.2 : Removing the transmission gear).

– Position and tighten the transmission gear housing (1) in the vice – Remove the protective cap from the screw (2).

– Unscrew the wheel shaft screw (3) (tightening torque : 195 Nm).

– Unscrew the wheel shaft screw (13) – Remove the thread protection ring (4) NOTE

With the ring resting against 1 screwdriver, tap the end of the wheel shaft with a hammer to uncouple it.

– Remove the wheel axle sealing ring (5) using a screwdriver – Remove the wheel shaft (6) – Drain and clean the transmission gear (7).

– Clean and check the mating face of the seal.

Refitting : NOTE

Before fitting the transmission gear, ensure that the housing is completely clean.

– Fit the wheel shaft in the housing – Screw in and tighten the wheel shaft screw (tightening torque : 195 Nm).

– Fit a new sealing ring (8) on the housing – Position the sealing ring 7 mm from the edge of the transmission gear housing (9) NOTE

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

11528012006 EN - 07/2017

23-9

23

Transmission

Transmission gear 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 – Fit a new protective cap on the wheel shaft screw.

Removing the sealing ring of the traction motor bearing – Remove the sealing ring (10) using a screwdriver

Refitting : – Clean the ring holding fixture – Fit a new sealing ring in place of the old one.

23-10

11528012006 EN - 07/2017

Transmission

23 Transmission gear

Draining the transmission gear The transmission gear should be drained every 6000 hours or at least every 3 years.

NOTE

For this operation, plan for the removal of the transmission gear and the replacement of its seals (see chapter 23.2 : Transmission gear).

– Follow the same procedure as for the replacement of the sealing ring of the wheel hub (see chapter 23.2 : Changing the transmission gear seals).

Refilling the transmission gear Reminder of the transmission gear oil quality: SAE 80 W90, API compatible GL4.

– Refill the transmission gear via the motor bearing orifice – Top up the oil level as shown opposite NOTE

The maximum oil level corresponds to mid-height on the pinion gear (6). The minimum oil level corresponds to 2 mm above the bottom of the pinion gear (6).

CAUTION Risk of transferring oil into the motor.

Do not exceed the indicated oil level.

11528012006 EN - 07/2017

23-11

23

Transmission

Transmission gear

23-12

11528012006 EN - 07/2017

Truck structure

30

a

Covers Access to the technical compartment

1 2 3 4 5 6

7 8 9 10 11

Front cover Left motor cover Right motor cover Battery cover Intermediate cover Lower cover

Sheet metal over-chassis Hc M10x25 pan head screw, quantity: 4 Hc M10x25 pan head screw, quantity: 2 Hc M10x35 pan head screw, quantity: 4 Motor cover fastenings

CAUTION Risk of short circuit.

Turn off and disconnect the battery connector for all operations involving the covers.

11528012006 EN - 07/2017

30-1

30

Truck structure

Covers Removing the lower cover – Remove the 4 screws (10) – Take off the lower cover (6) Installation: – To refit the lower cover, proceed in the reverse order to removal

Removing the front cover NOTE

To facilitate fitting and removal of the front cover and where possible, it is preferable to lift the load arms to their maximum height.

– Remove the 4 screws (8) – Remove the front cover from the top Installation: – To refit the front cover, proceed in the reverse order to removal

Removing the intermediate cover – Unscrew the 2 screws (9) – Remove the intermediate protective cover (5) Installation: – To refit the front cover, proceed in the reverse order to removal

30-2

11528012006 EN - 07/2017

Truck structure

30 Covers

Removing the protective covers from the motor and tiller joint The protective cover of the traction motor and tiller joint is made up of 2 sections (2) and (3): – Unscrew the 4 assembly screws (11)

– Unscrew the 2 cutting screws (12)

– Separate the 2 protective covers (2)and (3).

11528012006 EN - 07/2017

30-3

30

Truck structure

Covers Removing the sheet metal over-chassis The sheet metal over-chassis (7) is attached to the fixed chassis by 4 Hc M10X20 screws (13) and (14)

– Unscrew the 2 horizontal fixing screws (13)

– Unscrew the 2 vertical fixing screws (14)

30-4

11528012006 EN - 07/2017

Truck structure

30

Driver's platform (option) Overview

1 2 3 4 5 6 7

Mat Bottom plate Shock absorber pad Pin — Ø 6X40 Platform support assembly Platform bolt Spacer — 7 mm

8 9 10 11

Ring — 25x28x25 M8x25-A2R-8.8 button head screw or M8x2510.9-PHR socket head screw (with Loctite threadlock) Platform assembly Guard plate

The platform (standard version and cold store version) is made up of: • A shock-absorbing floor (11) with a touchsensitive mat (1) to detect the presence of the operator • A 1500-N gas spring

11528012006 EN - 07/2017

30-5

30

Truck structure

Driver's platform (option) Removing the platform

WARNING Dangerous materials handling procedure.

The platform is heavy, handle it with care. Wearing gloves is recommended.

Changing the gas spring – Unscrew the four mounting screws (1) from the gas spring guard plate (2).

30-6

11528012006 EN - 07/2017

Truck structure

30 Driver's platform (option)

– Remove the guard plate – Unscrew the 2 nuts (4) – Remove the cylinder (3) Installation: – To refit the gas spring, carry out the steps for removal in the reverse order.

Removing the platform – Chock the platform as shown.

– Unscrew the four mounting screws (5) of the platform.

11528012006 EN - 07/2017

30-7

30

Truck structure

Driver's platform (option) – Remove the platform from the chassis.

Installation: – To refit the platform, carry out the steps for removal in the reverse order.

NOTE

The tightening torque for the four mounting screws (5) is 7 Nm (± 10%).

30-8

11528012006 EN - 07/2017

Truck structure

30

Battery compartment Types of compartment

A: Vertical access battery

B: Side access battery

For standard batteries fitted in standard compartments, the battery capacity can be up to 250 Ah

For batteries fitted in standard compartments that are equipped with attachment points, the battery capacity can be up to 250 Ah For lithium-ion batteries fitted in special compartments that are equipped with attachment points, the battery capacity can be up to 410 Ah

Battery

Vertical battery compartment

Width (mm)

Height (mm)

Side battery compartment

Width (mm)

Height (mm)

2 PzS-B*

150 Ah

158

595

[-]

[-]

[-]

2 PzS

230/250 Ah Vertical battery compartment

198

627

198

627

Width (mm)

Height (mm)

Width (mm)

Height (mm)

[-]

[-]

230/250 Ah Side battery compartment 83 Ah/166 Ah 205 Ah/410 Ah

198

627

Li-ion** battery 2 PzS

[-]

*: fitted in special compartments **: only for EXU-H 20 and EXU-H 20S

11528012006 EN - 07/2017

30-9

30

Truck structure

Battery compartment Battery lock

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

30-10

Lever (general) Nut H M6-8-A2C Spring washer Plate 6x15x132 Pin Washer Button head screw M10x16-10.9-A2R Plate Slotted spring pin Nut H M8-04-A2C Spring element Spring washer

13 14 15 16 17 18 19 20 21 22 23 24

Socket head screw M6x25-8.8-A2C Spacer Sheet metal holder Assembly support Pin Pin Pin Button head screw M6x10-10.9-ULF-A2R Left-hand assembly stop Roller assembly Pin Cylindrical roller support

11528012006 EN - 07/2017

Steering, braking and wheels

42

a

Tiller General The head of the tiller is made up of a moulded housing (1) containing an electronic plate (2), five control buttons (raising/lowering of the forks, horn, raising/lowering of the load arms, two throttles for traction, a safety micro switch button (12) and three mounting flanges (4), (5) and (6).

If the tiller head is faulty, the complete plate unit must be replaced.

When the throttles are activated, they are connected to a potentiometer which varies the setpoint 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.

The communication between the tiller head and controller is "serial".

Layout of the different components of the tiller head • 1: Safety micro-switch • 2: Traction control • 3: Horn • 4: Raising of the forks • 5: Lowering of the forks • 6: Raising of the load arms • 7: Lowering of the load arms • 8: Month and year of manufacture

11528012006 EN - 07/2017

42-1

42

Steering, braking and wheels

Tiller 1B7 tiller foot potentiometer The tiller is composed of a tiller joint attached to the traction motor, a gas spring and a tiller foot potentiometer (1B7).

The tiller foot potentiometer authorises movement of the truck and lowering of the forks.

The traction speed of the truck varies depending on the tilt of the tiller.

The voltage is read at the potentiometer output.

The tiller foot potentiometer is connected using the connector (X6).

Assignment of connector X6: Pins X6: 3 X6: 4 X6: 5 X6: 6

Function 0 V supply

Wire colour

+5 V supply Tiller foot setting no. 1 Tiller foot setting no. 2

Yellow

White Blue

Tilt zones for the tiller: Zone 1: Linear increase in speed Zone 2: Maximum speed of the truck Zone 3: Reduction in speed X6 Tiller foot setting connector 1B7 Tiller foot potentiometer

Green

NOTE

For trucks with folding platforms, the Optispeed function is disabled.

Checking the 1B7 potentiometer – Connect the diagnostics PC to 6X7.

F4:Screen ▼

Traction ▼

Tiller feet ▼

1X1:37 Voltage 1 1X1:40 Voltage 2 1B7 potentiometer expected values — Tiller in the vertical position: • 1X1:37 ► 3.5 V • 1X1:40 ► 0.7 V NOTE

Regardless of the position of the tiller, the sum of the voltages "1X1:37" + "1X1:40" is 4.2 V.

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42 Tiller

Setting the tiller acceleration For standard trucks, it is possible to set the slope (by %) of the acceleration and deceleration gradient.

– Connect the diagnostics PC to 6X7.

– To set the slope of the acceleration gradient, go to the following menu:

F3:Setup ▼

Function ▼

On ▼

Tiller foot potentiometer – Use the < , << and > , >> keys to define a value of 0% to 30%.

– Press ENTER to confirm.

Calibrating the 1B7 potentiometer After changing the tiller foot potentiometer, proceed with calibration: – Connect the diagnostics PC to 6X7.

– To calibrate the tiller foot potentiometer, go to the following menu:

F2:Diagnostics ▼

Diagnostic start points ▼

Controller configuration Truck TypeWith potentiometer – Follow the instructions on the display.

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Steering, braking and wheels

Tiller "Cold store" resistors"" "Cold store" trucks have p. c. boards (1) with special resistors for the cold store duty. These resistors are supplied with power via connector (2).

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42 Tiller

Removing the tiller head Removing the printed circuit board – Remove the battery plug.

– Dismantle the two halves (1) and (2) of the flange by inserting a flat-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 flange are attached to each other.

– Remove the upper half (1) of the flange.

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Steering, braking and wheels

Tiller – Remove the 2 socket head screws (3).

– Remove the flange (4).

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

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42 Tiller

– 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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42

Steering, braking and wheels

Tiller Removing the tiller arm – Unscrew the two screws (8).

– The tiller head is now removed.

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

Removing the throttles – Pull firmly outwards to remove the two throttles (9).

NOTE

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.

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

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42 Tiller

Gas damper Removal CAUTION 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 flange by inserting a flat-head screwdriver into the notch located between the two halves (see chapter "Removing the tiller head").

– Remove the upper half (1) of the flange.

– 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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Steering, braking and wheels

Tiller – 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 difficult to put back in place).

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

– Then remove the bottom part of the damper.

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Steering, braking and wheels

42 Tiller

Reassembly 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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Steering, braking and wheels

Tiller Removing the tiller arm 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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42

Electromagnetic brake Electromagnetic parking brake Y1

1 2 3 4 5

Electromagnetic brake Y1 Friction disc / traction motor rotor coupling Friction disc Brake flange Electromagnetic brake mounting screw on the traction motor (tightening torque: 5.5 Nm)

6 7 e

Air gap adjustment banjo bolt (quantity 3) Brake spring (quantity 9) ensuring the mechanical braking torque Air gap e = 0.2 mm (+0.1/-0.05)

The truck is equipped with an electromagnetic parking brake The brake is applied when it is no longer powered.

The safety brake is applied automatically when at least one of the following conditions is met: • The drive direction selector is in the neutral position and the truck is stationary • The tiller is in the upper end position (vertical tiller) or in lower end position (horizontal tiller) • When the speed of the truck is too high (speed ≥ 8 km/h: error 207).

Characteristics Nominal brake torque

12 Nm

Supply voltage

24 V

Power Braking resistance (between 7X6:9 and 7X6:10)

25 W 16 (±1)

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Steering, braking and wheels

Electromagnetic brake Adjusting the air gap The brake must be checked in the braked position, i.e. with the power supply cut.

Check the air gap on the brake using a set of wheel chocks.

The value of the original air gap is 0.20 mm (+0.1/-0.05) and the maximum air gap after partial wear of the disc is 0.6 mm. Above this value, there is a risk of not being able to release the brake fully and a risk of overheating.

If the air gap is close to the limit value of 0.6 mm, it must be adjusted: – Unfasten the three fixing screws (7) – Adjust the three banjo bolts (6) to set the air gap to its original value of 0.20 mm.

– Retighten the three fixing screws (7) – Check the air gap at three points at 120° intervals.

– Make sure that the air gap is equal right around the brake.

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42

Stabilisers Stabilisers (standard)

A: Previous version B: New version 1 Stabiliser clevis 2 M27X1.5 tightening locknut (36 mm spanner) 3 Special ball bearing ∅ 80x21 2RS (36 mm flat spanner) 4 Locking rings DIN 472 80x2.5 5 125x40 stabiliser wheel 6 Thread guard 7 M14x75 calibrated pin 8 H ISO 4014 M12x80 screw 9 Support washer 10 Damper 11 H ISO 7040 M12x80 head nut 12 Spacer 13 Bearing shield 14 H M14 head nut

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Support wheel (unit) Hexagon nut M27x1.5 Bush Locking ring 80x2.5 Swivel fork Fork part Spacer Hexagon head screw M12x100-8.8-A2C Nut H M12-8-A2C Washer Spring element Stop (stop screw) Nut H M8-8-A2C Wheel Thread guard Spacer Nut H M12-8-A2C Lubricating nipple

Features: "Red" stabiliser Hardness of the buffers Preload (daN)

88° Shore A

Dimension: Bearing (mm)

203.5 ±0.7 x

35 ±5

Non-greased version (standard) Greased version (option)

x

.

