STILL STED Forklift Electric pallet truck EXU 16, EXU 18 EXU 20, EXU 20 S EXU 22, workshop Manual

....

STILL

Workshop literature

Electric pallet truck EXU 16, EXU 18 EXU 20, EXU 20 S EXU 22, EXU 22 S

CE: 0153 0154 0155 0157 2351 2353 2355 2357 11528070901 EN - 01/2020

first in intralogistics

First edition

Chapter 00: Addition of information on the lithium-ion battery (A1 and A2) Chapter 00: Lithium-ion battery CAN bus network added Chapter 00: List of lithium-ion battery error codes added

Chapter 00: Addition of information on the lithium-ion battery (B1 and B2) Chapter 60: FleetManager option updated

Chapter 01: Lithium-ion maintenance plan added Chapter 01: Maintenance operations added Chapter 02: Information on the CAN box 3 added Chapter 60: Lithium-ion side socket (option) added

Chapter 60: Addition of new temperature sensor type "PT1000" Chapter 60: Creation of the "On-board charger for lithium-ion/gel/lead batteries (option)" section created

Added the new type carriers Chapter 00: Addition of information about accreditation for technicians Chapter 42: Addition about stabilisers (specific to the lithium-ion battery) Chapter 42: Slow speed (Creep Speed) function added

Added the type carriers

Chapter 00: Lithium-ion safety guidelines added Chapter 01: Maintenance plans added

11528070901 EN - 01/2020

I

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-2

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-3 -3 -5

Changing the transmission gear seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining the transmission gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the electromagnetic brake air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the electromagnetic brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the height of the stabiliser wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-6 -6 -7 -8

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-9 -9

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-10

Checking the wear on collars and hinge pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Greasing the rings and articulations (greased option) . . . . . . . . . . . . . . . . . . . . . . . .

-10 -10

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-1

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Hydraulic circuit, draining the circuit

11528070901 EN - 01/2020

III

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-2

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-7

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-9

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-10

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-11 -11 -12 -16

Lithium-ion service base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Error codes for the lithium-ion battery A1-A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Troubleshooting flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-27 -27 -31

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-42

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-43

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-44

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-1

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-3

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-7

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IV

11528070901 EN - 01/2020

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11528070901 EN - 01/2020

V

VI

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-1

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-1

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-2

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-5

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-5

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-6

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-7

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-9

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-10

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-11

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Rev sensor (1B2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature sensor KTY (1B6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-14 -14 -18

Temperature sensor PT1000 (1B6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electromagnetic brake (Y1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-22 -25

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-27

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-27

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-30

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-30

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-31

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-32

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-32

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-33

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-34

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-34

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-37

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-39

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-39

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-43

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-45

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-47

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-47

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Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-49 -49 -51

Replacing the BMU harness

-53

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11528070901 EN - 01/2020

Replacing the SMU harness (A1 battery)

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-54

Replacing the SMU harness (A2 battery)

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-56

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Lithium-ion module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the A1 battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-58 -58 -59

Replacing the A2 battery module

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-61

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-63 -63

Replacing the contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the battery fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-65 -66

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-67

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-69

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-70

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-70

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-72

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-74

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-75

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-76

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-77

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-78 -78 -79

Overview

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lithium-ion module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembling the B1 and B2 battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reassembling the B1 and B2 battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-81 -81 -82 -85

Replacing the shunt

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-89

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Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-91 -91 -93

Replacing the fuse

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11528070901 EN - 01/2020

VII

VIII

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-107

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-111

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-112

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-113

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-115

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-1

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-4

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-4

11528070901 EN - 01/2020

EXU 16: capacity 1600 kg EXU 18: capacity 1800 kg EXU 20: capacity 2000 kg EXU 22: capacity 2200 kg EXU 20 S*: capacity 2000 kg

EXU 22 S*: capacity 2200 kg EXU 16 lithium-ion: capacity 1600 kg EXU 18 lithium-ion: capacity 1800 kg EXU 20 lithium-ion: capacity 2000 kg *S: Folding platform

6 km/h in both directions (ignition key in hare position) 4 km/h in both directions (ignition key in tortoise position) 1.2 kW (AC technology)

Electromagnetic safety device controlled by the emergency stop handle Electromagnetic safety brake controlled by the upper or lower position of the tiller electromagnetic parking, applied when the supply is cut Vertical access (2 PzS-B, 2 PzS, 3 PzS types) Side access (2 PzS, 3 PzS types)

EXU 16 and EXU 18: 1 kW EXU 20: 1.2 kW EXU 22: 1.4 kW EXU 16-18-20 CS*: 1.2 kW EXU 22 CS*: 1.4 kW *CS: Cold store (option) Counter-current, upon accelerator release Counter-current, by changing the drive direction Counter-current, controlled by the rear safety button

backrest digicode (LFM Go) Cold store version FleetManager reinforced stabilisers on-board charger accessory holder

11528070901 EN - 01/2020

-1

This truck is equipped with a battery with lithiumion technology.

Battery type A1 (1 module) A2 (2 modules)

-2

Dimensions Length (mm) 648 648

Height (mm) Depth (mm) Weight (kg) 627 627

156 156

50.5 70.5

11528070901 EN - 01/2020

Nominal Nominal cavoltage (V) pacity (Ah) 23.1 23.1

82 164

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

11528070901 EN - 01/2020

-3

Battery type B1 (one module) B2 (two modules)

-4

Dimensions Length (mm) 718 718

Height (mm) Depth (mm) Weight (kg) 618 618

210 210

110 151

11528070901 EN - 01/2020

Nominal Nominal cavoltage (V) pacity (Ah) 23.1 23.1

205 410

Risk of injury Use a hoist and hooks of sufficient capacity. Refer to the load weight shown on the truck's data plate.

– Attach a sling or a hook to the 2 points indicated (3).



Risk of damage to the truck 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.

No-one should be under a raised load.

To lift the truck, its sub-assemblies or additional equipment, lifting devices must be hooked only to the appropriate lifting points. When jacking, take appropriate measures (using chocks or wooden blocks) to prevent the truck from slipping or tipping over.

The truck must be jacked and chocked in order to perform certain maintenance operations. Always make sure:

11528070901 EN - 01/2020

-5

To use a jack with an adequate lifting capacity, Make sure that the truck is parked on level ground and is secured against rolling and tipping.

Electrical hazards Disconnect the battery connector before lifting the truck.

– Position the truck so that the fork arms touch the wall.

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

– Raise the truck with chocks.

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11528070901 EN - 01/2020

Maintenance operations must always be carried out by a competent person.

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

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

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

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

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

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

11528070901 EN - 01/2020

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-8

11528070901 EN - 01/2020

Depending on the application, environmental conditions and driving style, the following procedures should be carried out every 1000, 2000, 4000, 7000 and 8000 hours

Clean the truck (if necessary) Check the error codes (using the diagnostic tool) Check that the cables and bundling are in good condition Check for any possible oil leaks from the transmission gear Lubricate the ring gear Check the wear on the tyre tread of the wheels Check the brake air gap Check that the nuts are tight Clean and blow out the electrical plate Check the mounting of the electrical connections Check and adjust the battery electrolyte level Check the condition and mounting of the battery cables Check the system oil level Check the system for leaks Check the level of wear on the rings and clevis pins Oil or generously grease the rings and clevis pins Check the general condition of the forks and the chassis

Depending upon use, environmental conditions and driving style, the following procedures must be performed every 3000, 6000 and 9000 hours

Carry out all 1000-hour maintenance work Drain the transmission gear oil Drain the hydraulic system

11528070901 EN - 01/2020

-1

The lithium ion battery does not require special maintenance. However, it is necessary to perform some maintenance operations, in addition to the usual maintenance plan for the truck.

Clean the battery.

Check the battery connections and sockets.

Fully charge the battery at least once a week.

Check the tightness of the battery terminal. Retighten to the correct torque if necessary. The torque is 23 Nm. (For the vertical access battery only) Check the tightness of the battery mounting plate screw on the battery compartment. Retighten to the correct torque if necessary. The torque is 17 Nm. (For the side access battery only) Check the tightness of the battery mounting plate screw on the battery compartment. Retighten to the correct torque if necessary. The torque is 20 Nm.

Fully recharge the battery if it is in the storage area in or out of the truck

Visually check the battery

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11528070901 EN - 01/2020

– Remove the transmission gear (see chapter 23.2 : Removing the transmission gear).

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

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

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

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

– Remove the wheel axle sealing ring (5) using a screwdriver



– Remove the wheel shaft (6) – Drain and clean the transmission gear (7).

– Clean and check the mating face of the seal.

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

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

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

11528070901 EN - 01/2020

-3

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

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



– Fit the thread protection ring – Fit a new protective cap on the wheel shaft screw.

– Remove the sealing ring (10) using a screwdriver



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

-4

11528070901 EN - 01/2020

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

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

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

Reminder of the transmission gear oil quality: , API compatible GL4.

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



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

Risk of transferring oil into the motor.

Do not exceed the indicated oil level.

11528070901 EN - 01/2020

-5

The brake must be checked in the braked position, in other words with the power supply cut.

Check the air gap on the brake using a set of shims.

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

If the air gap is close to the limit value of 0.6 mm, it must be adjusted: – Loosen the three mounting screws (7).

– Adjust the three banjo bolts (6) to set the air gap to its original value of 0.20 mm.

– Retighten the three mounting screws (7).

– Check the air gap at three points at 120° intervals.

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

-6

11528070901 EN - 01/2020

To remove the electromagnetic brake: – Disconnect the battery connector.

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

– Remove the tiller arm (only for EXU / EXU-H type trucks).

– Remove the screw (1) (tightening torque: ).

– Remove the electromagnetic brake (2).

– Remove the brake disc.

– To refit the brake, proceed in the reverse order to the removal process.

– Check and/or adjust the air gap of the electromagnetic brake (see chapter 42.2: Electromagnetic parking brake Y1).

To note: Clearance = 0.2 mm Screw tightening torque = 

In order to protect the parking brake during use in difficult operating conditions (dusty atmospheres, humid conditions etc.), it is now possible to install a protective cap (3).

11528070901 EN - 01/2020

-7

PLEASE NOTE: Lower the stabiliser wheel if a more stable unit is required.

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

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

– After adjustment, lock the clevis (1) with the locknut (2) tightened to a torque of .

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

The stabilisers are heavy Use materials handling gloves to extract them from the chassis.

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

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

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

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11528070901 EN - 01/2020

– Lower the load arms to the ground to eliminate pressure in the hydraulic circuit.

– Switch off the ignition and unplug the battery connector.

– Disconnect the power supply to the solenoid valve (3).

– Disconnect the cylinder supply hose (1).

– Remove the 2 screws (2) that hold the upper support (angle bracket) in place.

– Lift out the hydraulic unit.

– Remove the unit's upper support and the filler tube/breather.

– Unscrew the tank's mounting clip.

– Remove the tank.

– Drain the oil.

– Fit new seals on the tank and couplings.

– Refit the unit in the technical compartment with its tube and upper support.

– Connect the pipes and the power supply.

– Unscrew the filler plug.

– Fill up the tank through the filler hole.

– Tighten the plug.

– Operate the lifting system several times.

Always use hydraulic oil in accordance with the specifications (see lubrication table).

11528070901 EN - 01/2020

-9

It is important to check the condition of the collars and hinge pins on the following elements of the lifting system : (1) Load arm shaft / support roller clevis (2) Push rod shaft / support roller clevis (3) Mobile chassis shaft / lift shaft (4) Fixed chassis / lift shaft (5) Cylinder / fixed chassis (6) Lift shaft / push rods

If significant wear is found, replace the worn collars and pins before the other components are damaged.

For trucks with greased cinematics, the articulation axes are provided with lubrication nipples.

Always use the lubricant recommended in the lubricants table. See the lubrication points attached.

-10

11528070901 EN - 01/2020

Thread M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 M30 M36

Grade 4.6 1 2.1 3.6 8.5 17 30 47 73 145 250 510 880

Grade 4.8 1.3 2.7 4.7 11 23 40 62 100 192 330 675 1170

Grade 5.8 1.7 3.4 5.9 14 29 50 78 122 240 410 840 1470

Grade 6.8 2 4.1 7.1 17 34 60 94 146 289 495 1000 1760

Class 8.8 2.7 5.5 9.5 23 46 80 125 195 385 660 1350 2350

Grade 10.9 Grade 12.9 3.8 4.6 8 9.5 13 16 32 39 64 77 110 135 180 215 275 330 540 650 930 1110 1850 2250 3300 3900

Thread M8x1 M10x1 M10x1.25 M12x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x1 M27x1 M30x2 M36x3

Grade 4.6 9.5 20 18 33 31 52 79 115 160 215 270 395 540 930

Grade 4.8 12 26 24 44 41 70 105 150 210 285 360 525 725 1250

Grade 5.8 16 32 30 55 52 87 130 190 265 355 450 655 905 1560

Grade 6.8 19 39 37 66 62 105 157 230 320 425 540 785 1085 1870

Class 8.8 25 52 49 88 83 140 210 305 425 570 720 1050 1450 2500

Grade 10.9 Grade 12.9 35 42 72 95 68 82 125 150 115 140 195 235 295 350 425 510 600 720 800 960 1000 1200 1500 1800 2050 2500 3500 4100

11528070901 EN - 01/2020

-11

USB CAN Box, unit with cables 50983605401 USB CAN Box 50983605400 Adaptor cable, CAN Box for diagnostics on the truck, diagnostic con0171381 nector, 7-pin Adaptor cable, CAN Box for diagnostics on the truck, diagnostic con0625028 nector, four-pin

STILL multimeter with measurement leads

0009418737

Test adaptor, SAAB, 42-pin

8426527

Replacement MetraHit measuring lines, pair of red and black Measuring tips, pair of red and black Crocodile clips, pair of red and black Measurement cables, pair of red and black

0143426 0143427 0143425

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

Hahn&Kolb 77200910

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11528070901 EN - 01/2020

1 2

3 4 5

Document category Document language

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

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



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

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

– Select the required document category (1).

– Select the required truck series (4).

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

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



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

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

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

11528070901 EN - 01/2020

-1

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

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

-2

11528070901 EN - 01/2020

USB cable: the service box must be loa1 ded with the current software. The USB cable will be omitted in later versions Connection for the adaptor cable, 7-pin, 4 2 pins assigned Connection for the adaptor cable, 7-pin, 6 3 pins assigned The LED lights up once the service box is 4 supplied with voltage via the diagnostic connector when the truck is switched on The LED indicates the status between the 5 notebook and the service box The LED indicates the status between the 6 service box (CAN 1) and the truck The LED indicates the status between the 7 service box (CAN 2) and the truck 8 The LED indicates the Bluetooth status 9 Antenna 10 STILL Bluetooth USB stick If all LEDs (3,4,5,6) are flashing, the service box is in programming mode. In this case, the service box must be reset.

1 2 3 4 5 6 7

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

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

11528070901 EN - 01/2020

-3

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

-4

11528070901 EN - 01/2020

1 2

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

3 5

USB CAN Box Laptop

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

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

1 2 3 4a

4b

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

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

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

5

Connecting line, serial serial and serial converter Laptop

The laptop (5) is connected to the CAN Box via the connecting line. The type of connection will depend on the type of ports available on the laptop. Laptops equipped with Sub-D plugs are connected using a "serial serial" connecting line (4a). Laptops that are not equipped with Sub-D plugs are connected using a "serial serial" connecting line and a serial converter (4b).

11528070901 EN - 01/2020

-5

6X7 1A1

Diagnostic connector LAC controller

6P4

Multi-function indicator

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

Checking the CAN bus network: Using an ohmmeter, the measured value of the diagnostic connector (6X7) between terminals (1) and (2) is . This value is measured between the CAN high and the CAN low when the truck Using a voltmeter, the measured value of the diagnostic connector (6X7) between terminals (4) and (1) and between terminals (4) and (2) is when the truck .

