STILL STED forklift CX-CXD-CXM KANVAN -CXS CXT-CXH Workshop Manual

....

STILL

Workshop literature STILL ELECTRONIC DOCUMENTATION SYSTEM

CX-CXD-CXM KANVAN -CXS CXT-CXH

CE first in intralogistics 50108042301 EN - 05/2014

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a

This workshop manual essentially has two parts: General information on the product, diagnosis of malfunctions and special tools: Group 0 Repair instructions: Groups 1 to 9 Each part of the current manual is composed of a set of separate sheets that are led in a STILL binder according to their group number.

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

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

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

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

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

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

The diagnostic software makes it possible to quickly locate the source of a problem identi ed in the electrical system and to accurately determine its cause. It has been set out as follows: Using a notebook Controller setting Menus Diagrams of the hydraulic and electrical circuits are available in the relevant publications

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

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

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

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

It may be accompanied by additional comments.

This symbol indicates important communications for the assistance technician.

It may be accompanied by additional comments.

This warning indicates serious risk of damaging the truck.

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

It may be accompanied by additional comments.

50108042301 [EN]

-1

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

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

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

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

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

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

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

Do not disperse oils or other operating liquids!

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

Always comply with anti-pollution regulations!

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

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

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

Do not allow to come into contact with the skin.

Do not inhale oil vapors.

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

-2

Do not inhale the vapor: it is poisonous.

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

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

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

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

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

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

50108042301 [EN]

Quantity (l)

TUTELA TRANSMISSION W90/LA TUTELA TRANSMISSION W90/LA* 1.5 Hydraulic oil HLF 32 EQUIVIS XV32* Tutela MP 02 STATERMELF EP2 GREASE* Structovis EHD Structovis FHD*

* For Cold-Storage Room version

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2

3

5

4

6

7

1

20 19 8 18 9 10 17

11 16

1 2 3 4 5 6 7 8 9 10

-4

15

14

13

12

Battery connector Cockpit Button for driving in pedestrian mode (option) Back panel Button for driving in pedestrian mode (option) Load wheels Forks Lift cylinder Steering and traction current controller Operator platform

1044_000-005

11 12 13 14 15 16 17 18 19 20

Traction battery Brake Traction motor Gearbox Traction wheel Steering motor Stabiliser wheel Hydraulic oil tank Pump motor Fuse carrier

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4

3

6

7

2

1

20 19

1045_000_001

18 8 9 10

17 16 1 2 3 4 5 6 7 8 9 10

15

14

13 12

Battery connector Cockpit Button for driving in pedestrian mode (option) Back panel Button for driving in pedestrian mode (option) Load wheels Forks Lift cylinder Steering and traction current controller Operator platform

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Traction battery Brake Traction motor Gearbox Traction wheel Steering motor Stabiliser wheel Hydraulic oil tank Pump motor Fuse carrier

-5

3

4

5

6

7

2

1

8

20 19

1046_003-002

9

18

10 12

17

13 16

1 2 3 4 5 6 7 8 9 10

-6

11

15

14

Battery connector Cockpit Button for driving in pedestrian mode (option) Back panel Button for driving in pedestrian mode (option) Load wheels Forks Lift cylinder Steering and traction current controller Operator platform

11 12 13 14 15 16 17 18 19 20

Traction battery Brake Traction motor Gearbox Traction wheel Steering motor Stabiliser wheel Hydraulic oil tank Pump motor Fuse carrier

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Battery socket Cockpit Button for driving in pedestrian mode (option) Backrest Tow coupling Wheels Traction controller Operator platform Traction battery

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Power steering motor Drive wheel Reducer Traction motor Brake Fuse carrier Horn Steering controller

-7

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

-8

Horn Battery connector Cockpit Backrest Guard grille Mast Button for driving in pedestrian mode (option) Tow coupling Foldable forks Load wheels Traction controller Operator platform

13 14 15 16 17 18 19 20 21 22 23

Battery equipment Steering controller Power steering motor Drive wheel Reducer Traction motor Electromagnetic brake Hydraulic tank Pump motor Fuses Buttons for fork extension/folding

50108042301 [EN]

1 Names used in the text: forward travel (1), reverse travel (3), to the right (2) and to the left (4) refer to component installation position with respect to the driver s compartment, the load being positioned to the rear.

4

2

3

1047_003-001

The truck serial number is marked on the chassis frame and is inside the battery frame.

The battery hood must be unclipped in order to reach the serial number on the chassis frame.

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F2 1063 D Complete serial number

F2: Luzzara (Italy)

1063: CX 20 1064: CX 10 M 1065: CX 16 S 1066: CX-T 1067: Kanvan 05 1068: Kanvan 10 1069: CX-D

Example : D: 2013

00001: Ascending number

Please state this serial number for all technical questions.

1 2 3 4 5 6 7 -10

Model Manufacturer Serial no.

Year of manufacture Unladen weight (without battery) Maximum battery weight Minimum battery weight

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Additional weight (ballast) Nominal power rating Battery voltage Rated capacity EC conformity symbol

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a

Before performing any services on the electric components of the pallet truck with the service case, block up the traction wheels so that they can rotate freely.

For safety reasons place squared timbers under the frame to prevent the truck from rolling accidentally.

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The CAN data bus of the device interconnects the following devices: Cockpit(1) Traction motor controller (2) Steering motor controller (3) Information of the cockpit to the traction motor controller: Desired value for traction Desired value for hydraulic system Desired value for horn Information of the traction motor controller to the cockpit: Error Hour meter Battery state of charge Information of the steeringcontroller to the cockpit: Error

-2

50108042301 [EN]

CAN-BOX

CAN-BOX USB

RS 232 serial cable

7-pin diagnosis cable

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200

201

202 203 204 205 206 207

208 209

210

211

212

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Communication Software (Internal fault) If permanent => change controller problem between WATCHDOG Could be linked to diagnose tool conmaster and slave - Error nection - Truck stopped Wrong voltage in Hardware (Internal fault) If permanent => change controller the current sensor STBY I HIGH feedback circuit - Error Truck stopped Capacitors don t charge Capacitor Charge Failed Check the screwing of the contoller, at key-on - Error - Truck CAPACITOR CHARGE and check if not accessories pluged bedo not start tween B- & B+, if Ok change controller Main contactor driver Main Contactor Fault Change controller doesn t close - Error CONTACTOR DRIVER Truck stopped Short circuit on main Main Contactor Fault Check if no short-circuit between A17 & contactor driver - Error - DRIVER SHORTED A30, if Ok change controller Truck stopped Short circuit on main Main Contactor Fault - COIL Check if no "short-circuit" between A17 contactor - Error - Truck SHORTED & A30 (normal brake resistance 30-65 stopped Ohms) Problem on read Hardware (Internal fault) If permanent => change controller analogic input - Error ANALOG INPUT - Truck stopped Wrong voltage on motor Motor shorted - POWER Check motor connexion (open wires & power outputs;failure MOS SHORTED short circuit), if Ok change controller. in the power or in the mosfet driver circuit or in the motor - Error Truck stopped Micro slave is in alarm Software (Internal fault) If permanent => change controller "input mismatch" - Error SLAVE ALARM 1 - Truck stopped Positive line contactor Safety circuit Failure - NO Check Safety circuit D6 => C2 => C14 is not present. - Error - POS-GEN EF => A7. (See Failure Tree) - Could be Truck stopped linked to error of the steering or the cockpit.

Communication Software (Internal fault) If permanent => change controller problem between WATCHDOG PUMP Could be linked to diagnose tool conmaster and slave - Error nection - Truck stopped Communication CAN Bus Fault - NO CAN If permanent => change controller problem between MESSAGE 2 Could be linked to diagnose tool conmaster and slave - Error nection - Truck stopped Vmn and Vbatt different Hardware (Internal fault) Check contactor (dust in the contactor or - Error - Truck stopped VMN LOW oxydation of contacts ). Check motor connexion (open wires & short circuit)If permanent=> change controller - Wrong voltage on motor power outputs;failure in the power or in the mosfet driver circuit or in the motor

50108042301 [EN]

213 Internal problem Hardware (Internal fault) (over ow, pll LOGIC FAILURE #1 problem ) - Error Truck stopped 217 Wrong driving Sequencing Failure sequence during 20 sec -INCORRECT START - Error - Truck stopped

218 Problem on read Pump fault - ANALOG analogic input pump INPUT PUMP - Error - Truck stopped 219 Wrong voltage output Pump fault - PUMP VMN of pump chopper; the LOW motor voltage feedback is not coherent with applied pwm - Error Truck stopped 220 Wrong voltage output Pump fault - PUMP VMN of pump chopper; the HIGH motor voltage feedback is not coherent with applied pwm - Error Truck stopped 221 An overvoltage or Battery Fault - BATTERY undervoltage condition NOT OK has been detected on master - Error - Truck stopped 222 Failure in U,V,W Hardware (Internal fault) voltage feedback circuit LOGIC FAILURE #2 - Error - Truck stopped 224 Hardware problems Hardware (Internal fault) Error - Truck stopped HW FAULT 225 Driver EVP is shorted - Lowering Valve Failure Error - Truck stopped DRIVER SHORTED EVP 226

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227 Main contactor always Main Contactor Fault closed - Error - Truck CONTACTOR CLOSED stopped 228 Wrong voltage on motor Hardware (Internal fault) power outputs;failure VMN HIGH in the power or in the mosfet driver circuit or in the motor - Error Truck stopped 229 Battery not ok at key-on Battery Fault - WRONG - Error - Truck stopped SET BATTERY 231

Problem on signal of Hardware (Internal fault) current and tension on WRONG ZERO the slave - Error - Truck stopped

50108042301 [EN]

If permanent => change controller

Check if all commands (included BP) released - In the diagnose tool: Measurment => Cockpit => Accelerator state Measurment => Drive => Inching command Measurment => Cockpit => Cockpit button If permanent => change controller Check motor pump connexion. Check the battery voltage. - In the diagnose tool: Measurment => Battery

Check motor pump connexion. Check the battery voltage. - In the diagnose tool: Measurment => Battery

Check battery (voltage ) - In the diagnose tool: Measurment => Battery

Check the traction motor. If permanent => change controller.

If permanent => change controller Check the valve Y1 (connexion, coil ) between A3 and A4. If permanent => change controller Check if contactor can be open Check motor connexion (open wires & short circuit)If permanet=> change controller

Check battery voltage and status of battery plug - In the diagnose tool: Measurment => Battery If permanent => change controller

-5

232 235 236 237

238 239

240 241 243 244 248

249 250

251

252

253

-6

The master does not CAN Bus Fault - CAN BUS If permanent => change controller or the comunicate with tiller - KO TILLER cockpit - Could be linked to diagnose Error - Truck stopped tool connection Problem on hardware - Hardware (Internal fault) If permanent => change controller Error - Truck stopped HARDWARE FAULT PUMP EM Brake contact does Brake Fault - AUX DRIVER Check the EM Brake between A30 and not pull-in - Error - Truck OPEN A31 ( normal resistance 5 - 15 Ohms). If stopped permanent => change controller Communication CAN Bus Fault - NO CAN If permanent => change controller problem between MESSAGE 5 Could be linked to diagnose tool conmaster and slave - Error nection - Truck stopped Short on EBrake coil - Brake Fault - AUX DRIVER Check the EM Brake between A30 and Error - Truck stopped SHORTED A31 ( normal resistance 5 - 15 Ohms). If permanent => change controller Line contactor power Main Contactor Fault Check the Main Contactor between A17 contact does not pull-in CONTACTOR OPEN and A30 ( normal resistance 30 - 65 - Error - Truck stopped Ohms). If permanent => change controller Micro slave in alarm Software (Internal fault) If permanent => change controller "wrong setpoint" - Error SLAVE ALARM 3 - Truck stopped Micro slave in alarm Software (Internal fault) If permanent => change controller "output mismatch" SLAVE ALARM 4 Error - Truck stopped Mismatch on Master Software (Internal fault) If permanent => change controller commands - Error SAFETY FEED Truck stopped When the truck type is Software (Internal fault) If permanent => change controller changed - Error - Truck TRUCK TYPE CHANGE Restart the truck stopped Motor speed Speed Encoder Failure Check Encoder connexion (X12). If persensor(encoder) does ENCODER ERROR manent => change encoder. - In the not work properly - Error diagnose tool: Measurment =>Drive => - Truck stopped Power traction => Rotor frequency Failure in over-load Hardware (Internal fault) If permanent => change controller protection hw circuit LOGIC FAILURE #3 Error - Truck stopped The sensor of board rail Sensor Rail Failure Check the connexion/wiring of the board is brocken - Warning SENSOR RAIL KO rail sensor pin A40.