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Steering, braking and wheels

Stabilisers Stabilisers (option)

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

Swivel fork Rocker arm Cylinder Spring (stiffness: 12.9 N/mm) Spacer 18x4x10 Safety ring DIN 471-AS 12x1,5 Spacer 18x3x4 Bolt 12x51/10x14 Support washer Screw DIN 912-M12X80-8.8-A2F Spacer 20x3,5x53,5 Nut DIN 934-M12-8-A2F

13 14 15 16 17 18 19 20 21 22 23 24

Safety ring DIN 471-A 10x1 Bearing DIN 625-6307.2RS Safety ring DIN 472-80x2,5 Safety ring DIN 471-AS 35x2,5 Sliding bearing 30x21/23x1,5-20 Spacer 15x2x4 Screw DIN 912-M10x75-8.8-A2F Nut DIN 934-M10-8-A2F, Bi-Loc Wheel ALTH 125/15K-761772 Thread guard Spacer 20x17/15x3,5-10 Screw M10x85-8.8-A2F

CAUTION Forbidden on 1152 type trucks with a BS or lithium-ion battery.

These stabilisers, requiring no adjustment and almost no maintenance, are equipped with: • 2 hydraulic cylinders (3) whose function is to limit • 2 springs (4) allowing the wheels to follow the profile of the ground and ensure the wheels are in swaying and the effects of "pumping" caused by uneven ground and the reaction of the springs. permanent contact with it.

Features: Cylinder

Spring

Stabilisers

Input force of the rod (N)

2000

Output force of the rod (N)

120

Steepness (N/mm)

12.9

Da (mm)

40

d (mm)

5

Lo (mm)

120

Hardness of the buffers

.

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92° ±3 Shore A

Steering, braking and wheels

42 Stabilisers

Adjusting the height of the stabiliser wheel PLEASE NOTE: • Lower the stabiliser wheel if a more stable unit is required.

• Raise the stabiliser wheel if the truck often negotiates obstacles and if maximum grip is required To adjust the height of the stabiliser wheel, follow these instructions: – Loosen the locknut (2) (36 mm spanner) while holding the ball bearing (3) by its flat surface (36 mm spanner).

– Tighten the clevis (1) using a 14 mm Allen key to lower the wheel or: – Loosen the clevis (1) using a 14 mm Allen key to lift the wheel.

– After adjustment, lock the clevis (1) with the locknut (2) tightened to a torque of 100 (+20) Nm. NOTE

To tighten, loosen or lock the clevis (1) always hold the ball bearing (3) by its flat surface (36 mm spanner) during the procedure.

Removing a stabiliser WARNING The stabilisers are heavy Use materials handling gloves to extract them from the chassis.

To partially or completely remove a stabiliser, follow these instructions: – Raise and secure the truck.

– Remove the lock nut (2) (36 spanner) – Tighten the clevis (1) using a 14 mm Allen key until the stabiliser wheel is extracted from the bottom.

– Remove the retaining circlips (4) from the bearing – Remove the bearing (3) from the bottom.

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Steering, braking and wheels

Wheels Description of the wheels

A B C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

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Drive wheel Stabiliser wheels Load wheels (bogies) Wheel Nut (tightening torque: 80 Nm) Transmission gear Hexagon nut M27x1.5 Bush Locking ring Fork part Fork part Spacer Hexagon head screw M12x100-8.8-A2C Nut H M12-8-A2C Washer Spring element Stop (screw) Hexagon nut M8-8-A2C Wheel Thread guard

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Spacer Nut H M12-8-A2C Lubricating nipple Pin Roller assembly wheel Bush 20x23x15 Wheel DX bogie assembly Bearing bush 20x23x25-DX Bearing bush 25W28x15-S2-LN1 Washer Lubricating nipple (cone) AM6 Pin Slotted spring pin 6x36-A-ST Hexagon head screw M12x20-8.8-A2C Washer Slotted spring pin 4x12-St-DAC Rocker arm bearing flange Washer

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42 Wheels

Types of drive wheel

A B C

Polyurethane Notched polyurethane Non-marking

D E F

Slippery floors Greythane Notched Greythane

Applications for the main types of drive wheel: Wheel types Polyurethane

Advantages

Disadvantages

Best solution for standard applications Less abrasive wear

Traction not as good as a Greythane wheel

Suitable for extremely wet ground Notched polyurethane surfaces (sheets of water) More robust than a Greythane wheel

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Traction not as good as a Greythane wheel In the dairy shops, the tyre may come loose

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Steering, braking and wheels

Wheels

Non-marking

Slippery floors

More traction than a polyurethane wheel Anti-static Non-marking Recommended for damp ground surfaces Less abrasive wear More robust than a Greythane wheel

.

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More abrasive wear than a polyurethane wheel Traction not as good as a Greythane wheel

Steering, braking and wheels

42 Wheels

Types of stabiliser wheels

A B 1

Wheels compatible with standard stabilisers Wheels compatible with greased stabilisers (option) Lubricating nipple (option)

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Steering, braking and wheels

Wheels Types of load wheel

1 A B

Lubricating nipple Single wheel Single wheel with lubricating nipples (option)

C D E

Bogies Bogies with lubricating nipples (option) Piek with attachments A, B, C or D

The Piek wheels are used for anti-noise trucks.

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42 Wheels

Removing the drive wheel

1 2

Drive wheel ∅ 230 x 75 mm Wheel nut DIN 74361 A12-10-A2C (quantity 5)

– Remove the 5 wheel nuts (2)

WARNING Dangerous materials handling procedure. The drive wheel is heavy, proceed with care when replacing it.

The wearing of gloves is recommended.

– Remove the drive wheel and release it via the lower side of the battery compartment.

Installation:

– Fully lift the load arms.

– Remove the sheet metal over-chassis (see Chapter 30: Accessing the technical compartment).

To fit the drive wheel, carry out these instructions in reverse order.

NOTE

– Direct the drive wheel using the tiller to gain access to the wheel nuts (2).

The tightening torque for the wheel nuts (2) is 80 Nm.

– Loosen the wheel nuts by moving the spanner under the bumper.

Note: after replacing the drive wheel, the height of the stabiliser wheels should be adjusted in order to improve the traction of the truck.

– Chock the truck a few centimetres from the ground

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Steering, braking and wheels

Wheels Removing the stabiliser wheels

Equipment required

– Remove the screw and the nut.

• A jack

– Press out the wheel (4).

• A wooden wedge • A size 19 open-ended spanner

Refitting

• A ratchet handle and size 19 socket

To fit the stabiliser wheels, proceed in the reverse order to removal.

• A torque wrench and size 19 fitting – Fully lift the load arms.

– Disconnect the battery connector.

If the wheel does not interlock directly with the stabiliser (5):

– Raise the truck chassis a few centimetres either using a jack or by slinging it (1).

– Slightly loosen the screw and the nut at the rear of the stabiliser (6).

– Chock the truck using wooden wedges (2) so that the wheels do not touch the ground.

– Refit the wheel.

– On one side, hold the nut in place using a size 19 open-ended spanner.

– On the other side, unscrew the screw using a ratchet handle with a size 19 socket (3) (tightening torque: 60 Nm).

42-24

– Retighten the screw at the rear of the stabiliser using the torque wrench and size 19 fitting.

Retighten the nut using the size 19 openended spanner (tightening torque: 60 Nm).

– Proceed in the reverse order to removal.

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42 Wheels

Removing the load arm components Equipment required

• A ratchet tool holder with an 8 mm socket

• A jack

• A pin punch

• Wooden wedges

• A hammer

• A block of wood

Removing the load wheels

– Carry out the initial lift operation (fully lift the load arms).

– Disconnect the battery connector.

– Raise the truck a few centimetres using a jack or sling the truck, so that the wheels do not touch the ground.

– Place wooden wedges under the load arms (1).

– For a single wheel assembly, use a ratchet tool holder with an 8 mm socket to remove the screw (tightening torque: 50 Nm).

– For a bogie assembly, use a ratchet tool holder with an 8 mm socket to remove the two screws (2) (tightening torque: 50 Nm).

– Remove the load roller(s).

Refitting the load wheels To fit the load wheels, proceed in the reverse order to removal.

NOTE

If the pattern of screw heads is damaged, refit using new screws.

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Steering, braking and wheels

Wheels Removing the fork clevis

– Carry out the main lift operation (fully raise the forks).

– Carry out the initial lift operation (fully lift the load arms).

– Insert a block of wood between the forks and the load arms (1).

– Disconnect the battery connector.

– Raise the truck a few centimetres using a jack or sling the truck, so that the wheels do not touch the ground.

– Place wooden wedges under the load arms.

– Use a pin punch and a hammer to remove the central pin from the push rod (3).

NOTE

The lift shaft and the flat iron keep the push rod in place. This prevents the pin withdrawing from the fork clevis.

– Use a pin punch and a hammer to remove the pin from the lift shaft (4).

– Use a pin punch and a hammer to remove the pin from the lift shaft (5).

– Use a pin punch and a hammer to remove the pin from the bogie pivot shaft pin (2).

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42 Wheels

– Use a pin punch and a hammer to remove the pivot pin, the spacer and the bearing bush (6).

– Remove the load wheels (described previously).

– Lift the push rod off the load arm (7).

– Pull out the bearing flange and the spacer (10) to change the fork clevis.

– Use a pin punch and a hammer to remove the push rod pin from the fork clevis (8).

– Remove the assembly (fork clevis and wheels) (9).

Refitting the fork clevis To fit the fork clevis, proceed in the reverse order to removal.

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Steering, braking and wheels

Wheels

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Electrical/electronic equipment

60

a

Safety Safety guidelines for electrical equipment CAUTION Damage to electrical components due to working on live parts.

Before any work on electrical equipment, always: – Pull the emergency stop handle – Unplug the battery connector – Wait until the intermediate circuit capacitors have been discharged.

Only when the battery plug has been disconnected and the capacitors in the power modules have been discharged may plugs be disconnected and electrical components removed.

To check that the capacitors have been discharged, measure the capacitor voltage across terminals 1 and 2 of the power module.

When this voltage is less than 5 V, the capacitors are discharged.

CAUTION The sealing elements may be damaged when the operating unit is opened.

On no account open the control module.

In addition, check that the diaphragm on the front of the operating unit is not damaged.

Opening it may invalidate the warranty.

CAUTION Operating units can be damaged by electrostatic discharge.

Do not touch the connections at the plug. Some spare operating units are supplied with a protective cover over the plug for protection against electrostatic discharge. When transporting the operating unit, this cover must be put back in place.

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Electrical/electronic equipment

Safety Cleaning the electrical system The components of the electrical system can be cleaned thoroughly on the outside. The best medium for cleaning is oil-free compressed air. If the components are very strongly contaminated on the outside, a high-pressure cleaner can be used for cleaning. Only water may be used for this. Under no circumstances should chemical cleaning additives be added when using a highpressure cleaner. Chemical cleaning additives may attack the plastic parts of the electrical components.

CAUTION Moisture must not enter the electrical components.

When cleaning with a high-pressure cleaner, a sufficient distance must be observed between the jet lance and the component, particularly the connector plug.

However, if moisture does enter the components, they must be dried by heating (hot air blower, heating system) to prevent corrosion damage.

60-2

CAUTION Electrical components can be destroyed by overtemperature.

Observe the maximum temperature when using a hot air blower.

Electrical components can also be cleaned using an electric cleaner (e.g. S. L. X. electric cleaner – www.rivolta.de). These electric cleaning materials have a dielectric strength of up to 100,000 V/cm and are free from hydrocarbons such as CHCs, CFCs, aromatics, PCB/PCTs and other pollutants.

• PCB – polychlorinated biphenyls • PCT – polychlorinated terphenyls • CHCs – chlorinated hydrocarbons • CFCs – chlorofluorocarbons

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60 Safety

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Electrical/electronic equipment

Safety Insulation testing The purpose of this test is to ensure that the truck chassis is not connected to any potential.

– Measurement 1 from battery female connector + to chassis

This test limits the risk of an electrical fire (short circuit).

– Measurement 2 from battery female connector - to chassis

Insulation testing of the truck

General

50 V test voltage

For the truck to function correctly, the electrical system and the motor windings for the truck chassis must have sufficient insulation resistance.

NOTE

The emergency off switch must not be switched off during insulation testing. An unpainted, clean area must be selected as a reference measurement point on the chassis. Controllers and plug connectors do not have to be disconnected before the measurement.

The insulation resistance for the following measurements must be greater than or equal to 1 k /V (24 k for a 24 V battery).

– Ensure that the device is in the "50 V" position and the unit is in "MΩ" Measuring points: • Truck connector: between the + and the (emergency stop connector handle removed) • Test the + terminal of the truck connector and a threaded stud of the chassis • Test the - terminal of the truck connector and a threaded stud of the chassis

Insulation resistance must be tested in accordance with EN 1175-1 (DIN VDE 0117-1) using an approved and calibrated insulation measuring device.

The insulation resistance of the truck must be tested at regular intervals as part of the regular testing in accordance with FEM 4.004 (formerly the UVV accident prevention regulations).

Different regulations may apply in other countries.

CAUTION Electronic controls and components may be damaged if the test voltage of the insulation measuring device is too high.

The test voltage of the insulation measuring device used for the insulation testing of the truck and the traction battery must be set to 50 V.

CAUTION

• Test the + (red) terminal of the LAC controller and a threaded stud of the chassis

Hazardous voltages are present at the insulation measuring device terminals during testing.

• Test the - (blue) terminal of the LAC controller and a threaded stud of the chassis

Do not touch the insulation measuring device terminals during testing.

The insulation resistance of the truck, the traction battery and the motor windings must be tested individually.

Traction battery insulation resistance 50 V test voltage The insulation resistance of the disconnected, filled and charged battery must be greater than or equal to 50 Ω/V (1200 Ω for a 24 V battery).

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60 Safety

Electromagnetic compatibility Electromagnetic compatibility (EMC) is an essential quality feature for trucks (according to standard EN12895).

Different electrical measurements are taken to ensure the electromagnetic compatibility of the truck.

EMC involves: • Limiting the emission of electromagnetic interference to a level that ensures the undisturbed operation of other equipment in the same environment.

• Ensuring sufficient resistance to external electromagnetic interference.

NOTE

The truck is qualified as having EMC in an approved laboratory which ensures its compliance with legislation.

CAUTION

It ensures good truck function in the area of intended use and in the electromagnetic interference conditions expected.

The EMC regulations for the truck must be observed.

An EMC test measures the electromagnetic interference emitted by the truck and also checks that it has sufficient resistance towards external electromagnetic interference in relation to the area of intended use.

– Do not remove ferrites.

When replacing components on the truck, EMC protection components must be installed and connected again (example: ferrites).

– Position all the bundling in their original locations.

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Electrical/electronic equipment

General Functions of EXU-H trucks equipped with LAC 02

There are 2 versions: • EXU-H 18, EXU-H 20 with pedestrian mode • EXU-H 20S with pedestrian and ride-on mode Tiller in park position: • the truck is mechanically immobilised by the electromagnetic brake Y1 • no traction when the accelerator is activated • the hour meter only counts when an actuator is in operation (e.g.lift or traction motor).

• Lifting of load arms and auxiliary mast authorised • Lowering control on tiller authorised.

