Still FXH 20N FXH 25N Pallet truck with driver seated Workshop Literature Manual - PDF DOWNLOAD

Workshop literature

Pallet truck with driver seated FXH 20N, FXH 25N

1326 1327 11548012111 EN - 09/2017

History of changes g Edition 09/2017 • First edition

11548012111 EN - 09/2017

I

Table of contents g 00 Product information Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 1 Pallet truck with driver seated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 1 Serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 2 Recommended lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 6

Description of the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 7 Description of the lithium-ion battery B1 and B2

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Safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 8 Slinging the truck

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Lifting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 8

Lithium-ion safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 10 Technician electrical accreditation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 10

01 Service Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01- 1 1000-hour maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01- 1 5000-hour maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01- 1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01- 2 Standardised tightening torques for standard-pitch threads and fine-pitch threads . . . 01- 2 Measuring and testing equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01- 3

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

Truck diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 2 Accessing truck information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 2 Diagnostics service box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 4 Connecting a laptop to the USB CAN Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 5 CAN Bus network with LAC and ES30-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 6

Lithium-ion battery diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 8 Diagnostic connector of the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 8 CAN bus network of the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 9 Indicator light for the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 10 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 11 Error codes for the lithium-ion battery B1-B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 12 Troubleshooting flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 15

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Table of contents g Analysing the battery condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 26 Questionnaire to identify battery condition

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Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 28 Reading and deleting the error list

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Pictograms of error codes on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 30

11 Traction motor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 1 Features of the traction motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 3

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 4 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 4 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 4 Traction motor winding test

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Rotor testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 4 Cleaning the motor

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Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 6 Rev sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 6 Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 7

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

Transmission gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23- 2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23- 2 Reducer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23- 4

30 Chassis, bodywork and fittings Fixed chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 1 Accessing the technical compartment

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Accessing the dashboard components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 2

Driver’s platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 3 Description of the adjustable floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 3 Operator presence detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 4

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 5 Description of the seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 5 Seat heater (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 7

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Table of contents g Linkage of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 8 Load lift system with level compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 8 Load lift system without level compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 10

Battery compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 11 Types of compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 11 Battery lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 12

42 Steering, braking and wheels ES30-24 steering unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 3 Adjusting the electric steering ES30-24

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Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 6 Description of the steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 6 Description of the steering knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 7 Description of the control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 8 Description of the joystick (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 10

Setpoint sensor 3B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 11 Steering centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 11 Description of the pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 12 Features of the Hall effect setpoint sensor

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Principle of the Hall effect sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 14

Electromagnetic brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 15 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 15

Stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 16 Features of the fixed stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 16 Stabiliser height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 17

Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 19 Description of the wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 19 Types of drive wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 20 Types of wear on drive wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 21 Types of stabiliser wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 22 Types of load wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 23

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Table of contents g 50 Control devices Control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50- 1 Traction function on the control module

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Initial lift function on the control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50- 2 Horn function on the control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50- 3

Joystick (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50- 4 Functions of the joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50- 4

60 Electrics/electronics 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 FXH 20N / FXH 25N technical compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 6 Location of connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 7 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 8 Contact switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 10 Emergency off switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 10 Horn (4H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 11

Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 12 Traction and lift controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 12 Functions of the inputs/outputs of the LAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 13 Activating controllers 1A1 and 3A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 15 Speed reductions

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Central negative point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 18 Central positive point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 20 Parameterising the control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 21 Operational checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 22 Rev sensor (1B2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 22 Checking the operation of the temperature sensor (1B6) . . . . . . . . . . . . . . . . . . . . . . 60- 25 Electromagnetic brake (Y1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 27 Operator presence detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 28 Fan (9M1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 29 Control module (1B1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 30

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Table of contents g Electric steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 31 Electric steering unit ES30-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 31 Functions of the "inputs/outputs" of the ES30-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 32 Switching on the ES30-24 unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 33

Lithium-ion battery B1 and B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 35 Location of connectors for the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 35 Replacing the cover provided . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 36 Replacing the push button provided . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 38 Replacing the diagnostic harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 39 Replacing the terminal block

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 40

Replacing the power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 41 BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 42 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 42 Replacing the BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 43 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 45 Lithium-ion module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 45 Disassembling the B1 and B2 battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 46 Reassembling the B1 and B2 battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 49 Replacing the shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 52 Power box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 54 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 54 Replacing the contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 55 Replacing the fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 57

11548012111 EN - 09/2017

VII

Table of contents g Charger for lithium-ion batteries (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 58 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 58 Installing the external charger

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 61

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 62 Description of the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 62 Display operating unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 64

Operation of the display unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 64

Electronic key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 69 Digicode LFM GO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 69

FleetManager™ (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 71 FleetManager description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 71 TDU: Access control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 72 FleetManager™ option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 73

70 Hydraulics Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70- 1 Features of the initial lift cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70- 1 Main hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70- 2 Operational logic of the initial lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70- 3 Main hydraulic system (FXH 25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70- 4 Operational logic of the initial lift (FXH 25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70- 5

Pump-motor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70- 6 Description of the pump-motor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70- 6 Description of the pump-motor unit (FXH 25)

VIII

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70- 7

11548012111 EN - 09/2017

Product information

00

a

Foreword Pallet truck with driver seated

Features Nominal capacity

FXH 20N 2000 kg

FXH 25N 2500 kg

Speed when laden/unladen

10 km/h / 12 km/h

Traction/lift controller

LAC 04 3 kW (asynchronous) Asynchronous steering motor 0.185 kW (S1) Electromagnetic Control module (traction/lift) and steering wheel (steering) Joystick (traction/lift) and steering knob (steering) Fixed Seated with adjustable floor 1.2 kW (S3: 10%) 1.5 kW (S3: 10%) Side access (3 PzS and 4 PzS) FleetManager, electronic key

Traction motor ES30-24 electric steering unit (maintenance-free) Brake type Control unit

as standard as options

Platform Driving Pump-motor unit (maintenance free) Battery Option .

11548012111 EN - 09/2017

00-1

00

Product information

Foreword Serial numbers Truck label The serial number can be found on the identification label on the truck.

This number provides information about the production location (1), the series (2), the year of production (3) and the sequential production number (4).

Four-digit

Year of production (3) One-digit

Sequential number (4) Five-digit

1326 = FXH 20

H = 2017

e.g. 00020

Production location (1)

Series (2)

Two-digit W4 = Fenwick Linde, Châtellerault Year of production table (3) 0

1

2

3

4

5

6

7

8

198x

0

1

2

3

4

5

6

7

8

9

199x

A

B

C

D

E

F

G

H

J

K

200x

L

M

N

P

R

S

T

U

W

Z

201x

A

B

C

D

E

F

G

H

J

K

202x

L

M

N

P

R

S

T

U

W

Z

Year 197x

X

.

LAC controller label The serial number of the LAC controller is listed on the label as shown opposite:

00-2

9

11548012111 EN - 09/2017

Product information

00 Foreword

Traction motor label The serial number of the traction motor is listed on the label as shown opposite:

Transmission gear label The serial number of the transmission gear is listed on the label as shown opposite:

ES30-24 steering unit label The steering motor label is located on the side.

11548012111 EN - 09/2017

00-3

00

Product information

Foreword Control unit: small module

Control unit: joystick (option)

Steering centre with steering wheel or steering knob (option)

Pump-motor unit label For the FXH 20: The serial number of the pump-motor unit is listed on the label as shown opposite:

00-4

11548012111 EN - 09/2017

Product information

00 Foreword

For the FXH 25: The serial number of the pump-motor unit is listed on the label as shown opposite:

11548012111 EN - 09/2017

00-5

00

Product information

Foreword Recommended lubricants SAE 85W 90 API GL4

CAUTION Damage to equipment if non-recommended lubricants are used Only use recommended lubricants. Only the lubricants listed below are approved by the manufacturer. Do not mix lubricants. If in doubt, please contact the After-Sales Service Centre.

Aerosol can for chains Linde standard chain spray A167.

Grease for pinion gear and steering ring CAUTION

Hydraulic oil

Follow the maintenance and safety instructions.

Recommended oil for standard use: ISO-L-HM 46 as per ISO 6743-4 or ISO VG46HLP as per DIN 51524-2 Recommended oil for heavy-duty use: ISO-L-HM 68 as per ISO 6743-4 or ISO VG68HLP as per DIN 51524-2 Recommended oil for the cold store version: ISO-L-HM 32 as per ISO 6743-4 or ISO VG32HLP as per DIN 51524-2

Transmission oil Recommended oil:

00-6

Multi-purpose grease Lithium soap grease with EP agents and MoS 2 KPF 2N - 20 complying with the standard DIN 51825.

ENVIRONMENT NOTE

Used oil must be stored safely until it is disposed of in compliance with environmental protection measures. No one should have access to the used oil. Do not dispose of used oil in drains or allow it to penetrate soil.

11548012111 EN - 09/2017

Product information

00

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

Battery type

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

Nominal voltage (V)

Nominal capacity (Ah)

B1 (1 module)

718

618

210

108

23,1

205

B2 (2 modules)

718

618

210

139

23,1

410

.

11548012111 EN - 09/2017

00-7

00

Product information

Safety guidelines Slinging the truck DANGER Danger of truck falling Only use slings and a hoist of sufficient quality.

Check the weight of the machine (including battery) in order to choose a suitable device.

Refer to the technical features.

Observe the following instructions: – Switch off the truck and disconnect the battery connector.

– Remove any items that could fall.

– Protect all parts that come into contact with the lifting device.

– Attach the lifting device (1).

NOTE

Do not sling the truck by the steering wheel or the control module.

– Carefully lift the truck.

DANGER Risk of falling Make sure no one is under or near the truck when slinging the truck.

Lifting the truck DANGER Danger of truck tipping over Truck lifting must be performed carefully.

For certain types of work, it is necessary to lift the truck: – Use a jack with adequate lifting capacity.

Front section of the truck: – Place the jack under the chassis (1).

For work on the lifting device: – Position the jack under the battery frame (2).

Maintenance of the load wheels: – To service the load wheels, the jack must be positioned under the load arms in the locations indicated (3).

00-8

11548012111 EN - 09/2017

Product information

00 Safety guidelines

As a safety precaution, always insert a wooden chock.

WARNING Risk of truck falling Immobilise and chock the truck after lifting it.

11548012111 EN - 09/2017

00-9

00

Product information

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.

00-10

11548012111 EN - 09/2017

Service

01

a

Maintenance 1000-hour maintenance plan Depending on the application, environmental conditions and driving style, the following procedures should be carried out every 1000, 2000, 3000, 4000, 6000, 7000, 8000 and 9000 hours Preparation Clean the truck Check the error codes using the diagnostic tool Chassis and equipment Check the condition of the forks Check the electromagnetic brake and ensure that it is working correctly Check and lubricate the hinges Check the pump motor brushes for wear Ensure that the floor adjusts and locks correctly Ensure that the seat adjusts and locks correctly Check the transmission gear for noise and leaks Lubricate the gears Wheels Check the condition and tightness of the wheels Check the stabilisers Electrical equipment Clean the electric steering system and lifting motors Check the condition of the cables and the battery sockets and ensure that they are positioned correctly Check the electrical insulation between the chassis and the electric components Check the electrical insulation between the chassis and the electronic components Check the fuses Check the battery acid level and the electrolyte level Hydraulics Check the hydraulic oil level .

5000-hour maintenance plan Depending on the application, environmental conditions and driving style, the following procedures should be carried out every 5000 and 10,000 hours Information Carry out all 1000-hour maintenance work Motor Drain the transmission gear oil Hydraulics Drain the hydraulic oil .

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01-1

01

Service

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

.

01-2

11548012111 EN - 09/2017

Service

01 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

.

11548012111 EN - 09/2017

01-3

01

Service

Tools

01-4

11548012111 EN - 09/2017

Diagnostics

02

a

Diagnostic tools 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.

11548012111 EN - 09/2017

02-1

02

Diagnostics

Truck diagnostics Accessing truck information

The truck diagnostics are carried out using a laptop, on which the diagnostic software and the corresponding Service Base for the truck are installed.

NOTE

Truck settings and diagnostics can only be carried out by technician laptops equipped with the diagnostic software.

The laptop is connected via an interface unit (CAN Box) to the truck's diagnostics connector.

Depending on the type of CAN Box used (serial or USB), the laptop can be connected using a Sub-D plug or a USB cable. In both cases, the diagnostic options remain identical.

The diagnostics equipment is connected to a single connector (6X7) which is located below the dashboard. This diagnostic connector acts as an interface with the CAN Bus and enables all modules to be diagnosed.

02-2

11548012111 EN - 09/2017

Diagnostics

02 Truck diagnostics

NOTE

After diagnostics are completed, the lid must be screwed back onto the diagnostic connector to prevent moisture from getting in.

Parameterising

1 2 3

F2: Diagnostics Start points for the diagnostics Jobs

A guided diagnosis process can be used to individually select and carry out various diagnostic sequences and jobs. The user is continuously guided by the program. Always follow the relevant specifications provided.

– Park the truck safely.

– Lift the truck.

– Start the truck.

– Switch on the laptop and start the diagnostic tools.

– Connect the laptop to the truck.

– Select the desired diagnostics and doubleclick on it to start.

It may take a while to establish a connection with the truck and to start diagnostics.

