STILL STED forklift EXD20 N Double pallet stacker Workshop Manual - PDF DOWNLOAD

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STILL

Workshop literature

Double pallet stacker FXD 20 N

(€ 1540 2379 11648012111 EN - 01/2020

first in intralogistics

First edition

Chapter 00: Serial numbers updated Chapter 01: Maintenance plan updated Chapter 01: Adjustment of the brake air gap added Chapter 11: Description of the traction motor added Chapter 11: Description of the sensors (speed and temperature) added Chapter 23: Description of the transmission gear added Chapter 42: Description of the electromagnetic brake added

Chapter 60: Technical compartment updated Chapter 60: Location of the connectors updated Chapter 60: LAC controller inputs/outputs updated Chapter 60: Fitting and connecting lithium-ion battery cables added Chapter 60: Lithium-ion side socket (option) added Chapter 60: Operational checks updated

Added the new type carrier

Updated the type carrier

11648012111 EN - 01/2020

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Checking the air gap of the electromagnetic brake

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Checking the air gap of the electromagnetic brake

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11648012111 EN - 01/2020

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11648012111 EN - 01/2020

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-25

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

Checking the operation of the temperature sensor (1B6) . . . . . . . . . . . . . . . . . . . . . .

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

Operator presence detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-26 -26 -29 -31 -32

Fan (9M1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control module (1B1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-33 -34

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-35 -35

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

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

-38 -42

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-43

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-43

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-45

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-46

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-48 -48 -51 -53 -54

Rev sensor (1B2)

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

Checking the operation of the temperature sensor (1B6) . . . . . . . . . . . . . . . . . . . . . .

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

Operator presence detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11648012111 EN - 01/2020

VII

Fan (9M1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control module (1B1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-56

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-57

. . . . . . . . . . . . . . . . . . . . . . . . . . .

-57

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-58

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-60

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-61

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-62

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-63

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-64 -64 -65

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

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

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

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

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

Replacing the shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-67 -67 -68 -71 -75

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

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

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

-77 -77 -78 -80

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-81

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-81

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-84

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-85

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-88

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-88

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-92

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-92

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-94

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-94

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-99

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-99

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-101

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-101

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-102

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-103

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VIII

-55

11648012111 EN - 01/2020

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-2

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-3

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-3

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-4

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-5

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-6

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-8

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-8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-1

. . . . . . . . . . . . . . . . . . . . . . . . .

-2

. . . . . . . . . . . . . . . . . . .

-3

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-4

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-4

11648012111 EN - 01/2020

IX

: 1000 kg max. on the forks + 1000 kg max. on the load arms : 1200 kg on the forks : 2000 kg max. on the load arms 10 km/h / 10 km/h LAC 04 3 kW (asynchronous)

Nominal capacity Speed when laden/unladen Traction/lift controller Traction motor Electric steering unit ES30-24 (maintenance free) Brake type Control unit

as standard as options Platform Driving

0.185-kW asynchronous steering motor (S1) Electromagnetic Control module (traction/lift) and steering wheel (steering) Joystick (traction/lift) and steering knob (steering) Fixed Seated with adjustable floor

11648012111 EN - 01/2020

-1

Pump-motor unit (maintenance free) Battery

-2

2.2 kW (S3: 10%) Side access (3 PzS and 4 PzS)

11648012111 EN - 01/2020

Production location (1)

Series (2)

Year of production (3)

Sequential number (4)

W4 = Fenwick Linde, Châtellerault

1540 = FXD 20

H = 2017

e.g. 00020

Year of production table (3) Year 197x 198x 199x 200x 202x 203x

0

1

2

3

4

5

6

0 A L A X U

1 B M B Y W

2 C N C K Z

3 D P D L A

4 E R E M B

5 F S F N C

6 G T G P D

The truck's serial number provides information about the production location (1), series (2), year of production (3) and the sequential production number (4). The serial number can be found on the identification label on the truck (see next page).



The identification label (5) is positioned on the chassis of the truck.



11648012111 EN - 01/2020

8 7 H U R E

8 J W J S F

9 X 9 K Z V T G

-3

This reference is engraved on the left-hand outer profile of the lift mast and includes the type of mast (e.g. 21S).



Mast code



Assembly (1)

Mast (2)

W4X= Châtellerault factory

180 = mast

Traction and lift controller

-4

Year of production Sequential number (3) (4) F = 2015

Five-digit e.g. 02683



11648012111 EN - 01/2020

Reference and type of mast (5) e.g.

21S = 3150 mm S = standard

Traction motor (up to 10/2018)



Traction motor (from 10/2018)



ES30-24 steering unit



Control unit: control module



11648012111 EN - 01/2020

-5

Control unit: joystick (option)



Steering centre with steering wheel or steering knob (option)



Pump-motor unit



-6

11648012111 EN - 01/2020

SAE 85W 90 API GL4 Damage to equipment if non-recommended lubricants are used Only use recommended lubricants. Only the lubricants listed below are approved by the manufacturer.

Do not mix lubricants. If in doubt, please contact the After-Sales Service Centre.

Standard chain spray.

Follow the maintenance and safety instructions.

ISO-L-HM 46 as per ISO 6743-4 or ISO VG46HLP as per DIN 51524-2 ISO-L-HM 68 as per ISO 6743-4 or ISO VG68HLP as per DIN 51524-2 ISO-L-HM 32 as per ISO 6743-4 or ISO VG32HLP as per DIN 51524-2

Lithium soap grease with EP agents and MoS 2 complying with the standard DIN 51825.

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

11648012111 EN - 01/2020

-7

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

-8

Dimensions Length (mm) 718 718

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

210 210

110 151

11648012111 EN - 01/2020

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

205 410

Only use slings and a hoist of sufficient quality. Check the weight of the machine (including battery) in order to choose a suitable device. Refer to the technical features.

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

– Remove any items that could fall.

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

– Attach the lifting device to the sling ring (1).

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

– Carefully lift the truck.

Make sure no one is under or near the truck when slinging the truck.

Truck lifting must be performed carefully.

For some work, it is necessary to lift the truck.

– Lift the load arms.

– Switch off the ignition and disconnect the battery connector.

– Use a jack with adequate lifting capacity.

– Place a jack under the chassis (1).

– Position the jack under the battery frame (2).

11648012111 EN - 01/2020

-9

– Place the jack under the forks in the indicated locations (3).

As a safety precaution, always insert a wooden chock.

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

-10

11648012111 EN - 01/2020

The mast must be secured before any operation.

Select a chain whose lifting strength is appropriate for each type of mast. Take into account the maximum authorised lift height.

– Remove the protective screen using a suitable tool.

– Raise the forks to the stop.

– Close the chain after passing it over the upper cross member of the outer mast (1) and under the lower cross member of the inner mast (2).

– Lower the inner mast until the chain becomes taut.

– Remove the protective screen using a suitable tool.

– Raise the forks to the stop.

– Close the chain after passing it over the upper cross member of the outer mast (3) and under the lower cross member of the inner mast (4).

– Fully lower the fork carriage.

11648012111 EN - 01/2020

-11

The emergency control (1) allows the mast to be lowered manually in the event of a problem.

This operation is to be performed as follows: – Open the technical compartment door.

– Loosen the screw (1) using an 8 mm openended spanner.

Do not walk underneath raised loads!

Check that no one is in the danger area before manually lowering the mast.

When the forks are fully lowered: – Loosen the screw (1) using an 8 mm openended spanner.

– Close the technical compartment door.

-12

11648012111 EN - 01/2020

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

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

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

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

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

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

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

11648012111 EN - 01/2020

-13

-14

11648012111 EN - 01/2020

Depending on the application, environmental conditions and driving style, the following procedures should be carried out every 1000, 2000, 3000, 4000, 6000, 7000, 8000 and 9000 hours

Clean the truck Check the error codes using the diagnostic tool Check the condition of the forks Check the electromagnetic brake and ensure that it is working correctly Check and lubricate the hinges Check the pump motor brushes for wear Ensure that the floor adjusts and locks correctly Ensure that the seat adjusts and locks correctly Check the transmission gear for noise and leaks Lubricate the gears Check the condition and tightness of the wheels Check the stabilisers Clean the electric steering system and lifting motors Check the condition of the cables and the battery sockets and ensure that they are positioned correctly Check the electrical insulation between the chassis and the electric components Check the electrical insulation between the chassis and the electronic components Check the fuses Check the battery acid level and the electrolyte level Check the hydraulic oil level Check the condition of the pipe lines Check the condition and the length of the mast chain Lubricate the forks and the mast guide rollers Check the condition and mounting of the guard grille Check the pin clearance

Depending on the application, environmental conditions and driving style, the following procedures should be carried out every 5000 and 10,000 hours

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

11648012111 EN - 01/2020

-1

Lithium-ion batteries do not require any specific maintenance. However, they do require several maintenance operations. These operations are in addition to the standard maintenance schedule for the truck.

Clean the battery.

Check the battery connections and sockets.

Fully charge the battery at least once a week.

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

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

Visually check the battery.

-2

11648012111 EN - 01/2020

The mechanical braking torque is factory set and cannot be modified.

The brake is designed to be used normally for the duration of the truck service life.

– The brake must be checked in the engaged position and with no load on the load lift system; in other words, with the power switched off.

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

New brake: 0.18 mm minimum (air gap) Worn brake: 0.37 mm (maximum wear of the air gap) – The brake must be replaced when the maximum wear is reached.

– Immobilise the truck.

– Lower the load lift system.

– Switch off the ignition and remove the key.

– Press the emergency off switch.

– Open the battery hood.

– Disconnect the battery connector.

– Open the technical compartment door.

– Disconnect the brake power supply.

It is essential that the truck is positioned on level ground. As the power supply to the brake has been cut, the truck could move on its own if it is not on level ground.

– Close the technical compartment door.

– Reconnect the battery connector.

– Return the truck to service.

– Supply the brake and check that the brake releases completely.

This operation should preferably be carried out by the After-Sales Service Centre.

11648012111 EN - 01/2020

-3

Depending on the application, environmental conditions and driving style, the following procedures should be carried out every 1000, 2000, 3000, 4000, 6000, 7000, 8000 and 9000 hours

Clean the truck Check the error codes using the diagnostic tool Check the condition of the forks Check the electromagnetic brake and ensure that it is working correctly Check and lubricate the hinges Check the pump motor brushes for wear Ensure that the floor adjusts and locks correctly Ensure that the seat adjusts and locks correctly Check the transmission gear for noise and leaks Lubricate the gears Check the condition and tightness of the wheels Check the stabilisers Clean the electric steering system and lifting motors Check the condition of the cables and the battery sockets and ensure that they are positioned correctly Check the electrical insulation between the chassis and the electric components Check the electrical insulation between the chassis and the electronic components Check the fuses Check the battery acid level and the electrolyte level Check the hydraulic oil level Check the condition of the pipe lines Check the condition and the length of the mast chain Lubricate the forks and the mast guide rollers Check the condition and mounting of the guard grille Check the pin clearance

Depending on the application, environmental conditions and driving style, the following procedures should be carried out every 5000 and 10,000 hours

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

-4

11648012111 EN - 01/2020

Depending on the application, environmental conditions and driving style, the following procedures should be carried out every 10,000 hours

Carry out all 1000-hour maintenance work Carry out all 5000-hour maintenance work Drain the transmission gear oil

11648012111 EN - 01/2020

-5

Lithium-ion batteries do not require any specific maintenance. However, they do require several maintenance operations. These operations are in addition to the standard maintenance schedule for the truck.

Clean the battery.

Check the battery connections and sockets.

Fully charge the battery at least once a week.

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

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

Visually check the battery.

-6

11648012111 EN - 01/2020

The mechanical braking torque is factory set and cannot be modified.

The brake is designed to be used normally for the duration of the truck service life. However, depending on operating and environmental conditions, the brake may wear prematurely and will need to be replaced.

– The brake must be checked in the engaged position and with no load on the load lift system; in other words, with the power switched off.

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

New brake: 0.3 mm (air gap allowed) Worn brake: 1.67 mm (maximum wear allowed) – The brake must be replaced when the maximum wear is reached.

– Immobilise the truck.

– Lower the load lift system.

– Switch off the ignition and remove the key.

– Press the emergency off switch.

– Open the battery hood.

– Disconnect the battery connector.

– Open the technical compartment door.

– Disconnect the brake power supply.

It is essential that the truck is positioned on level ground. As the power supply to the brake has been cut, the truck could move on its own if it is not on level ground.

– Close the technical compartment door.

– Reconnect the battery connector.

– Return the truck to service.

– Supply the brake and check that the brake releases completely.

11648012111 EN - 01/2020

-7

This operation should preferably be carried out by the After-Sales Service Centre.

-8

11648012111 EN - 01/2020

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

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

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

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

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

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

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

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

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

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

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

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

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

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

11648012111 EN - 01/2020

-9

– Do not use tools with damaged or worn insulation.

– Use only genuine bits with a maximum length of 25 mm.

– Do not use a tool if the bit locking system is loose.

Bits could fall out of the support mounting and cause a short circuit between live components.