-6

11528070901 EN - 01/2020

1 2 3 4

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

5 6 7

11528070901 EN - 01/2020

Emergency signal N/A N/A

-7

6X7 X33

Truck diagnostic socket Diagnostic connector of the lithium-ion battery

1A1 6P4

Controller Multifunction indicator of the lithium-ion battery

The CAN bus network for communication between the lithium-ion battery and the controller is composed of: CAN high CAN low Two "Rt" terminating resistors (one in the controller and one in the lithium-ion battery) fitted in parallel in the circuit Checking the CAN bus network of the lithium-ion battery: Using an ohmmeter, the measured value of the diagnostic connector (X33) between terminals (1) and (2) is . This value is measured between the CAN high and the CAN low when the truck Using a voltmeter, the measured value of the diagnostic connector (X33) between terminals (4) and (1) and between terminals (4) and (2) is when the truck .

-8

11528070901 EN - 01/2020

X33:1 X33:2 X33:3 X33:4 X33:5

CAN-H CAN-L 12 V DC 0V 0 V if the contactor K10 is open, 24 V if the contactor K10 is closed

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

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-9

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

C

Open

No

No

A

Closed

Activated

No

B

Closed

Activated

No

C

Activated

No

Safety

C

Open Open Closed if the contactor is stuck

Activated

Yes

Warning Alarm

Battery contactor status Closed Open

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

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

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11528070901 EN - 01/2020

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

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

11528070901 EN - 01/2020

-11

Reset levels: Automatic reset: If required, move the battery to somewhere that is at ambient temperature.

Truck reset: Press the button for . for

ON/OFF reset (safe mode): Press the button OR .

*BMS: Battery Management System = Assembly made up of the BMU and SMU *BMU: Battery Monitoring Unit = Battery controller *SMU: Safety and Monitoring Unit *SOC: state of charge *IMD: Maximum discharge current allowed *IMR: Maximum charging current

-12

11528070901 EN - 01/2020

100 101 102 103 110

111 113 114 115 116 118

200

201

202 203 204 205 206

Temperature of the module > 60°C for 1 second Temperature of the A module is under heatmodule < -23°C for 1 ed 1st level second A cell is overloading Voltage of a cell > 4.05 1st level V for 2 seconds Voltage of a cell < 2.9 V A cell is under voltage for 2 seconds Measured charging curDifference in charging rent of the battery > max current 1st level (2.10000 x IMR*; 2.00000) for 5 seconds Measured charging curDifference in charging rent of the battery > max current 2nd level (2.20000 x IMR*; 2.00000) for 5 seconds Minimum SOC 0% for Low SOC* 1st level 5 seconds SOC * not authorised SOC not authorised for within the required time more than one month At least one BMS (SMU) BMS (SMU) communiassignment has failed cation problem more than three times Maximum temperature A module connection is connection > 80°C for 1 overheating second Maximum difference in Inconsistent temperatemperature of the modtures ule > 10°C for 1 second The redundant hardRedundant safety ware emergency chain events reported by the is active for more than BMS (SMU modules 500 milliseconds Battery current > 220 A Activation of the battery or the voltage drops in contactor after a short the fuse > 5 V for 2 seccircuit (blown fuses) onds Temperature of the A module is overheating module > 65°C for 1 2nd level second Temperature of the A module is under heatmodule < -25°C for 1 ed 2nd level second A cell is overloading Voltage of a cell > 4.13 2nd level V for 2 seconds Voltage of a cell < 2.3 V A cell is under voltage for 2 seconds If the voltage of at least Cell voltage outside the one cell is outside the range range for 2 seconds A module is overheating 1st level

11528070901 EN - 01/2020

Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset ON/OFF reset

ON/OFF reset

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

-13

208

209

210

211

212

213

214

215

216

217

218

-14

A connection temperaA connection temperature < -29°C or > 115°C ture is outside the range for 1 second Inconsistency between the contactor control Unexpected status of (closed) and the actual battery contactor (open) state of the contactor (open) for 5 seconds Inconsistency between the control of the conUnexpected status of tactor (open) and the battery contactor actual state of the con(closed) tactor (closed) for 5 seconds Measured charging curExcess current when rent of the battery > max charging (2.10000 x IMR*; 2.00000) for 5 seconds Measured discharge Excess current during current of the battery > discharge max (1.00000 x IMD*; 2.00000) for 5 seconds Detection of a blown fuse (difference between the voltage of the Blown fuse fuse and the voltage of the battery > 4.00000 V) for more than 3 seconds CAN message not received correctly by the BMS (BMU) for 5 secCommunication with the onds when the battery is truck lost outside the tolerance range (charging or discharging) Number of attempts to BMS (SMU) reconnec- reconnect greater than tion failure three for the BMS (SMU) Maximum temperature A module connection is connection > 90°C for 1 overheating second If the integrated tests (at start-up, continuously, on request, when Self-testing failure switching off) have failed (1 unsuccessful attempt is regarded as a failure) If the voltage of the battery contactor is still > 4.00000 V three secPre-charge failure onds after the command to close the main precharge contactor or if a

11528070901 EN - 01/2020

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

222

224

225

contactor is open even though it was ordered to close Battery voltage above Battery voltage > 28.35 the limit V for 2 seconds The battery current is outside the range for 2 seconds or the main Battery current sensor contactors are open and outside the range (lost) the battery current > 2.00000 A or < -2.00000 A for 2 seconds If the BMS (SMU) supply is active on the BMS Low supply voltage of (BMU) and the supply BMS (SMU) voltage is not detected in 0.2 seconds

11528070901 EN - 01/2020

ON/OFF reset

ON/OFF reset

ON/OFF reset

-15

BIS: Battery Information Sheet

Description: A module is overheating (1st level) Error code 207 appears Error code 118 appears High ambient temperature Stop using the battery until the temperature decreases Follow the procedure for error code 207 Follow the procedure for error code 118

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Description: A module is under heated (1st level) Error code 207 appears Error code 118 appears Low ambient temperature Expose the battery to a higher temperature so that it warms up Follow the procedure for error code 207 Follow the procedure for error code 118

Description: A cell is overloading (1st level) Discharge the battery for 10 minutes at a rate of 20 A Error code 102 still appears Replace the battery, referring to the BIS Error resolved (or corrected)

Go to step 2 Go to step 3

Go to step 4

END

END

Description: A cell is under voltage Charge the battery for 20 minutes at 10 A Error code 103 still appears Replace the battery Refer to the BIS Error resolved (or corrected)

-16

Go to step 2 Go to step 3

Go to step 5 Go to step 4

END

11528070901 EN - 01/2020

END

Description: Invalid state of charge (SOC) Switch the battery off and on again Error code 217 appears Error code 107 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 217

Go to step 2 Go to step 6 Go to step 4

Go to step 3 Go to step 5

END

END

Go to step 3

Go to step 2

END

END

Go to step 3

Go to step 2

END

END

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Description: Difference in charging current (1st level) Error code 211 appears Charge or regeneration problem They do not meet the IMR thresholds After restarting, the battery should be functional Follow the procedure for error code 211

Description: Difference in charging current (2nd level) Error code 211 appears Charge or regeneration problem They do not meet the IMR thresholds After restarting, the battery should be functional Follow the procedure for error code 211

Description: Low state of charge (1st level) Error code 103 appears Error code 205 appears The battery charge level is low: charge the battery Follow the procedure for error code 103 Follow the procedure for error code 205

Description: Low state of charge (2nd level)

11528070901 EN - 01/2020

-17

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

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Go to step 8 Go to step 4

Go to step 3 Go to step 7

Description: State of charge not authorised within the required time Switch the battery off and on again Error code 217 appears Error code 114 still appears Charge the battery to SOC>95>% and wait 5 seconds (with or without current) Error code 114 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 217

Go to step 2

Go to step 5 Go to step 6

Go to step 7

END

END

Go to step 6 Go to step 4

Go to step 3 Go to step 5

END

END

Go to step 9 Go to step 10

Go to step 2 Go to step 3

Description: Communication problem with the SMU card Switch the battery off and on again Error code 217 appears Error code 115 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 217

Go to step 2

Description: A module connection is overheating Error code 100 appears Error code 202 appears Check the tightening torque of the power connections for the module and wait 20 minutes Switch the battery off and on again Error code 217 appears Error code 116 still appears

-18

Go to step 4 Go to step 5 Go to step 11 Go to step 7

11528070901 EN - 01/2020

Go to step 6 Go to step 8

Replace the battery Error resolved (or corrected) Follow the procedure for error code 100 Follow the procedure for error code 202 Follow the procedure for error code 217

END

END

Description: Inconsistent temperatures Replace the module (see chapter 6: Lithium-ion battery, Module) Refer to the BIS

Go to step 2 END

END

Go to step 6 Go to step 4

Go to step 3 Go to step 5

Description: The IMD/IMR charging/discharge currents of the algorithm are invalid Switch the battery off and on again Error code 217 appears Error code 121 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 217

Go to step 2

Go to step 10 END

END

Go to step 10 Go to step 11 Go to step 12

Go to step 2 Go to step 3 Go to step 4

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

Error code 202 appears Error code 205 appears Error code 204 appears Cut off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 200 still active?

Replace the battery, referring to the BIS Error code 200 still active?

Error resolved (or corrected) Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Follow the procedure for error code 202 Follow the procedure for error code 205 Follow the procedure for error code 204

Go to step 5 Go to step 6

Go to step 8

Go to step 12 END

Go to step 9 END

Go to step 7

11528070901 EN - 01/2020

-19

Description: Activation of the battery contactor after a short circuit (fuse blown) Error code 224 appears Error code 213 appears Error code 211 or error code 212 appears Error code 210 appears Follow the procedure for error code 210 Truck problem: IMR/IMD not met Follow the procedure for error code 224 Follow the procedure for error code 213 Replace the BMS (see chapter 6: Lithium-ion battery, BMS)

Go to step 6 Go to step 7

Go to step 2 Go to step 3

Go to step 4

Go to step 8

Go to step 5

Go to step 8

END

END

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Description: A module is overheating (2nd level) Error code 207 appears Error code 118 appears Ambient temperature too high Stop using the battery until the temperature decreases Follow the procedure for error code 207 Follow the procedure for error code 118

Description: A module is under heated (2nd level) Error code 207 appears Error code 118 appears Ambient temperature too low Expose the battery to a higher temperature so that it warms up Follow the procedure for error code 207 Follow the procedure for error code 118

Description: A cell is overloading (2nd level) Discharge the battery for 10 minutes at a rate of 20 A Switch the battery off and on again Error code 204 still appears

-20

Go to step 2 Go to step 3 Go to step 4

11528070901 EN - 01/2020

Go to step 5

Replace the battery, referring to the BIS Error resolved (or corrected)

END

END

END

END

Go to step 3

Go to step 9

Description: A cell is under voltage Replace the battery Refer to the BIS

Go to step 2

Description: Cell voltage outside the range Switch the battery off and on again Error code 206 still appears Switch off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 206 still appears Replace the battery Refer to the BIS Switch on the battery Error code 206 still appears Error resolved (or corrected)

Go to step 2

Go to step 12 Go to step 5

Go to step 4 Go to step 9 Go to step 6 Go to step 7 Go to step 8

Go to step 9 END

Go to step 9 END

Go to step 3

Go to step 10

Description: Too many modules have a temperature that is outside the range Switch the battery off and on again Error code 207 still appears Switch off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 207 still appears

Go to step 2

Go to step 4 Go to step 5

Go to step 10

Replace the battery

Go to step 6

Refer to the BIS

Go to step 7

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

Go to step 8 Go to step 9

Go to step 10

END

END

11528070901 EN - 01/2020

-21

Description: A connection temperature is outside the range Switch the battery off and on again Error code 208 still appears Switch off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 208 still appears Replace the battery

Go to step 2 Go to step 3

Go to step 9 Go to step 4

Go to step 5

Go to step 9 Go to step 6

Switch on the battery

Go to step 7

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

Go to step 8

Go to step 9

END

END

Go to step 10 Go to step 4

Go to step 3 Go to step 9

Description: Unexpected status of battery contactor (open) Switch the battery off and on again Error code 217 appears Error code 209 appears Switch off the battery Disconnect and reconnect the signal connector for the power plate Switch on the battery Error code 209 appears Replace the contactor (see chapter 6: Lithium-ion battery, power plate) Error code 209 appears Replace the BMU harness (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 217

Go to step 2

Go to step 5 Go to step 6

Go to step 9 Go to step 7

Go to step 8

Go to step 9

END

END

Description: Unexpected status of battery contactor (closed) Check that the truck is disconnected during the test

-22

11528070901 EN - 01/2020

Go to step 2

Press the button to switch off the battery Press the button to switch on the battery Error code 217 appears Error code 210 appears Switch off the battery Disconnect and reconnect the signal connector for the power plate Switch on the battery Error code 210 appears Replace the contactor (see chapter 6: Lithium-ion battery, power plate) Error code 210 appears Replace the BMU harness (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 217

Go to step 10 Go to step 4

Go to step 3 Go to step 9 Go to step 5

Go to step 6

Go to step 9 Go to step 7

Go to step 8

Go to step 9

END

END

Go to step 6 Go to step 7

Go to step 2 Go to step 3

Go to step 8

Go to step 5

END

END

Go to step 6 Go to step 7

Go to step 2 Go to step 3

Go to step 8

Go to step 5

END

END

Description: Excess current when charging Error code 224 appears Error code 210 appears Restart the battery Error code 210 appears Charge or regeneration problem They do not meet the IMR thresholds After restarting, the battery should be functional Follow the procedure for error code 224 Follow the procedure for error code 213 Follow the procedure for error code 217

Go to step 4

Description: Excess current during discharge Error code 224 appears Error code 213 appears Restart the battery Error code 217 appears Discharge problem: The IMD thresholds have not been met After restarting, the battery should be functional Follow the procedure for error code 224 Follow the procedure for error code 213 Follow the procedure for error code 217

Go to step 4

11528070901 EN - 01/2020

-23

Description: Blown fuse Switch the battery off and on again Error code 213 appears Check that the battery fuse is in good condition Fuse OK? Error code 213 appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Replace the battery fuse (see chapter 6: Lithium-ion battery, power plate)

Go to step 2 Go to step 3

Go to step 7 Go to step 4

Go to step 5 Go to step 6

Go to step 8 Go to step 7

END

END

Go to step 6 Go to step 4

Go to step 3 Go to step 5

END

END

Go to step 9 Go to step 10

Go to step 2 Go to step 3

Description: SMU card reconnection failure Switch the battery off and on again Error code 217 appears Error code 215 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 217

Go to step 2

Description: A module connection is overheating Error code 100 appears Error code 202 appears Check the tightening torque of the power connections for the module and wait 30 minutes Switch the battery off and on again Error code 217 appears Error code 216 still appears Replace the battery Error resolved (or corrected) Follow the procedure for error code 100 Follow the procedure for error code 202 Follow the procedure for error code 217

Go to step 4 Go to step 5 Go to step 11 Go to step 7

Go to step 6 Go to step 8

END

END

Description: Battery current sensor outside the range (lost) -24

11528070901 EN - 01/2020

Switch the battery off and on again Error code 217 appears Error resolved (or corrected) Follow the procedure for error code 217

Go to step 2 Go to step 4 END

Go to step 3 END

END

END

Description: Self-testing failure Dump the BMU Black Box and contact SAFT (Linde support maintenance technician contacts and SAFT support contacts)

Description: Pre-charge failure

Switch off the battery Check that no additional electrical components are connected to the battery Switch on the battery Error code 218 appears Disconnect the battery from the truck Switch the battery off and on again Error code 218 appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Problem on the truck electrical harness

Go to step 2 Go to step 3

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

Go to step 6

Go to step 8

END

END

Description: Low supply voltage of the SMU card Switch the battery off and on again Error code 225 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

Go to step 2 Go to step 3

Go to step 4

END

END

Description: Total number of invalid cells

11528070901 EN - 01/2020

-25

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

Go to step 2 Go to step 3

Go to step 4

END

END

Description: Battery voltage above the limit Switch the battery off and on again Error code 222 still appears Error code 102 appears Error code 204 appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 102 Follow the procedure for error code 204

-26

Go to step 2 Go to step 3 Go to step 7 Go to step 8

Go to step 6 Go to step 4 Go to step 5

END

END

11528070901 EN - 01/2020

Reset levels: Automatic reset: If required, move the battery to somewhere that is at ambient temperature.

