STILL STED forklift FV-X(12-16) FV-X(12-16)i Workshop Manual - PDF DOWNLOAD

5TI

STILL ELECTRONIC DOCUMENTATION SYSTEM

CE: FV-X(12-16) FV-X(12-16)i

ldent no. 45578042305 - 09/2008 - EN

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V

a

This chapter gives information taken from the instruction and maintenance manual, considered as of interest for the assistance technician

Consult the truck instruction and maintenance manual for detailed information on the use of the truck

This forklift has the following characteristics: It is battery powered; The driver sits aboard the forklift.

The forklift is a stacker with supporting sidemembers and forks whose arms cover the sidemembers themselves. In addition to stacking, the version with initial spoke lifting may also be used for handling.

Given its construction, the forklift is used to lift, stack and arrange loads of well defined weight and volume on racks. The version with initial spoke lifting function, the forklift may also be used to handle loads of well defined weight and volume.

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A

The direction of travel for standard models is defined as follows: = Direction of travel away from the forks (forward) = Direction of travel fork side (reverse) " " is the preferred direction of travel

B

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45578042305 [EN]

OM1404

OM1403

1.2 Model Propelling unit: 1.3 electr., diesel, petrol, gas, mains electr.

FV-X12

FV-X16

Load distance from 1.8 load wheel axle with forks raised

FV-X16i

Electric

Driving: tiller, accompanied, 1.4 standing, sitting, order picker 1.5 Load capacity / Load Load centre-of1.6 gravity distance

FV-X12i

sitting with steering wheel Q (t)

1200

1600

c (mm) x (mm)

1200

1600

600 672(2)

45578042305 [EN]

647(2) (3)

-3

1.9

Distance between y (mm) axles with forks raised

1475

1458(3)

2.1

Dead weight (without battery)

kg

1260(4)

1249(4)

2.2

Load per axle when loaded (front/rear)

kg

2.3

Load per axle when empty (front / rear)

kg

1317 / 1612(4)

1336 / 1994(4)

1270 / 1649(3) (4)

1262 / 468(4)

Full set of tyres, superelastic, 3.1 pneumatic, polyurethane

1251 / 468(4)

Vulkollan

3.2 Front wheel size

mm

250x80 / 125x50

3.3 Back wheel size Wheels: front / rear 3.5 quantity (x=drive wheel)

mm

85x60 1x-2/4

3.6 Front track

b10(mm)

582

3.7 Rear track

b11(mm)

380

Height with lift mast retracted 4.3 Free lift 4.4 Lifting 4.2

Height with mast removed 4.6 Initial lift 4.7 Roof height 4.5

1280 / 2039 (3)

h1(mm)

2220(6)

2226(6) 150(6)

h2(mm)

3444(6)

h3(mm) h4(mm)

3975(4) (8)

3981(4) (8)

h5(mm)

/ 2220(6)

80 2226(6)

h6(mm)

4.9 Sitting height 4.15Lowered forks height

h7(mm)

4.19Total length Length including 4.20 shoulder of forks 4.21Total width

l1(mm)

85 2220(5)

91 2225(3) (5)

l2(mm)

1070(5)

1075(3) (5)

4.22Fork dimensions

h13(mm)

b1(mm)

886

s/e/l (mm

60 / 189 / 1150

b3(mm) 4.24Frontal width 4.25External gauge - forks b5(mm) m1 Free gap under load 4.31 (mm) stand Clear span at mid m2(mm) 4.32 wheelabase Working corridor with 4.33pallet 1000x1200 fork Ast3(mm) insertion 1200 Working corridor with 4.34pallet 800x1200 fork Ast3(mm) insertion 800 4.35Radiuses of curvature Wa(mm) -4

890

680 564 30

23.5

30

23.5

2644

2639(3)

2622

2626(3)

1760

1743(3)

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(4)

5.1

Travel speed (loaded/empty)

km/h

8 / 10

7 / 10

8 / 10

7 / 10

5.2

Lifting speed (loaded/empty)

m/s

0.16 / 0.23

0.14 / 0.23

0.16 / 0.23

0.14 / 0.23

5.3

Descent speed (loaded/empty)

m/s

Surmountable 5.7 gradient KB 30I (loaded/empty) (1)

%

Max. surmountable 5.8 gradient KB5I (loaded/empty) (1)

%

0.33 / 0.28

/

5.10Operating brake 6.1

Electric

Traction motor, performance KB 60I

Lifting motor, 6.2 performance 15% ED Battery according to 6.3 British Standard / DIN 43531/35/36 A, B, C Voltage / Nominal 6.4 capacity Battery weight (+/6.5 5%) 6.6

kW

3

kW

3 DIN A

V/Ah

24 / 440 (560-640)

kg

372 (502-502)

Energy consumption kWh/h according to VDI cycle

8.1 Type of drive control Noise level in driver s 8.4 ear

Electronic dB (A)

< 70

1) Pallet truck use 2) -10 mm with Triplex lifters 3) Values refer to forks up condition 4) With Simplex 3444 lifters 5) +10 mm with Triplex lifters 6) Refer to table for other lifters 7) For version with initial lift of +6 mm 8) With load holder grid +554mm Type

SPX

h3

h3+h13

h1(7)

h2

h2

h4(7)

3444

3529

2220

150

/

3975

3544

3629

2270

150

/

4075

3744

3829

2370

150

/

4275

4144

4229

2570

150

/

4675

4644

4729

2820

150

/

5175

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-5

DPX

TPX

3444

3529

2220

1689

1722

3975

3544

3629

2270

1739

1772

4075

3744

3829

2370

1839

1872

4275

4144

4229

2570

2039

2072

4675

4644

4729

2820

2289

2322

5175

4716

4801

2070

1539

1572

5247

5166

5251

2220

1689

1722

5697

5466

5551

2320

1789

1822

5997

Component length

Terminals

CompoComponent nent series initials and type

Voltage

Capacity ±5%

Dimensions

24

360

830x273x537 312

7021

4 PzS 360 L

LD

83

24

440

830x273x627 372

7021

4PzS 440 L

LF

83

24

560

835x277x784 502

7021

4PzS 560 L

LG

83

24

640

835x277x784 502

7021

-

LG

83

Weight ±5%

Colour

The forklift is normally transported by road and rail. If the forklift s dimensions exceed the max. clearance size allowed, it is transported disassembled. The sales network is in charge of the disassembly and reassembly operations. The forklift must be secured to the transport means during transport using appropriate restraint systems. Block the wheels with wedges to prevent even the slightest movement.

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screw type screw type screw type screw type

OM0747

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Use a lifting crane to load and unload the forklift, or use an inclined plane or a movable platform (with a slope and structural strength compatible with the specifications stated by the manufacturer, which must be suitably positioned and anchored).

1 2

1 2

To lift the forklift, hook slings (1) suitable for the weight of the forklift into points (2) on the body, then connect the other end of the slings to the hook of a crane.

The slings should have a suitable length so as not to rub against the casing or any additional equipment during lifting. Use a lifting beam if necessary. The slings must be pulled vertically.

OM1406

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-8

10

10

8

8

8

7

7

6

2.5

2.5

2.5

2.5

45578042305 [EN]

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

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

It may be accompanied by additional comments.

This symbol indicates important communications for the assistance technician.

It may be accompanied by additional comments.

This warning indicates serious risk of damaging the truck.

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

It may be accompanied by additional comments.

Do the following before performing maintenance operations:

Switch off the vehicle.

Press the emergency pushbutton.

Place the forklift on a flat surface and make sure that it cannot move accidentally.

Lower the forks fully.

Most accidents that occur in workshops are caused by failure to observe some simple and fundamental rules of prudence and safety.

paying attention to possible causes of accident and their consequences, scrupulously following the safety rules.

For this reason, accidents can be avoided in most cases by the necessary care and prudence,

A careful and wise mechanic is the best guarantee against accidents.

Only allow qualified, trained and authorised personnel to use the forklift.

The data plates found on the forklift must be kept in good condition and replaced if damaged.

Do not install equipment on the forklift unless supplied or indicated by the manufacturer.

Maintain the forklift in full working efficiency in order to keep any type of risk to the minimum.

Do not use the forklift with hoods and doors open.

45578042305 [EN]

Carefully read and follow all of the safety indications found on the forklift.

Make sure that the forklift has sufficient overhead clearance.

Do not park the forklift in front of fire-fighting devices or fire escapes or anywhere that it blocks traffic.

-9

If the forklift shows signs of failure or breakage and there is reason to consider it unsafe, stop, park it and notify the maintenance manager.

Pay attention to the distances from high voltage overhead cables. Comply with the safety distances established by the competent authorities.

Never raise the load using just one fork.

Do not drive with loads decentralised laterally with respect to the forklift s median axis.

Lack of compliance with this regulation can compromise forklift stability.

Make sure that the surface on which the load rests is able to support its weight.

Always use safety clothing that complies with the current regulations.

Place the load on the fork carriage or in such a way that the centre of gravity of the load is as close as possible to the fork carriage.

Do not travel on loose or hilly ground or on steps.

The load must be placed on the forks so that the centre of gravity falls on the mid point between the forks.

Do not overload the forklift beyond the capacity limits indicated on the capacity plates.

Do not turn or stack on slopes.

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

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

Do not allow to come into contact with the skin.

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

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

The operating materials may be flammable, so avoid contact with hot objects or open flames.

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

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

Do not inhale oil vapors.

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

The used oils (brake, motor, transmission, gearbox and hydraulic oil) and relative filters contain substances hazardous to the environment and must be disposed of according to current regulations. We advise you to contact the authorised service network.

Do not disperse oils or other operating liquids!

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

Always abide by the regulations of the antipollution laws!

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

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

-10

45578042305 [EN]

Do not inhale the vapor: it is poisonous.

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

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

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

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

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

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

45578042305 [EN]

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45578042305 [EN]

a

In order to keep the forklift safe and in good condition, have it serviced according to the scheduled maintenance operations indicated in the following "synoptic table of maintenance intervals".

When the forklift is used in dusty environments, at below zero temperatures and for especially heavy uses, it is necessary to reduce the interval between the various scheduled maintenance operations.

Fork wear check Clean the steering and lift electric motors Apply grease to linkages, struts and front sliding profiles Check insulation between chassis and any electric motors Check insulation between chassis and electronic controls Check the condition of the piping Check hydraulic system oil level Check reduction gear oil level Check the steering and lift motor manifolds Lubricate gears Lubricating the mast Clean and lubricate chains Adjust chains Check chain wear and conditions Check and adjust front bearings Check and lubricate the fork carriage and slide guides Replace the lifting motor brushes Change hydraulic system oil = Every 1000 hours or at least every 12 months = Every 1000 hours or at least every 3 months

During the maintenance operations, follow the instructions contained in the paragraph "Safety Regulations Relative to Operating Materials" in "Chapter 2".

45578042305 [EN]

-1

Quantity (lt)

Quantity (lt)

Tutela Matrix

Tutela Matrix

1.5

1.5

Idraulicar AP31

TUTELA GI/M

9 Structovis EHD Tutela MP 02

9 Structovis FHD TUTELA JOTA1

Drive wheel fastening nut

M14x1.5 8.8 /

M14x1.5 8.8 /

Reducer to chassis or drive unit plate fastening screw

M10x1.5 8.8 /

M10x1.5 8.8 /

Traction motor to flange fastening screw

M6x1.0 8.8 /

M6x1.0 8.8 /

Pinion to drive motor fastening nut

M14x1.5 8 /

M14x1.5 8 /

Brake to motor fastening screw

M6x1.0 8.8 /

M6x1.0 8.8 /

Pivoting wheel unit to chassis fastening screw

M12x1.75 8.8 /

Electrical steering pinion fastening screw-nut

M8x1.25 8.8 /

Electrical steering flange to reducer

M8x1.25 8.8 /

M8x1.25 8.8 /

Electrical steering unit to chassis of drive unit plate fastening screw

M8x1.25 8.8 /

M8x1.25 8.8 /

Drive unit plate to chassis fastening screw

M10x1.5 8.8 /

M10x1.5 8.8 /

Idle pin to load chassis fastening nut

M24x1.5 8 /

M24x1.5 8 /

Lower column fastening screw

M16x2.0 8.8 /

M16x2.0 8.8 /

Spare to tandem rocker arm fastening screw

M12x1.75 8.8 /

M12x1.75 8.8 /

Tandem rocker arm fastening nut

M12x1.75 8.8 /

M12x1.75 8.8 /

M20x1.5 /

M20x1.5 /

Front compensation lever pin fastening nut Roof to column fastening screw

M12x1.75 8.8 / +*

M8x1.25 8.8 /

M12x1.75 8.8 /

M12x1.75 8.8 /

Power lead fastening screw

M8x1.25 /

M8x1.25 /

System fuse nut

M8x1.25 /

M8x1.25 /

* with safety washer.

-2

45578042305 [EN]

+*

a

The diagnostic connectors can be accessed through the appropriate door by unscrewing the screw (1) using an M4 Allen key.

(A): Connector for the Zapi system diagnostics.

(B): Connector for the LES electrical drive diagnostics.

45578042305 [EN]

-1

PC CONSOLE software is used for programming parameters and diagnostics.

The functions and the features of the software are described in the specific paragraphs.

Connect the PC to the electronic control system using the internal cable.

The connection between PC and forklift must be performed with the forklift off.

Access the software through the relative icon.

Switch on the truck.

Press the START button to establish the connection.

Set port for correct communication using the CONFIGURATION - COM PORT function.

The diagnostic software may be used to access both the MASTER section and the SLAVE section of the electronic control system.

The MASTER section mainly contains drive parameters. The SLAVE section main contains pump parameters.

Use the FUNCTION - PARAMETER - SET MODEL menu to select the section you want to connect to and define the parameter as shown in the table.

CONNECTED TO

2

MASTER

5

SLAVE

The functions SPECIAL ADJUST, HARDWARE SETTINGS are not used for this model.

-2

45578042305 [EN]

Traction drive Pump

Connect the PC to the electronic control system using the internal cable.

The connection between PC and forklift must be performed with the forklift off.

Access the software through the relative icon.

The software opens with the following screen:

Switch on the forklift (closing the key contact).

Press the START button to establish the connection.

45578042305 [EN]

-3

The following will appear as soon as the software is connected to the control system: (1) control system software version (2) nominal voltage (3) nominal current (4) number of hours of work (5) outstanding alarms, if any.

The software has five menus: FILE CONFIGURATION CONNECTION FUNCTION HELP

-4

45578042305 [EN]

Some menus are available only after establishing a connection with the electronic controller.

The FILE menu allows to perform operations with the files: OPEN : to display the parameters contained in

a previously saved file.

TX FROM FILE : to load the parameters contained a previously saved file to the microcontroller memory.