Service case with tools insulated up to 1000 V, fully equipped 1 Torque wrench, insulated, reversible, 3/8", 2.5 25 Nm 2 Reversible ratchet, insulated, 3/8", 32 tooth 3 Extender for socket, insulated, short, 3/8", 125 mm 4 Extender for socket, insulated, long, 3/8", 250 mm 5 Socket, insulated, 3/8", 7 mm 6 Socket, insulated, 3/8", 8 mm 7 Socket, insulated, 3/8", 10 mm 8 Socket, insulated, 3/8", 13 mm 9 Socket, insulated, 3/8", 15 mm 10 Socket, insulated, 3/8", 16 mm 11 Socket, insulated, 3/8", 17 mm 12 Hexagon hole screwdriver, insulated, 2.5 mm 13 Hexagon hole Allen key, insulated, 3 mm

0009419915 0009419916 0009419917 0009419918 0009419919 0009419920 0009419921 0009419922 0009419923 0009419924 0009419925 0009419926 0009419927

14 15 16 17 18 19 20 21 22 23 24 25 26

0009419928 0009419929 0009419930 0009419931 0009419932 0009419933 0009419934 0009419935 0009419936 0009419937 0009419938 0009419939 0009419940

-10

Hexagon hole Allen key, insulated, 4 mm Hexagon hole Allen key, insulated, 5 mm Hexagon hole Allen key, insulated, 6 mm Hexagon hole Allen key, insulated, 8 mm Open-ended spanner, insulated, 10 mm Open-ended spanner, insulated, 17 mm Long-nosed pliers, insulated, 230 mm Tweezers, insulated, bent, 11.5 mm Extender for bit, insulated, short, 3/8", 125 mm Extender for bit, insulated, long, 3/8", 250 mm Bit set for hexagon hole and Torx, 24 piece Insulated grommet with clamping cap, 17.5 mm, x4 Insulated grommet with clamping cap, 26 mm, x4

11648012111 EN - 01/2020

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

STILL multimeter with measurement leads

0009418737

Test adaptor, SAAB, 42-pin

8426527

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

0143426 0143427 0143425

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

Hahn&Kolb 77200910

11648012111 EN - 01/2020

-11

-12

11648012111 EN - 01/2020

1 2

3 4 5

Document category Document language

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

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



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

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

– Select the required document category (1).

– Select the required truck series (4).

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

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



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

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

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

11648012111 EN - 01/2020

-1

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

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

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

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

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

-2

11648012111 EN - 01/2020

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

1 2

F2: Diagnostics Start points for the diagnostics

3

Jobs

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

– Park the truck safely.

– Lift the truck.

– Start the truck.

– Switch on the laptop and start the diagnostic tools.

– Connect the laptop to the truck.

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

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

11648012111 EN - 01/2020

-3

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

1 2 3 4 5 6 7

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

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

-4

11648012111 EN - 01/2020

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

11648012111 EN - 01/2020

-5

1 2

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

3 5

USB CAN Box Laptop

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

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

1 2 3 4a

4b

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

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

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

-6

5

Connecting line, serial serial and serial converter Laptop

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

11648012111 EN - 01/2020

1X1:14 CAN high (traction and lift) 1X1:28 CAN low (traction and lift) 3X1:C1 CAN 1 high (steering) 3X1:C2 CAN 1 low (steering) 6X2:4 CAN high (display) 6X2:3 CAN low (display) 6X7 Diagnostic connector

2X31 2X38 1A1 3A1 6P4

The CAN Bus communication network between the multifunction indicator and the controllers includes: CAN HIGH CAN LOW two 120- "Rt" terminating resistors fitted in parallel in the circuit.

Load Management connector Load Management/technical compartment link connector LAC traction/lift controller Steering controller ES30-24 Display

(4) and (1) must be between 2.5 V and 3.5 V when the truck is Using a voltmeter, the measured value of the diagnostic connector (6X7) between terminals (4) and (2) must be between 1.5 V and 2.5 V when the truck is

Checking the CAN Bus: The measurable resistance value of the diagnostic connector (6X7) between the terminals (1) and (2) is approximately 60 This value is measured between the CAN high and the CAN low when the truck Using a voltmeter, the measured value of the diagnostic connector (6X7) between terminals

11648012111 EN - 01/2020

-7

1 2 3

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

-8

4 5 6 7

0V Emergency stop signal N/A N/A

11648012111 EN - 01/2020

6X7 X33

Truck diagnostic socket Diagnostic connector of the lithium-ion battery

The CAN bus network for communication between the lithium-ion battery and the controller is composed of:

6P4

Multifunction indicator of the lithium-ion battery

(4) and (1) and between terminals (4) and (2) is when the truck

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

11648012111 EN - 01/2020

-9

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

C

Open

No

No

A

Closed

Activated

No

B

Closed

Activated

No

C

Activated

No

Safety

C

Open Open Closed if the contactor is stuck

Activated

Yes

Warning Alarm

Battery contactor status Closed Open

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

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

-10

11648012111 EN - 01/2020

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

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

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

11648012111 EN - 01/2020

-11

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

Truck reset: Press the button for . for

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

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

-12

11648012111 EN - 01/2020

100 101 102 103 110

111 113 115 116 118

200

201

202 203 204 205 206 208

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

11648012111 EN - 01/2020

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

ON/OFF reset

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

-13

209

210

211

212

213

214

215

216

217

218

-14

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

11648012111 EN - 01/2020

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

ON/OFF reset

222

224

225

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

11648012111 EN - 01/2020

ON/OFF reset

ON/OFF reset

ON/OFF reset

-15

BIS: Battery Information Sheet

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

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

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

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

Go to step 2 Go to step 3

Go to step 4

END

END

Go to step 3

Go to step 5

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

-16

Go to step 2 Go to step 4 END

11648012111 EN - 01/2020

END

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

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

Go to step 3 Go to step 5

END

END

Go to step 3

Go to step 2

END

END

Go to step 3

Go to step 2

END

END

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

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

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

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

Description: Low state of charge (2nd level)

11648012111 EN - 01/2020

-17

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

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Go to step 6 Go to step 4

Go to step 3 Go to step 5

END

END

Go to step 9 Go to step 10

Go to step 2 Go to step 3

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

Go to step 2

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

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

Go to step 6 Go to step 8

END

END

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

-18

Go to step 2 END

11648012111 EN - 01/2020

END

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

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

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

END

END

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

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

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

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

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

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

Go to step 5 Go to step 6

Go to step 8

Go to step 12 END

Go to step 9 END

Go to step 6 Go to step 7

Go to step 2 Go to step 3

Go to step 4

Go to step 8

Go to step 5

Go to step 8

END

END

Go to step 7

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

11648012111 EN - 01/2020

-19

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

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

Go to step 4 Go to step 5

Go to step 2 Go to step 3

END

END

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

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

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

Go to step 5

END

END

END

END

Go to step 3 Go to step 12

Go to step 9

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

Go to step 2

Description: Cell voltage outside the range Switch the battery off and on again Error code 206 still appears Switch off the battery -20

Go to step 2

11648012111 EN - 01/2020

Go to step 4

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

Go to step 5

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

Go to step 9 END

Go to step 9 END

Go to step 3

Go to step 10

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

Go to step 2

Go to step 4 Go to step 5

Go to step 10

Replace the battery

Go to step 6

Refer to the BIS

Go to step 7

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

Go to step 8 Go to step 9

Go to step 10

END

END

Go to step 3

Go to step 9

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

Go to step 2

Go to step 4 Go to step 5

Go to step 9 Go to step 6

Switch on the battery Error code 208 still appears

Go to step 7 Go to step 8

11648012111 EN - 01/2020

Go to step 9

-21

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

END

END

Go to step 10 Go to step 4

Go to step 3 Go to step 9

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

Go to step 2

Go to step 5 Go to step 6

Go to step 9 Go to step 7

Go to step 8

Go to step 9

END

END

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

-22

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

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

Go to step 6

Go to step 9 Go to step 7

Go to step 8

11648012111 EN - 01/2020

Go to step 9

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

END

END

Go to step 6 Go to step 7

Go to step 2 Go to step 3

Go to step 8

Go to step 5

END

END

Go to step 6 Go to step 7

Go to step 2 Go to step 3

Go to step 8

Go to step 5

END

END

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

Go to step 4

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

Go to step 4

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

Go to step 2 Go to step 3

Go to step 7 Go to step 4

Go to step 5 Go to step 6

Go to step 8 Go to step 7

END

END

11648012111 EN - 01/2020

-23

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

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

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

Go to step 3 Go to step 5

END

END

Go to step 9 Go to step 10

Go to step 2 Go to step 3

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

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

Go to step 6 Go to step 8

END

END

Go to step 4 END

Go to step 3 END

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

Go to step 2

Description: Self-testing failure

-24

11648012111 EN - 01/2020

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

END

END

Description: Pre-charge failure

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

Go to step 2 Go to step 3

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

Go to step 6

Go to step 8

END

END

Go to step 3

Go to step 4

END

END

Go to step 3

Go to step 4

END

END

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

Go to step 2

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

Go to step 2

Description: Battery voltage above the limit

11648012111 EN - 01/2020

-25

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

-26

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

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

END

END

11648012111 EN - 01/2020

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

Determination of damage or fault

Not damaged or faulty

Damaged or faulty

No warning, no alarm

New

Used

Category 1

For destruction or recycling

Warning (no alarm)

Measures to take

Category 3

Determination of risk

Category 2 Category 6

No risk

Risk

Category 4

Category 5

There are six categories: Category 1 2

Function New battery or new module Used battery or module

3

Battery with warning

4 5 6

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

11648012111 EN - 01/2020

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

-27

-28

11648012111 EN - 01/2020

(*) Description of measure s

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

YES

Not determined

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

Vapour or fumes observed? NO

YES

Abnormal heat or increased temperature? NO YES

Abnormal, combustion-like smell? NO

YES

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

Is one of the following error codes active? NO

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

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

Could the battery be damaged or faulty? NO

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

YES Not determined

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

YES Not determined

NO YES

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

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

Category 4: Damaged or faulty battery or module without risk

Repair/exchange to obtain the initial design?

Category 5: Damaged or faulty battery or module with risk

Product deactivated? NO

Category 6: Battery or module for destruction or recycling

NO YES N/A

YES N/A

Other *

11648012111 EN - 01/2020

-29

1 2 3

F2: Diagnostics Jobs Execute

4 4 4

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

F2: Diagnostics Jobs

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

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

Select job (4)

Execute

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

-30

3

Read error list Delete error list Read error ring buffer

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

11648012111 EN - 01/2020

1 A B 2

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

3 4 5 6 7 8

Traction Hydraulics Steering Electrical (sensor) Electrical (internal to the LAC) CAN

9 10

Internal error display Other

11 12

Brake: Fault detected Lower the load arms: the height of the forks is greater than 1.80 m Temperature: the temperature of the motor the controller is too high Low battery: the battery is almost discharged (remaining charge between 20% and 0%) Maintenance: maintenance scheduled today next maintenance (in hours or date)

13 14 15

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

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

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

11648012111 EN - 01/2020

-31

-32

11648012111 EN - 01/2020

1 2 3 4 5 6 7 8 9 10

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

11 12 13 14 15 16 17 18

11648012111 EN - 01/2020

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

-1

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

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

Model Voltage

1 2 3 4 5

-2

3 kW 166 A 4865 rpm 5.2 Nm 35 Nm (590 rpm)

Three-phase asynchronous motor 24 V

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

6 7 8

Nominal power Current Motor speed (S2 - 60 min.)

Torque at maximum speed Maximum torque

9 10A 10B 11 12 13 14

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

11648012111 EN - 01/2020

1 2 3 4 5

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

6 7 8 9

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

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

These connections are secured with a nut (tightening torque for hexagon nut: ).

The wiring nuts may be damaged if the tightening torque is too high.

When checking or tightening the nuts, a torque wrench with a suitable adjustment range (e.g. 1 20 Nm) must always be used. Torque wrenches with greater adjustment ranges are too imprecise and must not be used. The connecting nuts may be damaged if the tightening torque is above 17 Nm. Tightening by hand is not permitted due to the limited torque range (10 17 Nm).

11648012111 EN - 01/2020

-3

1 2 3 4 5 6 7 8 9 10

Hexagon head screw - M6x25 Bearing shield Temperature sensor (1B6) PT1000 Rev sensor (1B2) Screw M6x16 Stator Splined shaft Ring gear Rotor Drive shaft

11 12 13 14 15 16 17 18 19 20

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

Maintenance-free motor controlled by: One rev sensor (1B2) - Connector (1X2) and screw M6x16 - (tightening torque: ) One motor temperature sensor (1B6) - Connector (1X25)

Ball bearing 2RS1/C2 Serial number Terminal block Seal Cap Socket head screw M6x16 Locking ring Locking ring Ball bearing Locking ring

Nominal power Current Motor speed (S2 - 60 min.)

Torque at maximum speed Torque at minimum speed

Three-phase asynchronous motor Voltage 14 V

-4

11648012111 EN - 01/2020

3.0 kW 166 A 2040 rpm 1.3 Nm at 5995 rpm 38.6 Nm at 850 rpm

11648012111 EN - 01/2020

-5

1 2 3 4

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

5 6 7

Temperature sensor connector 1X25 Rev sensor connector 1X2 Brake connector 7X6

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

These connections are secured with a nut (tightening torque for hexagon nut: ).