11548012111 EN - 09/2017

02-3

02

Diagnostics

Truck diagnostics Diagnostics service box Service box , BT USB cable: the service box must be loaded 1 with the current software. The USB cable will be omitted in later versions Connection for the adaptor cable, 7-pin, 4 2 pins assigned Connection for the adaptor cable, 7-pin, 6 3 pins assigned The LED lights up once the service box 4 is supplied with voltage via the diagnostic connector when the truck is switched on The LED indicates the status between the 5 notebook and the service box The LED indicates the status between the 6 service box (CAN 1) and the truck The LED indicates the status between the 7 service box (CAN 2) and the truck 8 The LED indicates the Bluetooth status 9 Antenna 10 STILL Bluetooth USB stick If all LEDs (3,4,5,6) are flashing, the service box is in programming mode. In this case, the service box must be reset.

Service box, USB 1 2 3 4 5 6 7

USB cable: the service box is connected to the notebook Connection for the adaptor cable, 7-pin, 4 pins assigned Connection for the adaptor cable, 7-pin, 6 pins assigned The LED lights up once the service box is supplied with voltage via the diagnostic connector when the truck is switched on The LED indicates the status between the notebook and the service box The LED indicates the status between the service box (CAN 1) and the truck The LED indicates the status between the service box (CAN 2) and the truck

If all LEDs (3,4,5,6) are flashing, the service box is in programming mode. In this case, the service box must be reset.

Resetting the service box Switching the truck off and on again will trigger a reset of the service box. Switching the truck off interrupts the CAN bus power supply.

02-4

11548012111 EN - 09/2017

Diagnostics

02 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

11548012111 EN - 09/2017

02-5

02

Diagnostics

Truck diagnostics CAN Bus network with LAC and ES30-24

6X2:3 6X7 1A1 3A1 6P4

1X1:14 CAN high (traction and lift) 1X1:28 CAN low (traction and lift) 3X1:C1 CAN 1 high (steering) 3X1:C2 CAN 1 low (steering) 6X2:4 CAN high (display)

CAN low (display) Diagnostic connector LAC traction/lift controller Steering controller ES30-24 Display

The CAN Bus communication network between the multifunction indicator and the controllers includes: • "CAN HIGH" • "CAN LOW" • Two 120- "Rt" terminating resistors fitted in parallel in the circuit Checking the CAN Bus: • The measurable resistance value of the diagnostics connector (6X7) between the terminals (1) and (2) is around 60 . This value is measured between the CAN high and the CAN low when the truck is not switched on • Using a voltmeter, the measured value of the diagnostic connector (6X7) between terminals

02-6

11548012111 EN - 09/2017

Diagnostics

02 Truck diagnostics

(4) and (1) must be between 2.5 V and 3.5 V when the truck is switched on.

• Using a voltmeter, the measured value of the diagnostic connector (6X7) between terminals (4) and (2) must be between 1.5 V and 2.5 V when the truck is switched on.

11548012111 EN - 09/2017

02-7

02

Diagnostics

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

Assignment of battery connector X33 1 CAN high 2 CAN low 3 12 V DC (for diagnosis with the CAN box)

02-8

4 5 6 7

0V Emergency signal N/A N/A

11548012111 EN - 09/2017

Diagnostics

02 Lithium-ion battery diagnostics

CAN bus network of the lithium-ion battery

6X7 X33

Truck diagnostic socket Diagnostic connector 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

6P4

Multifunction indicator of the lithium-ion battery

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 switched on • 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 switched on

11548012111 EN - 09/2017

02-9

02

Diagnostics

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

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.

02-10

11548012111 EN - 09/2017

Alarm activated No

Diagnostics

02 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

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

11548012111 EN - 09/2017

02-11

02

Diagnostics

Lithium-ion battery diagnostics 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

02-12

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

11548012111 EN - 09/2017

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)

11548012111 EN - 09/2017

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

02-13

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

.

02-14

11548012111 EN - 09/2017

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

YES

NO

1

INSTRUCTIONS Charge the battery for 20 minutes at 10 A

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)

.

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

5

NOTE Go to step 2 Go to step 4

END

END

.

11548012111 EN - 09/2017

02-15

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

.

02-16

11548012111 EN - 09/2017

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

11548012111 EN - 09/2017

02-17

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

02-18

11548012111 EN - 09/2017

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

11548012111 EN - 09/2017

02-19

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

02-20

NOTE Go to step 2

11548012111 EN - 09/2017

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

11548012111 EN - 09/2017

Go to step 3 02-21

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

.

02-22

NOTE

11548012111 EN - 09/2017

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

.

11548012111 EN - 09/2017

02-23

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 .

02-24

11548012111 EN - 09/2017

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

.

11548012111 EN - 09/2017

02-25

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

.

02-26

11548012111 EN - 09/2017

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

11548012111 EN - 09/2017

02-27

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

02-28

11548012111 EN - 09/2017

Diagnostics

02 Error codes

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

11548012111 EN - 09/2017

02-29

02

Diagnostics

Error codes Pictograms of error codes on the display

Faults 1 A B 2

9 10

Warning icon A fault appears Several faults appear Navigation between the screens

Internal error display Other

Types of warnings 11 Brake: brake worn 12 Lower the load arms: the height of the forks is greater than 1.80 m 13 Temperature: the temperature of the motor OR the controller is too high 14 Low battery: the battery is almost discharged (remaining charge between 20% and 0%) 15 Maintenance: maintenance scheduled today OR next maintenance (in hours or date)

Types of error 3 Traction 4 Hydraulics 5 Steering 6 Electrical (sensor) 7 Electrical (internal to the LAC) 8 CAN

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

In case of multiple faults, errors are displayed on multiple screens.

It is possible to navigate between the different screens using the arrows (2).

02-30

11548012111 EN - 09/2017

Traction motor

11

a

Description Features of the traction motor

1 2 3 4 5 6 7 8 9 10

Lock ring 25x1.2 Lock ring 30x1.5 Hexagon head screw - DE-M6x25-St-A3C Button head screw - CE-M6x12-St-A2C Speed sensor (1B2) Terminal block Motor temperature sensor (1B6) Castellated nut Protective cap O-ring

Asynchronous traction motor (AC) fitted vertically on the transmission gear, which is itself fixed to the drive unit support.

11 12 13 14 15 16 17 18

Bearing housing Lock ring 20x1.2 Grooved ball bearing 6204-2RSH Lock ring 47x1.75 Parallel key Lock ring 55x2 Grooved ball bearing 6006-2RS Electromagnetic brake without hydraulic assistance

Technical features Voltage

Three-phase asynchronous motor 24 V

Nominal power

3 kW

Current Motor speed (S2 - 60 min.)

Torque at maximum speed Maximum torque

166 A

Model

Maintenance-free motor controlled by: • One speed sensor (1B2) - Connector (1X2) and screw CE-M6x12-St-A2C - (tightening torque: 5 Nm) • One motor temperature sensor 1B6 - Connector (1X25)

4865 rpm 5.2 Nm 35 Nm (590 rpm)

.

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11-1

11

Traction motor

Description Overview

1 2 3 4 5 6 7 8

11-2

Bearing shield Lock ring - 30 x 1.5 FST - DIN 471 Parallel key - 8 x 7 x 20 DIN 6825 Ball bearing - 6006 2 RS1 / C3GJN DIN 625 Screw, DE-M 6 x 25-St-A2E - DIN 7500 (tightening torque: 12 Nm) Lock ring 55 x 2 FST - DIN 472 Ring gear (for speed measurement) Rotor

9 10A 10B 11 12 13 14

Lock ring 47 x 1.75 FST - DIN 472 Ball bearing 2RSH Ball bearing ICOS-D1B04 TN9 Lock ring 20 x 1.2 FST - DIN 471 O-ring 56 x 3.90 SHORE A Roller bearing (housed in the transmission gear) Stator

11548012111 EN - 09/2017

Traction motor

11 Description

Location of components

1 2 3 4 5

Electromagnetic brake Rev sensor 1B2 Traction motor 1M1 Traction/lifting controller 1A1 Temperature sensor 1B6

6 7 8 9

U, V and W power cables of the traction motor Rev sensor connector 1X2 Brake connector 7X6 Temperature sensor connector 1X25

The connections of the traction motor (terminals U, V, W) are connected to the controller 1A1 (4).

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) must 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).

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11-3

11

Traction motor

Checking Preparation If the motor does not start when the accelerator is activated, there may be a fault related to the power module or the control module.

These components should be first checked before testing the motor.

NOTE

It is only possible to test three-phase motors without the appropriate measuring and test instruments.

Visual inspection The following points must be checked if a motor operating fault is detected:

• speed sensor

External check: corrosion, contamination, cracks, correct mounting of the following components:

Also check the following:

• speed sensor connector • cleanliness of motor (oil, grease, dirt).

• connections U, V, W of the traction motor • temperature sensor connector

Traction motor winding test Between U and V Between U and W Between V and W 7.5 ±1 m

Resistance value Damaged winding insulation may cause a short circuit in one or more turns within a coil or coil group. The winding resistances can be tested to only a limited extent as the coils are hardwired together in the motor. The test must be carried out with a resistance measuring bridge as the winding resistances are very low (m range).

This allows the total resistance between two motor connections to be measured, although not that of individual coil groups. To ensure correct measurement, the motor connections from the power module to the motor must be

disconnected. The motor connections must be cleaned to prevent any measuring differences due to contact resistances.

Three resistance measurements must be performed on each motor at the connections U, V, W. If comparative measurements show different resistance values or an interruption, there is probably a defect in one or more coils of the stator or at the connections or supply cable inside the motor.

Rotor testing After dismantling, the rotor must be subjected to thorough cleaning and examination. Here a check should be make for cracks in the end ring as well as detached end rings. Less current will flow in areas with cracks due to the increased resistance. The rotor should be checked for

11-4

exposure to excessive heat or local heat build-up.

This may be identified by discolouration of the rotor.

However, brown discolouration of the rotor is normal.

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Traction motor

11 Checking

Cleaning the motor To ensure adequate cooling of the electric motors, the drive axle must be cleaned at the specified inspection and maintenance intervals.

The outside of the drive axle can be cleaned thoroughly. The best cleaning agent is oil-free compressed air. If the outside of the axle housing is very heavily soiled, a high-pressure cleaner can be used. However, depending on the level of contamination, it is recommended that the air ducts and power modules are removed.

Special care should be taken to ensure that the spaces between the cooling fins on the motor are free from contamination, so as to ensure correct cooling of the motor. Only water may be used for this. Under no circumstances should chemical cleaning agents be added when using a high-pressure cleaner. Chemical cleaning additives may attack the plastic parts of the motor. Sufficient distance must be maintained between the jet lance and the motor.

NOTE

After disassembly of the motor connections, the electrical contact surfaces should be cleaned thoroughly before reassembly to avoid damage and error messages due to excessive contact resistance.

Intensive cleaning with a high-pressure cleaner should be avoided around the motor connections.

No moisture should be allowed to enter the motor. If despite all precautions, moisture does penetrate the motor, the truck must be driven for

an extended period to avoid corrosion damage (drying through heat generated by truck), or the motors must be dried using a heat source (hot-air blower or heating system).

A motor that has been dismantled must not be cleaned with a high-pressure cleaner in the area around the stator. Do not use compressed air for cleaning, as compressed air may contain oil or moisture. Firstly, any large particles of electrically conductive foreign matter should be removed by suction. Dust and grease should then be removed from the stator using a cloth and a solvent that will remove oxides and sulphides as well as gummed oils and greases. A final cleaning of the stator should be carried out with an electric cleaning material (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. This allows all dirt to be rinsed thoroughly from the windings. After rinsing, the stator must be dried with a hot-air blower. Here it must be ensured that the blower temperature does not exceed 150 °C or the finish on the windings may be irreparably damaged.

The rotor can be cleaned with conventional cleaning methods .

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

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11

Traction motor

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 module 1A1 by a connecting cable.

Mounting position The rev sensor (1B2) is located at the front of the traction motor.

NOTE

The rev sensor can be tested using the diagnostic tool (see Chapter 60 -> Traction -> Checking the operation of the rev sensor).

11-6

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Traction motor

11 Sensors

Temperature sensor

The reference number of the traction motor enables the type of temperature sensor to be identified.

It is KTY84-130 type.

The temperature sensor (1B6) is located on the traction motor.

It is connected to the traction motor power module.

It is dust-proof and splash-proof.

The power module controls the temperature and sends this information to the truck control unit via the CAN Bus. NOTE

The temperature sensor can be parameterised using the diagnostic tool (see Chapter 60 -> Traction -> Checking the operation of the temperature sensor).

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11

Traction motor

Sensors

11-8

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Transmission

23

a

Drive unit Description of the drive unit

115400_23-002 1 2 3

4 5 6

Electromagnetic brake Traction motor Turntable

Drive wheel Transmission gear Electric steering ES30-24

The drive unit is mounted on a turntable. Steering is provided by the electric steering that positions the turntable.

The drive wheel is driven by the transmission gear with a first stage reduction and a spur and pinion final drive.