SAVE : to save the parameters present in the microcontroller in a file.

PRINT : to print.

EXIT : to exit the program.

45578042305 [EN]

-5

The CONFIGURATION menu allows the following functions.

COM PORT to select the COM PORT. ENTER PASSWORD to enter a password. Use of

the password is reserved to the Central Technical Service Department. It is used to enable the last 2 submenus of the FUNCTION menu.

The CHANGE PASSWORD option for changing the password becomes active when the password is entered.

LANGUAGE to change the program language.

Shut down and open the program again to make the change effective.

The only way to restore the original password is to install the software again.

-6

45578042305 [EN]

The CONNECTION menu is use to start START ) and stop ( STOP ) the connection to the electronic module.

The FUNCTION menu is subdivided into 7 submenus: PARAMETER TESTER ALARM LOGBOOK PROGRAM VACC MOTOR DATA

45578042305 [EN]

-7

RAM FUNCTION EEPROM FUNCTION The PARAMETER and TESTER menus are described in detail in specific paragraphs.

The RAM FUNCTION and EEPROM FUNCTION menus are accessible only by password and are reserved to the Central Technical Service Department.

The MOTOR DATA menu is not available.

The ALARM LOGBOOK menu allows to access the list of alarms containing the alarm name, occurrence, temperature and hour in which they occurred.

The following operations can be performed: UPDATE : to update the alarm list.

CLEAR : to clear the alarm list.

CLOSE : to close the active window.

PRINT : to print the alarm list.

Press CLEAR to open a dialog. Confirmation is required before deleting.

-8

45578042305 [EN]

The PROGRAM VACC menu allows calibration of the potentiometers. The analog signal acquisition procedure is described in the chapter "Analog signals".

The HELP menu allows to access the online guide.

45578042305 [EN]

-9

The PARAMETER menu is subdivided into 6 submenus: PARAMETER CHANGE SET OPTIONS SET MODEL ADJUSTMENT SPECIAL ADJUST HARDWARE SETTINGS

This menus is used to display and edit a parameter list. When opened, the PARAMETER CHANGE window is empty.

Press RECEIVE to load all the parameters of the electronic module selected by means of the SET MODEL function. Press RECEIVE MENU to load only the parameters related to the current page.

On completion of receipt of the menu, all the available parameters will be listed in the window.

To edit a parameter, click on the value to be edited: this activates the right hand part (1)of the window where the new value can be set. The parameter can be edited by entering a number from 0 to 9 which corresponds to a step variation that differs according to the parameter.

-10

45578042305 [EN]

This menu is used to display and edit an additional list of parameters, mainly connected with the selection of optional setups.

When opened, the SET OPTIONS window may be empty.

The parameters are loaded and edited in the same as in the PARAMETER CHANGE menu.

45578042305 [EN]

-11

This menu is used to select/change the connected electronic module.

The window shows a single parameter: CONNECTED TO. The value of parameter (1) indicates the connected electronic module.

Click on the value of parameter (1) to select another module. This activates the right hand part (2) where another module can be selected using the selection menu (3).

There is no correspondence between the value of the parameter (1)and the selection menu item (3).

It is also possible to select non-existent nodes.

Be careful when making the selection.

After changing the module, click on STORE to make the change active.

-12

45578042305 [EN]

This menu allows to access additional parameters.

The other parameters are loaded and edited in the same as in the PARAMETER CHANGE menu.

This menu allows the modification of additional parameters.

The parameters are loaded and edited in the same as in the PARAMETER CHANGE menu.

This menu allows the modification of additional parameters.

The parameters are loaded and edited in the same as in the PARAMETER CHANGE menu.

45578042305 [EN]

-13

The TESTER menu allows to monitor the most useful variables for diagnostic purposes.

The variables are provided in a list (1) in which it is possible to select and deselect the quantities to be monitored.

The selected variables appear in the right part of the screen(2).

Only four quantities can be monitored simultaneously.

To select a variable to monitor, click on the name of the variable in the list (1); to deselect the variable, click again on the name of the variable in the list (1).

The button functions are described below: ADVANCED : to select the sampling time (minimum 1/10 second) and the number of required samples.

START REC. : to start recording samples.

STOP REC. : to stop recording samples.

-14

45578042305 [EN]

SAVE REC. : to save the recorded samples in a file so that they can be viewed and analyzed.

PRINT : to print the values of the variables.

CLOSE : to close the active window.

45578042305 [EN]

-15

This determines the top speed of the forklift.

This determines the acceleration ramp.

The parameter indicates the time required to reach top speed.

This determines the deceleration ramp from when the throttle is fully released.

The parameter indicates the time required to go from top speed to zero.

This determines the deceleration ramp when reversing direction.

This determines the deceleration ramp when the throttle is not fully released (still moving).

This determines the deceleration ramp when a speed reduction is activated, i.e. when switching from a higher speed to a lower one (except for speed reduction on curves).

This determines the deceleration ramp when speed reduction on curves is active.

This defines the acceleration in curves when speed reduction on curves is active.

Top speed with forks trailing (MOF).

Top speed with forks leading (MF).

This determines the top speed percentage applied when speed reduction with load (pin 11) is active (forward only).

This determines the top speed percentage applied when speed reduction with load (pin 11) is active (reverse only).

This determines the top speed applied when slow speed for h>1800 mm is selected (pin 38), active low.

This defines the reduction in speed when the motor reaches a certain temperature.

This is the maximum speed reduction on curves corresponding to maximum steering angle.

This is the minimum speed applied (forward and reverse) when the throttles are in minimum position.

This is the delay in electromagnetic brake activation when the electric braking has ended.

This is the maximum admissible battery voltage.

This defines a dead zone on the acceleration curve (throttles in neutral position).

This parameter, along with Throttle Y, changes the characteristics of the acceleration curve.

This parameter, along with Throttle X, changes the characteristics of the acceleration curve.

-16

45578042305 [EN]

This is set to ON after the service request to clear the check up needed warning has been performed.

This enables truck deceleration after a predetermined number of working hours.

Max. potentiometer voltage with drive wheel fully to the right.

Max. potentiometer voltage with drive wheel fully to the left.

Potentiometer voltage with drive wheel centred.

Angle at which the speed is at the minimum.

45578042305 [EN]

-17

Top speed for diagonal.

This is the pump motor acceleration ramp.

This is the pump motor deceleration ramp.

This is the top fork lifting speed. A percentage of the maximum voltage applied to the pump motor.

Straddle lifting speed.

This is the minimum voltage applied to the pump motor. A percentage of the maximum voltage applied to the pump motor.

This determines the maximum voltage applied to the EVP when the potentiometer is at minimum.

This determines the maximum voltage applied to the EVP when the potentiometer is at maximum.

This defines the EVP solenoid valve opening ramp.

This defines the EVP solenoid valve closing ramp.

This sets the buzzer output (reverse).

This defines the EVP solenoid current control type (analogue/digital).

This establishes a dead zone in the fork arm lifting curve.

This parameter, along with THROTTLE Y POINT, is used to change the lifting curve characteristics.

This parameter, along with THROTTLE X POINT, is used to change the lifting curve characteristics.

This establishes a dead zone in the fork arm lowering curve.

This parameter, along with THROTTLE Y POINT, is used to change the lowering curve characteristics.

This parameter, along with THROTTLE X POINT, is used to change the lowering curve characteristics.

-18

45578042305 [EN]

Battery voltage.

V

Voltage supplied to drive motor. Expressed as battery voltage percentage.

%

Booster contribution to voltage actually supplied to the motor expressed as a percentage of the battery voltage.

%

Frequency of the waveform generated by the inverter.

Motor speed measured by the encoder expressed in the same unit of measure as the frequency.

Hz Hz

Motor speed expressed in rpm.

rpm

Difference between value expressed by frequency and encoder (slip).

Hz

Motor current rms value.

Shows the residual battery charge expressed as a percentage of the max. charge level.

A.

Temperature of the electronic control system.

Temperature of the motor measured by an analog sensor placed inside the motor itself.

°C

Drive potentiometer voltage (pin 24).

V

Lift potentiometer voltage (pin 25).

V

%

°C

Logical level of the dead man s pedal input (pin 35), active high.

ON/ OFF

Logical level of the LES drive input (pin 7), active high.

ON/ OFF

Logical level of the forward input non-fork side (pin 18), active high.

ON/ OFF

Logical level of the forward input fork side (pin 33), active high.

ON/ OFF

Logical level of the brake pot (pin 20), active low.

ON/ OFF

Logical level of the load pressure switch input (pin 11), active low.

ON/ OFF

Logical level of the select model input (pin 34).

ON/ OFF

Logical level of the oil micro switch 1800mm (pin 38), active low.

Logical level of the lift input (pin 36), active high.

Logical level of the fork arm/wheel lowering input (pin 5), active high.

Logical level of the lifting block input (pin 37), active low.

Logical level of the wheels enable input (pin 6), active high.

Logical level of the wheel limit input (pin 19), active low.

Drive wheel potentiometer analog input (the indicated value is 1/3.3 of the real value).

45578042305 [EN]

ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF V

-19

Pump motor current controlled by slave.

A

Pump motor voltage controlled by slave.

V

Estimated value of the traction motor power.

W

Traction motor speed.

Hz

Estimated traction motor slip.

Hz

Not used Traction potentiometer voltage monitoring by slave.

Lift potentiometer voltage monitoring by slave.

V

LES traction interlock input logical level monitoring by slave.

ON/OFF

Logical level of the fork arm/straddle lowering input (pin 5), active high.

ON/OFF

Logical level of the load pressure switch input (pin 11), active low.

ON/OFF

Logical level of the op.-side forward travel input (pin 18), active high.

ON/OFF

V

Not used Not used Not used Not used Logical level of the dead man s pedal input (pin 35), active high.

Logical level of the straddle enable input (pin 6), active high.

Logical level of straddles on ground limit switch input (pin 21), active low.

PWM on proportional valve 2Y2.

ON/OFF ON/OFF %

Solenoid valve 2Y1 (forks).

ON/OFF

Solenoid valve 2Y3 (straddles up)

ON/OFF

Solenoid valve 2Y4 (straddles down).

ON/OFF

Reverse buzzer (opt).

ON/OFF

External hour counter.

ON/OFF

Fan.

ON/OFF

Not used.

-20

ON/OFF

45578042305 [EN]

(extract from table 45488089001 - 1/2 (rev.01 26/10/2007)

130

-

130

10

1,6

-

1,6

4,0

1,6

-

0,5

4,0

1,2

-

1,0

4,0

9,0

-

5,0

9,0

2,8

-

2,8

4,0

2,0

-

1,0

2,0

2,0

-

2,0

4,0

100%

-

10%

100%

80%

-

10%

60%

80%

70%

10%

80% or 70%

70%

60% -

10%

70% or 60%

10%

25%

30% 40,00%

-

30% 10,10%

50% 40,00%

1,40Hz

-

1,40

3

0,4

-

0,1

1

33

-

33

35

25%

5%

0%

30%

40%

40%

60%

30%

20%

60%

OFF

OFF

ON

LEVEL=0

0,0

3,0

1,5V

1,2V

1,8V

25°

15°

30°

2,7V 0,2V

24,5V 0% 0% 0,0Hz 0,0Hz

45578042305 [EN]

-21

0 rpm 0,0Hz 0A 100% 23°C 36°C 0,0V 1,5V OFF GND OFF GND OFF OFF OFF +VB OFF GND OFF +VB OFF +VB OFF OFF OFF +VB OFF OFF +VB 2,3V

(extract from table 45488089001 - 2/2 (rev.01 26/10/2007)

133Hz 0,3

5

133

0,30

1

0,1

0,10

1

100%

100%

0%

100%

100%

0%

8%

8%

10%

25,0

50,1

83,5

0 50,1

0,7

0,50

1

0,0

0,0

1

OFF

ON

OFF

ANALOG ON (*1) / OFF(*2)

ANALOG

DIGITAL

ON

OFF

(*1) ON: version with initial spoke lifting.

-22

100

45578042305 [EN]

(*2) OFF: version without initial spoke lifting.

0,0%

0,00%

60,0%

0,00%

100%

20%

0,00%

1000%

16% 75,2%

0,00%

100%

0,00%

100%

25,8%

0,00%

100%

100%

0A 0% 0,0Hz 0,0Hz 0°C 0,0V 1,5V OFF GND OFF GND ON GND OFF GND ON +VB ON +VB OFF GND ON +VB OFF GND OFF GND ON +VB 0% 0% OFF OFF OFF OFF OFF OFF

45578042305 [EN]

-23

- Load in parallel to capacitor battery.

- Open load resistor.

The input capacitor battery is not - Load circuit error in control charging. system.

- Power control system problem.

Motor output voltage is lower than expected.

Motor output voltage is higher than expected.

The software monitors phase voltage.

The alarm is generated if the voltage does not increase adequately.

The software monitors phase voltage.

The alarm is generated if the voltage does not decrease adequately.

Internal error.

Internal error.

Brake coil or general contactor short circuit.

External error.

The general contactor coil driver External error. has short circuited.

General contactors driver control Internal error. circuit fault.

The general contactor coil is powered but the contact did not close.

External error.

The general contactor contact is External error. jammed.

- Check for load (short circuit) between positive and negative.

- Replace the electronic control system if the problem persists.

Check: - Motor connections.

- Motor wiring.

- Insulation between motor and chassis.

- General contactor contact.

Replace the electronic control system if the problem persists.

Check: - Motor connections.

- Motor wiring.

- Insulation between motor and chassis.

Replace the electronic control system if the problem persists.

Replace electronic control system.

Replace electronic control system.

Check wiring and repair if necessary.

Replace the brake and/or the contactor if the problem persists.

Check wiring and repair if necessary.

Check the contactor and replace it if required.

Replace electronic control system.

Check wiring and repair if necessary.

Check the contactor and replace it if required.

Check the general contactor contact and replace it if required.

The electromagnetic brake coil driver has short circuited.

External error.

Check wiring and repair if necessary.

Replace the electromagnetic brake if the problem persists.

The electromagnetic brake coil driver is open circuit.

Internal error.

Replace electronic control system.

-24

45578042305 [EN]

The output supplying positive power to the electromagnetic Internal or external error. brake is high when the LES drive is on.

Voltage surges (>45V) or voltage Internal or external error. drops (<9V).

Internal error.

Internal error.

Internal error.

The battery voltage is too low.

Internal or external error.

Internal error.

The encoder frequency increases too rapidly.

External error.

Conflict between wheel enable input and LES drive enable.

Problem on pins 6 and 7.

Internal error.

Internal error.

Internal error.

Internal error.

Internal error.

Internal error.

Internal error.

45578042305 [EN]

Check wiring and repair if necessary.

Replace the electronic control system if the problem persists.

Check: - Wiring.

- Key connection.

- Battery state.

