STILL STED forklift EXD-S-20 Stand-on Stacker Workshop Manual

....

STILL

Workshop literature STILL ELECTRONIC DOCUMENTATION SYSTEM

Stand-on Stacker EXD-S-20

CE 0249 50218070901 EN - 08.2010

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50218070901 [EN]

V

a

The manual is structured according to the same rules as the parts catalogue, ie it is divided into groups and subgroups.

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

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

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

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

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

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

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

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

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

STILL S.A.S. 4, avenue de la Libération Square John Saxby B.P. 50129 F-60160 MONTATAIRE Cedex The design and construction of our products are subject to continuous development. For this reason we reserve the right to make changes in the speci cations and the design without prior notice.

Menus

50218070901 [EN]

-1

1 2 3 4 5 6 7 8 9 10

Lift cylinder, main lift Mast Emergency isolator button Cockpit Lift cylinder, initial lift Pump motor Hydraulic oil reservoir Stabilisers Gearbox Traction wheel

-2

11 12 13 14 15 16 17 18 19 20

Traction motor Steering motor Steering controller Brake Fuse carrier Battery Load wheels Forks Traction controller (frequency converter) Protective screen

50218070901 [EN]

1 2 3

Forward travel Reverse travel Lifting

4 5 6

50218070901 [EN]

Lowering Right Left

-3

Manufacturer Platform

STILL

STILL

Rear access

Lateral access

Battery

Battery

Stand-on

Stand-on

Power source: Electric, diesel, petrol, LP gas, mains power Operation: Hand, pedestrian, stand-on, seated, order picker Load capacity/load

Q (kg)

2000

2000

Load centre distance

c (mm)

600

600

Load distance

x (mm)

942

942

Wheelbase

y (mm)

1729

1729

Truck weight (with battery and tray 113)

kg

1527

1527

1164/362

1164/362

V

V

Axle loading with load (driver s end/load end) kg Axle loading without load (driver s end/load end)

kg

Tyres: Superelastic (SE), air (L), Vulkollan (V) Tyre size (driver s end)

mm

Ø250 x 100

Ø250 x 100

Tyre size (load end)

mm

Stabilisers (dimensions)

mm

Ø85 X 61.5 2x ø 140 x 54

Ø85 X 61.5 2x ø 140 x 54

1x -2/4

1x -2/4

Number of wheels (x = driven) Distance between centreline of tyres, front

b 10 (mm)

470

470

Distance between centreline of tyres, rear

b 11 (mm)

380

380

Height with mast lowered

h1 (mm)

1280

1280

Height with mast lowered with initial lift

h1 (mm)

1410

1410

Lift

h 3 (mm)

1580

1580

Overall height with mast raised

h4 (mm)

2070

2070

Seat height/standing height Height of cockpit in driving position (min./max.)

Fork height, lower position

h7 (mm) h14 (mm)

210 1245

210 1245

h13 (mm)

91

91

Overall length without load

l1 (mm)

2568

2639

Length of powerhead, to fork heel

l2 (mm)

1418

1489

-4

50218070901 [EN]

Overall width

b1 (mm)

720

720

Fork dimensions

s/e/l (mm)

52/180/1150

52/180/1150

Fork carriage width

b3 (mm)

711

711

Width across forks

b5 (mm)

560

560

Ground clearance, centre of wheelbase

m2 (mm)

25

25

Working aisle width with 800 x 1200 pallets (b12 X l6) Turning radius

Ast (mm)

2768

2839

Wa (mm)

2362

2432

Travel speed with/without load

km/h

8/11

8/11

Lifting speed with/without load

m/s

Lowering speed with load/without load

m/s

Gradeability with load/without load

%

7/15

7/15

Acceleration time (0 - 10 m) with/without load s

7/5

7/5

Electromagnetic

Electromagnetic

Service brake

Traction motor, rating S2 = 60 min

kW

3

3

Lift motor, rating S3 = 15%

kW

2.2

2.2

IEC 254 - 2;B

IEC 254 - 2;B

24/450

24/450

Battery to DIN 43531/35/36 A, B, C, no Battery voltage, rated capacity C5

V/Ah

Battery weight (depending on supplier)

kg (+/- 5%)

410

410

Power consumption acc. to VDI cycle

kWh/h

<1.2

<1.2

dB (A)

AC frequency converter <70

AC frequency converter <70

Type of drive control Noise level at driver s ear

50218070901 [EN]

-5

The values were determined in accordance with the test procedure of standard EN 12053 (Noise testing on industrial trucks on the basis of ISO 11201 and EN ISO 3744 and the requirements of EN ISO 4871). This machine emits the following noise level: Continuous noise level at the driver s station: LpAz : < 70 Db (A)

(Stand-on or seated) 1.53 m/s2

The data were determined in the test cycle on identical machines from the weighted data in the operating modes driving, lifting and idle.

Uncertainty K +/-0.5 m/s2

Investigations have shown that the amplitude of the hand and arm vibrations on the steering wheel or the controls in industrial trucks are less than 2.5 m/s 2. For this reason there is no test directive for these measurements.

Time percentages: Lifting: 10% Idling 58% Driving: 32% The speci ed noise levels at the truck, however, can not be used to determine the noise emissions occurring at workplaces in accordance with in its latest valid version (Daily personal noise pollution). These, if re-

During charging the traction battery emits a mix of oxygen and hydrogen (detonating gas). This gas mix is explosive and must not be ignited. The danger of explosion can be avoided with suitable

Capacity in Ah

The vibrations are determined according to the CEN standard EN 13059, "Test methods for measuring vibration", on an identical truck.

Weighted effective value of the stress on the body through acceleration:

Uncertainty KpA: 4 Db (A)

Battery designation

quired, must be determined directly at the workplaces under the actually existing in uences (further sources of noise, particulars of use, sound re ections).

The driver s personal exposure to vibrations over a work day must be measured, if necessary, at the site in question in order to take all other in uencing quantities such as distance, intensity of work, etc into consideration.

ventilation and the keeping naked res away.

Observe the safety rules for handling the traction battery.

Max. tray dimensions in mm

Weight in kg +/- 5%

Height

Length

Width

Tray 70

450

405

784

289

719

Tray 71

600

510

784

374

719

It is absolutely necessary that the batteries used correspond to the DIN standard. The battery tray must be closed at the bottom. Do not change the location of ballast weights!

-6

50218070901 [EN]

Height of mast lowered

h1

1280

Height of mast

h1

1410

Free lift

h2

0

Full free lift Lift height

h2

150

h3

1580

Height of mast, extended

h4

2070

Initial lift

h5

130

Only the wheel types listed in the parts catalogue may be used.

50218070901 [EN]

-7

71 0249 A 00001

Complete serial number

71: Montataire (France)

0249: EXD S 20

Example: A: 2010 0148_000-005

00001: Ascending number from start of manufacture

Please indicate the serial no. for all technical enquiries.

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

-8

Model Manufacturer Serial no.