The wiring nuts may be damaged if the tightening torque is too high.

When checking or tightening the nuts, a torque wrench with a suitable adjustment range (e.g. 1 20 Nm) must always be used. Torque wrenches with greater adjustment ranges are too imprecise and must not be used. The connecting nuts may be damaged if the tightening torque is above 17 Nm. Tightening by hand is not permitted due to the limited torque range (10 17 Nm).

-6

11648012111 EN - 01/2020

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

These components should be first checked before testing the motor.

The following points must be checked if a motor operating fault is detected: External check: corrosion, contamination, cracks, correct mounting of the following components: connections U, V, W of the traction motor temperature sensor connector

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

speed sensor speed sensor connector Also check the following: cleanliness of motor (oil, grease, dirt).

Between U and V Between U and W Between V and W 7.5 ±1 m

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

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

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

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

posure to excessive heat or local heat build-up.

This may be identified by discolouration of the rotor.

Three resistance measurements must be performed on each motor at the connections .

If comparative measurements show different resistance values or an interruption, there is probably a defect in one or more coils of the stator or at the connections or supply cable inside the motor.

However, brown discolouration of the rotor is normal.

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-7

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

The outside of the drive axle can be cleaned thoroughly. The best cleaning agent is compressed air. If the outside of the axle housing is very heavily soiled, a high-pressure cleaner can be used. However, depending on the level of contamination, it is recommended that the air ducts and power modules are removed. Special care should be taken to ensure that the spaces between the cooling fins on the motor are free from contamination, so as to ensure correct cooling of the motor. Only water may be used for this. Under no circumstances should chemical cleaning agents be added when using a high-pressure cleaner. Chemical cleaning additives may attack the plastic parts of the motor.

Sufficient distance must be maintained between the jet lance and the motor.

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

Intensive cleaning with a high-pressure cleaner should be avoided around the motor connections. No moisture should be allowed to enter the motor. If despite all precautions, moisture does penetrate the motor, the truck must be

-8

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

A motor that has been dismantled must be cleaned with a high-pressure cleaner in the area around the stator. Do use compressed air for cleaning, as compressed air may contain oil or moisture. Firstly, any large particles of electrically conductive foreign matter should be removed by suction. Dust and grease should then be removed from the stator using a cloth and a solvent that will remove oxides and sulphides as well as gummed oils and greases. A final cleaning of the stator should be carried out with an electric cleaning material (e.g. S.L.X. electric cleaner www.rivolta.de) . These electric cleaning materials have a dielectric strength of up to 100,000 V/cm and are free from hydrocarbons such as CHCs, CFCs, aromatics, PCB/PCTs and other pollutants. This allows all dirt to be rinsed thoroughly from the windings. After rinsing, the stator must be dried with a hot-air blower. Here it must be ensured that the blower temperature does not exceed 150 °C or the finish on the windings may be irreparably damaged.

The rotor can be cleaned with conventional cleaning methods .

PCB polychlorinated biphenyls PCT polychlorinated terphenyls CHCs chlorinated hydrocarbons CFCs chlorofluorocarbons

11648012111 EN - 01/2020

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

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

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

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

11648012111 EN - 01/2020

-9

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

It is

type.

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

It is connected to the traction motor power module.

It is dust-proof and splash-proof.

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

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

-10

11648012111 EN - 01/2020

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

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

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

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

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

The type is

.

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

It is connected to the traction motor power module.

It is dust-proof and splash-proof.

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

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

11648012111 EN - 01/2020

-11

-12

11648012111 EN - 01/2020

1 2 3

Electromagnetic brake Traction motor Turntable

4 5 6

Drive wheel Transmission gear Electric steering ES30-24

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

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

11648012111 EN - 01/2020

-1

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

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

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

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

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

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

-2

11648012111 EN - 01/2020

Gear reducer Load on the drive wheel 1.5T maxi Number of teeth: slewing ring 108 Reduction ratio 19.67 Volume of oil 1.5 litres Maximum torque on the wheel 1375 Nm (static) Maximum torque on the wheel (dy916 Nm namic) Torque on the wheel 229 Nm The type and serial number are indicated on a data plate fitted to the transmission gear.

11648012111 EN - 01/2020

-3

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

-4

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

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

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

11648012111 EN - 01/2020

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

Socket head screw M8x75-8.8-A1F Bearing Ring gear O-ring 68x2.0 Shaft seal 35x52x7 Socket head screw M8x25-8.8-A1F Gearbox cover Housing Breather Threaded ring 128212/S14790 Socket head screw M8x16-8.8-A1F Centring pin M6x20 ST O-ring 143x2 Tapered roller bearing 33205 Gear Bush F Tapered roller bearing 33205 Shim ring

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

Bevel gear Z3=9/Z4=49 Wheel bolt M14x1.5 Protection disc 110.5x86x2 Shaft Tapered roller bearing 30309 Shaft seal 90x110x10 Bush B = 8.85 Tapered roller bearing 32210 Shim ring 50x62x1 Shaft Washer O-ring 150x3.5 Hexagon head screw M16x45 Bearing shield Socket head screw M6x16-A1F Sealing ring 10x13.5x2 Drain plug G1/8

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

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

11648012111 EN - 01/2020

-5

Transmission gear Load on the drive wheel 1.5 T max.

Number of teeth: slewing 100 ring Reduction ratio 20.8 Oil volume 0.98 litres Force transmitted to the 5500 N wheel Maximum torque on the 750 Nm wheel (dynamic) Drive wheels 230 and 254 The type and serial number are indicated on a data plate fitted to the transmission gear.

1

Oil level

-6

11648012111 EN - 01/2020

Ratchet handle, a size 15 socket and 2 extenders

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

To access the technical compartment:

– Open the technical compartment door.

– Immobilise the truck.

– Proceed in the reverse order to close.

– Lower the load lift system.

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

– Press the emergency off switch.

– Disconnect the battery connector.

Tightening torque of the mounting screw: Nm.

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

11648012111 EN - 01/2020

-1

b1

-2

= 820 mm (width of the fixed chassis)

11648012111 EN - 01/2020

1 2 3 4 5 6

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

7 8 9 10 11 12

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

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

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

11648012111 EN - 01/2020

-3

1 3

2

4 5 CS 25 Nm

CS 50 Nm

7 6

CS 10 Nm

115401_30-001

1 2 3 4

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

5 6 7

Operator presence detection pedal Gas spring Bottom plate

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

-4

11648012111 EN - 01/2020

A

Operator not present on the platform

B

Operator present on the platform

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

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

11648012111 EN - 01/2020

-5

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

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

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

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

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

-6

11648012111 EN - 01/2020

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

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

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

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

– Check the seat weight adjustment.

11648012111 EN - 01/2020

-7

1K0

1A1 :+

:1

1X10 1X10-A

1F10

BK ( 92 ) 1²

:37

WH ( 37 )

:32

WH ( 32 )

RD ( 123 ) 1.5²

1X1

:1

:3

:2

BK ( 92 ) 1²

WH ( 37 )

RD ( 234 ) 1²

WH ( 32 )

:2

BK ( 292 ) 1²

RD ( 334 )

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

:85 :87 1K10

WH ( 237 )

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

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

1X10-B

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

:4

9S3

:1

BK ( 192 )

WH ( 137 )

RD ( 434 ) 1²

(9S3) equipped with an (H5)

BN ( 394 ) 1²

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

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

:86 :30

:3

:2

:5

1S29

H5

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

t°

9E3

t°

9E5

L225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240

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

No visual information is shown on the display.

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

– Press the switch to reactivate the heating system.

-8

115401_30-006

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

11648012111 EN - 01/2020

43 42

41

47 46 39 40 38 36

44 37 45

40

43

42

41

39 38 37 36

49 30

1

48 34 35

29

33

12 11 10

27 15

7

16

6 13 14

28

32

26 8 9

31

25 24 23

2 3 4 5

22 21

19 20 17 18 115400_30-014

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

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

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

11648012111 EN - 01/2020

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

-9

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

-10

11648012111 EN - 01/2020

22 21

20

26 25

23 16

18 19 17

24

15

19

21

20

22

18 17 16 15

28 1

27 13 14

8

12

6

32

4

30

31

7

11

5

34 33 35 29

9

10

2 3 36

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

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

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

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

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

11648012111 EN - 01/2020

-11

For batteries fitted in special compartments that are equipped with attachment points, the battery capacity can be up to 500 Ah. Battery

Compartment for the side access battery

Width (mm)

Height (mm)

3 PzS

345/375 Ah

198

627

4 PzS

460/500 Ah

198

627

Battery Lithium ion

Compartment for the side access battery

Width (mm)

Height (mm)

4 PzS

205/410 Ah

198

618

-12

11648012111 EN - 01/2020

2

1

3

15 16

19

18

23

17

45

6

14

13

12

22

11 10

78 9

20 21

115401_30-003

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

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

13 14 15 16 17 18 19 20 21 22 23

11648012111 EN - 01/2020

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

-13

-14

11648012111 EN - 01/2020

1 2 3 4

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

5 6 7 8

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

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

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

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

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

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

11648012111 EN - 01/2020

-1

1

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

2 3

4 5 6 7

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

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

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

All of its parts are maintenance-free.

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

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

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

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

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

-2

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

11648012111 EN - 01/2020

Nominal voltage Nominal capacity Nominal speed Maximum torque Protection type Category of insulating material Weight

Number of teeth Module Contact angle Sideways shift Shorter offset

1 2 3 4 5 6 7 8

24 V DC 185 W S1 100 rpm 110 Nm IP 54 F 7.5 kg

22 2.5 20° 0 0

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

9 10 11 12 13 14 15

11648012111 EN - 01/2020

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

-3

To ensure the electric steering works correctly, it is important to calibrate parts before repair or replacement.

Parts requiring calibration: Setting potentiometer the wheel potentiometer.

– Connect the diagnostic PC to 6X7.

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

F2:Diagnostics Jobs Calibration 5 Control Potentiometer The control potentiometer is calibrated.

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

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

F2:Diagnostics Jobs Calibration 6 Wheel Potentiometer

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

-4

11648012111 EN - 01/2020

– Start the diagnostic tool.

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

F3:Setup Error Codes Steering Main Control Device (CP)/Security Control Device (CS)

11648012111 EN - 01/2020

-5

1 2 3 4

Handle M5x40 socket head screw Steering wheel Washer

5 6 7 8

Adaptor Steering centre Washer Nut

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

-6

11648012111 EN - 01/2020

1 2 3

Steering knob Adaptor Steering centre

4 5

Washer Nut

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

11648012111 EN - 01/2020

-7

1B1 2B4 2B15 4S1

Traction controller (front/rear) Main lift proportional control Initial lift control Warning horn control

1 2 3 4

Screw Joystick Control module Base

The control module is equipped with four Hall effect sensors: Traction setpoint sensor 1B1 Fork lifting/lowering setpoint sensor 2B4 Load arm lifting/lowering setpoint sensor 2B15 Horn sensor 4S1

-8

11648012111 EN - 01/2020

Pin 1X3: 1 1X3: 2 1X3: 3 1X3: 4 1X3: 5 1X3: 6 1X3: 7 1X3: 8 1X3: 9 1X3: 10 1X3: 11 1X3: 12 1X3: 13 1X3: 14

Colour Yellow Orange Grey Red White Violet Pink Brown White/Brown White/Violet

11648012111 EN - 01/2020

Signal +5 V supply Traction setting track 1 0V Horn Initial lift Initial lowering 0 V Horn Traction setting track 2 Mast lift track 1 Mast lift track 2

-9

1B1 2B4

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

2B15 4H1

Initial lift controller (depending on the version) Horn

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

-10

11648012111 EN - 01/2020

1

Steering centre 7A5

Marking

Colour

X13:1

Red

X13:2

Black

X13:3 X13:4

Green Orange

X13:5

Blue

X13:6

White

2

Connector X13 for the centre

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

11648012111 EN - 01/2020

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1 2 3 4

Magnetic flux Powder Stator Rotor

5 6 7 8

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

Coil Bundling Magnet Hall effect sensor

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

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

-12

11648012111 EN - 01/2020

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

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

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

Its position is defined when the steering box is assembled.

FEATURES

VALUES

Supply voltage Sensor type Output voltage range Possible electrical travel Linearity Interlinearity

10 V ± 0.5 V Contactless, Hall effect 0.5 V - 4.5 V (not ratiometric) 360° ±2% of 5 V (±0.1 V) 4% of 5 V (0.2 V)

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-13

A Hall effect sensor gives a voltage when it detects a magnetic field or a metal part.