Replace the electronic control system if the problem persists.

Replace electronic control system.

Replace electronic control system.

Replace electronic control system.

Check charge state of battery Check that the battery is correct and replace it if required.

Replace the electronic control system if the problem persists.

Replace electronic control system.

Check electrical and mechanical functions of the encoder.

Check mechanical installation of the encoder.

Check for electromagnetic interference.

Replace the encoder if the problem persists.

Check voltage on pins 6 and 7.

Replace the electronic control system if the problem persists.

Replace electronic control system.

Replace electronic control system.

Replace electronic control system.

Replace electronic control system.

Replace electronic control system.

Replace electronic control system.

Replace electronic control system.

-25

Drive request has been activated Problem in wiring or to drive control micro switches. in both directions at the same time.

Incorrect start-up sequence.

The accelerator potentiometer voltage upon release is higher than 1V with respect to the minimum acquired value.

Request active during forklift start-up.

Check correct start-up sequence.

Check wiring and operation of micro switches.

Replace the electronic control system if the problem persists.

External error.

Check functionality of potentiometer.

Perform calibration.

The support base temperature is Internal error. higher than 85°C.

Battery charge problems.

EEPROM or EEPROM management error.

The drive potentiometer negative is out of range.

Internal or external error.

Internal error.

Check conditions of use of the forklift.

Replace the electronic control system if the problem persists.

Check charge state of battery Check that the battery is correct and replace it if required.

Replace the electronic control system if the problem persists.

Try to run the CLEAR EEPROM operation.

The parameter default settings will be restored if the alarm disappears.

Replace the electronic control system if the problem persists.

The number of working hours of the forklift have exceeded the threshold.

Set the parameter CHECK UP DONE to ON after servicing.

Internal error.

The alarm ends when internal data acquisition is done.

Broken or short circuited wires.

Check potentiometer connection.

The forklift has been on and the dead man s pedal has not been pressed for longer than 30sec.

-26

Check wiring and correct operation of the drive control micro switches (TESTER MENU).

Replace the electronic control system if the problem persists.

The alarm will clear as soon as the dead man s pedal is pressed.

Internal error.

Replace the electronic system.

Internal error.

Replace the electronic system.

45578042305 [EN]

The EVP solenoid valve driver has short-circuited.

Internal or external short circuit.

The pump motor output is too low Internal or external error. with respect to the applied PWM.

The pump motor output is too high with respect to the applied PWM.

- Check for short-circuiting between EVA coil negative and battery negative.

- Replace the electronic control system if the problem persists.

Check: - Internal motor connections (ohmic continuity).

- Motor wiring.

- Insulation between motor and chassis.

- General contactor contact.

Replace the electronic control system if the problem persists.

Internal or external error.

Check: - Motor connections.

- Insulation between motor and chassis.

Replace the electronic control system if the problem persists.

Internal error.

Replace electronic control system.

Voltage surges (>45V) or voltage External error. drops (<9V) have been detected.

Internal error.

Internal error.

Internal error.

Check charge state of battery Check the wiring.

Replace the electronic control system if the problem persists.

Replace electronic control system.

Replace electronic control system.

Replace electronic control system.

Internal error.

Replace electronic control system.

Internal error.

Replace electronic control system.

Internal error.

Replace electronic control system.

Internal error.

Internal error.

Internal error.

45578042305 [EN]

Replace electronic control system.

Replace electronic control system.

Replace electronic control system.

-27

Internal error.

Internal error.

Short circuit concerning the valve coils.

External error.

Check and replace the valves.

Replace the electronic control system if the problem persists.

Internal or external error.

- Check for short-circuiting between valve coil negative and battery negative.

- Replace the electronic control system if the problem persists.

Internal error.

Internal error.

The pump chopper current sensor feedback is too high (>0.8V).

Internal error.

No current is detected even while Internal or external error. the motor is running.

High pump motor temperature (>150°C).

External error.

Internal error.

Incorrect hydraulic function request sequence.

External error (wiring or contacts).

The lifting/lowering potentiomeExternal error. ter signal does not correspond to expectations.

Lift and lower request at the same time.

-28

Replace electronic control system.

Replace electronic control system.

Replace electronic control system.

Replace electronic control system.

Replace electronic control system.

Check motor connections.

Check current sensor.

Check motor temperature (TESTER MENU).

Replace the electronic control system if the problem persists.

Replace electronic control system.

Check correct function activation sequence.

Check the wiring.

Check the micro switches.

Replace the electronic control system if the problem persists.

Check the potentiometer.

Calibrate the potentiometer.

Internal error.

Replace electronic control system.

Internal error. SSS

Try to run the CLEAR EEPROM operation.

Replace the electronic control system if the problem persists.

Micro switch problem.

Check the wiring.

Check the micro switches.

Replace the electronic control system if the problem persists.

45578042305 [EN]

EEPROM errors.

The temperature detected by the sensor is >150°C.

The power section basic temperature is >75°C.

Internal error.

Try to run the CLEAR EEPROM operation.

The parameter default settings will be restored if the alarm disappears.

Replace the electronic control system if the problem persists.

Internal or external error.

Check correct operation of the temperature sensor.

Increase motor cooling.

Replace the electronic control system if the problem persists.

Internal or external error.

Internal error.

45578042305 [EN]

Check correct operation of the temperature sensor.

Check current consumption and mechanical transmission efficiency.

Replace the electronic control system if the problem persists.

Replace electronic control system.

-29

Connect the PC to the MASTER module (parameter CONNECTED TO = 2) In the FUNCTION menu, select PROGRAM VACC Press the dead man s pedal.

With the drive control throttle in the central position, left click once on ACQUIRE .

Slowly bring the throttle to the full setting for forwards travel.

The minimum and maximum voltage acquired values corresponding to the FORWARD parameter will appear on the video.

Left click once on SAVE .

Note: The acquired values will not be loaded to the memory until the SAVE button is pressed.

With the drive control throttle in the central position, left click once on ACQUIRE .

Slowly bring the throttle to the full setting for backwards travel.

Left click once on SAVE .

The minimum and maximum voltage acquired values corresponding to the BACKWARD parameter will appear on the video.

Left click once on CLOSE to exit.

-30

45578042305 [EN]

Connect to the SLAVE module with the PC (parameter CONNECTED TO = 5) In the FUNCTION menu, select PROGRAM VACC Press the dead man s pedal.

Left click once on ACQUIRE .

Slowly press the lifting button until the forks are fully raised.

The minimum and maximum voltage acquired values corresponding to the FORWARD parameter will appear on the video.

Left click once on SAVE .

Release the lifting button.

Note: The acquired values will not be loaded to the memory until the SAVE button is pressed.

Left click once on ACQUIRE .

Slowly press the lowering button until the forks are fully lowered.

The minimum and maximum voltage acquired values corresponding to the BACKWARD parameter will appear on the video.

Left click once on SAVE .

Left click once on CLOSE to exit.

45578042305 [EN]

-31

The diagnostics PC and LES control are connected through the sheathed cable interface code 300 365 25 01 The diagnostic software can be used to change parameters and display alarms.

The procedure to be carried out is the following: Connect the PC with the sheathed cable interface to the 4-pin Saab connector leading from the LES control (see the "Connectors for diagnostics" section).

Switch on power to the truck and close the contact key.

Click on the LES program icon.

On opening, the program shows the window (1) which displays general information.

1st line

Programming environment.

2nd line

Software version of 1st processor / software version of 2nd processor.

3rd line

System identification.

4th line

Truck type identification code.

The correct connection between PC and LES control is represented by the symbol in the lower part of the LES program window.

If the connection between PC and LES control is not made correctly, a failed connection symbol is shown in the lower part of the LES program window. .

To effectively use this programming environment, it is necessary to know the functionalities related to the various keys. The description is provided in the table.

ESC

-32

Terminatesthe function being used

45578042305 [EN]

F1

Help that describes how to use the software

F3

Loads the last parameter vector (only if the controller is active)

F9

Prints the parameters in the window (only if the printer is connected and the controller is active)

ALT X

Exits the program

F4

Exits the program

SHIFT F1 PgUp

Provides the program version Moves to the page above

PgDn

Moves to the page below

HOME

Moves to the beginning of the text

END

Moves to the end of the text

1 ... 9

Allows to select the desired window Stores the value of the parameters (only if the controller is active)

F2 Up arrow

Increases the value of the parameter

Down arrow Backspace

Decreases the value of the parameter

ENTER

Accepts the value of the parameter To select a function

For example, press the F1 key at any point in the program to access the help page of each window.

To scroll through the windows, press the PgUp and PdDn keys.

1:

Software version, truck control and identification

2:

Display of alarms occurring during the last time the truck was switched on

3+:

Display of alarms memorised in the microprocessor after the last maintenance action (if cancellation is allowed)

31+:

Display of all alarms that have occurred (Alarms history)

32+:

Display of values of important variables memorised at the moment of the breakdown

33+:

Time passed since last switch-on and time passed between last switch-on and appearance of last error

45578042305 [EN]

-33

34+:

Total cancellation of breakdowns from the memory (only PC MASTER)

4+:

Display of the status of logic inputs of the main microprocessor

41+:

Display of the status of logic inputs of the supervisor microprocessor (only PC MASTER)

5+:

Display of the status of the logic outputs of the main microprocessor

51+:

Display of the status of the logic outputs of the supervisor microprocessor (only PC MASTER)

6+:

Display of the status of the analog inputs: PWM, motor current, temperature, battery voltage

61+:

Display of the status of the analog inputs: potentiometer voltages and potentiometer power supply

62+:

Display of the status of the analog inputs: potentiometer voltages compared to a power supply of 10V

63+:

Display of the status of the analog inputs seen by the supervisor microprocessor (only PC MASTER)

7+:

Adjustable parameters: Y and PowerSave

71+:

Adjustable parameters: P, D, Ft

8+:

Steering potentiometer adjustments

81+:

Drive wheel potentiometer adjustment

82 +:

Reading of the potentiometer adjustments: gain and offset (only PC MASTER)

-34

45578042305 [EN]

The data in the table are for reference only.

45578042305 [EN]

-35

Vs1

Voltage reading on steering potentiometer No.1 (Pin 19)

32+/61+

Vs2

Voltage reading on steering potentiometer No.2 (Pin 20)

32+/61+

Vpo

Power supply of potentiometers (Pin 8)

32+/61+

Ub

Battery voltage

32+/6+

Va1

Voltage reading on drive wheel potentiometer No. 1 (Pin 22)

32+/61+

Va2

Voltage reading on drive wheel potentiometer No. 2 (Pin 10)

32+/61+

Tpo

Temperature of module at the power MOS-FET

32+/6+

On Time

Time passed since last switch-on

33+

Error Time

Time passed between last switch-on and last error detected

33+

DeadM

Dead man (0 polarised input, 1 non-polarised input)

4+/41+

SecRel AuxAB

Status of contacts inside the safety circuit relay (0 relay open, 1 relay 4+/41+ closed) Auxiliary inputs for coding the type of truck for the wiring (0 polarised 4+/41+ input, 1 non-polarised input)

StErr

Status of "drive deactivation" emergency output (0 drive abled, 1 drive disabled)

ForSt

Status of input of permanent steering activation (0 drive always activated, 1 the drive determines its activation automatically on the 4+/41+ basis of the presence of the operator, sudden piloting variations, truck speed, etc.)

Code

Input coding (Pin 4) to encode the type of truck by the wiring (0 polarised input, 1 non-polarised input)

4+/41+

SteerError

Steering error with drive blocked (0 activation, 1 deactivation)

5+

Motor Relay

Allows for piloting the power relay, and thus for stabilising the drive motor power supply (0 relay open, 1 relay closed)

5+

Enable PWM

Control of MOS-FET enabled by PWM signal (0 deactivated, 1 activated)

51+

MotRelay

Power relay activation enabled by emergency microprocessor (0 relay deactivated, 1 relay activated)

51+

4+/41+

X

Emergency relay activation enabled (0 relay deactivated, 1 relay activated) Motor current Motor temperature Cyclical ratio of PWM signal (%)

Vt

Truck speed (Km/h)

6+

Us1

Voltage of steering potentiometer No. 1 (relative value)

62+

Us2 Ua1

Voltage of steering potentiometer No. 2 (relative value) Voltage of drive wheel potentiometer No. 1 (relative value)

62+ 62+

Ua2

Voltage of drive wheel potentiometer No. 2 (relative value)

62+

Uak

Correct value of drive wheel potentiometer No. 1 according to initial adjustment

62+

Ust

Voltage of steering potentiometer No. 1 in respect of value foreseen for drive wheel potentiometer

62+

Dif

Voltage differential between Ust and Uak

62+

SecRelay Imo Tmo

-36

45578042305 [EN]

51+ 6+ 6+ 6+

Uset1

Conversion value of voltage of steering potentiometer No. 1 (from 0 to 255)

PWML

Conversion value of left PWM signal (from 0 to 255)

Uact1 PWMR

63+

63+ Conversion value of voltage of drive wheel potentiometer No. 1 (from 63+ 0 to 255) Conversion value of right PWM signal (from 0 to 255)

63+

Breakdowns are always managed and displayed by means of a numeric code in the corresponding windows

Breakdowns codes and control state at the moment of the truck block

2

Breakdown codes and relative frequency memorised after the last RESET

3+

Breakdown sequence memorised in the LES card memory

31+

Cancellation of all errors memorised in window 31 (only with PC MASTER)

34+

The following list shows how alarms are displayed.

The window (2) shows the errors that have appeared since last switch-on with the key and allows for immediate diagnosis as soon as a breakdown occurs

The window (3) shows the breakdowns memorised in the microprocessor since the last maintenance The windows (2) and (3) are interpreted as follows: Error No. 28 appears once (2) and 3 times (3); Error No. 33 appears once;

45578042305 [EN]

-37

1

truck code

02

truck type identification code, displayed in the window (1) when the LES is connected to the diagnostics PC

71+

P

2.20

parameter that adjusts the response speed and intensity of the steering motor to the steering control; the value shown represents the standard value

71+

D.

0.15

parameter that adjusts the response speed and intensity of the steering motor to the steering control; the value shown represents the standard value

20-23

Problems in truck identification by Pincodes

24

Incorrect truck coding: for electrical drive, truck is identified by wiring (combination of inputs 21, 18 and 4).

Check the code given in window 4 (AuxAB and Code) Check the corresponding wiring

The emergency relay K1 does not open on initialisation: On ignition, relay K1 must be open.

If this code appears, the contact may be stuck or short circuited. Check that there is no short circuit between Pins 2 and 14 on the module side and on the wiring side (switch off the truck)

Emergency relay open during functioning: the safety relay is closed by the LES during normal functioning and opened in the case of breakdown.

