Still STED forklift Electric pallet truck EXU-S 22 EXU-S 24 Workshop Manual - PDF DOWNLOAD

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STILL

Workshop literature STILL ELECTRONIC DOCUMENTATION SYSTEM

Electric pallet truck EXU-S 22 EXU-S 24

CE 0148 0149 50158070901 EN - 01 .2011

first in intralogistics

Table of contents

00 Product information Product information - general points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 1 Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 1

Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00- 2

Definition of directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00- 6

Composition of the truck serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00- 7

Overall view

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 8

Dimensions, left side access

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 10

Technical characteristics, left side access platform . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions, rear access platform

00- 11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 14

Technical characteristics, rear access platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00- 15

Table of tightening torques in Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00- 17

Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 22 Park the truck

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 22

Battery socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slinging, lifting and chocking the truck

00- 23

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 24

02 Diagnostics Diagnostics - general points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 1 Diagnostic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

02- 1

Diagnostic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

02- 3

CAN-bus (Controller Area Network) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

02- 8

Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02- 11 Diagnostic software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

02- 11

10 Motor - general points Motor - general points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 1 Triphase asynchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

10- 1

Electric motors Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 - 1

Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 - 1

Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5 Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 - 5

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

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I

Table of contents

22 Mechanical transmission Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22- 1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22- 1

Reduction gear - Dismantling - Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22- 2

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22- 5

31

Traction system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22- 5

Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22- 6

Chassis Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 - 1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Covers

31 - 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 - 3

Motor covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 - 4

Battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 - 5

Load backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 - 5

Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 - 6

42 Steering system Electrical steering

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42- 1

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42- 1

. . . . . . . . . . . . . . . . . . . . . . 42- 1

Driving behaviour depending on the steering lock angle

Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42- 2

Power steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42- 3

Desired value potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42- 5

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

42- 7

Description of the recopy potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42- 8

Dismantling and reassembling - recopy potentiometer

. . . . . . . . . . . . . . . . . . . . . . . 42- 8

Potentiometer pinion bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42- 10

46 Wheels and tyres Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46- 1 Traction Wheel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46- 1

Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46- 2 Stabiliser rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46- 2

Load wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46- 5

Load wheels - Dismantling and reassembly

II

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46- 7

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Table of contents

49 Braking system Electrical braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49- 1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49- 1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49- 2 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49- 3 Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49- 4

50 Control units Control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50- 1 Cockpit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50- 1

Entering the user code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50- 2

Digicode control

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50- 4

Adding the master code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50- 5

Deleting the master code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50- 6

Adding the driver's code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50- 8

Deleting a driver's code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50- 9

Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50- 11

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50- 11

Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50- 12

60 Electrics/ Electronics Electrics/ electronics - general points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 1 Wiring diagram

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 1

Description of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60- 2

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60- 4

Location of units

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 5

Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 6 Emergency isolator button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60- 6

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60- 7

Contactor K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60- 7

Battery and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 9 Battery PzS (open-lead) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60- 9

Changing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60- 10

Changing the battery using a hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60- 12

Battery change with a roller battery holder

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 13

Closing the battery compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60- 14

Dismantling - Reassembling the battery plug

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 15

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III

STILL

Table of contents Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 16 Presence pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60- 16

Presence pedal - general points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60- 17

Dismantling and Reassembly - Presence pedal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60- 17

Height sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60- 19

64 Electronic controls Variable speed traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64- 1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64- 1

Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64- 1

Dismantling - Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64- 1

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64- 2

Variable speed steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64- 6 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64- 6

Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64- 6

Dismantling - Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64- 6

70 Hydraulics General Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70- 1 Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70- 1

71 Working hydraulics Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 - 1 Technical Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 - 1

Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 - 2 Dismantling - Reassembly of the holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 - 3 Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 - 4 Dismantling - Reassembly of the tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 - 5 Intake filter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 - 5

Motor and driving plate pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 - 6 Brushes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 - 7

Roller bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 - 9

76 Valves - Check valves Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76- 1 Pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Table of contents

80 Lifting system Lifting system - general points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80- 1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80- 1

Basic lifting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80- 2 Lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80- 2

84 Load holder Fork holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84- 1 Traction rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling and Reassembly - Traction rods

84- 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84- 1

Separation of fork chassis/motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84- 4

Lateral lifting guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84- 5

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Product information a

Product information - general points Introduction Structure The manual is structured according to the same rules as the parts catalogue, ie it is divided into groups and subgroups.

To simplify the marking of the treated assemblies, the number of the relevant assembly is located at the top right corner of each page.

There are tables with technical data for maintenance, which must be observed.

This manual contains a detailed description of the design characteristics as well as the functional description of individual components and assemblies.

Notes and instructions and explanatory illustrations are inserted in the description of the tasks in this manual.

There are wiring diagrams in the A4 format in Section 60, but also a copy in better quality in the STEDS (General documents -> Wiring schematics).

Remarks, imprint The following must be observed when reading this manual

This workshop manual contains the standard trucks of the corresponding industrial trucks and some popular variants.

No warranty claims will result by working according to this manual. The STILL warranty conditions remain unaffected.

Editor STILL S.A.S. 4, avenue de la Libération Square John Saxby B.P. 50129 F-60160 MONTATAIRE Cedex

Fault diagnosis The fault diagnosis allows a quick detection of the cause of a problem detected in the electrical installation of the truck and also the determination of the precise cause.

The fault diagnosis is structured as follows: Use of a Notebook Parameterisation

The design and construction of our products are subject to continuous development. For this reason we reserve the right to make changes in the speci cations and the design without prior notice.

Menus

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50158070901 [EN]

00-1

This robust ride-on electric pallet truck is ideal for loading and unloading lorries, and its high travel speed makes it easy to transport over longer runs.

The EXU-S was designed for loading/unloading lorries and has excellent handling on slopes and in the con ned spaces of lorries.

The even chassis moves smoothly and never catches on protruding edges of ramps, whilst the platform s tapered sides protect the operator from colliding with side walls, even when working on the end two pallet rows.

The platform is an integral part of the chassis and it has an enclosed, high-resistance structure providing extreme reliability, even on violent impacts on the dock.

To optimise traction and braking, the centre-mounted drive unit is sprung and features variable wheel pressure on the ground proportional to the load on the forks.

For lateral stability, two exclusive STILL twin-wheels have been specially designed for the EXU-S for extreme reliability in the most arduous applications.

-2

50158070901 [EN]

Fully electric steering "with automatic return to neutral".

In the centre angle range, any unintentional steering movements are damped by means of an electronic lter, guaranteeing precise steering.

Automatic speed reduction during cornering combined with the stabilising wheels gives high lateral stability and reduces centrifugal force effects on the operator and the load.

The new console "cockpit" contains all the functions for access, operation and control on the EXU-S. Due to the ergonomic layout of the controls, all functions can be operated with either hand.

The following functions are integrated into the cockpit: Steering and speed control Raising/lowering of forks Hour meter connected to functions Battery discharge indicator with fork lift cut-out Operator pro les with two performance modes Performance mode selection by electronic key Service centre diagnosis for maintenance (by means of service codes) In addition, the cockpit provides a secure support for the operator whilst driving, so that he does not get tired or have to keep turning backwards and forwards.

Depending on the application, the EXU-S is available with two platform types that are ergonomically suited to the operator s needs.

These needs are very different from one type of job to another, so we have designed two different platforms.

For typical loading/unloading applications where pallet transfer or long runs require the driver to spend a long time standing on the truck, the platform with side access will offer the greatest comfort and safety for driving in both directions.

If the driver has to step in and out frequently for any peripheral work, (scanning products, manual handling etc.), then the platform with rear access is best suited.

50158070901 [EN]

-3

Either EXU-S platform type always provides great comfort due to an innovative, unique, fully sprung platform oor.

The truck incorporates various storage facilities and a holder for rolls of stretch wrap integrated within the hood.

A clipboard is available as standard.

The asynchronous traction technology is powerful and economical. Travel power is 3.0 kW. The latest generation of asynchronous controller combined with the cockpit offers the possibility of selecting two drive modes by touching one of the two performance mode buttons: In "ECO" mode (Tortoise button), the controller supplies the travel motor with low current and it accelerates gradually. This results in 15 % more battery economy, but the same productivity as other machines of this type.

In "BOOST" mode (Hare button), the controller drives the travel motor to provide very high torque and acceleration, even when fully loaded. While economy remains unchanged, productivity increases by around 25 %.

With each mode, the drive characteristics can be adjusted (speed, acceleration, braking) to precisely match the application or driver preference.

Thanks to the controller s speed control system, the EXU-S will start smoothly and accelerate to maximum travel speed, regardless of the load on the forks.

The service brake is activated by releasing the butter y valves or by reversing the direction of travel.

To avoid any unintentional movements whilst on a ramp, the (electromagnetic) parking brake is activated once the butter y valves are in neutral position or the operator leaves the platform.

A pump unit comprising a compact, 2.2-kW pump motor with built-in oil tank, solenoid valve and safety valve controlling electrical end-of-travel lift cut-out.

This hydraulic system offers very short lift times, even with a full load, thereby providing high productivity for loading and unloading lorries with the EXU-S.

-4

50158070901 [EN]

There are two independent brake circuits.

Progressive service brake with energy recovery activated by releasing or reversing the butter y valves.

Emergency brake with electromagnetic disc activated by a button in the cockpit.

Driving is only possible when the operator is on the platform, which acts as a contact switch.

The battery is easily accessible so that it can be recharged or maintenance work can be carried out (for example, " lling the water up").

Two- or three-shift operations can be changed vertically with a sling, or from the side using rollers.

Two different battery compartments allow batteries with 450 Ah or 600 Ah capacities to be used.

Our trucks are built to meet EU Directive 98/37 and carry the "CE" symbol.