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

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

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

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

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

-14

11648012111 EN - 01/2020

1 2 3 4

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

5 6

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

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

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

11648012111 EN - 01/2020

25 Nm 24 V 31 W

-15

1 2 3

Air gap: (+0.12 mm, -0.05 mm) Screw M6x16 (tightening torque: ) Hexagon countersunk socket head screw M5x30 (tightening torque: )

4 5

Hexagon socket mushroom head screw M5x12 (tightening torque ) Brake connector 7X6

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

The safety brake is applied automatically when at least one of the following conditions is met: Drive direction double throw switch in neutral position and the machine is stationary Truck in safety mode Nominal brake torque Supply voltage (laden/unladen) Power (laden/unladen)

-16

25 Nm 24 V/12 V 61 W/15 W

11648012111 EN - 01/2020

A B 1 2 3

Ungreased stabiliser Greased stabiliser Fork part Bolt Bearing block

4 5 6 7 8

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

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

11648012111 EN - 01/2020

-17

Torque wrench Ratchet handle, extender and 10 mm male bit Size 16 and 17 open-ended spanner Ratchet handle, extender and size 15 socket Size 6 Allen key Spirit level (option) – Remove the mat from the platform



– Move the seat all the way forwards.

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

– Press the adjustment knob to fully raise the floor



The floor raises.

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

-18

11648012111 EN - 01/2020

– Loosen the locking screw (1) of the stabiliser (accessed on the side), using a ratchet handle, extender and 10 mm male bit



– Loosen the locknut (2) using a size 17 openended spanner (4) – Adjust the adjusting screw (3) using a size 16 open-ended spanner (5) to compensate for wear to the drive wheel or the stabiliser wheel.

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

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

– Use a spirit level to make the adjustment.

– After adjustment, tighten the locking screw and the locknut (1)

Risk of truck tipping over The correct adjustment of the stabiliser ensures the stability of the truck.

Tightening torque of the locking screw (1): Nm

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

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1 2 3 4 5 6 7 8 9 10

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

)

11 12 13 14 15 16 17 18 19 20

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

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

-20

11648012111 EN - 01/2020

The following wheels can be fitted to this truck:

(A)

Rubber

(B) Notched rubber

(C) Solid wheel (notched Vulkollan) (D) Polyurethane (Vulkollan) (E) Non-marking rubber

Good traction

Considerable abrasive wear Leaves marks

Suitable for extremely wet ground surfaces (sheets of More abrasive wear than a water) polyurethane wheel More traction than a polyLeaves marks urethane wheel Cannot be touched up Robust Anti-static Suitable for extremely wet ground surfaces (sheets of Traction not as good as a water) rubber wheel. In dairies, the More robust than a rubber tyre may come loose wheel Best solution for standard Traction not as good as a applications rubber wheel Less abrasive wear More traction than a polyMore abrasive wear than a urethane anti-static nonpolyurethane wheel marking wheel

11648012111 EN - 01/2020

70 ±3

800

75 ±3

1200

92 ±3

1200

92 ±3

2010

70 ±3

800

-21

Marking A

B

C D E F

-22

Type of wear

Causes Transporting a load that exceeds Material damaged due to thermal the nominal capacity while travoverloading elling at a high speed Using or storing the wheel in harsh conditions (high temperaDamage caused by hydrolysis tures) with considerable exposure to water Irregular transverse or longitudinal impacts caused by significant Cauliflower "effect" driving effort and friction with the ground surface Cracked wheel Excessive loads Sharp object embedded in the Mechanical damage tyre tread Thermal overloading, impacts Wear to wheel structure and excessive speed

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1

Lubricating nipple

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

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-23

The following wheels can be fitted to this truck:

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

-24

Recommended for use on flat surfaces.

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

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

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

Used for cold stores, corrosive environments and wet environments.

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1 2

Joystick in neutral position Joystick to the right-hand stop

3 4

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

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

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

Joystick to the left-hand stop Control module

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

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

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

11648012111 EN - 01/2020

-1

1 2

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

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

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

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

-2

3 4

Initial lowering control (lowered position) Control module

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

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

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

11648012111 EN - 01/2020

1 2

Control flap at lower stop position Control flap in neutral position

When the operator moves the control flap downwards (1) or upwards (3), the mast is lifted or lowered.

The setpoint sensor 2B4 (Hall effect sensor) is integrated into the control module and sends back two output signals.

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

3 4

Control flap at upper stop position Control module

Using a voltmeter, the measurable value of the reference signal must be 4.6 V when the operator does not move the control flap (neutral position) (2).

Using a voltmeter, the measurable value of the reference signal must be between 0 V and 1.5 V when the operator moves the control flap downwards (1).

Using a voltmeter, the measurable value of the reference signal must be between 0 V and 1.5 V when the operator moves the control flap upwards (3).

11648012111 EN - 01/2020

-3

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

tor does not press the control module button (button released) (2).

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

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

It is supplied by the traction controller with: 24 V: (1X1:13) 0 V: Earth

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

You can use the diagnostic tool to test the output signal.

Using a voltmeter, the measurable value of the reference signal must be +24 V when the opera-

-4

11648012111 EN - 01/2020

1B1 2B4

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

Pin for connector 1X1 1X1:9 1X1:12 1X1:25 1X1:26 1X1:27 1X1:36 1X1:39 1X1:42

Purpose Lowering the load arms Lift Poti 1 Traction Poti 1 Lift Poti 2 +5V Lifting the load arms Traction Poti 2 0V

Analogue

2B15

Initial lift setpoint sensor (depending on the version) Horn

4S1

Digital

Input

X

X

X X X

Output

X X X X X

X

X X X

11648012111 EN - 01/2020

-5

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

-6

11648012111 EN - 01/2020

Damage to electrical components due to working on live parts.

Before any work on electrical equipment, always: – Pull the emergency stop handle – Unplug the battery connector – Wait until the intermediate circuit capacitors have been discharged.

Only when the battery plug has been disconnected and the capacitors in the power modules have been discharged may plugs be disconnected and electrical components removed.

To check that the capacitors have been discharged, measure the capacitor voltage across terminals 1 and 2 of the power module.

When this voltage is less than 5 V, the capacitors are discharged.

The sealing elements may be damaged when the operating unit is opened.

On no account open the control module.

In addition, check that the diaphragm on the front of the operating unit is not damaged.

Opening it may invalidate the warranty.

Operating units can be damaged by electrostatic discharge.

Do not touch the connections at the plug. Some spare operating units are supplied with a protective cover over the plug for protection against electrostatic discharge. When transporting the operating unit, this cover must be put back in place.

11648012111 EN - 01/2020

-1

The components of the electrical system can be cleaned thoroughly on the outside. The best medium for cleaning is oil-free compressed air. If the components are very strongly contaminated on the outside, a high-pressure cleaner can be used for cleaning. Only water may be used for this. Under no circumstances should chemical cleaning additives be added when using a highpressure cleaner. Chemical cleaning additives may attack the plastic parts of the electrical components.

Moisture must not enter the electrical components.

When cleaning with a high-pressure cleaner, a sufficient distance must be observed between the jet lance and the component, particularly the connector plug.

However, if moisture does enter the components, they must be dried by heating (hot air

-2

blower, heating system) to prevent corrosion damage.

Electrical components can be destroyed by overtemperature.

Observe the maximum temperature when using a hot air blower.

Electrical components can also be cleaned using an electric cleaner (e.g. S. L. X. electric cleaner www.rivolta.de). These electric cleaning materials have a dielectric strength of up to 100,000 V/cm and are free from hydrocarbons such as CHCs, CFCs, aromatics, PCB/PCTs and other pollutants.

PCB polychlorinated biphenyls PCT polychlorinated terphenyls CHCs chlorinated hydrocarbons CFCs chlorofluorocarbons

11648012111 EN - 01/2020

11648012111 EN - 01/2020

-3

The purpose of this test is to ensure that the truck chassis is not connected to any potential.

– Measurement 1 from battery female connector + to chassis

This test limits the risk of an electrical fire (short circuit).

– Measurement 2 from battery female connector - to chassis

For the truck to function correctly, the electrical system and the motor windings for the truck chassis must have sufficient insulation resistance.

The emergency off switch must not be switched off during insulation testing. An unpainted, clean area must be selected as a reference measurement point on the chassis. Controllers and plug connectors do not have to be disconnected before the measurement.

The insulation resistance for the following measurements must be greater than or equal to 1 k /V (24 k for a 24 V battery).

– Ensure that the device is in the "50 V" position and the unit is in "M " Measuring points: Truck connector: between the + and the (emergency stop connector handle removed) Test the + terminal of the truck connector and a threaded stud of the chassis Test the - terminal of the truck connector and a threaded stud of the chassis Test the + (red) terminal of the LAC controller and a threaded stud of the chassis Test the - (blue) terminal of the LAC controller and a threaded stud of the chassis

Insulation resistance must be tested in accordance with EN 1175-1 (DIN VDE 0117-1) using an approved and calibrated insulation measuring device.

The insulation resistance of the truck must be tested at regular intervals as part of the regular testing in accordance with FEM 4.004 (formerly the UVV accident prevention regulations).

Different regulations may apply in other countries.

Electronic controls and components may be damaged if the test voltage of the insulation measuring device is too high.

The test voltage of the insulation measuring device used for the insulation testing of the truck and the traction battery must be set to 50 V.

Hazardous voltages are present at the insulation measuring device terminals during testing.

Do not touch the insulation measuring device terminals during testing.

The insulation resistance of the disconnected, filled and charged battery must be greater than or equal to 50 /V (1200 for a 24 V battery).

-4

The insulation resistance of the truck, the traction battery and the motor windings must be tested individually.

11648012111 EN - 01/2020

Electromagnetic compatibility (EMC) is an essential quality feature for trucks (according to standard EN12895).

EMC involves: Limiting the emission of electromagnetic interference to a level that ensures the undisturbed operation of other equipment in the same environment.

Ensuring sufficient resistance to external electromagnetic interference.

It ensures good truck function in the area of intended use and in the electromagnetic interference conditions expected.

An EMC test measures the electromagnetic interference emitted by the truck and also checks that it has sufficient resistance towards external electromagnetic interference in relation to the area of intended use.

Different electrical measurements are taken to ensure the electromagnetic compatibility of the truck.

The truck is qualified as having EMC in an approved laboratory which ensures its compliance with legislation.

The EMC regulations for the truck must be observed.

When replacing components on the truck, EMC protection components must be installed and connected again (example: ferrites).

– Do not remove ferrites.

– Position all the bundling in their original locations.

11648012111 EN - 01/2020

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1 2 3 4 5 6 7 8 9

Traction/lift contact switch 1K2 Line contact switch 1K0 Pump-motor unit 2M1 Steering contact switch 3K1 Fuses (control circuit) Fan 9M1 Horn Electromagnetic brake Y1 Rev sensor 1B2

10 11 12 13 14 15 16 17

Traction motor 1M1 Electric steering unit 3A1 Stabiliser LAC traction and lift controller 1A1 Floor adjustment cylinder Operator presence pedal Mobile floor Floor adjustment knob

The truck is equipped with the following components: Drive and steering unit with AC motor (3 kW) .

Pump-motor unit (2.2 kW) .

Electromagnetic brake .

Traction and lift controller LAC .

Electric steering unit ES30-24 .

Stabiliser

-6

11648012111 EN - 01/2020

X13 1X1 1X2 1X3 1X7

Steering centre connector Traction/lift controller connector Speed sensor connector Plate/control unit interface connector Link connector for the driver s compartment/ technical compartment

1X25 2X14 2X35 3X1 9X11

11648012111 EN - 01/2020

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

-7

1 2 3 4 5 6 7 8

Fuses (control circuit) Steering contact switch 3K1 Pump-motor unit 2M1 Fan 9M1 Horn Electromagnetic brake Y1 Rev sensor 1B2 Temperature sensor 1B6

9 10 11 12 13 14 15 16

Traction motor 1M1 Electric steering unit 3A1 Stabiliser LAC traction and lift controller 1A1 Floor adjustment cylinder Forklift operator presence pedal Mobile floor Floor adjustment knob

The truck is equipped with the following components: Drive and steering unit with AC motor (3 kW) .

Pump-motor unit (2.2 kW) .

Electromagnetic brake .

Traction and lift controller LAC .

Electric steering unit ES30-24 .

Stabiliser

-8

11648012111 EN - 01/2020

X13 1X2 1X3 1X7 1X25

Steering centre connector Rev sensor connector Plate/control unit interface connector Link connector for the driver's compartment/ technical compartment Motor temperature connector

2X14 2X35 3X1 3X8 9X11

11648012111 EN - 01/2020

Initial lift upper/lower cut-out connector Pump/truck link connector Electric steering connector (control) Electric steering connector (power) Fan connector

-9

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

– Disconnect the battery connector.

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

1 2

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

-10

3 4

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

11648012111 EN - 01/2020

– The 7.5-A fuse cuit.

– The 5-A fuse cuit.

(1) protects the control cir(2) protects the control cir-

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

– The 300-A fuse lift power circuit.

protects the traction and



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



11648012111 EN - 01/2020

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

Risk of short circuit Before carrying out any operations:

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

– Press the emergency off switch.

– Disconnect the battery connector.

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

– The line contact switch er to 1K2 and 3K1

provides the pow-

– The steering contact switch power to the electric steering.

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

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

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

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

-12

provides

11648012111 EN - 01/2020

The horn circuit is powered directly from the emergency stop contact.

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

11648012111 EN - 01/2020

-13

1 2 3 4 5

U phase L1 of the traction motor V phase L2 of the traction motor W phase L3 of the traction motor Li control terminal for the lift motor + positive terminal of the +24 V power sup-

6 7

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

ply for the power unit

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

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

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

-14

If an error occurs, it is instantly detected and the control system places the truck in safety mode, which may lead to a reduction in performance or stoppage of a controller depending on the type of fault.