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

50218070901 [EN]

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

10.9

12.9

8.8

10.9

12.9

M3 x 0.5

1.3

1.9

2.3

-

-

-

M4 x 0.7

3

4.5

5

-

-

-

X 0.8

6

8.5

10

-

-

-

M6 x 1

10

15

17.5

9

13

15.5

M8 x 1.25

25

36

42

22

32

37

M10 x 1.5

48

71

83

42

63

73

M12 x 1.75

84

123

144

74

108

126

M14 x 2

133

195

229

116

171

201

M16 X 2

206

302

354

181

264

309

DIN 7984 DIN 6912 8.8

10.9

12.9

8.8

10.9

12.9

M3 x 0.5

1

1.35

1.6

-

-

-

M4 x 0.7

2.1

3

3.5

-

-

-

M5 x 0.8

4.2

6

7

-

-

-

M6 x 1

7

10

12.5

6

8.8

11

M8 x 1.25

17.5

24.5

30

15.5

22

27

M10 x 1.5

34.5

49

59

30

43

52

M12 x 1.75

60

84

101

53

74

89

M14 x 2

95

137

161

-

-

-

M16 X 2

147

210

252

129

185

222

50218070901 [EN]

-9

Vervus-Ripp Cl.100 -

10.9

-

-

10.9

-

M6 x 1

-

15

-

-

13.6

-

M8 x 1.25

-

37

-

-

33

-

M10 x 1.5

-

73

-

-

65

-

M12 x 1.75

-

-

-

127 -

-

M14 x 2

-

-

111 -

-

M16 X 2

-

311

-

-

272

-

-

For tightening of screws in aluminium parts the torque must be multiplied with the following factor:

DIN 7991 Ic 110.91 -

10.9

-

-

10.9

-

M6 x 1

-

11

-

-

9.5

-

M8 x 1.25

-

28

-

-

25

-

M10 x 1.5

-

56

-

-

50

-

M12 x 1.75

-

96

-

-

85

-

M14 x 2

-

156

-

-

137

-

M16 X 2

-

240

-

-

211

-

-10

50218070901 [EN]

ULS / ISO 7380 ULF -

10.9

-

-

10.9

-

M6 x 1

-

11

-

-

10

-

M8 x 1.25

-

27

-

-

25

-

M10 x 1.5

-

52

-

-

48

-

M12 x 1.75

-

100

-

-

90

-

DIN 7500

Useable as retaining screws 10.9

M6 x 1

10

M8 x 1.25

24

M10 x 1.5

48

M12 x 1.75

83

M14 x 2

-

These torques are guide values and can be varied depending on the required security.

The torque to be used must therefore be determined beforehand with tests.

eg: ECO SYN

50218070901 [EN]

-11

Useable as retaining screws

D 2.5

0.8

D3

1.4

D 3.5

2

D4

3

D5

5.5

These torques are guide values and can be varied depending on the required security. The torque to be used must therefore be determined beforehand with tests.

D6 9 If a torque wrench is used: max 600 rpm

DIN 74361-2 (Form G)

DIN 74361-2 (Form A)

8.8

10.9

-

M12 x 1.5

83

125

M14 x 1.5

135

210

45 H

M6 x 1 5

8.8

10.9

-

-

83

125

-

-

135

210

-

M14 x 2

M16 X 2

63

90

M8 x 1.25 M10 x 1.25 M12 x 1.75 10

20

This table applies only for joining two metal parts.

If washers are used, the torque must be multiplied with the factor stated in the table.

When installing in aluminium parts it must be observed that the torque must be multiplied with the factor stated in the table.

-12

50218070901 [EN]

45

If this information is not applicable for a certain application, please request further information.

Tightening safety-related parts Wheel fasteners, motors, reduction gearboxes and hydraulic cylinders, mast-to-frame fasteners, mast rollers, steering stop, brake fasteners, support roller fasteners, pump unit, turntable: ±10% Other parts (bonnet, accessories, etc...): ±20%

50218070901 [EN]

-13

Do not park the truck on gradients. In exceptional cases, secure the truck with chocks.

Lower the forks (1) to the ground.

Lower the load fully before leaving the truck unattended.

Operate the emergency isolator switch(2).

If the truck is left unattended and the electronic control is not switched off, the truck will switch it off automatically (delay time can be set with the diagnostic unit).

The driver s code must therefore be re-entered to resume work.

Operate the emergency isolator switch (2).

Open the battery cover (see tery change", P. 60- 9 ).

-14

Chapter "Bat-

50218070901 [EN]

Disconnect the battery connector.

Re tting is a reversal of removal.

Do not do any work as long as the truck carries voltage.

50218070901 [EN]

-15

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

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

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

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

Before lifting the truck disconnect the battery.

Place the truck with its fork against the wall.

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

Place the jack in the slot (1).

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

Make the truck safe with blocks.

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

Lift the truck.

-16

50218070901 [EN]

Make the truck safe with blocks.

No-one should be under a raised load.

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

Wedge battens between the chassis and slings to prevent damage.

50218070901 [EN]

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-18

50218070901 [EN]

a

50218070901 [EN]

-1

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

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

-2

50218070901 [EN]

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

STILL 149 544

Gossen-Metrawatt

8392452 8430163 0 143 920

Beckmann

LCD multimeter Metra Hit Leads, pair, Metra Hit

0 158 061

Gossen-Metrawatt

0 146 344

Gossen-Metrawatt

Leads, pair

0 143 425

Leads Clip-on ammeter (600 A)

Alligator clips, pair

143 427

Test probes, pair

0 143 426

Extra-length test clips, pair

0 143 424 1675079 8052115 144 087

Desoldering tool Crimping tool

(France) AMP

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

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

50218070901 [EN]

-3

Ident. No. : 172359

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

-4

50218070901 [EN]

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

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

(Ident. No.: 0 143 920)

50218070901 [EN]

-5

(Ident. No.: 0 158 031)

(Ident. No.: 146 344)

(Ident. No.: 143 425)

(Ident. No.: 143 427)

(Ident. No.: 143 426)

-6

50218070901 [EN]

(Ident. No.: 143 424)

The CAN data bus of the device interconnects the following devices: Cockpit (1), which feeds and establishes communication Traction motor controller (2) Steering motor controller (3) The relevant components permanently exchange information in the form of a "data telegram transfer " via this communication bus. The transfer speed is 250 KB/s.

Desired values for traction drive Desired values for hydraulic system Desired values for horn Information of the traction motor controller to the cockpit:

Fault Hour meter Battery state of charge Information of the traction motor controller to the cockpit: Fault The steering controller and the traction controller are the beginning and the end of the bus. These ends must be provided with a so-called "bus terminal resistor" (120 ). The control console has a high impedance (about 40 k ).

Thus it is possible to determine if the bus is physically OK with a simple resistance test (see illustration).

Reading:

50218070901 [EN]

-7

60 : 120 : 40 k : In nite:

-8

The network is OK. The steering controller or the traction controller is not connected.

The steering controller and the traction controller are not connected.

No unit is connected to the network.

The bus components are interconnected by 4 wires: 2 cables for 24 V power supply 2 cables for the signals CAN_H (CAN-High) and CAN_L (CAN-Low)

50218070901 [EN]

Power supply upon key-on: Power to the cockpit and the CAN Bus by connecting the battery connector (marked red) Acquisition of code (2)

Power to/activation of the controllers (marked blue) Feedback from the controllers (OK or not OK) (4).

If the motor controllers are OK, the transistor inside the cockpit is red, then the internal

50218070901 [EN]

-9

safety relay in the steering motor controller is activated. Contactor K1 is activated (green marking).

-10

50218070901 [EN]

The fault diagnosis is a software for performing different types of interventions for which speci c parameters must be indicated or changed.

The truck and the Notebook are connected with the following cables: Ident. No.: 8392452 and 8430163 ( Chapter "Diagnostic equipment", P. 02- 3 ) to CAN bus connector (see photo).

50218070901 [EN]

-11

Before the software can be started, the Notebook must be connected to the truck with the aforementioned cables.

Start "STEDS".

Click on the "Diagnosis" symbol.

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

The following window will appear: Enter your code ("22113").

The following operations can be carried out with the software: Display the fault list.

Teach-in.

Change the parameterisation.

Display various values.

Load, save and print the con guration.

-12

50218070901 [EN]

The software has three main menus: "F2: Diagnosis": Test menu (teach-in of the steering ...) and fault diagnosis / start menu.

"F3: Setup": Truck parameterisation menu (con guration of the truck).

"F4: Monitor": Test menu (test of inputs and outputs).

For the selection press the short-cut keys (F2, F3, F4) or click the appropriate button.

The menus F3 and F4 consist of several screen pages which in turn can be subdivided into further screens.

This menu is also the starting screen. Here you can nd: Introduction to diagnosis (teach-in procedures, error suppression display ...).

Activities (List of PTX les, list of all possible error codes, available software versions). should be done in 2 steps: Block up the truck on squared timbers for the presetting during the teach-in of the truck.