- lower platform is stopped Wrong voltage in Hardware (Internal fault) If permanent (E201) => change conthe current sensor STBY I HIGH troller - Need release of butterfy to feedback circuit restart. If still present => E201 Warning - Truck stopped Capacitors don t charge Capacitor Charge Failed Check the screwing of the contoller, at key-on - Warning CAPACITOR CHARGE and check if not accessories pluged beTruck stopped tween B- & B+, if Ok change controller Need release of butterfy to restart. If still present => E202 Main contactor driver Main Contactor Fault Check if no short-circuit between A17 & doesn t close - Warning CONTACTOR DRIVER A30, if Ok change controller - Need re- Truck stopped lease of butterfy to restart. If still present => E203

50108042301 [EN]

254

255

Short circuit on main contactor driver Warning - Truck stopped Short circuit on main contactor coil - Warning - Truck stopped

Main Contactor Fault DRIVER SHORTED

Check if no short-circuit between A17 & A30, if Ok change controller - Need release of butterfy to restart. If still present => E204 Main Contactor Fault - COIL Check if no "short-circuit" between A17 SHORTED & A30 (normal brake resistance 30-65 Ohms) - Need release of butterfy to restart. If still present => E205 Hardware (Internal fault) If permanent (E206) => change conANALOG INPUT troller - Need release of butterfy to restart. If still present => E206

256 Problem on read analogic input Warning - Truck stopped 257 Wrong voltage on motor Motor shorted - POWER power outputs;failure MOS SHORTED in the power or in the mosfet driver circuit or in the motor - Warning Truck stopped 258 Thermic sensor not OK Hardware (Internal fault) - Warning - Speed is THERMIC SENSOR KO reduced at 39% and curmax is halved 259 Positive line contactor is Safety circuit Failure - NO not present. - Warning - POS-GEN EF Truck stopped 260 Problems with eeprom Software (Internal fault) checksum on master EEPROM KO - Warning - Truck stopped 261 Communication CAN Bus Fault - NO CAN problem between MESSAGE 2 master and slave - Warning - Truck stopped 262 Vmn and Vbatt different Hardware (Internal fault) - Warning - Truck VMN LOW stopped

263

Temperature of controller is >85° - Warning - The maximum current is reduced linear until 0 at 115° The maximum current of pump is reduced linear until 0 at 115° 264 Problem with steer wire - Warning - Speed is reduced at 39%

Controller Temperature CONTOLLER TEMPERATURE

265

Output Failure - COIL SHORTED VALVE

Short circuit on valve coil - Warning - valve on/off are stopped

Steering failure - STEERING HAZARD

50108042301 [EN]

Check motor connexion (open wires & short circuit), if Ok change controller. Need release of butterfy to restart. If still present => E207 If permanent => change controller

Check Safety circuit D6 => C2 => C14 => A7. - Need release of butterfy to restart. If still present => E209 If permanent (E210)=> change controller - Need release of butterfy to restart. If still present => E210 If permanent (E211)=> change controller - Need release of butterfy to restart. If still present => E211 Check contactor (dust in the contactor or oxydation of contacts ). Check motor connexion (open wires & short circuit)If permanet=> change controller - Need release of butterfy to restart. If still present => E212 Leave the truck in standly. Check the Fans pin A16(connexion/wiring) and in the diagnose tool (test mode of the Fans) . - Check environment of the truck (load, ramp ) - In the diagnose tool: Measurment =>Drive => Temperature

Check voltage at input A23 (value should be between 1V and 8V) - In the diagnose tool: Measurment => Drive => Power section => Speed reduction Check all the outputs (connexion/wiring/short circuit) A14, A15, A16, A28, A32, A39 .

-7

266

267

268

269

270

271

272

273

274 275 276

277

-8

Two traction direction requests together Warning - traction is stopped Wrong driving sequence during 10 sec - Warning - Truck stopped

Sequencing Failure FORW+BACK Sequencing Failure INCORRECT START

Problem on read Pump fault - ANALOG analogic input pump INPUT PUMP - Warning - pump is stopped Wrong boltage output Pump fault - PUMP VMN of pump chopper; the LOW motor voltage feedback is not coherent with applied pwm - Warning - pump is stopped Wrong voltage output Pump fault - PUMP VMN of pump chopper; the HIGH motor voltage feedback is not coherent with applied pwm - Warning - pump is stopped An overvoltage or Battery Fault - BATTERY undervoltage condition NOT OK has been detected on master - Warning - Truck stopped Failure in U,V,W Hardware (Internal fault) voltage feedback circuit LOGIC FAILURE #2 - Warning - Truck stopped No pwm applied to Pump fault - PUMP STBY I pump chopper, the HIGH pump current sensor feedback is out the zero current window - Warning - pump is stopped Hardware problems Hardware (Internal fault) - Warning - Truck HW FAULT stopped Driver EVP is shorted - Lowering Valve Failure Warning - lift and lower DRIVER SHORTED EVP is stopped The battery is too low Battery Fault - WEAK < 15 volts during 2 BATTERY seconds - Warning - lift with traction is stopped Main contactor always Main Contactor Fault closed - Warning CONTACTOR CLOSED Truck stopped

Check S17, S18, S31, S32 switchs Need release of inching forward /backward. - In the diagnose tool: Measurment => Drive => Inching command Check if all commands (included BP) released - Need release of butterfy to restart. If still present => E217 - In the diagnose tool: Measurment => Cockpit => Accelerator state Measurment => Drive => Inching command Measurment => Cockpit => Cockpit button If permanent (E218) => change controller - Need release of lifting to restart.

If still present => E218 Check motor pump connexion. Check the battery voltage. - Need release of lifting to restart. If still present => E219 - In the diagnose tool: Measurment => Battery Check motor pump connexion. Check the battery voltage. - Need release of lifting to restart. If still present => E220 - In the diagnose tool: Measurment => Battery Check the battery (voltage ) - Need release of butterfy to restart. If still present => E221 - In the diagnose tool: Measurment => Battery If permanent (E222) => change controller - Need release of butterfy to restart. If still present => E222 Check motor pump connexion.

If permanent (E224) => change controller - Need release of butterfy to restart. If still present => E224 Check the valve Y1 (connexion, coil ) between A3 and A4. If permanent => change controller Check the battery (voltage ) - In the diagnose tool: Measurment => Battery Check if contactor can be open - Need release of butterfy to restart. If still present => E227

50108042301 [EN]

278 Wrong voltage on motor Hardware (Internal fault) power outputs;failure VMN HIGH in the power or in the mosfet driver circuit or in the motor - Warning Truck stopped 279 Battery not ok at key-on Battery Fault - WRONG - Warning - Truck SET BATTERY stopped 280 Low voltage in the Pump fault - CURRENT current sensor (pump) SENSOR LOW PUMP feedback circuit Warning - pump is stopped 281 Problem on signal of Hardware (Internal fault) current and tension on WRONG ZERO the slave - Warning Truck stopped 282 The master does not CAN Bus Fault - CAN BUS comunicate with tiller KO TILLER - Warning - Truck stopped 283 Gray code not OK Software (Internal fault) Warning - traction is GRAY CODE stopped 284 Lift/low requests from Sequencing Failure can together - Warning - LIFT+LOWER lift and lower is stopped

285 286

287

288

289

Check motor connexion (open wires & short circuit)If permanet=> change controller - Need release of butterfy to restart. If still present => E228 Check battery voltage and status of battery plug - Need release of butterfy to restart. If still present => E229 - In the diagnose tool: Measurment => Battery If permanent => change controller

If permanent (E231) => change controller - Need release of butterfy to restart. If still present => E231 If permanent (E232) => check error list of the cockpit and change controller Need release of butterfy to restart. If still present => E232 If permanent => check error list of the cockpit and change controller

Check hydraulics commands. If permanent => change controller - Need release hydraulic command to restart - In the diagnose tool: Measurment => Cockpit Measurment => Drive => Lifting command Problem on hardware Hardware (Internal fault) If permanent (E235)=> change con- Warning - pump is HARDWARE FAULT PUMP troller - Need release of lifting to restart. stopped If still present => E235 EM Brake contact does Brake Fault - AUX DRIVER Check the EM Brake between A30 and not pull-in - Warning OPEN A31 ( normal resistance 5 - 15 Ohms). If Truck stopped permanent (E236)=> change controller - Need release of butterfy to restart. If still present => E236 Communication CAN Bus Fault - NO CAN If permanent (E237)=> change conproblem between MESSAGE 5 troller - Need release of butterfy to master and slave restart. If still present => E237 - Warning - Truck stopped Brake Fault - AUX DRIVER Check the EM Brake between A30 and Short on EBrake coil SHORTED - Warning - Truck A31 ( normal resistance 5 - 15 Ohms). If stopped permanent (E238)=> change controller - Need release of butterfy to restart. If still present => E238 Line contactor power Main Contactor Fault Check the Main Contactor between A17 contact does not pull-in CONTACTOR OPEN and A30 ( normal resistance 30 - 65 - Warning - Truck Ohms). If permanent (E239)=> change stopped controller - Need release of butterfy to restart. If still present => E239

50108042301 [EN]

-9

290

Motor temperature is >150° - Warning Speed is reduced at 39% and curmax is halved

Motor Temperature MOTOR TEMPERATURE

291

Problems with eeprom checksum on pump - Warning - Truck stopped Wrong lift/lower sequence - Warning lift and lower is stopped

Software (Internal fault) EEPROM KO PUMP

292

293 294

295

296

297 298

299

Leave the truck in stanby. Check the thermal sensor (connexion/wiring).

(Normal resistance at 20°C = 1070Ohms) - Check environment of the truck (load, ramp ) - In the diagnose tool: Measurment =>Drive => Temperature If permanent (E241)=> change controller - Need release of butterfy to restart. If still present => E241

Sequencing Failure - PUMP Check hydraulics commands. - Need INCORRECT START release hydraulic command to restart - In the diagnose tool: Measurment => Cockpit Measurment => Drive => Lifting command Lowering Valve Failure Driver of evp not ok Check the valve Y1 (connexion, coil, DRIVER KO EVP - Warning - evp is short circuit ) between A3 and A4. If stopped permanent => change controller Mismatch on inputs Deadman Failure Check the deadman (connexion/wiring) deadman - Warning DEADMAN MISMATCH on pin A34 (NC) and A35(NO) and metraction is stopped chanical adjustment. - In the diagnose tool: Measurment => Drive =>Power section Valve on/off contactor Output Failure - VALVE Check all the outputs (connexdriver doesn t close CONTACTOR DRIVER ion/wiring/short circuit) A14, A15, A16, Warning - valve on/off A28, A32, A39 .If permanent => change are stopped controller.

Short circuit on valve Output Failure - VALVE Check all the outputs (connexon/off contactor driver DRIVER SHORTED ion/wiring/short circuit) A14, A15, A16, - Warning - valve on/off A28, A32, A39 . If permanent => change are stopped controller.

Wrong setting of Software (Internal fault) Update all parameters with .ptx le parameter - Warning WRONG PARAMETER - traction is stopped Motor speed Speed Encoder Failure Check Encoder connexion (X12). If persensor(encoder) does ENCODER ERROR manent (E248)=> change encoder. not work properly Need release of butterfy to restart. If still - Warning - Truck present => E248 - In the diagnose tool: stopped Measurment =>Drive => Power traction => Rotor frequency Failure in over-load Hardware (Internal fault) If permanent (E249)=> change conprotection hw circuit LOGIC FAILURE #3 troller - Need release of butterfy to - Warning - Truck restart. If still present => E249 stopped

.

300 301

-10

Internal problem Hardware (Internal fault) (Butter y) - Error - Truck Bad zero position stopped Internal problem Hardware (Internal fault) (Butter y) - Error - Truck Bad up/down detection stopped

If permanent => change the cockpit If permanent => change the cockpit

50108042301 [EN]

310 No voltage on power Safety circuit Failure line - Warning - Truck Power line error ON stopped 311 Internal problem(Stop Software (Internal fault) switch) - Error - Truck Secondary processor error stopped detection 312 Internal problem(Stop Hardware (Internal fault) switch) - Error - Truck Main switch error On stopped 313 Internal problem(Stop Hardware (Internal fault) switch) - Error - Truck Secondary Switch error ON stopped 314 Internal problem(Stop Hardware (Internal fault) switch) - Error - Truck - Secondary Switch error stopped OFF 315 Short circuit on power Hardware (Internal fault) transistor - Error - Truck - Short circuit on power stopped transistor 316 Short circuit on internal Hardware (Internal fault) relay - Error - Truck Short circuit on relay stopped 317 No voltage on power Hardware (Internal fault) line - Error - Truck Power Line Error OFF stopped 318 Internal problem(Stop Hardware (Internal fault) switch) - Error - Truck Main Switch error OFF stopped 330 Short circuit on CAN CAN Bus Fault - Bad CAN bus - Error - Truck transmission stopped 331 Internal problem (e2p) - Software (Internal fault) Error - Truck stopped E2p error 340 Traction controller Traction Controller Failure problem - Error - Truck - Traction controller stopped emergency 341 Steering or Traction Controller Emergency problem - Error - Truck Controller Emergency stopped 342 Traction controller Traction Controller Failure poblem at init - Error Bad traction controller init - Truck stopped 344 Steering controller Steering Controller Failure problem - Error - Truck - Steering controller stopped emergency 346 Steering controller Steering Controller Failure problem at init - Error Bad steering controller init - Truck not started 350 Butter y switch ON at Sequencing Failure - Bad start-up - Warning initial position Truck not started

50108042301 [EN]

Check voltage pin D6 at start-up (should be 24V)/Check the diode connected pin D6/ Else change the cockpit If permanent => change the cockpit If permanent => change the cockpit If permanent => change the cockpit If permanent => change the cockpit Check if pin D6 is not in short circuit else change the cockpit Check if pin D6 is not in short circuit else change the cockpit Check the fuse F3 and voltage on pin D5, else change the cockpit If permanent => change the cockpit If permanent, check the CAN bus in all the harness. - Could be linked to diagnose tool connection If permanent => change the cockpit Check the error list of the traction controller Check the error list of the traction and steering controllers.