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23

Transmission

Transmission gear Description

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

Hexagon head screw M8x60-8.8-A2C Hub Ring gear Shaft Wheel bolt Tapered roller bearing 30210 Lipped ring B75X95X5 Washer Ring Bush Housing Tapered roller bearing 32012X Washer Gear (assembly) Washer Hexagon head screw M16x45-8.8-A2C

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

O-ring 140x3-NBR90 Cover Screw plug M14x1.5 - Magnet M14x1.5 Seal ring A14X18 Socket head screw M8x16-10.9 Tapered roller bearing 32012X Washer Bush Screw plug PLIH-M14x1.5-FKM80 Gear Nut H M20x1.5 Pinion gear Threaded pin M8x8-4.6 Parallel pin 8m6x20-St Socket head screw M8x30-8.8

The drive wheel is driven by a transmission gear with first stage reduction and ring and pinion at the outlet.

The rotation of the transmission gear is guided by a slewing ring fixed to the chassis.

23-2

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Transmission

23 Transmission gear

Technical features Gear reducer Load on the drive wheel Number of teeth: slewing ring

1.5T maxi 108

Reduction ratio

19.67

Volume of oil Maximum torque on the wheel (static) Maximum torque on the wheel (dynamic) Torque on the wheel

1.5 litres 1375 Nm 916 Nm 229 Nm

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

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23

Transmission

Transmission gear Reducer unit

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

23-4

Lubrication conduit Set screw M8X1.8 (for specific applications, two grease nipples can be fitted instead of the set screw) Nut (tightening torque: 170 Nm) Brake nut Straight gear Tapered roller bearings (inner rings fitted with Loctite 603) Spacer Spacing washer O-Ring seal Bevel pinion shaft Cover Screw CHC M8X16 ( torque value 23Nm) Screw H ISO 4017 M16x45 - 8.8-A2C (torque value 290Nm) Locking washer Adjustment spacers Bevel gear Drain plug

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

Drain plug gasket Taper roller bearing Protective cowling Wheel shaft Taper roller bearing Bracing ( 60 / 7.5) Spacing washer Sealing ring (fitted with loctite 574) Wheel pin (torque value 35Nm ) Toothed gear Socket head screw M8X30 to secure the ring gear (see the tightening torque in point 31) Guide pin Reducer case Torque value 23Nm Toothed steering ring (z=108; m=2.5) Socket head screw M8X60 to secure the pivot bearing (see the tightening torque in point 31) Turntable Threaded spacer mounting holes

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Chassis, bodywork and fittings

30

a

Fixed chassis Accessing the technical compartment

Equipment required • Ratchet handle, a size 15 socket and 2 extenders To access the technical compartment: – Immobilise the truck.

– Raise the floor to the maximum level using the adjustment knob.

– Remove the mounting screws using a ratchet handle (1), a size 15 socket (2) and extenders (3).

– Open the technical compartment door.

– Lower the load lift system.

– Switch off the truck (key or electronic key).

– Proceed in the reverse order to close.

– Press the emergency off switch.

– Disconnect the battery connector.

NOTE

Tightening torque of the mounting screw: 77 Nm.

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30

Chassis, bodywork and fittings

Fixed chassis Accessing the dashboard components

1 2 3 4 5 6

Control module Control module connector 1X3 Joystick (option) Display Display connector 6X2 Steering knob (option) and braking module

7 8 9 10 11 12

Braking module connector X13 Steering wheel and braking module Switch key connection Switch key Electronic key Electronic key connection

CAUTION Risk of accident Before commencing work: – Lower the load lift system.

– Switch off the truck (key or electronic key) – Press the emergency off switch – Disconnect the battery connector

30-2

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Chassis, bodywork and fittings

30

Driver’s platform Description of the adjustable floor

1 3

2

4 5 CS 25 Nm

CS 50 Nm

7 6

CS 10 Nm

115401_30-001

1 2 3 4

Push button Carriage assembly Step plate Connector of the operator presence detection pedal (1X9)

5 6 7

Operator presence detection pedal Gas spring Bottom plate

Adjustable floor equipped with a sliding system that comprises: • A flexible rubber non-slip mat for the floor (7) • A flexible rubber non-slip mat for the step plate (3) • A push button (1) controls the gas spring (6) of the carriage assembly (2) • An operator presence detection pedal (5) on the step plate (3)

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30

Chassis, bodywork and fittings

Driver’s platform Operator presence detection

A

Operator not present on the platform

B

Operator present on the platform

The operator presence detection system consists of: • An operator presence contact (1S9) (pedal) Operator not present on the platform: • Pedal in raised position • Contact (1S9) closed - switch not activated • Traction not authorised Operator present on the platform: • Pedal depressed • Contact (1S9) open - switch activated • Traction authorised NOTE

Refer to Chapter 60: Electrical equipment for checking the operation of the operator presence detection.

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30

Seat Description of the seat CAUTION Risk of damage to the seat if the technical compartment is opened.

– Always move the seat forward before opening the technical compartment.

The position of the driver's seat can be changed: • The lever (1) allows you to adjust the horizontal position • The lever (2) allows you to adjust the tilt of the backrest The driver's seat is equipped with an operator presence detector, which includes: • An operator presence contact (1S29) The operator must adjust his weight by increments of 10 kg with the adjustment wheel (3) to trigger this detection.

1 2 3

Operator on the seat:

Lever for adjusting the horizontal position Lever for adjusting the position of the seat backrest Adjustment wheel for the weight of the operator

• Operator in a sitting position • Operator weight adjusted correctly • Contact (1S29) closed - switch activated • Traction authorised Operator not present on the seat: • Contact (1S29) open - switch not activated • Traction not authorised NOTE

The seat's operator presence detector cannot be activated if the weight setting is too high or too low.

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30

Chassis, bodywork and fittings

Seat Operator indicator light When the operator sits on the seat, the operator presence indicator light for the seat (4) is displayed.

NOTE

The operator presence indicator light for the seat (4) is linked to the activation of the operator presence contact (1S29).

Operator on the seat: • Operator in a sitting position • Contact (1S29) closed - switch activated • The indicator for the operator's presence on the seat (4)is displayed No operator on the seat: • Contact (1S29) open - switch not activated • The indicator for the operator's presence on the seat (4)is not displayed NOTE

The operator is sitting down but the operator presence indicator light for the seat(4) does not come on.

– Check the seat weight adjustment.

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Chassis, bodywork and fittings

30 Seat

Seat heater (option) Controlling the seat heater

Electric circuit diagram 1K0

1A1 :+

:1

1X10 1X10-A

1F10

BK ( 92 ) 1²

:37

WH ( 37 )

:32

WH ( 32 )

RD ( 123 ) 1.5²

1X1

:3

:1

BK ( 92 ) 1²

WH ( 37 )

RD ( 234 ) 1²

WH ( 32 )

:2

:2

BK ( 292 ) 1²

RD ( 334 )

1X10-B :3 1X10-B :2

:85 :87 1K10

WH ( 237 )

The driver's seat may be equipped with the seat heater option.

Activation of the heating system is linked to the operator presence contact for the seat (1S29).

:86 :30

• A switch (9S3) equipped with an indicator light (H5)

1X10-B :4

When the heating system is activated, the indicator light (H5) illuminates.

9S3

:1

BK ( 192 )

WH ( 137 )

RD ( 434 ) 1²

The control system for the seat heater (1) includes:

BN ( 394 ) 1²

1X10-A :3 1X10-A :2

:3

:2

:5

1S29

H5

Switch (9S3) activated: • Seat heater indicator light (H5) on

t°

9E3

t°

9E5

• Activation of the seat heater (9E3/9E5) Switch (9S3) deactivated: • Seat heater indicator light (H5) off • Seat heater (9E3/9E5) cut-out L-

NOTE

225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240

When the driver gets up from the seat, the heating system turns off in order to conserve battery power.

No visual information is shown on the display.

Solutions: – Check whether the seat heater indicator light (H5) is illuminated.

– Press the switch to reactivate the heating system.

115401_30-006

1S9 Operator presence contact 9S3 Seat heater switch H5 Seat heater indicator light 9E3/9E5 Seat heater resistor 1F3 Seat heater fuse 5 A 1F10 Fuse block 7.5 A 1K10 Seat heater relay 1X10 Seat connector 1X10–A/B Seat heater connector

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30

Chassis, bodywork and fittings

Linkage of the truck Load lift system with level compensator 43 42

41

47 46 39 40 38 36

44 37 45

40

43

42

41

39 38 37 36

49 48

30

1 34 35

29

33

12 11 10

27 15

7

16

6 13 14

28

32

26 8 9

31

25 24 23

2 3 4 5

22 21

19 20 17 18 115400_30-014

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30-8

Fork chassis Lift shaft Stop Greased bolt Lubricating nipple (cone) - AM6 Threaded pin Nut H HC screw - M12x25 -45H Nut (h.hm) Lift shaft bearing Greased bolt Lubricating nipple (cone) - AM6 Hexagon head screw - M10x30-8.8-A2C Hexagon nut - M10-04-A2C Screw H - M20x45-8.8 Washer Bearing Bolt Nut (h,m) HC screw - M12x25 -45H Hexagon head screw Washer Bolt Tapered roller bearing Push rod

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

Bolt (push rod) Slotted spring pin Load castor (DX Bogie) Load castor (DU Bogie) Load castor Bolt Slotted spring pin Bolt Threaded pin Nut H Castor support Bolt Support roller '17x40x20 Screw - M10 Boss Socket head screw - M10x25-8.8-A2C Spacer (adjustment shim) Socket head screw - M12x25-8.8-A2C Part (undefined) FHC screw - M5x12-8.8-A2C Wiring harness (initial lift cut-out) Socket head screw - M4x25-8.8-A2C Screw (F/60, F/90) Support

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Chassis, bodywork and fittings

30 Linkage of the truck

The level compensator enables adjustment of: • Stability of the contact points in relation to the ground • The truck’s drive quality The compensation system is provided by the lift shaft, which allows the effort produced on the two push rods to be balanced.

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30

Chassis, bodywork and fittings

Linkage of the truck Load lift system without level compensator 22 21

20

26 25

23 16

18 19 17

24

15

19

21

20

22

18 17 16 15

28 1

27 13 14

8

12

6

32

11

10

4

30

31

7

5

34 33 35 29

9

2 3 36

115400_30-015 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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

Fork chassis HC screw - M12x25 -45H Nut (h.hm) Push rod Bolt (push rod) Slotted spring pin Load castor (DX Bogie) Load castor (DU Bogie) Load castor Bolt Slotted spring pin Bolt Threaded pin Nut H Castor support Bolt Support roller '17x40x20 Screw - M10

Boss Socket head screw - M10x25-8.8-A2C Spacer (adjustment shim) Socket head screw - M12x25-8.8-A2C Part (undefined) Countersunk screw Wiring harness (initial lift cut-out) Socket head screw - M4x25-8.8-A2C Screw (F/60, F/90) Support Greased bolt Screw H - M20x45-8.8 Washer Bolt Greased bolt Bolt Lift shaft Slotted spring pin

NOTE

Trucks equipped with forks that are longer than 1400 mm do not require a level compensator.

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Chassis, bodywork and fittings

30

Battery compartment Types of compartment

Side access battery For batteries fitted in special compartments that are equipped with attachment points, the battery capacity can be up to 500 Ah. Width (mm)

Height (mm)

3PzS

Battery compartment Side 345 / 375 Ah

198

627

4PzS

460 / 500 Ah

Battery Lithium ion

Battery compartment Side

198 Width (mm)

627 Height (mm)

4PzS

205/410 Ah

198

618

Battery

.

11548012111 EN - 09/2017

30-11

30

Chassis, bodywork and fittings

Battery compartment Battery lock

2

1

3

15 16

19

18

23

17

45

6

14

13

12

22

11 10

78 9

20 21

115401_30-003

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

30-12

Lock assembly Socket head screw Washer Socket head screw Washer Battery lock Tap axle Spring Clamping piece Plug Washer nut Compression spring

13 14 15 16 17 18 19 20 21 22 23

Compression part Label Stop Flat Countersunk screw Washer Button head screw Roller assembly Pin Handle Torsion spring

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Steering, braking and wheels

42

a

ES30-24 steering unit General

1 2 3 4

5 6 7 8

Steering wheel Steering knob (option) Steering centre Electromagnetic brake (Y1)

The ES30-24 electric steering unit is made up of the following elements: • A steering wheel (1) or a steering knob (2) • A steering centre (3) with a setpoint sensor (3B2) to control the steering and a magnetic system to provide the resisting force • An asynchronous steering geared motor (7) to turn the drive unit steering ring • An ES30-24 control box (6) to power the steering geared motor (7) • A potentiometer to read the position of the wheel (8) (internal) located in the ES30-24 steering unit

Traction motor (1M1) ES30-24 unit (3A1) Asynchronous steering geared motor (3M1) Wheel position potentiometer (internal)

The variable power-assisted steering is controlled by a steering wheel or a steering knob (option).

The drive unit is mounted on a steering ring and turning is provided by the steering geared motor.

The asynchronous steering geared motor (7) is controlled by the ES30-24 unit (6).

It receives information from both the steering wheel/steering knob and the angular position of the wheel.

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42

Steering, braking and wheels

ES30-24 steering unit Description

1 2 3

Control electronics with integrated power module Asynchronous steering geared motor Drive gear

4 5 6 7

Spur gear Integrated wheel position potentiometer Connector 3X1 Connector 3X8

The ES30-24 electric steering unit is a single unit and is maintenance-free.

The upper bearing of the transmission gear is equipped with a Hall effect sensor.

All of its parts are maintenance-free.

The optical sensor and the Hall effect sensor inform the electronic controller about the direction of rotation of the transmission gear and about the position of the wheel.