Open the LES module and check: If the internal k1 relay has a mechanical or electrical defect, the module must be replaced Before replacement check: If the relay is mechanically intact, that the RC circuit is not oxidised if the relay contacts are not burnt out, that the truck is correctly wired

27

28

29

30

31

32

-38

The 3K1 external power relay contact is not Check the 3K1 relay. If the contacts are at rest before activation of the command. stuck together, the probable clause is a short : when the key contact is closed, the circuit in the motor; in this case check: LES circuit examines the protection devices the power cable, which may be damaged before supplying the power relay. the FU4 fuse the mos-fet (LES card) Breakdown in the external 3K1 power relay Breakdown inside the LES module piloting.

The external 3K1 power relay contact has Possible causes: been unable to close. there is no power supply to the relay the mechanical contact is broken the contact is oxidised The right and left motor connections are This error may appear only at the end of inverted the assembly line or in the case of a SAV intervention that requires disconnection of the motor wires This breakdown code may appear also in association with another defect. In this case, other errors appear in the window (3)

45578042305 [EN]

33

34

Power status of the motor: Short circuited or Possibilities: Blown fuse motor disconnected.

HS motor (breakdown?)

Low quality connections on the whole power line Motor brushes damaged Voltage supply to potentiometers outside limits.

The voltage of the potentiometer is beyond the action allowed by the processor to guarantee good functioning of the steering.

Open the window (61) to check the voltage reading (between 9 and 9.5V) Then open the window (32) which shows the voltage at the moment of the breakdown.

The defect also appears when: The battery is very low The potentiometer power supplier is short circuited Defect in the internal adjustment device

Anomalous value of the steering potentiometer: Cut out or short circuit of one or more connections.

Possible causes: Interrupted wire (cut or broken) Poor connection Oxidised connector Potentiometer badly fitted mechanically, involving stress at the edge of the tracks Potentiometer damaged Mechanical limits of the stroke-end have been exceeded The same possible causes of error 35

35

36

Anomalous value of the drive wheel potentiometer.

Interruption or short circuit of one or more connections.

Overheating of the stage at MOS-FET.

37

38

39

40

41

42

This overheating occurs in the module that contains all the MOS-FET power components, free wheel diode, and the voltage regulator

24V short circuit at the output of the wheel position indicator.

The steering potentiometer signals are incompatible in the sense that under normal conditions the sum of the two signals must be equal to the 10V power supply (Vpo).

Possible causes: Potentiometer breakdown Low quality wiring contact Disconnected cursor

The drive wheel potentiometer signals are incompatible in the sense that under normal conditions the sum of the two signals must be equal to the 10V power supply (Vpo).

Possible causes: Potentiometer breakdown Low quality wiring contact Disconnected cursor

Output 11, which enables functioning of the LDC module, is already at the battery negative when the control is supplied with power: when functioning normally before the end of initialisation, output 11 is not at negative

Causes of the error: External LES connections short circuited Problem inside the cars To identify the cause of the error, detach Pin 11 and initialise the truck again. If the problem persists, the cause is inside the module.

As for code 41

Output 11, which enables functioning of the LCD module, is inactive during normal functioning of the truck.

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-39

43

44

45

46 50 70 71 72 73

74 80 81 82

83

84 90+

-40

The drive wheel potentiometer is outside the tolerance limits.

On starting, this potentiometer is not in the normal position (probable cause: forcing of the wheel outside the steering range when the truck is off).

The LES does not put the truck in emergency conditions, but attempts to restore drive wheel potentiometer voltage to its normal working interval.

If the operation is carried out correctly, error 43 is memorised and truck functioning is enabled.

The 3K1 power relay control output (Pin 3) is short circuited at the battery positive.

The motor terminals are short circuited with the battery voltage: the motor power relay contacts have probably fused together.

Low voltage: of battery (<13V) of potentiometer supplier (<7.9V) Broken or short circuited wire between Pins 16 and 24 (reduced speed signal).

Subsequent to variations in the ratios between the steering gears and the mechanics inside the potentiometer, the steering range may be altered.

Therefore, if error 43 is present in the LES memory (window 3) the drive wheel potentiometer must be adjusted. : if the LES cannot restore voltage to the drive wheel potentiometer in its normal interval, truck functioning is not enabled.

This error occurs if the processor reads a voltage of 24V on foot 3 during functioning..

Failure to "RESET" the emergency microprocessor.

Low quality transmission of data series for initialisation of the emergency processor.

Different results on initialisation of the two processors.

Low quality transmission of data between the main processor and the emergency processor.

Low quality transmission of data between the main processor and the emergency processor.

The left PWM signal does not correspond to the difference between order and reading.

The right PWM signal does not correspond to the difference between order and reading.

Transmission error during testing or after transmission of a new order/reading curve.

Lack of synchrony between the main processor and the control.

Cause: main processor synchrony signal absent on start up.

The first transfer of the correspondence curve by the main processor has not been carried out within the established time interval.

Typical microprocessor errors.

Error generated only by the control processor Error generated only by the control processor Error generated only by the control processor Error generated only by the control processor

Error generated only by the control processor

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a

Preparations: open the motor compartment; remove the entire electronic panel.

Disassembly: Unscrew the drive motor fastening screws.

Screw a suitable eyebolt onto the drive motor.

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-1

Attach the motor to a hoist or similar lifting system and lift it vertically until the drive motor is taken completely off the reducer gearbox group.

Protect the pinion appropriately and put down the motor.

During this phase, it is essential to avoid blows to the teeth of the pinion.

For reassembly, proceed in the reverse order, adopting the tactics described below to facilitate the various operations.

Replace the motor in its seat.

Do not strike the teeth of the pinion "A" and do not damage the OR on the bushing of the drive shaft.

Observe the orientation as well, ensuring that the terminal board "B" is located at the side guard "C".

-2

45578042305 [EN]

Use a ¼ inch drive 5 mm hexagon bit "D" a slender ¼ inch drive extension "E" with a length of at least 300 mm. Insert all the fastening screws and tighten them to the correct tightening torque as shown in the paragraph "Safety screws tightening torque table".

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-4

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a

Preparations: open the motor compartment; remove the entire electronic panel; Remove the traction motor.

Remove the side door by slipping it off upwards.

In order to avoid blows and relative damage, the position potentiometer group must be removed (see relative instructions).

Using a jack, raise the truck from the drive group side by about 4÷5 cm above the ground; block it with a wooden block " " under the body. At the same time, place slats " " under the drive wheel so as to create a thickness close to the thickness of the wheel itself.

Unscrew and remove the screws fastening the plate to the body; at this point the drive wheel should be rested on the slats underneath " ".

Drag the plate with the reducer gearbox group in the direction opposite the fork arms, rest the entire group on the fascia of the body and block the drive wheel from behind with the wooden chock " ".

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Remove the 8 screws which fix the plate to the reducer gearbox.

Hold the plate and separate it from the reducer gearbox group by pulling it upwards.

Replace the plate, being careful to suitably protect the pinion of the steering motor reducer gearbox in order to avoid blows that may damage it.

At this point we have freed the reducer gearbox group, then to extract it we will use no.2 M10 eye bolts.

-2

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The eye bolts should be screwed onto the two holes diametrically opposed on the fifth wheel of the reducer gearbox and with the aid of a sling and lifting equipment (hoist) with suitable capacity, we will hook it, lift it and separate it from the machine.

For reassembly, proceed in the reverse order, adopting the tactics described below to facilitate the various operations.

Add a slat "A" with a thickness of about 1 cm in the resting point of the drive wheel so that, once the wheel is rested, it remains raised by 2 cm.

Position the reducer gearbox complete with wheel inside its compartment, resting it on the fascia of the body.

Do not strike the ring gear of the reducer gearbox.

Block the movement of the wheel with a wheel chock "B".

The wheel must be positioned straight, the body of the reducer gearbox must be positioned towards the platform and the holes on the fifth wheel must be positioned approximately as shown in the figure (pair of fastening holes of the motor parallel to the body).

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Position the plate, complete with motor reducer gearbox and electrical drive, on the reducer gearbox assembly being careful to match up the fastening holes of the plate on the reducer gearbox and being careful that the pinion of the motor reducer gearbox engages in the ring gear of the reducer gearbox without receiving mechanical blows.

If the fastening holes are not perfectly aligned, centre the plate as follows:

Hold the plate stationary using the electronic system support bar "C".

Manipulate the pinion "D" of the motor reducer gearbox on the ring gear of the reducer gearbox: in this manner the reducer gearbox itself moves in a fine manner until the fastening holes of the plate / reducer gearbox coincide.

Fasten the anchor plate to the reducer with the 8 M10 screws and tighten to the correct torque, as shown in paragraph "Safety screw tightening torque table".

Remove the wooden block that blocks the wheel.

-4

45578042305 [EN]

Push the entire assembly towards its housing, or rather towards the battery, and fit the fastening screws of the anchorage plate onto the body, tightening them by hand as far as possible.

Using a jack, raise the body from the drive group side until the anchorage plate rests against the body.

Tighten all screws to the correct tightening torque, as shown in paragraph "Safety screw tightening torque table".

Remove the wooden slats under the drive wheel, and rest the machine on the side chock "D".

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Check the oil level in the reducer gearbox and top up if necessary: the level is correct when the oil just touches the bottom part of the top ring gear

-6

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

Ring with incorporated bearing Helicoidal pinion

To guarantee an always perfect operation of the reducer, the maintenance must be performed by qualified technical personnel.

The guide bearing is supplied full of grease.

The reducer is supplied without drive motor.

During the assembly of the motor, it is necessary to check that the contact surfaces of the motor and guide ring have not be scratched or damaged.

It is also very important, in order to prevent the gears from damaging one another, that the pinion axis is parallel to the axis of the gear with which the pinion couples.

If the profiles of the teeth have been damaged, excessive noise will be produced during operation of the reducer, normally in a single operation direction.

The technical service interventions on the reducer include the following points:

For normal use, the guide bearing does not require any maintenance.

If a fixing column of the wheel is replaced, it is important to clean the thread of the wheel shaft flange after having unscrewed the worn column.

Before mounting a new column, make sure that the thread of the column and the threaded cavity are clean and free of any oil or grease residues.

To replace the wheel shaft gasket, disassemble the lower cover of the reducer, where the oil cap is also located. This allows access to the central screw of the wheel shaft so that it can be unscrewed.

Once the wheel shaft is disassembled, replace the old gasket of the shaft with a new one.

The helicoidal pinion is installed directly on the drive shaft.

Before inserting the gasket on the shaft in the correct position, it is important to clean and immediately protect the contact surface of the shaft gasket housing.

During assembly of the helicoidal pinion it is important to avoid striking the pinion with a hammer or other object.

Before remounting the wheel shaft in the reducer, spread some grease on the internal part of the shaft gasket to facilitate assembly.

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Before being able to extract the bevel pinion from its housing, it is necessary to unscrew the safety nut located on the threaded end of the bevel pinion shaft.

To complete the assembly of the wheel shaft, screw on the central screw until it is completely tight.

The nut is blocked by a caulking that must be removed in order to unscrew it.

If the reducer is reassembled after the replacement of any component, it is very important that the position of the taper roller bearings is set correctly and that the form of the contact impressions on the profile of the bevel gears is correct. This can only be obtained with a perfect shimming of the taper roller bearings.

Before fixing the screw, check that the entire threaded cavity and the screw are clean and free of any oil/grease residue.

Then protect the thread. It is also important to use, as for any screw, the proper tightening torque.

For the replacement of gears and/or bearings, remove the wheel shaft (as indicated in the previous point) and the bevel pinion if necessary.

It is very important that the form of the contact impressions on the teeth of the bevel gear system is correct!!

In order to perform this check, oil paint must be applied on the teeth of the bevel gears. Then,

-8

For a better understanding of the correct form for the contact impressions on the gear teeth of a bevel gear transmission system, see the drawings shown below.

putting the reducer into motion, after a few revolutions dots of colour will appear along the profiles, shiny areas that represent the contact zones of the gear teeth.

To adjust the bevel gear system, the following rule holds:

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Internal side Crest of the tooth Shiny impression positioned on the internal side and towards the crest of the pinion tooth.

Shiny impression positioned on the internal side and towards the crest of the crown tooth.

Based on the real impressions and their comparison with the theoretical ones, some corrections can be made by inserting shimming rings under the bevel pinion so as to re-establish the correct crown wheel and pinion clearance.

Excessive distance 45578042305 [EN]

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Impression towards the external side on the lower part of the pinion tooth.

When the contact impressions of the teeth appear as shown in the figure, the pinion must be advanced towards the crown by adding shims behind the pinion itself.

Impression towards the internal side on the lower part of the pinion tooth.

Impression towards the internal side on the lower part of the crown tooth.

Impression towards the external side on the lower part of the crown tooth.

Insufficient clearance Impression towards the external side, towards the crest of the pinion tooth Impression towards the internal side, towards the crest of the pinion tooth Impression towards the internal side, towards the lower part of the crown tooth.

Impression towards the external side, towards the lower part of the crown tooth.

Pour the oil into the upper part of the reducer. The correct oil level corresponds to the lower edge of the upper crown wheel (large gear ).

Perform the first oil change after the first 250 hours of operation and the subsequent oil changes every 2000 hours of operation or, alternatively, at least once a year.

To extract the oil from the reducer, unscrew the lower oil cap located on the lower cover of the reducer.

Before reusing this cap, make sure that the magnetised part is clean and free of any contamination.

When the contact impressions of the teeth appear as shown in the figure, the pinion must be moved back by removing shims.

SAE 80 W 90 oil is recommended for the oil change.

The reducer is supplied without oil. Thus make sure to have filled with oil before using the reducer for the first time.

-10

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1.

2.

3.

23 Nm 170 Nm 300 Nm

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-11

-12

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a

In order to use the truck, the covers for access to the inner parts must be closed and secured properly.

To access the upper part of the battery, disconnect the battery plug (1) from the socket, push the battery cover release lever (2) in the direction (A) and raise the battery cover (3) using the handle (4); block the cover using the lever (5) and check that the lever (5) is fixed correctly inside the appropriate seat (6)marks.

A 2 4

3 1 5 3

6 5

OM1334

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-1

To access the auxiliary fuses, unscrew the screw (8) and open the door (9)marks.

To access the side of the battery, remove the side covers (6)by pushing the two bushings positioned inside the slots (7) inwards, tilting the cover outwards and raising it.

8

9

7

3 1

6

-2

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2

OM1335

To access the motor compartment, fold the seat back down over the seat using the lever (10), unscrew the screw (11)and completely raise the seat using the handle (12)marks.

10

11

12 OM1336

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Unscrew the two screws (13) and open the motor compartment cover (14) by rotating it around its own fastening axis.

13

14 OM1337

-4

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a

Fold the seat back over the seat using the appropriate lever.