Tiller in operating position: • truck brake released when accelerator is activated • traction when accelerator is activated • 1B7 tiller accelerator (optional) active; • Lifting of load arms and auxiliary mast authorised at tiller • Lowering of load arms and auxiliary mast authorised • The hour meter only counts when an actuator is in operation (e.g. lift or traction motor).

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60 General

Characteristics • Speed limited to 6 km/h in both directions of travel • Parking brake applied automatically when: - The tiller is released in the park position - Emergency braking by hitting the tiller foot rubber stop - Truck stationary, direction reverser in neutral - Power off - There is a fault in the traction control • Counter-current and regenerative braking upon accelerator release and by reversing the direction of travel.

Safety features • 1S3 anti-crush safety device at the end of the tiller. Recirculation to the throttle valves.

• 7S5 auxiliary lift safety with automatic lifting/lowering fixture* (emergency stop switch) *: optional Lifting 2M1 lift motor power: • EXU-H: 1.2 kW The pump motor 2M1 is controlled by an integral power MOSFET in the control module 1A1 (LAC) On the EXU-H, the single pump supplies the Main Lift circuit or the Initial Lift circuit via a circuit selection hydraulic block controlled by 2 solenoid valves — 2Y4 (Initial Lift) and 2Y5 (Main Lift) Fork lifting • Switch 1K0 supplied; • Controlled by the potentiometer 2B4 on the tiller; • Selection of the Main Lift circuit by 2Y5 • Progression of the lifting movement depends on the pump rate and therefore on the 2M1 motor rotational speed; • Lifting stopped by releasing potentiometer throttle valve; • Upper fork position: cuts off lift with 2B3 inductive position sensor Lowering the forks: • Switch 1K0 supplied; • Controlled by the potentiometer 2B4 on the tiller; • Selection of the Main Lift circuit by 2Y5

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60

Electrical/electronic equipment

General • Progression of the lowering movement depends on the proportional opening of the solenoid valve 2Y2; • Lowering stopped by releasing potentiometer throttle valve; Raising the Initial Lift: • Switch 1K0 supplied; • Controlled by 2S7 on the tiller • Selection of the Initial Lift circuit by 2Y4 • Stop the Initial Lift by releasing the control button; • Safety: Initial Lift cut out by the fork in upper position gauge 1B4 to prevent maximum pressure being reached in the hydraulic system (IL cylinder at the top mechanical stop).

Lowering the load arms • Switch 1K0 supplied; • Controlled by 2S6 on the tiller • Selection of the Initial Lift circuit by 2Y4 • Stop lowering by releasing the control button; Default settings of the LAC 02 controller with min./max. interval: PARAMETERS

Standby times (min)

Activation of standby function (on/off)

Fork direction speed (km/h) Operator direction speed (km/h) Hare mode acceleration (m/s²) Hare mode deceleration (m/s²)

60-8

ADJUSTMENT INTERVAL

EXU-H 18/20

EXU-H 20S

Fault

5

5

Min

1

1

Max

5

5

Fault

Off

Off

Min

Off

Off

Max

On

On

Fault

6

6

Min

1

1

Max

6

6

Fault

6

6

Min

1

1

Max

6

6

Fault

2

2

Min

0.1

0.1

Max

3

3

Fault

2.5

2.5

Min

0.1

0.1

Max

3

3

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60 General

PARAMETERS Tortoise mode speed (km/h) Tortoise mode acceleration (m/s²) Tortoise mode deceleration (m/s²)

Anti-crush speed Button pressed (km/h) Operating time of anti-crushing function (s)

Braking torque by reversing the direction of travel (N) Braking torque throttle valve released (N)

Booster torque (N)

Angle of tiller for maximum speed (%)

Initial Lift: pump motor rotation speed (%)

Mast: lifting speed

Mast: lowering speed

Mast: lowering deceleration

ADJUSTMENT INTERVAL Fault

EXU-H 18/20

EXU-H 20S

4

4

Min

1

1

Max

6

6

Fault

2.5

2.5

Min

0.1

0.1

Max

3

3

Fault

2.5

2.5

Min

0.1

0.1

Max

3

3

Fault

4

4

Min

1

1

Max

4

4

Fault

6

6

Min

3

3

Max

10

10

Fault

3000

3000

Min

1000

1000

Max

4000

4000

Fault

2600

2600

Min

1000

1000

Max

4000

4000

Fault

900

900

Min

0

0

Max

900

900

Fault

7.5

7.5

Min

0

0

Max

50

50

Fault

100%

100%

Min

0%

0%

Max

100%

100%

Fault

1

1

Min

5

5

Max

1

1

Fault

3

3

Min

5

5

Max

1

1

Fault

1

1

Min

5

5

Max

1

1

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Electrical/electronic equipment

General PARAMETERS Mast: lifting acceleration

Mast: lifting deceleration

Mast: lowering acceleration

Hour meter setting (h)

ADJUSTMENT INTERVAL Fault

Next service (h)

Service reminder (h)

Battery type

5

1

1

Fault

1

1

Min

5

5

Max

1

1

Fault

1

1

Min

5

5

Max

1

1

Fault

0

0

Min

0

0

Max

99999.9

99999.9

60-10

Counts with traction or lift Counts with traction or lift

Min

Other modes

Other modes

Max

Continuous count

Continuous count

Fault

1000

1000

Min

0

0

Max

32767

32767

Fault

50

50

Min

0

0

Max

10000

10000

Fault

Pb

Pb

Min

Gel

Gel

Min Max

Indicator adjustment

1

5

Fault

Cut-off threshold (%)

1

Min

Max

Battery discharged

EXU-H 20S

Max

Fault Hour meter count mode

EXU-H 18/20

Pb Pb Lift cut-out "+" Without Lift cut-out "+" Without reducing traction speed reducing traction speed No lift cut-out "+" Traction No lift cut-out "+" Traction speed reduction speed reduction Lift cut-out "+" Traction Lift cut-out "+" Traction speed reduction speed reduction

Fault

0

0

Min

0

0

Max

40

40

Fault

0

0

Min

-10

-10

Max

10

10

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60 General

General

1 2 3 4 5 6 7 8 9

Battery female connector - X1 Diagnostic socket connector - 6X7 7.5A control circuit fuse - 1F3 125A power circuit fuse - 1F1 Line switch mechanism - 1K0 Traction and lift controller (LAC) - 1A1 Electromagnetic brake - Y1 Traction motor - 1M1 Tiller connectors assembly 1X3, motor temperature and speed sensor 7X6, tiller foot potentiometer X6, auxiliary lift options

10 11 12 13 14 15 16 17 18 19

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Circuit selection hydraulic block (Main Lift or Initial Lift) Proportional lowering solenoid valve - 2Y2 Pump unit - 2M1 Initial Lift circuit selection solenoid valve - 2Y4 Main Lift circuit selection solenoid valve (auxiliary mast) - 2Y5 Initial lift cylinder Location for on board battery charger - G2 Horn - 4H1 Key switch - S1 Hour meter, battery discharge indicator - 6P4

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Electrical/electronic equipment

General Electrical components mounting plate

Fixed on the chassis, the electrical plate (1) is fitted with: • The battery socket connector X1 (5) • The ignition key S1 (7) • The multifunction indicator 6P4 (6) • The diagnostic connector 6X7 (4) • The control fuse holder 1F3 (8) • The LFM Go digicode (option) S2 (3) • The fan 9M1 • The horn 4H1 (9) NOTE

Replacing one of these components requires the removal of the electrical plate (1).

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60 General

Removing the electrical plate CAUTION Risk of short circuit.

Before working on electrical components, always disconnect the battery connection. Do not remove or change components when the truck is switched on.

– Unscrew the 5 securing nuts(2) on the plate (1)

– Remove the plate from the chassis to access the components.

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General Fitting the electrical plate CAUTION Risk of crimping resulting in failure.

Place the wires and electric cables correctly in the guides designed for this purpose.

To fit the electrical plate on the chassis, proceed in the reverse order to removal.

NOTE

The tightening torque for the 5 M8 securing nuts (2) on the chassis plate is 9 Nm.

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60

Traction Traction and hydraulic controller - LAC 02/ 1A1

1 2 3 4 5

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

6 7 8

"-" negative power supply terminal for the power unit "-" negative power supply terminal for the various electrical equipment "1X1"control module connector

The LAC (Linde Asynchronous Control) 1A1 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 (1A1' on the diagram) uses two microprocessors (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 1X1 connector.

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Traction Functions of the "Inputs/Outputs" of the LAC 02

Measured/original value

1

Function Brake Y1 power supply

24V / +Ub LAC

2

LAC +24V power supply

24V / +Ub via S1 or LFM GO

4

2S7 Initial Lift control 0V signal

0V via 2S7

6

Forks upper end of travel cut-out

8

Speed sensor path A

0V / -Ub via 2S10 Variable signal 0V-6V / 1B2

9

Tiller anti-crush safety device power supply

+4.3V / LAC

10

Tiller anti-crush safety device in OFF position 0V / -Ub via 1S3 Tiller anti-crush safety device in ON position +4.3V via 1S3

1X1:

17

1B6 motor temperature signal Variable signal Internal stabilised voltage circuit +24V power 24V / +Ub via S1 or LFM GO supply Lowering solenoid valve 2Y2 0V / LAC 1K0 line switch negative 0V / LAC

18

2S6 Initial Lift lowering control 0V signal

22

27

Speed sensor path B 1B1 channel 1 accelerator potentiometer setting 1B1 accelerator potentiometer +4.3V power supply CAN high (traction)

28

Safety device connected to 0V

not-used

29

2Y2, 1K0 solenoid valve +24V power supply

24V / +Ub LAC

12 13 15

24 26

60-16

0V via 2S6 Variable signal 0V-6V / 1B2 _% / 1B1 +4.3V / LAC

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60 Traction

1X1: 30 31

Function Internal safety relay +24V power supply

Measured/original value 24V / +Ub via S1 or LFM GO 0V / LAC (brake release)

34

Y1 brake control Creep Speed 0V signal in OFF position

35

Creep Speed 0V signal in ON position

0V via 1S10

36

Tiller in work position 0V signal

37

Channel 1 1B7 tiller potentiometer setting

0V via 1S4 _% / 1B7

38

Tiller in park position 0V signal Channel 2 1B1 accelerator potentiometer setting Channel 2 1B7 tiller potentiometer setting 0V power supply of 1B1 accelerator potentiometer and of 1B7 tiller potentiometer CAN low (traction)

39 40 41 42

0V via 1S10

0V via 1S4 _% / 1B1 _% / 1B7 0V / -Ub via LAC power

.

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Electrical/electronic equipment

Traction Activation of the 1A1 controller

The activation procedure for the 1A1 controller is as follows: • 1) Connection of the X1 battery socket: +Ub (24V) on the 1K0 line switch (open) via the 1F1 power fuse; +Ub (24V) on the S1 key switch via the 1F3 control fuse; -Ub (0V) on all the electrical components via the "-" power terminal of the 1A1 controller.

• 2) Switch in "ON" position

A +4.3V internal voltage regulator supplies: ► the 1B1 accelerator potentiometer ► the 1S3 anti-crush button in 1X1:9 ► the 1B7 tiller accelerator potentiometer (optional) A +5V internal voltage regulator supplies the traction and hydraulic microprocessors • 4) Authorising traction and lift After the controller self test, safety relay closure

► 1A1 controller supply: +24V in 1X1:2, 1X1:13 and 1X1:30 0V on the internal control module via the power module ► +24V at the 1B2 speed sensor in 7X6: 1 ► +24V at the battery discharge indicator in 6X2: 2 ► +24V at the 6X7 diagnostic socket terminals

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• 3) 1A1 controller activated

• 5) Operational lift and traction power stage +24V in 1X1:1 and 1X1:29 1K0 line switch closure: ► +Ub (24V) on the"+" power terminal ► +Ub (24V) at the 2M1 lift motor terminals in D1

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60 Traction

Speed reductions Nominal speed:

EXU-H / EXU-H S

Fork direction

6 km/h

Tiller direction

6 km/h

Traction speed settings Speed reduction (km/h):

Description

1->6

Traction speed

1->6 0.5->1.5

Anti-crush button activated Creep Speed activated

1->6

Speed reduction sensor (1X1: 20). On UPA* trucks only

*: Customer options truck

Technical faults Speed reduction (km/h):

Description

1.8

The accelerator potentiometer 1B1 is not calibrated

1.8

Internal error Change of status (1 or 0) of an input (except butterfly valve 1B1) too fast (> 10Hz) The controller temperature signal is outside the tolerance range >80° The motor temperature signal is outside the tolerance range >130° The controller temperature signal is outside the tolerance range >70° and <80° The controller temperature signal is outside the tolerance range <50° or >200° The motor temperature signal is outside the tolerance range <50° or >200°

1.8 1.8 1.8 4.5 4.5 4.5 .

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Electrical/electronic equipment

Traction Creep Speed function (optional)

1S10

Creep Speed function pull switch

The Creep Speed function enables driving in both directions of travel in confined spaces with the tiller in the vertical position.

Creep Speed function, simply release the button and actuate it again.

Tiller in raised position when the Creep Speed button is pressed:

When the Creep Speed button is activated and the tiller is tilted from the high cut-off position to the work position:

• The truck release control is only possible when the 1B1 accelerator is actuated

• The Creep Speed function is automatically deactivated and

• The maximum speed in both directions of travel is limited by default to 1.5 km/h

• The truck speeds up slowly to reach the accelerator setpoint value

• The speed depends on the position of the accelerator throttle valves • The acceleration and the traction torque are limited • The Y1 brake is applied when the accelerator returns to the neutral position • The Y1 brake is applied when the 1S3 anticrush safety device is activated • Initial lift is possible but initial lowering is not possible

• Tiller direction: The Y1 brake is applied • Load arm direction: Speed reduction until the Creep Speed value is reached

Checking the Creep Speed button – Connect the CAN box to the 6X7 diagnostic connector – Connect the CAN box to the laptop connector

NOTE

The Creep Speed function is deactivated after 3 to 5 seconds (adjustment in the diagnostic tool) if the accelerator is not operated. To activate the

60-20

When the Creep Speed button is activated and the tiller is tilted from the work position to the high cut-off position:

– Start and diagnostic software and log in – Check the status of the Creep Speed button on the screen in the following menu:

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60 Traction

▼

– Connect the CAN box to the 6X7 diagnostic connector

Traction

– Connect the CAN box to the laptop connector

F4:Screen

▼

– Start and diagnostic software and log in

Traction Validation ▼

– To adjust the Creep Speed function, go to the following menu:

:35 Creep 1:34 Creep 2 F4:Screen Creep Speed function active: •

1 :35 Creep 1

•

0 :34 Creep 2

▼

Traction ▼

Speed settings

Creep Speed function deactivated: •

0 :35 Creep 1

▼

•

1 :34 Creep 2

Creep Speed – Use the < , << and > , >> keys to specify a speed from 0.5 km/h to 1.5 km/h.