The ES30-24 unit consists of airtight moulded aluminium housing equipped with cooling fins.

The AC-type, 350 W motor is housed in this enclosure.

The upper bearing of the motor is fitted with an optical sensor.

The transmission gear gives a maximum torque of 110 Nm on the output pinion gear.

42-2

The unit is controlled by an electronic card that is interfaced by two connectors: – Connector 3X8: power section – Connector 3X1: control section

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Steering, braking and wheels

42 ES30-24 steering unit

Technical data Type: ES30-24 Nominal voltage

24 V DC

Nominal capacity Nominal speed

185 W S1 100 rpm

Maximum torque

110 Nm

Protection type Category of insulating material Weight

IP 54 F 7.5 kg

Pinion gear Number of teeth

22

Module Contact angle

2.5

Sideways shift

0

Shorter offset

0

20°

Identification label

1 2 3 4 5 6 7 8

Data matrix code Equipment number Customer logo Hardware ID Text: electric steering (fixed) Manufacturer identification: 150 (fixed) Text: HW-ID (fixed) Nominal voltage

9 10 11 12 13 14 15

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Protection class Nominal power Mode of operation Nominal speed Date code (fixed), YYWW schedule Serial number Type designation

42-3

42

Steering, braking and wheels

ES30-24 steering unit Adjusting the electric steering ES30-24 To ensure the electric steering works correctly, it is important to calibrate parts before repair or replacement.

Parts requiring calibration: • Setting potentiometer • the wheel potentiometer.

Calibrating the setpoint potentiometer 3B2 – Connect the diagnostic PC to 6X7.

– Launch the diagnostic tool, go to the following menu and follow the instructions on the screen:

F2:Diagnostics ▼

Jobs ▼

Calibration 5 Control Potentiometer The control potentiometer is calibrated.

Calibrating the wheel position potentiometer Once the setting potentiometer has been adjusted, the wheel position potentiometer must be calibrated: – Connect the diagnostic PC to 6X7.

– Launch the diagnostic tool, go to the following menu and follow the instructions on the screen:

F2:Diagnostics ▼

Jobs ▼

Calibration 6 Wheel Potentiometer .

Checking settings After adjusting the steering: – Turn full lock to the left and to the right successively; the centre of rotation should be located between the load castors.

– Start the diagnostic tool.

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Steering, braking and wheels

42 ES30-24 steering unit

– Check that there are no more breakdown codes in the following menu:

F3:Setup ▼

Error Codes ▼

Steering Main Control Device (CP)/Security Control Device (CS) .

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42

Steering, braking and wheels

Control unit Description of the steering wheel

Steering wheel ∅125 for left-hand configuration 1 Handle 2 M5x40 socket head screw 3 Steering wheel 4 Washer

5 6 7 8

Adaptor Steering centre Washer Nut

The truck is equipped with: • A steering wheel • A steering centre

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Steering, braking and wheels

42 Control unit

Description of the steering knob

1 2 3 4 5

Steering knob Adaptor Steering centre Washer Nut

The truck is equipped with: • A steering wheel OR: • A steering knob (optional) • A steering centre • And a control module

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42-7

42

Steering, braking and wheels

Control unit Description of the control module

1 2

Control module Base

3 4

Joystick Screw

The control module includes the following controls: • (2B15): Initial lift control (lifting/lowering of load arms) • (1B1): Truck traction controller (front/rear) • (4H1): Horn The control module can be fitted to the right or the left of the dashboard.

Three Hall effect sensors are fitted on the control module (see Chapter 50: Operating devices): • One sensor for the load arms • One sensor for the direction of travel • One sensor for the horn

42-8

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Steering, braking and wheels

42 Control unit

Pin assignment for connector 1X3:

Pin

Colour

Signal

1

Supply (+5 V)

2

Yellow Orange

3

Grey

4 5

Red -

6

White

Initial lift

7

Violet

8

Pink -

Initial Horn (switch) 0 V

9 10 11 12

Signal no. 1 (traction) 0 V Horn (switch) -

Brown -

13

White/Brown -

14

White/Violet

Signal no. 2 (traction) Signal no. 1 of the proportional control Signal no. 2 of the proportional control

.

Operations on the control module The disassembly operation is described in Chapter 30: Access to the dashboard components.

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42-9

42

Steering, braking and wheels

Control unit Description of the joystick (option)

1B1 2B4

Traction controller (forward/reverse travel) Main lift controller (depending on the version)

2B15 4H1

Initial lift controller (depending on the version) Horn

The joystick is fitted with the following Hall effect sensors: • 1 sensor for the initial lift (depending on the version) • 1 sensor for traction • 1 sensor for the main lift (depending on the version)

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Steering, braking and wheels

42

Setpoint sensor 3B2 Steering centre Overview

1

Steering centre 7A5

2

Connector X13 for the centre

Pin assignment for connector X13 Marking

Colour

X13:1

Red

X13:2

Black

X13:3 X13:4

Green Orange

X13:5

Blue

X13:6

White

Function 10 V supply for sensor 3B2 10 V supply for sensor 3B2 Setting track 1 Setting track 2 Supply voltage brake coil V+ Supply voltage brake coil V-

.

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42

Steering, braking and wheels

Setpoint sensor 3B2 Description of the pivot

1 2 3 4

Magnetic flux Powder Stator Rotor

5 6 7 8

The pivot and its "steering brake" function consist of a coil (5) whose current is controlled by the ES30-24, which magnetises a powder (2) inside the pivot.

Coil Bundling Magnet Hall effect sensor

The steering controller varies the intensity of the current depending on the driving parameters (travel speed, rotational speed of the steering wheel, etc.).

The higher the current in the coil (max. 1 A), the more the powder will freeze and stop movement depending on the pivot bolt, and vice versa.

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Steering, braking and wheels

42 Setpoint sensor 3B2

Features of the Hall effect setpoint sensor The Hall effect sensor allows the pivot angle to be measured.

The sensor sends this information to the steering controller, which adjusts the direction of the truck wheel.

NOTE

The sensor must not be removed, this is not a spare part.

• Its position is defined when the steering box is

assembled.

FEATURES Supply voltage

VALUES

Output voltage range

10 V ± 0.5 V Contactless, Hall effect 0.5 V - 4.5 V (not ratiometric)

Possible electrical travel Linearity

360° ±2% of 5 V (±0.1 V)

Interlinearity

4% of 5 V (0.2 V)

Sensor type

.

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42

Steering, braking and wheels

Setpoint sensor 3B2 Principle of the Hall effect sensor Description A Hall effect sensor gives a voltage when it detects a magnetic field or a metal part.

The Hall voltage (from the name of the person who observed the phenomenon in 1879) is amplified in the sensor.

If an Io current passes through a bar made out of conductive or semi-conductive material, and if an induction magnetic field B is applied perpendicular to the direction of the current flow, a Vh voltage, proportional to the magnetic field and the Io current appears on the side faces of the bar.

Vh = Kh * B * Io with Kh: Hall constant, which depends on the material used.

As the Hall constant is inversely proportional to the density of carriers, the Hall voltage is much higher in semi-conductors than in metals.

B Io Vh

Magnetic field Current Voltage

B Io Vh e

Magnetic field Current Voltage Lorentz force

Causes of the Hall effect The electrons are deflected by the magnetic field, creating a potential difference called Hall voltage. The magnetic field distorts the trajectory of electrons because it generates a Lorentz ( e ) force.

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Steering, braking and wheels

42

Electromagnetic brake Features

1 2 3 4

Electromagnetic brake Y1 Friction disc/traction motor rotor coupling Friction disc Brake spring ensuring the mechanical braking torque

5 6

Brake connector 7X6 Air gap of the brake (0.18 mm min./0.37 mm max.) to be checked

The truck is equipped with an electromagnetic parking brake without current.

The safety brake is applied automatically when at least one of the following conditions is met: • Drive direction reverser in neutral position and the machine is stationary • Truck in safety mode Features Nominal braking torque

25 Nm

Supply voltage

24 V

Power

31 W

.

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42

Steering, braking and wheels

Stabiliser Features of the fixed stabiliser

A B 1 2 3

Ungreased stabiliser Greased stabiliser Fork part Bolt Bearing block

4 5 6 7 8

Hexagon nut M10-04-A2C Hexagon head screw M10x40-8.8-A2C Spring washer B10-A2C Hexagon head screw M10x30-8.8-A2C Lubricating nipple

The truck is equipped with: • Either an ungreased stabiliser • Or a greased stabiliser

42-16

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Steering, braking and wheels

42 Stabiliser

Stabiliser height adjustment Equipment required • Torque wrench • Ratchet handle, extender and 10 mm male bit • Size 16 and 17 open-ended spanner • Ratchet handle, extender and size 15 socket • Size 6 Allen key • Spirit level (option) – Remove the mat from the platform – Move the seat all the way forwards.

– Loosen the door mounting screws using a ratchet handle, a size 15 socket and extenders – Open the door fully

– Press the adjustment knob to fully raise the floor The floor raises.

– Unscrew the two M6 mounting screws from the lower floor using a size 6 Allen key – Remove the lower floor

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42

Steering, braking and wheels

Stabiliser – Loosen the locking screw (1) of the stabiliser (accessed on the side), using a ratchet handle, extender and 10 mm male bit – Loosen the locknut (2) using a size 17 openended spanner (4) – Adjust the adjusting screw (3) using a size 16 open-ended spanner (5) to compensate for wear to the drive wheel or the stabiliser wheel.

– Tighten the screw to lower the stabiliser OR – Loosen the screw and push the stabiliser back to raise the stabiliser NOTE

Ensure that the truck is resting evenly on its 4 support points: drive wheel, load castors (single or bogies) and stabiliser.

– Use a spirit level to make the adjustment.

– After adjustment, tighten the locking screw and the locknut (1) CAUTION Risk of truck tipping over The correct adjustment of the stabiliser ensures the stability of the truck.

NOTE

Tightening torque of the locking screw (1): 80 Nm

Periodic fixed stabiliser wheel checks Periodically check: – The condition and free rotation of the two stabiliser wheels – Replace the wheels if necessary – That the tightness of the mounting screws is at the recommended torque, using the torque wrench

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Steering, braking and wheels

42

Wheels Description of the wheels

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

Drive wheel Nut (tightening torque: 140 Nm) Transmission gear Fork part Bolt Bearing Hexagon head screw Hexagon nut Hexagon head screw Washer

Stabiliser wheels Load wheels (bogies) Socket head screw Load castor Bearing bush Washer Wheel Bush Bolt Pin

Contact with the ground is provided by • One drive wheel (1) • One fixed stabiliser (4) • Two load wheels (12)

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Steering, braking and wheels

Wheels Types of drive wheel

The following wheels can be fitted to this truck: Wheel types (A) — Rubber

Advantages

Disadvantages

Shore A hardness

Load (kg)

Good traction

Considerable abrasive wear Leaves marks

70 ±3

800

75 ±3

1200

92 ±3

1200

92 ±3

2010

70 ±3

800

Suitable for extremely wet ground surfaces More abrasive wear than a (sheets of water) polyurethane wheel (B) — Notched More traction than a Leaves marks rubber polyurethane wheel Cannot be touched up Robust Anti-static Suitable for extremely Traction not as good as a wet ground surfaces (C) — Solid wheel rubber wheel. In dairies, the (sheets of water) (notched Vulkollan) tyre may come loose More robust than a rubber wheel (D) — Best solution for standard Traction not as good as Polyurethane applications a rubber wheel (Vulkollan) Less abrasive wear More traction than a More abrasive wear than a (E) — Non-marking polyurethane anti-static polyurethane wheel rubber non-marking wheel .

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Steering, braking and wheels

42 Wheels

Types of wear on drive wheels

Marking

Type of wear

A

Material damaged due to thermal overloading

B

Damage caused by hydrolysis

C

Cauliflower "effect"

D

Cracked wheel

E

Mechanical damage

F

Wear to wheel structure

Causes Transporting a load that exceeds the nominal capacity while travelling at a high speed Using or storing the wheel in harsh conditions (high temperatures) with considerable exposure to water Irregular transverse or longitudinal impacts caused by significant driving effort and friction with the ground surface Excessive loads Sharp object embedded in the tyre tread Thermal overloading, impacts and excessive speed

.

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Steering, braking and wheels

Wheels Types of stabiliser wheels

1

Lubricating nipple

The truck is equipped with: • (A): Either wheels compatible with the ungreased stabilisers • (B): Or wheels compatible with the greased stabilisers

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Steering, braking and wheels

42 Wheels

Types of load wheel

The following wheels can be fitted to this truck: Wheel types

Uses

(A) - Single wheel (B) - Single wheel with grease nipples (C) - Double wheels (bogie) (D) - Bogie with grease nipples

Recommended for use on flat surfaces.

Recommended for use on flat surfaces in cold stores, corrosive environments and wet environments.

Recommended for both indoor and outdoor use that includes the frequent crossing of docks.

Enable movement across these areas by adapting to the ground height.

Used for cold stores, corrosive environments and wet environments.

.

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42

Steering, braking and wheels

Wheels

42-24

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Control devices

50

a

Control module Traction function on the control module

1 2

Joystick in neutral position Joystick to the right-hand stop

3 4

When the operator moves the joystick to the right (2) or to the left (3), the truck moves forwards or backwards.

A potentiometer (Hall effect proportional sensor) is integrated into the control module and sends back two output signals.