Repeat the teach-in, but this time on the ground for the ne adjustment.

The teach-in of the electric steering is carried out as follows: Select "Teach-in of the electric steering".

Click on Execute .

50218070901 [EN]

-13

In response to the question "Do you want to start the teach-in-procedure?" select "Yes".

Click on Execute .

Then follow the instructions step for step.

In the window "Activities" in the left lower part of the screen: Select "All error codes".

Click on Execute .

-14

50218070901 [EN]

The error list will be displayed.

Proceed as follows to display or change truck parameters: Click on F3: Adjust .

Click on the appropriate tab for the desired page.

The following window will appear (the window for displaying the error list determined by the control console during the diagnosis of the truck is located to the right):

Use the arrows to access certain lines.

The small round yellow buttons beside the settings indicate that the standard factory settings have been modi ed.

Click on ^F4: Load "" to load all the parameters of the truck to which you are connected (see: Loading and Saving).

Important information and help for parameterisation are available in the white elds.

50218070901 [EN]

-15

The different sections of the "Monitor" menu allow the individual inputs/outputs of the CAN bus to be checked.

This menu displays various readings on the screen: Conditions of the different inputs and outputs of the motor controls and cockpit Measured values such as voltage, amperage and temperature Testing of the various controllers To access these screens: Click on F4: Monitor .

Click on the appropriate tab for the desired page.

Click on ^F3: STOP to stop the measurements.

To resume the measurements, click on ^F3: Measurement .

Important information and tips is given in the white elds. The values are indicated with a tolerance of about +/-10 %. To perform more -16

50218070901 [EN]

exact measurements, a suitable and calibrated meter must be used.

These functions allow the following actions: Loading of data into the menu" F3: Setup" from the existing truck data ( ) or from a text con guration le (in ptx format) and binary ( ).

Saving of the values contained in the menu "F3: Setup" into the truck ( ) or into a text con guration le (in ptx format) and binary ( ).

After selecting the type of saving, you can choose the data you want to save by making the appropriate selection in the following window:

Printing of parameters

Keyboard short-cuts (fast access to a diagnosis screen)

Reloading of the parameters due to errors on one or more pages of the diagnosed truck.

To determine if the electric steering is unsymmetrical, proceed as follows: Select F4: Monitor .

Select the "Electric steering" tab.

Select "Speed reduction when cornering".

50218070901 [EN]

-17

Carry out the different tests to determine if the truck has a steering asymmetry (the box changes to green when the reduction in starts during cornering).

The electric steering is unsymmetrical if the box changes to green far before or after the tiller with the cockpit has reached an angle of 17° (for activation) or 15° (for deactivation).

In this case the electric steering teach-in must be repeated.

-18

50218070901 [EN]

a

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

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

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

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

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

1044_100-001

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

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

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

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

0148_100-001

50218070901 [EN]

-1

-2

50218070901 [EN]

a

Manufacturer Type of motor

AF 103 L1

Juli

Operating voltage

24 V

Strength of current Rated speed

166 A 2040 rpm

Rated power

3.0 kW

Operating mode

S2/60 min

Protection class

IP00/44

Insulation class Weight

F 27 kg

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

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

Park the truck and disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Use squared timbers to prevent the truck from rolling.

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

Chapter "Mo-

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

50218070901 [EN]

-1

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

Disconnect these plugs: X 12

Speed sensor (4-pin)

X 13

Temperature sensor (2-pin)

X 14

Electromagnetic brake (2-pin)

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

Remove the cable ties.

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

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

-2

50218070901 [EN]

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

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

Lift out the traction motor upwards.

Proceed in the reverse order of removal.

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

Do not contaminate the gearbox oil.

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

Check the hydraulic oil level.

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

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

50218070901 [EN]

-3

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

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

-4

50218070901 [EN]

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

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

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

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

0148_112-002

50218070901 [EN]

-5

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

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

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

Park the truck and disconnect the battery connector (see Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

Disconnect plug X12.

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

Remove the screws fastening sensor to the motor.

Pull the sensor off.

-6

50218070901 [EN]

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

This sensor is connected directly to the traction controller.

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

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

Disconnect plug X13.

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

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

Measure the temperature on the motor casing.

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

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

1000

1403

1019

1422

1039

1441

1058

1460

1077

1479

1097

1498

1116

1517

1136

1535

1155

1554

50218070901 [EN]

-7

1174

1573

1193

1591

1213

1610

1232

1629

1251

1647

1270

1666

1289

1684

1308

1703

1327

1721

1347

1740

1366

1756

1385

-8

50218070901 [EN]

a

Designation of drive unit

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

Mounting on the frame Mounting of gearbox on motor Gear oil Oil quantity

1.5 L

Gear ratio

1 : 19.67

Park the truck and disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Use squared timbers to prevent the truck from rolling.

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

Chapter "Mo-

Remove the traction wheel (see ter "Traction Wheel", P. 46- 1 ).

Chap-

Raise the truck 230 mm off the ground and secure it with squared timbers.

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

Drain the oil in the reduction gearbox. Carefully remove any particles of metal on the oil drain plug (2).

Danger of burns!

The hydraulic oil can be very hot!

2

1044_223-002

50218070901 [EN]

-1

Replace the two screws (3) fastening the gearbox to the gear ring by two eyebolts.

Secure reduction gearbox with a lifting sling and a hoist.

Remove the eight fastening bolts on the reduction gearbox (4).

Carefully lower the gearbox to the ground until it can be removed from between the squared timbers.

Re tting is a reversal of removal.

Coat the 8 fastening screws (4) of the gearbox with Loctite 242 and tighten with a torque of 42 Nm.

Fill the gearbox with gear oil.

If the oil level is correct, the pinion (5) (toothing) should be immersed approx. 1/3 of its height in oil.

Avoid lling too much oil as this could damage the seals and the operating temperature can no longer be kept within its range.

Do not ll the gearbox beyond the maximum level.

-2

50218070901 [EN]

50218070901 [EN]

-3

Park the truck and disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Lift the truck with a hoist and secure with a squared timbers (see Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

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

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

Chapter "Lift

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

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

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

-4

50218070901 [EN]

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

A1 Red D1 Blue D2 White

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

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

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

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

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

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

50218070901 [EN]

-5

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

Re tting is a reversal of removal.

In order to achieve an even distribution of the ground pressure of the centrally mounted traction wheel, the bias springs must be adjusted as follows: Value A must be adjusted with the truck fully on the ground (all wheels must contact the ground).

Value A: EXD-S : A = 173 mm Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

Loosen the locknut (1).

Screw the adjusting nut (2) in or out until value A is obtained.

Tighten the locknut (1).

The spring is always tensioned, even if the nuts are screwed out as far as the end of the threaded rod.

-6

50218070901 [EN]

a

The chassis of the trucks are made using mechanised welding.

Rear access chassis.

Side access chassis.

50218070901 [EN]

-1

Fork chassis.

-2

50218070901 [EN]

1 2 3 4 5

Battery cover Instrument panel Motor cover Cushion Back rest

50218070901 [EN]

-3

Disconnect the battery plug (4) (See ter "Safety information", P. 00-14).

Chap-

Remove the 2 nuts (1).

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

Do not damage the electric cables.

0148_311-005

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

Proceed in reverse order.

-4

50218070901 [EN]

Open the battery cover.

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Batteries with naked poles or connectors should be covered with a rubber mat.

Remove the 4 socket head screws (1).

Remove the cover.

Re tting is a reversal of removal.

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

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

0148_311-008

50218070901 [EN]

-5

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

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

Proceed in reverse order.

0148_311-009

Disconnect the battery plug (4) (See ter "Safety information", P. 00-14).

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

Chap-

Chapter "Mo-

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

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

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

Unscrew the red part of the emergency stop button.

-6

50218070901 [EN]

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

Put down the horn assembly.

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

Continue with the 2nd screw.

Then undo the 3rd screw.