Operate the horizontal adjustment lever and drag the seat towards the control panel until it is completely extracted from the slide guides.

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Raise the seat support using the handle.

Remove the seat support by releasing it from the two hinge points.

For reassembly, proceed in the reverse order.

-2

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Remove the seat and open the motor compartment.

Remove the " " connector (dead man s micro switch connector) from the electrical panel and remove the dead man s switch micro switch sheath.

Remove the two platform fastening screws.

Use the two holes, extract the platform from its housing by pulling it upwards and remove the carriage from the platform.

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For reassembly, proceed in the reverse order.

Operate the button, depress the mobile structure to its lower stop, closing the gas spring pack and supporting the mobile part.

Holding the gas spring compressed with a size 15 wrench, loosen or remove the upper fastening nut.

With a size 5 Allen key with extension, remove the lower fastening nut from the gas spring rod and release the lower part of the gas spring itself.

-4

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Remove the mobile part of the structure upwards and place a wooden wedge between the mobile part and the body to support the mobile part.

Remove the gas spring from its seat.

To remove the gas spring, remove the control latch from the operating button with two size 19 wrenches.

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The gas spring may be disassembled into two parts: the body and the sheath with pneumatic actuator.

Operate with two size 17 wrenches on the nut and lock nut on the actuator fastened onto the gas spring for disassembly.

Holding the latch on the end of the spring rod pressed, compress the gas spring to make the rod recede by approximately half its stroke.

Release the latch so as to keep the rod at mid stroke.

(A)Gas spring removal latch.

Fit the lock nut on the rod.

Fasten the actuator to the rod gradually and stop as soon as the rod start moving out. Go back by approximately half a turn and then fasten the actuator in this position with respect to the rod using the lock nut.

Refit the spring in the platform holder structure and fasten it with the corresponding screw and nut.

Position the sheath in its housing and insert the other end of the actuator in the button and in the specific support.

-6

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Fasten the actuator in the support with the nut and lock nut so as to leave a small clearance between the control rod and the button in its home position.

Test operation of the platform holder structure.

The mobile part of the platform must be in the fully raised position in order to access the four fastening screws of the structure. Therefore, if removal is performed with the gas spring fitted, the mobile part will be kept up by the gas spring. If instead the gas spring has previously been removed, keep the mobile part of the platform structure raised on wooden wedges.

Access the screws directly with a size 5 Allen key and corresponding extension.

A spacer for supporting the fixed structure during removal and refitting of the structure may be useful.

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Remove the platform holder structure from the truck.

If the bearings need replacing, rest the platform holder structure on the work bench and replace the components (all parts are accessible and clearly visible).

For easy refitting, first work at the bench to install the gas spring which holds the structure fully open.

-8

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a

The LES (Linde Electrical Steering) applied to the steering wheel is used.

The steering wheel is stiffened using a clutch system.

The maximum rotation of the steering wheel is equal to 4.25 turns, while that of the drive wheel is +80° clockwise and -100° anticlockwise.

The steering motor is of the serial type with two split field coils. Specifications: Power supply voltage 24V DC Power 0.15 kW The steering system is started by pressing the dead man s switch (DM) pedal.

When changing from condition the system requires switch to STAND-BY mode.

Released

STAND-BY (Steering motor not powered)

Pressed

ON (Steering motor constantly delivering traction)

to condition , to

The software is invoked by means of an appropriate connection to the TRUCK CODE input pins, as shown in the following table:

Connected to -B

Not connected

Connected to -B

(side motor)

This electronic module supplies power to and receives electrical signals from the potentiometers, controls the steering motor and manages system safety. In the event of a breakdown, the truck is automatically blocked by the electronic braking.

Braking is guaranteed by the simultaneous presence of two separate control signals: An electronic command opens the LES internal relay contacts and disconnects the power supply to the electromagnetic brake.

The LES unit disconnects the power supply to relay 7K1, deactivating the dead man s switch and consequently activating the brakes.

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-1

An ENABLE TRACTION output monitoring function when the dead man s switch pedal is released has been introduced.

The electric steering system is enabled by activating the following signals: KEY-ON: the electric steering system is activated for 35 s. also with dead man s pedal released; KEY-ON + DM (key + dead man s pedal): the electric steering stays on for approximately 35 s. after the dead man s pedal has been released; KEY-ON + FORCE STEERING (key + general contactor K2): when the general contact is activated, the electric steering is activated regardless of the dead man s pedal, because the FORCE STEERING input is connected to the general contactor coil; the electric steering system stays on for approximately 35 s. after the dead man s pedal has been released.

The calibration procedure of the electrical steering system consists of the following steps: centre the steering and drive wheel potentiometers: this step is required after potentiometer replacement and during potentiometer assembly; PC required check steering potentiometer using PC: this step is required whenever the steering potentiometer or electrical steering system is replaced check drive wheel potentiometer using PC: this step is required whenever the drive wheel potentiometer or electrical steering control system is replaced.

The steering and drive wheel potentiometer are based on the same principle.

They are opposite sense signal (redundant) potentiometers: when one is at maximum the other is at minimum.

Each potentiometer has two tracks, completely separate from each other, which manage two separate voltages.

-2

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The steering potentiometer, directly operated by the steering wheel through a resilient joint, generates signals proportional to the set rotation angle. In the diagnostic software, the value of the two cursors are indicated as Vs1 and Vs2. The value must be Vs1=Vs2 with steering wheel and potentiometer in central position.

The drive wheel position potentiometer is coupled to the main crown of the drive unit through an planetary gear reducer and generates signals proportional to the position of the drive wheel. In the diagnostic software, the value of the two cursors are indicated as Va1 and Va2.

With the wheel in central position, the value must be Va2=Va1+0.6V. Therefore, the steering is centred when the wheel is in straight position and Va2=Va1+0.6V with the steering wheel in central position and Vs1 = Vs2.

The calibration procedure is described in the following paragraphs.

This procedure is required after replacing one of the potentiometers and is used to identity the electrical middle point of the potentiometer itself thus allowing correct assembly with the steering wheel in central position (steering potentiometer) and the wheel in central position (drive wheel potentiometer).

For this purpose, menu 61 in the LES program (see chapter 02) is used to check the two potentiometer signal voltages.

Arrange the steering wheel in central position.

The steering wheel is fully steered in 4.25 turns.

By default, the steering wheel is centred with rotation of approximately 2 turns and with knob 45578042305 [EN]

-3

at approximately 9 o clock. The position may be changed using PC. Arrange the wheel in straight position, i.e. parallel to the fork arms.

This operation is easier if the truck is lifted on a jack.

Remove the power fuse 3F1

Removing the fuse will prevent uncontrolled movements of the reducer/wheel during calibration.

Connect the PC to the diagnostic interface (see chapter 02).

Switch on the truck.

Start the LES program (see chapter 02).

Key in 6 1 to access calibration menu 61.

Menu 61 displays the following voltages: supply voltage of the potentiometers. = voltage of the two signals from the steering potentiometer = voltage of the two signals from the drive wheel potentiometer Check that voltage Vpo is approximately 9.2 v.

If this is not so, the electrical steering system may need to be replaced.

Check that the voltage values of the steering potentiometer Vs1 and Vs2 are reciprocally equal: .

The voltage difference between Vs1 and Vs2 can be up to 1 V. Proceed as follows if the two values are not the same and the voltage difference is higher than 1 V: remove the potentiometer fastening screws and release them from the steering wheel unit adjust the shaft of the potentiometer itself to obtain the required voltages only when you see Vs1 = Vs2 = Vpo/2, fit the potentiometer back it its seat without moving it and fasten its position.

Check the voltage values related to the drive wheel potentiometer: Va1 and Va2 must be: .

-4

45578042305 [EN]

On some PCs, you may need to press white space to view the values.

To obtain the required voltages Va1 and Va2, loosen the two screws (A) and turn the potentiometer unit, exploiting the possibility of rotation offered by the two slots on the potentiometer fastening flange.

If you cannot obtain the required values, turn the shaft of the potentiometer itself, then fully loosen the two screws (A), extract the potentiometer unit. Leaving leave it electrically connected, turn the pinion until the required voltages are obtained.

Fit the potentiometer back in its seat without moving it and fine-tune it using the fastening slots.

At this point, you may secure the two fastening screws(A).

Run a further test using the diagnostic software.

Turn off the truck.

Insert fuse 3F1.

Switch on the truck.

Arrange the PC on-board the truck and start the LES software.

Check of the steering potentiometer calibration.

Check of the drive wheel potentiometer calibration.

The procedure described below assumes that the steering and drive wheel potentiometers have been assembled and set correctly.

Arrange the steering wheel in central position.

The steering wheel is fully steered in 4.25 turns.

By default, the steering wheel is centred with rotation of approximately 2 turns and with knob at approximately 9 o clock. During this operation, the position of the centred steering wheel may be slightly changed by positioning the knob between 6 o clock and 9 o clock approximately according to the user s preferences.

Arrange the wheel parallelly to the fork arms.

Switch on the truck.

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Do not move the steering wheel until prompted to do so.

Key in 8 .

Press ENTER (first adjustment step).

A 0 will appear between dashes or arrows if the potentiometer is working correctly; otherwise, perform the electrical/mechanical centring procedure and search for the middle point again.

Press SPACE BAR to confirm; a confirmation will be heard.

Check for the OK message on the SetPadj C line.

The software will automatically go to the second setting step: Turn the steering wheel stroke.

to end of

Press SPACE BAR (to display the current value).

A 0 will appear between dashes or arrows if the potentiometer is working correctly; otherwise, perform the electrical/mechanical centring procedure and search for the middle point again.

Press SPACE BAR to confirm; a confirmation will be heard.

Check for the OK message on the SetPadj R line.

The adjustment of the steering potentiometer is finished.

Perform this check after checking the steering potentiometer calibration. The initial conditions are: truck on PC connected and LES program running

-6

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Key in 8 1 Arrange the steering wheel in central position.

Press ENTER (first setting step).

A 0 will appear between dashes or arrows if the potentiometer is working correctly.

If the 0 is not present, press ARROW UP or ARROW DOWN to display it.

The space bar may need to be pressed on some PCs at the same time.

If you cannot display the 0 symbol in any way, perform the electrical/mechanical centring and middle point search procedure again.

The value indicated by the ActPadj C variable may be adjusted by a few mV to the right and to the left of the zero point (error voltage).

Check that the truck is moving in a straight line.

The truck must move in a straight line; operate on the ActPadj C parameter again.

Press SPACE BAR to confirm; a confirmation will be heard.

Check for the OK message on the Actpadj C line.

The software will automatically go to the second setting step: Automatic access to the second setting point.

Turn the steering wheel clockwise to end of stroke.

Press SPACE BAR (to display the current value).

A 0 will appear between dashes or arrows if the potentiometer is working correctly.

If the 0 is not present, press ARROW UP or ARROW DOWN to display it.

The space bar may need to be pressed on some PCs at the same time.

Press SPACE BAR to confirm; a confirmation will be heard.

Check for the OK message on the Actpadj R line.

This completes the calibration procedure.

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Access the motor compartment.

Remove the four retaining screws of the steering motor.

An M6 articulated Allen key is required to access the retaining screws of the steering motor.

The articulated joint allows to access the screws which are more difficult to reach.

-8

45578042305 [EN]

Once all the screws have been removed, the motor can be extracted.

During assembly, follow the above steps in the reverse order, and insert the motor in its seat while keeping the flat part of the flange facing the body.

Before carrying out this operation, make sure that the drive wheel is completely parallel with the side of the truck; we suggest using two straight-edges, place one straight-edge at the drive wheel and the other at the side of the truck, position the drive wheel so that the two straight-edges are parallel.

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Insert the pinion of the potentiometer into its seat,

Be careful that the pinion does not move and that the marks made on the pinion and the plate line up.

Do not strike the ring gear of the potentiometer pinion.

Check the electrical calibration of the potentiometer using the Diagnostics PC, as described in the relative section.

The electrical calibration of the potentiometer is essential if the potentiometer is being replaced; otherwise, if the potentiometer is being reassembled, it acts as a check to verify that the pinion has not moved and that the reference marks have been kept aligned.

Reconnect the cables.

Reinstall the entire electronic panel.

Reconnect the battery.

Test operation of the drive with the wheel raised.

If it works properly, raise the machine with the jack "A" and remove the wooden blocks.

Replace the machine on the ground and complete reassembly of the covers and seat.

-10

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a

To access the retaining nuts of the drive wheel, position the truck so that the appropriate slots on the body are completely aligned with the nuts.

1

Check the wheel nut tightening according to the intervals indicated in the maintenance table and when a wheel is replaced.

3

Follow the instructions provided in the relative chapter when replacing a wheel.

The figures at the side indicate the order in which the wheel fastening nuts should be tightened.

The nut tightening torque values are given below.

4 2

140 ±5% Nm / 14 ±5% kgm

5 OM0963

The wheels and rollers on the forklift should be replaced when they appear to be worn.

Contact the service center authorized by the manufacturer for replacement of the wheels and rollers.

OM1290

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-1

Loosen the locking nuts using the appropriate slots.

Raise the body with the aid of a jack.

Rest the body on a wooden block.

Operate the steering to position the traction wheel so that the nuts are accessible from the front side.

Unscrew and remove the locking nuts.

-2

45578042305 [EN]

At this point the wheel can be removed.

To reassemble the wheel, proceed in the reverse order and tighten the nuts as indicated in the section "Wheel nut tightening check".

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-3

-4

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a

Before removing the electromagnetic brake, first immobilise the truck, disconnect the battery, and remove the casing Position the system support in the position for access to the motor compartment.

Disconnect the electromagnetic brake connector.

The electromagnetic brake is equipped with a connector fastened to the support, so disconnect the connector from the support.

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-1

Unscrew the Allen screws.

Remove the coil "A" and the disk-pusher "B".

Remove the brake disk.

Extract the brake plate.

-2

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Remove the seeger blocking the pinion, using a special pair of pliers.

Pull out the motor pinion, using a wide, flat screwdriver as a lever.

When replacing the electromagnetic brake, carry out the sequence of operations in the opposite order.

45578042305 [EN]

-3

The system is composed of the following components: Dead man s switch pedal (DM) Electronic controller eABS module Traction motor.

This is a compound type of braking, where the e-ABS system controls the motor brake/electromagnetic brake (patented system) combination in an appropriate manner.

During braking, the e-ABS system acts on the electromagnetic brake to avoid, as far as possible, locking the wheel.

The advantages are the following: The set deceleration prevents, as far as possible, the wheel from locking during braking.

Reduction of drive wheel wear.

Stopping distances are reduced with respect to friction braking when grip is poor.

-4

45578042305 [EN]

The e-ABS module manages braking when the dead man foot interlock switch is released.