• Signal no. 1: Reference signal • Signal no. 2: Control signal It is supplied by the traction controller with: • +5 V: (1X1: 27) • 0 V: (1X1: 42) Both output signals No. 1 and No. 2 can be tested using the diagnostic tool.

Joystick to the left-hand stop Control module

Checking the joystick: Using a voltmeter, the measurable value of the reference signal must be 2.5 V (± 5%) when the operator does not move the joystick (neutral position) (1).

Using a voltmeter, the measurable value of the reference signal must be between 2.5 V and 4.5 V when the operator moves the joystick to the right (2).

Using a voltmeter, the measurable value of the reference signal must be between 0.5 V and 2.5 V when the operator moves the joystick to the left (3).

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50

Control devices

Control module Initial lift function on the control module

1 2

Initial lifting/lowering control (neutral position) Initial lifting control (raised position)

When the operator moves the initial lifting (2)/lowering (3) control, the initial lift or the initial lowering of the load arms occurs.

A potentiometer (Hall effect sensor) is integrated into the control module and sends back two output signals.

• Signal no. 1: Initial lowering signal • Signal no. 2: Initial lift signal It is supplied by the traction controller with: • +5 V: (1X1: 27) • 0 V: (1X1: 42) Both output signals No. 1 and No. 2 can be tested using the diagnostic tool.

50-2

3 4

Initial lowering control (lowered position) Control module

Checking the joystick: Using a voltmeter, the measurable value of the reference signal must be 4.6 V when the operator does not activate the lifting/lowering (neutral position) (1).

Using a voltmeter, the measurable value of the reference signal must be between 0 V and 1.5 V when the operator activates initial lifting (raised position) (2).

Using a voltmeter, the measurable value of the reference signal must be between 0 V and 1.5 V when the operator activates initial lowering (lowered position) (3).

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Control devices

50 Control module

Horn function on the control module

When the operator presses the button on the control module (1), the horn sounds.

A Hall effect sensor (all or nothing) is integrated into the control module and returns a status signal for the button (output signal).

It is supplied by the traction controller with: • 24 V: (1X1:13) • 0 V: Earth You can use the diagnostic tool to test the output signal.

Checking the joystick: Using a voltmeter, the measurable value of the reference signal must be +24 V when the operator does not press the control module button (button released) (2).

Using a voltmeter, the measurable value of the reference signal will move from +24 V to 0 V when the operator begins to press the button.

Using a voltmeter, the measurable value of the reference signal must be 0 V when the operator presses the control module button (button pressed) (3).

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50

Control devices

Joystick (option) Functions of the joystick

1B1 2B4

Traction setpoint sensor Main lift setpoint sensor (depending on the version)

2B15

Initial lift setpoint sensor (depending on the version) Horn

4S1

Assignments Pin for connector 1X1

Analogue

Digital

Input

X

X

1X1:12

Lowering the load arms Lift Poti 1

1X1:25

Traction Poti 1

X

X

1X1:26

Lift Poti 2

X

X

1X1:27

1X1:39

+5V Lifting the load arms Traction Poti 2

1X1:42

0V

1X1:9

1X1:36

50-4

Purpose

X

Output

X

X X X

X X X

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Control devices

50 Joystick (option)

The joystick is fitted with: • Three Hall effect sensors (1B1, 2B4 and 2B15) • An all or nothing button (4S1)

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50

Control devices

Joystick (option)

50-6

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Electrics/electronics

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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60

Electrics/electronics

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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Electrics/electronics

60 Safety

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60

Electrics/electronics

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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Electrics/electronics

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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60

Electrics/electronics

General FXH 20N / FXH 25N technical compartment

1 2 3 4 5 6 7 8 9 10

Floor adjustment knob Line contact switch 1K0 Steering contact switch 3K1 Traction contact switch 1K2 Control fuses Fan Horn Electromagnetic brake Traction motor Speed sensor

11 12A 12B 13 14 15 16 17 18

ES30–24 steering unit FXH 20N pump-motor unit FXH 25N pump-motor unit Traction/lift controller (LAC) Stabiliser Floor adjustment cylinder Operator presence pedal Mobile floor Seat

The FXH 20N and FXH 25N are equipped with the following components:

• LAC traction and lifting control module

• Drive and steering unit with AC motor (3 kW)

• Stabiliser

• 1.2-kW pump-motor unit (FXH 20N) and 1.5-kW pump-motor unit (FXH 25N)

• Steering control module

• Electromagnetic brake without hydraulic assistance

60-6

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Electrics/electronics

60 General

Location of connectors

X13 1X1 1X2 1X3 1X7

Braking module connector Traction/lift controller connector Speed sensor connector Plate/control unit interface connector Link connector for the driver’s compartment/technical compartment

1X25 2X14 2X35 3X1 9X11

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Motor temperature connector Initial lift upper/lower cut-out connector Pump/truck link connector Electric steering connector Fan connector

60-7

60

Electrics/electronics

General Fuses CAUTION Risk of short circuit Before carrying out any operations: – Press the emergency off switch.

– Disconnect the battery connector.

– Open the technical compartment to gain access to the fuses.

Location

1 2

60-8

Control fuse (1F4) Control fuse (1F3)

3 4

Power fuse (1F1) Power fuse (3F1)

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Electrics/electronics

60 General

Function – The 7.5-A fuse 1F3(1) protects the control circuit.

– The 5-A fuse 1F4(2) protects the control circuit.

NOTE

For the cold store truck version, the 7.5-A fuse is replaced with a 10-A fuse (3).

– The 300-A fuse 1F1 protects the traction and lift power circuit.

NOTE

The tightening torque for the power circuit fuse terminals is 9 Nm. – The 40-A fuse 3F1 protects the steering power circuit on the ES30-24 unit.

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60

Electrics/electronics

General Contact switches

– The traction and lifting contact switch 1K2 provides power to the traction motor and the lifting motor

CAUTION Risk of short circuit Before carrying out any operations:

If it detects a malfunction on the traction or lifting functions, the traction/lifting controller can cut their power circuit using the contact switch 1K2.

– Press the emergency off switch.

– Disconnect the battery connector.

– Open the technical compartment to gain access to the contact switches.

– The steering contact switch 3K1 provides power to the electric steering.

– The line contact switch 1K0 provides the power to 1K2 and 3K1

If it detects a malfunction on the steering function, the steering controller can cut its power circuit using the contact switch 3K1.

It is used to open the power circuit if the user presses the emergency off switch.

Emergency off switch The emergency off switch (7S5) is linked to the 1K0 line contact switch.

Operating The status of the contact depends directly on the status of the button: • If the button is in the upper position, the contact is closed; • If the button is in the lower position (emergency shutdown), the contact is open.

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Electrics/electronics

60 General

Horn (4H1) The horn circuit is powered directly from the emergency stop contact.

The push-button (4S1) is under the head of the control module. Pressing (4S1) applies a voltage of +24 V to the horn (4H1).

1X3 1X7

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Plate/control unit interface connector Link connector for the driver’s compartment/technical compartment

60-11

60

Electrics/electronics

Traction Traction and lift controller

1 2 3 4 5

U phase L1 of the traction motor

6

W phase L3 of the traction motor

7

V phase L2 of the traction motor

Li control terminal for the lift motor

+ positive terminal of the +24 V power supply for the power unit

The 1A1 controller is made up of a control stage and a power stage for traction and lift.

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

The controller uses a self-checking microprocessor (traction and lift).

60-12

- negative power supply terminal for the power unit - negative power supply terminal for the various electrical consumers

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 stoppage of a controller depending on the type of fault.

The controller is fitted with a 42-pin 1X1 connector.

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Electrics/electronics

60 Traction

Functions of the inputs/outputs of the LAC

1

Signal

Function

1X1

Default value -

Contact switch positive

Active value 24 V

Type of signal

Input/Output

Supply All or nothing All or nothing Digital

/

4

Load-retaining solenoid valve 2Y11 Proportional solenoid valve 2Y3 Initial lift top cut in 1B4

5

Platform presence

0V

0V

6

Fan

24 V

0V

7

Not used

Not used

Not used

Not used

8

Rev sensor track A

-

Digital

Input

9

Initial lowering signal 2B16

5V

Not used Frequency variable 0 V/6 V 0V

Digital

Input

10

Not used

12

Lift setting no. 1 2B4

-

13

Battery voltage

-

Not used Supply Analogue Supply

Not used

11

Not used Battery voltage

14

CAN high

-

15

Safety relay status

-

2 3

-

0V

-

PWM* signal

0V

24 V

Not used -

24 V Variable voltage 0 V/5 V 24 V Variable voltage 0 V/5 V 24 V

11548012111 EN - 09/2017

Digital All or nothing

Digital Supply

Output Output Input Input Output

/ Input / Input/Output /

60-13

60

Electrics/electronics

Traction Signal

Type of signal

Input/Output

1X1

Function

Default value

Active value

16

Lowering solenoid valve 2Y2

-

0V

-

PWM* signal

Not used

Not used

Not used

Not used

24 V

0V

Digital

Input

Not used

Not used

Not used

Not used

Not used

Not used Frequency variable 0 V/6 V

Not used

Not used

Digital

Input

0V

24 V

Digital

Input

24 V

0V Variable voltage 0 V/5 V Variable voltage 0 V/5 V

Digital Analogue Analogue

Input

20

Traction/lift contact switch 1K2 Not used Operator presence pedal 1S9 Not used

21

Not used

22

Rev sensor track B

17 18 19

-

Output Output

24

Initial lift low position cut in 1B3 Mast height 0.3 m 2B1

25

Traction setting no. 1

-

26

Lift setting no. 2 2B4

-

27

+5 V supply Potentiometers 1B1, 2B4 and 2B15

-

5V

Supply

/

28

CAN low

-

Variable voltage 0 V/5 V

Digital

Input/Output

29

Brake Y1

-

0V

30

Not used Switching solenoid valve 2Y12 Operator seat presence 1S29 track 1 Not used Mast height 1.5 m 2B6

Not used

Not used

-

0V

0V Not used 24 V

0V

Not used

Not used

5V

38

Not used Initial lift signal 2B17 Operator seat presence 1S29 track 2 Not used

39

Traction setting no. 2 1B1

-

40

Pressure sensor

41 42

23

31 32 33 34 35 36 37

All or nothing

Input Input

Output

Not used All or nothing

Not used

24 V

Digital

Input

Not used

Not used Digital

Not used Input

0V

Not used Digital

Not used Input

24 V

0V

Digital

Input

Not used

Temperature sensor 1B6

-

Variable signal

0 V supply for potentiometers

-

0V

Not used Analogue Digital Analogue Supply

Not used

0V

Not used Variable voltage 0 V/5 V 24 V

PWM* signal: Pulse Width Modulation = variable signal

60-14

All or nothing All or nothing

11548012111 EN - 09/2017

Output

Input Input Input /

Electrics/electronics

60 Traction

Activating controllers 1A1 and 3A1

The procedure for activating the truck is as follows:

►ES30-24 a +10 V internal voltage regulator supplies:

• 1) Connecting the battery connector

- The setting potentiometer (handlebar/steering wheel) (3B2)

Presence of the positive +24 V battery on the switch key (S1) and on the switch coil (1K2) Positive battery +24 V direct on 3X1 : A8 (ES30-24) and 1X1 : 1 (LAC) • 2) S1 switch key set to "ON" ►Supply of control modules LAC and ES30-24 :

• 4) Advance authorisation for traction and hydraulic functions : ►LAC : launch of the internal test program ES30-24 : checking for correct operation of the two electric steering potentiometers with double signals (redundant potentiometers)

LAC : +24 V power supply in 1X1 : 13; 0 V direct in 1X1 : 42 ;

• 5) Authorisation for traction and hydraulic functions :

ES30-24 : +24 V power supply in 3X1 : A7 / A8, 0 V direct in 3X1 : B5 ;

- The steering relay (3K1) is supplied ;

• 3) The 1A1 (LAC) and 3A1 (ES30-24) controllers are supplied ►LAC : a +5 V internal voltage regulator supplies:

►From the power supply of the ES30-24 : - The pivot break is supplied ; ►If the steering setpoint potentiometer check is OK :

- The accelerator potentiometer (1B1)

- Closure of the MOSFET (internal to the ES30-24) ;

- The rev sensor (1B2) (not shown)

- Power supply for the LAC(1X1 : 1) ; - ►LAC: If the self-test is OK :

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60

Electrics/electronics

Traction - Closure of the safety relay +24 V on 1X1 : 1

- (+24 V) in 1X1 : 1

- ►CAN Bus : traction authorisation sent by the ES30-24

- Closure of (1K2)

• 6) 1A1 power stage supplied ►LAC:

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- Power stage (1A1) supplied - (+Ub: 24 V) on the "+" power terminal - (+Ub: 24 V) on the lift motor terminals (2M1)

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60 Traction

Speed reductions

1: Minimum speed

4: Level 1

2: Level 3

5: Between level 1 and maximum level

3: Level 2 FXH 20

FXH 20 N with steering knob

1.5 m/s²

1.5 m/s²

1.4 m/s²

1.4 m/s²

2 m/s²

2 m/s²

10°

10°

Level 1

12°

12°

Level 2

20°

20°

Level 3 Minimum angle

35°

35°

50°

50°

Level 1

8.5 km/h

7.5 km/h

Level 2

7.5 km/h

6.5 km/h

Level 3 Minimum speed

6.5 km/h

6 km/h

6 km/h

6 km/h

Maximum acceleration

1 m/s²

0.6 m/s²

Maximum deceleration

0.9 m/s²

1.1 m/s²

Truck parameters

Speeds (default values)

Maximum acceleration Maximum deceleration (by releasing the drive switch) Maximum deceleration (by reversing the drive switch) Starting angle

Angles (default values)

Speeds when cornering (default values) Acceleration/deceleration when cornering depending on the angle (SRWS*)

SRWS: Speed Reduction Wheel Steering

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Traction Central negative point

The central negative point is located on the LAC(1) at the wiring.