STILL is certi ed to ISO 9001.

Unique STILL modular accessory system with horizontal bar.

A4 clipboard.

Preparation for on-board IT terminals.

Load support backrest (1200 mm or 1600 mm in height from the top of the forks).

Cold store version (-30 °C).

24 Volt 600 Ah battery compartment.

Steel battery hood.

Access control and eet management with STILL FleetManager .

50158070901 [EN]

-5

1 2 3

Forward travel Reverse travel Lifting

-6

4 5 6

Lowering Right Left

50158070901 [EN]

71 0148 A 00001

Complete serial number

71: Montataire (France)

0148: EXU S 22 0149: EXU S 24

Example: A : 2010

0148_000-005

00001: Number increasing from start of production

Please indicate the serial no. for all technical enquiries.

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

50158070901 [EN]

Model Manufacturer Serial no.

Year of manufacture Tare weight (kg) Max battery weight in kg Min battery weight in kg Additional weight (ballast) in kg Nominal drive power in kW Battery voltage in V Rated capacity in kg EC conformity symbol

-7

6

5

4

23

3

7 8

2 1

9 10 11 22

12 21 20

0148_000-001

13

19 18 17 1 2 3 4 5 6 7 8 9 10 11 12

Forks Traction battery Battery cover Battery lock Battery socket Tiller Lifting cylinder Pump motor Back rest Hydraulic oil reservoir Brake Drive motor

-8

13 14 15 16 17 18 19 20 21 22 23

16

15

Platform (presence area) Stabilising roller Drive wheel Reducer Stabilising roller Power steering motor Variable speed steering Fuse holder Variable speed traction Rollers Accessory holder cradle (option)

50158070901 [EN]

14

50158070901 [EN]

-9

-10

50158070901 [EN]

Manufacturer Platform Travel, battery, Diesel, petrol, LPG, network current Driving, by hand, pedestrian accompanied, ride-on, sitting, order picking Capacity / Load Q (kg)

STILL Side access

STILL Side access

Electric

Electric

Ride-on standing

Ride-on standing

2200

2400

Load centre of gravity

c (mm)

600

600

Load distance

x (mm)

1023

1005

Wheelbase

y (mm)

1617

1599

Tare (with battery, trog 113)

kg

1120

1120

Load per axle with load (driver/load)

kg

1320/1800

1320/1800

Load per axle without load (driver/load)

kg

908/212

908/212

V

V

mm

Ø250 x 100

Ø250 x 100

mm mm

Ø85 x 80 2x ø 140 x 54

Ø85 x 80 2x ø 140 x 54

1x -2/4

1x -2/4

Tyres, superelastics (SE), pneumatics (L), Vulkollan (V) Wheel sizes (driver side) Wheel sizes (load side) Stabiliser wheels (sizes) Wheels (x = drive wheels), number (driver/load) Front track

b 10 (mm)

470

470

Rear track

b11(mm)

388

388

Lift height

h3(mm) h7(mm)

130 200

130 200

Platform height Fork height

h13(mm)

85

85

Tiller height (min/max) Total length Length, drive section

h14(mm) l1 (mm) l2 (mm)

1030 24751) 12851)

1030 24751) 12851)

Overall width

b1(mm)

720

720

Fork arm size

s/e/l (mm

55/172/1190

61/172/1190

1) With batter boot 600 Ah: + 85 mm 50158070901 [EN]

-11

Exterior distance between forks

b5(mm)

560

560

Ground clearance

m2(mm) Ast (mm)

30 26851)

30 26851)

Wa (mm)

23081)

22901)

Width of pallet aisle 800 x 1200 long Turning radius

1) With batter boot 600 Ah: + 85 mm

Travel speed with/without load

km/h

10/12

9/12

Lift speed with/without load

m/s

2.1/1.7

2.2/1.7

Lowering speed with/without load

m/s

1.7/2.9

1.5/2.9

Slope with/without load Acceleration time (after 10m) with / without load Service braking

%

15/15

15/15

s

-

-

electromagnetic

electromagnetic

Travel motor, capacity S2 = 60 min

kW

3.0

3.0

2.2

2.2

IEC 254 - 2;B

IEC 254 - 2;B

24/450

24/450

410

410

-

-

AC controller 68.5

AC controller 68.5

Lift motor, capacity S3 = 15% kW Battery depending on DIN 43531/35/36 A, B C, not Battery voltage, rated capacity C5 V/Ah Battery weight (depending on supplier) kg (+/- 5%) Energy consumption depending on VDI cycle kWh/h

Speed control Noise level, for operator s ears

-12

dB (A)

50158070901 [EN]

50158070901 [EN]

-13

-14

50158070901 [EN]

Manufacturer Platform Travel, battery, Diesel, petrol, LPG, network current Driving, by hand, pedestrian accompanied, ride-on, sitting, order picking Capacity/Load Q (kg)

STILL Rear access

STILL Rear access

Electric

Electric

Ride-on standing

Ride-on standing

2200

2400

Load centre of gravity

c (mm)

600

600

Load distance

x (mm)

1023

1005

Wheelbase

y (mm)

1617

1599

Tare (with battery, trog 113)

kg

1120

1120

Load per axle with load (driver/load)

kg

1320/1800

1320/1800

Load per axle without load (driver/load)

kg

908/212

908/212

V

V

mm

Ø250 x 100

Ø250 x 100

mm mm

Ø85 x 80 2x ø 140 x 54

Ø85 x 80 2x ø 140 x 54

1x -2/4

1x -2/4

Tyres, superelastics (SE), pneumatics (L), Vulkollan (V) Wheel sizes (driver side) Wheel sizes (load side) Stabiliser wheels (sizes) Wheels (x = drive wheels), number (driver/load) Front track

b 10 (mm)

470

470

Rear track

b11(mm)

388

388

Lift height

h3(mm) h7(mm)

130 200

130 200

Platform height Fork height

h13(mm)

85

85

Tiller height (min/max) Total length Length, drive section

h14(mm) l1 (mm) l2 (mm)

1030 24051) 12151)

1030 24051) 12151)

Overall width

b1(mm)

720

720

Fork arm sizes

s/e/l (mm

55/172/1190

61/172/1190

1) With battery boot 600 Ah: + 85 mm 50158070901 [EN]

-15

External distance between the forks

b5(mm)

560

560

Ground clearance

m2(mm) Ast (mm)

30 26151)

30 26151)

Wa (mm)

22381)

22201)

Width of pallet aisle 800 x 1200 long Turning radius

1) With battery boot 600 Ah: + 85 mm

Speed of travel with/without load

km/h

10/12

9/12

Lift speed with/without load

m/s

2.1/1.7

2.2/1.7

Lowering speed with/without load

m/s

1.7/2.9

1.5/2.9

Slope with/without load Acceleration time (after 10m) (with/without load) Service braking

%

15/15

15/15

s

-

-

electromagnetic

electromagnetic

Travel motor, capacity S2 = 60 min

kW

3.0

3.0

2.2

2.2

IEC 254 - 2;B

IEC 254 - 2;B

24/450

24/450

410

410

-

-

AC controller

AC controller

68.5

68.5

Lift motor , capacity S3 = 15% kW Battery depending on DIN 43531/35/36 A, B C, not Battery voltage, rated capacity C5 V/Ah Battery weight (depending on supplier) kg (+/- 5%) Energy consumption depending on VDI cycle kWh/h

Speed control Noise level, for operator s ears

-16

dB (A)

50158070901 [EN]

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

10.9

12.9

8.8

10.9

12.9

M3 x 0.5

1.3

1.9

2.3

-

-

-

M4 x 0.7

3

4.5

5

-

-

-

MS x 0.8

6

8.5

10

-

-

-

M6 x 1

10

15

17.5

9

13

15.5

M8 x 1.25

25

36

42

22

32

37

M10 x 1.5

48

71

83

42

63

73

M12 x 1.75

84

123

144

74

108

126

M14 x 2

133

195

229

116

171

201

M16 x 2

206

302

354

181

264

309

DIN 7984 DIN 6912 8.8

10.9

12.9

M3 x 0.5

1

1.35

1.6

8.8 -

10.9 -

12.9 -

M4 x 0.7

2.1

3

3.5

-

-

-

M5 x 0.8

4.2

6

7

-

-

-

M6 x 1

7

10

12.5

6

8.8

11

M8 x 1.25

17.5

24.5

30

15.5

22

27

M10 x 1.5

34.5

49

59

30

43

52

M12 x 1.75

60

84

101

53

74

89

M14 x 2

95

137

161

-

-

-

M16 x 2

147

210

252

129

185

222

50158070901 [EN]

-17

Verbus-Ripp cl.100 -

10.9

-

-

10.9

-

M6 x 1

-

15

-

-

13.6

-

M8 x 1.25

-

37

-

-

33

-

M10 x 1.5

-

73

-

-

65

-

M12 x 1.75

-

-

-

127 -

-

M14 x 2

-

-

111 -

-

M16 x 2

-

311

-

-

272

-

-

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

DIN 7991 cl.10.9 -

10.9

-

-

10.9

-

M6 x 1

-

11

-

-

9.5

-

M8 x 1.25

-

28

-

-

25

-

M10 x 1.5

-

56

-

-

50

-

M12 x 1.75

-

96

-

-

85

-

M14 x 2

-

156

-

-

137

-

M16 x 2

-

240

-

-

211

-

-18

50158070901 [EN]

ULS / ISO 7380 ULF -

10.9

-

-

10.9

-

M6 x 1

-

11

-

-

10

-

M8 x 1.25

-

27

-

-

25

-

M10 x 1.5

-

52

-

-

48

-

M12 x 1.75

-

100

-

-

90

-

DIN 7500

cannot be used for safety torques 10.9

M6 x 1

10

M8 x 1.25

24

M10 x 1.5

48

M12 x 1.75

83

M14 x 2

-

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

e.g. : ECO SYN

50158070901 [EN]

-19

cannot be used for safety torques

D 2.5

0.8

D3

1.4

D 3.5

2

D4

3

D5

5.5

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

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

DIN 74361-2 (form G)

DIN 74361-2 (form A)

8.8

10.9

-

M12 x 1.5

83

125

M14 x 1.5

135

210

45 H

-20

M6 x 1 5

8.8

10.9

-

-

83

125

-

-

135

210

-

M14 x 2

M16 x 2

63

90

M8 x 1.25 M10 x 1.25 M12 x 1.75 10

20

50158070901 [EN]

45

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

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

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

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

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

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

50158070901 [EN]

-21

Do not park the truck on slopes or, if this is necessary, make sure it is safe with chocks.