Main features of the e-ABS module: Nominal supply voltage 24V DC. Inputs and output drivers protected from short circuits.

Built-in LED for signalling status and failures.

The following table shows the inputs and outputs of the e-ABS module in detail:

1 2

14-pole connector.

Diagnostics LED.

1

B+

Input +24V DC

2

GND

Negative

3

HSD_In

High Side Driver FEM IN

4 5

HSD_Out

High Side Driver FEM OUT

INT

6

Traction interlock K1 diagnosis

7

K1-contact TLR Gen K1-out TLR gen

8

CH_A

Channel A encoder

9

CH_B

Channel B encoder

10

Unused

12

Gear on forks side Gear on side opposite the fork arms Poti_Traz

13

BPW

Unused Analogue braking signal

14

nc

-

11

K1 general TLR coil negative

Unused

The status LED "A" of the e-ABS is incorporated in the same card. In the case of an alarm, the LED "A "creates a code (flash code) to indicate the type of anomaly. To interpret the code, the activated flashing must be observed.

Note: All alarms block the truck (power supply to the electromagnetic brake is opened by the internal High Side - Driver and the general K1 contactor is opened). To reset the machine, it must be switched off and then on again.

45578042305 [EN]

-5

One short pulse One flash Two flashes Three flashes Four flashes Five flashes Six flashes LED always on LED always off

Module functioning No alarm Sicstate error

Constate error

Genstate error

Auxiliary MOSFETs already short-circuited at start-up Internal relay series to the electromagnetic brake already short circuited at start-up Contactor K1 already closed at start-up

/ Check wiring and replace module if necessary Check wiring and replace module if necessary Check wiring and replace contactor if necessary Check wiring and replace encoder or module if necessary Check wiring and replace encoder or module if necessary

Channel A encoder error

Incorrect channel "A" encoder signal

Channel B encoder error

Incorrect channel "B" encoder signal

Electromagnetic brake error

Brake coil or wiring open

Check the electromagnetic brake coil and associated wiring

Microprocessor KO

Replace module

Microprocessor KO or no power supply to logics

Check power supply fuse and replace if necessary

Main microprocessor error Main microprocessor error

-6

/

45578042305 [EN]

a

1 2 3 4 5 6 7 7 8

24V dc Battery Plug/socket Handlebar card Lifting motor INVERTER Drive motor Drive motor temperature sensor Drive motor encoder Dead man s pedal

9 10 11 12 13 14 15 16 17

45578042305 [EN]

IBS (flat battery indicator) eABS module 9K1 relay 9M1 fan 9M2 fan 3K1 relay Steering motor LES Controller PC with PC CONSOLE software

-1

18 18 18 18 18 18 18 18

9K1 fan relay coil Horn relay coil Oil level sensor 7K1 drive enable coil Electromagnetic braking Alarm horn Emergency stop button K2 remote control switch coil

18 18 18 18 19 19 19 19

Fuses Ignition key Load detector pressure switch Fork lowering solenoid valve Drive wheel potentiometer Steering potentiometer Traction cut-out safety 3K1 relay control

To simplify the diagram, the optional elements have not been included.

The electronic controller manages: The by means of a static converter called an INVERTER, capable of transforming battery voltage (VDC) into a three-phase voltage/current system (VAC) for controlling the drive motor.

The by means of a static converter called CHOPPER which uses pulsewidth modulation (PWM) to control the voltage applied to the pump motor.

The electronic logic and power cards are situated inside a container that gives good protection from dust, shavings or small particles (IP65 as declared by the manufacturer). It is compact in size: 150mmx230mmx125mm.

The electronic controller is mounted on an aluminium heat sink with the following dimensions: 150mmx27mmx240mm.

The COMBI AC1 has two microcontrollers with the following features: The first microcontroller (MASTER) controls the drive motor.

The second microcontroller (SLAVE) controls the pump motor and monitors some functions controlled by the MASTER.

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45578042305 [EN]

Nominal supply voltage 24 V DC. Maximum delivered current: 350A rms (drive).

Maximum delivered current: 350A rms (pump).

MOS technology.

Various functional configurations, which can be selected from the console to respond to the user s needs.

Full diagnostics via PC. Regenerating braking function when accelerator is fully or partially released allowing a (modest) battery energy recovery.

Inputs and output drivers protected from short circuits Automotive-type IP65 interface connector.

45578042305 [EN]

-3

1

NCLTXD

Negative serial transmission

2

Positive serial transmission

5

PCLTXD Forks down proportioning solenoid valve +24V AUX Lowering

6

Wheel consent

7

LES drive enable

8

CH_A

9

+5V

Channel A encoder Encoder positive supply feed

10

N ENC Load pressure switch

Load detector pressure switch

3 4

11 12 13 14 15 16

Drive motor temperature +KEY Forks up/down proportioning solenoid valve Wheels up solenoid valve Wheels down solenoid valve

17

2nd TLR

18 19

FWD Wheels up limit switch

20

BRAKE pot

21 22 23

Wheels 0 mm limit switch CH_B Deceleration when turning

Proportioning valve negative +24V auxiliary power Fork arms/wheels lowering Wheel consent LES drive enable

Encoder negative supply feed Drive motor temperature Key input Fork arm solenoid valve negative Wheels up solenoid valve negative Wheels down solenoid valve negative

Unused Unused Unused

K2 master contactor negative Forward operator side Wheels up limit switch Brake and ABS on Wheels on ground limit switch Channel B encoder Deceleration when turning

24

C_potT

Traction potentiometer

25

C_potL

Fork arm potentiometer

26

P_pot

Potentiometer power

27

CANH Reverse buzzer (optional)

28 29 30

NCLRXD P_EB

31

N_EB

32

Hour meter

33

REV Select_model

34

-4

Unused Reverse gear warning buzzer Serial reception negative Unused Electromagnetic brake negative Hour meter (*1)

Reverse fork arm side 1200Kg or 1600Kg model

45578042305 [EN]

35 36 37

DM micro Lifting

Dead man Fork arm/wheels up Oil micro switch 1800 mm

39

Lift block Oil micro switch 1800 mm Fan relay

40

BOOTSTRAP

Bootstrap flash memory

41

GND

GND

42

CANL

Unused

38

Lift block

Fan relay negative

(*1) Pin 34 is used to select the forklift model.

Specifically, if connected to +24V the selected model is that with a maximum capacity of 1200Kg; if not connected, the selected model is that with maximum capacity of 1600Kg.

The electrical devices are all positioned on a single electronic panel.

The electronic panel is fastened so that it can be moved in order to conveniently access the interior of the motor compartment without having to remove the entire panel.

To access the electronic panel: Access the motor compartment as described in the "Internal Accessibility" section.

For more convenient access, remove the seat and seat support as well.

45578042305 [EN]

-5

The panel rests on two buffers (1) and (2) and is locked by the two pins (3) and (4).

Another pin (4) is inserted that acts as a safety stop.

To move the electronic panel and access the interior of the motor compartment: Extract the retaining pin on the pin (4).

Raise the panel to release it from the pin (3).

Rotate the panel anticlockwise while keeping it constrained to the pin (4).

Finally rest the panel on the anchorage plate of the reducer.

It is not necessary to disconnect the connectors of the sheathed cables in order to perform this manoeuvre, since the sheathed cables are laid so as to allow this movement.

To completely remove the electronic panel, follow the instructions below.

-6

45578042305 [EN]

Disconnect the power cables on the system and on the contactors Disconnect the steering potentiometer Disconnect the connector of the encoder on the drive motor Disconnect the cables on the terminal board on the panel

Disconnect the connectors on the appropriate bracket on the back of the panel Disconnect the oil level sensor on the tank.

Disconnect the connector X11.

At this point, the entire panel can be removed by raising it.

45578042305 [EN]

-7

3

V2

V2

4

1

9

F2

F2

5

9F1

6

F3

F3

7

4

12

F1

F1

2

3

5

10

9F1 11

13

V1

V1

5

13

8

R1

9

3F1

3F1

8

16

7

1

R1 15

Turn off the forklift and perform the operations preliminary to maintenance.

2 OM1402

Access to the fuses is shown in the " " paragraph.

The power fuse (2) is positioned on the electronic panel. The power fuse (3) is positioned near the relays. The service fuses (fuses 4, 5, 6, 7, 8) are positioned in the corresponding fuse holder(1).

Before replacing the fuse, eliminate the cause that led to the fuse blowing. The blown fuse must only be replaced with a fuse of the same amperage. Do not tamper with the forklift s electrical system.

Loosen the screws, exchange the fuses (2) and (3) fasten the screws again.

Remove the cover and replace the blown fuse, then replace the cover.

-8

45578042305 [EN]

= Fan and horn fuse = Electronic panel fuse = Lifting fuse = Fuse

= 200A

= 250A

= Fuse

= 7.5A

= Fuse

= 10A

= Steering fuse

= 1A

= 5A

=30A

Particular care is required during assembly.

This fuse is actually fitted to a bolt which carries the cables both prior to and following after the fuse.

In order to avoid continuity between the cables prior to and following after the fuse, a plastic material bush insulates the cable prior to the fuse from the bolt.

Incorrect assembly of the fuse will prevent its operation in case of overcurrent.

Pay the utmost attention to fuse assembly.

45578042305 [EN]

-9

(for example: battery charger installed on board) the reset voltage is equal to per cell.

Battery voltages : Volts per cell (Adjustable with the switch located on the back of the indicator.

See figure above).

These voltages can be measured only while the battery is working.

In the absence of special conditions (gel batteries, hermetic batteries, work in a cold-storage room, etc.) the indicator is set on the letter .

The low battery charge indicator has a fixed reset voltage threshold.

For normal recharge conditions, with the from the truck while recharging, the reset voltage is equal to or greater than per cell.

This function totals the hours of operation in a permanent manner and indicates the result on the Display The Display is composed of 10 LEDs distributed respectively from right to left in this manner: 5 green, 3 yellow and 2 red. As the work hours pass, the LEDs shut off from right to left. The illuminated LEDs indicate the residual charge of the battery. At the prealarm threshold the next-to-last red LED begins to flash. When the 80% discharge level is reached, the last red LED also begins to flash alternatively with the next-to-last LED and at the same time the interlock relay is activated. figure above).

For recharge conditions with the to the truck system while recharging,

-10

45578042305 [EN]

(see

Turn off the forklift and perform the operations preliminary to maintenance.

Disconnect the plug from the battery socket.

Open the battery cover and the battery side doors as described in the "Internal accessibility" section.

Lift the battery holding bar it.

, tilt it and remove

5

Position the extraction roller unit next to the forklift (see the relevant section on using the roller unit), then remove the battery onto the roller unit.

4

Replace the battery and reassemble it by performing the extraction procedures in reverse.

Position the plugs mounted on the battery doors in the best position to reduce the lateral clearance of the battery to a minimum.

The plugs should be positioned according to the width of the battery and have three possible settings .

Maximum width setting

3

:

1

The plugs should be placed in the upper housing on both battery side doors.

Intermediate width setting

:

2

One plug should be placed in the upper housing on one of the two side doors, while the other plug should be placed in the lower housing on the opposite battery side door.

Minimum width setting

:

The plugs should be placed in the lower housing on both battery side doors.

6

A When closing the battery cover, be careful to position the battery plug cables in their holding fixture to prevent damaging them.

To decide which type of battery to use, check the battery characteristics provided in the "TECHNICAL DATA" chapter.

B C OM1344

45578042305 [EN]

-11

A

C

D B B 1 OM1343

Position the stand with battery extraction roller unit at the battery outlet.

Adjust the height of the supports so that the surface of the roller unit is perfectly horizontal.

Slide the battery up to the mechanical stop .

Raise the battery latch .

Line up the height of the stand with the height at which the battery is to be removed; the height adjustment is made using the adjustable supports .

Slide the battery latch and insert it into the most appropriate slot of those available to lock the battery into place.

1

Raise the hood (1) and check the level and density of the electrolyte as indicated in the battery instructions.

OM0766

-12

45578042305 [EN]

Turn on the external battery charger.

Connect plug the battery charger in to begin charging.

The battery is recharged with the forklift off.

After the battery charging operation is completed, turn off the battery charger.

Unplug the battery charger.

Replace the battery caps (if removed previously).

Plug the battery in again.

Lower the battery compartment cover.

Access the upper part of the battery as described in the "Internal accessibility" paragraph.

Refer to the battery charger manual for more information.

Remove the battery caps (if indicated in the battery maintenance booklet).

45578042305 [EN]

-13

-14

45578042305 [EN]

a

(P)pump delivery (T)return to tank 45578042305 [EN]

-1

(C1)fork lift branch (C2)wheel lift branch (1)2Y2 proportioning solenoid valve (2)2Y1 solenoid valve (3)2Y3 solenoid valve (4)2Y4 solenoid valve with manual control (5)145÷190 bar maximum pressure valve (6)wheels lowering valve

Operate on valve and on the manual control of the solenoid valve to move the fork arms down in an emergency.

-2

45578042305 [EN]

(1) pump delivery (2) emergency lowering valve (3) 2Y2 solenoid valve (4) return to tank

Operate on tap quired.

if emergency lowering is re-

45578042305 [EN]

-3

Access the motor compartment.

Remove the metal band (A) that holds the pump motor to the body, operating on the closing block screw (B), and remove the two rubber spacers (C) as well.

In preparation for detaching the supply and drain pipes, protect the unit and body from any oil leaks by arranging cloths underneath the respective fittings.

Prepare plugs for closing the pipes as well.

Proceed with detaching the pipes.

An M22 crowfoot spanner, which facilitates access, should be used to detach the pipes.

Once the pipes have been detached, the tankpump-motor unit can be removed.

For assembly, proceed in the reverse order.

-4

45578042305 [EN]

a

Position the basic truck in an area with a level, horizontal floor equipped with a crane having suitable capacity for the weight of the lift to be handled; use wooden blocks to prevent any accidental movement of the truck.

Attach the crane to the lift using a sling with suitable capacity, restraining all sections of the lift itself.

Bring the lift alongside the truck base.

45578042305 [EN]

-1

Move the lift slowly, bringing it near the truck and lowering it so that the cross traverse on the back of the lift is positioned inside the appropriate mechanical stop .

Allow the lift itself to rest on the lower part of the truck.

With the lift resting and blocked by the mechanical stops, remove the sling that lifts and restrains the sections of the lift and hook it onto the inner mast only: in this manner it will be possible to raise the movable sections of the lift while keeping the fixed mast stationary.

-2

45578042305 [EN]

Position a wooden block under the movable parts for safety.

Proceed with bolting the fixed part of the lift to the truck, without tightening the bolts to their tightening torque, and connect the hydraulic pipes. (C)bolts; (D)pipes.

Use an electronic level to measure the inclination of the lift: it must be 90°.

If the inclination is less than this, loosen the fastening bolts of the lift and insert shims.