Truck reset: Press the button for . for

ON/OFF reset (safe mode): Press the button OR .

*BMS: Battery Management System = Unit made up of the BMU and SMU. *BMU: Battery Monitoring Unit = Battery controller. *SMU: Safety and Monitoring Unit. *SOC: State Of Charge. *IMD: Maximum discharge current allowed. *IMR: Maximum charging current allowed.

11528070901 EN - 01/2020

-27

100 101 102 103 110

111 113 115 116 118

200

201

202 203 204 205 206 208

-28

Temperature of the module > 60°C for 1 second Temperature of the A module is under heatmodule < -23°C for 1 ed 1st level second A cell is overloading Voltage of a cell > 1st level 4.05 V for 2 seconds Voltage of a cell < 2.9 V A cell is under voltage for 2 seconds Measured charging curDifference in charging rent of the battery > max current 1st level (1.05 x IMR*; 2.00000) for 5 seconds Measured charging curDifference in charging rent of the battery > max current 2nd level (1.1 x IMR*; 2.00000) for 5 seconds Minimum SOC 0% for Low SOC* 1st level 5 seconds At least one BMS (SMU) BMS (SMU) communiassignment has failed cation problem more than three times Maximum temperature A module connection is connection > 80°C for 1 overheating second Maximum difference in Inconsistent temperatemperature of the modtures ule > 10°C for 1 second The redundant hardRedundant safety ware emergency chain events reported by the is active for 500 millisecBMS (SMU) modules onds Battery current > 340 A Activation of the battery or the voltage drops in contactor after a short the fuse > 5 V for 2 seccircuit (blown fuses) onds Temperature of the A module is overheating module > 65°C for 1 2nd level second Temperature of the A module is under heatmodule < -25°C for 1 ed 2nd level second A cell is overloading Voltage of a cell > 2nd level 4.13 V for 2 seconds Voltage of a cell < 2.3 V A cell is under voltage for 2 seconds If the voltage of at least Cell voltage outside the one cell is outside the range range for 2 seconds A connection temperaA connection temperature < -29°C or > 115°C ture is outside the range for 1 second A module is overheating 1st level

11528070901 EN - 01/2020

Automatic reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset Automatic reset / truck reset / ON/OFF reset ON/OFF reset

ON/OFF reset

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

209

210

211

212

213

214

215

216

217

218

Inconsistency between the contactor control Unexpected status of (closed) and the actual battery contactor (open) state of the contactor (open) for 5 seconds Inconsistency between the control of the conUnexpected status of tactor (open) and the battery contactor actual state of the con(closed) tactor (closed) for 5 seconds Measured charging curExcess current when rent of the battery > max charging (1.15 x IMR*; 2.00000) for 5 seconds Measured discharge Excess current during current of the battery > discharge max (1.10 x IMD*; 2.00000) for 5 seconds Detection of a blown fuse for more than 3 seconds (difference between the Blown fuse voltage of the fuse and the voltage of the battery > 4 V for more than 3 seconds) CAN message not received correctly by the BMS (BMU) for 5 secCommunication with the onds when the battery is truck lost outside the tolerance range (charging or discharging) Number of attempts to BMS (SMU) reconnec- reconnect greater than tion failure three for the BMS (SMU) Maximum temperature A module connection is connection > 90°C for 1 overheating second If the integrated tests (at start-up, continuously, on request, when Self-testing failure switching off) have failed (one unsuccessful attempt is regarded as a failure) If the voltage of the battery contactor is still > 4.00000 V 3 seconds afPre-charge failure ter the command to close the main precharge contactor or if a

11528070901 EN - 01/2020

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

-29

222

224

225

-30

contactor is open even though it was ordered to close Battery voltage above Battery voltage > the limit 28.35 V for 2 seconds The battery current is outside the range for 2 seconds or the main Battery current sensor contactors are open and outside the range (lost) the battery current > 2.00000 A or < -2.000 A for 2 seconds If the BMS (SMU) supply is active on the BMS Low supply voltage of (BMU) and the supply BMS (SMU) voltage is not detected in 0.2 seconds

11528070901 EN - 01/2020

ON/OFF reset

ON/OFF reset

ON/OFF reset

BIS: Battery Information Sheet

Description: A module is overheating (1st level) Error code 207 appears Error code 118 appears High ambient temperature Stop using the battery until the temperature decreases Follow the procedure for error code 207 Follow the procedure for error code 118

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Description: A module is under heated (1st level) Error code 207 appears Error code 118 appears Low ambient temperature Expose the battery to a higher temperature so that it warms up Follow the procedure for error code 207 Follow the procedure for error code 118

Description: A cell is overloading (1st level) Discharge the battery for 10 minutes at a rate of 20 A Error code 102 still appears Replace the battery, referring to the BIS Error resolved (or corrected)

Go to step 2 Go to step 3

Go to step 4

END

END

Description: A cell is under voltage Charge the battery for 20 minutes at 10 A Error code 103 still appears Replace the battery Refer to the BIS Error resolved (or corrected)

Go to step 2 Go to step 3

Go to step 5 Go to step 4

END

11528070901 EN - 01/2020

END

-31

Description: Invalid state of charge (SOC) Switch the battery off and on again Error code 217 appears Error code 107 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 217

Go to step 2 Go to step 6 Go to step 4

Go to step 3 Go to step 5

END

END

Go to step 3

Go to step 2

END

END

Go to step 3

Go to step 2

END

END

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Description: Difference in charging current (1st level) Error code 211 appears Charge or regeneration problem They do not meet the IMR thresholds After restarting, the battery should be functional Follow the procedure for error code 211

Description: Difference in charging current (2nd level) Error code 211 appears Charge or regeneration problem They do not meet the IMR thresholds After restarting, the battery should be functional Follow the procedure for error code 211

Description: Low state of charge (1st level) Error code 103 appears Error code 205 appears The battery charge level is low: charge the battery Follow the procedure for error code 103 Follow the procedure for error code 205

Description: Low state of charge (2nd level)

-32

11528070901 EN - 01/2020

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

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Go to step 6 Go to step 4

Go to step 3 Go to step 5

END

END

Go to step 9 Go to step 10

Go to step 2 Go to step 3

Description: Communication problem with the SMU card Switch the battery off and on again Error code 217 appears Error code 115 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 217

Go to step 2

Description: A module connection is overheating Error code 100 appears Error code 202 appears Check the tightening torque of the power connections for the module and wait 20 minutes Switch the battery off and on again Error code 217 appears Error code 116 still appears Replace the battery Error resolved (or corrected) Follow the procedure for error code 100 Follow the procedure for error code 202 Follow the procedure for error code 217

Go to step 4 Go to step 5 Go to step 11 Go to step 7

Go to step 6 Go to step 8

END

END

Description: Inconsistent temperatures Replace the module (see chapter 6: Lithium-ion battery, Module) Refer to the BIS

Go to step 2 END

11528070901 EN - 01/2020

END

-33

Description: The IMD/IMR charging/discharge currents of the algorithm are invalid Switch the battery off and on again Error code 217 appears Error code 121 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 217

Go to step 2 Go to step 6 Go to step 4

Go to step 3 Go to step 5 Go to step 10

END

END

Go to step 10 Go to step 11 Go to step 12

Go to step 2 Go to step 3 Go to step 4

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

Error code 202 appears Error code 205 appears Error code 204 appears Cut off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 200 still active?

Replace the battery, referring to the BIS Error code 200 still active?

Error resolved (or corrected) Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Follow the procedure for error code 202 Follow the procedure for error code 205 Follow the procedure for error code 204

Go to step 5 Go to step 6

Go to step 8

Go to step 12 END

Go to step 9 END

Go to step 6 Go to step 7

Go to step 2 Go to step 3

Go to step 4

Go to step 8

Go to step 5

Go to step 8

END

END

Go to step 7

Description: Activation of the battery contactor after a short circuit (fuse blown) Error code 224 appears Error code 213 appears Error code 211 or error code 212 appears Error code 210 appears Follow the procedure for error code 210 Truck problem: IMR/IMD not met Follow the procedure for error code 224 Follow the procedure for error code 213 Replace the BMS (see chapter 6: Lithium-ion battery, BMS) -34

11528070901 EN - 01/2020

Description: A module is overheating (2nd level) Error code 207 appears Error code 118 appears Ambient temperature too high Stop using the battery until the temperature decreases Follow the procedure for error code 207 Follow the procedure for error code 118

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Description: A module is under heated (2nd level) Error code 207 appears Error code 118 appears Ambient temperature too low Expose the battery to a higher temperature so that it warms up Follow the procedure for error code 207 Follow the procedure for error code 118

Description: A cell is overloading (2nd level) Discharge the battery for 10 minutes at a rate of 20 A Switch the battery off and on again Error code 204 still appears Replace the battery, referring to the BIS Error resolved (or corrected)

Go to step 2 Go to step 3 Go to step 4

Go to step 5

END

END

END

END

Go to step 3 Go to step 12

Go to step 9

Description: A cell is under voltage Replace the battery Refer to the BIS

Go to step 2

Description: Cell voltage outside the range Switch the battery off and on again Error code 206 still appears Switch off the battery

Go to step 2

11528070901 EN - 01/2020

Go to step 4 -35

Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 206 still appears Replace the battery Refer to the BIS Switch on the battery Error code 206 still appears Error resolved (or corrected)

Go to step 5

Go to step 9 Go to step 6 Go to step 7 Go to step 8

Go to step 9 END

Go to step 9 END

Go to step 3

Go to step 10

Description: Too many modules have a temperature that is outside the range Switch the battery off and on again Error code 207 still appears Switch off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 207 still appears

Go to step 2

Go to step 4 Go to step 5

Go to step 10

Replace the battery

Go to step 6

Refer to the BIS

Go to step 7

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

Go to step 8 Go to step 9

Go to step 10

END

END

Go to step 3

Go to step 9

Description: A connection temperature is outside the range Switch the battery off and on again Error code 208 still appears Switch off the battery Change the SMU harness (see chapter 6: Lithium-ion battery, BMS) Switch on the battery Error code 208 still appears Replace the battery

Go to step 2

Go to step 4 Go to step 5

Go to step 9 Go to step 6

Switch on the battery Error code 208 still appears

-36

Go to step 7 Go to step 8

11528070901 EN - 01/2020

Go to step 9

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

END

END

Go to step 10 Go to step 4

Go to step 3 Go to step 9

Description: Unexpected status of battery contactor (open) Switch the battery off and on again Error code 217 appears Error code 209 appears Switch off the battery Disconnect and reconnect the signal connector for the power plate Switch on the battery Error code 209 appears Replace the contactor (see chapter 6: Lithium-ion battery, power plate) Error code 209 appears Replace the BMU harness (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 217

Go to step 2

Go to step 5 Go to step 6

Go to step 9 Go to step 7

Go to step 8

Go to step 9

END

END

Description: Unexpected status of battery contactor (closed) Check that the truck is disconnected during the test Press the button to switch off the battery Press the button to switch on the battery Error code 217 appears Error code 210 appears Switch off the battery Disconnect and reconnect the signal connector for the power plate Switch on the battery Error code 210 appears Replace the contactor (see chapter 6: Lithium-ion battery, power plate) Error code 210 appears Replace the BMU harness (see chapter 6: Lithium-ion battery, BMS)

Go to step 2 Go to step 10 Go to step 4

Go to step 3 Go to step 9 Go to step 5

Go to step 6

Go to step 9 Go to step 7

Go to step 8

11528070901 EN - 01/2020

Go to step 9

-37

Error resolved (or corrected) Follow the procedure for error code 217

END

END

Go to step 6 Go to step 7

Go to step 2 Go to step 3

Go to step 8

Go to step 5

END

END

Go to step 6 Go to step 7

Go to step 2 Go to step 3

Go to step 8

Go to step 5

END

END

Description: Excess current when charging Error code 224 appears Error code 210 appears Restart the battery Error code 210 appears Charge or regeneration problem They do not meet the IMR thresholds After restarting, the battery should be functional Follow the procedure for error code 224 Follow the procedure for error code 213 Follow the procedure for error code 217

Go to step 4

Description: Excess current during discharge Error code 224 appears Error code 213 appears Restart the battery Error code 217 appears Discharge problem: The IMD thresholds have not been met After restarting, the battery should be functional Follow the procedure for error code 224 Follow the procedure for error code 213 Follow the procedure for error code 217

Go to step 4

Description: Blown fuse Switch the battery off and on again Error code 213 appears Check that the battery fuse is in good condition Fuse OK? Error code 213 appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Replace the battery fuse

-38

Go to step 2 Go to step 3

Go to step 7 Go to step 4

Go to step 5 Go to step 6

Go to step 8 Go to step 7

END

END

11528070901 EN - 01/2020

(see chapter 6: Lithium-ion battery, power plate)

Description: SMU card reconnection failure Switch the battery off and on again Error code 217 appears Error code 215 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 217

Go to step 2 Go to step 6 Go to step 4

Go to step 3 Go to step 5

END

END

Go to step 9 Go to step 10

Go to step 2 Go to step 3

Description: A module connection is overheating Error code 100 appears Error code 202 appears Check the tightening torque of the power connections for the module and wait 30 minutes Switch the battery off and on again Error code 217 appears Error code 216 still appears Replace the battery Error resolved (or corrected) Follow the procedure for error code 100 Follow the procedure for error code 202 Follow the procedure for error code 217

Go to step 4 Go to step 5 Go to step 11 Go to step 7

Go to step 6 Go to step 8

END

END

Go to step 4 END

Go to step 3 END

Description: Battery current sensor outside the range (lost) Switch the battery off and on again Error code 217 appears Error resolved (or corrected) Follow the procedure for error code 217

Go to step 2

Description: Self-testing failure

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-39

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

END

END

Description: Pre-charge failure

Switch off the battery Check that no additional electrical components are connected to the battery Switch on the battery Error code 218 appears Disconnect the battery from the truck Switch the battery off and on again Error code 218 appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Problem on the truck electrical harness

Go to step 2 Go to step 3

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

Go to step 6

Go to step 8

END

END

Go to step 3

Go to step 4

END

END

Go to step 3

Go to step 4

END

END

Description: Low supply voltage of the SMU card Switch the battery off and on again Error code 225 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

Go to step 2

Description: Total number of invalid cells Switch the battery off and on again Error code 221 still appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected)

Go to step 2

Description: Battery voltage above the limit

-40

11528070901 EN - 01/2020

Switch the battery off and on again Error code 222 still appears Error code 102 appears Error code 204 appears Replace the BMS (see chapter 6: Lithium-ion battery, BMS) Error resolved (or corrected) Follow the procedure for error code 102 Follow the procedure for error code 204

Go to step 2 Go to step 3 Go to step 7 Go to step 8

Go to step 6 Go to step 4 Go to step 5

END

END

11528070901 EN - 01/2020

-41

The battery or the module must be stored for a minimum of four hours prior to completing the checklist.

Determination of damage or fault

Not damaged or faulty

Damaged or faulty

No warning, no alarm

New

Used

Category 1

For destruction or recycling

Warning (no alarm)

Measures to take

Category 3

Determination of risk

Category 2 Category 6

No risk

Risk

Category 4

Category 5

There are six categories: Category 1 2

Function New battery or new module Used battery or module

3

Battery with warning

4 5 6

-42

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

11528070901 EN - 01/2020

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

(*) Description of measure s

Has the product been identified as faulty for safety reasons? NO YES Not determined Is electrolyte leaking from the product? NO

YES

Not determined

Has the product suffered material or mechanical damage? NO YES Not determined Was it not possible to carry out the diagnostic before transport? NO YES Not determined

Vapour or fumes observed? NO

YES

Abnormal heat or increased temperature? NO YES

Abnormal, combustion-like smell? NO

YES

Is at least one alarm activated? (not applicable for a single module) NO YES Not determined

Is one of the following error codes active? NO

Could the anomaly or fault impact the results of UN test certification? NO YES Not determined

Error codes: 200, 202, 204, 205+100, 210, 218, 224

Could the battery be damaged or faulty? NO

Do the following apply? LED illuminated + no communication with the battery (no signal from the BMU) NO YES Not determined

YES Not determined

: Battery not damaged or faulty = CATEGORY 1, 2, 3 or 6, go to step 4 : Battery damaged or faulty = CATEGORY 4 or 5, go to step 2

YES Not determined

NO YES

Category 1: New battery or new module Category 2: Used battery or module Category 3: Battery with warning

Rest period after a fault or non-compliN/A ance:

Category 4: Damaged or faulty battery or module without risk

Repair/exchange to obtain the initial design?