All of the truck's negative cables are attached to this connection point.

To ensure correct operation of the truck, the correct sequence for attaching the cables must be observed.

There is a negative point (2) for the negative power supply terminal for the power unit.

And a negative point (3) for the negative power supply terminal "central" for the electrical systems.

The sequence for attaching the cables from bottom to top is as follows: • (4): Cable to the main harness • (5): Cable to the data terminal option

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60 Traction

NOTE

The sequence for attaching the cables from bottom to top is defined such that the current of the cable goes from the lowest to the highest.

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Traction Central positive point

The central positive point is located on the LAC(1) at the wiring.

All of the truck's positive power cables are attached to this connection point (2).

To ensure correct operation of the truck, the correct sequence for attaching the cables must be observed.

The sequence for attaching the cables from bottom to top is as follows: • (3): Cable to the contact switches/battery connector • (4): Cable to the pump-motor unit

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60 Traction

Parameterising the control module – Follow the instructions on the display.

WARNING Considerable risk of injury and/or material damage.

The accelerator potentiometer is calibrated.

Chock the truck so that the drive wheel does not touch the ground during the control module configuration process.

Step three: Restore factory settings

F3:Setup ▼

Before launching the diagnostic tool, the truck must be switched on and connected to the PC.

Error Codes ▼

– Select "Truck Service Base".

Traction Lift

– The diagnostic tool connects to the controllers installed on the truck.

▼

Start

Step one: Truck identification

– Follow the instructions on the screen in:

F2:Diagnostics

– In the "Traction" field

▼

Jobs

– Click on Start

▼

– In the "Lift" field

Setting Truck Type

– Click on Start

▼

Execute – Follow the instructions on the screen in:

All settings will be restored to factory values with the exception of the truck type and calibration data.

Step two: calibration of the accelerator potentiometer

F2:Diagnostics

Final step: Initialise the new parameters.

▼

To initialise the new values:

Jobs

– Switch off the truck power supply and restart it.

▼

– Close the diagnostic tool and relaunch the program.

Calibration ▼

1- Accelerator Potentiometer

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Traction Operational checks Rev sensor (1B2)

1X1

Traction/lift controller connector

1X2

Rev sensor connector

A sensor (1B2) is fitted to the traction motor. This sensor monitors a gear mounted on the rotor.

The sensor is supplied with +24 V and supplies two 90° out-of-phase impulsion gaps.

These signals are transmitted to the traction control module (input pins 1X1:8/22 of the LAC) as well as to the steering controller where they are processed to determine the speed and the direction of rotation of the traction motor.

No adjustment is needed for the rev sensor.

CAUTION Risk of improper use of the traction motor If the sensor is improperly fitted or if the plug (1X2) is disconnected, the traction speed will be 0.2 km/h and the effective motor current will increase to the Imax current of 270 A (according to standard factory settings for the truck).

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Function The sensor (2) has two built-in inductive sensors that measure the revolution speed and direction of rotation of the relevant motor via a gear (1) on the rotor shaft.

The revolution speed is determined from the frequency of the output signal, and the direction of rotation from the sequence of the output signals.

The direction of rotation is defined by the traction motor. A four-pin plug (3) is used to connect the rev sensor with the power module (1A1).

Rev sensor connector 1X2 Pin 1X2:1

Function +24 V power supply

1X2:2

Output signal A

1X2:3

Battery negative

1X2:4

Output signal B

.

Output signals The revolution speed of the motor is determined from the frequency of the output signals A and B. The sequence of signals from the two outputs A and B varies depending on the direction of rotation of the motor.

When the motor rotates anti-clockwise, first output B is switched on and then output A. Output B is then switched off, followed by output A.

Checking the truck speed and the motor rotation speed (1M1) – Connect the CAN box to the 6X7 diagnostic connector – Connect the CAN box to the laptop connector – Start and connect the diagnostic tool

F4:Screen ▼

Traction ▼

Traction motor ▼

Motor speed – Drive the truck.

– Check the speed indicators on the display.

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Traction NOTE

In practice, 4100 rpm corresponds to approximately 10 km/h.

NOTE

If the signal is incorrect, the supply voltage, connector and connection must be checked.

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60 Traction

Checking the operation of the temperature sensor (1B6)

1X25 Connector of the heat sensor 1X25:1 Temperature signal

1X25:2 Negative

A resistance sensor (1B6) is integrated into the stator windings. This sensor monitors the temperature and reduces performance when the temperature is too high: • If the temperature of the motor exceeds 160°C, the truck speed is reduced to 2 km/h.

• If the temperature sensor is faulty or if the wiring harness is disconnected, the LAC controller will reduce the speed to 4 km/h.

Parameterising the sensor The KTY 84 sensor does not need to be parameterised because it is set by default in the LAC controller.

Checking the temperature sensor (1B6) – Connect the CAN box to the 6X7 diagnostic connector – Connect the CAN box to the laptop connector – Start and connect the diagnostic tool

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Traction F4:Screen ▼

Traction ▼

Traction motor ▼

Motor temperature – Go to the menu shown to check the motor temperature values (1M1).

Motor temperature: T° (1M1) normal working temperature approx.

30°C Normal operating speed of the truck

T° (1M1) ≤ -50°C

T° (1M1) ≥ 160°C

Speed reduction = Speed reduction = 4.5 km/h 2 km/h Fault in the sensor 1B6 (fault code 245)

170°C ≤ T° (1M1) ≥ 200°C Truck stopped

Speed reduction = 4.5 km/h .

Identifying the temperature sensor type The resistance of the temperature sensor increases as the motor temperature increases.

The resistance value can be checked at the two connections of the temperature sensor.

– Disconnect the connector from the truck.

– Check the resistance at the two connections of the temperature sensor using a multimeter, making sure that it matches the values in the table.

KTY 84-130: Ambient temperature (°C)

Ambient temperature (°C)

Resistance ( )

0

493

80

880

10

533

90

939

20

576

100

1000

25

598

130

1197

30

621

170

1493

40

668

200

1739

50

718

230

2006

60

769

270

2392

70

824

299

2668

If the values are incorrect, repeat the test.

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Resistance ( )

Electrics/electronics

60 Traction

Electromagnetic brake (Y1)

7X6

Electromagnetic brake connector

▼

This electromagnetic brake without current is used as a parking brake and also as an emergency brake.

Safety relay and brake

The air gap must be between 0.18 mm and 0.37 mm for the check.

x1:29 Brake

Checking the operation of the brake Y1

▼ – Check the on-screen indications in the following menu:

– Connect the CAN box to the 6X7 diagnostic connector

Brake transistor control in 1X1:29 •

0 ► Brake applied

– Connect the CAN box to the laptop connector

•

1 ► Brake released

– Start and connect the diagnostic tool

Blue window - Voltage (V) of the brake in 1X1:29

– Go to the following menu:

• +24 V ► Brake applied

F4:Screen ▼

General

• 0 V ► Brake released Red window - Current (mA) of the brake in 1X1:29 • 0 mA ► Brake applied • 1600 mA ► Brake released

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Traction Operator presence detection

1S9 1X1 1X7 1X9 6X7

Operator presence contact Traction/lift controller connector Link connector for the driver’s compartment/technical compartment Operator presence connector Diagnostic socket connector

– Connect the CAN box to the 6X7 diagnostic connector – Connect the CAN box to the laptop connector – Start and diagnostic software and log in – Check that the contact (1S9) is operating correctly in the following menu:

F4:Screen ▼

Traction ▼

Platform ▼

x1:19 Driver present The information in the ":19 Driver present" field is as follows: •

0 ► without operator

•

1 ► with operator

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60 Traction

Fan (9M1)

1X1

Traction/lift controller connector (LAC)

9X11

Fan connector

F3:Setup

NOTE

▼

When the fan is faulty or disconnected, the truck is stopped (fault code T34 displayed and traction function and lifting are disabled) A temperature sensor inside the LAC actuates the fan (9M1) when the internal temperature of the power stage exceeds 50°C, and stops it when the temperature drops below 40°C. • (9M1) ON = LAC > 50°C

Function ▼

Drive control ▼

Fan:

Test

Fan transistor control:

• (9M1) OFF = LAC < 40°C

• T° > 50° Fan activated (1X1: 6 = 1)

A 24 V DC brushless fan fitted with long-life bearings is used to cool the traction controller LAC.

LAC controller temperature:

Testing the control of the fan (9M1) – Connect the CAN Box to the 6X7 diagnostic connector – Connect the CAN Box to the laptop connector – Launch the diagnostic tool

• T° < 40° Fan deactivated (1X1: 6 = 0) • LAC normal working T° approx. 30°C → Normal operating speed of the truck • LAC T° ≤ -50°C → Speed reduction = 4.5 km/h • LAC T° ≥ 95°C → Speed reduction = 2 km/h • 100°C ≤ T° LAC≤ 200°C

– Follow the instructions on the display to check the control of the fan (9M1)

→ Truck stopped • Faulty sensor (fault code 240) → Speed reduction = 4.5 km/h

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Traction Control module (1B1)

1B1 1X1

Control of the direction of travel (forwards/backwards) of the truck Traction controller connector

1X3 1X7

Plate/control unit interface connector Link connector for the driver’s compartment/technical compartment

Checking the operation:

F4:Screen

– Connect the CAN box to the 6X7 diagnostic connector

Traction

▼ ▼

– Connect the CAN box to the laptop connector

Accelerator

– Start and the diagnostic tool and log in

▼

– Go to the following menu to check the operation of the traction controller of the truck:

x1:25 Poto 1 accelerator (1B1) x1:39 Poto 2 accelerator (1B1) .

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Electric steering Electric steering unit ES30-24

I: Connector 3X8: power section

II: Connector 3X1: control section

The electric steering unit ES30-24 comprises a control card with two VR and SR microprocessors.

The transistors are controlled internally.

The motor wiring is internal.

If an anomaly occurs, it is detected instantly and the control system goes into safety mode and orders the truck to stop.

Identifying the ES30-24 using the diagnostic software To check the identity of the ES30-24 unit: – Connect the CAN Box to the 6X7 diagnostic connector.

– Connect the CAN Box to the laptop connector.

– Launch the diagnostic software and go to the following menu:

F3:Setup ▼

Control device info ▼

Steering control device (ES) ▼

Steering main line .

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Electric steering Functions of the "inputs/outputs" of the ES30-24 Control connector 3X1 3X1

Function

Signal

Type of signal

Input/output

Analogue

Input

/

/

A1

Position sensor 3B2 (setpoint), track 2

A2

Not used

/

Active value Variable voltage 0 V/5 V /

A3

Not used

/

/

/

/

A4

Not used

/

0 V sensor Power supply for the position sensor (setpoint) Power supply for the control card Power supply for the control card Position sensor 3B2 (setpoint), track 1

0V

/ Supply

/

A5

/ – –

10 V

Supply

/

–

24 V

Supply

/

–

24 V

Supply

/

Analogue

Input

A6 A7 A8

Default value –

/

B2

Not used

/

Variable voltage 0 V/5 V /

/

/

B3

Not used

/

/

/

/

B4

Not used

/

0 V CAN A Power supply for the steering switch 3K1

0V

/ Supply

/

B5

/ –

/

–

24 V

Supply

Output

–

24 V

Supply

Output

–

Supply

Output

Digital

Input/output

Digital

Input/output

Analogue

Input

Digital

Input/output

Digital

Input/output

Digital

Input

B1

B6 B7

–

B8

Pivot brake 7A5 Safety loop

C1

CAN A high

C2

CAN A low

–

C3

CAN B earth

–

C4

CAN B high

–

C5

CAN B low

–

C6

–

C7

Pivot brake 7A5 Steering switch 3K1

24 V Approximately 2.5 V Approximately 2.5 V 0V Approximately 2.5 V Approximately 2.5 V PWM* signal

–

0V

Supply

Input

C8

Not used

/

/

/

/

Type of signal

Input/output

*PWM: Pulse Width Modulation

Power connector 3X8 3X8

Function

1

Positive after battery

2

Battery negative

Signal Default value –

Active value 24 V

Supply

/

–

0V

Supply

/

.

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60 Electric steering

Switching on the ES30-24 unit

If the ES230-24 unit fails, the truck stops and no further operation is allowed (lifting included).

The ES30-24 unit is the main safety device.

Power up procedure: (the steps described enable you to carry out rapid diagnosis of the malfunction):

4) The ES30-24 drives an internal safety relay. This relay 1) ES30-24 power up after switching on the supplies the positive rail on outputs 3X1:B6 and 3X1:B7 key switch inputs 3X1:A7/3X1:A8 => +24 V. => +24 V (for the steering contactor 3K1) The supply negative is direct on input 3X1:B5 and a negative via a MOSFET transistor on output 3X1: => -Ub. C7 => -Ub (for the steering contactor 3K1).

2) The ES30-24 generates a stabilised voltage on outputs 3X1:A6 => 8.2 V for the positive and on outputs 3X1:A5 => -Ub for the negative.