Lower the forks (1) to the ground.

Never leave the truck with the load in the raised position.

Lock the emergency stop (2).

When the truck is left alone with the electronic control powered up, this automatically powers down the truck after a delay of about 15 min.

To start work with the truck again, entering the user code is again necessary.

-22

50158070901 [EN]

Lock the emergency stop (2).

Open the battery compartment (See ter "Changing the battery", P. 60-10.

Chap-

Unplug the battery connector.

Proceed in reverse order.

Never perform any manipulation when the truck is switched on.

50158070901 [EN]

-23

To lift up the truck, its sub-assemblies or the additional equipment, it is necessary to attach the lifting devices, in the locations provided for this only. For lifting, take appropriate measures (blocks, pieces of wood) to prevent any slipping or tipping over.

Some maintenance work requires the truck to be lifted and placed on blocks.

Always make sure: To use a jack, a hoist and hooks with suf cient capacity. For the weight, see the truck data plate.

That the truck is placed on at ground and it cannot move or fall back.

Before lifting the truck disconnect the battery.

Place the truck with its fork against the wall.

Run your hand under the chassis on the platform to locate the slot (1) where the jack can be placed securely.

Place the jack in the slot (1).

Lift up the truck until the wheels are no longer in contact with the ground.

Make the truck safe with blocks.

-24

50158070901 [EN]

Attach a sling to each location indicated by a hook symbol (1).

Lift the truck.

Make the truck safe with blocks.

No-one should be under a raised load.

It is strictly prohibited to sling the truck by the tiller or other points not designed for this.

Wedge battens between the chassis and slings to prevent damage.

50158070901 [EN]

-25

-26

50158070901 [EN]

a

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

For safety reasons, place wooden blocks under the chassis, in this way preventing any untimely movement of the truck.

Adhere to the following information for the use of the connecting leads:

50158070901 [EN]

-1

To connect to the truck, use the "Can peak". (Ref. : 8430163)

The following cable is necessary (Ref. : 8392452)

-2

50158070901 [EN]

The following testers and tools must be available for the performance of the tests and the possibly required remedy: Service case METRISO 500D isolation resistance tester

STILL 149 544

Gossen-Metrawatt

8392452 8430163 0 143 920

Beckmann

LCD multimeter Metra Hit Leads, pair, Metra Hit

0 158 061

Gossen-Metrawatt

0 146 344

Gossen-Metrawatt

Leads, pair

0 143 425

Leads Clip-on ammeter (600 A)

Alligator clips, pair

143 427

Test probes, pair

0 143 426

Extra-length test clips, pair

0 143 424 1675079 8052115 144 087

Desoldering tool Crimping tool

(France) AMP

A knowledge of how to use the meters and tools is assumed. Always follow the instructions of the manufacturer in each case.

Check the batteries of the test equipment before beginning the checks and trials. If needed, replace or recharge the batteries.

50158070901 [EN]

-3

Ident. No. : 172359

The special tool "Can peak" (Ident No.: 8430163) must be used.

-4

50158070901 [EN]

The following cable is also required (Ident No.: 8392452)

The following cable must be used and connected to the service case. Set the switch for using the CAN box. For downloads the version in the CAN box must be higher than 1.24.

(Ident. No.: 0 143 920)

50158070901 [EN]

-5

(Ident. No.: 0 158 031)

(Ident. No.: 146 344)

(Ident. No.: 143 425)

(Ident. No.: 143 427)

(Ident. No.: 143 426)

-6

50158070901 [EN]

(Ident. No.: 143 424)

50158070901 [EN]

-7

The "CAN-bus" network of the truck links: The cockpit (1) which powers and establishes communication The variable speed traction (2) The variable speed steering (3) Using this communication bus, the components concerned exchange information permanently in the form of a transfer" of data telegrams."

Transmission speed is 250 Kbits/sec.

Traction setting

Defaults The variable speed traction and steering make up the start and end of the bus. These extremities must be tted with what is called the "bus terminal resistance" (120 ). The cockpit is in high impedance (about 40 k ).

Thus it is possible to check, using just a measurement of the resistance (see gure), if the bus is physically correct.

Measurement:

Hydraulic setting

60 :

Horn setting

120 :

Information from variable speed traction to the cockpit: Defaults Hour meter Battery charge status Information from variable speed steering to the cockpit:

-8

40 k : In nity:

The network is correct.

The variable speed steering or traction is not connected.

The variable speed steering and traction are not connected.

No unit on the network.

The elements of the bus are linked using 4 wires: 2 wires for the 24V supply 2 wires for the signals CAN_H (CAN-High) and CAN_L (CAN-Low)

50158070901 [EN]

Electrical supply for switching on Supply to the cockpit and the CAN-bus by connection of the battery plug (red marking)

Supply/activation of speed changers (blue marking)

Entry of code (2)

50158070901 [EN]

-9

Return of information coming from speed changers (OK or not OK) (4) If the changers are OK, activation of the internal transistor of the cockpit, then activation

-10

of the safety relays inside the variable speed steering. Locking of contactor K1 (green marking).

50158070901 [EN]

Diagnosis of breakdowns is made by software allowing different types of intervention to be performed, for which it is necessary to view or to change certain settings.

The connection between the truck and the laptop is made using the following leads: Ref. : 8392452 and 8430163 ( Chapter "Diagnostic equipment", P. 02- 3 ) on the CAN-bus plug (see photo).

50158070901 [EN]

-11

Before starting the software, the laptop must be connected to the truck with the leads.

Start "STEDS".

Click on the "Diagnosis" tab.

Choose the type of truck and double click (automatic launch of the diagnosis).

Then the following window appears: Enter the code that has been sent to you ("22113").

The software makes it possible to perform the following operations: Display the list of faults.

Proceed to a trial of the electric steering.

Change the settings.

View the various values.

Load, save or print the con guration.

-12

50158070901 [EN]

In the software, there are 3 main menus: "F2:Diagnosis": menu of tests (steering trial) and faults / start menu.

"F3:Adjustment": settings menu for the truck (con guration of the truck).

"F4:Screen": measurement menu (test of inputs/outputs).

To select them, use the short-cut keys (respectively F2, F3, F4) or click the buttons.

Menus F3 and F4 contain several pages can themselves contain sub-pages.

These different functions are available on the welcome screen below: "F2:Diagnosis": menu of tests and faults (steering trial).

Steering trial. twice:

must be performed

Perform the trial with the truck on blocks for pre-setting.

Perform the trial again but this time on the ground for ne adjustment.

The electric steering trial is performed in 5 stages: Adjustment of the wheelbase.

Reading of the cockpit potentiometer value in a "straight line".

Reading of the cockpit potentiometer value at the left limit Adjustment of the position of the wheel in a straight line.

Adjustment of the position of the wheel at the left limit.

To start the electric steering trial: Select "Electric steering trial".

Click on Enter .

50158070901 [EN]

-13

When asked "Start the electric steering trial ?" select "Yes".

Click on Enter .

Then follow, perform and respond to the information stage by stage.

In the window at the bottom left of the screen: Select "All the fault codes".

Click on Enter .

Click the link "ft_frn.htm".

-14

50158070901 [EN]

The fault list is displayed:

To view or change the truck settings: Click on F3:Adjustment .

Click on the screen tab corresponding to the required page.

The following window is displayed (making it possible to view the list of faults compiled on the truck cockpit in the diagnosis):

To access certain pages, use the arrows .

The small yellow circles situated beside the adjustments mean that the standard factory settings have been changed.

Click on ^F4:Load to load all the truck settings to which you are connected (see: "Handling of loading/saving").

Important information and help relating to settings are available in the white boxes.

50158070901 [EN]

-15

The different leaves of the "Screen" menu make it possible to test the various inputs/outputs of the CAN-bus.

In this menu the various values are displayed on the screen: the status of various inputs/outputs of the controllers and the cockpit values measured such as voltages, intensities, temperatures to test the different control units To access this screen: Click on F4:Screen .

Click on the screen tab corresponding to the required page.

To stop the measurements, click on ^F3: STOP .

To restart the measurements, click on ^F3: Measure .

Important information and help relating to the measurements are available in the white boxes.

The values are displayed with a range of +/- 10%

-16

50158070901 [EN]

approximately. To perform more precise measurements, it is necessary to use an appropriate, calibrated measuring instrument.

Respectively these functions make it possible to: Load data in the menu F3 "Adjustment", from data contained in the truck from a text con guration le (format ptx) or binary le

Save the values contained in the menu F3 "Adjustment" in the truck in a text con guration le (format ptx) or binary f ).

Once the type of backup is chosen, it is possible to choose data that you want to save by making a selection in the following window:

Print the settings.

Navigation short-cuts (rapid access to a diagnosis screen).

Reloading of settings because of faults on one or more pages of the truck undergoing diagnosis.