Check the error list of the traction controller Check the error list of the steering controller Check the error list of the steering controller Release the butter y at start-up/Check if the buter y turn easily/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Accelerator state

-11

360

Internal problem(Stop switch) - Warning Truck not started

Sequencing Failure - Safe Button activate on reset

361

No voltage on power line - Warning - Truck not started Internal problem(Stop switch) - Warning Truck not started Button switch ON at start-up - Warning Truck not started

Hardware (Internal fault) Power fail detection

362 370

371

Button switch ON at start-up - Warning Truck not started

372

Button switch ON at start-up - Warning Truck not started

373

Button switch ON at start-up - Warning Truck not started

374

Button switch ON at start-up - Warning Truck not started

375

Button switch ON at start-up - Warning Truck not started

376

Button switch ON at start-up - Warning Truck not started

377

Button switch ON at start-up - Warning Truck not started

378

Button switch ON at start-up - Warning Truck not started

-12

Hardware (Internal fault) Main Switch error ON

Release the stop switch at startup/Check if the stop switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state Check the fuse F3 and voltage on pin D5, else change the cockpit If permanent => change the cockpit

Sequencing Failure Left-Lift

Release the left-lift switch at startup/Check if the left-lift switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state Sequencing Failure Release the left-lowering switch at Left-Lowering start-up/Check if the left-lowering switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state Sequencing Failure Release the left-horn switch at startLeft-Horn up/Check if the left-lift switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state Sequencing Failure - Turtle Release the turtle switch at startup/Check if the left-horn switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state Release the 123 switch at startSequencing Failure - 123 up/Check if the 123 switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state Release the 456 switch at startSequencing Failure - 456 up/Check if the 456 switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state Release the 789 switch at startSequencing Failure - 789 up/Check if the 789 switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state Sequencing Failure - PROG Release the PROG switch at startup/Check if the PROG switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state Release the VAL switch at startSequencing Failure - VAL up/Check if the VAL switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state

50108042301 [EN]

379

Button switch ON at start-up - Warning Truck not started

Sequencing Failure - Hare

380

Button switch ON at start-up - Warning Truck not started

Sequencing Failure Right-Horne

381

Button switch ON at start-up - Warning Truck not started

Sequencing Failure Right-Lowering

382

Button switch ON at start-up - Warning Truck not started

Sequencing Failure Right-Lift

Release the Hare switch at startup/Check if the Hare switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state Release the right-horn switch at start-up/Check if the right-horn switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state Release the right-lowering switch at start-up/Check if the right-lowering switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state Release the right-lift switch at startup/Check if the right-lift switch is free/If permanent => change the cockpit - In the diagnose tool: Measurement => Cockpit => Switch cockpit state

.

421 Truck Type has changed - Error - Truck stopped 427 Internal safety-relay closed at Start-up Error - Truck stopped

428

429

430

431

Software (Internal fault) Type change

Restart the truck - Present if changing truck type in diagnose tool

Hardware (Internal fault) Safety relay init

Check voltage in C14 and C2. If relay still closed (short circuit), change the controller - The exit C15 is shorten to 24V while controller is starting-up: Contact is welded/Driver-electronics of relay defect Safety-relay open Hardware (Internal fault) If permanent => change controller during runtime - Error Safety relay runtime Driver-electronics of internal-relay de- Truck stopped fect: Relay defect/Short against GND in the connected wires External relay is closed External relay - Cut-off relay Check relay K6 and motor power conat start up - Error - Truck init nections. If still closed => change the stopped relay - Pin C2 shorten to 24V.· Contact is welded· Internal capacitor could not be uncharged for test-reasons at sart-up Driver electronics of External relay - Cut-off relay Check the coil of the relay K6. - Exit C3 external relay is defect - driver is not connected to relay pins 85 or 86 Error - Truck stopped · Exit of external relay has short-cut to Battery-minus· The coil of the relay is shorten· Driverhardware is defect.

External relay could not External relay - Safety relay Check relay K6 and motor power conbe closed - Error - Truck off nections. If still closed => change the stopped relay - No 24V at pins C1, C3 after relay was closed· one of the motorwires C1, C3 shorten to battery minus· fuse defect / If error in addition with 49x-error see below 49x-431

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-13

432

Mixed connection of Motor-wires - Error Truck stopped motor PowerMOSStage is shorted or open - Error - Truck stopped poti-supply-voltage out of range - Error - Truck stopped

Motor fault - Connection motor wire

Check motor connection

Motor fault - Motor power stage

435

Setpoint-poticonnection to Plus or Minus cut or under short-circuit - Error Truck stopped

Set-Poti fault - Set-poti cut

436

act-poti-connection to + Actual-Poti fault - Actualor - cut */ - Error - Truck poti cut stopped

437

Temperature of PowerMOS-stage too high - Error - Truck stopped

Check motor connection (short circuit) else if permanent => change controller - Should be consecutive error of E432,E440,E439,E480,E481 Check voltage on pin C8 (between C6 and C8) and in the window Steering poti in the Measurement menu of the diagnose tool. If voltage of poti supply < 8V or >10V, change the controller.

Else check voltage between L3 and L1 and between E4 and E1, if problem change the defective poti. - Supply-voltage for poti or/and test-display (C8) is shorted to battery-minus or 24 [Volt]· Battery voltage exceeds limit of 32 [Volt] at power-on for more than 2.5 [sec] In the diagnose tool: Measurement => Electrical steering => Poti supply voltage Switch on the truck and check the sum of set poti voltage in window Steering poti in the Measurement menu of the diagnose tool. It should be between 8V and 10V under normal conditions else check the harness and the set poti. The connection to the setpoint-poti C19 and/or C20 is broken or in short-circuit to battery-minus, to 24V or to poti-supply-voltage (C8) - In the diagnose tool: Measurement => Electrical steering => Poti supply voltage and Set poti voltage Switch on the truck and check the sum of actual poti voltage in window Steering poti in the Measurement menu of the diagnose tool. It should be between 8V and 10V under normal conditions else check the harness and the set poti. - The connection to the actual-value-poti C10 and/or C22 is broken or in short-circuit to battery-minus, to 24V or to poti-supply-voltage (C8) - In the diagnose tool: Measurement => Electrical steering => Poti supply voltage and Actual poti voltage Check motor connection and mechanical assemby of the motor. Leave the truck in standby few minutes. If permanent => change controller - The temperature of the LES-controller s powerstage has exceeded 85°C. - In the diagnose tool:

433

434

-14

Poti supply voltage

Temperature - Temp.

Power stage high

50108042301 [EN]

439 set-point-potis incompatible - Error Truck stopped

440

443

444

446

Set-Poti fault - Set point poti In the window Steering poti in the Measurement menu of the diagnose tool check the set-poti voltages.Check connector to the setpoint-poti for loose contacts, broken or damaged wires.In case of a short-circuit to 24V, the set-poti must be exchanged, too. - The cursor-voltages of the dual setpoint-poti C19 and C20 do not match together due to bad contacts in the connector or a poti-failure. - In the diagnose tool: Measurement => Electrical steering => Poti supply voltage and Set poti voltage act-point-potis Actual-Poti fault - ActualIn the window Steering poti in the Meaincompatible - Error point potis surement menu of the diagnose tool Truck stopped check the actual-poti voltages.Check connector to the actual-value-poti for loose contacts, broken or damaged wires.In case of a short-circuit to 24V, the actual-poti must be exchanged, too. - The cursor-voltages of the dual actual-value-poti C10 and C22 do not match together due to bad contacts in the connector or a poti-failure. - In the diagnose tool: Measurement => Electrical steering => Poti supply voltage and Actual poti voltage Actual-value-poti was Actual-Poti fault - Bad actual Check the Actual-poti voltages in winout of position at startup value dow Steering poti in the Measurement - Error - Truck stopped menu of the diagnose tool. If out of range, readjust the actual value poti using the teaching window of the diagnose tool. If permanent => change actual-poti - The steered wheel has been moved mechanically out of its normal operating-position while the truck was switched off. - In the diagnose tool: Measurement => Electrical steering => Poti supply voltage and Actual poti voltage External relay - PowerOutput of the powerCheck the harness for permanent or relay-driver was under relay-driver shorted temporary short-circuits of C3 to 24V. short circuit to Ubat - · The output of the power-relay-driver C3 was under short-circuit to 24V for at Error - Truck stopped least 110 ms.

Both, battery- and Battery failure - PowerCheck the harness for permanent or poti-supply voltages are supply low temporary short-circuits of pins C8 and far below their normal C25 to battery-minus. - The following levels for a longer time. conditions are both met at a time for at - Error - Truck stopped least 400 ms: the battery supply-voltage at pin C25 is below 13V and the poti-supply-voltage at pin C8 is below 7,9 V - In the diagnose tool: Measurement => Electrical steering => Steering Motor Command

50108042301 [EN]

-15

447

Only: LES-34/V1.69 or higher: no heartbeatsignal available on the CAN bus from the truck controller.

Only: LES-34/V1.63 or higher: Wrong Driver-present Signal Wrong "SpeedReduction-WithSteering -signal - Error - Truck stopped

No CAN bus connection tot he truck controller for at least 500[ms]

- Check CAN bus connector and/or connecting cables - Check start-up conditions in truck controller

Level at input 3X1:9 does not match received CAN-Status

- Check link to pin 3X1:9 - Check CAN-communication

Speed reduction - Speed reduction

451

EEPROM-value of center-position of steered wheel is out of range at run-time Error - Truck stopped

Actual-Poti fault - Center point lost

452

EEPROM-value of center-position of steered wheel is out of range at run-time Error - Truck stopped

Actual-Poti fault - Wrong center position

459 to 469 470

Deal with CAN Interface CAN Bus Fault - Error - Truck stopped

Check the connection between C16 and C24.If connection is correct, change the controller. - At exit C16 is the wrong logic -signal: LES switches driver of the exit on but the voltage at the pin is off sate or verse-wise/Driverhardware defect/External feedback wire to C24 defect/Short-circuit on the wire between C16 and C24 between C16 and Drivecontroller - In the diagnose tool: Measurement => Electrical steering => Speed reduction Teach act-poti again. If error is permanently existing, replace controller.

(EEPROM-defective) - The act-poti value stored in EEPROM is out of range - In the diagnose tool: Measurement => Electrical steering => Poti supply voltage and Actual poti voltage Teach act-poti again. If error is permanently existing, replace controller.

(EEPROM-defective) - The act-poti value stored in EEPROM is out of range - In the diagnose tool: Measurement => Electrical steering => Poti supply voltage and Actual poti voltage Deal with CAN Interface => Probably present during the connection with the diagnose interface If permanent => change controller Timeout between handshake-signals

449

450

472

473

-16

Syncronize-problem Software (Internal fault) between uC1 and uC2 Uc2-reset failed at start-up - Error - Truck stopped different checksums Software (Internal fault) between uC1 and uC2 - Uc2-checksum failed Error - Truck stopped bad transmission Software (Internal fault) between uC1 and uC2 - - Uc1-Uc2 transmission Error - Truck stopped failed

If permanent => change controller - The transfer of the transformation-curve from main- to supervisor-µP failed after two trials: the calculated checksums on both sides do not match.

If permanent => change controller - The transmission of data via the internal serial lines between main- and supervisor-µP is disturbed. Probably, there is a hardware-failure within the controller.

50108042301 [EN]

474 cyclic data-exchange Software (Internal fault) from Uc2 to uC1 failed - Uc1-Uc2 data-exchange Error - Truck stopped failed

480

Supervisormicroprocessor: Left PWM-signal does not match setpoint-actual value-difference - Error - Truck stopped 481 Supervisormicroprocessor: Right PWM-signal does not match setpoint-actual value-difference - Error - Truck stopped 482 Supervisor-microprocessor: checksum-difference between supervisor- and main-microprocessor - Error Truck stopped 483 - Error - Truck stopped 484

485

486

49x and 431

Software (Internal fault) Uc2 Error-offset

If permanent => change controller - The cyclic transfer of diagnostic-data from supervisor- to main-micro was not serviced by the supervisor-micro for 1000 ms. Probably, there is a hardware-failure within the controller If permanent => change controller - The supervisor-µP detected that the generated left PWM-signal was not according to the difference between setpoint and actual-value

Software (Internal fault) Uc2 Error-offset

If permanent => change controller - The supervisor-µP detected that the generated right PWM-signal was not according to the difference between setpoint and actual-value.

Software (Internal fault) Uc2 Error-offset

If permanent => change controller - The supervisor-µP detected a difference between received and calculated checksum of the transformation-curve-data.