The same number of shims must be used on both fastening points of the lift.

Repeat the shimming until the inclination is correct.

45578042305 [EN]

-3

Screw on the side screws until they rest against the body.

Tighten the fastening bolts to their tightening torque.

-4

45578042305 [EN]

Remove the battery by extracting it sideways.

Remove the object tray top cover.

Remove the lifting limit switch microswitch.

Remove the side covers.

Remove the lift cylinders.

Raise both the body and the mobile structure off the ground and rest them on wooden shims so that the fork arms remain horizontal and the body remains supported even after having removed the hinge pins.

Remove the two hinge pins of the rear levers with the fixed structure:

1) The pins are blocked with an elastic pin that should be extracted by striking it downwards with a suitable plug remover using the appropriate hole.

45578042305 [EN]

-5

2) The two pins are extracted by striking them inwards from the outside.

Using two slings of suitable capacity, hook the body in the two holes provided and raise it slowly until the side bearings come out of the guide profiles.

While keeping the body raised, move it away from the mobile frame.

Replace the body on the ground on wooden shims located on both the front and rear sides.

For reassembly, proceed in the reverse order taking the following tactics into consideration.

Rehook the body in the two top side points and raise it with the hoist so that the body remains hanging in a centred manner, symmetrical and perpendicular to the ground.

-6

45578042305 [EN]

Reassemble the body to the mobile structure by moving the body close to the mobile structure and inserting the side bearings into the guide stands, then rest it on the ground on the wooden shims .

Hook the mobile structure with the hoist using the two anchoring holes of the lift cylinders and raise the mobile structure slightly. This allows clearance on the lever systems so that by manually operating the "Tandem rollers" group, the rear levers can be moved to align the relative holes with the attachment holes on the body.

45578042305 [EN]

-7

Then it is possible to insert the pins and the relative elastic pins on both sides of the machine.

Using the hoist, move the mobile structure up and down to check that there are no mechanical obstacles.

Rest the mobile structure on wooden shims on the ground.

Reassemble the lift cylinders.

Adjust the bearings.

Reassemble the lifting limit switch microswitch.

Remove the battery.

Remove the side covers.

Through the appropriate windows from the battery compartment, disconnect the supply tubes of the lift cylinders and use suitable male and female hydraulic plugs to prevent foreign matter from entering the cylinders and hydraulic circuit.

With an articulated Allen key, remove the retaining screw of the lower safety split pin of the cylinder and remove the split pin itself.

-8

45578042305 [EN]

Use pliers to rotate the rod of the cylinder so as to position the top pin at the hole on the stand and extract it.

45578042305 [EN]

-9

Position the jack on the front side of the mobile structure and raise it until the side cylinders are completely freed. Place timber baulks under the mobile structure in order to be able to work safely.

-10

45578042305 [EN]

Extract the cylinders from the machine.

The reassembly of the cylinders is carried out by performing the various operations described up until now in the reverse order, with the only difference of inserting spherical washers in the lower and upper part of the cylinder according to the order shown in the photo.

This adjustment should be carried out with the machine on a flat surface and the fork arms on the ground.

The mobile structure is supported on its sides by a pair of "load bearings" that work inside the guide profiles of the mobile structure.

45578042305 [EN]

-11

The mobile structure is also guided sideways by a second pair of "side grip bearings" that work crosswise on the side of the guide profile of the mobile structure.

The load bearings are equipped with an eccentric pin that can be turned with an Allen key to move the top part of the mobile structure forward or backward and thus adjust the inclination of the fork arms.

Usually, if the adjustment of the tension rods has been performed correctly, the position of the eccentric pin is established a priori with the engraving positioned at 8 o clock when observing the pin from the side of the hexagonal hole for the wrench.

In this position the bearings keep the top part of the structure almost completely towards the operator and the tip of the fork arms at the highest point.

The fixing of the pin is carried out by holding the eccentric pin stationary with an Allen key and tightening the lock nut with an open-end spanner suitable for the torque value.

If it is necessary to modify this attitude, both sides must be worked on, turning the eccentric pins by the same amount.

-12

45578042305 [EN]

For the adjustment of the "side grip bearings" , proceed as follows: Loosen the central fastening screw of the bearings.

Stand on the fork arms and use crosswise movements to make the entire mobile structure oscillate in order to make it settle mechanically.

Using the nut of the eccentric pin, turn the two pins until the two side grip bearings rest on the rib of the profile; hold the eccentric pin stationary in this position and tighten the central fastening screw.

Perform some lifting and lowering manoeuvres to check that there is no jamming or excessive play. If jamming or excessive play is found, the adjustment must be repeated.

Disassemble the lift cylinders of the machine and remove the feed line connection from each cylinder.

Completely drain the oil from the cylinder.

Extract the rod to the end position.

45578042305 [EN]

-13

With the rod at the end position, look through the feed hole; a metal retaining ring can be seen, housed in its seat, along with a groove that will be used only during the reassembly of the rod.

The groove must not be used for disassembly since doing so would cause, when extracting the rod, the retaining ring to become stuck in the gasket.

Use a sturdy screwdriver passing through the hole to force the metal retaining ring and push it towards the blind end of the cylinder.

Slipping off the retaining ring towards the end of the barrel, it is possible to extract the rod, once the rod is completely extracted it is also possible to extract the metal retaining ring left in the barrel.

Now the worn gaskets can be extracted and replaced, see the figure at the side.

Heat the new gaskets in hot water in order to be able to insert them in their seats without damaging them.

After replacement of the gaskets, position the retaining ring inside the deepest groove on the rod.

Spread grease on the surface of the rod at the metal retaining ring and the gaskets zone on the barrel and insert the rod.

Position the retaining ring at the hole of the feed line and use a sturdy screwdriver to move the retaining ring from the deepest groove to the smallest groove.

Perform some movements with the rod, up to the end position, to check the efficiency of the mechanical stop.

Reassemble the feed line connection.

-14

45578042305 [EN]

To access the lever systems, it is necessary to separate the mobile structure from the body .

45578042305 [EN]

-15

Position the mobile structure upside down using a hoist, see the figures for phase 1 and 2.

-16

45578042305 [EN]

In this manner, all parts will be accessible and within reach and thus easy to replace, without the need for particular instructions since they simply involve pivots and pins.

During reassembly, some adjustments must be made in order to obtain a correct attitude of the mobile structure, minimizing the need for adjustments on the assembled machine which are rather difficult with the machine on the ground.

45578042305 [EN]

-17

FORK ARM LENGTH

1150

DIMENSION " "

680.5

DIMENSION " "

808.1

If the struts must be completely disassembled for maintenance reasons, before reassembling them adjust them so that dimension " " corresponds to the value indicated in the table.

To adjust the struts in position, refer to dimension " " using the procedure described below: Use two clamps to block the front roller levers at the end position against the fork arm.

Place a piece of gummed paper tape at the retaining pin centre on the pin hinging the strut with the front levers.

-18

45578042305 [EN]

Place a piece of gummed paper tape on the rear levers at the centre of the hinge pin of the strut and the centre of the hinge pin of the levers ; in this manner the tape transversally crosses the eye of the strut, creating the reference point for the measurement of dimension " ".

Perform the measurement of dimension " " between the two references created.

45578042305 [EN]

-19

-20

45578042305 [EN]

The strut length is adjusted by operating on the hexagonal block located between the rod of the strut and the ball-and-socket head and blocking it with the lock nuts, as shown in the figure.

Check the centring of the rear lever, following the procedure described below:

Make certain that both the clamps on the front wheels are fixed correctly and keep the front levers at the end position against the upper part of the fork arms.

45578042305 [EN]

-21

If the adjustment of the struts has been performed correctly, the rear lever group will automatically be centred and the distance measured between the deflection plate and the inside of the lever hinging to the body will be 95 mm on both the right and the left.

If the two dimensions are different, then it is necessary to adjust the hexagonal adjustment blocks of the struts in order to shorten the strut on the side that measures less than 95 mm and lengthen the strut on the side that measures more than 95 mm until both the dimensions are 95 mm.

Adjust the two struts gradually, unscrewing the hexagonal adjustment block of a strut by one turn at a time and simultaneously tightening the hexagonal block of the other strut by the same amount. a

22

When finished, fix the hexagonal adjustment blocks with the respective lock nuts.

45578042305 [EN]

Still GmbH Berzeliusstrasse 10 D-22113 Hamburg Ident no. 45578042305 EN

a

45578042305 [EN]

-1

white

blue orange

BU

violet

red yellow

grey

VT

RD

GY

-2

YE

brown green

GN

BN

OG

black

WH

CABLE COLOURS

Electronic traction/lift control, 7-12/18-21 Electronic control of electrical steering, 2-5 Electronic e-ABS control, 13 Electrical steering terminal board, 2-5 Safety fuse 10A, 14 Safety fuse 1A, 13 Aux safety fuse 5A, 24 Drive safety fuse 200A, 8-9 Lifting safety fuse (250A), 7 Steering safety fuse 30A, 2 Fan + horn safety fuse 5A, 28 Battery, 1

BK

A1 A2 A4 A5 F1 F2 F4 1F1 2F1 3F1 9F1 G1

4H1 K1 K2 3K1 4K1 9K1 4L1 9L1 1M1 2M1 3M1 9M1

Horn, 30 General contactor contact, 9 Traction contactor contact, 9 Electrical steering relay contact, 2 Horn relay contact, 30 Fan relay contact, 28 Suppressor, 31 Suppressor, 26 Traction motor 3000W (AC), 10-12 Lift motor 2200W (DC), 7 Electrical steering geared motor 600W (DC), 3-4 Fan, 28

9M2 9M3 6P1 9P1 S1 7S1 V4 X1 X2 X4 X5 X6

Fan, 27 Fan (opt), 25 Low battery charge indicator, 16-21 Data terminal, 24 Key, 22-23 Emergency stop button, 11-14 Diode, 22 Battery socket/plug, 1 SAAB 42-pin connector, 18-21 Molex Mini fit jr. 14-pin connector, 13 MTA UNIVAL 8-way fuse box, 2/13/14/28 SAAB 10-pin connector, BK, 14/18/21/24/28

SAAB 2-pin connector, BK (aux socket), 24 Molex Mini Fit jr. 4-pin connector, 11 Welded cables, 2-5 Wittrin connector for micro-relay, 30 Molex Mini Fit jr. 8-pin connector, 16-21 Wittrin connector for micro-relay, 28 SAAB 4-pin connector, GY, 27-28 AMP SuperSeal 2-pin connector, 25 K1 diagnosis Lift block Hour meter

45578042305 [EN]

X7 X10 3X2 4X1 6X1 9X1 9X2 9X3 (*1) (*2) (*3)

45578042305 [EN]

-3

blue orange

grey

GY

-4

YE

red yellow

violet

RD

GN VT

BN

brown green

white

BU

OG

black

WH

CABLE COLOURS

Electronic traction + lift control, 33-49/55-57 Electronic control of electrical steering, 58-60 Electronic e-ABS control, 50-54/61-65 Traction motor overheat protection, 56 Safety fuse 7.5A, 32 Reverse buzzer (optional), 46 Contactor coil 1, 62 Contactor coil 2, 57 Traction interlock relay contact, 41 Fan relay coil, 39 Model selection jumper (ON=1200kg, OFF=1600kg), 45 Resistor, 51 Fork load pressure switch (no load), 38 Oil level micro switch (forks below 1800 mm), 44 Straddles up limit micro switch (with straddles on floor), 42

BK

R1 1S2 1S3 2S5

A1 A2 A4 1B2 F3 4H2 K1 K2 7K1 9K1 J1 7S2 V1 V2 V3 X2 X4 X5 X6 X9 X10 X12 1X1 1X2 1S4 2X1

2S6

Straddle micro switch 0 mm (with straddles on floor), 43 Dead man s pedal, 53 Diode, 51 LED, 47 Diode, 61 SAAB 42-pin connector, 33-49/55-57 Molex Mini fit jr. 14-pin connector, 50-54/61-65 MTA UNIVAL 8-way fuse box, 32/47/51 SAAB 10-pin connector, BK, 40 SAAB 10-pin connector, BU, 34-38/51/53/55 Molex Mini fit jr. 4-pin connector, 42-43 Molex Mini fit jr. 4-pin connector, 45 SAAB 2-pin connector, BK, 48 SAAB 2-pin connector, GY, 56 Load pressure switch on straddles, 38 JPT 2-pin connector, 35

2X2 2X3 2X4 2X5 2X6 3X1 7X1 7X2 9X1 Y1 2Y1 2Y2 2Y3 2Y4 (*4) (*5) (*6)

DIN connector for solenoid valve, 34 JPT 2-pin connector, 36 JPT 2-pin connector, 37 ITT CANNON 4-pin connector, 42 ITT CANNON 4-pin connector, 43 AMP25-pin connector, 58-60 Wittrin connector for micro-relay, 41 AMP JPT4-pin connector, BK, 53 Wittrin connector for micro-relay, 39 Electromagnetic brake, 48 Forks solenoid valve, 35 Forks down proportional solenoid valve, 34 Straddles solenoid valve, 36 Straddles down solenoid valve, 37 Forks down proportional solenoid valve Forks up/down proportional solenoid valve Straddles up solenoid valve

Straddles down solenoid valve Load pressure switch Fan relay LES traction interlock Straddles up limit switch Straddle limit switch 0 mm Oil micro switch 1800 mm Model selection Reverse buzzer (optional) Dead man s micro switch Braking potentiometer Traction interlock Traction motor temperature Steering activation

45578042305 [EN]

(*7) (*8) (*9) (*10) (*11) (*12) (*13) (*14) (*15) (*16) (*17) (*18) (*19) (*20)

45578042305 [EN]

-5

white

blue orange

BU

violet

red yellow

grey

VT

RD

GY

-6

YE

brown green

GN

BN

OG

black

WH

CABLE COLOURS

Electronic traction control, 79-99 Electronic control of electrical steering, 66-70/100-104 Pushbutton controls, 74-96 Electronic e-ABS control, 74-75 Drive wheel position indicator, 69-71 Traction motor encoder, 96-99 Electrical steering relay coil, 68 Horn relay coil, 72 Traction interlock relay coil, 67 In-circuit programming jumper, 89-90 Combi system console, 91-95 LES console, 109-112 Steering potentiometer, 106-107

BK

A1 A2 A3 A4 A6 1B1 3K1 4K1 7K1 J2 6P2 6P3 3R2

3R3 X2 X3 X4 2S9 X6 X8 1X4 3X1 3X3 3X4 4X1 6X2

Drive wheel potentiometer, 101-103 Saab 42-pin connector, 78-99 Molex Micro Fit 18-pin connector, 74-88 Molex Mini Fit jr. 14-pin connector, 74-75 Straddle lifting/lowering pushbutton, 91-95 SAAB 10-pin connector, BK, 105-108 SAAB 10-pin connector, GY, 76-88 JPT4-pin connector, 96-99 AMP 25-pin connector, 66-70/100-114 SAAB 4-pin connector, BK, 105-108 DEUTSCH 4-pin connector, 100-104 Written connector for micro-relay, 72 SAAB 6-pin connector, BK, 91-95