Adjusting the Creep Speed When the function is active, the speed is limited by default to 1.5 km/h. However, it is possible to adjust this speed from 0.5 km/h to 1.5 km/h:

– Press ENTER to confirm.

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Electrical/electronic equipment

Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Location of connectors for the lithium-ion battery DANGER

CAUTION

Electrical danger

Safety regulations

Do not touch the lithium-ion battery when the battery is charging and do not wear rings or jewellery.

Use protection goggles and a mask with a protective visor.

CAUTION Safety regulations When carrying out work inside the battery, do not wear clothes with metal objects (belt, shirt buttons).

Connectors on the power plate

1

60-22

Power plate connector

2

Relay connector

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Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Connectors on the battery

3 4 5

Power box connector Module harness connector BMU connector

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Electrical/electronic equipment

Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) BMS Description

The BMS (Battery Monitoring System) is the computer for the lithium-ion battery.

It monitors and controls the status of the battery with the following functions:

It comprises the BMU (Battery Management Unit) and the SMU (Safety and Monitoring Unit) card.

• To supply the SMU card and the BMU (DC)

The Black Box is located inside the BMU , with important parameters such as SOC (State Of Charge) and SOH (State Of Health).

• To measure the current of the lithium-ion battery module

The Black Box records the various battery parameters and events.

• To communicate with the LAC controller via the CAN bus network

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• To receive data from the SMU card

• To calculate the data

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Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Inputs/outputs of the BMS connector

1 2

Nuts BMS (BMU+SMU)

3

SMU card The SMU (Safety and Monitoring Unit) card is located inside the BMS.

SMU connectors

If the SMU card is faulty, the entire BMS must be replaced.

This enables cell management (balancing, sending information such as end of charge, overheating, overloading, excessive discharge etc.).

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Electrical/electronic equipment

Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Replacing the BMS Removing

On the A1 battery: – Connect the diagnostic kit to the diagnostic connector (3).

– Download the Black Box program and the shunt parameters. Refer to the operating instructions for the diagnostic tool.

– Disconnect the diagnostic kit.

– Identify and disconnect the SMU(2) card connectors.

Push the release clip.

– Loosen the two M5 washer nuts (1) of the BMS(4).

On the A2 battery: – Connect the diagnostic kit to the diagnostic connector (4).

– Download the Black Box program and the shunt parameters. Refer to the operating instructions for the diagnostic tool.

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Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) – Disconnect the diagnostic kit.

– Identify and disconnect the SMU(3) card connectors.

Push the release clip.

– Loosen the four M5 washer nuts (1) of the BMS(2).

– Remove the BMS from the battery.

Replacing – Install the BMS in the battery.

A1 battery: Slide the BMS in the locking plate (tightening torque: 4 Nm).

A2 battery: Put the BMS on the steel plate (tightening torque: 4 Nm).

– Attach the BMS. A1 battery: Tighten the two M5 washer nuts (1).

A2 battery: Tighten the four M5 washer nuts (1).

– Connect the identified SMU connectors.

Push the release clip.

– Connect the diagnostic kit to the diagnostic connector.

Follow the procedure in the operating instructions for the diagnostic tool to update the Black box of the old BMS in the new one.

– Disconnect the diagnostic tool.

– Fit the cover provided on the battery.

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Electrical/electronic equipment

Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Replacing the BMU harness

Removing

– Connect and secure the connector supports (push-button and diagnostics harness) (3).

CAUTION Do not loosen the nuts and washers inside the battery.

– Loosen the M5 nut (1) and remove the clip.

– Disconnect the BMU(2) harness connector from the Power plate.

Push the release clip.

– Connect the BMU harness connector to the Power plate(2) connector.

Push the release clip.

– Tighten the M5 nut (1) of the clip (tightening torque: 4 Nm).

– Disconnect the two connectors (push-button and diagnostics harness) (3).

– Connect the BMU harness to the BMS.

Push the release clips.

Push the release clip.

– Remove the BMU(4) harness.

– Fit the cover provided on the battery.

Replacing – Insert the BMU(4) harness in the battery.

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60

Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Replacing the SMU harness (A1 battery)

Removing

Replacing

– Remove the protective cap of the positive power cable from the lid on the Power plate(6).

– Connect the SMU harness connector to the front of the module (3).

– Loosen the CBLX M8 screw (5) of the positive power cable and remove the washers.

Push the release clip.

– Remove the protective cap of the negative power cable from the lid on the Power plate(7).

– Loosen the CBLX M8 screw (8) of the negative power cable and remove the washers.

– Loosen the M5 nut (4) and remove the clip.

– Disconnect the SMU(1) harness connector at the front of the module (3).

Push the release clip.

– Identify and disconnect the SMU harness connectors from the BMS. Push the release clip.

– Remove the SMU harness.

– Connect the SMU harness connectors to each BMS connector.

Push the release clip.

– Install the clip and tighten with the M5 nut (4) (tightening torque: 4 Nm).

– Connect the negative power cable (7) of the lid with the CBLX M6 screw (8) and the washers (tightening torque: 5 Nm).

– Connect the positive power cable (6) of the lid with the CBLX M8 screw (5) and the washers (tightening torque: 13 Nm).

Push the release clip.

– Fit the cover provided on the battery.

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Electrical/electronic equipment

Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Replacing the SMU harness (A2 battery)

Removing

Push the release clip.

– Remove the protective cap of the positive power cable from the lid on the Power plate(4).

– Remove the SMU(1) harness.

– Loosen the CBLX M8 screw (3) of the positive power cable and remove the washers.

Replacing

– Remove the protective cap of the negative power cable from the lid on the Power plate(8).

– Loosen the CBLX M8 screw (7) of the negative power cable and remove the washers.

– Remove the protective cap of the power cables from the modules (6).

– Unscrew the CBLX M8 screws (5) of the positive power cable from the module.

Protect with an insulated cap for maintenance.

– Disconnect the SMU(9) harness connector at the front of the module.

Push the release clip.

– Disconnect the SMU(2) harness connectors from the BMS. 60-30

– Connect the SMU(2) harness connectors to the BMS. Push the release clip.

– Connect the SMU(1) harness connector to the front of the module (9).

Push the release clip.

– Remove the protective cap for maintenance from the positive power cable and from the module (6).

– Connect the positive power cables (5) with the washers (tightening torque: 13 Nm).

Fit the protective cap.

– Connect the negative power cable (8) of the lid with the CBLX M6 screw (7) and the washers (tightening torque: 5 Nm).

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Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Fit the protective cap.

– Connect the positive power cable (4) of the lid with the CBLX M8 screw (3) and the washers (tightening torque: 13 Nm).

– Fit the cover provided on the battery.

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Electrical/electronic equipment

Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Module Lithium-ion module

A B

Module connector - terminal

C D

+ terminal Cover

Description (A1 battery) The A1 battery is equipped with a 24M Fe module comprising seven rows of two cells.

The module supplies the energy as well as voltage measurements via the SMU card.

Description (A2 battery) The A2 battery is equipped with two 24M Fe modules comprising seven rows of two cells.

The modules supply the energy as well as voltage measurements via the SMU card.

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Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Replacing the A1 battery module

Removing – Remove the harness from the BMU (see the description of how to remove and refit the BMU harness).

– Remove the harness from the SMU (see the description of how to remove and refit the SMU harness).

– Remove the Power plate provided (see the description of how to remove and replace the Power plate provided).

– Check that the power cables are protected with insulated caps.

– Loosen the four H M5 nuts (1) from the plate (2) and remove them.

– Loosen the two H M5 nuts (3) from the plate (4) and remove them.

– Loosen the two H M5 nuts (5) on the two plate supports (6) and remove them.

– Remove the upper support (7) of the module.

– Remove the module (8) from the battery by hand.

CAUTION The module is fragile When removing the module, you must be very careful not to let it fall.

– Loosen the negative power cable (9) (CBLX M6 screw) of the module.

– Loosen the positive power cable (10) (CBLX M8 screw) of the module.

Replacing – Ensure that the positive cable has an insulated cap on one connection (to be connected to the Power plate during installation of the Power plate).

– Connect the other connection of the positive power cable to the module with the CBLX M6 screw with the disc spring and the flat washer (tightening torque: 5 Nm).

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Electrical/electronic equipment

Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) – Ensure that the negative cable has an insulated cap on one connection (to be connected to the Power plate during installation of the Power plate).

– Connect the other connection of the negative power cable to the module with the CBLX M6 screw with the disc spring and the flat washer (tightening torque: 5 Nm).

– Insert the module (8) into the battery using the handle.

– Position the upper support (7) on the module.

– Fit the two side supports (6) and attach each of them using two H M5 nuts (5) (tightening torque: 4 Nm).

60-34

– Fit the plate support (4) and secure it using the two H M5 nuts (3) (tightening torque: 4 Nm).

– Fit the steel plate (2) and secure it using four H M5 nuts (1) (tightening torque: 6 Nm).

– Fit the Power plate provided (see the description of how to remove and replace the harness of the Power plate provided).

– Fit the SMU harness (see the description of how to remove and replace the SMU harness).

– Fit the BMU harness (see the description of how to remove and replace the BMU harness).

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Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Replacing the A2 battery module

Removing

– Check that the power cables are well insulated.

If not, protect them with insulated caps.

WARNING The BMU connector must be disconnected from the BMS.

NOTE

If something falls on the top of the battery, remove it.

– Remove the BMU harness (see the description of how to remove and replace the BMU harness).

– Remove the SMU harness from the BMS (see the description of how to remove and replace the SMU harness).

– Remove the BMS (see the description of how to remove and replace the BMS harness).

– Remove the Power plate provided (see the description of how to remove and replace the Power plate provided).

– Loosen the four H M5 nuts (1) on the two steel plates (2) and remove them.

– Loosen the two H M5 nuts (3) on the two plate supports (4) and remove them.

– Loosen the two H M5 nuts (5) on the four side supports (6) and remove them.

– Remove the two upper supports (7) from the modules.

– Remove the harness connector SMU from the modules (see the description of how to remove and replace the SMU harness).

– Remove the modules (8) from the battery using the handle.

CAUTION The modules are fragile When removing the modules, you must be very careful not to let them fall.

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Electrical/electronic equipment

Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) – On each module, loosen the negative power cable (9) (CBLX M6 nuts) of the module.

– On each module, loosen the positive power cable (10) (CBLX M8 nuts) of the module.

Replacing – Ensure that the positive cables have an insulated cap on one connection (to be connected to the Power plate or the BMS during installation of the Power plate or the BMS).

– Connect the module positive power cable for each module with the CBLX M8 screw (10) and the disc spring and the flat washer (tightening torque: 13 Nm).

– Ensure that the negative cables have an insulated cap on one connection (to be connected to the Power plate or the BMS during installation of the Power plate or the BMS. – Connect the negative power cable (10) to the module for each module with the CBLX M6 screws (9) and the disc spring and the flat washer (tightening torque: 5 Nm).

– Insert the modules (8) into the battery using the handle.

60-36

– Connect the SMU harness connectors to the modules (see the description of how to remove and replace the SMU harness).

– Position the upper support (7) on the modules.

– Fit the four side supports (6) and attach each of them using two H M5 nuts (5) (tightening torque: 4 Nm).

– Fit the plate support (4) and secure it using the two H M5 nuts (3) (tightening torque: 4 Nm).

– Fit the steel plates (2). The plates are the same. The rounded sides of the steel plates must be downward. Secure each side with four H M5 nuts (1) (tightening torque: 6 Nm).

– Fit the Power plate provided on the side identified on the battery (see the description of how to remove and replace the Power plate).

– Fit the BMS on the side identified on the battery (see the description of how to remove and replace the BMS).

– Connect the SMU harness connectors to the BMS (see the description of how to remove and replace the SMU).

– Fit the BMU harness (see the description of how to remove and replace the BMU harness).

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Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Power plate Overview

1 2 3

4 5

Pre-charge contactor support Pre-charge contactor Shunt

Fuse (125 A) Contactor

The function of the power plate is to check and provide the supply for the user of the Lithium Ion battery in a safe way.

The power plate contains devices that can cut off the supply, manage its safety and measure the physical values.

Fuse This helps protect the plate from a possible short-circuit of the external terminals.

Contactor This cuts off the battery when it is stopped. It has a safety function

Shunt This allows the current of the lithium-ion battery to be measured.

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Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Pre-charge resistor This prevents currents that are too large when the Lithium Ion battery is started.

It also serves to dissipate the energy of the peak of current in order to start the battery safely.

Pre-charge relay Located below the plate, this activates precharging.

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Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Replacing the contactor

Removing

Replacing

– Make sure that the Power plate is removed.

– Install the contactor (6).

– Loosen the two CBLX M8 screws (1) of the fuse and remove the washers.

– Secure the contactor (6) using the two CBLX M5 screws (3) (tightening torque: 3 Nm).

– Remove the fuse (2).

– Connect the two Faston(8) terminals.

– Loosen the last CBLX M5 screw of the rigid connection (3) and remove the washers.

– Connect the contactor (7).

– Loosen the two nuts (4) of the contactor connections and remove the washers.

– Remove the rigid connections (5) of the contactor (6).

– Disconnect the connector (7): push the release clip.

– Disconnect the two Faston (8) terminals.

– Loosen the two M5 screws (9) from the contactor and remove the washers.

– Remove the contactor (6) from the Power plate.

– Install the rigid connections (5) and tighten the two H M8 nuts with the washers (4) (tightening torque: 10 Nm).

– Tighten the last CBLX M8 screw of the rigid connections (3) with the washers (tightening torque: 13 Nm).

– Install the fuse (2).

– Tighten the two CBLX M8 screws (1) of the fuse with the washers (tightening torque: 13 Nm).

– Install the Power plate.

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Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Replacing the battery fuse

Removing

Replacing

– Loosen the two CBLX M8 screws (1) and remove the washers.

– Install the 125-A fuse (2) on the Power plate(3).

– Remove the 125-A fuse (2) from the Power plate(3).

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– Tighten the two CBLX M8 screws (1) with the washers (tightening torque: 13 Nm).

– Fit the cover provided on the battery.

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Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Lithium-ion battery socket 160-A MRC connector coding system

160 A/24 V coding system (A) Coding pin for the battery female connector (B) Coding pin for the male connector of the Lithium Ion battery

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Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Voltage coding (keying pin):

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Lithium-ion battery A1 and A2 (EXU H20 ion - EXU H20S ion) Display for lithium-ion batteries

1 2 3 4

CAN 6P4 multifunction indicator Red LED Green LED 6X2 connector: 6X2: 1: 0 V 6X2: 2: +24 V

5 1A1

6X2: 3: CAN low 6X2: 4: CAN high 6X8 connector: 6X8: 1: green LED 6X8: 2: red LED Traction controller

The 6P4 multifunction indicator, linked to the CAN bus network of the truck, displays:

The 6P4 multifunction indicator is fitted with two indicator lights:

• The charge/discharge level of the battery

•

Red (2): alarms, errors with the truck function or the on-board charger (if fitted)

•

Green (3): truck powered up or battery charge status if the truck is fitted with an on-board charger

• The operating hours of the truck (hour meter) • Alarm pictograms accompanied by red indicator lights • Error codes for troubleshooting assistance

NOTE

NOTE

The terminating resistor (120 ) has been removed for the version with a lithium-ion battery.