Software (Internal fault) Uc2 Error-offset Software (Internal fault) Uc2 Error-offset

If permanent => change controller -

Supervisormicroprocessor: transformationcurve from mainmicroprocessor was not received in time Error - Truck stopped SupervisorSoftware (Internal fault) microprocessor: Uc2 Error-offset main-micro did not handle serial interface-line regularily - Error - Truck stopped SupervisorSoftware (Internal fault) microprocessor: Wrong Uc2 Error-offset Speed-ReductionWith_Steering -signal Error - Truck stopped While start-up test is Hardware (Internal fault) running an Défaut at Power MOSFET init the external relay was detected - Error - Truck stopped

If permanent => change controller - The supervisor-µP did not receive the transformation-curve from the main-µP in time

If permanent => change controller - The supervisor-µP was not serviced by the main-µP in time; the serial interface-line between both µP has not been used by the main-µP for at least 100 ms.

If consecutive error of E433, E434 and E435, rst correct them/If permanent => change controller - The SRWS-signal at C16 did not t to the steeringangle If permanent => change controller The functional test of the powerpart at start-up was not ending correctly / Switching of the relay by one of the two processors was not possible.

.

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-17

The wiring and interfaces needed for connection to the truck are described in the chapter Chapter "Diagnostics equipment", P. 02- 3

-18

50108042301 [EN]

The .ptx les contain the truck s con gurations.

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

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

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

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

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

50108042301 [EN]

-19

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

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

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

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

-20

50108042301 [EN]

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

Open "STEDS Navigator".

Click on the "Diagnosis" symbol.

Select the truck type and click twice (automatic start of the diagnosis).

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-21

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

If the window will not load, check the wiring.

The software has three main menus: "F2:Diagnosis": Test menu (teach-in of the steering) and fault diagnosis / start menu "F3:Setup": Truck parameterisation menu (con guration of the truck) "F4:Monitor": Test menu (test of inputs and outputs) For the selection press the short-cut keys (F2, F3, F4) or click the appropriate button.

-22

50108042301 [EN]

From the diagnostics menu you can access the following functions: "Select sector" submenu Fan operation test "Jobs" submenu Steering teach in Delete error list Re-establish connection with truck Show error list

From this menu you can access the following functions:

To perform this procedure, follow the guided procedure detailed in diagnostic software

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-23

Allows you to delete the list of errors for each control unit of the truck, or delete the errors for all of the control units

Allows you to view the list of errors for each control unit of the truck, or view the errors for all of the control units

-24

50108042301 [EN]

From the Setup menu you can access the following functions:

Cockpit

This page shows the software and hardware speci cations for the components installed on the truck.

It is also possible to select the "Truck type".

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-25

The optional TDU can also be activated on this page.

The number of times that an error can be repeated before the truck is stopped can be set on this page.

The optionals for the cockpit can be con gured on this page.

-26

50108042301 [EN]

The truck access codes can be set on this page.

The access codes can be con gured for the following users: Service Fleet manager Truck drivers

This page shows the truck working hours.

The following can be con gured on this page:

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-27

The hours offset for the truck in the event that the electronic system is replaced The duration of the truck maintenance intervals The display mode for the hour meter on the truck display It is also possible to reset the maintenance interval indication on the display.

You can calibrate the correct way to display the battery level on this page. allows you to con gure the threshold at which the battery is identi ed as being 100% charged allows you to con gure the threshold at which the battery is identi ed as being 20% charged allows you to set the threshold below which the truck checks if the battery has been recharged.

If the truck is put on charge when the battery is 70% charged and the parameter is at 60%, the truck will not show as 100% charged after charging.

Enables con guration of correct reading for the voltmeter inside the electronic system.

This parameter must be changed if the voltage displayed in is different from

-28

50108042301 [EN]

the voltage present between the positive and negative pole of the electronic control Enables a block on lifting or slow speed to be set if the battery level falls below 20% charged

At least one of the parameters between and must be active to enable the con guration to be saved to the truck

The following can be con gured on this page: The allows the user to select whether the operator should change the drive program from the cockpit or whether a xed drive program should be set. (%) (%) Truck acceleration, expressed in seconds needed for the truck to reach maximum speed Truck braking when the throttle is partially released, expressed in seconds Truck braking when the throttle is partially released, expressed in seconds needed for the truck to stop Truck braking when the throttle is fully released, expressed in seconds needed for the truck to stop

50108042301 [EN]

-29

The following can be con gured on this page: The speed of travel of the truck using backing push-buttons The speed of travel of the truck by actuating the throttle without the operator being on the step plate

The traction speed of the truck can be con gured on this page: When cornering

-30

50108042301 [EN]

The following can be con gured in this parameter:

Enables use of the lifting/lowering functions during travel Activates the lift block function if a lift block sensor is installed on the truck

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-31

The model of the temperature sensor for the traction motor can be set on this page: bly

Associated with motor assemAssociated with motor assembly Not used

If the wrong sensor is selected, the temperature of the traction motor will be read incorrectly

The following optionals can be activated on this page:

For trucks equipped with a raisable platform, the parameter must be disabled

-32

50108042301 [EN]

A reduced speed can be set on this page, or the truck can be set to stop if a signi cant impact is detected.

This parameterising is only available for trucks with the installed.

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-33

The activation mode for the pump unit with the optional can be selected on this page The lift is activated using the lift push-button on the cockpit The lift is activated when the operator is on the step plate The parameters for minimum and maximum pressure limits can also be edited for controlling the lift with the operator on the step plate

If the pump unit does not stop when the operator is on the step plate once the is raised, we recommend lowering the parameter by a few points (by default set to 97)

The period of inactivity (in seconds) after which the truck switches off automatically can be set on this page.

If the parameter is set to , automatic switch-off is deactivated.

-34

50108042301 [EN]

The distance between the traction wheel and the load rollers can be changed manually on this page

The parameters relating to electrical steering responsiveness can be modi ed on this page This is the parameter that de nes the steering responsiveness between 0 km/h and 2 km/h as shown in the graph in the diagnostic program This is the parameter that de nes the steering responsiveness between 2 km/h and

50108042301 [EN]

-35

the maximum speed as shown in the graph in the diagnostic program The parameters are proportional derivative control parameters. Modi cation of these parameters is not recommended as they are already optimised for each truck type.

This is the parameter that de nes the sensitivity of the tiller potentiometer.

This enables a dead band to be set in the potentiometer This is the parameter that de nes the sensitivity of the wheel potentiometer.

This enables a dead band to be set in the potentiometer

All of the parameters available on this page have already been optimised for each truck type.

They do not need to be changed other than in particularly dif cult usage conditions.

-36

50108042301 [EN]

The Tester menu shows the truck inputs and outputs

This page shows: The voltage (V) supplied to the system The battery charge level shown on the cockpit

This page shows the operation of the buttons on the Cockpit

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-37

This page shows: The digital actuation value of the cockpit throttle The rotation direction of the cockpit throttle

This page shows whether or not the truck is moving

-38

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This page shows: Tiller potentiometer signal that regulates the slow speed when cornering The actuation percentage of the accelerator located on the cockpit safety relay

The operating status of the

The operating status of the operator presence sensor. When the operator climbs onto the step plate, both input statuses must change These two inputs indicate whether the truck is moving forwards or backwards

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-39

This page shows: The supply percentage of the electromagnetic brake (for the rst two seconds it is supplied at 100%, then at 60%) The supply percentage of the main contactor (for the rst two seconds it is supplied at 100%, then at 70%) The supply percentage of the traction motor The current consumed by the motor The immediate truck speed

-40

50108042301 [EN]

This page shows: The current consumed by the pump unit The activation percentage of the solenoid valve (Y1) The activation percentage of the solenoid valve (Y3) The presence of the lifting/lowering signals The valve supply (Y5/Y6) The status of the input connected to the stroke-end inductive sensor of the initial lift The status of the two inputs (NO/NC) related to activation of slow speeds

This page shows the operation of the buttons located on the operator s backrest

50108042301 [EN]

-41

This page shows: The activation of the lifting and lowering buttons for the elevating platform The activation of the input relating to the upper stroke-end of the platform The activity status of the solenoid valve (Y5/Y6) The activation percentage of the pump unit

-42

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This page shows: The activation of the A16 output relating to the cooling fan of the traction controller The electronic control temperature The traction motor temperature

This page shows: The activation of the horn button The output that drives the operation of the horn The output that drives the operation of the optional buzzer

50108042301 [EN]

-43

This page shows the status of the sensors relating to the fork folding actuator for The following table describes the correct input situations in the different possible conditions

Pin Sensor

Vertical forks sensor A19

Horizontal forks sensor A37

S7

Actuator closed

Forks lowered

A33

A38

S10

S35

S8

ON

OFF

OFF

OFF

ON

OFF

OFF

Traction

Lifting/lowering

Fork folding

Fork opening

ON

Yes

No

No

Yes

ON

OFF

Yes

Yes

Yes

No

OFF

ON

No

No

Yes

Yes

.

-44

50108042301 [EN]

a

This is a three-phase motor with an internal triangular connection with the following characteristics: Supply voltage 14 V AC Nominal power 3 kW The use of a three-phase motor and the dedicated software present in the inverter allow for the motor to be run with the following bene ts: Low rotation noise Energy recovery with decreased energy consumption

It must also be emphasised that the motor is tted onto the xed part of the drive reducer and therefore remains immobile during steering. This gives the following advantages: It eliminates the risk of breakage of the electromagnetic brake cable due to torsion It eliminates the risk of breakage of the motor cables It reduces the minimum distance between the motor body and the surrounding parts, allowing for a more compact motor compartment

No type of maintenance required

50108042301 [EN]

-1

Type of motor Operating voltage Strength of current

AF 4G3 L1 1 14 V

Rated speed

166 A 2040 rpm

Rated power

3.0 kW

Operating mode

S2/60 min

Protection class

IP00/44

Insulation class Weight

F 27 kg

.

-2

50108042301 [EN]

When the traction motor is removed, the truck is no longer braked. It is therefore necessary to chock the truck to prevent it from rolling.

Disconnect the battery connector.

Jack up the machine and chock it.

Remove the motor cover (see Chapter "Motor compartment cover", P. 31- 1 ).

Disconnect the three cables U, V and W from the traction motor.

50108042301 [EN]

-3

Disconnect the temperature sensor (1), brake (2) and speed sensor (3) connectors.

Release the sheath cables.

Remove the electromagnetic brake (see Chapter "Removing the electromagnetic brake", P. 49- 3 ).

Unscrew the traction motor s eight xing screws (4).

Screw an M8 lifting ring (5) into the traction motor.

Sling the traction motor by the lifting ring.

Disengage the traction motor from above..

-4

50108042301 [EN]

Remove any oil likely to damage the reducer seals.

For reassembly, proceed in the reverse order.

Replace the O-ring (5) and lubricate it before re tting the motor (4) in the reducer (7).

Check the tightening torque of all of the fasteners and connections of the motor.

50108042301 [EN]

-5

Risk of short circuit!

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

Use an open-ended spanner to hold them while tightening.

Check the adjustment of the air gap for the electromagnetic brake (see Chapter "Operation", P. 49- 1 ).

Remove the traction motor by following the above steps.

Remove the circlip (1).

Remove the pinion (2) using a screwdriver as a lever.

-6

50108042301 [EN]

Remove the circlip (3).

Remove the tab (4) using pliers and a cloth.

Remove the motor bolt using a mallet.

50108042301 [EN]

-7

Remove the circlip (5).

Change the bearing.

To re t the bolt, proceed in reverse order to removal.

Before re tting, clean the bolt using compressed air.

-8

50108042301 [EN]

Disconnect the battery connector and open the battery compartment (see Chapter "Changing the battery", P. 60-17).

Jack up the machine and chock it.

Remove the motor cover (see Chapter "Motor compartment cover", P. 31- 1 ).

Disconnect the connector (1).

Unscrew the xing screw (2) from the speed sensor.

Remove the speed sensor and release the cable from the sheath.

For reassembly, proceed in the reverse order.

50108042301 [EN]

-9

The behaviour of the temperature sensor (1) largely resembles that of a variable resistor (increase in temperature = increase in the value of the resistance).

This sensor is directly connected to the traction controller.

The temperature sensor cannot be replaced.

If this sensor is faulty, the entire traction motor housing must be changed.

SAAB 2-pole connector: X 13 X 13-1 (X 1-10): Earth X 13-2 (X 1-12): Signal

Unplug the X 13 battery (point (4)).

Measure the resistance of the temperature sensor between X 13- 1 and X 13-2.

Measure the temperature of the motor casing.

The values measured must tally with those of the table opposite to + or - 20 .

It is possible to view the temperatures in the diagnostic tool.

-10

50108042301 [EN]

0

1000.00

5

1019.53

10

1039.02

15

1058.49

20

1077.93

25

1097.34

30

1116.72

35

1136.07

40

1155.39

45

1174.69

50

1183.95

55

1213.19

60

1232.39

65

1251.57

70

1270.72

75

1289.84

80

1306.93

85

1327.99

90

1347.02

95

1366.03

100

1385.00

105

1403.95

110

1422.86

115

1441.75

120

1450.51

125

1479.44

130

1498.24

135

1517.01

140

1535.75

145

1554.48

150

1573.15

155

1591.80

160

1610.43

165

1629.03

170

1647.60

175

1666.14

180

1684.65

185

1703.13

190

1721.58

195

1740.00

200

1758.40

.