6X3 7X1 X11 X12 (*21) (*22) (*23) (*24) (*25) (*26) (*27) (*28) (*29)

SAAB 4-pin connector, BK, 109-112 Written connector for micro-relay, 67 SAAB 2-pin connector, BK, 70 Molex Mini Fit jr. 4-pin connector, 89-90 Free Speed sensor (B) Traction cut-out Speed sensor (A) Steering position Deceleration when turning Lifting Lowering Straddle interlock

Drive wheel potentiometer (B) Potentiometer ground Drive wheel potentiometer (A) Steering potentiometer (A) Steering potentiometer (B) Logical ground Truck code Travel in direction of operator Fork arms lifting Fork arms lowering Travel in direction of forks Straddles up Contacts side view

45578042305 [EN]

(*30) (*31) (*32) (*33) (*34) (*35) (*36) (*37) (*38) (*39) (*40) (*41) (*45)

45578042305 [EN]

-7

white

blue orange

BU

violet

red yellow

grey

VT

RD

GY

-8

YE

brown green

GN

BN

OG

black

WH

CABLE COLOURS

Safety fuse 20A, 115 Bimetallic switch, 114 Safety fuse 20A, 121 Bimetallic switch, 115

BK

9F3 9F4 9F5 9F6

9K2 9K3 9M4 9M5

Heater fan activation relay, 114/115 Heater fan activation relay, 123 Heater fan, 115 Heater fan, 117

9M6 9R2 9R3 9R4

Heater fan, 123 Heater resistor, 116 Heater resistor, 118 Resistor Straddle limit switch heater (100R), 119

Resistor Straddle limit switch heater (100R), 119 Heater resistor, 124 ITT CANNON 2-pin connector, BK, 119 ITT CANNON 2-pin connector, BK, 119

45578042305 [EN]

9R5 9R6 9X5 9X6

45578042305 [EN]

-9

white

blue orange

BU

violet

red yellow

grey

VT

RD

GY

-10

YE

brown green

GN

BN

OG

black

WH

CABLE COLOURS

Fleet Manager, 133-136 RC filter, 127-130 3-way fastin-faston connector with male contacts, 135-137

BK

S4 Z1 X12

X13 (*42) (*44)

ITT CANNON 4-pin connector, black, 133-136 Filter Contacts output side

45578042305 [EN]

45578042305 [EN]

-11

white

blue orange

BU

violet

red yellow

grey

VT

RD

GY

-12

YE

brown green

GN

BN

OG

black

WH

CABLE COLOURS

Programmable Security Lock, 140-143 3-way fastin-faston connector with male contacts, 141-145

BK

S5 X14

X21

ITT CANNON SURE-SEAL 4-pin connector, BK, 141-147

(*43) (*44)

PSL keypad/key Contacts output side

45578042305 [EN]

45578042305 [EN]

-13

white

blue orange

BU

violet

red yellow

grey

VT

RD

GY

-14

YE

brown green

GN

BN

OG

black

WH

CABLE COLOURS

Steering potentiometer, 149-152 Molex MiniFit 4-way connector, 149-152 Molex MiniFit 4-way connector, 149-152

BK

3R2 3X3 3X3

45578042305 [EN]

45578042305 [EN]

-15

white

blue orange

BU

violet

red yellow

grey

VT

RD

GY

-16

YE

brown green

GN

BN

OG

black

WH

CABLE COLOURS

Electronic traction/lift control, 7-12/18-21 Electronic control of electrical steering, 2-5 Electronic e-ABS control, 13 Electrical steering terminal board, 2-5 Safety fuse 10A, 14 Safety fuse 1A, 13 Aux safety fuse 5A, 25 COMBI safety fuse 200A, 8-9 Steering safety fuse 30A, 2 Fan + horn safety fuse 5A, 29 Battery, 1 Horn, 31

BK

A1 A2 A4 A5 F1 F2 F4 1F1 3F1 9F1 G1 4H1

K1 K2 3K1 4K1 9K1 4L1 9L1 1M1 2M1 3M1 9M1 9M3

General contactor contact, 9 Traction contactor contact, 9 Electrical steering relay contact, 2 Horn relay contact, 31 Fan relay contact, 29 Suppressor, 32 Suppressor, 27 Traction motor 3000W (AC), 10-12 Lift motor 2200W (DC), 7 Electrical steering geared motor 600W (DC), 3-4 Fan, 29 Fan (opt), 26

9M2 6P1 9P1 S1 7S1 V4 X1 X2 X4 X5 X6 X7

Fan, 28 Low battery charge indicator, 16-21 Data terminal, 25 Key Emergency stop button, 11-14 Diode, 23 Battery socket/plug, 1 SAAB 42-pin connector, 18-21 Molex Mini fit jr. 14-pin connector, 13 MTA UNIVAL 8-way fuse box, 2/13/14/29 SAAB 10-pin connector, BK, 14/18/21/25/29 Auxiliary plug connector, 25

Molex Mini fit jr. 4-pin connector, 11 Welded cables, 2-5 Wittrin connector for micro-relay, 31 Molex Mini fit jr. 8-pin connector, 16-21 Wittrin connector for micro-relay, 29 SAAB 4-pin connector, GY, 28-29 AMP SuperSeal 2-pin connector, 26 Lifting safety fuse (250A), 7 K1 diagnosis Lift block Hour meter

45578042305 [EN]

X10 3X2 4X1 6X1 9X1 9X2 9X3 2F1 (*1) (*2) (*3)

45578042305 [EN]

-17

blue orange

grey

GY

-18

YE

red yellow

violet

RD

GN VT

BN

brown green

white

BU

OG

black

WH

CABLE COLOURS

Electronic traction + lift control, 34-49/57-60 Electronic control of electrical steering, 61-63 Electronic e-ABS control, 51-56/64-68 Safety fuse 7.5A, 33 Traction motor overheat protection, 58 Reversing buzzer (opt), 46 Contactor coil 1, 65 Contactor coil 2, 60 Traction interlock relay contact, 42 Fan relay coil, 40 Model selection jumper (ON=1200kg, OFF=1600kg), 59 Resistor, 52 Fork load pressure switch, 39

BK

R1 1S2

A1 A2 A4 F3 1B2 4H2 K1 K2 7K1 9K1 J1 7S2 V1 V2 V3 X2 X4 X5 X6 X9 X10 X12 1X1

1S3

Oil level micro switch (normally open with forks below 1800mm), 45 Dead man s pedal, 55 Diode, 50 LED, 47 Diode, 64 SAAB 42-pin connector, 34-49/57-60 Molex Mini fit jr. 14-pin connector, 51-56/64-68 MTA UNIVAL 8-way fuse box, 33/47/50/52 SAAB 10-pin connector, BK, 41 SAAB 10-pin connector, BU, 35-39/53/55/57 Molex Mini fit jr. 4-pin connector, 43-44 Molex Mini fit jr. 4-pin connector, 59 SAAB 2-pin connector, BK, 48

1X2 2X2 2X5 2X6 3X1 7X1 7X2 9X1 Y1 2Y2 (*4) (*5) (*6) (*7)

SAAB 2-pin connector, GY, 58 DIN connector for solenoid valve, 35 ITT CANNON 4-pin connector, 43 ITT CANNON 4-pin connector, 44 AMP 25-pin connector, 61-63 Wittrin connector for micro-relay, 42 AMP jr. POWER TIMER 4-pin connector, 54-55 Wittrin connector for micro-relay, 40 Electromagnetic brake, 48 Forks down solenoid valve, 35 Forks down proportional solenoid valve Forks up/down proportional solenoid valve Straddles up solenoid valve Straddles down solenoid valve

Load pressure switch Fan relay LES traction interlock Straddles up limit switch Straddle limit switch 0 mm Oil micro switch 1800 mm Reverse buzzer (optional) Dead man s micro switch Braking potentiometer Traction interlock Traction motor temperature Optional deceleration Steering activation Safety relay

45578042305 [EN]

(*8) (*9) (*10) (*11) (*12) (*13) (*14) (*15) (*16) (*17) (*18) (*19) (*20) (*21)

45578042305 [EN]

-19

white

blue orange

BU

violet

red yellow

grey

VT

RD

GY

-20

YE

brown green

GN

BN

OG

black

WH

CABLE COLOURS

Electronic traction control, 81-101 Electronic control of electrical steering, 69-73/102-116 Pushbutton controls, 76-91 Electronic e-ABS control, 76-78 Drive wheel position indicator, 72-74 Traction motor encoder, 97-100 Electrical steering relay coil, 71 Horn relay coil, 79 Traction interlock relay coil, 70 In-circuit programming jumper, 90-91 Combi system console, 92-96 LES console, 111-114 Steering potentiometer, 108-109

BK

A1 A2 A3 A4 A6 1B1 3K1 4K1 7K1 J2 6P2 6P3 3R2

3R3 X2 X3 X4 X6 X8 1X4 3X1 3X3 3X4 4X1 6X2 6X3

Drive wheel potentiometer, 103-105 Saab 42-pin connector, 81-101 Molex Micro Fit 18-pin connector, 76-91 Molex Mini Fit jr. 14-pin connector, 76-78 SAAB 10-pin connector, BK, 107-110 SAAB 10-pin connector, GY, 78-89 JPT 4-pin connector, 97-100 AMP 25-pin connector, 69-73/102-116 SAAB 4-pin connector, BK, 107-110 DEUTSCH 4-pin connector, 102-106 Written connector for micro-relay, 79 SAAB 6-pin connector, BK, 92-96 SAAB 4-pin connector, BK, 111-114

7X1 X11 X12 (*22) (*23) (*24) (*25) (*26) (*27) (*28) (*29) (*30) (*31)

Written connector for micro-relay, 70 SAAB 2-pin connector, BK, 73 Molex Mini Fit jr. 4-pin connector, 90-91 Unused Speed sensor (B) Traction cut-out Speed sensor (A) Steering position Start micro switch Lifting Lowering Straddle interlock Deceleration when turning

Drive wheel potentiometer Steering potentiometer Logical ground Program select Program select / Not used Travel in direction of operator Fork arms lifting Fork arms lowering Travel in direction of forks Straddles up

45578042305 [EN]

(*32) (*33) (*34) (*35) (*36) (*37) (*38) (*39) (*40) (*41)

45578042305 [EN]

-21

white

blue orange

BU

violet

red yellow

grey

VT

RD

GY

-22

YE

brown green

GN

BN

OG

black

WH

CABLE COLOURS

Safety fuse 20A, 115 Bimetallic switch, 114 Safety fuse 20A, 121 Bimetallic switch, 115

BK

9F3 9F4 9F5 9F6

9K2 9K3 9M4 9M5

Heater fan activation relay, 114/115 Heater fan activation relay, 123 Heater fan, 115 Heater fan, 117

9M6 9R2 9R3 9R4

Heater fan, 123 Heater resistor, 116 Heater resistor, 118 Resistor Straddle limit switch heater (100R), 119

Resistor Straddle limit switch heater (100R), 119 Heater resistor, 124 ITT CANNON 2-pin connector, BK, 119 ITT CANNON 2-pin connector, BK, 119

45578042305 [EN]

9R5 9R6 9X5 9X6

45578042305 [EN]

-23

white

blue orange

BU

violet

red yellow

grey

VT

RD

GY

-24

YE

brown green

GN

BN

OG

black

WH

CABLE COLOURS

Fleet Manager, 133-136 RC filter, 127-130 3-way fastin-faston connector with male contacts, 135-137

BK

S4 Z1 X12

X13 (*42) (*44)

ITT CANNON 4-pin connector, black, 133-136 Filter Contacts output side

45578042305 [EN]

45578042305 [EN]

-25

white

blue orange

BU

violet

red yellow

grey

VT

RD

GY

-26

YE

brown green

GN

BN

OG

black

WH

CABLE COLOURS

Programmable Security Lock, 140-143 3-way fastin-faston connector with male contacts, 141-145

BK

S5 X14

X21

ITT CANNON SURE-SEAL 4-pin connector, BK, 141-147

(*43) (*44)

Keypad Contacts output side

45578042305 [EN]

45578042305 [EN]

-27

white

blue orange

BU

violet

red yellow

grey

VT

RD

GY

-28

YE

brown green

GN

BN

OG

black

WH

CABLE COLOURS

Steering potentiometer, 149-152 Molex MiniFit 4 pin connector, 149-152 Molex MiniFit 4 pin connector, 149-152

BK

3R2 3X3 3X3

45578042305 [EN]

45578042305 [EN]

-29

Forks Straddles

ON

2Y2

-30

(*3) (*4)

ON

2Y1 OFF

2Y3

SPECIFICATIONS TABLE

* : the straddles automatically descend at each "forks up" request.

FORKS DOWN

(*1) (*2)

OFF

2Y4

DPX-TPX lift masts Up

OFF

PUMP MOTOR

(*5) (*6)

Filling Down

FORKS UP STRADDLES UP STRADDLES DOWN ON

OFF

OFF

ON

OFF

OFF

45578042305 [EN]

ON

ON

OFF

OFF

OFF

ON *

OFF

ON

ON

45578042305 [EN]

-31

Forks Straddles

ON

2Y2

-32

(*3) (*4)

ON

2Y1 OFF

2Y3

SPECIFICATIONS TABLE

* : the straddles automatically descend at each "forks up" request.

FORKS DOWN

(*1) (*2)

OFF

2Y4

SPX lift mast Up

OFF

PUMP MOTOR

(*5) (*6)

Filling Down

FORKS UP STRADDLES UP STRADDLES DOWN ON

OFF

OFF

ON

OFF

OFF

45578042305 [EN]

ON

ON

OFF

OFF

OFF

ON *

OFF

ON

ON

45578042305 [EN]

-33

-34

(*1) (*2)

2Y2

PUMP MOTOR

SPECIFICATIONS TABLE

Fork arms DPX-TPX lifts

(*3) (*4)

Up Filling

FORKS DOWN FORKS UP Off

ON

Off ON

45578042305 [EN]

45578042305 [EN]

-35

-36

Off

ON

Off

PUMP MOTOR

ON

2Y2

SPECIFICATIONS TABLE

Fork arms SPX lift

FORKS DOWN FORKS UP

(*1) (*2)

(*3) (*4)

Up Filling

45578042305 [EN]

45578042305 [EN]

-37

Ident no. 45578042305 EN

Still GmbH Berzeliusstrasse 10 D-22113 Hamburg