The controller is fitted with a 42-pin tor.

11648012111 EN - 01/2020

connec-

1 2 3 4 5

Contact switch positive Load-retaining solenoid valve 2Y11 Proportional solenoid valve 2Y3 Initial lift top position cut-out 1B4 Platform presence

0V 0V

6

Fan

7

Not used

8

Rev sensor track A

9 10 11

Initial lowering signal 2B16 Not used Battery voltage

12

Lift setting no. 1 2B4

-

13

Battery voltage

-

14

CAN high

-

15

Safety relay status

-

24 V Supply 0V All or nothing PWM* signal All or nothing 24 V Digital 0V Digital

/ Output Output Input Input

24 V

0V

All or nothing

Output

Not used

Not used Frequency variable 0 V/6 V 0V Not used 24 V Variable voltage 0 V/5 V 24 V Variable voltage 0 V/5 V 24 V

Not used

Not used

Digital

Input

Digital Not used Supply

Input Not used /

Analogue

Input

Supply

/

Digital

Input/output

Supply

/

5V Not used -

11648012111 EN - 01/2020

-15

16 17 18 19 20 21

Lowering solenoid valve 2Y2 Traction/lift contact switch 1K2 Not used Operator presence pedal 1S9 Not used Not used

22

Rev sensor track B

23 24

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

25

Traction setting no. 1

-

26

Lift setting no. 2 2B4

-

27

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

-

28

CAN low

-

29 30 31 32 33 34 35 36 37 38

Brake Y1 Not used Switching solenoid valve 2Y12 Operator seat presence 1S29 track 1 Not used Mast height 1.5 m 2B6 Not used Initial lift signal 2B17 Operator seat presence 1S29 track 2 Not used

39

Traction setting no. 2 1B1

-

40

Pressure sensor

0V

41

Temperature sensor 1B6

-

42

0 V supply for potentiometers

-

signal

-16

Not used 24 V Not used Not used 0V 24 V

Not used 0V Not used 24 V Not used 5V 24 V Not used

0V All or nothing PWM* signal All or nothing Not used Not used 0V Digital Not used Not used Not used Not used Frequency variable Digital 0 V/6 V 24 V Digital 0V Digital Variable voltage Analogue 0 V/5 V Variable voltage Analogue 0 V/5 V 5V

Supply

Output Output Not used Input Not used Not used Input Input Input Input Input /

Variable voltage Digital Input/output 0 V/5 V 0V All or nothing Output Not used Not used Not used 0V All or nothing Output 24 V Digital Input Not used Not used Not used 0V Digital Input Not used Not used Not used 0V Digital Input 0V Digital Input Not used Not used Not used Variable voltage Analogue Input 0 V/5 V 24 V Digital Input Variable sigAnalogue Input nal 0V Supply /

signal: Pulse Width Modulation = variable

11648012111 EN - 01/2020

1 2 3 4 5

Contact switch positive Load-retaining solenoid valve 2Y11 Proportional solenoid valve 2Y3 Initial lift high position cut-out 1B4 Not used

0V Not used

6

Fan

7

Not used

8

Rev sensor track A

9 10 11

Initial lowering signal 2B16 Not used Battery voltage

12

Lift setting no. 1 2B4

-

13

Battery voltage

-

24 V Not used 5V Not used -

14 CAN 1 High

-

15

-

Safety relay status

11648012111 EN - 01/2020

24 V Power supply 0V All or nothing PWM* signal All or nothing 24 V Digital Not used Not used 0V

All or nothing

/ Output Output Input Not used Output

Not used Not used Not used Frequency variable Digital Input 0 V/6 V 0V Digital Input Not used Not used Not used 24 V Power supply / Variable voltage Analogue Input 0 V/5 V 24 V Power supply / Variable voltage Digital Input/Output 0 V/5 V 24 V Power supply / -17

16 17 18 19 20 21

Lowering solenoid valve 2Y2 Traction/lift contact switch 1K2 Not used Forklift operator presence pedal 1S9 Not used Not used

Not used 24 V Not used Not used

22

Rev sensor track B

-

23

Initial lift low position cut-out 1B3

0V

24

CAN 2 High

-

25

Traction setting no. 1

-

26

Lift setting no. 2 2B4

-

27

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

-

28

CAN 1 Low

-

29 30 31 32 33

Brake Y1 Not used Needle solenoid valve 2Y12 Height sensor mast 1 Not used

34

CAN 2 Low

35 36 37 38

Not used Initial lift signal 2B17 Height sensor mast 2 Not used

39

Traction setting no. 2 1B1

-

40

Pressure sensor

0V

41

Temperature sensor 1B6

-

42

0-V supply for potentiometers

-

Not used 0V Not used Not used 5V 24 V Not used

0V All or nothing Output PWM* signal All or nothing Output Not used Not used Not used 0V Digital Input Not used Not used Not used Not used Not used Not used Frequency variable Digital Input 0 V/6 V 24 V Digital Input Variable voltage Digital Input/Output 0 V/5 V Variable voltage Analogue Input 0 V/5 V Variable voltage Analogue Input 0 V/5 V 5V

/

Variable voltage Digital Input/Output 0 V/5 V 0V All or nothing Output Not used Not used Not used 0V All or nothing Output 24 V Digital Input Not used Not used Not used Variable voltage Digital Input/Output 0 V/5 V Not used Not used Not used 0V Digital Input 0V Digital Input Not used Not used Not used Variable voltage Analogue Input 0 V/5 V 24 V Digital Input Variable sigAnalogue Input nal 0V Power supply /

signal: Pulse Width Modulation = Variable signal

-18

Power supply

11648012111 EN - 01/2020

The procedure for activating the truck is as follows: Presence of the battery +24 V positive on the switch key (S1) and on the switch coil (1K2) Battery +24 V positive direct on 3X1: A8 (ES30-24) and 1X1: 1 (LAC) LAC and ES30-24 control module power supply: LAC: +24 V power supply in 1X1: 13; 0 V direct in 1X1: 42 ES30-24: +24 V power supply in 3X1: A7/A8, 0 V direct in 3X1: B5

LAC: a +5 V internal voltage regulator supplies: - The accelerator potentiometer (1B1) - The rev sensor (1B2) (not shown) ES30-24: a +10 V internal voltage regulator supplies:

- The setpoint sensor (3B2)

LAC: launch of the internal test program ES30-24: checking for correct operation of the two electric steering potentiometers with double signals (redundant potentiometers)

From the ES30-24 power supply: - The steering relay (3K1) is supplied - The pivot break is supplied If the steering potentiometer check is OK: - Closure of the MOSFET (inside the ES30-24) - Power supply to LAC (1X1 : 1) - LAC : If the self-test is OK: - Closure of the +24 V safety relay on 1X1: 1 - CAN bus: traction authorisation sent by the ES30-24

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-19

LAC: - +24 V in 1X1:1 - Closure of (1K2)

-20

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

11648012111 EN - 01/2020

1: Minimum speed 2: Level 3 3: Level 2

4: Level 1 5: Between level 1 and maximum level

Truck parameters

Speeds (default values)

Angles (default values)

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

Maximum acceleration Maximum deceleration (by releasing the drive switch) Maximum deceleration (by reversing the drive switch) Starting angle Level 1 Level 2 Level 3 Minimum angle Level 1 Level 2 Level 3 Minimum speed Maximum acceleration Maximum deceleration

1.5 m/s²

FXD 20N with steering knob 1.5 m/s²

1.4 m/s²

1.4 m/s²

2 m/s²

2 m/s²

10° 12° 20° 35° 50° 7.5 km/h 6.5 km/h 6 km/h 5 km/h 1 m/s²

10° 12° 20° 35° 50° 7.5 km/h 6.5 km/h 6 km/h 5 km/h 0.6 m/s²

0.9 m/s²

1.1 m/s²

FXD 20N

: Speed Reduction Wheel Steering

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-21

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

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

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

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

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

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

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11648012111 EN - 01/2020

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

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-23

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

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

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

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

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11648012111 EN - 01/2020

– Follow the instructions on the display.

Considerable risk of injury and/or material damage.

The accelerator potentiometer is calibrated.

Restore factory settings

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

F3:Setup

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

Error Codes

– Select "Truck Service Base".

Traction Lift

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

Truck identification

– Follow the instructions on the screen in: – In the "Traction" field

F2:Diagnostics

– Click on Start

Jobs

– In the "Lift" field

Setting Truck Type Execute – Follow the instructions on the screen in: ometer

Start

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

calibration of the accelerator potenti-

F2:Diagnostics To initialise the new values:

Jobs

– Switch off the truck power supply and restart it.

Calibration 1- Accelerator Potentiometer

– Close the diagnostic tool and relaunch the program.

11648012111 EN - 01/2020

-25

1X1

Traction/lift controller connector

1X2

Rev sensor connector

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

This sensor monitors a gear mounted on the rotor.

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

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

No adjustment is needed for the rev sensor.

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

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11648012111 EN - 01/2020

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

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

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

Rev sensor connector 1X2 1X2:1 1X2:2 1X2:3 1X2:4

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

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

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

– Connect the CAN box to the connector

diagnostic

– Connect the CAN box to the laptop connector – Start and connect the diagnostic tool

F4:Screen Traction Traction motor Motor speed – Drive the truck.

– Check the speed indicators on the display.

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

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

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

1X25:2 Negative

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

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

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

– Connect the CAN box to the connector

diagnostic

– Connect the CAN box to the laptop connector – Start and connect the diagnostic tool

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F4:Screen Traction Traction motor Motor temperature – Go to the menu shown to check the motor temperature values (1M1).

T° (1M1) normal working temperature approx.

30°C Normal operating speed of the truck

T° (1M1)

-50°C

T° (1M1)

160°C

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

170°C

T° (1M1) 200°C

Truck stopped

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

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

– Disconnect the connector from the truck.

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

0 10

493 533

30 40 50 60 70

621 668 718 769 824

80 90 100 130 170 200 230 270 299

If the values are incorrect, repeat the test.

-30

11648012111 EN - 01/2020

880 939 1000 1197 1493 1739 2006 2392 2668

7X6

Electromagnetic brake connector

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

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

– Connect the CAN box to the connector

diagnostic

– Connect the CAN box to the laptop connector – Start and connect the diagnostic tool – Go to the following menu:

F4:Screen General

Safety relay and brake x1:29 Brake – Check the on-screen indications in the following menu: Brake transistor control in 1X1:29 0 Brake applied 1 Brake released Blue window - Voltage (V) of the brake in 1X1:29 +24 V Brake applied 0 V Brake released Red window - Current (mA) of the brake in 1X1:29 0 mA Brake applied 1600 mA Brake released

11648012111 EN - 01/2020

-31

1S9 1X1 1X7

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

– Connect the CAN box to the connector

1X9 6X7

Operator presence connector Diagnostic socket connector

diagnostic

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

F4:Screen Traction Platform x1:19 Driver present The information in the ":19 Driver present" field is as follows: 0 without operator 1 with operator

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11648012111 EN - 01/2020

1X1

Traction/lift controller connector (LAC)

9X11

Fan connector

F3:Setup When the fan is faulty or disconnected, the truck is stopped (fault code T34 displayed and traction function and lifting are disabled) A temperature sensor inside the LAC actuates the fan (9M1) when the internal temperature of the power stage exceeds 50°C, and stops it when the temperature drops below 40°C. (9M1) ON = LAC > 50°C (9M1) OFF = LAC < 40°C A 24 V DC brushless fan fitted with long-life bearings is used to cool the traction controller LAC.

– Connect the CAN Box to the connector

diagnostic

– Connect the CAN Box to the laptop connector – Launch the diagnostic tool – Follow the instructions on the display to check the control of the fan (9M1)

Function Drive control Fan: Test T° > 50° Fan activated (1X1: 6 = ) T° < 40° Fan deactivated (1X1: 6 = ) LAC normal working T° approx. 30°C Normal operating speed of the truck LAC T° -50°C Speed reduction = 4.5 km/h LAC T° 95°C Speed reduction = 2 km/h 100°C T° LAC 200°C Truck stopped Faulty sensor (fault code 240) Speed reduction = 4.5 km/h

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1B1 1X1

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

1X3 1X7

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

Traction – Connect the CAN box to the connector

diagnostic

– Connect the CAN box to the laptop connector – Start and the diagnostic tool and log in – Go to the following menu to check the operation of the traction controller of the truck:

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

F4:Screen

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11648012111 EN - 01/2020

1B2 1X1

Rev sensor Traction/lift controller connector

1X2

Rev sensor connector

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

This sensor monitors a gear fitted on the rotor.

The sensor is supplied with +24 V (pin 1X2:1) and supplies two 90° out-of-phase impulsion gaps.

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

No adjustment is needed for the rev sensor.

Truck applications: SXH 20, SXD 20 FXH 20 N, FXH 25 N, FXD 20 N, FXV 14 N, FXV 16 N FXH 20, FXH 25, FXD 20, FXV 14, FXV 16

Risk of incorrect use of the traction motor.