Category 5: Damaged or faulty battery or module with risk

Product deactivated? NO

Category 6: Battery or module for destruction or recycling

NO YES N/A

YES N/A

Other *

11528070901 EN - 01/2020

-43

1

Full charge: 100% Battery charge level represenLow charge: 10% Discharged: ted by 10 bars 0%

2

Maintenance alarm (red)

3

Red indicator light

4

Green indicator light

5

Error code

6

Fault or brake wear (air gap)

7

Hour meter

-44

91% 100%: 10 bars 1% 10%: 1 bar 0%: 1 flashing bar (lift function not permitted).

Note: To protect the battery, 0% corresponds to max. 80% discharge.

Flashing: less than 50 hours' truck operation until the next service Constant: service date overdue Switched on: fault or alarm Switched off: truck switched off Switched on: truck switched on E3 294

Indicates the number of operating hours of the machine

11528070901 EN - 01/2020

These codes will help the AfterSales Service to decide on the appropriate response from the service engineer.

Do not operate the truck - The meter starts running when the machine is switched on and a control is used.

8

STOP alarm (red)

9

Temperature alarm (red)

10 Tortoise position

- When counting, the dot next to the tenths of an hour flashes.

- The hour meter displays hours and tenths of an hour.

- When the power supply is cut, the hours are stored in the memory.

Miscellaneous problems Do not operate the truck.

-> Truck is stopped Constant: control module overIn general, wait a few minutes temperature and then continue.

Gentle acceleration and decelMaximum speed: 4 km/h eration

The alarm indicator lights go out as soon as the fault disappears.

To find the description of a given error code, see the Error codes module.

11528070901 EN - 01/2020

-45

1 2 3

F2: Diagnostics Jobs Execute

4 4 4

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

F2: Diagnostics Jobs

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

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

Select job (4)

Execute

Different types of error list can be selected: 1 Current errors Details all errors that are currently active 2 Errors since the last start-up

-46

3

Read error list Delete error list Read error ring buffer

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

11528070901 EN - 01/2020

1 2 3 4 5

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

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

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

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

6 7 8 9

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

Three-phase asynchronous motor Operating voltage (V) 24 Power rating (kW) 1.2 Amperage (A) 76 Nominal speed (rpm) 2720 Service rate S2 - 60 mins* Power supply fre95 quency (Hz) Model

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

11528070901 EN - 01/2020

-1

1 2 3 4

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

-2

5 6 7 8

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

11528070901 EN - 01/2020

– Disconnect the battery connector.

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

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

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

– Remove the cable ties.

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

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

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



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

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

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

– Remove the hub (7).

Dangerous materials handling procedure. The motor is heavy.

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

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

The wearing of gloves is recommended.

– Remove the traction motor from above.

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

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

11528070901 EN - 01/2020

-3

Risk of short circuit!

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

-4

11528070901 EN - 01/2020

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

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

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

– Disconnect the battery connector.

– Remove all the covers from the technical compartment (see Chapter 01 -> Maintenance -> Chassis, bodywork and fittings: Accessing the technical compartment).

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

– Disconnect the connector (7X6).

– Remove the cable ties.

11528070901 EN - 01/2020

-5

– Unscrew the socket head screw (2).

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

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

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

Rev sensors from other trucks should not be used.

Risk of short circuit and overheating.

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

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

The temperature sensor can be parameterised using the diagnostic tool (see Chapter 60 -> LAC 02 traction -> Checking the operation of the rev sensor 1B2).

-6

11528070901 EN - 01/2020

Up to 07/2018: The motor is equipped with a KTY84 temperature sensor.

From 07/2018: The motor is equipped with a PT1000 temperature sensor.

The KTY84 temperature sensor has different characteristics to the PT1000 temperature sensor.

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

The temperature sensor can be configured using the diagnostic tool (see Chapter 60 -> LAC traction and lift -> Checking the operation of the temperature sensor).

The resistance values are listed in Chapter 60 -> LAC traction and lift -> Checking the operation of the KTY and PT1000 temperature sensors.

11528070901 EN - 01/2020

-7

-8

11528070901 EN - 01/2020

1 2 3 4 5

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

6 7 8 9 10 11

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

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

Turning is provided by the tiller.

Drive wheel driven by a transmission gear (3).

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

11528070901 EN - 01/2020

-1

– Disconnect the battery connector.

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

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



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

– Remove the cable ties.

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

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

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



– Fit a lifting eye bolt (5).

– Sling the motor.

– Unscrew the six screws (6).

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

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

– Remove the drive wheel.

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

Wearing gloves is recommended.

– Remove the drive unit from below.

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

Risk of short circuit and overheating.

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

-2

11528070901 EN - 01/2020

Drive wheel driven by a transmission gear.

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

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

11528070901 EN - 01/2020

-3

-4

11528070901 EN - 01/2020

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

Sealing ring 35 x 62 x 7 Breather (fitted with loctite 603) Tapered roller bearing 30204 DIN 720 M8 x 25 mounting socket head screw of the reducer housing / turntable (tightening torque 23 Nm) Stop ring Helical teeth wheel ( z=96) Bevel pinion shaft Tapered roller bearing 30303 DIN 720 Spacing washer Reducer housing Sealing ring 100 x 140 x 1 Wheel shaft (tapered torque) H M14 x 1.5 x 55 head screw (tightening torque 195 Nm)

14 15 16 17 18 19 20 21 22 23

11528070901 EN - 01/2020

Locking washer 59 mm M12 x 1.5 x 25 wheel stud (tightening torque 35 Nm) Tapered roller bearing 32010 DIN 720 Guide pin M8 x 25 mounting socket head screw of the reducer housing / turntable (tightening torque 23 Nm) Turntable (Note: permanently lubricated) M10 chassis mounting tapped holes Stop ring Traction motor bearing casing 6007 DIN 625 Thread protection ring

-5

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

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



– Remove the drive wheel.

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



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



-6

11528070901 EN - 01/2020

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



– Chock the truck using wooden wedges (5).



Dangerous materials handling procedure.

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

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

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

– Lubricate the bearing of the transmission gear.

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



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

11528070901 EN - 01/2020

-7

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

-8



11528070901 EN - 01/2020

1 2 3 4 5 6 7

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

8 9

Ring 25x28x25 M8x25-A2R-8.8 button head screw or M8x25-10.9-PHR socket head screw (with Loctite threadlock) Platform assembly Guard plate

10 11

The platform (standard version and cold store version) is made up of:

A shock-absorbing floor (11) with a touchsensitive mat (1) to detect the presence of the operator A 1500-N gas spring

11528070901 EN - 01/2020

-1

Dangerous materials handling procedure.

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

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

-2



11528070901 EN - 01/2020

– Remove the guard plate



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

– Chock the platform as shown.



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



11528070901 EN - 01/2020

-3

– Remove the platform from the chassis.



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

The tightening torque for the four mounting screws (5) is .

-4

11528070901 EN - 01/2020

1 2 3 4 5 6

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

7 8 9 10 11

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

Risk of short circuit.

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

11528070901 EN - 01/2020

-5

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

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

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

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

-6

11528070901 EN - 01/2020

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

– Unscrew the 2 cutting screws (12)



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



11528070901 EN - 01/2020

-7

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

– Unscrew the 2 horizontal fixing screws (13)



– Unscrew the 2 vertical fixing screws (14)



-8

11528070901 EN - 01/2020

For standard batteries fitted in standard compartments, the battery capacity can be up to 375 Ah. For lithium-ion batteries fitted in standard compartments, the battery capacity can be up to 164 Ah. Battery Standard 2 PzS-B 2 PzS 3 PzS Battery Li-ion 2 PzS-B 2 PzS

Battery compartment Vertical 150 Ah 230/250 Ah 345/375 Ah Battery compartment Vertical 82/164 Ah [-]

For batteries fitted in special compartments that are equipped with attachment points, the battery capacity can be up to 375 Ah. For lithium-ion batteries fitted in special compartments that are equipped with attachment points, the battery capacity can be up to 410 Ah

Width (mm)

Height (mm)

158 198 198

595 627 627

Width (mm)

Height (mm)

158 [-]

627 [-]

11528070901 EN - 01/2020

Battery compartment Side [-] 230/250 Ah 345/375 Ah Battery compartment Side [-] 205/410 Ah

Width (mm)

Height (mm)

[-] 198 198

[-] 627 627

Width (mm)

Height (mm)

[-] 198

[-] 618

-9

-10

11528070901 EN - 01/2020

The standard tiller head consists of a formed double handle (1) containing a p. c. board (2), 3 pushbuttons (lifting, lowering and horn), 2 butterfly switches (throttles) for traction, a safety microswitch with belly button (12) and 3 covers (4, 5 and 6).

In the event of a failure of the tiller head, the whole p. c. board assembly must be replaced.

When the throttles are operated, they are connected with a potentiometer, which changes the desired value according to of the rotation angle of the throttles (butterflies). The 3 pushbuttons are "on/off" switches.

The communication between the tiller head and the controller is by "wire".

Safety microswitch (7) PC board assy (2) Throttles for directions of travel (8) Horn push (9) Lift button (10) Lowering button (11) Belly button (12)

From now on, all tiller heads have a label with the week and the year of the manufacture affixed.

11528070901 EN - 01/2020

-1

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

-2

11528070901 EN - 01/2020

– Remove the battery plug.

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

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



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



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

11528070901 EN - 01/2020

-3

– Remove the 2 socket head screws (3).



– Remove the flange (4).



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



-4

11528070901 EN - 01/2020

– Unscrew the screw (5) located below the unit.



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



– Then remove the printed circuit board.

11528070901 EN - 01/2020

-5

– Unscrew the two screws (8).



– The tiller head is now removed.

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



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



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

For reassembly, proceed in reverse order to removal.

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

-6

11528070901 EN - 01/2020

The gas-filled spring inside the tiller is under high pressure.

For its removal, set the tiller to the home position.

– Separate the two shells (1) and (2) by placing a flat screwdriver in the slot between the two shells (see removal of the tiller head for procedure).



– Remove the cover (1).

– Remove the screw (3).

– Also remove the two other screws (4) at the base of the tiller.



– Remove the tiller cover (5).



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-7

– Remove the two pivot locks (6) and (7).



– Use a flat screwdriver to take the two locks off.



– Remove the top part of the cylinder with a flat screwdriver.



– Also remove the bottom part of the cylinder.

-8

11528070901 EN - 01/2020

The installation is carried out in the reverse order of removal: – First insert the lower part of the cylinder and lock it.

– Insert the upper part of the cylinder and lock it.

The tiller cable must always be removed first.

– The tiller head must be removed so that the cable loom can be disconnected from the p. c. board in the tiller Chapter "Removing the tiller head ", Page 42-3 .

– Open the tiller and take the top part of the gas-filled spring out of its mounting Chapter "Gas-filled spring", Page 42-7 .

– Continue to drive out the pin (1) until pin (2) can be extracted from the tiller base.



– Pull the pin out of the tiller base (2).

– Remove the tiller.

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-9

1 2 3 4 5

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

6 7 e

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

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

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

Nominal brake torque Supply voltage Power Braking resistance (between 7X6:9 and 7X6:10)

-10

11528070901 EN - 01/2020

12 Nm 24 V 25 W 16 (±1)

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

Stabiliser clevis M27X1.5 tightening locknut (36 mm spanner) Special ball bearing 80x21 2RS (36 mm flat spanner) Locking rings DIN 472 80x2.5 125x40 stabiliser wheel Thread guard M14x75 calibrated pin H ISO 4014 M12x80 screw Support washer Damper H ISO 7040 M12x80 head nut Spacer Bearing shield H M14 head nut

15

Support wheel (unit)

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

Hexagon nut M27x1.5 Bush Locking ring 80x2.5 Swivel fork Fork part Spacer Hexagon head screw M12x100-8.8-A2C Nut H M12-8-A2C Washer Spring element Stop (stop screw) Nut H M8-8-A2C Wheel Thread guard Spacer Nut H M12-8-A2C Grease nipples (lubricated version only)

(B): "green" stabiliser 83° Shore A 30 204 ±0.7 x x

Hardness of the buffers Preload (daN) Distance (bearing/ground) (mm) Non-lubricated version (standard) Lubricated version (option)

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-11

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

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

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

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

Forbidden on 1152 type trucks with a BS or lithiumion battery.

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

Cylinder

Spring

-12

Input force of the rod (N) Output force of the rod (N) Steepness (N/mm) Da (mm) d (mm) Lo (mm)

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2000 120 12.9 40 5 120

1 2 3 4 5 6 7 8 9

Support wheel (unit) Hexagon nut M27x1.5 Bush Locking ring 80x2.5 Swivel fork Fork part Spacer Hexagon head screw M12x100-8.8-A2C Nut H M12-8-A2C

10 11 12 13 14 15 16 17 18

Washer Spring element 31x44 Stop (stop screw) Nut H M8-8-A2C Wheel Thread guard Spacer Nut H M12-8-A2C Grease nipples (lubricated version only)

Trucks with a lithium-ion battery are only equipped with these stabilisers.

"Black" stabiliser 70° ± 4° Shore A x x

Hardness of the buffers Non-lubricated version Lubricated version (option)

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-13

1

Drive wheel

230 x 75 mm

2

Wheel nut DIN 74361 A12-10-A2C (quantity 5)

– Remove the 5 wheel nuts (2) Dangerous materials handling procedure. The drive wheel is heavy, proceed with care when replacing it.

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

The wearing of gloves is recommended.

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

– Fully lift the load arms.

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

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

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

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

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

– Chock the truck a few centimetres from the ground

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– Remove the screw and the nut.

A jack A wooden wedge A size 19 open-ended spanner A ratchet handle and size 19 socket A torque wrench and size 19 fitting – Fully lift the load arms.

– Press out the wheel (4).

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

– Disconnect the battery connector.

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

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

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

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

– Refit the wheel.

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

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

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

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

– Proceed in the reverse order to removal.

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A jack Wooden wedges

-16

A power screwdriver and its bit A pin punch

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– Fully lift the load arms.

– Disconnect the battery connector.

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-17

– Raise the truck a few centimetres using a jack.

– Raise the truck a few centimetres using a jack.

– Sling the truck until the wheels are off the ground.

– Sling the truck until the wheels are off the ground (other possibility).

– Chock the load arms using wooden wedges (1).

– Chock the load arms using wooden wedges.

– Loosen the screw for a single wheel.

– Loosen the screws for a double wheel (2).

– Remove the load arm shaft using a pin punch (5).

– Remove the screw for a single wheel.

– Remove the screws for a double wheel (3) (tightening torque: ).

– Remove the load roller(s).

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

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

– Perform an initial lift.

– Use a pin punch (4) to remove the pin from the bogie pivot shaft.

– Remove the bogie clevis shaft and its spacer (6).

– Use a pin punch (7) to remove the central pin from the push rod.

– Remove the push rod shaft using a pin punch (8).

– Remove the fork clevis (9).

– Remove the load wheels (see above).

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

– Disconnect the battery connector.