50218070901 [EN]

-7

Disconnect the SAAB (G) type connector .

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

Remove the instrument panel.

Proceed in reverse order.

Operate the lift function with the control on the cockpit.

Block up the forks.

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Remove the screws.

-8

50218070901 [EN]

Remove the cylinder protective covers.

When this removal is a work step for another procedure, it may become necessary to remove the supports: Connect the battery connectors (see Chapter "Safety information", P. 00-14).

Turn on the truck and raise the forks.

Remove the supports.

Lower the forks completely.

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

50218070901 [EN]

-9

-10

50218070901 [EN]

a

DC current with 2 windings

Motor Manufacturer Type

Schabmüller R 100/0.15 150 W IMS reinforced planetary gear

Reduction gear

Reduction ratio 18 : 1

Reduction ratio of gear ring to pinion

1 : 4.15

Heat class

F

Protection class and S3

IP20/S3 78 %

Resistance of windings

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

Actual value potentiometer

Potentiometer connected by 2 with 22 k

Desired value potentiometer

Potentiometer connected by 2 with 22 k

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

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

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

50218070901 [EN]

-1

F3 F5 G1 K6

-2

Control fuse Steering fuse Battery Steering relay

M3 P3 P4

Steering motor Desired value potentiometer for steering Actual value potentiometer for steering

50218070901 [EN]

Park the truck and remove the battery plug (See Chapter "Safety information", P. 00-14).

Chock the truck to prevent it moving.

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

Chapter "Mo-

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

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

Remove the pinion (4).

50218070901 [EN]

-3

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

Take out the power steering motor.

Proceed in reverse order.

-4

50218070901 [EN]

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

A B Pp1 Pp2

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

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

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

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

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

Remove the screws (2).

50218070901 [EN]

-5

Remove the potentiometer.

Re tting is a reversal of removal.

-6

50218070901 [EN]

50218070901 [EN]

-7

The steering angle actual value potentiometer consists of two identical tracks (single potentiometers) arranged crosswise and operated by the rotation of the cockpit. They are supplied with 10V . The characteristics of the two tracks is shown in the diagram to the right.

A: B: Pp1: Pp2:

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

4-pin SAAB plug: L L1 : 0V (earth) L2 : wiper 2 (Pp2) L3 : 10V L4 : wiper 1 (Pp1) Functionality: between 0.15V and 9.85V

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

When the cockpit is in the rest position (position of the desired value potentiometer is 0°, ie straightahead position), the two tracks of the actual value potentiometer for steering angle (Pp1 and Pp2) must ful l the following conditions: The difference in voltage between Pp1 and Pp2 must be less than +/- 400mV. If this condition is not met, the centre position of the steering angle actual value potentiometer must be adjusted (see the following removal and installation instructions)

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

-8

50218070901 [EN]

When the cockpit is in the rest position (position of the desired value potentiometer is 0°, ie straightahead position), the two tracks of the actual value potentiometer for steering angle (Pp1 and Pp2) must ful l the following conditions: The difference in voltage between Pp1 and Pp2 must be less than +/- 400mV. If this condition is not met, the centre position of the steering angle actual value potentiometer must be adjusted (see the following removal and installation instructions)

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

Park the truck and disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Use squared timbers to prevent the truck from rolling.

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

Chapter "Mo-

Disconnect the plug (L).

L: actual value potentiometer connector

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

50218070901 [EN]

-9

Loosen the locknut (2).

Unscrew the hex head screw (3) from the support (4).

Loosen the locknut (6).

Loosen the socket head screw (7) on the driver (8).

Remove the potentiometer and its support.

Loosen the 2 setscrews (9) and their locknuts (10).

Pull out the driver.

Set the traction wheel to the straight-ahead position.

If necessary, re t the driver.

Connect a multimeter set to resistance testing and the following test range to the potentiometer in order to adjust the : Pin 4 and pin 1: 850

± 10

Pin 4 and pin 3: 850

± 10

Turn the potentiometer by hand until the speci ed values are obtained.

After the adjustment of the centre position the steering must be readjusted with the diagnostic unit.

-10

50218070901 [EN]

Lock the potentiometer in the driver (8) so that it will stay in the centre position.

Fix the axle of the potentiometer in the driver (8) with the socket head screws (7).

Tighten the locknut (6).

Install the hex head screw (3) in the support (4).

Tighten the locknut (2).

Connect the plug (L) of the potentiometer.

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

Chapter "Mo-

Connect the battery connector.

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

50218070901 [EN]

-11

Take the circlips (2) out of the shaft.

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

Remove the circlips.

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

Proceed in reverse order.

-12

50218070901 [EN]

a

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

Type of rubber: VULKOLLAN

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

Park the truck and remove the battery plug (See Chapter "Safety information", P. 00-14).

Chock the truck in order to prevent it moving.

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

Chap-

Loosen the wheel nuts.

Put the truck on blocks..

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

2

Unscrew the wheel nuts (2).

Remove the drive wheel.

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

Put the drive wheel in place.

Screw the 5 nuts up by hand.

Put the truck on the ground.

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

Chap-

1044_462-005

Remove the chocks.

Unlock the emergency stop.

50218070901 [EN]

-1

Dimensions of a new roller: 150 x 50 mm.

Place the truck on at, level ground.

Park the truck.

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

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

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

Chapter "Mo-

Undo the 4 screws.

Remove the stabiliser roller from underneath the truck.

-2

50218070901 [EN]

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

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

Correct installation

Incorrect installation

50218070901 [EN]

-3

0148_465-001

Raise the forks to their maximum height.

-4

50218070901 [EN]

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

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

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

Secure the truck with squared timbers (2).

Remove the two fastening screws (3).

Renew the load wheels.

Installation is the reverse of removal.

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

Never grease the bushings (4).

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

50218070901 [EN]

-5

-6

50218070901 [EN]

a

Type:

BFK 457 - 12

Manufacturer Braking torque:

INTORQ 40 Nm

Power consumption of coil at 20°C:

40 W ± 10%

Voltage: Weight:

24 V 4.7 kg

Min air gap:

0.3 mm

Max air gap:

0.8 mm

Wear of brake disc:

Max 0.5 mm

50218070901 [EN]

-1

1

7

a

6 1 2 3 4

5

4

3

Inductor body Brake backing plate Hub Clutch spring

5 6 7 a

Rotor with friction lining Spacer Coil Air gap

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

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

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

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

-2

2

50218070901 [EN]

1044_491-004

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

1

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

0148_491-001

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

Yes

No

No

Yes

50218070901 [EN]

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

-3

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

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

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

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

Measure the resistance of the brake winding.

Resistance of brake winding Nominal

Max.

Min.

10

15

5

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

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

Park the truck and disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Use squared timbers to prevent the truck from rolling.

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

Chapter "Mo-

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

-4

50218070901 [EN]

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

Remove the three socket head screws (2).

Lift out the electromagnetic brake.

Installation is the reverse of removal.

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

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

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

50218070901 [EN]

-5

-6

50218070901 [EN]

a

1 2 3 4 5 6 7 8 9

Lift button Lower button Horn button "Tortoise" button "PRG " (scrolling) button Numbers "123" button Display "I" (ON) button Numbers "456" button

10 11 12 13 14 15 16 17

50218070901 [EN]

Numbers "789" button "PRG " (enter) button "Hare" button Handle Throttle Belly switch Main lift down button Main lift up button

-1

1

2

3

4

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

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

123

789

456

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

PRG

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

PRG

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

7

5

6

1044_505-001

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

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

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

1044_505-002

9

1044_505-003

-2

50218070901 [EN]

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

2

1044_505-004

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

The meter goes up to 9999.

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

3

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

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

1044_505-005

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

Contact a competent after-sales service.

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

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

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

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

50218070901 [EN]

-3

Access to the electronic control is granted with three different codes: Driver s code Master code Service code

The driver s code consists of four digits and it is created by the Pool Manager.

The knowledge of the code is like an access key for the truck. The driver s code must not be given to other persons without express order.