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

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-35

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

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

The direction of rotation is defined by the traction motor.

A four-pin connector (3) is used to connect the rev sensor with the power module (1A1).

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

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

– Connect the CAN box to the connector

diagnostic

– Connect the CAN box to the laptop connector – Drive the truck.

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

F4:Screen Traction Traction motor Motor speed

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11648012111 EN - 01/2020

– Check the speed indicators on the display.

1X2:1 1X2:2 1X2:3 1X2:4

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

Red White Black White

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-37

1B6 1X1 1X25

Temperature sensor Traction/lift controller (LAC) connector Temperature sensor connector

1X25:1 Temperature signal 1X25:2 Negative

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

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

Truck applications: SXH 20, SXD 20 FXH 20 N, FXH 25 N, FXD 20 N, FXV 14 N, FXV 16 N FXH 20, FXH 25, FXD 20, FXV 14, FXV 16

The PT1000 sensor does not need to be parameterised because it is set by default in the LAC controller.

– Connect the CAN box to the diagnostic connector – Connect the CAN box to the laptop socket

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11648012111 EN - 01/2020

– Launch the diagnostic tool and go to the menu shown to check the temperature values of the motor (1M1)

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

F4:Screen Traction Traction motor Motor temperature T° (1M1) normal working temperature approx.

30°C Normal operating speed of the truck

T° (1M1)

-50°C

T° (1M1)

160°C

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

11648012111 EN - 01/2020

170°C

T° (1M1) 200°C

Truck stopped

-39

A

Temperature (T/°C)

B

Resistance (R/ )

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

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

– Disconnect the connector from the truck.

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

-40 -35 -30 -25 -20 -15 -10 -5 -40

842.71 862.48 882.22 901.92 921.24 941.24 960.86 980.44 11648012111 EN - 01/2020

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200

1000.00 1019.53 1039.03 1058.49 1077.94 1097.35 1116.73 1136.08 1155.41 1174.70 1193.97 1213.21 1232.42 1251.60 1270.75 1289.87 1308.97 1328.03 1347.07 1366.08 1385.06 1404.00 1422.93 1441.82 1460.68 1479.51 1498.32 1517.10 1535.84 1554.56 1573.25 1591.91 1610.54 1629.15 1647.72 1666.24 1684.78 1703.27 1721.73 1740.16 1758.56

If the values are incorrect, repeat the test.

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1X1 7X6

Traction/lift controller (LAC) connector Electromagnetic brake connector

Y1

Electromagnetic brake

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

– Connect the CAN box to the connector.

diagnostic

– Connect the CAN box to the laptop connector.

– Launch the diagnostic tool.

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

Inputs/Outputs - Monitoring Traction Brake Brake transistor control in 1X1: 29 0 Brake lifting or traction 1 Brake lifting or traction Blue window - Voltage (V) of the brake in 1X1: 29 Red window - Current (mA) of the brake in 1X1: 29 +24 V Brake lifting or traction 0 mA Brake lifting or traction 0 V Brake lifting or traction 1600 mA Brake lifting or traction

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11648012111 EN - 01/2020

: Connector

: power section

: Connector

: control section

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

The transistors are controlled internally.

The motor wiring is internal.

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

To check the identity of the ES30-24 unit: – Connect the CAN Box to the connector.

diagnostic

– Connect the CAN Box to the laptop connector.

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

F3:Setup Control device info Steering control device (ES)

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Steering main line

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11648012111 EN - 01/2020

B7 B8

Position sensor 3B2 (setpoint), track 2 Not used Not used Not used 0 V sensor Power supply for the position sensor (setpoint) Power supply for the control card Power supply for the control card Position sensor 3B2 (setpoint), track 1 Not used Not used Not used 0 V CAN A Power supply for the steering switch 3K1 Pivot brake 7A5 Safety loop

C1

CAN A high

C2

CAN A low

C3

CAN B earth

C4

CAN B high

C5

CAN B low

C6 C7 C8

Pivot brake 7A5 Steering switch 3K1 Not used

A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6

/ / /

/ / /

/

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

Analogue

Input

/ / / Supply

/ / / /

10 V

Supply

/

24 V

Supply

/

24 V

Supply

/

Analogue

Input

/ / / Supply

/ / / /

24 V

Supply

Output

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

Supply Supply

Output Output

Digital

Input/output

Digital

Input/output

Analogue

Input

Digital

Input/output

Digital

Input/output

Digital Supply /

Input Input /

Supply Supply

/ /

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

*PWM: Pulse Width Modulation

1 2

Positive after battery Battery negative

24 V 0V

11648012111 EN - 01/2020

-45

The ES30-24 unit is the main safety device.

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

Power up procedure: (the steps described enable you to carry out rapid diagnosis of the malfunction): 1) ES30-24 power up after switching on the 4) The ES30-24 drives an internal safety relay. This rekey switch . lay supplies the positive rail on The supply negative is direct on (for the steering contactor 3K1) . and a negative via a MOSFET transistor on (for the steering contactor 3K1).

5) The 3K1 steering contactor and the coil of the steer2) The ES30-24 generates a stabilised volt- ing centre 7A5 are thus supplied with power. The power age on for the pos- stage is checked, the motor is stopped, itive . and on for the nega- The steering centre itself is current-driven (between 5 tive. and 750 mA), a cut bundle causes the truck to stop via the CAN Bus connection.

3) The steering controls the correct opera6) The ES30-24 gives the two activation signals to opertion of the two setting and wheel potentiomate the traction: eters via the double signals (redundant

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11648012111 EN - 01/2020

potentiometers) on (voltages measured when the setting and the wheel are in alignment with the forks).

The steering controls its second safety relay giving the positive rail for the traction (positive for input 1X1:1 for the internal relay contact to the LAC) on .

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

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

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1X1

Traction/lift controller connector

1X2

Rev sensor connector

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

This sensor monitors a gear mounted on the rotor.

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

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

No adjustment is needed for the rev sensor.

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

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11648012111 EN - 01/2020

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

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

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

Rev sensor connector 1X2 1X2:1 1X2:2 1X2:3 1X2:4

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

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

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

– Connect the CAN box to the connector

diagnostic

– Connect the CAN box to the laptop connector – Start and connect the diagnostic tool

F4:Screen Traction Traction motor Motor speed – Drive the truck.

– Check the speed indicators on the display.

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-49

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

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

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11648012111 EN - 01/2020

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

1X25:2 Negative

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

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

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

– Connect the CAN box to the connector

diagnostic

– Connect the CAN box to the laptop connector – Start and connect the diagnostic tool

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F4:Screen Traction Traction motor Motor temperature – Go to the menu shown to check the motor temperature values (1M1).

T° (1M1) normal working temperature approx.

30°C Normal operating speed of the truck

T° (1M1)

-50°C

T° (1M1)

160°C

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

170°C

T° (1M1) 200°C

Truck stopped

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

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

– Disconnect the connector from the truck.

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

0 10

493 533

30 40 50 60 70

621 668 718 769 824

80 90 100 130 170 200 230 270 299

If the values are incorrect, repeat the test.

-52

11648012111 EN - 01/2020

880 939 1000 1197 1493 1739 2006 2392 2668

7X6

Electromagnetic brake connector

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

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

– Connect the CAN box to the connector

diagnostic

– Connect the CAN box to the laptop connector – Start and connect the diagnostic tool – Go to the following menu:

F4:Screen General

Safety relay and brake x1:29 Brake – Check the on-screen indications in the following menu: Brake transistor control in 1X1:29 0 Brake applied 1 Brake released Blue window - Voltage (V) of the brake in 1X1:29 +24 V Brake applied 0 V Brake released Red window - Current (mA) of the brake in 1X1:29 0 mA Brake applied 1600 mA Brake released

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1S9 1X1 1X7

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

– Connect the CAN box to the connector

1X9 6X7

Operator presence connector Diagnostic socket connector

diagnostic

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

F4:Screen Traction Platform x1:19 Driver present The information in the ":19 Driver present" field is as follows: 0 without operator 1 with operator

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11648012111 EN - 01/2020

1X1

Traction/lift controller connector (LAC)

9X11

Fan connector

F3:Setup When the fan is faulty or disconnected, the truck is stopped (fault code T34 displayed and traction function and lifting are disabled) A temperature sensor inside the LAC actuates the fan (9M1) when the internal temperature of the power stage exceeds 50°C, and stops it when the temperature drops below 40°C. (9M1) ON = LAC > 50°C (9M1) OFF = LAC < 40°C A 24 V DC brushless fan fitted with long-life bearings is used to cool the traction controller LAC.

– Connect the CAN Box to the connector

diagnostic

– Connect the CAN Box to the laptop connector – Launch the diagnostic tool – Follow the instructions on the display to check the control of the fan (9M1)

Function Drive control Fan: Test T° > 50° Fan activated (1X1: 6 = ) T° < 40° Fan deactivated (1X1: 6 = ) LAC normal working T° approx. 30°C Normal operating speed of the truck LAC T° -50°C Speed reduction = 4.5 km/h LAC T° 95°C Speed reduction = 2 km/h 100°C T° LAC 200°C Truck stopped Faulty sensor (fault code 240) Speed reduction = 4.5 km/h

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1B1 1X1

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

1X3 1X7

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

Traction – Connect the CAN box to the connector

diagnostic

– Connect the CAN box to the laptop connector – Start and the diagnostic tool and log in – Go to the following menu to check the operation of the traction controller of the truck:

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

F4:Screen

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11648012111 EN - 01/2020

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

Use protection goggles and a mask with a protective visor.

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

1 2 3

Switch connector Diagnostic harness connector BMS (BMU) connector

4

On/off button connector

5

Module harness to BMS (SMU) connector(s)

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– Install the battery in the support provided for battery maintenance.

– Unscrew the four CBLX M6 screws (1) and remove the spring washer and the flat washer from the cover provided.

– Lift the battery cover provided (2).

– Disconnect the SMU harness connectors (6) from the BMS (7) by pushing the release clip.

– Identify the positive power cable connected to the contact switch provided (4).

Unscrew the mounting nut and then remove the spring washer, the corresponding flat washer and the shoe located at the end of the harness from the contact switch.

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Refit the maintenance insulation cover.

– Locate the negative power cable connected to the shunt (3).

Remove the insulation protection. Unscrew the mounting nut and then remove the spring washer and the corresponding washer.

Refit the maintenance insulation cover.

– Identify and disconnect the earth cable (5) from the side of the cover provided.

– Remove the BMS cover provided.

– If the BMS has to be reused, remove it from the cover provided.

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– Install the BMS (old or new) on the cover provided.

– Move the battery cover provided (2) closer.

– Install the positive power cable for the contact switch provided (4) and the shoe located at the end of the harness from the contact switch. Then tighten the nut with the spring washer and the flat washer (tightening torque: 10 Nm).

– Locate and connect the earth cable (5) on the side of the cover provided.

– Connect the SMU harness connectors (6) to the BMS: push the release clip.

– Remove the maintenance insulation cover from the negative power cable.

– Fit the battery cover provided (2).

– Check whether the cover seal is damaged.

Replace if necessary.

– Connect the negative power cable to the shunt (3). Connect it with the H M6 nut and with the spring washer and the flat washer (tightening torque: 5 Nm).

Refit the insulation protection.

– Fit the cover provided (2) with the four CBLX M6 screws (1) and with the spring washer and the flat washer (tightening torque: 10 Nm).

– If the battery is being stored, attach adhesive tape to the insulation covers on the power terminal block.

– Remove the maintenance insulation cover from the positive power cable.

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The seal of the push button must be on the outside of the cover.

– Remove the four nylon clips (2).

– Disconnect the push button connector (3).

– Unscrew the M22 nut (6) on the push button provided (1) and then remove it.

– Remove the push button (1) and its O-ring (5) from the cover provided (7).

– Install the push button provided (1) on the cover provided (7). Put the connector through the hole.

– Place the M22 nut (6) on the push button (1) and then screw in the nut (tightening torque: 6 Nm).

– Attach the push button cable with the four nylon clips (2).

– Place the O-ring (5) on the head of the push button (4).

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– Connect the push button connector (3).

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– Unscrew the nut from the contact switch (6) and then remove the nut, the washers and the O-ring from the diagnostic harness (4).

– Install the head of the diagnostic harness (3) on the cover provided (8) through the hole provided for this purpose.

– Remove the nylon rope clamp (7).

– Screw the mounting ring (2) on the diagnostic connector.

– Disconnect the diagnostic harness connector (5).

– Screw on the cap (1) using its retaining tab.

– Unscrew the protective cap (1) and its retaining tab.

– Connect the diagnostic harness connector (5).

– Unscrew the protective ring (2) from the diagnostic connector.

– Fit the nylon rope clamp (7).

– Remove the head of the diagnostic harness (3) from the cover provided (8).

– Fit the O-ring on the diagnostic harness (4).

Fit the washers and the nut (6) and then screw on the nut of the contact switch (tightening torque: 10 Nm).

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– Unscrew the two cover fastening nuts (1) and then remove them.

– Remove the cover (2).

– Unscrew the M8 screw (3) (corresponding to the + terminal).

– Unscrew the M6 screw (4) (corresponding to the - terminal).