To see if there is asymmetry in the electric steering: Select F4:Screen .

Select the "Electric steering "tab.

50158070901 [EN]

-17

Select "Speed reduction on bends".

Perform the various tests to see if the truck has asymmetry (the square turns green when curve reduction clicks in).

If the square turns green well before or well after the cockpit has reached an angle of 17° (for activation) and 15° (for deactivation), then there is asymmetry in the electric steering.

In this case, perform the electric steering trial again.

-18

50158070901 [EN]

a

The traction motor is a triphase asynchronous motor with a short-circuit rotor (or "squirrel cage").

Its excitation is provided by a traction controller which, using battery voltage, generates an alternative, triphase sinusoidal voltage.

By cutting the magnetic eld lines, the triphase rotary stator eld generates a voltage in the short-circuit rotor (1) (voltage induction principle).

This induced voltage is short-circuited by the rings which are themselves short-circuited (2).

The resulting current in turn generates a rotor magnetic eld. The rotor eld is out of phase with the stator eld. The stator eld speed is greater than that of the rotor eld,hence the name: asynchronous. This speed difference is called "slip".

1044_100-001

This operating principle suppresses the brushes and, thus, the impurities getting into the interior of the motor following use of the brushes.

A change in the speed of the stator eld makes it possible in this way to adjust the rotation speed of the motor, whilst a change in voltage make it possible to adjust the current indirectly and also the turning torque.

Recording of the rotation speed is provide by a speed sensor incorporated into the motor and directly connected to the traction controller.

The motor also incorporates a temperature sensor (in the stator coil). This sensor is directly connected to the traction control.

0148_100-001

50158070901 [EN]

-1

-2

50158070901 [EN]

a

Manufacturer Type of motor

AF 103 L1

Juli

Operating voltage

24 V

Strength of current 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

If the traction motor is removed, the truck can no longer be braked.

For this reason block the truck up on squared timbers to secure it against rolling.

Park the truck and disconnect the battery connector (see Chapter "Safety Regulations", P. 00-22).

Use squared timbers to prevent the truck from rolling.

Remove the motor cover (see tor covers", P. 31- 4 ).

Chapter "Mo-

Remove the instrument panel (see Chapter "Instrument panel", P. 31- 6 ) without removing the cockpit and horn button: To do this, only the leads to the sockets connected with the cockpit (D and E) and the plugs for the horn need to be disconnected.

50158070901 [EN]

-1

Mark the traction motor leads (U, V, W) and disconnect them.

Disconnect these plugs: X 12

Speed sensor (4-pin)

X 13

Temperature sensor (2-pin)

X 14

Electromagnetic brake (2-pin)

The arrangement of the plugs may not be the one shown in the gure. Other arrangements are possible.

Remove the cable ties.

Remove the electromagnetic brake Chapter "Removal and installation", P. 49- 4 .

Remove the 8 socket head screws with a socket wrench using a 30 cm extension and a exible socket to get between the ribs of the motor casing.

-2

50158070901 [EN]

Screw an eyebolt (diameter M8) into the traction motor.

Using the eyebolt, attach a lifting sling to the traction motor.

Lift out the traction motor upwards.

Proceed in the reverse order of removal.

The following conditions must always be ful lled before installation: Clean the mating face of the motor and the reduction gear.

Do not contaminate the gearbox oil.

Align the traction wheel to the longitudinal axis of the vehicle.

Check the hydraulic oil level.

If the oil level is correct, about 1/3 of the pinion (1) (helical teeth) should be in the oil.

Do not ll too much oil as this could damage the seals and possibly lead to overheating.

50158070901 [EN]

-3

Position the traction motor correctly on the reduction gear (terminals U, V, W facing the steering motor), taking care not to damage the seal (2).

The motor must be guided on to the reduction gear , during installation to avoid damage to the shaft splines (else danger of louder operating noises).

-4

50158070901 [EN]

The speed sensor (1) consists of 2 Hall sensors installed with a slight offset (detects the interstices of a gear wheel on the rotor of the motor).

There are therefore 2 staggered signals (A and B).

The traction controller processes the anks generated by these two signals.

Supply voltage : 10 V Pulses per revolution: 64 Temperature: -40 °C to +160 °C

0148_112-002

50158070901 [EN]

-5

4-pin plug: X 12 X12-1 (A9) : 10 V X12-3 (A10) : earth X12-2 (A22) and X12-4 (A8): signals A and B

The traction controller needs the information from the speed sensor for the rpm control of the traction motor. If no signal reaches the controller, the motor is only minimally excited, ie the truck moves only very slowly (<0.5 km/h) and has no torque.

This sensor is monitored by the traction controller and in case of failure it generates a fault code which can be shown on the diagnostic unit. It is also possible to indicate the speed and frequency of the traction motor with the unit.

Park the truck and disconnect the battery connector (see Chapter "Safety Regulations", P. 00-22).

Remove the motor cover (see tor covers", P. 31- 4 ).

Chapter "Mo-

Disconnect plug X12.

The arrangement of the plugs may not be the one shown in the gure. Other arrangements are possible.

Remove the screws fastening sensor to the motor.

Pull the sensor off.

-6

50158070901 [EN]

The temperature sensor (2) functions somewhat like a variable resistor (increase in temperature = increase in resistance).

This sensor is connected directly to the traction controller.

The temperature sensor is only installed in the rst trucks delivered.

2-pin SAAB plug: X 13 X13-1 (A10) : earth X13-2 (A12) : signal

Disconnect plug X13.

The pin arrangement of the connectors may not be the one shown in the gure. Other arrangements are possible.

Measure the resistance of the temperature sensor between X13- 1 and X13- 2.

Measure the temperature on the motor casing.

The readings must correspond to the values in the table below with a deviation of +/- 20 .

It is possible to indicate the temperatures with the diagnostic unit.

1000

1403

1019

1422

1039

1441

1058

1460

1077

1479

1097

1498

1116

1517

1136

1535

1155

1554

50158070901 [EN]

-7

1174

1573

1193

1591

1213

1610

1232

1629

1251

1647

1270

1666

1289

1684

1308

1703

1327

1721

1347

1740

1366

1756

1385

-8

50158070901 [EN]

a

Designation of drive unit Mounting on the frame Mounting of gearbox on motor Gear oil Oil quantity Gear ratio

5.53.315.1 (Kordel) Cheese head screw 912 M 10 X 30 Torque = 42 Nm Cheese head screw 912 M 6 X 20 Torque = 40 Nm SAE 85W90; API GL 4 1.5 L 1 : 19.67

50158070901 [EN]

-1

Park the truck and remove the battery plug (See Chapter "Safety Regulations", P. 00-22).

Chock the truck in order to prevent it moving.

Take off the motor covers (See tor covers", P. 31- 4 ).

Remove the wheel (See Wheel", P. 46- 1 ).

Chapter "Mo-

Chapter "Traction

Lift and chock the truck at a height of 230mm off the ground.

Remove the traction motor (See Chapter "Removal and installation ", P. 11- 1 ).

Drain the reduction gear. Take care to remove the ne metallic particles on the magnetic drain plug (2).

Risk of burns!

The oil may be very hot!

2

1044_223-002

-2

50158070901 [EN]

Replace the two screws (3) linking the reduction gear to the turret bearing by two threaded rings.

Using a strap and a hoist secure the reduction gear .

Undo the eight xing nuts of the reduction gear (4).

Lower the reduction gear carefully to the oor, then take it out from above.

For reassembly proceed in reverse order.

Put Loctite 242 on the eight xing screws (4) of the reduction gear and tighten them with 42 Nm torque.

50158070901 [EN]

-3

Fill up with gearbox oil.

If the level is correct, the pin (5) (helical teeth) must be immersed in oil over 1/3 of its height approximately.

Avoid over lling, because the impermeability seals risk deterioration and it may no longer be possible to maintain the operating temperature within limits.

Do not ll the reduction gear too full.

-4

50158070901 [EN]

0148_230-001

50158070901 [EN]

-5

Park the truck and disconnect the battery connector (see Chapter "Safety Regulations", P. 00-22).

Lift the truck with a hoist and secure with a squared timbers (see Chapter "Safety Regulations", P. 00-22).

Remove the motor cover (see tor covers", P. 31- 4 ).

Chapter "Mo-

Remove the instrument panel (see Chapter "Instrument panel", P. 31- 6 ) without removing the cockpit and horn button: To do this, only the leads to the sockets connected with the cockpit (D and E) and the plugs for the horn need to be disconnected.

Remove the lift cylinder (see cylinder", P. 80- 2 ).

Chapter "Lifting

Mark the traction motor leads (U, V, W) and disconnect them.

Disconnect these plugs: X12 Speed sensor (4-pin) X13 Temperature sensor (2-pin) X14 Electromagnetic brake (2-pin)

The arrangement of the plugs may not be the one shown in the gure. Other arrangements are possible.

-6

50158070901 [EN]

Disconnect the electric cables at the terminals of the steering motor.

A1 Red D1 Blue D2 White

Screw an eyebolt (diameter M8) into the traction motor.

Secure the drive unit with a sling attached to the eyebolt.

Remove the 2 socket head screws (1) on the traction motor mounting.

Remove the other 6 socket head screws using a ratchet wrench with a 30cm extension.

For some screws, rst install the extension and then the socket.

Tilt the unit slightly back and then lift it out carefully.

50158070901 [EN]

-7

Deposit the power unit on the ground and brace it to prevent it from tilting over.

Re tting is a reversal of removal.

-8

50158070901 [EN]

a

The chassis of the trucks are made using mechanised welding.

Rear access chassis.

Side access chassis.

50158070901 [EN]

-1

Fork chassis.