A maximum of 200 driver s codes can be stored in the control. A driver s code can be added or deleted with the master code.

The master code consists of four digits and is reserved for the Pool Manager.

Upon delivery, the master code is "1234". It is recommended that the pool manager replace this code with a new master code (see Chapter "Deleting the master code", P. 50- 6 and Chapter "Adding the master code", P. 50- 5 ).

Like the driver s code, it is intended for normal use and operation of the truck, but it also allows a driver s code to be added or deleted. The control can store a maximum of 5 master codes.

If master codes or driver s codes are forgotten or get lost, please contact the Service Engineer, for he alone can make the stored codes visible.

The service code is only intended for the aftersales service. It allows the diagnosis of the truck in case of an inspection and access to the driver s and master code.

-4

50218070901 [EN]

1

If a fault code, eg E380 (1) appears, the truck must be stopped and the power-on procedure must be repeated Chapter "Entering the user code", P. 50- 2 . If the fault code persists, please contact your Service Engineer.

%

1044_505-008

The truck is turned off, the battery is connected.

Push button I (driving) (5).

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

1

2

123

3

789

456

PRG PRG

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

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

50218070901 [EN]

1044_505-010

1044_505-011

4

5

1044_505-009

7

10

-5

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

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

1044_505-012

8

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

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

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

Add (10)will appear again in the display.

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

1044_505-013

1044_505-011

1044_505-014

10

11 %

The truck is turned off, the battery is connected.

-6

9

50218070901 [EN]

Push button I (driving) (5).

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

1

2

123

3

789

456

PRG PRG

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

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

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

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

5

1044_505-010

1044_505-009

7

1044_505-015

1044_505-012

4

10

8

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

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

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

50218070901 [EN]

1044_505-013

9

-7

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

1044_505-015

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

10

1044_505-014

11 %

The truck is turned off, the battery is connected.

Push the I button (driving) (5).

1

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

2

123

3

789

456

PRG PRG

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

1044_505-016

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

-8

1044_505-011

50218070901 [EN]

4

5

1044_505-009

7

10

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

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

1044_505-012

8

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

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

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

Add (10) will appear again in the display.

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

1044_505-013

1044_505-011

1044_505-014

9

10

11 %

The truck is turned off, the battery is connected.

50218070901 [EN]

-9

Push button I (driving) (5).

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

1

2

123

3

789

456

PRG PRG

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

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

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

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

5

1044_505-016

1044_505-009

7

1044_505-015

1044_505-012

4

10

8

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

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

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

-10

1044_505-013

50218070901 [EN]

9

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

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

1044_505-015

1044_505-014

10

11 %

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

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

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

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

50218070901 [EN]

-11

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

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

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

Remove the three cockpit fastening screws (3).

Remove the cockpit.

Re tting is a reversal of removal.

-12

50218070901 [EN]

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

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

50218070901 [EN]

-13

-14

50218070901 [EN]

a

50218070901 [EN]

-1

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

Name A1 A11 A111 A112

Traction controller Battery charger Row of electroluminescent diodes Plug holder

P2

Hydraulic potentiometer

P3

Steering setting potentiometer

P4

Steering recopy potentiometer

P5

Tiller inclination potentiometer Battery discharge and/or hour meter potentiometer

6P20 RC

Heating resistance

Generic names Key or Digicode S1

S7

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

S8

Anti-foot compression sensor

Control fuse

S9

Push-button unlocking

S10

Speed reduction sensor

F5

Control fuse Steering fuse

S11

Emergency stop

F6

Option fuse

S12

Emergency stop

F7

Option fuse

S13

F8

Option fuse

S14

Fold-up platform sensor Fold-up railing sensor 1

F9

Option fuse

S15

Fold-up railing sensor 2

S16

Emergency stop

Battery

S17

Push-button, forward travel, right

S18

4H1

Warning horn;

S19

H2

Indicator or rotating light

S20

K1

S21

K2

Traction or line contactor Pump contactor

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

S22

Lift button, right-hand backrest

K3

Braking relay

S23

K4

Option relay

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

K5

Option relay

K6

Steering relay

A2 A3

Control box Steering controller

2A3

Hydraulic module

C1

Capacitor

F1 F2

Traction or line fuse Pump fuse

F3 F4

S2 S3 S4 S5

G1

M1 M2

Traction motor Pump motor

M3

Steering motor

M4

Fan motor

P1

Traction potentiometer

-2

S6

S24 S25 S31

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

S33

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

S34

Button, computer con rmation

S82

Push button, slow travel

S83

Push button, slow travel

S32

Traction names

50218070901 [EN]

1S2

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

1S30

Anti-collision micro-contact shield

1S1

X10

Tiller bundle connector

X11

Various connectors

X12

Various connectors

X13

2S1

Lowering push-button

X15

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

2S2

Lifting push-button

X16

Various connectors

2S80

Push-button, low lift, "lifting"

X17

Various connectors

2S81

Push-button, low lift, "lowering"

X18

Various connectors

X19 X20

Various connectors Connector,tiller case 1

X14

Hydraulic names

Signalling names 4S1

Horn push-button

X21

Connector, tiller case 2

X1

Controller connector Display connector

Y1

Lowering solenoid valve

Y2

X3

Battery connector

Y3

Brake Loading frame solenoid valve

X4

Various connectors

Y4

X5

Various connectors

X6

Y5

X7

Various connectors Negative terminal

X8

Positive terminal

X9

Various connectors

X2

Y6

50218070901 [EN]

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

-3

AC frequency inverter

Electronic motor controller

3-phase inverter

Traction motor controller Pump motor controller

1-quadrant speed control

Rated voltage

24 V

Current limit for the traction motor Pump motor

300 A 125 A Adjustable with driving programs

Speed range

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

Speed reduction Contactor Relay

K1

24 V (30

)

K6

24 V (winding 330

)

Fuses - Main circuit fuses

F1, F2 (400 A)

- Control circuit fuses

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

Traction battery

G1

24 V 450 Ah

Insulation resistance - Electrical system - Electric motors - Traction battery

1000

/V

G1

Protection class - Electrical system - Impulse control - Electric motors

-4

IP 64 Traction motor Pump motor

50218070901 [EN]

IP 22 IP 54

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

Park the truck and disconnect the battery connector (see Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

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

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

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

Do not remove the cockpit and horn hereby.

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

Unscrew the 2 countersunk screws (3).

Re tting is a reversal of removal.

50218070901 [EN]

-5

1 2 3 4

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

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

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

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

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

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

Check the impedance of the coil.

Coil impedance

-6

Rated

Max

Min

44

60

35

50218070901 [EN]

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

Park the truck and disconnect the battery connector (see Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

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

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

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

A : 2 brown leads.

B : 1 brown lead.

Unscrew the socket head screws (4).

Remove the contactor.

Re tting is a reversal of removal.

50218070901 [EN]

-7

Battery charging

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

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

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

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

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

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

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

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

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

Only charge using direct current.

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

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

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

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

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

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

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

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

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

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

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

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

Acid density in the battery completely:

-8

50218070901 [EN]

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The battery may only be changed by trained personnel according to the instructions of the manufacturer of the battery, battery charger and truck. Observe the battery handling instructions.

50218070901 [EN]

-9

Smoking and naked ames are not allowed when servicing the battery.

No in ammable or spark-producing materials may be located within at least 2 metres of the parked truck to be charged and the charger. The room must be well ventilated. Fire extinguishers must be kept at hand.

Park the truck.

Operate the emergency isolator switch (2).

Turn the battery compartment lock (3) 90° to unlock the battery cover (1). To open the battery cover, fold it forward.

Disconnect the battery connector (4).

Park the truck (see tion", P. 00-14).

Chapter "Safety informa-

Park the truck (see tion", P. 00-14).

Chapter "Safety informa-

-10

50218070901 [EN]

Open the battery cover.

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Raise the battery latch (5).

Danger of crushing.

Do not put your hands between the frame and battery during the removal and installation of the battery!