– Unscrew the three M5 mounting screws (7) and remove them from the terminal block (5).

– Remove the terminal block (5) from the cover provided (8).

– Remove the seal from the terminal block (6).

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– Fit the seal of the terminal block (6).

– Install the terminal block (5) on the cover provided (8).

– Attach the terminal block (5) using the three M5 mounting screws (7) and corresponding washers (tightening torque: 4 Nm).

– Tighten the M6 screw (4) (negative terminal) (tightening torque: 5 Nm).

– Tighten the M8 screw (3) (positive terminal) (tightening torque: 13 Nm).

– Fit the terminal block cover (2).

– Fit the two cover fastening nuts (1) and then screw them in (tightening torque: 3 Nm).

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– Fit the power cable from the connector to the terminals of the contact switch (1).

Positive power cable from the fuse.

– Fit the fuse.

– Remove the fuse.

– Remove the positive power cable (1).

Negative power cable from the power pack.

– Remove the protective cap (3).

– Unscrew the mounting screw from the cable to the negative terminal of the power pack (4).

Negative power cable from the power pack.

– Install the negative power cable (2). Fit the rigid joining plate of the contact switch (4) to the negative terminal of the terminal block and then screw it in (tightening torque: 6 Nm).

– Fit the protective cap (3).

– Remove the negative power cable (2).

Positive power cable from the fuse.

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

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

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

The Black Box records the various battery parameters and events.

It monitors and controls the status of the battery with the following functions: To supply the SMU card and the BMU (DC) To receive data from the SMU card

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To measure the current of the lithium-ion battery module To calculate the data To communicate with the LAC controller via the CAN bus network

The SMU (Safety and Monitoring Unit) card is located inside the BMS. This enables cell management (balancing, sending information such as end of charge, overheating, overloading, excessive discharge etc.).

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

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– Unscrew the cap of the battery diagnostics connector using the tab (1).

– Unscrew the four mounting nuts (4) of the BMS.

– Connect the diagnostic tool to the battery diagnostics connector (2).

– Remove the BMS(5).

– If possible, start the diagnostic tool software and download data from the BMS (black box, shunt calibration parameters etc.).

– Disconnect the diagnostic tool.

– Install the BMS(5).

– Tighten the four mounting nuts (4) on the BMS (tightening torque: ).

– Connect the diagnostic harness connector (3).

It is also possible to access the BMS directly via the RS485 output of the BMS using the SAFT tool (WINDIAG_BMS).

– Screw on the cap (1).

– Install the cover provided.

– Unscrew the cap (1) of the battery diagnostics connector using the tab.

– Remove the cover provided.

– Connect the diagnostic tool to the battery diagnostics connector (2).

– Disconnect the diagnostic harness connector (3).

– Start the diagnostic tool software (KION CAN_KWP2000 tool) and transfer the data

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from the old BMS (black box, shunt calibration parameters etc.) if it can be recovered.

– If this is not possible, save the calibration parameters present on the shunt and enter them in the new BMS. Enter a value indicative of the SOH : State Of Health) in the BMS. Also enter the serial number of the battery and the module, as well as the BMU ID number.

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– Disconnect the diagnostic tool.

– Screw on the cap (1).

It is also possible to access the BMS directly via the RS485 output of the BMS using the SAFT tool (WINDIAG_BMS).

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A B

Module connector - terminal

C

+ terminal

The B1 battery is equipped with a 24M Fe module consisting of 35 cells (seven rows of five cells).

The B2 battery is equipped with two 24M Fe modules consisting of 35 cells (seven rows of five cells for each module).

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

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– Unscrew the negative output of the power pack (1).

– Unscrew the six mounting nuts on the reinforced plate (10).

– Remove the negative connection hose and then insulate the negative terminal of the power pack with insulating tape.

– Remove the rivets (11).

– Unscrew the mounting screws of the rigid connection (2), remove the rigid connection (3) and then insulate the positive terminal of the power pack with insulating tape.

Use a 2-mm punch to drive the rivet into the battery.

Use a 10-mm twist drill to drill out the rivet heads.

Use a 4-mm punch to mark out the shape of the rivets in the battery.

– Unscrew the four mounting nuts on the fuse holder (4) and then remove the fuse holder (5).

– Carefully remove the side cover provided (12).

– Unscrew the five mounting nuts on the side plate (6) and then remove the side plate (7).

– Disconnect the connector for electrical continuity.

– Unscrew the mounting nuts (8a) and bolts (8b) from the angle bracket (9) and then remove the angle brackets.

– Remove the cover seal (13).

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– Remove the SMU harness (15).

– Remove the power pack (19) (blue arrow).

Unscrew the six retaining screws (17) on the retaining clamps of the SMU harness (16).

Disconnect the two SMU harness connectors (18) from the modules.

Remove the SMU harness (15).

The power pack is heavy (96.5 kg).

– Remove the four mounting screws from the power pack (14).

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– On the two sides (positive and negative), unscrew the rigid connection nuts (20) and then remove the rigid power connections (21 & 22).

– Unscrew the seven reinforced nuts on the reinforced plate (23) and then remove the reinforced plate (24).

– Separate the upper module (27) from the lower module (28).

A module weighs 43.3 kg.

– On the two sides (positive and negative), unscrew the reinforcement screws (25) and then remove the seven reinforcements (26).

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– Check that the box is not damaged.

– On the opening of the power pack, check that the holes intended for rivets are all cylindrical.

– Clean the box with a suction system (no dust on the metal parts).

– Also clean around the opening of the power pack (around the seal of the side cover).

If the box is damaged or if the holes (rivets) are not cylindrical, the box should not be used, so use another box.

– Place the upper module (27) on the lower module (28).

– On the two sides (positive and negative), position the seven reinforcements (26) and then screw in the reinforcement screws (25) (tightening torque: ).

reinforced plate (23) (tightening torque: ).

– On the two sides (positive and negative), position the rigid power connections (21 & 22) and then screw in the rigid connection screws (20) (tightening torque: ).

– Place the reinforced plate (24) on the modules and then screw in the seven nuts of the 11648012111 EN - 01/2020

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– Insert the power pack (19) in the box.

– Install the SMU harness (15).

The power pack is heavy (96.5 kg).

– Screw in the four mounting screws of the power pack (14) (tightening torque: ).

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Connect the SMU harness connectors (18) to the modules.

Position the SMU harness rope clamps (16) and then screw them (17) on to the modules (tightening torque: ).

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– Screw the six mounting nuts of the reinforced plate (10) on to the battery box (tightening torque: ).

– Position the two angle brackets (9) and then tighten the mounting nuts (8a) and bolts (8b) (tightening torque: ).

– Position the side plate (7) and then screw it in with the five mounting nuts (6) (tightening torque: ).

– Position the fuse holder (5) and then screw in the four mounting nuts on the fuse holder (4) (tightening torque: ).

– Remove the insulating tape from the power pack terminals.

– Position the rigid connection (3) and then screw in the mounting screws on the rigid connection (2) (tightening torque: ).

– Position the negative connection hose and then screw in the negative output of the power pack (1) (tightening torque: ).

– Connect the connector for electrical continuity.

– Put a new side protection seal (13) in place.

– Carefully position the side cover provided (12).

– Fit the new rivets (11).

– Unscrew the cap of the battery diagnostic connector using the tab (1).

– Connect the diagnostic tool to the battery diagnostic connector.

– Launch the diagnostic tool software.

– Enter the serial number of the module or modules.

– Update the diagnostic tool.

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– Screw in the protective cap.

It is also possible to access the BMS directly via the RS485 output of the BMS.

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– Remove the rigid connection (6).

– Unscrew the two mounting nuts on the insulation cover (1) and then remove them.

– Remove the shunt (7).

– Remove the insulation cover (2).

– Gently unscrew the mounting screws of the communication cable (3).

– Put the shunt (7) into position.

– Put the rigid connection (6) into position.

– Screw on the rigid connection nut (5) (tightening torque: 5 Nm).

The mounting screws of the communication cable are small in diameter. They are screwed on the shunt, which is made of copper.

Be careful not to damage the threads or lose the screws.

– Screw the mounting nut on the shunt (4a) (tightening torque: slight tightening).

– Screw the other mounting nut on the shunt (4b) (tightening torque: 5 Nm).

– Put the screws of the shunt communication cable (3) in place and then screw them in (tightening torque: 3 Nm).

– Unscrew the two mounting nuts on the shunt (4a and 4b).

– Unscrew the rigid connection nut (5).

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The mounting screws of the communication cable are small in diameter. They are screwed on the shunt, which is made of copper.

– Fit the two mounting nuts on the insulation cover (1) and then screw them in (tightening torque: 3 Nm).

– Unscrew the battery diagnostic connector with trap (8).

– Connect the diagnostic tool to the battery diagnostic connector (7).

Be careful not to damage the threads or lose the screws.

– Fit the insulation cover (2).

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– Start the diagnostic software tool.

– Disconnect the diagnostic tool.

– Screw on the cap (1).

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A B

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

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

It contains devices that can cut off the supply, manage its safety and measure the physical values.

C

Contact switch

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

This prevents currents that are too large when the Lithium Ion battery is started.

This helps protect the plate from a possible short-circuit of the external terminals.

It also serves to dissipate the energy of the peak of current in order to start the battery safely.

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

Located below the plate, this activates precharging.

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– Remove the contact switch provided (9).

– Unscrew the two mounting nuts on the protective cover of the terminal block (1) and then remove them.

– Fit the contact switch provided (9).

– Remove the protective cover from the terminal block (2).

– Screw in the two M5 nuts on the contact switch (8) (tightening torque: ).

– Disconnect the connector from the contact switch (3).

– Install the rigid connection (7).

– Unscrew the M8 nut (4) (positive terminal) and then remove it with the corresponding washers.

– Unscrew the two nuts on the terminals of the contact switch and the corresponding washers (5).

– Remove the washer (6) from the + terminal of the contact switch.

– Fit the washer (6) on the + terminal of the contact switch.

– Fit the washers and nuts on the power contact switch (5) and then tighten (tightening torque: ).

– Fit the washers and the M8 screw on the + terminal (4) and then tighten (tightening torque: ).

– Remove the rigid connection (7).

– Connect the connector of the contact switch (3).

– Unscrew the two M5 mounting nuts on the contact switch (8).

– Install the terminal block cover (2).

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

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– Fit the fuse (5) in the fuse holder (4).

– Remove the protective cap (1).

– Unscrew the two CBLX M6 nuts (2) and remove the flat washers and the conical spring washers.

– Remove the fuse (5) from the fuse holder (4).

– Fit the flat washers, the conical spring washers and the nuts (2).

– Tighten the two CBLX M6 nuts (tightening torque: ).

– Fit the protective cap (1).

– Remove the hose connection (3).

– Fit the hose connection (3).

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There are three types of external chargers: A: An external 90-A charger (single phase) B: An external 160-A charger (three phase) C: An external 225-A charger (three phase)

Information about the charging status during charging is described below: 1: Battery voltage (V) 2: Charging current (A) 3: Charging status (%) 4: Charge supplied (Ah) 5: Charging time (t)

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OFF GREEN ORANGE RED RED FLASHING

Charger OFF Charger initialising Starting sequence Battery charged Battery charging Battery warning (failure) Battery alarm Charger alarm

If the light is flashing red, refer to the alarm codes described below: Check the status of the battery Maximum charging time excee(maximum charging time 780 mided nutes)

MAX. TIME OVERRANGE ERROR CHARGER HIGH VOLTAGE ERROR CHARGER

High battery voltage

INTERNAL TEMPERAT. ERROR CHARGER

Internal temperature of the charger is too high

ERROR BATTERY BATTERY ALARM BATT. UNEXPECTED ERROR BATTERY MEASURE ERROR

Provide adequate air circulation Check that the internal FANS are operating correctly

Battery error The battery has encountered an Consult battery documentation unrecoverable error Battery alarm An alarm has occurred on the Consult battery documentation battery Incompatible battery manufactur- Battery type and charger type er are from different brands Contact the After-Sales Service Voltage (and/or) amperage read- Centre (maximum voltage tolerings incorrect ance 2 V, maximum current tolerance 5 A)

In single phase (6), the cable has three wires (phase, neutral, earth).

Three types of plug are compatible: EUR (Europe): 16 A (7) SUI (Switzerland): 16 A (8) UK (United Kingdom): 13 A (9) In three phase (10), the cable has four or five wires (phase L1, phase L2, phase L3, neutral* and earth). *: Not used and not connected

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Check the battery status

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The identification label is positioned on the lower right-hand side of the external charger.

1 2 3 4 5 6 7 8 9 10 11

Designation Protection index Voltage/Output current Serial number Input current Table summarising charging times for different battery types CE standard Weight Power supply frequency Manufacturer Charger model

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The lithium-ion battery must be recharged only with a special charger.

Do not use a charger other than the one provided by the Kion group.

The temperature of the room where the charger is installed must be between 5° and 45°C. The humidity level must be below 95%.

The following wall chargers are available: An external wall charger An external charger that stays on the ground This is heavier The vertical access and the side access lithiumion batteries can be recharged with both types of external chargers.

The charger must be installed in a room without any inflammable elements.

Avoid the charger overheating.