If the red LED (2) flashes, completely recharge the lithium-ion battery as soon as possible.

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Location of connectors for the lithium-ion battery DANGER

CAUTION

Electrical danger

Safety regulations

Do not touch the lithium-ion battery when the battery is charging and do not wear rings or jewellery.

Use protection goggles and a mask with a protective visor.

CAUTION Safety regulations When carrying out work inside the battery, do not wear clothes with metal objects (belt, shirt buttons).

Connectors on the power plate

1

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Power plate connector

2

Relay connector

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Connectors on the battery

3 4 5

Power box connector Module harness connector BMU connector

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Replacing the cover provided Removing

– Install the battery in the support provided for battery maintenance.

– Unscrew the four CBLX M6 screws (1) and remove the spring washer and the flat washer from the cover provided.

– Lift the battery cover provided (2).

– Disconnect the SMU harness connectors (6) from the BMS (7) by pushing the release clip.

– Identify the positive power cable connected to the contact switch provided (4).

Unscrew the mounting nut and then remove the spring washer, the corresponding flat washer and the shoe located at the end of the harness from the contact switch.

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Refit the maintenance insulation cover.

– Locate the negative power cable connected to the shunt (3).

Remove the insulation protection. Unscrew the mounting nut and then remove the spring washer and the corresponding washer.

Refit the maintenance insulation cover.

– Identify and disconnect the earth cable (5) from the side of the cover provided.

– Remove the BMS cover provided.

– If the BMS has to be reused, remove it from the cover provided.

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Replacing

– Install the BMS (old or new) on the cover provided.

– Remove the maintenance insulation cover from the positive power cable.

– Check whether the cover seal is damaged.

Replace if necessary.

– Install the positive power cable for the contact switch provided (4) and the shoe located at the end of the harness from the contact switch.

Then tighten the nut with the spring washer and the flat washer (tightening torque: 10 Nm).

– Move the battery cover provided (2) closer.

– Locate and connect the earth cable (5) on the side of the cover provided.

– Remove the maintenance insulation cover from the negative power cable.

– Connect the negative power cable to the shunt (3). Connect it with the H M6 nut and with the spring washer and the flat washer (tightening torque: 5 Nm).

Refit the insulation protection.

– Connect the SMU harness connectors (6) to the BMS: push the release clip.

– Fit the battery cover provided (2).

– Fit the cover provided (2) with the four CBLX M6 screws (1) and with the spring washer and the flat washer (tightening torque: 10 Nm).

– If the battery is being stored, attach adhesive tape to the insulation covers on the power terminal block.

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Replacing the push button provided

Removing

The seal of the push button must be on the outside of the cover.

– Remove the four nylon clips (2).

– Disconnect the push button connector (3).

– Unscrew the M22 nut (6) on the push button provided (1) and then remove it.

– Install the push button provided (1) on the cover provided (7). Put the connector through the hole.

– Remove the push button (1) and its O-ring (5) from the cover provided (7).

– Place the M22 nut (6) on the push button (1) and then screw in the nut (tightening torque: 6 Nm).

Replacing

– Attach the push button cable with the four nylon clips (2).

– Place the O-ring (5) on the head of the push button (4).

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– Connect the push button connector (3).

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Replacing the diagnostic harness

Removing

Replacing

– Unscrew the nut from the contact switch (6) and then remove the nut, the washers and the O-ring from the diagnostic harness (4).

– Install the head of the diagnostic harness (3) on the cover provided (8) through the hole provided for this purpose.

– Remove the nylon rope clamp (7).

– Screw the mounting ring (2) on the diagnostic connector.

– Disconnect the diagnostic harness connector (5).

– Unscrew the protective cap (1) and its retaining tab.

– Unscrew the protective ring (2) from the diagnostic connector.

– Remove the head of the diagnostic harness (3) from the cover provided (8).

– Screw on the cap (1) using its retaining tab.

– Connect the diagnostic harness connector (5).

– Fit the nylon rope clamp (7).

– Fit the O-ring on the diagnostic harness (4). Fit the washers and the nut (6) and then screw on the nut of the contact switch (tightening torque: 10 Nm).

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Replacing the terminal block

Removing

Replacing

– Unscrew the two cover fastening nuts (1) and then remove them.

– Fit the seal of the terminal block (6).

– Remove the cover (2).

– Unscrew the M8 screw (3) (corresponding to the + terminal).

– Unscrew the M6 screw (4) (corresponding to the - terminal).

– Unscrew the three M5 mounting screws (7) and remove them from the terminal block (5).

– Remove the terminal block (5) from the cover provided (8).

– Remove the seal from the terminal block (6).

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– Install the terminal block (5) on the cover provided (8).

– Attach the terminal block (5) using the three M5 mounting screws (7) and corresponding washers (tightening torque: 4 Nm).

– Tighten the M6 screw (4) (negative terminal) (tightening torque: 5 Nm).

– Tighten the M8 screw (3) (positive terminal) (tightening torque: 13 Nm).

– Fit the terminal block cover (2).

– Fit the two cover fastening nuts (1) and then screw them in (tightening torque: 3 Nm).

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Replacing the power cable

Removing

Replacing

Positive power cable from the fuse.

Positive power cable from the fuse.

– Remove the fuse.

– Fit the power cable from the connector to the terminals of the contact switch (1).

– Remove the positive power cable (1).

Negative power cable from the power pack.

– Remove the protective cap (3).

– Unscrew the mounting screw from the cable to the negative terminal of the power pack (4).

– Remove the negative power cable (2).

– Fit the fuse.

Negative power cable from the power pack.

– Install the negative power cable (2). Fit the rigid joining plate of the contact switch (4) to the negative terminal of the terminal block and then screw it in (tightening torque: 6 Nm).

– Fit the protective cap (3).

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) BMS Description

The BMS (Battery Monitoring System) is the control unit for the lithium-ion battery.

• To measure the current of the lithium-ion battery module

It comprises the BMU (Battery Management Unit) and the SMU (Safety and Monitoring Unit) card.

• To calculate the data • To communicate with the LAC controller via the CAN bus network

The Black Box is located inside the BMU , with important parameters such as SOC (State Of Charge) and SOH (State Of Health).

SMU card

The Black Box records the various battery parameters and events.

The SMU (Safety and Monitoring Unit) card is located inside the BMS.

It monitors and controls the status of the battery with the following functions:

This enables cell management (balancing, sending information such as end of charge, overheating, overloading, excessive discharge etc.).

• To supply the SMU card and the BMU (DC) • To receive data from the SMU card

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If the SMU card is faulty, the entire BMS must be replaced.

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Replacing the BMS Removing

– Unscrew the cap of the battery diagnostics connector using the tab (1).

– Unscrew the four mounting nuts (4) of the BMS.

– Connect the diagnostic tool to the battery diagnostics connector (2).

– Remove the BMS(5).

– If possible, start the diagnostic tool software and download data from the BMS (black box, shunt calibration parameters etc.).

Replacing

– Disconnect the diagnostic tool.

– Install the BMS(5).

– Tighten the four mounting nuts (4) on the BMS (tightening torque: 4 Nm).

– Connect the diagnostic harness connector (3).

NOTE

It is also possible to access the BMS directly via the RS485 output of the BMS using the SAFT tool (WINDIAG_BMS).

– Screw on the cap (1).

– Remove the cover provided.

– Disconnect the diagnostic harness connector (3).

– Install the cover provided.

– Unscrew the cap (1) of the battery diagnostics connector using the tab.

– Connect the diagnostic tool to the battery diagnostics connector (2).

– Start the diagnostic tool software (KION CAN_KWP2000 tool) and transfer the data from the old BMS (black box, shunt calibration parameters etc.) if it can be recovered.

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) – If this is not possible, save the calibration parameters present on the shunt and enter them in the new BMS. Enter a value indicative of the SOH : State Of Health) in the BMS. Also enter the serial number of the battery and the module, as well as the BMU ID number.

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– Disconnect the diagnostic tool.

– Screw on the cap (1).

NOTE

It is also possible to access the BMS directly via the RS485 output of the BMS using the SAFT tool (WINDIAG_BMS).

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Module Lithium-ion module

A B C

Module connector - terminal + terminal

Description The B1 battery is equipped with a 24M Fe module consisting of 35 cells (seven rows of five cells).

The B2 battery is equipped with two 24M Fe modules consisting of 35 cells (seven rows of five cells for each module).

The module supplies the energy as well as voltage measurements via the SMU card.

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Disassembling the B1 and B2 battery module 1) Removing the upper parts and the side cover:

– Unscrew the negative output of the power pack (1).

– Unscrew the six mounting nuts on the reinforced plate (10).

– Remove the negative connection hose and then insulate the negative terminal of the power pack with insulating tape.

– Remove the rivets (11).

– Unscrew the mounting screws of the rigid connection (2), remove the rigid connection (3) and then insulate the positive terminal of the power pack with insulating tape.

– Unscrew the four mounting nuts on the fuse holder (4) and then remove the fuse holder (5).

Use a ∅2-mm punch to drive the rivet into the battery.

Use a ∅10-mm twist drill to drill out the rivet heads.

Use a ∅4-mm punch to mark out the shape of the rivets in the battery.

– Carefully remove the side cover provided (12).

– Unscrew the five mounting nuts on the side plate (6) and then remove the side plate (7).

– Disconnect the connector for electrical continuity.

– Unscrew the mounting nuts (8a) and bolts (8b) from the angle bracket (9) and then remove the angle brackets.

– Remove the cover seal (13).

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) 2) Removing the power pack:

– Remove the SMU harness (15).

• Unscrew the six retaining screws (17) on the retaining clamps of the SMU harness (16).

– Remove the four mounting screws from the power pack (14).

– Remove the power pack (19) (blue arrow).

• Disconnect the two SMU harness connectors (18) from the modules.

• Remove the SMU harness (15).

NOTE

The power pack is heavy (96.5 kg).

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) 3) Removing the power pack:

– On the two sides (positive and negative), unscrew the rigid connection nuts (20) and then remove the rigid power connections (21 & 22).

– Unscrew the seven reinforced nuts on the reinforced plate (23) and then remove the reinforced plate (24).

– On the two sides (positive and negative), unscrew the reinforcement screws (25) and then remove the seven reinforcements (26).

– Separate the upper module (27) from the lower module (28).

NOTE

A module weighs 43.3 kg.

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Reassembling the B1 and B2 battery module 1) Checking and cleaning the box: – Check that the box is not damaged.

– On the opening of the power pack, check that the holes intended for rivets are all cylindrical.

NOTE

If the box is damaged or if the holes (rivets) are not cylindrical, the box should not be used, so use another box.

– Clean the box with a suction system (no dust on the metal parts).

– Also clean around the opening of the power pack (around the seal of the side cover).

1) Reassembling the power pack:

– Place the upper module (27) on the lower module (28).

– On the two sides (positive and negative), position the seven reinforcements (26) and then screw in the reinforcement screws (25) (tightening torque: 3.5 Nm).

– Place the reinforced plate (24) on the modules and then screw in the seven nuts of the reinforced plate (23) (tightening torque: 10 Nm).

– On the two sides (positive and negative), position the rigid power connections (21 & 22) and then screw in the rigid connection screws (20) (tightening torque: 4 Nm).

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) 2) Inserting the power pack:

– Install the SMU harness (15).

– Insert the power pack (19) in the box.

• Connect the SMU harness connectors (18) to the modules.

NOTE

The power pack is heavy (96.5 kg).

– Screw in the four mounting screws of the power pack (14) (tightening torque: 10 Nm).

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• Position the SMU harness rope clamps (16) and then screw them (17) on to the modules (tightening torque: 3.5 Nm).

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) 3) Reassembling the upper parts and the side cover:

– Screw the six mounting nuts of the reinforced plate (10) on to the battery box (tightening torque: 10 Nm).

– Position the two angle brackets (9) and then tighten the mounting nuts (8a) and bolts (8b) (tightening torque: 10 Nm).

– Position the side plate (7) and then screw it in with the five mounting nuts (6) (tightening torque: 3 Nm).

– Position the fuse holder (5) and then screw in the four mounting nuts on the fuse holder (4) (tightening torque: 4 Nm).

– Remove the insulating tape from the power pack terminals.

– Position the rigid connection (3) and then screw in the mounting screws on the rigid connection (2) (tightening torque: 5 Nm).

– Position the negative connection hose and then screw in the negative output of the power pack (1) (tightening torque: 5 Nm).

– Connect the connector for electrical continuity.

– Put a new side protection seal (13) in place.

– Carefully position the side cover provided (12).

– Fit the new rivets (11).

4) Updating the BMS data: – Unscrew the cap of the battery diagnostic connector using the tab (1).

– Connect the diagnostic tool to the battery diagnostic connector.

– Launch the diagnostic tool software.

– Enter the serial number of the module or modules.

– Update the diagnostic tool.

NOTE

It is also possible to access the BMS directly via the RS485 output of the BMS. – Screw in the protective cap.

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Replacing the shunt

Removing

– Unscrew the rigid connection nut (5).

– Unscrew the two mounting nuts on the insulation cover (1) and then remove them.

– Remove the rigid connection (6).

– Remove the insulation cover (2).

– Gently unscrew the mounting screws of the communication cable (3).

Replacing – Put the shunt (7) into position.

– Put the rigid connection (6) into position.

NOTE

The mounting screws of the communication cable are small in diameter. They are screwed on the shunt, which is made of copper.

– Screw on the rigid connection nut (5) (tightening torque: 5 Nm).

– Screw the mounting nut on the shunt (4a) (tightening torque: slight tightening).

– Screw the other mounting nut on the shunt (4b) (tightening torque: 5 Nm).

NOTE

Be careful not to damage the threads or lose the screws.

– Unscrew the two mounting nuts on the shunt (4a and 4b).

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– Remove the shunt (7).

– Put the screws of the shunt communication cable (3) in place and then screw them in (tightening torque: 3 Nm).

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) NOTE

The mounting screws of the communication cable are small in diameter. They are screwed on the shunt, which is made of copper.

– Fit the two mounting nuts on the insulation cover (1) and then screw them in (tightening torque: 3 Nm).

– Unscrew the battery diagnostic connector with trap (8).

– Connect the diagnostic tool to the battery diagnostic connector (7).

NOTE

Be careful not to damage the threads or lose the screws.

– Start the diagnostic software tool.

– Fit the insulation cover (2).

– Screw on the cap (1).

– Disconnect the diagnostic tool.