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

Electrical plate mounting Initial lift cylinder LFM GO option Diagnostic plug connector 7.5A control circuit fuse Battery socket connector Hour meter, battery discharge indicator Key switch 125A power circuit fuse Line switch Traction and lift controller (LAC) Traction controller connector -

13 14 15 16 17 18 19 20

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Tiller harness connector Tiller foot sensor (or potentiometer) connector Motor temperature and speed sensor connector Tiller Pump unit Lowering solenoid valve, Initial Lift Location of the on-board battery charger option Warning horn -

-1

There are 2 versions: pedestrian mode pedestrian and ride-on mode the truck is mechanically immobilised by the electromagnetic brake no traction when the accelerator is activated the hour meter only counts when an actuator is in operation (e.g. lift or traction motor). authorised lifting of load arms; lowering of the load arms not authorised. truck brake released when accelerator is activated traction when accelerator is activated tiller accelerator (optional) active; lifting of the load arms authorised at the tiller lowering of the load arms authorised the hour meter only counts when an actuator is in operation (e.g. lift or traction motor).

Speed limited to 6 km/h in both directions of travel Parking brake applied automatically when: - The tiller is released in the park position - Emergency braking by hitting the tiller foot rubber stop - Truck stationary, direction reverser in neutral - Power off

-2

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- There is a fault in the traction control Counter-current and regenerative braking upon accelerator release and by reversing the direction of travel.

Standby times (min)

Default Min Max

5 1 5

5 1 5

Activation of standby function (on/off)

Default Min Max

Off Off On

Off Off On

Default Min Max Default Min Max Default Min Max Default Min Max

6 1 6 6 1 6 2 0.1 3 2.5 0.1 3

6 1 6 6 1 6 2 0.1 3 2.5 0.1 3

Default Min Max Default Min Max Default Min Max

4 1 6 2.5 0.1 3 2.5 0.1 3

4 1 6 2.5 0.1 3 2.5 0.1 3

Default Min Max Default Min Max

4 1 4 6 3 10

4 1 4 6 3 10

Default

3000

3000

Min

1000

1000

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

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

Anti-crush speed - Button pressed (km/h) Operating time of anticrushing function (s) Braking torque by reversing the direction of travel (N)

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-3

Max Default Min Max Default Min Max

4000 2000 1000 4000 900 0 900

4000 2000 1000 4000 900 0 900

Angle of tiller for maximum speed (%)

Default Min Max

7.5 0 50

7.5 0 50

Pump motor rotation speed (%)

Default Min Max

100% 0% 100%

100% 0% 100%

Hour meter setting (h)

Default Min Max

Braking torque butterfly valve released (N) Booster torque (N)

Default Hour meter count mode

Next service (h)

Service reminder (h)

Battery type

Min Max Default Min Max Default Min Max Default Min Max Default

Battery discharged

Min Max

Cut-off threshold (%)

Indicator adjustment

-4

Default Min Max Default Min Max

0 0 0 0 99999.9 99999.9 Counts with traction or Counts with traction or lift lift Other modes Other modes Continuous count Continuous count 1000 1000 0 0 32767 32767 50 50 0 0 10000 10000 Pb Pb Gel Gel Pb Pb Lift cut-out "+" Without Lift cut-out "+" Without reducing traction speed reducing traction speed No lift cut-out "+" Trac- No lift cut-out "+" Traction speed reduction tion speed reduction Lift cut-out "+" Traction Lift cut-out "+" Traction speed reduction speed reduction 0 0 0 0 40 40 0 0 -10 -10 10 10

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1 2 3 4 5

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

6 7 8

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

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

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

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

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-5

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

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

-6

A +4.3V internal voltage regulator supplies: the 1B1 accelerator potentiometer the 1S3 anti-crush button in 1X1:9 the 1B7 tiller accelerator potentiometer (optional) A +5V internal voltage regulator supplies the traction and hydraulic microprocessors After the controller self test, safety relay closure +24V in 1X1:1 and 1X1:29 1K0 line switch closure: +Ub (24V) on the"+" power terminal +Ub (24V) at the 2M1 lift motor terminals in D1

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1 2 4 6 8 9 10 12 13 15 17 18 22 24 26 27 28

Brake Y1 power supply 24V / +Ub LAC LAC +24V power supply 24V / +Ub via S1 or LFM GO 2S7 Initial Lift control 0V signal 0V via 2S7 Forks upper end of travel cut-out 0V / -Ub via 2S10 Speed sensor path A Variable signal 0V-6V / 1B2 Tiller anti-crush safety device power supply +4.3V / LAC Tiller anti-crush safety device in OFF position 0V / -Ub via 1S3 Tiller anti-crush safety device in ON position +4.3V via 1S3 1B6 motor temperature signal Variable signal Internal stabilised voltage circuit +24V power 24V / +Ub via S1 or LFM GO supply Lowering solenoid valve 2Y2 0V / LAC 1K0 line switch negative 0V / LAC 2S6 Initial Lift lowering control 0V signal 0V via 2S6 Speed sensor path B Variable signal 0V-6V / 1B2 1B1 channel 1 accelerator potentiometer set_% / 1B1 ting 1B1 accelerator potentiometer +4.3V power +4.3V / LAC supply CAN high (traction) Safety device connected to 0V not-used

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-7

29 30 31 34 35 36 37 38 39 40 41 42

-8

2Y2, 1K0 solenoid valve +24V power supply 24V / +Ub LAC Internal safety relay +24V power supply 24V / +Ub via S1 or LFM GO Y1 brake control 0V / LAC (brake release) Creep Speed 0V signal in OFF position 0V via 1S10 Creep Speed 0V signal in ON position 0V via 1S10 Tiller in work position 0V signal 0V via 1S4 Channel 1 1B7 tiller potentiometer setting _% / 1B7 Tiller in park position 0V signal 0V via 1S4 Channel 2 1B1 accelerator potentiometer set_% / 1B1 ting Channel 2 1B7 tiller potentiometer setting _% / 1B7 0V power supply of 1B1 accelerator potenti0V / -Ub via LAC power ometer and of 1B7 tiller potentiometer CAN low (traction)

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Fork direction Tiller direction

6 km/h

6 km/h

6 km/h

6 km/h

6 km/h

6 km/h

6 km/h

6 km/h

1->6

Traction speed

1->6 0.5->1.5 1->6

Anti-crush button activated Creep Speed activated Speed reduction sensor (1X1: 20). On UPA* truck only

*: Customer options truck

1.8 1.8 1.8 1.8 4.5 4.5 4.5

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

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291-> 297 209 41 45 40 241; 242 246; 247

-9

The traction potentiometer is operated with the throttle. It consists of two identical, cross-mounted single potentiometers. They are supplied with a voltage of +10 V and are wired so that in the home position of the throttle 5 V is applied to each of the outputs (wiper contacts) and 0 V or 10 V when fully operated. The exact relationship between modulation of the traction potentiometer and desired value for the traction motor controller can be seen in the functional diagram.



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

A B C

Desired traction potentiometer voltages Angle of potentiometer rotation Desired value for traction motor

-10

ZN MAR MAV

Neutral zone of throttle "Reverse" direction of travel "Forward" direction of travel

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1S10

Creep Speed function pull switch

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

Tiller in raised position when the Creep Speed button is pressed: The truck release control is only possible when the accelerator is actuated The maximum speed in both directions of travel is limited by default to 1.5 km/h The speed depends on the position of the accelerator throttle valves The acceleration and the traction torque are limited The Y1 brake is applied when the accelerator returns to the neutral position The Y1 brake is applied when the anticrush safety device is activated Initial lift is possible but initial lowering is not possible

When the Creep Speed button is activated and the tiller is tilted from the high cut-off position to the work position: The Creep Speed function is automatically deactivated and The truck speeds up slowly to reach the accelerator setpoint value When the Creep Speed button is activated and the tiller is tilted from the work position to the high cut-off position: Tiller direction: The Y1 brake is applied Load arm direction: Speed reduction until the Creep Speed value is reached

– Connect the CAN box to the 6X7 diagnostic connector – Connect the CAN box to the laptop connector – Start and diagnostic software and log in

The Creep Speed function is deactivated after 3 to 5 seconds (adjustment in the diagnostic tool) if the accelerator is not operated. To activate the Creep Speed function, simply release the button and actuate it again.

– Check the status of the Creep Speed button on the screen in the following menu:

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F4:Screen Traction

-11

– Connect the CAN box to the laptop connector

Traction Validation

– Start and diagnostic software and log in – To adjust the Creep Speed function, go to the following menu:

:35 Creep 1:34 Creep 2 :

F4:Screen

1 :35 Creep 1 0 :34 Creep 2

Traction :

Speed settings

0 :35 Creep 1 1 :34 Creep 2

Creep Speed

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

– Use the < , << and > , >> keys to specify a speed from to .

– Press ENTER to confirm.

– Connect the CAN box to the 6X7 diagnostic connector

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-13

1B2 1X1

Rev sensor LAC controller connector

7X6

Rev sensor connector

A sensor (1B2) is fitted to the traction motor.

This sensor monitors a gear mounted on the rotor.

The sensor is supplied with +24 V (pin 7X6: 1) and supplies two 90° out of phase impulsion gaps.

These signals are transmitted to the traction controller module (input pins 1X1:8 and 22 of the LAC) They are processed to determine the speed and direction of rotation of the traction motor.

No adjustment is needed for the rev sensor.

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Risk of improper use of the traction motor If the sensor is improperly fitted or if (7X6) is disconnected, the traction speed will be 0.2 km/h and the effective motor current will increase to the Imax current of 270 A (according to standard factory settings for the truck).

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

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

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

The motor revolution speed (48 revolutions) is determined from the frequency of output signals A and B. The sequence of signals from the two outputs A and B varies depending on the direction of rotation of the motor.

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

– Connect the CAN box to the diagnostic connector – Connect the CAN box to the laptop socket – Drive the truck – Launch the diagnostic tool, go to the following menu and follow the instructions on the screen:

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-15

F4: Measurement Function Traction Power controls Speed/engine speed – Check the speed indicators on the display.

7X6:1 7X6:2 7X6:3 7X6:4

-16

+24 V power supply Output signal A Battery negative Output signal B

Red White Black Blue

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-17

1B6 7X6

Temperature sensor Temperature sensor connector

7X6:5 7X6:6

Temperature signal Negative

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

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

Truck applications: Series EXU, EXU H EXD

-18

Application Up to Up to

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

– Connect the CAN box to the diagnostic connector – Connect the CAN box to the laptop socket – Launch the diagnostic tool and go to the menu shown to check the temperature values of the motor (1M1)

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

F4: Measurement Function Traction Power controls Motor temperature T° (1M1) normal working temperature approx.

30°C Normal operating speed of the truck

T° (1M1)

-50°C

T° (1M1)

160°C

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

170°C

T° (1M1) 200°C

Truck stopped

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

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

– Disconnect the connector from the truck.

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

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-19

:

0 10 20 25 30 40 50 60 70

493 533 576 598 621 668 718 769 824

80 90 100 130 170 200 230 270 300

If the values are incorrect, repeat the test.

-20

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880 939 1000 1197 1493 1739 2006 2392 2668

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-21

1B6 7X6

Temperature sensor Temperature sensor connector

7X6:5 7X6:6

Temperature signal Negative

The sensor (1B6) monitors the temperature and reduces performance when the temperature is too high: If the motor temperature exceeds 160°C, the truck speed is reduced to 2 km/h.

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

Truck applications: Series EXU, EXU H EXD

Application From From

– Start the diagnostic tool.

– Choose the service base that corresponds to the truck type.

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– Select the sensor type by going to the following menu:

F3: Configuration General Vehicle option Traction motor temperature sensor KTY or PT1000

– Connect the CAN box to the diagnostic connector – Connect the CAN box to the laptop socket – Launch the diagnostic tool and go to the menu shown to check the temperature values of the motor (1M1)

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

T° (1M1) normal working temperature approx.

30°C Normal operating speed of the truck

T° (1M1)

-50°C

T° (1M1)

160°C

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

170°C

T° (1M1) 200°C

Truck stopped

The resistance of the temperature sensor decreases as the motor temperature increases.

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

– Disconnect the connector from the truck.

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

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-23

:

0 10 20 25 30 40 50 60 70

1000 1039 1078 1097 1117 1155 1194 1232 1271

80 90 100 130 170 200 230 270 300

If the values are incorrect, repeat the test.

-24

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1309 1347 1385 1498 1648 1758 1868 2013 2117

1X1 7X6

Traction/lift controller (LAC) connector Electromagnetic brake connector

Y1

Electromagnetic brake

The electromagnetic brake is used as a parking brake and also as an emergency brake.

– Connect the CAN box to the diagnostic connector .

– Connect the CAN box to the laptop socket.

– Start the diagnostic tool.

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

F4: Measurement Traction Brake Brake 11528070901 EN - 01/2020

-25

Brake transistor control in 1X1:31 0 Brake applied 1 Brake released Blue window: Voltage (V) of the brake in 1X1:31

Red window: Current (mA) of the brake in 1X1:31

24 V Brake applied 0 V Brake released

0 mA Brake applied 1600 mA Brake released

-26

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Fixed on the chassis, the electrical plate (1) is fitted with: The battery socket connector (5) The ignition key (7) The multifunction indicator (6) The diagnostic connector (4) The control fuse holder (8) The LFM Go digicode (option) (3) The fan The horn (9)

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

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-27

Risk of short circuit.

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

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



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



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11528070901 EN - 01/2020



Risk of crimping resulting in failure.

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

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

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

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-29

1 2 3 4

CAN

multifunction indicator red diode green diode connector: PIN 1: 0 V PIN 2: +24 V PIN 3: CAN-L

5 1A1 G2

PIN 4: CAN-H connector: PIN 1: green LED PIN 2: red LED Traction controller Built-in charger (option)

The 6P4 multifunction indicator, linked to the CAN bus network of the truck, displays: The level of battery discharge The operating hours of the truck (hour meter) Alarm pictograms accompanied by red indicator lights Error codes for troubleshooting assistance The 6P4 multifunction indicator is fitted with two indicator lights: alarms, errors with the truck function or the built-in charger (if fitted) truck powered up or battery charge status if the truck is fitted with an on-board charger

-30

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– Remove the electrical plate from the chassis (see Section 6) – Disconnect (11) and (12)(if the truck is equipped with a built-in charger) – Undo the 2 nuts (10) on the mounting bracket – Remove the multifunction indicator (6) from its housing.

To fit a new multifunction indicator, proceed in the reverse order to the removal.

After changing a multifunction indicator, it is necessary to set the old parameters on the new one as shown below:

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-31

1 2 3

Switch ON (operating mode) Switch OFF or programming accepted Programming mode

Operation

4 5

Key in

LED status

* 0 0 0 0 0 #

ON

OU * 1 2 3 4 5 # (by default)

OFF

# (3 seconds)

* 0 0 0 0 0 0 0 0 # (by

default)

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

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

Restoring the initial administrator code

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

Activating the automatic switch-off

* * 2 * 1 #

Setting the time delay of the automatic switch-off

* * 3 * 6 0 #

-32

Key error Time delay of automatic switch-off

red off continuous green (1)(correct PIN) red flashing green off (4)(incorrect PIN) red off green flashing (2)

Notes 0 0 0 0 0

OU

1 2 3 4 5 default PIN

Truck power off

Once the diodes have continuous red contin- gone out, the electronic uous green (3) key automatically reverts to "operating mode" red off green flashing (2)(code applied) red off green flashing (2)(code applied) red off green flashing (2)(deletion accepted) red off green flashing (2)(code applied)

Example of new operator code: 54321 *2*: operator reference 10 options from 0 to 9 *2*: operator reference (between 0 and 9)

Reactivating the default administrator code (00000000) Power switches off autored flashing green matically after 10 mins flashing (5)(5 s before cut(600 s by default) if the off) truck is not being used.

Example: automatically red off green flashing switches off after 1 min.

(2)(value accepted) (60s) when not used. red off green flashing (2)(code applied)

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Minimum setting = 10 s / maximum = 3000 s Deactivating the automatic switchoff

* * 2 * 0 #

red off green flashing (2)(command accepted)

Risk of short circuit.