5) The 3K1 steering contactor and the coil of the steering centre 7A5 are thus supplied with power. The power stage is checked, the motor is stopped, outputs: 3X8:1 and 3X8:2 => 24 V. The steering centre itself is current-driven (between 5 and 750 mA), a cut bundle causes the truck to stop via the CAN Bus connection.

3) The steering controls the correct operation 6) The ES30-24 gives the two activation signals to operof the two setting and wheel potentiometers ate the traction: via the double signals (redundant potenThe steering controls its second safety relay giving the tiometers) on inputs 3X1:B1 and 3X1:A1 => positive rail for the traction (positive for input 1X1:1 for the 4.1 V (voltages measured when the setting internal relay contact to the LAC) on 3X1:B8 => +24 V. and the wheel are in alignment with the forks).

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Electric steering Validating the traction and the hydraulics For safety reasons, the traction and hydraulics validation test is performed by two different signals; one positive from the safety relay of the ES30-24 that supplies power to the traction and hydraulics line contactor, and the other negative, controlled by a transistor transmitting the steering status to the LAC controller.

Finally, a last traction authorisation is sent by the ES30-24 via the CAN Bus. This authorisation concerns traction only.

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Lithium-ion battery B1 and B2 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).

Cover provided and battery

Cover provided 1 Switch connector 2 Diagnostic harness connector 3 BMS (BMU) connector

4

On/off button connector

Battery 5 Module harness to BMS (SMU) connector(s)

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Electrics/electronics

Lithium-ion battery B1 and B2 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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60 Lithium-ion battery B1 and B2

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 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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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 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).

60-40

– 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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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 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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60 Lithium-ion battery B1 and B2

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 – 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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60 Lithium-ion battery B1 and B2

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 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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60 Lithium-ion battery B1 and B2

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 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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60 Lithium-ion battery B1 and B2

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 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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60 Lithium-ion battery B1 and B2

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 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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60 Lithium-ion battery B1 and B2

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 Power box Overview

A B C

250-A battery fuse Shunt (under the protective cap) Contact switch

The function of the power box is to check and provide the supply for the user of the Lithium Ion battery in a safe way.

It 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.

This allows the current of the lithium-ion battery to be measured.

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

Contact switch This cuts off the battery when it is stopped. It has a safety function.

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Shunt

Located below the plate, this activates precharging.

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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).

– 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 – Install the two cover fastening nuts (1) of the terminal block and then tighten them (tightening torque: 3 Nm).

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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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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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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

11

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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 5 6 7

Serial number Input current Table summarising charging times for different battery types

8

CE standard Weight

9

Power supply frequency

10

Manufacturer Charger model

11 .

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60 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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Display Description of the display

1 2 3

Multifunction indicator Blue-Q button Left navigation button

4 5 6

Right navigation button Confirm/back button Connector 6X2

The multifunction indicator 6P4, linked to the CAN Bus network of the truck, displays: • The level of battery discharge • The date and time • The operating hours of the truck (hour meter) • The position of the drive wheel • The forklift operator presence indicator • Activation/deactivation of Blue-Q • Error codes for troubleshooting assistance It can be configured using the diagnostic tool.

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Assignments for connector 6X2 Designation

Pins

Specifications Switch key or access control: OFF = not connected Switch key or access control: ON = battery positive

6X2:1

Battery voltage +24 V

6X2:2

Earth 0 V

6X2:3

CAN Low

6X2:4

CAN High

No terminating resistor between CAN High and CAN Low

6X2:5

Not used

Not used

6X2:6

Not used

Not used

6X2:7

Not used

6X2:8

Not used CAN Low (option)

6X2:9

CAN High (option)

6X2:10

Not used

Not used

The display is equipped with a 10-pin connector 6X2, which is connected to the truck harness.

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Display Display operating unit

1 2 3 4 5 6 7 8

9 10

Operator presence indicator light Battery indicator light Temperature indicator light Settings indicator light Warning indicator light Drive programme indicator light Activity indicator light Error Code menu

11 12 13 14

Settings menu Load Management and Drive wheel position menu Status menu Display of the operating time of the truck Display of the battery charge Display of the date and time

For more information, refer to chapter 4 Using the display operating unit.

Operation of the display unit Operator presence For the truck to operate, the operator must be detected on the seat and then on the pedal.

When the truck is switched on, the light indicating the operator's presence on the seat (1) comes on and flashes.

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– Sit on the seat The light indicating the operator's presence on the seat (1) is replaced by the light indicating the operator's presence on the pedal (2), which flashes.

– Press the operator presence pedal with your left foot The light indicating the operator's presence on the pedal (2) remains continuously illuminated for two seconds and then goes out.

Managing battery charging The operating unit shows the battery charge level.

The operator can refer to the battery icon (1) or (2).

The number of bars shown indicates the battery charge level.

• From 0 to 20%: 1 bar • From 21 to 40%: 2 bars • From 41 to 60%: 3 bars • From 61 to 80%: 4 bars • From 81 to 100%: 5 bars The battery light (3) comes on in the event of a deep discharge of the battery or in the event of a fault.

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Display Two distinct warnings may be displayed if the battery charge is insufficient: • 1) 25% of charge remaining: The (3) and (4) icons flash and an audible beep sounds. A warning message appears at the (4) icon and remains on until the battery is recharged.

• 2) 20% of charge remaining: Three regular beeps sound, lifting is restricted, the (3) icon flashes and the (4) icon remains on with a new warning message.

Temperature, settings and warning lights The temperature light (1) comes on in the event of overheating of the traction motor or the controller.

A warning is shown on the display.

The settings light (2) comes on to indicate the date of the next maintenance.

A warning is shown on the display.

The warning light (3) comes on in the event of a fault in a truck component.

Drive program The drive program light (1) is permanently illuminated when a travel mode is selected.

There are three different drive modes: • Tortoise mode (2) • Hare mode (3) • Blue Q mode (4) The icon of the drive mode selected appears on the display.

– Select the desired drive mode using the navigation keys

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60 Display

Activity indicator The activity indicator light (1) flashes continuously while the truck is in operation.

When the indicator is off, the display unit is locked or frozen. A warning is shown on the display.

Settings menu It is possible to access different settings through the Settings menu.

– Select the Settings menu (1) This menu allows access to a drop-down menu (2) consisting of: • Language • Unit • Date format • Date • Time • Adjustment of the Load Management warning sounds • Adjustment of the contrast • Adjustment of the brightness – Select the desired option

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Display Error codes menu It is possible to access error messages that are disrupting the operation of the truck.

– Select the Error messages menu (1) The operator can access the error codes. If several codes are affecting the truck, the operator can scroll through several successive displays.

The number of error messages is indicated at the bottom of the display (2).

Start-up screen In addition to the various menus and lights mentioned above, additional data is available: • The Truck status menu (1) displays the truck menu • The hourglass icon (2) indicates the operating time of the truck • The clock icon (3) indicates the time and date

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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

* 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.

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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)

.

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Example: automatically switches off after 1 min.

(60s) when not used.

Minimum setting = 10 s / maximum = 3000 s

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FleetManager™ (option) FleetManager description The FleetManager fleet management system allows access control and transmission of truck data.

• Access control and GPRS module

This system consists of two reading device versions for access control.

This system and the additional options are fitted on trucks from:

Additional options:

• EXD: from W40286E00186

• Shock sensor

• LTX: from 07/2015

• Tools for wireless data management: ▶ GPRS radio module (1)

with GSM antenna

(2)

• Access control, shock sensor and GPRS module

• SXD and SXH: from 10/2016 • FXH N, FXD N, FXV N from 09/2017

The variants available on the truck are:

(1)

• Access control

(2)

• Access control and shock sensor

GPRS: General Packet Radio Service

GSM: Global System for Mobile Communication

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FleetManager™ (option) 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:

Assignment of connector 6X16

• A reading device with a keypad (1) OR

6X16: 1

• A RFID reading device with truck access by:

6X16: 3

▶ RFID transponder card, 13.56 MHz (2A)

6X16: 5

0V Analogue 2

▶ RFID transponder, 13.56 MHz (2B)

6X16: 7

Relay 1

Some of the data is transferred via Bluetooth.

6X16: 8

Relay 1

6X16: 11

CAN 2 High

6X16: 12 6X16: 13

CAN 2 Low CAN 1 High

6X16: 14

CAN 1 Low

Pins

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.

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Function Battery voltage

Electrics/electronics

60 FleetManager™ (option)

FleetManager™ option

6P4 6B1 S5 W1 W2

Multifunction indicator Shock sensor FleetManager unit GSM antenna GPRS module

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FleetManager™ (option) 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.

The fleet manager is the only person who is able to change certain parameters.

NOTE Replace the sensor if it is faulty.

Assignment of connector 6X12 (fitted alone) Pins

Function

6X12: 1

+24 V Variable voltage (shock signal)

6X12: 2 6X12: 3

0V

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 module.

GPRS module The GPRS module is located under the dashboard.

It consists of a communication unit and a GSM antenna.

The module allows you to: – Access truck information remotely – Use geolocation This data is located on a server.

1 2 3 4 5

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6X14: 1 6X14: 2 6X14: 3 6X14: 4 GSM antenna connector 6X15

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a

Hydraulic system Features of the initial lift cylinders

1

Cylinder barrel

2

Cylinder rod

The initial lift is provided by two single-acting side cylinders.

The cylinders are fitted with a ∅ 35 mm rod • Max. travel: 130 mm • Operating pressure: 280 bar • Test pressure: 420 bar • Weight: 3 kg

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Hydraulic system Main hydraulic system

12 14 16 13 15 23

19 17 18 19 20 21 22 Hydraulic circuit diagram 1 Plug 2 Lowering solenoid valve ( 2Y2) 3 Filter 4 Non-return valve 5 Main pressure cut-off 6 Lowering retarder 7 Filler plug with breather (60 µ) 8 Pump 9 Suction screen 10 Hydraulic tank 11 Initial lift cylinders

115400_70-001

Hydraulic system 12 Hexagon head screw 13 Washer 14 Support 15 Round nut 16 Pump-motor unit 17 Pipe line 18 Bolt 19 Initial lift cylinders 20 Bolt 21 Threaded pin 22 Nut H 23 Chassis

1.2 kW pump-motor unit Flow limiter (6) (Ø in mm)

2.2

Suction screen (9) (in µ)

450

Pump motor (8) (in cm3/rev)

1

Filter (3) (in µ)

300

Pressure cut-off setting (5) (in Bar)

200

.

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Operational logic of the initial lift

A B

Load arm lifting control (initial lift) Load arm lowering control (initial lowering)

1B3 1B4

Load arms in lowered position detector Load arms in upper position detector

Summary table: 2M1*

2Y2*

Lifting of load arms

1

0

Lowering of load arms

0

1

Comments ► Pump motor: powered ► Solenoid valve: not activated ► Pump motor: not powered ► Solenoid valve: activated

* 2M1: Lifting motor * 2Y2: Lowering solenoid valve

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Hydraulics

Hydraulic system Main hydraulic system (FXH 25)

12 14 16 13 15 23

19 17 18 19 20 21 22 Hydraulic circuit diagram 1 Plug 2 Lowering solenoid valve (2Y2) 3 Filter 4 Non-return valve 5 Lowering retarder 6 Filler plug with breather (60 µ) 7 Pressure cut-off 8 Pump 9 Suction screen 10 Hydraulic tank 11 Initial lift cylinders

115400_70-003

Hydraulic system 12 Hexagon head screw 13 Washer 14 Support 15 Round nut 16 Pump-motor unit 17 Pipe line 18 Bolt 19 Cylinder 20 Bolt 21 Threaded pin 22 Nut H 23 Chassis

1.5 kW pump-motor unit Flow limiter (6) (Ø in mm)

2.4

Suction screen (9) (in µ)

450

Pump motor (8) (in cm3/rev)

1

Filter (3) (in µ)

300

Pressure cut-off setting (5) (in bar)

225

.

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Operational logic of the initial lift (FXH 25)

A B

Load arm lifting control (initial lift) Load arm lowering control (initial lowering)

1B3 1B4

Load arms in lowered position detector Load arms in upper position detector

Summary table: 2M1*

2Y2*

Lifting of load arms

1

0

Lowering of load arms

0

1

Comments ► Pump motor: powered ► Solenoid valve: not activated ► Pump motor: not powered ► Solenoid valve: activated

* 2M1: Lifting motor * 2Y2: Lowering solenoid valve

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Pump-motor unit Description of the pump-motor unit

1 2 3 4 5 6 7

1.2 kW pump motor Electric cable Catch plate Valve Pipe Non-return valve Special wrench

8 9 10 10a 10b 10c

Pressure relief valve Pipe Oil tank (0.75 L) Mounting O-ring Plug

Features of the 1.2 kW pump-motor unit Circuit pressure: 250 bar Nominal capacity Motor Running-in Tank Setting

kg

2000

P (kW)

1.2

U (V/DC)

24

Service number S3 (in %)

10

Speed (rpm)

3000

Capacity (L)

0.75

Filling volume (L)

0.6

Opening cut-off (bar mini)

185 200 (0/-5)

Full flow cut-off (bar)

.