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Power plate Overview

1 2 3

4 5

Pre-charge contactor support Pre-charge contactor Shunt

Fuse (125 A) Contactor

The function of the power plate is to check and provide the supply for the user of the Lithium Ion battery in a safe way.

The power plate contains devices that can cut off the supply, manage its safety and measure the physical values.

Fuse This helps protect the plate from a possible short-circuit of the external terminals.

Contactor This cuts off the battery when it is stopped. It has a safety function

Shunt This allows the current of the lithium-ion battery to be measured.

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Pre-charge resistor This prevents currents that are too large when the Lithium Ion battery is started.

It also serves to dissipate the energy of the peak of current in order to start the battery safely.

Pre-charge relay Located below the plate, this activates precharging.

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Replacing the contact switch

Removing

– Remove the contact switch provided (9).

– Unscrew the two mounting nuts on the protective cover of the terminal block (1) and then remove them.

Replacing

– Remove the protective cover from the terminal block (2).

– Disconnect the connector from the contact switch (3).

– Unscrew the M8 nut (4) (positive terminal) and then remove it with the corresponding washers.

– Unscrew the two nuts on the terminals of the contact switch and the corresponding washers (5).

– Remove the washer (6) from the + terminal of the contact switch.

– Remove the rigid connection (7).

– Unscrew the two M5 mounting nuts on the contact switch (8).

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– Fit the contact switch provided (9).

– Screw in the two M5 nuts on the contact switch (8) (tightening torque: 4 Nm).

– Install the rigid connection (7).

– Fit the washer (6) on the + terminal of the contact switch.

– Fit the washers and nuts on the power contact switch (5) and then tighten (tightening torque: 10 Nm).

– Fit the washers and the M8 screw on the + terminal (4) and then tighten (tightening torque: 13 Nm).

– Connect the connector of the contact switch (3).

– Install the terminal block cover (2).

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) – Install the two cover fastening nuts (1) of the terminal block and then tighten them (tightening torque: 3 Nm).

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Replacing the fuse

Removing

Replacing

– Remove the protective cap (1).

– Fit the hose connection (3).

– Unscrew the two CBLX M6 nuts (2) and remove the flat washers and the conical spring washers.

– Fit the fuse (5) in the fuse holder (4).

– Remove the fuse (5) from the fuse holder (4).

– Remove the hose connection (3).

– Fit the flat washers, the conical spring washers and the nuts (2).

– Tighten the two CBLX M6 nuts (tightening torque: 5 Nm).

– Fit the protective cap (1).

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Lithium-ion battery socket 160-A MRC connector coding system

160 A/24 V coding system (A) Coding pin for the battery female connector (B) Coding pin for the male connector of the Lithium Ion battery

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Voltage coding (keying pin):

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Display for lithium-ion batteries

1 2 3 4

CAN 6P4 multifunction indicator Red LED Green LED 6X2 connector: 6X2: 1: 0 V 6X2: 2: +24 V

5 1A1

6X2: 3: CAN low 6X2: 4: CAN high 6X8 connector: 6X8: 1: green LED 6X8: 2: red LED Traction controller

The 6P4 multifunction indicator, linked to the CAN bus network of the truck, displays:

The 6P4 multifunction indicator is fitted with two indicator lights:

• The charge/discharge level of the battery

•

Red (2): alarms, errors with the truck function or the on-board charger (if fitted)

•

Green (3): truck powered up or battery charge status if the truck is fitted with an on-board charger

• The operating hours of the truck (hour meter) • Alarm pictograms accompanied by red indicator lights • Error codes for troubleshooting assistance

NOTE

NOTE

The terminating resistor (120 ) has been removed for the version with a lithium-ion battery.

If the red LED (2) flashes, completely recharge the lithium-ion battery as soon as possible.

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Lithium-ion battery B1 and B2 (EXU H20 ion - EXU H20S ion) Replacing the power cable

Removing

Replacing

Positive power cable from the fuse.

Positive power cable from the fuse.

– Remove the fuse.

– Fit the power cable from the connector to the terminals of the contact switch (1).

– Remove the positive power cable (1).

– Fit the fuse.

Negative power cable from the power pack.

Negative power cable from the power pack.

– Remove the protective cap (3).

– Unscrew the mounting screw from the cable to the negative terminal of the power pack (4).

– Remove the negative power cable (2).

– Install the negative power cable (2). Fit the rigid joining plate of the contact switch (4) to the negative terminal of the terminal block and then screw it in (tightening torque: 6 Nm).

– Fit the protective cap (3).

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Charger for lithium-ion batteries (option) Description

There are three types of external chargers: A: An external 90-A charger (single phase) B: An external 160-A charger (three phase) C: An external 225-A charger (three phase)

Display: Information about the charging status during charging is described below: 1: Battery voltage (V) 2: Charging current (A) 3: Charging status (%) 4: Charge supplied (Ah) 5: Charging time (t)

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Charger for lithium-ion batteries (option) Status of lights:

GREEN

Meaning Charger OFF Charger initialising Starting sequence Battery charged

ORANGE

Battery charging

RED RED FLASHING

Battery warning (failure) Battery alarm Charger alarm

Status OFF

If the light is flashing red, refer to the alarm codes described below: Message

Meaning

MAX. TIME OVERRANGE ERROR CHARGER

Maximum charging time exceeded

HIGH VOLTAGE ERROR CHARGER

High battery voltage

INTERNAL TEMPERAT. ERROR CHARGER

Internal temperature of the charger is too high

Check the battery status

BATT. UNEXPECTED ERROR BATTERY

Battery error The battery has encountered an unrecoverable error Battery alarm An alarm has occurred on the battery Incompatible battery manufacturer

MEASURE ERROR

Voltage (and/or) amperage readings incorrect

ERROR BATTERY BATTERY ALARM

Solution Check the status of the battery (maximum charging time 780 minutes) Provide adequate air circulation Check that the internal FANS are operating correctly Consult battery documentation Consult battery documentation Battery type and charger type are from different brands Contact the After-Sales Service Centre (maximum voltage tolerance 2 V, maximum current tolerance 5 A)

.

Electrical interface: In single phase (6), the cable has three wires (phase, neutral, earth).

Three types of plug are compatible: • EUR (Europe): 16 A (7) • SUI (Switzerland): 16 A (8) • UK (United Kingdom): 13 A (9) In three phase (10), the cable has four or five wires (phase L1, phase L2, phase L3, neutral* and earth). *: Not used and not connected

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11

Inside the charger

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Charger for lithium-ion batteries (option) Technical data: The identification label is positioned on the lower right-hand side of the external charger.

Parameter details: Marking

Function

1

Designation

2

Protection index Voltage/Output current

3 4

Serial number Input current Table summarising charging times for different battery types

5 6 7 8

CE standard Weight

9

Power supply frequency

10

Manufacturer Charger model

11 .

Using the side socket to charge the battery A side socket (1) can be installed on the battery on the side of the truck. The socket allows you to charge the battery without removing the battery connector (emergency stop handle) of the truck.

CAUTION Risk of damage to the battery It is essential not to switch off the lithium-ion battery during charging.

CAUTION Risk of damage to the battery Do not connect two external chargers to charge the battery. The operator must use either the side socket or the truck socket (emergency stop handle) for charging.

Proceed as follows: – Park the truck close to the charging station.

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Charger for lithium-ion batteries (option) – Immobilise the machine. Lower the fork arms.

– Switch off the ignition (key or electronic key).

– Disconnect any additional electrical equipment before charging. Charging cuts off the electrical supply to the truck and to additional equipment.

– Plug the connector of the charging station into the side socket (1) located on the side of the truck.

– Switch the charger on as directed in the specific instructions for the charger. A screen appears displaying the words Battery connected. Charging of the battery is automatically managed by the on-board electronics of the battery.

A green LED (2) lights up. The LED indicates that the connector of the side socket (1) is correctly inserted and that charging is in progress.

NOTE

If the LED remains off, the connector is not detected. Please contact the After-Sales Service Centre.

– When charging is complete and the charger has stopped, unplug the charger.

NOTE

It is possible to stop charging before the end of the complete cycle. The operator can resume work more quickly. It is advisable to recharge the battery after each use if possible. The battery charge percentage is indicated on the display screen. The charging time is indicated on the screen of the charger.

– Switch on the ignition (key or electronic key) and check the charging status of the truck on the display.

The truck is now ready for use.

CAUTION Risk of damage to the side socket The side socket is intended only for charging the battery.

If the socket is faulty, please contact the After-Sales Service Centre.

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Charger for lithium-ion batteries (option) Charging lithium-ion batteries using an external charger Read the information in the documentation provided with the charger.

It provides information on: • the various charger screens • possible error messages • precautions for use.

CAUTION Risk of damage to the battery It is essential to use the charger supplied with the battery for charging lithium-ion batteries.

DANGER Electrical danger Do not touch the lithium-ion battery when it is charging and do not wear rings or jewellery. Do not place metal objects on or near the battery. Do not light a naked flame in the vicinity of the charging zone or near charging batteries.

WARNING Risk of sparks Always connect the battery connector before switching on the battery charger and disconnect the connector after switching off the charger.

WARNING Risk of damage to the battery It is important to charge the lithium-ion battery fully at least once a week.

The LED located on the display flashes red. You must therefore recharge the battery to 100%.

Charging the vertical access lithium-ion battery using an external charger CAUTION Risk of damage to the battery It is essential not to switch off the lithium-ion battery during charging.

To recharge the lithium-ion battery, proceed as follows: – Park the truck close to the charging station.

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Charger for lithium-ion batteries (option) – Secure the truck. Lower the fork arms.

– Switch off the ignition (2).

– Open the battery compartment cover.

– Unplug the battery connector (1).

– Plug the socket of the charging station into the connector (1) located on the battery.

– Switch the charger on as directed in the specific instructions for the charger. A screen appears displaying the words Battery connected.

Charging the battery is automatically managed by the on-board electronics of the battery.

– When charging is complete and the charger has stopped, unplug the charger.

NOTE

It is possible to stop charging before the end of the complete cycle. The operator can resume work more quickly. It is advisable to recharge the battery after each use if possible. The battery charge percentage is indicated on the display screen. The charging time is indicated on the screen of the charger.

– Reconnect the battery connector (1) on the truck.

– Then close the battery compartment cover.

– Switch on the ignition (2) and check the charging status of the truck on the display (3).

The truck is now ready for use.

If the charger stops before charging is complete, follow these steps: – Press the UP button for five seconds.

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Charger for lithium-ion batteries (option) The charger will stop charging. The external charger display shows the following message: Manual Stop.

– Reconnect the battery connector (1) on the truck.

– Then close the battery compartment cover.

– Return the truck to service.

Charging the side access lithium-ion battery using an external charger CAUTION Risk of damage to the battery It is essential not to switch off the lithium-ion battery during charging.

To recharge the lithium-ion battery, proceed as follows: – Park the truck close to the charging station.

– Secure the truck. Lower the fork arms.

– Switch off the ignition (2) (key or electronic key).

– Pull the emergency stop handle to disconnect the battery connector (1).

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Charger for lithium-ion batteries (option) – Plug the socket of the charging station into the connector (3) located in the technical compartment.

– Switch the charger on as directed in the specific instructions for the charger. A screen appears displaying the words Battery connected.

Charging the battery is automatically managed by the on-board electronics of the battery.

– When charging is complete and the charger has stopped, unplug the charger.

NOTE

It is possible to stop charging before the end of the complete cycle. The operator can resume work more quickly. It is advisable to recharge the battery after each use if possible. The battery charge percentage is indicated on the display screen. The charging time is indicated on the screen of the charger.

– Reconnect the emergency stop connector (1) to the truck.

– Switch on the ignition (2) (key or electronic key) and check the charging status of the truck on the display.

The truck is now ready for use.

If the charger stops before charging is complete, follow these steps: – Press the UP button for five seconds.

The charger will stop charging. The external charger display shows the following message: Manual Stop.

– Reconnect the battery connector (1) on the truck.

– Then close the battery compartment cover.

– Return the truck to service.

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Charger for lithium-ion batteries (option) Installing the external charger The lithium-ion battery must be recharged only with a special charger.

Do not use a charger other than the one provided by the Kion group.

The temperature of the room where the charger is installed must be between 5° and 45°C. The humidity level must be below 95%.

The following wall chargers are available: • An external wall charger • An external charger that stays on the ground This is heavier The vertical access and the side access lithiumion batteries can be recharged with both types of external chargers.

DANGER Electrical danger The charger must be installed and maintained only by electrical engineers or qualified staff.

DANGER There is a risk of fire.

The charger must be installed in a room without any inflammable elements.

WARNING Avoid the charger overheating.

Do not obstruct the air vents. The air must be able to circulate correctly.

Do not install the charger near a heat source or in a place exposed to direct sunlight.

Do not install it in an area that is subject to excessive dust or shocks or mechanical vibrations.

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Hydraulic controls EXU-H

1

Detection magnet

2B3

Fork in upper position gauge

Proportional actuation Main Lift (auxiliary lift) and Initial Lift are controlled from the controller(1A1).

The L.A.C. controller (1A1) makes precise control of the hydraulic lifting functions possible by acting directly on: • a pump unit (2M1) • a circuit selection hydraulic block (Main Lift or Initial Lift) • 1 "Initial Lift" circuit selection solenoid valve (2Y4).

• 1 "Main Lift" circuit selection solenoid valve (2Y5).

• 1 proportional lowering solenoid valve(2Y2).

Mast lifting is managed by: • 1 redundant potentiometer (2B4); • 1 fork upper position sensor(2B3)

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Initial lift movement is managed by: • 2 pull switches (2S6) and (2S7) on tiller • 1 pull switch (2S10) for the upper stroke-end for the load arms

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Hydraulic controls Automatic fork lifting/lowering option

The automatic fork lifting and lowering (option) is managed by:

– Crossed beams from (2B12) and (2B13) will detect the load on the forks.

• One selector with three automatic levelling positions (lifting/OFF/lowering) (2S4)

– Fork lifting will stop.

• One illuminated control button (S4) (indicator light (H4)) • One fork in upper position sensor (2B3) • One fork in lowered position sensor at 0.2 m from the ground (2B11)

– The buzzer will stop.

– The forks will lift automatically following unloading.

NOTE

• Two optical sensors (2B12) / (2B13) for fork load detection.

The pallet will be levelled as it is unloaded.

Safety:

Operation of the crossed beam load detection for pallet unloading:

• One emergency off switch (7S5)

• If 2B12 = 1 and 2B13 = 1 (load detected): fork lifting stops

• One buzzer (4H2)

Operating reminder for the automatic levelling UNLOADING a pallet: – Select automatic fork lifting using (2S4).

– Turn on the automatic lifting by pressing (S4) once; it will light up – For the safety of the user, the buzzer (4H2) will sound just before and during fork lifting.

– The forks will lift.