-2

50158070901 [EN]

1 2 3 4 5

Battery cover Instrument panel Motor cover Cushion Back rest

50158070901 [EN]

-3

Disconnect the battery plug (4) (See ter "Safety Regulations", P. 00-22).

Chap-

Remove the 2 nuts (1).

Take out the 2 Chc screws (2) + washers.

Do not damage the electric cables.

0148_311-005

Tip the top of the cover towards the rear and take it off.

Proceed in reverse order.

-4

50158070901 [EN]

Open the battery compartment.

Disconnect the battery plug (4) (See ter "Safety Regulations", P. 00-22).

Chap-

It is recommended that batteries with polar terminals or unprotected connections be covered with a rubber mat.

Remove the 2 Chc screws (1) + washers.

Remove the cover.

Proceed in reverse order.

0148_311-007

For the side access platform: Remove the 3 nuts (3).

Lift the backrest in order to take out the locking bolts.

0148_311-008

50158070901 [EN]

-5

For the rear access platform: Remove the 4 nuts (4).

Lift the backrests in order to take out the locking bolts.

Proceed in reverse order.

0148_311-009

Disconnect the battery plug (4) (See ter "Safety Regulations", P. 00-22).

Take off the motor covers (See tor covers", P. 31- 4 ).

Chap-

Chapter "Mo-

Dismantle the cockpit (See Chapter "Removal and installation", P. 50-12).

Undo the 2 Chc screws on the top of each side of the cover.

Block the rotation of the shaft of the emergency stop button with a screwdriver.

Unscrew the red part of the emergency stop button.

-6

50158070901 [EN]

Undo the Chc screw of the horn holder (horn).

Put down the horn assembly.

Undo the remaining 3 Chc screws holding the instrument panel. Start with the 1st screw.

Continue with the 2nd screw.

Then undo the 3rd screw.

50158070901 [EN]

-7

Disconnect the SAAB (G) type connector .

G: Connector for the connection of the "CAN bus" to the CAN socket on the instrument panel.

Remove the instrument panel.

Proceed in reverse order.

-8

50158070901 [EN]

a

DC current with 2 windings

Motor Manufacturer Type

Schabmüller R 100/0.15 150 W IMS reinforced planetary gear

Reduction gear

Reduction ratio 18 : 1

Reduction ratio of gear ring to pinion

1 : 4.15

Heat class

F

Protection class and S3

IP20/S3 78 %

Resistance of windings

Armature: 265.5 m ± 3 % Field winding: 325.4 m ± 3 % Inductivity: 8 mH

Actual value potentiometer

Potentiometer connected by 2 with 22 k

Desired value potentiometer

Potentiometer connected by 2 with 22 k

To optimise driving comfort and safety, this vehicle is equipped,in series, with a speed control device for cornering. This device is responsible for reducing speed when a steering lock angle of 17° (for activation) is reached and of 15° (for deactivation).

The steering system has 2 sensors: Potentiometer for steering setting (setting value) Potentiometer for steering indication (true value)

See Chapter "Variable speed steering", P. 64- 6 for the operating principle for the steering power assistance.

50158070901 [EN]

-1

F3 F5 G1 K6

-2

Control fuse Steering fuse Battery Steering relay

M3 P3 P4

Power steering motor Steering setting potentiometer Steering recopy potentiometer

50158070901 [EN]

Park the truck and remove the battery plug (See Chapter "Safety Regulations", P. 00-22).

Chock the truck to prevent it moving.

Take off the motor covers (See tor covers", P. 31- 4 ).

Chapter "Mo-

Disconnect the electric cables to the steering motor terminals : A1 red D1 blue D2 white

Take off the circlips which hold the steering pinion (4) located under the truck.

Remove the pinion (4).

50158070901 [EN]

-3

Undo the 4 xing screws of the power steering motor (5) located underneath.

Take out the power steering motor.

Proceed in reverse order.

-4

50158070901 [EN]

The desired value potentiometer is integrated in the cockpit (in the same way as the desired value potentiometer of the travel drive). This potentiometer is therefore not accessible (see Chapter "Wiring diagram", P. 60- 1 ). It consists of two independent, identical tracks (potentiometers) arranged crosswise and actuated by the rotation of the cockpit. They are supplied with a voltage of less than 10 V. The characteristics of this double potentiometer are shown on the diagram to the right.

A B Pp1 Pp2

Operating voltage Steering angle Potentiometer contact track 1 Potentiometer contact track 2

4-pin SAAB plug: E E1 : 0V (earth) E2 : Wiper 1 (Pp1) E3 : Wiper 2 (Pp2) E 4 : 10V Operating range : between 0.15V and 9.85V.

It is possible to indicate the voltages with the diagnostic unit.

Disconnect the battery connector (see Chapter "Safety Regulations", P. 00-22).

Disconnect SAAB plug E. Loosen the cable fastening screws (1).

Remove the screws (2).

50158070901 [EN]

-5

Remove the potentiometer.

Re tting is a reversal of removal.

-6

50158070901 [EN]

0148_421-007

50158070901 [EN]

-7

The recopy potentiometer consists of two individual, identical tracks (potentiometers) mounted as a cross and operated by the rotation of the cockpit (See Chapter "Wiring diagram", P. 60- 1 ).

They have a 10V power supply. The behaviour of the double track potentiometer is described in the diagram opposite.

A -B Pp1: Pp2:

Voltage Angle Track 1 of the potentiometer Track 2 of the potentiometer

4-pole SAAB connector: L L1: 0V (Earth) L2: Cursor 2 (Pp2) L3: 10V L4: Cursor 1 (Pp1) Operating range: between 0.15V and 9.85V.

When the cockpit is released (position of setting potentiometer 0° and thus right wheel), the two tracks of the recopy potentiometer (Pp1 and Pp2) must con rm this rule: The difference in potential between Pp1 and Pp2 must be less than +/- 400 mV. If this condition is not veri ed, please carry out the adjustment at the centre point of the recopy potentiometer (See Chapter "Dismantling and reassembling - recopy potentiometer", P. 42- 8 ).

It is possible to view the voltages on the diagnostic tool.

Park the truck and remove the battery plug (See Chapter "Safety Regulations", P. 00-22).

-8

50158070901 [EN]

Chock the truck to prevent it moving.

Dismantle the motor covers (See ter "Motor covers", P. 31- 4 ).

Chap-

Disconnect the connector (L).

L: Recopy potentiometer connector.

Undo the lock nut (2).

Undo the Chc screw (3) of the holder (4).

Undo the lock nut (6).

Undo the screw without a hexagonal socket head (7) of the drive pinion (8).

Take out the potentiometer and its holder.

Undo the screw without hexagonal socket head (9).

Undo the lock nut (10).

Remove the drive pinion.

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

Reassemble the drive pinion if necessary.

50158070901 [EN]

-9

Place a multimeter, con gured as an ohm meter, on the following terminals of the potentiometer in order to adjust it at : prong 4 and prong 1: 850

± 10

prong 4 and prong 3: 850

± 10

Operate the potentiometer manually so as to obtain the above values.

Try out the steering via the diagnostic tool after adjustment at the mid-point.

Fix the potentiometer in the drive pinion (8) so that the potentiometer remains at the mid-point.

Tighten the screw without hexagonal socket head (7) of the drive pinion (8) on the potentiometer shaft.

Tighten the lock nut (6).

Put in the Chc screw (3) of the holder (4).

Tighten the lock nut (2).

Connect the connector (L) of the potentiometer.

Put on the motor covers (See covers", P. 31- 4 ).

Chapter "Motor

Connect the battery plug.

Dismantle the potentiometer (See previous paragraph)

-10

50158070901 [EN]

Remove the drive pinion (1) (See previous paragraph).

Take the circlips (2) out of the shaft.

Take the pinion (3) out with a suitable ring (4).

Remove the circlips.

50158070901 [EN]

-11

Remove the bearing, taking it out from above with a suitable ring.

Proceed in reverse order.

-12

50158070901 [EN]

a

Sizes of a new drive wheel: 250mm x 100mm The drive wheel must be replaced if: the tyre tread is badly damaged or out-of-round the tyre diameters have reduced by more than 10%.

Type of rubber: VULKOLLAN

Turning the wheels when stopped increases the wear on the drive wheel! This is why any excessive turning of the wheel when stopped must be avoided.

Park the truck and remove the battery plug (See Chapter "Safety Regulations", P. 00-22).

Chock the truck in order to prevent it moving.

Dismantle the motor covers (See ter "Motor covers", P. 31- 4 ).

Chap-

Loosen the wheel nuts.

Put the truck on blocks..

Turn the drive wheel so as to be able to loosen the 5 wheel nuts (2).

2

Unscrew the wheel nuts (2).

Remove the drive wheel.

Before putting on the drive wheel, clean its bearing surface and make sure it is in perfect condition.

Put the drive wheel in place.

Screw the 5 nuts up by hand.

Put the truck on the ground.

Tighten the nuts (2) with a torque of 140 Nm. Dismantle the motor covers (See ter "Motor covers", P. 31- 4 ).

Chap-

1044_462-005

Remove the chocks.

Unlock the emergency stop.

50158070901 [EN]

-1

Dimensions of a new roller: 150 x 50 mm

Park the truck on solid, level ground.

Lift and chock the truck to release the support rollers from the ground.

Lift the truck suf ciently to allow the rollers to be taken out from underneath the truck.

Remove the motor cover (see tor covers", P. 31- 4 ).

Chapter "Mo-

Undo the 4 screws.

Remove the stabiliser rollers from underneath the truck.

-2

50158070901 [EN]

Use a exible 2.5 mm 2 copper wire (length 1.2 m) and two M12 nuts.

Pass the wire diagonally through two of the screw access holes in the chassis.

Remove the two ends of the wire under the chassis, then insert them diagonally into the holes in the wheel. Attach an M12 nut at each end of the wire.