50108042301 [EN]

-11

-12

50108042301 [EN]

a

1 3 5 8 10 12 13 17 19 20 21 23

Gearbox Cover Dummy shaft Pinion gear Ball stop Pinion gear Straight gear Dowel pin M14 x 1.5 x 33 8.8 Spacer ring 60/7.5 Grooved protection ring Spacer ring 33.7/34.5 Washer 55/12

27 31 32 33 35 37 47 48 49 50 58 59

Drive system name

Roller bearings Roller bearings Roller bearings Roller bearings Shaft seal 75 x 95 x 5 B1 DIN 3760 O-ring 140 x 3 Screw M8 x 30 8.8 DIN 912 Screw M8 x 60 8.8 DIN 912 Screw M16 x 4510.9 DIN 933 Grower washer 8 DIN 7980 Magnetic plug M14 x 1.5 DIN 908 Sealing ring A14 x 18 x 1.5 DIN 7603

5.53.315.1 (Kordel) Cheese-headed screw DIN 912 M10 x 25 Tightening torque Ma = 48 Nm Cheese-headed screw DIN 912 M6 x 20 Tightening torque Ma = 13.5 Nm SAE 80W90; API GL 4

Chassis mounting Motor block reducer Reducer oil Oil quantity

1.5 l

Reduction ratio

1:19.67

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

Rotation of gear reducer guided by a slewing ring xed to the chassis.

50108042301 [EN]

-1

Maintenance: Slewing ring permanently lubricated.

The type and serial number are indicated on a name plate tted to the reducer.

The reducer connects to the drive shaft with a guide ring and incorporated bearing that inserts into a seat of the reducer box and a pinion xed directly onto the drive shaft.

Ring with incorporated bearing Helicoidal pinion

-2

50108042301 [EN]

Disconnect the battery from the truck.

Remove the hood (see Chapter "Motor compartment cover", P. 31- 1 ).

Raise the truck off the ground and rest it on wooden blocks at least 35 cm high.

Remove the traction motor (see Chapter "Disassembling the traction motor", P. 11- 3 ).

Remove the drive wheel (see Chapter "Rear wheels (CXT and KANVAN only)", P. 46- 3 ).

1 350 mm 1044_223-001

Allow the oil from the reducer to drain into a container by unscrewing the bleed screw (2).

Thoroughly clean the screw to remove any metallic deposits.

Plug the upper part of the reducer with a stopper to prevent oil leakages.

2

1044_223-002

50108042301 [EN]

-3

Replace the two screws (3) that connect the reducer to the steering turntable.

Use a strap and a hoist to partially lift the reducer to prevent the reducer from falling once the screws (4) are unscrewed.

Unscrew the eight xing screws (5).

Carefully lower the reducer and then remove it by passing it under the truck chassis.

For reassembly, proceed in the reverse order.

Use Loctite 242 on the eight mounting screws of the reducer, and then tighten them to 48 Nm. Fill the reducer with the recommended oil.

If the oil level is correct, approximately 1/3 of the pinion (6) will be immersed in oil.

Filling the reducer with more oil than the recommended volume will cause premature damage to the seals

-4

50108042301 [EN]

a

Open the battery cover.

Remove the two screws (1 e 2).

Do not damage the electrical wiring.

1

Remove the cover (3).

2 3

1044_311-004

Fit the cover (3), inserting the two tabs (5) into the appropriate slots (4) in the chassis.

Secure the cover with both screws (1 e 2).

3

Close the battery cover again.

5

4

50108042301 [EN]

1044_311-003

-1

Chock the truck.

Remove the four screws (1) from the rear protective plate.

Remove the rear protective plate.

-2

50108042301 [EN]

If the vehicle is tted for the "pedestrian mode" option, remove the two sets of push-buttons located on either side of the rear cover. To remove them, unscrew the four xing screws (1).

Cut the straps that secure the cable to the cover.

Remove the four screws (2) from the rear cover.

50108042301 [EN]

-3

Remove the rear cover.

Screw a lifting ring to the back of the counterweight so that it will not fall once all xing screws have been removed.

Undo the 4 screws (3).

-4

50108042301 [EN]

Remove the four screws (4) from the cross piece.

The counterweight may now be detached from the truck.

Follow the steps for disassembly in reverse order.

Refer to the main table for all tightening torques.

50108042301 [EN]

-5

Unscrew the four screws (5) in order to remove the coupling.

Follow the steps for disassembly in reverse order.

Refer to the main table for all tightening torques.

Unscrew the four screws to remove the coupling.

Follow the steps for disassembly in reverse order.

Refer to the main table for all tightening torques.

-6

50108042301 [EN]

a

To remove the folding step plate, unscrew the two nuts (1).

To replace the seat holder (2), remove the four retaining screws (3).

50108042301 [EN]

-1

Chock the truck.

Remove the four screws (1) from the rear protective plate.

Remove the rear protective plate.

-2

50108042301 [EN]

Remove the ve screws (1).

Follow the steps for disassembly in reverse order.

Refer to the main table for all tightening torques.

Disconnect the battery connector.

Unscrew the two screws.

50108042301 [EN]

-3

Unscrew the four xing screws (3).

Disconnect the connectors.

Remove the rear plate from the top.

Unscrew the ve screws (4).

Remove the operator s backrest.

For reassembly, proceed in the reverse order.

-4

50108042301 [EN]

a

Engine

Dual-winding DC

Type

R 100/0.15 150 W Reinforced IMS sun gear

Reducer

Reduction 18:1

Turret/pinion reduction

1:4.15

Heat class

F

Protection classi cation and S3

IP20 / S3 78% Induced: 265.5 m ± 3%

Winding resistance

Inductive: 325.4 m ± 3% Inductance: 8 mH

Potentiometer actual value Set-point potentiometer

Two 22 k resistances Two 22 k resistances

.

Disconnect the battery connector.

Raise the truck on wooden blocks and chock it.

Remove the motor cover (see Chapter "Motor compartment cover", P. 31- 1 ).

Disconnect the electrical cables from the terminal block of the motor reducer (1).

50108042301 [EN]

-1

Under the truck, remove the locking ring (2) holding the steering pinion.

Remove the pinion (3).

Staying under the machine, unscrew the four mounting screws (4) from the steering motor reducer.

Remove the motor reducer by pulling it upwards.

For reassembly, proceed in the reverse order.

Pull the spring (1) to open the guard grille (2).

Lift the compression springs (3).

Remove the brushes (4) using a screwdriver.

Loosen the screws (5).

Change the brushes when they have reached the minimum permitted length.

Before reassembling, check that there are no traces of burning on the manifold.

The new brushes must be bedded in before reassembly.

If the old brushes are re tted, do not reverse them or turn them over.

-2

50108042301 [EN]

You are advised to blow-clean the manifold once a year.

50108042301 [EN]

-3

Disconnect the battery connector.

Remove the motor cover (see Chapter "Motor compartment cover", P. 31- 1 ).

Unclip the clips (1) holding the connector (2) and unclip the connector.

Disconnect the electrical cables from the terminal block of the motor reducer (1).

-4

50108042301 [EN]

Disconnect the cable connected to the relay (2).

Disconnect the connector (3).

For reassembly, proceed in the reverse order.

50108042301 [EN]

-5

Disconnect the battery connector.

Remove the motor cover (see Chapter "Motor compartment cover", P. 31- 1 ).

Disconnect the connector (1).

-6

50108042301 [EN]

Unscrew the nut (4).

Unscrew the screw (3).

Unscrew the locknut (7).

Unscrew the screw (6) from the drive pinion.

Remove the recopy potentiometer (2) and its support (8).

Turn the drive wheel until it is in a straight line.

Set the potentiometer (2) to its mid-point using a multimeter.

Measurement values: Pin 4 and pin 1: 850 ± 10 Pin 4 and pin 3: 850 ± 10 Fit the pinion (5) to keep the potentiometer (2) in the intermediate position.

Tighten the screw (6) and lock it in place with the locknut (7).

Tighten the screw (3).

Tighten the nut (4).

Reconnect the connector (1).

Reconnect the battery connector.

50108042301 [EN]

-7

Remove the potentiometer angle sensor.

Remove the circlip (1).

Unscrew the screw (6) and remove the drive pinion (8).

Remove the pinion (4) with the shaft (5).

Remove the circlip (2).

Detach the bearing (3) using a bearing puller.

For reassembly proceed in reverse order.

-8

50108042301 [EN]

a

The new drive wheel has a diameter of 250 mm.

The traction wheel must be replaced if: The surface is badly damaged or is not worn in a uniform way The wheel is worn, reducing the diameter by more than 10%.

Disconnect the battery connector.

Raise the truck to a height of at least 230 mm off the ground (1). Position the truck on wooden blocks with a square base, ensuring that it is stable. Rest the forks against a wall to prevent the truck from slipping. If possible, secure the truck using a sling attached to the bridge crane.

1 230 mm 1044_462-004

Turn the traction wheel so that the ve wheel nuts (2) can be loosened.

2

Remove the wheel nuts (2).

Remove the traction wheel.

Clean the wheel to check that it is in good condition before the installation.

Install the traction wheel.

Tighten the ve nuts (2) by hand.

Tighten the nuts (2) to a torque of 140 Nm. Adjust the pivot wheel (with the exception of CXT and KANVAN, which are not tted with pivot wheels).

50108042301 [EN]

1044_462-005

-1

Dimensions of a new stabiliser: 150 X 50 mm.

Put the truck on a level surface.

Measure the distance between the ground and the lower edge of the chassis at the axle beam in the traction wheel area.

Loosen the clamping screw (1).

Turn the screw (2) until the distance between the ground and the lower edge of the chassis in the pivot wheel area reaches the dimension previously measured.

Tighten the screw (1) to a tightening torque of 200 Nm. Check that the screw (2) has been tightened correctly.

Check that the pivot wheel works once installed.

When the truck direction of movement is reversed, the pivot wheel must rotate 180° after a short distance.

-2

50108042301 [EN]

Unscrew and remove the hexagon head screw (2).

Loosen the locking screw (1). The wheel can now be removed and placed on a workbench for disassembly.

Remove the cap (4).

Drive out the pin (6) Loosen the nut (8) Remove the bearing (5) and sleeve (7). These two parts must be removed with a puller.

Installation is the reverse of removal.

Tighten the nut (8) until the sleeve (7) is secured.

Preload the conical bearing, then loosen the nut (8) by a 1/4 turn and lock it in place with the pin (6).

Disconnect the battery connector.

Secure the truck safely on a at surface.

Use a at-head screwdriver to lift the bent tooth of the lock washer.

Unscrew the nut by inserting a at-head screwdriver in one of the notches and tapping the screwdriver with a mallet.

50108042301 [EN]

-3

Remove the nut and the washer.

Remove the wheel.

-4

50108042301 [EN]

Position the wheel on the pin.

Fit the washer and the nut to the pin.

Tighten the nut by hand.

To ensure that the nut is tightened correctly, insert a at-head screwdriver into one of the four notches on the nut. Gently strike the screwdriver with a mallet until one of the notches on the nut is aligned with one of the teeth of the lock washer.

Bend the washer tooth into the nut notch.

Remove the rear wheels as shown above.

Unscrew the six retaining screws on the hub knuckle pin.

Remove the hub knuckle pin.

For reassembly, proceed in the reverse order.

The tightening torque of the six screws must be 48 Nm.

50108042301 [EN]

-5

Remove the rear wheels as shown above.

Unscrew the two mounting screws.

For reassembly, proceed in the reverse order.

-6

50108042301 [EN]

Raise the forks to the maximum height.

Disconnect the battery connector.

Loosen the mounting screws of the load rollers (1).

Raise the forks with a jack until the load rollers no longer touch the ground, then secure the truck with squared timbers (2).

Remove the two fastening screws (3).

Replace the load rollers.

50108042301 [EN]

-7

Installation is the reverse of removal.

Place the part in a vice to remove the bushes (4). Remove the bushes by striking them with a hammer, then replace them.

Never lubricate the bushes (4).

Tighten the two fastening screws (3) to 85 Nm.

Raise the forks and secure them.

Raise the side members off the ground.

Secure the side members in this raised position using squared timbers so that the load wheels are no longer touching the ground.

Remove both pins (5).

-8

50108042301 [EN]

Remove both load wheels (2).

Install in reverse order to removal.

Check that the rotating supports (4) move easily.

Never lubricate bearing races that are Te on coated.

Raise the forks and secure them.

Raise the side members of the scissor lift and insert a block of wood between their ends and the ground.

Remove the four screws (1) on the load wheels (2).

Remove the pins (3) and then the rollers (2).

Install in reverse order to removal.

2

3

Once installed, check that the rotating supports (4) move easily. Never lubricate bearing races that are Te on coated.

4 1

3

1045_465-001

50108042301 [EN]

-9

-10

50108042301 [EN]

a

1

7

a

6 1 2 3 4

5

4

Inductor body Brake backing plate Hub Compression spring

3 5 6 7 a

2

1044_491-004

Rotor with friction lining Spacer ring Coil Air gap

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

The compression springs (4) pin the brake baking plate (2) on its axis (5) to the lining, and pin the lining to the plate attached to the engine.