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

– Open the battery cover to access the fastening clips of the LFM box – Apply pressure to the clips (13) to release the LFM box from the electrical plate – Disconnect (16) terminals

(14) and the

(15) and

When fitting a new LFM box, proceed in reverse order to removal. the default PIN for operating the truck is:

0 0 0 0 0.

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-33

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

The on-board charger can be connected to any 2P+T, 230-V, 16-A socket. However, before charging in this way, the user must ensure that the location selected for charging satisfies all of the appropriate safety requirements: The electric installation must comply with the standards defined by the country in which the truck is used.

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

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

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

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

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

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

Charging must be carried out with the truck stopped.

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

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

The charger is designed: To be incorporated inside an industrial truck To be used on board the truck (the charger must never be used alone) To stay permanently connected to the battery To operate in all positions To stay connected to the mains during periods when the truck is not being used to ensure the availability of the machine (see the section on "Other charging details") "Opportunity charging" is permitted -34

11528070901 EN - 01/2020

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

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

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

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

Mains voltage Network frequency Maximum output power Maximum output current Nominal battery voltage Tolerance on the voltage of bearing U

Battery type Number of components

190 V < U < 260 V 50 / 60 Hz +/-1% (automatic adaption) No inrush current to the mains connection 1040 W +/-3% 35 A +/-2% 24 V 1%

Gel or open lead-acid traction battery 12 x 2 V components 140 Ah minimum to 375 Ah maximum (adaption of the charging curve by a selector)

Capacity

Storage temperature Operating temperature Weight

-45°C to +80°C -15°C to +40°C 2 kg

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

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

Mains protection: protected by a 250-V, 10-A fuse. The mains fuse is fitted directly on the electronic card. The user is not authorised to change this fuse. If this fuse is faulty, the charger must be returned to the After-Sales Service Centre.

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The charger is supplied without indicator lights.

Only a 2x0.5 mm2 lead can be used to connect the charger to the truck LED. Operation of the LEDs: Mains socket disconnected Phases I1, P, U1, I2, U2 Stopped/Equalisation/Maintenance phase Charging process too long Charger polarity reversed (+bat and -bat charger cables reversed, with the battery normally remaining connected to the truck assembly) Battery polarity reversed Selector in neutral position

Off Flashing

Off Off

Continuously lit

Off

Off

Continuously lit

Continuously lit

Continuously lit

Off Flashing

Off Flashing

A 2x1.5-mm2 lead can be used to connect the safety relay. The relay has a maximum cut-off power of 16 A. Contact A: blue wire (towards the truck) Contact B: brown wire (towards the 24-V battery) When the charger is not connected either to the mains or to the battery, the "contact A" and "contact B" outputs are electrically insulated from one another.

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

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

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

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When the truck is delivered with its battery, the charger settings are adjusted in the factory.

When the truck is delivered without its battery, the settings are adjusted in the factory in accordance with the battery type selected.

The curve is selected using the selector located on the front face of the charger.

The curve selector is protected by a cap.

The charger is supplied in the neutral position.

Risk of premature damage to the battery.

Select the correct battery type on the selector.

The four thin lines indicate neutral positions.

The charger does not flow and the two diodes flash simultaneously to indicate that no curve has been selected.

The four thick lines indicate the four charging curves: Open lead-acid battery with a capacity below 210 Ah Open lead-acid battery with a capacity greater than 210 Ah Gel battery with a capacity below 210 Ah Gel battery with a capacity greater than 210 Ah If the battery type or type of charger is changed during the service life of the truck: – Check that the charger setting corresponds to the new type of battery.

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

The charger adapts automatically to the battery discharge situation and therefore allows any

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

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

If the mains power is cut off, all the existing charging parameters are stored for 13 minutes.

As soon as the mains power returns, charging resumes from the point (I, U) at which it was cut off.

The number of Ah already injected is stored in the memory.

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

If the duration of phases I1 + P + U is more than 16 hours, the charger automatically stops.

This can happen if a battery has a short-circuited component.

The mains power must be reset to clear the fault.

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

The fan runs when the mains power is connected.

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

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

The charger stops if the microcontroller detects a temperature measurement fault.

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The on-board charger does not have a terminating resistor.

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

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

However, before charging in this way, the user must ensure that the location selected for charging satisfies all the required safety guarantees: The electric installation must comply with the standards defined by the country in which the truck is used.

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

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

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

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

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

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

Charging must be carried out with the truck stopped.

The increase in the temperature of the unit in relation to the ambient temperature is 10°C maximum. The temperature of the expelled air is 25°C maximum.

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

Wait 10 minutes after stopping the charger before touching the unit.

The charger is designed:

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To be incorporated inside an industrial truck To be used on board the truck (the charger must never be used alone) To stay permanently connected to the battery To operate in all positions To stay connected to the mains during periods when the truck is not being used to ensure the availability of the machine (see the section on "Other charging details") "Opportunity charging" is permitted

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

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

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

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

Mains voltage

Maximum output power Maximum output current Nominal battery voltage Tolerance on the voltage of bearing U

190 V < U < 260 V 50 / 60 Hz +/-1% (automatic adaption) No inrush current to the mains connection 1040 W +/-3% 35 A +/-2% 24 V 1%

Battery type Nominal voltage Capacity

Compatible lead and lithium-ion batteries 24 V From 140 Ah to a maximum of 375 Ah

Storage temperature Operating temperature (charge mode) Weight

From -45 C to +80 C From +5 C to +40 C 2 kg

Network frequency

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

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

Mains protection: protected by a 250-V, 10-A fuse. The mains fuse is fitted directly on the electronic card.

If this fuse is faulty, the charger must be returned to the After-Sales Service Centre.

The charger is supplied without indicator lights.

Only a 2x0.5-mm2 lead can be used to connect the charger to the truck LED. Operation of the LEDs: Mains socket disconnected Charging Stopped/Equalisation/Maintenance phase Charging process too long (lead battery) Battery alarm (lithium-ion battery) Charger polarity reversed (+bat and -bat charger cables reversed, with the battery normally remaining connected to the truck assembly) Battery polarity reversed Charging curve not selected or charger error Battery alarm or error Communication problem

Off Flashing

Off Off

Continuously lit

Off

Off

Continuously lit

Off

Continuously lit

Continuously lit

Continuously lit

Off

Off

Flashing

Flashing

Off Flashing

Flashing Continuously lit

The charger has an internal safety relay.

The relay has a maximum cut-off power of 16 A. Contact A: blue wire (towards the truck) Contact B: brown wire (towards the 24-V battery) When the charger is connected to neither the mains nor the battery, the "contact A" and "contact B" outputs are electrically insulated from one another.

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

When the charger is connected to the mains and to the battery, the "contact A" and

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

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

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In the event of a suspected failure and before carrying out a replacement, the following summary table makes it possible to: Improve the quality of the diagnostics.

Better identify the problems encountered with on-board chargers. * 1152 353 11 25 * 300 353 26 04

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When the truck is delivered with its battery, the charger settings are adjusted in the factory.

When the truck is delivered without its battery, the settings are adjusted in the factory in accordance with the battery type selected.

– Connect the CAN box to the diagnostic connector .

– Connect the CAN box to the laptop socket.

– Start the diagnostic tool.

– Select the truck's service base.

– Go to the following menu:

F3: Configuration Function On-board charger Charging curve – Select the battery type then confirm.

The charging curve is recorded.

The charger is supplied in the neutral position.

Risk of premature damage to the battery.

Select the correct battery type in the truck's service base.

If the battery type or type of charger is changed during the service life of the truck: – Check that the charger setting corresponds to the new type of battery.

– Go to the following menu to check the charger information:

F3: Configuration General

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Control On-board charger

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

Use protection goggles and a mask with a protective visor.

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

1

Power plate connector

2

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Relay connector

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3 4

Power box connector Module harness connector

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5

BMU connector

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

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

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

The Black Box records the various battery parameters and events.

It monitors and controls the status of the battery with the following functions: To supply the SMU card and the BMU (DC) To receive data from the SMU card To measure the current of the lithium-ion battery module To calculate the data To communicate with the LAC controller via the CAN bus network

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1 2

Nuts BMS (BMU+SMU)

3

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

SMU connectors

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

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

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– Connect the diagnostic kit to the diagnostic connector (3).

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

– Disconnect the diagnostic kit.

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

Push the release clip.

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

– Connect the diagnostic kit to the diagnostic connector (4).

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

– Disconnect the diagnostic kit.

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

Push the release clip.

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

– Remove the BMS from the battery.

– Install the BMS in the battery.

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

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

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

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

– Connect the identified SMU connectors.

Push the release clip.

– Connect the diagnostic kit to the diagnostic connector.

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

– Disconnect the diagnostic tool.

– Fit the cover provided on the battery.

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

Push the release clip.

Do not loosen the nuts and washers inside the battery.

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

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

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

Push the release clip.

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

– Connect the BMU harness to the BMS.

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

Push the release clip.

Push the release clips.

– Fit the cover provided on the battery.

– Remove the BMU(4) harness.

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

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– Remove the SMU harness.

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

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

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

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

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

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

Push the release clip.

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

Push the release clip.

– Connect the SMU harness connectors to each BMS connector.

Push the release clip.

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

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

– Identify and disconnect the SMU harness connectors from the BMS.

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

Push the release clip.

Push the release clip.

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– Fit the cover provided on the battery.

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

– Disconnect the SMU(2) harness connectors from the BMS. Push the release clip.

– Remove the SMU(1) harness.

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

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

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

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

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

Protect with an insulated cap for maintenance.

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

Push the release clip.

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

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

Push the release clip.

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

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

Fit the protective cap.

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

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

Fit the protective cap.

– Fit the cover provided on the battery.

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A B

Module connector - terminal

C D

+ terminal Cover

The A1 battery is equipped with a 24M Fe module comprising seven rows of two cells.

The module supplies the energy as well as voltage measurements via the SMU card.

The A2 battery is equipped with two 24M Fe modules comprising seven rows of two cells.

The modules supply the energy as well as voltage measurements via the SMU card.

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– Remove the harness from the BMU (see the description of how to remove and refit the BMU harness).

– Remove the harness from the SMU (see the description of how to remove and refit the SMU harness).

– Remove the Power plate provided (see the description of how to remove and replace the Power plate provided).

– Check that the power cables are protected with insulated caps.

– Loosen the four H M5 nuts (1) from the plate (2) and remove them.

– Loosen the two H M5 nuts (3) from the plate (4) and remove them.

– Loosen the two H M5 nuts (5) on the two plate supports (6) and remove them.

– Remove the upper support (7) of the module.

– Remove the module (8) from the battery by hand.

The module is fragile When removing the module, you must be very careful not to let it fall.

– Loosen the negative power cable (9) (CBLX M6 screw) of the module.

– Loosen the positive power cable (10) (CBLX M8 screw) of the module.

– Ensure that the positive cable has an insulated cap on one connection (to be connected to the Power plate during installation of the Power plate).

– Connect the other connection of the positive power cable to the module with the CBLX M6

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screw with the disc spring and the flat washer (tightening torque: ).

– Ensure that the negative cable has an insulated cap on one connection (to be connected to the Power plate during installation of the Power plate).

– Connect the other connection of the negative power cable to the module with the CBLX M6 screw with the disc spring and the flat washer (tightening torque: ).

– Insert the module (8) into the battery using the handle.

– Position the upper support (7) on the module.

– Fit the two side supports (6) and attach each of them using two H M5 nuts (5) (tightening torque: ).

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– Fit the plate support (4) and secure it using the two H M5 nuts (3) (tightening torque: ).

– Fit the steel plate (2) and secure it using four H M5 nuts (1) (tightening torque: ).

– Fit the Power plate provided (see the description of how to remove and replace the harness of the Power plate provided).

– Fit the SMU harness (see the description of how to remove and replace the SMU harness).

– Fit the BMU harness (see the description of how to remove and replace the BMU harness).

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– Remove the Power plate provided (see the description of how to remove and replace the Power plate provided).

The BMU connector must be disconnected from the BMS.

– Check that the power cables are well insulated. If not, protect them with insulated caps.

– Loosen the four H M5 nuts (1) on the two steel plates (2) and remove them.

If something falls on the top of the battery, remove it.

– Remove the BMU harness (see the description of how to remove and replace the BMU harness).

– Remove the SMU harness from the BMS (see the description of how to remove and replace the SMU harness).

– Remove the BMS (see the description of how to remove and replace the BMS harness).

– Loosen the two H M5 nuts (3) on the two plate supports (4) and remove them.

– Loosen the two H M5 nuts (5) on the four side supports (6) and remove them.

– Remove the two upper supports (7) from the modules.

– Remove the harness connector SMU from the modules (see the description of how to remove and replace the SMU harness).

– Remove the modules (8) from the battery using the handle.

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The modules are fragile When removing the modules, you must be very careful not to let them fall.

– On each module, loosen the negative power cable (9) (CBLX M6 nuts) of the module.

– On each module, loosen the positive power cable (10) (CBLX M8 nuts) of the module.

– Ensure that the positive cables have an insulated cap on one connection (to be connected to the Power plate or the BMS during installation of the Power plate or the BMS).

– Connect the module positive power cable for each module with the CBLX M8 screw (10) and the disc spring and the flat washer (tightening torque: ).

– Ensure that the negative cables have an insulated cap on one connection (to be connected to the Power plate or the BMS during installation of the Power plate or the BMS. – Connect the negative power cable (10) to the module for each module with the CBLX M6 screws (9) and the disc spring and the flat washer (tightening torque: ).

– Connect the SMU harness connectors to the modules (see the description of how to remove and replace the SMU harness).

– Position the upper support (7) on the modules.

– Fit the four side supports (6) and attach each of them using two H M5 nuts (5) (tightening torque: ).

– Fit the plate support (4) and secure it using the two H M5 nuts (3) (tightening torque: ).

– Fit the steel plates (2). The plates are the same. The rounded sides of the steel plates must be downward. Secure each side with four H M5 nuts (1) (tightening torque: ).

– Fit the Power plate provided on the side identified on the battery (see the description of how to remove and replace the Power plate).

– Fit the BMS on the side identified on the battery (see the description of how to remove and replace the BMS).

– Connect the SMU harness connectors to the BMS (see the description of how to remove and replace the SMU).

– Fit the BMU harness (see the description of how to remove and replace the BMU harness).

– Insert the modules (8) into the battery using the handle.

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1 2 3

Pre-charge contactor support Pre-charge contactor Shunt

4 5

Fuse (125 A) Contactor

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

The power plate contains devices that can cut off the supply, manage its safety and measure the physical values.

This helps protect the plate from a possible short-circuit of the external terminals.

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

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

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This prevents currents that are too large when the Lithium Ion battery is started.

It also serves to dissipate the energy of the peak of current in order to start the battery safely.

Located below the plate, this activates precharging.

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– Make sure that the Power plate is removed.

– Install the contactor (6).

– Loosen the two CBLX M8 screws (1) of the fuse and remove the washers.

– Secure the contactor (6) using the two CBLX M5 screws (3) (tightening torque: ).

– Remove the fuse (2).

– Connect the two Faston(8) terminals.

– Loosen the last CBLX M5 screw of the rigid connection (3) and remove the washers.

– Connect the contactor (7).

– Loosen the two nuts (4) of the contactor connections and remove the washers.

– Remove the rigid connections (5) of the contactor (6).

– Disconnect the connector (7): push the release clip.

– Disconnect the two Faston (8) terminals.

– Loosen the two M5 screws (9) from the contactor and remove the washers.

– Remove the contactor (6) from the Power plate.

– Install the rigid connections (5) and tighten the two H M8 nuts with the washers (4) (tightening torque: ).

– Tighten the last CBLX M8 screw of the rigid connections (3) with the washers (tightening torque: ).

– Install the fuse (2).

– Tighten the two CBLX M8 screws (1) of the fuse with the washers (tightening torque: ).

– Install the Power plate.

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– Loosen the two CBLX M8 screws (1) and remove the washers.

– Tighten the two CBLX M8 screws (1) with the washers (tightening torque: ).

– Fit the cover provided on the battery.

– Remove the 125-A fuse (2) from the Power plate(3).

– Install the 125-A fuse (2) on the Power plate (3).