50158070901 [EN]

-3

Pull the wheel upwards from the inside and attach it to the chassis using two screws.

Remove the wire and then put the two missing screws in place.

Correct installation

Incorrect installation The stabilising wheel (1) is made up of two rollers, the treads (2) of which are transported in relation to the rim (3). When reassembling, take care to t the rollers in the right position; if they are facing the wrong direction, dimension "a" will be too large and will prevent the stabilising wheel from turning correctly in the chassis.

After assembling the roller, it is necessary to check its operation when the direction of travel is changed; the stabiliser roller should pivot 180° after a short distance.

-4

50158070901 [EN]

0148_465-001

Raise the forks to their maximum height.

50158070901 [EN]

-5

Disconnect the battery connector (see Chapter "Safety Regulations", P. 00-22).

Loosen the fastening screws of the load wheels (1).

Raise the forks with a car jack until the load wheels no longer touch the ground.

Secure the truck with squared timbers (2).

Remove the two fastening screws (3).

Renew the load wheels.

Installation is the reverse of removal.

Use clamps to replace the bushings (4). Then drive them out with a blow of the hammer and replace them.

Never grease the bushings (4).

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

-6

50158070901 [EN]

Raise the fork to the maximum position.

Remove the battery plug.

Undo the xing screws of the wheels (1).

Using a jack, lift the fork so that the wheels do not touch the ground.

Make the truck safe with wooden blocks (2).

Remove the two xing screws (3).

Replace the wheels.

For reassembly proceed in reverse order.

To replace the rings (4) use the lifting slings.

Remove them using a jet, then replace them.

Never lubricate the rings (4).

Tighten the two xing (3) screws with a torque of 85 Nm.

50158070901 [EN]

-7

-8

50158070901 [EN]

a

Type:

BFK 457 - 12

Manufacturer Braking torque:

INTORQ 40 Nm

Power consumption of coil at 20°C:

40 W ± 10%

Voltage: Weight:

24 V 4.7 kg

Min air gap:

0.3 mm

Max air gap:

0.8 mm

Wear of brake disc:

Max 0.5 mm

50158070901 [EN]

-1

1

7

a

6 1 2 3 4

5

4

3

Inductor body Brake backing plate Hub Clutch spring

5 6 7 a

Rotor with friction lining Spacer Coil Air gap

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

The clutch springs (4) push the brake backing plate (2) axially against the lining (5) and the lining against the plate xed on the motor.

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 goes back up towards the magnetic section, the air gap (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.)

-2

2

50158070901 [EN]

1044_491-004

Consider checking the air gap (with the brake released)! The air gap of this brake is not adjustable. It is factory installed with an air gap of 0.3mm.

1

Min. air gap : 0.3mm Max. air gap : 0.8mm

0148_491-001

The brake is supplied with power by the safety circuit (D6). The supply voltage comes from the cockpit. If there is no steering error, a relay makes and connects the power. The power is supplied to the traction controller via input A7. If the controller functions properly and no further errors exist, the brake can be released (output A30).

Yes

No

No

Yes

50158070901 [EN]

Interrogating of the travel drive (throttle operated) Emergency isolator button operated or red "safety switch" pressed or 2 seconds after a truck stop without a driving command (throttle released)

-3

SAAB plug, 2-pin: X 14 X14-2 (A31) : controller (0 V) X14-1 (A30) : 24 V

The arrangement of the plugs may not be the one shown in the gure. Other arrangements are possible.

Check the continuity of the cables X14-1 to A30 and X14-2 to A31.

Measure the 24 V voltage between X14-1 and B-.

Measure the resistance of the brake winding.

Resistance of brake winding Nominal

Max.

Min.

10

15

5

It is possible to display the state of the brake with the diagnostic unit.

Under unfavourable conditions the surface can reach a temperature of 130°C. Danger of burns!

Park the truck and disconnect the battery connector (see Chapter "Safety Regulations", P. 00-22).

Use squared timbers to prevent the truck from rolling.

Remove the motor cover (see tor covers", P. 31- 4 ).

Chapter "Mo-

If the brake is removed, the truck can no longer be braked. For this reason block up the truck on squared timbers before removing the brake to prevent it from rolling.

-4

50158070901 [EN]

Disconnect SAAB plug X14 (1) (electric brake).

Remove the three socket head screws (2).

Lift out the electromagnetic brake.

Installation is the reverse of removal.

The three socket head screws (2) are torqued to 9.5 Nm. Check the clearance (see beginning of section).

In case of an electrical fault or when the battery is removed, the brake can be released manually.

To do this, screw in two M6 screws at least 70 mm long into the holes (3) until the brake disc is released.

50158070901 [EN]

-5

-6

50158070901 [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

50158070901 [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

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

-2

50158070901 [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.

50158070901 [EN]

-3

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.

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- 6 Chapter "Adding the master code", P. 50- 5 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.

-4

50158070901 [EN]

1044_505-007

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- 2 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.

50158070901 [EN]

1044_505-010

1044_505-011

4

5

1044_505-009

7

10

-5

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.

-6

9

50158070901 [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.

50158070901 [EN]

1044_505-013

9

-7

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

1044_505-015

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.

10

1044_505-014

11 %

The truck is turned off, the battery is connected.

Push the I button (driving) (5).

1

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

2

123

3

789

456

PRG PRG

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

1044_505-016

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

-8

1044_505-011

50158070901 [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.

50158070901 [EN]

-9

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.

-10

1044_505-013

50158070901 [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.

1044_505-015

1044_505-014

10

11 %

Connector D (SAAB 6 poles): D1: Logic supply (24V) D2: Can-H D3: Can-L D4: GND supply D5: 24V supply D6: Safety supply Connector E (SAAB 4 poles): Potentiometer, electrical steering setting (See Chapter " 42 Steering system", P. 42- 1 ).

The cockpit has an automatic re-starting procedure if there is a fault in the electric steering or the variable speed traction. This is to avoid re-starting using the Digicode if there is a minor problem.

If the fault persists (number of repeats set by the diagnostic software), the default code will be shown on the display.

It is possible to view and set the relative information for the cockpit in the diagnostic tool (Veri cation of control information - Potentiometer for settings for steering, traction, etc.).

50158070901 [EN]

-11

Disconnect the battery connector (see Chapter "Safety Regulations", P. 00-22).

Remove the motor cover (see tor covers", P. 31- 4 ).

Chapter "Mo-

Disconnect the cockpit electrically by separating the SAAB connector (D) and (E) and raise the cover with a small at blade screwdriver.

D : SAAB plug of cockpit (CAN bus, power supply) E : SAAB plug of desired value potentiometer

Remove the three cockpit fastening screws (3).

Remove the cockpit.

Re tting is a reversal of removal.

-12

50158070901 [EN]

When reinstalling the cockpit, make sure that the guide stop (4) is inserted in the slot (5).

After the replacement of the cockpit, the steering must be readjusted with the diagnostic unit.

50158070901 [EN]

-13

-14

50158070901 [EN]

a

50158070901 [EN]

-1

The units listed below are not necessarily assembled on all trucks.

Name A1 A11 A111 A112

Traction controller Battery charger Row of electroluminescent diodes Plug holder

P2

Hydraulic potentiometer

P3

Steering setting potentiometer

P4

Steering recopy potentiometer

P5

Tiller inclination potentiometer Battery discharge and/or hour meter potentiometer

6P20 RC

Heating resistance

Generic names Key or Digicode S1

S7

Emergency stop Presence sensor (dead man s handle) 1 Tiller sensor Height of low lift sensor Presence sensor (dead man s handle) 2 Loading frame height sensor

S8

Anti-foot compression sensor

Control fuse

S9

Push-button unlocking

S10

Speed reduction sensor

F5

Control fuse Steering fuse

S11

Emergency stop

F6

Option fuse

S12

Emergency stop

F7

Option fuse

S13

F8

Option fuse

S14

Fold-up platform sensor Fold-up railing sensor 1

F9

Option fuse

S15

Fold-up railing sensor 2

S16

Emergency stop

Battery

S17

Push-button, forward travel, right

S18

4H1

Warning horn;

S19

H2

Indicator or rotating light

S20

K1

S21

K2

Traction or line contactor Pump contactor

Push-button, forward travel, left Push-button, driving platform lifting Push-button, driving platform lowering Driving platform raising sensor

S22

Lift button, right-hand backrest

K3

Braking relay

S23

K4

Option relay

Lift button, left-hand backrest Lower button, right-hand backrest

K5

Option relay

K6

Steering relay

A2 A3

Control box Steering controller

2A3

Hydraulic module

C1

Capacitor

F1 F2

Traction or line fuse Pump fuse

F3 F4

S2 S3 S4 S5

G1

M1 M2

Traction motor Pump motor

M3

Steering motor

M4

Fan motor

P1

Traction potentiometer

-2

S6

S24 S25 S31

Lower button, left-hand backrest Push-button, reverse travel, right

S33

Push-button, reverse travel, left Button, computer con rmation

S34

Button, computer con rmation

S82

Push button, slow travel

S83

Push button, slow travel

S32

Traction names

50158070901 [EN]

1S2

Forward travel or forward/reverse travel throttle valves Reverse travel throttle valve

1S30

Anti-collision micro-contact shield

1S1

X10

Tiller bundle connector

X11

Various connectors

X12

Various connectors

X13

2S1

Lowering push-button

X15

Various connectors Connector, brake/tiller on-off switch Various connectors

2S2

Lifting push-button

X16

Various connectors

2S80

Push-button, low lift, "lifting"

X17

Various connectors

2S81

Push-button, low lift, "lowering"