If the throttle valves are moved from the rest position to the operating position, the brake coil (7) is supplied with direct current. The magnetic circuit between the brake backing plate (2) and the coil closes. The brake backing plate moves back up towards the magnetic section, the air gap (a) has become "nil" and the lining (5) is released.

If the throttle valves are put in the rest position, the power supply to the coil (7) is cut (with a time-out of about 2 seconds.)

50108042301 [EN]

-1

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

Braking torque:

40 Nm

Power consumption of coil at 20°C:

40 W ± 10%

Voltage:

24 V

Min air gap:

0.20 mm

Max air gap:

0.35 mm

Braking torque:

34 Nm

Power consumption of coil at 20°C: Voltage:

40 W ± 10% 20 V

Min air gap:

0.20 mm

Max air gap:

0.4 mm

.

-2

50108042301 [EN]

Secure the machine with chocks.

Remove the battery plug.

Remove the motor cover (see Chapter "Motor compartment cover", P. 31- 1 ).

Unclip the fuse holder.

Remove the electromagnetic brake connector (1).

Undo the three hexagonal socket head screws (2).

Release the sheath cables.

Remove the electromagnetic brake.

For reassembly, proceed in the reverse order.

The three hexagonal socket head screws (2) must be tightened with a torque of 9.5 Nm.

If there is an electrical fault or if the truck has no battery, the brake can be unlocked manually.

To do this, place two M5x45 screws in the holes (3) and tighten them until the brake disc is released.

50108042301 [EN]

-3

-4

50108042301 [EN]

a

1 2 3 4 5 6 7 8

Lowering button Lifting button Horn button Button, "tortoise" "PRG " button (scroll) Number button "123" Display Button "I" (start)

9 10 11 12 13 14 15

50108042301 [EN]

Number button "456" Number button "789" "PRG " button (con rmation) Button, "hare" Handle Drive control throttle valve Push-button for emergency braking (anticrash)

-1

Disconnect the battery connector.

Open the battery compartment cover.

Remove the six protective plate fastening screws (1).

Disconnect the tiller head electrically by separating the two cable connectors (2).

Remove the three cockpit fastening screws (3).

Remove the cockpit.

Installation is the reverse of removal.

-2

50108042301 [EN]

When installing the new cockpit, make sure that the steering stop (4) is inserted in the centre take-up (5).

50108042301 [EN]

-3

1

2

3

4

Press the (on) I key (6). The display (4)} shows the message "CodE" (8) and after about 1 second this message goes out. You may now enter a valid 4- gure user code. Entering the gures is similar to the principle of entering letters on a mobile telephone.

Press the keys, (1), (2), and (3) as many times as necessary until the required gure is shown:

123

789

456

For the code gures 1-2-3, the 123 key (1)

PRG

4-5-6, the 456 key (2)

PRG

7-8-9, the 789 key (3) After entering a gure, the display moves to the next position. The display shows a ashing line, (9) (the illustration shows an example).

7

5

6

1044_505-001

8 If the gure entered is wrong, it is possible to cancel it by pressing the key, PRG (scrolling) (7).

The gure will be deleted and the ashing line, (9) reappears. Entering gures is again possible.

After entering the fourth gure, this code must be validated by pressing the key, PRG 5 For a moment the manufacturer s message appears on the display. The truck is in operation.

1044_505-002

9

1044_505-003

-4

50108042301 [EN]

1 It is possible to view the following displays by repeatedly pressing the key, PRG (scrolling): Hour meter Battery charge Display of the operating hours (1)appears about 4 to 5 seconds after the truck is switched on, accompanied by an hourglass symbol (2). The meter records the total use time from the rst operation of the pallet truck. The meter records the traction and lifting.

2

1044_505-004

It is also possible to display maintenance intervals; only the technician can activate this function.

The meter goes up to 9999.

Press the key, PRG and scroll until the amount of battery charge (3) available is displayed.

3

% The correct amount of charge will only be displayed about one minute after the battery is connected.

The battery charge is shown in % in steps of 10%.

1044_505-005

Factory adjustment of the battery discharge indicator is made for an open lead battery, but adjustment for a gel electrolyte battery is also possible.

Contact a competent after-sales service.

When the available residual charge is only 5 % (25% on the display), the display ashes. The battery will soon need recharging.

When the charge indicator shows 20%, lifting is stopped or the speed is reduced (option).

An heavy overnight discharge of the battery and the electrical components of the truck.

Charge the battery immediately, because now the heavy discharge starts.

50108042301 [EN]

-5

Access to the electronic control is possible using three different codes: user code master code TAV (after-sales technician) code.

123

456

789

PRG PRG

The user code is made up of four numbers.

The code should be created by the vehicle eet manager.

Knowledge of the code number is an access key, the abuse of which is forbidden. Without direct instructions from your superior, this code must not be communicated to a third party.

1044_505-007

The control can memorise a maximum of 200 user codes. The master code allows the addition or removal of a user code.

The master code is made up of four numbers and is reserved for the vehicle eet manager.

On leaving the factory this code is "1234". It is recommended that the vehicle eet manager replaces this by a new master code. Chapter "Deleting the master code", P. 50- 8 Chapter "Adding the master code", P. 50- 7 This code serves as a user code for the use and regular manoeuvring of the pallet truck. In addition, it allows the addition or removal of a user code. The control can memorise a maximum of 5 master codes.

If the master or user codes are forgotten call a TAV (After-sales technician) who alone can view the codes which are recorded.

The TAV code is only provided for the aftersales service. It enables truck diagnostics for inspection and gives access to user and master codes.

-6

50108042301 [EN]

1

If a breakdown code is displayed, example E380 (1) stop the truck and go through the starting procedure again. Chapter "Entering the user code", P. 50- 4 If the breakdown code is still displayed call a TAV (after-sales service technician).

%

1044_505-008

The truck is turned off, the battery is connected.

Push button I (driving) (5).

Enter the valid 4-digit master code with the 123 (1), 456 (2) and 789 (3) buttons.

1

2

123

3

789

456

PRG PRG

6 Scroll with the PRG (scrolling) button (6) until Pin (7) appears in the display.

Acknowledge with the PRG (Enter) button (4) until Add (10) appears in the display.

50108042301 [EN]

1044_505-010

1044_505-011

4

5

1044_505-009

7

10

-7

Con rm with the PRG (Enter) button (4).

A ashing line cursor (8) will appear in the display.

1044_505-012

8

Enter the new 4-digit master code with the buttons (1), (2) or (3) as described above.

The controller can store a maximum of ve master codes. If a sixth master code is to be added, Err will appear in the display.

Acknowledge with the PRG (Enter) button (4)until the new master code (9) ashes (an example is shown). Then release the button.

Add (10)will appear again in the display.

Operate the PRG (scrolling) button (6) until a normal operation indication (11) (eg battery charge) is displayed. This means that the new driver s code has been accepted.

1044_505-013

1044_505-011

1044_505-014

10

11 %

The truck is turned off, the battery is connected.

-8

9

50108042301 [EN]

Push button I (driving) (5).

Enter the valid 4-digit master code with the 123 (1), 456 (2), 789 (3) buttons.

1

2

123

3

789

456

PRG PRG

6 Scroll with the PRG (scrolling) button (6) until Pin (7) appears in the display.

Con rm with the PRG (enter) button (4) until dEL (10) appears in the display.

Con rm with the PRG (Enter) button (4).

A ashing line cursor (8) will appear in the display.

5

1044_505-010

1044_505-009

7

1044_505-015

1044_505-012

4

10

8

Enter the 4-digit master code to be deleted with the buttons (1), (2) or (3) as described above.

If one attempts to delete an erroneous master code, Errwill appear in the display. If only one master code remains, None will appear in the display.

Con rm with the PRG (enter) button (4) until the master code (9) to be deleted blinks.

50108042301 [EN]

1044_505-013

9

-9

Then release the button. dEL (10) will reappear in the display.

Press the PRG (scrolling) button (6) until a normal operating message (11) (eg battery charge) appears in the display. The master code is now deleted.

1044_505-015

10

1044_505-014

11 %

The truck is turned off, the battery is connected.

Push the I button (driving) (5).

Enter the valid 4-digit master code with the 123 (1), 456 (2), 789 (3) buttons.

1

2

123

3

789

456

PRG PRG

6 Using the PRG (scrolling) button (6), scroll until USER (7) appears in the display.

Continue to a acknowledge with the PRG (Enter) button (4) until Add (10) appears in the display.

-10

1044_505-016

1044_505-011

50108042301 [EN]

4

5

1044_505-009

7

10

Con rm with the PRG (Enter) button (4).

A ashing line cursor (8) will appear in the display.

1044_505-012

8

Enter the new driver s code with the buttons (1), (2) and (3) as described above.

A maximum of 200 driver s codes can be stored in the control. If one wants to enter a 201st driver s code, the message Err will appear in the display.

Con rm with the PRG (Enter) button (4) until the new driver s code (9) ashes. Then release the button.

Add (10) will appear again in the display.

Operate the PRG (scrolling) button (6) until a normal operation indication (11) (eg battery charge) is displayed. This means that the new driver s code has been accepted.

1044_505-013

1044_505-011

1044_505-014

9

10

11 %

The truck is turned off, the battery is connected.

50108042301 [EN]

-11

Push button I (driving) (5).

Enter a valid 4-digit master code with the buttons 123 (1), 456 (2) or 789 (3).

1

2

123

3

789

456

PRG PRG

6 Using the PRG (scrolling) button (6), scroll until USEr (7) appears in the display.

Con rm with the PRG (enter) button (4) until dEL (10) appears in the display.

Con rm with the PRG (enter) button (4).

A ashing line cursor (8) will appear in the display.

5

1044_505-016

1044_505-009

7

1044_505-015

1044_505-012

4

10

8

Enter the 4-digit driver s code to be deleted with the buttons (1), (2) or (3) as described above.

If one attempts to delete an erroneous driver s code, Err will appear in the display.

Con rm with the PRG (enter) button (4) until the driver s code (9) to be deleted blinks.

-12

1044_505-013

50108042301 [EN]

9

Then release the button. dEL (10) will reappear in the display.

Press the PRG (scrolling) button (6) until a normal operating message (11) (eg battery charge) appears in the display. The driver s code is now deleted.

50108042301 [EN]

1044_505-015

1044_505-014

10

11 %

-13

-14

50108042301 [EN]

a

1 Electrical actuator Auxiliary solenoid valve (HD) + solenoid 2 valve Y4 3 CAN signal of the LES control 4 Traction motor temperature sensor (X13) 5 Electromagnetic brake (X14) 6 Actual value potentiometer (L) 7 Traction motor temperature sensor (X12) .

50108042301 [EN]

-1

1 Steering relay (K6) LES control fuse and steering motor reducer 2 (F5) 3 cockpit fuse (F3) 4 Auxiliary components fuse (F4) 5 Flashing beacon fuse (F8) 6 Kanvan actuator fuse (F9) .

1 Battery connector 2 Main contactor (K1) 3 Warning horn (4H1) 4 400-A power supply fuse (F1) 5 Power cable of the electronic system 6 Power cable 8 "+" battery cable 9 Power cable 10 Power cable .

-2

50108042301 [EN]

1 2 3 4 5

"-" cable of the pump unit "U" phase traction motor cable Power cable of the electronic control "-" cable of the electronic control "V" phase traction motor cable

6 7 8 9

"W" phase traction motor cable Cable to negative Cable to negative Controller connector

1 W phase cable 2 V phase cable 3 U phase cable 4 Electromagnetic brake 5 Speed sensor 6 Temperature sensor .

50108042301 [EN]

-3

1 Steering controller .

1-2-6 Steering motor cable 3 A1 power cable 4

D2 power cable

5

D1 power cable

.

1 "-" power cable 2 "+" power cable 3 Y1 solenoid valve 4 Y4 solenoid valve .

-4

50108042301 [EN]

50108042301 [EN]

-5

BP KV PF

Push-button KANVAN general power supply

X11

Platform Presence sensor (presence pedal) High forks

X16

Fork tilt push-button

X20

Computer power supply connector

X23

Flashing beacon connector

S3

.

S7 Forks in a vertical position detection sensor S8 Forks raised speed reduction sensor S10 Forks on the ground detection sensor S35 Actuator end of stroke sensor KVA Actuator power supply connector

For more information on sensor combinations, please refer to the relative table in DiagnosticsMonitor

1 Actuator control relay (K11) .

-6

50108042301 [EN]

Disconnect the battery connector.

Raise the machine on wooden blocks and chock it.

Remove the motor cover (see Chapter "Motor compartment cover", P. 31- 1 ).

Disconnect the cables (1) and the connector (2) from the line switch.

Unscrew the two screws (3) on the line switch and remove it.

Disconnect the cables (1) from the traction controller and unclip the connector (2).

50108042301 [EN]

-7

Unclip connectors (1), (2), (3), (4), (5), (6) and (7).

Unclip the clips (1) holding the connector (2) and unclip the connector.

Disconnect the solenoid valves (4) and(5) from the pump unit.

-8

50108042301 [EN]

Unscrew the two screws (1) and the two nuts (2) holding the plate onto the chassis.

Cut the clips holding the battery cables to the plate.

Remove the electronic panel.