Place the trolley (8) alongside the battery.

Stand on the side opposite the cover and slide the battery ((7)) on to the trolley ((8)).

The weight and size of the battery in uence the stability of the truck. Do not change the weight conditions when changing the battery. Do not remove nor change the position of additional weights.

Observe the information on the battery.

Notes on charging the battery are contained in this workshop manual at the start of this section (Service the battery).

Reinstall and connect the charged battery in the reverse order of removal. Make sure that all covers are re tted correctly.

Take care not to damage the battery leads when removing and installing the battery.

Danger of crushing!

When closing the battery cover, there should be nothing between the cover and edge of the frame.

50218070901 [EN]

-11

Disconnect the battery connector (see () Chapter "Safety information", P. 00-14).

Push the battery lock (5) down.

Close the battery cover (1).

Turn the key (3) for the battery compartment lock 90° and remove it.

Release the emergency isolator button (2).

-12

50218070901 [EN]

Chock the truck at the rear.

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

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

Chapter "Mo-

Disconnect the battery plug (4) (See ter "Safety information", P. 00-14).

Chap-

Remove the pin from the cylinder.

Sling the fork chassis Chapter "Safety information", P. 00-14).

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

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

Then

remove the 4 nuts.

Proceed in reverse order.

50218070901 [EN]

-13

-14

50218070901 [EN]

The detection of the presence of the driver is ensured by a redundant switch (S3). The state of the switch is controlled directly by 2 inputs of the traction controller (A34 and A35).

This switch carries 12V. The state is changed according to the movements of suspended driver s platform.

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

Unoperated

Active

Error (interruption)

Error (short circuit)

12 V

0V

0V

12 V

0V

12 V

0V

12 V

Check with the diagnostic unit (eg E294).

Check the mechanical position of the switch.

Check the operation of the switch according to the table above.

0148_608-002

It is possible to indicate the state of the contact with the diagnostic unit.

Park the truck (see tion", P. 00-14).

Chapter "Safety informa-

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

50218070901 [EN]

-15

Remove the 2 screws.

Slide the platform forward.

Lift the platform slightly and pull it step by step forward until it can be lifted out completely.

Disconnect the microswitch (2) (mark the cable for reinstallation).

-16

50218070901 [EN]

Remove the platform oor plate.

Re tting is a reversal of removal.

Park the truck (see tion", P. 00-14).

Chapter "Safety informa-

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Remove the motor compartment cover (see Chapter "Motor covers", P. 31- 4 ).

Disconnect plug N (inductive proximity switch for detection of the maximum lift height).

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

50218070901 [EN]

-17

Perform the installation in the reverse order of removal and adjust the height of the sensor so that the pump unit is shut off electrically when the forks reach a height of 200 mm (3) above the ground.

It is possible to indicate the state of the sensor with the diagnostic unit.

This sensor (S8) is an inductive proximity switch with a digital output (all-or-nothing). It activates a speed reduction function as soon as the forks are raised (forks more than approx. 250-300 mm over the ground or difference between forks and initial lift = approx. 160 mm). If the speed reduction function is not on, there is a metal strut of the moving part of the mast before the sensor.

Inductive proximity switch S8 is connected with the 4-pin SAAB plug X10: X10-1 : 24V X10-2 : normally open contact (NOC) X10-3 : normally closed contact (NCC) X10-4 : 0V

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Remove the protective cover for the lift cylinders (see Chapter "Cylinder protective covers", P. 31- 8 ).

Remove and support the mast and fork carriage (see Chapter "Mast and fork carriage", P. 81- 2 ).

-18

50218070901 [EN]

Remove the sensor fastening screw.

Disconnect the SAAB connector X10.

Remove the battery.

Remove the cable clamps (2).

Remove the sensor (3).

Re tting is a reversal of removal.

Route the sensor cable as shown (see red mark in the picture).

It is possible to adjust the gap of the sensor.

Proceed as follows for the adjustment:

50218070901 [EN]

-19

To adjust the desired gap, use adjustment screw provided for this purpose.

-20

50218070901 [EN]

a

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

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

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

B-: Input - (Earth).

U: U output to traction motor (Control).

V: V output to traction motor (Control).

W: W output to traction motor (Control).

P : Output - to pump motor (Control).

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

Park the truck and take out the battery plug (See Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

50218070901 [EN]

-1

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

Disconnect the SAAB (A1) plug.

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

Proceed in reverse order.

Park the truck and remove the battery plug (See Chapter "Safety information", P. 00-14).

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

-2

Chap-

50218070901 [EN]

Take out the fuse holder (1).

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

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

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

50218070901 [EN]

-3

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

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

A: 2 brown wires.

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

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

Undo screw H (11).

Remove the cover (12).

Undo the 2 CHc screws (13).

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

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50218070901 [EN]

Undo the 4 Philips screws (16).

Remove the fan.

Proceed in reverse order.

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-5

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

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

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

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

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

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

Example: Setting and recopy potentiometer.

Park the truck and remove the battery plug (See Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

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

Red, blue, black and white wires.

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50218070901 [EN]

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

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

Take out the steering controller.

Proceed in reverse order.

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

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-8

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1 2 3 4 5 7 8 9 10

Initial lift cylinder (Z1) Slow lowering valve Main lift cylinder (Z2) Main lift cylinder (Z2) Slow lowering valve Valve block Main lift solenoid valve (Y4) Initial lift solenoid valve (Y3) Hydraulic unit

Initial lift Main lift lowering Initial lift lowering

-2

Lowering solenoid valve (Y1) Flow restrictor Pressure relief valve Hydraulic oil reservoir Strainer Pump motor Pump Non-return valve

Active components

Function Main lift

11 12 13 14 15 16 17 18

M x

Y1

Y4 x

x

x

x

Y3 x

x

50218070901 [EN]

x

When the motor (1) is supplied with power, it drives the gear type pump (2), which immediately supplies oil from the reservoir to the boost pressure port (P) via the suction lter (3) and the non-return valve (4).

A high-pressure pipe is connected to this port, which supplies boost pressure to the lift cylinders.

When the pressure at port (P) rises, the pressure at the pressure relief valve also rises: The pressure relief valve opens then and the oil ows back into the reservoir.

|Legend : |... : Overpressure |--- : Working pressure |H : Oil pressure of pump |R : Return line to reservoir

50218070901 [EN]

-3

If the load is to be lowered, the solenoid valve (1) must be activated via the "lowering" control.

This causes the valve spool in the solenoid valve to change its position.

To prevent the load from lowering too fast, a slow lowering valve (2) is installed downstream of the 2-port directional control valve which allows only speci c quantity of oil to pass through over a speci ed period, thus a achieving a controlled lowering speed (11 litres/min).

|Legend: |... : Return line

Lower the forks with the control on the cockpit and continue to operate this function for 5 seconds after the complete lowering of the forks.

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Pull off the solenoid valve.

Disconnect the motor leads.

Disconnect the hydraulic hose from the valve block.

The oil can be pressurised. Danger of oil squirting out! After prolonged operation the oil can be very hot.

Danger of scalding! Wear protective gear (gloves, protective goggles ...).

Remove the pump unit fastening screw.

Lift the whole unit to remove the reservoir retainer.

Proceed in the reverse order of removal.

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Even if properly routed and not exposed to excessive stress, the hoses are subject to natural ageing. This limits their shelf life and their service life.

During use, the hoses must be inspected for ageing, cracks and damages at least once a month and replaced, if necessary.

When replacing damaged hoses, the following must be observed: The position and natural movement of the hoses must not be restricted.

50218070901 [EN]

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During use, they must not be stressed by external in uences (pulling, twisting or squeezing).

Avoid painting the hoses.

Do not choose too small a bending radius.

Do not re-use worn hoses.

Remove the protective cover for the lift cylinders (see Chapter "Cylinder protective covers", P. 31- 8 ).

Remove and support the mast-fork carriage unit (see Chapter "Mast and fork carriage", P. 81- 2 ).