X18

Various connectors

X19 X20

Various connectors Connector,tiller case 1

X14

Hydraulic names

Signalling names 4S1

Horn push-button

X21

Connector, tiller case 2

X1

Controller connector Display connector

Y1

Lowering solenoid valve

Y2

X3

Battery connector

Y3

Brake Loading frame solenoid valve

X4

Various connectors

Y4

X5

Various connectors

X6

Y5

X7

Various connectors Negative terminal

X8

Positive terminal

X9

Various connectors

X2

Y6

50158070901 [EN]

Low lift solenoid valve Driving platform raising solenoid valve Solenoid valve, disconnection of hydraulic accumulator

-3

AC frequency inverter

Electronic motor controller

3-phase inverter

Traction motor controller Pump motor controller

1-quadrant speed control

Rated voltage

24 V

Current limit for the traction motor Pump motor

300 A 125 A Adjustable with driving programs

Speed range

Max. speed: 12 km/h Adjustable with driving programs

Speed reduction Contactor Relay

K1

24 V (30

)

K6

24 V (winding 330

)

Fuses - Main circuit fuses

F1, F2 (400 A)

- Control circuit fuses

F3, F4 (7.5 A) F5 (20 A)

Traction battery

G1

24 V 450 Ah

Insulation resistance - Electrical system - Electric motors - Traction battery

1000

/V

G1

Protection class - Electrical system - Impulse control - Electric motors

-4

IP 64 Traction motor Pump motor

50158070901 [EN]

IP 22 IP 54

1 2 3 4 5 6 7 8 9 10

Horn Traction controller Contactor, K1 (traction+pump) Fuse holder Fuse, F1 (traction+pump) Pump Y1 solenoid valve Battery locking/unlocking handle Battery socket Battery

11 12 13 14 15 16 17 18 19

50158070901 [EN]

Electromagnetic brake Drive motor Steering recopy potentiometer Steering motor Floor mat (presence detection) Cockpit Steering controller Contactor, K6 (Steering motor) Emergency stop button

-5

The main function of the emergency stop button is the quick and easy stopping of the truck in case of errors, malfunctions or safety problems. It disconnects the power module and the power supply of the cockpit logic via the switch below.

Park the truck and disconnect the battery connector (see Chapter "Safety Regulations", P. 00-22).

Remove the motor cover (see tor covers", P. 31- 4 ).

Chapter "Mo-

Disconnect the 2 leads (1) and (2).

(A) : Red lead (B) : 2 brown leads.

Remove the instrument panel / electrics panel (see Chapter "Instrument panel", P. 31- 6 ).

Do not remove the cockpit and horn hereby.

Only disconnect the connections at the cockpit (D and E) and the plug at the horn.

Unscrew the 2 countersunk screws (3).

Re tting is a reversal of removal.

-6

50158070901 [EN]

1 2 3 4

Line fuse (400 A) F3 (7.5 A) F43 (7.5 A) F5 (20 A)

Like the brake, the main line contactor is supplied with power via the safety circuit (see Chapter "Electrical system", P. 49- 3 ). The main line contactor K1 is activated (closes) upon power-up after the validation of the driver s code.

The contactor opens in the event of errors, pushing of the "stop" button or when the vehicle is stopped.

Controller A17 : Controller (0 V) A30 : 24 V

Check the brake for continuity of leads K1A1 to A30 and K1A2 to A31.

Check for the presence of 24 V tension between A30 and B-.

Check the impedance of the coil.

Coil impedance Rated

Max

Min

44

60

35

50158070901 [EN]

-7

The relevant contactor information can be displayed with the diagnostic unit.

Park the truck and disconnect the battery connector (see Chapter "Safety Regulations", P. 00-22).

Remove the motor cover (see tor covers", P. 31- 4 ).

Chapter "Mo-

Unscrew the nuts (1) and disconnect the white cable to contactor.

Unscrew nut (2) in order to be able to move the fuse.

Disconnect the 2 connectors (3) (contactor control).

A : 2 brown leads.

B : 1 brown lead.

Unscrew the socket head screws (4).

Remove the contactor.

Re tting is a reversal of removal.

-8

50158070901 [EN]

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:

50158070901 [EN]

-9

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

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

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

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

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

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

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

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.

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).

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

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

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.

Changing the battery must only be done by specially trained personnel, following the instructions of the manufacturers of the battery, the battery

-10

50158070901 [EN]

charger and the truck. Follow the battery maintenance instructions.

Do not smoke or use a naked ame when handling batteries.

There must be no combustible material or tools that produce sparks in the area within a minimum radius of 2m around the truck on charge and the battery charger.

The area must be well ventilated. Fire extinguishers must be availably close by.

Park the truck.

Lock the emergency stop (2).

Turn the battery compartment lock (3) through 90°. The battery cover (1) unlocks. To open, tip the cover forwards.

2

3

1

0148_606-001

Pull the battery plug(4.)

Park the truck (See tions", P. 00-22).

Chapter "Safety Regula-

4

5

Lock the emergency stop (2).

0148_606-002

50158070901 [EN]

-11

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.

Park the truck (See tions", P. 00-22).

Chapter "Safety Regula-

Lock the emergency stop.

Open the battery compartment.

Disconnect the battery plug (4) (See ter "Safety Regulations", P. 00-22).

Chap-

4

5

Lift the battery lock (5).

0148_606-002

Fix the lifting device (5) to the battery (6) correctly.

Carefully lift the battery out of the truck.

5

The lifting device must exercise vertical traction in order to avoid the boot being damaged. The hooks must be placed so that they cannot fall on the battery cells when the lifting device is slackened.

6

No-one should be under a raised load.

0148_606-003

-12

50158070901 [EN]

Park the truck (See tions", P. 00-22).

Chapter "Safety Regula-

Lock the emergency stop.

Open the battery compartment.

Disconnect the battery plug (4) (See ter "Safety Regulations", P. 00-22).

Chap-

4

5

Lift the battery lock (5).

There is a risk of pinching your ngers!

During dismantling or installation of the battery never put your hands between the chassis and the battery!

0148_606-002

Position the roller holder (8) beside the battery.

Go to the side opposite the cover and push the battery (7) to engage it on the roller holder (8).

The weight and size of the battery affect the stability of the truck. The replacement battery must weight the same as the old one. Do not remove extra weight or change its position.

Please observe the characteristics of the battery.

To charge the battery, you will nd the necessary information in the workshop maintenance instructions at the beginning of the chapter (Battery maintenance).

Install a charged battery by carrying out these operations in reverse order. Make sure all the covers are properly in place.

7

8 0148_606-004

Do not damage the cables when changing the battery.

50158070901 [EN]

-13

Risk of jamming!

Do not leave anything between the battery and the edge of the chassis when closing the cover.

Connect the battery plug (4) (See Chapter "Safety Regulations", P. 00-22).

4

5

Undo the lock (5) on the battery.

Take off the battery cover.

0148_606-002

Turn the key (3) of the battery compartment lock 90°, then remove it.

2

Unlock the emergency stop (2).

3

1

0148_606-001

-14

50158070901 [EN]

Chock the truck at the rear.

Dismantle the dashboard (See Chapter "Instrument panel", P. 31- 6 ) without dismantling the cockpit and the horn. Simply disconnect the sockets linked to the cockpit (D and E) and the plugs for the horn.

Remove the motor cover (See tor covers", P. 31- 4 ).

Chapter "Mo-

Disconnect the battery plug (4) (See ter "Safety Regulations", P. 00-22).

Chap-

Remove the pin from the cylinder.

Sling the fork chassis Chapter "Safety Regulations", P. 00-22).

Do not lift higher than necessary. Do not forget that the chassis fork is always kept at the level of the draw bars!

Lift the fork chassis until the 4 Chc screws of the battery plug appear.

Then

remove the 4 nuts.

Proceed in reverse order.

50158070901 [EN]

-15

-16

50158070901 [EN]

Electrically, the detection of driver presence is provided by a redundant switch (S3). The switch status is connected and controlled directly by 2 variable speed traction entries (A34 and A35).

This switch uses 12 V. It changes status depending on the movements of the presence plate.

S3-1 (A9)= 12 V Inputs S3-2 (A34) S3-4 (A35)

Rest

Active

Default (circuit open)

Default (shortcircuit)

12 V

0V

0V

12 V

0V

12 V

0V

12 V

Check by diagnostic tool (e.g. E294).

Check the mechanical positioning of the switch.

Check the operation of the switch against the above table.

0148_608-002

It is possible to view the contact status in the diagnostic tool.

Park the truck (See tions", P. 00-22).

Chapter "Safety Regula-

Lock the emergency stop.

Disconnect the battery plug (See Chapter "Safety Regulations", P. 00-22).

Remove the motor cover (See tor covers", P. 31- 4 ).

Chapter "Mo-

50158070901 [EN]

-17

Partially lift the rubber mat on the presence pedal to access the 3 Chc screws (1).

Remove the 3 Chc screws (1).

Push the plate forwards.

Lift the plate.

Remove the plate.

-18

50158070901 [EN]

Remove the 2 Chc screws (2).

Disconnect the micro-contact (3) (locate the wires for reassembly).

Proceed in reverse order.

Park the truck (See tions", P. 00-22).

Chapter "Safety Regula-

Lock the emergency stop.

Disconnect the battery plug (See Chapter "Safety Regulations", P. 00-22).

Remove the motor cover (See tor covers", P. 31- 4 ).

Chapter "Mo-

Disconnect connector N (magnetic detection sensor for max. cylinder height. position).

50158070901 [EN]

-19

Remove the two xing screws from the height sensor and take it off (2).

Proceed in reverse order and adjust the height of the sensor so that the pump cuts out electrically when the fork reaches a height of 200mm above the ground (3).

It is possible to view the sensor status in the diagnostic tool.