For reassembly, proceed in the reverse order.

50108042301 [EN]

-9

Disconnect the battery connector.

Raise the truck on wooden blocks and chock it.

Remove the motor cover (see Chapter "Motor compartment cover", P. 31- 1 ).

Remove the cables (1).

Remove the warning horn (2) (see ter "Warning horn", P. 60-15).

Chap-

Unclip the relay holder(3) using a screwdriver.

Unclip the connector (4).

Remove the two screws (5).

For reassembly, proceed in the reverse order.

-10

50108042301 [EN]

Remove the battery plug.

Jack up the machine and chock it.

Remove the motor cover (see Chapter "Motor compartment cover", P. 31- 1 ).

Remove the electrical plate (see ter "Electronic panel", P. 60- 7 ).

Chap-

Unclip the connector (1).

Cut the mounting clip (2).

Remove the fan.

For reassembly, proceed in the reverse order.

Disconnect the battery connector.

Jack up the machine and chock it.

Unscrew the four screws (1).

50108042301 [EN]

-11

Remove the plate from its housing.

Unclip the connector (2).

Unscrew the push-buttons from the plate.

Desolder the wires that link the push-buttons to the connector.

For reassembly, proceed in the reverse order.

Disconnect the battery connector.

Jack up the machine and chock it.

-12

50108042301 [EN]

Unscrew the four screws (1).

Remove the plate from its housing.

Unclip the connector (2).

Unscrew the push-buttons from the plate.

50108042301 [EN]

-13

Desolder the wires that link the push-buttons to the connector.

For reassembly, proceed in the reverse order.

-14

50108042301 [EN]

Disconnect the battery connector.

Jack up the machine and chock it.

Remove the bonnet (see Chapter "Motor compartment cover", P. 31- 1 ).

Disconnect the two warning horn connectors (1).

Unscrew the screw (2) to remove the warning horn.

For reassembly, proceed in the reverse order.

50108042301 [EN]

-15

Battery charging

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

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

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

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

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

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

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

Only charge using direct current.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Acid density in the battery completely:

-16

50108042301 [EN]

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The battery must only be changed by specially trained personnel, following the instructions of the manufacturers of the battery, the battery charger

50108042301 [EN]

-17

and the truck. Follow the battery maintenance instructions.

Do not smoke or use an open ame when handling batteries.

There must be no combustible material or tools that produce sparks within a minimum radius of 2 m around the truck being charged and the battery charger. The work area must be well ventilated. Fire extinguishers must be provided and located near the work area.

When the battery is being worked on, the truck must be parked safely. The truck may only be started after all covers and plugs have been re tted in their operating positions.

Unplug the battery connector (1).

1

1044_606-001

-18

50108042301 [EN]

Lift the battery lock (4) 90°.

4

Danger of short-circuits!

In order to avoid short-circuits, it is recommended that batteries with polar terminals or unprotected connections be covered with a rubber mat.

Disconnect the battery connector.

Open the battery compartment .

Unlock the battery by lifting the lock (4).

1044_606-003

Correctly attach the lifting device (5) to the battery (6).

5 The lifting device must exercise vertical traction to avoid damaging the case. The hooks must be positioned such that they cannot fall on the battery cells when the lifting device is slackened.

Carefully lift the battery out of the truck.

6

1044_606-004

Position the truck so that the battery (9) is aligned with the side removal trolley (10).

Unplug the battery connector (7).

Open the battery compartment (8).

Unlock the battery.

Stand on the opposite side of the battery cover and push the battery (9) out onto the trolley (10).

Connect an extension cable to the charged battery and then connect it to the truck.

Start the truck.

Position the truck battery compartment so that it is aligned with the new battery.

Switch off the truck and remove the extension cable.

50108042301 [EN]

-19

Push the battery completely into the battery compartment.

Lock the battery.

Close the battery compartment (8).

Connect the battery plug (7).

The weight and size of the battery in uence the stability of the truck. The weight of the replacement battery must be the same as the old one. Do not remove or move any ballast weight.

Observe the battery characteristics.

You will nd all necessary information regarding battery charging in the maintenance instructions provided in the chapter on "Maintaining the battery".

Re t a charged battery by performing the aforementioned operations in reverse order.

Make sure all covers are properly tted.

Be careful not to damage any wiring when replacing the battery.

Risk of jamming!

Be sure not to leave anything between the battery cover and the edge of the chassis when closing the cover.

-20

50108042301 [EN]

Connect the battery plug (13).

11

Fit the battery lock (11).

12

13

Push the battery cover (14) forward until it clicks into the lock (12).

4

±5%

Weight

±5%

1044_606-006

Cell type

Capacity

24 V 3 PzV

345

402

TROG 53

24 V 3 PzV

375

402

53

24 V 3 PzV

420

402

53

24 V 3 PzV

465 300 (gel)

402

53

24 V 3 PzV

402

53

24 V 3 PzV

330 (gel)

402

53

24 V 3 PzV

360 (gel)

402

53

24 V 3 PzV

420 (gel)

443

53

24 V 4 PzV

560

515

54

24 V 4 PzV

620 480 (gel)

515

54

24 V 4 PzV

515

54

24 V 4 PzV

560 (gel)

557

54

.

50108042301 [EN]

-21

Remove the load backrest Chapter "Height sensor", P. 60-25.

Lower the forks fully.

Disconnect the battery connector.

Remove the two retaining plates of the buttons to the side of the rear cover. Lift the four corners of the sticker to access the screws (1) (the plates have two or four buttons, depending on the model).

Disconnect the connectors from the buttons.

Remove the rear cover after removing the six small locking plates (2).

Remove the oor mat from the foot interlock pedal.

-22

50108042301 [EN]

Remove the two screws and remove the sensor.

Remove the nuts (5).

Open the battery cover and slide the battery so that you can access and remove the retaining screws (6) of the battery cover (tightening torque: 25 Nm).

Raise the battery cover slightly to allow the pedals and the fasteners of the rubber mounts (7) to be removed and replaced.

Using washers and nuts, attach to the step plate:

50108042301 [EN]

-23

Two exible shock absorbers. Tighten to a torque of 8 Nm using a screwdriver

Four shock absorbers, tightened to a torque of 34 Nm

Fit the two screws on the step plate panel using a screwdriver

-24

50108042301 [EN]

Fit the two sections. Tighten to a torque of 8 Nm using a screwdriver

Raise the forks to gain access to the four lateral load backrest fastening bolts (1).

Remove the screws and take off the load backrest.

50108042301 [EN]

-25

Remove the two height sensor fastening screws (2) and take off the height sensor.

Install a new height sensor.

Adjust the height of the sensor so that the pump unit cuts out electrically when the forks reach a height of 200 mm (3) from the oor.

Install the load backrest and torque the four lateral fastening bolts to 25 Nm.

Truck turned off, battery disconnected.

Remove the 2 x 2 CHC screws (1) at the bottom of the protective screen on both sides of the truck.

Remove the screw ((2) ), take off the mounting for the protective screen at the fork carriage upwards.

-26

50108042301 [EN]

Remove the two fastening screws (3) at the protective plate on the upper mast cross member.

Under the cover, disconnect the electric connectors (1) on each of the two lateral control buttons for lifting/lowering/forward/reverse (4).

Remove the 4 cross-slotted screws under the label and remove the controls upwards (mark the forward travel direction of the truck good, well to avoid an interchanging of the travel directions upon installation ).

Remove the 6 fastening screws on the back wall assy. (backrest and plastic housing) (5) on both sides of the mast with the 6 cable ties bundling the electric cables.

Take off both transmitters (6) (remove 2 screws each).

Truck turned off, battery disconnected.

Remove the 2 x 2 CHC screws (1) at the bottom of the protective screen on both sides of the truck.

Remove the two fastening screws (3) at the protective plate on the upper mast cross member.

50108042301 [EN]

-27

Under the cover, disconnect the electric connectors (A) on each of the two lateral control buttons for lifting/lowering/forward/reverse (4).

Remove the 4 cross-slotted screws and remove the controls upwards (mark the forward travel direction of the truck good, well to avoid an interchanging of the travel directions upon installation ).

Remove the 6 fastening screws on the back wall assy. (backrest and plastic housing) (5) on both sides of the mast with the 6 cable ties bundling the electric cables.

Take off both transmitters (6) (remove 2 screws each).

-28

50108042301 [EN]

a

Disconnect the battery connector.

Jack up the machine and chock it.

Remove the motor cover (see Chapter "Motor compartment cover", P. 31- 1 ).

Locate the electrical connections on the traction controller (1) and disconnect them.

Unclip the connector (2).

Unscrew the four screws (3).

Remove the traction controller.

For reassembly, proceed in the reverse order.

50108042301 [EN]

-1

-2

50108042301 [EN]

a

50108042301 [EN]

-1

1 2 3 4 5 6

Lift cylinder Hydraulic block Lowering solenoid valve Flow restrictor (throttle) Hydraulic oil tank Pump motor

-2

7 8 9 10 11

Oil screen Lift pump Pressure limiter Non-return valve Filter

50108042301 [EN]

a

Type:

K3.823.16.409 Motor, 4-pole series

Motor performance: Voltage V

24 V

Current (A):

134 A at 100 bar

Excitation:

No

Power (kW):

2.2 kW

Operating method:

S3 - 8 %

Protection:

IP43

Insulation class:

F

a) Size:

16 mm

b) Wear limit:

11 mm

c) Quantity (number):

4

d) Carbon brush monitoring:

No

Weight (kg):

11 kg

Ventilation:

No

Pump 3.6 cm 3/rev

Output: .

Lower the forks fully.

Disconnect the battery connector.

50108042301 [EN]

-1

Disconnect the electric leads from the motor (2) and of the solenoid valve (1).

Disconnect the hydraulic lines (3) at the pump unit.

Oil will ow out.

Catch the oil.

The fastening bolts of the pump unit are accessible through the battery compartment.

Unlatch the battery (4).

Fold the latch down again; it will serve as a safety stop.

-2

50108042301 [EN]

Remove the pump unit fastening bolts (5) (torque 25 Nm).

Installation is the reverse of removal.

Remove the four socket head screws (1) (torque: 10 Nm).

Loosen the strap (2) of the hydraulic oil tank.

Remove the hydraulic oil tank.

Remove the suction lter (3).

Loosen both retaining screws (4) (tightening torque: 25 Nm).

To install, follow the removal procedure in reverse order, using the tightening torques given.

50108042301 [EN]

-3

Brushes must be replaced when their length reaches 11 mm. Always replace all four at once.

Disconnect the battery connector.

Disconnect the electric motor cables.

Unscrew the screws (2).

Remove the nuts from the terminals and remove the cover (3).

Disconnect the cables between the brush and the brush holder (4).

-4

50108042301 [EN]

Remove the brush holder ring (5).

Replace the brushes.

Installation is the reverse of removal.

To access the bearings, follow the procedure for replacing the bushes.

Extract the bearings using a suitable extraction tool.

To re t the bearings, use a suitable rubber mallet.

50108042301 [EN]

-5

Before working on the hydraulics, lower the forks completely!

Extend the forks and lower them to the lower stop. Press the lowering button several times so that there is no more pressure in the system.

Disconnect the battery connector.

Jack up the machine and chock it.

Remove the motor cover (see Chapter "Motor compartment cover", P. 31- 1 ).

Disconnect the power supply cables (1) and (2), clearly marking their respective positions for re tting.

Disconnect the solenoid valve connections (3) and (4).

Disconnect the connection (5).

-6

50108042301 [EN]

Cut the two clips.

Move the battery to access the two screws (6) holding the pump unit to the chassis.

Fully unscrew one of the screws and loosen the other one.

Remove the pump unit.

For reassembly, proceed in the reverse order.

Remember to check the oil level.

Oil may escape.

50108042301 [EN]

-7

Remove the pump unit (see above).

Loosen the mounting clip (1).

Remove the hydraulic oil tank pump motor.

For reassembly, proceed in the reverse order.

When reassembling, remember to: Clean the suction lter, Remove any dirt from the pipes, Fill the oil pump, Please refer to the tightening torque tables for the tightening torques.

Remove the pump unit (if necessary; see above) and the hydraulic pump.

Remove the two screws (1).

Uncouple the hydraulic pump motor.

-8

50108042301 [EN]

Remove the coupling plug (2).

For reassembly, proceed in the reverse order.

Disconnect the connector for solenoid valve Y1 (1) and the connector for solenoid valve Y6 (2).

Unscrew the coils and remove them.

Unscrew the bodies of the solenoid valves.

Take the solenoid valves out of their housings.

For reassembly, proceed in the reverse order.

Lower the forks.

Open the battery cover.

Disconnect the battery connector.

Chock the machine.

Remove the motor cover (see Chapter "Motor compartment cover", P. 31- 1 ).

Connect an output pressure gauge.

Reconnect the battery connector.

Place the forks at the upper stop.

Check the pressure obtained.

50108042301 [EN]

-9

To adjust the pressure relief valve, loosen the locknut with a no. 23 spanner and adjust the pressure using an Allen key.

Gradually increase or reduce the pressure until the appropriate pressure setting is obtained.

KANVAN Pressure relief valve setting (bar)

175

The pressure must always be increased slowly. Never increase the pressure too suddenly or there is a risk of exceeding the maximum pressure and damaging the pump unit.