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160 A/24 V coding system



(A) Coding pin for the battery female connector (B) Coding pin for the male connector of the Lithium Ion battery

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Voltage coding (keying pin):

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

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1 2 3 4

CAN multifunction indicator Red LED Green LED connector: 6X2: 1: 0 V 6X2: 2: +24 V

The 6P4 multifunction indicator, linked to the CAN bus network of the truck, displays: The charge/discharge level of the battery The operating hours of the truck (hour meter) Alarm pictograms accompanied by red indicator lights Error codes for troubleshooting assistance

The terminating resistor (120 ) has been removed for the version with a lithium-ion battery.

5 1A1

6X2: 3: CAN low 6X2: 4: CAN high connector: 6X8: 1: green LED 6X8: 2: red LED Traction controller

The 6P4 multifunction indicator is fitted with two indicator lights: alarms, errors with the truck function or the on-board charger (if fitted) truck powered up or battery charge status if the truck is fitted with an on-board charger

If the red LED (2) flashes, completely recharge the lithium-ion battery as soon as possible.

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

Use protection goggles and a mask with a protective visor.

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

1

Power plate connector

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2

Relay connector

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3 4

Power box connector Module harness connector

5

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BMU connector

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– Install the battery in the support provided for battery maintenance.

– Unscrew the four CBLX M6 screws (1) and remove the spring washer and the flat washer from the cover provided.

– Lift the battery cover provided (2).

– Disconnect the SMU harness connectors (6) from the BMS (7) by pushing the release clip.

– Identify the positive power cable connected to the contact switch provided (4).

Unscrew the mounting nut and then remove the spring washer, the corresponding flat washer and the shoe located at the end of the harness from the contact switch.

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Refit the maintenance insulation cover.

– Locate the negative power cable connected to the shunt (3).

Remove the insulation protection. Unscrew the mounting nut and then remove the spring washer and the corresponding washer.

Refit the maintenance insulation cover.

– Identify and disconnect the earth cable (5) from the side of the cover provided.

– Remove the BMS cover provided.

– If the BMS has to be reused, remove it from the cover provided.

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– Install the BMS (old or new) on the cover provided.

– Move the battery cover provided (2) closer.

– Install the positive power cable for the contact switch provided (4) and the shoe located at the end of the harness from the contact switch. Then tighten the nut with the spring washer and the flat washer (tightening torque: 10 Nm).

– Locate and connect the earth cable (5) on the side of the cover provided.

– Connect the SMU harness connectors (6) to the BMS: push the release clip.

– Remove the maintenance insulation cover from the negative power cable.

– Fit the battery cover provided (2).

– Check whether the cover seal is damaged.

Replace if necessary.

– Connect the negative power cable to the shunt (3). Connect it with the H M6 nut and with the spring washer and the flat washer (tightening torque: 5 Nm).

Refit the insulation protection.

– Fit the cover provided (2) with the four CBLX M6 screws (1) and with the spring washer and the flat washer (tightening torque: 10 Nm).

– If the battery is being stored, attach adhesive tape to the insulation covers on the power terminal block.

– Remove the maintenance insulation cover from the positive power cable.

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The seal of the push button must be on the outside of the cover.

– Remove the four nylon clips (2).

– Disconnect the push button connector (3).

– Unscrew the M22 nut (6) on the push button provided (1) and then remove it.

– Remove the push button (1) and its O-ring (5) from the cover provided (7).

– Install the push button provided (1) on the cover provided (7). Put the connector through the hole.

– Place the M22 nut (6) on the push button (1) and then screw in the nut (tightening torque: 6 Nm).

– Attach the push button cable with the four nylon clips (2).

– Place the O-ring (5) on the head of the push button (4).

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– Connect the push button connector (3).

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– Unscrew the nut from the contact switch (6) and then remove the nut, the washers and the O-ring from the diagnostic harness (4).

– Install the head of the diagnostic harness (3) on the cover provided (8) through the hole provided for this purpose.

– Remove the nylon rope clamp (7).

– Screw the mounting ring (2) on the diagnostic connector.

– Disconnect the diagnostic harness connector (5).

– Screw on the cap (1) using its retaining tab.

– Unscrew the protective cap (1) and its retaining tab.

– Connect the diagnostic harness connector (5).

– Unscrew the protective ring (2) from the diagnostic connector.

– Fit the nylon rope clamp (7).

– Remove the head of the diagnostic harness (3) from the cover provided (8).

– Fit the O-ring on the diagnostic harness (4).

Fit the washers and the nut (6) and then screw on the nut of the contact switch (tightening torque: 10 Nm).

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– Unscrew the two cover fastening nuts (1) and then remove them.

– Remove the cover (2).

– Unscrew the M8 screw (3) (corresponding to the + terminal).

– Unscrew the M6 screw (4) (corresponding to the - terminal).

– Unscrew the three M5 mounting screws (7) and remove them from the terminal block (5).

– Remove the terminal block (5) from the cover provided (8).

– Remove the seal from the terminal block (6).

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– Fit the seal of the terminal block (6).

– Install the terminal block (5) on the cover provided (8).

– Attach the terminal block (5) using the three M5 mounting screws (7) and corresponding washers (tightening torque: 4 Nm).

– Tighten the M6 screw (4) (negative terminal) (tightening torque: 5 Nm).

– Tighten the M8 screw (3) (positive terminal) (tightening torque: 13 Nm).

– Fit the terminal block cover (2).

– Fit the two cover fastening nuts (1) and then screw them in (tightening torque: 3 Nm).

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– Fit the power cable from the connector to the terminals of the contact switch (1).

Positive power cable from the fuse.

– Fit the fuse.

– Remove the fuse.

– Remove the positive power cable (1).

Negative power cable from the power pack.

– Remove the protective cap (3).

– Unscrew the mounting screw from the cable to the negative terminal of the power pack (4).

Negative power cable from the power pack.

– Install the negative power cable (2). Fit the rigid joining plate of the contact switch (4) to the negative terminal of the terminal block and then screw it in (tightening torque: 6 Nm).

– Fit the protective cap (3).

– Remove the negative power cable (2).

Positive power cable from the fuse.

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

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

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

The Black Box records the various battery parameters and events.

It monitors and controls the status of the battery with the following functions: To supply the SMU card and the BMU (DC) To receive data from the SMU card

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To measure the current of the lithium-ion battery module To calculate the data To communicate with the LAC controller via the CAN bus network

The SMU (Safety and Monitoring Unit) card is located inside the BMS. This enables cell management (balancing, sending information such as end of charge, overheating, overloading, excessive discharge etc.).

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

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– Unscrew the cap of the battery diagnostics connector using the tab (1).

– Unscrew the four mounting nuts (4) of the BMS.

– Connect the diagnostic tool to the battery diagnostics connector (2).

– Remove the BMS(5).

– If possible, start the diagnostic tool software and download data from the BMS (black box, shunt calibration parameters etc.).

– Disconnect the diagnostic tool.

– Install the BMS(5).

– Tighten the four mounting nuts (4) on the BMS (tightening torque: ).

– Connect the diagnostic harness connector (3).

It is also possible to access the BMS directly via the RS485 output of the BMS using the SAFT tool (WINDIAG_BMS).

– Screw on the cap (1).

– Install the cover provided.

– Unscrew the cap (1) of the battery diagnostics connector using the tab.

– Remove the cover provided.

– Connect the diagnostic tool to the battery diagnostics connector (2).

– Disconnect the diagnostic harness connector (3).

– Start the diagnostic tool software (KION CAN_KWP2000 tool) and transfer the data

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from the old BMS (black box, shunt calibration parameters etc.) if it can be recovered.

– If this is not possible, save the calibration parameters present on the shunt and enter them in the new BMS. Enter a value indicative of the SOH : State Of Health) in the BMS. Also enter the serial number of the battery and the module, as well as the BMU ID number.

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– Disconnect the diagnostic tool.

– Screw on the cap (1).

It is also possible to access the BMS directly via the RS485 output of the BMS using the SAFT tool (WINDIAG_BMS).

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A B

Module connector - terminal

C

+ terminal

The B1 battery is equipped with a 24M Fe module consisting of 35 cells (seven rows of five cells).

The B2 battery is equipped with two 24M Fe modules consisting of 35 cells (seven rows of five cells for each module).

The module supplies the energy as well as voltage measurements via the SMU card.

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– Unscrew the negative output of the power pack (1).

– Unscrew the six mounting nuts on the reinforced plate (10).

– Remove the negative connection hose and then insulate the negative terminal of the power pack with insulating tape.

– Remove the rivets (11).

– Unscrew the mounting screws of the rigid connection (2), remove the rigid connection (3) and then insulate the positive terminal of the power pack with insulating tape.

Use a 2-mm punch to drive the rivet into the battery.

Use a 10-mm twist drill to drill out the rivet heads.

Use a 4-mm punch to mark out the shape of the rivets in the battery.

– Unscrew the four mounting nuts on the fuse holder (4) and then remove the fuse holder (5).

– Carefully remove the side cover provided (12).

– Unscrew the five mounting nuts on the side plate (6) and then remove the side plate (7).

– Disconnect the connector for electrical continuity.

– Unscrew the mounting nuts (8a) and bolts (8b) from the angle bracket (9) and then remove the angle brackets.

– Remove the cover seal (13).

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– Remove the SMU harness (15).

– Remove the power pack (19) (blue arrow).

Unscrew the six retaining screws (17) on the retaining clamps of the SMU harness (16).

Disconnect the two SMU harness connectors (18) from the modules.

Remove the SMU harness (15).

The power pack is heavy (96.5 kg).

– Remove the four mounting screws from the power pack (14).

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– On the two sides (positive and negative), unscrew the rigid connection nuts (20) and then remove the rigid power connections (21 & 22).

– Unscrew the seven reinforced nuts on the reinforced plate (23) and then remove the reinforced plate (24).

– Separate the upper module (27) from the lower module (28).

A module weighs 43.3 kg.

– On the two sides (positive and negative), unscrew the reinforcement screws (25) and then remove the seven reinforcements (26).

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– Check that the box is not damaged.

– On the opening of the power pack, check that the holes intended for rivets are all cylindrical.

– Clean the box with a suction system (no dust on the metal parts).

– Also clean around the opening of the power pack (around the seal of the side cover).

If the box is damaged or if the holes (rivets) are not cylindrical, the box should not be used, so use another box.

– Place the upper module (27) on the lower module (28).

– On the two sides (positive and negative), position the seven reinforcements (26) and then screw in the reinforcement screws (25) (tightening torque: ).

reinforced plate (23) (tightening torque: ).

– On the two sides (positive and negative), position the rigid power connections (21 & 22) and then screw in the rigid connection screws (20) (tightening torque: ).

– Place the reinforced plate (24) on the modules and then screw in the seven nuts of the 11528070901 EN - 01/2020

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– Insert the power pack (19) in the box.

– Install the SMU harness (15).

The power pack is heavy (96.5 kg).

– Screw in the four mounting screws of the power pack (14) (tightening torque: ).

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Connect the SMU harness connectors (18) to the modules.

Position the SMU harness rope clamps (16) and then screw them (17) on to the modules (tightening torque: ).

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– Screw the six mounting nuts of the reinforced plate (10) on to the battery box (tightening torque: ).

– Position the two angle brackets (9) and then tighten the mounting nuts (8a) and bolts (8b) (tightening torque: ).

– Position the side plate (7) and then screw it in with the five mounting nuts (6) (tightening torque: ).

– Position the fuse holder (5) and then screw in the four mounting nuts on the fuse holder (4) (tightening torque: ).

– Remove the insulating tape from the power pack terminals.

– Position the rigid connection (3) and then screw in the mounting screws on the rigid connection (2) (tightening torque: ).

– Position the negative connection hose and then screw in the negative output of the power pack (1) (tightening torque: ).

– Connect the connector for electrical continuity.

– Put a new side protection seal (13) in place.

– Carefully position the side cover provided (12).

– Fit the new rivets (11).

– Unscrew the cap of the battery diagnostic connector using the tab (1).

– Connect the diagnostic tool to the battery diagnostic connector.

– Launch the diagnostic tool software.

– Enter the serial number of the module or modules.

– Update the diagnostic tool.

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– Screw in the protective cap.

It is also possible to access the BMS directly via the RS485 output of the BMS.

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– Remove the rigid connection (6).

– Unscrew the two mounting nuts on the insulation cover (1) and then remove them.

– Remove the shunt (7).

– Remove the insulation cover (2).

– Gently unscrew the mounting screws of the communication cable (3).

– Put the shunt (7) into position.

– Put the rigid connection (6) into position.

– Screw on the rigid connection nut (5) (tightening torque: 5 Nm).

The mounting screws of the communication cable are small in diameter. They are screwed on the shunt, which is made of copper.

Be careful not to damage the threads or lose the screws.

– Screw the mounting nut on the shunt (4a) (tightening torque: slight tightening).

– Screw the other mounting nut on the shunt (4b) (tightening torque: 5 Nm).

– Put the screws of the shunt communication cable (3) in place and then screw them in (tightening torque: 3 Nm).

– Unscrew the two mounting nuts on the shunt (4a and 4b).

– Unscrew the rigid connection nut (5).

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The mounting screws of the communication cable are small in diameter. They are screwed on the shunt, which is made of copper.

– Fit the two mounting nuts on the insulation cover (1) and then screw them in (tightening torque: 3 Nm).

– Unscrew the battery diagnostic connector with trap (8).

– Connect the diagnostic tool to the battery diagnostic connector (7).

Be careful not to damage the threads or lose the screws.

– Fit the insulation cover (2).

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– Start the diagnostic software tool.

– Disconnect the diagnostic tool.

– Screw on the cap (1).

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1 2 3

Pre-charge contactor support Pre-charge contactor Shunt

4 5

Fuse (125 A) Contactor

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

The power plate contains devices that can cut off the supply, manage its safety and measure the physical values.

This helps protect the plate from a possible short-circuit of the external terminals.

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

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

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This prevents currents that are too large when the Lithium Ion battery is started.

It also serves to dissipate the energy of the peak of current in order to start the battery safely.

Located below the plate, this activates precharging.

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– Remove the contact switch provided (9).

– Unscrew the two mounting nuts on the protective cover of the terminal block (1) and then remove them.

– Fit the contact switch provided (9).

– Remove the protective cover from the terminal block (2).

– Screw in the two M5 nuts on the contact switch (8) (tightening torque: ).

– Disconnect the connector from the contact switch (3).

– Install the rigid connection (7).

– Unscrew the M8 nut (4) (positive terminal) and then remove it with the corresponding washers.

– Unscrew the two nuts on the terminals of the contact switch and the corresponding washers (5).

– Remove the washer (6) from the + terminal of the contact switch.

– Fit the washer (6) on the + terminal of the contact switch.

– Fit the washers and nuts on the power contact switch (5) and then tighten (tightening torque: ).

– Fit the washers and the M8 screw on the + terminal (4) and then tighten (tightening torque: ).

– Remove the rigid connection (7).

– Connect the connector of the contact switch (3).

– Unscrew the two M5 mounting nuts on the contact switch (8).

– Install the terminal block cover (2).

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

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– Fit the fuse (5) in the fuse holder (4).

– Remove the protective cap (1).

– Unscrew the two CBLX M6 nuts (2) and remove the flat washers and the conical spring washers.

– Remove the fuse (5) from the fuse holder (4).

– Fit the flat washers, the conical spring washers and the nuts (2).

– Tighten the two CBLX M6 nuts (tightening torque: ).

– Fit the protective cap (1).

– Remove the hose connection (3).

– Fit the hose connection (3).

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160 A/24 V coding system



(A) Coding pin for the battery female connector (B) Coding pin for the male connector of the Lithium Ion battery

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Voltage coding (keying pin):



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1 2 3 4

CAN multifunction indicator Red LED Green LED connector: 6X2: 1: 0 V 6X2: 2: +24 V

5 1A1

The 6P4 multifunction indicator, linked to the CAN bus network of the truck, displays: The charge/discharge level of the battery The operating hours of the truck (hour meter) Alarm pictograms accompanied by red indicator lights Error codes for troubleshooting assistance

The terminating resistor (120 ) has been removed for the version with a lithium-ion battery.