Do not obstruct the air vents. The air must be able to circulate correctly.

Do not install the charger near a heat source or in a place exposed to direct sunlight.

Do not install it in an area that is subject to excessive dust or shocks or mechanical vibrations.

The charger must be installed and maintained only by electrical engineers or qualified staff.

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H13 R1K

Charger socket presence LED (illuminated when the socket is connected, turned off when charging) Resistor (1K 2W)

S8 X100 7S13

Truck CAN cut-off switch Charger socket connector Supply cut-off switch

The lithium-ion battery can be charged using a side socket.

Advantages: Can be charged without moving the hood.

No other sockets need to be disconnected.

Detection: S8: The detection switch prevents the CAN from communicating between the battery and the truck.

7S13: The switch cuts the 24 V power supply for the battery.

H8: The blue LED only indicates that the side socket is connected. It does not indicate that the battery has been charged.

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1 2 3 4 5 6

Battery Terminal block Diagnostic connector Battery connector Truck Protective cover

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7 8 9 10 11 12

Detection switch 2 (CAN H) Charger socket Charger Detection switch 1 (+24 V supply) LED Side socket

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Auxiliary contact (1) Auxiliary contact (2) Pilot contact (3) Pilot contact (4)

Controller power supply Earth CAN high CAN low

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- The hydraulic control module is located in the same box (1A1) as the traction control module.

- Logical circuit supply: +24 V in 1X1:13 Negative in 1X1:42 - Lift authorisation from lift contact switch 1K2 following safety self-test: +24 V signal in 1X1:13 - The lift sensor/potentiometer and is only used for the main lift.

is redundant

- Fork lifting and lowering speeds are determined by the position of the cursor . This automatically returns to the neutral position when it is released.

- The lifting speed depends on the motor speed .

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- The lowering speed depends on the proportional solenoid valve .

- A progressive shutoff device for the carriage prevents the buffer from being hit at the lower stroke-end.

- A pressure sensor prevents the maximum pressure in the hydraulic system from being reached, protecting the truck from discrepancies in braking when unladen.

Operational safety: Main lift stops when forks reach sensor at 1.50 m from the ground

– Connect the PC to the nector.

diagnostic con-

– To check the operation of the main lift, go to the following menu:

F4:Screen Lift Mast lift control 0 1

Main lift lowering control not activated Main lift lowering control activated

Voltage at the terminals of the proportional solenoid valve in 1X1: 3 of the control module 1A1. +24 V closing solenoid valve 2Y3.

->1.5 V progressive opening of 2Y3.

Current at the terminals of the proportional solenoid valve in 1X1: 3 of the control module 1A1.

0 mA closing solenoid valve 2Y3.

->1500 mA progressive opening of 2Y3.

0 1

Initial lift hydraulic system selected Main lift hydraulic system selected

Voltage at the terminals of the needle solenoid valve in 1X1: 31 of the control module 1A1. +24 V: Initial lift circuit selected.

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0 V: Main lift circuit selected.

0 Tank return solenoid valve closed (main lift lowering not selected) 1 Tank return solenoid valve open (main lift lowering selected)

Voltage at the terminals of the load retaining solenoid valve in 1X1: 2 of the control module 1A1. +24 V: Tank return solenoid valve closed (main lift lowering not selected).

0 V: Tank return solenoid valve open (main lift lowering selected).

if fork height is >0.3 m from the ground: - Traction speed limited to 6 km/h 1 if fork height is 0.3 m from the ground: - Traction speed not limited 0

if fork height is >0.3 m from the ground: - Lowering speed of the forks proportional to the position of cursor 2B4 1 if fork height is 0.3 m from the ground: - Fork lowering speed slowed 0

0 If the fork height is >1.5 m from the ground: - Traction speed limited to 2 km/h 1 If the fork height is 1.5 m from the ground: - Traction speed limited to 6 km/h

The value of the lift potentiometer signal 2B4 as a (%) of the supply voltage (5 V): - 50% : Control flap in the neutral position - 15% to 2% or 85% to 98% : maximum lifting speed

Voltage at the "-"/"Li" terminals of the motor power module 2M1 24 V motor stopped

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0 V motor running

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1 2 3

Multifunction indicator Blue-Q button Left navigation button

4 5 6

Right navigation button Confirm/back button Connector 6X2

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

6X2:1

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Battery voltage +24 V

Switch key or access control: OFF = not connected 11648012111 EN - 01/2020

Switch key or access control: ON = battery positive 6X2:2 6X2:3

Earth 0 V CAN Low

6X2:4

CAN High

No terminating resistor between CAN High and CAN Low

6X2:5 6X2:6 6X2:7

Not used Not used Not used

Not used Not used Not used

6X2:8

CAN Low (option)

6X2:9 6X2:10

CAN High (option) Not used

Not used

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

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1 2 3 4 5 6 7 8

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

9 10 11 12 13 14

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

For the truck to operate, the operator must be detected on the seat and then on the pedal.

When the truck is switched on, the light indicating the (1) comes on and flashes.

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– Sit on the seat



The light indicating the (1) is replaced by the light indicating the (2), which flashes.

– Press the operator presence pedal with your left foot



The light indicating the (2) remains continuously illuminated for two seconds and then goes out.

The operating unit shows the battery charge level.

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

The number of bars shown indicates the battery charge level.

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

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

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

The light (1) comes on in the event of overheating of the traction motor or the controller.

A warning is shown on the display.

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

A warning is shown on the display.

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

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

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

– Select the desired drive mode using the navigation keys

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

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

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

– Select the

menu (1)

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

It is possible to access error messages that are disrupting the operation of the truck.

– Select the

menu (1)

The operator can access the error codes. If several codes are affecting the truck, the operator can scroll through several successive displays.

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

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In addition to the various menus and lights mentioned above, additional data is available: The menu (1) displays the truck menu The icon (2) indicates the operating time of the truck The icon (3) indicates the time and date

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1 2 3

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

Operation

Key in * 0 0 0 0 0 #

ON

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

OFF

# (3 seconds)

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

default)

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

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

Restoring the initial administrator code

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

Activating the automatic switch-off

* * 2 * 1 #

Setting the time delay of the automatic switch-off

* * 3 * 6 0 #

4 5

Key error Time delay of automatic switch-off

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

Notes 0 0 0 0 0

OU

1 2 3 4 5 default PIN

Truck power off

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

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

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

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

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

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

-100

* * 2 * 0 #

red off green flashing (2)(command accepted)

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The FleetManager fleet management system allows access control and transmission of truck data.

Access control and GPRS module Access control, shock sensor and GPRS module

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

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

Additional options: Shock sensor Tools for wireless data management: GPRS radio module (1) with GSM antenna (2)

The variants available on the truck are: Access control Access control and shock sensor

EXD: LTX: SXD and SXH: FXH N, FXD N, FXV N (1)GPRS: General Packet Radio Service (2)GSM: Global System for Mobile Communica-

tion

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1 2 2A 2B

Reading device with a keypad RFID reading device (1) RFID transponder card RFID transponder

3 4 5

TDU connector 6X16 Green diode Red diode

The TDU (Truck Data Unit) access control is available in two versions: A reading device with a keypad (1) OR A RFID reading device with truck access by: RFID transponder card, 13.56 MHz (2A) RFID transponder, 13.56 MHz (2B) Some of the data is transferred via Bluetooth.

Parameterising is done using the of the After-Sales Service.

(1) RFID: Radio Frequency Identification

The only way to find out the access control version is by connecting it.

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Battery voltage 0V Analogue 2 Relay 1 Relay 1 CAN 2 High CAN 2 Low CAN 1 High CAN 1 Low

6P4 6B1 S5

Multifunction indicator Shock sensor FleetManager unit

W1 W2

GSM antenna GPRS module

This sensor allows you to record the shocks received by the truck.

If the truck receives a shock, its speed can be reduced.

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

Replace the sensor if it is faulty.

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6X12: 1 6X12: 2 6X12: 3

+24 V Variable voltage (shock signal) 0V

There are two reference numbers for shock sensors.

One reference number when the sensor is fitted alone and another when it is fitted with the GPRS module.

The GPRS module is located under the dashboard.

It consists of a communication unit and a GSM antenna.

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

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A B LI 2M1

Lifting the load arms Lowering the load arms Initial lift (LI) cylinders Lifting motor + pump

Lifting the load arms Lowering the load arms

2Y2 2Y3 2Y11 2Y12

1 0

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Initial lift lowering solenoid valve Proportional solenoid valve Load retaining solenoid valve Needle solenoid valve (main lift/initial lift)

0 1

0 0

-1

C D 2M1

Lifting the mast Lowering the mast Lifting motor + pump

Fork lifting Fork lowering

-2

2Y3 2Y11 2Y12

1 0

Proportional solenoid valve Load retaining solenoid valve Needle solenoid valve (main lift/initial lift)

0 1

11648012111 EN - 01/2020

0 1

1 0

Engine

Pump Connections Adjusting the pressure cut-off (fully open) Pressure sensor 7B7

Power Service number S3 Intensity Voltage Nominal speed Displacement LP1 LP2 LI Pressure filter FP

2.2 kW 13% 180 A 24 V 3000 rpm 2 cm3/rev G 1/2 G 1/2 G 1/4 20 µm 230 bar

Signal

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4-20 mA

-3

The main lift (proportional control) and the initial lift are controlled from the (1A1) controller.

The (1A1) controller enables precise control of the hydraulic lifting functions by acting directly on: The pump-motor unit (2M1) The needle solenoid valve (2Y12) "main lift" or "initial lift" The proportional solenoid valve (2Y3) to control mast lowering The load retaining solenoid valve (2Y11), controlled simultaneously with (2Y3) when lowering the mast The initial lift lowering solenoid valve (2Y2)

position and overload safety device on the forks

Lifting or lowering of the load arms is controlled by: Two Hall effect sensors (2B16) and (2B17) Two lower (1B3) and upper (1B4) stroke-end sensors that manage the position of the load arms

Fork lifting or lowering is controlled by: A Hall effect sensor (2B4) Two height sensors (2B1) and (2B4) for fork positions at 0.30 cm and 1.50 m from the ground A pressure sensor (7B7) with the following functions: stroke-end for forks in the raised -4

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LI LP 2Y2 2Y3 2Y11

Initial lift Main lift Initial lift lowering solenoid valve (red 2X9 connector) Proportional solenoid valve (yellow 2X24 connector) Load retaining solenoid valve (green 2X23 connector)

2Y12 7B7 FP S 2M1

Circuit selection solenoid valve of the main lift/initial lift (blue 2X22 connector) Pressure sensor Pressure filter 20 µm Main lift emergency lowering control Lift motor (24 V - 2.2 kW) + pump (2 cm3/rev)

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-6

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The pump unit is equipped with a pressure sensor that manages the following functions: Overload safety on the forks The upper cut-off of the main lift

To adjust the main lift cut-out pressure, follow the instructions given in chapter

The traction speed limitation with the load raised is managed by the height sensor (at 1.5 m from the ground).

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1 2 3

Traction speed Traction speed Traction speed

2B1 2B6

For stability reasons, the truck is equipped with a fork height detector that limits traction speed: 1 intermediate fork position detector 1.5 m from the ground)

(at

Lower fork height detector (0.3 m) Intermediate fork height detector (1.5 m)

The truck is equipped with a fork height detector that limits the lowering speed of the mast: 1 lower fork position detector from the ground)

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(at 0.3 m

-1

For stability reasons, the truck is equipped with a fork height detector at 0.3 m from the ground that: Limits the fork traction speed in the raised position Prohibits the initial lift when the forks are over 0.3 m from the ground

Risk of loss of stability to the truck After changing a fork height magnetic detector 2B1, use the diagnostic tool to ensure that is when the forks are 0.3 m from the ground and when the forks are 0.3 m from the ground.

If the signals are reversed, pass a magnet in front of the detector to enable this mast safety function to operate correctly.

Pull switch 2B1 open 1X1:24 not connected to 0 V Speed reduction = 6 km/h Pull switch 2B1 closed 0 V in 1X1:24 No reduction in speed

-2

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For stability reasons, the truck is equipped with a fork height detector at 1.5 m from the ground that: Limits the fork traction speed in the raised position Prohibits the initial lift when the forks are over 1.5 m from the ground

Risk of loss of stability to the truck After changing a fork height magnetic detector 2B6, use the diagnostic tool to ensure that is when the forks are 1.5 m from the ground and when the forks are 1.5 m from the ground.

If the signals are reversed, pass a magnet in front of the detector to enable this mast safety function to operate correctly.

Pull switch 2B6 open 1X1:34 not connected to 0 V Speed reduction = 4 km/h Pull switch 2B6 closed 0 V in 1X1:34 No reduction in speed

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The "Dynamic Drive Control" option provides an optimised traction speed in relation to the load.

It is only available on double pallet stackers.

Speed management is carried out between the two sensors (between 0.3 m and 1.80 m).

Height at 1.80 m detector Inductive sensor to 0.3 m Pressure sensor 7B7 on the pump for the main lift

Three information levels are available on the display for the user: Low speed = 1 orange bar Medium speed = 2 orange bars High speed = 3 orange bars

-4

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STILL GmbH 11648012111 EN - 01/2020