This operation should only be carried out by a person authorised by STILL.

Brush length must not be less than the minimum length: Minimum brush length 2.2 kW motor

11 mm

Remove the pump unit (if necessary; see above).

-10

50108042301 [EN]

Unscrew the two screws on the pump motor cover and release the stator.

Open the cover.

Release the rotor to free the brushes.

50108042301 [EN]

-11

Release the brush from its housing.

Unscrew the brush, release it from its support using pliers and replace it.

-12

50108042301 [EN]

Draining is recommended every 2000 hours or at least every year (even if 2000 hours have not been reached) due to water absorption by the oil.

The hydraulic oil is harmful to health and the environment.

Follow the safety instructions.

Place the truck on a horizontal surface.

Disconnect the battery connector.

Remove the motor cover (see Chapter "Motor compartment cover", P. 31- 1 ).

Remove the pump unit (see sembly", P. 71- 6 ).

Chapter "Disas-

50108042301 [EN]

-13

Remove the hydraulic oil tank pump motor (12).

Replace the lter (10).

Recover the hydraulic oil and drain it in accordance with the safety and environmental protection instructions.

Re t the pump unit.

Unscrew the plug (13) and ll the hydraulic oil tank.

Drain off the used oil in accordance with the instructions.

-14

50108042301 [EN]

a

Remove the solenoid.

Using a spanner, unscrew the valve (1) (tightening torque: 45 Nm).

Installation is the reverse of removal.

50108042301 [EN]

-1

-2

50108042301 [EN]

a

Remove the load backrest Chapter "Height sensor", P. 60-25.

Lower the forks fully.

Disconnect the battery connector.

Remove the hydraulic tting on the cylinder (1) completely.

Remove the setscrew on the rod at the base of the cylinder (2).

Remove the plug from the end of the piston rod.

Raise the forks slightly using a jack so that you can remove the rod at the base of the cylinder.

Remove the cylinder.

Replace the cylinder.

Installation is the reverse of removal.

Truck turned off, battery disconnected.

Remove the 2 x 2 CHC screws ((1)) at the bottom of the protective screen on both sides of the truck.

50108042301 [EN]

-1

Remove the screw ((2)), take off the mounting for the protective screen at the fork carriage upwards.

Remove the two fastening screws ((3)) at the protective plate on the upper mast cross member.

Under the cover, disconnect the electric connectors (A) on each of the two lateral control buttons for lifting/lowering/forward/reverse (4).

Remove the 4 cross-slotted screws under the label and remove the controls upwards (mark the forward travel direction of the truck good, well to avoid an interchanging of the travel directions upon installation ).

Remove the 6 fastening screws on the back wall assy. (backrest and plastic housing) (5) on both sides of the mast with the 6 cable ties bundling the electric cables.

Take off both transmitters (6) (remove 2 screws each).

-2

50108042301 [EN]

Remove the 2 x 2 CHC adjustment screws (7) (screw + lock screw) for the adjustment of the lateral play of the inner mast (B).

Remove the 2 screws ((17)) on the chain anchor.

Using a hoist, set the truck on squared timbers about 25 cm high (forks stay in lowered position).

Accident hazard

Sling the forks and then tauten the sling lightly with the hoist (C).

Installation is exactly the reverse order of removal.

Do not forget to ll oil to the correct level.

For all torques see the General Table.

50108042301 [EN]

-3

Truck turned off, battery disconnected.

Remove the 2 x 2 CHC screws ((1) ) at the bottom of the protective screen on both sides of the truck.

Remove the two fastening screws (3) at the protective plate on the upper mast cross member.

Under the cover, disconnect the electric connectors (A) on each of the two lateral control buttons for lifting/lowering/forward/reverse (4).

Remove the 4 cross-slotted screws and remove the controls upwards (mark the forward travel direction of the truck good, well to avoid an interchanging of the travel directions upon installation ).

-4

50108042301 [EN]

Remove the 6 fastening screws on the back wall assy. (backrest and plastic housing) (5) on both sides of the mast with the 6 cable ties bundling the electric cables.

Take off both transmitters (6) (remove 2 screws each).

Remove the 2 x 2 CHC adjustment screws (7) (screw + lock screw) for the adjustment of the lateral play of the inner mast (B).

Remove the 2 screws (17) on the chain anchor.

50108042301 [EN]

-5

Using a hoist, set the truck on squared timbers about 25 cm high (forks stay in lowered position).

Accident hazard.

For the removal of the forks secure the driver s stand safely (at least 3 resting points).

Chocking the driver s stand

Connect the forks using the slings (C), then tighten the slings with the hoist.

Loosen the nut and locknut at the chain tensioner (8) to take the lift chains out off the frame, then detach the other chain end (fastened to the inner mast) (D).

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50108042301 [EN]

Remove the 2 x 4 CHC screws (12) on the two anchor plates of the scissors.

Unscrew the stop (13) at the top of the inner mast.

Separate the forks from the scissors by pulling them up with the hoist and then depositing them on the ground.

After a longer operating time the oil can be very hot.

Slide a pan under the truck directly under the cylinder, then slowly screw out the hydraulic tting ( (10) and let the oil drain out of the cylinder. Then screw out the second hydraulic tting (11) from the cylinder.

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-7

Lash the inner mast (15), tauten the sling lightly, remove four pins (14) and then take off the inner mast.

Installation is exactly the reverse order of removal.

Do not forget to ll oil to the correct level.

For all torques see the General Table.

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50108042301 [EN]

Remove the rear cover.

Remove the fork carriage (see above).

Remove the cylinder (see Chapter "Removing the Kanvan cylinder", P. 84- 9 ).

Unscrew the four screws (1).

Unscrew the four screws (2).

Remove the mast.

For reassembly, proceed in the reverse order.

50108042301 [EN]

-9

Extend the forks.

Lift the fork carriage.

Place a chock under the fork carriage as shown on the photograph.

Lower the fork carriage so that it rests on the chock and the cylinder chain is slack.

Disconnect the battery connector.

Remove the four screws from the guard grille.

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50108042301 [EN]

Remove the pin (1).

Take the chain off the pulley and turn the cylinder rod as shown on the photograph so that the operation of the fork carriage is not hindered.

Strap the fork carriage.

Lift the fork carriage by using a hoist to remove it from the mast.

Watch out for the rollers!

For reassembly, proceed in the reverse order.

Check that the rollers are correctly wedged and chock them again if necessary.

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-11

Lower the forks.

Take out the pins (1).

Remove the bolt (2).

For reassembly, proceed in the reverse order.

The two screws (1) are used to adjust the horizontal position of the forks.

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50108042301 [EN]

a

Remove the mast together with the fork carriage. Chapter "Mast and fork carriage", P. 80- 1 Loosen the nut and the self-locking nut on the chain tensioner (8) to extract the lifting chain from the chassis, then disconnect the other end of the chain (secured to the inner mast).

Unscrew the stop ((13)) at the top of the inner mast.

Using the hoist, remove the forks by pulling them up and then deposit them on the ground.

Slide a pan under the truck directly under the cylinder, then slowly screw out the hydraulic tting ( (10) and let the oil drain out of the cylinder. Then screw out the second hydraulic tting ( (11) ) from the cylinder.

50108042301 [EN]

-1

Lash the inner mast (15), tauten the sling lightly, remove the two pins (14) and then take off the inner mast.

Installation is step by step in the reverse order of removal. For all torques see the General Table.

Installation of mast with fork carriage ter "Mast and fork carriage", P. 80- 1

Chap-

Truck turned off, battery disconnected.

Remove the 2 x 2 CHC screws (1) at the bottom of the protective screen on both sides of the truck.

Remove the two fastening screws (3) at the protective plate on the upper mast cross member.

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50108042301 [EN]

Under the cover, disconnect the electric connectors (A) on each of the two lateral control buttons for lifting/lowering/forward/reverse (4).

Remove the 4 cross-slotted screws and remove the controls upwards (mark the forward travel direction of the truck good, well to avoid an interchanging of the travel directions upon installation ).

Remove the 6 fastening screws on the back wall assy. (backrest and plastic housing) (5) on both sides of the mast with the 6 cable ties bundling the electric cables.

Take off both transmitters (6) (remove 2 screws each).

Remove the 2 screws retaining the chains in their mountings (17).

Accident hazard.

For the removal of the forks secure the driver s stand safely (at least 3 resting points).

50108042301 [EN]

-3

Using a hoist, position the truck on squared timbers.

Position the squared timbers so they are symmetrical with the scissor lift. Connect them using a suitable method so that they cannot be separated (G).

Unhook the fork carriage chains.(To the relax the chains, press on the head end of the cylinder piston to start a lowering movement.)

Secure the forks.

Remove the cotter pins from the upper and lower plugs.

Do not forget to mark the shims (18) for the correct side play upon re tting.

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50108042301 [EN]

Guide the four upper pins (two on the righthand side and two on the left-hand side) towards the interior of the truck (J).

Move the forks upwards (K).

Insert the scissor lift into the inner mast (L).

When it is connected to the inner mast, the scissor lift may suddenly move a few centimetres before it reaches full tension.

Remove the squared timbers (M).

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-5

Pull out the lower pins (N).

Separate the scissor blades of the truck, one after the other (O).

Put the forks and scissors upside down.

Install the pins: There are two different pin lengths: 16 mm and 20 mm. Assemble two pins for each hole (16 mm + 20 mm for upper pins and 16 mm + 16 mm for lower pins).

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50108042301 [EN]

Individually install each part of the scissor lift into the relevant fork.

Connect the scissors to the forks with the upper pins. Remember to re-install the side spacers (1). Secure them with pins and plugs.

Connect the scissor lift to the forks.

Re t the fork unit at the hoist.

Using the hoist, re t the fork unit onto the inner mast.

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-7

Position the forks at the upper end of the mast (as high as possible (1) and with an anti-lock safety device (2) in place) so that the scissors can be connected more easily to the inner mast using the lower pins. Remember to install the side spacers and to secure them with pins and a plug.

For all torques see the General Table.

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50108042301 [EN]

Extend the forks.

Lift the fork carriage.

Place a chock under the fork carriage as shown on the photograph.

Lower the fork carriage so that it rests on the chock and the cylinder chain is slack.

Disconnect the battery connector.

Remove the four screws from the guard grille.

Remove the rear covers.

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-9

Remove the pin (1).

Take the chain off the pulley.

Unscrew the connection (4).

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Unscrew the two screws (5) holding the cylinder to the mast.

Remove the cylinder.

For reassembly, proceed in the reverse order.

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-11

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Mast Disassembly . . . . . . . . . . . . . . . . . .

Battery Changing . . . . . . . . . . . . . . . . . . . . .

- 17

Brake Disassembly . . . . . . . . . . . . . . . . . .

- 9

Mast and fork carriage CX 10 M . . . . . . . . . . . . . . . . . . . . . .

- 1

- 3 Operator s backrest

Composition of the truck serial number . .

- 10

Conditions for diagnosis . . . . . . . . . . . . .

- 1

Cylinder Removal . . . . . . . . . . . . . . . . . . . . .

- 9

Removal . . . . . . . . . . . . . . . . . . . . .

- 3

Pump unit Disassembly . . . . . . . . . . . . . . . . . .

- 6

Push-buttons . . . . . . . . . . . . . . . . . . . . .

- 11

Recopy potentiometer . . . . . . . . . . . . . .

- 6

Fan Disassembly . . . . . . . . . . . . . . . . . .

- 11

Removal of fork carriage and mast CX 10 M . . . . . . . . . . . . . . . . . . . . . .

Height sensor CX 10 M . . . . . . . . . . . . . . . . . . . . . .

- 26

CX 16 S . . . . . . . . . . . . . . . . . . . . . .

- 27

CX 20 . . . . . . . . . . . . . . . . . . . . . . .

- 25

Hydraulic system Maintenance . . . . . . . . . . . . . . . . . .

- 13

Load wheels CX 10 M . . . . . . . . . . . . . . . . . . . . . .

- 8

CX 16 S . . . . . . . . . . . . . . . . . . . . . .

- 9

CX 20 . . . . . . . . . . . . . . . . . . . . . . .

- 7

- 1

Speed sensor Disassembly . . . . . . . . . . . . . . . . . .

- 9

Steering controller Removal . . . . . . . . . . . . . . . . . . . . .

- 4

Temperature sensor Replacing . . . . . . . . . . . . . . . . . . . .

- 10

Traction controller Disassembly . . . . . . . . . . . . . . . . . .

- 1

Traction motor Maintaining joining pins Removal . . . . . . . . . . . . . . . . . . . . .

- 3

Warning horn . . . . . . . . . . . . . . . . . . . . .

- 15

- 2

Maintaining scissors and joining pins Installation . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . .

- 6

Maintaining the lift cylinder and/or inner mast CX 16 S . . . . . . . . . . . . . . . . . . . . . .

- 4

Installation . . . . . . . . . . . . . . . . . . . .

- 8

Removal . . . . . . . . . . . . . . . . . . . . .

- 4

50108042301 [EN]

1

STILL GmbH Berzeliusstrasse 10 D-22113 Hamburg Ident no. 50108042301 EN