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11548012111 EN - 09/2017

Hydraulics

70 Pump-motor unit

Description of the pump-motor unit (FXH 25)

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

1.5 kW pump motor Carbon brush set Support Coupling Non-return valve Pressure cut-off O-ring Plug Oil tank (1.5 L) Plug Support O-ring

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

Socket head screw M6x20 - 8.8 - A2C Pipe Pipe Pipe Pressure relief valve Valve block O-ring Socket head screw M4x40 - 8.8 + DRILOC 3G VNF valve O-ring Back-up ring O-ring

Features of the 1.5 kW pump-motor unit Circuit pressure: 250 bar Nominal capacity Motor Running-in Tank Setting

kg

2500

P (kW)

1.5

U (V/DC)

24

Service number S3 (in %)

10

Speed (rpm)

3000

Capacity (L)

1.5

Filling/working volume (L)

1.1

Opening cut-off (bar mini)

205 225 (0/-5)

Full flow cut-off (bar)

.

11548012111 EN - 09/2017

70-7

70

Hydraulics

Pump-motor unit

70-8

11548012111 EN - 09/2017

Index g A

Digicode LFM GO . . . . . . . . . . . . . . . . . 60- 69 Display

Adjustable floor Description of the adjustable floor . . . 30- 3 Adjusting the electric steering Calibrating the setpoint potentiometer 3B2 . . . . . . . . . . . . . . . . . . . . . . 42- 4

Description of the display . . . . . . . . . 60- 62 Display operating unit . . . . . . . . . . . . . . . 60- 64 Display unit Activity indicator . . . . . . . . . . . . . . . . 60- 67

Calibrating the wheel position potentiometer . . . . . . . . . . . . . . 42- 4

Drive program . . . . . . . . . . . . . . . . . 60- 66

Checking settings . . . . . . . . . . . . . . . 42- 4

Operator presence . . . . . . . . . . . . . . 60- 64

Aerosol can for chains . . . . . . . . . . . . . . 00- 6

Settings . . . . . . . . . . . . . . . . . . . . . . 60- 66

Error codes menu . . . . . . . . . . . . . . . 60- 68

Start-up screen . . . . . . . . . . . . . . . . 60- 68

B

Temperature . . . . . . . . . . . . . . . . . . 60- 66

Battery compartment

Warnings . . . . . . . . . . . . . . . . . . . . . 60- 66

Types of compartment . . . . . . . . . . . 30- 11

Driver’s platform

Battery lock . . . . . . . . . . . . . . . . . . . . . . 30- 12 Brake Y1

Operator presence detection . . . . . . 30- 4 Drivetrain

Checking the operation . . . . . . . . . . . 60- 27

Description of the drive unit . . . . . . . . 23- 1

C

E

CAN bus network of the lithium-ion battery . . . . . . . . . . . . . . . . . . . . 02- 9

Electrical equipment

Checking the motor rotation speed (1M1) . . . . . . . . . . . . . . . . . . . . . 60- 23 Checking the operation of the temperature sensor (1B6) Checking the temperature sensor (1B6) . . . . . . . . . . . . . . . . . . . . . 60- 25 Parameterising the sensor . . . . . . . . 60- 25 Cleaning the motor . . . . . . . . . . . . . . . . . 11- 5 Control devices Functions of the joystick . . . . . . . . . . 50- 4 Control unit Description of the control module . . . 42- 8 Description of the joystick (option) . . . 42- 10 Description of the steering knob . . . . 42- 7 Description of the steering wheel . . . 42- 6 Operations on the control module . . . 42- 9

D

Contact switches . . . . . . . . . . . . . . . 60- 10 Emergency off switch . . . . . . . . . . . . 60- 10 Fuses . . . . . . . . . . . . . . . . . . . . . . . 60- 8 Horn (4H1) . . . . . . . . . . . . . . . . . . . . 60- 11 Electrics/electronics Functions of the inputs/outputs of the LAC . . . . . . . . . . . . . . . . . . . . . . 60- 13 Electrics/Electronics Traction and lift controller . . . . . . . . . 60- 12 Electromagnetic brake Features . . . . . . . . . . . . . . . . . . . . . 42- 15 Electromagnetic compatibility . . . . . . . . . 60- 5 Emergency off switch Operating . . . . . . . . . . . . . . . . . . . . 60- 10 Error codes Reading and deleting the error list . . . 02- 28 ES30-24 Adjusting the electric steering . . . . . . 42- 4

Description of the lithium-ion battery B1 and B2 . . . . . . . . . . . . . . . . . . . . 00- 7 Diagnostics Accessing truck information . . . . . . . 02- 2 CAN Bus network with LAC and ES30-24 . . . . . . . . . . . . . . . . . . 02- 6 Parameterising . . . . . . . . . . . . . . . . 02- 3 Pictograms of error codes on the display . . . . . . . . . . . . . . . . . . . . 02- 30

Electric steering unit ES30-24 . . . . . . 60- 31 Functions of the inputs/outputs of the ES30-24 . . . . . . . . . . . . . . . . . . 60- 32 General . . . . . . . . . . . . . . . . . . . . . . 42- 1 Identifying the ES30-24 using the diagnostic software . . . . . . . . . . 60- 31 Switching on the ES30-24 unit . . . . . 60- 33 ES30-24 steering unit Technical data . . . . . . . . . . . . . . . . . 42- 3

11548012111 EN - 09/2017

1

Index g Linkage of the truck

External charger

Load lift system with level compensator . . . . . . . . . . . . . . . . . . . . . 30- 8

Description . . . . . . . . . . . . . . . . . . . 60- 58 Display . . . . . . . . . . . . . . . . . . . . . . 60- 58

Load lift system without level compensator . . . . . . . . . . . . . . . 30- 10

Electrical interface . . . . . . . . . . . . . . 60- 59 Status of lights . . . . . . . . . . . . . . . . . 60- 59 Technical features . . . . . . . . . . . . . . 60- 60

F

Lithium Ion Battery LTroubleshooting flow chart B1-B2 . . 02- 15 Lithium-ion battery Analysing the battery condition . . . . . 02- 26

Fixed chassis

Block diagram of the lithium-ion battery . . . . . . . . . . . . . . . . . . . . 02- 11

Accessing the dashboard components . . . . . . . . . . . . . . . . . . . . . 30- 2

Description of the BMS . . . . . . . . . . . 60- 42

Accessing the technical compartment . . . . . . . . . . . . . . . . . . . . . 30- 1

Diagnostic connector . . . . . . . . . . . . 02- 8 Disassembling the B1 and B2 battery module . . . . . . . . . . . . . . . . . . . 60- 46

Fleet Manager TDU: Access control . . . . . . . . . . . . . 60- 72

Error codes for the lithium-ion battery B1-B2 . . . . . . . . . . . . . . . . . . . . 02- 12

FleetManager™ FleetManager™ description . . . . . . . 60- 71

Indicator light . . . . . . . . . . . . . . . . . . 02- 10

FleetManager™ option . . . . . . . . . . . 60- 73

Power box overview . . . . . . . . . . . . . 60- 54 Questionnaire to identify battery condition . . . . . . . . . . . . . . . . . . 02- 27

G General

Reassembling the B1 and B2 battery module . . . . . . . . . . . . . . . . . . . 60- 49

FXH 20N / FXH 25N technical compartment . . . . . . . . . . . . . . . 60- 6

Replacing the BMS . . . . . . . . . . . . . 60- 43

Location of connectors . . . . . . . . . . . 60- 7

Replacing the contact switch . . . . . . . 60- 55

Grease for pinion gear and steering ring . 00- 6

Replacing the cover provided . . . . . . 60- 36

H

Replacing the diagnostic harness . . . 60- 39

Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . 00- 6

Replacing the power cable . . . . . . . . 60- 41

Replacing the fuse . . . . . . . . . . . . . . 60- 57

Hydraulics

Replacing the push button provided . 60- 38

Description of the pump-motor unit . . 70- 6 Description of the pump-motor unit (FXH 25) . . . . . . . . . . . . . . . . . . 70- 7 Features of the initial lift cylinders . . . 70- 1 Main hydraulic system . . . . . . . . . . . 70- 2 Main hydraulic system (FXH 25) . . . . 70- 4

Replacing the terminal block . . . . . . . 60- 40 Lithium-ion module . . . . . . . . . . . . . . . . . 60- 45 Location of connectors for the lithium-ion battery . . . . . . . . . . . . . . . . . . . . 60- 35

Operational logic of the initial lift . . . . 70- 3

M

Operational logic of the initial lift (FXH 25) . . . . . . . . . . . . . . . . . . . . . . . 70- 5

Maintenance plan 1000 hours . . . . . . . . . . . . . . . . . . . . 01- 1 5000 hours . . . . . . . . . . . . . . . . . . . . 01- 1

I Installing the external charger . . . . . . . . . 60- 61 Insulation testing . . . . . . . . . . . . . . . . . . 60- 4 intercooler fan (9M1) Testing the control of the fan (9M1) . . 60- 29

L

Managing battery charging . . . . . . . . . . . 60- 65 Motor Rotor testing . . . . . . . . . . . . . . . . . . 11- 4 Visual inspection . . . . . . . . . . . . . . . 11- 4 Motors Cleaning . . . . . . . . . . . . . . . . . . . . . 11- 5

Lifting the truck . . . . . . . . . . . . . . . . . . . . 00- 8

2

Replacing the shunt . . . . . . . . . . . . . 60- 52

Testing . . . . . . . . . . . . . . . . . . . . . . 11- 4 Multi-purpose grease . . . . . . . . . . . . . . . 00- 6

11548012111 EN - 09/2017

Index g O

T

Operating device

Technical features

Horn function on the control module . 50- 3

ES30-24 steering unit label . . . . . . . . 00- 3

Initial lift function on the control module . . . . . . . . . . . . . . . . . . . 50- 2

LAC controller label . . . . . . . . . . . . . 00- 2

Traction function on the control module . . . . . . . . . . . . . . . . . . . 50- 1

Pump-motor unit label . . . . . . . . . . . 00- 4

Pallet truck with driver seated . . . . . . 00- 1 Serial numbers . . . . . . . . . . . . . . . . . 00- 2

option . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 7

Traction motor label . . . . . . . . . . . . . 00- 3 Transmission gear label . . . . . . . . . . 00- 3

P Parameterising the control module . . . . . 60- 21 Principle of the Hall effect sensor . . . . . . 42- 14

Truck label . . . . . . . . . . . . . . . . . . . . 00- 2 Technician electrical accreditation . . . . . 00- 10 Traction Activating controllers 1A1 and 3A1 . . 60- 15

R Recommended lubricants . . . . . . . . . . . . 00- 6

Traction motor Features of the traction motor . . . . . . 11- 1

Reducer unit . . . . . . . . . . . . . . . . . . . . . 23- 4

Location of components . . . . . . . . . . 11- 3

Rev sensor (1B2) . . . . . . . . . . . . . . . . . . 60- 23

Overview . . . . . . . . . . . . . . . . . . . . . 11- 2

S

Rev sensor . . . . . . . . . . . . . . . . . . . 11- 6 Technical features . . . . . . . . . . . . . . 11- 1

Safety guidelines

Temperature sensor . . . . . . . . . . . . . 11- 7

Electrical equipment . . . . . . . . . . . . . 60- 1 Seat Description of the seat . . . . . . . . . . . 30- 5

Winding test . . . . . . . . . . . . . . . . . . . 11- 4 Traction: Checking the operation Checking the operation of the temperature sensor (1B6) . . . . . . 60- 25

Seat heater . . . . . . . . . . . . . . . . . . . . . . 30- 7 Settings menu . . . . . . . . . . . . . . . . . . . . 60- 67

Control module (1B1) . . . . . . . . . . . . 60- 30

Slinging the truck . . . . . . . . . . . . . . . . . . 00- 8

Electromagnetic brake (Y1) . . . . . . . 60- 27

Speed reductions . . . . . . . . . . . . . . . . . . 60- 17

Fan (9M1) . . . . . . . . . . . . . . . . . . . . 60- 29

Stabiliser

Operator presence detection . . . . . . 60- 28

Features of the fixed stabiliser . . . . . 42- 16 Periodic fixed stabiliser wheel checks . . . . . . . . . . . . . . . . . . . . 42- 18

Rev sensor (1B2) . . . . . . . . . . . . . . . 60- 22 Traction: LAC Central negative point . . . . . . . . . . . 60- 18

Stabiliser height adjustment . . . . . . . 42- 17 Steering Description . . . . . . . . . . . . . . . . . . . 42- 2 Steering centre . . . . . . . . . . . . . . . . . . . 42- 11 Description of the pivot . . . . . . . . . . . 42- 12 Overview . . . . . . . . . . . . . . . . . . . . . 42- 11 Pin assignment for connector X13 . . . 42- 11 Steering setpoint 3B2 Features of the Hall effect setpoint sensor . . . . . . . . . . . . . . . . . . . . 42- 13

Central positive point . . . . . . . . . . . . 60- 20 Transmission Description . . . . . . . . . . . . . . . . . . . 23- 2 Transmission gear Technical features . . . . . . . . . . . . . . 23- 3 Transmission oil . . . . . . . . . . . . . . . . . . . 00- 6

W Wear Drive wheels . . . . . . . . . . . . . . . . . . 42- 21 Wheels Description of the wheels . . . . . . . . . 42- 19 Types of drive wheel . . . . . . . . . . . . . 42- 20 Types of load wheel . . . . . . . . . . . . . 42- 23 Types of stabiliser wheels . . . . . . . . . 42- 22

11548012111 EN - 09/2017

3

STILL GmbH 11548012111 EN – 09/2017