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• If 2B12 = 0 and 2B13 = 0 (no load detected): fork lifting is enabled • If 2B12 = 1 and 2B13 = 0 or 2B12 = 0 and 2B13 = 1 (cell malfunction): lifting stops • Lifting stops automatically when upper fork position is detected by the sensor (2B3) LOADING a pallet: – Raise the fork to the desired height using the tiller control.

– Select automatic fork lowering using (2S4).

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– Turn on automatic lowering by pressing (S4) once; it will light up.

Operation of the crossed beam load detection for pallet loading:

– For the safety of the user, the buzzer (4H2) will sound just before and during fork lowering.

• If 2B12 = 1 and 2B13 = 1 (load detected): fork lifting is enabled

NOTE

The pallet will be levelled as it is loaded.

• If 2B12 = 0 and 2B13 = 0 (no load detected): fork lowering stops • If 2B12 = 1 and 2B13 = 0 or 2B12 = 0 and 2B13 = 1 (cell malfunction): lowering stops • Lowering stops automatically when lowered fork position is detected by the sensor (2B11)

NOTE

When the forks are lowered, the upper level of the load is aligned at 800 mm from the ground (levelled by the two gauges 2B12 and 2B13).

NOTE

The traction is enabled, even if the selector is not in the 'OFF’ position.

Application of this authorisation: • EXU-H: From truck serial number W40162B03298

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Display Multifunction indicator 6P4 (CAN bus)

1 2 3 4

CAN 6P4 multifunction indicator 6H3 red diode 6H1 green diode 6X2 connector: PIN 1: 0 V PIN 2: +24 V PIN 3: CAN-L

5 1A1 G2

PIN 4: CAN-H 6X8 connector: PIN 1: Green diode PIN 2: Red diode Traction controller Built-in charger (option)

The 6P4 multifunction indicator, linked to the CAN bus network of the truck, displays: • The level of battery discharge • The operating hours of the truck (hour meter) • Alarm pictograms accompanied by red indicator lights • Error codes for troubleshooting assistance The 6P4 multifunction indicator is fitted with two indicator lights: • Green (3): truck powered up or battery charge status if the truck is fitted with a built-in charger • Red (2): alarms, errors with the truck function or the built-in charger (if fitted)

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Operating reminder

DESCRIPTION

1

Battery charge level represented by 10 bars

2

Maintenance alarm (red)

3

Red indicator light

4

Green indicator light

5

Error code

6

Fault or brake wear (air gap)

COMMENTS/SCREEN MESSAGES 91%–100%: 10 bars 1%–10%: 1 bar 0%: 1 flashing bar (lift function Full charge: 100% Low charge: 10% Discharged: not permitted) Note: To protect the battery, 0% 0% corresponds to max. 80% discharge 1) Flashing: less than 50 hours' truck operation until the next service 2) Constant: service date overdue Switched on: fault or alarm Switched off: truck switched off Switched on: truck switched on These codes will help the After-Sales Service Centre to decide on the appropriate E3 294 response from the service engineer Do not operate the truck EXPLANATION

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Display DESCRIPTION

7

Hour meter

8

STOP alarm (red)

9

T° alarm (red)

10 Tortoise position

COMMENTS/SCREEN MESSAGES - The meter starts running when the machine is switched on and a control is used - When counting, the dot next to the tenths of an hour flashes Indicates the number of operating hours of the machine - The hour meter displays hours and tenths of an hour - When the power supply is cut, the hours are stored in the memory Miscellaneous problems Do not operate the truck -> Truck is stopped Constant: control module In general, wait a few minutes overtemperature and then continue Gentle acceleration and Maximum speed: 4 km/h deceleration EXPLANATION

NOTE

The alarm indicator lights go out as soon as the fault disappears.

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Changing the multifunction indicator – Remove the electrical plate from the chassis (see Section 6) – Disconnect 6X2(11) and 6X8 (12)(if the truck is equipped with a built-in charger) – Undo the 2 nuts (10) on the mounting bracket – Remove the multifunction indicator (6) from its housing.

Fitting a new multifunction indicator To fit a new multifunction indicator, proceed in the reverse order to the removal.

NOTE

Only connect the battery during the programming stage for the new indicator.

Programming the new multifunction indicator After changing a multifunction indicator, it is necessary to set the old parameters on the new one as shown below: • 1) Record the value from the old hour meter to count the real operating time for the truck; • 2) Select the count mode for the hour meter; • 3) Set the maintenance indicator light activation; • 4) Set the discharge indicator according to the battery type and use.

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Electronic key Digicode LFM GO

1 2 3 4 5

Switch ON (operating mode) Switch OFF or programming accepted Programming mode Key error Time delay of automatic switch-off

Operation

Key in

LED status

Notes

USE * 0 0 0 0 0 #

ON

OU

* 1 2 3 4 5 # (by

default)

OFF

# (3 seconds)

red off continuous green (1)(correct PIN) red flashing green off (4)(incorrect PIN) red off green flashing (2)

PROGRAMMING (truck switch OFF only (2)) ADMINISTRATOR CODE ESSENTIAL * 0 0 0 0 0 0 0 0 continuous red FOR ALL # (by default) continuous green (3) DIGICODE SETTINGS red off green flashing * 0 * 5 4 3 2 1 # New operator code (2)(code applied) red off green flashing Allocating operator * 2 * 5 4 3 2 1 # (2)(code applied) codes red off green flashing Deleting operator * 2 * # (2)(deletion accepted) codes * * 9 * 1 2 3 4 5 red off green flashing Modifying 6 7 8 # (2)(code applied) administrator codes Restoring the initial administrator code Activating the automatic switch-off

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

* * 2 * 1 #

red off green flashing (2)(code applied) red flashing green flashing (5)(5 s before cut-off)

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0 0 0 0 0

OU

1 2 3 4 5 default PIN

Truck power off

Once the diodes have gone out, the electronic key automatically reverts to "operating mode" Example of new operator code: 54321 *2*: operator reference 10 options from 0 to 9 *2*: operator reference (between 0 and 9)

Reactivating the default administrator code (00000000) Power switches off automatically after 10 mins (600 s by default) if the truck is not being used.

Electrical/electronic equipment

60 Electronic key

PROGRAMMING (truck switch OFF only (2)) Setting the time delay of the automatic switch-off

* * 3 * 6 0 #

red off green flashing (2)(value accepted)

Deactivating the automatic switch-off

* * 2 * 0 #

red off green flashing (2)(command accepted)

Example: automatically switches off after 1 min.

(60s) when not used.

Minimum setting = 10 s / maximum = 3000 s

.

Changing the LFM box CAUTION Risk of short circuit.

Before working on electrical components, always disconnect the battery connection. Do not remove or change components when the truck is switched on.

– Open the battery cover to access the fastening clips of the LFM box – Apply pressure to the clips (13) to release the LFM box from the electrical plate – Disconnect 6X5 (14) and the IN (15) and OUT (16) terminals

Fitting a new LFM box When fitting a new LFM box, proceed in reverse order to removal.

Note: the default PIN for operating the truck is: 0 0 0 0 0.

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FleetManager™ (option) Description of Fleet Manager The Fleet Manager fleet management system allows access control and transmission of truck data.

This system is for access control and consists of: • Two reading device versions Additional options: • Shock sensor • Tools for wireless data management:

▶ GPRS radio module (1) with its GSM antenna (2)

The variants available on the truck are: • Access control • Access control and shock sensor • Access control and GPRS module • Access control, shock sensor and GPRS module This system and the additional options are fitted on trucks from: • W40153C01729: For 1152 (EXU) truck types • W40161C01712: For 1152 (EXUH) truck types (1)

GPRS: General Packet Radio Service

(2)

GSM: Global System for Mobile Communication

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TDU: Access control

1 2 2A 2B

Reading device with a keypad RFID reading device (1) RFID transponder card RFID transponder

3 4 5

TDU connector 6X16 Green diode Red diode

The TDU (Truck Data Unit) access control is available in two versions: • A reading device with a keypad (1) OR • A RFID reading device with truck access by: ▶ RFID transponder card, 13.56 MHz (2A) ▶ RFID transponder, 13.56 MHz (2B) Some of the data is transferred via Bluetooth.

Parameterising is done using the Service Base of the After-Sales Service.

(1)

RFID: Radio Frequency Identification NOTE

The only way to find out the access control version is by connecting it.

Assignment of connector 6X16 Pins 6X16: 1

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FleetManager™ (option) 6X16: 5

0V Analogue 2

6X16: 7

Relay 1

6X16: 8

Relay 1

6X16: 11

CAN 2 High

6X16: 12 6X16: 13

CAN 2 Low CAN 1 High

6X16: 14

CAN 1 Low

6X16: 3

.

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FleetManager option

1 2 3

Shock sensor GSM antenna CAN Box GPRS

4 5

Truck diode Antenna diode

A B

Old shock sensor New shock sensor

The shock sensor and CAN Box GPRS have been modified and the modified versions are fitted on trucks from: • W40154F01178: For EXU type trucks

Shock sensor This sensor allows you to record the shocks received by the truck.

If the truck receives a shock, its speed can be reduced.

Some settings can only be changed by the fleet manager.

If the sensor is faulty, replace it.

CAUTION There are two reference numbers for shock sensors.

One reference number when the sensor is fitted alone and another when it is fitted with the GPRS unit.

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FleetManager™ (option) CAN Box GPRS This is composed of a communication unit, also called a "radio module" (1) and a GSM antenna (5).

The CAN Box allows you to: • Access truck information remotely • Locate the truck This data is located on a server.

The status of the diodes indicates the status of the communication unit.

A B

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Old CAN Box GPRS New CAN Box GPRS

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On-board charger (optional) On-board battery charger CAUTION It is strictly prohibited to use an on-board charger other than the one recommended.

Precautions for installation and use 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 satisfies 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 sufficient 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 sufficient 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.

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On-board charger (optional) • 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".

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

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

CAUTION 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.

DANGER Danger to life!

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

DANGER Danger to life!

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

Electrical characteristics of the charger Mains voltage

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

35 A +/-2%

Nominal battery voltage

24V

Tolerance on the voltage of bearing U

1%

Network frequency

.

Battery characteristics 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)

Capacity .

General conditions for use Storage temperature

-45° C to +80° C

Operating temperature

-15° C to +40° C

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Relative humidity Weight

90% 2 kg

Volume

1.4 litres

.

Electrical safety • 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 fitted 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.

Indicator lights 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: Phase

Red LED

Green LED

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)

Relay 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

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On-board charger (optional) "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)

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

CAUTION 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 flow and the two LEDs flash 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. CAUTION The charger is supplied in the NEUTRAL position.

Other charging characteristics Maintenance charges 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.

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

60-100

11528012006 EN - 07/2017

Electrical/electronic equipment

60 On-board charger (optional)

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

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

Protection during charging Mains micro-break protection 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.

Time protection 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.

Temperature safety 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.

11528012006 EN - 07/2017

60-101

60

Electrical/electronic equipment

On-board charger (optional)

60-102

11528012006 EN - 07/2017

Hydraulic

70

a

Pump-motor unit Description

A B C D 2Y4 2Y5 1 2

Previous circuit selection hydraulic block New circuit selection hydraulic block Previous lowering proportional solenoid valve New proportional lowering solenoid valve (2Y2) from 01/2016 Initial lift circuit selection solenoid valve Main lift (mast) circuit selection solenoid valve Initial lift cylinder Main lift cylinder

3

Circuit selection hydraulic block (main lift or initial lift) (198 ±7 bar) 2M1 pump motor (24V - 1,2 kW) Pump (1 cm3/rev) Non-return valve 300μ filter Proportional lowering solenoid valve (2Y2) Main pressure cut-off (set at 215 bar) Breather plug Flow limiter

4 5 6 7 8 9 10 11

Tiller controls Central flow Pressure (Bar) LP speed (cm/s) (l/min)

Remote button controls Central flow LP speed (cm/s) (l/min)

Unladen lifting

20

18.4

5.9

15

4.8

Laden lifting Lowering with no load Lowering with load

190

11.5

3.7

9

2.9

20

13

4.2

6.5

2.1

190

31

10

22.2

7.2

.

11528012006 EN - 07/2017

70-1

70

Hydraulic

Pump-motor unit Disassembling the pump unit

70-2

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Hydraulic

70 Pump-motor unit

Removing the pump unit To extract the pump unit from the chassis, proceed as follows: – Remove the covers from the technical compartment, except the traction motor protection – Lower the load arms and the fork – Switch off the ignition and remove the battery socket – Unscrew the Initial Lift (2) and Main Lift (3) cylinder supply hydraulic connections

– Remove the electrical bundling clip (4)

11528012006 EN - 07/2017

70-3

70

Hydraulic

Pump-motor unit – Unscrew the supply cables from the pump motor on the LAC controller (power terminals "+" and "LI") – Disconnect the connector (2X36) for circuit selection solenoid valves 2Y4 and 2Y5 – Disconnect lowering solenoid valve 2Y2

– Unscrew the 2 screws (5) from the pump unit mounting bracket

– From above, remove the pump unit from the chassis.

WARNING Dangerous materials handling procedure. The pump unit is heavy; proceed with caution when releasing it from the chassis.

The wearing of gloves is recommended.

Installation: To fit the pump unit in the chassis, proceed in the reverse order to removal.

70-4

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Hydraulic

70 Pump-motor unit

– Check the condition of the 2 bushings (6) screwed onto the back of the hydraulic block.

NOTE

During installation, check that the 2 bushings (6) are correctly positioned in their chassis holding fixtures.

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70-5

70

Hydraulic

Pump-motor unit

70-6

11528012006 EN - 07/2017

Lifting system

81

a

Initial Lift Initial lift cylinder

1

Cylinder barrel

2

Cylinder rod

Description Initial lift is provided by 1 central single cylinder.

EXU-H 18 and EXU-H 20: cylinder fitted with a ∅ 50-mm rod • Max. travel: 130 mm • Max. operating pressure: 245 bar • Test pressure: 320 bar • Max. push force: 4810 daN • Max. radial force: 500 daN • Weight: 8 kg

Removing the Initial Lift cylinder WARNING Risk of injury The cylinder is a heavy and fragile component that must be handled with care. Safety footwear must be worn and gloves are recommended.

Carry out the following procedures to remove the Initial Lift cylinder: – Remove the covers from the technical compartment (see relevant chapter)

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81

Lifting system

Initial Lift – Lower the load arms to return the cylinder rod and lower the pressure in the circuit – Remove the battery, taking the precautions described in the truck's user manual – Drive out the stop pin from the cylinder rod (1)

– Unscrew the hydraulic union (2) from the cylinder – Remove the electrical plate (see the relevant chapter, section 6)

81-2

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Lifting system

81 Initial Lift

– Drive out the stop pin (3)from the cylinder clevis pin – Remove the clevis pin using an extractor – Raise the fork carriage slightly using a jack – From above, remove the cylinder from the chassis.

Fitting the cylinder When fitting a new cylinder, proceed in the reverse order to removal.