Unscrew the pipe ttings on the cylinder.

Remove the pipe.

Re tting is a reversal of removal.

Do not forget to bleed the hydraulic system. If necessary, replenish the oil.

Remove the protective cover for the lift cylinders (see Chapter "Cylinder protective covers", P. 31- 8 ).

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Retract the mast cylinders with the related control on the cockpit and hold the control for a few seconds after the cylinders have retracted completely so that there is as little oil and pressure in the hydraulic circuit as possible.

Raise the front part of the frame and support it with squared timbers.

Raise the front part of the frame with the initial lift.

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

50218070901 [EN]

-7

Unscrew the 3 ttings.

Risk of oil running out. Wear the appropriate protective gear, therefore, and have a collecting vessel at hand.

Remove the battery.

-8

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Remove screw and washer (A) to loosen the pipe clamp (B).

Remove the pipe.

Re tting is a reversal of removal.

Do not forget to bleed the hydraulic system. If necessary, replenish the oil.

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a

Type:

42.823.16.0035 Oil system

Manufacturer: Motor type

4-pole series-wound motor

Voltage (V):

24 V

Current (A)

134 A at 100 bar

Excitation:

No

Power (kW):

2.2 kW

Operating mode:

S3 - 5%

Protection class:

IP43

Insulation class:

F

Brushes: a) Length:

16 mm

b) Wear limit:

11 mm

c) Quantity (number)

4

d) Motor brush monitor:

No

Weight ( kg):

11 kg

Ventilation:

No

Pump: 4 cm 3/rev

Delivery capacity: Oil quantity (for standard model)

90 µ

Suction lter and return lter: Oil change:

Annually

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-1

Lower the forks fully.

-2

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Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

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

Unscrew the hydraulic hose (3) at the pump unit.

Seal the connection with an M22 plug.

Since hydraulic oil can run out, keep a collecting vessel at hand.

Unscrew and remove the screw, nut and washer (4) with which the pump unit is fastened on the mounting bracket.

Raise the pump unit and tilt it slightly in order to free the hydraulic oil reservoir from its mounting.

Lift out the pump unit.

Do not tilt the pump unit too much as there is still oil in the hydraulic oil reservoir.

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Remove the mounting bracket of the pump unit by unscrewing the two screws (5).

Re tting is a reversal of removal.

After installation, bleed the hydraulic system and, if necessary, replenish the hydraulic oil.

-4

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Removal of the pump unit and attaching parts (see Chapter "Pump unit ", P. 71- 2 ).

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-5

Loosen the tightening strap (6) retaining the reservoir.

Remove the hydraulic oil reservoir.

Re tting is a reversal of removal.

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Remove the pump unit (see unit ", P. 71- 2 ).

Chapter "Pump

Remove the hydraulic oil reservoir (see Chapter "Hydraulic oil reservoir", P. 71- 5 ).

Screw off the suction lter (3).

Re tting is a reversal of removal.

-6

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Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

Disconnect the electric leads (1) on the pump motor.

Unscrew the 2 fastening screws (1) in the cover.

Remove the motor.

Remove the driver (2).

Re tting is a reversal of removal.

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

Disconnect the battery plug (4) (See ter "Safety information", P. 00-14).

Chap-

Dismantle the motor (See Chapter "Pump motor and driver", P. 71- 7 ).

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

Slip out the insulators (3).

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

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50218070901 [EN]

Extract the brush holder ring gear (5).

Proceed in reverse order.

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

Extract the roller bearings with an appropriate extractor.

Removal of the pump unit (see ter "Pump unit ", P. 71- 2 ).

Chap-

Remove the hydraulic oil reservoir (see Chapter "Hydraulic oil reservoir", P. 71- 5 ).

Remove the 4 screws at the pump (1).

Remove the hydraulic pump.

Re tting is a reversal of removal.

During assembly: Fill the pump with hydraulic uid.

Check the sense of rotation (indicated by an arrow on the pump housing).

Clean the pipe and hose lines to eliminate impurities.

Clean the hydraulic oil reservoir.

Clean the suction strainer.

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-9

Connect a pressure gauge to the valve block.

Loosen the locknut.

Lift the nominal load with the forks and determine the working pressure (record the reading).

The maximum pressure value results from the working pressure during the lifting of the nominal load +10%.

Raise the load as far as top stop and set the maximum pressure with the setscrew.

Lock the locknut.

If no nominal load is available, the maximum pressure can be set to 195 bar.

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The accumulator is pre-loaded. Do not change the bias pressure.

Unscrew the accumulator (1).

Hydraulic oil can run out. Keep a catch tray at hand and wear personal protective gear.

Re tting is a reversal of removal.

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-11

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a

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

Disconnect the plug (1) from the solenoid valve.

Unscrew the plastic parts.

Pull off the solenoid valve.

50218070901 [EN]

-1

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

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

Re tting is a reversal of removal.

Fully lower the forks with the control on the cockpit and keep it actuated for a few seconds after the forks are completely lowered so that there is as little oil and pressure in the hydraulic circuit as possible.

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Remove the 2 screws at the solenoid valves (1).

Pull the solenoid valves off.

Disconnect the 3 hydraulic lines (2).

Hydraulic oil can run out. Keep a catch tray at hand and wear personal protective gear.

In this state the solenoid valve bodies can be removed by unscrewing the 8 screws (3). The accumulator (4) can also be unscrewed and removed.

-2

50218070901 [EN]

Remove the fastening screw and washer (5) for the directional control valve (6).

Remove the directional control valve (6).

Re tting is a reversal of removal.

Bleed the hydraulic system and, if needed, replenish the oil.

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-4

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Fastening bolts on mast channels

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

Line safety valve (safety valve)

Torque = 60 Nm ± 6 Nm

Chain

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

Lowering speed

Max admissible speed = 0.6 m/s

50218070901 [EN]

-1

1st method: Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

Drive out the pin at the cylinder head.

Raise the fork part slightly with a jack in order to be able to disconnect the piston rod from the ring on the frame (remove the battery, if necessary).

2nd method: Raise the forks.

Secure the truck with squared timbers (at the forks, at the centre, rear and under the battery).

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

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

Chapter "Mo-

Drive out the pin at the cylinder head.

-2

50218070901 [EN]

Disconnect plug N (inductive proximity switch for sensing the maximum lift height).

Connect the battery connector (see ter "Safety information", P. 00-14).

Chap-

Retract the cylinder by operating the appropriate control on the cockpit.

The cylinder is now separated from the fork part.

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Disconnect the hydraulic hose (2) at the cylinder.

Risk of oil running out.

Drive out the pins at the cylinder head (3).

Remove the washers (4).

Drive out the pin (5).

The cylinder could fall down.

Remove the cylinder.

Re tting is a reversal of removal.

50218070901 [EN]

-3

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50218070901 [EN]

a

consists of 2 sections: the outer mast and the inner mast.

The lift cylinders (6) are mounted in the outer mast (1) and raise the inner mast (2). The lift chain (8) raises the fork carriage twice as fast as the inner mast.

50218070901 [EN]

-1

Remove the protective cover for the lift cylinders (see Chapter "Cylinder protective covers", P. 31- 8 ).

Fully lower the forks with the control on the cockpit and keep it actuated for a few seconds after the forks are completely lowered so that there is as little oil and pressure in the hydraulic circuit as possible.

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Secure the truck against rolling with squared timbers.

-2

50218070901 [EN]

Unscrew the hydraulic coupling.

The oil can be pressurised. Danger of oil squirting out! After prolonged operation the oil can be very hot.

Danger of scalding! Wear protective gear (gloves, protective goggles ...).

Fasten the inner mast to a suitable hoist.

Raise the inner mast for at least 100 mm with the hoist.

50218070901 [EN]

-3

Prevent the inner mast from lowering by supporting it securely (for example, with blocks of wood).

Remove the 2 hex head screws and note the number of shim washers installed on each side. Torque: 278 Nm +/- 10 % (27 Nm).