-20

50158070901 [EN]

a

The traction controller and the pump controller are designed, on the one hand, to generate, from the direct current from the battery, a triphase alternating current to supply the traction motor, and, on the other hand, to supply the pump motor with direct current.

For the traction motor section: A speed sensor informs the controller of the speed and direction of rotation of the motor. With the internal measurement of the phases, you obtain a closed regulation circuit, depending on the information from the traction potentiometer (cockpit throttle valve) that the controller receives by the CAN bus.

B+: 24 V input in the variator and 24V junction (to the pump motor).

B-: Input - (Earth).

U: U output to traction motor (Control).

V: V output to traction motor (Control).

W: W output to traction motor (Control).

P : Output - to pump motor (Control).

Plug, SAAB (A1) : Various information and variator controls (See Chapter "Wiring diagram", P. 60- 1 ).

Park the truck and take out the battery plug (See Chapter "Safety Regulations", P. 00-22).

Take off the motor covers (See tor covers", P. 31- 4 ).

Chapter "Mo-

50158070901 [EN]

-1

Locate the following electrical connections on the variable speed traction drive and disconnect them: B+, B-, U, V, W, P-.

Disconnect the SAAB (A1) plug.

Undo the six Chc screws (1, 2, 3 and 4) and take out the variable speed traction drive.

Proceed in reverse order.

Park the truck and remove the battery plug (See Chapter "Safety Regulations", P. 00-22).

Dismantle the motor covers (See ter "Motor covers", P. 31- 4 ).

-2

Chap-

50158070901 [EN]

Take out the fuse holder (1).

Disconnect the red wire (2) of the fuse holder terminal.

Take the K6 relay (3) out of its holder (5).

Undo the CHc screws (4) to free the relay holder (5).

50158070901 [EN]

-3

Disconnect the white cable (6) for relay K1 (8).

Disconnect the 2 plugs (7) for relay K1 (8).

A: 2 brown wires.

B: 1 brown wire Unscrew the 2 nuts (9).

Remove the support plate (10) with the electrical units (relay K1 and fuse holders).

Undo screw H (11).

Remove the cover (12).

Undo the 2 CHc screws (13).

Remove the support assembly (14) and the fans (15).

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Undo the 4 Philips screws (16).

Remove the fan.

Proceed in reverse order.

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The steering and pump controller is used to supply the steering motor with direct current.

Turning the cockpit changes the desired value (desired value potentiometer for steering: see Chapter " 42 Steering system", P. 42- 1 ), which is compared with the actual value in the steering logic (actual value potentiometer for steering angle: see Chapter " 42 Steering system", P. 42- 1 ). As soon as there is a difference between the desired value and actual value, the steering controller processor sends signals to the steering motor to compensate the difference between the desired and actual value.

Red: 24V input into the variator (coming from the + terminal of the steering motor).

Blue/White: Motor control (Earth) Black: Input - (Earth).

Red shunt: repeat of 24V (red wire) from the steering motor to contactor K6.

SAAB (G) plug: G1: Can_H. G2: Can_L. SAAB (A3) plug : Various information and variator controls (See Chapter "Wiring diagram", P. 60- 1 ).

Example: Setting and recopy potentiometer.

Park the truck and remove the battery plug (See Chapter "Safety Regulations", P. 00-22).

Take off the motor covers (See tor covers", P. 31- 4 ).

Chapter "Mo-

Disconnect all the cables from the steering controller: SAAB A3 and G plugs.

Red, blue, black and white wires.

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Undo the nut (1) and remove the metallic part of the holder.

Undo the nut (2) and remove the metallic part of the holder.

Take out the steering controller.

Proceed in reverse order.

Consider performing a steering trial via the diagnostic tool after changing the steering controller.

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1 2 3 4 5 6

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

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7 8 9 10 11

Oil screen Lift pump Pressure limiter Non-return valve Filter

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a

Type:

K3.823.16.409 Oil-System

Manufacturer

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

Carbon brushes: 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: Oil capacity (for standard equipment): Filter on suction and return:

90 microns

Oil replacement:

Once a year

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0148_711-001

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Lower the forks completely.

Disconnect the battery plug (See Chapter "Safety Regulations", P. 00-22).

Take off the motor covers (See tor covers", P. 31- 4 ).

Chapter "Mo-

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

Disconnect the hydraulic hose (3) of the pump.

Plug the hole with an M"" stopper.

Oil ows out. Use a collecting basin.

Remove the two xing screws (4) Chc M6 (with " Loctite 242") Remove the pump holder.

Proceed in reverse order.

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0148_711-004

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Dismantle the pump.

Remove the 3 Chc screws (5), tightening torque 6+1 Nm.

Remove the screws (6), tightening torque 10 Nm. Undo the collar (7) which fastens the tank.

Remove the tank.

Proceed in reverse order.

Remove the battery plug (See Chapter "Safety Regulations", P. 00-22).

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Dismantle the pump unit (See previous paragraph).

Dismantle the tank (See previous paragraph).

Dismantle the intake lter (3) and its plastic connector.

Undo the 2 xing screws (4), tightening torque : 25 Nm.

Proceed in reverse order.

Disconnect the battery (See Regulations", P. 00-22).

Chapter "Safety

Dismantle the motor covers (See ter "Motor covers", P. 31- 4 ).

Chap-

Disconnect the electric cables (2) of the motor.

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Remove the 2 xing screws (1) of the cover.

Take out the motor.

Take out the driving plate pin (2).

Proceed in reverse order.

Replacement of brushes is necessary when their length is reduced to 11 mm. Always replace the complete set of brushes (4 pieces).

Disconnect the battery plug (4) (See ter "Safety Regulations", P. 00-22).

Chap-

Dismantle the motor (See Chapter "Motor and driving plate pin", P. 71 - 6 ).

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Take off the covers after undoing the 2 screws (2).

Slip out the insulators (3).

Disconnect the brush connections on the brush holder (4).

Extract the brush holder ring gear (5).

Proceed in reverse order.

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To access the roller bearings, follow the procedure for changing the brushes.

Extract the roller bearings with an appropriate extractor.

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Disconnect the battery connector (see Chapter "Safety Regulations", P. 00-22).

Remove the motor cover (see tor covers", P. 31- 4 ).

Chapter "Mo-

Disconnect the plug (1) from the solenoid valve.

Unscrew the plastic parts.

Pull off the solenoid valve.

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Remove the valve with a long 24 mm socket head or a bent ring spanner (1) (torque: 3.5+5 Nm maximum)

If tightened too much: The tube of the winding carrier can become deformed so that the solenoid valve can jam during lowering.

Re tting is a reversal of removal.

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Fastening bolts on mast channels

Torque = 275 Nm (M16x700/10.9) (M16x150/10.9)

Line safety valve (safety valve)

Torque = 60 Nm ± 6 Nm

Chain

Max admissible elongation: 3 % acc. to accident prevention regulations

Lowering speed

Max admissible speed = 0.6 m/s

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1st possibility: Disconnect the battery plug (4) (See ter "Safety Regulations", P. 00-22).

Take off the motor cover (See tor covers", P. 31- 4 ).

Chap-

Chapter "Mo-

Remove the pin on top of the cylinder.

Using a jack, slightly lift the fork section to dislodge the cylinder rod from the chassis ring (Remove the battery if necessary).

2nd possibility: Place the forks in the upper position.

Wedge the truck (at the forks, the middle, the rear and under the battery).

Disconnect the battery plug (4) (See ter "Safety Regulations", P. 00-22).

Take off the motor cover (See tor covers", P. 31- 4 ).

Chap-

Chapter "Mo-

Remove the pin on top of the cylinder.

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Disconnect the connector N (magnetic detection sensor for the max. height position. of the cylinder).

Reconnect the battery plug (See Chapter "Safety Regulations", P. 00-22).

Lower the forks by pressing the appropriate control in the cockpit.

The cylinder is taken off the fork section.

Disconnect the battery plug (See Chapter "Safety Regulations", P. 00-22).

Disconnect the hydraulic hose (2) cylinder side.

There is a risk of oil running out.

Remove the Chc screw at the base of the cylinder.

Take out the safety pin.

Remove the shaft.

Cylinder may fall.

Remove the cylinder.

Proceed in reverse order.

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Disconnect the battery (See Regulations", P. 00-22).

Chapter "Safety

Take out the battery (See Chapter "Changing the battery", P. 60-10directly.

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Chock the truck (See Chapter "Safety Regulations", P. 00-22).

Remove the Chc screws.

Take out the pins..

Remover the shafts with a drift punch.

2 washers are shown on either side of the calliper between the calliper and the chassis.

Remove the pin for each fork.

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Remove the shafts.

The callipers and traction rods could drop.

Dismantle the roller holder levers of the traction rods.

To replace the rings (7) of the lever brackets, countersink them using a jet, then proceed with their replacement.

Never lubricate the rings (7).

7

Proceed in reverse order.

1044_841-008

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Carry out the dismantling procedure for the traction rods (See Chapter "Dismantling and Reassembly - Traction rods", P. 84- 1 ).

Dismantle the lifting cylinder (See ter "Lifting cylinder", P. 80- 2 ).

Chap-

Disconnect the (+) cable linked to the emergency stop button.

Disconnect the (-) cable linked to the changer.

Remove the collars which can be a hindrance when separating the chassis.

Sling the front section.

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Lift until dismantled.

Proceed in reverse order.

Lift the forks.

Chock the truck (See Chapter "Safety Regulations", P. 00-22).

Disconnect the battery plug (4) (See ter "Safety Regulations", P. 00-22).

Chap-

Remove the 2 CHC screws.

Take out the assembly.

Proceed in reverse order.

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STILL GmbH Berzeliusstrasse 10 D-22113 Hamburg Ident no. 50158070901 EN