– Bleed the hydraulic system by raising/lowering the Initial Lift several times – Top up the hydraulic oil if necessary.

11528012006 EN - 07/2017

81-3

81

Lifting system

Initial Lift Removing the lift shaft assembly + push rods

1 2 3 4 5 6 7

Fork carriage Spring-type straight pin 6X28 mm Clevis pin/push rod Clevis pin/fork carriage Spring-type straight pin 6X36 mm Lift shaft pin/fork carriage Hc M12X35 teat screw

8 9 10 11 12 13

H M12 locknut KA ∅36 x ∅62 x 1.5 washer Push rod pin Push rod Lift shaft Lift shaft pin/fixed chassis

WARNING Dangerous materials handling procedure. The lifting system is heavy, proceed with caution to release it from the chassis.

The wearing of gloves is recommended.

To change all or part of the lifting system, proceed in the following manner: – Raise the Initial Lift to the highest point – Turn off the power and remove the truck battery connector

81-4

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Lifting system

81 Initial Lift

– Chock the fork carriage in the upper position

– Unscrew the pin stop screw (14) on either side of the truck

– Remove the pin (13) using an inertial extractor (∅ rod M8) on either side of the fixed chassis

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81

Lifting system

Initial Lift – Loosen the locknut (8) then unscrew the teat screw (7) on each side under the lift shaft

– Chock the lift shaft (12) under each push rod (11)

– Remove the pin (6) using an inertial extractor (∅ rod M12) on either side of the fork carriage The lift shaft is uncoupled.

81-6

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Lifting system

81 Initial Lift

– Remove the pin (5) on each load castor clevis pin

– Drive out the pin (4) on each load arm The lift shaft assembly + push rods are now uncoupled from the chassis.

– Slide the assembly under the chassis to release it

Fitting the lifting system – To fit the lifting system, reverse the order for removal.

NOTE

When fitting, do not forget the Teflon shim rings(9) between the ends of the lift shaft and the fork carriage.

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81-7

81

Lifting system

Main Lift Main Lift Cylinder

81-8

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Lifting system

81 Main Lift

1 2 3 4 5 6 7 8 9 10

Belt pulley Wiper Upper guide Rod seal Cylinder body Rod Snap ring Lower guide Right power supply connector G 3/8 M16x1.5 (tightening torque 80 Nm) Cable gland

11 12 13 14 15 16 17 18 19 20 21

Bleeder screw Mounting bracket LB2C safety valve (tightening torque 12 Nm) Cylinder mounting nut on chassis Rigid supply pipe Chassis-side chain anchor Cylinder drum holding fixture in the chassis Magnet Fork holder carriage Fork holder carriage-side chain anchor O-ring

Disassembling the main lift cylinder – Remove the cowling from the auxiliary lift – Lower the load arms and the fork to the lowered position in order to retract the cylinder rods – Switch off the ignition and remove the battery socket

– Unscrew the cylinder mounting screw (5) – Take out the pin (2) and remove the axle (3) from the chain anchor (4) – Slide the chain (1) out of the cylinder pulleys (6) and set it down

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81-9

81

Lifting system

Main Lift – Lift the fork carriage (7) about twenty centimetres off the ground using a jack positioned in the middle of the carriage – Wedge the fork carriage at the top in order to secure it

– Unscrew the power connection (8) from the cylinder (9) – Remove the complete cylinder from above.

Fitting the cylinder

To fit the cylinder on the chassis, proceed in reverse order to removal.

– Ensure that the cylinder mounting screw (5) on the chassis is tightened to a torque of 46 ± 4 Nm

81-10

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Lifting system

81 Main Lift

Removing the fork carriage To remove the fork carriage, proceed as follows: – Remove the main lift cylinder (see relevant chapter) – Unscrew the 2 top mechanical stops from the mast (10) – Sling the carriage and lift it using a hoist with sufficient capacity – Remove the fork carriage from above DANGER Risk of personal injury.

Always use lifting equipment with sufficient capacity.

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81-11

81

Lifting system

Main Lift

81-12

11528012006 EN - 07/2017

Index g NUMBERS AND SYMBOLS

Disassembling the pump unit . . . . . . . . . . 70-2

1B7 tiller foot potentiometer . . . . . . . . . . . 42-2

Display Multifunction indicator 6P4 (CAN bus) . . . . . . . . . . . . . . . . . . . . . . 60-86

A Access to the technical compartment . . . . 30-1 Accessing truck information . . . . . . . . . . . 02-2 Activation of the 1A1 controller . . . . . . . . 60-18 Adjusting the air gap . . . . . . . . . . . . . . . . 42-14

Operating reminder . . . . . . . . . . . . . 60-87 Display for lithium-ion batteries Lithium-ion battery . . . . . . . . 60-43, 60-71 Driver’s platform Changing the gas spring . . . . . . . . . . . 30-6

Adjusting the Creep Speed . . . . . . . . . . . 60-21

Removing the platform . . . . . . . 30-6 – 30-7

Automatic fork lifting/lowering option Operating reminder for the automatic levelling . . . . . . . . . . . . . . . . . . . 60-84

B

E Electrical components mounting plate . . . 60-12 Electrical equipment Creep Speed function (optional) . . . . 60-20

Battery compartment Battery lock . . . . . . . . . . . . . . . . . . . 30-10 Types of compartment . . . . . . . . . . . . 30-9

C

Electromagnetic compatibility . . . . . . . . . . 60-5 Electromagnetic parking brake Y1 . . . . . 42-13 Error codes Reading and deleting the error list . . . 02-42

Calibrating the 1B7 potentiometer . . . . . . . 42-3

External charger

CAN bus network . . . . . . . . . . . . . . . . . . . 02-5

Description . . . . . . . . . . . . . . . . . . . 60-73

CAN bus network of the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . 02-7

Display . . . . . . . . . . . . . . . . . . . . . . 60-73 Electrical interface . . . . . . . . . . . . . . 60-74

Changing the LFM box . . . . . . . . . . . . . . 60-91

Status of lights . . . . . . . . . . . . . . . . . 60-74

Changing the multifunction indicator . . . . 60-89

Technical features . . . . . . . . . . . . . . 60-75

Checking the 1B7 potentiometer . . . . . . . . 42-2

EXU-H standard hydraulic equipment . . . 60-82

Checking the Creep Speed button . . . . . 60-20 Connectors on the power plate . . 60-22, 60-44

F Fault codes . . . . . . . . . . . . . . . . . . . . . . 02-45

D Description of the drive unit . . . . . . . . . . . . 23-1

Fitting a new multifunction indicator . . . . . . . . . . . . . . . . . 60-89, 60-91

Description of the EXU-H 18 and EXU-H 20 electric pallet trucks with auxiliary fork lift . . . . . . . . . . . . . . 00-1

Fitting the cylinder . . . . . . . . . . . . . . . . . . 81-3

Description of the lithium-ion battery A1 and A2 . . . . . . . . . . . . . . . . . . . . . 00-3

Description of Fleet Manager . . . . . . 60-92

Description of the lithium-ion battery B1 and B2 . . . . . . . . . . . . . . . . . . . . . 00-4 Diagnostic connector of the Lithium-Ion battery . . . . . . . . . . . . . . . . . . . . . 02-6 Diagnostics Pictograms of error codes on the display . . . . . . . . . . . . . . . . . . . . 02-44 Digicode LFM GO . . . . . . . . . . . . . . . . . 60-90 Disassembling the main lift cylinder . . . . . . 81-9

Fitting the lifting system . . . . . . . . . . . . . . 81-7 Fleet Manager FleetManager™ FleetManager™ option . . . . . . . . . . . 60-95 Functions of EXU-H trucks equipped with LAC 02 . . . . . . . . . . . . . . . . . . . . 60-6 Functions of the Inputs/Outputs of the LAC 02 . . . . . . . . . . . . . . . . . . . . . . . 60-16

G General General . . . . . . . . . . . . . . . . . . . . . . 60-11

11528012006 EN - 07/2017

1

Index g H

Lithium-ion battery Analysing the battery condition . . . . . 02-40

Hydraulic controls

Block diagram of the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . 02-8

Automatic fork lifting/lowering option . . . . . . . . . . . . . . . . . . . . 60-84

Charging lithium-ion batteries using an external charger . . . . . . . . . . 60-77

Hydraulic equipment Description . . . . . . . . . . . . . . . . . . . . 70-1

Charging using an external charger . . . . . . . . . . . . . 60-77, 60-79

I

Description of the BMS . . . . . 60-24, 60-52

Initial lift cylinder . . . . . . . . . . . . . . . . . . . . 81-1

Disassembling the B1 and B2 battery module . . . . . . . . . . . . . . . . . . . 60-56

Initial lift cylinder description . . . . . . . . . . . 81-1 Installing the external charger . . . . . . . . . 60-81 Insulation testing . . . . . . . . . . . . . . . . . . . 60-4

Error codes for the lithium-ion battery A1-A2 . . . . . . . . . . . . . . . . . . . . 02-11

L

Error codes for the lithium-ion battery B1-B2 . . . . . . . . . . . . . . . . . . . . 02-26

Lithium Ion Battery

Indicator light . . . . . . . . . . . . . . . . . . . 02-9 Inputs/outputs of the BMS connector . . . . . . . . . . . . . . . . . . . . . . . 60-25

LTroubleshooting flow chart B1-B2 . . 02-29

Power plate overview . . . . . . 60-37, 60-64 Questionnaire to identify battery condition . . . . . . . . . . . . . . . . . . 02-41 Reassembling the B1 and B2 battery module . . . . . . . . . . . . . . . . . . . 60-59 Replacing the A1 battery module . . . 60-33 Replacing the A2 battery module . . . 60-35 Replacing the battery fuse . . . . . . . . 60-40 Replacing the BMS . . . . . . . 60-26, 60-53 Replacing the BMU harness . . . . . . . 60-28 Replacing the contact switch . . . . . . . 60-66 Replacing the contactor . . . . . . . . . . 60-39 Replacing the cover provided . . . . . . 60-46 Replacing the diagnostic harness . . . 60-49 Replacing the fuse . . . . . . . . . . . . . . 60-68 Replacing the power cable . . 60-51, 60-72 Replacing the push button provided . 60-48 Replacing the shunt . . . . . . . . . . . . . 60-62 Replacing the SMU harness (A1 battery) . . . . . . . . . . . . . . . . . . . 60-29 Replacing the SMU harness (A2 battery) . . . . . . . . . . . . . . . . . . . 60-30 Replacing the terminal block . . . . . . . 60-50 Lithium-ion battery socket . . . . . . 60-41, 60-69 Lithium-ion module . . . . . . . . . . . 60-32, 60-55 Lithium-ion service base . . . . . . . . . . . . . 02-10 Location of connectors for the lithium-ion battery . . . . . . . . . . . . . . 60-22, 60-44

M Main Lift cylinder description . . . . . . . . . . . 81-8

2

11528012006 EN - 07/2017

Index g Maintenance plan

Stabiliser wheels

1000-hour/annual maintenance plan . . 01-1 3000 hours . . . . . . . . . . . . . . . . . . . . . 01-2 Male connector of the lithium-ion battery Coding system . . . . . . . . . . . 60-41, 60-69

Removing . . . . . . . . . . . . . . . . . . . . 42-24

T Technician electrical accreditation . . . . . . 00-5

P

Traction and hydraulic controller - LAC 02/ 1A1 . . . . . . . . . . . . . . . . . . . . . . 60-15

Platform

Traction motor Features of the traction motor . . . . . . . 11-1

Overview . . . . . . . . . . . . . . . . . . . . . . 30-5

Overview . . . . . . . . . . . . . . . . . . . . . . 11-2

Power module Connections . . . . . . . . . . . . . . . . . . . 11-3 Programming the new multifunction indicator . . . . . . . . . . . . . . . . . . . 60-89

Technical features . . . . . . . . . . . . . . . 11-1 Traction speed settings . . . . . . . . . . . . . 60-19 Transmission gear . . . . . . . . . . . . . . . . . . 23-3

R

Changing the transmission gear seals . . . . . . . . . . . . . . . . . . . . . . 23-9

Reducer unit . . . . . . . . . . . . . . . . . . . . . . 23-4

Draining the transmission gear . . . . . 23-11 Refitting . . . . . . . . . . . . . . . . . . . . . . . 23-7

Removing a stabiliser . . . . . . . . . . . . . . . 42-17

Refitting the sealing ring of the traction motor bearing . . . . . . . . . . . . . . . 23-10

Removing the drive unit . . . . . . . . . . . . . . 23-2 Removing the electrical plate . . . . . . . . . 60-13

Refitting the wheel shaft sealing ring . . 23-9

Removing the fork carriage . . . . . . . . . . . 81-11

Removing the sealing ring of the traction motor bearing . . . . . . . . . 23-10

Removing the front cover . . . . . . . . . . . . . 30-2 Removing the Initial Lift cylinder . . . . . . . . 81-1

Removing the transmission gear . . . . . 23-6

Removing the intermediate cover . . . . . . . 30-2

Removing the wheel shaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . 23-9

Removing the lift shaft assembly + push rods . . . . . . . . . . . . . . . . . . . . . . . 81-4

U

Removing the load arm components Removing the fork clevis . . . . . . . . . . 42-26 Removing the load wheels . . . . . . . . 42-25 Removing the lower cover . . . . . . . . . . . . 30-2

Using the side socket to charge the battery . . . . . . . . . . . . . . . . . . . . 60-75

Removing the motor covers . . . . . . . . . . . 30-3

W

Removing the pump unit . . . . . . . . . . . . . . 70-3

Wheels

Removing the sheet metal over-chassis . . 30-4 Removing the traction motor . . . . . . . . . . . 11-4

Adjusting the height of the stabiliser wheel . . . . . . . . . . . . . . . . . . . . . 42-17

Rev sensor . . . . . . . . . . . . . . . . . . . . . . . 11-5

Description of the wheels . . . . . . . . . 42-18 Removing the drive wheel . . . . . . . . . 42-23

S

Removing the load arm components . . . . . . . . . . . . . . . . . . . . . 42-25

Safety guidelines Electrical equipment . . . . . . . . . . . . . . 60-1

Removing the stabiliser wheels . . . . . 42-24

Setting the acceleration . . . . . . . . . . . . . . 42-3

Stabilisers (option) . . . . . . . . . . . . . . 42-16

Speed reduction following a technical fault . . . . . . . . . . . . . . . . . . . . . . 60-19

Stabilisers (standard) . . . . . . . . . . . . 42-15 Types of drive wheel . . . . . . . . . . . . . 42-19

Speed reductions . . . . . . . . . . . . . . . . . . 60-19

Types of load wheel . . . . . . . . . . . . . 42-22 Types of stabiliser wheels . . . . . . . . . 42-21

11528012006 EN - 07/2017

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STILL GmbH 11528012006 EN – 07/2017