Remove the shim washers (1).

Raise the inner mast slightly.

Remove the supports.

Install the inner mast.

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50218070901 [EN]

Position the hoist so that both parts of the mast can be raised.

Danger of tipping over!

Raise the mast slowly with the hoist and lift it out of the frame.

Installation is the reverse of removal.

Do not forget to bleed the hydraulic system and to correct the oil level.

50218070901 [EN]

-5

Remove the protective cover for the lift cylinders (see Chapter "Cylinder protective covers", P. 31- 8 ).

Raise the mast about 500 mm with the related control.

Secure the truck against rolling with squared timbers.

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Support the mast so that the inner mast can not lower (eg with squared timbers).

Remove the circlip on the piston rod.

-6

50218070901 [EN]

Using a suitable tool, push the piston rod to its lowest point into the cylinder while operating the directional control valve block (lower).

50218070901 [EN]

-7

Unscrew the tting at the base of the cylinder.

The oil can be pressurised. Danger of oil squirting out! After prolonged operation the oil can be very hot.

Danger of scalding! Wear protective gear (gloves, protective goggles ...).

-8

50218070901 [EN]

Remove the clamp at the base of the cylinder.

50218070901 [EN]

-9

Lift the cylinder and remove it.

-10

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Installation is a reversal of removal.

Re t the rubber ring at the proper position on the cylinder.

If the hydraulic circuit has been opened (removal / installation of cylinders), it must be bled and the oil level must be corrected.

50218070901 [EN]

-11

Remove the drain plug.

Raise the forks slowly via the control on the cockpit so that the trapped air can escape. The plug can be re tted as soon as oil (bubble-free) emerges.

The oil can be pressurised. Danger of oil squirting out! After prolonged operation the oil can be very hot.

Danger of scalding! Wear protective gear (gloves, protective goggles ...).

Correct the oil level after bleeding.

-12

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-13

Remove the cylinder head (1) with a grooved nut key.

Hydraulic oil can run out. Place a container beneath the lter.

Pull out the piston rod (2).

In case of leaks renew the complete set of seals.

A pipe safety valve is installed in the bottom of the lift cylinder (4).

After the removal of the cylinder, the hydraulic circuit must be bled with the drain plug (3). If necessary, ll the hydraulic oil reservoir up to the correct level.

-14

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The distance of dimension S determines the response point of the valve.

Do not change this factory setting.

The slow lowering valves are installed at the bottom of the two lift cylinders.

50218070901 [EN]

-15

The mast rollers (1) are used for the vertical guidance of the mast.

Except for a light lm of grease on the running surface (corrosion protection), the mast rollers do not need servicing during maintenance.

The chain rollers (2) are used to regulate the tension of the lift chains.

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50218070901 [EN]

Remove the fork carriage (see carriage", P. 84- 6 ).

Chapter "Fork

Deposit the mast on a level surface (see Chapter "Mast and fork carriage", P. 81- 2 ).

Remove the chain rollers (see ter "Chains ", P. 81-18).

Chap-

50218070901 [EN]

-17

Move the two mast segments apart until the rollers can be accessed.

Remove the rollers and the spacers.

Mark the top and lower rollers and note the number of spacers per roller in order to be able to reinstall them correctly.

The mast rollers are used for the vertical guidance of the mast. Except for a light lm of grease on the running surface (corrosion protection), the mast rollers do not need servicing during maintenance.

Re tting is a reversal of removal.

The chains elongate with time. If the established tolerance is exceeded, they must be replaced.

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50218070901 [EN]

The chains must be inspected when tted with less than 10% of the nominal load. The measurement is carried out in the working range of the chain. A measurement range must be established (about 1 metre if possible). The number of chain links in this section multiplied with the chain pitch gives the nominal value. The difference between this value and the measured length gives the wear, which should not exceed 3% of the nominal length.

If a new lift chain is available, the elongation due to wear of 3% can easily be determined by comparison. The elongation due to wear is 3% if 33 links of the currently installed lift chain have the same length as 34 links of a new lift chain.

New lift chain (63 links) : Lc = 63 links X 15.875 mm = 1000.1 mm.

New lift chain (nominal length of 34 links): Lc = 34 links X 15.875 = 539.7 mm Worn lift chain: Lc (33 links) >= 539.7 mm.

To reduce wear as much as possible, the following services should be performed every three months: Check the lift chain, chain anchor and tensioning bolt for proper condition.

Clean the chain regularly with compressed air (in special cases with a steam jet washer without cleaning additives) and then lubricate with chain spray.

Make sure that the chain tension is correct.

The chains are tightened with two chain tensioners.

50218070901 [EN]

-19

Tighten the chains lightly with the chain tensioner using the nut and locknut.

Extend the mast

.

Retension the chains until the stop bolt is 2 mm from the stop.

Check the lowered height (91 mm maximum).

The lowered height of the forks is measured between the ground and the top edge of the forks.

Raise the forks until the chain anchor on the fork carriage becomes visible (use either the control console or a suitable hoist).

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Support the fork carriage, for example, with squared timbers.

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50218070901 [EN]

Relieve the chain tension slightly with the chain tensioner (nut and locknut).

Remove the cotter pin.

Take out the pin.

50218070901 [EN]

-21

Remove the cotter pin (1).

Take out the pin (2).

Remove the chain.

Re tting is a reversal of removal.

Tension the lift chain again lightly in order to remove the supports. Then do the adjustment of the chain tension.

Fully lower the forks with the control on the cockpit and keep it actuated for a few seconds after the forks are completely lowered so that there is as little oil and pressure in the hydraulic circuit as possible.

Disconnect the battery connector (see Chapter "Safety information", P. 00-14).

Remove the lift chain or slacken it enough so that the chain roller to be removed.

Remove the screw.

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Remove the chain roller.

Re tting is a reversal of removal.

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50218070901 [EN]

a

Disconnect the battery (See information", P. 00-14).

Chapter "Safety

Take out the battery (See Chapter "Battery change", P. 60- 9 directly.

50218070901 [EN]

-1

Chock the truck (See Chapter "Safety information", P. 00-14).

Remove the Chc screws.

Take out the pins..

Remover the shafts with a drift punch.

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

Remove the pin for each fork.

-2

50218070901 [EN]

Remove the shafts.

The callipers and traction rods could drop.

Dismantle the roller holder levers of the traction rods.

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

Never lubricate the rings (7).

7

Proceed in reverse order.

1044_841-008

Remove the pull rods (see Chapter "Dismantling and Reassembly - Traction rods", P. 84- 1 ).

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

Chapter "Lift

50218070901 [EN]

-3

Disconnect the (+) lead at the emergency isolator button.

Disconnect the (-) lead to the steering and traction controllers.

Remove all cable ties hindering their disconnection.

Attach lifting ropes on the front part of the truck.

-4

50218070901 [EN]

Lift up until both parts are separated from each other.

Re tting is a reversal of removal.

Lift the forks.

Chock the truck (See Chapter "Safety information", P. 00-14).

Disconnect the battery plug (4) (See ter "Safety information", P. 00-14).

Chap-

Remove the 2 CHC screws.

Take out the assembly.

Proceed in reverse order.

50218070901 [EN]

-5

The fork carriage moves in the inner mast. It requires four guide rollers.

The guide rollers are not adjustable. They must be greased lightly when the truck is serviced (corrosion protection).

The fork carriage is provided with stop bolts which need adjustment.

Attach the fork carriage securely to a hoist.

Raise and support the fork carriage (about 100 mm).

-6

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Loosen the chains at the chain tensioners (remove the 2 split pins and pins).

Deposit the chains on the forks.

Attach the fork carriage properly.

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-7

Raise the fork carriage until the stop bolt can be removed.

Remove the carriage upwards.

Installation is the reverse of removal.

It may be necessary to retension the chains.

-8

50218070901 [EN]

STILL GmbH Berzeliusstrasse 10 D-22113 Hamburg Ident no. 50218070901 EN