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6X2: 3: CAN low 6X2: 4: CAN high connector: 6X8: 1: green LED 6X8: 2: red LED Traction controller

The 6P4 multifunction indicator is fitted with two indicator lights: alarms, errors with the truck function or the on-board charger (if fitted) truck powered up or battery charge status if the truck is fitted with an on-board charger

If the red LED (2) flashes, completely recharge the lithium-ion battery as soon as possible.

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– Fit the power cable from the connector to the terminals of the contact switch (1).

Positive power cable from the fuse.

– Fit the fuse.

– Remove the fuse.

– Remove the positive power cable (1).

Negative power cable from the power pack.

– Remove the protective cap (3).

– Unscrew the mounting screw from the cable to the negative terminal of the power pack (4).

Negative power cable from the power pack.

– Install the negative power cable (2). Fit the rigid joining plate of the contact switch (4) to the negative terminal of the terminal block and then screw it in (tightening torque: 6 Nm).

– Fit the protective cap (3).

– Remove the negative power cable (2).

Positive power cable from the fuse.

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There are three types of external chargers: A: An external 90-A charger (single phase) B: An external 160-A charger (three phase) C: An external 225-A charger (three phase)

Information about the charging status during charging is described below: 1: Battery voltage (V) 2: Charging current (A) 3: Charging status (%) 4: Charge supplied (Ah) 5: Charging time (t)

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OFF GREEN ORANGE RED RED FLASHING

Charger OFF Charger initialising Starting sequence Battery charged Battery charging Battery warning (failure) Battery alarm Charger alarm

If the light is flashing red, refer to the alarm codes described below: Check the status of the battery Maximum charging time excee(maximum charging time 780 mided nutes)

MAX. TIME OVERRANGE ERROR CHARGER HIGH VOLTAGE ERROR CHARGER

High battery voltage

INTERNAL TEMPERAT. ERROR CHARGER

Internal temperature of the charger is too high

ERROR BATTERY BATTERY ALARM BATT. UNEXPECTED ERROR BATTERY MEASURE ERROR

Check the battery status Provide adequate air circulation Check that the internal FANS are operating correctly

Battery error The battery has encountered an Consult battery documentation unrecoverable error Battery alarm An alarm has occurred on the Consult battery documentation battery Incompatible battery manufactur- Battery type and charger type er are from different brands Contact the After-Sales Service Voltage (and/or) amperage read- Centre (maximum voltage tolerings incorrect ance 2 V, maximum current tolerance 5 A)

In single phase (6), the cable has three wires (phase, neutral, earth).

Three types of plug are compatible: EUR (Europe): 16 A (7) SUI (Switzerland): 16 A (8) UK (United Kingdom): 13 A (9) In three phase (10), the cable has four or five wires (phase L1, phase L2, phase L3, neutral* and earth). *: Not used and not connected

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The identification label is positioned on the lower right-hand side of the external charger.

1 2 3 4 5 6 7 8 9 10 11

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Designation Protection index Voltage/Output current Serial number Input current Table summarising charging times for different battery types CE standard Weight Power supply frequency Manufacturer Charger model

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The instructions for the following repairs can be accessed: Replacing the input cable (AC) Replacing the output cable (DC) Maintenance manual for the charger By using the following link:

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H13 R1K

Charger socket presence LED (illuminated when the socket is connected, turned off when charging) Resistor (1K 2W)

S8 X100 7S13

Truck CAN cut-off switch Charger socket connector Supply cut-off switch

The lithium-ion battery can be charged using a side socket.

All trucks fitted with a B1 or a B2 battery are affected.

Advantages: Can be charged without moving the hood No other sockets need to be disconnected

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Detection: S8: The detection switch prevents the CAN from communicating between the battery and the truck.

7S13: The switch cuts the 24 V power supply for the LAC controller.

H8: The blue LED only indicates that the side socket is connected. It does not indicate that the battery has been charged.

1 2 3 4 5 6

Battery Terminal block Diagnostic connector Battery connector Truck Protective cover

7 8 9 10 11 12

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S8 detection switch 2 (CAN H) Charger socket Charger 7S13 detection switch 1 (+24 V supply) LED Side socket

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Auxiliary contact (1) Auxiliary contact (2) Pilot contact (3) Pilot contact (4)

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+24 V controller supply Earth CAN high CAN low

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Read the information in the documentation provided with the charger.

It provides information on: the various charger screens possible error messages precautions for use.

Risk of damage to the battery It is essential to use the charger supplied with the battery for charging lithium-ion batteries.

Do not touch the lithium-ion battery when it is charging and do not wear rings or jewellery. Do not place metal objects on or near the battery. Do not light a naked flame in the vicinity of the charging zone or near charging batteries.

Risk of sparks Always connect the battery connector before switching on the battery charger and disconnect the connector after switching off the charger.

Risk of damage to the battery It is important to charge the lithium-ion battery fully at least once a week.

The LED located on the display flashes red. You must therefore recharge the battery to 100%.

Risk of damage to the battery It is essential not to switch off the lithium-ion battery during charging.

To recharge the lithium-ion battery, proceed as follows: – Park the truck close to the charging station.

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– Secure the truck. Lower the fork arms.



– Switch off the ignition (2).

– Open the battery compartment cover.



– Unplug the battery connector (1).

– Plug the socket of the charging station into the connector (1) located on the battery.

– Switch the charger on as directed in the specific instructions for the charger. A screen appears displaying the words . Charging the battery is automatically managed by the on-board electronics of the battery.

– When charging is complete and the charger has stopped, unplug the charger.

It is possible to stop charging before the end of the complete cycle. The operator can resume work more quickly. It is advisable to recharge the battery after each use if possible. The battery charge percentage is indicated on the display screen. The charging time is indicated on the screen of the charger.

– Reconnect the battery connector (1) on the truck.

– Then close the battery compartment cover.

– Switch on the ignition (2) and check the charging status of the truck on the display (3).

The truck is now ready for use. ,

follow these steps: – Press the UP button for five seconds.

The charger will stop charging. The external charger display shows the following message: .

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– Reconnect the battery connector (1) on the truck.

– Then close the battery compartment cover.

– Return the truck to service.

Risk of damage to the battery It is essential not to switch off the lithium-ion battery during charging.

To recharge the lithium-ion battery, proceed as follows: – Park the truck close to the charging station.

– Secure the truck. Lower the fork arms.

– Switch off the ignition (2) (key or electronic key).



– Pull the emergency stop handle to disconnect the battery connector (1).

– Plug the socket of the charging station into the connector (3) located in the technical compartment.



– Switch the charger on as directed in the specific instructions for the charger. A screen appears displaying the words . Charging the battery is automatically managed by the on-board electronics of the battery.

– When charging is complete and the charger has stopped, unplug the charger.

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It is possible to stop charging before the end of the complete cycle. The operator can resume work more quickly. It is advisable to recharge the battery after each use if possible. The battery charge percentage is indicated on the display screen. The charging time is indicated on the screen of the charger.

– Reconnect the emergency stop connector (1) to the truck.

– Switch on the ignition (2) (key or electronic key) and check the charging status of the truck on the display.

The truck is now ready for use. ,

follow these steps: – Press the UP button for five seconds.

The charger will stop charging. The external charger display shows the following message: .

– Reconnect the battery connector (1) on the truck.

– Then close the battery compartment cover.

– Return the truck to service.

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The lithium-ion battery must be recharged only with a special charger.

Do not use a charger other than the one provided by the Kion group.

The temperature of the room where the charger is installed must be between 5° and 45°C. The humidity level must be below 95%.

The following wall chargers are available: An external wall charger An external charger that stays on the ground This is heavier The vertical access and the side access lithiumion batteries can be recharged with both types of external chargers.

The charger must be installed in a room without any inflammable elements.

Avoid the charger overheating.

Do not obstruct the air vents. The air must be able to circulate correctly.

Do not install the charger near a heat source or in a place exposed to direct sunlight.

Do not install it in an area that is subject to excessive dust or shocks or mechanical vibrations.

The charger must be installed and maintained only by electrical engineers or qualified staff.

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The Fleet Manager fleet management system allows access control and transmission of truck data.

This system is for access control and consists of: Two reading device versions Additional options: Shock sensor Tools for wireless data management: GPRS radio module (1) with its GSM antenna (2) The variants available on the truck are: Access control Access control and shock sensor Access control and GPRS module Access control, shock sensor and GPRS module This system and the additional options are fitted on trucks from:

types

: For 1152 (EXU) truck types : For 1152 (EXUH) truck

(1)GPRS: General Packet Radio Service (2)GSM: Global System for Mobile Communica-

tion

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1 2 2A 2B

Reading device with a keypad RFID reading device (1) RFID transponder card RFID transponder

3 4 5

TDU connector 6X16 Green diode Red diode

The TDU (Truck Data Unit) access control is available in two versions: A reading device with a keypad (1) OR A RFID reading device with truck access by: RFID transponder card, 13.56 MHz (2A) RFID transponder, 13.56 MHz (2B) Some of the data is transferred via Bluetooth.

Parameterising is done using the of the After-Sales Service.

(1) RFID: Radio Frequency Identification

The only way to find out the access control version is by connecting it.

Battery voltage

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0V Analogue 2 Relay 1 Relay 1 CAN 2 High CAN 2 Low CAN 1 High CAN 1 Low

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1 2 3

Shock sensor GSM antenna CAN Box GPRS

4 5

Truck diode Antenna diode

The shock sensor and CAN Box GPRS have been modified and the modified versions are fitted on trucks from: : For EXU type trucks

This sensor allows you to record the shocks received by the truck.

If the truck receives a shock, its speed can be reduced.

Some settings can only be changed by the fleet manager.

If the sensor is faulty, replace it.

There are two reference numbers for shock sensors.

One reference number when the sensor is fitted alone and another when it is fitted with the GPRS unit.

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This is composed of a communication unit, also called a "radio module" (1) and a GSM antenna (5).

The CAN Box allows you to: Access truck information remotely Locate the truck This data is located on a server.

The status of the diodes indicates the status of the communication unit.

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1 2 3 4 5

Initial lift cylinder Non-return valve 300 filter Lowering solenoid valve 2Y2 Pump (1 cm 3/rev)

6 7 8 9 10

Main pressure relief valve Lowering retarder Breather Pump motor (2M1) Hydraulic reservoir

A single cylinder provides the initial lift for the truck.

(6)

1.0 kW (S3: 15%) 1600 / 1800

1.2 kW (S3: 15%) 2000

1.4 kW (S3: 15%) 2200

194 mini

180 mini

194 mini

209 0/-8

196 0/-8

210 0/-8

1.8 mm

2 mm

2 mm

The pump motor (2M1) is controlled by a power transistor, which is an integral part of the LAC (Linde Alternate Control) controller.

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-1

To extract the pump unit from the chassis, proceed as follows: – Remove the covers from the technical compartment, except the traction motor protection; – Lower the load arms; – Switch off the ignition and remove the battery socket; – Unscrew the supply cables (2) from the pump motor on the LAC controller (power terminals "+" and "LI"); – Disconnect the connector (4) from the lowering solenoid valve – Unscrew the union (3) from the cylinder hose on the pump unit; – Remove the left-hand lower cover mounting support (5); – Unscrew the 2 screws from the mounting bracket (1) of the pump unit; – From above, remove the pump unit from the chassis.



Dangerous materials handling procedure. The pump unit is heavy, proceed with caution to release it from the chassis.

The wearing of gloves is recommended.

To fit the pump unit in the chassis, proceed in the reverse order to removal.

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11528070901 EN - 01/2020

– Check the condition of the 2 bushings (6) screwed onto the back of the hydraulic block.



During fitting, check that the 2 bushings (6) are correctly positioned in their chassis housings.

11528070901 EN - 01/2020

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A

1 kW pump-motor unit for truck types 1152 T16; T18 and EXU16; EXU18 1,2 kW pump-motor unit for truck types 1152 T20 and EXU20

B

C

1,4 kW pump-motor unit for truck types EXU22

In order to resolve the sealing issues, the electro poppet valve (VNF 2G) was replaced with an electro poppet valve (VNF 3G) on the pump-motor unit.

This new electro poppet valve "(VNF 3G)" is mounted on: 1 kW pump-motor units 1152

T16/T18

1152

EXU16/EXU18

1,2 kW pump-motor units

From W41152D00435 From W40153D00244

1152

T20

1152

EXU20

From W41152D00624 From W40155D00232

1,4 kW pump-motor units 1152

-4

EXU22

From W40157C04324

1152

EXU22 CF(2)

11528070901 EN - 01/2020

From W40157C04324

(2) : CF : cold store

11528070901 EN - 01/2020

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-6

11528070901 EN - 01/2020

1

Cylinder barrel

2

Cylinder rod

Initial lift is provided by 1 central single cylinder.

The pallet trucks are fitted with 2 types of cylinder: cylinder fitted with a rod Max. travel: 130 mm Max. operating pressure: 245 bar Test pressure: 320 bar Max. push force: 3895 DaN Max. radial force: 500 DaN Weight: 7 kg cylinder fitted with a rod Max. travel: 130 mm Max. operating pressure: 245 bar Test pressure: 320 bar Max. push force: 4810 DaN Max. radial force: 500 DaN Weight: 8 kg

11528070901 EN - 01/2020

-1

Risk of injury The cylinder is a heavy and fragile component that must be handled with care. Safety footwear must be worn and gloves are recommended.

Carry out the following procedures to remove the Initial Lift cylinder: – Remove the covers from the technical compartment (see relevant chapter) – Lower the load arms to return the cylinder rod and lower the pressure in the circuit – Remove the battery, taking the precautions described in the truck's user manual – Drive out the stop pin from the cylinder rod (1)



– Unscrew the hydraulic union (2) from the cylinder



– Remove the electrical plate (see the relevant chapter, section 6)

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11528070901 EN - 01/2020

– Drive out the stop pin (3)from the cylinder clevis pin



– Remove the clevis pin using an extractor – Raise the fork carriage slightly using a jack – From above, remove the cylinder from the chassis.

When fitting a new cylinder, proceed in the reverse order to removal.

– Bleed the hydraulic system by raising/lowering the Initial Lift several times – Top up the hydraulic oil if necessary.

11528070901 EN - 01/2020

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1 2 3 4 5 6 7

Fork carriage Spring-type straight pin 6X28 mm Clevis pin/push rod Clevis pin/fork carriage Spring-type straight pin 6X36 mm Lift shaft pin/fork carriage Hc M12X35 teat screw

8 9 10 11 12 13

H M12 locknut KA 36 x 62 x 1.5 washer Push rod pin Push rod Lift shaft Lift shaft pin/fixed chassis

Dangerous materials handling procedure. The lifting system is heavy, proceed with caution to release it from the chassis.

The wearing of gloves is recommended.

To change all or part of the lifting system, proceed in the following manner: – Raise the Initial Lift to the highest point – Turn off the power and remove the truck battery connector

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11528070901 EN - 01/2020

– Chock the fork carriage in the upper position



– Unscrew the pin stop screw (14) on either side of the truck



– Remove the pin (13) using an inertial extractor ( rod M8) on either side of the fixed chassis



11528070901 EN - 01/2020

-5

– Loosen the locknut (8) then unscrew the teat screw (7) on each side under the lift shaft



– Chock the lift shaft (12) under each push rod (11)



– Remove the pin (6) using an inertial extractor ( rod M12) on either side of the fork carriage



The lift shaft is uncoupled.

-6

11528070901 EN - 01/2020

– Remove the pin (5) on each load castor clevis pin



– Drive out the pin (4) on each load arm



The lift shaft assembly + push rods are now uncoupled from the chassis.

– Slide the assembly under the chassis to release it



– To fit the lifting system, reverse the order for removal.

When fitting, do not forget the Teflon shim rings (9) between the ends of the lift shaft and the fork carriage.

11528070901 EN - 01/2020

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-8

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STILL GmbH 11528070901 EN - 01/2020